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KOMATSU D155AX-6 BULLDOZER SHOP MANUAL SN:80001 and up – PDF
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KOMATSU D155AX-6 BULLDOZER SHOP MANUAL SN:80001 and up – PDF DOWNLOAD
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KOMATSU D155AX-6 BULLDOZER SHOP MANUAL SN:80001 and up – PDF DOWNLOAD
Language : English
Pages : 1997
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D155AX-6 BULLDOZER SHOP MANUAL SN:80001 and up – PDF DOWNLOAD
Cover............................................................................................... 1 00 Index and foreword............................................................................... 3 Index........................................................................................... 3 Composition of shop manual.................................................................. 4 Table of contents........................................................................... 6 Foreword and general information................................................................ 19 Safety notice............................................................................... 20 How to read the shop manual................................................................. 25 Explanation of terms for maintenance standard............................................... 27 Handling of electric equipment and hydraulic component...................................... 29 Handling of connectors newly used for engines............................................... 38 How to read electric wire code.............................................................. 41 Precautions when carrying out operation..................................................... 44 Method of disassembling and connecting push-pull type coupler............................... 47 Standard tightening torque table............................................................ 50 Conversion table............................................................................ 54 01 Specification.................................................................................... 61 Specification and technical data................................................................ 61 Specification dimension drawings............................................................ 62 Specifications.............................................................................. 63 Weight table................................................................................ 69 Table of fuel, coolant and lubricants....................................................... 72 10 Structure, function and maintenance standard..................................................... 75 Engine and cooling system....................................................................... 75 Radiator, oil cooler........................................................................ 76 Engine mount................................................................................ 79 Cooling fan pump............................................................................ 80 Cooling fan motor........................................................................... 88 Power train, Part 1............................................................................. 95 Power train skeleton........................................................................ 96 Overall drawing of power train unit......................................................... 98 Power train hydraulic piping drawing........................................................ 100 Damper, universal joint..................................................................... 102 Torque converter, PTO....................................................................... 104 Torque converter control valve.............................................................. 113 Lockup clutch ECMV, stator clutch ECMV...................................................... 114 Transmission control........................................................................ 120 Transmission................................................................................ 122 Transmission ECMV........................................................................... 138 Main relief valve and torque converter relief valve......................................... 144 Lubrication relief valve.................................................................... 146 Scavenging pump............................................................................. 147 Power train and steering lubrication pump................................................... 148 Power train, Part 2............................................................................. 151 HSS system.................................................................................. 152 HSS motor................................................................................... 154 Hydraulic, HSS pump......................................................................... 164 Hydraulic oil cooler bypass valve........................................................... 187 Steering, brake control..................................................................... 188 Steering unit............................................................................... 190 Brake control valve......................................................................... 212 Brake ECMV.................................................................................. 214 Parking brake solenoid valve................................................................ 218 Sudden stop prevention valve................................................................ 220 Final drive................................................................................. 222 Sprocket.................................................................................... 228 Undercarriage and frame......................................................................... 231 Track frame................................................................................. 232 Recoil spring............................................................................... 234 Idler....................................................................................... 236 Track roller................................................................................ 238 Carrier roller.............................................................................. 240 Track shoe.................................................................................. 242 Main frame.................................................................................. 248 Suspension.................................................................................. 250 Hydraulic system................................................................................ 253 Work equipment hydraulic piping diagram..................................................... 254 Work equipment control piping diagram....................................................... 257 Work equipment control...................................................................... 260 Hydraulic tank and filter................................................................... 262 Accumulator................................................................................. 267 PCCS lever.................................................................................. 268 Work equipment lock valve................................................................... 272 Control valve............................................................................... 274 Work equipment cylinder..................................................................... 310 Piston valve................................................................................ 312 Quick drop valve............................................................................ 314 Self pressure reducing valve................................................................ 319 Work equipment.................................................................................. 327 Cylinder stay............................................................................... 328 Blade....................................................................................... 330 Cutting edge, end bit....................................................................... 332 Ripper...................................................................................... 334 Cab and its attachments......................................................................... 341 Cab mount + ROPS pin........................................................................ 342 ROPS cab.................................................................................... 343 Air conditioner............................................................................. 344 Electrical system............................................................................... 347 Engine control.............................................................................. 348 Engine control system....................................................................... 349 Deceleration potentiometer.................................................................. 350 Monitor system.............................................................................. 352 Sensors..................................................................................... 371 Palm command control system................................................................. 374 KOMTRAX system.............................................................................. 377 20 Standard value table............................................................................. 381 Standard service value table.................................................................... 381 Standard value table for engine............................................................. 382 Standard value table for machine............................................................ 383 30 Testing and adjusting............................................................................ 393 Testing and adjusting, Part 1................................................................... 393 Tools for testing, adjusting, and troubleshooting........................................... 395 Measuring engine speed...................................................................... 399 Measuring intake air pressure (boost pressure).............................................. 401 Measuring exhaust temperature............................................................... 402 Measuring exhaust gas color................................................................. 404 Adjusting valve clearance................................................................... 405 Measuring compression pressure.............................................................. 406 Measuring blow-by pressure.................................................................. 408 Measuring engine oil pressure............................................................... 409 Testing EGR valve and bypass valve drive oil pressure....................................... 410 Handling fuel system parts.................................................................. 411 Releasing residual pressure from fuel system................................................ 411 Measuring fuel pressure..................................................................... 412 Measuring fuel return rate and fuel leakage................................................. 413 Bleeding air from fuel circuit.............................................................. 417 Measuring fuel circuit for leakage.......................................................... 419 Testing and adjusting alternator belt tension............................................... 420 Testing and adjusting air conditioner compressor belt tension............................... 421 Measuring fan speed......................................................................... 422 Measuring fan circuit oil pressure.......................................................... 423 Bleeding air from fan pump.................................................................. 424 Adjusting fuel control dial and decelerator pedal........................................... 425 Testing and adjusting, Part 2................................................................... 429 Measuring power train oil pressure.......................................................... 431 Adjusting transmission output shaft speed sensor............................................ 439 Simple test procedure for brake performance................................................. 440 Adjusting brake pedal....................................................................... 441 Adjusting parking brake lever............................................................... 443 Emergency escape method when power train has trouble........................................ 445 Adjusting idler clearance................................................................... 448 Testing and adjusting track shoe tension.................................................... 449 Measuring and adjusting work equipment and HSS oil pressure................................. 450 Bleeding air from work equipment and HSS pump............................................... 454 Measuring control circuit basic pressure.................................................... 455 Measuring work equipment lock solenoid valve output pressure................................ 456 Emergency operation method when work equipment has trouble.................................. 457 Measuring ripper pin puller solenoid valve output pressure.................................. 459 Testing parts which cause hydraulic drift of blade and ripper............................... 460 Measuring internal leakage of work equipment cylinder....................................... 461 Releasing residual pressure from work equipment cylinder.................................... 462 Bleeding air from work equipment cylinder................................................... 462 Adjusting work equipment lock lever......................................................... 463 Adjusting blade............................................................................. 464 Adjusting operator's cab.................................................................... 466 Testing and adjusting, Part 3................................................................... 471 Special functions of machine monitor (EMMS)................................................. 472 Testing and adjusting, Part 4................................................................... 551 Handling of power supply circuit of engine controller....................................... 552 Preparation work for troubleshooting of electrical system................................... 553 Pm Clinic................................................................................... 555 40 Troubleshooting.................................................................................. 567 Failure code table and fuse locations........................................................... 567 Failure codes table......................................................................... 568 Fuse locations.............................................................................. 575 Information in troubleshooting table........................................................ 579 General information on troubleshooting.......................................................... 583 Points to remember when troubleshooting..................................................... 584 Sequence of events in troubleshooting....................................................... 585 Check before troubleshooting................................................................ 586 Classification and procedures for troubleshooting........................................... 587 Connection table for connector pin numbers.................................................. 590 T-branch box and T-branch adapter table..................................................... 626 Troubleshooting by failure and error codes, Part 1.............................................. 631 Failure code [1500L0]....................................................................... 633 Failure code [15SAL1]....................................................................... 634 Failure code [15SALH]....................................................................... 636 Failure code [15SBL1]....................................................................... 638 Failure code [15SBLH]....................................................................... 640 Failure code [15SEL1]....................................................................... 642 Failure code [15SELH]....................................................................... 644 Failure code [15SFL1]....................................................................... 646 Failure code [15SFLH]....................................................................... 648 Failure code [15SGL1]....................................................................... 650 Failure code [15SGLH]....................................................................... 652 Failure code [15SJL1]....................................................................... 654 Failure code [15SJLH]....................................................................... 656 Failure code [2301L1]....................................................................... 658 Failure code [2301LH]....................................................................... 660 Failure code [2302L1]....................................................................... 662 Failure code [2302LH]....................................................................... 664 Failure code [7RFAKA]....................................................................... 666 Failure code [AA10NX]....................................................................... 668 Failure code [AB00MA]....................................................................... 670 Failure code [B@BAZG]....................................................................... 672 Failure code [B@BCNS]....................................................................... 673 Failure code [B@BCZK]....................................................................... 674 Failure code [B@CENS]....................................................................... 675 Failure code [B@HANS]....................................................................... 676 Troubleshooting by failure and error codes, Part 2.............................................. 679 Failure code [CA111]........................................................................ 681 Failure code [CA115]........................................................................ 683 Failure code [CA122]........................................................................ 685 Failure code [CA123]........................................................................ 688 Failure code [CA131]........................................................................ 689 Failure code [CA132]........................................................................ 691 Failure code [CA135]........................................................................ 692 Failure code [CA141]........................................................................ 695 Failure code [CA144]........................................................................ 696 Failure code [CA145]........................................................................ 698 Failure code [CA153]........................................................................ 699 Failure code [CA154]........................................................................ 701 Failure code [CA187]........................................................................ 701 Failure code [CA221]........................................................................ 702 Failure code [CA222]........................................................................ 705 Failure code [CA227]........................................................................ 706 Failure code [CA234]........................................................................ 709 Failure code [CA238]........................................................................ 710 Failure code [CA263]........................................................................ 712 Failure code [CA265]........................................................................ 714 Failure code [CA271]........................................................................ 715 Failure code [CA272]........................................................................ 717 Failure code [CA273]........................................................................ 719 Failure code [CA274]........................................................................ 721 Failure code [CA322]........................................................................ 723 Failure code [CA323]........................................................................ 725 Failure code [CA324]........................................................................ 727 Failure code [CA325]........................................................................ 729 Failure code [CA331]........................................................................ 731 Failure code [CA332]........................................................................ 733 Failure code [CA342]........................................................................ 735 Failure code [CA351]........................................................................ 736 Failure code [CA352]........................................................................ 739 Failure code [CA386]........................................................................ 740 Failure code [CA441]........................................................................ 742 Failure code [CA442]........................................................................ 742 Failure code [CA449]........................................................................ 743 Failure code [CA451]........................................................................ 744 Failure code [CA452]........................................................................ 747 Failure code [CA553]........................................................................ 748 Failure code [CA554]........................................................................ 750 Failure code [CA559]........................................................................ 751 Failure code [CA689]........................................................................ 756 Troubleshooting by failure and error codes, Part 3.............................................. 759 Failure code [CA731]........................................................................ 761 Failure code [CA757]........................................................................ 762 Failure code [CA778]........................................................................ 763 Failure code [CA1228]....................................................................... 766 Failure code [CA1625]....................................................................... 768 Failure code [CA1626]....................................................................... 769 Failure code [CA1627]....................................................................... 771 Failure code [CA1628]....................................................................... 772 Failure code [CA1629]....................................................................... 775 Failure code [CA1631]....................................................................... 776 Failure code [CA1632]....................................................................... 779 Failure code [CA1633]....................................................................... 780 Failure code [CA1642]....................................................................... 781 Failure code [CA1653]....................................................................... 782 Failure code [CA2185]....................................................................... 785 Failure code [CA2186]....................................................................... 787 Failure code [CA2249]....................................................................... 787 Failure code [CA2271]....................................................................... 788 Failure code [CA2272]....................................................................... 791 Failure code [CA2351]....................................................................... 792 Failure code [CA2352]....................................................................... 794 Failure code [CA2555]....................................................................... 795 Failure code [CA2556]....................................................................... 796 Failure code [D110KA]....................................................................... 798 Failure code [D110KB]....................................................................... 800 Failure code [D130KA]....................................................................... 802 Failure code [D130KB]....................................................................... 805 Failure code [D161KA]....................................................................... 807 Failure code [D161KB]....................................................................... 809 Failure code [D190KA]....................................................................... 811 Failure code [D190KB]....................................................................... 813 Failure code [D5ZKKX]....................................................................... 815 Failure code [DAFRKR]....................................................................... 817 Failure code [DAFRMC]....................................................................... 818 Failure code [DB2RKR]....................................................................... 825 Failure code [DB90KK]....................................................................... 830 Failure code [DB90KR]....................................................................... 833 Troubleshooting by failure and error codes, Part 4.............................................. 835 Failure code [DB90KT]....................................................................... 837 Failure code [DB95KK]....................................................................... 838 Failure code [DB97KK]....................................................................... 840 Failure code [DB99KQ]....................................................................... 842 Failure code [DB9RKR]....................................................................... 844 Failure code [DBE0KK]....................................................................... 847 Failure code [DBE0KT]....................................................................... 849 Failure code [DBE5KK]....................................................................... 850 Failure code [DBE6KK]....................................................................... 853 Failure code [DBE9KQ]....................................................................... 855 Failure code [DD12KA]....................................................................... 857 Failure code [DD12KB]....................................................................... 859 Failure code [DD13KA]....................................................................... 861 Failure code [DD13KB]....................................................................... 863 Failure code [DD14KA]....................................................................... 865 Failure code [DD14KB]....................................................................... 867 Failure code [DDDDKA]....................................................................... 869 Failure code [DDDDKB]....................................................................... 871 Failure code [DDDDKX]....................................................................... 873 Failure code [DDN7KA]....................................................................... 874 Failure code [DDN7KB]....................................................................... 876 Failure code [DDN9KA]....................................................................... 878 Failure code [DDN9KB]....................................................................... 880 Failure code [DDNLKA]....................................................................... 882 Failure code [DDNLKB]....................................................................... 884 Failure code [DDTSL1]....................................................................... 886 Failure code [DDTSLH]....................................................................... 888 Troubleshooting by failure and error codes, Part 5.............................................. 891 Failure code [DFA4KX]....................................................................... 893 Failure code [DFA4KZ]....................................................................... 893 Failure code [DFA4L8]....................................................................... 894 Failure code [DFA5KA]....................................................................... 895 Failure code [DFA5KB]....................................................................... 897 Failure code [DFA6KA]....................................................................... 899 Failure code [DFA6KB]....................................................................... 901 Failure code [DFA7KX]....................................................................... 903 Failure code [DFA7KZ]....................................................................... 903 Failure code [DFA7L8]....................................................................... 904 Failure code [DFA8KA]....................................................................... 905 Failure code [DFA8KB]....................................................................... 907 Failure code [DFA9KA]....................................................................... 909 Failure code [DFA9KB]....................................................................... 911 Failure code [DFAAKX]....................................................................... 913 Failure code [DFAAKZ]....................................................................... 913 Failure code [DFAAL8]....................................................................... 914 Failure code [DFABKA]....................................................................... 915 Failure code [DFABKB]....................................................................... 917 Failure code [DFACKA]....................................................................... 919 Failure code [DFACKB]....................................................................... 921 Failure code [DFADKX]....................................................................... 923 Failure code [DFADKZ]....................................................................... 923 Failure code [DFADL8]....................................................................... 924 Failure code [DFAEKA]....................................................................... 925 Failure code [DFAEKB]....................................................................... 927 Failure code [DFAFKA]....................................................................... 929 Failure code [DFAFKB]....................................................................... 931 Failure code [DGT1KA]....................................................................... 933 Failure code [DGT1KX]....................................................................... 935 Failure code [DH21KA]....................................................................... 937 Failure code [DH21KB]....................................................................... 940 Failure code [DHT5KA]....................................................................... 942 Failure code [DHT5KB]....................................................................... 944 Failure code [DHT7KA]....................................................................... 946 Failure code [DHT7KB]....................................................................... 948 Failure code [DK10KX]....................................................................... 950 Troubleshooting by failure and error codes, Part 6.............................................. 953 Failure code [DK30KA]....................................................................... 955 Failure code [DK30KB]....................................................................... 958 Failure code [DK30KX]....................................................................... 960 Failure code [DK30KZ]....................................................................... 960 Failure code [DK30L8]....................................................................... 961 Failure code [DK31KA]....................................................................... 962 Failure code [DK31KB]....................................................................... 965 Failure code [DK40KA]....................................................................... 967 Failure code [DK40KB]....................................................................... 969 Failure code [DK55KX]....................................................................... 971 Failure code [DK55KZ]....................................................................... 971 Failure code [DK55L8]....................................................................... 972 Failure code [DK56KA]....................................................................... 973 Failure code [DK56KB]....................................................................... 976 Failure code [DK57KA]....................................................................... 978 Failure code [DK57KB]....................................................................... 981 Failure code [DKH1KA]....................................................................... 983 Failure code [DKH1KB]....................................................................... 985 Failure code [DLT3KA]....................................................................... 987 Failure code [DLT3KB]....................................................................... 989 Failure code [DW7BKA]....................................................................... 991 Failure code [DW7BKB]....................................................................... 993 Failure code [DWN1KA]....................................................................... 995 Failure code [DWN1KB]....................................................................... 997 Failure code [DWN1KY]....................................................................... 999 Failure code [DWN2KA].......................................................................1001 Failure code [DWN2KB].......................................................................1003 Failure code [DWN2KY].......................................................................1005 Failure code [DWN3KA].......................................................................1007 Failure code [DWN3KB].......................................................................1009 Failure code [DWN3KY].......................................................................1011 Failure code [DWN5KA].......................................................................1013 Failure code [DWN5KB].......................................................................1015 Failure code [DWN5KY].......................................................................1017 Failure code [DXA0KA].......................................................................1019 Failure code [DXA0KB].......................................................................1021 Failure code [DXA0KY].......................................................................1023 Failure code [DXH1KA].......................................................................1025 Failure code [DXH1KB].......................................................................1027 Failure code [DXH1KY].......................................................................1029 Failure code [DXH4KA].......................................................................1031 Troubleshooting by failure and error codes, Part 7..............................................1035 Failure code [DXH4KB].......................................................................1038 Failure code [DXH4KY].......................................................................1040 Failure code [DXH5KA].......................................................................1042 Failure code [DXH5KB].......................................................................1044 Failure code [DXH5KY].......................................................................1046 Failure code [DXH6KA].......................................................................1048 Failure code [DXH6KB].......................................................................1050 Failure code [DXH6KY].......................................................................1052 Failure code [DXH7KA].......................................................................1054 Failure code [DXH7KB].......................................................................1056 Failure code [DXH7KY].......................................................................1058 Failure code [DXH8KA].......................................................................1060 Failure code [DXH8KB].......................................................................1062 Failure code [DXH8KY].......................................................................1064 Failure code [DXHBKA].......................................................................1066 Failure code [DXHBKB].......................................................................1068 Failure code [DXHBKY].......................................................................1070 Failure code [DXHCKA].......................................................................1072 Failure code [DXHCKB].......................................................................1074 Failure code [DXHCKY].......................................................................1076 Failure code [DXHRKA].......................................................................1078 Failure code [DXHRKB].......................................................................1080 Failure code [DXHRKY].......................................................................1082 Failure code [DXHSKA].......................................................................1084 Failure code [DXHSKB].......................................................................1086 Failure code [DXHSKY].......................................................................1088 Failure code [DXHTKA].......................................................................1090 Failure code [DXHTKB].......................................................................1092 Failure code [DXHTKY].......................................................................1094 Failure code [DXHUKA].......................................................................1096 Failure code [DXHUKB].......................................................................1098 Failure code [DXHUKY].......................................................................1100 Failure code [DXHWKA].......................................................................1102 Failure code [DXHWKB].......................................................................1104 Failure code [DXHWKY].......................................................................1106 Failure code [DXHXKA].......................................................................1108 Failure code [DXHXKB].......................................................................1110 Failure code [DXHXKY].......................................................................1112 Failure code [DXHYKA].......................................................................1114 Failure code [DXHYKB].......................................................................1116 Failure code [DXHYKY].......................................................................1118 Failure code [DXHZKA].......................................................................1120 Failure code [DXHZKB].......................................................................1122 Failure code [DXHZKY].......................................................................1124 Failure code [DXJ4KA].......................................................................1126 Failure code [DXJ4KB].......................................................................1128 Troubleshooting by failure and error codes, Part 8..............................................1131 Failure code [DXJ8KA].......................................................................1132 Failure code [DXJ8KB].......................................................................1134 Failure code [DXJ8KY].......................................................................1136 Failure code [DXJ9KA].......................................................................1138 Failure code [DXJ9KB].......................................................................1140 Failure code [DXJ9KY].......................................................................1142 Failure code [DXJAKA].......................................................................1144 Failure code [DXJAKB].......................................................................1146 Failure code [DXJAKY].......................................................................1148 Failure code [DXJBKA].......................................................................1150 Failure code [DXJBKB].......................................................................1152 Failure code [DXJBKY].......................................................................1154 Troubleshooting of electrical system (E-mode)...................................................1157 Information in troubleshooting table........................................................1159 E-1 When starting switch turned ON, machine monitor displays nothing........................1160 E-2 When starting switch turned ON (before starting engine), basic check item lights up.....1163 E-3 Engine does not start (Engine does not turn)............................................1165 E-4 Preheater does not operate..............................................................1168 E-5 Precaution item lights up while engine is running.......................................1172 E-6 Emergency stop item lights up while engine is running...................................1174 E-7 Engine coolant temperature gauge does not indicate normally.............................1178 E-8 Fuel level gauge does not indicate normally.............................................1180 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally..............1183 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally...................1185 E-11 Contents of display by machine monitor are different from applicable machine...........1188 E-12 Machine monitor does not display some items............................................1188 E-13 Function switch does not work..........................................................1189 E-14 Operation mode does not change.........................................................1190 E-15 Gearshift mode does not change.........................................................1191 E-16 Customize function does not operate normally...........................................1192 E-17 Customize memory function does not normally............................................1193 E-18 Float mode does not change.............................................................1194 E-19 Alarm buzzer cannot be stopped.........................................................1195 E-20 Air conditioner does not operate normally (including air conditioner fault history)....1196 E-21 When starting switch is turned OFF, service meter is not displayed.....................1217 E-22 Machine monitor cannot be set in service mode..........................................1217 E-23 Ripper pin puller cylinder does not operate............................................1218 E-24 Backup alarm does not sound or does not stop...........................................1220 E-25 Headlamp, rear lamp, and ripper point lamp do not light up.............................1222 E-26 Windshield wiper and window washer do not operate......................................1228 E-27 KOMTRAX system does not operate normally...............................................1256 Troubleshooting of hydraulic and mechanical system (H-mode).....................................1259 Information in troubleshooting table........................................................1261 H-1 Power is low (Drawbar pull is low)......................................................1262 H-2 Machine does not travel (at 2nd or 3rd gear speed)......................................1264 H-3 Machine does not start at any gear speed................................................1266 H-4 Machine can travel only forward or in reverse...........................................1268 H-5 When gear speed or travel direction is changed, time lag is large.......................1270 H-6 Machine cannot be steered (Machine does not turn right or left).........................1272 H-7 Steering speed or steering force is low.................................................1273 H-8 Brake does not work.....................................................................1274 H-9 Power train oil is overheated...........................................................1275 H-10 Abnormal sound comes out from around HSS pump or HSS motor.............................1277 H-11 Speed of all work equipment is low.....................................................1279 H-12 No work equipment moves................................................................1281 H-13 Blade lift speed or power is low.......................................................1283 H-14 Blade tilt speed or power is low.......................................................1285 H-15 Ripper lift speed or power is low......................................................1286 H-16 Ripper tilt speed or power is low......................................................1288 H-17 Hydraulic drift of blade lift is large.................................................1290 H-18 Hydraulic drift of blade tilt is large.................................................1291 H-19 Hydraulic drift of ripper lift is large................................................1292 H-20 Ripper pin puller cylinder does not operate............................................1293 H-21 Blade does not pitch...................................................................1294 H-22 Abnormal sound comes out from around work equipment pump...............................1295 H-23 Fan speed is abnormal (Abnormally large sound or vibration of fan).....................1296 Troubleshooting of engine (S-mode)..............................................................1299 Method of using troubleshooting chart.......................................................1301 S-1 Starting performance of engine is poor..................................................1304 S-2 Engine does not start...................................................................1306 S-3 Engine does not pick up smoothly........................................................1310 S-4 Engine stops during operation...........................................................1311 S-5 Engine does not rotate smoothly.........................................................1312 S-6 Engine lack output (or lacks power).....................................................1313 S-7 Exhaust gas is black (incomplete combustion)............................................1314 S-8 Oil consumption is excessive (or exhaust gas is blue)...................................1316 S-9 Oil becomes dirty quickly...............................................................1317 S-10 Fuel consumption is excessive..........................................................1318 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)..................1319 S-12 Oil pressure drops.....................................................................1320 S-13 Oil level rises (Entry of coolant or fuel).............................................1322 S-14 Coolant temperature becomes too high (Overheating).....................................1324 S-15 Abnormal noise is made.................................................................1325 S-16 Vibration is excessive.................................................................1326 50 Disassembly and assembly.........................................................................1329 General information on disassembly and assembly.................................................1329 How to read this manual.....................................................................1330 Coating materials list......................................................................1332 Special tool list...........................................................................1335 Sketches of special tools...................................................................1344 Engine and cooling system.......................................................................1359 Removal and installation of fuel supply pump assembly.......................................1360 Removal and installation of fuel injector assembly..........................................1367 Removal and installation of cylinder head assembly..........................................1375 Removal and installation of radiator assembly...............................................1396 Removal and installation of aftercooler assembly............................................1402 Removal and installation of engine assembly.................................................1409 Removal and installation of engine hood assembly............................................1418 Removal and installation of engine front seal...............................................1422 Removal and installation of engine rear seal................................................1426 Removal and installation of fuel tank assembly..............................................1432 Removal and installation of cooling fan drive assembly......................................1437 Removal and installation of fan motor assembly..............................................1441 Power train, Part 1.............................................................................1445 Removal and installation of damper assembly.................................................1446 Disassembly and assembly of damper assembly.................................................1451 Removal and installation of power train unit assembly.......................................1457 Disconnection and connection of power train unit assembly...................................1470 Power train, Part 2.............................................................................1477 Disassembly and assembly of PTO assembly....................................................1478 Disassembly and assembly of torque converter assembly.......................................1487 Disassembly and assembly of transmission assembly...........................................1498 Disassembly and assembly of HSS case assembly...............................................1517 Removal and installation of HSS motor assembly..............................................1537 Power train, Part 3.............................................................................1541 Removal and installation of final drive assembly............................................1542 Disassembly and assembly of final drive assembly............................................1549 Undercarriage and frame.........................................................................1567 Removal and installation of track frame assembly............................................1569 Removal and installation of idler assembly..................................................1576 Disassembly and assembly of idler assembly..................................................1581 Removal and installation of recoil spring assembly..........................................1586 Disassembly and assembly of recoil spring assembly..........................................1589 Removal and installation of track roller assembly...........................................1594 Disassembly and assembly of track roller assembly...........................................1598 Removal and installation of 1st bogie assembly..............................................1601 Removal and installation of 2nd, 3rd, and 4th bogie assemblies..............................1611 Disassembly and assembly of bogie assembly..................................................1620 Removal and installation of carrier roller assembly.........................................1623 Disassembly and assembly of carrier roller assembly.........................................1626 Removal and installation of pivot shaft assembly............................................1631 Separation and connection of track shoe assembly............................................1634 General disassembly and assembly of track shoe..............................................1639 Disassembly and assembly of 1 link in field.................................................1652 Disassembly and assembly of master link.....................................................1657 Removal and installation of equalizer bar assembly..........................................1661 Disassembly and assembly of equalizer bar assembly..........................................1666 Removal and installation of segment teeth...................................................1668 Hydraulic system................................................................................1673 Removal and installation of hydraulic tank assembly.........................................1674 Removal and installation of hydraulic pump assembly.........................................1680 Disassembly and assembly of hydraulic cylinder assembly.....................................1691 Work equipment..................................................................................1703 Removal and installation of blade assembly..................................................1704 Disassembly and assembly of multi-shank ripper..............................................1708 Cab and its attachments.........................................................................1713 Removal and installation of operator's cab assembly.........................................1714 Removal and installation of operator's cab glass (adhered window glass).....................1719 Removal and installation of operator's cab and floor frame assembly.........................1729 Removal and installation of air conditioner unit assembly...................................1738 Electrical system...............................................................................1747 Removal and installation of engine controller assembly......................................1748 Removal and installation of power train controller..........................................1751 Removal and installation of work equipment controller assembly..............................1754 80 Air conditioner..................................................................................1757 Structure, function, testing, adjusting, and troubleshooting....................................1757 Structure and function......................................................................1759 Air conditioner component...............................................................1759 Configuration and function of refrigerating cycle.......................................1760 Outline of refrigerating cycle..........................................................1761 Air conditioner unit....................................................................1763 Functions of major components in the air conditioner unit...............................1765 Control plate...........................................................................1767 Compressor..............................................................................1769 Condenser...............................................................................1770 Receiver drier..........................................................................1771 Testing, adjusting and troubleshooting......................................................1773 Caution about refrigerant...............................................................1773 Troubleshooting procedure...............................................................1774 Basic flow of troubleshooting.......................................................1774 Block diagram...........................................................................1775 Circuit diagram and arrangement of connector pins.......................................1776 Detail of air conditioner unit..........................................................1778 Part and connector locations............................................................1780 Testing air leakage (duct)..............................................................1787 Testing with self-diagnosis function....................................................1789 Testing temperature control.............................................................1792 Testing vent (mode) changeover..........................................................1795 Testing Recirc/Fresh changeover.........................................................1798 Testing inner sensor....................................................................1800 Testing evaporator temperature sensor...................................................1801 Testing sunlight sensor.................................................................1804 Testing (dual) pressure switch for refrigerant..........................................1805 Testing relays and diodes...............................................................1807 Troubleshooting chart 1.................................................................1809 Troubleshooting chart 2.................................................................1810 Troubleshooting for electrical system (E mode)..........................................1813 E-1 Power supply system (Air conditioner does not operate)..........................1814 E-2 Compressor system (Air is not cooled)...........................................1818 E-3 Blower motor system (No air comes out or air flow is abnormal)..................1822 E-4 Temperature cannot be controlled................................................1828 E-5 Vent (mode) cannot be changed over..............................................1831 E-6 Recirc/Fresh air cannot be changed over.........................................1834 Troubleshooting with gauge pressure.....................................................1837 Connection of service tool..............................................................1839 Precautions for connecting air conditioner piping.......................................1840 Handling of compressor oil..............................................................1841 1. Control of compressor oil........................................................1841 2. Adding of compressor oil.........................................................1841 3. Compressor replacement...........................................................1842 4. Applying compressor oil for O-ring...............................................1842 90 Diagrams and drawings............................................................................1845 Hydraulic diagrams and drawings.................................................................1845 Power train hydraulic circuit diagram.......................................................1845 Hydraulic circuit diagram (1/2) Serial No.: 80001 to 80806..................................1849 Hydraulic circuit diagram (2/2) Serial No.: 80001 to 80806..................................1851 Hydraulic circuit diagram (1/2) Serial No.: 80807 and up....................................1853 Hydraulic circuit diagram (2/2) Serial No.: 80807 and up....................................1855 Electrical diagrams and drawings................................................................1859 Electrical circuit diagram (1/12)...........................................................1861 Electrical circuit diagram (2/12)...........................................................1863 Electrical circuit diagram (3/12)...........................................................1865 Electrical circuit diagram (4/12)...........................................................1867 Electrical circuit diagram (5/12)...........................................................1869 Electrical circuit diagram (6/12)...........................................................1871 Electrical circuit diagram (7/12)...........................................................1873 Electrical circuit diagram (8/12)...........................................................1875 Electrical circuit diagram (9/12)...........................................................1877 Electrical circuit diagram (10/12)..........................................................1879 Electrical circuit diagram (11/12)..........................................................1881 Electrical circuit diagram (12/12)..........................................................1883 Electrical circuit diagram for inside cab...................................................1885 Connector/electrical wiring connection table................................................1887 Connectors table and arrangement drawing....................................................1951 Wiring harness diagram (1/19)...............................................................1953 Wiring harness diagram (2/19)...............................................................1955 Wiring harness diagram (3/19)...............................................................1957 Wiring harness diagram (4/19)...............................................................1959 Wiring harness diagram (5/19)...............................................................1961 Wiring harness diagram (6/19)...............................................................1963 Wiring harness diagram (7/19)...............................................................1965 Wiring harness diagram (8/19)...............................................................1967 Wiring harness diagram (9/19)...............................................................1969 Wiring harness diagram (10/19)..............................................................1971 Wiring harness diagram (11/19)..............................................................1973 Wiring harness diagram (12/19)..............................................................1975 Wiring harness diagram (13/19)..............................................................1977 Wiring harness diagram (14/19)..............................................................1979 Wiring harness diagram (15/19)..............................................................1981 Wiring harness diagram (16/19)..............................................................1983 Wiring harness diagram (17/19)..............................................................1985 Wiring harness diagram (18/19)..............................................................1987 Wiring harness diagram (19/19)..............................................................1989
DESCRIPTION:
KOMATSU D155AX-6 BULLDOZER SHOP MANUAL SN:80001 and up – PDF DOWNLOAD
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
80. Appendix
The section explains the equipment which can not be included in the other sections. This section
explains the structure, function, testing, adjusting, and troubleshooting of the equipment.
S.S 12/12/24
