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Description
KOMATSU D455A-1 SHOP MANUAL SEBM0198A05 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D455A-1 SHOP MANUAL SEBM0198A05 – PDF DOWNLOAD
Language : English
Pages : 1202
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D455A-1 SHOP MANUAL SEBM0198A05 – PDF DOWNLOAD
COVER................................................................................................................................... 1 CONTENTS................................................................................................................................ 9 01 GENERAL.............................................................................................................................. 18 GENERAL............................................................................................................................. 19 GENERAL LOCATIONS............................................................................................................... 20 SPECIFICATIONS.................................................................................................................. 23 GENERAL ASSEMBLY DRAWING........................................................................................................ 27 ENGINE SPECIFICATIONS........................................................................................................... 29 WEIGHT TABLE.................................................................................................................... 30 SERIAL NUMBER POSITIONS......................................................................................................... 33 LIST OF OIL AND WATER CAPACITY.................................................................................................. 35 ENGINE.................................................................................................................................. 36 11 STRUCTURE AND FUNCTION (CHASSIS RELATED)......................................................................................... 36 STRUCTURE AND FUNCTION.......................................................................................................... 37 ENGINE MOUNTING............................................................................................................. 38 RADIATOR.................................................................................................................... 39 P.T.O.(POWER TAKE-OFF)...................................................................................................... 43 OIL COOLER.................................................................................................................. 49 OIL COOLER FAN DRIVE HYDRAULIC PIPING DIAGRAM............................................................................... 57 OIL COOLER FAN DRIVE PUMP (MACHINE SERIAL NO.1301 AND UP)................................................................... 59 OIL COOLER FAN DRIVE MOTOR (MACHINE SERIAL NO.1301 AND UP).................................................................. 60 OIL COOLER FAN DRIVE OIL FILTER (MACHINE SERIAL NO.1301 AND UP)............................................................. 61 OIL COOLER FAN DRIVE HYDRAULIC SYSTEM DIAGRAM............................................................................... 62 OIL COOLER FAN DRIVE HYDRAULIC CIRCUIT DIAGRAM.............................................................................. 62 FUEL PIPING DIAGRAM......................................................................................................... 64 ENGINE CONTROL.............................................................................................................. 66 ETHER STARTING CONTROL...................................................................................................... 68 12 TESTING AND ADJUSTING (CHASSIS RELATED0.......................................................................................... 69 TESTING AND ADJUSTING........................................................................................................... 70 TESTING AND ADJUSTING ENGINE................................................................................................ 71 13 DISASSEMBLY AND ASSEMBLY......................................................................................................... 91 TORQUE SPECIFICATIONS FOR NUTS AND BOLTS........................................................................................ 92 DISASSEMBLY AND ASSEMBLY........................................................................................................ 93 REPLACEMENT OF FAN BELT..................................................................................................... 94 DISMOUNTING STARTING MOTOR.................................................................................................. 96 MOUNTING STARTING MOTOR..................................................................................................... 98 DISMOUNTING ALTERNATOR...................................................................................................... 100 MOUNTING ALTERNATOR......................................................................................................... 102 DISMOUNTING OIL FILTER...................................................................................................... 104 MOUNTING OIL FILTER......................................................................................................... 105 DISMOUNTING OIL COOLER・BRACKET.............................................................................................. 106 MOUNTING OIL COOLER・BRACKET................................................................................................. 109 DISMOUNTING AFTER-COOLER.................................................................................................... 112 MOUNTING AFTER-COOLER....................................................................................................... 115 DISMOUNTING WATER PUMP...................................................................................................... 118 MOUNTING WATER PUMP......................................................................................................... 121 DISMOUNTING TURBOCHARGER.................................................................................................... 124 MOUNTING TURBOCHARGER....................................................................................................... 126 DISMOUNTING CYLINDER HEAD................................................................................................... 128 MOUNTING CYLINDER HEAD...................................................................................................... 137 DISMOUNTING P.T.PUMP........................................................................................................ 149 MOUNTING P.T.PUMP........................................................................................................... 152 DISMOUNTING RADIATOR........................................................................................................ 155 MOUNTING RADIATOR........................................................................................................... 159 DISMOUNTING RADIATOR GUARD.................................................................................................. 163 MOUNTING RADIATOR GUARD..................................................................................................... 168 DISMOUNTING ENGINE (MACHINE SERIAL NO.1013～1500)............................................................................ 173 MOUNTING ENGINE (MACHINE SERIAL NO.1013～1500)............................................................................... 186 DISMOUNTING ENGINE (MACHINE SERIAL NO.1501 AND UP).......................................................................... 200 MOUNTING ENGINE (MACHINE SERIAL NO.1501 AND UP)............................................................................. 211 DISMOUNTING P.T.O.FROM ENGINE (MACHINE SERIAL NO.1013～1500)................................................................. 223 MOUNTING P.T.O. ON ENGINE (MACHINE SERIAL NO.1013～1500)..................................................................... 228 DISMOUNTING P.T.O. FROM ENGINE (MACHINE SERIAL NO.1501 AND UP).............................................................. 233 MOUNTING P.T.O. ON ENGINE (MACHINE SERIAL NO.1501 AND UP)................................................................... 236 DISASSEMBLY OF P.T.O. (MACHINE SERIAL NO.1013～1500)......................................................................... 239 ASSEMBLY OF P.T.O. (MACHINE SERIAL NO.1013～1500)............................................................................ 245 DISASSEMBLY OF P.T.O. (MACHINE SERIAL NO.1501 AND UP)....................................................................... 253 ASSEMBLY OF P.T.O. (MACHINE SERIAL NO.1501 AND UP).......................................................................... 259 DISMOUNTING FUEL TANK....................................................................................................... 265 MOUNTING FUEL TANK.......................................................................................................... 268 POWER TRAIN............................................................................................................................. 271 21 STRUCTURE AND FUNCTION........................................................................................................... 271 STRUCTURE AND FUNCTION.......................................................................................................... 272 GENERAL .................................................................................................................... 273 POWER TRAIN DIAGRAM......................................................................................................... 275 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM....................................................................................... 279 TORQUE CONVERTER............................................................................................................ 282 TORQFLOW TRANSMISSION....................................................................................................... 292 TRANSFER.................................................................................................................... 302 TORQFLOW HYDRAULIC PIPING DIAGRAM........................................................................................... 304 TRANSMISSION CONTROL VALVE.................................................................................................. 307 TRANSMISSION PUMP........................................................................................................... 321 TRANSMISSION,STEERING OIL STRAINER.......................................................................................... 322 TRANSMISSION OIL FILTER..................................................................................................... 323 TRANSMISSION LUBRICATION VALVE.............................................................................................. 325 TORQUE CONVERTER DIVIDER VALVE.............................................................................................. 326 TORQFLOW HYDRAULIC SYSTEM DIAGRAM........................................................................................... 327 TORQFLOW HYDRAULIC CIRCUIT DIAGRAM.......................................................................................... 328 TRANSMISSION CONTROL ....................................................................................................... 329 COUNTERROTATION CONTROL..................................................................................................... 331 STEERING CONTROL............................................................................................................ 333 STEERING BRAKE.............................................................................................................. 335 BRAKE CHECK VALVE........................................................................................................... 341 BRAKE CONTROL VALVE......................................................................................................... 343 BRAKE BOOSTER............................................................................................................... 344 BRAKE AND CENTER CLUTCH INTERCONNECTING VALVE............................................................................... 353 BRAKE,TRANSFER LUBRICATION VALVE............................................................................................ 357 STEERING BRAKE HYDRAULIC SYSTEM DIAGRAM (MACHINE SERIAL NO.1013～1500)....................................................... 359 STEERING BRAKE HYDRAULIC CIRCUIT DIAGRAM (MACHINE SERIAL NO.1013～1500)...................................................... 360 STEERING BRAKE HYDRAULIC SYSTEM DIAGRAM (MACHINE SERIAL NO.1501 AND UP)..................................................... 361 STEERING BRAKE HYDRAULIC CIRCUIT DIAGRAM (MACHINE SERIAL NO.1501 AND UP).................................................... 362 BRAKE CONTROL ............................................................................................................. 363 BEVEL GEAR SHAFT,CENTER CLUTCH.............................................................................................. 365 STEERING HYDRAULIC PIPING DIAGRAM........................................................................................... 368 CENTER CLUTCH CONTROL VALVE................................................................................................. 371 STEERING PUMP............................................................................................................... 377 STEERING OIL FILTER......................................................................................................... 378 TORQUE CONVERTER LUBRICATION CIRCUIT DIVIDER VALVE.......................................................................... 379 CENTER CLUTCH HYDRAULIC SYSTEM DIAGRAM (MACHINE SERIAL NO.1013～1069)........................................................ 380 CENTER CLUTCH HYDRAULIC CIRCUIT DIAGRAM (MACHINE SERIAL NO.1013～1069)....................................................... 381 CENTER CLUTCH HYDRAULIC SYSTEM DIAGRAM (MACHINE SERIAL NO.1070～1500)........................................................ 382 CENTER CLUTCH HYDRAULIC CIRCUIT DIAGRAM (MACHINE SERIAL NO.1070～1500)....................................................... 383 CENTER CLUTCH HYDRAULIC SYSTEM DIAGRAM (MACHINE SERIAL NO.1501 AND UP)...................................................... 384 CENTER CLUTCH HYDRAULIC CIRCUIT DIAGRAM (MACHINE SERIAL NO.1501 AND UP)..................................................... 385 FINAL DRIVE................................................................................................................. 386 22 TESTING AND ADJUSTING............................................................................................................ 390 TESTING AND ADJUSTING........................................................................................................... 391 GENERAL..................................................................................................................... 392 OIL PRESSURE AND OIL TEMPERATURE MEASURING PROCEDURE........................................................................ 394 MEASUREMENT OF TRAVEL....................................................................................................... 399 MEASUREMENT OF OPERATING FORCE.............................................................................................. 413 STANDARD VALUE TABLE........................................................................................................ 415 PROCEDURE FOR RELEASING EMERGENCY BRAKE..................................................................................... 417 23 DISASSEMBLY AND ASSEMBLY......................................................................................................... 418 TORQUE SPECIFICATIONS FOR NUTS AND BOLTS........................................................................................ 419 DISASSEMBLY AND ASSEMBLY........................................................................................................ 420 DISMOUNTING TORQUE CONVERTER RELIEF VALVE................................................................................... 423 MOUNTING TORQUE CONVERTER RELIEF VALVE...................................................................................... 425 DISMOUNTING TORQUE CONVERTER REGULATOR VALVE................................................................................ 427 MOUNTING TORQUE CONVERTER REGULATOR VALVE................................................................................... 429 DISMOUNTING L.H. TORQUE CONVERTER (MACHINE SERIAL NO.1013～1500)............................................................. 431 MOUNTING L.H. TORQUE CONVERTER (MACHINE SERIAL NO.1013～1500)................................................................ 435 DISMOUNTING R.H.TORQUE CONVERTER (MACHINE SERIAL NO.1013～1500).............................................................. 439 MOUNTING R.H. TORQUE CONVERTER (MACHINE SERIAL NO.1013～1500)................................................................ 444 DISMOUNTING TORQUE CONVERTER (MACHINE SERIAL NO.1501 AND UP)................................................................ 448 MOUNTING TORQUE CONVERTER (MACHINE SERIAL NO.1501 AND UP)................................................................... 453 DISASSEMBLY OF TORQUE CONVERTER............................................................................................. 458 ASSEMBLY OF TORQUE CONVERTER................................................................................................ 468 DISMOUNTING TRANSMISSION CONTROL VALVE (MACHINE SERIAL NO.1013～1500)........................................................ 478 MOUNTING TRANSMISSION CONTROL VALVE (MACHINE SERIAL NO.1013～1500)........................................................... 481 DISMOUNTING TRANSMISSION CONTROL VALVE (1/2) (MACHINE SERIAL NO.1501 AND UP)................................................ 484 MOUNTING TRANSMISSION CONTROL VALVE (1/2) (MACHINE SERIAL NO.1501 AND UP)................................................... 484 DISMOUNTING COUNTER ROTATION VALVE.......................................................................................... 486 MOUNTING COUNTER ROTATION VALVE............................................................................................. 489 DISMOUNTING L.H. BRAKE BOOSTER (MACHINE SERIAL NO.1013～1300)................................................................ 492 MOUNTING L.H. BRAKE BOOSTER (MACHINE SERIAL NO.1013～1300)................................................................... 496 DISMOUNTING L.H. BRAKE BOOSTER (MACHINE SERIAL NO.1013～1500)................................................................ 502 MOUNTING L.H. BRAKE BOOSTER (MACHINE SERIAL NO.1013～1500)................................................................... 505 DISMOUNTING R.H.BRAKE BOOSTER (MACHINE SERIAL NO.1013～1300)................................................................. 509 MOUNTING R.H. BRAKE BOOSTER (MACHINE SERIAL NO.1013～1300)................................................................... 513 DISMOUNTING R.H.BRAKE BOOSTER (MACHINE SERIAL NO.1013～1500)................................................................. 519 MOUNTING R.H. BRAKE BOOSTER (MACHINE SERIAL NO.1013～1500)................................................................... 523 DISMOUNTING BRAKE BOOSTER (MACHINE SERIAL NO.1501 AND UP)................................................................... 528 MOUNTING BRAKE BOOSTER (MACHINE SERIAL NO. 1501 AND UP)..................................................................... 528 DISASSEMBLY OF BRAKE BOOSTER................................................................................................ 529 ASSEMBLY OF BRAKE BOOSTER................................................................................................... 532 DISASSEMBLY OF BRAKE VALVE.................................................................................................. 535 ASSEMBLY OF BRAKE CONTROL VALVE............................................................................................. 537 DISMOUNTING INSTRUMENT PANEL BOX COVER...................................................................................... 539 MOUNTING INSTRUMENT PANEL BOX COVER......................................................................................... 542 DISMOUNTING DASHBOARD....................................................................................................... 545 MOUNTING DASHBOARD.......................................................................................................... 548 DISMOUNTING FLOOR FRAME (MACHINE SERIAL NO.1013～1300)....................................................................... 551 MOUNTING FLOOR FRAME (MACHINE SERIAL NO.1013～1300).......................................................................... 556 DISMOUNTING FLOOR FRAME (MACHINE SERIAL NO.1301 AND UP)..................................................................... 562 MOUNTING FLOOR FRAME (MACHINE SERIAL NO.1301 AND UP)........................................................................ 567 DISMOUNTING TRANSMISSION.................................................................................................... 572 MOUNTING TRANSMISSION....................................................................................................... 581 DISMOUNTING TRANSFER AND BRAKE FROM TRANSMISSION............................................................................ 592 MOUNTING TRANSFER AND BRAKE FROM TRANSMISSION............................................................................... 594 DISASSEMBLY OF TRANSMISSION................................................................................................. 596 ASSEMBLY OF TRANSMISSION.................................................................................................... 613 DISASSEMBLY OF TRANSFER FROM BRAKE (MACHINE SERIAL NO.1013～1300)............................................................ 631 ASSEMBLY OF TRANSFER TO BRAKE (MACHINE SERIAL NO.1013～1300)................................................................. 633 DISASSEMBLY OF TRANSFER FROM BRAKE (MACHINE SERIAL NO.1301 AND UP).......................................................... 635 ASSEMBLY OF TRANSFER TO BRAKE (MACHINE SERIAL NO.1301 AND UP)............................................................... 637 DISASSEMBLY OF TRANSFER (MACHINE SERIAL NO.1013～1300)....................................................................... 639 ASSEMBLY OF TRANSFER (MACHINE SERIAL NO.1013～1300).......................................................................... 641 DISASSEMBLY OF TRANSFER (MACHINE SERIAL NO.1301 AND UP)..................................................................... 642 ASSEMBLY OF TRANSFER (MACHINE SERIAL NO.1301 AND UP)........................................................................ 644 DISASSEMBLY OF BRAKE (MACHINE SERIAL NO.1013～1300).......................................................................... 646 ASSEMBLY OF BRAKE (MACHINE SERIAL NO.1013～1300)............................................................................. 650 DISASSEMBLY OF BRAKE (MACHINE SERIAL NO.1301 AND UP)........................................................................ 654 ASSEMBLY OF BRAKE (MACHINE SERIAL NO.1301 AND UP)........................................................................... 659 DISMOUNTING TRANSMISSION PUMP (MACHINE SERIAL NO.1013～1500)................................................................. 663 MOUNTING TRANSMISSION PUMP (MACHINE SERIAL NO.1013～1500).................................................................... 665 DISMOUNTING TRANSMISSION PUMP (MACHINE SERIAL NO.1501 AND UP)............................................................... 667 MOUNTING TRANSMISSION PUMP (MACHINE SERIAL NO.1501 AND UP).................................................................. 673 DISMOUNTING BEVEL PINION.................................................................................................... 679 MOUNTING BEVEL PINION....................................................................................................... 680 DISASSEMBLY OF BEVEL PINION................................................................................................. 681 ASSEMBLY OF BEVEL PINION.................................................................................................... 682 DISMOUNTING STEERING CONTROL VALVE (MACHINE SERIAL NO.1013～1500)............................................................ 683 MOUNTING STEERING CONTROL VALVE (MACHINE SERIAL NO. 1013～1500).............................................................. 684 DISMOUNTING STEERING VALVE AND BRAKE VALVE (MACHINE SERIAL NO. 1501 AND UP)................................................. 685 MOUNTING STEERING VALVE AND BRAKE VALVE (MACHINE SERIAL NO. 1501 AND UP).................................................... 685 DISASSEMBLY OF STEERING CONTROL VALVE....................................................................................... 687 ASSEMBLY OF STEERING CONTROL VALVE.......................................................................................... 690 DISMOUNTING CENTER CLUTCH (MACHINE SERIAL NO. 1013～1500).................................................................... 693 MOUNTING CENTER CLUTCH (MACHINE SERIAL NO. 1013～1500)....................................................................... 697 DISMOUNTING CENTER CLUTCH (MACHINE SERIAL NO. 1501 ADN UP).................................................................. 701 MOUNTING CENTER CLUTCH (MACHINE SERIAL NO. 1501 AND UP)..................................................................... 701 DISASSEMBLY OF CENTER CLUTCH................................................................................................ 702 ASSEMBLY OF CENTER CLUTCH................................................................................................... 704 DISMOUNTING BEVEL GEAR AND BEVEL GEAR SHAFT................................................................................. 706 MOUNTING BEVEL GEAR AND BEVEL GEAR SHAFT.................................................................................... 712 DISMOUNTING TRANSMISSION AND STEERING OIL COOLER (MACHINE SERIAL NO. 1013～1300)............................................. 722 MOUNTING TRANSMISSION AND STEERING OIL COOLER (MACHINE SERIAL NO. 1013～1300)................................................ 724 DISMOUNTING TRANSMISSION AND STEERING OIL COOLER (MACHINE SERIAL NO. 1301 AND UP)........................................... 726 MOUNTING TRANSMISSION AND STEERING OIL COOLER (MACHINE SERIAL NO. 1301 AND UP).............................................. 728 DISMOUNTING OIL COOLER AND GUARD (MACHINE SERIAL NO. 1013～1300)............................................................. 730 MOUNTING OIL COOLER AND GUARD (MACHINE SERIAL NO. 1013～1300)................................................................ 734 DISMOUNTING OIL COOLER AND GUARD (MACHINE SERIAL NO. 1301 AND UP)........................................................... 740 MOUNTING OIL COOLER AND GUARD (MACHINE SERIAL NO. 1301 AND UP).............................................................. 744 DISMOUNTING STEERING PUMP................................................................................................... 748 MOUNTING STEERING PUMP...................................................................................................... 749 DISASSEMBLY OF FINAL DRIVE.................................................................................................. 750 ASSEMBLY OF FINAL DRIVE..................................................................................................... 760 24 MAINTENANCE STANDARD............................................................................................................. 771 MAINTENANCE STANDARD............................................................................................................ 772 TORQUE CONVERTER............................................................................................................ 773 TORQFLOW TRANSMISSION....................................................................................................... 779 TRANSFER.................................................................................................................... 781 TRANSMISSION CONTROL VALVE.................................................................................................. 783 TRANSMISSION PUMP........................................................................................................... 785 TORQUE CONVERTER FLOW DIVIDER............................................................................................... 786 TRANSMISSION LUBRICATION VALVE.............................................................................................. 787 STEERING BRAKE.............................................................................................................. 788 BRAKE CHECK VALVE (MACHINE SERIAL NO. 1013～1500)............................................................................ 790 BRAKE CONTROL VALVE (MACHINE SERIAL NO. 1013～1500).......................................................................... 791 BRAKE AND CENTER CLUTCH INTERCONNECTING VALVE (MACHINE SERIAL NO. 1501 AND UP).............................................. 792 BRAKE BOOSTER............................................................................................................... 794 BRAKE,TRANSFER LUBRICATION VALVE (MACHINE SERIAL NO. 1070～1500)............................................................. 795 BEVEL GEAR SHAFT,CENTER CLUTCH.............................................................................................. 796 CENTER CLUTCH CONTROL VALVE................................................................................................. 800 TORQUE CONVERTER LUBRICATION CIRCUIT DIVIDER VALVE (MACHINE SERIAL NO. 1501 AND UP)......................................... 802 STEERING PUMP............................................................................................................... 803 FINAL DRIVE................................................................................................................. 804 25 TROUBLE SHOOTING................................................................................................................. 806 TROUBLE SHOOTING................................................................................................................ 807 GENERAL..................................................................................................................... 808 1. TORQUE CONVERTER......................................................................................................... 809 PROBLEM NO.1............................................................................................................ 809 NORMAL TRACTIONAL FORCE CANNOT BE OBTAINED AND TRAVELING SPEED DOES NOT INCREASE.(LACK OF DRIVING POWER)............ 809 PROBLEM NO.2............................................................................................................ 809 1. THE SAME AS NO.1................................................................................................. 809 2. THE TORQUE CONVERTER OVERHEATS................................................................................... 809 3. TORQUE CONVERTER OIL PRESSURE IS TOO HIGH........................................................................ 809 PROBLEM NO.3............................................................................................................ 810 1. THE SAME SYMPTOM AS DESCRIBED IN NO.1............................................................................ 810 2. OVERHEATING (OIL TEMPERATURE GAUGE POINTER SWING INTO THE RIGHT SIDE RANGE BEYOND THE GREEN OPERATING RANGE)..... 810 2. TRANSMISSION............................................................................................................. 811 PROBLEM NO.4............................................................................................................ 811 1. THE SAME SYMPTOM AS DESCRIBED IN NO.1............................................................................ 811 2. CLUTCH SLIPS..................................................................................................... 811 3. WHEN THE BLADE IS LOADED,THE MACHINE WILL STOP EVEN IF THE UNIVERSAL JOINT ROTATES............................... 811 PROBLEM NO.5............................................................................................................ 812 AN EXCESSIVELY LARGE SHOCK IS FELT WHEN STARTING THE MACHINE OR SHIFTING GEAR SPEEDS................................ 812 PROBLEM NO.6............................................................................................................ 813 THE TRANSMISSION FAILS TO TRANSMIT DRIVING POWER AT ALL SPEED POSITIONS............................................. 813 PROBLEM NO.7............................................................................................................ 814 INSUFFICIENT TRACTIONAL FORCE AND SLOW TRAVELING SPEED.............................................................. 814 PROBLEM NO.8............................................................................................................ 816 THE MACHINE MOVES WHEN THE ENGINE IS STARTED........................................................................ 816 PROBLEM NO.9............................................................................................................ 816 THE MACHINE TANDS TO STOP ON AN UPHILL GRADE........................................................................ 816 PROBLEM NO.10........................................................................................................... 817 1. EXCESSIVE TIME LAG WHEN STARTING THE MACHINE OR SHIFTING THE TRANSMISSION SPEEDS................................. 817 2. THE MACHINE DOES NOT INSTANTLY FOLLOW THE SHIFTING OF THE TRANSMISSION........................................... 817 PROLBEM NO.11........................................................................................................... 818 EXCESSIVE SHOCK WHEN STARTING THE MACHINE OR SHIFTING THE TRANSMISSION.............................................. 818 PROLBEM NO.12........................................................................................................... 818 THE TRANSMISSION CONTROL LEVER TENDS TO SEPARATE FROM THE SET POSITION.............................................. 818 PROLBEM NO.13........................................................................................................... 818 THE TRANSMISSION CONTROL LEVER DOES NOT MOVE EASILY................................................................. 818 PROLBEM NO.14........................................................................................................... 818 THE MACHINE DOES NOT MOVE WHEN THE TRANSMISSION IS SHIFTED TO ANY SPEED POSITION,AND THE TORQUE CONVERTER STALLS.... 818 PROLBEM NO.15........................................................................................................... 818 THE TRANSMISSION IS AUTOMATICALLY SHIFTED DOWN DURING TRAVELING..................................................... 818 3. STEERING BRAKE........................................................................................................... 819 PROLBEM NO.16........................................................................................................... 819 BRAKE DOES NOT ACT AT ALL OR ACTS INEFFECTIVELY..................................................................... 819 PROLBEM NO.17........................................................................................................... 821 1. THE SAME AS PROBLEM NO.6......................................................................................... 821 2. MACHINE FAILS TO START AT SOME SPEED POSITION.................................................................... 821 PROLBEM NO.18........................................................................................................... 822 BRAKE ACTS WHEN TRANSMISSION CONTROL LEVER IS SHIFT................................................................. 822 4. CENTER CLUTCH............................................................................................................ 823 PROLBEM NO.19........................................................................................................... 823 MACHINE WILL NOT TURN IN EITHER DIRECTION (INCL.COUNTER ROTATION)................................................... 823 PROLBEM NO.20........................................................................................................... 824 MACHINE FAILS TO KEEP STRAIGHT TRAVEL ON ROUGH GROUND............................................................... 824 UNDERCARRIAGE........................................................................................................................... 825 31 STRUCTURE AND FUNCTION........................................................................................................... 825 STRUCTURE AND FUNCTION.......................................................................................................... 826 TRACK GROUP................................................................................................................. 827 RECOIL SPRING............................................................................................................... 828 IDLER....................................................................................................................... 829 TRACK ROLLERS............................................................................................................... 830 CARRIER ROLLERS............................................................................................................. 831 PIVOT SHAFTS................................................................................................................ 832 TRACK....................................................................................................................... 834 SUSPENSION.................................................................................................................. 837 33 DISASSEMBLY AND ASSEMBLY......................................................................................................... 838 TORQUE SPECIFICATIONS FOR NUTS AND BOLTS........................................................................................ 839 DISASSEMBLY AND ASSEMBLY........................................................................................................ 840 SEPARATION OF TRACK......................................................................................................... 841 CONNECTION OF TRACK......................................................................................................... 843 DISMOUNTING CARRIER ROLLER.................................................................................................. 846 MOUNTING CARRIER ROLLER..................................................................................................... 848 DISMOUNTING TRACK ROLLER.................................................................................................... 850 MOUNTING TRACK ROLLER....................................................................................................... 852 DISMOUNTING IDLER AND RECOIL SPRING......................................................................................... 854 MOUNTING IDLER AND RECOIL SPRING............................................................................................ 858 DISASSEMBLY OF RECOIL SPRING................................................................................................ 862 ASSEMBLY OF RECOIL SPRING................................................................................................... 864 DISMOUNTING TRACK FRAME..................................................................................................... 866 MOUNTING TRACK FRAME........................................................................................................ 870 DISMOUNTING PIVOT SHAFT..................................................................................................... 873 MOUNTING PIVOT SHAFT........................................................................................................ 877 34 MAINTENANCE STANDARD............................................................................................................. 882 MAINTENANCE STANDARD............................................................................................................ 883 TRACK FRAMES................................................................................................................ 884 RECOIL SPRING............................................................................................................... 885 IDLER....................................................................................................................... 886 TRACK ROLLERS............................................................................................................... 888 CARRIER ROLLERS............................................................................................................. 890 PIVOT SHAFT................................................................................................................. 891 TRACK ...................................................................................................................... 893 SUSPENSION.................................................................................................................. 899 HYDRAULIC SYSTEM........................................................................................................................ 900 61 STRUCTURE AND FUNCTION........................................................................................................... 900 STRUCTURE AND FUNCTION.......................................................................................................... 901 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM..................................................................................... 902 WORK EQUIPMENT PUMP......................................................................................................... 906 HYDRAULIC FILTER............................................................................................................ 907 HYDRAULIC TANK.............................................................................................................. 908 WORK EQUIPMENT HYDRAULIC CONTROL VALVES..................................................................................... 912 WORK EQUIPMENT HYDRAULIC CYLINDERS.......................................................................................... 917 RIPPER SELECTOR VALVE,PILOT CHECK VALVE..................................................................................... 921 PILOT VALVE................................................................................................................. 925 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (MACHINE SERIAL NO.1013～1300)....................................................... 927 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (MACHINE SERIAL NO.1013～1300)...................................................... 928 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (MACHINE SERIAL NO.1013～1500)....................................................... 929 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (MACHINE SERIAL NO.1013～1500)...................................................... 930 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (MACHINE SERIAL NO.1501 AND UP)..................................................... 931 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (MACHINE SERIAL NO.1501 AND UP).................................................... 932 PIN-PULLER VALVE............................................................................................................ 933 PIN-PULLER CYLINDER......................................................................................................... 937 PIN PULLER HYDRAULIC SYSTEM DIAGRAM......................................................................................... 938 PIN PULLER HYDRAULIC CIRCUIT DIAGRAM........................................................................................ 938 ROTARY SERVO VALVE (MACHINE SERIAL NO.1013～1300)............................................................................ 939 SERVO PUMP (MACHINE SERIAL NO.1013～1300).................................................................................... 942 ROTARY SERVO VALVE (MACHINE SERIAL NO.1301 AND UP).......................................................................... 945 SERVO VALVE HYDRAULIC SYSTEM DIAGRAM (MACHINE SERIAL NO.1013～1300).......................................................... 949 SERVO VALVE HYDRAULIC CIRCUIT DIAGRAM (MACHINE SERIAL NO.1013～1300)......................................................... 949 SERVO VALVE HYDRAULIC SYSTEM DIAGRAM (MACHINE SERIAL NO.1301 AND UP)........................................................ 950 SERVO VALVE HYDRAULIC CIRCUIT DIAGRAM (MACHINE SERIAL NO.1301 AND UP)....................................................... 950 WORK EQUIPMENT CONTROL...................................................................................................... 951 62 TESTING AND ADJUSTING............................................................................................................ 952 TESTING AND ADJUSTING........................................................................................................... 953 GENERAL..................................................................................................................... 954 HYDRAULIC CONTROL........................................................................................................... 955 MEASUREMENT POINTS OF OIL PRESSURE.......................................................................................... 957 OIL PRESSURE AND TEMPERATURE CHECK POSITION................................................................................. 958 HYDRAULIC OIL PUMP.......................................................................................................... 959 MEASUREMENT PROCEDURE OF OIL PRESSURE....................................................................................... 960 ADJUSTMENT PROCEDURE OF OIL PRESSURE........................................................................................ 961 MEASURING THE HYDRAULIC PUMP DELIVERY....................................................................................... 962 MEASUREMENT OF OPERATING FORCE,STROKE....................................................................................... 963 ADJUSTMENT OF BLADE (STRAIGH TILT DOZER).................................................................................... 964 63 DISASSEMBLY AND ASSEMBLY......................................................................................................... 965 TORQUE SPECIFICATIONS FOR NUTS AND BOLTS........................................................................................ 966 DISASSEMBLY AND ASSEMBLY........................................................................................................ 967 DISMOUNTING L.H.HYDRAULIC PUMP (MACHINE SERIAL NO.1013～1500)................................................................ 970 MOUNTING L.H.HYDRAULIC PUMP (MACHINE SERIAL NO.1013～1500)................................................................... 973 DISMOUNTING R.H.HYDRAULIC PUMP (MACHINE SERIAL NO.1013～1500)................................................................ 975 MOUNTING R.H.HYDRAULIC PUMP (MACHINE SERIAL NO.1013～1500)................................................................... 979 DISMOUNTING HYDRAULIC PUMP (MACHINE SERIAL NO.1501 AND UP).................................................................. 983 MOUNTING HYDRAULIC PUMP (MACHINE SERIAL NO.1501 AND UP)..................................................................... 989 DISMOUNTING OIL COOLER GUARD................................................................................................ 995 MOUNTING OIL COOLER GUARD................................................................................................... 999 DISMOUNTING RIPPER AND BLADE LIFT VALVE.....................................................................................1005 MOUNTING RIPPER AND BLADE LIFT VALVE........................................................................................1009 DISASSEMBLY OF RIPPER AND BLADE LIFT VALVE..................................................................................1012 ASSEMBLY OF RIPPER AND BLADE LIFT VALVE.....................................................................................1017 DISMOUNTING BLADE TILT VALVE................................................................................................1021 MOUNTING BLADE TILT VALVE...................................................................................................1024 DISASSEMBLY OF BLADE TILT VALVE.............................................................................................1026 ASSEMBLY OF BLADE TILT VALVE................................................................................................1027 DISMOUNTING HYDRAULIC TANK..................................................................................................1028 MOUNTING HYDRAULIC TANK.....................................................................................................1033 DISMOUNTING RIPPER SELECTOR VALVE...........................................................................................1037 MOUNTING RIPPER SELECTOR VALVE..............................................................................................1041 DISASSEMBLY OF RIPPER SELECTOR VALVE........................................................................................1045 ASSEMBLY OF RIPPER SELECTOR VALVE...........................................................................................1050 DISMOUNTING PIN PULLER VALVE................................................................................................1055 MOUNTING PIN PULLER VALVE...................................................................................................1056 DISASSEMBLY OF PIN PULLER VALVE.............................................................................................1057 ASSEMBLY OF PIN PULLER VALVE................................................................................................1058 DISMOUNTING BLADE LIFT CYLINDER.............................................................................................1059 MOUNTING BLADE LIFT CYLINDER................................................................................................1060 DISASSEMBLY OF BLADE LIFT CYLINDER..........................................................................................1061 ASSEMBLY OF BLADE LIFT CYLINDER.............................................................................................1067 DISMOUNTING BLADE TILT CYLINDER.............................................................................................1073 MOUNTING BLADE TILT CYLINDER................................................................................................1075 DISASSEMBLY OF BLADE TILT CYLINDER..........................................................................................1077 ASSEMBLY OF BLADE TILT CYLINDER.............................................................................................1083 DISMOUNTING RIPPER LIFT CYLINDER............................................................................................1089 MOUNTING RIPPER LIFT CYLINDER...............................................................................................1091 DISMOUNTING RIPPER TILT CYLINDER............................................................................................1093 MOUNTING RIPPER TILT CYLINDER...............................................................................................1095 DISASSEMBLY OF RIPPER CYLINDER..............................................................................................1097 ASSEMBLY OF RIPPER CYLINDER.................................................................................................1103 DISMOUNTING RIPPER PIN PULLER CYLINDER......................................................................................1107 MOUNTING RIPPER PIN PULLER CYLINDER.........................................................................................1108 64 MAINTENANCE STANDARD.............................................................................................................1109 MAINTENANCE STANDARD............................................................................................................1110 HYDRAULIC CONTROL VALVE.....................................................................................................1111 HYDRAULIC PUMP..............................................................................................................1115 HYDRAULIC CYLINDER..........................................................................................................1116 QUICK DROP VALVE............................................................................................................1120 RIPPER SELECTOR VALVE,PILOT CHECK VALVE.....................................................................................1121 PILOT VALVE.................................................................................................................1122 RIPPER PIN-PULLER VALVE.....................................................................................................1123 PIN-PULLER CYLINDER.........................................................................................................1124 SERVO PUMP..................................................................................................................1125 ROTARY SERVO VALVE..........................................................................................................1126 65 TROUBLE SHOOTING.................................................................................................................1129 TROUBLE SHOOTING................................................................................................................1130 PROBLEM NO.1. HYDRAULIC PRESSURE IS INSUFFICIENT TO RAISE THE BLADE.........................................................1131 PROBLEM NO.2. THE BLADE RAISES TOO SLOWLY...................................................................................1132 PROBLEM NO.3. BLADE MOVES VERTICALLY DURING GROUND LEVELLING OPERATION......................................................1132 PROBLEM NO.4 ...............................................................................................................1132 (1) BLADE LOWERS SOME DISTANCE WHEN THE CONTROL LEVER IS SHIFTED FROM SUPPORT TO RAISE POSITION.........................1132 (2) BLADE LOWERS GRADUALLY WHEN THE ENGINE IS STOPPED AND THE CONTROL LEVER IS SHIFTED TO THE RAISE POSITION............1132 PROBLEM NO.5. RIGHT AND LEFT ENDS OF THE BLADE DO NOT RAISED EVENLY.........................................................1132 PROBLEM NO.6. CYLINDER FAILS TO LIFT THE BLADE..............................................................................1133 PROBLEM NO.7. BLADE FALLS TO JACK UP THE MACHINE............................................................................1133 PROBLEM NO.8. EXCESSIVE RATE OF BLADE LOWERING BY ITS OWN WEIGHT............................................................1134 WORK EQUIPMENT..........................................................................................................................1135 71 STRUCTURE AND FUNCTION...........................................................................................................1135 STRUCTURE AND FUNCTION..........................................................................................................1136 STRAIGHT-TILT DOZER.........................................................................................................1137 VARIABLE GIANT RIPPER.......................................................................................................1139 73 DISASSEMBLY AND ASSEMBLY.........................................................................................................1141 TORQUE SPECIFICATIONS FOR NUTS AND BOLTS........................................................................................1142 DISASSEMBLY AND ASSEMBLY........................................................................................................1143 DISMOUNTING BLADE ASS'Y.....................................................................................................1144 MOUNTING BLADE ASS'Y........................................................................................................1146 DISASSEMBLY OF BLADE ASS'Y..................................................................................................1148 ASSEMBLY OF BLADE ASS'Y.....................................................................................................1151 DISASSEMBLY OF RIPPER ASS'Y.................................................................................................1154 ASSEMBLY OF RIPPER ASS'Y....................................................................................................1160 74 MAINTENANCE STANDARD.............................................................................................................1165 MAINTENANCE STANDARD............................................................................................................1166 STRAIGHT-TILT DOZER.........................................................................................................1167 VARIABLE GIANT RIPPER.......................................................................................................1170 OTHERS..................................................................................................................................1172 90 ELECTRICAL SYSTEM................................................................................................................1172 ELECTRICAL SYSTEM...............................................................................................................1173 ELECTRICAL CIRCUIT (MACHINE SERIAL NO.1013～1300)............................................................................1174 ELECTRICAL CIRCUIT (MACHINE SERIAL NO.1301～1500)............................................................................1176 ELECTRICAL CIRCUIT (MACHINE SERIAL NO.1501 AND UP)..........................................................................1178 TROUBLE SHOOTING............................................................................................................1180 93 DISASSEMBLY AND ASSEMBLY.........................................................................................................1189 DISASSEMBLY AND ASSEMBLY........................................................................................................1190 TURNING OVER ROPS CAB (MACHINE SERIAL NO.1501 AND UP).......................................................................1191 TURNING BACK ROPS CAB (MACHINE SERIAL NO.1501 AND UP).......................................................................1197
DESCRIPTION:
KOMATSU D455A-1 SHOP MANUAL SEBM0198A05 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid in improving the quality of repairs by giving the serviceman an accurate understanding of the product and by showing the correct way to perform repairs and make judgments. Make sure you understand the contents of this manual and use it to full effect at every available 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 chapters for each main group of components. These chapters are further divided into the following sections:
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to provide an understanding of the structure but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains the checks to be made before and after performing repairs, as well as adjustments to be made at the completion of the checks and repairs. Troubleshooting charts correlating “Diagnoses” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling, or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARDS
This section provides the judgment standards when inspecting disassembled parts.
S.S 25/12/24
