Komatsu D455A-1 Shop Manual SEBM0198A05 – PDF DOWNLOAD

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Komatsu D455A-1 Bulldozer Shop Manual SEBM0198A05 – PDF DOWNLOAD

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Komatsu D455A-1 Bulldozer Shop Manual SEBM0198A05 – PDF DOWNLOAD

Language : English
Pages : 1202
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D455A-1 Bulldozer 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 Bulldozer Shop Manual SEBM0198A05 – PDF DOWNLOAD

FOREWORD
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 him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every availably opportunity.
Organization
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 give an understanding of the structure, but also serves as reference material for troubleshooting.
Testing and adjusting
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “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 gives the judgement standards when inspecting disassembled parts.

G.B  14/12/24