KOMATSU D155A-3 SHOP MANUAL SEBM005305 – PDF DOWNLOAD
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KOMATSU D155A-3 SHOP MANUAL SEBM005305 – PDF DOWNLOAD
Language : English
Pages : 729
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TABLE OF CONTENTS:
KOMATSU D155A-3 SHOP MANUAL SEBM005305 – PDF DOWNLOAD
COVER.............................................................................................................................. 1 CONTENTS........................................................................................................................... 2 01 GENERAL......................................................................................................................... 21 SPECIFICATION DRAWING.......................................................................................................... 22 SPECIFICATIONS................................................................................................................. 24 WEIGHT TABLE................................................................................................................... 30 TABLE OF FUEL,COOLANT AND LUBRICANTS........................................................................................... 32 10 STRUCTURE AND FUNCTION.......................................................................................................... 33 RADIATOR....................................................................................................................... 34 OIL COOLER..................................................................................................................... 36 ENGINE CONTROL................................................................................................................. 38 POWER TRAIN.................................................................................................................... 39 POWER TRAIN SYSTEM............................................................................................................. 40 POWER TRAIN UNIT MOUNT......................................................................................................... 41 OVERALL DRAWING OF POWER TRAIN UNIT............................................................................................ 42 POWER TRAIN HYDRAULIC PIPING DIAGRAM........................................................................................... 43 POWER TRAIN HYDRAULIC SYSTEM DRAWING........................................................................................... 44 POWER TRAIN HYDRAULIC CIRCUIT DAIGRAM.......................................................................................... 45 DAMPER,UNIVERSAL JOINT......................................................................................................... 46 TORQUE CONVERTER,PTO........................................................................................................... 48 TRANSMISSION CONTROL........................................................................................................... 50 TRANSMISSION................................................................................................................... 51 TRANSMISSION CONTROL VALVE..................................................................................................... 57 MAIN RELIEF VALVE.............................................................................................................. 62 LUBRICATION RELIEF VALVE....................................................................................................... 64 STEERING,BRAKE CONTROL......................................................................................................... 65 BEVEL GEAR SHAFT, STEERING CLUTCH,STEERING BRAKE............................................................................... 67 STEERING CONTROL VALVE......................................................................................................... 73 REDUCING VALVE................................................................................................................. 80 SCAVENGING PUMP STRAINER....................................................................................................... 81 POWER TRAIN PUMP STRAINER...................................................................................................... 82 POWER TRAIN OIL FILTER......................................................................................................... 83 FINAL DRIVE.................................................................................................................... 84 RADIATOR GUARD................................................................................................................. 87 MAIN FRAME,UNDERGUARD.......................................................................................................... 88 TRACK FRAME.................................................................................................................... 89 RECOIL SPRING.................................................................................................................. 91 TRACK ROLLER BOGIE............................................................................................................. 92 SUSPENSION..................................................................................................................... 93 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM........................................................................................ 95 PPC CONTROL PIPING DIAGRAM..................................................................................................... 98 WORK EQUIPMENT CONTROL......................................................................................................... 99 WORK EQUIPMENT HYDRAULIC SYSTEM DAIAGRAM.......................................................................................100 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.......................................................................................101 HYDRAULIC TANK AND FILTER......................................................................................................104 PPC CHARGE VALVE...............................................................................................................106 ACCUMULATOR....................................................................................................................108 PPC LOCK VALVE.................................................................................................................109 PPC VALVE......................................................................................................................110 MAIN CONTROL VALVE.............................................................................................................121 OPERATION OF MAIN CONTROL VALVE................................................................................................125 OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT....................................................................................140 PISTON VALVE...................................................................................................................144 QUICK DROP VALVE...............................................................................................................145 CYLINDER STAY..................................................................................................................146 WORK EQUIPMETN.................................................................................................................147 PIN PULLER SWITCH..............................................................................................................151 PIN PULLER SOLENOID VALVE......................................................................................................152 TILT/PITCH SELECTOR SWITCH.....................................................................................................154 PITCH SOLENOID VALVE...........................................................................................................155 CAB MOUNT......................................................................................................................157 CAB............................................................................................................................158 AIR CONDITIONER................................................................................................................160 ELECTRICAL WIRING DIAGRAM......................................................................................................161 ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................162 MACHINE MONITOR SYSTEM.........................................................................................................165 SENSORS........................................................................................................................170 ENGINE STARTING SYTEM..........................................................................................................173 20 TESTING AND ADJUSTING...........................................................................................................175 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS..................................................................................176 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS.................................................................................178 STANDARD VALUE TABLE FOR MACHINE MONITOR.......................................................................................183 TESTING AND AJUSTING...........................................................................................................186 TOOLS FOR TESTING,ADJUSTING,AND TROUBGLESHOOTING...........................................................................187 MEASURING ENGINE SPEED.....................................................................................................188 MEASURING EXHAUST COLOR....................................................................................................189 ADJUSTING EXHAUST CLEARANCE................................................................................................190 MEASURING COMPRESSION PRESSURE.............................................................................................191 MEASURING BLOW-BY PRESSURE.................................................................................................192 MEASURING ENGINE OIL PRESSURE..............................................................................................193 TESTING AND ADJUSTIN FUEL INJECTION TIMING.................................................................................194 TESTING AND ADJUSTING ALTERNATOR BELT TENSION..............................................................................196 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION..............................................................196 MEASURING EXHAUST TEMPERATURE..............................................................................................197 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE).............................................................................198 MEASURING TORQUE CONVERTER STALL SPEED ....................................................................................199 MEASURING TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL)SPEED.................................................200 ADJUSTING FUEL CONTROL LINKAGE.............................................................................................201 ADJUSTING DECELERATOR PEDAL................................................................................................203 ADJUSTING JOYSTICK (STEERING,DIRECTIONAL,GEAR SHIFT LEVER),PARKING LEVER LINKAGE...........................................204 ADJUSTING BRAKE PEDAL LINKAGE..............................................................................................208 ADJUSTING WORK EQUIPMENT CONTROL LINKAGE...................................................................................209 TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE..............................................................212 MEASURING PPC VALVE OUTPUT PRESSURE........................................................................................213 ADJUSTING PPC VALVE........................................................................................................214 MEASURING ON-OFF SOLENOID VALVE OUTPUT PRESSURE............................................................................215 MEASURING POWER TRAIN OIL PRESSURE.........................................................................................216 TESTING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE..................................................................219 BLEEDING AIR FROM HYDRAULIC CYLINDERS......................................................................................220 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..........................................................................220 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER..........................................................221 MEASURING LEAKAGE INSIDE CYLINDER..........................................................................................222 ADJUSTING SEMI-U-TILTDOZER.................................................................................................223 ADJUSTING CLEARANCE OF IDLER...............................................................................................225 SIMPLE PROCEDURE FOR TESTING BREAKE PERFORMANCE............................................................................226 TROUBLESHOOTING................................................................................................................227 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................................228 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................................................229 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...........................................................................230 CHECKS BEFORE TROUBLESHOOTING..............................................................................................238 TYPE OF CONNECTOR AND POSITION OF INSTALLATION.............................................................................239 CONNECTOR ARRANGEMENT DIAGRAM..............................................................................................241 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................................245 METHOD OF USING TROUBLESHOOTING CHARTS.....................................................................................255 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..............................................................................257 E-1 ENGINE DOES NOT START .............................................................................................258 E-2 PIN-PULLER CYLINDER DOES NOT WORK..................................................................................264 E-3 BLADE PITCH DOES NOT WORK..........................................................................................265 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)..................................................................................266 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................267 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..........................................................271 S-2 ENGINE DOES NOT START..............................................................................................272 ① ENGINE DOES NOT TURN.............................................................................................272 ② ENGINE RUNS BUT EXHAUST GAS DOES NOT COMES OUT (FUEL IS NOT BEING INJECTED)......................................273 ③ EXHAUST GAX COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).........................................274 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...............................................................275 S-4 EINGINE STOP DURING OPERATION......................................................................................276 S-5 ENGINE NOT ROTATE SMOOTHLY (HUNTING)...............................................................................277 S-6 ENGINE LACKS OUTPUT (NO POWER).....................................................................................278 S-7 EXHAUST GAX IS BLACK (INCOMPLETE COMBUSTION).......................................................................279 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)..............................................................280 S-9 OIL BECOMES CONTAMINATED QUICKLY...................................................................................281 S-10 FUEL CONSUMPTION IS EXCESSIVE.....................................................................................282 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN.............................................283 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)........................................................284 S-13 OIL LEVEL RISES (WATER MIXED WITH FUEL)...........................................................................285 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..................................................................286 S-15 ABNORMAL NOISE IS MADE............................................................................................287 S-16 VIBRATION IS EXCESSIVE............................................................................................288 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...............................................................289 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)...................................................290 H-1 MACHINE TRAVELS ONLY IN ONE DIRECTION (FORWARD OR IN REVERSE)......................................................291 H-2 MACHINE DOES NOT MOVE (F2,F3,ENGINE RUNNING).......................................................................292 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE...........................................................................294 H-4 TIME LAG IS EXCESSIVE WHEN SHIFTING GEAR OR CHANGING DIRECTION (FORWARD/REVERSE)...................................296 H-5 MACHINE LACKS POWER (LACKS DRAWBAR PULL)...........................................................................297 H-6 MACHINE DOES NOT TURN (CAN TRAVEL IN STRAIGHT LINE)................................................................299 H-7 MACHINE TURNS TOO FAR..............................................................................................300 H-8 MACHINE TURNS ONLY IN ONE DIRECTION (LEFT OR RIGHT) (JOYSTICK (STEERING,DIRECTIONAL,GEAR SHIFT LEVER) OPERATED)....301 H-9 BRAKES DO NOT WORK.................................................................................................302 H-10 POWER TRAIN OIL OVERHEATS.........................................................................................303 H-101 ALL WORK EQUIPMENT SPEEDS ARE SLOW...............................................................................305 H-102 WORK EQUIPMENT DOES NOT MOVE.....................................................................................306 H-103 BLADE RAISE SPEED IS SLOW OR LACKS POWER.........................................................................307 H-104 BLADE TILT SPEED IS SLOW OR LACKS POWER..........................................................................307 H-105 RIPPER RAISE SPEED IS SLOW OR LACKS POWER........................................................................308 H-106 RIPPER TILT SPEED IS SLOW OR LACKS POWER.........................................................................308 H-107 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT..........................................................................309 H-108 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT..........................................................................309 H-109 EXCESSIVE HYDRAULIC DRIFT OF RIPPER..............................................................................310 H-110 PIN-PULLER CYLINDER DOES NOT WORK (MACHINES WITH GIANT RIPPER ONLY)..............................................310 H-111 BLADE PITCH DOES NOT WORK........................................................................................311 H-112 ABNORMAL NOISE FROM AROUND HYDRAULIC PUMP........................................................................311 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).........................................................................312 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR RELATED PARTS...........................................................313 M-1 MONITOR PANEL DISPLAY DOES NOT APPEAR WHEN STARTING SWITCH IS TURNED ON............................................315 M-2 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL LAMPS ALL LIGHT UP BUT DO NOT GO OUT...............................315 M-3 ABNORMALITY IN PREHEATING..........................................................................................316 a) PREHEATING MONITOR LAMP DOES NOT LIGHT UP.......................................................................316 b) PREHEATING MONITOR LAMP IS LIGHTED UP CONTINUOUSLY..............................................................316 M-4 CAUTION ITEM LIGHTS UP OR FLASHES..................................................................................318 a) BATTERY CHARGE LIGHTS UP OR FLASHES.............................................................................318 b) WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,ENGINE OIL PRESSURE LIGHTS UP OR FLASHES................319 c) COOLANT TEMPERATURE FLASHES.....................................................................................320 d) POWER TRAIN OIL TEMPERATURE FLASHES ............................................................................321 M-5 ABNORMALITY IN BUZZER..............................................................................................322 a) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND..................................................................322 b) MONITOR DISPLAY IS NORMAL BUT BUZZER SOUNDS.....................................................................322 M-6 ABNORMALITY IN WARNING LAMP........................................................................................323 a) CAUTION ITEMS FLASHES BUT LAMP DOES NOT FLASH...................................................................323 b) MONITOR DISPLAY IS NORMAL BUT LAMP LIGHTS UP....................................................................323 M-7 ABNORMALITY IN GAUGE...............................................................................................324 a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE.................................................................324 b) ABNORMALITY IN POWER OIL TEMPERATURE GAUGE......................................................................325 c) ABNORMALITY IN FUEL LEVEL GAUGE.................................................................................326 M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED................................................................327 M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMP IS NORMAL)....................................................328 M-10 LAMP DOES NOT LIGHT UP............................................................................................329 a) FRONT LAMP......................................................................................................329 b) REAR LAMP (RIPPER LAMP).........................................................................................330 M-11 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS SET TO AUTO...........................................331 M-12 WIPER DOES NOT WORK...............................................................................................333 M-13 WASHER FLUID IS NOT SPRAYED OUT...................................................................................336 M-14 AIR CONDITIONER HAS NO EFFECT.....................................................................................338 a) AIR DOES NOT BLOW OUT...........................................................................................338 b) THERE IS NO COOLING EFFECT......................................................................................342 M-15 DEFECTIVE OPERATION OF BACKUP ALARM...............................................................................346 a) BACKUP ALARM DOES NOT SOUND.....................................................................................346 b) BACKUP ALARM CONTINUES TO SOUND.................................................................................346 30 DISASSEMBLY AND ASSEMBLY........................................................................................................347 METHOD OF USING MANUAL.........................................................................................................350 PRECAUTIONS WHEN CARRYING OUT OPERATION........................................................................................352 SPECIAL TOOL LIST..............................................................................................................354 SPECIAL TOOL SKETCH............................................................................................................363 STARTING MOTOR.................................................................................................................373 REMOVAL AND INSTALLATION...................................................................................................373 ALTERNATOR.....................................................................................................................374 REMOVAL AND INSTALLATION...................................................................................................374 ENGINE OIL COOLER CORE.........................................................................................................375 REMOVAL AND INSTALLATION...................................................................................................375 FUEL INJECTION PUMP............................................................................................................376 REMOVAL ...................................................................................................................376 INSTALLATION...............................................................................................................377 WATER PUMP.....................................................................................................................378 REMOVAL AND INSTALLATION...................................................................................................378 TURBOCHARGER...................................................................................................................379 REMOVAL AND INSTALLATION...................................................................................................379 NOZZLE HOLDER..................................................................................................................380 REMOVAL AND INSTALLATION...................................................................................................380 ENGINE FRONT SEAL..............................................................................................................381 REMOVAL AND INSTALLATION...................................................................................................381 ENGINE REAR SEAL...............................................................................................................382 REMOVAL....................................................................................................................382 INSTALLATION...............................................................................................................383 CYLINDER HEAD..................................................................................................................385 REMOVAL....................................................................................................................385 INSTALLATION...............................................................................................................389 THERMOSTAT.....................................................................................................................398 REMOVAL AND INSTALLATION...................................................................................................398 AIR CONDITIONER COMPRESSOR.....................................................................................................399 REMOVAL....................................................................................................................399 INSTALLATION...............................................................................................................400 AIR CONDITIONER CONDENSER......................................................................................................401 REMOVAL....................................................................................................................401 INSTALLATION...............................................................................................................402 FUEL TANK......................................................................................................................403 REMOVAL....................................................................................................................403 INSTALLATION...............................................................................................................404 RADIATOR.......................................................................................................................405 REMOVAL....................................................................................................................405 INSTALLATION...............................................................................................................407 RADIATOR,OIL DCOOLER,GUARD.....................................................................................................408 REMOVAL....................................................................................................................408 INSTALLATION...............................................................................................................410 FAN DRIVE......................................................................................................................411 REMOVAL....................................................................................................................411 INSTALLATION...............................................................................................................413 HYDRAULIC COOLER...............................................................................................................414 REMOVAL AND INSTALLATION...................................................................................................414 ENGINE.........................................................................................................................415 REMOVAL....................................................................................................................415 INSTALLATION...............................................................................................................416 DAMPER.........................................................................................................................417 REMOVAL....................................................................................................................417 INSTALLATION...............................................................................................................418 DISASSEMBLY................................................................................................................419 ASSEMBLY...................................................................................................................422 POWER TRAIN UNIT...............................................................................................................426 REMOVAL....................................................................................................................426 INSTALLATION...............................................................................................................431 SEPARATION.................................................................................................................432 CONNECTION ................................................................................................................437 PTO............................................................................................................................440 DISASSEMBLY................................................................................................................440 ASSEMBLY...................................................................................................................446 TORQUE CONVERTER...............................................................................................................452 DISASSEMBLY................................................................................................................452 ASSEMBLY...................................................................................................................455 TORQFLOW TRANSMISSION..........................................................................................................458 DISASSEMBLY................................................................................................................458 ASSEMBLY...................................................................................................................467 STEERING CASE..................................................................................................................478 DISASSEMBLY................................................................................................................478 ASSEMBLY...................................................................................................................486 POWER TRAIN,LUBRICATION PUMP...................................................................................................497 REMOVAL AND INSTALLATION...................................................................................................497 SCAVENGING PUMP................................................................................................................498 REMOVAL AND INSTALLATION...................................................................................................498 POWER TRAIN MAIN RELIEF VALVE..................................................................................................499 REMOVAL AND INSTALLATION...................................................................................................499 DISASSEMBLY AND ASSEMBLY...................................................................................................500 TRANSMISSION CONTROL VALVE.....................................................................................................501 REMOVAL....................................................................................................................501 INSTALLATION...............................................................................................................502 DISASSEMBLY AND ASSEMBLY...................................................................................................503 REDUCING VALVE.................................................................................................................505 REMOVAL AND INSTALLATION...................................................................................................505 DISASSEMBLY AND ASSEMBLY...................................................................................................506 STEERING CONTROL VALVE.........................................................................................................507 REMOVAL AND INSTALLATION...................................................................................................507 DISASSEMBLY................................................................................................................508 ASSEMBLY...................................................................................................................510 FINAL DRIVE....................................................................................................................512 REMOVAL....................................................................................................................512 INSTALLATION...............................................................................................................515 DISASSEMBLY................................................................................................................516 ASSEMBLY...................................................................................................................521 TRACK FRAME....................................................................................................................527 REMOVAL....................................................................................................................527 INSTALLATION...............................................................................................................529 IDLER..........................................................................................................................530 REMOVAL....................................................................................................................530 INSTALLATION...............................................................................................................531 DISASSEMBLY................................................................................................................532 ASSEMBLY...................................................................................................................534 RECOIL SPRING..................................................................................................................537 REMOVAL AND INSTALLATION...................................................................................................537 DISASSEMBLY................................................................................................................538 ASSEMBLY...................................................................................................................543 TRACK ROLLER...................................................................................................................547 REMOVAL....................................................................................................................547 INSTALLATION...............................................................................................................548 DISASSEMBLY................................................................................................................549 ASSEMBLY...................................................................................................................552 BOGIE..........................................................................................................................555 REMOVAL....................................................................................................................555 INSTALLATION...............................................................................................................557 DISASSEMBLY................................................................................................................558 ASSEMBLY...................................................................................................................561 CARRIER ROLLER.................................................................................................................565 REMOVAL AND INSTALLATION...................................................................................................565 DISASSEMBLY................................................................................................................566 ASSEMBLY...................................................................................................................568 TRACK SHOE.....................................................................................................................571 CHECKING BEFORE REMOVAL....................................................................................................571 REMOVAL (NORMAL)...........................................................................................................571 REMOVAL (WHEN THERE IS ABNROMALITY INSIDE TRACK FRAME).....................................................................572 INSTALLATION...............................................................................................................573 OVERALL DISASSEMBLY........................................................................................................574 OVERALL ASSEMBLY...........................................................................................................579 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS...............................................................................593 ONE LINK.......................................................................................................................594 FIELD DISASSEMBLY..........................................................................................................594 FIELD ASSEMBLY.............................................................................................................596 MASTER LINK....................................................................................................................598 DISASSEMBLY................................................................................................................598 ASSEMBLY...................................................................................................................600 PIVOT SHAFT....................................................................................................................603 REMOVAL AND INSTALLATION...................................................................................................603 EQUALIZER BAR..................................................................................................................604 REMOVAL....................................................................................................................604 INSTALLATION...............................................................................................................605 EQUALIZER BAR SIDE BUSHING.....................................................................................................606 REMOVAL AND INSTALLATION...................................................................................................606 SEGENT TEETH...................................................................................................................607 REMOVAL AND INSTALLATION...................................................................................................607 HYDRAULIC TANK.................................................................................................................608 REMOVAL AND INSTALLATION...................................................................................................608 HYDRAULIC,PPC PUMP.............................................................................................................609 REMOVAL AND INSTALLATION...................................................................................................609 MAIN CONTROL VALVE.............................................................................................................610 REMOVAL....................................................................................................................610 INSTALLATION...............................................................................................................611 DISASSEMBLY................................................................................................................612 ASSEMBLY...................................................................................................................615 PPC CHARGE VALVE...............................................................................................................619 REMOVAL AND INSTALLATION...................................................................................................619 DISASSEMBLY AND ASSEMBLY...................................................................................................620 BLADE PPC VALVE ...............................................................................................................621 REMOVAL....................................................................................................................621 INSTALLATION...............................................................................................................622 RIPPER PPC VALVE...............................................................................................................625 REMOVAL....................................................................................................................625 INSTALLATION...............................................................................................................626 PPC VALVE......................................................................................................................629 DISASSEMBLY................................................................................................................629 ASSEMBLY...................................................................................................................630 BLADE PPC VALVE ...............................................................................................................631 DISASSEMBLY................................................................................................................631 ASSEMBLY...................................................................................................................632 BLADE LIFT CYLINDER............................................................................................................634 REMOVAL AND INSTALLATION...................................................................................................634 BLAND TILT CYLINDER............................................................................................................635 REMOVAL AND INSTALLATION...................................................................................................635 RIPPER LIFT CYLINDER...........................................................................................................636 REMOVAL AND INSTALLATION...................................................................................................636 RIPPER TILT CYLINDER...........................................................................................................637 REMOVAL AND INSTALLATION...................................................................................................637 HYDRAULIC CYLINDER.............................................................................................................638 DISASSEMBLY................................................................................................................638 ASSEMBLY...................................................................................................................641 BLADE..........................................................................................................................645 REMOVAL....................................................................................................................645 INSTALLATION...............................................................................................................646 DISASSEMBLY................................................................................................................647 ASSEMBLY...................................................................................................................649 MULTI-SHANK RIPPER.............................................................................................................651 DISASSEMBLY................................................................................................................651 ASSEMBLY...................................................................................................................653 ROPS GUARD.....................................................................................................................655 REMOVAL AND INSTALLATION...................................................................................................655 OPERATOR CAB...................................................................................................................656 REMOVAL AND INSTALLATION...................................................................................................656 HOOD ..........................................................................................................................657 REMOVAL AND INSTALLATION...................................................................................................657 FLOOR FRAME....................................................................................................................658 REMOVAL....................................................................................................................658 INSTALLATION...............................................................................................................663 DASHBOARD......................................................................................................................664 REMOVAL....................................................................................................................664 INSTALLATION...............................................................................................................665 MONITOR........................................................................................................................666 REMOVAL AND INSTALLATION...................................................................................................666 40 MAINTENANCE STANDARD............................................................................................................667 ENGINE MOUNT...................................................................................................................668 POWER TRAIN UNIT MOUNT.........................................................................................................669 DAMPER,UNIVERSAL JOINT.........................................................................................................670 TORQUE COVERTER,PTO............................................................................................................671 TRANSMISSION...................................................................................................................673 TRANSMISSION CONTROL VALVE.....................................................................................................675 MAIN RELIEF VALVE..............................................................................................................676 BEVEL GEAR SHAFT,STEERING CLUTCH,STEERING BRAKE................................................................................677 STEERING COTROL VALVE..........................................................................................................680 SCAVENGING PUMP................................................................................................................682 POWER TRAIN,LUBRICATION PUMP...................................................................................................683 FINAL DRIVE....................................................................................................................684 MAIN FRAME.....................................................................................................................686 TRACK FRAME....................................................................................................................688 RECOIL SPRING..................................................................................................................689 TRACK ROLLER BOGIE.............................................................................................................690 IDLER..........................................................................................................................691 TRACK ROLLER...................................................................................................................693 CARRIER ROLLER.................................................................................................................695 TRACK SHOE (DRY TRACK).........................................................................................................696 TRACK SHOE (SELAED AND LUBRICATED TRACK).......................................................................................698 SUSPENSION.....................................................................................................................700 HYDRULIC,PPC CHARGE PUMP.......................................................................................................702 PPC CHARGE VALVE...............................................................................................................703 PPC VALVE......................................................................................................................704 MAIN CONTROL VALVE.............................................................................................................707 WORK EQUIPMENT CYLINDER........................................................................................................717 QUICK DROP VALVE...............................................................................................................721 CYLINDER STAY..................................................................................................................722 WORK EQUIPMENT ................................................................................................................723
DESCRIPTION:
KOMATSU D155A-3 SHOP MANUAL SEBM005305 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” 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 STANDARD
This section gives the judgement standards when inspecting disassembled parts.
S.S 12/12/24
