Komatsu D155AX-5 Bulldozer Shop Manual SEBM034805 PDF

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Komatsu D155AX-5 Bulldozer Shop Manual SEBM034805 – PDF DOWNLOAD

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Komatsu D155AX-5 Bulldozer Shop Manual SEBM034805 – PDF DOWNLOAD 

Language : English
Pages : 1159
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D155AX-5 Bulldozer Shop Manual SEBM034805 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
D155AX-5                  76001 and up

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 8
SAFETY NOTICE 8
FOREWORD 10
GENERAL 10
HOW TO READ THE SHOP MANUAL 11
HOISTING INSTRUCTIONS 12
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 13
COATING MATERIALS 15
STANDARD TIGHTENING TORQUE 17
ELECTRIC WIRE CODE 20
CONVERSION TABLE 21
UNITS 27
01 GENERAL 28
SPECIFICATION DRAWING 29
SPECIFICATIONS 31
WEIGHT TABLE 37
TABLE OF FUEL, COOLANT AND LUBRICANT 39
10 STRUCTURE AND FUNCTION 40
RADIATOR, OIL COOLER 41
POWER TRAIN SYSTEM 45
OVERALL DRAWING OF POWER TRAIN UNIT 47
POWER TRAIN HYDRAULIC EQUIPMENT LAYOUT 49
DAMPER, UNIVERSAL JOINT 51
TORQUE CONVERTER, PTO 53
TRANSMISSION CONTROL 57
TRANSMISSION 59
TRANSMISSION ECMV 69
MAIN RELIEF VALVE 74
LUBRICATION RELIEF VALVE 77
SCAVENGING PUMP STRAINER 78
POWER TRAIN PUMP STRAINER 79
POWER TRAIN OIL FILTER 80
HSS SYSTEM 81
HSS PUMP 93
HSS MOTOR 109
COOLING FAN PUMP 117
COOLING FAN MOTOR 125
HSS CHARGE FILTER BYPASS VALVE 131
HSS OIL COOLER BYPASS VALVE 132
STEERING BRAKE CONTROL 133
BEVEL GEAR SHAFT, HSS, BRAKE 135
BRAKE VALVE 149
FINAL DRIVE 153
TRACK FRAME 156
TRACK ROLLER BOGIE 158
RECOIL SPRING 159
MAIN FRAME 160
SUSPENSION 161
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 163
PPC CONTROL PIPING DIAGRAM 166
WORK EQUIPMENT CONTROL 167
HYDRAULIC TANK AND FILTER 169
ACCUMULATOR 171
PPC LOCK VALVE 172
PPC VALVE 173
PCCS LEVER 183
PISTON VALVE 186
PIN PULLER SWITCH 187
PIN PULLER SOLENOID VALVE 189
MAIN CONTROL VALVE 191
SELF PRESSURE REDUCING VALVE 217
CYLINDER STAY 224
WORK EQUIPMENT 225
CAB MOUNT 229
CAB 230
AIR CONDITIONER 232
ENGINE CONTROL 233
ENGINE CONTROL SYSTEM 234
CRI ENGINE CONTROL SYSTEM 235
MONITOR SYSTEM 237
MONITOR PANEL 239
SENSORS 242
DECELERATION POTENTIOMETER 246
PALM COMMAND CONTROL SYSTEM 248
20 TESTING AND ADJUSTING 250
STANDARD VALUE TABLE FOR ENGINE 251
STANDARD VALUE TABLE FOR CHASSIS 252
TESTING AND ADJUSTING 258
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 259
MEASURING ENGINE SPEED 261
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 264
MEASURING EXHAUST TEMPERATURE 266
MEASURING EXHAUST GAS COLOR 268
ADJUSTING VALVE CLEARANCE 270
MEASURING COMPRESSION PRESSURE 271
MEASURING BLOW-BY PRESSURE 273
MEASURING ENGINE OIL PRESSURE 274
HANDLING OF FUEL SYSTEM DEVICES 275
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM 275
MEASURING FUEL PRESSURE 276
BLEEDING AIR FROM FUEL CIRCUIT 277
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE 279
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 280
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT 281
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL 282
MEASURING POWER TRAIN OIL PRESSURE 284
TESTING AND ADJUSTING HSS OIL PRESSURE 289
ADJUSTING TRANSMISSION SPEED SENSOR 294
BLEEDING AIR FROM HSS PUMP 295
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE 295
ADJUSTING BRAKE PEDAL 296
ADJUSTING AT PARKING BRAKE LEVER 298
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE 299
INSPECTING WEAR OF SPROCKET 301
ADJUSTING CLEARANCE OF IDLER 302
TESTING AND ADJUSTING TRACK SHOE TENSION 303
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE 304
TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE 307
MEASURING PPC VALVE OUTPUT PRESSURE 308
ADJUSTING PLAY OF PPC VALVE 310
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE 311
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER 312
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER 313
RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDER 314
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER 314
ADJUSTING SAFETY LOCK LEVER 315
MEASURING FAN MOTOR SPEED 316
MEASURING FAN CIRCUIT OIL PRESSURE 317
BLEEDING AIR FROM FAN PUMP 318
ADJUSTING BLADE (SEMI-U TILTDOZER) 319
TESTING AND ADJUSTING OF OPERATOR’S CAB 321
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 325
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER 366
ADJUSTMENT METHOD OF REPLACED CONTROLLER 366
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM 368
PM CLINIC SERVICE 370
UNDERCARRIAGE TROUBLESHOOTING REPORT 377
TROUBLESHOOTING 382
POINTS TO REMEMBER WHEN TROUBLESHOOTING 383
SEQUENCE OF EVENTS IN TROUBLESHOOTING 384
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 385
CHECKS BEFORE TROUBLESHOOTING 393
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 394
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM 397
CONNECTOR ARRANGEMENT DRAWING 403
CIRCUIT DRAWING FOR MONITOR PANEL (M CIRCUIT) 409
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT) 411
CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (S CIRCUIT) 413
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 415
T-BRANCH BOX AND T-BRANCH TABLE 438
PARTS & SERVICE OPERATION TIPS 440
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE) 464
ERROR CODES TABLE 465
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 469
ERROR CODE 1500L0 (TRANSMISSION CLUTCH: DOUBLE ENGAGEMENT) 471
ERROR CODE 15SAL1 (FORWARD CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS TURNED OFF) 472
ERROR CODE 15SALH (FORWARD CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS TURNED ON) 473
ERROR CODE 15SBL1 (REVERSE CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS TURNED OFF) 474
ERROR CODE 15SBLH (REVERSE CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS TURNED ON) 475
ERROR CODE 15SEL1 (1ST CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS TURNED OFF) 476
ERROR CODE 15SELH (1ST CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS TURNED ON) 477
ERROR CODE 15SFL1 (2ND CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS TURNED OFF) 478
ERROR CODE 15SFLH (2ND CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IS TURNED ON) 479
ERROR CODE 15SGL1 (3RD CLUTCH ECMV: FILL SIGNAL IS ON WHEN COMMAND CURRENT IN TURNED OFF) 480
ERROR CODE 15SGLH (3RD CLUTCH ECMV: FILL SIGNAL IS OFF WHEN COMMAND CURRENT IF TURNED ON) 481
ERROR CODE A000N1 (ENGINE: OVERRUN) 482
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION) 483
ERROR CODE AD00L2 (COMMON RAIL: ABNORMAL FUEL PRESSURE) 483
ERROR CODE AD00MA (COMMON RAIL: MALFUNCTION) 484
ERROR CODE AD10L3 (FUEL SUPPLY PUMP: OBJECTIVE PART CANNOT BE CONTROLLED) 485
ERROR CODE AD10MA (FUEL SUPPLY PUMP: MALFUNCTION) 487
ERROR CODE AD10MB (FUEL SUPPLY PUMP: PERFORMANCE REDUCTION) 487
ERROR CODE AD11KA (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION IN WIRING) 489
ERROR CODE AD11KB (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT) 491
ERROR CODE AD51KA (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN WIRING) 493
ERROR CODE AD51KB (FUEL SUPPLY PUMP SOLENOID 2: SHORT CIRCUIT) 495
ERROR CODE ADA1KA (NO 1 INJECTOR SOLENOID: DISCONNECTION IN WIRING) 497
ERROR CODE ADAZKB (NO 1, 2, AND 3 INJECTOR SOLENOIDS: SHORT CIRCUIT) 499
ERROR CODE ADB1KA (NO 2 INJECTOR SOLENOID: DISCONNECTION IN WIRING) 501
ERROR CODE ADC1KA (NO 3 INJECTOR SOLENOID: DISCONNECTION IN WIRING) 502
ERROR CODE ADD1KA (NO 4 INJECTOR SOLENOID: DISCONNECTION IN WIRING) 503
ERROR CODE ADDZKB (NO 4, 5, AND 6 INJECTOR SOLENOIDS: SHORT CIRCUIT) 505
ERROR CODE ADE1KA (NO 5 FUEL INJECTOR SOLENOID: DISCONNECTION IN WIRING) 507
ERROR CODE ADF1KA (NO 6 FUEL INJECTOR SOLENOID: DISCONNECTION IN WIRING) 508
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION) 509
ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT) 509
ERROR CODE B@CENS (POWER TRAIN OIL: OVERHEAT) 510
ERROR CODE B@CHZG (HSS CHARGE PRESSURE: OIL PRESSURE REDUCTION) 510
ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT) 511
ERROR CODE D110KA (BATTERY RELAY: DISCONNECTION IN WIRING) 513
ERROR CODE D110KB (BATTERY RELAY: SHORT CIRCUIT) 515
ERROR CODE D130KA (NEUTRAL SAFETY RELAY: DISCONNECTION IN WIRING) 517
ERROR CODE D130KB (NEUTRAL SAFETY RELAY: SHORT CIRCUIT) 519
ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION IN WIRING) 521
ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT) 523
ERROR CODE D182KZ (PREHEATER RELAY COIL: DISCONNECTION IN WIRING OR SHORT CIRCUIT) 525
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY: SHORT CIRCUIT) 527
ERROR CODE D5ZFKA (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION IN WIRING) 529
ERROR CODE D5ZFKB (TRANSMISSION NEUTRAL SIGNAL: SHORT CIRCUIT) 530
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION) 531
ERROR CODE DAQ0KK DB30KK (STEERING AND TRANSMISSION CONTROLLER POWER SOURCE: SOURCE VOLTAGE REDUCTION) 533
ERROR CODE DAQ0KT DB30KT (STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER) 535
ERROR CODE DAQ5KK DB35KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 5V POWER SUPPLY: VOLTAGE REDUCTION) 537
ERROR CODE DAQ6KK DB36KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY: SOURCE VOLTAGE REDUCTION) 539
ERROR CODE DAQ9KQ DB39KQ (STEERING AND TRANSMISSION CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY) 541
ERROR CODE DAQRKR DB3RKR (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION) 543
ERROR CODE DB20KQ (MALFUNCTION OF ENGINE CONTROLLER MACHINE MODEL COLLECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS) 545
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER) 547
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE VOLTAGE REDUCTION) 549
ERROR CODE DB29KQ (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY) 551
ERROR CODE DB2AMA (ENGINE CONTROLLER Q-ADJUSTMENT SWITCH: MALFUNCTION) 552
ERROR CODE DB2RKR (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION) 553
ERROR CODE DB2RMC (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION) 555
ERROR CODE DB30KK DAQ0KK (STEERING AND TRANSMISSION CONTROLLER POWER SOURCE: SOURCE VOLTAGE REDUCTION) 557
ERROR CODE DB30KT DAQ0KT (STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER) 557
ERROR CODE DB35KK DAQ5KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 5V POWER SUPPLY: SOURCE VOLTAGE REDUCTION) 557
ERROR CODE DB36KK DAQ6KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY: SOURCE VOLTAGE REDUCTION) 557
ERROR CODE DB39KQ DAQ9KQ (STEERING AND TRANSMISSION CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY) 557
ERROR CODE DB3RKR DAQRKR (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION) 557
ERROR CODE DD11KB (STARTING SWITCH: SHORT CIRCUIT) 559
ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION IN WIRING) 561
ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT) 563
ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION IN WIRING) 565
ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT) 567
ERROR CODE DD14KA DDQ2KA (TRAVEL LOCK SWITCH: DISCONNECTION IN WIRING) 569
ERROR CODE DD14KB DDQ2KB (TRAVEL LOCK SWITCH: SHORT CIRCUIT) 571
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: OPERATION STATE AND STOP STATE OF ENGINE DO NOT AGREE WITH SIGNALS) 573
ERROR CODE DDN7KA (BLADE KNOB PITCH SWITCH: DISCONNECTION IN WIRING) 575
ERROR CODE DDN7KB (BLADE KNOB PITCH SWITCH: SHORT CIRCUIT) 577
ERROR CODE DDQ2KA DD14KA (TRAVEL LOCK SWITCH: DISCONNECTION IN WIRING) 579
ERROR CODE DDQ2KB DD14KB (TRAVEL LOCK SWITCH: SHORT CIRCUIT) 579
ERROR CODE DGE2KX (ENGINE COOLANT TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE) 580
ERROR CODE DGE3L6 (ENGINE COOLANT TEMPERATURE SENSOR (FOR LOW TEMPERATURE): OPERATION STATE AND STOP STATE OF ENGINE DO NOT AGREE WITH SIGNALS) 581
ERROR CODE DGE4KX (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE) 582
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE) 583
ERROR CODE DH21KB (HYDRAULIC PUMP OIL PRESSURE SENSOR: DISCONNECTION IN WIRING OR SHORT CIRCUIT) 585
ERROR CODE DH22KA (HYDRAULIC PUMP OIL PRESSURE SENSOR: DISCONNECTION IN WIRING) 587
ERROR CODE DH22KB (HYDRAULIC PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT) 589
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE) 591
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE) 593
ERROR CODE DHH3KA (HSS PUMP OIL PRESSURE SENSOR A: DISCONNECTION IN WIRING) 595
ERROR CODE DHH3KB (HSS PUMP OIL PRESSURE SENSOR A: SHORT CIRCUIT) 597
ERROR CODE DHH4KA (HSS PUMP OIL PRESSURE SENSOR B: DISCONNECTION IN WIRING) 599
ERROR CODE DHH4KB (HSS PUMP OIL PRESSURE SENSOR B: SHORT CIRCUIT) 601
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE) 603
ERROR CODE DK12KX (DECELERATION PEDAL POTENTIOMETER: INPUT IS OUT OF NORMAL RANGE) 605
ERROR CODE DK30KA (STEERING LEVER POTENTIOMETER 1: DISCONNECTION IN WIRING) 607
ERROR CODE DK30KB (STEERING LEVER POTENTIOMETER 1: SHORT CIRCUIT) 609
ERROR CODE DK30KX (STEERING LEVER POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE) 611
ERROR CODE DK30KZ (STEERING LEVER POTENTIOMETER: DOUBLE FAILURE) 611
ERROR CODE DK30L8 (STEERING LEVER POTENTIOMETER: ANALOG SIGNALS DO NOT AGREE WITH EACH OTHER) 612
ERROR CODE DK31KA (STEERING LEVER POTENTIOMETER 2: DISCONNECTION IN WIRING) 613
ERROR CODE DK31KB (STEERING LEVER POTENTIOMETER 2: SHORT CIRCUIT) 615
ERROR CODE DK40KA (BRAKE PEDAL POTENTIOMETER: DISCONNECTION IN WIRING) 617
ERROR CODE DK40KB (BRAKE PEDAL POTENTIOMETER: SHORT CIRCUIT) 619
ERROR CODE DK55KX (FORWARD-REVERSE LEVER POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE) 621
ERROR CODE DK55KZ (FORWARD-REVERSE LEVER POTENTIOMETER: DOUBLE FAILURE) 621
ERROR CODE DK55L8 (FORWARD-REVERSE LEVER POTENTIOMETER: ANALOG SIGNALS DO NOT AGREE WITH EACH OTHER) 622
ERROR CODE DK56KA (FORWARD-REVERSE LEVER POTENTIOMETER 1: DISCONNECTION IN WIRING) 623
ERROR CODE DK56KB (FORWARD-REVERSE LEVER POTENTIOMETER 1: SHORT CIRCUIT) 625
ERROR CODE DK57KA (FORWARD-REVERSE LEVER POTENTIOMETER 2: DISCONNECTION IN WIRING) 627
ERROR CODE DK57KB (FORWARD-REVERSE LEVER POTENTIOMETER 2: SHORT CIRCUIT) 629
ERROR CODE DKH1KA (BODY PITCH ANGLE SENSOR: DISCONNECTION IN WIRING) 631
ERROR CODE DKH1KB (BODY PITCH ANGLE SENSOR: SHORT CIRCUIT) 633
ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: MALFUNCTION) 635
ERROR CODE DLF1KA (TRANSMISSION BEVEL SPEED SENSOR: DISCONNECTION IN WIRING) 636
ERROR CODE DLH1LC (ENGINE G SPEED SENSOR: MALFUNCTION) 637
ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT) 638
ERROR CODE DW5AKA (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION IN WIRING) 639
ERROR CODE DW5AKB (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT) 640
ERROR CODE DW7BKA (FAN REVERSE SOLENOID: DISCONNECTION IN WIRING) 641
ERROR CODE DW7BKB (FAN REVERSE SOLENOID: SHORT CIRCUIT) 642
ERROR CODE DWN1KA (HSS PUMP SOLENOID B: DISCONNECTION IN WIRING) 643
ERROR CODE DWN1KB (HSS PUMP SOLENOID B: SHORT CIRCUIT) 644
ERROR CODE DWN2KA (HSS PUMP SOLENOID A: DISCONNECTION IN WIRING) 645
ERROR CODE DWN2KB (HSS PUMP SOLENOID A: SHORT CIRCUIT) 646
ERROR CODE DWN5KA (FAN PUMP SOLENOID: DISCONNECTION IN WIRING) 647
ERROR CODE DWN5KB (FAN PUMP SOLENOID: SHORT CIRCUIT) 648
ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION IN WIRING) 649
ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT) 650
ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION IN WIRING) 651
ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT) 652
ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION IN WIRING) 653
ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT) 654
ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION IN WIRING) 655
ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT) 656
ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION IN WIRING) 657
ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT) 658
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 660
BEFORE CARRYING OUT TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E MODE) 661
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 662
E-1 THE ENGINE DOES NOT START 663
E-2 THE PREHEATER DOES NOT OPERATE (MANUAL PREHEATING FUNCTION) 665
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE (GIANT RIPPER ATTACHMENT MACHINE) 667
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON 669
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT 671
E-6 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION FLASHES 673
E-7 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES 675
E-8 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON 679
E-9 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 681
E-10 INDICATION OF THE POWER TRAIN OIL TEMPERATURE GAUGE IS ABNORMAL 682
E-11 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 683
E-12 INDICATION OF THE FUEL GAUGE IS ABNORMAL 684
E-13 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL 685
E-14 INDICATION OF THE SHIFT MODE AND SERVICE METER ARE ABNORMAL 685
E-15 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT 686
E-16 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP 687
E-17 AUTO SHIFT DOWN SWITCH DOES NOT WORK 688
E-18 THE FAN ROTATION SELECT SWITCH DOES NOT WORK 689
E-19 THE BUZZER CANCEL SWITCH DOES NOT WORK 691
E-20 THE INFORMATION SWITCH DOES NOT WORK 693
E-21 CANNOT ENTER INTO SERVICE MODE 695
E-22 THE BACK-UP ALARM DOES NOT SOUND 697
E-23 THE HEAD LAMP, PANEL NIGHT LAMP, REAR LAMP, AND RIPPER POINT LAMP DO NOT LIGHT UP 699
E-24 MALFUNCTION OF WIPERS 701
E-25 WASHING WATER DOES NOT COME OUT 714
E-26 THE AIR CONDITIONER DOES NOT OPERATE 720
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 726
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 727
H-1 NO TRAVEL POWER (NO DRAWBAR PULL) 728
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED) 729
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE 730
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE 731
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE 732
H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD) 733
H-7 STEERING SPEED OR POWER IS LOW 733
H-8 BRAKE DOES NOT WORK 734
H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE 734
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS PUMP OR HSS MOTOR 735
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW 736
H-12 WORK EQUIPMENT DOES NOT MOVE 736
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER 737
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER 737
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER 738
H-16 RIPPER TILT SPEED IS SLOW OR LACKS POWER 738
H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT 739
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT 739
H-19 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT 740
H-20 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE) 740
H-21 BLADE PITCH DOES NOT WORK (PITCH DOZER ATTACHMENT MACHINE) 741
H-22 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP 741
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 742
METHOD OF USING TROUBLESHOOTING CHARTS 743
S-1 Starting performance is poor (starting always takes time) 747
S-2 Engine does not start 748
a) Engine does not turn 748
b) Engine turns but no exhaust smoke comes out 749
c) Exhaust smoke comes out but engine does not start (Fuel is being injected) 750
S-3 Engine does not pick up smoothly (follow-up is poor) 751
S-4 Engine stops during operations 752
S-5 Engine does not rotate smoothly (hunting) 753
S-6 Engine lacks output (or lacks power) 754
S-7 Exhaust smoke is black (incomplete combustion) 755
S-8 Oil consumption is excessive (or exhaust smoke is blue) 756
S-9 Oil becomes contaminated quickly 757
S-10 Fuel consumption is excessive 758
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) 759
S-12 Oil pressure caution lamp lights up (drop in oil pressure) 760
S-13 Oil level rises (water, fuel in oil) 761
S-14 Water temperature becomes too high (overheating) 762
S-15 Abnormal noise is made 763
S-16 Vibration is excessive 764
30 DISASSEMBLY AND ASSEMBLY 765
METHOD OF USING MANUAL 767
PRECAUTIONS WHEN CARRYING OUT OPERATION 768
SPECIAL TOOL LIST 770
SPECIAL TOOL SKETCH 780
STARTING MOTOR 789
REMOVAL AND INSTALLATION 789
ALTERNATOR 790
REMOVAL AND INSTALLATION 790
ENGINE OIL COOLER CORE 791
REMOVAL AND INSTALLATION 791
FUEL SUPPLY PUMP 792
REMOVAL 792
INSTALLATION 794
WATER PUMP 796
REMOVAL AND INSTALLATION 796
TURBOCHARGER 797
REMOVAL AND INSTALLATION 797
FUEL INJECTOR 798
REMOVAL 798
INSTALLATION 799
NOZZLE TIP 801
REMOVAL 801
INSTALLATION 802
ENGINE FRONT SEAL 804
REMOVAL 804
INSTALLATION 805
ENGINE REAR SEAL 807
REMOVAL 807
INSTALLATION 808
CYLINDER HEAD 812
REMOVAL 812
INSTALLATION 817
THERMOSTAT 821
REMOVAL AND INSTALLATION 821
AIR CONDITIONER COMPRESSOR 822
REMOVAL 822
INSTALLATION 823
AIR CONDITIONER CONDENSER 824
REMOVAL AND INSTALLATION 824
FUEL TANK 825
REMOVAL AND INSTALLATION 825
RADIATOR 826
REMOVAL 826
INSTALLATION 828
RADIATOR, OIL COOLER, GUARD 829
REMOVAL 829
INSTALLATION 831
FAN DRIVE 832
REMOVAL AND INSTALLATION 832
FAN MOTOR 833
REMOVAL AND INSTALLATION 833
HYDRAULIC COOLER 834
REMOVAL AND INSTALLATION 834
ENGINE 835
REMOVAL 835
INSTALLATION 837
DAMPER 838
REMOVAL 838
INSTALLATION 839
DISASSEMBLY 840
ASSEMBLY 843
POWER TRAIN UNIT 847
REMOVAL 847
INSTALLATION 851
SEPARATION 852
POWER TRAIN 856
PTO 857
DISASSEMBLY 857
ASSEMBLY 861
TORQUE CONVERTER 866
DISASSEMBLY 866
ASSEMBLY 869
TORQFLOW TRANSMISSION 872
DISASSEMBLY 872
ASSEMBLY 881
HSS CASE 892
DISASSEMBLY 892
ASSEMBLY 901
HYDRAULIC PUMP 914
REMOVAL 914
INSTALLATION 918
HSS MOTOR 919
REMOVAL AND INSTALLATION 919
POWER TRAIN MAIN RELIEF VALVE 920
REMOVAL AND INSTALLATION 920
POWER TRAIN MAIN RELIEF VALVE 921
DISASSEMBLY AND ASSEMBLY 921
HSS, PPC CHARGE VALVE 922
REMOVAL AND INSTALLATION 922
HSS AND PPC CHARGE VALVE 923
DISASSEMBLY AND ASSEMBLY 923
TRANSMISSION CONTROL VALVE 924
REMOVAL 924
INSTALLATION 925
TRANSMISSION CONTROL VALVE 926
DISASSEMBLY AND ASSEMBLY 926
BRAKE VALVE 928
REMOVAL AND INSTALLATION 928
BRAKE VALVE 929
DISASSEMBLY AND ASSEMBLY 929
FINAL DRIVE 931
REMOVAL 931
INSTALLATION 933
FINAL DRIVE 934
DISASSEMBLY 934
ASSEMBLY 939
TRACK FRAME 945
REMOVAL 945
INSTALLATION 947
IDLER 948
REMOVAL 948
INSTALLATION 949
IDLER 950
DISASSEMBLY 950
ASSEMBLY 952
RECOIL SPRING 955
REMOVAL AND INSTALLATION 955
RECOIL SPRING 956
DISASSEMBLY 956
ASSEMBLY 961
TRACK ROLLER 965
REMOVAL 965
INSTALLATION 966
TRACK ROLLER 967
DISASSEMBLY 967
ASSEMBLY 970
BOGIE 973
REMOVAL 973
INSTALLATION 975
BOGIE 976
DISASSEMBLY 976
ASSEMBLY 979
CARRIER ROLLER 983
REMOVAL AND INSTALLATION 983
CARRIER ROLLER 984
DISASSEMBLY 984
ASSEMBLY 986
TRACK SHOE 989
REMOVAL 989
INSTALLATION 991
OVERALL DISASSEMBLY 992
OVERALL ASSEMBLY 997
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS 1011
ONE LINK 1012
FIELD DISASSEMBLY 1012
FIELD ASSEMBLY 1014
MASTER LINK 1016
DISASSEMBLY 1016
ASSEMBLY 1018
PIVOT SHAFT 1021
REMOVAL AND INSTALLATION 1021
EQUALIZER BAR 1022
REMOVAL 1022
INSTALLATION 1023
EQUALIZER BAR SIDE BUSHING 1024
REMOVAL AND INSTALLATION 1024
SEGMENT TEETH 1025
REMOVAL AND INSTALLATION 1025
HYDRAULIC TANK 1026
REMOVAL AND INSTALLATION 1026
MAIN CONTROL VALVE 1027
REMOVAL 1027
INSTALLATION 1028
DISASSEMBLY 1029
ASSEMBLY 1032
HSS OIL COOLER BYPASS VALVE 1036
REMOVAL AND INSTALLATION 1036
DISASSEMBLY AND ASSEMBLY 1037
BLADE PPC VALVE 1038
REMOVAL 1038
INSTALLATION 1039
RIPPER PPC VALVE 1040
REMOVAL 1040
INSTALLATION 1041
BLADE PPC VALVE 1042
DISASSEMBLY 1042
ASSEMBLY 1043
BLADE LIFT CYLINDER 1045
REMOVAL AND INSTALLATION 1045
BLADE TILT CYLINDER 1046
REMOVAL AND INSTALLATION 1046
RIPPER LIFT CYLINDER 1047
REMOVAL AND INSTALLATION 1047
RIPPER TILT CYLINDER 1048
REMOVAL AND INSTALLATION 1048
HYDRAULIC CYLINDER 1049
DISASSEMBLY 1049
ASSEMBLY 1052
BLADE 1056
REMOVAL 1056
INSTALLATION 1057
DISASSEMBLY 1058
ASSEMBLY 1060
MULTI-SHANK RIPPER 1062
DISASSEMBLY 1062
ASSEMBLY 1064
ROPS GUARD 1066
REMOVAL AND INSTALLATION 1066
OPERATOR’S CAB 1067
REMOVAL 1067
INSTALLATION 1068
HOOD 1069
REMOVAL AND INSTALLATION 1069
FLOOR FRAME 1070
REMOVAL 1070
INSTALLATION 1074
DASHBOARD 1075
REMOVAL 1075
INSTALLATION 1076
MONITOR 1077
REMOVAL AND INSTALLATION 1077
HSS CONTROLLER 1078
REMOVAL AND INSTALLATION 1078
40 MAINTENANCE STANDARD 1079
ENGINE MOUNT 1080
POWER TRAIN UNIT MOUNT 1081
DAMPER, UNIVERSAL JOINT 1082
TORQUE CONVERTER, PTO 1083
TRANSMISSION 1086
MAIN RELIEF VALVE 1088
BEVEL GEAR SHAFT, HSS, BRAKE (1/2) 1090
BEVEL GEAR SHAFT, HSS, BRAKE (2/2) 1092
BRAKE VALVE 1094
SCAVENGING PUMP, HSS, PPC CHARGE PUMP 1095
POWER TRAIN PUMP, LUBRICATION PUMP 1096
OIL COOLER BYPASS VALVE 1097
FINAL DRIVE 1098
SPROCKET 1100
MAIN FRAME 1102
TRACK FRAME 1104
RECOIL SPRING 1105
TRACK ROLLER BOGIE 1106
IDLER 1108
TRACK ROLLER 1110
CARRIER ROLLER 1112
TRACK SHOE 1113
SUSPENSION 1120
WORK EQUIPMENT PUMP 1122
HSS PUMP 1123
HSS MOTOR 1124
COOLING FAN PUMP 1125
COOLING FAN MOTOR 1127
PPC VALVE 1128
MAIN CONTROL VALVE 1130
SELF PRESSURE REDUCING VALVE 1135
WORK EQUIPMENT CYLINDER 1136
QUICK DROP VALVE 1140
CYLINDER STAY 1141
WORK EQUIPMENT 1142
90 OTHERS 1149
HYDRAULIC CIRCUIT DIAGRAM (1/2) 1150
HYDRAULIC CIRCUIT DIAGRAM (2/2) 1151
ELECTRIC CIRCUIT DIAGRAM (1/6) 1152
ELECTRIC CIRCUIT DIAGRAM (2/6) 1153
ELECTRIC CIRCUIT DIAGRAM (3/6) 1154
ELECTRIC CIRCUIT DIAGRAM (4/6) 1155
ELECTRIC CIRCUIT DIAGRAM (5/6) 1156
ELECTRIC CIRCUIT DIAGRAM (6/6) 1157
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB 1158
ELECTRIC CIRCUIT DIAGRAM OF AIR CONDITIONER 1159

DESCRIPTION:

Komatsu D155AX-5 Bulldozer Shop Manual SEBM034805 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
D155AX-5                  76001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

S.V 28/12/24