Komatsu D155AX-7 Bulldozer Shop Manual SEN05653-13 – PDF DOWNLOAD 

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Komatsu D155AX-7 Bulldozer Shop Manual SEN05653-13 – PDF DOWNLOAD

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Komatsu D155AX-7 Bulldozer Shop Manual SEN05653-13 – PDF DOWNLOAD 

Language : English
Pages : 2560
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D155AX-7 Bulldozer Shop Manual SEN05653-13 – PDF DOWNLOAD 

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 19
Important safety notice 19
How to read the shop manual 26
Explanation of terms for maintenance standard 28
Handling equipment of fuel system devices 30
Handling of intake system parts 31
Handling of hydraulic equipment 32
Method of disconnecting and connecting of push-pull type coupler 34
Handling of electrical equipment 37
How to read electric wire code 45
Precautions when performing operation 48
Practical use of KOMTRAX 53
Standard tightening torque table 54
List of abbreviation 60
Conversion table 65
01 Specification 71
Table of contents 72
Specifications 73
Specification drawing 73
Specification 75
Weight table 83
Table of fuel, coolant, and lubricants 85
10 Structure and function 87
Table of contents 88
Engine and cooling system 90
Engine related parts 90
KVGT 92
EGR system piping drawing 98
EGR system circuit diagram 100
EGR valve 101
EGR cooler 103
KCCV layout drawing 105
KCCV ventilator 107
KDPF 109
Damper 113
Cooling system 115
Cooling fan pump 118
Cooling fan motor 128
Power train 136
Power train system 136
HSS system 139
Overall drawing of power train unit 141
Power train mount 143
Layout of power train hydraulic piping 145
Transmission, steering, and brake control 147
Universal joint 149
Torque converter and PTO 150
Torque converter control valve 158
Lockup clutch ECMV 159
Stator clutch ECMV 164
Transmission 168
Transmission ECMV 182
Main relief valve and torque converter relief valve 191
Transmission lubrication relief valve 193
Bevel gear shaft, HSS, and brake 194
Brake control valve 212
Brake ECMV 215
Brake solenoid valve 219
Sudden stop prevention valve 221
Final drive 223
Undercarriage and frame 226
Main frame 226
Suspension 228
Track frame and idler cushion 230
Hydraulic system 232
Hydraulic component layout 232
Work equipment control 235
Hydraulic tank 238
CLSS 242
Scavenging pump 246
Steering lubrication pump and power train pump 247
Work equipment and HSS pump 249
HSS motor 273
Control valve 281
Quick drop valve 319
Work equipment lock solenoid valve 325
Hydraulic oil cooler bypass valve 326
Accumulator 327
Self-pressure reducing valve 329
Work equipment 336
Cylinder stay 336
Blade 337
Ripper 338
Piston valve 340
Cab and its attachments 341
ROPS cab 341
Function 342
Cab mount 343
Electrical system 344
Engine control 344
Engine control system 345
Palm command control system 346
System operating lamp function 350
Battery disconnect switch function 352
Machine monitor system 354
KOMTRAX system 376
System component parts 378
Sensor 396
20 Standard value tables 411
Table of contents 412
Standard service value table 413
Standard value table for engine 413
Standard value table for machine 415
Standard value table for electrical system 426
30 Testing and adjusting 437
Table of contents 438
Related information on testing and adjusting 440
Tools for testing and adjusting 440
Sketch of tools for testing and adjusting 445
Engine and cooling system 449
Testing engine speed 449
Testing boost pressure 451
Testing exhaust gas temperature 452
Testing exhaust gas color 455
Adjusting valve clearance 457
Measuring compression pressure 459
Testing blowby pressure 462
Testing engine oil pressure 463
Testing EGR valve and KVGT driving oil pressure 464
Measuring fuel pressure 466
Testing fuel return rate and leakage 467
Bleeding air from fuel system 470
Testing fuel circuit for leakage 472
Handling cylinder cutout mode operation 473
Handling no-injection cranking operation 474
Replacing belt for alternator and air conditioner compressor, adjusting belt tension 475
Adjusting fuel control dial and decelerator pedal 476
Procedures for cleaning fuel doser 478
Writing compensation values at replacement of injector and engine controller 481
Power train 485
Testing power train oil pressure 485
Adjusting transmission output shaft speed sensor (replacement procedure) 491
Simple test procedure for brake performance 492
Adjusting brake pedal 493
Adjusting parking brake lever 495
Retrieval of disabled machine by using brake release device 497
Undercarriage and frame 500
Adjusting idler clearance 500
Testing and adjusting track tension 502
Hydraulic system 503
Releasing remaining pressure in work equipment cylinder 503
Testing and adjusting work equipment and HSS oil pressures 504
Bleeding air from work equipment and HSS pump 508
Testing source pressure of control circuit 509
Testing work equipment lock solenoid valve output pressure 510
Isolating the parts causing hydraulic drift in blade and ripper 511
Checking fan speed 512
Testing fan circuit oil pressure 513
Bleeding air from fan pump 515
Testing internal oil leakage of work equipment cylinder 516
Bleeding air from work equipment cylinders 517
Emergency operating method when work equipment has trouble 518
Testing ripper pin puller solenoid valve output pressure 520
Work equipment 521
Adjusting work equipment lock lever 521
Adjusting blade 523
Testing and adjusting play of blade electric lever 525
Cab and its attachments 533
Adjusting operator’s cab 533
Electrical system 536
Special functions of machine monitor 536
Angle adjustment of rear view camera 615
Handling voltage circuit of engine controller 616
Handling battery disconnect switch 617
Testing diodes 618
Pm clinic 619
Pm Clinic service 619
Check sheet 624
40 Troubleshooting 631
Table of contents 632
Related information on troubleshooting 642
Troubleshooting points 642
Sequence of events in troubleshooting 644
Checks before troubleshooting 646
Inspection procedure before troubleshooting 648
Preparation for troubleshooting of electrical system 666
Classification and procedures for troubleshooting 672
Symptom and troubleshooting numbers 674
Information in troubleshooting table 677
Connector/electrical wiring connection table 679
Layout of connectors 752
Connector contact identification 759
T-branch box and T-branch adapter table 798
Fuse location table 803
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 807
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 810
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 811
Failure codes table 812
Troubleshooting by failure code (Display of code) 826
Failure code [1500L0] 826
Failure code [15SAL1] 827
Failure code [15SALH] 829
Failure code [15SBL1] 831
Failure code [15SBLH] 833
Failure code [15SEL1] 835
Failure code [15SELH] 837
Failure code [15SFL1] 839
Failure code [15SFLH] 841
Failure code [15SGL1] 843
Failure code [15SGLH] 845
Failure code [15SJL1] 847
Failure code [15SJLH] 849
Failure code [1800MW] 851
Failure code [2300NR] 853
Failure code [2301L1] 854
Failure code [2301LH] 856
Failure code [2302L1] 858
Failure code [2302LH] 860
Failure code [879AKA] 862
Failure code [879AKB] 863
Failure code [879BKA] 864
Failure code [879BKB] 865
Failure code [879CKA] 866
Failure code [879CKB] 867
Failure code [879DKZ] 868
Failure code [879EMC] 869
Failure code [879FMC] 870
Failure code [879GKX] 871
Failure code [989L00] 872
Failure code [989M00] 873
Failure code [989N00] 874
Failure code [A1U0N3] 875
Failure code [A1U0N4] 878
Failure code [AA10NX] 881
Failure code [AB00KE] 883
Failure code [B@BAZG] 885
Failure code [B@BCNS] 886
Failure code [B@BCZK] 887
Failure code [B@CENS] 889
Failure code [B@HANS] 890
Failure code [CA115] 891
Failure code [CA122] 892
Failure code [CA123] 895
Failure code [CA131] 898
Failure code [CA132] 901
Failure code [CA135] 904
Failure code [CA141] 907
Failure code [CA144] 910
Failure code [CA145] 913
Failure code [CA153] 916
Failure code [CA154] 919
Failure code [CA187] 922
Failure code [CA221] 925
Failure code [CA222] 928
Failure code [CA227] 931
Failure code [CA234] 932
Failure code [CA238] 934
Failure code [CA239] 936
Failure code [CA271] 938
Failure code [CA272] 940
Failure code [CA273] 942
Failure code [CA274] 944
Failure code [CA322] 946
Failure code [CA323] 949
Failure code [CA324] 952
Failure code [CA325] 955
Failure code [CA331] 958
Failure code [CA332] 961
Failure code [CA343] 964
Failure code [CA351] 965
Failure code [CA352] 966
Failure code [CA356] 968
Failure code [CA357] 971
Failure code [CA386] 975
Failure code [CA441] 976
Failure code [CA442] 980
Failure code [CA449] 981
Failure code [CA451] 982
Failure code [CA452] 985
Failure code [CA515] 988
Failure code [CA516] 990
Failure code [CA553] 992
Failure code [CA555] 994
Failure code [CA556] 995
Failure code [CA559] 997
Failure code [CA595] 1003
Failure code [CA687] 1004
Failure code [CA689] 1007
Failure code [CA691] 1011
Failure code [CA692] 1014
Failure code [CA697] 1017
Failure code [CA698] 1018
Failure code [CA731] 1019
Failure code [CA778] 1020
Failure code [CA1117] 1025
Failure code [CA1664] 1026
Failure code [CA1691] 1030
Failure code [CA1695] 1034
Failure code [CA1696] 1036
Failure code [CA1843] 1039
Failure code [CA1844] 1042
Failure code [CA1879] 1045
Failure code [CA1881] 1048
Failure code [CA1883] 1051
Failure code [CA1921] 1057
Failure code [CA1922] 1060
Failure code [CA1923] 1066
Failure code [CA1924] 1069
Failure code [CA1925] 1072
Failure code [CA1927] 1075
Failure code [CA1928] 1078
Failure code [CA1942] 1081
Failure code [CA1963] 1083
Failure code [CA1977] 1090
Failure code [CA1993] 1093
Failure code [CA2185] 1096
Failure code [CA2186] 1098
Failure code [CA2249] 1100
Failure code [CA2265] 1101
Failure code [CA2266] 1103
Failure code [CA2271] 1106
Failure code [CA2272] 1109
Failure code [CA2349] 1112
Failure code [CA2353] 1115
Failure code [CA2357] 1118
Failure code [CA2381] 1121
Failure code [CA2382] 1124
Failure code [CA2383] 1127
Failure code [CA2386] 1130
Failure code [CA2387] 1133
Failure code [CA2555] 1136
Failure code [CA2556] 1139
Failure code [CA2637] 1142
Failure code [CA2639] 1145
Failure code [CA2732] 1148
Failure code [CA2733] 1151
Failure code [CA2741] 1154
Failure code [CA2765] 1156
Failure code [CA2878] 1157
Failure code [CA2881] 1161
Failure code [CA3133] 1168
Failure code [CA3134] 1171
Failure code [CA3135] 1174
Failure code [CA3167] 1179
Failure code [CA3251] 1184
Failure code [CA3253] 1189
Failure code [CA3254] 1193
Failure code [CA3255] 1198
Failure code [CA3256] 1203
Failure code [CA3311] 1208
Failure code [CA3312] 1213
Failure code [CA3313] 1218
Failure code [CA3314] 1223
Failure code [CA3315] 1229
Failure code [CA3316] 1236
Failure code [CA3317] 1241
Failure code [CA3318] 1247
Failure code [CA3319] 1254
Failure code [CA3321] 1260
Failure code [CA3322] 1265
Failure code [CA3419] 1272
Failure code [CA3421] 1274
Failure code [D130KA] 1277
Failure code [D130KB] 1280
Failure code [D190KA] 1283
Failure code [D190KB] 1286
Failure code [D19JKZ] 1289
Failure code [D811MC] 1293
Failure code [D862KA] 1294
Failure code [D8ALKA] 1295
Failure code [D8ALKB] 1298
Failure code [D8AQKR] 1301
Failure code [DAF0MB] 1303
Failure code [DAF0MC] 1304
Failure code [DAF8KB] 1305
Failure code [DAF9KQ] 1307
Failure code [DAFGMC] 1308
Failure code [DAFLKA] 1309
Failure code [DAFLKB] 1312
Failure code [DAFQKR] 1315
Failure code [DAZ9KQ] 1316
Failure code [DAZQKR] 1317
Failure code [DB2QKR] 1319
Failure code [DB2RKR] 1327
Failure code [DB90KT] 1334
Failure code [DB90MC] 1335
Failure code [DB91KK] 1336
Failure code [DB92KK] 1339
Failure code [DB95KK] 1342
Failure code [DB97KK] 1345
Failure code [DB99KQ] 1347
Failure code [DB9LKA] 1348
Failure code [DB9LKB] 1351
Failure code [DB9QKR] 1354
Failure code [DB9RKR] 1356
Failure code [DBE0KT] 1359
Failure code [DBE0MC] 1360
Failure code [DBE1KK] 1361
Failure code [DBE2KK] 1364
Failure code [DBE5KK] 1367
Failure code [DBE6KK] 1370
Failure code [DBE9KQ] 1373
Failure code [DBELKA] 1375
Failure code [DBELKB] 1378
Failure code [DBEQKR] 1381
Failure code [DBERKR] 1383
Failure code [DD12KA] 1386
Failure code [DD12KB] 1388
Failure code [DD13KA] 1390
Failure code [DD13KB] 1392
Failure code [DD14KA] 1394
Failure code [DD14KB] 1396
Failure code [DDDDKA] 1399
Failure code [DDDDKB] 1401
Failure code [DDDDKX] 1404
Failure code [DDKAKA] 1405
Failure code [DDKAKB] 1408
Failure code [DDKBKA] 1411
Failure code [DDKBKB] 1414
Failure code [DDKCL4] 1417
Failure code [DDKEL4] 1420
Failure code [DDN7L4] 1423
Failure code [DDN8L4] 1426
Failure code [DDNLKA] 1429
Failure code [DDNLKB] 1431
Failure code [DDTSL1] 1433
Failure code [DDTSLH] 1435
Failure code [DFA4KX] 1437
Failure code [DFA4KZ] 1438
Failure code [DFA4L8] 1439
Failure code [DFA5KA] 1440
Failure code [DFA5KB] 1444
Failure code [DFA6KA] 1447
Failure code [DFA6KB] 1451
Failure code [DFA7KX] 1454
Failure code [DFA7KZ] 1455
Failure code [DFA7L8] 1456
Failure code [DFA8KA] 1457
Failure code [DFA8KB] 1461
Failure code [DFA9KA] 1464
Failure code [DFA9KB] 1468
Failure code [DFAAKX] 1471
Failure code [DFAAKZ] 1472
Failure code [DFAAL8] 1473
Failure code [DFABKA] 1474
Failure code [DFABKB] 1478
Failure code [DFACKA] 1481
Failure code [DFACKB] 1485
Failure code [DGS1KA] 1488
Failure code [DGS1KX] 1491
Failure code [DGT1KA] 1493
Failure code [DGT1KX] 1496
Failure code [DH21KA] 1498
Failure code [DH21KB] 1501
Failure code [DHA4KA] 1504
Failure code [DHT5KA] 1506
Failure code [DHT5KB] 1509
Failure code [DHT7KA] 1512
Failure code [DHT7KB] 1515
Failure code [DK10KA] 1518
Failure code [DK10KB] 1522
Failure code [DK30KA] 1525
Failure code [DK30KB] 1529
Failure code [DK30KX] 1532
Failure code [DK30KZ] 1533
Failure code [DK30L8] 1534
Failure code [DK31KA] 1535
Failure code [DK31KB] 1539
Failure code [DK40KA] 1542
Failure code [DK40KB] 1545
Failure code [DK55KX] 1548
Failure code [DK55KZ] 1549
Failure code [DK55L8] 1550
Failure code [DK56KA] 1551
Failure code [DK56KB] 1555
Failure code [DK57KA] 1558
Failure code [DK57KB] 1562
Failure code [DKH1KA] 1565
Failure code [DKH1KB] 1568
Failure code [DLM3KA] 1571
Failure code [DLM3MB] 1573
Failure code [DLT3KA] 1574
Failure code [DLT3KB] 1576
Failure code [DR21KX] 1578
Failure code [DR31KX] 1579
Failure code [DV20KB] 1580
Failure code [DW7BKA] 1582
Failure code [DW7BKB] 1584
Failure code [DWN1KA] 1586
Failure code [DWN1KB] 1588
Failure code [DWN1KY] 1590
Failure code [DWN2KA] 1592
Failure code [DWN2KB] 1594
Failure code [DWN2KY] 1596
Failure code [DWN3KA] 1598
Failure code [DWN3KB] 1600
Failure code [DWN3KY] 1602
Failure code [DWN5KA] 1604
Failure code [DWN5KB] 1606
Failure code [DWN5KY] 1608
Failure code [DXA2KA] 1611
Failure code [DXA2KB] 1613
Failure code [DXA2KY] 1615
Failure code [DXH1KA] 1617
Failure code [DXH1KB] 1619
Failure code [DXH1KY] 1621
Failure code [DXH4KA] 1624
Failure code [DXH4KB] 1626
Failure code [DXH4KY] 1628
Failure code [DXH5KA] 1631
Failure code [DXH5KB] 1633
Failure code [DXH5KY] 1635
Failure code [DXH6KA] 1638
Failure code [DXH6KB] 1640
Failure code [DXH6KY] 1642
Failure code [DXH7KA] 1644
Failure code [DXH7KB] 1646
Failure code [DXH7KY] 1648
Failure code [DXH8KA] 1651
Failure code [DXH8KB] 1653
Failure code [DXH8KY] 1655
Failure code [DXHBKA] 1658
Failure code [DXHBKB] 1660
Failure code [DXHBKY] 1662
Failure code [DXHCKA] 1665
Failure code [DXHCKB] 1667
Failure code [DXHCKY] 1669
Failure code [DXHRKA] 1672
Failure code [DXHRKB] 1674
Failure code [DXHRKY] 1676
Failure code [DXHSKA] 1678
Failure code [DXHSKB] 1680
Failure code [DXHSKY] 1682
Failure code [DXHTKA] 1684
Failure code [DXHTKB] 1686
Failure code [DXHTKY] 1688
Failure code [DXHUKA] 1690
Failure code [DXHUKB] 1692
Failure code [DXHUKY] 1694
Failure code [DXHWKA] 1696
Failure code [DXHWKB] 1698
Failure code [DXHWKY] 1700
Failure code [DXHXKA] 1702
Failure code [DXHXKB] 1704
Failure code [DXHXKY] 1706
Failure code [DXHYKA] 1708
Failure code [DXHYKB] 1710
Failure code [DXHYKY] 1712
Failure code [DXHZKA] 1714
Failure code [DXHZKB] 1716
Failure code [DXHZKY] 1718
Failure code [DXJ4KA] 1720
Failure code [DXJ4KB] 1722
Failure code [DXJ8KA] 1724
Failure code [DXJ8KB] 1726
Failure code [DXJ8KY] 1728
Failure code [DXJ9KA] 1730
Failure code [DXJ9KB] 1732
Failure code [DXJ9KY] 1734
Failure code [DXJAKA] 1736
Failure code [DXJAKB] 1738
Failure code [DXJAKY] 1740
Failure code [DXJBKA] 1742
Failure code [DXJBKB] 1744
Failure code [DXJBKY] 1746
Troubleshooting of electrical system (E-mode) 1749
E-1 Engine does not start (Engine does not crank) 1749
E-2 Manual preheating system does not work 1755
E-3 Automatic preheating system does not work 1758
E-4 While preheating is working, preheating monitor does not light up 1760
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1762
E-6 When starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow 1765
E-7 Air cleaner clogging monitor lights up in yellow while engine is running 1767
E-8 Charge level monitor lights up in red while engine is running 1768
E-9 Engine coolant temperature monitor lights up in red while engine is running 1770
E-10 Engine oil pressure monitor lights up in red while engine is running 1771
E-11 Power train oil temperature monitor lights up in red while engine is running 1772
E-12 Hydraulic oil temperature monitor lights up in red while engine is running 1773
E-13 Engine coolant temperature gauge does not indicate correct temparature 1774
E-14 Fuel level gauge does not indicate correct level 1775
E-15 Power train oil temperature gauge does not indicate correct temperature 1777
E-16 Hydraulic oil temperature gauge does not indicate correct temperature 1778
E-17 Operation mode does not change 1779
E-18 Gear shift mode does not change 1780
E-19 Operating customize switch does not display customize screen 1781
E-20 Modifying setting on customize screen does not change setting of machine 1782
E-21 Some areas of machine monitor screen are not displayed 1783
E-22 Alarm buzzer does not sound or does not stop sounding 1784
E-23 While starting switch is in OFF position, service meter is not displayed 1785
E-24 Service mode cannot be selected 1786
E-25 Horn does not sound 1787
E-26 Horn does not stop sounding 1789
E-27 Backup alarm does not sound 1790
E-28 Backup alarm does not stop sounding 1791
E-29 Headlamp does not light up 1792
E-30 Rear lamp and ripper point lamp do not light up 1795
E-31 No wiper operates continuously or intermittently 1798
E-32 Front wiper does not operate (failed continuous and intermittent operations) 1802
E-33 Rear wiper does not operate (failed continuous and intermittent operations) 1806
E-34 Left door wiper does not operate (failed continuous and intermittent operations) 1810
E-35 Right door wiper does not operate (failed continuous and intermittent operations) 1814
E-36 Front washer does not operate 1818
E-37 Rear washer does not operate 1820
E-38 Left door washer does not operate 1822
E-39 Right door washer does not operate 1824
E-40 Ripper pin puller does not work 1826
E-41 Fan does not rotate in reverse 1828
E-42 Fuel feed pump does not operate or stop automatically 1829
E-43 Gear cannot be shifted 1831
E-44 KOMTRAX system does not operate properly 1832
Troubleshooting of hydraulic and mechanical system (H-mode) 1834
Information described in troubleshooting table (H-mode) 1834
System chart of hydraulic and mechanical systems 1835
Failure mode and cause table 1839
H-1 Machine lacks power (insufficient drawbar pull) 1845
H-2 Machine does not travel (at 2nd or 3rd gear speed) 1848
H-3 Machine does not start at all gear speeds 1850
H-4 Machine travels only in one direction, either forward or in reverse 1853
H-5 Large time lag is in gear shifting or directional change 1854
H-6 Machine cannot be steered (machine does not turn to left or right) 1856
H-7 Steering speed or power is insufficient 1857
H-8 Brake does not work 1858
H-9 Torque converter lockup clutch does not engage 1859
H-10 Power train oil overheats 1860
H-11 Unusual noise is heard from around HSS pump or HSS motor 1862
H-12 All work equipment operates slowly 1863
H-13 All work equipment do not operate 1864
H-14 Blade lift speed or power is low 1865
H-15 Blade tilt speed or power is low 1867
H-16 Ripper lift speed or power is low 1869
H-17 Ripper tilt speed or power is low 1871
H-18 Hydraulic drift of lifted blade is large 1873
H-19 Hydraulic drift of tilted blade is large 1874
H-20 Hydraulic drift of lifted ripper is large 1875
H-21 Ripper pin puller cylinder does not operate 1876
H-22 Blade pitch cylinder does not operate 1877
H-23 Unusual noise is heard from around work equipment pump 1878
H-24 Fan speed is abnormal (too high or low, or stationary) 1879
H-25 Unusual noise is heard from around fan 1880
Troubleshooting of engine (S-mode) 1881
Information mentioned in troubleshooting table (S mode) 1881
S-1 When starting switch is turned to START position, engine is not cranked 1882
S-2 The engine cranks but exhaust smoke does not come out 1883
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) 1884
S-4 Engine startability is poor 1885
S-5 Engine does not pick up smoothly 1887
S-6 Engine stops during operation 1889
S-7 Engine runs rough or is unstable 1891
S-8 Engine lacks power 1892
S-9 KDPF gets clogged in a short time 1894
S-10 Engine oil consumption is excessive 1896
S-11 Engine oil becomes contaminated early 1897
S-12 Fuel consumption is excessive 1898
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1899
S-14 Oil pressure drops 1900
S-15 Fuel mixes into engine oil 1901
S-16 Water mixes into engine oil (milky) 1902
S-17 Coolant temperature rises too high (overheating) 1903
S-18 Unusual noise is heard 1904
S-19 Vibration is excessive 1905
S-20 Air cannot be bled from fuel circuit 1906
S-21 Active regeneration is executed frequently 1907
S-22 Active regeneration takes a long time 1908
S-23 White smoke is exhausted during active regeneration 1909
50 Disassembly and Assembly 1911
Table of contents 1912
Related information on disassembly and assembly 1914
How to read this manual 1914
Coating materials list 1916
Special tools list 1920
Sketches of special tools 1930
Engine and cooling system 1944
Removal and installation of fuel supply pump assembly 1944
Removal and installation of fuel injector assembly 1949
Removal and installation of cylinder head assembly 1961
Removal and installation of air cleaner assembly 1979
Removal and installation of KDPF assembly 1981
Disassembly and assembly of KDPF assembly 1984
Removal and installation of KCCV assembly 1994
Removal and installation of engine assembly 1995
Removal and installation of engine front seal 2001
Removal and installation of engine rear seal 2005
Removal and installation of radiator assembly 2010
Removal and installation of aftercooler assembly 2014
Removal and installation of hydraulic oil cooler assembly 2016
Removal and installation of cooling fan drive assembly 2018
Removal and installation of cooling in fan motor assembly 2020
Removal and installation of engine hood assembly 2021
Removal and installation of fuel tank assembly 2024
Power train 2026
Removal and installation of damper assembly 2026
Disassembly and assembly of damper assembly 2029
Removal and installation of power train unit assembly 2037
Disconnection and connection of power train unit assembly 2050
Disassembly and assembly of PTO assembly 2054
Disassembly and assembly of torque converter assembly 2061
Disassembly and assembly of transmission assembly 2070
Disassembly and assembly of HSS assembly 2086
Removal and installation of HSS motor assembly 2102
Removal and installation of final drive assembly 2103
Disassembly and assembly of final drive 2105
Undercarriage and frame 2118
Removal and installation of track frame assembly 2118
Removal and installation of idler assembly 2122
Disassembly and assembly of idler assembly 2124
Removal and installation of recoil spring assembly 2128
Disassembly and assembly of recoil spring assembly 2129
Removal and installation of track roller assembly 2134
Disassembly and assembly of track roller assembly 2136
Removal and installation of 1st bogie assembly 2139
Removal and installation of 2nd, 3rd, or 4th bogie assembly 2144
Disassembly and assembly of bogie assembly 2149
Removal and installation of carrier roller assembly 2153
Disassembly and assembly of carrier roller assembly 2154
Removal and installation of pivot shaft assembly 2157
Separation and connection of track shoe assembly 2159
Overall disassembly and assembly of track shoe assembly 2162
Field disassembly and assembly of one link 2175
Disassembly and assembly of master link 2179
Removal and installation of equalizer bar assembly 2182
Disassembly and assembly of equalizer bar bushing 2184
Removal and installation of segment teeth 2186
Hydraulic system 2187
Removal and installation of hydraulic tank assembly 2187
Removal and installation of control valve assembly 2189
Removal and installation of work equipment pump and HSS pump assembly 2191
Removal and installation of power train pump and steering lubrication pump assembly 2193
Removal and installation of cooling fan pump assembly 2195
Removal and installation of scavenging pump assembly 2197
Disassembly and assembly of hydraulic cylinder assembly 2198
Work equipment 2209
Removal and installation of blade assembly 2209
Removal and installation of blade lift cylinder assembly 2212
Disassembly and assembly of blade assembly 2221
Disassembly and assembly of multi-shank ripper assembly 2225
Disassembly and assembly of giant ripper assembly 2229
Cab and its attachments 2233
Removal and installation of operator’s cab assembly 2233
Removal and installation of operator’s cab glass (adhesion glass) 2238
Removal and installation of operator’s seat 2244
Removal and installation of seat belt 2245
Removal and installation of air conditioner unit assembly 2246
Removal and installation of air conditioner compressor assembly 2250
Removal and installation of air conditioner condenser assembly 2252
Electrical system 2254
Removal and installation of machine monitor assembly 2254
Removal and installation of engine controller assembly 2255
Removal and installation of power train controller assembly 2257
Removal and installation of work equipment controller assembly 2258
Removal and installation of mass air flow and temperature sensor 2259
Removal and installation of KOMTRAX terminal 2261
60 Maintenance standard 2267
Table of contents 2268
Engine and cooling system 2269
Engine mount 2269
Damper 2270
Cooling system 2272
Cooling fan pump 2275
Cooling fan motor 2279
Power train 2281
Power train mount 2281
Universal joint 2283
Torque converter and PTO 2284
Torque converter control valve 2290
Lockup clutch ECMV 2291
Stator cluch ECMV 2292
Transmission 2293
Transmission ECMV 2298
Main relief valve and torque converter relief valve 2299
Transmission lubrication relief valve 2300
Bevel gear shaft, HSS, and brake 2301
Brake control valve 2307
Brake ECMV 2309
Brake solenoid valve 2310
Sudden stop prevention valve 2311
Final drive 2312
Sprocket 2315
Full-scale drawing of sprocket tooth profile 2316
Undercarriage and frame 2317
Main frame 2317
Suspension 2319
Track frame and idler cushion 2321
Idler 2323
Track roller 2325
Carrier roller 2327
Track shoe 2328
Hydraulic system 2332
Hydraulic tank 2332
Scavenging pump 2333
Steering lubrication pump and power train pump 2334
Work equipment and HSS pump 2336
PC-EPC valve 2338
HSS motor 2339
Control valve 2342
Quick drop valve 2355
Self-pressure reducing valve 2357
Work equipment 2359
Cylinder stay 2359
Blade 2360
Cutting edge and end bit 2362
Ripper 2363
Blade lift cylinder 2371
Blade tilt cylinder 2372
Ripper lift cylinder 2373
Ripper tilt cylinder 2374
Cab and its attachments 2375
Cab mount 2375
80 Appendix 2377
Table of contents 2378
Air conditioner components 2379
Precautions for refrigerant 2379
Air conditioner component 2380
Configuration and function of refrigeration cycle 2382
Outline of refrigeration cycle 2383
Air conditioner unit 2385
Air conditioner controller 2392
Compressor 2393
Condenser 2394
Receiver drier 2395
Sunlight sensor 2396
Outer temperature sensor (outside air temperature sensor) 2397
Procedure for testing and troubleshooting 2398
Circuit diagram and arrangement of connector pins 2400
System diagram 2402
Parts and connectors layout 2405
Testing air leakage (duct) 2413
Testing with self-diagnosis function 2416
Testing vent (mode) changeover 2419
Testing FRESH/RECIRC air changeover 2420
Testing sunlight sensor 2421
Testing (dual) pressure switch for refrigerant 2422
Testing relays 2424
Troubleshooting chart 1 2425
Troubleshooting chart 2 2426
Information in troubleshooting table 2428
Failure code list related to air conditioner 2429
Failure code [879AKA] A/C Inner Sensor Open Circuit 2430
Failure code [879AKB] A/C Inner Sensor Short Circuit 2431
Failure code [879BKA] A/C Outer Sensor Open Circuit 2432
Failure code [879BKB] A/C Outer Sensor Short Circuit 2434
Failure code [879CKA] Ventilating Sensor Open Circuit 2436
Failure code [879CKB] Ventilating Sensor Short Circuit 2437
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 2438
Failure code [879EMC] Ventilation Damper Abnormality 2440
Failure code [879FMC] Air Mix Damper Abnormality 2441
Failure code [879GKX] Refrigerant Abnormality 2442
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 2443
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 2445
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 2449
A-4 Troubleshooting for FRESH/RECIRC air changeover 2451
Troubleshooting with gauge pressure 2453
Connection of service tool 2456
Precautions for disconnecting and connecting refrigerant piping 2458
Handling of compressor oil 2460
90 Drawings 2463
Table of contents 2464
Hydraulic circuit diagram 2465
Symbols in hydraulic circuit diagram 2465
Power train hydraulic circuit diagram 2469
Hydraulic circuit diagram 2471
Electric circuit diagram 2475
Symbols in electric circuit diagram 2475
Electrical circuit diagram 2479
Air conditioner electrical circuit diagram 2505
Wiring harness diagram 2507
INDEX 2551

DESCRIPTION:

Komatsu D155AX-7 Bulldozer Shop Manual SEN05653-13 – PDF DOWNLOAD 

SERIAL NUMBERS 90001 and up

How to read the shop manual (ALL-0320-010-A-01-A)
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

S.V 30/12/24