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KOMATSU D155C-1 SHOP MANUAL SEBM032300 – PDF DOWNLOAD
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Description
KOMATSU D155C-1 SHOP MANUAL SEBM032300 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D155C-1 SHOP MANUAL SEBM032300 – PDF DOWNLOAD
Language : English
Pages : 536
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D155C-1 SHOP MANUAL SEBM032300 – PDF DOWNLOAD
COVER............................................................................................. 1 CONTENTS.......................................................................................... 2 01 GENERAL........................................................................................ 23 GENERAL ASSEMBLY DRAWING...................................................................... 24 SPECIFICATIONS................................................................................ 25 WEIGHT TABLE.................................................................................. 29 TABLE OF FUEL,COOLANT AND LUBRICANTS.......................................................... 31 10 STRUCTURE AND FUNCTION......................................................................... 34 RADIATOR FAN ................................................................................. 35 RADIATOR SHUTTER ............................................................................. 37 PTO (POWER TAKE-OFF).......................................................................... 38 OIL COOLER.................................................................................... 39 POWER TRAIN DIAGRAM .......................................................................... 40 TORQFLOW HYDRAULIC CIRCUIT.................................................................... 42 HYDRAULIC CIRCUIT DIAGRAM .................................................................... 43 TORQUE CONVERTER.............................................................................. 44 TRANSMISSION CONTROL.......................................................................... 49 TRANSMISSION.................................................................................. 50 TRANSMISSION CONTROL VALVE.................................................................... 58 TRANSMISSION LUBRICATION RELIEF VALVE......................................................... 65 STEERING AND BRAKE CONTROL ................................................................... 66 AXLE,STEERING CLUTCH.......................................................................... 67 STEERING BRAKE HYDRAULIC PIPING .............................................................. 70 STEERING AND BRAKE HYDRAULIC CIRCUIT DIAGRAM.................................................. 71 STEERING BRAKE ............................................................................... 73 STEERING CONTROL VALVE ....................................................................... 78 FINAL DRIVE .................................................................................. 83 TRACK GROUP .................................................................................. 85 RECOIL SPRING ................................................................................ 86 SUSPENSION.................................................................................... 87 WINCH CONTROL................................................................................. 88 HYDRAULIC CIRCUIT DIAGRAM FOR WINCH........................................................... 91 WINCH......................................................................................... 92 DETAILED WORKING CIRCUIT DIAGRAM FOR CLUTCH AND BRAKE OF WINCH ............................... 97 POWER TRAIN ON WINCH ......................................................................... 99 HIGH-LOW VALVE................................................................................105 PPC VALVE.....................................................................................106 FLOW DIVIDER VALVE............................................................................108 COUNTERWEIGHT HYDRAULIC TANK .................................................................110 COUNTERWEIGHT PIPING..........................................................................111 COUNTERWEIGHT CONTROL ........................................................................112 COUNTERWEIGHT HYDRAULIC CIRCUIT DIAGRAM ......................................................113 COUNTERWEIGHT ................................................................................114 COUNTERWEIGHT CONTROL VALVE...................................................................117 BOOM..........................................................................................118 SAFETY DEVICE.................................................................................119 CAB...........................................................................................125 ACTUAL ELECTRIC WIRING DIAGRAM ...............................................................126 20 TESTING AND ADJUSTING..........................................................................127 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS ................................................128 STANDARD VALUE TABLE FOR CHASSIS..............................................................130 TESTING AND ADJUSTING ........................................................................134 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING ..........................................135 ADJUSTING VALVE CLEARANCE ................................................................136 MEASURING COMPRESSION PRESSURE............................................................137 TESTING AND ADJUSTING FUEL INJECTION TIMING ..............................................138 MEASURING ENGINE OIL PRESSURE.............................................................139 MEASURING EXHAUST COLOR...................................................................140 MEASURING EXHAUST TEMPERATURE ............................................................141 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.............................................142 MEASURING BLOW-BY.........................................................................143 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)............................................144 MEASURING ENGINE SPEED....................................................................145 NEASURING TORQUE CONVERTER STALL SPEED....................................................146 BLEEDING AIR FROM COUNTERWEIGHT CYLINDER .................................................147 ADJUSTING WINCH CONTROL INTERLOCK MECHANISM...............................................148 MEASURING OIL PRESSURE ...................................................................149 MEASURING COUNTERWEIGHT OIL PRESSURE .....................................................151 MEASURING WINCH OIL PRESSURE .............................................................152 HYDRAULIC CIRCUIT DIAGRAM FOR WINCH ......................................................153 MEASURING LEAKAGE INSIDE CYLINDER.........................................................154 REINSTALLATION (IF MOMENT LIMITER WAS REMOVED) AND ADJUSTING .............................155 ADJUSTMENT PROCEDURE FOR MOMENT LIMITER PERFORMANCE.......................................156 TROUBLESHOOTING ..............................................................................159 POINTS TO REMEMBER WHEN TROUBLESHOOTING ..................................................160 SEQUENCE OF EVENTS IN TROUBLESHOOTING ....................................................161 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..........................................162 CHECKS BEFORE TROUBLESHOOTING ............................................................170 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).................................................171 METHOD OF USING TROUBLESHOOTING CHARTS................................................172 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).........................176 S-2 ENGINE DOES NOT START.............................................................177 (1) ENGINE DOES NOT TURN .........................................................177 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)......178 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....179 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..............................180 S-4 ENGINE STOPS DURING OPERATIONS....................................................181 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).........................................182 S-6 ENGINE LACKS OUTPUT (NO POWER)....................................................183 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)......................................184 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).............................185 S-9 OIL BECOMES CONTAMINATED QUICKLY..................................................186 S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................187 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..........188 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................189 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)..............................................190 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................191 S-15 ABNORMAL NOISE IS MADE...........................................................192 S-16 VIBRATION IS EXCESSIVE...........................................................193 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)...................................194 H-1 TORQUE CONVERTER OIL TEMPERATURE IS TOO HIGH .....................................195 H-2 MACHINE DOES NOT MOVE.............................................................196 H-3 MACHINE LACKS POWER OR SPEED......................................................197 H-4 MACHINE MOVES WHEN ENGINE IS STARTED..............................................198 H-5 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.........................198 H-6 EXCESSIVE SHOCK WHEN STARTING OFF OR SHIFTING GEAR................................199 H-7 MACHINE MOVES IN ONLY ONE DIRECTION (FORWARD OR REVERSE)..........................200 H-8 STEERING CLUTCH IS NOT DISENGAGED.................................................201 H-9 STEERING CLUTCH SLIPS.............................................................202 H-10 STEERING BRAKE DOES NOT WORK ....................................................203 H-11 LACK OF POWER,SPEED WHEN RETRACT COUNTERWEIGHT ..................................204 H-12 IMPOSSIBLE TO RETRACT COUNTERWEIGHT .............................................205 H-13 EXCESSIVE HYDRAULIC DRIFT OF COUNTERWEIGHT CYLINDER .............................206 H-14 DEFECTIVE BOOM RAISE,LOWER (SPEED,RAISING FORCE,LOWERING FORCE)..................207 H-15 DEFECTIVE HOOK RAISE,LOWER (SPEED,RAISING FORCE,LOWERING FORCE)..................208 H-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM................................................209 H-17 EXCESSIVE HYDRAULIC DRIFT OF HOOK ...............................................210 H-18 PLAY WHEN OPERATING HOOK ........................................................211 H-19 PLAY WHEN OPERATING BOOM.........................................................212 H-20 EXCESSIVE TIME LAG WHEN OPERATING HOOK ..........................................213 H-21 EXCESSIVE TIME LAG WHEN OPERATING BOOM...........................................214 H-22 EXCESSIVE INCHING AMOUNT.........................................................215 H-23 WINCH FREE FALL DOES NOT WORK ...................................................216 H-24 WINCH OVERHEATS..................................................................217 H-25 EXCESSIVE NOISE WHEN OPERATING WINCH CLUTCH,BRAKE ...............................218 H-26 CONTROL LEVER IS HEAVY...........................................................219 H-27 HOOK OVERWIND HORN DOES NOT SOUND................................................220 30 DISASSEMBLY AND ASSEMBLY ......................................................................221 METHOD OF USING MANUAL .......................................................................223 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................225 SPECIAL TOOL LIST.............................................................................227 REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY...........................................230 REMOVAL AND INSTALLATION OF ALTERNATOR ASSEMBLY...............................................231 REMOVAL AND INSTALLATION OF ENGINE OIL COOLER CORE ASSEMBLY...................................233 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY......................................235 REMOVAL AND INSTALLATION OF WATER PUMP ASSEMBLY ..............................................237 REMOVAL AND INSTALLATION OF TURBOCHARGER ASSEMBLY ...........................................240 REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY ...........................................242 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY............................................243 REMOVAL AND INSTALLATION OF THERMOSTAT ASSEMBLY...............................................257 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY ................................................258 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY................................................269 REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND WINCH OIL COOLER ASSEMBLY....................271 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY...................................................273 REMOVAL AND INSTALLATION OF PTO ASSEMBLY .....................................................282 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY......................................................286 REMOVAL AND INSTALLATION OF TRANSMISSION PUMP ASSEMBLY........................................293 REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY..............................................294 REMOVAL AND INSTALLATION OF TORQUE CONVERTER ASSEMBLY.........................................301 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY.........................................306 REMOVAL AND INSTALLATION OF TORQUE CONVERTER RELIEF VALVE ASSEMBLY............................316 REMOVAL AND INSTALLATION OF TORQUE CONVERTER REGULATING VALVE ASSEMBLY........................317 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER RELIEF VALVE ASSEMBLY............................318 REMOVAL AND INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY...............................319 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY...............................322 REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY.............................................326 DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY....................................328 REMOVAL AND INSTALLATION OF TRANSMISSION LUBRICATION VALVE ASSEMBLY...........................354 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION LUBRICATION VALVE ASSEMBLY...........................355 REMOVAL AND INSTALLATION OF STEERING CONTROL VALVE ASSEMBLY...................................356 DISASSEMBLY AND ASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY ..................................358 REMOVAL AND INSTALLATION OF BRAKE SAFETY VALVE ASSEMBLY.......................................362 DISASSEMBLY AND ASSEMBLY OF BRAKE SAFETY VALVE ASSEMBLY ......................................363 REMOVAL AND INSTALLATION OF STEERING PUMP ASSEMBLY ...........................................364 REMOVAL AND INSTALLATION OF STEERING CLUTCH ASSEMBLY..........................................365 DISASSEMBLY AND ASSEMBLY OF BRAKE BOOSTER ASSEMBLY............................................368 DISASSEMBLY AND ASSEMBLY OF STEERING RELIEF VALVE ASSEMBLY ...................................369 DISASSEMBLY AND ASSEMBLY OF STEERING CLUTCH ASSEMBLY .........................................370 DISASSEMBLY AND ASSEMBLY OF BEVEL GEAR SHAFT ASSEMBLY.........................................372 DISASSEMBLY AND ASSEMBLY OF FIRST PINION ASSEMBLY.............................................379 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY..............................................382 REMOVAL AND INSTALLATION OF TRACK ASSEMBLY....................................................393 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY...........................................396 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY.............................................398 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY ...........................................400 REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY..............................................402 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY....................................................406 REMOVAL AND INSTALLATION OF WINCH CONTROL VALVE ASSEMBLY .....................................407 DISASSEMBLY AND ASSEMBLY OF WINCH CONTROL VALVE ASSEMBLY .....................................408 REMOVAL AND INSTALLATION OF HIGH/LOW SPEED SELECTOR VALVE ASSEMBLY............................413 DISASSEMBLY AND ASSEMBLY OF HIGH/LOW SPEED SELECTOR VALVE ASSEMBLY............................414 REMOVAL AND INSTALLATION OF TOWING WINCH PUMP ASSEMBLY .......................................418 REMOVAL AND INSTALLATION OF COUNTERWEIGHT PUMP ASSEMBLY ......................................419 REMOVAL AND INSTALLATION OF COUNTERWEIGHT CYLINDER ASSEMBLY...................................420 DISASSEMBLY AND ASSEMBLY OF COUNTERWEIGHT CYLINDER ASSEMBLY...................................421 REMOVAL AND INSTALLATION OF COUNTERWEIGHT CONTROL VALVE ASSEMBLY..............................425 DISASSEMBLY AND ASSEMBLY OF COUNTERWEIGHT CONTROL VALVE ASSEMBLY..............................426 REMOVAL AND INSTALLATION OF GATE FRAME ASSEMBLY...............................................430 REMOVAL AND INSTALLATION OF COUNTERWEIGHT/FRAME...............................................433 REMOVAL AND INSTALLATION OF BOOM/FRAME........................................................437 REMOVAL AND INSTALLATION OF TOWING WINCH ASSEMBLY.............................................438 DISASSEMBLY AND ASSEMBLY OF TOWING WINCH ASSEMBLY ............................................442 REMOVAL AND INSTALLATION OF HEATER ASSEMBLY...................................................477 40 MAINTENANCE STANDARD...........................................................................478 ENGINE MOUNT .................................................................................479 PTO...........................................................................................480 TORQFLOW TRANSMISSION ........................................................................481 (1) TORQUE CONVERTER......................................................................481 (2) RELIEF VALVE AND REGULATOR VALVE......................................................483 TRANSMISSION .................................................................................484 TRANSMISSION CONTROL VALVE ...................................................................486 TRANSMISSION PUMP ............................................................................488 BEVEL GEAR SHAFT AND STEERING CLUTCH .........................................................489 STEERING BRAKE ...............................................................................493 STEERING CONTROL VALVE........................................................................495 STEERING PUMP ................................................................................497 FINAL DRIVE...................................................................................498 TRACK FRAME ..................................................................................502 RECOIL SPRING ................................................................................503 TRACK ........................................................................................504 IDLER.........................................................................................506 TRACK ROLLER..................................................................................508 CARRIER ROLLER................................................................................510 SUSPENSION ...................................................................................511 WINCH PUMP ...................................................................................512 COUNTERWEIGHT PUMP ...........................................................................513 HI-LO VALVE...................................................................................514 PPC VALVE.....................................................................................515 FLOW DIVIDER VALVE............................................................................516 WINCH.........................................................................................517 LOWER CLUTCH..................................................................................519 RAISE CLUTCH..................................................................................521 WINCH BRAKE...................................................................................523 CONTROL VALVE (FOR COUNTERWEIGHT).............................................................525 COUNTERWEIGHT CYLINDER .......................................................................527 SLOW RETURN VALVE ............................................................................528 COUNTERWEIGHT ................................................................................529 BOOM .........................................................................................531 90 OTHERS ........................................................................................533 ELECTRIC CIRCUIT DIAGRAM (STD)................................................................534 ELECTRIC CIRCUIT DIAGRAM (-50℃ SPEC.).........................................................535 CAB ELECTRIC CIRCUIT DIAGRAM..................................................................536
DESCRIPTION:
KOMATSU D155C-1 SHOP MANUAL SEBM032300 – PDF DOWNLOAD
Foreword
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
Disassembly and assembly
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 29/12/24
