Komatsu D155A-2 Bulldozer (57001 and up) Shop Manual - SEBM018602

This complete Service Repair Workshop Manual PDF Download for the D155A-2 Komatsu Bulldozer (57001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu D155A-2 Bulldozer
Serial Numbers : 57001 and up


TABLE OF CONTENTS :

- GENERAL
- STRUCTURE AND FUNCTION
- TESTING AND ADJUSTING
- DISASSEMBLY AND ASSEMBLY
- MAINTENANCE STANDARD
- OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM018602
Total Pages : 462


This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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Komatsu D155A-2 Bulldozer (57001 and up) OEM Manual PDF Download

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COVER
CONTENTS

01 GENERAL
- SPECIFICATION DRAWING
- SPECIFICATIONS
- WEIGHT TABLE
- TABLE OF FUEL,COOLANT AND LUBRICANTS

10 STRUCTURE AND FUNCTION
- ENGINE CONTROL
- RADIATOR,OIL COOLER
- PTO
- POWER TRAIN
- POWER TRAIN SYSTEM
- POWER TRAIN HYDRAULIC PIPING DIAGRAM
- POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
- TORQUE CONVERTER
- TRANSMISSION CONTROL
- TRANSMISSION
- TRANSMISSION CONTROL VALVE
- TRANSMISSION LUBRICATION RELIEF VALVE
- STEERING CONTROL
- BEVEL GEAR SHAFT AND STEERING CLUTCH
- STEERING MAIN RELIEF VALVE
- STEERING BRAKE
- STEERING AND BRAKE CONTROL VALVE
- SPRING ASSIST BRAKE SYSTEM
- FINAL DRIVE
- TRACK FRAME
- RECOIL SPRING
- SUSPENSION
- WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
- WORK EQUIPMENT CONTROL
- WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
- HYDRAULIC TANK
- ROTARY SERVO VALVE
- PISTON VALVE
- PIN PULLER SWITCH
- PIN-PULLER SOLENOID VALVE
- MAIN CONTROL VALVE
- RIPPER SELECTOR VALVE AND PILOT CHECK VALVE
- PILOT SOLENOID VALVE
- CYLINDER STAY
- WORK EQUIPMENT
- CAB
- AIR CONDITIONER
- ACTUAL ELECTRIC WIRING DIAGRAM
- MONITOR SYSTEM
- SENSOR

20 TESTING AND ADJUSTING
- STANDARD VALUE TABLE FOR FUNCTIONS RELEVANT TO THE ENGINE
- STANDARD VALUE TABLE FOR FUNCTIONS RELEVANT TO THE MACHINE BODY
- STANDARD VALUE TABLE FOR ELECTRIC EQUIPMENT AND PARTS
- TESTING AND ADJUSTING
- - LIST OF EQUIPMENT,PARTS AND TOOLS NECESSARY FOR INSPECTIONS,ADJUSTMENTS AND FOR TROUBLESHOOTING
- - MEASURING THE ENGINE REVOLUTION
- - MEASURING THE INTAKE MANIFOLD PRESSURE (BOOST PRESSURE)
- - MEASURING THE EXHAUST TEMPERATURE
- - MEASURING THE EXHAUST GAS COLOR
- - ADJUSTING THE VALVE CLEARANCE
- - MEASURING THE COMPRESSION PRESSURE
- - MEASURING THE BLOWBY PRESSURE
- - MEASURING THE ENGINE OIL PRESSURE
- - INSPECTING AND ADJUSTING THE FUEL INJECTION TIMING
- - INSPECTING AND ADJUSTING THE ALTERNATOR BELT TENSION
- - INSPECTING AND ADJUSTING THE AIR COMPRESSOR BELT TENSION
- - MEASURING THE TORQUE CONVERTER STALLING REVOLUTION RATE
- - MEASURING THE TORQUE CONVERTER STALLING + WORK EQUIPMENT PUMP RELIEVING REVOLUTION RATE (FULL STALL REVOLUTION RATE)
- - MEASURING THE OIL PRESSURE
- - ADJUSTING THE STROKES AND LINKAGES
- TROUBLESHOOTING
- - POINTS TO REMEMBER WHEN TROUBLESHOOTING
- - SEQUENCE OF EVENTS IN TROUBLESHOOTING
- - POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
- - CHECKS BEFORE TROUBLESHOOTING
- - CONNECTOR TYPES AND CONNECTING EQUIPMENT AND PART NAMES
- - CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
- - HOW TO FOLLOW THE TROUBLESHOOTING FLOW DIAGRAMS
- - TROUBLESHOOTING FOR ELECTRIC EQUIPMENT (E-MODE)
- - - ELECTRIC CIRCUIT DIAGRAM FOR THE E-MODE SYSTEM CIRCUITS
- - - E-1 THE ENGINE DOES NOT START.(IN CASE THE ENGINE DOES NOT ROTATE)
- - - E-2 THE LAMPS DO NOT TURN ON
- - - - a) HEAD LAMPS
- - - - b) WORKING LAMP
- - - - c) REAR LAMP
- - - E-3 PRE-HEATING CANNOT BE EFFECTED
- - - E-4 THE BACKING ALARM DOES NOT SOUND
- - - E-5 THE PIN PULLER CYLINDER CANNOT BE ACTIVATED (WITH MACHINES EQUIPPED WITH THE GIANT RIPPER)
- - - - a) THE PIN CANNOT BE PULLED OUT. (THE SOLENOID CANNOT BE EXCITED.)
- - - - b) THE PIN CANNOT BE PUSHED IN. (THE SOLENOID CANNOT BE DEMAGNETIZED.)
- - TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL EQUIPMENT (H-MODE)
- - - HOW TO PROCEED WITH THE TROUBLESHOOTING
- - - H-1 TORQUE CONVERTER OIL TEMPERATURE IS TOO HIGH
- - - H-2 THE MACHINE WOULD NOT START TRAVELING
- - - H-3 THE TRACKING FORCE IS TOO WEAK OR THE TRAVELING SPEED IS TOO SLOW
- - - H-4 THE MACHINE MOVES FORWARD OR BACKWARD WHEN THE ENGINE IS STARTED
- - - H-5 STARTING OR SPEED SHIFTING TIME LAG IS TOO LONG
- - - H-6 STARTING OR SPEED SHIFTING SHOCK IS TOO BIG
- - - H-7 THE MACHINE TRAVELS ONLY IN THE FORWARD DIRECTION OR IN REVERSE DIRECTION
- - - H-8 THE STEERING CLUTCH CANNOT BE DISENGAGED
- - - H-9 THE STEERING CLUTCH SLIPS
- - - H-10 THE STEERING BRAKE IS NOT EFFECTIVE
- - - H-11 THE BLADE LIFTING POWER AND SPEED ARE INSUFFICIENT
- - - H-12 THE BLADE CANNOT BE LIFTED
- - - H-13 THE MACHINE BODY CANNOT BE RAISED BY USE OF THE BLADE
- - - H-14 HYDRAULIC DRIFT OF THE BLADE LIFT CYLINDER IS EXCESSIVE
- - - H-15 THE BLADE SHAKES UNSTEADILY UP AND DOWN WHEN MAKING GROUND LEVELING WORKS (WHILE THE CONTROL LEVER IS BEING SET TO THE "HOLD" POSITION)
- - - H-16 THE BLADE COMES DOWN
- - - - 1) WHEN THE WORK EQUIPMENT CONTROL LEVER IS SHIFTED FROM THE "HOLD" POSITION TO THE "UP" POSITION:
- - - - 2) THE BLADE COMES DOWN GRADUALLY WHEN THE ENGINE IS STOPPED EVEN WHEN THE WORK EQUIPMENT CONTROL LEVER IS BEING SET TO THE "UP" POSITION:
- - - H-17 THE BLADE IS LIFTED WITH ITS LH AND RH END AT UNEVEN ELEVATIONS (WITH THE STRAIGHT-DOZERS ONLY)
- - - H-18 THE MACHINE BODY CANNOT BE RAISED BY TILTING OF THE BLADE OWING TO INSUFFICIENT TILTING FORCE AND SPEED
- - - H-19 THE BLADE CANNOT BE TILTED
- - - H-20 HYDRAULIC DRIFT OF THE BLADE TILT CYLINDER IS EXCESSIVE
- - - H-21 HYDRAULIC DRIFT OF THE RIPPER CYLINDER IS EXCESSIVE
- - - H-22 THE OPERATING EFFORTS FOR THE CONTROL LEVER ARE TOO HIGH
- - TROUBLESHOOTING FOR MONITOR PANEL AND RELATED PARTS (M-MODE)
- - - ELECTRIC CIRCUIT DIAGRAM FOR THE M-MODE SYSTEM CIRCUITS
- - - M-1 THE MONITOR PANEL INDICATIONS DO NOT APPEAR EVEN WHEN THE STARTING SWITCH IS TURNED "ON"
- - - - a) WHEN THE MONITOR PANEL INDICATIONS DO NOT APPEAR TOTALLY:
- - - - b) WHEN THE MONITOR PANEL INDICATIONS APPEAR ONLY PARTLY:
- - - M-2 THE MONITOR PANEL LIGHTS TOTALLY WHEN THE STARTING SWITCH IS TURNED "ON" AND IT CANNOT BE TURNED OFF
- - - M-3 THE "EVERYDAY CHECKUP ITEMS" FLASH WHEN THE STARTING SWITCH IS TURNED ON (BUT NOT AS FAR AS STARTING THE ENGINE)
- - - M-4 THE (PRE-HEATING INDICATION) APPEARS EVEN THOUGH THE PRE-HEATING OPERATION HAS NOT BEEN MADE
- - - M-5 THE "EVERYDAY CHECKUP ITEMS" FLASH WHEN THE STARTING SWITCH IS TURNED ON AND WHEN THE ENGINE IS STARTED
- - - - a) ALTERNATOR CIRCUITS
- - - - b) ENGINE OIL PRESSURE CIRCUITS
- - - M-6 THE CAUTION ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON (BUT NOT AS FAR AS STARTING THE ENGINE)
- - - M-7 THE CAUTION ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON AND WHEN THE ENGINE IS STARTED
- - - - a) (ENGINE OIL PRESSURE) FLASHES
- - - - b) (RADIATOR WATER LEVEL) FLASHES
- - - - c) (ENGINE WATER TEMPERATURE) FLASHES
- - - - d) (CHARGING LEVEL) FLASHES
- - - - e) (TORQUE CONVERTER OIL TEMPERATURE) FLASHES
- - - M-8 THE BUZZER DOES NOT SOUND FOR ONE SECOND WHEN THE STARTING SWITCH IS TURNED ON (BUT NOT AS FAR AS STARTING THE ENGINE)
- - - - a) THE BUZZER DOES NOT SOUND EVEN THOUGH THE CAUTION ITEM IS FLASHING
- - - - b) THE BUZZER SOUNDS EVEN THOUGH NO ALARM IS BEING INDICATED ON THE MONITOR
- - - M-9 THE LAMP DOES NOT TURN ON FOR TWO SECONDS WHEN THE STARTING SWITCH IS TURNED ON (BUT NOT AS FAR AS STARTING THE ENGINE)
- - - - a) THE LAMP DOES NOT FLASH EVEN THOUGH THE CAUTION ITEM IS FLASHING
- - - - b) THE LAMP LIGHTS EVEN THOUGH NO ALARM IS BEING INDICATED ON THE MONITOR
- - - M-10 THE PANEL ILLUMINATION DOES NOT TURN ON.(EVEN THOUGH THE LCD INDICATIONS ARE NORMAL.)
- - - M-11 THE SERVICE METER DOES NOT WORK EVEN THOUGH THE ENGINE HAS BEEN STARTED
- - - M-12 THE ENGINE WATER TEMPERATURE GAUGE IS INDICATING ABNORMALLY LOW TEMPERATURE READING
- - - M-13 THE ENGINE WATER TEMPERATURE GAUGE IS UNWORKABLE
- - - M-14 THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS INDICATING ABNORMALLY LOW TEMPERATURE READING
- - - M-15 THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS UNWORKABLE
- - - M-16 THE FUEL GAUGE ALWAYS INDICATE THE FULL TANK STATE
- - - M-17 THE FUEL GAUGE DOES NOT MAKE INDICATIONS

30 DISASSEMBLY AND ASSEMBLY
- METHOD OF USING MANUAL
- PRECAUTIONS WHEN CARRYING OUT OPERATION
- SPECIAL TOOL LIST
- FUEL INJECTION PUMP ASSEMBLY
- - REMOVAL
- - INSTALLATION
- CYLINDER HEAD ASSEMBLY
- - REMOVAL
- - INSTALLATION
- RADIATOR GUARD ASSEMBLY
- - REMOVAL
- - INSTALLATION
- RADIATOR,TORQUE CONVERTER OIL COOLER ASSEMBLY
- - REMOVAL
- - INSTALLATION
- PTO ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- FUEL TANK ASSEMBLY
- - REMOVAL
- - INSTALLATION
- ENGINE,TORQUE CONVERTER ASSEMBLY
- - REMOVAL
- - INSTALLATION
- TORQUE CONVERTER ASSEMBLY
- - REMOVAL
- - INSTALLATION
- - DISASSEMBLY
- - ASSEMBLY
- TORQUE CONVERTER RELIEF VALVE ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- TORQUE CONVERTER REGULATOR VALVE
- - DISASSEMBLY
- - ASSEMBLY
- TRANSMISSION ASSEMBLY
- - REMOVAL
- - INSTALLATION
- TORQUE FLOW TRANSMISSION ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- TRANSMISSION CONTROL VALVE ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- TRANSMISSION LUBRICATION VALVE ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- BEVEL GEAR SHAFT ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- STEERING CLUTCH ASSEMBLY
- - REMOVAL
- - INSTALLATION
- - DISASSEMBLY
- - ASSEMBLY
- BRAKE BOOSTER ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- STEERING RELIEF VALVE ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- VALVE ASSEMBLY LINKED TO STEERING,BRAKE
- - DISASSEMBLY
- - ASSEMBLY
- FIRST PINION ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- FINAL DRIVE ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- TRACK FRAME ASSEMBLY
- - REMOVAL
- - INSTALLATION
- RECOIL SPRING ASSEMBLY
- - REMOVAL
- - INSTALLATION
- - DISASSEMBLY
- - ASSEMBLY
- IDLER ASSEMBLY
- - REMOVAL
- - INSTALLATION
- TRACK SHOE ASSEMBLY
- - REMOVAL
- - INSTALLATION
- - ENTIRE DISASSEMBLY
- - ENTIRE ASSEMBLY
- 1 LINK IN FIELD
- - DISASSEMBLY
- - ASSEMBLY
- MASTER LINK
- - DISASSEMBLY
- - ASSEMBLY
- BLADE,RIPPER CONTROL VALVE ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- BLADE TILT CONTROL VAVLE
- - DISASSEMBLY
- - ASSEMBLY
- RIPPER SELECTOR VALVE ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- OIL CYLINDER ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- PIN PULLER CYLINDER ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- WORK MACHINE ASSEMBLY
- - REMOVAL
- - INSTALLATION
- - DISASSEMBLY
- - ASSEMBLY
- RIPPER ASSEMBLY
- - DISASSEMBLY
- - ASSEMBLY
- CABIN ASSEMBLY
- - REMOVAL
- - INSTALLATION
- CABIN FLOOR FRAME ASSEMBLY
- - REMOVAL
- - INSTALLATION
- FLOOR FRAME ASSEMBLY
- - REMOVAL
- - INSTALLATION

40 MAINTENANCE STANDARD
- ENGINE MOUNT
- TORQUE CONVERTER
- TRANSMISSION
- TRANSMISSION CONTROL VALVE
- TRANSMISSION LUBRICATION RELIEF VALVE
- TRANSMISSION PUMP
- BEVEL GEAR SHAFT
- STEERING CLUTCH
- STEERING PUMP
- STEERING MAIN RELIEF VALVE
- STEERING AND BRAKE CONTROL VALVE
- STEERING BRAKE
- SPRING ASSIST BRAKE CYLINDER
- AUTOMATIC DRAIN VALVE
- FINAL DRIVE
- TRACK FRAME
- RECOIL SPRING
- LDLER
- TRACK ROLLER
- CARRIER ROLLER
- TRACK SHOE (DRY TYPE)
- TRACK SHOE (SEALED AND LUBRICATED TYPE)
- SUSPENSION
- WORK EQUIPMENT PUMP
- ROTARY SERVO VALVE (FOR BLADE LIFT)
- MAIN CONTROL VALVE
- BLADE TILT VALVE
- RIPPER SELECTOR VALVE AND PILOT CHECK VALVE
- WORK EQUIPMENT CYLINDER
- QUICK DROP VALVE
- CYLINDER STAY
- WORK EQUIPMENT

90 OTHERS
- ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.57001-57284)
- ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.57285 AND UP)

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