Komatsu D155C-1 PipeLayer Shop Manual SEBM032300

Description

• Model List:
  • D155C-1 PipeLayer

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL ASSEMBLY DRAWING
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. TABLE OF FUEL,COOLANT AND LUBRICANTS
• 4. STRUCTURE AND FUNCTION
• 4.1. RADIATOR FAN
• 4.2. RADIATOR SHUTTER
• 4.3. PTO (POWER TAKEOFF)
• 4.4. OIL COOLER
• 4.5. POWER TRAIN DIAGRAM
• 4.6. TORQFLOW HYDRAULIC CIRCUIT
• 4.7. HYDRAULIC CIRCUIT DIAGRAM
• 4.8. TORQUE CONVERTER
• 4.9. TRANSMISSION CONTROL
• 4.10. TRANSMISSION
• 4.11. TRANSMISSION CONTROL VALVE
• 4.12. TRANSMISSION LUBRICATION RELIEF VALVE
• 4.13. STEERING AND BRAKE CONTROL
• 4.14. AXLE,STEERING CLUTCH
• 4.15. STEERING BRAKE HYDRAULIC PIPING
• 4.16. STEERING AND BRAKE HYDRAULIC CIRCUIT DIAGRAM
• 4.17. STEERING BRAKE
• 4.18. STEERING CONTROL VALVE
• 4.19. HYDRAULIC CIRCUIT DIAGRAM FOR WINCH
• 4.20. WINCH
• 4.21. DETAILED WORKING CIRCUIT DIAGRAM FOR CLUTCH AND BRAKE OF WINCH
• 4.22. POWER TRAIN ON WINCH
• 4.23. HIGHLOW VALVE
• 4.24. PPC VALVE
• 4.25. FLOW DIVIDER VALVE
• 4.26. COUNTERWEIGHT HYDRAULIC TANK
• 4.27. COUNTERWEIGHT PIPING
• 4.28. COUNTERWEIGHT CONTROL
• 4.29. COUNTERWEIGHT HYDRAULIC CIRCUIT DIAGRAM
• 4.30. COUNTERWEIGHT
• 4.31. COUNTERWEIGHT CONTROL VALVE
• 4.32. BOOM
• 4.33. SAFETY DEVICE
• 4.35. ACTUAL ELECTRIC WIRING DIAGRAM
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
• 5.2. STANDARD VALUE TABLE FOR CHASSIS
• 5.3. TESTING AND ADJUSTING
• 5.3.1. TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING
• 5.3.2. ADJUSTING VALVE CLEARANCE
• 5.3.3. MEASURING COMPRESSION PRESSURE
• 5.3.4. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 5.3.5. MEASURING ENGINE OIL PRESSURE
• 5.3.6. MEASURING EXHAUST COLOR
• 5.3.7. MEASURING EXHAUST TEMPERATURE
• 5.3.8. TESTING AND ADJUSTING ALTERNATOR BELT TENSION
• 5.3.9. MEASURING BLOWBY
• 5.3.10. MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
• 5.3.11. MEASURING ENGINE SPEED
• 5.3.12. NEASURING TORQUE CONVERTER STALL SPEED
• 5.3.13. BLEEDING AIR FROM COUNTERWEIGHT CYLINDER
• 5.3.14. ADJUSTING WINCH CONTROL INTERLOCK MECHANISM
• 5.3.15. MEASURING OIL PRESSURE
• 5.3.16. MEASURING COUNTERWEIGHT OIL PRESSURE
• 5.3.17. MEASURING WINCH OIL PRESSURE
• 5.3.18. HYDRAULIC CIRCUIT DIAGRAM FOR WINCH
• 5.3.19. MEASURING LEAKAGE INSIDE CYLINDER
• 5.3.20. REINSTALLATION (IF MOMENT LIMITER WAS REMOVED) AND ADJUSTING
• 5.3.21. ADJUSTMENT PROCEDURE FOR MOMENT LIMITER PERFORMANCE
• 5.4. TROUBLESHOOTING
• 5.4.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.4.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.4.3. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 5.4.4. CHECKS BEFORE TROUBLESHOOTING
• 5.4.5. TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
• 5.4.6. TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. METHOD OF USING MANUAL
• 6.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 6.3. SPECIAL TOOL LIST
• 6.4. REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY
• 6.5. REMOVAL AND INSTALLATION OF ALTERNATOR ASSEMBLY
• 6.6. REMOVAL AND INSTALLATION OF ENGINE OIL COOLER CORE ASSEMBLY
• 6.7. REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
• 6.8. REMOVAL AND INSTALLATION OF WATER PUMP ASSEMBLY
• 6.9. REMOVAL AND INSTALLATION OF TURBOCHARGER ASSEMBLY
• 6.10. REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY
• 6.11. REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
• 6.12. REMOVAL AND INSTALLATION OF THERMOSTAT ASSEMBLY
• 6.13. REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
• 6.14. REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
• 6.15. REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND WINCH OIL COOLER ASSEMBLY
• 6.16. REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
• 6.17. REMOVAL AND INSTALLATION OF PTO ASSEMBLY
• 6.18. DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
• 6.19. REMOVAL AND INSTALLATION OF TRANSMISSION PUMP ASSEMBLY
• 6.20. REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY
• 6.21. REMOVAL AND INSTALLATION OF TORQUE CONVERTER ASSEMBLY
• 6.22. DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
• 6.23. REMOVAL AND INSTALLATION OF TORQUE CONVERTER RELIEF VALVE ASSEMBLY
• 6.24. REMOVAL AND INSTALLATION OF TORQUE CONVERTER REGULATING VALVE ASSEMBLY
• 6.25. DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER RELIEF VALVE ASSEMBLY
• 6.26. REMOVAL AND INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY
• 6.27. DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY
• 6.28. REMOVAL AND INSTALLATION OF TRANSMISSION ASSEMBLY
• 6.29. DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY
• 6.30. REMOVAL AND INSTALLATION OF TRANSMISSION LUBRICATION VALVE ASSEMBLY
• 6.31. DISASSEMBLY AND ASSEMBLY OF TRANSMISSION LUBRICATION VALVE ASSEMBLY
• 6.32. REMOVAL AND INSTALLATION OF STEERING CONTROL VALVE ASSEMBLY
• 6.33. DISASSEMBLY AND ASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY
• 6.34. REMOVAL AND INSTALLATION OF BRAKE SAFETY VALVE ASSEMBLY
• 6.35. DISASSEMBLY AND ASSEMBLY OF BRAKE SAFETY VALVE ASSEMBLY
• 6.36. REMOVAL AND INSTALLATION OF STEERING PUMP ASSEMBLY
• 6.37. REMOVAL AND INSTALLATION OF STEERING CLUTCH ASSEMBLY
• 6.38. DISASSEMBLY AND ASSEMBLY OF BRAKE BOOSTER ASSEMBLY
• 6.39. DISASSEMBLY AND ASSEMBLY OF STEERING RELIEF VALVE ASSEMBLY
• 6.40. DISASSEMBLY AND ASSEMBLY OF STEERING CLUTCH ASSEMBLY
• 6.41. DISASSEMBLY AND ASSEMBLY OF BEVEL GEAR SHAFT ASSEMBLY
• 6.42. DISASSEMBLY AND ASSEMBLY OF FIRST PINION ASSEMBLY
• 6.43. DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
• 6.44. REMOVAL AND INSTALLATION OF TRACK ASSEMBLY
• 6.45. REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY
• 6.46. REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY
• 6.47. DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
• 6.48. REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY
• 6.49. REMOVAL AND INSTALLATION OF IDLER ASSEMBLY
• 6.50. REMOVAL AND INSTALLATION OF WINCH CONTROL VALVE ASSEMBLY
• 6.51. DISASSEMBLY AND ASSEMBLY OF WINCH CONTROL VALVE ASSEMBLY
• 6.52. REMOVAL AND INSTALLATION OF HIGH/LOW SPEED SELECTOR VALVE ASSEMBLY
• 6.53. DISASSEMBLY AND ASSEMBLY OF HIGH/LOW SPEED SELECTOR VALVE ASSEMBLY
• 6.54. REMOVAL AND INSTALLATION OF TOWING WINCH PUMP ASSEMBLY
• 6.55. REMOVAL AND INSTALLATION OF COUNTERWEIGHT PUMP ASSEMBLY
• 6.56. REMOVAL AND INSTALLATION OF COUNTERWEIGHT CYLINDER ASSEMBLY
• 6.57. DISASSEMBLY AND ASSEMBLY OF COUNTERWEIGHT CYLINDER ASSEMBLY
• 6.58. REMOVAL AND INSTALLATION OF COUNTERWEIGHT CONTROL VALVE ASSEMBLY
• 6.59. DISASSEMBLY AND ASSEMBLY OF COUNTERWEIGHT CONTROL VALVE ASSEMBLY
• 6.60. REMOVAL AND INSTALLATION OF GATE FRAME ASSEMBLY
• 6.61. REMOVAL AND INSTALLATION OF COUNTERWEIGHT/FRAME
• 6.62. REMOVAL AND INSTALLATION OF BOOM/FRAME
• 6.63. REMOVAL AND INSTALLATION OF TOWING WINCH ASSEMBLY
• 6.64. DISASSEMBLY AND ASSEMBLY OF TOWING WINCH ASSEMBLY
• 6.65. REMOVAL AND INSTALLATION OF HEATER ASSEMBLY
• 7. MAINTENANCE STANDARD
• 7.1. ENGINE MOUNT
• 7.3. TORQFLOW TRANSMISSION
• 7.3.1. TORQUE CONVERTER
• 7.3.2. RELIEF VALVE AND REGULATOR VALVE
• 7.4. TRANSMISSION
• 7.5. TRANSMISSION CONTROL VALVE
• 7.6. TRANSMISSION PUMP
• 7.7. BEVEL GEAR SHAFT AND STEERING CLUTCH
• 7.8. STEERING BRAKE
• 7.9. STEERING CONTROL VALVE
• 7.10. COUNTERWEIGHT PUMP
• 7.11. HILO VALVE
• 7.12. PPC VALVE
• 7.13. FLOW DIVIDER VALVE
• 7.14. WINCH
• 7.15. LOWER CLUTCH
• 7.16. RAISE CLUTCH
• 7.17. WINCH BRAKE
• 7.18. CONTROL VALVE (FOR COUNTERWEIGHT)
• 7.19. COUNTERWEIGHT CYLINDER
• 7.20. SLOW RETURN VALVE
• 7.21. COUNTERWEIGHT
• 7.22. BOOM
• 8. OTHERS
• 8.1. ELECTRIC CIRCUIT DIAGRAM (STD)
• 8.2. ELECTRIC CIRCUIT DIAGRAM (50 SPEC.)
• 8.3. CAB ELECTRIC CIRCUIT DIAGRAM