Komatsu D155C-1 PIPELAYER Shop Manual SEBM032300 – PDF DOWNLOAD

Komatsu D155C-1 PIPELAYER Shop Manual SEBM032300 – PDF DOWNLOAD

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Komatsu D155C-1 PIPELAYER Shop Manual SEBM032300 – PDF DOWNLOAD

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Komatsu D155C-1 PIPELAYER Shop Manual SEBM032300 – PDF DOWNLOAD

Machine model Serial number
D155C-1 31586 and up

GENERAL PRECAUTIONS:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.1 .Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

•  Always wear safety glasses when hitting parts with a hammer.
•  Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.4.When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.PREPARATIONS FOR WORK:
7. Before adding or making any repairs, park the machine on hard, level ground, and block the wheels to
prevent the machine from moving.
8. Before starting work, lower outrigger, bucket or any other work equipment to the ground. If this is not possible,
use blocks to prevent the work equipment from falling down. In addition, be sure to lock all the control levers and hang warning sign on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting
work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine.Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

TABLE OF CONTENTS:

Komatsu D155C-1 PIPELAYER 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