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Komatsu D155AX-7 Shop Manual

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SEN05653-03
BULLDOZER
D155AX
-7
90001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu D155AX-7

  • Page 1 SEN05653-03 BULLDOZER D155AX 90001 SERIAL NUMBERS and up...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 SHOP MANUAL BULLDOZER D155AX-7 Model Serial Number D155AX-7 90001 and up 00 Index and foreword 1 00 Index and foreword D155AX-7 00-1 Find manuals at https://best-manuals.com...
  • Page 4 Stator clutch ECMV ......................10-78 Transmission ........................10-82 Transmission ECMV......................10-96 Main relief valve and torque converter relief valve ............... 10-105 Transmission lubrication relief valve................... 10-107 Bevel gear shaft, HSS, and brake ..................10-108 Brake control valve......................10-126 00-2 D155AX-7 Find manuals at https://best-manuals.com...
  • Page 5 Sketch of tools for testing and adjusting ................. 30-7 Engine and cooling system ......................30-9 Testing engine speed ......................30-9 Testing boost pressure ....................... 30-11 Testing exhaust gas temperature ..................30-12 Testing exhaust gas color ....................30-15 Adjusting valve clearance ....................30-17 00-3 D155AX-7 Find manuals at https://best-manuals.com...
  • Page 6 40 Troubleshooting..........................40-1 Table of contents ........................40-2 Related information on troubleshooting..................40-11 Troubleshooting points ....................... 40-11 Sequence of events in troubleshooting................. 40-13 Checks before troubleshooting .................... 40-15 Inspection procedure before troubleshooting ................ 40-17 00-4 D155AX-7 Find manuals at https://best-manuals.com...
  • Page 7 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ..........40-189 Failure code [CA122] Chg Air Press Sensor High Error ............40-190 Failure code [CA123] Chg Air Press Sensor Low Error ............40-192 00-5 D155AX-7 Find manuals at https://best-manuals.com...
  • Page 8 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............40-288 Failure code [CA1843] Crankcase Press Sens High Error............ 40-290 Failure code [CA1844] Crankcase Press Sens Low Error ............ 40-292 Failure code [CA1879] KDPF Delta P Sensor High Error ............. 40-294 00-6 D155AX-7 Find manuals at https://best-manuals.com...
  • Page 9 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ..........40-438 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........... 40-441 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........40-446 00-7 D155AX-7 Find manuals at https://best-manuals.com...
  • Page 10 Failure code [DDKBKA] Blade auto pitch Sw:Open ............. 40-549 Failure code [DDKBKB] Blade auto pitch Sw:Short circuit ............ 40-551 Failure code [DDKCL4] Ripper tilt in Sw:Signal mismatch ............ 40-553 Failure code [DDKEL4] Ripper tilt back Sw:Signal mismatch..........40-555 00-8 D155AX-7 Find manuals at https://best-manuals.com...
  • Page 11 Failure code [DK57KA] FR lever2:Open ................40-651 Failure code [DK57KB] FR lever2:Hot Short ............... 40-653 Failure code [DKH1KA] Pitch angle sensor:Open..............40-655 Failure code [DKH1KB] Pitch angle sensor:Hot Short............40-657 Failure code [DLM3KA] Fan rev. sensor:Open ..............40-659 D155AX-7 00-9...
  • Page 12 Failure code [DXHTKY] Blade tilt right head EPC:Hot short..........40-734 Failure code [DXHUKA] Blade tilt right bottom EPC:Open............ 40-735 Failure code [DXHUKB] Blade tilt right bottom EPC:Short circuit .......... 40-737 Failure code [DXHUKY] Blade tilt right bottom EPC:Hot short ..........40-738 00-10 D155AX-7...
  • Page 13 E-27 Backup alarm does not sound ................... 40-814 E-28 Backup alarm does not stop sounding................ 40-815 E-29 Headlamp does not light up..................40-816 E-30 Rear lamp and ripper point lamp do not light up............40-819 E-31 No wiper operates continuously or intermittently............40-822 D155AX-7 00-11...
  • Page 14 S-9 KDPF gets clogged in a short time ................40-918 S-10 Engine oil consumption is excessive ................40-920 S-11 Engine oil becomes contaminated early..............40-921 S-12 Fuel consumption is excessive .................. 40-922 S-13 Oil is in coolant (or coolant spurts or coolant level goes down)........40-923 00-12 D155AX-7...
  • Page 15 Removal and installation of 1st bogie assembly ..............50-217 Removal and installation of 2nd, 3rd, or 4th bogie assembly ..........50-222 Disassembly and assembly of bogie assembly ..............50-227 Removal and installation of carrier roller assembly .............. 50-229 D155AX-7 00-13...
  • Page 16 Lockup clutch ECMV ......................60-25 Stator cluch ECMV......................60-26 Transmission ........................60-27 Transmission ECMV......................60-32 Main relief valve and torque converter relief valve ..............60-33 Transmission lubrication relief valve..................60-34 Bevel gear shaft, HSS, and brake ..................60-35 Brake control valve......................60-41 00-14 D155AX-7...
  • Page 17 Parts and connectors layout....................80-29 Testing air leakage (duct) ....................80-37 Testing with self-diagnosis function ..................80-40 Testing vent (mode) changeover..................80-43 Testing FRESH/RECIRC air changeover................80-44 Testing sunlight sensor ....................... 80-45 Testing (dual) pressure switch for refrigerant................. 80-46 D155AX-7 00-15...
  • Page 18 Symbols in hydraulic circuit diagram ..................90-3 Power train hydraulic circuit diagram..................90-7 Hydraulic circuit diagram....................... 90-9 Electric circuit diagram ......................90-13 Symbols in electric circuit diagram ..................90-13 Electrical circuit diagram ..................... 90-17 Air conditioner electrical circuit diagram ................90-43 Index..................................1 00-16 D155AX-7...
  • Page 19 Komatsu. Some of these methods require the use of the special tools designed by Komatsu for the specific purpose. • The symbol mark k is used for such matters that require special cautions during the work. The work indicated by the caution mark should be performed according to the instructions with special attention to the cautions.
  • Page 20 • Keep putting on the gloves during sling work. • When removing piping, prevent the fuel or oil (Put on the leather gloves, if available.) from spilling out. If any fuel or oil drips onto the 00-18 D155AX-7...
  • Page 21 • Before starting work, check the wire ropes, • Apply wire ropes to the middle part of the hook. brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter D155AX-7 00-19...
  • Page 22 However, do not apply oil to the threaded 22.6 part of a bolt, nut or union. 28.6 35.3 Manufacturer Part name 55.3 DENSO ND-OIL8 79.6 ZXL100PG (equivalent to VALEO THERMAL 141.6 14.4 PAG46) SYSTEMS 221.6 22.6 SANDEN SP-10 318.3 32.4 00-20 D155AX-7...
  • Page 23 (Use a torque wrench for tightening). a Example of fitting of O-ring • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see "Others", "Precautions for disconnection and connection of air conditioner piping". D155AX-7 00-21...
  • Page 24 • Fire around the machine due to highly heated materials to a safe place before starting. exhaust gas Some machines are equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying soot in exhaust gas. Its exhaust...
  • Page 25 • As for rubber, plastics, or parts (hoses, cables, and wiring harnesses, etc.) which contain those materials, ask the industrial waste treatment firms for their disposals in accordance with the local regulations. D155AX-7 00-23...
  • Page 26 • Some attachments and optional parts described in this shop manual may not be arranged for certain areas. Contact your Komatsu distributor if one or some of them are required. • Materials and specifications are subject to change without notice.
  • Page 27 Unit • In this shop manual, the units are indicated with International System of units (SI). • For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }. D155AX-7 00-25...
  • Page 28 • The dimensions of parts change because of the of new products or equivalent are called the wear or deformation while they are used. When "standard value", which is indicated by a range the dimension changes exceeding certain value, or a target value. 00-26 D155AX-7...
  • Page 29 "allowable interference". • The allowable interference shows the repair limit of the part of smaller tolerance. • The parts whose interferences are out of the allowable interference must be replaced or repaired. D155AX-7 00-27...
  • Page 30 • If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel. Precautions for replacing fuel filter cartridge • Be sure to use the Komatsu genuine fuel filter cartridge. • The common rail fuel injection system (CRI)
  • Page 31 Foreword, safety and general information Handling of intake system parts (PC220-A900-2A4-K-00-A) (Rev.2013/10) • The Komatsu Variable Geometry Turbocharger consists of more precise parts (variable mechanism) than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the air intake system.
  • Page 32 If the old oil is left in the system, the contaminant and sludge in the oil mix with the new oil and shorten the life of the new hydraulic oil. 00-30 D155AX-7...
  • Page 33 The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment can not remove. So, it is an extremely effective device. D155AX-7 00-31...
  • Page 34 3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the (Fig. 3) rubber cap will move approximately 3.5mm toward the hose, however, it is not a problem. a Since some hydraulic oil flows out, prepare an oil container. 00-32 D155AX-7...
  • Page 35 (Fig. 9) 2. While keeping the condition of Step 1, turn lever (8) to the right (clockwise). (Fig. 7) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (7) to disconnect it. (Fig. 8) D155AX-7 00-33...
  • Page 36 (10) straight until it hits contact surface (b) of the hexagonal portion on the male side. (Fig. 3. While keeping the conditions of Steps 1 and 2, pull out whole body (9) to disconnect it. (Fig. 12) 00-34 D155AX-7...
  • Page 37 The corroded or oxidized harness may be broken. contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times. D155AX-7 00-35...
  • Page 38 If any oil or grease, mud or dirt is stuck to the connector, wipe it off with a dry cloth or 00-36 D155AX-7...
  • Page 39 If the connector cannot be corrected easily, remove the clamp and adjust the position. Connecting connectors 1. Check the connector visually. D155AX-7 00-37...
  • Page 40 3. Perform a continuity test on the connector. After drying, leave wiring harness disconnected and perform a continuity test to check for any short circuits between pins caused by water. a After the connector is completely dried, blow the contact restorer and reassemble them. 00-38 D155AX-7...
  • Page 41 1. Insert the connector securely until a click is (FRAMATOME-24) heard. Disconnection Pull lock type 1. Slide down lock (red) (L1). (PACKARD-2) Disconnection 1. Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward. D155AX-7 00-39...
  • Page 42 [1] since you cannot insert your fingers. While pushing up lock (C) of the connector Connection with flat-head screwdriver [1], pull out 1. Insert the connector securely until a click is connector (3) in the direction of the arrow. heard. 00-40 D155AX-7...
  • Page 43 Housing (H1) is left on the wiring harness in a place where it is exposed to rain. side. • Do not place the controller on oil, water, or soil, or in a place that can be heated to a high D155AX-7 00-41...
  • Page 44 If there is any value change on the multimeter, there may be a defective contact in the circuit. 00-42 D155AX-7...
  • Page 45 CAVS automobile (nominal No. 1.25 and lower) (Type 2) Heat- General wiring for extremely resistant low- cold weather specification Heat-resistant cross voltage wire -50 to +110 linked polyethylene Wiring at high ambient temperature place automobile D155AX-7 00-43...
  • Page 46 — — — compression compression compression Diameter of strand Conductor Cross- sectional — — — 0.56 0.88 1.29 area (mm d (approx.) — — — — — — CAVS Standard a "f" of nominal No. denotes "flexible". 00-44 D155AX-7...
  • Page 47 — — — — — — — — — Others — — — — — — — — — — — — — — — — — — — — — — — — — — — — D155AX-7 00-45...
  • Page 48 Disconnection of face seal type hoses and tubes Pipe joint side Hose side O-ring (3) Nominal No. Plug (1) Nut (2) 07376-70210 02789-00210 02896-11008 07376-70315 02789-00315 02896-11009 07376-70422 02789-00422 02896-11012 07376-70522 02789-00522 02896-11015 07376-70628 02789-00628 02896-11018 00-46 D155AX-7...
  • Page 49 52.4 26.2 07371-31049 07378-11000 07000-13032 01643-51032 01044 51035 07379- 07372- 58.7 30.2 07371-31255 07378-11200 07000-13038 01643-51032 01250 51035 07379- 01010- 66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232 01260 81245 07379- 07372- 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232 01460 51240 D155AX-7 00-47...
  • Page 50 O-ring (2) Nominal No. 07040-10807 07002-10823 07040-11007 07002-11023 07040-11209 07002-11223 07040-11409 07002-11423 07040-11612 07002-11623 07040-11812 07002-11823 07040-12012 07002-12034 07040-12412 07002-12434 07041-13012 07002-13034 07040-13316 07002-13334 07041-13612 07002-13634 07040-14220 07002-14234 07040-15223 07002-15234 Removal of pipe joints of taper pipe thread type 00-48 D155AX-7...
  • Page 51 If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is pushed out, and that can cause oil leakage. D155AX-7 00-49...
  • Page 52 • When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 53 3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, see "Global KOMTRAX Web Reference Manual (For Key Person)". D155AX-7 00-51...
  • Page 54 824 to 1,030 {84 to 105} 1,180 to 1,470 {120 to 150} 1,520 to 1,910 {155 to 195} 1,960 to 2,450 {200 to 250} 2,450 to 3,040 {250 to 310} 2,890 to 3,630 {295 to 370} *1: Split flange bolt. *2: Flanged bolt. 00-52 D155AX-7...
  • Page 55 333 to 451 {34 to 46} 392 {40} -7UNC 1,598 to 2,157 {163 to 220} 1,873 {191} 451 to 608 {46 to 62} 530 {54} -7UNC 2,354 to 3,177 {240 to 324} 2,765 {282} 657 to 892 {67 to 91} 775 {79} -6UNC D155AX-7 00-53...
  • Page 56 35 to 63 {3.5 to 6.5} 44 {4.5} Varies — 59 to 98 {6.0 to 10.0} 78 {8.0} depending on type of 84 to 132 {8.5 to 13.5} 103 {10.5} 03, 04 connector. 128 to 186 {13.0 to 19.0} 157 {16.0} 05, 06 00-54 D155AX-7...
  • Page 57 Table of tightening torque for hose (taper seal type and face seal type) a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque shown in the table below. a The table is applied to the threads coated with engine oil (wet threads) D155AX-7 00-55...
  • Page 58 Thread diameter (mm) Tightening torque (Nm {kgm}) 10 ± 2 {1.02 ± 0.20} 24 ± 4 {2.45 ± 0.41} 43 ± 6 {4.38 ± 0.61} 77 ± 12 {7.85 ± 1.22} — 00-56 D155AX-7...
  • Page 59 20 ± 2 {2.04 ± 0.20} 35 ± 4 {3.57 ± 0.41} 25 ± 3 {2.55 ± 0.31} 55 ± 6 {5.61 ± 0.61} 35 ± 4 {3.57 ± 0.41} 75 ± 8 {7.65 ± 0.82} 45 ± 5 {4.59 ± 0.51} D155AX-7 00-57...
  • Page 60 Electronic control device uses the signals from the sensors on the machine. This signal Electronic Control Electronic control system indicates the optimum actuation to the Module actuators. (Same as E.C.U.) 00-58 D155AX-7...
  • Page 61 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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90001