Komatsu D155AX-5 User Manual

SEBM016205

1

-

MACHINE MODEL SERIAL NUMBER

D155AX-5 70001 and up

This shop manual may contain attachments and optional equipment that are not available in your

•

area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.

D155AX-5 mounts the SA6D140E-2 or SA6D140E-3 engine.

•

For details of the engine, see the 6D140-2 or 140-3 Series Engine Shop Manual.

C 2001 1
All Rights Reserved
Printed in Japan 04-01(03)

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CONTENTS

No. of page

01 GENERAL ..............................................................................01-1

10 STRUCTURE AND FUNCTION ............................................10-1

20 TESTING AND ADJUSTING................................................20-1

30 DISASSEMBLY AND ASSEMBLY .......................................30-1

40 MAINTENANCE STANDARD...............................................40-1

90 OTHERS ................................................................................90-1

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(Blank page)

30

DISASSEMBLY AND ASSEMBLY

Method of using manual ............................ 30- 3

Precautions when carring out operation ... 30- 5

Special tool list............................................. 30- 7

Special tool sketch ....................................... 30-17

STARTING MOTOR

Removal and Installation ...................... 30-26

ALTERNATOR

Removal and Installation ...................... 30-27

ENGINE OIL COOLER CORE

Removal and Installation ...................... 30-28

FUEL INJECTION PUMP

Removal .................................................. 30-29

Installation .............................................. 30-30

WATER PUMP

Removal and Installation ...................... 30-31

TURBOCHARGER

Removal and Installation ...................... 30-32

NOZZLE HOLDER

Removal and Installation ...................... 30-33

FUEL INJECTOR

Removal and Installation ................... 30-33-1

ENGINE FRONT SEAL

Removal .................................................. 30-34

Installation .............................................. 30-35

ENGINE REAR SEAL

Removal .................................................. 30-37

Installation .............................................. 30-38

CYLINDER HEAD

Removal .................................................. 30-42

Installation .............................................. 30-47

THERMOSTAT

Removal and Installation ...................... 30-49

AIR CONDITIONER COMPRESSOR

Removal .................................................. 30-50

Installation .............................................. 30-51

AIR CONDITIONER CONDENSER

Removal and Installation ...................... 30-52

FUEL TANK

Removal and Installation ...................... 30-53

RADIATOR

Removal .................................................. 30-54

Installation .............................................. 30-56

RADIATOR, OIL COOLER, GUARD

Removal .................................................. 30-57

Installation .............................................. 30-59

FAN DRIVE

Removal .................................................. 30-60

Installation .............................................. 30-61

HYDRAULIC COOLER

Removal and Installation ...................... 30-62

ENGINE

Removal .................................................. 30-63

Installation .............................................. 30-65

DAMPER

Removal .................................................. 30-66

Installation .............................................. 30-67

Disassembly ........................................... 30-68

Assembly ................................................ 30-71

POWER TRAIN UNIT

Removal .................................................. 30-75

Installation .............................................. 30-79

Separation .............................................. 30-80

Connection ............................................. 30-84

PTO

Disassembly ........................................... 30-85

Assembly ................................................ 30-89

TORQUE CONVERTER

Disassembly ........................................... 30-94

Assembly ................................................ 30-97

TORQFLOW TRANSMISSION

Disassembly ......................................... 30-100

Assembly .............................................. 30-109

HSS CASE

Disassembly ......................................... 30-120

Assembly .............................................. 30-129

HYDRAULIC PUMP

Removal ................................................ 30-142

Installation ............................................ 30-146

HSS PUMP

Disassembly ...................................... 30-146-1

Assembly ........................................... 30-146-8

HSS MOTOR

Removal and Installation .................... 30-147

POWER TRAIN MAIN RELIEF VALVE

Removal and Installation .................... 30-148

Disassembly and Assembly ............... 30-149

HSS, PPC CHARGE VALVE

Removal and Installation .................... 30-150

HSS, PCC CHARGEING VALVE

Disassembly ......................................... 30-151

Assembly .............................................. 30-152

TRANSMISSION CONTROL VALVE

Removal ................................................ 30-153

Installation ............................................ 30-154

Disassembly and Assembly ............... 30-155

30-1D155AX-5

5

BRAKE VALVE

Removal and Installation .................... 30-157

Disassembly and Assembly ............... 30-158

FINAL DRIVE

Removal ................................................ 30-160

Installation ............................................ 30-162

Disassembly ......................................... 30-163

Assembly .............................................. 30-168

TRACK FRAME

Removal ................................................ 30-174

Installation ............................................ 30-176

IDLER ASSEMBLY

Removal ................................................ 30-177

Installation ............................................ 30-178

Disassembly ......................................... 30-179

Assembly .............................................. 30-181

RECOIL SPRING

Removal and Installation .................... 30-184

Disassembly ......................................... 30-185

Assembly .............................................. 30-190

TRACK ROLLER

Removal ................................................ 30-194

Installation ............................................ 30-195

Disassembly ......................................... 30-196

Assembly .............................................. 30-199

BOGIE

Removal ................................................ 30-202

Installation ............................................ 30-204

Disassembly ......................................... 30-205

Assembly .............................................. 30-209

CARRIER ROLLER

Removal and Installation ................... 30-213

Disassembly ......................................... 30-214

Assembly .............................................. 30-216

TRACK SHOE

Checking before removal ................... 30-219

Removal (normal) ................................ 30-219

Removal (when there is abnorma-

lity inside track frame) ................. 30-220

Installation ............................................ 30-221

Overall disassembly ............................ 30-222

Overall assembly ................................. 30-227

Press-fitting jig dimention table for

link press .............................................. 30-241

ONE LINK

Disassembly ......................................... 30-242

Assembly .............................................. 30-244

MASTER LINK

Disassembly ......................................... 30-246

Assembly .............................................. 30-248

PIVOT SHAFT

Removal and Installation .................... 30-251

EQUALIZER BAR

Removal ................................................ 30-252

Installation ............................................ 30-253

EQUALIZER BAR SIDE BUSHING

Removal and Installation .................... 30-254

SEGMENT TEETH

Removal and Installation .................... 30-255

HYDRAULIC TANK

Removal and Installation .................... 30-256

MAIN CONTROL VALVE

Removal ................................................ 30-257

Installation ............................................ 30-258

Disassembly ......................................... 30-259

Assembly .............................................. 30-262

HSS OIL COOLER BYPASS VALVE

Removal and Installation .................... 30-266

Disassembly, assembly of HMT

oil cooler bypass valve ....................... 30-267

BLADE PPC VALVE

Removal ................................................ 30-268

Installation ............................................ 30-269

RIPPER PPC VALVE

Removal ................................................ 30-270

Installation ............................................ 30-271

BLADE PPC VALVE

Disassembly ......................................... 30-272

Assembly .............................................. 30-273

BLADE LIFT CYLINDER

Removal and Installation .................... 30-275

BLADE TILT CYLINDER

Removal and Installation .................... 30-276

RIPPER LIFT CYLINDER

Removal and Installation .................... 30-277

RIPPER TILT CYLINDER

Removal and Installation .................... 30-278

HYDRAULIC CYLINDER

Disassembly ......................................... 30-279

Assembly .............................................. 30-282

BLADE

Removal ................................................ 30-286

Installation ............................................ 30-287

Disassembly ......................................... 30-288

Assembly .............................................. 30-290

MULTI-SHANK RIPPER

Disassembly ......................................... 30-292

Assembly .............................................. 30-294

ROPS GUARD

Removal and Installation .................... 30-296

OPERATOR CAB

Removal and Installation .................... 30-297

HOOD

Removal and Installation .................... 30-298

FLOOR FRAME

Removal ................................................ 30-299

Installation ............................................ 30-304

DASHBOARD

Removal ................................................ 30-305

Installation ............................................ 30-306

MONITOR

Removal and Installation .................... 30-307

HSS CONTROLLER

Removal and Installation .................... 30-308

30-2

1

D155AX-5

DISASSEMBLY AND ASSEMBLY

P Sleeve

SPECIAL TOOL SKETCH

02

01

SYM.

30°

3

+0.4

+0.2

ø190.7

ø180±0.2

ø175

C0.5

STKM16A 1

PLATE

PART NAME MATERIAL

S400P

80

30°

R1

60

1 2.7

QTY/SET

17.7

MASS
(kg)

465.5±0.2

ø190 x t10TUBE

t22

REMARKES

)2

)1

C2

C2

+0.4

ø178

+0.2

ø210

C1

8

HEAT TREATMENT

PART NAME QTY

20

DDD00866

MATERIAL

- - -

SLEEVE 1

SEE DWG

7 9 1 T - 6 5 0 - 2 1 1 0

P Plate

C1

22

C1

2-20 D R I L L S

200

102

HEAT TREATMENT

- - -

PART NAME QTY

PLATE 1

7 9 1 T - 6 5 0 - 2 1 2 0

DDD00867

MATERIAL

SS400P

D155AX-5

30-25

1

DISASSEMBLY AND ASSEMBLY

STARTING MOTOR

REMOVAL OF STARTING
MOTOR ASSEMBLY

 Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Open engine right side cover (top) and remove
cover (bottom).

2. Disconnect 3 starting motor wires (1) and 1 wir­ing connector (2).

3. Remove 3 bolts, then remove starting motor
assembly (3).

INSTALLATION OF STARTING
MOTOR ASSEMBLY

• Carry out installation in the reverse order to

removal.

Serial 70001 – 75000

2

1

DED00001

Serial No. 75001 and up

1

3

DED00002

30-26

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF ALTERNATOR
ASSEMBLY

 Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Open engine right side cover (top) and remove
cover (bottom).

2. Disconnect alternator wiring (1) and (2).

3. Loosen locknut (3), then turn adjustment nut (4)

to loosen tension of V-belt (5).

4. Remove bolts (6) and (7), then remove alterna­tor assembly (8) together with belt cover. 1
e Remove the V-belt from the pulley when re-

moving the alternator assembly.

ALTERNATOR

Serial No. 70001-75000

1

2

DED00003

Serial No. 75001 and up

INSTALLATION OF
ALTERNATOR ASSEMBLY

• Carry out installation in the reverse order to

removal.

1

e After installing the alternator, adjust the belt

tension. For details, see TESTING AND AD­JUSTING, TESTING AND ADJUSTING AL­TERNATOR BELT TENSION.

8

6

5

3

4

7

DED00004

D155AX-5

30-27

5

5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF ENGINE OIL
COOLER CORE ASSEMBLY

e Drain coolant.

ENGINE OIL COOLER

Serial No. 70001 – 75000

6

1. Remove wiring clamp (1).

2. Remove muffler water drain tube (2).

3. Remove adiabatic plate (3).

4. Disconnect turbocharger lubrication tube (4) at

turbocharger end, then move it towards rear.

5. Disconnect connector (5).

6. Remove oil cooler assembly (6).

7. Remove core assembly (8) from cover (7).

1

4

2

Serial No. 75001 and up

3

1

5

DED00005

INSTALLATION OF ENGINE OIL
COOLER CORE ASSEMBLY

• Carry out installation in the reverse order to

removal.

• Refilling with water

Add water through water filler to the specified
level.
e Run the engine to circulate the water through

the system. Then check the water level again.

78

DDD00006

30-28

5

D155AX-5

DISASSEMBLY AND ASSEMBLY

DED00009

9

10

REMOVAL OF FUEL INJECTION
PUMP ASSEMBLY

Serial No. 70001 – 75000

1. Close valve of fuel supply piping.

2. Rotate crankshaft in normal direction and align

match mark of fuel injection pump.
fl This makes it easier to check the compres-

sion top dead center position of the No. 1
cylinder when installing the fuel injection
pump.

3. Open engine left side cover (top) and remove
cover (bottom).

4. Disconnect fuel control rod (1), and fuel hoses
(2), (3), (4), and (5). 1

FUEL INJECTION PUMP

7

5. Remove boost compensator tube (19).

6. Disconnect fuel hose (6) and tube (7).

7. Remove coupling cover (8).

8. Remove lubrication tubes (9) and (10).

9. Disconnect 6 delivery tubes (11). 2

6

8

DED00008

D155AX-5

11

DED00010

30-29

5

5

DISASSEMBLY AND ASSEMBLY

10. Loosen tightening bolt (12) at drive shaft end,

and remove 4 pump mounting bolts (13).

11. Remove fuel injection pump assembly (14) to-

gether with coupling. 3

FUEL INJECTION PUMP

12

13

DED00011

14

INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to

removal.

1

e Adjust the linkage. For details, see TEST-

ING AND ADJUSTING, ADJUSTING FUEL
CONTROL LINKAGE.

2

3 Sleeve nut: 123.5 ± 1.0 Nm {2.4 ± 0.1 kgm}

3

e Install the fuel injection pump as follows.

1) After installing pump assembly, align
damper (I,J) marks (15) and pointer (16)
correctly.

2) Loosen bolt of coupling (18) to align
match mark (17) of injection pump.

13

18

17

13

DED00012

16

15

DED00013

30-30

5

DED00014

D155AX-5

DISASSEMBLY AND ASSEMBLY

3

4

5

DED00016

REMOVAL OF WATER PUMP
ASSEMBLY

1. Drain coolant.

2. Using an adjustable wrench, push tension pul-

ley (2) of fan belt (1), and remove fan belt.

3. Loosen locknut (3), then loosen adjustment nut

(4), and remove V-belt (5). 1

WATER PUMP

1

4. Remove connectors (6) and (7).

5. Remove pulley (8).

6. Remove water pump assembly (9).

INSTALLATION OF WATER
PUMP ASSEMBLY

• Carry out installation in the reverse order to

removal.

2

DED00015

Serial No. 70001 – 75000

Serial No. 75001 and up

1

e After installing the V-belt, adjust the belt ten-

sion. For details, see TESTING AND AD­JUSTING, TESTING AND ADJUSTING AL­TERNATOR BELT TENSION.

• Refilling with water

Add water through water filler to the specified
level.
e Run the engine to circulate the water through

the system. Then check the water level again.

8

D155AX-5

DED00018

30-31

1

5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF
TURBOCHARGER ASSEMBLY

Serial No. 70001 - 75000

1. Remove hood assembly.

For details, see REMOVAL OF HOOD ASSEM­BLY.

2. Remove adiabatic covers (2) and (3).

3. Disconnect tube (4) and hose (5), then lift off air

cleaner assembly (6).

4 Air cleaner assembly: 35 kg

4. Disconnect lubrication hose (7) and drain tube

(8). 1

5. Remove turbocharger assembly (9). 2

TURBOCHARGER

INSTALLATION OF
TURBOCHARGER ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to

removal.

1

3 Hose mounting bolt:

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

2

3 Turbocharger mounting bolt:

49.0 ± 9.8 Nm {5 ± 1 kgm}

6

5

4

DBD00026

7

8

DED00021

30-32

5

9

DED00020

D155AX-5

DISASSEMBLY AND ASSEMBLY

REMOVAL OF
TURBOCHARGER ASSEMBLY

Serial No. 75001 and up

1. Remove hood assembly.

For details, see REMOVAL OF HOOD ASSEM­BLY.

2. Remove adiabatic covers (1) and (2).

3. Disconnect tube (3) and hose (4), then lift off air

cleaner assembly (5).

4 Air cleaner assembly: 35 kg

4. Disconnect lubrication hose (6) and drain tube

(7). 1

5. Remove turbocharger assembly (8). 2

TURBOCHARGER

INSTALLATION OF
TURBOCHARGER ASSEMBLY

Serial No. 75001 and up

• Carry out installation in the reverse order to

removal.

1

3 Hose mounting bolt:

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

2

3 Turbocharger mounting bolt:

49.0 ± 9.8 Nm {5 ± 1 kgm}

D155AX-5

30-32-1

5

30-32-2 (Blank Page)

D155AX-5

DISASSEMBLY AND ASSEMBLY

1

2

DBD00413

3

4

5

DBD00414

3

4

5

6

DBD00415

REMOVAL OF NOZZLE
HOLDER ASSEMBLY

Serial No. 70001 – 75000

1. Remove hood assembly.

For details, see REMOVAL OF HOOD ASSEM­BLY.

2. Remove cylinder head cover (1). 1

e For No. 4 and 5 cylinders, remove the air

cleaner assembly and air supply connector.

3. Disconnect delivery tube (2). 2

4. Loosen locknut (3), and remove connector (4).

3

5. Remove holder (5). 4

6. Using tool A, remove nozzle holder assembly

(6). 5

NOZZLE HOLDER

INSTALLATION OF NOZZLE
HOLDER ASSEMBLY

Serial No. 70001 – 75000

• Carry out installation in the reverse order to

removal.

1

3 Cylinder head cover mounting bolt:

24.5 ± 4.9 Nm {2.5 ± 0.5 kgm}

2

3 Delivery tube sleeve nut:

23.5 ± 0.98 Nm {2.4 ± 0.1 kgm}

3

3 Connector:

31.9 ± 2.5 Nm {3.25 ± 0.25 kgm}

3 Locknut: 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}

4

3 Holder mounting bolt:

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

5

e When assembling the nozzle holder, clean

the nozzle holder mount and check that there
is no dirt or dust inside the sleeve before
assembling.
Tighten the mounting bolts uniformly in turn
to prevent excessive tightening on one side.

A

6

DBD00416

D155AX-5

30-33

5

5