SEBMO170A07R STOW IM TAN INOA\ Ls KOMATSU DIS0A-1 DID9A-1 MACHINE MODEL’ SERIAL No D150A-1 8408 and up D155A-1 15001 and up Printed in Japan 00-1 11-88(01, 03)07461 ®CONTENTS No. of page GENERAL s : O11 ENGINE 11. STRUCTURE AND FUNCTION ....... coven ceeeeeeeee MT 12 TESTING AND ADJUSTING ... ceeeeeeeees sees 124 13 DISASSEMBLY AND ASSEMBLY .............0000000cc000eeeeeee 134 POWER TRAIN 21 STRUCTURE AND FUNCTION - 214 22 TESTING AND ADJUSTING . 5 . 224 23 DISASSEMBLY AND ASSEMBLY .. vets eet ete eeeeseeerees QB 24 MAINTENANCE STANDARD 241 UNDERCARRIAGE 31 STRUCTURE AND FUNCTION .. 314 33 DISASSEMBLY AND ASSEMBLY 33-1 34 MAINTENANCE STANDARD 34-1 HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION ................5 See Eee eee mG iiel 62 TESTING AND ADJUSTING .........0.. 0.0.00 ce eee eee eee 621 63 DISASSEMBLY AND ASSEMBLY ....... - 63-1 64 MAINTENANCE STANDARD .............0.00005 Renee eee G41) WORK EQUIPMENT 71 STRUCTURE AND FUNCTION . m4 72 TESTING AND ADJUSTING .. : 724 73 DISASSEMBLY AND ASSEMBLY ....... 73-1 74 MAINTENANCE STANDARD 74-1 OTHERS 90 ELECTRICAL SYSTEM 90-1 D150,1554LIST OF REVISED PAGES The affected pages are indicated by the use of the following marks. 1 is requested that necessary actions be Mark Indication Action required taken to these pages according to the table below. | Page to be newly added Aad © | Page to be replaced Replace (}) Page to be deteted Discard Pages having no marks are those previously revised or ‘made additions. LIST OF REVISED PAGES ark Pave TES! | naark Pape MEOH | wyark page TM OF | atork Page TPO! | atark Page Time of sor F ore a2 =6@ wat 13.18 © 02 7 or a4 0128 12.42 1348 © oa 7 or 82 1243 13.47 © 022 7 ore wi 8 1244 1948 * 023 7 or0 2 @® 1248 1349 © 024 7 or 94 na ® 1246 1320 + 025 7 or 93 wa @ 1321 © o26 7 or 94 wa. ® 13.22 os 095 @ waa @ 31S 12.23 © 04 o96 @ wag 1324 + 05 or. 97 ms 3 13.25 = 06 or 98 6 @ 13.26 2 7 oro mw? @ 1327 oe ot @ 1328 + me oz @ 1329 = 0010 os @ m1 6 1330 (00-11) oa 3 22 © 1331 ons @ 224 ® 1392 one oss 3 1222 © 139 o2 @ oris2 @ 1223 © 13.94 oer @ ons 3 23 6 13.95 os on @ 124 @ 13.38 oe oso 2s 6 5 1337 oar ® ons 26° ® 13.38 os @ | © oo 7 127 1339 ors: @ | ©o or F oa) 13.40 os @ oa ® 129 1341 7 @ ow ««@ 1240 1342 150,154LIST OF REVISED PAGES Mark fage TITEST | Mark Page RES} mark Page TIMEST | Mark Page TMCS] atark Page eS 135330 © 13-7023 ©) 2130 © 2163 r 136331 © 13-7024 © © 2st t (21-63-41) 136332 © 13-72 © 2132 2164 D ns ® nna @ [+ ass 7 (2165) ns ® nm ® 2104 2 266 2 i 1356 1378 21.35 + 267 1357 1378 2136 + 168 1358 2137 (2168-1 1359 220 (21682 1360 aa 7 2109 (208-4) ® 1361 ® 2-2 21-40 (21-685) ® Be ® a3 at e2r486) ® cr) a4 naz @ 2168.71 ® 13-64 25 2424 @ (21-688) ® 1365 ee) + mas op |e 20 2 ® 1366 en ema GF (21691) ® 1367 eral «mas 7 |e 270 ® 138 er) ema op |e a © 1369 aso 3 fe aap fw zee ® 13-70 2 * 2148 T (21-724) 135010 ©) 13702 © aise some 7 17221 ns011 ©) 13703 © 23 + ns 7 21729 135912 © 13704 © asa sas 7 |e am @ 25019 © 13705 © ais 2 arse evra 135314 © 13706 © nae a 1512) oom 7 125215 © 13707 ® 217 somsz 7 |e as 7 135216 © a8 ae 2159) * 79 7 138317 © 13709 @ aig 3 (21894) eo 7 135318 © 137010 © 2120 (21892) ery 135319 © 137081 © 221 sone 7 (avr) 135320 ©) 137012 © 2122 ons 7 e779) nasa ©) wu 2120 a e174) 135222 © w7045 6 228 ons 7 e778) 135223 © 137016 © 228 some 7 (av778) 135328 137017 © 2128 o mse 7 |e ae 9 135925 © 137018 © 2127 + ng 7 fo om 135328 @ 137019 az 9 [+ ner b |e ro @ 135327 © 137020 @ |o zara 7 |« ar 7 fo re o 135928 w7027 @ | + a8 7 eare2n1 one 135329 © 137022 © 2129 21622) o 28 | ® 150,154,LIST OF REVISED PAGES mark Page TIMEOH | mark Page TimeO! | mark page TE F | ark Page MEO! | mark Page [met 21-85 7 22-93 23-9 23:24 ® 23-62 o 286 P 2410 «@ 2340 23.25 2363 o nee 7 zu ® zt 2328 naa o me 7 zis @ zat na n6s ° 21-90 24112 © a2 F 23-28 ® ° 2346 t o 2191 D 2212 ana @ 23-29 ® 23467 © 12 nuns @ ns ® 23.68 cone 7 maa mis 3 a @) 23.69 ems mis mis 3 a2 @ 270 © nes 7 2246 mus a 23.33 an © 21-96 2247 ane F 233 © 23-72 ° nar 228 nis © ns © a7 ° 298 220 w1140 3 23.8 nm @ ° 2199 nar ® wun 5 2362 ® 23.75 21-00 na © mana 3 23353 @ 2376 2 arto nn ® maa 3 23364 © an © 21-102 nw ® aad 7 23.65 @ 23723 © © zea ns ® mais 3 368 ® 279 2r-o4 226 © nie © 2287 6 2.0 © 21105 nw © B4147 © 23368 © 23-81 2 21-108 D 2B © B18 3 23:38 ® 2382 oar) na & mia 3 nao @ | + za 220 © msi20 3 maz @ | © 2384 na ® mata 3 nas 20.85 m4 222 maa 3 ns ® 23854 22 ns @ nsi23 3 nar @ 23.952 zo no & m2 3 na @ 2452 24 © nu © zits 3 nao @ 2854 © 225 7 2235 ® 23412 ® 23-50 23.855, 22-6 ® 230 |S 23.13 23-51 23256 © em 7 mia 23.52 2957 ©) sae 7 2048 250 nee ©) 212 7 a4 26 @ 238 2059 © o 278 7 32 @ 2347 23-55 23-85-10 ©) oT 7 233 © 2348 256 «© 2a 6 some 7 24 219 2387 207 + mer 7 a6 2320 288 ne ©) 22 © 2.6 221 289 209 291 @ 23-7 23-22 260 6 6®) © 2300 22-92 © 23-8 23:23 23-61 ®o ° 2301 150.1554LIST OF REVISED PAGES Mark Pipe TITEST | Mark page TIME OF | atark Page TITECT | Mark Page EO | mark Page Teo + ne @ 2312 © 23.166 @ asco @ |e m2 fp + me ® 234167 nae @ 2425 @ + 208 @ ® 23.68 2192 «= @ 23280 «@ o 205 D ® nim © mis. @ ma @ ns © ® man 18 ® 22 @ noe | © © 23.172 23.198 2430 @ 2209 ® aim @ 23.196 aa @ 2100 ©) S 23475 @ 23-197 24311 @ 23-401 231331 © 23-176 23-198 24312 © 2102 © 23.1332 © aan 23.199 uae © 22109 2am © 217% @ 73200 2493 21104 2313 na79 201 @ 24934 22105 21% © m1 6 2494 221051 © 25.1382 @ nw © 2498 21052 © 2139 © 2.1811 © 2 2435 @ 231053 © nas © na82 ® 24.2 23.1054 &) 23.1392 © 23-1813 © 24 3 3 231055 © 240 nas © m4 3 as 21056 © rae nis @ | s m5 oD a2 231057 © 2.42 nws @ | + m6 oD a2 © 231058 @) 2asea mir @ |s m7 o> aa @ 23106 ©) 23.148 21818 © a8 @ a2 © 2107 23.145 nia @ |o mo @ ana 23108 246 mas @ | © 210 ans 2100 © zaaar ae @ |e wat @ a6 © 2110 2aa4a aw @ | + m2 @ a7 pan 249 2.418119 © 2404 a8 @ 23.412 23-181.14 © 24.15 319 @ zai ries © 23114 . 2348116 © 2315 © 2318117 @ 33-1 aus nai @ | + 210 @ a2 © 23417 23182 @) © 2420 @Q 333 zane nas @ [+ ua @ as © 2418 nie @ | o mar @ a5 23120 ws =©@ | o m2 @ 33: 54 mam ns © |e uz 9 33.52 222 23.487 un 33:54 27 23.198 © mama @ 33. 54 zai 23.199 ° mae 33-6 150.1554 00-2-4 ®LIST OF REVISED PAGES Mork Page Time!) atark Page Tim*®.ot | ark Pope MEO! | mark Page [net] Mark Page Tue ot 33-7 weg ens 6334 33-8 49 @ e116 ® 63.35 33-9 3410 @® ear @ ® 63.36 33:10 oon 7 ene =D i) 6337 33.1 a412@ o9 @ 63.38 33.12 est © 63.39 33.13 e192 © 63.40 33414 orf e120 = «@ 6.1 6341 3345 a2 a2 © 63-2 342 33.16 oar @ e121 63 2 6343 3347 a3 e212 © 63.4 e344 33.8 eat OD e2 © 63.5 6345 33.49 a4 e123 860 63.6 63.46 33.20 rar D 61231 @ 3-7 6247 33.21 os 61232 @ 63.8 63.48 33.22 e541 @ e128 @ 63.9 6349 33.23 652 © 61.25 6310 6350 + 3324 616 612541 63.1 6351 33.25 67 61.252 6312 + es 7 33.26 ore 61.26 63.13 6353 33.27 eet 6127 63.44 63.56 33-28 e9 e127 63.45 62.55 33.29 61-10 e1272 63.46 63.56 33.0 erat © 6128 63.17 6357 3331 erat 61.29 63.18 63.58 3332 ern 1201 © 63.19 63.59 3a ® e112 122 © 63.20 6360 e124 e130 ® 63.21 6361 61122 63.22 63.62 34 e123 63.23 63.69 42 G ert24 621 63.24 63-64 43 @ 61125 62.2 63.25 63.65 rr e127 62.4 63.26 63.66 war @ e128 62.5 6327 6367 3442 © 61129 62.6 63.28 63-68 o 45 @ eri210 2-8 63.29 63.69 34514 @® era241 @ 20 © 63.30 + 63-70 34 52 11212 @ e210 ® 63:31 6371 34.6 e143 en ® 69.32 63.72 oe a © e212 63.33 63.73 150.1554, 00-2-5 oOLIST OF REVISED PAGES Mark Page TUNES | mark Page TME°F | Mark Page TLE OF | Mark Page TIMES! | ntark Page rs oF ar eois ne m4 «975 eons m9 742 876 eae m0 m3 @ en eaa7 744 7 ene m6 @ «379 eone m4 m7 @ 63-80 63-120 72-2 ® 14-8 ® ce 62.121 232 © m9 © eae enna m4 74.10 oes 62123 saa oo. 6395 60125 4 + 1 7 ee 3 e226 13.2 2 3 eer 73.3 93 3 cage 346 © wa 3 e299 or 3 736 5 3 «390 o2 5 73.6 me @ os oes 3 13.7 sor GF 63.92 64.3 a 73-8 290-74 sa99 43 9 72 © cao es 3 73.10 90-8 e208 oe 3 90.9 e398 oer 3 9010 cas o47 mat 901 cas oe 732 soz «299 eo m3 so 62.100 e410 m4 so e101 m5 ® sos e202 mie @ | © sore e210 ms mar | © soo e204 m2 m1 8 © 60.105 na ® vase vo © «2108 cn) 7320 60.107 ns © 721 «0.108 154 @ m2 62:109 152 @ 73.23 2.110 ne © 7324 nT oO ean nm ® ean 112 © D150,155A 00-2-6 ©Ai important SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this ‘manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols AM and "A" are used to mark safety pre- cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation, A SAFETY 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 3.1f 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 workshep 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 ‘loor. Smoke only in the areas provided for smoking. Never smoke while working, PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level grounc, and block the wheels or tracks to prevent the machine from moving. 8 Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, sup- port 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. 00-3PRECAUTIONS DURING WORK 11, When removing the oil filer cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit 12. The water and oil in the circuits are hot when the engine is stopped, so be careful notto get burned. Wait for the oil and water to cool before car- rying out any work on the oil or water circuits, 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14.Whan raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the tuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil ‘on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 00-4 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts ‘When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at, either end of the track.FOREWORD: This shop manual 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 shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of ‘components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as wall as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section, DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES, ‘Shop manuals are issued as 2 guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models Electrical volume Attachments volume These various volumes are designed to avoid du- pplicating the same information. Therefore to dez with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready, DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up- to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page umber. Example 1 (Chassis volume}: 21-3 Unit number (2. Power train) Hem number (1. Structure and Function) Consecutive page number for each item Example 2 (Engine volume): 12-410 Unit number (1. Engine) tern number (2. Testing and Adjusting) Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 12-203-1 12-203-2 12-204 REVISED EDITION MARK (O@ @- When @ manual is revised, an edition mark is recorded on the bottom outside comer of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. ‘Symbol | Item Remarks ‘Special safety precautions are A necessary when performing the work Safety Extra special safety precautions “ar are necessary when performing * ‘the work because itis under internal pressure. Special techoical precautions or tier preceutons for | caution | preserving standards are necessary when performing the work Weight of parts or systems. a Caution necessary when (iw) | Weight |selecting hoisting wire, or when working posture is important, te sgnten. | laces that require special Saw | Tighten: | attention for the tightening jing torque torque during assembly. Feces obo costes wah —_ Coat | adhesives and lubricants etc. Faces wher of ter orto! ‘ap |ou woter| neste sSsadianite aces where aor watr must a Re drained.HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS AY Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and As- sembly section, every part weighing 25 kg, or ‘more is indicated clearly with the symbol ys 1. Ha part cannot be smoothly removed from the machine by hoisting, the following checks should bbe made: @ Check for removal of all bolts fastening the part to the relative parts. ¢ Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “2” or “S" twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 1.0 112 14 125 16 14 22 16 28 18 36 20 44 224 56 30 10.0 40 18.0 50 28.0 60 40.0 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook Slinging near the edge of the hook may cause the rope to slip off the hook during hsisting, and a serious accident can result. Hooks have ‘maximum strength at the middle portion. 100% = 8% 79% 71% Fs0064 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically ‘wound on to the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling @ heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes ‘make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling 2 2000 kg load at a lifting angle of 150°. *g 3 Losd capacity Ltting angle : a 00-7STANDARD TIGHTENING TORQUE Ayam] STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly”. Thread diameter Width of bolt across flat ‘mm) ram) kgm Nm 6 10 1.354015 13.2214 a 13 32403 31.4229 10 7 67407 65.768 12 19 115210 112498 14 22 18.0420 177419 16 24 2853 27929 18 27 3924 383+39 20 30 56+6 549458 22 32 76+8 745+78 24 36 94.5410 927+98 27 a 135215 1320140 30 46 175+20 1720+190 33 50 225425 2210+240 36 55 28030 2780290 39 60 335+35 3280+340 This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque. ‘+ Nm (newton meter): 1Nm 5 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. ‘Thread diameter 00-8 ‘of bolt (mm) 10 12 16 Tightening torque with across fats tenn) km | Nm 14 67207 | 65.7268 7 1821 | n2z98 2 2853 27928STANDARD TIGHTENING TORQUE 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared, Thread diameter ‘of nut part (om) Width across flats ‘of nut part (om) Seating surface Tightening torque 14 18 22 24 30 33 36 42 19 24 27 32 36 a 46 55 kgm Nm 25205 245+4.9 8x2 492196 8+2 785+196 1423 137.3294 18+3 17654294 20+5 196.1+49 25+5 246.2249 306 294.2249 COATING MATERIALS (aw The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. ‘Nomenclature Applications uaa Used to apply rubber pas, rubber gaskets, and cork gs ae romnstatc pats when fon strong sells neded. Adesives ure Preventing bolts, nuts and plugs from loosening ane eskng ol Provides an aright, elacrialy insulating 203. Li Used for sluminom surfaces tea Used with gaskets and packings to increase seating etfect. Le Heatresstant gasket for precombuston chambers and exhaust piping A Used by tet on mounting surfaces onthe fina drive and wansmianion cases. o thickness ater tightening. 007 ~ 8.08 mm re Used by sot wo seal grease ings, oped sore fing and aperedscrew fittings la hyarauie eveuts of less than SO mm in ameter Tanifcton compound fAnusricson compos ime ‘Applied to bearings and taper shalt to facitate pressing and to rmolyedenurs dsl) ‘prevent steking, burning or rusting Grease Gu “Applied to bearings, sing pare and o sal or ubreation, rst (Cthiom greased prevention and feitation of assemiing work Vaseline Used for protecting battery electrode terminals from corrosion *UT-2 ie aso called LOCTITE in the shop manuals 00-9ELECTRIC WIRE CODE italy ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number § and white coating with black stripe. CLASSIFICATION BY THICKNESS. Nene | Namear JB otavencs] Conssegvon] Tema: [UMS*S) ——Appteabe cet Tone [OO toe] ta cee pt] ose cas 2a Ta] Strina lahing sore 2 a) 208 [at 20 | “unhing sonal 15 84 0.45 13.36 70 59 ‘Starting (Glow plug) 7 eC co] aa? [080 sae] a0] a8 | arin CLASSIFICATION BY COLOR AND CODE Page guess Charging Ground Sterting Lighting Instrument Signal ‘Other "Jr Color White Black ‘Black Red Yellow Green Blue a co a m aw oe 2 Color] White & Red - Black & White | Red & White | Yellow & Red | Green & White | Blue & White 3 iv [Code WL BR ‘RY, YG wy ‘ Color] White & Blue - Black & Red | Red & Yellow | Yellow & Green | Green & Yellow | Blue & Yellow. 5 | Color} White & Green = Red & Green | Yellow & Blue | (Green & Black) | (Blue & Black) ® Color | - Red& Blue | Yellow & White | (Green & Blue) - 00-10SOP MUAY D150,155A-1 Serial No. D150A-1 8408 and up D155A-1 15001 and up OI GENERALD150, 1554 GENERAL General views Specitic ce General assembly drawing. Engine assembly drawing Weight table... Positions of serial numbers Table of oil and water quantities. Oil and water filling and drain points . or 2 01 6 or 8 01-10 01-14 01-18 01-20 01-21 01-1GENERAL VIEWS 26 GENERAL GENERAL VIEWS 150A C8408 ~ C8420 7 01001 Exhaust pine Blade litt cylinder Operas Fuel tank Track shoe Track frame Carcier roller “Track roller guard Ctrame, Straight frame 10, Brace 11. End bit 13, Cutting edge o1Po02 01-2 D150,1554 ®GENERAL D150A C8454 and up 150.1554 GENERAL VIEWS 01P003, Exhaust pipe Blade lift evlinder Operator’ seat Fue tank “Track shoe Track frame Carrie rotor “Track roller guard Straight frame Brace End bit Blade cutting edgeGENERAL ecm on is GENERAL VIEWS, D150, 1554 01-3GENERAL VIEWS it GENERAL DI55A 15001 ~ 717000 D155A 117001 ~ T19000 Exnoust pipe Blade it eylinder Operator's seat Fuel tk 1 2 a 4 5, Traek shoe 6, Track frame 7, Carver roller 8, Track roller guard 8, Straight trame 10, Brace 11, End it 12, Bode 12. Cutting edge 01P005 D150,1554GENERAL D155A 19001 ~ 25000 D1S5A 25001 and up D150,1554 ‘01P0068 175P002:3 GENERAL VIEWS. Exhaust pipe Blade litt eyinder Operator’ scat Fu tank Track shoe Track frame Carrer roller Track roller guard Straight frame Brace End bit Blade cutting edge Exhaust pipe Blade litt evlinder ROPS cab Fuel tank ‘rack hoe Track frame Carrier roller Track roller guard Stright trae End bit Blade Ccurting edge 01-4-1 ®GENERAL VIEWS ee it wn GENERAL D155A 15001 ~ 25000 10. " 12, 13. 14 16. 16. . 18 19 21 2, 2 2m 25, 26. 27. Fuel contra! lever Gear site ever Compression release lever Brake pedal (ett) Steering lever (lett) Steering lever (eight) Safety lever Blade control lever Safety lever {for blade contro! lever) 2098 Ammater Starting switeh Preshaterswiteh Lame switen Heater signal Dust indicator 01-5 D150,1554 ®GENERAL, i cnc GENERAL VIEWS. D155A 25001 and up 2 With ROPS cab Fue control ever Deceerator pedal Gear sit ever rake lock ever Blade contr lever Sefety lock (for blade control ever) Safety lever (for gear shift ever) Warning check switeh Fear lamp switch Head lamp switch Panel lamp switch Prehester switch Starting switen Torque converter ol temperature gauge Engine water ter Engine water temperature warning lamp Engine ol pressure warning lamp aie fi warning lamp Radiator water level warning lamp Engine ol filter warning lamp Preheater indicator lamp Fuel gauge Service meter 1-5-1 D150,155A 0 e‘SPECIFICATIONS. HIvieesmennanenanemnt cern GENERAL SPECIFICATIONS DisoA DISA Machine model 1 1. Machine Serial Numb 3408 ~ 6420 17001 ~ 26000 | 26001 ~ Operating weight ine! ROPS cabin) Tractor es) 220 23160 a0 2210 27150 | cAnsecoee (i) s3770 33670 33770 33670 38795 E | esuaignesieozer 3) 33800 33600 3800 33690 35015 saSuaighe dozer with mult 4g) 30220 38850 39220 38850 0975 aBieighettdocer with gant 4g) 38740 38290 38740 38200 40a1s «Tractor (rom) 5420 3420 3420 420 420 Angledozer (em) 40 6940 6040 40 940 rat] ester tn 80 880 6880 280 880 *Singemenrpeer mm) ‘9560 ‘8560 ‘8860 ‘9560 ‘9560 Seater Wi ny e045 aos aos 8945, 8045, Tractor (rom) 770 2510 2780 7a10 210 overt! angedocer (om) 4850 4250 4950 4350 4850 esusightatdozer (mm) 4130 4130 4130 4130 4120 Overt] pipe eT ten 3640 ‘3640 3640 ‘3640 3725 het] eo te repot tm) 2620 2600 2600 2500 2605 “reek oouse (emmt 21a0) 2140 2140 2140 2140 Length of tack on ground (ev) 3180 3150 3180 3160 3180 Shoe width (STO) {oom} 860 560 560 560 860 Ground clearance (ev) 500 500 500 500 500 Ground pressure Akalem?) Track o77 on on on on ‘Anoledozer 0.95 095 095 095 101 ‘Seaighttitdozer 0.95 095 0.95 095 101 = Suipneitdozer with variable an 1.10 1at 110 116 Sight ttdoer with variate 1.09 1.08 1.09 108 1 PR iting Sas OUR aT 38 38 38 38 38 Groceabitty (429. 30 30 30 20 20 1 ‘min 28 25 o~37 o~a7 o~37 2nd (mm) 35 38 o~68 o~68 o~6a Sea (mm) 49 49 one o~ns | o~n8 | 8 | Formara = ah (umm) 64 64 = = 5 ak com | oe | ws | : - z/= eh (emi) 129 129 = - S i te (imma) 38 38 o-as | 0-05 i (hmm) 50 50 o~s2 | o~82 Revere 3rd (imi) 6s 68 o~1a7 | o~s37 am (hema) 90 20 2 = = ERs re tans 35 36 38 7 35 D150,1554GENERAL © “ eee SPECIFICATIONS DISOA DISA Machine mode! 1 7 ‘Machine Serial Numbers 8408 ~ 8420 Baz ~ 15001 ~ 17000 | 17001~ 25000 | 25001~ ‘Wie, multiple dae inertia brake, Main clutch hand opereted with hydraulic, - “Torque converter - 3 element single stage and single phase Planetary ost ond maltiple ise Helical gear, constant mesh, clutch, Rysraulealy actuated, “Transmission hand operated, forced libricaton. | Fores lurietion Forword 6 spect Formard 3 speeds Reverse 4 speeds Revere 3 speeds Bevel geo heft Spiral bevel gar splash lubrication ‘Steering clutch Wet, multi-ie, hydraulic with spring type ‘Wet contracting band with clutch booster ‘Steering brake Interconnected with steering clutch — soup, len oma Zahn GB rect 1c ie 0, 0,0,8,0,0,8) > Shrrack ‘Assembled, single grouser, 41 each side, shoe pitch 228.85 mm, width 560 mm (STO) i respec ae 2 Varios cloning sole pe Max. digging depth: 1240 mm D150,1554,GENERAL ASSEMBLY DRAWING |) si coco GENERAL GENERAL ASSEMBLY DRAWING 150A ANGLEDOZER 8408 ~ 8420 o1FO10 D150A ANGLEDOZER 8421 and up oirort 01-8 1D150,1554 @GENERAL § mee eee GENERAL ASSEMBLY DRAWING DI50A STRAIGHT-TILTDOZER C8408 ~ C8420 a0 9 e be oFoo! DI50A STRAIGHT-TILTDOZER oiro12 , 01-8-1 D150,1554 aGENERAL ASSEMBLY DRAWING #htiiitistteteeeR Seen GENERAL 150A STRAIGHT-TILTDOZER WITH VARIABLE MULTI RIPPER C8408 ~ C8420 o1rois o1rora 150.1554GENERAL sities | GENERAL ASSEMBLY DRAWING D150A STRAIGHT-TILTDOZER WITH VARIABLE GIANT RIPPER 8408 ~ 8420 a [ cea igt IS 3 sd Ya Tr al"| | oom a = T x ae oIro1s DI50A STRAIGHT-TILTDOZER WITH VARIABLE GIANT RIPPER 8421 and up oIFoIS D150,1 01-9 558 iGENERAL ASSEMBLY DRAWING se seaoneecamt oo) GENERAL D155A ANGLEDOZER 15001 ~ 17000 o1Fo17 D155A ANGLEDOZER 17001 ~ 25000 o1rois, Ora D150,1554(GENERAL eee GENERAL ASSEMBLY DRAWING D155A ANGLEDOZER 25001 and up 1 75F008-2 1-9-2 0150,1554 org.(GENERAL Sensor DI55A STRAIGHT-TILTDOZER 15001 ~ 17000 out GENERAL ASSEMBLY DRAWING DI55A STRAIGHT-TILTDOZER 17001 ~ 25000 0 01-9-3 @ oirois Tr oom OG ae ka! aq i | Stren i o1rozo 150,154,GENERAL jth GENERAL ASSEMBLY DRAWING 155A STRAIGHT-TILTDOZER — 25001 and up = IT ——— ; & ‘ lO| Hore r 0 ae 10 [x0 Lo S ra § = + ——— a ee (ie a 4 { 3150 sl Is 7 8 —_________ \7sF008-2 1-9-4 150,155 org.GENERAL ASSEMBLY DRAWING {9 income GENERAL D15SA STRAIGHT-TILTDOZER WITH VARIABLE MULTI RIPPER 15001 ~ 17000 o1ro2! DI55A STRAIGHT-TILTDOZER WITH VARIABLE MULTI RIPPER 17001 ~ 25000 oiroze D150,1554(GENERAL {itera GENERAL ASSEMBLY DRAWING DIS5A STRAIGHT-TILTDOZER WITH VARIABLE MULTI RIPPER 25001 and up 4 Jem] nx] aa. em t78F007-2 150,154 01-9-6 @GENERAL © ee ee oer GENERAL ASSEMBLY DRAWING DI5SA STRAIGHT-TILTDOZER WITH VARIABLE GIANT RIPPER 15001 ~ 17000 a o1roz3 D155A STRAIGHT-TILTDOZER WITH VARIABLE GIANT RIPPER 17001 ~ 25000 ——— 1) Too is fF a || oat “LPR Lo Et 1k T = i TL o1rooz 01-9-7 @ 150,154‘GENERAL [Silleeseteaienettttimt GENERAL ASSEMBLY DRAWING 155A STRAIGHT-TILTDOZER WITH VARIABLE GIANT RIPPER —25001 and up 210 a0. 1600 \78F008-2 . 01-9-8 150.1554 3ENGINE ASSEMBLY DRAWING = ss © GENERAL ENGINE ASSEMBLY DRAWING Starting motor Bypass ol fiter Corrosion esstor utter Thermostat housing Alternator “Tension pulley Accessory drive pulley Vibration damper 01-10 D150, 1554(GENERAL. ‘sessions neta LI ENGINE SPECIFICATIONS wi ENGINE SPECIFICATIONS D150A DI1SsA Mode! 1 1 Machine Serial Number 3408~ 8420 | 8421~ | 15001~ 17000] 17001 ~ ‘$6D185-4 Engine model S6D155-4D “A-cycle, straight vertical, water cooling, direct injection type, turbocharged, diesel engine ee a oy § | RERBERayowarspsony (mm) v8 ‘0 5 Overall width (Front support) (mm) 1,190 5 | EMU stp) tm) 276 Ss zi fs a g Max, torque (kgm/rpm) 134/1400 1144/1400, & | ax rotting seed (no toxd 2.230250 220060 < Min, rotating speed (no load) 600 +50 or = Dry weight (ka) 2600 | 2580 Fuel pump Bosch PES-PD type — See eee Lubrication system Gear pump forced lubrication Oil fier Fulllow filter and bypass filter used jointly Starting motor 2av 11 kW Alternator | 2av 358 Battery 12V, 200Ahx2 | 12v, 170Ahx2 | 12v, 2008hx2 [12V, 170Ahx2 Turbocharger KTR 120 0150.1554 01-11 @ENGINE ASSEMBLY DRAWING * ae tment GENERAL S6D1554A D150A-1 ateshorse power 00120009 Maximum torque. 134kgm/1,400 rpm Minuet eoumetion elo taDarPn Toraue ra 2s =e = ro 20 100 & on ao & a : jo 2 0 P \ 20 . ° : 2 200 a 20 150} 220 £ = a0 2 Loo € rr 3 hoo 8 P| evetconsumtion —-t-—~—| 3 20 a 170 dl wea feu ees O12 D150, 1554GENERAL es erreeeteeromemmmaeerboetoaesneams ENGINE ASSEMBLY DRAWING S6D155-4D D155A-1 Rated hore power 3201P/2,000%5m Maximum toraue 14g 400 rpm Minimum fuel consumption below 1809/HPh + | veo Tor cue [| ™~ 140 350] 1 | << . | 4+ 100 § 300) woe & s 60 & 20 20 20 A ° t 2 mo 6 290 i 20 € ao & | poe 100 . 4 190 § Fuel consumption 8 P—|_Fue! consumption] 7 | ba 2 0 170 oéa5 e000 ~~ —~—Ca «0 rem c1rooe D150, 1554 01-13 @WEIGHT TABLE i ae GENERAL WEIGHT TABLE Model DIS0A4 Serial number 8408~8420 8421~8453 8454~ Engine, main clutch ass'y 2,908 2,900 © Engine ass'y (with P.T.0.) 2,600 2.200 © Main clutch ass'y 225 210 Engine torque converter ass'y © Engine ass'y (with P.T.O.) - © Torque converter ass'y Radiator guard, blade lift cylinder ass'y 1,100 1,100 © Radiator guard 690 680 © Radiator ass'y 420 435 © Lifteylinder ass'y (each) 400 400 Fuel tank ass'y (Full) 710 720 Universal joint ass'y 20 Transmission ass'y 660 TOROFLOW transmission ass'y © Control valve ass'y Bevel ear shaft, steering clutch ass'y = © Steering clutch, brake band ass'y (each) 160 © Bevel gear shaft 35 © Bevel gear 36 ‘Steering control valve ass'y 60 Brake band, link ass'y {each) 50 Final drive case ass'y (each) 185 1st gear, 2nd pinion ass'y (each) 100 2nd gear, sprocket hub ass'y (each) 300 D150,1554 01-14 @GENERAL Unit: ko D1ssAA 15001~17000 | 17001~19000 | 19001 ~ 25000 25001 ~ 2870 2,880 2.580 2,580 210 225 1550 1570 ooo 690 a0 435 400 | 400 700 720 20 00 160 35 40 60 12 50 185 100 300 150.155 WEIGHT TABLE 1-15 aWEIGHT TABLE fs —— . GENERAL Mode! D1s0AA Serial number swos~eazo | eazineass ease~ Sproat ay (exc 310 Steering ae, min Fame any 40 3,000 © sterng cose, mainframe 240 2.700 #spreket shat (eae us 4s | raterus ane s'y (690 mmc 2200 | xem sevice sho ane (680 mm, each 2520 E | scoria disposal shoe as'y (B60 mm, each) 2545 “Track group assy (with yoke) (each) 3570 3s | 3,580 © Idler ass’y (with yoke) (each) 450, 450 450 Track roller ay tingle 120 120 130 (double 10 140 40 © Carrer otter as'y (each side 0 10 os Rec sringasty (each ass 225 285 @ Trac frame (eae 1310 ta0 | tam 335 40 Engine underguard 360 $0 “Transmision underguard 270 175 Floor frame as'y 400 PT.O.e5'y 0 @ Hyetauic pump as'y 45 © Traramiton man teh pura en'y 6 steering pum as'y 25 Para ank sy 30 360 © Coniol ve ay 06 8s D150,1554,GENERAL fist a Unit: kg D1S5A-4 veoor-roco | rvor~se000 | rs001~asee0 | 2s001~ 310 3,140 | 3,000 | 2,840 2,700 145 145 2,290 2,520 2,545, 3.870 3,590 3,580 3,580 450 450 450 450 130 130 130 130 140 140 140 140 70 70 65 65 285 285 285 285 1310 1,330 1,330 1,330 335 340 360 300 270 175 400 80 45 15 25 330 360 95, 95 D150,1554 WEIGHT TABLE 01-15-2WEIGHT TABLE {ise a GENERAL Model DIS0A1 Serial number 8408~8420 8421~8453 8454~ Blade lft cylinder ass'y (each) 200 Blade tlt cylinder ass'y (each) 245 Ripper lift cylinder ass'y {each) 250 265 Ripper tilt cylinder ass'y (each) 300 290 ‘Angledozer ass'y 4,100 © Argle blade 2,000 © Ctrame 2,100 ‘Straight titdozer ass'y 4,500 4,300 © Straight blade 2,600 2,220 © Straight frame (each) 660 660 © Tilt cylinder ass'y 245 245 Variable multi-ipper ass'y 5,560 © Shank ass'y (each) 285 © Lifteylinder ass'y (each) 250 © Tilteylinder ass'y (each) 300 Variable giant ripper ass'y 4,740 © Shank ass'y (each) 450 © Lifteylinder ass'y (each) 250 © Tilteylinder ass'y (each) 300 © Pin puller cylinder ass'y 10 Ripper bracket, (each) 325 290 D150,1554 01-16 ®GENERAL cna oy WEIGHT TABLE Unit: kg DI1S6A-1 18001~17000 17001~19000 | 19001 ~ 25000 25001 ~ 200 245 250 265 300 280 4,100 2,000 4,500 4,300 2,600 2.220 660 660 245 245 5,560 285 250 300 4,740 450 250 300 10 325 290 1 D150,1554 18 7POSITIONS OF SERIAL NUMBERS *" eno me GENERAL, POSITIONS OF SERIAL NUMBERS (ENGINE) D150A 8408 and up D155A 15001 and up © Engire No, © Radiator ‘© Turbocharger eae © Injection pump No, © Alternator No. ——_ © Steering pump No. ‘© Main clutch pump No. © Hydraulic pump No. © Transmission pump No. 01-18 D150, 155A @GENERAL oe POSITIONS OF SERIAL NUMBERS POSITIONS OF SERIAL NUMBERS(BODY) 150A 8408 and up D155A 15001 and up © Blade No, ‘© Torque converter No, (D155) © Machine serial No. DISOA 8408~8420 ISSA 15001 ~ 17000 DIS0A 8421 and up ISSA 17001 and up o1roos nin ry +E * = e = 175P014:4 D150, 155A‘TABLE OF OIL AND COOLANT QUANTITIES oS GENERAL TABLE OF OIL AND COOLANT QUANTITIES (D150A-1) PROPER SLELECTION OF FUEL, COOLANT AND LUBRICANTS, IDOE "AMBIENT TEMPERATURE CAPACITY (0) RESERVOIR en rr a iT ee ee ee mount | _capocty SHE 30) Engine oil pan 87 SAE 100-30 SAE 15W-40) Steering auten SRE ae tranamitsion care Engine oil ‘e Main cluten case 30 2 Fale oe ST (en) °°) s is 7 SAE 100-30) SAE 15W-20) Hydraulic system 2” Titozer 1 Angledocer 103 103 039-045 039-045 063 - 0.72 fae (each) 3 Teock roller (each) Carrier rater (een) Geer oit C0140 Fuel tank Diese fut 600 ASTM DS7E No.2 ‘ooling system | ‘Add antifreeze % ASTM D975 No.1 Serial No. 8421 and up: Dry type NOTE: ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute Specified capacity: Total amount of oil including oil for components and oil in piping Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. (1) When fuel sulphur content is less than 0.5%, change (2) When starting the engine in an atmospheric tempera: cil in the oil pan every periodic maintenance hours ture of lower than O°C, be sure to use engine oil of described in this manual. SAE10W, SAE10W-30 and SAE15W-40, even though Change oil according to the following table if fuel ‘an atmospheric temperature goes up to 10°C more or sulphur content is above 0.5%. less in the day time. 1 _ 3) Use API classification CD as engine oil and if API Fuel sulphur content change interes Of ci) classification CC, reduce the engine oil change in engine oil pan interval to halt 0510 1.0% 1/2 of regular interval ‘Above 1.0% 1/4 of regular interval 01;20 150,154GENERAL © TABLE OF OIL AND COOLANT QUANTITIES TABLE OF OIL AND COOLANT QUANTITIES (D155A-1) PROPER SLELECTION OF FUEL, COOLANT AND LUBRICANTS vain OF AMBIENT TEMPERATURE CAPAETV RESERVOIR FLUID rn ‘Specied | Rei “3% 8 8 Se SS SRE AE Tot TT SAE OW 30 ‘SAE 15W-40 a T + L Bes a Engine ot re 185 136 Soom oboe ET sorese Fp aE Sar TOT —— = T Rec pnagene Te 3 a Real a PO nls Ex SAE TOW’ == rate system ER . z SAE 10030 Boe] 3 (Ti TSAE igwon © Ider (each) —_ — (0.39 - 0.45 > Track roller (each) Gear oil (G0 140, | 0.29 - 0.45 - Corer eth low ossnor | = z rust tn Datu co | - ae ASTM D975 No. 2. AST PETE He Seana Weer | Add antreeze w]e % ASTM D975 No. 1 % Serial No. 17001 and up: Dry type. NOTE: ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute Specified capacity: Total amount of oil including oil for components and oil in piping Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. (1) When fuel sulphur content is less than 0.5%, change (2) When starting the engine in an atmospheric tempera: oil in the oil pan every periodic maintenance hours ture of lower than 0°C, be sure to use engine oi! of described in this manual. SAE10W, SAETOW-30 and SAE15W-40, even though Change oil according to the following table if fuel fan atmospheric temperature goes up to 10°C more or sulphur content is above 0.5%, less in the day time. (3) Use API classification CO as engine oil and if API ‘Change interval of oi! Classification CC, reduce the engine oil change Fuel sulphur content arene interval to halt 05 t0 1.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval D150,1554 01-20-1 OGENERAL OIL AND WATER FILLING AND DRAIN POINTS OIL AND WATER FILLING AND DRAIN POINTS (ENGINE) (This subject is also described in the operation and maintenance manual) D150A C8408 and up D155A 15001 and up © Cooling water drain © Cooling water filling port a= ie * © Engine oil drain © Cooling water drain (oil coller) D150, 1554 01-21 @OIL ANDWATER FILLING AND DRAIN POINTS come GENERAL, OIL AND WATER FILLING AND DRAIN POINTS (BODY) D150 8408 and up © Main clutch filing port ‘© Transmission drain © Hydrualic tank filling port ° © Steering case filling port } | | a: \ {Hh _ A forross) — Serer Saas we J © Steering case drain ; : a 01,22 0150, 155AGENERAL OIL AND WATER FILLING AND DRAIN POINTS. D155A 15001 and up © Torque converter drain le © ‘Steering case drain © Steering case filling port = ~a Final drive filling port «suas tan filing por 15001 ~ 19000 nid J > ae * 7 f biregr 19001 and up © Final drive drain © Hydraulic tank drain D150, 155A 01-23MEMO 01-24 1150, 1554SHOP NOAM G D150,155A-1 Serial No. D150A-1 8408 and up D155A-1 15001 and up 41 ENGINE STRUCTURE AND FUNCTION150.1554 STRUCTURE AND FUNCTION 11-1‘RADIATOR, FAN li htteeaneeeaentaaeeaeteeantattetett STRUCTURE AND FUNCTION RADIATOR, FAN DIS50A 5508 ~ 8513 D155A 15001 ~ 25000 ppeene £ upper nk Hose tole tube Fan guard Pulley Section A-A 10, 1. 12, 178FO11 Shaft Box Outlet tube Lower tank Radiator core Fan 150,154STRUCTURE AND FUNCTION jive ‘The radiator is made up of upper tank (1), radiator core (11), and tower tank (10). Cooling water, after flowing through the engine ‘thermostat, is temporarily stored in the upper tank ‘order to remove air in the water. It then flows from the inlet tube (3) to the lower tank (10) through the radiator core. As cooling water flows from the inlet tube (3) to lower tank (10), its heat is dissipated so that the ‘temperature falls to 85 to 95°C which is the best for engine. ‘The core consists of multiple flat drawn tubes and fin for raising the heat radiation efficiency, and is clasified as D type, G type, and K type according to the tube arrangement system. In this model D150, 186A, D type is used in which tubes are arranged in series, 150,154 cease emmcueeeme RADIATOR, FAN 175F012 Cooling water in the lower tank, now at ¢ lower temperature as a result of heat radiation, is returned to the engine block by the water pump, Pressure valve, which is equipped to upper tank, prevents air bubbles from entering cooling water by keeping upper tank pressure at less than 0.75 kg/cm? of gauge pressure and avoiding boiling of cooling water at more than 100°C. Hose between upper tank and tube (9) of wate: pump suction side plays the role of supplying cooling water from upper tank to prevent production of air bubblos at ‘the suction side of water pump. Radiator fan (12), which is driven by fan belt cunning between the fan and the pulley to the engine, impels air to the radiator core, increasing heat radiation efficiency. In model D150, 185A, the discharge method is employ- 4, in which air is blown toward the radiator.RADIATOR, FAN iii?ftitiancteene yee STRUCTURE AND FUNCTION D150A 8514 and up D155A 25001 and up 11-3-1 @ Upper tank Hose Inlet tube Hose Fan guard Pulley Section A-A 175FONI-1 Shaft Boss Outlet tube Lower tank Radiator core 1 Fan 150,154RADIATOR, FANRADIATOR, FAN [iii STRUCTURE AND FUNCTION “och STRUCTURE AND FUNCTION Presurevvg = DS Baffle plate Radiator core and fin “Aeration” and the excessive aeration wi adverse effect on the engine as described below; 1) Aeration lowers water pump performance and reduces coolant circulation, causing the engine to become overheated. 2) Aeration causes corrosion inside the engine (such as in the cylinder liner) 3) When coolant temperature rises, aeration will cause coolant to overflow, because the mixed air expands more quickly than water. 4) Aeration reduces the heat transfer surface area (Radiator core), resulting in lowered cooling efficiency. 11-3-3 ‘This system is intended to prevent the aeration. To prevent aeration, a baffle plate is provided in the Upper tank to divide it into chamber A and chamber B. When flowing into the radiator from the engine side, coolant encounters the baffle plate where bubbles are separated, and then flows into the radiator core, The separated sir passes through a thin pipe C and escapes into the air space in chamber A of the upper tank. Air breather line D in the upper tank also functions to permit air bubbles to escape out of the engine water jacket. Consequently, coolant in the chamber A of the upper tank contains little air. When bubbles are generated on ‘the suction side ot the water pump during engine operation, the baffle plate will also assist in supplying more coolant. ‘The pressure valve combined with the vacuum valve pressurize the coolant in excess of the specified 0.75 kg/em* and the coolant will not boil even if itis ‘heated to aproximately 108°C. D150,155ACOIL COOLER ensemennntnnemamencomemeeesontnsmemeememe® STRUCTURE AND FUNCTION OIL COOLER Coatant Coolant [Toit inet []}— oi outer 21F00s Ccoupting Tube Tube cover Cover Tube Ccousting 9, Tube 10, Housing 11, Tube 12, Cooter 12, Drain plug 1 2. a 4 5. Gasket 6 2. 8 11-4 D150, 1554 @‘STRUCTURE AND FUNCTION P.T.O(POWER TAKE-OFF) ‘The P.T.O. system, installed on the engine flywheel, consists of main shaft (4) (connected to the spline on which the gear engaging with the external teeth of the engine flywheel is installed), drive gear (5) on the main shaft, and two driven gears (3) and (8). ‘Steering pump Flywheel housing P10. case Driven gear Shae vive gear D150, 1554 Ss a Pro. (On the boss spline of gear (8), @ hydraulic pump is mounted, while on the boss spline of gear (3) TORO- F LOW pump or main clutch pump is mounted. ‘The steering pump is mounted on the front face of the flywheel housing. ‘As for lubrication of P.T.O., lubricant fram backway hhose of oil cooler, being devided with block (10) lubricates each gear and bearing. Driven gear Tube g 10. BlockENGINE CONTROL, a eee STRUCTURE AND FUNCTION ENGINE CONTROL D150A 8408 and up D155A 15001 ~ 25000 175FO15, 155A 25001 and up i Decorator ped! —_ 175FO15-1 11-6 D150,1554STRUCTURE AND FUNCTION ast oo FUELPIPING FUEL PIPING D150A 8408 and up D155A 15001 ~ 25000 l75F016 D155A 25001 and up > Fuel tank l7sF016-1 D150,155A 1 lvSHOP NWA D150,155A-1 Serial No. D150A-1 8408 and up D155A-1 15001 and up 12, ENGINE TESTING AND ADJUSTINGD150, 1554 TESTING AND ADJUSTING + Described herein are testing and adjusting machine with engine mounted. For testing and adjusting engine itself, refer to the ‘Shop Manual of Komatsu engine 155-4 series. Testing and adjusting tool list... . 2 6ee eee eeeeee 12 Testing and adjusting, trouble shootingeriteria. ...... eee Me 2d General instructions Measuring engine speed .. 62-0... 0- 212 4 Cranking method . 12.5 Intake and exhaust system Checking air cleaner element for clogging +126 Inspection of turbocharger L127 Adjustment of valve clearance 1128 Checking exhaust color . . . 112.9 Engine body Measuring blow-by .... . 5 ceeee 1240 ‘Measuring compression pressure , 12.11 Lubrication system Checking oi! . : = 1242 Measuring oil pressure and temperature 21243 Fuel system Checking fuel... cece eee 1214 Checking fuel control lever position ............. 1214 Air-bleeding of fuel circuit 21245 Checking fuel delivery timing 21245 Test and adjust after parking machine on level ground and confirming safety pins When you work in group, enforce signals and never let unauthorized persons approach the machine. Be careful not to be caught by rotating parts or be burnt by heated parts.