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Komatsu D155A-6 Bulldozer Service Manual

1,346 pages · Publication SEN02854-11

$139.85
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Models
D155A-6
Serial coverage
85001 and up
Manual type
Service Manual
Pages
1,346
Publication
SEN02854-11
Condition
Brand new
Komatsu D155A-6 Bulldozer Service Manual, publication SEN02854-11

What's inside

From the manual's own table of contents: 245 sections, 474 entries. See sample pages (PDF, 762 KB)

Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification dimension drawings
Specifications
Weight table
Table of fuel, coolant and lubricants
Radiator, oil cooler
Engine mount
Cooling fan pump
Cooling fan motor
Power train skeleton
Overall drawing of power train unit
Power train hydraulic piping drawing
Damper, universal joint
Torque converter, PTO
Show all 245 sections
Transmission
Transmission ECMV
Main relief valve and torque converter relief valve
Lubricating oil relief valve
Scavenging pump
Power train and steering lubrication pump
Work equipment pump
Work equipment cooler bypass valve
Steering, brake control
Steering unit
Steering control valve
Steering clutch ECMV, steering brake ECMV
Parking brake solenoid valve
Sudden stop prevention valve
Final drive
Sprocket45 topics
  • Track frame
  • Recoil spring
  • Idler
  • Track roller
  • Carrier roller
  • Track shoe
  • Main frame
  • Suspension
  • Work equipment hydraulic piping diagram
  • Work equipment control piping diagram
  • Work equipment control
  • Hydraulic tank and filter
  • Accumulator
  • PPC valve
  • Work equipment lock valve
  • Control valve
  • Work equipment cylinder
  • Piston valve
  • Quick drop valve
  • Self pressure reducing valve
  • Cylinder stay
  • Blade
  • Cutting edge, end bit
  • Ripper
  • Cab mount + ROPS pin
  • ROPS cab
  • ROPS floor
  • Air conditioner
  • Engine control
  • Engine control system
  • Deceleration potentiometer
  • Monitor system
  • Sensors
  • Palm command control system
  • KOMTRAX system
  • Standard value table for engine
  • Standard value table for machine
  • Tools for testing, adjusting, and troubleshooting
  • Sketches of special tools
  • Measuring engine speed
  • Measuring intake air pressure (boost pressure)
  • Measuring exhaust temperature
  • Measuring exhaust gas color
  • Adjusting valve clearance
  • Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Measuring fuel return rate and fuel leakage
Bleeding air from fuel circuit
Measuring fuel circuit for leakage
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Measuring fan speed
Measuring fan circuit oil pressure
Bleeding air from fan pump
Bleeding air from work equipment pump
Adjusting fuel control dial and decelerator pedal
Measuring power train oil pressure
Adjusting transmission output shaft speed sensor
Simple test procedure for brake performance
Adjusting brake pedal
Adjusting parking brake lever
Emergency escape method when power train has trouble
Adjusting idler clearance
Testing and adjusting track shoe tension
Measuring and adjusting work equipment oil pressure
Measuring control circuit basic pressure
Measuring work equipment lock solenoid valve output pressure (PPC valve basic pressure)
Measuring PPC valve output pressure
Adjusting work equipment PPC valve play
Measuring ripper pin puller solenoid valve output pressure
Testing parts which cause hydraulic drift of blade and ripper
Measuring internal leakage of work equipment cylinder
Releasing residual pressure from work equipment cylinder
Bleeding air from work equipment cylinder
Adjusting work equipment lock lever
Adjusting blade
Adjusting operator's cab
Special functions of machine monitor (EMMS)
Handling of power supply circuit of engine controller
Preparation work for troubleshooting of electrical system
Pm Clinic
Failure codes table
Fuse locations
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Information in troubleshooting table
Connection table for connector pin numbers
T-branch box and T-branch adapter table52 topics
  • Failure code [1500L0] Transmission clutch: Abnormal
  • Failure code [15SAL1] Forward clutch: Fill high
  • Failure code [15SALH] Forward clutch: Fill low
  • Failure code [15SBL1] Reverse clutch: Fill high
  • Failure code [15SBLH] Reverse clutch: Fill low
  • Failure code [15SEL1] Speed 1st clutch: Fill high
  • Failure code [15SELH] Speed 1st clutch: Fill low
  • Failure code [15SFL1] Speed 2nd clutch: Fill high
  • Failure code [15SFLH] Speed 2nd clutch: Fill low
  • Failure code [15SGL1] Speed 3rd clutch: Fill high
  • Failure code [15SGLH] Speed 3rd clutch: Fill low
    • fill signal is ON
    • fill signal is OFF
    • fill signal is ON
    • fill signal is OFF
  • Failure code [2300KM] Stall in 1st gear speed
  • Failure code [2301L1] Right brake: Fill high
  • Failure code [2301LH] Right brake: Fill low
  • Failure code [2302L1] Left brake: Fill high
  • Failure code [2302LH] Left brake: Fill low
  • Failure code [7RFAKA] ECM HOLD RELAY: Disconnection
  • Failure code [AA10NX] Air Cleaner Clogging
  • Failure code [AB00MA] Battery Charge Abnormal
  • Failure code [B@BAZG] Eng Oil Press Low
  • Failure code [B@BCNS] Eng Water Overheat
  • Failure code [B@BCZK] Eng Water Level Low
  • Failure code [B@CENS] T/C Oil Overheat
  • Failure code [B@HANS] Hyd Oil Overheat
  • Failure code [CA111] EMC Critical Internal Failure
  • Failure code [CA115] Eng Ne and Bkup Speed Sens Error
  • Failure code [CA122] Chg (boost) Air Press Sensor High Error
  • Failure code [CA123] Chg (boost) Air Press Sensor Low Error
  • Failure code [CA131] Throttle Sensor High Error
  • Failure code [CA132] Throttle Sensor Low Error
  • Failure code [CA135] Eng Oil Press Sensor High Error
  • Failure code [CA141] Eng Oil Press Sensor Low Error
  • Failure code [CA144] Coolant Temp Sens High Error
  • Failure code [CA145] Coolant Temp Sens Low Error
  • Failure code [CA153] Chg (boost) Air Temp Sensor High Error
  • Failure code [CA154] Chg (boost) Air Temp Sensor Low Error
  • Failure code [CA187] Sens Supply 2 Volt Low Error
  • Failure code [CA221] Ambient Press Sens High Error
  • Failure code [CA222] Ambient Press Sens Low Error
  • Failure code [CA227] Sens Supply 2 Volt High Error
  • Failure code [CA234] Eng Overspeed
  • Failure code [CA238] Ne Speed Sens Supply Volt Error
  • Failure code [CA263] Fuel Temp Sensor High Error
  • Failure code [CA265] Fuel Temp Sensor Low Error
  • Failure code [CA271] PCV1 Short Error
  • Failure code [CA272] PCV1 Open Error
  • Failure code [CA273] PCV2 Short Error
  • Failure code [CA274] PCV2 Open Error
Failure code [CA322] Inj #1 Open/Short Error
Failure code [CA323] Inj #5 Open/Short Error
Failure code [CA324] Inj #3 Open/Short Error
Failure code [CA325] Inj #6 Open/Short Error
Failure code [CA331] Inj #2 Open/Short Error
Failure code [CA332] Inj #4 Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [D110KA] Battery relay: Disconnection
Failure code [D110KB] Battery Relay: Drive Short Circuit
Failure code [D130KA] Neutral relay: Disconnection
Failure code [D130KB] Neutral relay: Short circuit
Failure code [D161KA] Back-up alarm relay: Disconnection
Failure code [D161KB] Back-up alarm relay: Short circuit
Failure code [D190KA] ACC signal relay: Disconnection
Failure code [D190KB] ACC signal relay: Short circuit
Failure code [D5ZKKX] Throttle Dial: Out of normal range
Failure code [DAFRKR] CAN Disconnection (Monitor)
Failure code [DB2RKR] CAN Disconnection (Engine controller)
Failure code [DB90KR] PT controller: Can communication lost
Failure code [DBE0KK] PT controller: Source voltage reduction
Failure code [DBE0KT] PT controller: Abnormality in controller
Failure code [DBE6KK] PT controller: Source voltage reduction
Failure code [DBE7KK] PT controller: Source voltage reduction
Failure code [DBE9KQ] PT controller: Type select signal
Failure code [DD12KA] Shift up Sw: Disconnection
Failure code [DD12KB] Shift up Sw: Short circuit
Failure code [DD13KA] Shift down Sw: Disconnection
Failure code [DD13KB] Shift down Sw: Short circuit
Failure code [DD14KA] Parking lever Sw: Disconnection
Failure code [DD14KB] Parking lever Sw: Short circuit
Failure code [DDDDKA] Back up brake Sw: Disconnection
Failure code [DDDDKB] Back up brake Sw: Short circuit
Failure code [DDDDKX] Back up brake Sw: Signal mismatch
Failure code [DGT1KA] T/C oil temp sensor: Abnormal
Failure code [DGT1KX] T/C oil temp sensor: Abnormal
Failure code [DH21KA] Weq pressure sensor: Disconnection58 topics
  • Failure code [DH21KB] Weq pressure sensor: Short circuit
  • Failure code [DK10KX] Fuel control Dial: Out of normal range
  • Failure code [DK30KA] ST lever 1: Disconnection
  • Failure code [DK30KB] ST lever 1: Short circuit
  • Failure code [DK30KX] ST lever 1: Out of normal range
  • Failure code [DK30KZ] RL lever: Disconnection or short circuit
  • Failure code [DK30L8] ST lever: Signal mismatch
  • Failure code [DK31KA] ST lever 2: Disconnection
  • Failure code [DK31KB] ST lever 2: Short circuit
  • Failure code [DK40KA] Brake potentiometer: Disconnection
  • Failure code [DK40KB] Brake potentiometer: Short circuit
  • Failure code [DK55KX] FR lever: Out of normal range
  • Failure code [DK55KZ] FR lever: Disconnection or short circuit
  • Failure code [DK55L8] FR lever: Signal mismatch
  • Failure code [DK56KA] FR lever 1: Disconnection
  • Failure code [DK56KB] FR lever 1: Short circuit
  • Failure code [DK57KA] FR lever 2: Disconnection
  • Failure code [DK57KB] FR lever 2: Short circuit
  • Failure code [DKH1KA] Pitch angle sensor: Disconnection
  • Failure code [DKH1KB] Pitch angle sensor: Short circuit
  • Failure code [DLT3KA] T/M out-speed sensor: Disconnection
  • Failure code [DLT3KB] T/M out-speed sensor: Abnormal
  • Failure code [DW7BKA] Fan rev EPC: Disconnection
  • Failure code [DW7BKB] Fan rev EPC: Short circuit
  • Failure code [DWN3KA] Ssp solenoid: Disconnection
  • Failure code [DWN3KB] Ssp solenoid: Short circuit
  • Failure code [DWN3KY] Ssp solenoid: Short circuit
  • Failure code [DWN5KA] Fan pump solenoid: Disconnection
  • Failure code [DWN5KB] Fan pump solenoid: Short circuit
  • Failure code [DXH4KA] 1st clutch ECMV: Disconnection
  • Failure code [DXH4KB] 1st clutch ECMV: Short circuit
  • Failure code [DXH4KY] 1st clutch ECMV: Short circuit
  • Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
  • Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
  • Failure code [DXH5KY] 2nd clutch ECMV: Short circuit
  • Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
  • Failure code [DXH6KB] 3rd clutch ECMV: Short circuit
  • Failure code [DXH6KY] 3rd clutch ECMV: Short circuit
  • Failure code [DXH7KA] R clutch ECMV: Disconnection
  • Failure code [DXH7KB] R clutch ECMV: Short circuit
  • Failure code [DXH7KY] R clutch ECMV: Short circuit
  • Failure code [DXH8KA] F clutch ECMV: Disconnection
  • Failure code [DXH8KB] F clutch ECMV: Short circuit
  • Failure code [DXH8KY] F clutch ECMV: Short circuit
  • Failure code [DXH9KA] Right steering clutch ECMV disconnection
  • Failure code [DXH9KB] Right steering clutch ECMV short circuit
  • Failure code [DXH9KY] Right steering clutch ECMV hot short
  • Failure code [DXHAKA] Left steering clutch ECMV disconnection
  • Failure code [DXHAKB] Left steering clutch ECMV short circuit
  • Failure code [DXHAKY] Left steering clutch ECMV hot short
  • Failure code [DXHBKA] Right brake ECMV: Disconnection
  • Failure code [DXHBKB] Right brake ECMV: Short circuit
  • Failure code [DXHBKY] Right brake ECMV: Short circuit
  • Failure code [DXHCKA] Left brake ECMV: Disconnection
  • Failure code [DXHCKB] Left brake ECMV: Short circuit
  • Failure code [DXHCKY] Left brake ECMV: Short circuit
  • Failure code [DXJ4KA] Weq lock Sol.: Disconnection
  • Failure code [DXJ4KB] Weq lock Sol.: Short circuit
Before carrying out troubleshooting for electrical system
When starting switch turned ON, machine monitor displays nothing
When starting switch turned ON (before starting engine), basic check item lights up
Engine does not start (Engine does not turn)
Preheater does not operate
Precaution item lights up while engine is running
Emergency stop item lights up while engine is running
Engine coolant temperature gauge does not indicate normally
Fuel level gauge does not indicate normally
Power train oil temperature gauge (multi-gauge) does not indicate normally
Hydraulic temperature gauge (multi-gauge) does not indicate normally
Contents of display by machine monitor are different from applicable machine
Machine monitor does not display some items
Function switch does not work
Operation mode does not change
Gearshift mode does not change
Customize function does not operate normally
Customize memory function does not normally
Alarm buzzer cannot be stopped
Air conditioner does not operate normally (including air conditioner fault history)
When starting switch is turned OFF, service meter is not displayed
Machine monitor cannot be set in service mode
Ripper pin puller cylinder does not operate
Backup alarm does not sound or does not stop
Headlamp, rear lamp, and ripper point lamp do not light up
Windshield wiper and window washer do not operate
KOMTRAX terminal does not operate normally
Fan does not reverse
Gear cannot be shifted
Electric priming pump does not operate or does not stop automatically
Power is low (Drawbar pull is low)
Machine does not travel (at 2nd or 3rd gear speed)
Machine does not start at any gear speed
Machine can travel only forward or in reverse
When gear speed or travel direction is changed, time lag is large
Steering is not possible
Steering is possible only on one side
Steering overrun occurs
Brake does not work
Power train oil is overheated
Speed of all work equipment is low
No work equipment moves
Blade lift speed or power is low
Blade tilt speed or power is low
Ripper lift speed or power is low
Ripper tilt speed or power is low
Hydraulic drift of blade lift is large
Hydraulic drift of blade tilt is large
Hydraulic drift of ripper lift is large
Abnormal sound comes out from around work equipment pump47 topics
  • (Sound and/or vibration are abnormally large or engine over heats)
  • Method of using troubleshooting chart
  • Starting performance of engine is poor
  • Engine does not start
  • Engine does not pick up smoothly
  • Engine stops during operation
  • Engine does not rotate smoothly
  • Engine lack output (or lacks power)
  • Exhaust gas is black (incomplete combustion)
  • Oil consumption is excessive (or exhaust gas is blue)
  • Oil becomes dirty quickly
  • Fuel consumption is excessive
  • Oil is in coolant (or coolant spurts back or coolant level goes down)
  • Oil pressure drops
  • Oil level rises (Entry of coolant or fuel)
  • Coolant temperature becomes too high (Overheating)
  • Abnormal noise is made
  • Vibration is excessive
  • Air cannot be bled from fuel circuit
  • How to read this manual
  • Coating materials list
  • Special tool list
  • Removal and installation of fuel supply pump assembly
  • Removal and installation of fuel injector assembly
  • Removal and installation of cylinder head assembly
  • Removal and installation of radiator assembly
  • Removal and installation of aftercooler assembly
  • Removal and installation of engine assembly
  • Removal and installation of engine hood assembly
  • Removal and installation of engine front seal
  • Removal and installation of engine rear seal
  • Removal and installation of fuel tank assembly
  • Removal and installation of fan drive assembly
  • Removal and installation of fan motor assembly
  • Removal and installation of damper assembly
  • Disassembly and assembly of damper assembly
  • Removal and installation of power train unit assembly
  • Disconnection and connection of power train unit assembly
  • Disassembly and assembly of PTO assembly
  • Disassembly and assembly of torque converter assembly
  • Disassembly and assembly of transmission assembly
  • Disassembly and assembly of steering case assembly
  • Removal and installation of final drive assembly
  • Disassembly and assembly of final drive assembly
  • Removal and installation of track frame assembly
  • Removal and installation of idler assembly
  • Disassembly and assembly of idler assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of pivot shaft assembly
Spreading and installation of track shoe assembly
General disassembly and assembly of track shoe
Disassembly and assembly of 1 link in field
Disassembly and assembly of master link
Removal and installation of equalizer bar assembly
Disassembly and assembly of equalizer bar assembly
Removal and installation of segment teeth
Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic pump assembly
Disassembly and assembly of hydraulic cylinder assembly
Removal and installation of blade assembly
Disassembly and assembly of multi-shank ripper
Removal and installation of operator's cab assembly
Removal and installation of operator's cab glass (Stuck glass)
Removal and installation of operator's cab and floor frame assembly
Removal and installation of air conditioner unit assembly
Removal and installation of engine controller assembly
Removal and installation of power train controller assembly
Removal and installation of KOMTRAX assembly
Structure and function
Air conditioner component
Configuration and function of refrigerating cycle
Outline of refrigerating cycle
Air conditioner unit
Functions of major components in the air conditioner unit
Control plate
Compressor
Condenser
Receiver drier
Testing, adjusting and troubleshooting
Caution about refrigerant
Troubleshooting procedure
Block diagram
Circuit diagram and arrangement of connector pins
Detail of air conditioner unit
Part and connector locations
Testing air leakage (duct)
Testing with self-diagnosis function
Testing temperature control
Testing vent (mode) changeover
Testing Recirc/Fresh changeover
Testing inner sensor27 topics
  • Testing evaporator temperature sensor
  • Testing sunlight sensor
  • Testing (dual) pressure switch for refrigerant
  • Testing relays and diodes
  • Troubleshooting chart 1
  • Troubleshooting chart 2
  • Troubleshooting for electrical system (E mode)
    • Power supply system (Air conditioner does not operate)
    • Compressor system (Air is not cooled)
    • Blower motor system (No air comes out or air flow is abnormal)
    • Temperature cannot be controlled
    • Vent (mode) cannot be changed over
    • Recirc/Fresh air cannot be changed over
  • Troubleshooting with gauge pressure
  • Connection of service tool
  • Precautions for connecting air conditioner piping
  • Handling of compressor oil
    • Control of compressor oil
    • Adding of compressor oil
    • Compressor replacement
    • Applying compressor oil for O-ring
  • Power train hydraulic circuit diagram
  • Hydraulic circuit diagram Serial No.: 85001 – 85024
  • Hydraulic circuit diagram Serial No.: 85025 and up
  • Electrical circuit diagram
  • Electrical circuit diagram for inside cab
  • Connectors table and arrangement drawing

Inside this manual

Real pages from this service manual (1,346 pages). Open the sample pages (PDF, 761 KB)

Sample pages from the Komatsu D155A-6 Bulldozer Service Manual: Diagram, Troubleshooting, Specifications, Foldout diagram
  • Diagram, page 576: Failure code [15SELH] Speed 1st clutch: Fill low
  • Troubleshooting, page 816: Failure code [DXH8KB] F clutch ECMV: Short circuit
  • Specifications, page 1,176: 50 Disassembly and assembly
  • Foldout diagram, page 1,332: Electrical circuit diagram (4/14)

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Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the D155A-6 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN02854-11$139.85
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Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,346 pages

Quantity one is the manual described above.

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