Komatsu D155A-6 Bulldozer (85001 and up) Service Repair Shop Manual - SEN02854-06


This complete Service Repair Workshop Manual PDF Download for the D155A-6 Komatsu Bulldozer (85001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu D155A-6 Bulldozer
Serial Numbers : 85001 and up


TABLE OF CONTENTS :

00 Index and foreword
01 Specification
10 Structure, function and maintenance standard
20 Standard value table
30 Testing and adjusting
40 Troubleshooting
50 Disassembly and assembly
60 Air conditioner
90 Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN02854-06
Total Pages : 1331


This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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COVER
00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
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

01 Specification
Specification and technical data
Specification dimension drawings
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure, function and maintenance standard
Engine and cooling system
Radiator, oil cooler
Engine mount
Cooling fan pump
Cooling fan motor
Power train, Part 1
Power train skeleton
Overall drawing of power train unit
Power train hydraulic piping drawing
Damper, universal joint
Torque converter, PTO
Transmission
Transmission ECMV
Main relief valve and torque converter relief valve
Lubricating oil relief valve
Scavenging pump
Power train and steering lubrication pump
Power train, Part 2
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
Sprocket
Undercarriage and frame
Track frame
Recoil spring
Idler
Track roller
Carrier roller
Track shoe
Main frame
Suspension
Hydraulic system
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
Work equipment
Cylinder stay
Blade
Cutting edge, end bit
Ripper
Cab and its attachments
Cab mount + ROPS pin
ROPS cab
ROPS floor
Air conditioner
Electrical system
Engine control
Engine control system
Deceleration potentiometer
Monitor system
Sensors
Palm command control system
KOMTRAX system

20 Standard value table
Standard service value table
Standard value table for engine
Standard value table for machine

30 Testing and adjusting
Testing and adjusting, Part 1
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
Testing and adjusting, Part 2
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 play of work equipment PPC valve
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
Testing and adjusting, Part 3
Special functions of machine monitor (EMMS)
Testing and adjusting, Part 4
Handling of power supply circuit of engine controller
Preparation work for troubleshooting of electrical system
Pm Clinic

40 Troubleshooting
Failure code table and fuse locations
Failure codes table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Information in troubleshooting table
CConnection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure and error codes, Part 1
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
Failure code [2201L1] When right steering clutch oil pressure command current is OFF, fill signal is ON
Failure code [2201LH] When right steering clutch oil pressure command current is ON, fill signal is OFF
Failure code [2202L1] When left steering clutch oil pressure command current is OFF, fill signal is ON
Failure code [2202LH] When left steering clutch oil pressure command current 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 [[email protected]] Eng Oil Press Low
Failure code [[email protected]] Eng Water Overheat
Failure code [[email protected]] Eng Water Level Low
Failure code [[email protected]] T/C Oil Overheat
Failure code [[email protected]] 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
Troubleshooting by failure and error codes, Part 2
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] Sense Supply 1 Volt Low Error
Failure code [CA386] Sense 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
Troubleshooting by failure and error codes, Part 3
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: Disconnection
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
Troubleshooting by failure and error codes, Part 4
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
Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting for electrical system
Information in troubleshooting table
E-1 When starting switch turned ON, machine monitor displays nothing
E-2 When starting switch turned ON (before starting engine), basic check item lights up
E-3 Engine does not start (Engine does not turn)
E-4 Preheater does not operate
E-5 Precaution item lights up while engine is running
E-6 Emergency stop item lights up while engine is running
E-7 Engine coolant temperature gauge does not indicate normally
E-8 Fuel level gauge does not indicate normally
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-11 Contents of display by machine monitor are different from applicable machine
E-12 Machine monitor does not display some items
E-13 Function switch does not work
E-14 Operation mode does not change
E-15 Gearshift mode does not change
E-16 Customize function does not operate normally
E-17 Customize memory function does not normally
E-18 Alarm buzzer cannot be stopped
E-19 Air conditioner does not operate normally (including air conditioner fault history)
E-20 When starting switch is turned OFF, service meter is not displayed
E-21 Machine monitor cannot be set in service mode
E-22 Ripper pin puller cylinder does not operate
E-23 Backup alarm does not sound or does not stop
E-24 Headlamp, rear lamp, and ripper point lamp do not light up
E-25 Windshield wiper and window washer do not operate
E-26 KOMTRAX terminal does not operate normally
E-27 Fan does not reverse
E-28 Gear cannot be shifted
E-29 Electric priming pump does not operate or does not stop automatically
Troubleshooting of hydraulic and mechanical system (H-mode)
Information in troubleshooting table
H-1 Power is low (Drawbar pull is low)
H-2 Machine does not travel (at 2nd or 3rd gear speed)
H-3 Machine does not start at any gear speed
H-4 Machine can travel only forward or in reverse
H-5 When gear speed or travel direction is changed, time lag is large
H-6 Steering is not possible
H-7 Steering is possible only on one side
H-8 Steering overrun occurs
H-9 Brake does not work
H-10 Power train oil is overheated
H-11 Speed of all work equipment is low
H-12 No work equipment moves
H-13 Blade lift speed or power is low
H-14 Blade tilt speed or power is low
H-15 Ripper lift speed or power is low
H-16 Ripper tilt speed or power is low
H-17 Hydraulic drift of blade lift is large
H-18 Hydraulic drift of blade tilt is large
H-19 Hydraulic drift of ripper lift is large
H-20 Ripper pin puller cylinder does not operate
H-21 Abnormal sound comes out from around work equipment pump
H-22 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance of engine is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operation
S-5 Engine does not rotate smoothly
S-6 Engine lack output (or lacks power)
S-7 Exhaust gas is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust gas is blue)
S-9 Oil becomes dirty quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (Overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
S-17 Air cannot be bled from fuel circuit

50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
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
Power train, Part 1
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
Power train, Part 2
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
Power train, Part 3
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame
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
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic pump assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of blade assembly
Disassembly and assembly of multi-shank ripper
Cab and its attachments
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
Electrical system
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

60 Air conditioner
Structure, function, testing, adjusting, and troubleshooting
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 sensor
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)
E-1 Power supply system (Air conditioner does not operate)
E-2 Compressor system (Air is not cooled)
E-3 Blower motor system (No air comes out or air flow is abnormal)
E-4 Temperature cannot be controlled
E-5 Vent (mode) cannot be changed over
E-6 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
1. Control of compressor oil
2. Adding of compressor oil
3. Compressor replacement
4. Applying compressor oil for O-ring

90 Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Hydraulic circuit diagram Serial No.: 85001 - 85024
Hydraulic circuit diagram Serial No.: 85025 and up
Electrical diagrams and drawings
Electrical circuit diagram (Cab spec.)
Electrical circuit diagram (Cab less spec.)
Electrical circuit diagram for inside cab
Connectors table and arrangement drawing

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