Komatsu D155A-6 Bulldozer Shop Manual SEN02854-24 Serial 85001 and Up

Description

Komatsu D155A-6 Bulldozer Shop Manual SEN02854-24 Serial 85001 and Up

This Komatsu D155A-6 Bulldozer Shop Manual SEN02854-24 Serial 85001 and Up is the chassis workshop volume written for the D155A-6 crawler dozer from serial number 85001 onward. It gathers specification data, component structure and maintenance standards, service-value tables, testing and adjusting procedures, failure-code and symptom troubleshooting, removal and assembly sequences, air-conditioner service, and the hydraulic and electrical diagrams used on this machine. The binder form number printed on the cover is SEN02854-24. Individual section form numbers appear throughout the book, including SEN02855-24 through SEN02875-01 and later revisions such as SEN04441-03 for the air conditioner.

Komatsu shop manuals for this family are split into a chassis volume and a separate engine volume. This file is the chassis volume. For internal overhaul of the engine unit itself, the engine volume for the mounted engine model is required. Chassis-side engine work that is in this book includes cooling-system service, fuel-system tests on the machine, injector and supply-pump removal, cylinder-head removal, front and rear seal replacement, and engine-assembly R&I.

File Details

• Manual type: Shop manual (chassis volume)
• Brand / model: Komatsu D155A-6 bulldozer
• Serial range: 85001 and up
• Document / binder number: SEN02854-24
• Language: English
• Page count: 1566
• File format: PDF
• Copyright notice in the index section: © 2022 Komatsu, printed in Japan 12-22 (01)

Machine and Powerplant Coverage

The specification section identifies one machine model, D155A-6, serial numbers 85001 and up. The mounted engine is named SAA6D140E-5: a 4-cycle, water-cooled, in-line, vertical, direct-injection diesel with turbocharger and aftercooler. Cylinder layout is 6 − 140 × 165 mm, piston displacement 15.24 ℓ (15,240 cc). Flywheel horsepower is given as 239 kW {320 HP} at 1,900 rpm, maximum torque 1,834 Nm {187 kgm} at 1,300 rpm, no-load maximum speed 2,100 rpm, and no-load minimum speed 740 rpm. Starting motor is 24 V, 11 kW; alternator 24 V, 50 A; batteries 12 V, 136 Ah × 2.

Published machine weights include a bare tractor of 31,200 kg and 41,700 kg with semi U-tilt dozer, variable giant ripper, ROPS cab, air conditioner, 560 mm HD shoe, and side cover (42,080 kg with multi ripper). Track gauge is 2,140 mm, length of track on ground 3,150 mm, standard shoe width 560 mm, and minimum ground clearance to the undercover 500 mm. Forward transmission speeds are listed as 3.9 / 5.7 / 7.5 / 11.4 km/h and reverse as 4.7 / 6.8 / 9.2 / 13.7 km/h. Power-train architecture is a 3-element, 1-stage, 1-phase torque converter; planetary hydraulically actuated transmission with three forward and three reverse speeds; wet multi-disc steering clutches and brakes; and a final drive of one spur-gear stage plus one planetary stage.

Work-equipment hydraulics use a variable swash-plate pump HPV112 with maximum delivery pressure 27.5 MPa {280 kg/cm²} and theoretical delivery 216 ℓ/min at 2,250 rpm. Blade options documented are hydraulic sigma-tilt, semi U-tilt, and U-tilt dozers (SAE capacities 9.4 m³ on sigma and semi-U, 11.9 m³ on full U). Rear attachments include the variable multi-shank ripper and variable giant ripper. Fluid capacities in the specification tables are engine oil pan 45 ℓ specified / 37 ℓ refill, power-train case 105 ℓ / 70 ℓ, damper case 1.5 ℓ, final drive 31 ℓ each side, hydraulic system with blade and without ripper 240 ℓ specified / 85 ℓ refill, fuel tank 625 ℓ, and cooling system 82 ℓ.

Some piping and pump notes change at serial 85025. The scavenging pump is listed as gear type SAR(4)+125 for 85001–85024 and SAR(3)+125 for 85025 and up. Section 90 reprints separate work-equipment hydraulic circuit diagrams for serial 85001–85024 and for 85025 and up.

Chapters Covered

• 00 Index and foreword — composition of shop manual; safety notice; how to read the shop manual; maintenance-standard terms; handling of electric equipment and hydraulic components; engine connectors; electric wire code; operation precautions; push-pull coupler method; tightening torque table; conversion table
• 01 Specification — specification dimension drawings; specifications; weight table; table of fuel, coolant and lubricants
• 10 Structure, function and maintenance standard — engine and cooling system (radiator and oil cooler, engine mount, cooling fan pump, cooling fan motor)
• Power train, Part 1 — skeleton, overall unit drawing, hydraulic piping, damper and universal joint, torque converter and PTO, transmission, transmission ECMV, main and torque-converter relief valves, lubricating oil relief valve, scavenging pump, power-train and steering lubrication pump
• Power train, Part 2 — work equipment pump, cooler bypass valve, steering and brake control, steering unit and control valve, steering clutch and brake ECMV, parking brake solenoid, 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 piping and control, hydraulic tank and filter, accumulator, PPC valve, lock valve, control valve, cylinders, piston valve, quick-drop valve, self-pressure reducing valve
• Work equipment — cylinder stay, blade, cutting edge and end bit, ripper
• Cab and attachments — cab mount and ROPS pin, ROPS cab and floor, air conditioner outline
• Electrical system — engine control and decelerator potentiometer, monitor system, sensors, palm command control system (PCCS), KOMTRAX
• 20 Standard value table — standard service values for engine and machine
• 30 Testing and adjusting, Parts 1–4 — tools and special-tool sketches; engine speed, boost, exhaust temperature and color, valve clearance, compression, blow-by, oil and fuel pressures; belt and fan checks; power-train pressures; brake and parking-brake adjustments; track tension; work-equipment pressures and drift; EMMS special functions; engine-controller power circuit and electrical troubleshooting preparation; Pm Clinic
• 40 Troubleshooting — failure-code table and fuse locations; general troubleshooting method; failure and error codes Parts 1–4; electrical E-mode; hydraulic and mechanical H-mode; engine S-mode
• 50 Disassembly and assembly — general information, coating materials, special tools; engine and cooling R&I; damper and power-train unit; PTO, torque converter, transmission, steering case; final drive; undercarriage (track frame, idler, recoil, rollers, bogies, carrier roller, pivot shaft, track shoe, equalizer bar, segment teeth); hydraulic tank, pump, and cylinders; blade and ripper; cab glass and floor frame; air-conditioner unit, engine controller, power-train controller, KOMTRAX
• 60 Air conditioner — refrigerating cycle, unit components, testing and self-diagnosis, electrical E-mode for A/C, gauge-pressure diagnosis, compressor-oil handling (refrigerant R134a)
• 90 Diagrams and drawings — power-train hydraulic circuit; work-equipment hydraulic circuits by serial break; electrical circuit diagrams; in-cab electrical diagram; connector and wiring tables; harness drawings

Taken together, the Komatsu D155A-6 shop manual is the chassis reference a workshop uses to identify a component, compare it with the maintenance standard, measure it against the standard-value table, run the matching test or adjustment, then follow the matching failure code or H/E/S-mode chart and the matching R&I procedure. Diagrams at the back close the loop when a harness, solenoid, or hydraulic line has to be traced.

Testing, Adjusting, and Service Values

Section 20 publishes new-machine standard values and service limits used throughout testing. Engine-speed examples include high idle 2,100 (0/−50) rpm and decelerator-pedal speed 875 ± 25 rpm. Travel-speed checks on flat ground list F1 3.8 ± 0.2 km/h, F2 7.5 ± 0.4 km/h, F3 11.6 ± 0.6 km/h, R1 4.6 ± 0.2 km/h. Blade tilt relief pressure is given as 27.5 ± 1.5 MPa {280 ± 15 kg/cm²} at high idle. Hydraulic-drift limits include blade-bottom drop of max. 150 mm in 15 minutes on a new machine.

Testing and adjusting walks through boost-pressure measurement, exhaust-temperature pickup, smoke checks, valve-clearance setting at normal coolant temperature, compression with the monitor in no-injection cranking, blow-by, engine-oil pressure, residual-pressure release on the common-rail fuel circuit, fuel-return and leakage tests, air bleeding after filter or supply-pump work, and leak checks on high-pressure fuel joints. Chassis-side work continues with power-train pressure taps (main relief, steering, forward/reverse and 1st–3rd clutches, lubrication), transmission output-shaft speed-sensor gap, a simple brake-performance stall check, parking-brake lever stroke, idler clearance, track-shoe tension, PPC basic and output pressures, ripper pin-puller solenoid pressure, cylinder internal leakage, residual-pressure release and air bleed on work-equipment cylinders, blade geometry, blade-electric-lever play, and cab pressurization. Part 3 documents EMMS service-mode functions (monitoring codes, adjustment IDs, reduced-cylinder mode, no-injection cranking, fuel-consumption measurement). Part 4 covers engine-controller power-supply handling, T-adapter preparation, and the Pm Clinic inspection sheet.

Failure Codes and Symptom Troubleshooting

Section 40 opens with the failure-code table and fuse-box map, then connector-pin tables and T-branch adapter lists. Code chapters walk individual CA, D, DK, DXH, and related codes with action codes (E02–E04), controller response, machine symptoms, and step checks. Electrical E-mode charts cover a dark monitor, failed cranking, preheater, gauge faults, mode and customize problems, air-conditioner history, ripper pin puller, backup alarm, lamps, wiper and washer, KOMTRAX, fan reverse, gear-shift inhibit, and the electric priming pump. Hydraulic and mechanical H-mode charts cover low drawbar pull, no travel in selected gears, one-way travel only, shift lag, steering loss or overrun, weak brakes, overheated power-train oil, slow or dead work equipment, blade and ripper power and drift, pin-puller inaction, pump noise, and abnormal fan speed. Engine S-mode charts cover poor starting, no start, poor pickup, stalling, rough running, lack of power, black or blue smoke, oil consumption and dilution, overheating, noise, vibration, and inability to bleed the fuel circuit.

Disassembly, Special Tools, and Diagrams

Section 50 lists coating materials and special tools, then removal and installation sequences with component weights from the specification weight table (engine assembly 1,725 kg, power-train unit 2,412 kg, final drive 1,395 kg each, track group 3,900 kg per side, and so on). Tightening examples printed in the procedures include engine-mounting bolts 823.8–1,029 Nm {84–105 kgm} and damper-mounting bolts 98–122.6 Nm {10–12.5 kgm}. Undercarriage work includes field replacement of one track link and the master link. Section 90 supplies the power-train hydraulic circuit, two serial-split work-equipment hydraulic circuits, the full electrical circuit, the in-cab circuit, connector arrangement drawings, and harness diagrams.

Use This Manual for Accurate D155A-6 Chassis Work

The Komatsu D155A-6 Bulldozer Shop Manual SEN02854-24 Serial 85001 and Up supports shop jobs that depend on published pressures, speeds, drift limits, connector pin-outs, and sequenced R&I: diagnosing a no-travel or no-steer complaint, setting clutch and brake ECMV circuits, measuring work-equipment relief and PPC pressures, tracing a CA or DXH failure code, replacing a final drive or track group, or reading the hydraulic and electrical diagrams after a harness or hose repair. Using the values and steps printed for this serial range keeps torque-converter stall checks, common-rail fuel work, and steering-clutch service inside the criteria the book specifies for D155A-6 machines 85001 and up.

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