Description
Komatsu D155AX-6 GALEO Bulldozer Shop Manual β Complete Workshop Guide
This Komatsu D155AX-6 GALEO Bulldozer Shop Manual is the complete service and repair guide for machines from serial number D155AX-80001 and up. It covers the full range of systems on the machine β engine, cooling, power train, hydraulics, undercarriage, frame, work equipment, cab, and electrical system β with the specifications, testing procedures, troubleshooting charts, and step-by-step disassembly and assembly instructions needed by professional technicians and serious owner-operators.
Whether you are performing routine maintenance, diagnosing a fault code, measuring oil pressure, overhauling a transmission clutch, or removing the power train unit, this D155AX-6 GALEO shop manual provides the procedures and reference values to do the job correctly. The manual is structured across eight major sections: Index and Foreword, Specification, Structure Function and Maintenance Standard, Standard Value Table, Testing and Adjusting, Troubleshooting, Disassembly and Assembly, and Diagrams and Drawings. Each section is broken into numbered Form documents (SEN-series) covering individual systems and subassemblies.
File Details
- Manual type: Komatsu Shop Manual (Workshop / Service / Repair Manual)
- Brand: Komatsu
- Model: GALEO D155AX-6
- Serial number range: D155AX-80001 and up
- Language: English
- File format: PDF
- Page count: Approximately 1,146 pages
- Publication data: 2006 KOMATSU / Printed in Japan
- Document numbers: SEN00596-02 (contents binder), SEN00597-02 (Index), SEN00598-02 (Foreword & general information), SEN00599-00 (Foreword), SEN00600-00 (Specification), SEN00601-00 (Specifications & technical data), SEN00602-00 to SEN00610-00 (Structure, function & maintenance standard), SEN00678-01 (Standard value table), SEN00679-01 through SEN00682-01 (Testing & adjusting Parts 1β4), SEN00851-00 through SEN00852-01 (Troubleshooting), SEN01204-00 through SEN01206-00 (Disassembly & assembly), SEN00616-01 (Hydraulic circuit diagram), SEN00617-02 (Electrical circuit diagram)
Chapters Covered
- 00 β Index and Foreword: Safety notice, how to read the shop manual, standard tightening torque tables, conversion tables
- 01 β Specification and Technical Data: Specification dimension drawings, specifications, weight table, fuel/coolant/lubricant table
- 10 β Structure, Function and Maintenance Standard:
- Engine and cooling system: Radiator, oil cooler, engine mount, cooling fan pump, cooling fan motor
- Power train system Part 1: Power train skeleton, torque converter, PTO, transmission, ECMV, HSS
- Power train system Part 2: HSS system, HSS motor, HSS pump, steering and brake control, 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, control valve, work equipment cylinder, quick drop valve
- Work equipment: Cylinder stay, blade, cutting edge, ripper
- Cab and its attachments: Cab mount, ROPS cab, air conditioner
- Electrical system: Engine control, monitor system, sensors, PCCS lever
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the βKomatsu D155AX-6 GALEO Bulldozer Shop Manual β Complete Service & Repair Workshop Guideβ are as follows:
COVER
+00 INDEX AND FOREWORD
+INDEX
ORGANIZATION LIST OF THE SHOP MANUAL
TABLE OF CONTENTS
+FOREWORD AND GENERAL INFORMATION
SAFETY NOTICE
HOW TO READ THE SHOP MANUAL
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
HOW TO READ ELECTRIC WIRE CODE
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 SYSTEM, PART 1
POWER TRAIN SKELETON
OVERALL DRAWING OF POWER TRAIN UNIT
POWER TRAIN HYDRAULIC PIPING DRAWING
DAMPER, UNIVERSAL JOINT
TORQUE CONVERTER, PTO
TORQUE CONVERTER CONTROL VALVE
LOCKUP CLUTCH ECMV, STATOR CLUTCH ECMV
TRANSMISSION CONTROL
TRANSMISSION
TRANSMISSION ECMV
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
LUBRICATION RELIEF VALVE
SCAVENGING PUMP
POWER TRAIN AND STEERING LUBRICATION PUMP
+POWER TRAIN SYSTEM, PART 2
HSS SYSTEM
HSS MOTOR
HYDRAULIC, HSS PUMP
HYDRAULIC OIL COOLER BYPASS VALVE
STEERING, BRAKE CONTROL
STEERING UNIT
BRAKE CONTROL VALVE
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
PCCS LEVER
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
AIR CONDITIONER
+ELECTRICAL SYSTEM
ENGINE CONTROL
ENGINE CONTROL SYSTEM
DECELERATION POTENTIOMETER
MONITOR SYSTEM
SENSORS
PALM COMMAND CONTROL 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
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
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 AND HSS OIL PRESSURE
MEASURING CONTROL CIRCUIT BASIC PRESSURE
MEASURING WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE
EMERGENCY OPERATION METHOD WHEN WORK EQUIPMENT HAS TROUBLE
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
+GENERAL INFORMATION ON TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECK BEFORE TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES FOR TROUBLESHOOTING
CONNECTOR PIN NOS. AND CONNECTION TABLE
T-BOXES AND T-ADAPTERS TABLE
+TROUBLESHOOTING BY FAILURE AND ERROR CODES, PART 1
FAILURE CODES TABLE
BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS DISPLAYED
INFORMATION IN TROUBLESHOOTING TABLE
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 [15SJL1] L/U: FILL HIGH
FAILURE CODE [15SJLH] L/U: FILL LOW
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 [7RFRKA] 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
+TROUBLESHOOTING BY FAILURE AND ERROR CODES, PART 2
FAILURE CODE [CA111] EMC CRITICAL INTERNAL FAILURE
FAILURE CODE [CA115] ENG NE AND BKUP SPEED SENS ERROR
FAILURE CODE [CA122] CHG AIR PRESS SENSOR HIGH ERROR
FAILURE CODE [CA123] CHG 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 AIR TEMP SENSOR HIGH ERROR
FAILURE CODE [CA154] CHG 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 (L#1) OPEN/SHORT ERROR
FAILURE CODE [CA323] INJ #5 (L#5) OPEN/SHORT ERROR
FAILURE CODE [CA324] INJ #3 (L#3) OPEN/SHORT ERROR
FAILURE CODE [CA325] INJ #6 (L#6) OPEN/SHORT ERROR
FAILURE CODE [CA331] INJ #2 (L#2) OPEN/SHORT ERROR
FAILURE CODE [CA332] INJ #4 (L#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 [CA286] 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
+TROUBLESHOOTING BY FAILURE AND ERROR CODES, PART 3
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 [CA1228] EGR VALVE SERVO ERROR 1
FAILURE CODE [CA1625] EGR VALVE SERVO ERROR 2
FAILURE CODE [CA1626] BP VALVE SOL CURRENT HIGH ERROR
FAILURE CODE [CA1627] BP VALVE SOL CURRENT LOW ERROR
FAILURE CODE [CA1628] BYPASS VALVE SERVO ERROR 1
FAILURE CODE [CA1619] BYPASS VALVE SERVO ERROR 2
FAILURE CODE [CA1631] BP VALVE POS SENS HIGH ERROR
FAILURE CODE [CA1632] BP VALVE POS SENS LOW ERROR
FAILURE CODE [CA1633] KOMNET DATALINK TIMEOUT ERROR
FAILURE CODE [CA1642] EGR INLET PRESS SENS LOW ERROR
FAILURE CODE [CA1653] EGR INLET PRESS SENS HIGH 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 [CA2271] EGR VALVE POS SENS HIGH ERROR
FAILURE CODE [CA2272] EGR VALVE POS SENS LOW ERROR
FAILURE CODE [CA2351] EGR VALVE SOL CURRENT HIGH ERROR
FAILURE CODE [CA2352] EGR VALVE SOL CURRENT 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 [DB90KK] WE CONTROLLER: SOURCE VOLTAGE REDUCTION
FAILURE CODE [DB90KR] PT CONTROLLER: CAN COMMUNICATION LOST
+TROUBLESHOOTING BY FAILURE AND ERROR CODES, PART 4
FAILURE CODE [DB90KT] WE CONTROLLER: ABNORMALITY IN CONTROLLER
FAILURE CODE [DB95KK] WE CONTROLLER: SOURCE VOLTAGE REDUCTION
FAILURE CODE [DB97KK] WE CONTROLLER: SOURCE VOLTAGE REDUCTION
FAILURE CODE [DB99KQ] WE CONTROLLER: TYPE SELECT SIGNAL
FAILURE CODE [DB9RKR] WE 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 [DDN7KA] WEQ KNOB SW (DOWN): DISCONNECTION
FAILURE CODE [DDN7KB] WEQ KNOB SW (DOWN): SHORT CIRCUIT
FAILURE CODE [DDN9KA] WEQ KNOB SW (UP): DISCONNECTION
FAILURE CODE [DDN9KB] WEQ KNOB SW (UP): SHORT CIRCUIT
FAILURE CODE [DDNLKA] WEQ LOCK SW: DISCONNECTION
FAILURE CODE [DDNLKB] WEQ LOCK SW: SHORT CIRCUIT
FAILURE CODE [DDTSL1] S/C: FILL HIGH
FAILURE CODE [DDTSLH] S/C: FILL LOW
+TROUBLESHOOTING BY FAILURE AND ERROR CODES, PART 5
FAILURE CODE [DFA4KX] BL LEVER 1: OUT OF NORMAL RANGE
FAILURE CODE [DFA4KZ] BL LEVER: DISCONNECTION OR SHORT CIRCUIT
FAILURE CODE [DFA4L8] BL LEVER: SIGNAL MISMATCH
FAILURE CODE [DFA5KA] BL LEVER 1: DISCONNECTION
FAILURE CODE [DFA5KB] BL LEVER 1: SHORT CIRCUIT
FAILURE CODE [DFA6KA] BL LEVER 2: DISCONNECTION
FAILURE CODE [DFA6KB] BL LEVER 2: SHORT CIRCUIT
FAILURE CODE [DFA7KX] BT LEVER 1: OUT OF NORMAL RANGE
FAILURE CODE [DFA7KZ] BT LEVER: DISCONNECTION OR SHORT CIRCUIT
FAILURE CODE [DFA7L8] BT LEVER: SIGNAL MISMATCH
FAILURE CODE [DFA8KA] BT LEVER 1: DISCONNECTION
FAILURE CODE [DFA8KB] BT LEVER 1: SHORT CIRCUIT
FAILURE CODE [DFA9KA] BT LEVER 2: DISCONNECTION
FAILURE CODE [DFA9KB] BT LEVER 2: SHORT CIRCUIT
FAILURE CODE [DFAAKX] RL LEVER 1: OUT OF NORMAL RANGE
FAILURE CODE [DFAAKZ] RL LEVER: DISCONNECTION OR SHORT CIRCUIT
FAILURE CODE [DFAAL8] RL LEVER: SIGNAL MISMATCH
FAILURE CODE [DFABKA] RL LEVER 1: DISCONNECTION
FAILURE CODE [DFABKB] RL LEVER 1: SHORT CIRCUIT
FAILURE CODE [DFACKA] RL LEVER 2: DISCONNECTION
FAILURE CODE [DFACKB] RL LEVER 2: SHORT CIRCUIT
FAILURE CODE [DFADKX] RL LEVER 1: OUT OF NORMAL RANGE
FAILURE CODE [DFADKZ] RL LEVER: DISCONNECTION OR SHORT CIRCUIT
FAILURE CODE [DFADL8] RL LEVER: SIGNAL MISMATCH
FAILURE CODE [DFAEKA] RL LEVER 1: DISCONNECTION
FAILURE CODE [DFAEKB] RL LEVER 1: SHORT CIRCUIT
FAILURE CODE [DFAFKA] RL LEVER 2: DISCONNECTION
FAILURE CODE [DFAFKB] RL LEVER 2: SHORT CIRCUIT
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 [DHT5KA] T/C IN-PRESSURE SENSOR: DISCONNECTION
FAILURE CODE [DHT5KB] T/C IN-PRESSURE SENSOR: SHORT CIRCUIT
FAILURE CODE [DHT7KA] T/C OUT-PRESSURE SENSOR: DISCONNECTION
FAILURE CODE [DHT7KB] T/C OUT-PRESSURE SENSOR: SHORT CIRCUIT
FAILURE CODE [DK10KX] FUEL CONTROL DIAL: OUT OF NORMAL RANGE
+TROUBLESHOOTING BY FAILURE AND ERROR CODES, PART 6
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 [DB40KA] BRAKE POTENTIOMETER: DISCONNECTION
FAILURE CODE [DB40KB] 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 [DWN1KA] HSS EPC1: DISCONNECTION
FAILURE CODE [DWN1KB] HSS EPC1: SHORT CIRCUIT
FAILURE CODE [DWN1KY] HSS EPC1: SHORT CIRCUIT
FAILURE CODE [DWN2KA] HSS EPC2: DISCONNECTION
FAILURE CODE [DWN2KB] HSS EPC2: SHORT CIRCUIT
FAILURE CODE [DWN2KY] HSS EPC2: 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 [DXA0KA] TVC SOL.: DISCONNECTION
FAILURE CODE [DXA0KB] TVC SOL.: SHORT CIRCUIT
FAILURE CODE [DXA0KY] TVC SOL.: SHORT CIRCUIT
FAILURE CODE [DXH1KA] LOCK-UP ECMV: DISCONNECTION
FAILURE CODE [DXH1KB] LOCK-UP ECMV: SHORT CIRCUIT
FAILURE CODE [DXH1KY] LOCK-UP ECMV: SHORT CIRCUIT
FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV: DISCONNECTION
+TROUBLESHOOTING BY FAILURE AND ERROR CODES, PART 7
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 [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 [DXHRKA] BLADE UP EPC: DISCONNECTION
FAILURE CODE [DXHRKB] BLADE UP EPC: SHORT CIRCUIT
FAILURE CODE [DXHRKY] BLADE UP EPC: SHORT CIRCUIT
FAILURE CODE [DXHSKA] BLADE DOWN EPC: DISCONNECTION
FAILURE CODE [DXHSKB] BLADE DOWN EPC: SHORT CIRCUIT
FAILURE CODE [DXHSKY] BLADE DOWN EPC: SHORT CIRCUIT
FAILURE CODE [DXHTKA] BLADE LEFT 1 EPC: DISCONNECTION
FAILURE CODE [DXHTKB] BLADE LEFT 1 EPC: SHORT CIRCUIT
FAILURE CODE [DXHTKY] BLADE LEFT 1 EPC: SHORT CIRCUIT
FAILURE CODE [DXHUKA] BLADE RIGHT 1 EPC: DISCONNECTION
FAILURE CODE [DXHUKB] BLADE RIGHT 1 EPC: SHORT CIRCUIT
FAILURE CODE [DXHUKY] BLADE RIGHT 1 EPC: SHORT CIRCUIT
FAILURE CODE [DXHWKA] RIPPER UP EPC: DISCONNECTION
FAILURE CODE [DXHWKB] RIPPER UP EPC: SHORT CIRCUIT
FAILURE CODE [DXHWKY] RIPPER UP EPC: SHORT CIRCUIT
FAILURE CODE [DXHXKA] RIPPER DOWN EPC: DISCONNECTION
FAILURE CODE [DXHXKB] RIPPER DOWN EPC: SHORT CIRCUIT
FAILURE CODE [DXHXKY] RIPPER DOWN EPC: SHORT CIRCUIT
FAILURE CODE [DXHYKA] RIPPER TILT IN EPC: DISCONNECTION
FAILURE CODE [DXHYKB] RIPPER TILT IN EPC: SHORT CIRCUIT
FAILURE CODE [DXHYKY] RIPPER TILT IN EPC: SHORT CIRCUIT
FAILURE CODE [DXHZKA] RIPPER TILT BACK EPC: DISCONNECTION
FAILURE CODE [DXHZKB] RIPPER TILT BACK EPC: SHORT CIRCUIT
FAILURE CODE [DXHZKY] RIPPER TILT BACK EPC: SHORT CIRCUIT
FAILURE CODE [DXJ4KA] WEQ LOCK SOL.: DISCONNECTION
FAILURE CODE [DXJ4KB] WEQ LOCK SOL.: SHORT CIRCUIT
+TROUBLESHOOTING BY FAILURE AND ERROR CODES, PART 8
FAILURE CODE [DXJ8KA] BLADE LEFT 2 EPC: DISCONNECTION
FAILURE CODE [DXJ8KB] BLADE LEFT 2 EPC: SHORT CIRCUIT
FAILURE CODE [DXJ8KY] BLADE LEFT 2 EPC: SHORT CIRCUIT
FAILURE CODE [DXJ9KA] BLADE RIGHT 2 EPC: DISCONNECTION
FAILURE CODE [DXJ9KB] BLADE RIGHT 2 EPC: SHORT CIRCUIT
FAILURE CODE [DXJ9KY] BLADE RIGHT 2 EPC: SHORT CIRCUIT
FAILURE CODE [DXJAKA] Q-DROP EPC: DISCONNECTION
FAILURE CODE [DXJAKB] Q-DROP EPC: SHORT CIRCUIT
FAILURE CODE [DXJAKY] Q-DROP EPC: SHORT CIRCUIT
FAILURE CODE [DXJBKA] S/C ECMV: DISCONNECTION
FAILURE CODE [DXJBKB] S/C ECMV: SHORT CIRCUIT
FAILURE CODE [DXJBKY] S/C ECMV: 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 FLOAT MODE DOES NOT CHANGE
E-19 ALARM BUZZER CANNOT BE STOPPED
E-20 AIR CONDITIONER DOES NOT OPERATE NORMALLY (INCLUDING AIR CONDITIONER FAULT HISTORY)
E-21 WHEN STARTING SWITCH IS TURNED OFF, SERVICE METER IS NOT DISPLAYED
E-22 MACHINE MONITOR CANNOT BE SET IN SERVICE MODE
E-23 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE
E-24 BACKUP ALARM DOES NOT SOUND OR DOES NOT STOP
E-25 HEADLAMP, REAR LAMP, AND RIPPER POINT LAMP DO NOT LIGHT UP
E-26 WINDSHIELD WIPER AND WINDOW WASHER DO NOT OPERATE
E-27 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
+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 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN RIGHT OR LEFT)
H-7 STEERING SPEED OR STEERING FORCE IS LOW
H-8 BRAKE DOES NOT WORK
H-9 POWER TRAIN OIL IS OVERHEATED
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS PUMP OR HSS MOTOR
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 BLADE DOES NOT PITCH
H-22 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP
+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
+50 DISASSEMBLY AND ASSEMBLY
+GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
LIST OF ADHESIVES
SPECIAL TOOL LIST
+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
+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
+90 DIAGRAMS AND DRAWINGS
+HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAMοΌ1/2οΌ
HYDRAULIC CIRCUIT DIAGRAMοΌ2/2οΌ
+ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
CONNECTORS TABLE AND ARRANGEMENT DRAWING
- 20 β Standard Value Table: Standard value table for engine and machine
- 30 β Testing and Adjusting:
- Part 1: Engine speed, intake air pressure, exhaust temperature, valve clearance, compression pressure, blow-by, oil pressure, fuel system tests, fan speed, belt tension
- Part 2: Power train oil pressure, brake performance, idler clearance, track shoe tension, work equipment and HSS oil pressure, control circuit pressure
- Part 3: Special functions of machine monitor (EMMS)
- Part 4: Power supply circuit, electrical troubleshooting preparation, Pm Clinic
- 40 β Troubleshooting:
- General information on troubleshooting
- Troubleshooting by failure and error codes (Parts 1β8): Complete failure code tables covering transmission clutch, brakes, engine controller codes, EGR system, electrical circuits, sensors and actuators
- Electrical system (E-mode): Machine monitor, gauges, air conditioner, wipers, lamps
- Hydraulic and mechanical system (H-mode): Power train, steering, brake, work equipment
- Engine (S-mode): Starting, output, exhaust, oil consumption, overheating, noise, vibration
- 50 β Disassembly and Assembly:
- Engine and cooling system: Fuel supply pump, fuel injector, cylinder head, radiator, aftercooler, engine assembly, engine hood
- Power train Part 1: Damper assembly, power train unit assembly, disconnection and connection
- 90 β Diagrams and Drawings: Power train hydraulic circuit diagram, hydraulic circuit diagrams (1/2 and 2/2), electrical circuit diagram
The Komatsu D155AX-6 GALEO Bulldozer Shop Manual is organized so that a technician can move logically from specification data and structural understanding through testing, diagnosis, and finally to removal, disassembly, assembly, and installation. The Structure, Function and Maintenance Standard section explains how each component works and gives the criteria and remedies for disassembly and service. The Standard Value Table provides the judgment criteria used during testing and adjusting, so that worn or out-of-spec parts can be identified precisely. The Testing and Adjusting sections give the measuring instruments and methods for every adjustable system on the machine β engine speed, oil pressures, valve clearance, belt tensions, brake pedal, parking brake, track tension, idler clearance, and more. The Troubleshooting sections are divided by failure mode: electrical (E-mode), hydraulic and mechanical (H-mode), and engine (S-mode), with detailed failure code tables, connector pin reference tables, and T-box/T-adapter tables for effective fault finding. The Disassembly and Assembly sections cover special tools, tightening torques, coating materials, and procedures for the major components, including the fuel supply pump, fuel injectors, cylinder head, radiator, aftercooler, engine assembly, damper assembly, and power train unit.
For owners of the D155AX-6 GALEO dozer, this manual enables a wide range of work to be carried out accurately: engine valve clearance adjustment, compression and blow-by testing, fuel pressure and return rate measurement, torque converter stall speed testing, transmission clutch pressure testing, brake performance testing, HSS relief pressure checking, track tension adjustment, work equipment speed and drift measurement, and complete removal and installation of the power train unit. The electrical troubleshooting sections support diagnosis of the machine monitor, engine controller, power train controller, and work equipment controller, including CAN communication faults, sensor failures, and solenoid circuit faults, using the documented failure codes and their causes.
Having the correct procedures and specifications matters because the D155AX-6 is a large, hydraulically and electronically complex bulldozer. Incorrect adjustment of the transmission clutch pressures, brake pressures, or HSS system can lead to premature wear or unsafe operation. Incorrect torque values during assembly can cause failures. The D155AX-6 shop manual removes guesswork by giving the factory-developed criteria for every major system. The troubleshooting sections let you identify the root cause of a problem β whether it is a failed sensor, a wiring fault, a hydraulic pressure issue, or a mechanical wear condition β before parts are unnecessarily replaced. The disassembly and assembly procedures include the special tools and tightening torques needed to complete the work safely and to the correct standard.
This Komatsu D155AX-6 GALEO Bulldozer Shop Manual PDF is delivered instantly after purchase. There is no shipping and no waiting for a physical book. The PDF can be viewed on any device β laptop, tablet, or smartphone β and relevant pages can be printed for use in the workshop. Whether you are a professional heavy equipment technician, a fleet maintenance manager, or a knowledgeable owner-operator, having the complete D155AX-6 shop manual on hand means you can service, diagnose, repair, and maintain the machine with the full backing of Komatsu’s documented procedures and specifications.
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