Komatsu D155AX-5 Shop Manual SEBM016205 – Bulldozer Service, Repair & Testing PDF

Description

Komatsu D155AX-5 Shop Manual — Complete Service & Repair Documentation

This is the complete Komatsu D155AX-5 shop manual, document number SEBM016205, covering machine serial numbers 70001 and up. It is the same comprehensive service publication used by professional technicians to maintain, diagnose, and overhaul the D155AX-5 crawler dozer. The manual spans over 1,100 pages of structured technical content, from general specifications through to complete disassembly and assembly procedures, with testing and adjusting values and maintenance standards for every major system on the machine.

The D155AX-5 mounts the SA6D140E-2 or SA6D140E-3 engine. This shop manual covers the chassis, power train, hydraulic, electrical, and undercarriage systems in full detail. Engine-specific service information is referenced to the 6D140-2 or 140-3 Series Engine Shop Manual, which is a separate publication.

File Details

• Manual Type: Shop Manual (Service, Repair & Testing)
• Brand: Komatsu
• Model: D155AX-5
• Serial Numbers Covered: 70001 and up (with separate coverage for 70001–75000 and 75001 and up)
• Engine: SA6D140E-2 or SA6D140E-3
• Document Number: SEBM016205
• Language: English
• Page Count: 1176+ pages
• File Format: PDF

Chapters Covered

• 01 GENERAL
• 10 STRUCTURE AND FUNCTION
• 20 TESTING AND ADJUSTING
• 30 DISASSEMBLY AND ASSEMBLY
• 40 MAINTENANCE STANDARD
• 90 OTHERS

01 GENERAL

This chapter opens with the specification drawings for the D155AX-5, including overall dimensions for the bare tractor and configurations with semi U-dozer, U-dozer, and multi-shank or giant ripper attachments. It provides the machine specifications table covering operating weight, performance data including minimum turning radius and gradeability, ground pressure, travel speeds, and overall dimensions. The weight table gives component weights for transport and handling — engine and damper assemblies, radiator, fuel tank, power train unit, final drive, track group, and major work equipment assemblies. The table of fuel, coolant and lubricants specifies the correct fluids, capacities, and ambient temperature ranges for engine oil, power train oil, gear oil, diesel fuel, and coolant. This chapter also includes the tightening torque tables for standard bolts, flared nuts, split flange bolts, O-ring boss piping joints, O-ring boss plugs, and the 102 engine series, plus the electric wire code table and conversion tables for millimeters to inches, kilograms to pounds, liters to gallons, kgm to ft.lb, kg/cm² to lb/in², and Celsius to Fahrenheit.

10 STRUCTURE AND FUNCTION

This is the largest chapter in the manual and explains how every major system on the D155AX-5 is constructed and how it operates. It begins with engine control — both the mechanical fuel control lever and decelerator pedal system, and the electronic fuel control dial system with engine controller. The radiator, oil cooler, and hydraulic cooler are covered with their construction and the power train oil cooler built into the radiator lower tank.

The power train section covers the complete flow from engine through damper, universal joint, torque converter, transmission, bevel gear shaft, HSS (Hydrostatic Steering System), final drive, and sprocket. It includes the overall power train unit drawing, hydraulic system drawings, piping diagrams, and circuit diagrams. Each component is explained in detail: the damper and universal joint, torque converter and PTO, transmission control, the 3-forward/3-reverse transmission with its planetary gear sets and hydraulic clutches, the transmission control valve with modulating valve and quick return valve, main relief valve, lubricant relief valve, scavenging pump strainer, power train pump strainer, and power train oil filter.

The HSS system receives thorough coverage — the HSS pump (HPV160 variable swash plate piston pump), HSS motor (HMF140 fixed swash plate piston motor), PPC and HSS charge filter and valve, HSS oil cooler bypass valve, and the full HSS electronic control system. The steering and brake control section covers the bevel gear shaft, HSS brake, and brake valve. The final drive, track frame, recoil spring, track roller bogie, main frame, and suspension are all explained with their construction and function.

Work equipment hydraulic piping diagrams, PPC control piping diagrams, work equipment control, work equipment hydraulic system and HSS system diagrams, and the work equipment hydraulic circuit and HSS circuit diagrams are all included. The hydraulic tank and filter, accumulator, PPC lock valve, PPC valve, piston valve, pin puller switch and solenoid valve, tilt/pitch selector switch, pitch solenoid valve, main control valve, cylinder stay, work equipment, cap, air conditioner, electric wiring diagram, electric circuit diagram, monitor system, sensors, engine starting system, and HSS electronic control system complete this chapter.

20 TESTING AND ADJUSTING

This chapter provides the standard value tables for engine, chassis, and electrical parts, followed by detailed testing and adjusting procedures. The engine standard values cover high idling, low idling, rated speed, exhaust temperature, exhaust gas color, valve clearance, blow-by pressure, oil pressure, compression pressure, fuel injection timing, and alternator and air conditioner belt tension. The chassis standard values cover torque converter stall speed, control lever and pedal travel, operating forces, relief pressures, hydraulic drift, and operating times for blade and ripper functions.

The testing and adjusting procedures include measuring engine speed, intake air pressure (boost pressure), exhaust temperature, and exhaust color; adjusting valve clearance; measuring compression pressure and blow-by pressure; measuring engine oil pressure; testing and adjusting fuel injection timing; handling the fuel circuit including releasing remaining pressure, measuring fuel pressure, reduced cylinder mode operation, bleeding air, and checking for leakage; testing and adjusting alternator belt tension, air conditioner compressor belt tension, and fan belt tension; adjusting the engine speed sensor; handling the controller high voltage circuit; adjusting the fuel control lever and decelerator pedal; measuring torque converter stall speed and full stall speed; measuring power train oil pressure; testing and adjusting HSS main oil pressure, HSS charge oil pressure, HSS servo charge pressure, and PPC relief pressure; bleeding air from the HSS pump; simple brake performance testing; adjusting the joystick and parking lever; testing and adjusting the travel reverse sensing potentiometer and limit switch; adjusting steering neutral position; operating the emergency steering switch; adjusting initial current in the HSS steering system; adjusting the brake pedal; adjusting idler clearance; testing sprocket wear; testing and adjusting track shoe tension; testing and adjusting hydraulic pressure; measuring PPC valve output pressure; adjusting PPC valve play; measuring solenoid valve output pressure; testing the location causing hydraulic drift of blade and ripper; measuring leakage inside hydraulic cylinders; releasing remaining oil pressure and bleeding air from hydraulic cylinders; adjusting the work equipment safety lever; and adjusting the semi-U tiltdozer.

The troubleshooting section covers points to remember, sequence of events, maintenance points, checks before troubleshooting, connector types and positions, connection tables for connector pin numbers, function of the electronic control system, display of the HSS controller, display and special functions of the monitor panel, judgment tables, and troubleshooting procedures organized by mode: network system (N mode), engine system (S mode), HSS controller and electrical system (E mode), hydraulic and mechanical system (H mode), monitor system (M mode), engine controller system (G mode), and HSS controller and electrical system for later serial numbers.

30 DISASSEMBLY AND ASSEMBLY

This chapter provides the complete removal, installation, disassembly, and assembly procedures for every major component and system on the D155AX-5. It begins with the method of using the manual, precautions for operation, the special tool list with part numbers and sketches, and the general tightening torque tables.

Component-level procedures are provided for the starting motor, alternator, engine oil cooler core, fuel injection pump, water pump, turbocharger, nozzle holder, fuel injector (for serial 75001 and up), engine front seal, engine rear seal, cylinder head, thermostat, air conditioner compressor, air conditioner condenser, fuel tank, radiator, radiator/oil cooler/guard assembly, fan drive, hydraulic cooler, engine, damper, power train unit, PTO, torque converter, Torqflow transmission, HSS case, hydraulic pump, HSS pump (HPV160), HSS motor, power train main relief valve, HSS/PPC charge valve, transmission control valve, brake valve, final drive, track frame, idler assembly, recoil spring, track roller, bogie, carrier roller, track shoe (including overall disassembly and assembly, one-link, and master link procedures), pivot shaft, equalizer bar, equalizer bar side bushing, segment teeth, hydraulic tank, main control valve, HSS oil cooler bypass valve, blade PPC valve, ripper PPC valve, blade lift cylinder, blade tilt cylinder, ripper lift cylinder, ripper tilt cylinder, hydraulic cylinder, blade, multi-shank ripper, ROPS guard, operator cab, hood, floor frame, dashboard, monitor, and HSS controller.

Each procedure includes the removal sequence, any special techniques required, installation notes, tightening torques, lubrication and sealant requirements, and press-fitting forces or clearances where applicable.

40 MAINTENANCE STANDARD

This chapter provides the wear limits, clearances, interference values, and repair limits used when inspecting disassembled parts to determine whether they can be reused or must be replaced. It covers the engine mount, power train unit mount, damper and universal joint, torque converter and PTO, transmission, transmission control valve, main relief valve, bevel gear shaft and HSS brake, brake valve, scavenging pump and PPC/HSS charge pump, power train pump and lubrication pump, PPC/HSS charge valve, oil cooler bypass valve, final drive, sprocket, main frame, track frame, recoil spring, track roller bogie, idler, track roller, carrier roller, track shoe (for dry type, sealed and lubricated type, and single shoe), suspension, work equipment pump, HSS pump, HSS motor, PPC valve, steering lever, main control valve, work equipment cylinder, quick drop valve, cylinder stay, and work equipment including semi U-dozer, U-dozer, cutting edge and end bit, and multi-shank and giant ripper.

90 OTHERS

This final chapter contains the work equipment hydraulic circuit and HSS circuit diagram for machines equipped with the pitch dozer, and the complete electric circuit diagrams for both serial number ranges — 70001–75000 and 75001 and up — each split into three parts, plus the electric circuit diagram inside the cab for serial 75001 and up.

What You Can Do With This Komatsu D155AX-5 Shop Manual

This manual supports the full range of professional service work on the D155AX-5. You can carry out routine maintenance and adjustments using the testing and adjusting procedures and standard value tables. You can diagnose faults and troubleshoot system problems using the judgment tables and mode-specific troubleshooting charts. You can remove and install major components — engine, transmission, torque converter, final drive, hydraulic pumps and motors — following the step-by-step disassembly and assembly procedures. You can overhaul the transmission, HSS unit, final drive, and hydraulic cylinders using the detailed internal component illustrations and assembly notes. You can inspect wear parts and make reuse or replacement decisions using the maintenance standard tables. You can interpret the electrical and hydraulic circuit diagrams for fault-finding and repair verification.

Why the Komatsu D155AX-5 Shop Manual Matters

The D155AX-5 is a large, complex crawler dozer with hydrostatic steering, a torque converter transmission, and extensive hydraulic and electronic control systems. Working without the correct procedures and specifications risks damage to precision components, incorrect assembly, oil leaks, control system faults, and unsafe machine operation. This manual gives you the exact tightening torques, clearances, wear limits, pressure settings, and adjustment values that Komatsu specifies for the machine. The disassembly and assembly procedures show the correct order, the special tools required, and the precautions that prevent component damage. The testing and adjusting chapter gives you the measured values and the step-by-step methods to verify system performance. The troubleshooting charts connect observable symptoms to probable causes and direct you to the specific checks that isolate the fault. For anyone maintaining, repairing, or overhauling a D155AX-5, this shop manual is the reference that keeps the work accurate and the machine within specification.

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Instant PDF Delivery — No Shipping, No Waiting

This Komatsu D155AX-5 shop manual is delivered as an instant PDF download. There is no physical book to ship and no waiting for delivery. The file works on any device — desktop, laptop, tablet, or smartphone — and every page is printable, so you can print the sections you need for the workshop and keep the complete manual on your computer for quick reference. Whether you are servicing the engine, overhauling the transmission, troubleshooting the HSS system, or checking wear limits on undercarriage components, the information is available immediately after purchase.