Komatsu D155AX-5 2004 Bulldozer Shop Manual Set (P/N SEBM016206)

Use the shop manual matching the machine’s serial range. The iBlade supplement adds automatic blade-control information, while the connector bulletin supplies terminal and harness-repair procedures.

Engine overhaul coverage: These chassis volumes include engine testing and selected component replacement. Full internal engine detail remains in the separate 6D140-2 and 140-3 Series Engine Shop Manuals. The iBlade supplement covers specification differences and refers other repair work to the standard shop manual.

PDF Bookmarks, Text Search and Diagram Detail

Search and navigation: All three PDFs have embedded bookmarks. Text search is limited in the earlier shop manual; portions of the later manual have text-encoding limitations, and the embedded connector bulletin is not searchable. The supplement has searchable body text, but its schematic labels are not searchable. Small wiring labels require zooming.

The ZIP contains three printable PDFs totaling 2,287 pages. The later shop-manual PDF contains 1,145 pages, including the 23-page connector bulletin listed separately above. Covers, revision lists and the iBlade supplement are included in the total.

Power Train, HSS and Blade-System Service

Selected coverage: The following highlights show major workshop procedures rather than the complete contents. Other topics include air-conditioning component removal and bonded cab-glass replacement.

• Engine and fuel system: Operating tests, valve adjustment, fuel-pressure testing and bleeding, injector and fuel-pump replacement, front and rear crankshaft seals, cylinder-head work, and engine removal.

• TORQFLOW power train: Step-by-step unit removal, separation and connection, plus PTO, torque-converter, transmission clutch, HSS case, transmission-control valve and final-drive overhaul procedures.

• Steering and brakes: HSS pressure diagnosis, pump bleeding, earlier HSS pump overhaul, HSS motor removal and installation, steering-neutral adjustment, brake testing and brake-valve service.

• Undercarriage: Track-frame, idler, recoil-spring, bogie, roller, track-shoe and link service, including press-fitting references and lubricated-track rebuilding procedures.

• Work-equipment hydraulics: Main control valve, PPC valve and hydraulic-cylinder repair, blade/ripper drift isolation, cylinder-leakage checks, blade adjustment and multi-shank ripper assembly.

• Electrical diagnosis: Serial-specific controller troubleshooting, EMMS service modes, connector and pin-location references, wiring diagrams, and dedicated iBlade hydraulic and electrical circuits.

These Komatsu shop manuals were written for service personnel and are best suited to experienced technicians with heavy-component lifting equipment plus hydraulic and electrical test capability.

Serial Breaks and Control-System Differences

The earlier shop manual separates 70001–75000 machines with the SA6D140E-2 from 75001-and-up machines with the SA6D140E-3. Its controller troubleshooting further identifies the 75001–75999 build where applicable.

The dedicated 76001-and-up book documents common-rail engine controls, transmission ECMV, PCCS/Palm Command control and the hydraulic cooling-fan system. These distinctions help match wiring, pressure tests and controller procedures to the machine’s build.

Configuration drawings identify semi-U-tiltdozer and U-tiltdozer machines with giant or multi-shank rippers, including pitch-dozer and ripper pin-puller arrangements. The later material also documents full U-tiltdozer configurations.

The iBlade material explains the manual/automatic selector and PPC/EPC valve arrangement. Its ROPS guard procedure addresses the additional antenna cable and wiring connections.

Engine Testing and Cooling-System Work

Engine checks include compression, blow-by, boost pressure and lubrication pressure. Injection-timing procedures for the earlier fuel system are distinguished from common-rail checks and reduced-cylinder testing.

Component procedures cover the water pump, turbocharger, thermostat, radiator and oil coolers. The later book adds cooling-fan speed and circuit-pressure tests, fan-pump bleeding and fan-motor removal.

Fault Isolation, Wiring and EMMS

The earlier book uses N-, G-, E-, M-, H- and S-mode charts for network, engine-controller, HSS/electrical, monitor, hydraulic/mechanical and engine faults. The later manual ties error-code diagnosis to the affected sensor, solenoid, controller or harness.

EMMS coverage includes fault-code displays, load memory, real-time and dual-display monitoring, plus adjustment after controller replacement.

Power-train hydraulic layouts, work-equipment/HSS circuit diagrams and monitor, engine and steering/transmission controller schematics support fault tracing. The later electrical circuit spans six sheets, supplemented by connector allocations, T-branch tables and pin-number cross-references.

The embedded DEUTSCH bulletin covers DT and HD30 terminal removal, replacement and crimping, with connector-body and repair-kit references.

Inspection Data, Tools and Service Cautions

Reference material includes component weights, fuel/coolant/lubricant tables, refill capacities, torque data, pressure-test specifications, electrical test values and maintenance standards for judging wear on disassembled parts.

Special-tool tables identify gauges and overhaul fixtures by part number, including 799-301-1600 for TORQFLOW clutch-piston leakage testing, 790-701-3000 for track-link seal checking and 790-502-1003 for hydraulic-cylinder repair. Dimensioned tool sketches include material callouts for fixtures designated for local manufacture.

During track-link disassembly, poorly centered link-press tooling can damage the link bore, break the pin or crack the bushing. The crankshaft rear-seal procedures also warn that incorrect handling of the sleeve or installer can damage the crankshaft and seal lip.

The safety sections require stored fuel and hydraulic pressure to be released, the blade or ripper to be lowered or securely blocked, battery power to be isolated, and correctly rated lifting gear to be used for heavy assemblies.

Preview: Valve-Clearance and Belt-Inspection Data

For the SA6D140E-3 in the 76001-and-up shop manual, standard valve clearances at normal temperature are 0.35 mm intake and 0.57 mm exhaust.

The same engine reference table specifies alternator-belt deflection of 13–16 mm under a force of 98 N. These figures accompany the valve-adjustment and belt-inspection procedures.