Komatsu D155AX-5 / D155 Shop Manual (P/N SEBM016206)

• 2,287 PDF pages total across three Komatsu publications - SEBM016206: 1,127 pages for D155AX-5 serial 70001 and up, printed October 2004; SEBM034807: 1,145 pages for serial 76001 and up, printed June 2005; SEBM038800: a 15-page KOMATSU-iBLADE supplement for serial 76001 and up, printed March 2005.
• Factory testing and adjustment coverage includes pressure diagnosis and pump bleeding for the hydrostatic steering system (HSS), transmission and work-equipment pressure checks, brake testing, steering setup, hydraulic-drift isolation, cylinder leakage checks, and blade adjustment.
• Major drivetrain repair procedures address power-train unit removal, separation, and connection; PTO, torque converter, TORQFLOW power-shift transmission, HSS case, and HSS pump overhaul; HSS motor removal and installation; and transmission control valve, brake valve, and final-drive disassembly and assembly.
• Undercarriage and work-equipment sections cover the track frame, idler, recoil spring, bogies, rollers, track shoes and links, main control valve, PPC valves, hydraulic cylinders, blade, and multi-shank ripper, with removal, installation, inspection, and overhaul procedures.
• Serial-specific diagnostics use N-, G-, E-, M-, H-, and S-mode charts for network, engine, HSS/controller, monitor, electrical, hydraulic, and mechanical faults; the later book adds CRI engine control, transmission ECMV, PCCS/Palm Command control, EMMS service modes, and post-replacement controller adjustment.
• Diagram coverage includes the power-train hydraulic layout, work-equipment and HSS circuits, monitor/engine/steering-transmission controller schematics, connector and pin-location views, the six-sheet 76001-and-up electrical circuit, and dedicated iBlade hydraulic and electrical diagrams.

Coverage by Serial Range and Configuration

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. Coverage follows the machine's actual production changes rather than treating every D155AX-5 as the same build.

SEBM016206 divides its specifications and many test procedures at the serial break: machines 70001-75000 use the SA6D140E-2, while 75001 and up use the SA6D140E-3. Its controller troubleshooting further identifies the 75001-75999 build where applicable. SEBM034807 supplies the dedicated 76001-and-up material, including the later common-rail engine controls, electrically actuated transmission control, hydraulic cooling-fan system, and monitor-based diagnostics.

Configuration drawings and work-equipment sections identify semi-U-tiltdozer and U-tiltdozer machines with giant or multi-shank rippers, along with pitch-dozer and ripper pin-puller systems. The later material also documents full U-tiltdozer arrangements. SEBM038800 is limited to the iBlade specification: it adds the automatic blade-control/PPC arrangement, ROPS guard removal and installation, and iBlade-specific circuits, while directing all other repair work to the standard shop manual.

Repair and Diagnostic Depth

Engine-related content includes operating tests, fuel-system pressure release and bleeding, injection-timing or common-rail checks as applicable, injector and fuel-pump work, front and rear seal replacement, cylinder-head removal and installation, cooling-system components, and complete engine removal. Full internal engine detail remains in the separate 6D140-2 and 140-3 Series Engine Shop Manuals, so this set is not a substitute for those engine overhaul volumes.

The testing chapters combine standard-value tables with fault isolation. They cover torque-converter stall checks, power-train and HSS oil-pressure testing, brake performance, track tension and wear inspection, work-equipment pressure and PPC output, blade/ripper drift, fan-circuit testing, and EMMS fault-code, load-memory, real-time, and dual-display monitoring. Electrical support extends to connector allocation, T-branch tables, pin-number cross-references, Deutsch terminal replacement and crimping, and error-code troubleshooting tied to the affected sensor, solenoid, controller, or harness.

Shop Data, Tools, and Service Cautions

Reference material includes component weights, fuel/coolant/lubricant tables, refill capacities, general and component-specific torque data, pressure-test specifications, electrical test values, adjustment data, and maintenance standards for judging wear on disassembled parts. Special-tool tables identify factory gauges and overhaul fixtures by part number; examples include 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.

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.