Description

Komatsu D155AX-5 2001 Workshop Manual

You ever get halfway into a final drive rebuild and realize the aftermarket manual you bought has the wrong clearance specs? I have. That’s why I only trust factory documentation. This Komatsu D155AX-5 2001 Workshop Manual is the real deal – 1064 pages of the same binder that Komatsu techs use. No condensed reprints, no photocopied blur. This is the original factory document from 2001, serial number 70001 and up. If you are working on a D155AX-5 bulldozer, this is the only manual that gives you the correct torque values, hydraulic circuit diagrams, and test procedures straight from the engineers who built the machine.

1064 Pages of Factory Data

Most aftermarket manuals strip out half the content to save paper. Not this one. You get the full table of contents: SEGURIDAD (safety), PRECAUCIONES DURANTE EL TRABAJO, TORSIÓN DE APRIETE ESTÁNDAR, CÓDIGO DE ALAMBRES ELÉCTRICOS, and six major sections – GENERAL, ESTRUCTURA Y FUNCIONAMIENTO, PRUEBAS Y AJUSTES, DESENSAMBLE Y ENSAMBLE, MANTENIMIENTO ESTANDAR, and OTROS. That last section covers wiring diagrams, the monitor system, and the electronic HSS controller. Every page is part of the original PDF, so nothing is missing. Page 01-1 shows the general specifications drawing – you can see the overall dimensions and weight tables right there.

Safety Section: Not Optional

Komatsu starts every manual with a safety chapter. This one runs several pages and covers proper jacking, blocking, and personal protective equipment. It also lists the specific safety decals on the machine. If you are doing any welding, cutting, or heavy lifting, you need to read this first. The manual even details the correct procedure for disconnecting push-pull couplers – something a lot of guys get wrong and end up with hydraulic fluid spraying everywhere. I’ve seen it happen. Don’t skip this part.

Does This Manual Cover the HSS System?

Yes, and it does it right. The HSS (Hydraulic Static Steering) system is one of the trickiest parts of this dozer. Section 10 includes ACTUACIÓN DEL SISTEMA HSS, BOMBA HSS, MOTOR HSS, PPC FILTRO DE CARGA HSS, and the VÁLVULA DE DESVÍO DEL ENFRIADOR DE ACEITE HSS. There are hydraulic circuit diagrams and a full circuit diagram for the HSS and work equipment combined. If you need to troubleshoot a steering issue or replace the HSS motor, the step-by-step removal and testing procedures are in section 30 (DESENSAMBLE Y ENSAMBLE). The torque specs for the HSS pump mounting bolts are listed in the standard torque table on page 20-1.

Torque Specs and Fluid Capacities

Standard torque values for common bolt grades are listed in the opening pages. But the real gold is in section 20: PRUEBAS Y AJUSTES. That chapter has tables for engine standard values, chassis standard values, and electrical parts standard values. You want the correct oil for the transmission? The TABA DE COMBUSTIBLE, REFRIGERANTE Y LUBRICANTES in section 01 tells you the exact capacities and fluid specs. For example, the final drive oil capacity – it’s listed. No guesswork. The manual also includes conversion tables from metric to imperial units, so you don’t have to do math on the fly.

PRUEBAS Y AJUSTES: Where the Real Work Happens

This section is what separates a factory manual from a generic repair guide. It covers 30+ specific tests and adjustments, each with the required special tools, pressure specs, and tolerances. You get procedures for measuring engine speed, boost pressure, exhaust temperature, compression pressure, and valve clearance. There is a whole subsection on fuel injection timing. For the drivetrain, you can measure stall speed, clutch pressure, and HSS charge oil pressure. The manual even includes a simple brake performance check procedure. Every test gives you the acceptable range, not some vague “within spec” line. Use the Komatsu D155AX-5 2001 Service Manual to cross-reference part numbers when ordering components.

Wiring diagrams? Yes. The section on SISTEMA MONITOR and SENSORS gives you the complete electrical circuit diagrams for the engine controller, HSS controller, and all sensors. If you’re chasing an electrical gremlin, these diagrams are your roadmap. The color code chart for wires is included, so you can trace circuits without a meter. I still recommend you verify with a multimeter, but the diagram gets you close.

Now, about the language – this manual is in Spanish. Do not let that stop you. The diagrams, tables, and torque values are universal. If you can read a spec sheet, you can use this manual. The KOMATSU D155AX-5 Bulldozer Operator Manual covers daily operations in English, but for repair and overhaul, the Spanish workshop manual has all the technical data you need. And if you want the full package, grab the Komatsu D155AX-5 Bulldozer Operation and Maintenance Man as a companion.

I’ve been turning wrenches for 28 years. I’ve seen techs waste hours because they used a generic manual that said “torque to snug.” That doesn’t fly on a machine this size. The Komatsu manual gives you the exact torque in foot-pounds for every critical fastener. For example, the final drive gear teeth gap? Specified. The main relief valve pressure? Page 20-1. If you want to understand how the manual transmission-like power flow works through the torque converter and transmission, check out the explanation on Manual Transmission for general principles, but for this dozer’s specific PTO and transmission control, the manual is your only source.

Get the Right Tools First

Before you start any job, flip to the PRUEBAS Y AJUSTES section and read the HERRAMIENTAS PARA PRUEBAS, AJUSTES Y LOCALIZACIÓN DE FALLAS list. Komatsu lists the special tools needed for each procedure. Do not skip this step. Using the wrong adapter for a pressure test can ruin a port. The manual also tells you when you can substitute a standard tool and when you absolutely need the Komatsu tool. I keep this PDF on a tablet in my shop, but I also print out the torque table and laminate it. That’s how often I use it.

One more thing: this is not a reprint. This is the original OEM PDF from 2001, scanned from the factory source. The PDF markers are clean, the text is searchable, and the diagrams are high resolution. You can zoom into the hydraulic schematics and read every line. If you’ve ever tried to read a third-generation photocopy of a manual, you know the difference.

Is this manual in English?

No, it’s in Spanish. However, the diagrams and tables are universal.

Does this manual cover engine overhaul?

Yes, but engine-specific details are in the separate Komatsu 6D140 series engine manual. This manual covers the D155AX-5 chassis, hydraulics, powertrain, and electrical systems. The engine section is limited to tests and adjustments like compression pressure, valve clearance, injection timing, and turbocharger boost. For a full engine rebuild, you need the companion engine manual. That said, the PRUEBAS Y AJUSTES section starting on page 20-1 includes everything you need to diagnose and tune the SA6D140E-2 or -3 engine as installed in this dozer. You can measure boost pressure, exhaust temperature, and set valve lash correctly.

What about the HSS transmission system?

Covered in detail. The manual has a full chapter on the HSS system including pump, motor, control valves, and PPC. It also includes hydraulic circuit diagrams and testing procedures. This is the factory method, not a guess.

Can I use this manual for the D155AX-6?

No. This is for serial numbers 70001 and up of the D155AX-5 only. Different model, different specs.

If you are serious about keeping this dozer running at peak performance, get the real documentation. Access the Factory Manual today and stop chasing aftermarket nonsense. Your time and your machine deserve it.