Komatsu Utility D155AX-5 Manual

D155AX -5
SERIAL NUMBER
D155AX - 76243 and up
BULLDOZER
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
Operation &
Maintenance Manual
EEAM023402
WARNING

FOREWORD
11

FOREWORD FOREWORD
1-2
FOREWORD 1
This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-
cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci-
dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation
and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.
Always be sure to read and understand this manual thoroughly before performing operation and mainte-
nance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly
and be sure that you understand them fully.
Keep this manual in the storage location for the operation and maintenance manual given below, and have
all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual imme-
diately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating
the machine.
Location to Keep Operation & Maintenance Manual
qMachine equipped with cab
Inside of right and left doors

FOREWORD FOREWORD
1-3
qMachine equipped without cab
Back pocket of operator's seat

SAFETY INFORMATION FOREWORD
1-4
SAFETY INFORMATION 1
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place
the lock lever in the LOCK position.
If you accidentally touch the control levers when they are
not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is useful to know.
Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may
cause property damage.
DANGER
WARNING
CAUTION
NOTICE This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
REMARKS This word is used for information that is useful to know.

FOREWORD SAFETY INFORMATION
1-5
qSafety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side, and the method of avoiding the haz-
ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi-
bility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of
your machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1-> (1))
Part No.
Part No.

SAFETY INFORMATION FOREWORD
1-6
Noise emission levels 1
Two labels indicating the machine noise level are affixed on the machine.
qSound pressure level at the operator's station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle)
qSound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.
Vibration levels 1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera-
tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration
value for the body is less than or equal to 0.5 m/s².
These values were determined using a representative machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
Operating condition:
(WHEEL LOADER:) V-shape loading
(HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating)

FOREWORD SAFETY INFORMATION
1-7
(TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion
(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading, and
travelling without load)
Guide to Reduce Vibration Levels on Machine
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
qTire pressures (for wheeled machines), tension of crawler (for crawler machines)
qBrake and steering systems
qControls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
qRemove any large rocks or obstacles
qFill any ditches and holes
qSite manager should provide machine operators with machine and schedule time to maintain terrain con-
ditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
qAdjust the seat and suspension for the weight and size of the operator
qWear seat belt
qInspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
qWhen pushing with bucket or blade, avoid sudden loading; load gradually
qDrive around obstacles and rough terrain conditions
qSlow down when it is necessary to go over rough terrain
qMake the curve radius of traveling path as large as possible
qTravel at low speed when traveling around sharp curves
7. Minimize vibrations for long work cycle or long distance traveling
qReduce speed to prevent bounce
qTransport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain
qOperate the machine only when you are in good health.
qProvide breaks to reduce long periods of sitting in the same posture
qDo not jump down from the cab or machine
qDo not repeatedly handle and lift loads

INTRODUCTION FOREWORD
1-8
INTRODUCTION 1
This Komatsu machine is designed to be used mainly for the following work:
qDozing
qCutting into hard or frozen ground or ditching
qFelling trees, removing stumps
qPushing
qRipping
For further details, see “WORK POSSIBLE USING BULLDOZER (3-118)“ and “RIPPER OPERATION (3-111)“.
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.
Front
Right
Sprocket
Operator’s seat
Left
Rear

FOREWORD INTRODUCTION
1-9
BREAKING IN THE MACHINE 1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How-
ever, operating the machine under full load before breaking the machine in can adversely affect the perfor-
mance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.
qRun the engine at idling for 15 seconds after starting it. During this time, do not operate the control levers or
fuel control dial.
qIdle the engine for 5 minutes after starting it up.
qAvoid operation with heavy loads or at high speeds.
qImmediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.

NECESSARY INFORMATION FOREWORD
1-10
NECESSARY INFORMATION 1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE1
Under the front of the console box on the right side of the operator's seat.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE AND POSITION (1) 1
qOn the upper of the engine starting motor on the right side of the machine.
qThis also acts as the EPA plate.

FOREWORD NECESSARY INFORMATION
1-11
ENGINE SERIAL NO. PLATE AND POSITION (2) 1
qThis is the same content as engine serial No. plate (1).
qLocated on the top of the air cleaner mounting bracket on the left of the machine.
qThis also acts as the EPA plate.
EPA: Environmental Protection Agency, U.S.A.
BLADE SERIAL NO. PLATE POSITION 1
This is located on the upper right of blade back surface.

NECESSARY INFORMATION FOREWORD
1-12
RIPPER SERIAL NO. PLATE POSITION 1
This is located on the left side surface of ripper beam.
ROPS, FOPS NO. PLATE POSITION 1
This is located on the top left.
POSITION OF SERVICE METER 1
On top of the machine monitor
ROPS
FOPS

FOREWORD NECESSARY INFORMATION
1-13
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
MACHINE SERIAL NUMBER PLATE
Machine serial No.
Engine serial No.
Product Identification Number
Manufacturers name:
Address:
KOMATSU LTD.
3-6 Akasaka
Minato-ku, 101 Tokyo
Japan
Distributor
Address
Phone
Service personnel for your
machine:
Model
Seriel Number
Manufacturing year
Weight
Engine power
Product Identification Number
Manufacturer

NECESSARY INFORMATION FOREWORD
1-14

FOREWORD NECESSARY INFORMATION
1-15

CONTENTS
1-16
CONTENTS
FOREWORD
FOREWORD.........................................................................................................................................................1-2
SAFETY INFORMATION......................................................................................................................................1-4
Noise emission levels .................................................................................................................................1-6
Vibration levels............................................................................................................................................1-6
Guide to Reduce Vibration Levels on Machine..................................................................................1-7
INTRODUCTION...................................................................................................................................................1-8
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.......................................................................1-8
BREAKING IN THE MACHINE...................................................................................................................1-9
NECESSARY INFORMATION ...........................................................................................................................1-10
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE.....................................1-10
ENGINE SERIAL NO. PLATE AND POSITION (1) ..................................................................................1-10
ENGINE SERIAL NO. PLATE AND POSITION (2) ..................................................................................1-11
BLADE SERIAL NO. PLATE POSITION ..................................................................................................1-11
RIPPER SERIAL NO. PLATE POSITION.................................................................................................1-12
ROPS, FOPS NO. PLATE POSITION......................................................................................................1-12
POSITION OF SERVICE METER ............................................................................................................1-12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................1-13
MACHINE SERIAL NUMBER PLATE.......................................................................................................1-13
SAFETY
SAFETY................................................................................................................................................................2-2
SAFETY LABELS.................................................................................................................................................2-4
POSITIONS OF SAFETY PICTOGRAMS ..................................................................................................2-4
SAFETY LABELS .......................................................................................................................................2-5
GENERAL PRECAUTIONS ...............................................................................................................................2-11
PRECAUTIONS FOR OPERATION...................................................................................................................2-20
BEFORE STARTING ENGINE .................................................................................................................2-20
OPERATION.............................................................................................................................................2-22
TRANSPORTATION.................................................................................................................................2-26
BATTERY .................................................................................................................................................2-27
TOWING ...................................................................................................................................................2-29
PRECAUTIONS FOR MAINTENANCE..............................................................................................................2-30

CONTENTS
1-17
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE................................................................................................................. 3-2
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-5
FRONT PANEL........................................................................................................................................... 3-5
CHECK MONITOR GROUP.............................................................................................................. 3-7
CAUTION MONITOR GROUP ..........................................................................................................3-9
EMERGENCY CAUTION ITEMS .................................................................................................... 3-11
METER GROUP.............................................................................................................................. 3-14
SWITCHES...................................................................................................................................... 3-18
LAMPS............................................................................................................................................. 3-21
METHOD OF USING DISPLAY PANEL B (Multi-information) ........................................................ 3-23
SWITCHES............................................................................................................................................... 3-32
CONTROL LEVERS, PEDALS................................................................................................................. 3-37
DUST INDICATOR ................................................................................................................................... 3-44
POWER SOURCE.................................................................................................................................... 3-44
FUSE BOX................................................................................................................................................ 3-45
CIRCUIT BREAKER........................................................................................................................ 3-47
CIRCUIT BREAKER FOR MAIN POWER SUPPLY........................................................................ 3-47
FUSE CAPACITY AND NAME OF CIRCUIT................................................................................... 3-48
DOOR POCKET ....................................................................................................................................... 3-49
ASHTRAY................................................................................................................................................. 3-49
CAR RADIO, HANDLING ......................................................................................................................... 3-50
EXPLANATION OF COMPONENTS............................................................................................... 3-50
METHOD OF USE........................................................................................................................... 3-52
PRECAUTIONS WHEN USING ...................................................................................................... 3-54
CAR STEREO, HANDLING...................................................................................................................... 3-55
EXPLANATION OF COMPONENTS............................................................................................... 3-55
METHOD OF OPERATION.............................................................................................................3-58
PRECAUTION WHEN USING......................................................................................................... 3-60
AIR CONDITIONER.................................................................................................................................. 3-61
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL................................................ 3-61
METHOD OF OPERATION.............................................................................................................3-63
PRECAUTIONS WHEN USING ...................................................................................................... 3-64
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE.......... 3-64
CHECKS DURING OFF-SEASON.................................................................................................. 3-64
PROCEDURE FOR REPLACING RECEIVER................................................................................ 3-65
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL............................ 3-65
CLEANING AIR FILTER.................................................................................................................. 3-65
SKILLFUL USE OF AIR-CONDITIONER ........................................................................................ 3-66
HEATER, HANDLING............................................................................................................................... 3-67
METHOD OF OPERATION.............................................................................................................3-67
CLEANING AIR FILTER.................................................................................................................. 3-67
ACCUMULATOR, HANDLING.................................................................................................................. 3-68
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH

CONTENTS
1-18
ACCUMULATOR.............................................................................................................................3-68
OPERATION.......................................................................................................................................................3-69
CHECK BEFORE STARTING ENGINE, ADJUST....................................................................................3-69
WALK-AROUND CHECK ................................................................................................................3-69
CHECK BEFORE STARTING ......................................................................................................... 3-71
ADJUSTMENT.................................................................................................................................3-82
OPERATIONS AND CHECKS BEFORE STARTING ENGINE.......................................................3-86
STARTING ENGINE.................................................................................................................................3-88
NORMAL STARTING ......................................................................................................................3-88
STARTING IN COLD WEATHER....................................................................................................3-90
OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................................3-93
WARMING UP OPERATIONS ........................................................................................................3-93
IN COLD AREAS.............................................................................................................................3-94
STOPPING ENGINE.................................................................................................................................3-95
MOVING MACHINE..................................................................................................................................3-96
STOPPING MACHINE..............................................................................................................................3-98
SHIFTING GEAR......................................................................................................................................3-99
SHIFTING BETWEEN FORWARD AND REVERSE..............................................................................3-102
STEERING MACHINE............................................................................................................................3-104
NORMAL TURNING......................................................................................................................3-104
TURNING WHILE DESCENDING A SLOPE.................................................................................3-105
PRECAUTIONS FOR OPERATION .......................................................................................................3-106
PAY ATTENTION TO GAUGES....................................................................................................3-106
PERMISSIBLE WATER DEPTH....................................................................................................3-106
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS........................................................3-106
PRECAUTIONS ON SLOPE .........................................................................................................3-107
METHOD OF USING BRAKES .....................................................................................................3-107
PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS .........................................3-107
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-107
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY.....................3-108
PARKING MACHINE ..............................................................................................................................3-108
CHECK AFTER STOPPING ENGINE ....................................................................................................3-109
CHECK AFTER FINISHING WORK .......................................................................................................3-110
LOCKING................................................................................................................................................3-110
RIPPER OPERATION ............................................................................................................................3-111
EFFECTIVE METHOD OF USE....................................................................................................3-111
DIGGING UP BOULDERS OR ROCKBED ...................................................................................3-111
OPERATING ON SLOPES............................................................................................................3-112
METHOD OF OPERATING PIN PULLER.....................................................................................3-112
OPERATING METHOD FOR RIPPING OPERATIONS .........................................................................3-113
BASIC OPERATING METHOD .....................................................................................................3-113
RIPPING BY CLIFFS.....................................................................................................................3-114
RIPPING BY SLOPE FACES ........................................................................................................3-114
DIGGING UP BOULDERS ............................................................................................................3-115
PRECAUTIONS WHEN RIPPING.................................................................................................3-116
WORK POSSIBLE USING BULLDOZER...............................................................................................3-118