Komatsu D155A-6 Manual

BULLDOZER
PEN00319-00
D155A
-6
SERIAL NUMBERS
85025
and up
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
NOTICE
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 near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
WARNING

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FOREWORD
BEFORE READING THIS MANUAL
BEFORE READING THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety
rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you
or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance
of the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the
location shown on the right so that all relevant personnel can read
it at any time.
Location to Keep Operation & Maintenance Manual
Operation and Maintenance Manual pocket at the rear of the
operator's seat
If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details
regarding the machine serial No. you will need to provide your Komatsu distributor, see "TABLE TO ENTER SERIAL
NO. AND DISTRIBUTOR (PAGE 1-8)".
This manual uses the international units (SI) for units of measurement. For reference, units that have been used in
the past are given in ( ).
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For example:1→(1))
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, 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.
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FOREWORD
SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.
To identify important safety messages in the manual and on the machine labels, the following signal words are used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
This signal word indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
This signal word indicates a potentially hazardous situation exists which, if not avoided,
may result in minor or moderate injury.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
This precaution is given where the machine may be damaged or the service life reduced if
the precaution is not followed.
This word is used for information that is useful to know.
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FOREWORD
INTRODUCTION
INTRODUCTION
USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
Dozing
Cutting into hard or frozen ground or ditching
Felling trees, removing stumps
Pushing
Ripping
For further details, see "WORK POSSIBLE USING BULLDOZER (PAGE 3-143)" and "RIPPER OPERATION
(PAGE 3-145)".
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
(1)
(2)
Operator's seat
Sprocket
(A)
(B)
Front
Rear
(C)
(D)
Left
Right
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.
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FOREWORD
INTRODUCTION
VISIBILITY FROM OPERATOR'S SEAT
The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.
PROXIMITY VISIBILITY
The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown
in the diagram below. The hatched area (A) shows the area where the view is blocked by part of the machine when
mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot be
seen when operating the machine.
12M CIRCUMFERENCE VISIBILITY
The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show
the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Please be fully
aware that there are places that cannot be seen when operating the machine.
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FOREWORD
NECESSARY INFORMATION
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE
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
The engine Serial No. plate is on right side of the engine.
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FOREWORD
NECESSARY INFORMATION
BLADE SERIAL NO. PLATE POSITION
This is located on the upper right of blade back surface.
RIPPER SERIAL NO. PLATE POSITION
This is located on the left side surface of ripper beam.
ROPS, FOPS NO. PLATE POSITION
This is at the top rear of the cab.
POSITION OF SERVICE METER
On top of the machine monitor
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FOREWORD
NECESSARY INFORMATION
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD
CONTENTS
CONTENTS
FOREWORD 1- 1
BEFORE READING THIS MANUAL 1- 2
SAFETY INFORMATION 1- 3
INTRODUCTION 1- 4
USE OF MACHINE 1- 4
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 4
VISIBILITY FROM OPERATOR'S SEAT 1- 5
NECESSARY INFORMATION 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE 1- 6
ENGINE SERIAL NO. PLATE AND POSITION 1- 6
BLADE SERIAL NO. PLATE POSITION 1- 7
RIPPER SERIAL NO. PLATE POSITION 1- 7
ROPS, FOPS NO. PLATE POSITION 1- 7
POSITION OF SERVICE METER 1- 7
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 8
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
POSITIONS OF SAFETY PICTOGRAMS 2- 6
SAFETY LABELS 2- 7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 11
PRECAUTIONS BEFORE STARTING OPERATION 2- 11
PREPARATIONS FOR SAFE OPERATION 2- 11
FIRE PREVENTION 2- 13
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 14
DO NOT GET CAUGHT IN WORK EQUIPMENT 2- 16
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 16
UNAUTHORIZED MODIFICATION 2- 16
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 16
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 17
PRECAUTIONS FOR OPERATION 2- 18
PRECAUTIONS FOR JOBSITE 2- 18
STARTING ENGINE 2- 20
OPERATION 2- 23
TRANSPORTATION 2- 27
TOWING 2- 28
PRECAUTIONS FOR MAINTENANCE 2- 29
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 29
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 33
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 5
MACHINE MONITOR 3- 5
SWITCHES 3- 51
CONTROL LEVERS, PEDALS 3- 55
DUST INDICATOR 3- 61
FUSE BOX 3- 62
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FOREWORD
CONTENTS
CAP WITH LOCK 3- 66
DOOR POCKET 3- 68
ASHTRAY 3- 68
CAR RADIO, HANDLING 3- 69
CAR STEREO, HANDLING 3- 74
HANDLING AIR CONDITIONER 3- 81
OPERATION 3- 95
CHECK BEFORE STARTING ENGINE, ADJUST 3- 95
STARTING ENGINE 3-116
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-121
STOPPING ENGINE 3-124
MOVING MACHINE 3-125
STOPPING MACHINE 3-127
SHIFTING GEAR 3-128
SHIFTING BETWEEN FORWARD AND REVERSE 3-134
STEERING MACHINE 3-136
PRECAUTIONS FOR OPERATION 3-138
PARKING MACHINE 3-140
CHECK AFTER STOPPING ENGINE 3-142
CHECK AFTER FINISHING WORK 3-142
LOCKING 3-142
WORK POSSIBLE USING BULLDOZER 3-143
RIPPER OPERATION 3-145
OPERATING METHOD FOR RIPPING OPERATIONS 3-148
ADJUSTING POSTURE OF WORK EQUIPMENT 3-153
TIPS FOR LONGER UNDERCARRIAGE LIFE 3-160
TRANSPORTATION 3-163
LOADING, UNLOADING WORK 3-163
METHOD OF LIFTING MACHINE 3-167
PRECAUTIONS FOR TRANSPORTATION 3-168
TRAVELING ON ROADS 3-168
REMOVAL OF CAB 3-169
INSTALLATION OF CAB 3-171
COLD WEATHER OPERATION 3-172
PRECAUTIONS FOR LOW TEMPERATURE 3-172
AFTER COMPLETION OF WORK 3-174
AFTER COLD WEATHER 3-174
LONG-TERM STORAGE 3-175
BEFORE STORAGE 3-175
DURING STORAGE 3-175
AFTER STORAGE 3-175
TROUBLESHOOTING 3-176
AFTER RUNNING OUT OF FUEL 3-176
METHOD OF TOWING MACHINE 3-177
IF BATTERY IS DISCHARGED 3-178
OTHER TROUBLE 3-182
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 5
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FOREWORD
CONTENTS
OUTLINE OF ELECTRIC SYSTEM 4- 9
WEAR PARTS 4- 10
WEAR PARTS LIST 4- 10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 12
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS
OTHER THAN KOMATSU GENUINE OIL 4- 14
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 15
TORQUE LIST 4- 15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 16
SAFETY CRITICAL PARTS 4- 16
MAINTENANCE SCHEDULE CHART 4- 18
MAINTENANCE SCHEDULE CHART 4- 18
SERVICE PROCEDURE 4- 20
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 20
WHEN REQUIRED 4- 21
CHECK BEFORE STARTING 4- 54
EVERY 250 HOURS SERVICE 4- 55
EVERY 500 HOURS SERVICE 4- 64
EVERY 1000 HOURS SERVICE 4- 71
EVERY 2000 HOURS SERVICE 4- 82
EVERY 4000 HOURS SERVICE 4- 90
EVERY 8000 HOURS SERVICE 4- 94
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAUTIONS 6- 2
PRECAUTIONS RELATED TO SAFETY 6- 2
INTRODUCTION OF ATTACHMENTS AND OPTIONS 6- 3
INTRODUCTION OF ATTACHMENTS AND OPTIONS 6- 3
HEADREST, HANDLING 6- 4
PROCEDURE FOR SELECTING RIPPER POINT 6- 5
PROCEDURE FOR SELECTING RIPPER POINT 6- 5
HANDLING MACHINES EQUIPPED WITH KOMTRAX 6- 6
BASIC PRECAUTIONS 6- 6
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
SAFETY LABEL 2- 5
POSITIONS OF SAFETY PICTOGRAMS 2- 6
SAFETY LABELS 2- 7
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 11
PRECAUTIONS BEFORE STARTING OPERATION 2- 11
ENSURING SAFE OPERATION 2- 11
UNDERSTANDING THE MACHINE 2- 11
PREPARATIONS FOR SAFE OPERATION 2- 11
PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 11
INSPECTING MACHINE 2- 11
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2- 11
KEEP MACHINE CLEAN 2- 12
PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT 2- 12
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2- 12
IF ANY PROBLEM IS FOUND 2- 12
FIRE PREVENTION 2- 13
ACTION IF FIRE OCCURS 2- 13
PRECAUTIONS TO PREVENT FIRE 2- 13
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 14
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE 2- 14
NO JUMPING ON OR OFF MACHINE 2- 15
NO PEOPLE ON ATTACHMENTS 2- 15
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT 2- 15
PRECAUTIONS WHEN LEAVING MACHINE 2- 15
EMERGENCY EXIT FROM OPERATOR'S CAB 2- 15
DO NOT GET CAUGHT IN WORK EQUIPMENT 2- 16
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 16
UNAUTHORIZED MODIFICATION 2- 16
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 16
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 17
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SAFETY
SAFETY
PRECAUTIONS FOR OPERATION 2- 18
PRECAUTIONS FOR JOBSITE 2- 18
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 18
WORKING ON LOOSE GROUND 2- 18
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 19
ENSURE GOOD VISIBILITY 2- 19
CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 20
BEWARE OF ASBESTOS DUST 2- 20
STARTING ENGINE 2- 20
USE WARNING TAGS 2- 20
INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE 2- 21
PRECAUTIONS WHEN STARTING ENGINE 2- 21
PRECAUTIONS IN COLD AREAS 2- 21
STARTING WITH BOOSTER CABLES 2- 22
OPERATION 2- 23
CHECKS BEFORE OPERATION 2- 23
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 23
PRECAUTIONS WHEN TRAVELING 2- 24
TRAVELING ON SLOPES 2- 24
PRECAUTIONS WHEN OPERATING 2- 25
PROHIBITED OPERATIONS 2- 25
METHOD OF USING BRAKES 2- 25
TRAVELING ON SNOW-COVERED OR FROZEN SURFACES 2- 25
PARKING MACHINE 2- 26
TRANSPORTATION 2- 27
LOADING AND UNLOADING 2- 27
TOWING 2- 28
PRECAUTIONS WHEN TOWING 2- 28
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SAFETY
SAFETY
PRECAUTIONS FOR MAINTENANCE 2- 29
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 29
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 29
KEEP WORKPLACE CLEAN AND TIDY 2- 29
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 29
ONLY AUTHORIZED PERSONNE 2- 29
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 29
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 30
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 31
INSTALLING, REMOVING, OR STORING ATTACHMENTS 2- 31
PRECAUTIONS WHEN WORKING AT HIGH PLACES 2- 31
PRECAUTIONS WHEN WORKING ON TOP OF MACHINE 2- 32
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2- 32
PROPER TOOLS 2- 32
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 33
PRECAUTIONS WHEN WELDING 2- 33
HANDLING BATTERY 2- 33
PRECAUTIONS WHEN USING HAMMER 2- 34
PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT 2- 34
PRECAUTIONS WITH HIGH-TEMPERATURE OIL 2- 34
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 35
PRECAUTIONS WITH HIGH-PRESSURE FUEL 2- 35
HANDLING HIGH-PRESSURE HOSES AND PIPING 2- 35
NOISE 2- 35
PRECAUTIONS WITH HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION 2- 36
DO NOT DISASSEMBLE RECOIL SPRING 2- 36
HANDLING ACCUMULATOR AND GAS SPRING 2- 37
PRECAUTIONS WITH COMPRESSED AIR 2- 37
MAINTENANCE OF AIR CONDITIONER 2- 37
DISPOSING OF WASTE MATERIALS 2- 37
METHOD OF SELECTING WINDOW WASHER FLUID 2- 37
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2- 38
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY
SAFETY LABELS
POSITIONS OF SAFETY PICTOGRAMS
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SAFETY
SAFETY LABELS
SAFETY LABELS
(1) Caution for operation, inspection, and maintenance
(09651-A0641)
(2) Caution when traveling in reverse (09802-13000)
(3) Warning for leaving operator's seat (09654-B0641)
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