Komatsu D155AX-5 Manual

1-1
FOREWORD
11

FOREWORD FOREWORD
1-2
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precau-
tions 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. Accidents
can be prevented by knowing beforehand conditions that may cause hazard when performing operation and main-
tenance.
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
maintenance.
●Read the safety messages given in this manual and the safety labels affixed to the machine thor-
oughly and be sure that you understand them fully.
Keep this manual at 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
immediately 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 speciffications 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 operat-
ing the machine.
Storage location for the Operation and Maintenance Manual:
Machine equipped with cab
Inside of right and left doors
Machine without cab
Back pocket of operator's seat

FOREWORD FOREWORD
1-3

FOREWORD FOREWORD
1-4

FOREWORD SAFETY INFORMATION
1-5
SAFETY INFORMATION
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.
Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury. This signal word is to be limited to most extreme situations.
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 mod-
erate injury. It may also be used to alert against unsafe practices.
Example of safety message using signal word
WARNING
To avoid hitting unlocked operation levers, lower equipment to ground and move SAFETY LOCK LEVER
(located near seat) to LOCK position before starting up from operator's seat.
Sudden and unwanted machine movement can cause 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 are useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This gives information that is useful to know.
DANGER
WARNING
CAUTION
NOTICE
REMARKS

SAFETY INFORMATION FOREWORD
1-6
Safety 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
responsibility 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))
Part No.
Part No.

FOREWORD INTRODUCTION
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INTRODUCTION
This Komatsu machine is designed to be used mainly for the following works:
●Dozing
●Smoothing
●Cutting into hard or frozen ground or ditching.
●Felling trees, removing stumps
See the section "WORK POSSIBLE USING BULLDOZER (PAGE 3-108)" for further details.
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's cab when
the operator's cab is facing the front and the sprocket is at the rear of the machine.

NECESSARY INFORMATION FOREWORD
1-8
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NO. PLATE AND POSITION
Under the front of the console box on the right side of the operator's seat.
ENGINE SERIAL NO. PLATE AND POSITION
On the upper of the engine starting motor on the right side of the machine.

FOREWORD NECESSARY INFORMATION
1-9
EMISSION CONTROL INFORMATION LABEL
Located on the top of the air cleaner mounting bracket on the left of the machine.
EPA: Environmental Protection Agency, U.S.A.
BLADE SERIAL NO. PLATE POSITION
This is located at the right side of blade back surface.
RIPPER SERIAL NO. PLATE POSITION
This is located at the left side surface of ripper beam.

NECESSARY INFORMATION FOREWORD
1-10
POSITION OF SERVICE METER
This is at the left upper part of the monitor panel.
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Distributor name
Address
Service Personal
Phone/Fax

FOREWORD CONTENTS
1-11
CONTENTS
FOREWORD
FOREWORD......................................................................................................................................................... 1-2
SAFETY INFORMATION...................................................................................................................................... 1-5
INTRODUCTION................................................................................................................................................... 1-7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....................................................................... 1-7
NECESSARY INFORMATION ............................................................................................................................. 1-8
MACHINE SERIAL NO. PLATE AND POSITION....................................................................................... 1-8
ENGINE SERIAL NO. PLATE AND POSITION.......................................................................................... 1-8
EMISSION CONTROL INFORMATION LABEL ......................................................................................... 1-9
BLADE SERIAL NO. PLATE POSITION .................................................................................................... 1-9
RIPPER SERIAL NO. PLATE POSITION................................................................................................... 1-9
POSITION OF SERVICE METER ............................................................................................................ 1-10
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR............................................................................ 1-10
SAFETY
SAFETY................................................................................................................................................................ 2-2
SAFETY LABELS................................................................................................................................................. 2-4
POSITIONS OF SAFETY PICTOGRAMS..................................................................................................2-5
SAFETY LABELS ....................................................................................................................................... 2-6
GENERAL PRECAUTIONS ............................................................................................................................... 2-10
PRECAUTIONS FOR OPERATION................................................................................................................... 2-19
STARTING ENGINE................................................................................................................................. 2-19
OPERATION............................................................................................................................................. 2-21
TRANSPORTATION................................................................................................................................. 2-25
BATTERY ................................................................................................................................................. 2-26
TOWING................................................................................................................................................... 2-28
PRECAUTIONS FOR MAINTENENCE.............................................................................................................. 2-29
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE................................................................................................................. 3-2
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3

CONTENTS FOREWORD
1-12
EXPLANATION OF COMPONENTS....................................................................................................................3-6
FRONT PANEL...........................................................................................................................................3-7
SWITCHES...............................................................................................................................................3-24
CONTROL LEVERS, PEDALS, DIAL.......................................................................................................3-28
DUST INDICATOR ...................................................................................................................................3-35
POWER SOURCE....................................................................................................................................3-35
FUSE BOX................................................................................................................................................3-36
DOOR-OPEN LOCK.................................................................................................................................3-38
SASH GLASS INTERMEDIATE LOCK.....................................................................................................3-38
HOT AND COOL BOX..............................................................................................................................3-39
DOOR POCKET .......................................................................................................................................3-39
ASHTRAY.................................................................................................................................................3-39
TOOL BOX................................................................................................................................................3-40
USING CAR RADIO..................................................................................................................................3-41
AM/FM RADIO..........................................................................................................................................3-46
HANDLING AIR CONDITIONER ..............................................................................................................3-54
HANDLING HEATER................................................................................................................................3-58
HANDLING ACCUMULATOR...................................................................................................................3-59
OPERATION.......................................................................................................................................................3-60
CHECK BEFORE STARTING ENGINE....................................................................................................3-60
STARTING ENGINE.................................................................................................................................3-79
AFTER STARTING ENGINE ....................................................................................................................3-85
WARMING-UP OPERATION....................................................................................................................3-86
STOPPING ENGINE.................................................................................................................................3-90
CHECK AFTER STOPPING ENGINE ......................................................................................................3-91
MACHINE OPERATION...........................................................................................................................3-92
STEERING MACHINE..............................................................................................................................3-98
PRECAUTIONS FOR OPERATION .......................................................................................................3-101
PARKING MACHINE ..............................................................................................................................3-103
CHECK AFTER FINISHING WORK .......................................................................................................3-105
LOCKING................................................................................................................................................3-105
RIPPER OPERATION ............................................................................................................................3-106
WORK POSSIBLE USING BULLDOZER...............................................................................................3-108
ADJUSTING POSTURE OF WORK EQUIPMENT.................................................................................3-110
TIPS FOR LONGER UNDERCARRIAGE LIFE......................................................................................3-117
TRANSPORTATION.........................................................................................................................................3-120
LOADING, UNLOADING WORK ............................................................................................................3-120
PRECAUTIONS FOR LOADING ............................................................................................................3-120
METHOD OF LIFTING MACHINE..........................................................................................................3-121
PRECAUTIONS FOR TRANSPORTATION ...........................................................................................3-122
REMOVAL OF CAB................................................................................................................................3-123
COLD WEATHER OPERATION ......................................................................................................................3-125
COLD WEATHER OPERATION INFORMATION...................................................................................3-125
AFTER DAILY WORK COMPLETION....................................................................................................3-127
AFTER COLD WEATHER SEASON ......................................................................................................3-127

FOREWORD CONTENTS
1-13
LONG TERM STORAGE.................................................................................................................................. 3-128
BEFORE STORAGE............................................................................................................................... 3-128
DURING STORAGE............................................................................................................................... 3-128
AFTER STORAGE.................................................................................................................................. 3-128
TROUBLESHOOTING...................................................................................................................................... 3-129
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-129
METHOD OF TOWING MACHINE......................................................................................................... 3-130
DISCHARGED BATTERY ...................................................................................................................... 3-131
OTHER TROUBLE ................................................................................................................................. 3-135
MAINTENANCE
GUIDE TO MAINTENANCE................................................................................................................................. 4-2
OUTLINE OF SERVICE........................................................................................................................................ 4-5
OUTLINE OF OIL, FUEL, COOLANT......................................................................................................... 4-5
ELECTRIC SYSTEM MAINTENANCE.......................................................................................................4-8
WEAR PARTS...................................................................................................................................................... 4-9
WEAR PARTS LIST.................................................................................................................................... 4-9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE .................... 4-11
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ......................................................... 4-11
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-15
TORQUE LIST.......................................................................................................................................... 4-15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-16
SAFETY CRITICAL PARTS...................................................................................................................... 4-17
MAINTENANCE SCHEDURE CHART............................................................................................................... 4-19
MAINTENANCE SCHEDURE CHART ..................................................................................................... 4-19
SERVICE PROCEDURE .................................................................................................................................... 4-21
INITIAL 250 HOURS MAINTENANCE...................................................................................................... 4-21
WHEN REQUIRED................................................................................................................................... 4-22
CHECK BEFORE STARTING .................................................................................................................. 4-43
EVERY 250 HOURS SERVICE................................................................................................................ 4-44
EVERY 500 HOURS SERVICE................................................................................................................ 4-51
EVERY 1000 HOURS SERVICE.............................................................................................................. 4-57
EVERY 2000 HOURS SERVICE.............................................................................................................. 4-65
EVERY 4000 HOURS SERVICE.............................................................................................................. 4-69
EVERY 8000 HOURS SERVICE.............................................................................................................. 4-72
SPECIFICATIONS
SPECIFICATIONS................................................................................................................................................ 5-2

CONTENTS FOREWORD
1-14
ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS .................................................................................................................................6-2
PRECAUTIONS RELATED TO SAFETY ...................................................................................................6-2
INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS.......................................................................6-4
INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS..............................................................6-4
HANDLING HEADREST ......................................................................................................................................6-5
HANDLING REVERSIBLE FAN...........................................................................................................................6-6
REVERSING REVERSIBLE FAN...............................................................................................................6-6
HANDLING CAP WITH LOCK .............................................................................................................................6-7
OPENING AND CLOSING LOCKABLE CAP .............................................................................................6-7
PROCEDURE FOR SELECTING RIPPER POINT...............................................................................................6-8
PROCEDURE FOR SELECTING RIPPER POINT.....................................................................................6-8
INDEX ...................................................................................................................................................................7-1

2-1
SAFETY
21
WARNING
Please read and make sure that you fully understand the
precautions described in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precaustions strictly.

SAFETY SAFETY
2-2
SAFETY
SAFETY LABELS..................................................................................................................................................2-4
POSITIONS OF SAFETY PICTOGRAMS .......................................................................................................2-5
SAFETY LABELS.............................................................................................................................................2-6
GENERAL PRECAUTIONS................................................................................................................................2-10
SAFETY RULES.......................................................................................................................................2-10
IF ABNORMALITIES ARE FOUND ..........................................................................................................2-10
CLOTHING AND PERSONAL PROTECTIVE ITEMS ..............................................................................2-10
FIRE EXTINGUISHER AND FIRST AID KIT ............................................................................................2-10
SAFETY FEATURES................................................................................................................................2-11
KEEP MACHINE CLEAN..........................................................................................................................2-11
INSIDE OPERATOR'S COMPARTMENT.................................................................................................2-11
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT ............................................................2-11
HANDRAILS AND STEPS........................................................................................................................2-12
MOUNTING AND DISMOUNTING ...........................................................................................................2-13
NO PEOPLE ON ATTACHMENTS...........................................................................................................2-13
PREVENTION OF BURNS.......................................................................................................................2-14
FIRE PREVENTION .................................................................................................................................2-14
ACTION IF FIRE OCCURS ......................................................................................................................2-15
WINDOW WASHER LIQUID ....................................................................................................................2-15
PRECAUTIONS WHEN USING ROPS ....................................................................................................2-15
PRECAUTIONS FOR ATTACHMENTS ...................................................................................................2-16
UNAUTHORIZED MODIFICATION ..........................................................................................................2-16
SAFETY AT WORKSITE.......................................................................................................................... 2-16
WORKING ON LOOSE GROUND............................................................................................................2-17
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...............................................................................2-17
ENSURE GOOD VISIBILITY ....................................................................................................................2-17
VENTILATION FOR ENCLOSED AREAS................................................................................................2-18
CHECKING SIGNALMAN'S SIGNALS AND SIGNS ................................................................................2-18
BE CAREFUL ABOUT ASBESTOS DUST...............................................................................................2-18

SAFETY SAFETY
2-3
PRECAUTIONS FOR OPERATION ................................................................................................................... 2-19
STARTING ENGINE...................................................................................................................................... 2-19
CHECKS BEFORE STARTING ENGINE................................................................................................. 2-19
PRECAUTIONS WHEN STARTING......................................................................................................... 2-20
PRECAUTIONS IN COLD AREAS........................................................................................................... 2-20
OPERATION.................................................................................................................................................. 2-21
CHECKS AFTER OPERATION................................................................................................................ 2-21
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE ............................................. 2-21
PRECAUTIONS WHEN TRAVELING....................................................................................................... 2-22
TRAVELING ON SLOPES........................................................................................................................ 2-23
PROHIBITION OF DANGEROUS WORK................................................................................................ 2-23
USING BRAKES....................................................................................................................................... 2-23
OPERATE CAREFULLY ON SNOW........................................................................................................ 2-23
PARKING MACHINE................................................................................................................................ 2-24
TRANSPORTATION...................................................................................................................................... 2-25
LOADING AND UNLOADING................................................................................................................... 2-25
SHIPPING................................................................................................................................................. 2-25
BATTERY ...................................................................................................................................................... 2-26
BATTERY HAZARD PREVENTION......................................................................................................... 2-26
STARTING WITH BOOSTER CABLE...................................................................................................... 2-27
TOWING ........................................................................................................................................................ 2-28
WHEN TOWING....................................................................................................................................... 2-28
PRECAUTIONS FOR MAINTENENCE .............................................................................................................. 2-29
WARNING TAG........................................................................................................................................ 2-29
KEEP WORK PLACE CLEAN AND TIDY................................................................................................. 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................................................. 2-30
PROPER TOOLS...................................................................................................................................... 2-31
HANDLING ACCUMULATOR................................................................................................................... 2-31
NO UNAUTHORIZED PERSONNEL INTO AREA ................................................................................... 2-31
ATTACHMENTS....................................................................................................................................... 2-32
PRECAUTIONS FOR WORK UNDER MACHINE AND WORK EQUIPMENT......................................... 2-32
NOISE....................................................................................................................................................... 2-32
PRECAUTIONS WHEN USING HAMMER............................................................................................... 2-32
REPAIR WELDING................................................................................................................................... 2-33
REMOVING BATTERY TERMINAL.......................................................................................................... 2-33
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION ............. 2-33
DO NOT DISASSEMBLE RECOIL SPRING ............................................................................................ 2-33
PRECAUTION WITH HIGH-PRESSURE OIL .......................................................................................... 2-34
PRECAUTIONS WITH PRESSURIZED FUEL......................................................................................... 2-34
HANDLING HIGH-PRESSURE HOSES................................................................................................... 2-34
PRECAUTIONS WITH HIGH VOLTAGE.................................................................................................. 2-34
WASTE MATERIAL.................................................................................................................................. 2-35
MAINTENANCE FOR AIR CONDITIONER.............................................................................................. 2-35
COMPRESSED AIR ................................................................................................................................. 2-35
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................. 2-35

SAFETY LABELS SAFETY
2-4
SAFETY LABELS
The following warning signes 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, there may cause the labels to
peel off.
●There are also other labels in addition to the warning signes 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.

SAFETY SAFETY LABELS
2-5
POSITIONS OF SAFETY PICTOGRAMS