Komatsu D155AX-5 Manual

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FOREWORD
FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions 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 a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
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 thoroughly 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 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
Machine equipped with cab
Inside of right and left doors
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FOREWORD FOREWORD FOREWORD FOREWORD
Machine equipped without cab
Back pocket of operator's seat
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FOREWORD
FOREWORD
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FOREWORD FOREWORD
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FOREWORD
SAFETY INFORMATION
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
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal 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
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.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the safety 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
protect the machine or to give information that is 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 word is used for information that is useful to know.
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FOREWORD SAFETY INFORMATION
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 hazardous
condition equivalent to the signal word. These safety pictograms
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 condition at the top
or left side, and the method of avoiding the hazardous 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 precautions.
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-> (1))
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FOREWORD
INTRODUCTION
INTRODUCTION
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 3-118)" and "RIPPER OPERATION
(PAGE 3-111)".
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 seat when
the operator's seat is facing the front and the sprocket is at the rear of the machine.
BREAKING IN THE MACHINE
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the
machine under full load before breaking the machine in can adversely affect the performance 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.
Run the engine at idling for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
Idle the engine for 5 minutes after starting it up.
Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and
sudden changes in direction.
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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 (1)
On the upper of the engine starting motor on the right side of the machine.
This also acts as the EPA plate.
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FOREWORD
NECESSARY INFORMATION
ENGINE SERIAL NO. PLATE AND POSITION (2)
This is the same content as engine serial No. plate (1).
Located on the top of the air cleaner mounting bracket on the left of the machine.
This also acts as the EPA plate.
EPA: Environmental Protection Agency, U.S.A.
BLADE SERIAL NO. PLATE POSITION
This is located at the upper right of blade back surface.
RIPPER SERIAL NO. PLATE POSITION
This is located at the left side surface of ripper beam.
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FOREWORD NECESSARY INFORMATION
ROPS, FOPS NO. PLATE POSITION
This is located at the top left.
POSITION OF SERVICE METER
On top of the machine monitor
TABLE TO ENTER SERIAL NO. AND DISTRIBUTORN
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
FOREWORD 1- 2
SAFETY INFORMATION 1- 6
INTRODUCTION 1- 8
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 8
BREAKING IN THE MACHINE 1- 8
NECESSARY INFORMATION 1- 9
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE 1- 9
ENGINE SERIAL NO. PLATE AND POSITION (1) 1- 9
ENGINE SERIAL NO. PLATE AND POSITION (2) 1- 10
BLADE SERIAL NO. PLATE POSITION 1- 10
RIPPER SERIAL NO. PLATE POSITION 1- 10
ROPS, FOPS NO. PLATE POSITION 1- 11
POSITION OF SERVICE METER 1- 11
TABLE TO ENTER SERIAL NO. AND DISTRIBUTORN 1- 11
SAFETY 2- 1
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- 19
BEFORE STARTING ENGINE 2- 19
OPERATION 2- 21
TRANSPORTATION 2- 25
BATTERY 2- 26
TOWING 2- 28
PRECAUTIONS FOR MAINTENANCE 2- 29
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
FRONT PANEL 3- 5
SWITCHES 3- 31
CONTROL LEVERS, PEDALS 3- 36
DUST INDICATOR 3- 42
POWER SOURSE 3- 42
FUSE BOX 3- 43
DOOR POCKET 3- 47
ASHTRAY 3- 47
CAR RADIO, HANDLING 3- 48
CAR STEREO, HANDLING 3- 53
AIR CONDITIONER 3- 59
HEATER, HANDLING 3- 65
ACCUMULATOR, HANDLING 3- 66
OPERATION 3- 67
CHECK BEFORE STARTING ENGINE, ADJUST 3- 67
STARTING ENGINE 3- 86
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FOREWORD CONTENTS
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3- 91
STOPPING ENGINE 3- 94
MOVING MACHINE OFF 3- 95
STOPPING MACHINE 3- 97
SHIFTING GEAR 3- 98
SHIFTING BETWEEN FOEWARD AND REVERSE 3-102
STEERING MACHINE 3-104
PRECAUTIONS FOR OPERATION 3-106
PARKING MACHINE 3-108
CHECK AFTER STOPPING ENGINE 3-109
CHECK AFTER FINISHING WORK 3-110
LOCKING 3-110
RIPPER OPERATION 3-111
OPERATING METHOD FOR RIPPING OPERATIONS 3-113
WORK POSSIBLE USING BULLDOZER 3-118
ADJUSTING POSTURE OF WORK EQUIPMENT 3-120
TIPS FOR LONGER UNDERCARRIAGE LIFE 3-126
TRANSPORTATION 3-130
LOADING, UNLOADING WORK 3-130
PRECAUTIONS FOR LOADING 3-130
METHOD OF LIFTING MACHINE 3-131
PRECAUTIONS FOR TRANSPORTATION 3-132
TRAVELING ON ROADS 3-132
REMOVAL OF CAB 3-133
COLD WEATHER OPERATION 3-135
PRECAUTIONS FOR LOW TEMPERATURE 3-135
AFTER COMPLETION OF WORK 3-137
AFTER COLD WEATHER 3-137
LONG-TERM STORAGE 3-138
BEFORE STORAGE 3-138
DURING STORAGE 3-138
AFTER STORAGE 3-138
TROUBLESHOOTING 3-139
AFTER RUNNING OUT OF FUEL 3-139
METHOD OF TOWING MACHINE 3-141
IF BATTERY IS DISCHARGED 3-142
OTHER TROUBLE 3-146
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 5
OUTLINE OF ELECTRIC SYSTEM 4- 8
HANDLING HYDRAULIC RELATED EQUIPMENT 4- 8
WEAR PARTS LIST 4- 9
WEAR PARTS LIST 4- 9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 14
SAFETY CRITICAL PARTS 4- 14
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 16
TORQUE LIST 4- 16
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FOREWORD
CONTENTS
MAINTENANCE SCHEDULE CHART 4- 17
MAINTENANCE SCHEDULE CHART 4- 17
SERVICE PROCEDURE 4- 19
INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS) 4- 19
WHEN REQUIRED 4- 20
CHECK BEFORE STARTING 4- 42
EVERY 250 HOURS SERVICE 4- 43
EVERY 500 HOURS SERVICE 4- 52
EVERY 1000 HOURS SERVICE 4- 59
EVERY 2000 HOURS SERVICE 4- 67
EVERY 4000 HOURS SERVICE 4- 71
EVERY 8000 HOURS SERVICE 4- 74
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAURIONS 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
CAP WITH LOCK, HANDLING 6- 5
METHOD OF OPENING AND CLOSING CAP WITH LOCK 6- 5
PROCEDURE FOR SELECTING RIPPER POINT 6- 6
PROCEDURE FOR SELECTING RIPPER POINT 6- 6
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
Safety Labels 2- 4
Positions of Safety Pictograms 2- 4
Safety Labels 2- 5
General Precautions
Safety Rules 2- 11
If Abnormalities Are Found 2- 11
Clothing and Personal Protective Items 2- 11
Fire Extinguisher and First Aid Kit 2- 11
Safety Features 2- 11
Keep Machine Clean 2- 12
Inside Operator's Compartment 2- 12
Always Apply Lock When Leaving Operator's Seat 2- 12
Handrails and Steps 2- 13
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- 16
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
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SAFETY SAFETY
Precautions for Operation 2- 19
Before Starting Engine 2- 19
Checks Before Starting Engine 2- 19
Precautions When Starting 2- 19
Precautions in Cold Areas 2- 20
Operation 2- 21
Checks Before Operation 2- 21
Precautions When Moving Machine Forward or in Reverse 2- 21
Precautions When Traveling 2- 22
Traveling on Slopes 2- 23
Prohibited Operations 2- 23
Using Brakes 2- 23
Operate Carefully on Snow 2- 23
Parking Machine 2- 24
Transportation 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 Maintenance 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- 31
Proper Tools 2- 31
Handling Accumulator 2- 32
Personnel 2- 32
Attachments 2- 32
Work Under the Machine 2- 32
Noise 2- 33
Precautions When Using Hammer 2- 33
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- 34
Precaution with High-Pressure Oil 2- 34
Precaution for High Fuel Pressure 2- 34
Handling High-Pressure Hoses 2- 34
Precaution for High Voltage 2- 35
Waste Material 2- 35
Maintenance for Air Conditioner 2- 35
Compressed Air 2- 35
Periodic Replacement of Safety Critical Parts 2- 35
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SAFETY
SAFETY LABELS
SAFETY LABELS
POSITIONS OF SAFETY PICTOGRAMS
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SAFETY SAFETY LABELS
SAFETY LABELS
(1) Precautions for operation, inspection and maintenance
(09651-03001)
(2) Precautions when traveling in reverse
(09802-13000)
(3) Precautions for leaving the operator's seat
(09654-33001)
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