TEN00482-04 Operation & Maintenance Manual BULLDOZER D155AX-6 SNM eae EC0t3 warning Unsafe use of this machine may cause serious injury or death. Operators and maintenance personne! 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 NOTICE Komatsu has Operation & Maintenance Manuals written in some other languages. If a foreign language manual is necessary, contact your local distributor for “cn KOMATSUFOREWORD CALIFORNIA Proposition 65 Waring Mercury and mercury compounds are known to the State of Califor hia to cause developmental prob lems. Mercury in this machine is sealed in nen-removable backlight bulbs in the monitor display andlor HID lamps. Thare is na risk of ex posure unless tne lamps are bre- en, However, the monitor and lamps must be reused, recycled or properly disposed of in accordance with Local, State and Federal Laws at the end of their useful lives, CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of ts constituents aro known to the State of California to cause cancer, birth dafects, and other reproductive harm, CALIFORNIA Proposition 65 Warning Battery posts, terminals and related accessories contain laad and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm, Wash hands after handling.BEFORE READING THIS MANUAL FOREWORD BEFORE READING THIS MANUAL This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obayed in orderto use the machine safely. Most accidents are caused by the failure to follow fundamental safoty 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 resut 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 itis your responsibilty 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. youwill need to provide your Komatsu distributor, see “TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR (PAGE 1-9)". 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 forthe latest available information conceming 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)) 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. 1-2FOREWORD ‘SAFETY INFORMATION To enable you to use the machine safaly, 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, Toidentity 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 PNG death or serious injury. Pa This signal word indicates a potentially hazardous situation exists which, if not avoided, may result in minor or moderate injury. re elt) ‘The following signal words are used to alert you to information that must be followed to avoid damage to the machine. NOTICE This precaution is given where the machine may be damaged or the service life reduced if the precaution is not followed. REMARKS _ ™Swo'disused for information that is use to know. 1-3INTRODUCTION FOREWORD 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 3-160)" and "RIPPER OPERATION (PAGE 3-151)" FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE (1) Operator's seat (A) Front (C) Lett (2) Sprocket (8) Rear (0) 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. 1-4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 visibilty of this machine in the area 1 m (3 1t3in) from the outside surface of the machine at a height of 1.5m (4 ft 11 in) 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. saunrosse 1-5NECESSARY INFORMATION FOREWORD 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. wove St seo Se an | lo eects °FOREWORD NECESSARY INFORMATION EPA REGULATIONS, ENGINE NUMBER PLATE = On the upper of the engine starting motor on the right side of the machine. + This also acts as the EPA plate. ae ‘= This is on the top surface of the muffier mounting bracket on the left side of the machine. + This also acts as the EPA plate. EPA: Environmental Protection Agency, U.S.A.NECESSARY INFORMATION FOREWORD 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 surtace 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 \ savesFOREWORD NECESSARY INFORMATION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR [Machine serial No. Engine serial No. [Product identification number (PIN) Distributor name Address IService Personnel Phone/Fax 1-9CONTENTS FOREWORD CONTENTS FOREWORD ---- BEFORE READING THIS MANUAL ‘SAFETY INFORMATION -. INTRODUCTION USE OF MACHINE. FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE ------------~ z VISIBILITY FROM OPERATOR'S SEAT. NECESSARY INFORMATION PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE EPA REGULATIONS, ENGINE NUMBER PLATE BLADE SERIAL NO. PLATE POSITION RIPPER SERIAL NO. PLATE POSITION ROPS, FOPS NO. PLATE POSITION - POSITION OF SERVICE METER - TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR - SAFETY ---- SAFETY - ‘SAFETY LABELS 2 POSITIONS OF SAFETY PICTOGRAMS SAFETY LABELS ------ GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE PRECAUTIONS BEFORE STARTING OPERATION -. - PREPARATIONS FOR SAFE OPERATION ~ - FIRE PREVENTION PRECAUTIONS WHEN GETTING ON OR OFF MACHINE - DO NOT GET CAUGHT IN WORK EQUIPMENT --- PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES, UNAUTHORIZED MODIFICATION PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING - PRECAUTIONS FOR OPERATION a 7 - - PRECAUTIONS FOR JOBSITE STARTING ENGINE --~ OPERATION TRANSPORTATION TOWING - PRECAUTIONS FOR MAINTENANCE. PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE PRECAUTIONS FOR INSPECTION AND MAINTENANCE -----------------------00---eonensnonenonee OPERATION - coe GENERAL VIEW GENERAL VIEW OF MACHINE - GENERAL VIEW OF CONTROLS AND GAUGES ----- - - EXPLANATION OF COMPONENTS. - MACHINE MONITOR - SWITCHES, CONTROL LEVERS, PEDALS DUST INDICATOR - FUSE BOX---- PUN AOCOBMONTOARREONH ~ BRBSauennaeFOREWORD CONTENTS CAP WITH LOCK ~~ DOOR POCKET ASHTRAY CAR RADIO, HANDLING CAR STEREO, HANDLING HANDLING AIR CONDITIONER OPERATION CHECK BEFORE STARTING ENGINE, ADJUST: STARTING ENGINE -- OPERATIONS AND CHECKS AFTER STARTING ENGINE STOPPING ENGINE MOVING MACHINE. STOPPING MACHINE SHIFTING GEAR --~ SHIFTING BETWEEN FORWARD AND REVERSE -~ STEERING MACHINE -------- PRECAUTIONS FOR OPERATION - PARKING MACHINE -- CHECK AFTER STOPPING ENGINE CHECK AFTER FINISHING WORK LOCKING - RIPPER OPERATION OPERATING METHOD FOR RIPPING OPERATIONS -. WORK POSSIBLE USING BULLDOZER =--------------~ ADJUSTING POSTURE OF WORK EQUIPMENT TIPS FOR LONGER UNDERCARRIAGE LIFE TRANSPORTATION ---------------~ LOADING, UNLOADING WORK ------» - - METHOD OF LIFTING MACHINE - PRECAUTIONS FOR TRANSPORTATION ‘TRAVELING ON ROADS -- REMOVAL OF CAB COLD WEATHER OPERATION PRECAUTIONS FOR LOW TEMPERATURE AFTER COMPLETION OF WORK ------- AFTER COLD WEATHER -~ LONG-TERM STORAGE BEFORE STORAGE DURING STORAGE AFTER STORAGE ——----—----—---- STARTING MACHINE AFTER LONG-TERM STORAGE ‘TROUBLESHOOTING --- AFTER RUNNING OUT OF FUEL : METHOD OF TOWING MACHINE 3-189 IF BATTERY IS DISCHARGED 3-190 OTHER TROUBLE - 3-193 MAINTENANCE - a4 GUIDES TO MAINTENANCE - a2 OUTLINES OF SERVICE ------—- - - a5 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ----- a5 otCONTENTS FOREWORD OUTLINE OF ELECTRIC SYSTEM WEAR PARTS WEAR PARTS LIST RECOMMENDED FUEL, COOLANT, AND LUBRICANT - RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER ‘THAN KOMATSU GENUINE OIL --- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS -~ TORQUE LIST. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS. SAFETY CRITICAL PARTS — MAINTENANCE SCHEDULE CHART - MAINTENANCE SCHEDULE CHART SERVICE PROCEDURE -. INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) - - WHEN REQUIRED - CHECK BEFORE STARTING ---- - EVERY 250 HOURS SERVICE - EVERY 500 HOURS SERVICE - EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE EVERY 4000 HOURS SERVICE EVERY 8000 HOURS SERVICE - SPECIFICATIONS ~ - SPECIFICATIONS. ATTACHMENTS, OPTIONS ---------2-+------00s--soseeesneessnsessnneesnnnnsnneennnessnnensoneestanensnnee GENERAL PRECAUTIONS ----— PRECAUTIONS RELATED TO SAFETY INTRODUCTION OF ATTACHMENTS AND OPTIONS ----- INTRODUCTION OF ATTACHMENTS AND OPTIONS - HEADREST, HANDLING - PROCEDURE FOR SELECTING RIPPER POINT PROCEDURE FOR SELECTING RIPPER POINT z ‘STARTING IN COLD AREAS EXTERNAL POWER SOURCE TYPE PREHEATER HANDLING MACHINES EQUIPPED WITH KOMTRAX BASIC PRECAUTIONS INDEX - pet teoe HDGeonasoonn+nsSAFETY CSO 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 precautions strictly.SAFETY SAFETY SAFETY SAFETY LABEL --—----- a 2 5 POSITIONS OF SAFETY PICTOGRAMS 2 6 SAFETY LABELS ------ - 27 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE. 212 PRECAUTIONS BEFORE STARTING OPERATION 212 ENSURING SAFE OPERATION ~ - 212 UNDERSTANDING THE MACHINE -- - 212 PREPARATIONS FOR SAFE OPERATION - 212 PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT - 212 INSPECTING MACHINE --------~ 212 WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT - 212 KEEP MACHINE CLEAN -. - 213, PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT - - 213 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 213 IF ANY PROBLEM IS FOUND --~ - 218, FIRE PREVENTION —---—------ - 214 ACTION IF FIRE OCCURS -----—- - 214 PRECAUTIONS TO PREVENT FIRE -~ Bh PRECAUTIONS WHEN GETTING ON OR OFF MACHINE - - 215 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE - 215 NO JUMPING ON OR OFF MACHINE 216 NO PEOPLE ON ATTACHMENTS ----------+------020-00s0sscssessseessnnesoseesnnnesnnensssnennnnnns 2 16 PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT 216 PRECAUTIONS WHEN LEAVING MACHINE -~ 2 16 EMERGENCY EXIT FROM OPERATOR'S CAB 2 16 DO NOT GET CAUGHT IN WORK EQUIPMENT -- - BAT PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES. 217 UNAUTHORIZED MODIFICATION -~ - 217 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ---- 217 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 218 2-2‘SAFETY SAFETY PRECAUTIONS FOR OPERATION - PRECAUTIONS FOR JOBSITE ----- INVESTIGATE AND CONFIRM JOBSITE CONDITIONS —-- WORKING ON LOOSE GROUND -~ DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES . ENSURE GOOD VISIBILITY - CHECKING SIGNS AND SIGNALMAN'S SIGNALS BEWARE OF ASBESTOS DUST - STARTING ENGINE --~ USE WARNING TAGS INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE - PRECAUTIONS WHEN STARTING ENGINE PRECAUTIONS IN COLD AREAS -- STARTING WITH BOOSTER CABLES: OPERATION CHECKS BEFORE OPERATION -. PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE - PRECAUTIONS WHEN TRAVELING ‘TRAVELING ON SLOPES —--—---- PRECAUTIONS WHEN OPERATING PROHIBITED OPERATIONS METHOD OF USING BRAKES -. ‘TRAVELING ON SNOW-COVERED OR FROZEN SURFACES ~ PARKING MACHINE ------~ - eonecnnee on TRANSPORTATION --------~ LOADING AND UNLOADING TOWING PRECAUTIONS WHEN TOWING - - - BRBB 24 24 24 25 25 B8R8 2-3SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE, PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE. DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE KEEP WORKPLACE CLEAN AND TIDY ‘SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE - - ONLY AUTHORIZED PERSONNE --- APPOINT LEADER WHEN WORKING WITH OTHERS STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE -. TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING. INSTALLING, REMOVING, OR STORING ATTACHMENTS - PRECAUTIONS WHEN WORKING AT HIGH PLACES, PRECAUTIONS WHEN WORKING ON TOP OF MACHINE ~ PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT PROPER TOOLS -. PRECAUTIONS FOR INSPECTION AND MAINTENANCE - - PRECAUTIONS WHEN WELDING - coneeenee - HANDLING BATTERY PRECAUTIONS WHEN USING HAMMER PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT 2 PRECAUTIONS WITH HIGH-TEMPERATURE OIL --- PRECAUTIONS WITH HIGH-PRESSURE OIL - PRECAUTIONS WITH HIGH-PRESSURE FUEL - HANDLING HIGH-PRESSURE HOSES AND PIPING - NOISE PRECAUTIONS WITH HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION Co DO NOT DISASSEMBLE RECOIL SPRING - HANDLING ACCUMULATOR AND GAS SPRING PRECAUTIONS WITH COMPRESSED AIR MAINTENANCE OF AIR CONDITIONER DISPOSING OF WASTE MATERIALS. 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