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KOMATSU D155A-5 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:65139 &UP) KOMATSU D155A-5 – PDF DOWNLOAD
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- KOMATSU D155A-5 BULLDOZER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:65139 &UP
- PUBLICATION NUMBER:TEN00170-00
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Description
KOMATSU D155A-5 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:65139 &UP) KOMATSU D155A-5
KOMATSU D155A-5 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:65139 &UP) KOMATSU D155A-5 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D155A-5 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:65139 &UP) KOMATSU D155A-5
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.
TABLE OF CONTENTS:
KOMATSU D155A-5 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:65139 &UP) KOMATSU D155A-5
COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 FOREWORD................................................................................... 3 SAFETY INFORMATION......................................................................... 6 INTRODUCTION............................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE........................................... 8 VISIBILITY FROM OPERATOR'S SEAT........................................................ 9 BREAKING IN THE MACHINE................................................................ 10 NECESSARY INFORMATION...................................................................... 11 PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE.......................... 11 ENGINE SERIAL NO. PLATE AND POSITION................................................... 11 BLADE SERIAL NO. PLATE POSITION........................................................ 12 RIPPER SERIAL NO. PLATE POSITION....................................................... 12 POSITION OF SERVICE METER.............................................................. 12 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 13 CONTENTS....................................................................................... 14 SAFETY......................................................................................... 17 SAFETY..................................................................................... 18 SAFETY LABELS.............................................................................. 20 POSITIONS OF SAFETY PICTOGRAMS......................................................... 21 SAFETY LABELS.......................................................................... 22 GENERAL PRECAUTIONS........................................................................ 26 SAFETY RULES........................................................................... 26 IF ABNORMALITIES ARE FOUND............................................................. 26 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................. 26 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 26 SAFETY FEATURES........................................................................ 26 KEEP MACHINE CLEAN..................................................................... 27 INSIDE OPERATOR'S COMPARTMENT.......................................................... 27 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT......................................... 27 HANDRAILS AND STEPS.................................................................... 27 PRECAUTIONS WHEN WORKING IN HIGH PLACES................................................ 28 MOUNTING AND DISMOUNTING............................................................... 28 NO PEOPLE ON ATTACHMENTS............................................................... 28 CRUSHING OR CUTTING PREVENTION......................................................... 29 PREVENTION OF BURNS.................................................................... 29 FIRE PREVENTION........................................................................ 30 ACTION IF FIRE OCCURS.................................................................. 31 WINDOW WASHER LIQUID................................................................... 31 PRECAUTIONS WHEN USING ROPS............................................................ 31 PRECAUTIONS FOR ATTACHMENTS............................................................ 32 CAB WINDOW GLASSES..................................................................... 32 UNAUTHORIZED MODIFICATION.............................................................. 32 SAFETY AT WORKSITE..................................................................... 32 WORKING ON LOOSE GROUND................................................................ 32 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................. 33 ENSURE GOOD VISIBILITY................................................................. 33 VENTILATION FOR ENCLOSED AREAS......................................................... 34 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................. 35 BE CAREFUL ABOUT ASBESTOS DUST......................................................... 35 PRECAUTIONS FOR OPERATION.................................................................. 36 BEFORE STARTING ENGINE................................................................. 36 CHECKS BEFORE STARTING ENGINE...................................................... 36 PRECAUTIONS WHEN STARTING.......................................................... 36 PRECAUTIONS IN COLD AREAS.......................................................... 37 OPERATION.............................................................................. 38 CHECKS BEFORE OPERATION............................................................ 38 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE............................... 38 PRECAUTIONS WHEN TRAVELING......................................................... 39 TRAVELING ON SLOPES................................................................ 40 PROHIBITED OPERATIONS.............................................................. 40 USING BRAKES....................................................................... 40 OPERATE CAREFULLY ON SNOW.......................................................... 40 PARKING MACHINE.................................................................... 41 TRANSPORTATION......................................................................... 42 LOADING AND UNLOADING.............................................................. 42 SHIPPING........................................................................... 42 BATTERY................................................................................ 43 BATTERY HAZARD PREVENTION.......................................................... 43 STARTING WITH BOOSTER CABLE........................................................ 44 TOWING................................................................................. 45 WHEN TOWING........................................................................ 45 PRECAUTIONS FOR MAINTENANCE................................................................ 46 WARNING TAG............................................................................ 46 KEEP WORK PLACE CLEAN AND TIDY......................................................... 46 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 46 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............................. 46 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 48 PROPER TOOLS........................................................................... 48 HANDLING ACCUMULATOR................................................................... 49 PERSONNEL.............................................................................. 49 ATTACHMENTS............................................................................ 49 WORK UNDER THE MACHINE................................................................. 49 NOISE.................................................................................. 50 PRECAUTIONS WHEN USING HAMMER.......................................................... 50 REPAIR WELDING......................................................................... 50 REMOVING BATTERY TERMINAL.............................................................. 50 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION.................... 50 DO NOT DISASSEMBLE RECOIL SPRING....................................................... 51 PRECAUTION WITH HIGH-PRESSURE OIL...................................................... 51 PRECAUTION FOR HIGH FUEL PRESSURE...................................................... 51 HANDLING HIGH-PRESSURE HOSES........................................................... 51 PRECAUTION FOR HIGH VOLTAGE............................................................ 52 WASTE MATERIAL......................................................................... 53 MAINTENANCE FOR AIR CONDITIONER........................................................ 53 COMPRESSED AIR......................................................................... 53 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.......................................... 53 OPERATION...................................................................................... 54 GENERAL VIEW............................................................................... 55 GENERAL VIEW OF MACHINE................................................................ 55 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 56 EXPLANATION OF COMPONENTS.................................................................. 57 FRONT PANEL............................................................................ 57 SWITCHES............................................................................... 68 CONTROL LEVERS, PEDALS................................................................. 71 DUST INDICATOR......................................................................... 79 FUSE BOX............................................................................... 79 GREASE PUMP HOLDER..................................................................... 80 DOOR OPEN LOCK......................................................................... 81 SASH GLASS INTERMEDIATE LOCK........................................................... 81 HOT AND COOL BOX....................................................................... 82 DOOR POCKET............................................................................ 82 ASHTRAY................................................................................ 82 TOOL BOX............................................................................... 82 CAR RADIO, HANDLING.................................................................... 83 AIR CONDITIONER, HANDLING.............................................................. 88 HEATER, HANDLING....................................................................... 92 ACCUMULATOR, HANDLING.................................................................. 93 FIRE EXTINGUISHER, LOCATION............................................................ 94 OPERATION.................................................................................. 95 CHECK BEFORE STARTING ENGINE, ADJUST................................................... 95 STARTING ENGINE........................................................................113 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................117 STOPPING ENGINE........................................................................119 CHECK AFTER STOPPING ENGINE............................................................119 MACHINE OPERATION......................................................................120 STEERING MACHINE.......................................................................125 PRECAUTIONS FOR OPERATION..............................................................128 PARKING MACHINE........................................................................129 CHECK AFTER FINISHING WORK.............................................................131 LOCKING................................................................................131 WORK POSSIBLE USING BULLDOZER..........................................................132 RIPPER OPERATION.......................................................................134 OPERATING METHOD FOR RIPPING OPERATIONS................................................137 ADJUSTING POSTURE OF WORK EQUIPMENT....................................................143 TIPS FOR LONGER UNDERCARRIAGE LIFE.....................................................150 TRANSPORTATION.............................................................................153 TRANSPORTATION PROCEDURE...............................................................153 LOADING, UNLOADING WORK................................................................153 METHOD OF LIFTING MACHINE..............................................................157 TRAVELING ON ROADS.....................................................................158 REMOVAL OF CAB.........................................................................159 COLD WEATHER OPERATION.....................................................................160 PRECAUTIONS FOR LOW TEMPERATURE........................................................160 AFTER COMPLETION OF WORK...............................................................161 AFTER COLD WEATHER.....................................................................162 LONG-TERM STORAGE..........................................................................163 BEFORE STORAGE.........................................................................163 DURING STORAGE.........................................................................163 AFTER STORAGE..........................................................................163 TROUBLESHOOTING............................................................................164 AFTER RUNNING OUT OF FUEL..............................................................164 METHOD OF TOWING MACHINE...............................................................164 IF BATTERY IS DISCHARGED...............................................................165 OTHER TROUBLE..........................................................................169 MAINTENANCE....................................................................................174 GUIDES TO MAINTENANCE......................................................................175 OUTLINES OF SERVICE........................................................................178 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................178 OUTLINE OF ELECTRIC SYSTEM.............................................................181 WEAR PARTS LIST............................................................................182 WEAR PARTS LIST........................................................................182 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................183 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....185 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................186 TORQUE LIST............................................................................186 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................187 SAFETY CRITICAL PARTS..................................................................188 MAINTENANCE SCHEDULE CHART.................................................................190 MAINTENANCE SCHEDULE CHART.............................................................190 SERVICE PROCEDURE..........................................................................192 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).............................192 WHEN REQUIRED..........................................................................193 CLEAN INSIDE OF COOLING SYSTEM.....................................................193 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.......................................196 CHECK AND ADJUST TRACK TENSION.....................................................201 CHECK AND TIGHTEN TRACK SHOE BOLTS.................................................202 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES.................................204 REPLACE FAN BELT...................................................................206 CLEAN AND CHECK RADIATOR FINS......................................................207 CLEAN AND CHECK HYDRAULIC COOLER FINS..............................................207 ADJUST IDLER CLEARANCE.............................................................209 CHECK UNDERCARRIAGE OIL............................................................210 CLEAN HEATER AIR FILTER (FRESH/RECIRC FILTER)......................................212 LUBRICATE DOOR HINGE...............................................................212 CHECK DOOR LOCK STRIKER............................................................213 REPLACE DOOR DAMPER................................................................213 BLEED AIR FROM HEAD END OF RIGHT PITCH CYLINDER....................................213 REPLACE WIPER BLADE................................................................214 BLEEDING AIR IN HYDRAULIC SYSTEM...................................................215 CHECK ELECTRICAL INTAKE AIR HEATER.................................................215 LUBRICATING........................................................................215 CHECK BEFORE STARTING..................................................................217 EVERY 250 HOURS SERVICE................................................................218 LUBRICATING........................................................................218 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST........................................222 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................224 CHECK BRAKE PERFORMANCE............................................................226 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL............................................227 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................228 EVERY 500 HOURS SERVICE................................................................230 REPLACE FUEL FILTER CARTRIDGE......................................................230 REPLACE POWER TRAIN OIL FILTER ELEMENT.............................................231 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................232 REPLACE HYDRAULIC TANK BREATHER ELEMENT............................................233 EVERY 1000 HOURS SERVICE...............................................................234 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS.....................................234 CHECK, CLEAN FUEL STRAINER.........................................................236 CHECK FOR LOOSE ROPS MOUNT BOLTS...................................................236 REPLACE CORROSION RESISTOR CARTRIDGE...............................................237 CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................237 EVERY 2000 HOURS SERVICE...............................................................238 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT.................238 CHANGE OIL IN FINAL DRIVE CASE.....................................................240 CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER...................................241 CHECK PIVOT BEARING OIL LEVEL, ADD OIL.............................................242 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL....................243 CLEAN ENGINE BREATHER ELEMENT......................................................243 CHECK ALTERNATOR, STARTING MOTOR...................................................243 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................243 EVERY 4000 HOURS SERVICE...............................................................244 CHECK WATER PUMP...................................................................244 CHECK VIBRATION DAMPER.............................................................244 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.................244 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER................245 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)...................................246 EVERY 8000 HOURS SERVICE...............................................................247 REPLACE HIGH-PRESSURE PIPING CLAMPS................................................247 REPLACE FUEL SPLAY PREVENTION CAPS.................................................247 SPECIFICATIONS.................................................................................248 SPECIFICATIONS.............................................................................249 ATTACHMENTS, OPTIONS...........................................................................250 GENERAL PRECAUTIONS........................................................................251 PRECAUTIONS RELATED TO SAFETY..........................................................251 SELECTION OF TRACK SHOE....................................................................252 SELECTION OF TRACK SHOES...............................................................252 PROCEDURE FOR SELECTING RIPPER POINT.......................................................253 PROCEDURE FOR SELECTING RIPPER POINT...................................................253 CAP WITH LOCK, HANDLING....................................................................254 METHOD OF OPENING AND CLOSING CAP WITH LOCK............................................254 INDEX..........................................................................................255
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