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Komatsu D155AX-5 Bulldozer Printed Operation & Maintenance Manual – PDF Download
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Description
Komatsu D155AX-5 Bulldozer Printed Operation & Maintenance Manual
Description:
Komatsu D155AX-5 Bulldozer Printed Operation & Maintenance Manual
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 hazard when performing operation and maintenance.
Table Of Contents:
Komatsu D155AX-5 Bulldozer Printed Operation & Maintenance Manual
FOREWORD.............................................................................................. 3 FOREWORD.......................................................................................... 4 SAFETY INFORMATION................................................................................ 6 NOISE......................................................................................... 8 VIBRATION..................................................................................... 9 INTRODUCTION...................................................................................... 10 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.................................................. 10 NECESSARY INFORMATION............................................................................. 11 MACHINE SERIAL NO. PLATE AND POSITION......................................................... 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 OF ENTER SERIAL NO. AND DISTRIBUTOR..................................................... 13 FOREWORD 1-2.............................................................................. 15 SAFETY INFORMATION 1-4.................................................................... 15 NOISE 1-6............................................................................. 15 VIBRATION 1-7......................................................................... 15 INTRODUCTION 1-8.......................................................................... 15 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1-8...................................... 15 NECESSARY INFORMATION 1-9................................................................. 15 MACHINE SERIAL NO. PLATE AND POSITION 1-9............................................. 15 ENGINE SERIAL NO. PLATE AND POSITION 1-9.............................................. 15 BLADE SERIAL NO. PLATE POSITION 1-10.................................................. 15 RIPPER SERIAL NO. PLATE POSITION 1-10................................................. 15 POSITION OF SERVICE METER 1-10........................................................ 15 TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR 1-11........................................ 15 SAFETY 2-2................................................................................ 15 SAFETY LABELS 2-4......................................................................... 15 POSITIONS OF SAFETY PICTOGRAMS 2-5.................................................... 15 SAFETY LABELS 2-6..................................................................... 15 GENERAL PRECAUTIONS 2-11.................................................................. 15 PRECAUTIONS FOR OPERATION 2-20............................................................ 15 STARTING ENGINE 2-20.................................................................. 15 OPERATION 2-22........................................................................ 15 TRANSPORTATION 2-26................................................................... 15 BATTERY 2-27.......................................................................... 15 TOWING 2-29........................................................................... 15 PRECAUTIONS FOR MAINTENENCE 2-30.......................................................... 15 GENERAL VIEW 3-2.......................................................................... 15 GENERAL VIEW OF MACHINE 3-2........................................................... 15 GENERAL VIEW OF CONTROLS AND GAUGES 3-3............................................... 15 EXPLANATION OF COMPONENTS 3-6............................................................. 15 FRONT PANEL 3-7....................................................................... 15 SWITCHES 3-24......................................................................... 15 CONTROL LEVERS, PEDALS, DIAL 3-28..................................................... 15 DUST INDICATOR 3-35................................................................... 15 POWER SOURCE 3-35..................................................................... 15 FUSE BOX 3-36......................................................................... 15 TOOL BOX 3-40......................................................................... 15 AM/FM RADIO 3-46...................................................................... 15 HANDLING ACCUMULATOR 3-59............................................................. 15 OPERATION 3-60............................................................................ 15 CHECK BEFORE STARTING ENGINE 3-60..................................................... 15 STARTING ENGINE 3-79.................................................................. 16 AFTER STARTING ENGINE 3-84............................................................ 16 WARMING-UP OPERATION 3-85............................................................. 16 STOPPING ENGINE 3-89.................................................................. 16 CHECK AFTER STOPPING ENGINE 3-90...................................................... 16 MACHINE OPERATION 3-91................................................................ 16 STEERING MACHINE 3-97................................................................. 16 PRECAUTIONS FOR OPERATION 3-100....................................................... 16 PARKING MACHINE 3-102................................................................. 16 CHECK AFTER FINISHING WORK 3-104...................................................... 16 LOCKING 3-104......................................................................... 16 RIPPER OPERATION 3-105................................................................ 16 WORK POSSIBLE USING BULLDOZER 3-107................................................... 16 ADJUSTING POSTURE OF WORK EQUIPMENT 3-109............................................. 16 TIPS FOR LONGER UNDERCARRIAGE LIFE 3-116.............................................. 16 TRANSPORTATION 3-119...................................................................... 16 LOADING, UNLOADING WORK 3-119......................................................... 16 PRECAUTIONS FOR LOADING 3-119......................................................... 16 METHOD OF LIFTING MACHINE 3-120....................................................... 16 PRECAUTIONS FOR TRANSPORTATION 3-121.................................................. 16 COLD WEATHER OPERATION 3-124.............................................................. 16 COLD WEATHER OPERATION INFORMATION 3-124.............................................. 16 AFTER DAILY WORK COMPLETION 3-126..................................................... 16 AFTER COLD WEATHER SEASON 3-126....................................................... 16 LONG TERM STORAGE 3-127................................................................... 16 BEFORE STORAGE 3-127.................................................................. 16 DURING STORAGE 3-127.................................................................. 16 AFTER STORAGE 3-127................................................................... 16 TROUBLESHOOTING 3-128..................................................................... 16 AFTER RUNNING OUT OF FUEL 3-128....................................................... 16 METHOD OF TOWING MACHINE 3-129........................................................ 16 DISCHARGED BATTERY 3-130.............................................................. 16 OTHER TROUBLE 3-134................................................................... 16 GUIDE TO MAINTENANCE 4-2.................................................................. 16 OUTLINE OF SERVICE 4-5.................................................................... 16 OUTLINE OF OIL, FUEL, COOLANT 4-5..................................................... 16 ELECTRIC SYSTEM MAINTENANCE 4-8....................................................... 16 WEAR PARTS 4-9............................................................................ 16 WEAR PARTS LIST 4-9................................................................... 16 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4-11................. 16 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4-15....................................... 16 TORQUE LIST 4-15...................................................................... 17 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4-16........................................ 17 SAFETY CRITICAL PARTS 4-17............................................................ 17 MAINTENANCE SCHEDURE CHART 4-19........................................................... 17 MAINTENANCE SCHEDURE CHART 4-19....................................................... 17 SERVICE PROCEDURE 4-22.................................................................... 17 WHEN REQUIRED 4-23.................................................................... 17 CHECK BEFORE STARTING 4-44............................................................ 17 EVERY 250 HOURS SERVICE 4-45.......................................................... 17 EVERY 500 HOURS SERVICE 4-52.......................................................... 17 EVERY 1000 HOURS SERVICE 4-58......................................................... 17 EVERY 2000 HOURS SERVICE 4-66......................................................... 17 EVERY 4000 HOURS SERVICE 4-70......................................................... 17 EVERY 8000 HOURS SERVICE 4-73......................................................... 17 SPECIFICATIONS 5-2........................................................................ 17 GENERAL PRECAUTIONS 6-2................................................................... 17 PRECAUTIONS RELATED TO SAFETY 6-2..................................................... 17 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS 6-4........................................ 17 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS 6-4.................................... 17 HANDLING HEADREST 6-5..................................................................... 17 HANDLING REVERSIBLE FAN 6-6............................................................... 17 REVERSING REVERSIBLE FAN 6-6.......................................................... 17 HANDLING CAP WITH LOCK 6-7................................................................ 17 OPENING AND CLOSING LOCKABLE CAP 6-7.................................................. 17 PROCEDURE FOR SELECTING RIPPER POINT 6-8.................................................. 17 PROCEDURE FOR SELECTING RIPPER POINT 6-8.............................................. 17 SAFETY................................................................................................ 19 SAFETY............................................................................................ 20 SAFETY LABELS..................................................................................... 22 POSITIONS OF SAFETY PICTOGRAMS................................................................ 23 SAFETY LABELS................................................................................. 24 GENERAL PRECAUTIONS............................................................................... 29 SAFETY RULES.................................................................................. 29 IF ABNORMALITIES ARE FOUND.................................................................... 29 CLOTHING AND PERSONAL PROTECTIVE ITEMS........................................................ 29 FIRE EXTINGUISHER AND FIRST AID KIT........................................................... 29 SAFETY FEATURES............................................................................... 30 KEEP MACHINE CLEAN............................................................................ 30 INSIDE OPERATOR'S COMPARTMENT................................................................. 30 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT................................................ 30 HANDRAILS AND STEPS........................................................................... 31 MOUNTING AND DISMOUNTING...................................................................... 32 NO PEOPLE ON ATTACHMENTS...................................................................... 32 PREVENTION OF BURNS........................................................................... 33 FIRE PREVENTION............................................................................... 33 ACTION IF FIRE OCCURS......................................................................... 34 WINDOW WASHER LIQUID.......................................................................... 34 PRECAUTIONS WHEN USING ROPS................................................................... 34 PRECAUTIONS FOR ATTACHMENTS................................................................... 35 UNAUTHORIZED MODIFICATION..................................................................... 35 SAFETY AT WORKSITE............................................................................ 35 WORKING ON LOOSE GROUND....................................................................... 36 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES........................................................ 36 ENSURE GOOD VISIBILITY........................................................................ 36 VENTILATION FOR ENCLOSED AREAS................................................................ 37 CHECKING SIGNALMAN'S SIGNALS AND SIGNS........................................................ 37 BE CAREFUL ABOUT ASBESTOS DUST................................................................ 37 PRECAUTIONS FOR OPERATION......................................................................... 38 STARTING ENGINE............................................................................... 38 CHECKS BEFORE STARTING ENGINE............................................................. 38 PRECAUTIONS WHEN STARTING................................................................. 39 PRECAUTIONS IN COLD AREAS................................................................. 39 OPERATION..................................................................................... 40 CHECKS BEFORE OPERATION................................................................... 40 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE...................................... 40 PRECAUTIONS WHEN TRAVELING................................................................ 41 TRAVELING ON SLOPES....................................................................... 42 PROHIBITION OF DANGEROUS WORK............................................................. 42 USING BRAKES.............................................................................. 42 OPERATE CAREFULLY ON SNOW................................................................. 42 PARKING MACHINE........................................................................... 43 TRANSPORTATION................................................................................ 44 LOADING AND UNLOADING..................................................................... 44 SHIPPING.................................................................................. 44 BATTERY....................................................................................... 45 BATTERY HAZARD PREVENTION................................................................. 45 STARTING WITH BOOSTER CABLE............................................................... 46 TOWING........................................................................................ 47 WHEN TOWING............................................................................... 47 PRECAUTIONS FOR MAINTENENCE....................................................................... 48 WARNING TAG................................................................................... 48 KEEP WORK PLACE CLEAN AND TIDY................................................................ 48 APPOINT LEADER WHEN WORKING WITH OTHERS....................................................... 48 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.................................... 49 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................................ 49 PROPER TOOLS.................................................................................. 50 HANDLING ACCUMULATOR.......................................................................... 50 NO UNAUTHORIZED PERSONNEL INTO AREA........................................................... 50 ATTACHMENTS................................................................................... 51 PRECAUTIONS FOR WORK UNDER MACHINE AND WORK EQUIPMENT......................................... 51 NOISE......................................................................................... 51 PRECAUTIONS WHEN USING HAMMER................................................................. 51 REPAIR WELDING................................................................................ 52 REMOVING BATTERY TERMINAL..................................................................... 52 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION........................... 52 DO NOT DISASSEMBLE RECOIL SPRING.............................................................. 52 PRECAUTION WITH HIGH-PRESSURE OIL............................................................. 53 PRECAUTIONS WITH PRESSURIZED FUEL............................................................. 53 HANDLING HIGH-PRESSURE HOSES.................................................................. 53 PRECAUTIONS WITH HIGH VOLTAGE................................................................. 53 WASTE MATERIAL................................................................................ 54 MAINTENANCE FOR AIR CONDITIONER............................................................... 54 COMPRESSED AIR................................................................................ 54 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................. 54 OPERATION............................................................................................. 55 GENERAL VIEW...................................................................................... 56 GENERAL VIEW OF MACHINE....................................................................... 56 GENERAL VIEW OF CONTROLS AND GAUGES........................................................... 57 EXPLANATION OF COMPONENTS......................................................................... 60 FRONT PANEL................................................................................... 61 MONITOR PANEL............................................................................. 61 CAUTION ITEMS............................................................................. 63 EMERGENCY STOP ITEMS...................................................................... 64 METER DISPLAY PORTION..................................................................... 66 AIR CONDITIONER PANEL..................................................................... 69 HEATER PANEL.............................................................................. 72 SWITCH PANEL.............................................................................. 74 ALARM LAMPS............................................................................... 77 SWITCHES...................................................................................... 78 HORN SWITCH............................................................................... 78 ROOM LAMP SWITCH.......................................................................... 79 CIGARETTE LIGHTER......................................................................... 79 WIPER SWITCH.............................................................................. 79 ADDITIONAL WORKING LAMP SWITCH............................................................ 80 CONTROL LEVERS, PEDALS, DIAL.................................................................. 82 FUEL CONTROL DIAL......................................................................... 82 JOYSTICK.................................................................................. 83 BRAKE PEDAL............................................................................... 85 DECELERATION PEDAL........................................................................ 85 PARKING LEVER............................................................................. 85 SAFETY LEVER.............................................................................. 86 BLADE CONTROL LEVER....................................................................... 87 RIPPER CONTROL LEVER...................................................................... 88 PIN PULLER CONTROL SWITCH................................................................. 88 DUST INDICATOR................................................................................ 89 POWER SOURCE.................................................................................. 89 FUSE BOX...................................................................................... 90 FUSE CAPACITY AND NAME OF CIRCUIT......................................................... 91 DOOR-OPEN LOCK................................................................................ 92 SASH GLASS INTERMEDIATE LOCK.................................................................. 92 HOT AND COOL BOX.............................................................................. 93 DOOR POCKET................................................................................... 93 ASHTRAY....................................................................................... 93 TOOL BOX...................................................................................... 94 USING CAR RADIO............................................................................... 95 EXPLANATION OF PARTS...................................................................... 95 METHOD OF USE............................................................................. 98 PRECAUTIONS WHEN USING.................................................................... 99 AM/FM RADIO...................................................................................100 EXPLANATION OF COMPONENTS.................................................................100 METHOD OF OPERATION.......................................................................105 PRECAUTIONS WHEN USING....................................................................107 HANDLING AIR CONDITIONER......................................................................108 COOLING OPERATION.........................................................................108 HEATING OPERATION.........................................................................109 PRECAUTIONS WHEN USING AIR CONDITIONER....................................................110 INSPECTION DURING OFF-SEASON..............................................................110 PROCEDURE FOR REPLACING RECEIVER..........................................................110 CLEANING AIR FILTER.......................................................................111 CLEAN AIR CONDITIONER CONDENSER FINS......................................................111 HANDLING HEATER...............................................................................112 METHOD OF OPERATION.......................................................................112 CLEANING AIR FILTER.......................................................................112 HANDLING ACCUMULATOR..........................................................................113 METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR....113 OPERATION.........................................................................................114 CHECK BEFORE STARTING ENGINE..................................................................114 WALK-AROUND CHECK.........................................................................114 CHECK BEFORE STARTING.....................................................................115 ADJUSTING BEFORE STARTING OPERATION.......................................................127 USING SEAT BELT...........................................................................129 ADJUST ARMREST............................................................................130 OPERATIONS AND CHECKS BEFORE STARTING ENGINE..............................................131 STARTING ENGINE...............................................................................133 NORMAL STARTING...........................................................................133 STARTING IN COLD WEATHER..................................................................135 AFTER STARTING ENGINE.........................................................................138 BREAKING-IN THE NEW MACHINE...............................................................138 WARMING-UP OPERATION..........................................................................139 IN COLD AREAS.............................................................................141 STOPPING ENGINE...............................................................................143 CHECK AFTER STOPPING ENGINE...................................................................144 MACHINE OPERATION.............................................................................145 MOVING MACHINE OFF........................................................................145 STOPPING MACHINE..........................................................................147 SHIFTING GEAR.............................................................................148 SHIFTING BETWEEN FORWARD AND REVERSE......................................................149 STEERING MACHINE..............................................................................151 NORMAL TURNING............................................................................151 TURNING WHILE DESCENDING A SLOPE..........................................................153 PRECAUTIONS FOR OPERATION.....................................................................154 PERMISSIBLE WATER DEPTH...................................................................154 PAY ATTENTION TO GAUGES...................................................................154 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS...............................................154 PRECAUTIONS ON SLOPES.....................................................................154 METHOD OF USING BRAKES....................................................................155 IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS..................................155 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW...........155 PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY..............................155 PARKING MACHINE...............................................................................156 CHECK AFTER FINISHING WORK....................................................................158 LOCKING.......................................................................................158 RIPPER OPERATION..............................................................................159 EFFECTIVE METHOD OF USE...................................................................159 DIGGING UP BOULDERS OR ROCKBED............................................................159 OPERATING ON SLOPES.......................................................................160 METHOD OF OPERATING PIN PULLER............................................................160 WORK POSSIBLE USING BULLDOZER.................................................................161 DOZING....................................................................................161 SMOOTHING NOTICE..........................................................................161 CUTTING INTO HARD OR FROZEN GROUND OR DITCHING............................................162 FELLING TREES, REMOVING STUMPS............................................................162 PUSHER OPERATIONS.........................................................................162 ADJUSTING POSTURE OF WORK EQUIPMENT...........................................................163 METHOD OF ANGLING BLADE...................................................................163 ADJUSTING TILT AMOUNT.....................................................................164 ADJUSTING RIPPER..........................................................................167 ADJUST ANGLE OF BLADE EDGE................................................................168 TIPS FOR LONGER UNDERCARRIAGE LIFE............................................................170 OPERATION METHOD..........................................................................170 INSPECTION AND ADJUSTMENT.................................................................170 INSPECTION AND REPAIR.....................................................................171 TRANSPORTATION....................................................................................173 LOADING, UNLOADING WORK.......................................................................173 PRECAUTIONS FOR LOADING.......................................................................173 METHOD OF LIFTING MACHINE.....................................................................174 PRECAUTIONS FOR TRANSPORTATION................................................................175 REMOVAL OF CAB................................................................................176 COLD WEATHER OPERATION............................................................................178 COLD WEATHER OPERATION INFORMATION............................................................178 FUEL AND LUBRICANTS.......................................................................178 COOLING SYSTEM COOLANT....................................................................178 BATTERY...................................................................................179 AFTER DAILY WORK COMPLETION...................................................................180 AFTER COLD WEATHER SEASON.....................................................................180 LONG TERM STORAGE.................................................................................181 BEFORE STORAGE................................................................................181 DURING STORAGE................................................................................181 AFTER STORAGE.................................................................................181 TROUBLESHOOTING...................................................................................182 AFTER RUNNING OUT OF FUEL.....................................................................182 METHOD OF TOWING MACHINE......................................................................183 DISCHARGED BATTERY............................................................................184 REMOVAL AND INSTALLATION OF BATTERY.......................................................185 BATTERY CHARGES...........................................................................185 STARTING ENGINE WITH BOOSTER CABLES.......................................................186 OTHER TROUBLE.................................................................................188 ELECTRICAL SYSTEM.........................................................................188 MONITOR RELATED...........................................................................190 CHASSIS...................................................................................191 ENGINE....................................................................................193 MAINTENANCE...........................................................................................197 GUIDE TO MAINTENANCE..............................................................................198 CHECK SERVICE METER...........................................................................198 KOMATSU GENUINE REPLACEMENTPARTS:.............................................................198 KOMATSU GENUINE OILS:.........................................................................198 ALWAYS USE CLEAN WASHER FLUID:................................................................198 CLEAN OIL AND GREASE:.........................................................................198 CHECKING FOREIGN MATERIALS DRAINED OIL:.......................................................198 FUEL STRAINER:................................................................................198 WELDING INSTRUCTIONS:.........................................................................198 DO NOT DROP THINGS INSIDE MACHINE:............................................................199 DUSTY WORKSITES:..............................................................................199 AVOID MIXING OILS:............................................................................199 PRECAUTIONS FOR OPENING AND CLOSING ENGINE SIDE COVER.........................................199 LOOKING THE INSPECTION COVERS:................................................................200 HYDRAULIC SYSTEM - AIR BLEEDING...............................................................200 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES...................................................200 CHECK AFTER INSPECTION AND MAINTENANCE WORKS:.................................................200 FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE..........................................200 OUTLINE OF SERVICE................................................................................201 OUTLINE OF OIL, FUEL, COOLANT.................................................................201 OIL.......................................................................................201 FUEL......................................................................................201 COOLANT...................................................................................202 GREASE....................................................................................202 CARRYING OUT KOWA (Komatsu Oil Wear Analysis).............................................203 STORING OIL AND FUEL......................................................................204 FILTERS...................................................................................204 ELECTRIC SYSTEM MAINTENANCE...................................................................204 WEAR PARTS........................................................................................205 WEAR PARTS LIST...............................................................................205 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..............................207 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....................................................211 TORQUE LIST...................................................................................211 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....................................................212 SAFETY CRITICAL PARTS.........................................................................213 MAINTENANCE SCHEDURE CHART........................................................................215 MAINTENANCE SCHEDURE CHART....................................................................215 SERVICE PROCEDURE.................................................................................218 INITIAL 250 HOURS MAINTENANCE.................................................................218 WHEN REQUIRED.................................................................................219 CLEAN INSIDE OF COOLING SYSTEM............................................................219 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..............................................222 CHECK ELECTRICAL INTAKE AIR HEATER........................................................224 CHECK TRACK TENSION.......................................................................224 CHECK AND TIGHTEN TRACK SHOE BOLTS........................................................226 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES........................................227 CLEAN, CHECK RADIATOR FINS................................................................228 REPLACE AIR CONDITIONER BELT..............................................................229 CLEAN, CHECK HYDRAULIC COOLER FINS........................................................230 CLEAN, CHECK AIR CONDITIONER CONDENSER FINS...............................................231 ADJUST IDLER CLEARANCE....................................................................231 CHECK UNDERCARRIAGE OIL...................................................................232 CLEAN AIR CONDITIONER AIR FILTER..........................................................233 CHECK, ADJUST AIR CONDITIONER.............................................................234 GREASE DOOR HINGE.........................................................................235 CHECK DOOR LOCK STRIKER...................................................................235 CHECK DOOR LATCH..........................................................................236 REPLACE DOOR DAMPER.......................................................................237 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................237 REPLACE WIPER BLADE.......................................................................238 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM............................................239 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM.............................239 CHECK BEFORE STARTING.........................................................................240 EVERY 250 HOURS SERVICE.......................................................................241 LUBRICATING...............................................................................241 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..............................................244 CHECK LEVEL OF BATTERY ELECTROLYTE........................................................244 CHECK, ADJUST ALTERNATOR DRIVE BELT TENSION...............................................246 CHECK BRAKE PERFORMANCE...................................................................247 EVERY 500 HOURS SERVICE.......................................................................248 REPLACE FUEL FILTER CARTRIDGE.............................................................248 REPLACE POWER TRAIN OIL FILTER ELEMENT....................................................249 REPLACE HYDRAULIC TANK BREATHER ELEMENT...................................................250 CHECK AND REPLACE FAN BELT................................................................251 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........................252 EVERY 1000 HOURS SERVICE......................................................................254 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS............................................254 CHANGE OIL IN FINAL DRIVE CASE............................................................256 CLEAN POWER TRAIN CASE BREATHER...........................................................257 GREASE UNIVERSAL JOINT (2 PLACES).........................................................257 REPLACE CORROSION RESISTOR CARTRIDGE......................................................258 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER................................................258 GREASE TENSION PULLEY ASSEMBLY............................................................258 CHECK, CLEAN FUEL STRAINER................................................................259 REPLACE CHARGE FILTER ELEMENT.............................................................260 GREASE DLER ADJUSTMENT ROD................................................................261 CHECK FOR LOOSE ROPS MOUNT BOLTS..........................................................261 EVERY 2000 HOURS SERVICE......................................................................262 CHANGE OIL IN HYDRAULIC TANK,REPLACE HYDRAULIC OIL FILTER ELEMENT.........................262 CHECK PLAY OF TURBOCHARGER ROTOR..........................................................263 CLEAN, CHECK TURBOCHARGER.................................................................263 CLEAN ENGINE BREATHER ELEMENT.............................................................263 CHECK ALTERNATOR, STARTING MOTOR..........................................................263 CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................263 CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER..........................................264 CHECK PIVOT BEARING OIL LEVEL, ADD OIL....................................................265 CHECK INJECTOR............................................................................265 EVERY 4000 HOURS SERVICE......................................................................266 CHECK WATER PUMP..........................................................................266 CHECK FAN PULLEY AND TENSION PULLEY.......................................................266 CHECK VIBRATION DAMPER....................................................................266 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER........................267 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.......................268 REPLACE INJECTOR NOZZLE TIP...............................................................268 EVERY 8000 HOURS SERVICE......................................................................269 REPLACE HIGH-PRESSURE PIPING CLAMP........................................................269 REPLACE FUEL SPLAY PREVENTION CAP.........................................................269 SPECIFICATIONS........................................................................................271 SPECIFICATIONS....................................................................................272 ATTACHMENTS AND OPTIONS...............................................................................273 GENERAL PRECAUTIONS...............................................................................274 PRECAUTIONS RELATED TO SAFETY.................................................................274 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS....................................................276 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS................................................276 HANDLING HEADREST.................................................................................277 HANDLING REVERSIBLE FAN...........................................................................278 REVERSING REVERSIBLE FAN......................................................................278 HANDLING CAP WITH LOCK............................................................................279 OPENING AND CLOSING LOCKABLE CAP..............................................................279 PROCEDURE FOR SELECTING RIPPER POINT..............................................................280 PROCEDURE FOR SELECTING RIPPER POINT..........................................................280
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KOMATSU D155AX-5 BULLDOZER PRINTED OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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