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Komatsu D155AX-5 Bulldozer Operator Manual (SN 76001+) PDF Download
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- KOMATSU GALEO D155AX-5 BULLDOZER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:76001 & UP
- PUBLICATION NUMBER:SEAM059901T
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Description
KOMATSU GALEO D155AX-5 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:76001 & UP) KOMATSU D155AX-5
KOMATSU GALEO D155AX-5 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:76001 & UP) KOMATSU D155AX-5 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO D155AX-5 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:76001 & UP) KOMATSU D155AX-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 GALEO D155AX-5 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:76001 & UP) KOMATSU D155AX-5
COVER............................................................................................................... 1 FOREWORD............................................................................................................ 2 FOREWORD........................................................................................................ 3 SAFETY INFORMATION.............................................................................................. 7 INTRODUCTION.................................................................................................... 9 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................................................................ 9 BREAKING IN THE MACHINE..................................................................................... 9 NECESSARY INFORMATION........................................................................................... 10 PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE............................................... 10 ENGINE SERIAL NO. PLATE AND POSITION (1).................................................................... 10 ENGINE SERIAL NO. PLATE AND POSITION (2).................................................................... 11 BLADE SERIAL NO. PLATE POSITION............................................................................. 11 RIPPER SERIAL NO. PLATE POSITION............................................................................ 11 ROPS, FOPS NO. PLATE POSITION............................................................................... 12 POSITION OF SERVICE METER................................................................................... 12 TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN.................................................................. 12 CONTENTS............................................................................................................ 13 SAFETY.............................................................................................................. 16 SAFETY.......................................................................................................... 17 SAFETY LABELS................................................................................................... 19 POSITIONS OF SAFETY PICTOGRAMS.............................................................................. 19 SAFETY LABELS............................................................................................... 20 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......................................................................................... 28 MOUNTING AND DISMOUNTING.................................................................................... 28 NO PEOPLE ON ATTACHMENTS.................................................................................... 28 PREVENTION OF BURNS......................................................................................... 29 FIRE PREVENTION............................................................................................. 29 ACTION IF FIRE OCCURS....................................................................................... 30 WINDOW WASHER LIQUID........................................................................................ 30 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................................................ 31 PRECAUTIONS FOR ATTACHMENTS................................................................................. 31 UNAUTHORIZED MODIFICATION................................................................................... 31 SAFETY AT WORKSITE.......................................................................................... 31 WORKING ON LOOSE GROUND..................................................................................... 32 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...................................................................... 32 ENSURE GOOD VISIBILITY...................................................................................... 32 VENTILATION FOR ENCLOSED AREAS.............................................................................. 33 CHECKING SIGNALMAN'S SIGNALS AND SIGNS...................................................................... 33 BE CAREFUL ABOUT ASBESTOS DUST.............................................................................. 33 PRECAUTIONS FOR OPERATION....................................................................................... 34 BEFORE STARTING ENGINE...................................................................................... 34 CHECKS BEFORE STARTING ENGINE........................................................................... 34 PRECAUTIONS WHEN STARTING............................................................................... 34 PRECAUTIONS IN COLD AREAS............................................................................... 35 OPERATION................................................................................................... 36 CHECKS BEFORE OPERATION................................................................................. 36 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE.................................................... 36 PRECAUTIONS WHEN TRAVELING.............................................................................. 37 TRAVELING ON SLOPES..................................................................................... 38 PROHIBITED OPERATIONS................................................................................... 38 USING BRAKES............................................................................................ 38 OPERATE CAREFULLY ON SNOW............................................................................... 38 PARKING MACHINE......................................................................................... 39 TRANSPORTATION.............................................................................................. 40 SHIPPING................................................................................................ 40 BATTERY..................................................................................................... 41 BATTERY HAZARD PREVENTION............................................................................... 41 STARTING WITH BOOSTER CABLE............................................................................. 42 TOWING...................................................................................................... 43 WHEN TOWING............................................................................................. 43 PRECAUTIONS FOR MAINTENANCE..................................................................................... 44 WARNING TAG................................................................................................. 44 KEEP WORK PLACE CLEAN AND TIDY.............................................................................. 44 APPOINT LEADER WHEN WORKING WITH OTHERS..................................................................... 44 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ................................................. 45 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.......................................................... 46 PROPER TOOLS................................................................................................ 46 HANDLING ACCUMULATOR........................................................................................ 47 PERSONNEL................................................................................................... 47 ATTACHMENTS................................................................................................. 47 WORK UNDER THE MACHINE...................................................................................... 47 NOISE....................................................................................................... 48 PRECAUTIONS WHEN USING HAMMER............................................................................... 48 REPAIR WELDING.............................................................................................. 48 REMOVING BATTERY TERMINAL................................................................................... 48 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......................................... 48 DO NOT DISASSEMBLE RECOIL SPRING............................................................................ 49 PRECAUTION WITH HIGH-PRESSURE OIL........................................................................... 49 PRECAUTION FOR HIGH FUEL PRESSURE........................................................................... 49 HANDLING HIGH-PRESSURE HOSES................................................................................ 49 PRECAUTION FOR HIGH VOLTAGE................................................................................. 50 WASTE MATERIAL.............................................................................................. 50 MAINTENANCE FOR AIR CONDITIONER............................................................................. 50 COMPRESSED AIR.............................................................................................. 50 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................................... 50 OPERATION........................................................................................................... 51 GENERAL VIEW.................................................................................................... 52 GENERAL VIEW OF MACHINE..................................................................................... 52 GENERAL VIEW OF CONTROLS AND GAUGES......................................................................... 53 EXPLANATION OF COMPONENTS....................................................................................... 55 FRONT PANEL................................................................................................. 55 SWITCHES.................................................................................................... 81 CONTROL LEVERS, PEDALS...................................................................................... 86 DUST INDICATOR.............................................................................................. 92 POWER SOURSE................................................................................................ 92 FUSE BOX.................................................................................................... 93 DOOR POCKET................................................................................................. 97 ASHTRAY..................................................................................................... 97 CAR RADIO, HANDLING......................................................................................... 98 CAR STEREO, HANDLING........................................................................................103 AIR CONDITIONER.............................................................................................109 HEATER, HANDLING............................................................................................115 ACCUMULATOR, HANDLING.......................................................................................116 OPERATION.......................................................................................................117 CHECK BEFORE STARTING ENGINE, ADJUST........................................................................117 STARTING ENGINE.............................................................................................136 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................141 STOPPING ENGINE.............................................................................................144 MOVING MACHINE OFF..........................................................................................145 STOPPING MACHINE............................................................................................147 SHIFTING GEAR...............................................................................................148 SHIFTING BETWEEN FORWARD AND REVERSE........................................................................152 STEERING MACHINE............................................................................................154 PRECAUTIONS FOR OPERATION...................................................................................156 PARKING MACHINE.............................................................................................158 CHECK AFTER STOPPING ENGINE.................................................................................159 CHECK AFTER FINISHING WORK..................................................................................160 LOCKING.....................................................................................................160 RIPPER OPERATION............................................................................................161 OPERATING METHOD FOR RIPPING OPERATIONS.....................................................................163 WORK POSSIBLE USING BULLDOZER...............................................................................168 ADJUSTING POSTURE OF WORK EQUIPMENT.........................................................................170 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................................................176 TRANSPORTATION..................................................................................................180 LOADING, UNLOADING WORK.....................................................................................180 PRECAUTIONS FOR LOADING.....................................................................................180 METHOD OF LIFTING MACHINE...................................................................................181 PRECAUTIONS FOR TRANSPORTATION..............................................................................182 TRAVELING ON ROADS..........................................................................................182 REMOVAL OF CAB..............................................................................................183 COLD WEATHER OPERATION..........................................................................................185 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................185 AFTER COMPLETION OF WORK....................................................................................187 AFTER COLD WEATHER..........................................................................................187 LONG-TERM STORAGE...............................................................................................188 BEFORE STORAGE..............................................................................................188 DURING STORAGE..............................................................................................188 AFTER STORAGE...............................................................................................188 TROUBLESHOOTING.................................................................................................189 AFTER RUNNING OUT OF FUEL...................................................................................189 METHOD OF TOWING MACHINE....................................................................................191 IF BATTERY IS DISCHARGED....................................................................................192 OTHER TROUBLE...............................................................................................196 MAINTENANCE.........................................................................................................202 GUIDES TO MAINTENANCE...........................................................................................203 OUTLINES OF SERVICE.............................................................................................206 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................206 OUTLINE OF ELECTRIC SYSTEM..................................................................................209 HANDLING HYDRAULIC RELATED EQUIPMENT........................................................................209 WEAR PARTS LIST.................................................................................................210 WEAR PARTS LIST.............................................................................................210 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............................................211 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................215 SAFETY CRITICAL PARTS.......................................................................................215 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................217 TORQUE LIST.................................................................................................217 MAINTENANCE SCHEDULE CHART......................................................................................218 MAINTENANCE SCHEDULE CHART..................................................................................218 SERVICE PROCEDURE...............................................................................................220 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..................................................220 WHEN REQUIRED...............................................................................................221 CLEAN INSIDE OF COOLING SYSTEM..........................................................................221 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................224 CHECK ELECTRICAL INTAKE AIR HEATER......................................................................225 CHECK TRACK TENSION.....................................................................................226 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................................228 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES......................................................229 CLEAN, CHECK RADIATOR FINS..............................................................................231 REPLACE AIE CONDITIONER BELT............................................................................232 CLEAN, CHECK HYDRAULIC COOLER FINS......................................................................233 CLEAN, CHECK AIR CONDITIONER CONDENSER FINS.............................................................234 ADJUST IDLER CLEARANCE..................................................................................234 CHECK UNDERCARRIAGE OIL.................................................................................235 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..................................................236 CHECK, ADJUST AIR CONDITIONER...........................................................................237 LUBRICATE DOOR HINGE....................................................................................238 CHECK DOOR LATCH........................................................................................238 CHECK DOOR LOCK STRIKER.................................................................................238 REPLACE DOOR DAMPER.....................................................................................239 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................239 REPLACE WIPER BLADE.....................................................................................240 PROCEDURE FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT.......................................................241 PROCEDURE FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT..........................................242 CHECK BEFORE STARTING.......................................................................................243 EVERY 250 HOURS SERVICE.....................................................................................244 LUBRICATING.............................................................................................244 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................................248 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................248 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.............................................................251 CHECK BRAKE PERFORMANCE.................................................................................252 EVERY 500 HOURS SERVICE.....................................................................................253 REPLACE FUEL FILTER CARTRIDGE...........................................................................253 REPLACE EXTRA FUEL FILTER CARTRIDGE (WHEN EQUIPPED).....................................................255 REPLACE POWER TRAIN OIL FILTER ELEMENT..................................................................257 REPLACE HYDRAURIC TANK BREATHER ELEMENT.................................................................258 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......................................258 EVERY 1000 HOURS SERVICE....................................................................................260 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER)....260 CHANGE OIL IN FINAL DRIVE CASE..........................................................................262 WASH POWER TRAIN CASE BREATHER..........................................................................262 LUBRICATE UNIVERSAL JOINT...............................................................................263 REPLACE CORROSION RESISTOR CARTRIDGE....................................................................264 CHECK TIGHTENING PARTS OF TURBOCHARGER..................................................................265 CHECK, CLEAN FUEL STRAINER..............................................................................265 REPLACE CHARGE FILTER ELEMENT...........................................................................266 LUBRICATE IDLER ADJUSTMENT ROD..........................................................................267 CHECK FOR LOOSE ROPS MOUNT BOLTS........................................................................267 EVERY 2000 HOURS SERVICE....................................................................................268 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAURIC OIL FILTER ELEMENT......................................268 CLEAN ENGINE BREATHER ELEMENT...........................................................................269 CHECK ALTERNATOR, STARTING MOTOR........................................................................269 CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER........................................................270 CHECK PIVOT BEARING OIL LEVEL, ADD OIL..................................................................271 CHECK INJECTOR..........................................................................................271 EVERY 4000 HOURS SERVICE....................................................................................272 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................272 CLEAN, CHECK TURBOCHARGER...............................................................................272 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................................................272 CHECK WATER PUMP........................................................................................272 CHECK VIBRATION DAMPER..................................................................................272 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER......................................273 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.....................................274 REPLACE INJECTOR ASSEMBLY...............................................................................274 EVERY 8000 HOURS SERVICE....................................................................................275 REPLACE HIGH-PRESSURE PIPING CLAMP......................................................................275 REPLACE FUEL SPRAY PREVENTION CAP.......................................................................275 SPECIFICATIONS......................................................................................................276 SPECIFICATIONS..................................................................................................277 ATTACHMENTS, OPTIONS................................................................................................278 GENERAL PRECAUTIONS.............................................................................................279 PRECAUTIONS RELATED TO SAFETY...............................................................................279 INTRODUCTION OF ATTACHMENTS AND OPTIONS.........................................................................280 INTRODUCTION OF ATTACHMENTS AND OPTIONS.....................................................................280 HEADREST, HANDLING..............................................................................................281 CAP WITH LOCK, HANDLING.........................................................................................282 METHOD OF OPENING AND CLOSING CAP WITH LOCK.................................................................282 PROCEDURE FOR SELECTING RIPPER POINT............................................................................283 PROCEDURE FOR SELECTING RIPPER POINT........................................................................283 INDEX...............................................................................................................284
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