Komatsu D155AX-5 Bulldozer (75001 and up) Operation & Maintenance Manual – EEAM020802

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the Komatsu D155AX-5 Bulldozer (75001 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.

APPLICABLE MODELS :

Komatsu D155AX Bulldozer
Serial Numbers : 75001 and up

TABLE OF CONTENTS :

– SAFETY
– OPERATION
– MAINTENANCE
– SPECIFICATIONS
– ATTACHMENTS, OPTIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : EEAM020802
Total Pages : 290

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.

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FOREWORD
SAFETY INFORMATION
NOISE
VIBRATION
INTRODUCTION
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
NECESSARY INFORMATION
MACHINE SERIAL NO. PLATE AND POSITION
ENGINE SERIAL NO. PLATE AND POSITION
BLADE SERIAL NO. PLATE POSITION
RIPPER SERIAL NO. PLATE POSITION
POSITION OF SERVICE METER
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR
FOREWORD 1-2
SAFETY INFORMATION 1-4
NOISE 1-6
VIBRATION 1-7
INTRODUCTION 1-8
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1-8
NECESSARY INFORMATION 1-9
MACHINE SERIAL NO. PLATE AND POSITION 1-9
ENGINE SERIAL NO. PLATE AND POSITION 1-9
BLADE SERIAL NO. PLATE POSITION 1-10
RIPPER SERIAL NO. PLATE POSITION 1-10
POSITION OF SERVICE METER 1-10
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR 1-11
SAFETY 2-2
SAFETY LABELS 2-4
POSITIONS OF SAFETY PICTOGRAMS 2-5
SAFETY LABELS 2-6
GENERAL PRECAUTIONS 2-11
PRECAUTIONS FOR OPERATION 2-20
STARTING ENGINE 2-20
OPERATION 2-22
TRANSPORTATION 2-26
BATTERY 2-27
TOWING 2-29
PRECAUTIONS FOR MAINTENENCE 2-30
GENERAL VIEW 3-2
GENERAL VIEW OF MACHINE 3-2
GENERAL VIEW OF CONTROLS AND GAUGES 3-3
EXPLANATION OF COMPONENTS 3-6
FRONT PANEL 3-7
SWITCHES 3-24
CONTROL LEVERS, PEDALS, DIAL 3-28
DUST INDICATOR 3-35
POWER SOURCE 3-35
FUSE BOX 3-36
TOOL BOX 3-40
AM/FM RADIO 3-46
HANDLING ACCUMULATOR 3-59
OPERATION 3-60
CHECK BEFORE STARTING ENGINE 3-60
STARTING ENGINE 3-79
AFTER STARTING ENGINE 3-84
WARMING-UP OPERATION 3-85
STOPPING ENGINE 3-89
CHECK AFTER STOPPING ENGINE 3-90
MACHINE OPERATION 3-91
STEERING MACHINE 3-97
PRECAUTIONS FOR OPERATION 3-100
PARKING MACHINE 3-102
CHECK AFTER FINISHING WORK 3-104
LOCKING 3-104
RIPPER OPERATION 3-105
WORK POSSIBLE USING BULLDOZER 3-107
ADJUSTING POSTURE OF WORK EQUIPMENT 3-109
TIPS FOR LONGER UNDERCARRIAGE LIFE 3-116
TRANSPORTATION 3-119
LOADING, UNLOADING WORK 3-119
PRECAUTIONS FOR LOADING 3-119
METHOD OF LIFTING MACHINE 3-120
PRECAUTIONS FOR TRANSPORTATION 3-121
COLD WEATHER OPERATION 3-124
COLD WEATHER OPERATION INFORMATION 3-124
AFTER DAILY WORK COMPLETION 3-126
AFTER COLD WEATHER SEASON 3-126
LONG TERM STORAGE 3-127
BEFORE STORAGE 3-127
DURING STORAGE 3-127
AFTER STORAGE 3-127
TROUBLESHOOTING 3-128
AFTER RUNNING OUT OF FUEL 3-128
METHOD OF TOWING MACHINE 3-129
DISCHARGED BATTERY 3-130
OTHER TROUBLE 3-134
GUIDE TO MAINTENANCE 4-2
OUTLINE OF SERVICE 4-5
OUTLINE OF OIL, FUEL, COOLANT 4-5
ELECTRIC SYSTEM MAINTENANCE 4-8
WEAR PARTS 4-9
WEAR PARTS LIST 4-9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4-11
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4-15
TORQUE LIST 4-15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4-16
SAFETY CRITICAL PARTS 4-17
MAINTENANCE SCHEDURE CHART 4-19
MAINTENANCE SCHEDURE CHART 4-19
SERVICE PROCEDURE 4-22
WHEN REQUIRED 4-23
CHECK BEFORE STARTING 4-44
EVERY 250 HOURS SERVICE 4-45
EVERY 500 HOURS SERVICE 4-52
EVERY 1000 HOURS SERVICE 4-58
EVERY 2000 HOURS SERVICE 4-66
EVERY 4000 HOURS SERVICE 4-70
EVERY 8000 HOURS SERVICE 4-73
SPECIFICATIONS 5-2
GENERAL PRECAUTIONS 6-2
PRECAUTIONS RELATED TO SAFETY 6-2
INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS 6-4
INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS 6-4
HANDLING HEADREST 6-5
HANDLING REVERSIBLE FAN 6-6
REVERSING REVERSIBLE FAN 6-6
HANDLING CAP WITH LOCK 6-7
OPENING AND CLOSING LOCKABLE CAP 6-7
PROCEDURE FOR SELECTING RIPPER POINT 6-8
PROCEDURE FOR SELECTING RIPPER POINT 6-8
SAFETY
SAFETY
SAFETY LABELS
POSITIONS OF SAFETY PICTOGRAMS
SAFETY LABELS
GENERAL PRECAUTIONS
SAFETY RULES
IF ABNORMALITIES ARE FOUND
CLOTHING AND PERSONAL PROTECTIVE ITEMS
FIRE EXTINGUISHER AND FIRST AID KIT
SAFETY FEATURES
KEEP MACHINE CLEAN
INSIDE OPERATOR’S COMPARTMENT
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT
HANDRAILS AND STEPS
MOUNTING AND DISMOUNTING
NO PEOPLE ON ATTACHMENTS
PREVENTION OF BURNS
FIRE PREVENTION
ACTION IF FIRE OCCURS
WINDOW WASHER LIQUID
PRECAUTIONS WHEN USING ROPS
PRECAUTIONS FOR ATTACHMENTS
UNAUTHORIZED MODIFICATION
SAFETY AT WORKSITE
WORKING ON LOOSE GROUND
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES
ENSURE GOOD VISIBILITY
VENTILATION FOR ENCLOSED AREAS
CHECKING SIGNALMAN’S SIGNALS AND SIGNS
BE CAREFUL ABOUT ASBESTOS DUST
PRECAUTIONS FOR OPERATION
STARTING ENGINE
CHECKS BEFORE STARTING ENGINE
PRECAUTIONS WHEN STARTING
PRECAUTIONS IN COLD AREAS
OPERATION
CHECKS BEFORE OPERATION
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE
PRECAUTIONS WHEN TRAVELING
TRAVELING ON SLOPES
PROHIBITION OF DANGEROUS WORK
USING BRAKES
OPERATE CAREFULLY ON SNOW
PARKING MACHINE
TRANSPORTATION
LOADING AND UNLOADING
SHIPPING
BATTERY
BATTERY HAZARD PREVENTION
STARTING WITH BOOSTER CABLE
TOWING
WHEN TOWING
PRECAUTIONS FOR MAINTENENCE
WARNING TAG
KEEP WORK PLACE CLEAN AND TIDY
APPOINT LEADER WHEN WORKING WITH OTHERS
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
PROPER TOOLS
HANDLING ACCUMULATOR
NO UNAUTHORIZED PERSONNEL INTO AREA
ATTACHMENTS
PRECAUTIONS FOR WORK UNDER MACHINE AND WORK EQUIPMENT
NOISE
PRECAUTIONS WHEN USING HAMMER
REPAIR WELDING
REMOVING BATTERY TERMINAL
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION
DO NOT DISASSEMBLE RECOIL SPRING
PRECAUTION WITH HIGH-PRESSURE OIL
PRECAUTIONS WITH PRESSURIZED FUEL
HANDLING HIGH-PRESSURE HOSES
PRECAUTIONS WITH HIGH VOLTAGE
WASTE MATERIAL
MAINTENANCE FOR AIR CONDITIONER
COMPRESSED AIR
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
GENERAL VIEW OF CONTROLS AND GAUGES
EXPLANATION OF COMPONENTS
FRONT PANEL
MONITOR PANEL
CAUTION ITEMS
EMERGENCY STOP ITEMS
METER DISPLAY PORTION
AIR CONDITIONER PANEL
HEATER PANEL
SWITCH PANEL
ALARM LAMPS
SWITCHES
HORN SWITCH
ROOM LAMP SWITCH
CIGARETTE LIGHTER
WIPER SWITCH
ADDITIONAL WORKING LAMP SWITCH
CONTROL LEVERS, PEDALS, DIAL
FUEL CONTROL DIAL
JOYSTICK
BRAKE PEDAL
DECELERATION PEDAL
PARKING LEVER
SAFETY LEVER
BLADE CONTROL LEVER
RIPPER CONTROL LEVER
PIN PULLER CONTROL SWITCH
DUST INDICATOR
POWER SOURCE
FUSE BOX
FUSE CAPACITY AND NAME OF CIRCUIT
DOOR-OPEN LOCK
SASH GLASS INTERMEDIATE LOCK
HOT AND COOL BOX
DOOR POCKET
ASHTRAY
TOOL BOX
USING CAR RADIO
EXPLANATION OF PARTS
METHOD OF USE
PRECAUTIONS WHEN USING
AM/FM RADIO
EXPLANATION OF COMPONENTS
METHOD OF OPERATION
PRECAUTIONS WHEN USING
HANDLING AIR CONDITIONER
COOLING OPERATION
HEATING OPERATION
PRECAUTIONS WHEN USING AIR CONDITIONER
INSPECTION DURING OFF-SEASON
PROCEDURE FOR REPLACING RECEIVER
CLEANING AIR FILTER
CLEAN AIR CONDITIONER CONDENSER FINS
HANDLING HEATER
METHOD OF OPERATION
CLEANING AIR FILTER
HANDLING ACCUMULATOR
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR
OPERATION
CHECK BEFORE STARTING ENGINE
WALK-AROUND CHECK
CHECK BEFORE STARTING
ADJUSTING BEFORE STARTING OPERATION
USING SEAT BELT
ADJUST ARMREST
OPERATIONS AND CHECKS BEFORE STARTING ENGINE
STARTING ENGINE
NORMAL STARTING
STARTING IN COLD WEATHER
AFTER STARTING ENGINE
BREAKING-IN THE NEW MACHINE
WARMING-UP OPERATION
IN COLD AREAS
STOPPING ENGINE
CHECK AFTER STOPPING ENGINE
MACHINE OPERATION
MOVING MACHINE OFF
STOPPING MACHINE
SHIFTING GEAR
SHIFTING BETWEEN FORWARD AND REVERSE
STEERING MACHINE
NORMAL TURNING
TURNING WHILE DESCENDING A SLOPE
PRECAUTIONS FOR OPERATION
PERMISSIBLE WATER DEPTH
PAY ATTENTION TO GAUGES
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS
PRECAUTIONS ON SLOPES
METHOD OF USING BRAKES
IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY
PARKING MACHINE
CHECK AFTER FINISHING WORK
LOCKING
RIPPER OPERATION
EFFECTIVE METHOD OF USE
DIGGING UP BOULDERS OR ROCKBED
OPERATING ON SLOPES
METHOD OF OPERATING PIN PULLER
WORK POSSIBLE USING BULLDOZER
DOZING
SMOOTHING NOTICE
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING
FELLING TREES, REMOVING STUMPS
PUSHER OPERATIONS
ADJUSTING POSTURE OF WORK EQUIPMENT
METHOD OF ANGLING BLADE
ADJUSTING TILT AMOUNT
ADJUSTING RIPPER
ADJUST ANGLE OF BLADE EDGE
TIPS FOR LONGER UNDERCARRIAGE LIFE
OPERATION METHOD
INSPECTION AND ADJUSTMENT
INSPECTION AND REPAIR
TRANSPORTATION
LOADING, UNLOADING WORK
PRECAUTIONS FOR LOADING
METHOD OF LIFTING MACHINE
PRECAUTIONS FOR TRANSPORTATION
REMOVAL OF CAB
COLD WEATHER OPERATION
COLD WEATHER OPERATION INFORMATION
FUEL AND LUBRICANTS
COOLING SYSTEM COOLANT
BATTERY
AFTER DAILY WORK COMPLETION
AFTER COLD WEATHER SEASON
LONG TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
METHOD OF TOWING MACHINE
DISCHARGED BATTERY
REMOVAL AND INSTALLATION OF BATTERY
BATTERY CHARGES
STARTING ENGINE WITH BOOSTER CABLES
OTHER TROUBLE
ELECTRICAL SYSTEM
MONITOR RELATED
CHASSIS
ENGINE
MAINTENANCE
GUIDE TO MAINTENANCE
CHECK SERVICE METER
KOMATSU GENUINE REPLACEMENTPARTS:
KOMATSU GENUINE OILS:
ALWAYS USE CLEAN WASHER FLUID:
CLEAN OIL AND GREASE:
CHECKING FOREIGN MATERIALS DRAINED OIL:
FUEL STRAINER:
WELDING INSTRUCTIONS:
DO NOT DROP THINGS INSIDE MACHINE:
DUSTY WORKSITES:
AVOID MIXING OILS:
PRECAUTIONS FOR OPENING AND CLOSING ENGINE SIDE COVER
LOOKING THE INSPECTION COVERS:
HYDRAULIC SYSTEM – AIR BLEEDING
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES
CHECK AFTER INSPECTION AND MAINTENANCE WORKS:
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE
OUTLINE OF SERVICE
OUTLINE OF OIL, FUEL, COOLANT
OIL
FUEL
COOLANT
GREASE
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)
STORING OIL AND FUEL
FILTERS
ELECTRIC SYSTEM MAINTENANCE
WEAR PARTS
WEAR PARTS LIST
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
TORQUE LIST
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS
MAINTENANCE SCHEDURE CHART
MAINTENANCE SCHEDURE CHART
SERVICE PROCEDURE
INITIAL 250 HOURS MAINTENANCE
WHEN REQUIRED
CLEAN INSIDE OF COOLING SYSTEM
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
CHECK ELECTRICAL INTAKE AIR HEATER
CHECK TRACK TENSION
CHECK AND TIGHTEN TRACK SHOE BOLTS
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES
CLEAN, CHECK RADIATOR FINS
REPLACE AIR CONDITIONER BELT
CLEAN, CHECK HYDRAULIC COOLER FINS
CLEAN, CHECK AIR CONDITIONER CONDENSER FINS
ADJUST IDLER CLEARANCE
CHECK UNDERCARRIAGE OIL
CLEAN AIR CONDITIONER AIR FILTER
CHECK, ADJUST AIR CONDITIONER
GREASE DOOR HINGE
CHECK DOOR LOCK STRIKER
CHECK DOOR LATCH
REPLACE DOOR DAMPER
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID
REPLACE WIPER BLADE
PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM
PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM
CHECK BEFORE STARTING
EVERY 250 HOURS SERVICE
LUBRICATING
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
CHECK LEVEL OF BATTERY ELECTROLYTE
CHECK, ADJUST ALTERNATOR DRIVE BELT TENSION
CHECK BRAKE PERFORMANCE
EVERY 500 HOURS SERVICE
REPLACE FUEL FILTER CARTRIDGE
REPLACE POWER TRAIN OIL FILTER ELEMENT
REPLACE HYDRAULIC TANK BREATHER ELEMENT
CHECK AND REPLACE FAN BELT
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
EVERY 1000 HOURS SERVICE
CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS
CHANGE OIL IN FINAL DRIVE CASE
CLEAN POWER TRAIN CASE BREATHER
GREASE UNIVERSAL JOINT (2 PLACES)
REPLACE CORROSION RESISTOR CARTRIDGE
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER
GREASE TENSION PULLEY ASSEMBLY
CHECK, CLEAN FUEL STRAINER
REPLACE CHARGE FILTER ELEMENT
GREASE DLER ADJUSTMENT ROD
CHECK FOR LOOSE ROPS MOUNT BOLTS
EVERY 2000 HOURS SERVICE
CHANGE OIL IN HYDRAULIC TANK,REPLACE HYDRAULIC OIL FILTER ELEMENT
CHECK PLAY OF TURBOCHARGER ROTOR
CLEAN, CHECK TURBOCHARGER
CLEAN ENGINE BREATHER ELEMENT
CHECK ALTERNATOR, STARTING MOTOR
CHECK ENGINE VALVE CLEARANCE, ADJUST
CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER
CHECK PIVOT BEARING OIL LEVEL, ADD OIL
CHECK INJECTOR
EVERY 4000 HOURS SERVICE
CHECK WATER PUMP
CHECK FAN PULLEY AND TENSION PULLEY
CHECK VIBRATION DAMPER
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
REPLACE INJECTOR NOZZLE TIP
EVERY 8000 HOURS SERVICE
REPLACE HIGH-PRESSURE PIPING CLAMP
REPLACE FUEL SPLAY PREVENTION CAP
SPECIFICATIONS
SPECIFICATIONS
ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS
PRECAUTIONS RELATED TO SAFETY
INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS
INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS
HANDLING HEADREST
HANDLING REVERSIBLE FAN
REVERSING REVERSIBLE FAN
HANDLING CAP WITH LOCK
OPENING AND CLOSING LOCKABLE CAP
PROCEDURE FOR SELECTING RIPPER POINT
PROCEDURE FOR SELECTING RIPPER POINT

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