Komatsu Super D155AX-3 Operation & Maintenance Manual Download Page 69

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Summary of Contents for Super D155AX-3

Page 1: ...y to improve our products whenever it is possible and practical to do so We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes o...

Page 2: ...readily available place near the machine on machines with cab there is a door pocket to hold the manual and have all personnel involved in working on the machine read the manual periodically Some acti...

Page 3: ...These safety messages or labels usually describe precautions that must be taken to avoid the hazard Failure to avoid this hazard may also result in serious damage to the machine h CAUTION NOTICE This...

Page 4: ...ered with no coolant in the radiator flush the inside of the radiator thoroughly with tap water then fill the radiator with coolant Your Komatsu machine has been thoroughly adjusted and tested before...

Page 5: ...NO PLATE POSITION This is above the starting motor at the right side of the machine 4 3 BLADE SERIAL NO PLATE POSITION This is at the top right on the back of the blade 4 4 RIPPER SERIAL NO PLATE POS...

Page 6: ...General view 2 2 10 1 General view of machine 2 2 10 2 General view of controls and gauges 2 3 11 Explanation of compohents 2 5 11 1 Front panel meters lamps switches 2 6 11 2 Switches 2 18 11 3 Cont...

Page 7: ...2 60 2 64 2 66 2 68 2 69 2 70 2 73 2 74 2 76 2 77 2 78 2 79 2 79 2 80 2 82 2 84 2 90 13 Transportation 2 93 13 1 Loading unloading work 2 93 13 2 Precautions for loading 2 94 13 3 Method of lifting ma...

Page 8: ...s 3 14 21 1 Introduction of necessary tools 3 14 21 2 Torque list 3 15 22 Periodic replacement of safety critical parts 3 l 6 23 Maintenance schedule chart 3 20 24 Service Procedure 24 1 Initial 250 h...

Page 9: ...the following manner 5 3 5 3 28 Handling headrest 28 1 Adjusting height of headrest 5 4 5 4 29 Handling reversible fan 29 1 Reversing reversible fan 5 5 5 5 30 Handling cap with lock 5 6 30 1 Opening...

Page 10: ...SAFETY A WARNING Read and follow all safety precautions Failure to do so may result in serious injury or death This safety section also contains precautions for optional equip ment and attachments l l...

Page 11: ...S keep them in good operating condition Safety lever See 12 10 PARKING MACHINE Seat belts See 27 USING SEAT BELT Improper use of safety features could result in serious bodily injury or death CLOTHING...

Page 12: ...for any injury or damage caused by any unauthorized modification 4 STANDING UP FROM THE SEAT 1 To avoid hitting unlocked control levers before standing up from operator s seat do the follwing Move st...

Page 13: ...free of oil grease and excessive dirt When mounting or dismounting or when moving along the top of the track if you hold the door handle and the door is not properly closed the door may move and caus...

Page 14: ...reas Keep oil and fuel in the determined place and do not allow unauthorized persons to enter A0055020 AC055030 A0055040 BURN HAZARD PREVENTION l If the coolant engine oil power train oil or hydraulic...

Page 15: ...55060 CRUSHING OR ClJlTING PREVENTION l Do not enter or put your hand or arm or any other part of your body between movable parts such as between the work equipment and cylinders or between the machin...

Page 16: ...and repairs are carried out in the specified way When carrying out modification or repairs always consult your Komatsu distributor first Even when the ROPS is installed if you do not fasten your seat...

Page 17: ...dure given in the inspection and maintenance section Method of releasing pressure See 11 16 HANDLING ACCUMULATOR The accumulator is filled with high pressure nitrogen gas and it is extremely dangerous...

Page 18: ...If water lines gas lines and high voltage electrical lines may be buried under the worksite contact each utility and identify their locations Be careful not to sever or cut any of these lines Check th...

Page 19: ...in an enclosed area provide adequate ventilation Exhaust fumes from the engine can KILL 1 PRECAUTIONS FOR MIRRORS WINDOWS AND LIGHTS 1 l Remove all dirt from the surface of the windows and lights to e...

Page 20: ...he operator to ride in the cab or on the machine body Check that the backup alarm is working properly Do not add grease or oil after starting the engine PRECAUTIONS WHEN MOVING FORWARD OR BACKWARD Bef...

Page 21: ...These materials may allow the machine to slip if it is traveling sideways Keep travel speed very low When traveling downhill drive slowly and use the engine as a brake Reverse steering when traveling...

Page 22: ...hen working in places where there is danger of falling rocks or danger of the machine turning over install ROPS and a seat belt 1 PARKING THE MACHINE 1 Park on level ground whenever possible ground an...

Page 23: ...ps are wide and long enough to provide a safe loading slope Be sure that the ramps are securely positioned and fastened and that the two sides are at the same level as one another Be sure the ramp sur...

Page 24: ...efore working with batteries stop the engine and turn the starting switch to the OFF position Avoid short circuiting the battery terminals through accidental contact with metallic objects such as tool...

Page 25: ...your Komatsu distributor to have the brake released NEVER allow a disabled machine to be towed on a slope Do not use a kinked or frayed wire rope Do not straddle the towing cable or wire rope When con...

Page 26: ...atsu distributor PROPER TOOLS l Use only tools suited to the task Using damaged low quality faulty or makeshift tools could cause personal injury Tools See 21 1 INTRODUCTION OF NECESSARY TOOLS 9 4 0 I...

Page 27: ...nside of the radiator place the safety lock lever at the LOCK position and carry out the operation with two workers One worker should sit in the operator s seat so that he can stop the engine immediat...

Page 28: ...INE l Always lower all movable work equipment to the ground or to their lowest position before performing service or repairs under the machine l Always block the tracks of the machine securely l Never...

Page 29: ...l in a well ventilated place A0055020 A0055030 A0055040 j RADIATOR WATER LEVEL 1 l When checking the water level stop the engine and wait for the engine and radiator to cool down then check the water...

Page 30: ...re Avoid torching soldering or welding on pipes tubes and equipment that contain fuel or oils If heated they can generate flammable fumes or mist and could cause a fire or explosion Do not forget that...

Page 31: ...3 CHECK BEFORE STARTING Checking final drive case See 24 4 PERIODIC MAINTENANCE Changing oil replacing filters See 24 5 7 PERIODIC MAINTENANCE PRECAUTIONS WHEN USING HIGH PRESSURE GREASE TO ADJUST TR...

Page 32: ...CE l Never dump waste oil in a sewer system rivers etc l Always put oil drained from your machine in containers Never drain oil directly on the ground l Obey appropriate laws and regulations when disp...

Page 33: ...g them again or replace them with a new label There are other labels in addition to the safety labels listed as follows so handle them in the same way Safety labels may be available in languages other...

Page 34: ...people nearby l Be sure no one is on machine area 0 Use spotter if necessary particularly if you are moving in reverse Follow above even if equipped with back up alarm and mirrors 14X 98 11590 A WARN...

Page 35: ...low oil to cool 0 Slowly loosen cap to relieve pressure before removing 14X 98 11521 6 Warnings for adjusting track tension 14X 98 11551 High pressure hazard at track adjuster When adjusting track ten...

Page 36: ...LLOW FULL BRAKE PEDAL TRAVEL WITH OPERA TOR S BACK AGAINST SEAT BACK l AFTER ADJUSTING THE HEIGHT FORE AND AFT POSITIONS OF THE SEAT TIGHTEN THE TETHER BELT BEFORE SITTING IN THE SEAT I 195 98 12940 A...

Page 37: ...o prevent operation during maintenance 09963 03000 Hang this warning plate on the controls in the operator s com partment Do NOT operate When this plate is not being used keep it in the storage compar...

Page 38: ...OF OPERATION MAINTENANCE MANUAL 9 3 PLACE FOR STORING MANUAL To make it possible to read the Operation and Maintenance Manual at any time and to prevent loss of the manual keep the manual in the stora...

Page 39: ...MEMO I 30...

Page 40: ...m 0 2...

Page 41: ...CHINE If directions are indicated in this section they refer to the directions shown by the arrows in the diagram below Machines equipped with cab Lift cylinder Cab I Track shoe Ripper Spiocket Track...

Page 42: ...button Cigarette lighter w Ul control lever Fuel control dial q y 1 control switch Safety lever AD051 591 Engine water temperature gauge Transmission oil tempe ature gauge Chargelamp 1 Glow signal lam...

Page 43: ...k steering and direction Deceleration pedal Blade control lever Max speed setter control lever in puller v Fcontrol switch Fuel control dial AD051601 Engine water Transmission oil Glow signal lamp Mon...

Page 44: ...Switch panel canopy Switches Horn switch Room lamp switch Cigarette lighter Wiper switch Additional working lamp switch Dial control levers pedals switches Fuel control dial Joystick with speed max b...

Page 45: ...lashes to indicate that the meter is advancing Meter will advance by 1 for each hour of operation regardless of the engine speed 2 ENGINE WATER TEMPERATURE GAUGE This gauge indicates the cooling water...

Page 46: ...for the indicator of the engine water temperature gauge to go down to the white range I AD051617 6 CHARGE LAMP This lamp indicates malfunction of the alternator When the starting switch is turned ON i...

Page 47: ...ansmission is switched to the maximum travel speed and the lamp lights up If the button is pressed again the travel speed returns to the speed set by the max speed setter and the lamp goes out The lam...

Page 48: ...stop the engine and contact your Komatsu distributor AD05161H REMARK The alarm buzzer sounds in the following cases 1 When the engine water temperature is abnormally high 2 When the engine oil pressu...

Page 49: ...h normally to this position when strong cooling is needed In this position no ventilation or pressurizing is carried out l FRESH a takes in outside air This is the standard position for cooling and he...

Page 50: ...coming from the vents becomes higher The water valve is opened and the heating function is started STARTING SWITCH This switch is used to start the engine OFF position At this position the starting s...

Page 51: ...his position no ventilation or pressurizing is carried out FRESH a takes in outside air This is the standard position for cooling and heating In this position fresh air is brought in from outside to c...

Page 52: ...At this position the starting switch key can be inserted or removed When the switch is turned to this position the electrical circuits are switched off Do not the starting switch key at the OFF positi...

Page 53: ...CAB I I t_ 1 HEAD LAMP SWITCH This lights up the head lamps OFF position Lamps are out ON position Lamps light up 2 REAR LAMP SWITCH This lights up the rear lamps OFF position Lamps are out ON positi...

Page 54: ...o the ambient temperature when the ambient temperature is below approx 5 C AD051791 I position This is used when AUTO preheating is not enough to start the engine in cold weather simply with the glows...

Page 55: ...TH CANOPY AD051800 1 HEAD LAMP SWITCH This lights up the head lamps OFF position Lamps are out ON position Lamps light up OFF ON LJ AD051790 2 REAR LAMP SWITCH This lights up the rear lamps OFF positi...

Page 56: ...heating manually without using AUTO preheating When the switch is released it will return to the OFF position 4 STARTING SWITCH This switch is used to start the engine OFF position At this position th...

Page 57: ...EQUIPPED WITH CAB This lights up the room lamp ON position Lamp lights up OFF position Lamp is out 3 ClGARElTE LIGHTER MACHINES This is used to light cigarettes EQUIPPED WITH CAB When the cigarette l...

Page 58: ...w This is also used as the window washer switch The switch is operated as follows l Window washer only Keep the switch pressed to the OFF position to spray out water AD051850 0 Wiper only If this is s...

Page 59: ...lamp switch Push in the direction of the arrow to turn on the lamps REMARK When installing the cab check the colors of the washer tank and window washer hoses and be sure to connect correctly AD05188...

Page 60: ...used to adjust the engine speed and output Low idling MIN Position when dial is turned fully to the left 0 Full speed MAX Position when dial is turned fully to the right Front of machine 0 AD051910 R...

Page 61: ...d and the maximum travel speed l Switching between forward and reverse Position FORWARD Position REVERSE Position N Neutral 0 Steering operations Position 0 Left turn Position 0 Right turn When the le...

Page 62: ...ravel speed can be changed using this button only when the lever is at the FORWARD or REVERSE position If the lever is returned to the neutral position this button cancels the maximum speed and return...

Page 63: ...ng at low speed When traveling at low speed Traveling in reverse after ripping If the lever is set at this pqsition the machine Will travel at low speed even when the en Ina h rurmrg a full hKl le use...

Page 64: ...decelerator pedal to reduce the travel speed If the pedal is fully depressed on a level surface or gradual _ slope the machine will stop brake is not applied but on steep slopes if it is necessary to...

Page 65: ...is turned A safety control system is actuated To start the engine return the joystick to neutral before turning the starting key e When the engine is running if the joystick is at the FORWARD or REVER...

Page 66: ...diagram When parking the machine or when carrying out mainte nance always lower the blade and ripper to the ground then set the safety lever to the LOCK position This safety lever is a device to lock...

Page 67: ...Blade will move freely according to external force REMARK l When released from FLOAT position this lever will not return to HOLD position so it must be moved back by hand l When starting the engine se...

Page 68: ...RD PITCH Max digging angle press switch 0 then operate I First set the lever to the neutral position then keep switch in the center of the knob pushed down and carry out the tilt operation to change t...

Page 69: ...sition LOWER Digging angle reduced qti Cutting angle a becomes smaller Digging angle increased lyg 1 Cutting angle a becomes larger AD052060 IO PIN PULLER CONTROL SWITCH FOR GIANT RIPPER This is used...

Page 70: ...off the starting switch The fuses protect the electrical equipment and wiring from burning out If the fuse becomes corroded or white powder can be seen or the fuse is loose in the fuse holder replace...

Page 71: ...Controller HMT I I 15 A 2nd 3rd solenoid I 01 15 A 1st solenoid I 0 20 A Pin puller air conditioner 20 A Backup alarm 0i J 10 A Cab key switch Power circuit AD052120 Fuse box machine equipped with cab...

Page 72: ...11 8 SASH GLASS INTERMEDIATE LOCK MACHINES EQUIPPED WITH CAB When carrying out operations with the cab sash glass open use this block to prevent the glass from moving l When the lever is at the FREE...

Page 73: ...other heavy objects in the pocket If the pocket becomes dirty turn three clips 0 remove the pocket and wash it 11 I 1 ASHTRAY MACHINES EQUIPPED WITH CAB This is on the left side of the operator s sea...

Page 74: ...be displayed Press again to switch the power off Turn the knob clockwise to increase the sound and counterclockwise to reduce it 2 TONE CONTROL KNOB TONE Turn this knob clockwise from the center posi...

Page 75: ...r more than 2 seconds the station will be selected automatically When adjusting the time these change the hour display and minute display 5 PRESET BUT TON 1 2 3 4 5 6 These buttons can be used to prog...

Page 76: ...le to program one station for each preset button Method of manual tuning Press the tuning button lightly to adjust to the desired frequency Each time the button is pressed the frequency will change by...

Page 77: ...hour IO 30 II 00 advances to exact hour 11 13 3 PRECAUTIONS WHEN USING e For safety reasons when operating keep the sound to a level where you can enjoy the sound but still hear the sound from outsid...

Page 78: ...desired position Cooling FRESH c J AD051626 If the air inside the cab is no longer fresh set FRESH RECIRC selector lever to FRESH to bring in fresh air Keep the other switches at the same positions a...

Page 79: ...fresh air Keep the other switches at the same positions as for heating RECIRC In this position the inside of the cab is pressurized to prevent the entry of dust shown in the diagram REMARK If the cab...

Page 80: ...of vents when cooling l If the vents left and right in the middle of the dashboard are turned so that cold air plays directly on the cab door glass moisture may condense on the outside of the cab doo...

Page 81: ...of the compressor Precautions when replacing receiver l If the receiver is left for more than 15 minutes with the blind cover removed the moisture in the air will be absorbed and this will reduce the...

Page 82: ...continuously for a long period with the lever at the RECIRC position the air inside the cab will become stale so when the cab is warmed up always set the FRESH RECIRC selector lever to the FRESH posi...

Page 83: ...ntact your Komatsu distributor The accumulator is a device to store the pressure in the contrc circuit and when it is installed the control circuit can be operate1 for a short time even after the engi...

Page 84: ...E EXTINGUISHER When providing a fire extinguisher install it in the position shown below Position for installing fire extinguisher select the position Rear of operator seat Right stay of ROPS Front of...

Page 85: ...il and step at the side when getting on or off the machine When inspecting if the machine is at an angle move it to a horizontal place to carry out the check Before starting the engine look around the...

Page 86: ...it 4 Check for oil leakage of oil from power train case final drive case hydraulic tank hose joints Check that there is no oil leakage If any abnormality is found repair the place where the oil is le...

Page 87: ...ch coolant has been added 2 After adding water tighten the cap securely 3 If the sub tank is empty check for leakage of water then add water to the radiator and sub tank 4 After adding water close the...

Page 88: ...of the oil to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE After adding fuel tighten the cap securely Fuel capacity 500 e 132 US gal 110 UK gal REMARK If breather hol...

Page 89: ...EL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE If the oil is above the H mark drain the excess engine oil from drain plug and check the oil level again If the oil level is correct tighten...

Page 90: ...ing operations check with the engine stopped and use the dipstick COLD STOP side It is also possible to check the oil level after the engine has been run and the power train oil temperature is high bu...

Page 91: ...t out again The oil level should be between the H and L marks on dipstick 0 If the oil is below the L mark add engine oil through the dipstick holder For details of the oil to use see 20 USE OF FUEL C...

Page 92: ...tes before checking oil level If oil level is between H and L in sight gauge 0 2 If the level is below the L mark add engine oil through oil filler 0 mH 0 Proper range L For details of the oil to use...

Page 93: ...ston to its original position I CHECK ELECTRIC WIRINGS in the electric wiring always locate and repair the cause Check for damage of the fuse and any sign of disconnection or short circuit in the elec...

Page 94: ...GE Check the belt and mounting clamps and if they are worn or damaged replace the seat belt CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR DRAIN WATER The water separator separates water mixed in the...

Page 95: ...ment of seat Turn knob under the seat to match the weight adjustment scale with your own weight The weight can be adjusted within a range of 50 120 kg I 10 3 117 8 lb REMARK If you want to make the se...

Page 96: ...lower the seat back keep the lever pulled up and apply your weight to the seat back ADJUSTING VERTICAL HEIGHT OF SEAT Pull up levers I and in turn and adjust the angle After adjusting release the lev...

Page 97: ...he safety lever securely to the LOCK position 1 2 3 Machines eauiooed with cab Machines equipped with canopy I Check that the brake pedal is locked with parking lever 0 If this lever is not at the LOC...

Page 98: ...t the HOLD position If it is at the FLOAT position the engine will not start Check that the ripper is lowered to the ground Check that the safety lever is locked If safety lever is locked the blade co...

Page 99: ...before trying to start the engine again 1 Turn fuel control dial to a position midway between the low idling and full speed positions Machines equipped with cab _ AD052470 2 Insert the key into start...

Page 100: ...steps 2 and 3 after waiting for about 2 minutes 1 2 3 Carry out preheating Turn fuel control dial to a position midway between the low idling and full speed positions Machines equipped with cab f3 b 4...

Page 101: ...f the engine can not start after automatic preheating start it using manual preheating Manual preheating Turn glow switch to position I or II Lamp lights up during the preheating operation When the pr...

Page 102: ...starts release the key in starting switch 0 The key will return automatically to the ON position OFF I START AD052291 12 2 3 SPECIAL STARTING AFTER RUNNING OUT OF FUEL When starting the engine after...

Page 103: ...canopy or run at a medium speed from time to time J AD05161L 12 3 1 NORMAL OPERATION Turn fuel control dial to the center position between LOW IDLING and HIGH IDLING and run the engine at medium spee...

Page 104: ...l times If the oil temperature in the work equipment is not properly raised there will be a time lag in the response of the work equipment and steering After warm up run is completed check gauges and...

Page 105: ...achine up a steep slope turn fuel control dial fully to set the engine to full speed Then keep brake pedal depressed place max speed setter to the low speed position operate joystick in the direction...

Page 106: ...machine AD052480 Move joystick to the F FORWARD or R REVERSE position gradually release the decelerator pedal and allow the machine to Nd Forward 31 move off REMARK If the speed max button is pressed...

Page 107: ...is also possible to adjust the travel speed with the max speed setter while traveling Machines equipped with cab L REMARK l An automatic transmission is used so if the load on the engine increases du...

Page 108: ...ed and stop the machine before shifting 1 2 3 4 Depress decelerator pedal and reduce the engine speed Return joystick to the neutral position reduce the speed then depress the brake and stop the machi...

Page 109: ...machine may carry out a counterrotation turn so operate the lever fully to the forward or reverse position If the steering and directional lever is pushed forward and moved partially to the left L th...

Page 110: ...e steering and directional lever is placed at the N position and is operated partially to the left the left and right tracks will rotate in opposite directions and the machine will carry out a counter...

Page 111: ...rns to the right push the steering and directional lever forward and move it partially to the right Does not become reverse steering Do the same when traveling in reverse AD052440 l Making sharp turns...

Page 112: ...ment may move suddenly and this may lead to a serious accident Before leaving the operator s seat always operate the safety lever to place it securely at the LOCK position Machines equipped with cab 5...

Page 113: ...on the front monitor panel will flash and the buzzer will sound to warn of an abnormality Apply the brakes lower the work equipment to the ground and set the max speed setter to low speed to reduce t...

Page 114: ...CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW MACHINES EQUIPPED WITH CAB l For safety reasons do not install anything to the cab glass that will obstruct the view e Always keep the glass clean to...

Page 115: ...the work equipment may move suddenly and this may lead to a serious accident Before leaving the operator s seat always operate the safety lever to place it securely at the LOCK position 1 Depress brak...

Page 116: ...6 Set blade control lever and ripper control lever to the HOLD position 7 Lock blade control lever and ripper control lever with safety lever 0 12 11 CHECK AFTER FINISHING WORK Use the meters and cau...

Page 117: ...ptly stop it but run it at low speed to allow it to cool gradually then stop it 1 Place fuel control dial in the low idling position and run the engine at low idling speed for about 5 minutes to allow...

Page 118: ...re hazard 4 Remove any mud stuck to the undercarriage 12 14 LOCKING To prevent vandalism there are locks at the following places Places that can be locked with the starting switch key l Right and left...

Page 119: ...FLOW machines If there is frequent shoe slippage as on conventional machines and the R F deceleration must be operated set the speed slightly towards low speed position 0 60 Even when the engine is ru...

Page 120: ...a giant ripper 1 Stop the machine in a safe place and lower the shank to the ground 2 Operate the pin puller controller switch and remove the mount ing pin 3 Move the ripper up or down to set to the d...

Page 121: ...wn on the right The range within the arrows is the suitable range If frequent shoe slippage is noted during dozing operations move the max speed setter slightly towards the low speed position This wil...

Page 122: ...dug effectively by a tilted or angled blade 12 16 4 FELLING TREES REMOVING STUMPS NOTICE Do not up root trees or stumps or fell trees by angling or tilting the blade For trees with a diameter of 10 3...

Page 123: ...a safe condition then stop the engine and lock the work equipment securely with the safety lever l Be careful when removing arm 0 After arm is removed the blade can move freely 1 Raise the blade 300...

Page 124: ...mbling an angle dozer to the C frame adjust the clearance of the center joint by adjusting the length of arm and brace so that dimension S of center joint is 20 mm 0 8 in AD052690 Clearance S Section...

Page 125: ...lade does not come down 2 Loosen set bolt of the brace insert a suitable bar into of the brace and turn it REMARK When rotating the brace with the adjustment bar carry operation with the blade raised...

Page 126: ...4 in REMARK When adjusting the tilt in Steps 1 and 2 carry out the operation with the blade raised from the ground NOTICE The standard value for distance L between the joints is 1389 mm 54 7 in but ad...

Page 127: ...t pin 0 partially by hand then knock it in with a hammer The pin is made of one piece so insert it partially by hand then knock it in with a hammer When a giant ripper is installed use the pin puller...

Page 128: ...0 The standard for the cutting angle 6 is 54 The standard for the distance U between the joints is 1493 mm 58 8 in 2 Power tiltdozer Turn the brace with bar handle and the distance WI between the join...

Page 129: ...When making turns be careful not to allow the machine to stay to one side so operation in both turning directions can be done properly Make turns with the largest possible radius Prior to operation c...

Page 130: ...t proce dures refer to 24 2 WHEN REQUIRED 12 18 3 INSPECTION AND REPAIR Frequent inspection and prompt repair will reduce repair costs The following items for inspection will serve as a guide to maint...

Page 131: ...I in h 3 AD052880 MEASURING OUTSIDE DIAMETER OF TRACK ROLLER 1 2 3 Measure height size C of link tread as shown Stop machine at position where link tread whose size C has been measured completely cont...

Page 132: ...m and carry out the operations as follows 1 Properly apply the brakes on the trailer and insert blocks beneath the tires to ensure that it does not move Then fix the ramps in line with the centers of...

Page 133: ...ters to the minimum speed position Turn the starting switch to the OFF position stop the engine then remove the key Lock the cab door left and right engine side covers and the battery inspection cover...

Page 134: ...ne carry out the operation as follows on flat ground 1 2 Stop the engine and lock the brakes Fit the wire rope to the specified positions The external shape of the machine differs according to the typ...

Page 135: ...TH CAB If it is necessary to remove the cab for transportation disconnect the washer hoses cab wiring and washer motor wiring before removing the cab 1 Push the grommet portion from the hole in the ma...

Page 136: ...In this case clean the cooling system twice a year in spring and autumn When refilling the cooling system add antifreeze in autumn but do not add any in spring Absolutely avoid using any water leak p...

Page 137: ...of the battery will also drop If the battery charge ratio is low the battery electro lyte may freeze Maintain the battery charge as close as possible to lOO and insulate it against cold temperature so...

Page 138: ...d in the fuel system to prevent it from freezing l As the battery capacity drops markedly in low temperatures cover the battery or remove it from the machine keep it in a warm place and install it aga...

Page 139: ...hine and store it separately If the ambient temperature is expected to drop below OT always add antifreeze to the cooling water Place all control levers at the neutral position operate the safety leve...

Page 140: ...ored without carrying out the monthly rust prevention operation request your Komatsu distributor for service Carry out the following procedure when taking the machine out of long term storage l Wipe o...

Page 141: ...e max speed setter is at the minimum speed position 4 When the automatic transmission is used the sound of the clutches being shifted is heard when changing gear REMARK With this machine the transmiss...

Page 142: ...with fuel and bleed the air from the fuel system before starting For details of bleeding the air see 24 5 EVERY 500 HOURS SERVICE 16 3 METHOD OF TOWING MACHINE dh WARNING l When towing the machine us...

Page 143: ...tool touches the cable connecting the positive terminal and the chassis there is danger that it will cause sparks If the terminals are loose there is danger that the defective contact may generate spa...

Page 144: ...could cause serious injury Make sure that there is no mistake in the booster cable connections The final connection is to the engine block of the problem machine but sparks will be generated when this...

Page 145: ...THE ENGINE 1 Make sure the clips are firmly connected to the battery terminals 2 Start the engine of the normal machine and keep it to run at high idling speed 3 Turn the starting switch of the probl...

Page 146: ...eps going in and out l Insufficient battery charge l Charge Starting motor turns engine sluggishly l Insufficient battery charge l Charge l Defective starting motor o Replace Starting motor disengages...

Page 147: ...pressure caution lamp does not light up when starting switch is turned ON l Defective caution lamp l Defective wiring l Defective charge pressure sensor o Replace o Check repair o Replace Electronic...

Page 148: ...se clogged o Check replace l Add oil to specified level For details see CHECKS BEFORE STARTING 0 Clean For details see EVERY 1000 HOURS SERVICE Lack of drawbar pull travel speed does l Abnormality in...

Page 149: ...ting motor cranks engine sluggishly Glow signal does not glow red Defective compression o Defective valve clearance a Too much oil in oil pan l Improper fuel a Clogged air cleaner element l Defective...

Page 150: ...MAINTENANCE ALWARNING Always hang the DANGER DO NOT OPERATE sign in the opera tor s compartment when carrying out maintenance 3 l...

Page 151: ...nd grease Keeping the machine clean Always keep the machine clean This makes is easier to find parts causing problems Keep in particular grease fittings breathers and oil level gauges clean and avoid...

Page 152: ...Use nonflammable cleaner or light oil for cleaning parts Keep flame or cigarette light away from light oil Clamp faces When O rings or gaskets are removed clean the clamp faces and replace the O rings...

Page 153: ...to avoid clogging l Clean and replace the fuel filter frequently l Clean electrical components especially the starting motor and alternator to avoid accumulation of dust Avoid mixing oils Never mix oi...

Page 154: ...perature for use given in the Operation and Maintenance Manual Even if the oil is not dirty always replace the oil after the specified interval Oil corresponds to blood in the human body so always be...

Page 155: ...ecautions given in the Operation and Maintenance Manual Komatsu machines are supplied with Komatsu original anti freeze in the coolant when the machine is shipped This anti freeze is effective in prev...

Page 156: ...ur content being used l Never try to clean the filters cartridge type and use them again Always replace with new filters l When replacing oil filters check if any metal particles are stuck to the old...

Page 157: ...ade U blade t Part No 07063 01100 07000 72100 600 211 1230 600 311 7131 600 41 l l 150 07063 01100 07000 02135 07063 01054 07000 021 IO 6128 81 7042 600 181 4400 14x 91 1 7741 195 70 12492 17A 71 1135...

Page 158: ...tting edge Cutting edge Bolt Nut End bit left End bit right Bolt Nut 175 78 31230 Point Multi 195 78 21320 Protector 09244 02508 Pin Point Protector Pin Weight kg 48 8 64 1 37 37 15 13 15 13 o w 1 2 2...

Page 159: ...ERATURE 2 4 14 32 50 68 86 104 F 0 20 10 0 10 20 30 40 C Add antifreeze ASTM D975 No 1 r CAPACITY Specified Refill 42 Q 37 e 11 09 US gal 9 77 US gal 9 24 UK gal 8 14 UK gal 1 5 e 1 5 e 0 40 US gal 0...

Page 160: ...perature goes up to IO C more or less in the day time Use API classification CD as engine oil and if API classification CC reduce the engine oil change interval to half There is no problem if single g...

Page 161: ...P Energrease LS EP2 Antifreeze 6 CALTEX RPM delo 400 Universal thuban Mat fak all purpose 2 RPM delo 450 Universal thuban EP Ultra duty grease 2 AF engine coolant EP Turbomax EPX 7 CASTROL RX super HY...

Page 162: ...e bearing summer coolant grease 15 PETROFINA FINA kappa TD FINA potonic N FINA potonic NE FINA marson EPLP FINA tamidor 16 SHELL Rimula X Spirax EP Alvania EP grease Spirax heavy duty Sunoco ultra pre...

Page 163: ...1400 07950 90403 Remarks Applicable width across flats S S 8 mm 10 mm 12 mm 14 mm 13 mm 17 mm 19 mm 22 mm s2 24 mm 27 mm 30 mm 32 mm ADO53370 36mm 41 mm Applicable width across flats 46 mm Interchange...

Page 164: ...10 13 2 2 1 4 1 35 f 0 15 3 73 z1 03 8 13 31 4 f 2 9 3 2 T 0 3 23 2 2 2 1 10 17 65 7 6 8 6 7 0 7 48 5 5 0 12 19 112 r 9 8 11 5 2 1 0 82 6 2 7 2 14 22 177 19 18 0 k 2 0 131 2 14 16 24 18 27 20 30 22 32...

Page 165: ...ver it is difficult to judge the condition of the parts simply by periodic maintenance so they should always be replaced after a fixed time has passed regardless of their condition This is necessary t...

Page 166: ...e preset port 1 11 Hose PPC charge valve HMT pump servo port 1 12 Hose HMT pump servo port HMT motor servo port 1 13 Hose power train pump power train filter 1 Every 2 years or 4000 hours whichever co...

Page 167: ...cooler bypass valve relay tube 2 I 30 Hose relay tube hydraulic cooler inlet port 1 31 Hose relay tube hydraulic cooler outlet port 1 Every 2 years or 4000 hours 32 Hose hydraulic cooler bypass valve...

Page 168: ...22 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS AD054280...

Page 169: ...e and replace the end bits and cutting edges 3 34 Replace fan belt Clean check radiator fins 3 36 Replace air conditioner belt 3 37 Clean check hydaulic cooler fins 3 38 Adjust idler clearance 3 39 Ch...

Page 170: ...st indicator Check electric wirings Check that lamps light up 3 53 3 54 3 54 3 55 Check horn sound 3 55 Check backup alarm sound 3 55 Check seat belt for wear or damage 3 55 Check for water and sedime...

Page 171: ...thread 2 Placed Ripper l Tilt cylinder bottom pin 2 places l Lift cylinder bottom pin 2 places l Tilt cylinder rod end pin 2 places 3 59 3 59 3 59 l Lift cylinder rod end pin 2 places 3 59 l Arm pin...

Page 172: ...lean fuel strainer 3 71 Replace charge filter element 3 72 Grease idler adjustment rod left right 1 place each 3 72 Check for loose ROPS mount bolts 3 72 EVERY 2000 HOURS SERVICE Change oil in hydraul...

Page 173: ...IN OIL FILTER ELEMENT l CHANGE OIL IN POWER TRAIN CASE CLEAN STRAINERS l CHANGE OIL IN FINAL DRIVE CASE l REPLACE CHARGE FILTER ELEMENT l CHANGE OIL IN HYDRAULIC TANK REPLACE HYDRAULIC OIL FILTER ELEM...

Page 174: ...hand Remove the filler cap slowly to relieve pressure When removing drain plug avoid pouring coolant on your self Antifreeze is flammable so keep it away from any flame l Clean the inside of the cooli...

Page 175: ...ifreeze to water check the lowest temperature in the past and decide from the mixing rate table given below It is actually better to estimate a temperature about 10 C 50 F lower when deciding the mixi...

Page 176: ...tem with a flushing agent For details of the flushing method see the instructions on the flushing agent After flushing open drain valve 0 drain out all the water close drain valve and add tap water so...

Page 177: ...ean the inside of the sub tank then fill again with cooling water to a point midway between the FULL and LOW marks 15 Stop the engine wait for 3 minutes add city water until the water level reaches ne...

Page 178: ...of times the outer element has been cleaned can be seen by the number of removed seals 1 2 3 4 5 Replace the outer element which has been cleaned 6 times repeatedly or used throughout a year Replace t...

Page 179: ...tape to cover the air connector outlet side Clean the air cleaner body interior then remove the cover installed in Step 2 Fit a new inner element to the connector and tighten it with nuts Do not clean...

Page 180: ...e track tension is not at the standard value adjust it in the following manner ADJUSTMENT a WARNING Grease inside the adjusting mechanism is under high pressure Grease coming from lubricator under pre...

Page 181: ...come out smoothly move the machine backwards and forwards a short distance Tighten lubricator 0 To check that the correct tension has been achieved move the machine backwards and forwards Check the tr...

Page 182: ...further 120 i 10 l Method for tightening master link connecting bolt 1 First tighten to a tightening torque of 588 f 59 Nm 60 f 6 kgm 434 f 43 Ibft then check that the link contact surfaces are in clo...

Page 183: ...AND CUlTING EDGES worn out to the blade end 1 2 3 Raise the blade to a proper height and apply a block to the frame so as to prevent fall of the blade Operate the safety lever to the LOCK position Me...

Page 184: ...6 f 162 Nm 152 5 f 16 5 kgm 1103 f 119 Ibft Angledozer 869 f 130 Nm 88 6 a 13 3 kgm 641 f 96 Ibft If bolt and nut are damaged replace them with new ones at the same time Loosen nuts 0 remove bolts 0 t...

Page 185: ...ater hit your body directly there is danger of injury Always wear protective glasses mask and safety shoes If the radiator fins are clogged or dirty clean and inspect them 1 2 3 4 5 Remove bolts 4 bol...

Page 186: ...s and tighten bolt 0 I AD053131 24 2 9 REPLACE AIR CONDITIONER BELT 1 Loosen 4 bolts and jack bolt 0 then move compressor to the side 2 Replace the V belt REMARK When adjusting the V belt do not push...

Page 187: ...s plate by 8 mm 3 Remove cooler mounting bolts x 4 and I x 41 and hose clips 4 Open the hydraulic cooler to the hinge side then clean and check the fins The hydraulic cooler can be opened approx 40 5...

Page 188: ...nd links may result Therefore adjust the idlers according to the following proce dure ADJUSTMENT 1 Drive the machine on level ground for I 2 m 3 28 6 56 ft then remove covers both inside and outside a...

Page 189: ...t slowly and check if oil oozes out from the thread If oil oozes out the oil level has not gone down so tighten the bolt h AD053200 If no oil comes out even when seal bolt iJ is removed the oil level...

Page 190: ...nnecting hoses I and 0 be careful not to mistake 1 Open cover at the top of the right fender 2 Remove hoses 0 0 and 3 Remove connectors assembled to them and then wash and clean the screens A5254080 4...

Page 191: ...open cover 0 then remove FRESH filter 0 Open inspection cover under the front panel pull up RECIRC filter 0 and remove it Clean filters and with compressed air If there is oil stuck to the filter or i...

Page 192: ...dling and check the flow of the refrigerant in the refrigerant circuit through the sight glass of the receiver when the cooler is running at high speed l No bubbles in refrigerant flow Correct l Bubbl...

Page 193: ...fluid When adding fluid be careful not to let dirt or dust get in 24 2 20 BLEED AIR FROM HEAD END OF RIGHT PITCH CYLINDER POWER TILT POWER PITCH DOZER ONLY Bleed the air if the work equipment has bee...

Page 194: ...ce the blade Method of replacement l Front rear wiper 1 Remove screw 0 then remove the blade 2 Install a new blade then tighten screw securely l Door wiper 1 It is hooked at portion so move the blade...

Page 195: ...sis 2 Hold cover and gradually remove 2 bolts at the rear of the chassis Be careful when doing this as rain water may run out 3 Lower cover slowly and open it There is a hinge at the front of the cove...

Page 196: ...IO Refill the engine oil through oil filler 0 For details of the oil to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE If the spring or strainer are damaged replace the...

Page 197: ...water tighten the cap securely 3 If the sub tank is empty check for leakage of water then add water to the radiator and sub tank 4 After adding water close the engine side cover FULL LOW AD052280 24 3...

Page 198: ...completing work fill the fuel tank through oil filler port 0 For details of the oil to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENTTEMPERATURE 3 After adding fuel tighten the ca...

Page 199: ...OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE If the oil is above the H mark drain the excess engine oil from drain plug 8 and check the oil level again If the oil level is correct...

Page 200: ...level before starting operations check with the engine stopped and use the dipstick COLD STOP side It is also possible to check the oil level after the engine has been run and the power train oil tem...

Page 201: ...tick holder then pull it out again 4 The oil level should be between the H and L marks on dipstick 63 If the oil is below the L mark add engine oil through the dipstick holder For details of the oil t...

Page 202: ...ove the H line This will damage the hydraulic equipment and cause the oil to spurt out 1 2 Lower the blade to the ground stop the engine and wait for about 5 minutes before checking oil level If oil l...

Page 203: ...s frequently or there are traces of shortcircuiting in the electric wiring always locate and repair the cause Check for damage of the fuse and any sign of disconnection or short circuit in the electri...

Page 204: ...R DAMAGE Check the belt and mounting clamps and if they are worn or damaged replace the seat belt 24 3 16 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR DRAIN WATER The water separator separates wate...

Page 205: ...shed out l Grease fan pulley 1 place Front of engine side cover left 0 1 2 3 Grease equalizer bar side pin 4 places Two each on the left and right sides of the Remove all the sand and soil from the to...

Page 206: ...grease fitting marked by the arrow 4 Return hinged cover to its original position install bolt 0 to hold it in position then close the engine side cover l Power tilt dozer AD054220 1 Lift cylinder sup...

Page 207: ...t Power pitch dozer AD054240 1 Lift cylinder support yoke 4 places 2 Lift cylinder support shaft 2 places 3 Blade arm 2 places 4 Tilt cylinder ball joint I place 5 Pitch cylinder ball joint I place 6...

Page 208: ...Lift cylinder support shaft 2 places 3 Tilt brace thread 2 places l Ripper 1 Tilt cylinder bottom pin 2 places 2 Lift cylinder bottom pin 2 places 3 Tilt cylinder rod end pin 2 places 4 Lift cylinder...

Page 209: ...irectly at the bottom 1 AD053390 2 Remove oil level plug and check whether the final drive case is filled with oil to lower edge of the plug hole 3 If the oil level is low remove plug and add engine o...

Page 210: ...cap 0 and check that the electrolyte is at the specified level IO to 12 mm 0 39 to 0 47 in above the plate If the electrolyte level is low add distilled water to the specified level If the battery ele...

Page 211: ...nuts 0 0 and to secure alternator in position 4 Install the cover and tighten cover mounting bolts Check that the covers do not contact the rotating portion of the alternator REMARK l Check for damage...

Page 212: ...are excessive metal particles or foreign material please contact your Komatsu distributor 4 Install drain plug and drain valve 0 Tightening torque Drain plug 8 68 6 f 9 8 Nm 7 1 kgm 50 6 7 2 Ibft Drai...

Page 213: ...ing for a short time then stop the engine and check that the oil level is between the H and L marks on the dipstick For details see 24 3 CHECK BEFORE STARTING NOTICE Even if the machine has not been o...

Page 214: ...e FREE position then operate blade control lever and ripper control lever to raise the blade and ripper Leave the safety lever to the FREE position Machines equippg with cab m Set parking lever to the...

Page 215: ...er 5 When installing tighten until the packing surface contacts the seal surface of the filter holder then tighten it up 112 to 3 4 of a turn If the filter cartridge is tightened too far the packing w...

Page 216: ...oved parts and the inside of the case then install a new element Always use a genuine Komatsu element Close cover 0 tighten bolt 0 then close engine side cover iJ on the left side of the machine r ADO...

Page 217: ...ement in the power train oil filter For details see 24 5 EVERY 500 HOURS SERVICE Refill the specified quantity of engine oil through oil filler 0 I m f II I Ill Maintenance for every 250 and 500 hours...

Page 218: ...ghten the plugs Add engine oil to the specified level through the hole in oil filler plug 0 For details of the oil to use see 20 USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Che...

Page 219: ...e undercover is heavy Never try to open or close the cover when directly beneath it When removing bolts 0 carry out the work from the rear below the cover so that you can easily get out of the way 24...

Page 220: ...ys use a genuine Komatsu cartridge 24 6 7 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER Contact your Komatsu distributor to have the tightening portions checked 24 6 8 GREASE TENSION PULLEY ASSEMBLY 1 PL...

Page 221: ...er case 0 then install a new element Use a genuine Komatsu element 6 Install inspection cover with bolt 0 24 6 11 GREASE IDLER ADJUSTMENT ROD LEFT RIGHT 1 PLACE EACH 1 Remove bolt 0 then remove cover...

Page 222: ...0 then drain the oil After draining the oil tighten drain valve and plug 0 When loosening drain valve 0 be careful not to get oil on yourself Loosen mounting bolt of inspection cover of the fuel tank...

Page 223: ...O ring with a new part coat with engine oil I u AD053940 and install it 24 7 5 CHECK VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the rubber If any cracks or p...

Page 224: ...hen removing bolt 0 carry out the operation at the rear of the point immediately under the cover so that it is always possible to escape Container to catch drained oil Min 1 5 a capacity Refill capaci...

Page 225: ...ck that the oil is at the level 25 mm 0 99 in in the diagram If the oil level is low add engine oil through the hole of plug 0 For details of the fuel to use see 20 USE OF FUEL COOLANT AND LUBRICANTS...

Page 226: ...ECK WATER PUMP Check that there is oil leakage water leakage or clogging of the drain hole If any abnormality is found contact your Komatsu distributor for disassembly and repair or replacement 24 8 2...

Page 227: ...3 78...

Page 228: ...SPECIFICATIONS 4 l...

Page 229: ...2 km h 7 0 MPH 13 9 km h 8 6 MPH Komatsu S6D140 diesel engine 302 HP 1432 Nm 146 kgmYl250 rpm 0 Startina motor 24V 11 kW l Alternator l Batten 24V 35A 12 V 170 Ah x 2 pieces TOWING l Towing force SOU...

Page 230: ...25 SPECIFICATIONS Hydraulic tiltdozer semi U dozer With hydraulic variable multi shank ripper ROPS cab 560 mm single shoe side cover 3210 10 6 2510 8 3 I Overall length 8155 26 9 AD053610 4 3...

Page 231: ...MEMO 4 4...

Page 232: ...OPTIONS ATTACHMENTS n...

Page 233: ...I Specifications use Track shoes Ripper point Wide shoe width Wide shoe width Wide shoe width Heavy duty shoe width Heavy duty shoe width 610 mm 24 660 mm 26 710 mm 28 610 mm 24 660 mm 26 Reversible f...

Page 234: ...eat hold the tongue of reel 0 and pull the belt out slowly to a length which fully covers your lap Insert the tongue into buckle and push until there is a click Pull back reel until the belt fits secu...

Page 235: ...DJUSTING HEIGHT OF HEADREST l To make it higher Hold the headrest and pull it up AD053760 l To make it lower Keep knob pushed down and push the headrest down to the desired position Height adjustment...

Page 236: ...s but rotate the fan as follows Use the starting motor to rotate the fan Loosen the nut of the spring which applies tension to the tension pulley reduce the belt tension and rotate by hand Do not loos...

Page 237: ...s as follows WHEN OPENING CAP 1 1 Insert the key Make sure that you have inserted the key fully 1 before turning it If the key is turned when only partially inserted it may break 2 Turn the key counte...

Page 238: ...e granite chert Typical l Very high l Fairly high proportion of quartz 40 70 rock proportion of l Does not form seams or layers so there is excessive Features quartz 70 95 generation of heat from the...

Page 239: ...the operation is carried out by two or more workers determine signals and follow these during the operation When carrying heavy objects more than 25 kg 55 lb use a crane When removing heavy parts alw...

Page 240: ...ROPOSAL FOR MANUAL REVlslON Fax No 847 970 4186 PFMRl 081696 FOR INTERNAL USE ONLY No PMR 2 NAME OF COMPANY S DEPARTMENT E R NAME LOCATION PHONE NO DATE MANUAL NAME MANUAL NO MACHINE MODEL S N IF APPL...

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Komatsu Super D155AX-3, Operation & Maintenance Manual

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