Komatsu D155C-1 PIPELAYER Operation & Maintenance Manual PEN00060-00 – PDF DOWNLOAD

Komatsu D155C-1 PIPELAYER Operation & Maintenance Manual PEN00060-00 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D155C-1 PIPELAYER Operation & Maintenance Manual PEN00060-00 – PDF DOWNLOAD

Language : English
Pages : 226
Downloadable : Yes
File Type : PDF
Size: 6.84 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu D155C-1 PIPELAYER Operation & Maintenance Manual PEN00060-00 – PDF DOWNLOAD

SERIAL NUMBERS 31586 and up

FOREWORD:
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 D155C-1 PIPELAYER Operation & Maintenance Manual PEN00060-00 – PDF DOWNLOAD

COVER…………………………………………………………………………………………………….. 1
FOREWORD………………………………………………………………………………………………….. 2
FOREWORD………………………………………………………………………………………………. 3
SAFETY INFORMATION……………………………………………………………………………………… 6
INTRODUCTION…………………………………………………………………………………………… 8
FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHIHE……………………………………………………………. 8
BREAKING THE NEW MACHINE…………………………………………………………………………….. 8
NECESSARY INFORMATION…………………………………………………………………………………… 9
MACHINE SERIAL NO.PLATE AND POSITION………………………………………………………………….. 9
ENGINE SERIAL NO.PLATE AND POSITION…………………………………………………………………… 9
POSISION OF SERVICE METER……………………………………………………………………………. 10
TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR………………………………………………………………. 10
CONTENTS………………………………………………………………………………………………….. 11
SAFETY……………………………………………………………………………………………………. 14
SAFETY………………………………………………………………………………………………… 15
SAFETY LABELS………………………………………………………………………………………….. 17
POSITION OF SAFETY PICTOGRAMS………………………………………………………………………… 17
SAFETY LABELS………………………………………………………………………………………. 18
GENERAL PRECAUTIONS…………………………………………………………………………………….. 21
SAFETY RULES……………………………………………………………………………………….. 21
IF ABNORMALITIES ARE FOUND…………………………………………………………………………… 21
COLTHING AND PERSONAL PROTECTIVE ITEMS………………………………………………………………… 21
FIRE EXTINGUISHER AND FIRST AID KIT…………………………………………………………………… 21
SAFETY FEATURES…………………………………………………………………………………….. 21
KEEP MACHINE CLEAN………………………………………………………………………………….. 22
INSIDE OPERATOR’S COMPARTMENT………………………………………………………………………… 22
ALWAYS APPLY LOCK WHEN LEVAVING OPERATOR’S SEAT………………………………………………………… 22
HANDRAILS AND STEPS…………………………………………………………………………………. 23
MOUNTING AND DISMOUNTING…………………………………………………………………………….. 23
NO PEOPLE ON ATTACHMENTS…………………………………………………………………………….. 23
PREVENTION OF BURNS…………………………………………………………………………………. 24
FIRE PREVENTION…………………………………………………………………………………….. 24
ACTION IF FIRE OCCURS……………………………………………………………………………….. 25
WINDOW WASHER LIQUID………………………………………………………………………………… 25
PRECAUTIONS FOR ATTACHMENTS………………………………………………………………………….. 25
CAB WINDOW GLASSES………………………………………………………………………………….. 25
UNAUTHORIZED MODIFICATION……………………………………………………………………………. 26
SAFETY AT WORKSITE………………………………………………………………………………….. 26
WORKING ON LOOSE GROUND……………………………………………………………………………… 26
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES………………………………………………………………… 27
ENSURE GOOD VISIBILITY………………………………………………………………………………. 27
VENTILATION FOR ENCLOSED AREAS……………………………………………………………………….. 27
CHECKING SIGNALMAN’S SIGNALS AND SIGNS………………………………………………………………… 27
BE CAREFUL ABOUT ASBESTOS DUST……………………………………………………………………….. 28
PRECAUTIONS FOR OPERATION……………………………………………………………………………….. 29
BEFORE STARTING ENGINE………………………………………………………………………………. 29
CHECKS BEFORE STARTING ENGING…………………………………………………………………….. 29
PRECAUTIONS WHEN STARTING………………………………………………………………………… 29
PRECAUTIONS IN COLD AREAS………………………………………………………………………… 30
OPERATION …………………………………………………………………………………………. 31
CHECKS BEFORE OPERATION………………………………………………………………………….. 31
PRECAUTIONS FOR MOVING MACHINE FOEWARD OR IN REVERSE………………………………………………… 31
PRECAUTIONS WHEN TRAVELING……………………………………………………………………….. 32
TRAVELING ON SLOPES……………………………………………………………………………… 32
PROHIBITED OPERATIONS …………………………………………………………………………… 32
USING BRAKES……………………………………………………………………………………. 33
OPERATE CAREFULLY ON SNOW………………………………………………………………………… 33
PARKING MACHINE…………………………………………………………………………………. 33
TRANSPORTATION……………………………………………………………………………………… 34
SHIPPING……………………………………………………………………………………….. 34
BATTERY……………………………………………………………………………………………. 35
BATTERY HAZARD PREVENTION………………………………………………………………………… 35
STARTING WITH BOOSTER CABLE………………………………………………………………………. 36
TOWING…………………………………………………………………………………………….. 37
WHEN TOWING…………………………………………………………………………………….. 37
PRECAUTIONS FOR MAINTENANCE……………………………………………………………………………… 38
WARNING TAG………………………………………………………………………………………… 38
KEEP WORK PLACE CLEAN AND TIDY……………………………………………………………………….. 38
APPOINT LEADER WHEN WORKING WITH OTHERS……………………………………………………………….. 38
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE………………………………………………. 39
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING……………………………………………………… 40
PROPER TOOLS……………………………………………………………………………………….. 40
PERSONNEL………………………………………………………………………………………….. 40
ATTACHMENTS………………………………………………………………………………………… 41
WORK UNDER THE MACHINE………………………………………………………………………………. 41
NOISE……………………………………………………………………………………………… 41
PRECAUTIONS WHEN USING HAMMER………………………………………………………………………… 41
REPAIR WELDING……………………………………………………………………………………… 41
REMOVING BATTERY TERMINAL……………………………………………………………………………. 41
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION………………………………………. 42
DO NOT DISASSEMBLE RECOIL SPRING …………………………………………………………………….. 42
PRECAUTION WHEN HIGH-PRESSURE OIL…………………………………………………………………….. 42
HANDLING HIGH-PRESSURE HOSES…………………………………………………………………………. 43
WASTE MATERIAL …………………………………………………………………………………….. 43
MAINTENANCE FOR AIR CONDITIONER………………………………………………………………………. 43
COMPRESSED AIR……………………………………………………………………………………… 43
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS………………………………………………………….. 43
OPERATION…………………………………………………………………………………………………. 44
GENERAL VIEW…………………………………………………………………………………………… 45
GENERAL VIEW OF MACHINE……………………………………………………………………………… 45
GENERAL VIEW OF CONTROLS AND GAUGES…………………………………………………………………… 46
EXPLANATION OF COMPONENTS……………………………………………………………………………….. 48
FRONT PANEL………………………………………………………………………………………… 48
SWITCHES…………………………………………………………………………………………… 57
CONTROL LEVERS, PEDALS………………………………………………………………………………. 61
FUSE BOX…………………………………………………………………………………………… 77
DOOR OPEN LOCK……………………………………………………………………………………… 79
ASHTRAY……………………………………………………………………………………………. 79
TOOL BOX…………………………………………………………………………………………… 79
HEATER, HANDLING……………………………………………………………………………………. 80
AIR CONDITIONER, HANDLING……………………………………………………………………………. 81
OPERATION……………………………………………………………………………………………… 85
CHECK BEFORE STARTING ENGINE, ADJUST………………………………………………………………….. 85
STARTING ENGINE (NORMAL, IN COLD WEATHER)………………………………………………………………102
OPERATIONS AND CHECKS AFTER STARTING ENGINE (NORMAL, IN COLD WEATHER)……………………………………..106
STOPPING ENGINE……………………………………………………………………………………..110
MOVING MACHINE………………………………………………………………………………………111
STOPPING MACHINE…………………………………………………………………………………….113
SHIFTING GEAR……………………………………………………………………………………….113
SHIFTING BETWEEN FORWARD AND REVERSE…………………………………………………………………..114
STEERING MACHINE…………………………………………………………………………………….115
PRECAUTIONS FOR OPERATION…………………………………………………………………………….119
PARKING MACHINE……………………………………………………………………………………..121
CHECK AFTER FINISHING WORK……………………………………………………………………………123
LOCKING…………………………………………………………………………………………….123
TIPS FOR LONGER UNDERCARRIAGE LIFE…………………………………………………………………….124
TRANSPORTATION………………………………………………………………………………………….126
TRANSPORTATION PROCEDURE……………………………………………………………………………..126
LOADING, UNLOADING WORK………………………………………………………………………………126
PRECAUTIONS FOR LOADING………………………………………………………………………………126
METHOD OF LIFTING MACHINE…………………………………………………………………………….127
PRECAUTIONS FOR TRANSPORTATION………………………………………………………………………..127
TRAVELING ON ROADS…………………………………………………………………………………..127
PROCEDURE FOR REMOVAL AND INSTALLATION OF CAB…………………………………………………………..128
PROCEDURE FOR REMOVAL AND INSTALLATION OF BOOM………………………………………………………….130
PROCEDURE FOR REMOVAL AND INSTALLATION OF COUNTER WEINGHT………………………………………………..132
COLD WEATHER OPERATION…………………………………………………………………………………..134
PRECAUTIONS FOR LOW TEMPERATURE……………………………………………………………………….134
AFTER COMPLETION OF WORK……………………………………………………………………………..136
AFTER COLD WEATHER…………………………………………………………………………………..136
LONG-TERM STORAGE……………………………………………………………………………………….137
BEFORE STORAGE………………………………………………………………………………………137
DURING STORAGE………………………………………………………………………………………137
AFTER STORAGE……………………………………………………………………………………….137
TROUBLESHOOTING…………………………………………………………………………………………138
AFTER RUNNING OUT OF FUEL…………………………………………………………………………….138
METHOD OF TOWING MACHINE……………………………………………………………………………..138
IF BATTERY IS DISCHARGED……………………………………………………………………………..139
OTHER TROUBLE……………………………………………………………………………………….142
MAINTENANCE………………………………………………………………………………………………..145
GUIDES TO MAINTENANCE……………………………………………………………………………………146
OUTLINES OF SERVICE……………………………………………………………………………………..148
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…………………………………………………..148
OUTLINE OF ELECTRIC SYSTEM……………………………………………………………………………150
WEAR PARTS LIST…………………………………………………………………………………………151
WEAR PARTS LIST……………………………………………………………………………………..151
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE………………………………………….152
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS………………………………………………………..152
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS……………………………………………………………..157
TORQUE LIST…………………………………………………………………………………………157
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS………………………………………………………………158
SAFETY CRITICAL PARTS………………………………………………………………………………..158
MAINTENANCE SCHEDULE CHART……………………………………………………………………………….159
MAINTENANCE SCHEDULE CHART……………………………………………………………………………159
SERVICE PROCEDURE……………………………………………………………………………………….161
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)……………………………………………….161
WHEN REQUIRED……………………………………………………………………………………….162
CLEAN INSIDE OF COOLING SYSTEM…………………………………………………………………….162
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT………………………………………………………..165
CHECK AND ADJUST TRACK TENSION…………………………………………………………………….167
CHECK AND TIGHTEN TRACK SHOE BOLTS…………………………………………………………………169
CHECK ELECTRICAL INTAKE AIR HEATER…………………………………………………………………169
ADJUST IDLER CLEARANCE……………………………………………………………………………170
CLEAN AND CHECK RADIATOR FINS……………………………………………………………………..170
CLEAN FUEL TANK STRANER…………………………………………………………………………..171
DRAIN WATER AND SEDIMENT IN FUEL TANK………………………………………………………………171
REPLACE ALTERNATOR DRIVE BELT……………………………………………………………………..172
CHECK UNDERCARRIAGE OIL…………………………………………………………………………..173
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)……………………………………………….174
CHECK AIR CONDITIONER REFRIGER ANT GAS LEVEL………………………………………………………..174
LUBRICATE DOOR HINGE……………………………………………………………………………..175
CHECK DOOR LATCH…………………………………………………………………………………175
REPLACE WIPER BLADE………………………………………………………………………………176
BLEEDING AIR IN HYDRAULIC SYSTEM…………………………………………………………………..177
LUBRICATING……………………………………………………………………………………..177
CHECK BEFORE STARTING………………………………………………………………………………..178
EVERY 250 HOURS SERVICE………………………………………………………………………………179
LUBRICATING……………………………………………………………………………………..179
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST…………………………………………………………180
CHECK LEVEL OF BATTERY ELECTROLYTE…………………………………………………………………181
CHECK BRAKE PERFORMANCE…………………………………………………………………………..184
CHECK OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE………………………………………185
CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL…………………………………………………………186
CHECK OIL LEVEL IN COUNTERWEIGHT TANK,ADD OIL……………………………………………………….187
REPLACE TRANSMISSION FILTER ELEMENT………………………………………………………………..188
REPLACE STEERING CLUTCH CASE FILTER ELEMENT…………………………………………………………189
CHECK OPERATION OF MOMENT LIMITER………………………………………………………………….190
EVERY 500 HOURS SERVICE………………………………………………………………………………191
REPLACE FUEL FILTER CARTRIDGE……………………………………………………………………..191
CLEAN FINAL DRIVE CASE BREATHER……………………………………………………………………192
CLEAN STEERIMG CLUTCH CASE BREATHER………………………………………………………………..192
CLEAN WINCH CASE BREATHER…………………………………………………………………………192
EVERY 1000 HOURS SERVICE……………………………………………………………………………..193
CHANGE OIL IN STEERING CLUTCH CASE, (INCLUDING TRAINSMISSION CASE, TORGUE CONVERTER CASE), CLEAN STRAINER….193
CHANGE OIL IN FINAL DRIVE CASE…………………………………………………………………….195
CHANGE OIL IN WINCH CASE,CLEAN STRAINER…………………………………………………………….195
CHECK, CLEAN FUEL STRAINER………………………………………………………………………..197
CHECK IN UNDERCARRIAGE PARTS………………………………………………………………………197
CHECK OIL LEVEL IN RECOIL SPRING CASE, ADD OIL………………………………………………………198
CHECK, CLEAN RADIATOR FIN…………………………………………………………………………198
LUBRICATING……………………………………………………………………………………..199
REPLACE CORROSION RESISTOR CARTRIDGE……………………………………………………………….200
CHECK TIGTENING PARTS OF TURBOCHARGER………………………………………………………………200
EVERY 2000 HOURS SERVICE……………………………………………………………………………..201
LUBRICATING……………………………………………………………………………………..201
CHANGE OIL IN COUNTERWEIGHT TANK,REPLACE FIFLER ELEMENT………………………………………………204
CLEAN ENGINE BREATHER ELEMENT……………………………………………………………………..206
CLEAN AND CHECK TURBOCHARGER………………………………………………………………………206
CHECK PLAY OF TURBOCHAGER ROTOR……………………………………………………………………206
CHCEK ALTEMATOR, STARTING MOTOR……………………………………………………………………206
CHECK ENGINE VALVE CLEARANCE, ADJUST……………………………………………………………….206
EVERY 4000 HOURS SERVICE……………………………………………………………………………..207
CHECK WATER PUMP…………………………………………………………………………………207
CHECK VIBRATION DAMPER……………………………………………………………………………207
CHECK FAN PULLEY AND TENSION PULLEY………………………………………………………………..207
SPECIFICATIONS……………………………………………………………………………………………..208
SPECIFICATIONS………………………………………………………………………………………….209
LIFTING LOAD CAPACITY CURVE………………………………………………………………………………210
ATTACHMENTS, OPTIONS………………………………………………………………………………………..211
GENERAL PRECAUTIONS……………………………………………………………………………………..212
PRECAUTIONS RELATED TO SAFETY…………………………………………………………………………212
USING SEAT BELT…………………………………………………………………………………………213
HEADLING SEAT BELT…………………………………………………………………………………..213
SELECTION OF TRACK SHOE………………………………………………………………………………….214
SELECTION OF TRACK SHOES……………………………………………………………………………..214
CAP WITH LOCK, HANDLING………………………………………………………………………………….215
METHOD OF OPENING AND CLOSING CAP WITH LOCK…………………………………………………………….215
EXTERNAL POWER SOURCE ENGINE PREHEATING HEATER……………………………………………………………..216
PROCEDURE FOR SELECTING UP EXTERNAL POWER SOURCE………………………………………………………..216
PROCEDURE FOR HANDLING EXTERNAL POWER SUPPLY……………………………………………………………221
INDEX……………………………………………………………………………………………………..224