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Komatsu Bulldozer D155AX-76UP/M/EEAM020802/D155AX-5: EVERY 500 HOURS SERVICE MAINTENANCE

Use this maintenance checklist and follow the schedule interval for the proactive and preventive maintenance of your backhoe loader. This has been proven to lower costs by catching small service issues before they blossom into giant repair headaches.

MaintainX

11/04/2022

Komatsu Bulldozer D155AX-76UP/M/EEAM020802/D155AX-5: EVERY 500 HOURS SERVICE MAINTENANCE

Maintenance for every 250 hours service should be carried out at the same time.

REPLACE FUEL FILTER CARTRIDGE

Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replac- ing the filter cartridge, always use a genuine Komatsu part.

The common rail fuel injection system used on this machine consists of more precise parts than the conven- tional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.

When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of dirt. If dirt is stuck to any part, use fuel to wash it off completely.

Container to catch the oil

Filter wrench

Set the container to catch the fuel under the filter cartridge. The fuel filter is found by opening the engine side cover at the left of the machine.
Using a filter wrench, turn filter cartridge (1) counterclockwise to remove it.
Clean the filter holder, fill the new filter cartridge with clean fuel, coat the packing surface thinly with engine oil, then install to the filter holder.
When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it up 1/2 to 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten to the correct amount.
After completion of the replacement of fuel filter cartridge (1), bleed the air.
Bleed the air as follows. Add fuel to the fuel tank until full (to FULL mark on the fuel gauge).
After replacing filter cartridge (1), loosen air bleed plug (2).
Loosen the knob of priming pump (3), move it up and down (90 to 100 times), and continue until no bubbles come out with the fuel.
Tighten air bleed plug (2), push in the knob of priming pump (3), then tighten it. Use a genuine Komatsu part for the fuel filter cartridge. After replacing the filter cartridge, run the engine, and check for any leakage of oil from the filter seal surface.

NOTICE

When filling with fuel, use clean fuel and be careful not to let any dirt or dust get in. In particular, the center area is the clean side, so be careful not to let dirt or dust get in.

When filling with fuel, use clean fuel and be careful not to let any dust or dirt get in. Portion (B) at the center is the clean side, so be particularly careful not to let any dust or dirt get in.

When adding fuel, always add from small hole (A) at eight places on the dirty side.

If no clean fuel is available, bleed the air with priming pump (3) without removing the fuel cartridge.

REPLACE POWER TRAIN OIL FILTER ELEMENT

Open engine side cover at the left side of the machine, remove bolt (1), then open cover (2) to the outside using the hinge at the bottom as the fulcrum.

Remove mounting bolt (4) of filter (3), then remove cover (5).

Take out element (6).

Clean the removed parts and the inside of the case, then install a new element. Always use a genuine Komatsu element.

Close cover (2), tighten bolt (1), then close engine side cover on the left side of the machine.

REPLACE HYDRAULIC TANK BREATHER ELEMENT

Remove breather cap (1) at the top of the hydraulic tank.

Replace element (2) inside the cap.

CHECK AND REPLACE FAN BELT

Check the V-belt and when the following conditions exist, replace the V-belt.

When the V-belt makes contact with the bottom of the groove in each pulley.

When the V-belt is worn, and its surface is lower than the outer diameter of the pulley.

When cracking and peeling of the V-belt occurs.

A device is installed to maintain the tension constant regard- less of any elongation of the V-belt, so there is no need to carry out adjustment until the V-belt is replaced.

REPLACE

Fit a wrench to the tension pulley, push the pulley in the direction of the arrow to remove the V-belt, then replace the V-belt.

Replace the V-belts as a set.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE

Prepare the following.

Refill capacity: 37

Socket wrench, filter wrench.

Remove the cover (1) at the bottom of the machine and set a container to catch the oil under the drain plug.

To prevent getting oil on yourself, remove drain plug (P) slowly, then loosen drain valve (2) to drain the oil. Do not loosen the drain valve too far, otherwise,the stopper pin inside the valve may be deformed.

Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor.

Install drain plug (P) and drain valve (2) .

Tightening torque Drain plug (P): 68.6 ± 9.8 N•m (7 ± 1 kgf•m) Drain valve (2): 63.7 ± 14.7 N•m (6.5 ± 1.5 kgf•m)

Using a filter wrench, turn filter cartridge (3) counterclock- wise to remove it. When doing this, to prevent getting oil on yourself, do not carry out this operation from immediately under the cartridge. In particular, if this operation is carried out immediately after stopping the engine, a large amount of oil will come out, so wait for 10 minutes before starting the operation.

Clean the filter holder, fill the new filter cartridge with engine oil, coat the packing surface and thread with engine oil (or coat it thinly with grease), then install the fil- ter cartridge.

REMARK

Confirm that no remnants of old packing still adhere to the filter holder as this may result in oil leakage. Check that there is no old packing affixed to the filter holder. If there is any old packing affixed to the filter, it will cause leakage of oil.

When installing the filter cartridge, bring the packing surface into contact with the filter holder, then tighten a further 3/4 - 1 turn.

When using a filter wrench for tightening, be extremely careful not to damage the filter or cause dents.

After replacing the filter cartridge, add engine oil through oil filler (F) until the oil level is between the H and L marks on the dipstick.

Run the engine at idling 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 "CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL (PAGE 3- 65)".

Source: MaintainX (Community Member)

Please note that any procedure, checklist, or other document available in the MaintainX Procedure Hub is provided for general education and information only and does not constitute legal, medical, or financial advice. MaintainX makes the materials available AS IS and AS PROVIDED, without warranties of any kind. By downloading or using any such materials, you assume the risk that they may not be appropriate for your specific situation and agree that you are solely responsible for any such use, including compliance with applicable law and with meeting any conditions of product warranties.

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