Komatsu Bulldozer D155AX-5: EVERY 2000 HOURS SERVICE MAINTENANCE

Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time.

Prepare the following.

Refill capacity: 87

Lower the blade and ripper on the ground securely, stop the engine and slowly turn the cap of oil filler (F) to release the internal pressure. Then, remove the cap.

Remove plug (1) at the bottom of the hydraulic tank, loosen drain valve (2), then drain the oil. After draining the oil, tighten drain valve (2) and plug (1). When loosen- ing drain valve (2), be careful not to get oil on yourself.

Remove mounting bolt (7) of hydraulic filter (6), then remove cover (8).

Remove drain plug (3) (which can be seen from under the fender) and drain the oil from the hydraulic filter case. When loosening drain plug (3), be careful not to get oil on yourself.

Remove element (9).

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

Install drain plug (3).

Close filter cover (8), then tighten bolt (7).

Add engine oil through oil filler port (F) to the specified level.

After adding oil, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL (PAGE 3-68)".

CHECK PLAY OF TURBOCHARGER ROTOR

CLEAN, CHECK TURBOCHARGER

Contact your Komatsu distributor for cleaning or inspection.

CLEAN ENGINE BREATHER ELEMENT

Wipe off all the dirt around breather (1).

Remove breather (1).

Wash the whole breather in diesel oil or flushing oil,then blow it dry with compressed air.

Replace the breather O-ring with a new part, coat with engine oil, and install it.

CHECK ALTERNATOR, STARTING MOTOR

The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair.

If the engine is started frequently,carry out inspection every 1000 hours.

CHECK ENGINE VALVE CLEARANCE, ADJUST

As special tool is required for removing and adjusting the parts, contact your Komatsu distributor for inspection or adjustment.

CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER

Open the engine side cover at the left of the machine; you can see gauge (G).

Remove the undercover (2) at the bottom rear of the chassis as follows.

Remove the undercover (2) at the bottom rear of the chassis as follows.
Hold cover (1) and gradually remove 2 bolts (4) at the rear of the chassis. (Be careful when doing this. Rain water may run out.)
Lower cover (2) slowly and open it. Drain plug (P) can be seen at the top.

Remove dipstick (G), then remove drain plug (P) and drain the oil. After draining the oil,tighten drain plug (P).

Add engine oil through the holder of dipstick (G). After adding the oil, insert dipstick (G).

Remove any dirt or dust stuck to breather (5), then wash with clean diesel oil or flushing oil.If it cannot be cleaned completely, replace with a new part.

CHECK PIVOT BEARING OIL LEVEL, ADD OIL

Remove plug (1).

Check that the oil is at the level (25 m) in the diagram. If the oil level is low, add engine oil through the hole of plug (1).

Install plug (1).

CHECK INJECTOR

Check the color of the exhaust gasa visually. If there is any abnormally in the exhaust gas color, contact your Komatsu distributor for inspection.

Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time.

Maintenance for every 250, 500 and 1000 hours service should be carried out at the same time.

Prepare the following.

Refill capacity: 87

Lower the blade and ripper on the ground securely, stop the engine and slowly turn the cap of oil filler (F) to release the internal pressure. Then, remove the cap.

Remove plug (1) at the bottom of the hydraulic tank, loosen drain valve (2), then drain the oil. After draining the oil, tighten drain valve (2) and plug (1). When loosen- ing drain valve (2), be careful not to get oil on yourself.

Remove mounting bolt (7) of hydraulic filter (6), then remove cover (8).

Remove mounting bolt (7) of hydraulic filter (6), then remove cover (8).

Remove drain plug (3) (which can be seen from under the fender) and drain the oil from the hydraulic filter case. When loosening drain plug (3), be careful not to get oil on yourself.

Remove element (9).

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

Install drain plug (3).

Close filter cover (8), then tighten bolt (7).

Add engine oil through oil filler port (F) to the specified level.

After adding oil, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL (PAGE 3-68)".

CHECK PLAY OF TURBOCHARGER ROTOR

CHECK PLAY OF TURBOCHARGER ROTOR

CLEAN, CHECK TURBOCHARGER

Contact your Komatsu distributor for cleaning or inspection.

CLEAN ENGINE BREATHER ELEMENT

Wipe off all the dirt around breather (1).

Remove breather (1).

Wash the whole breather in diesel oil or flushing oil,then blow it dry with compressed air.

Replace the breather O-ring with a new part, coat with engine oil, and install it.

CHECK ALTERNATOR, STARTING MOTOR

The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair.

If the engine is started frequently,carry out inspection every 1000 hours.

CHECK ENGINE VALVE CLEARANCE, ADJUST

As special tool is required for removing and adjusting the parts, contact your Komatsu distributor for inspection or adjustment.

CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER

Open the engine side cover at the left of the machine; you can see gauge (G).

Remove the undercover (2) at the bottom rear of the chassis as follows.

Remove the undercover (2) at the bottom rear of the chassis as follows.

Hold cover (1) and gradually remove 2 bolts (4) at the rear of the chassis. (Be careful when doing this. Rain water may run out.)

Lower cover (2) slowly and open it. Drain plug (P) can be seen at the top.

Remove dipstick (G), then remove drain plug (P) and drain the oil. After draining the oil,tighten drain plug (P).

Add engine oil through the holder of dipstick (G). After adding the oil, insert dipstick (G).

Remove any dirt or dust stuck to breather (5), then wash with clean diesel oil or flushing oil.If it cannot be cleaned completely, replace with a new part.

Remove any dirt or dust stuck to breather (5), then wash with clean diesel oil or flushing oil.If it cannot be cleaned completely, replace with a new part.

CHECK PIVOT BEARING OIL LEVEL, ADD OIL

Remove plug (1).

Check that the oil is at the level (25 m) in the diagram. If the oil level is low, add engine oil through the hole of plug (1).

Install plug (1).

CHECK INJECTOR

Check the color of the exhaust gasa visually. If there is any abnormally in the exhaust gas color, contact your Komatsu distributor for inspection.