Maintenance

D155-6 April 2006 New Product Service Training

 Troubleshooting Tips
Training & Material Planning
Service Department 　
Product Support Division
N. NAMIKI

　 1. Listen Carefully to the Operator's Complaints.

・ Identify clearly what the real problem is.
・ Get as much information about the problem from the operator as possible.
・ Check the operating conditions when the problem was noticed.
　 ( Who, When, Where, Why, How, )
・ Ask the operator questions and ............ LISTEN.

　 2. Experience the Operators Complaints Yourself.

・ Operate the machine yourself. Or, ask the operator to re-enact the
problem.
　 Confirm the existence of these problems immediately.
・ If you find the problem, start troubleshooting immediately.
　 If you believe there is no problem, convince the operator.
・ If the problem is design related, document clearly the application of the
machine.
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 Troubleshooting Tips
3. Don't Forget the Basics.
・ Check the water and oil levels, measure engine speed,
oil pressure and electrical continuity.
( Simple checks sometimes solve 90% of the problem. )
・ Don’t forget to check error code No.
4. Narrow Down Possible Causes of the Problem.
・ Work quickly. One hour (during lunch break) is all that's usually allowed.
・ An initial visit to identify the problem is acceptable.
But the second trip must be used to fix the problem. -PLAN ACCORDINGLY.
・ Arrange for all needed tools to be on-site.
( jig, measurement tools, replacement parts, etc. )

5. Build up a Good Relationship With the Operator !

・ Be prepared to listen to the operator, and give him advice when needed.
・ Try to give the operator specific ideas that will improve his operating technique.

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 1. Water level check (Daily check)
Water level sensor

Strainer

Reserve tank (STD)

Water level sensor

Water drain cock

( 82 L )
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 2. Engine oil level check (Daily check)

Engine oil filler

Engine oil level gauge

Engine Engine
Stopped Idling
(Cold) (Hot) Engine oil drain
(37 L)
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 3. Power train case oil level check (Daily check)

P/L oil filler

Filler and Level gauge

P/L Drain plug

90 L
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4. Hydraulic tank oil level check
1. Pitch back the blade completely, and lower the blade
and ripper to the ground in horizontal position
shown in the picture at right.
2. If you have to start engine such as for adjusting
cylinders, Stop the engine and wait for about
You cannot check the oil level Drain plug
after the operation even after 3 minutes.
If oil level is between H and L in sight gauge 67 L
It is normal.
3. If the level is below the L mark,
add engine oil through oil filler (F) Blade : Pitch back
Don’t check oil level after operation Ripper shank : Vertical position
Standard position for check machine
 5. Damper case oil level check

Damper oil level gauge

Damper breather

Damper oil drain plug

1.5 L

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 6. Final drive oil level check

There is danger that the oil may spurt out under

internal pressure.
Oil level plug So to the side, and gradually turn the plug to
release the internal pressure before removing
the plug completely.

Oil drain plug Oil drain plug

31 L

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7. Pivot shaft oil level check

Measuring ruler
Oil level
25 mm

9L
 8. Battery water level check

C200 (OPTION)

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 Window washer tank

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 Fuel tank

Hole

Strainer guide
Expansion space

Fuel level
Hole

Fuel tank capacity : 625 L

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 1. Engine oil filter
(600-211-1340) 500Hr

Engine oil drain

(37 L)
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 2. Pre-fuel filter
Add fuel through inlet port A.
Outlet port B
(Clean side)

Pre-filter assy’
(600-319-3400)
Cap
Pre-filter (with cap)
500 Hr (600-319-3440)

(10μ)

Cup (600-311-3220)

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 Pre-fuel filter
Fuel drain cock

Water separator
Check water separator,
drain water and sediment Drain water and sediment
from fuel tank

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 3. Main fuel filter

Add fuel through inlet port Outlet port B

(2μ) A. (Clean side)
Cap

(600-319-3520)
1000 Hr

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 4. Corrosion resistor

Open

Close

Open

1000Hr (600-411-1161)

Close
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 5. Power line filter

(07063-51100)

500 Hr
Power line filter

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 P/L pump strainer Scavenging
pump strainer

P/L Drain

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 Hydraulic tank

(207-60-71181)

(207-60-71181)

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 6. Clean the breather element
Engine breather element : 2000Hr

P/L breather : When required

Hyd tank breather element (20Y-60-21470)
1000Hr

Damper breather : 2000Hr

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 After running out of fuel

Air bleed plug (A)

Priming pump (2)

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 After running out of fuel

Air bleed plug (5)

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 Shield cover for to prevent fire

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 Lubricating

Grease nipple
Grease nipple

1. Universal joint

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 Lubricating
2. Equalizer bar center pin 3. Equalizer bar side pin

Grease nipple

Grease nipple 250 Hr

250 Hr

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 Lubricating
4. Deceleration pedal When required

Grease nipple

5. Brake pedal When required

Grease
nipple
 Lubricating Sigma dozer

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 Lubricating

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Ripper ass'y grease point (250 Hr)
 Single tilt dozer
The standard cutting angle
Sigma 　 : 46°
Semi U : 52° Sigma : 1292 mm,
Semi U : 1372 mm

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 Reverse and replace the end bits and cutting edges
A : Sigma dozer B : Angle dozer

C : Semi U dozer

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 Alternator V-belt adjustment
・ REPLACE V-BELT (Alternator)
1.Remove cover mounting bolts ⑥ (2 places), and remove the cover.
2.Loosen bolts and nuts ①,②, and ,⑤,then turn nut ④ and adjust the belt tension.
3.After adjusting, tighten bolts and nut ①,②,and ⑤, to secure alternator③ in position.
4.Reinstall the cover removed in step 1. Confirm that no part of the cover touches any turning part of
the alternator.
＊ When adjusting the V-belt, do not push alternator③ directly with the bar. Use nut④.
＊ The standard deflection for the V-belt is 13--16mm, when pressed with a thumb with force of approx.
(10Kg)

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 Air compressor drive V-belt adjustment
・ REPLACE V-BELT (Air compressor)
1.Loosen 4 bolts① and jack bolt②, then remove
compressor③ to the side.
2.Replace the V-belt.
・ When adjusting the V-belt, do not push the compressor
directly with the bar. Use jack bolt② ．
3.Tighten jack bolt② and bolts①, and apply tension to the
V-belt. The standard deflection for the belt is approx. 10mm
when pressed with a finger force of approx. 6Kg

Air compressor③
Bolt①

Jack bolt②

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 Adjust idler clearance

＜ 3mm
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 Inspection and adjustment for track tension.
INSPECTION.
1. Stop the machine on level ground.
( Stop with the transmission in FORWARD with applying the brake slowly ). Clearance Ａ ： 20-
2. Place a straight bar on the track shoes between first carrier roller 30mm
and idler as shown in the figure.
3. Measure the clearance between the bar and the grouser at the midpoint.
・ Properly adjust track tension.
Tension should be measured at clearance Ａ shown in the diagram Top of grouser
--- usually ２０ to ３０ ｍｍ ( 0.8 to 1.2 in ) at this point.
For rocky terrain, tighten tracks slightly.
In clay or sandy areas, slightly loosen them.
　★ Adjusting the track tension 30 ｍｍ when the machine is new.
ADJUSTMENT. ( Initial 100Hr )
Fitting ②
・ When increasing tension..
1. Remove the cover.
2. Pump in grease through grease fitting② with a grease pump.
3. To check that the correct tension has been achieved. Plug ①
move the machine backwards and forwards.
4. Check the track tension again, and if the tension is not correct, adjust it again.
5. Grease may be pressurized till S will be 0mm ( 0 in ).
In case the tension is yet loose after applying pressurized injection of grease till
the above mentioned limit, it indicates that pin bush is reduced by too much abrasion.
So it is necessary either to turn or replace the pin and bushings.
Consult your Komatsu distributor for repair.
　・ When loosing tension..
1. Loosen plug① gradually to release the grease.
2. Turn the plug① a maximum one turn.
3. If the grease does not come out smoothly,
move the machine backwards and forwards a short distance.
4. Tighten plug①.
5. To check the correct tension has been achieved,
move the machine backwards and forwards.

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 Tighten track shoe bolts
1. Method for tightening Apply uniformly
1.Tighten torque MARUZEN MORIMAX No.2
or EQUIVALENTS.
Master bolt: ６０ ± ６ Kg ・ m (590 Ib ･ ft) LM-P (Parts No:09940-00040)
Regular bolt: ６０ ± ６ Kg ・ m (590 Ib ･ ft)
・ Don't use impact wrench. Check the link contact surface.
2.Check the link contact surface are
in close contact by thickness gauge.
3.Tighten torque
Master bolt: １８０ ± １０ °
Regular bolt: １２０ ± １０ °
2. Tighten in the following sequence.

①→②→③→④ When disassemble shoe

ass’y, At first loosen the
32 shoe tension.

Master bolt:175-32-41261
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