Komatsu 515C, 520C Operation and Maintenance Manual OM515C520C99-1E

Description

• Model List:
  • 515C
  • 520C

• 1. MAIN MENU
• 2. COVER
• 3. SECTION INDEX
• 4. SECTION CONTENTS
• 5. SECTION 1 INTRODUCTION
• 5.1. INTRODUCTION
• 5.1.1. INTRODUCTION
• 5.1.2. SERIAL NUMBERS
• 6. SECTION 2 SAFETY PRECAUTIONS
• 6.1. SAFETY PRECAUTSIONS
• 6.1.1. GENERAL
• 6.1.2. BEFORE STARTING ENGINE
• 6.1.3. OPERATING THE MACHINE
• 6.1.4. GENERAL MAINTENANCE PRECAUTIONS
• 6.1.5. WHEN PARKING
• 6.1.6. SAFETY GRAPHICS LOCATION
• 6.1.6.1. SAFETY GRAPHICS
• 6.1.6.2. SAFETY GRAPHICS (VERSION CE)
• 7. SECTION 3 STORAGE AND SHIPPING
• 7.1. MACHINE TRANSPORT AND STORAGE
• 7.1.1. MACHINE TRANSPORT
• 7.1.1.1. GENERAL
• 7.1.1.2. TRANSPORTATION ON TRAILER, RAILWAY CAR OR BY SEA
• 7.1.1.3. TRANSPORTATION BY MACHINE OWN DRIVE
• 7.1.2. LIFTING ON SLINGS
• 7.1.3. MOVING A DISABLED MACHINE
• 7.1.4. MACHINE STORAGE
• 7.1.4.1. PREPARING FOR STORAGE
• 7.1.4.2. SERVICING DURING STORAGE
• 7.1.4.3. PREPARING FOR OPERATION AFTER STORAGE
• 8. SECTION 4 OPERATING
• 8.1. OPERATING
• 8.1.1. GENERAL
• 8.1.2. UNIVERSAL SYMBOLS FOR INSTRUMENTS AND CONTROLS
• 8.1.3. INSTRUMENTS AND CONTROLS
• 8.1.4. CAB DOOR AND WINDOWS
• 8.1.5. OPERATORS SEAT
• 8.1.6. SEAT BELT
• 8.1.7. CAB HEATING AND VENTILATION
• 8.1.7.1. DEFROSTER FAN
• 8.1.7.2. HEATER
• 8.1.7.3. AIR CONDITIONER
• 8.1.8. AIR CLEANER SERVICE INDICATOR
• 8.1.9. ELECTRIC SYSTEM MASTER SWITCH
• 8.1.10. DOME LIGHT WITH SWITCHES
• 8.1.11. STARTING AND STOPPING THE ENGINE
• 8.1.11.1. NORMAL START (AMBIENT TEMPERATURE ABOVE 0 (C))
• 8.1.11.2. COLD WEATHER START (USING ETHER INJECTOR, AMBIENT TEMPERATURE BELOW 0 C)
• 8.1.11.3. STOPPING THE ENGINE
• 8.1.12. DRIVING THE MACHINE
• 8.1.13. SHIFTING GEARS
• 8.1.14. STEERING
• 8.1.15. STOPPING THE MACHINE
• 8.1.16. PARKING THE MACHINE
• 8.1.17. LOADER OPERATIONS
• 8.1.17.1. BOOM CONTROL LEVER POSITIONS
• 8.1.17.2. AUTOMATIC BOOM KICKOUT
• 8.1.17.3. BUCKET CONTROL LEVER POSITIONS
• 8.1.17.4. AUTOMATIC LEVELER
• 8.1.17.5. MULTIPURPOSE BUCKET CONTROL LEVER POSITIONS (IF EQUIPPED)
• 8.1.18. LOADER TECHNIQUES
• 8.1.18.1. LOADING, TRANSPORTING AND PILING
• 8.1.18.2. DIGGING, CLEARING AND LEVELING
• 8.1.19. ECONOMICAL OPERATION OF MACHINE
• 8.1.20. QUICKCOUPLING
• 8.1.20.1. QUICKCOUPLING WITH 3SPOOL VALVE
• 8.1.20.2. QUICKCOUPLING WITH 2SPOOL VALVE
• 8.1.21. RIDE STABILIZING MECHANISM
• 8.1.21.1. DRIVING A MACHINE WITH RSM SYSTEM
• 8.1.22. HIGHDUMP BUCKET
• 8.1.22.1. HIGHDUMP BUCKET CONTROL
• 8.1.22.2. OPERATING THE HIGHDUMP BUCKET
• 9. SECTION 5 MAINTENANCE
• 9.1. MAINTANENCE
• 9.1.1. GENERAL PRECAUTIONS
• 9.1.2. SCHEDULED MAINTENANCE GUIDE
• 9.1.2.1. GROUND LEVEL INSPECTION
• 9.1.3. MAINTENANCE AND SERVICE CHART
• 9.1.3.1. SERVICE POINTS
• 9.1.4. LUBRICATION
• 9.1.4.1. WHEN SHIPPED
• 9.1.4.2. WHEN SERVICED
• 9.1.4.3. LUBRICANT SELECTION
• 9.1.4.4. VISCOSITIES
• 9.1.4.5. REFILL SPECIFICATIONS AND CAPACITIES
• 9.1.4.6. LUBRICANT, COOLANT AND FUEL EQUIVALENTS
• 9.1.4.7. LUBRICATING FITTINGS (LUBRICATED WITH SOLID GREASE)
• 9.1.5. SEASONAL PREPARATION
• 9.1.5.1. FUEL SYSTEM
• 9.1.5.2. COOLING SYSTEM
• 9.1.5.3. ELECTRICAL SYSTEM
• 9.1.6. AIR CLEANING SYSTEM
• 9.1.6.1. AIR CLEANER
• 9.1.6.2. PRIMARY (OUTER) FILTER ELEMENT
• 9.1.6.3. SAFETY (INNER) FILTER ELEMENT
• 9.1.6.4. PRECLEANER SCREEN
• 9.1.6.5. DUST VACUATOR VALVE
• 9.1.6.6. CHECKING AIR INTAKE SYSTEM FOR LEAKS
• 9.1.7. BRAKES
• 9.1.7.1. SERVICE BRAKE SYSTEM
• 9.1.7.2. CHECKING THE BRAKE FLUID LEVEL
• 9.1.7.3. CHANGING THE BRAKE FLUID
• 9.1.7.4. FILLING AND VENTING THE SYSTEM
• 9.1.7.5. PARKING BRAKE
• 9.1.8. COOLING SYSTEM
• 9.1.8.1. WATER
• 9.1.8.2. ANTIFREEZE
• 9.1.8.3. RADIATOR CAP
• 9.1.8.4. CHECKING THE COOLANT LEVEL
• 9.1.8.5. DRAINING THE SYSTEM
• 9.1.8.6. CLEANING THE SYSTEM
• 9.1.8.7. FILLING THE SYSTEM
• 9.1.8.8. CLEANING THE RADIATOR
• 9.1.9. DRIVE AXLES
• 9.1.9.1. CHECKING THE OIL LEVEL
• 9.1.9.2. SERVICING THE BREATHER
• 9.1.9.3. CHANGINE THE OIL
• 9.1.10. ELECTRICAL SYSTEM
• 9.1.10.1. ELECTRIC WIRES
• 9.1.10.2. CIRCUIT BREAKERS
• 9.1.10.3. BULB OR LAMP REPLACEMENT
• 9.1.10.4. BATTERIES
• 9.1.11. ENGINE
• 9.1.11.1. CHECKING THE CRANKCASE OIL LEVEL
• 9.1.11.2. CHANGING THE CRANKCASE OIL AND FILTER
• 9.1.11.3. CHECKING THE CONDITION AND TENSION OF BELTS
• 9.1.11.4. CHECKING THE CONDITION OF FAN AND HUB
• 9.1.11.5. INSPECTION OF IDLER PULLEY
• 9.1.11.6. ADJUSTMENT OF ENGINE VALVES
• 9.1.12. ETHER INJECTOR
• 9.1.13. FUEL SYSTEM
• 9.1.13.1. FUEL TANK
• 9.1.13.2. CHANGING THE FUEL FILTERS
• 9.1.13.3. FUEL FILTER WITH WATER SEPARATOR
• 9.1.13.4. VENTING THE FUEL SYSTEM
• 9.1.14. HYDRAULIC SYSTEM
• 9.1.14.1. CHECKING THE RESERVOIR OIL LEVEL
• 9.1.14.2. CHANGING THE HYDRAULIC SYSTEM OIL
• 9.1.14.3. CHANGING THE HYDRAULIC OIL RETURN FILTER
• 9.1.14.4. SERVICING THE HYDRAULIC RESERVOIR BREATHER
• 9.1.15. SEAT BELT
• 9.1.16. STEERING GEAR
• 9.1.17. TIRES AND RIMS
• 9.1.18. TRANSMISSION SYSTEM
• 9.1.18.1. CHECKING THE OIL LEVEL
• 9.1.18.2. CHANGING THE OIL
• 9.1.18.3. CHANGING THE TRANMISSION PRESSURE FILTER
• 9.1.18.4. CLEANING THE TRANSMISSION SUCTION STRAINER
• 9.1.18.5. SERVICING THE BREATHER
• 9.1.19. ROPS CAB AND ROPS CANOPY
• 9.1.20. HOOD ASSEMBLY AND RADIATOR GRILL
• 9.1.21. LOADER EQUIPMENT
• 9.1.22. AIR CONDITIONER OR HEATER (IF EQUIPPED
• 9.1.22.1. INSIDE FILTER
• 9.1.22.2. OUTSIDE FILTER
• 9.1.22.3. AIR CONDITIONER OFF SEASON CARE
• 10. SECTION 6 SPECIFICATIONS
• 10.1. SPECIFICATIONS
• 10.1.1. APPLICATION
• 10.1.2. TECHNICAL DESCRIPTION
• 10.1.3. SCHEMATIC OF 515C AND 520C WHEEL LOADERS DRIVE TRAIN
• 10.1.4. SCHEMATICS OF TRANSMISSION HYDRAULIC SYSTEM
• 10.1.5. LOADER EQUIPMENT AND STEERING HYDRAULIC SCHEMATIC
• 10.1.6. WIRING DIAGRAMS
• 10.1.7. BRAKE HYDRAULIC SYSTEM SCHEMATIC
• 10.1.8. SPECIFICATIONS
• 10.1.8.1. GENERAL SPECIFICATIONS OF 515C AND 520C LOADERS
• 10.1.8.2. CAPACITIES
• 10.1.8.3. ENGINE
• 10.1.8.4. ELECTRICAL SYSTEM
• 10.1.8.5. TRANSMISSION
• 10.1.8.6. TORQUE CONVERTER
• 10.1.8.7. DRIVE AXLES
• 10.1.8.8. TIRES
• 10.1.8.9. RIMS
• 10.1.8.10. BRAKES
• 10.1.8.11. LOADER HYDRAULIC SYSTEM
• 10.1.8.12. STEERING SYSTEM
• 10.1.8.13. DRIVE TRAIN
• 10.1.8.14. CYCLE TIMES
• 10.1.8.15. FUEL CONSUMPTION
• 10.1.9. AND 520C LOADERS EQUIPMENT
• 10.1.9.1. QUICKCOUPLING
• 10.1.9.2. BUCKETS FOR QUICKCOUPLING
• 10.1.9.3. FORKLIFT FOR QUICKCOUPLING 520C
• 10.1.9.4. MULITPURPOSE BUCKET
• 10.1.9.5. LOADER HIGHDUMP BUCKET
• 10.1.10. TORQUE VALUES FOR STANDARD METRICK FASTENERS
• 10.1.11. TORQUE VALUES FOR STANDARD ENGLISH FASTENERS
• 10.1.12. TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS
• 10.1.13. TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS
• 10.1.14. TORQUE VALUES FOR HOSE CLAMPS
• 10.1.15. TORQUE VALUES FOR AIR CONDITIONING TUBES AND FITTINGS
• 10.1.16. TORQUE VALUES FOR AIR CONDITIONING ORING CONNECTIONS
• 10.1.17. SPECIAL TORQUES
• 10.1.18. LIST OF SERVICE TOOLS