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Komatsu Bulldozer D275A-5 Operation & Maintenance Manual SN 25187 and up – PDF DOWNLOAD
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Komatsu Bulldozer D275A-5 Operation & Maintenance Manual
SERIAL NUMBERS 25178 and up
Book Code : TEN00036-02
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Description
Komatsu Bulldozer D275A-5 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Bulldozer D275A-5 Operation & Maintenance Manual
Size : 8.13 MB
Format : PDF
Language : English
Number of Pages : 301 ages
Brand: Komatsu
Type of machine: Bulldozer
Type of document: Operation & Maintenance Manual
Model: D275A-5
Serial: 25187 and up
KOMATSU BULLDOZER D275A-5 OPERATION & MAINTENANCE MANUAL SN 25187 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Bulldozer D275A-5 Operation & Maintenance Manual
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 forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu Bulldozer D275A-5 Operation & Maintenance Manual
COVER............................................................................................................... 1 FOREWORD............................................................................................................ 2 FOREWORD........................................................................................................ 3 SAFETY INFORMATION.............................................................................................. 6 INTRODUCTION.................................................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................................................................ 8 NECESSARY INFORMATION........................................................................................... 9 MACHINE SERIAL NO. PLATE AND POSITION....................................................................... 9 ENGINE SERIAL NO. PLATE AND POSITION........................................................................ 9 BLADE SERIAL NO. PLATE POSITION............................................................................. 10 RIPPER SERIAL NO. PLATE POSITION............................................................................ 10 POSITION OF SERVICE METER................................................................................... 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................................... 11 CONTENTS............................................................................................................ 12 SAFETY.............................................................................................................. 16 SAFETY.......................................................................................................... 17 SAFETY LABELS................................................................................................... 19 POSITIONS OF SAFETY PICTOGRAMS.............................................................................. 19 SAFETY LABELS............................................................................................... 20 GENERAL PRECAUTIONS............................................................................................. 24 SAFETY RULES................................................................................................ 24 IF ABNORMALITIES ARE FOUND.................................................................................. 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT......................................................................... 24 SAFETY FEATURES............................................................................................. 24 KEEP MACHINE CLEAN.......................................................................................... 25 INSIDE OPERATOR'S COMPARTMENT............................................................................... 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.............................................................. 25 HANDRAILS AND STEPS......................................................................................... 26 PRECAUTIONS WHEN WORKING IN HIGH PLACES..................................................................... 26 MOUNTING AND DISMOUNTING.................................................................................... 26 NO PEOPLE ON ATTACHMENTS.................................................................................... 26 CRUSHING OR CUTTING PREVENTION.............................................................................. 27 PREVENTION OF BURNS......................................................................................... 27 FIRE PREVENTION............................................................................................. 28 ACTION IF FIRE OCCURS....................................................................................... 29 WINDOW WASHER LIQUID........................................................................................ 29 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................................................ 29 PRECAUTIONS FOR ATTACHMENTS................................................................................. 29 CAB WINDOW GLASSES.......................................................................................... 29 UNAUTHORIZED MODIFICATION................................................................................... 29 SAFETY AT WORKSITE.......................................................................................... 30 WORKING ON LOOSE GROUND..................................................................................... 30 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...................................................................... 31 ENSURE GOOD VISIBILITY...................................................................................... 31 VENTILATION FOR ENCLOSED AREAS.............................................................................. 32 CHECKING SIGNALMAN'S SIGNALS AND SIGNS...................................................................... 32 BE CAREFUL ABOUT ASBESTOS DUST.............................................................................. 32 PRECAUTIONS FOR OPERATION....................................................................................... 33 BEFORE STARTING ENGINE...................................................................................... 33 CHECKS BEFORE STARTING ENGINE........................................................................... 33 PRECAUTIONS WHEN STARTING............................................................................... 34 PRECAUTIONS IN COLD AREAS............................................................................... 34 OPERATION................................................................................................... 35 CHECKS BEFORE OPERATION................................................................................. 35 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE.................................................... 35 PRECAUTIONS WHEN TRAVELING.............................................................................. 36 TRAVELING ON SLOPES..................................................................................... 37 PROHIBITED OPERATIONS................................................................................... 37 USING BRAKES............................................................................................ 37 OPERATE CAREFULLY ON SNOW............................................................................... 37 PARKING MACHINE......................................................................................... 38 TRANSPORTATION.............................................................................................. 39 SHIPPING................................................................................................ 39 BATTERY..................................................................................................... 40 BATTERY HAZARD PREVENTION............................................................................... 40 STARTING WITH BOOSTER CABLE............................................................................. 41 TOWING...................................................................................................... 42 WHEN TOWING............................................................................................. 42 PRECAUTIONS FOR MAINTENANCE..................................................................................... 43 WARNING TAG................................................................................................. 43 KEEP WORK PLACE CLEAN AND TIDY.............................................................................. 43 APPOINT LEADER WHEN WORKING WITH OTHERS..................................................................... 43 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.................................................. 44 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.......................................................... 45 PROPER TOOLS................................................................................................ 45 HANDLING ACCUMULATOR........................................................................................ 46 PERSONNEL................................................................................................... 46 ATTACHMENTS................................................................................................. 46 WORK UNDER THE MACHINE...................................................................................... 46 NOISE....................................................................................................... 47 PRECAUTIONS WHEN USING HAMMER............................................................................... 47 REPAIR WELDING.............................................................................................. 47 REMOVING BATTERY TERMINAL................................................................................... 47 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......................................... 47 DO NOT DISASSEMBLE RECOIL SPRING............................................................................ 48 PRECAUTION WITH HIGH-PRESSURE OIL........................................................................... 48 PRECAUTION FOR HIGH FUEL PRESSURE........................................................................... 48 HANDLING HIGH-PRESSURE HOSES................................................................................ 48 PRECAUTION FOR HIGH VOLTAGE................................................................................. 49 WASTE MATERIAL.............................................................................................. 49 MAINTENANCE FOR AIR CONDITIONER............................................................................. 49 COMPRESSED AIR.............................................................................................. 49 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................................... 49 OPERATION........................................................................................................... 50 GENERAL VIEW.................................................................................................... 51 GENERAL VIEW OF MACHINE..................................................................................... 51 GENERAL VIEW OF CONTROLS AND GAUGES......................................................................... 52 EXPLANATION OF COMPONENTS....................................................................................... 54 FRONT PANEL................................................................................................. 54 SWITCHES.................................................................................................... 81 CONTROL LEVERS, PEDALS...................................................................................... 85 DUST INDICATOR.............................................................................................. 94 POWER SOURCE................................................................................................ 94 FUSE BOX.................................................................................................... 95 FUSIBLE LINK................................................................................................ 98 DOOR OPEN LOCK.............................................................................................. 99 SASH GLASS INTERMEDIATE LOCK................................................................................100 DOOR POCKET.................................................................................................100 ASHTRAY.....................................................................................................100 TOOL BOX....................................................................................................101 CAR STEREO, HANDLING........................................................................................102 AIR CONDITIONER, HANDLING...................................................................................110 ACCUMULATOR, HANDLING.......................................................................................116 OPERATION.......................................................................................................117 CHECK BEFORE STARTING ENGINE, ADJUST........................................................................117 STARTING ENGINE.............................................................................................138 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................141 STOPPING ENGINE.............................................................................................144 CHECK AFTER STOPPING ENGINE.................................................................................144 MOVING MACHINE..............................................................................................145 STOPPING MACHINE............................................................................................147 SHIFTING GEAR...............................................................................................148 SHIFTING BETWEEN FORWARD AND REVERSE........................................................................152 STEERING MACHINE............................................................................................154 PRECAUTIONS FOR OPERATION...................................................................................156 PARKING MACHINE.............................................................................................158 CHECK AFTER FINISHING WORK..................................................................................160 LOCKING.....................................................................................................160 WORK POSSIBLE USING BULLDOZER...............................................................................161 RIPPER OPERATION............................................................................................163 OPERATING METHOD FOR RIPPING OPERATIONS.....................................................................166 ADJUSTING POSTURE OF WORK EQUIPMENT.........................................................................171 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................................................174 TRANSPORTATION..................................................................................................176 TRANSPORTATION PROCEDURE....................................................................................176 LOADING, UNLOADING WORK.....................................................................................176 PRECAUTIONS FOR LOADING.....................................................................................177 METHOD OF LIFTING MACHINE...................................................................................177 PRECAUTIONS FOR TRANSPORTATION..............................................................................178 TRAVELING ON ROADS..........................................................................................178 REMOVAL OF CAB..............................................................................................179 INSTALLATION OF CAB.........................................................................................179 COLD WEATHER OPERATION..........................................................................................180 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................180 AFTER COMPLETION OF WORK....................................................................................181 AFTER COLD WEATHER..........................................................................................181 LONG-TERM STORAGE...............................................................................................182 BEFORE STORAGE..............................................................................................182 DURING STORAGE..............................................................................................182 AFTER STORAGE...............................................................................................182 STARTING MACHINE AFTER LONG-TERM STORAGE....................................................................182 TROUBLESHOOTING.................................................................................................183 AFTER RUNNING OUT OF FUEL...................................................................................183 METHOD OF TOWING MACHINE....................................................................................184 IF BATTERY IS DISCHARGED....................................................................................185 OTHER TROUBLE...............................................................................................188 MAINTENANCE.........................................................................................................194 GUIDES TO MAINTENANCE...........................................................................................195 OUTLINES OF SERVICE.............................................................................................198 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL.............................................................198 OUTLINE OF ELECTRIC SYSTEM..................................................................................201 WEAR PARTS......................................................................................................202 WEAR PARTS LIST.............................................................................................202 RECOMMENDED FUEL, COOLANT, AND LUBRICANT........................................................................203 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE........................................204 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.........................205 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................206 TORQUE LIST.................................................................................................206 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................207 SAFETY CRITICAL PARTS.......................................................................................208 MAINTENANCE SCHEDULE CHART......................................................................................209 MAINTENANCE SCHEDULE CHART..................................................................................209 SERVICE PROCEDURE...............................................................................................211 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..................................................211 WHEN REQUIRED...............................................................................................212 CLEAN INSIDE OF COOLING SYSTEM..........................................................................212 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................216 CHECK AND ADJUST TRACK TENSION..........................................................................221 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................................224 ADJUST IDLER CLEARANCE..................................................................................225 CLEAN AND CHECK RADIATOR FINS...........................................................................228 CLEAN FUEL TANK STRAINER................................................................................229 DRAIN WATER AND SEDIMENT IN FUEL TANK...................................................................229 CLEAN STEERING CLUTCH CASE BREATHER.....................................................................229 REPLACE AIR CONDITIONER BELT............................................................................229 CLEAN AND CHECK HYDRAULIC COOLER FINS...................................................................230 CHECK UNDERCARRIAGE OIL.................................................................................231 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..................................................232 CHECK AND ADJUST AIR CONDITIONER........................................................................233 LUBRICATE DOOR HINGE....................................................................................234 CHECK DOOR LATCH........................................................................................234 CHECK DOOR LOCK STRIKER.................................................................................234 REPLACE DOOR DAMPER.....................................................................................235 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................235 REPLACE WIPER BLADE.....................................................................................236 BLEEDING AIR IN HYDRAULIC SYSTEM........................................................................237 CHECK ELECTRICAL INTAKE AIR HEATER......................................................................237 LUBRICATING.............................................................................................238 CHECK BEFORE STARTING.......................................................................................239 EVERY 250 HOURS SERVICE.....................................................................................240 LUBRICATING.............................................................................................240 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.............................................................242 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................243 CHECK BRAKE PERFORMANCE.................................................................................246 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.................................................................247 EVERY 500 HOURS SERVICE.....................................................................................248 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......................................248 REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITHOUT ADDITIONAL FUEL FILTER CARTRIDGE)..............250 REPLACE POWER TRAIN OIL FILTER ELEMENT, STEERING LUBRICATING OIL FILTER ELEMENT.........................252 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................................253 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................................................253 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED WITH MACHINES)....................................254 EVERY 1000 HOURS SERVICE....................................................................................256 REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITH ADDITIONAL FUEL FILTER CARTRIDGE).................256 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER)....258 CHECK, CLEAN FUEL STRAINER..............................................................................260 CHECK FOR LOOSE ROPS MOUNT BOLTS........................................................................260 REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE..........................261 CHECK TIGHTENING PARTS OF TURBOCHARGER..................................................................261 EVERY 2000 HOURS SERVICE....................................................................................262 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER.......262 CHANGE OIL IN FINAL DRIVE CASE..........................................................................264 CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER........................................................265 CHECK PIVOT BEARING OIL LEVEL, ADD OIL..................................................................266 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL.........................................267 CLEAN ENGINE BREATHER ELEMENT...........................................................................267 CHECK ALTERNATOR, STARTING MOTOR........................................................................268 CHECK INJECTOR..........................................................................................268 EVERY 4000 HOURS SERVICE....................................................................................269 CHECK WATER PUMP........................................................................................269 CHECK VIBRATION DAMPER..................................................................................269 CLEAN, CHECK TURBOCHARGER...............................................................................269 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................269 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................................................269 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER......................................270 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.....................................271 REPLACE INJECTOR ASSEMBLY...............................................................................271 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)........................................................272 EVERY 8000 HOURS SERVICE....................................................................................273 REPLACE HIGH-PRESSURE PIPING CLAMPS.....................................................................273 REPLACE FUEL SPLAY PREVENTION CAPS......................................................................273 SPECIFICATIONS......................................................................................................274 SPECIFICATIONS..................................................................................................275 ATTACHMENTS, OPTIONS................................................................................................276 GENERAL PRECAUTIONS.............................................................................................277 PRECAUTIONS RELATED TO SAFETY...............................................................................277 SELECTION OF TRACK SHOE.........................................................................................278 SELECTION OF TRACK SHOES....................................................................................278 PROCEDURE FOR SELECTING RIPPER POINT............................................................................279 PROCEDURE FOR SELECTING RIPPER POINT........................................................................279 CAP WITH LOCK, HANDLING.........................................................................................280 METHOD OF OPENING AND CLOSING CAP WITH LOCK.................................................................280 EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER...............................................................281 BLADE CONDITION.............................................................................................281 DOZING WORK.................................................................................................283 LEVELING (SPREADING) OPERATION..............................................................................286 DITCHING OPERATION..........................................................................................286 BOULDER RAISING OPERATION...................................................................................286 SIDE-CUTTING OPERATIONS.....................................................................................287 HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND).................................................287 SHOE SLIP CONTROL...............................................................................................288 MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL).............................................................288 EFFECTIVE USE OF MODE SELECTION SYSTEM......................................................................289 IF MODE SELECTION SYSTEM FLASHES............................................................................295 HANDLING MACHINES EQUIPPED WITH KOMTRAX.........................................................................296 BASIC PRECAUTIONS...........................................................................................296 INDEX...............................................................................................................298
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