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Komatsu D275Ax-5E0 Bulldozer Operation & Maintenance Manual SN 30001 and up – PDF DOWNLOAD
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Komatsu D275Ax-5E0 Bulldozer Operation & Maintenance Manual
Book Code : TEN00134-03
MACHINE MODEL SERIAL NUMBER
D275AX-5E0 – 30001 and up
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Description
Komatsu D275Ax-5E0 Bulldozer Operation & Maintenance Manual
FILE DETAILS:
Komatsu D275Ax-5E0 Bulldozer Operation & Maintenance Manual
Size : 9.03 MB
Format : PDF
Language : English
Number of Pages : 331 pages
Brand: Komatsu
Type of machine: Bulldozer
Type of document: Operation & Maintenance Manual
Model: D275AX-5EO
Serial: 30001 and up
KOMATSU D275AX-5E0 BULLDOZER OPERATION & MAINTENANCE MANUAL SN 30001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu D275Ax-5E0 Bulldozer 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 D275Ax-5E0 Bulldozer Operation & Maintenance Manual
COVER....................................................................................................................... 1 FOREWORD.................................................................................................................... 2 FOREWORD................................................................................................................ 3 SAFETY INFORMATION...................................................................................................... 6 INTRODUCTION............................................................................................................ 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE........................................................................ 8 VISIBILITY FROM OPERATOR'S SEAT..................................................................................... 9 BREAKING IN THE MACHINE............................................................................................. 10 NECESSARY INFORMATION................................................................................................... 11 PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE....................................................... 11 EPA REGULATIONS, ENGINE NUMBER PLATE................................................................................ 11 BLADE SERIAL NO. PLATE POSITION..................................................................................... 12 RIPPER SERIAL NO. PLATE POSITION.................................................................................... 12 POSITION OF SERVICE METER........................................................................................... 12 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR........................................................................... 13 CONTENTS.................................................................................................................... 14 SAFETY...................................................................................................................... 18 SAFETY.................................................................................................................. 19 SAFETY LABELS........................................................................................................... 21 POSITIONS OF SAFETY PICTOGRAMS...................................................................................... 21 SAFETY LABELS....................................................................................................... 22 GENERAL PRECAUTIONS..................................................................................................... 26 SAFETY RULES........................................................................................................ 26 IF ABNORMALITIES ARE FOUND.......................................................................................... 26 CLOTHING AND PERSONAL PROTECTIVE ITEMS.............................................................................. 26 FIRE EXTINGUISHER AND FIRST AID KIT................................................................................. 26 SAFETY FEATURES..................................................................................................... 26 KEEP MACHINE CLEAN.................................................................................................. 27 INSIDE OPERATOR'S COMPARTMENT....................................................................................... 27 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...................................................................... 27 HANDRAILS AND STEPS................................................................................................. 28 PRECAUTIONS WHEN WORKING IN HIGH PLACES............................................................................. 28 MOUNTING AND DISMOUNTING............................................................................................ 28 NO PEOPLE ON ATTACHMENTS............................................................................................ 28 CRUSHING OR CUTTING PREVENTION...................................................................................... 29 PREVENTION OF BURNS................................................................................................. 29 FIRE PREVENTION..................................................................................................... 30 ACTION IF FIRE OCCURS............................................................................................... 31 WINDOW WASHER LIQUID................................................................................................ 31 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)........................................................ 31 PRECAUTIONS FOR ATTACHMENTS......................................................................................... 31 CAB WINDOW GLASSES.................................................................................................. 31 UNAUTHORIZED MODIFICATION........................................................................................... 31 SAFETY AT WORKSITE.................................................................................................. 32 WORKING ON LOOSE GROUND............................................................................................. 32 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.............................................................................. 33 ENSURE GOOD VISIBILITY.............................................................................................. 33 VENTILATION FOR ENCLOSED AREAS...................................................................................... 34 CHECKING SIGNALMAN'S SIGNALS AND SIGNS.............................................................................. 34 BE CAREFUL ABOUT ASBESTOS DUST...................................................................................... 34 PRECAUTIONS FOR OPERATION............................................................................................... 35 BEFORE STARTING ENGINE.............................................................................................. 35 CHECKS BEFORE STARTING ENGINE................................................................................... 35 PRECAUTIONS WHEN STARTING....................................................................................... 36 PRECAUTIONS IN COLD AREAS....................................................................................... 36 OPERATION........................................................................................................... 37 CHECKS BEFORE OPERATION......................................................................................... 37 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE............................................................ 37 PRECAUTIONS WHEN TRAVELING...................................................................................... 38 TRAVELING ON SLOPES............................................................................................. 39 PROHIBITED OPERATIONS........................................................................................... 39 USING BRAKES.................................................................................................... 39 OPERATE CAREFULLY ON SNOW....................................................................................... 39 PARKING MACHINE................................................................................................. 40 TRANSPORTATION...................................................................................................... 41 LOADING AND UNLOADING........................................................................................... 41 SHIPPING........................................................................................................ 41 BATTERY............................................................................................................. 42 BATTERY HAZARD PREVENTION....................................................................................... 42 STARTING WITH BOOSTER CABLE..................................................................................... 43 TOWING.............................................................................................................. 44 WHEN TOWING..................................................................................................... 44 PRECAUTIONS FOR MAINTENANCE............................................................................................. 45 WARNING TAG......................................................................................................... 45 KEEP WORK PLACE CLEAN AND TIDY...................................................................................... 45 APPOINT LEADER WHEN WORKING WITH OTHERS............................................................................. 45 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.......................................................... 46 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.................................................................. 47 PROPER TOOLS........................................................................................................ 47 HANDLING ACCUMULATOR................................................................................................ 48 PERSONNEL........................................................................................................... 48 ATTACHMENTS......................................................................................................... 48 WORK UNDER THE MACHINE.............................................................................................. 48 NOISE............................................................................................................... 49 PRECAUTIONS WHEN USING HAMMER....................................................................................... 49 REPAIR WELDING...................................................................................................... 49 REMOVING BATTERY TERMINAL........................................................................................... 49 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION................................................. 49 DO NOT DISASSEMBLE RECOIL SPRING.................................................................................... 50 PRECAUTION WITH HIGH-PRESSURE OIL................................................................................... 50 PRECAUTION FOR HIGH FUEL PRESSURE................................................................................... 50 HANDLING HIGH-PRESSURE HOSES........................................................................................ 50 PRECAUTION FOR HIGH VOLTAGE......................................................................................... 51 WASTE MATERIAL...................................................................................................... 51 MAINTENANCE FOR AIR CONDITIONER..................................................................................... 51 COMPRESSED AIR...................................................................................................... 51 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................................... 51 OPERATION................................................................................................................... 52 GENERAL VIEW............................................................................................................ 53 GENERAL VIEW OF MACHINE............................................................................................. 53 GENERAL VIEW OF CONTROLS AND GAUGES................................................................................. 54 EXPLANATION OF COMPONENTS............................................................................................... 56 FRONT PANEL......................................................................................................... 56 SWITCHES............................................................................................................ 87 CONTROL LEVERS, PEDALS.............................................................................................. 91 DUST INDICATOR......................................................................................................101 POWER SOURCE........................................................................................................101 FUSE BOX............................................................................................................102 CAP WITH LOCK.......................................................................................................106 DOOR OPEN LOCK......................................................................................................108 SASH GLASS INTERMEDIATE LOCK........................................................................................109 DOOR POCKET.........................................................................................................109 ASHTRAY.............................................................................................................109 TOOL BOX............................................................................................................110 CAR STEREO, HANDLING................................................................................................111 AIR CONDITIONER, HANDLING...........................................................................................119 OPERATION...............................................................................................................124 CHECK BEFORE STARTING ENGINE, ADJUST................................................................................124 STARTING ENGINE.....................................................................................................146 OPERATIONS AND CHECKS AFTER STARTING ENGINE.........................................................................151 STOPPING ENGINE.....................................................................................................154 MOVING MACHINE......................................................................................................155 STOPPING MACHINE....................................................................................................157 SHIFTING GEAR.......................................................................................................158 SHIFTING BETWEEN FORWARD AND REVERSE................................................................................163 STEERING MACHINE....................................................................................................165 PRECAUTIONS FOR OPERATION...........................................................................................168 PARKING MACHINE.....................................................................................................170 CHECK AFTER STOPPING ENGINE.........................................................................................171 CHECK AFTER FINISHING WORK..........................................................................................172 LOCKING.............................................................................................................172 WORK POSSIBLE USING BULLDOZER.......................................................................................173 EFFECTIVE USE OF MODE SELECTION SYSTEM..............................................................................175 RIPPER OPERATION....................................................................................................180 OPERATING METHOD FOR RIPPING OPERATIONS.............................................................................183 ADJUSTING POSTURE OF WORK EQUIPMENT.................................................................................188 TIPS FOR LONGER UNDERCARRIAGE LIFE..................................................................................191 TRANSPORTATION..........................................................................................................193 TRANSPORTATION PROCEDURE............................................................................................193 LOADING, UNLOADING WORK.............................................................................................193 METHOD OF LIFTING MACHINE...........................................................................................196 TRAVELING ON ROADS..................................................................................................197 REMOVAL OF CAB......................................................................................................198 INSTALLATION OF CAB.................................................................................................198 COLD WEATHER OPERATION..................................................................................................199 PRECAUTIONS FOR LOW TEMPERATURE.....................................................................................199 AFTER COMPLETION OF WORK............................................................................................201 AFTER COLD WEATHER..................................................................................................201 LONG-TERM STORAGE.......................................................................................................202 BEFORE STORAGE......................................................................................................202 DURING STORAGE......................................................................................................202 AFTER STORAGE.......................................................................................................202 STARTING MACHINE AFTER LONG-TERM STORAGE............................................................................202 TROUBLESHOOTING.........................................................................................................203 AFTER RUNNING OUT OF FUEL...........................................................................................203 METHOD OF TOWING MACHINE............................................................................................204 IF BATTERY IS DISCHARGED............................................................................................205 OTHER TROUBLE.......................................................................................................209 WHEN MODE SELECTION SYSTEM FLASHES..................................................................................214 MAINTENANCE.................................................................................................................216 GUIDES TO MAINTENANCE...................................................................................................217 OUTLINES OF SERVICE.....................................................................................................220 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC..............................................................220 OUTLINE OF ELECTRIC SYSTEM..........................................................................................224 HANDLING HYDRAULIC RELATED EQUIPMENT................................................................................225 WEAR PARTS..............................................................................................................226 WEAR PARTS LIST.....................................................................................................226 RECOMMENDED FUEL, COOLANT, AND LUBRICANT................................................................................227 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.................................229 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..........................................................................230 TORQUE LIST.........................................................................................................230 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...........................................................................231 SAFETY CRITICAL PARTS...............................................................................................231 MAINTENANCE SCHEDULE CHART..............................................................................................233 MAINTENANCE SCHEDULE CHART..........................................................................................233 SERVICE PROCEDURE.......................................................................................................235 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..........................................................235 WHEN REQUIRED.......................................................................................................236 CLEAN INSIDE OF COOLING SYSTEM..................................................................................236 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....................................................................240 CHECK AND ADJUST TRACK TENSION..................................................................................245 CHECK AND TIGHTEN TRACK SHOE BOLTS..............................................................................248 ADJUST IDLER CLEARANCE..........................................................................................249 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES..............................................................250 CLEAN AND CHECK RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS................................................252 CLEAN FUEL TANK STRAINER........................................................................................255 DRAIN WATER AND SEDIMENT IN FUEL TANK...........................................................................255 CLEAN STEERING CLUTCH CASE BREATHER.............................................................................256 CLEAN FUEL TANK BREATHER........................................................................................256 CLEAN HYDRAULIC TANK BREATHER...................................................................................256 CHECK UNDERCARRIAGE OIL.........................................................................................257 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..........................................................258 REPLACE AIR CONDITIONER BELT....................................................................................258 CHECK AND ADJUST AIR CONDITIONER................................................................................259 LUBRICATE DOOR HINGE............................................................................................260 CHECK DOOR LATCH................................................................................................260 CHECK DOOR LOCK STRIKER.........................................................................................260 REPLACE DOOR DAMPER.............................................................................................261 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID......................................................................261 REPLACE WIPER BLADE.............................................................................................262 BLEEDING AIR IN HYDRAULIC SYSTEM................................................................................263 LUBRICATING.....................................................................................................264 CHECK BEFORE STARTING...............................................................................................265 EVERY 250 HOURS SERVICE.............................................................................................266 LUBRICATING.....................................................................................................266 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.....................................................................268 CHECK LEVEL OF BATTERY ELECTROLYTE..............................................................................269 CHECK BRAKE PERFORMANCE.........................................................................................271 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.........................................................................272 EVERY 500 HOURS SERVICE.............................................................................................273 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...............................................273 REPLACE POWER TRAIN OIL FILTER ELEMENT, STEERING LUBRICATING OIL FILTER ELEMENT.................................275 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....................................................................276 REPLACE FUEL PRE-FILTER CARTRIDGE...............................................................................277 EVERY 1000 HOURS SERVICE............................................................................................279 REPLACE FUEL MAIN FILTER CARTRIDGE..............................................................................279 REPLACE FUEL TANK BREATHER ELEMENT..............................................................................281 REPLACE HYDRAULIC TANK BREATHER ELEMENT.........................................................................281 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER)............282 CHECK, CLEAN FUEL STRAINER......................................................................................284 CHECK FOR LOOSE ROPS MOUNT BOLTS................................................................................284 REPLACE CORROSION RESISTOR CARTRIDGE............................................................................285 CHECK HOSE CLAMPS BETWEEN AIR CLEANER AND TURBOCHARGER, TURBOCHARGER AND AFTERCOOLER, AFTERCOOLER AND ENGINE....286 REPLACE CHARGE FILTER ELEMENT...................................................................................287 EVERY 2000 HOURS SERVICE............................................................................................288 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER...............288 CHANGE OIL IN FINAL DRIVE CASE..................................................................................290 CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER................................................................291 CHECK PIVOT BEARING OIL LEVEL, ADD OIL..........................................................................293 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL.................................................293 CHECK ALTERNATOR................................................................................................294 CHECK ENGINE VALVE CLEARANCE, ADJUST............................................................................294 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)...................................294 EVERY 4000 HOURS SERVICE............................................................................................298 REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT).......................................................................298 CHECK WATER PUMP................................................................................................298 CHECK STARTING MOTOR............................................................................................298 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER..............................................299 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.............................................300 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)................................................................301 EVERY 8000 HOURS SERVICE............................................................................................302 REPLACE HIGH-PRESSURE PIPING CLAMPS.............................................................................302 REPLACE FUEL SPLAY PREVENTION CAPS..............................................................................302 SPECIFICATIONS..............................................................................................................304 SPECIFICATIONS..........................................................................................................305 ATTACHMENTS, OPTIONS........................................................................................................306 GENERAL PRECAUTIONS.....................................................................................................307 PRECAUTIONS RELATED TO SAFETY.......................................................................................307 SELECTION OF TRACK SHOE.................................................................................................308 SELECTION OF TRACK SHOES............................................................................................308 PROCEDURE FOR SELECTING RIPPER POINT....................................................................................309 EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER.......................................................................310 BLADE CONDITION.....................................................................................................310 DOZING WORK.........................................................................................................312 LEVELING (SPREADING) OPERATION......................................................................................315 DITCHING OPERATION..................................................................................................315 BOULDER RAISING OPERATION...........................................................................................315 SIDE-CUTTING OPERATIONS.............................................................................................316 HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND).........................................................316 SHOE SLIP CONTROL.......................................................................................................317 MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL).....................................................................317 EFFECTIVE USE OF MODE SELECTION SYSTEM..............................................................................319 IF MODE SELECTION SYSTEM FLASHES....................................................................................326 HANDLING MACHINES EQUIPPED WITH KOMTRAX.................................................................................327 BASIC PRECAUTIONS...................................................................................................327 INDEX.......................................................................................................................328
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