Komatsu Crawler Dozers D50-, D51-, D53- Operation Maintenance Manuals

Komatsu Crawler Dozers D50-, D51-, D53- Operation Maintenance Manuals

KEAM019300 - Crawler Dozer D51EXi-22, D51PXi-22 Operation & Maintenance Manual (SN-B13500&up).pdf
SEAM13FC00 - Bulldozer D50P,PL-16 Operation & Maintenance Manual (SN68001&up).pdf
SEAM026300P - Bulldozer D53A,P-17 Operation & Maintenance Manual (SN82727&up).pdf
SEAM01341703 - Bulldozer D53A,P-17 Operation & Maintenance Manual (SN80001&up).pdf

Complete Operation Maintenance Manuals for Komatsu Crawler Dozers D50P-16, D50PL-16, D51EXi-22, D51PXi-22, D53A-17, D53P-17, D53A-17, D53P-17, with all the service information to maintain & operate.

PRODUCT DETAILS:
Total Pages: 613 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
FOREWORD
BEFORE READING THIS MANUAL . . .
SAFETY INFORMATION . . . .
INTRODUCTION . . .
USE OF MACHINE . . . .
DIRECTIONS OF MACHINE . . . .
PRODUCT IDENTIFICATION . . . .
PRODUCT IDENTIFICATION PLATE . . . .
ENGINE SERIAL NUMBER AND EMISSION LABEL . . .
SERIAL NUMBERS AND DEALER INFORMATION . . .
MODEL: D51EXi/PXi-22 . . . .
INTRODUCTION . . .
MACHINE FEATURES . . .
SAFETY
SAFETY AND WARNING DECALS . . . 1-2
LOCATION OF THE SAFETY DECALS . . . 1-3
GENERAL SAFETY RULES AND PRECAUTIONS . . . 1-8
GENERAL SAFETY RULES . . . 1-8
UNAUTHORIZED MODIFICATIONS . . . . 1-9
GENERAL SAFETY AT JOB SITE . . . 1-9
WORKING ON LOOSE GROUND . . . 1-9
SAFETY FEATURES . . . . 1-10
PERSONAL PROTECTIVE EQUIPMENT . . . 1-10
FIRE AND EXPLOSION PREVENTION . . . . 1-11
FIRE CAUSED BY FUEL OR OIL . . . . 1-11
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL . . . 1-11
FIRE FROM ELECTRICAL SYSTEM . . . 1-12
FIRE FROM HYDRAULIC LINE . . . 1-12
WINDSHIELD WASHER FLUID . . . 1-12
ACTION IF FIRE OCCURS . . . 1-12
DUST HAZARDS . . . 1-12
BLAST ZONE HAZARD . . . 1-13
KEEP OPERATOR'S CAB CLEAN . . . 1-13
UNAUTHORIZED MODIFICATIONS . . . . 1-13
LEAVING OPERATOR’S COMPARTMENT . . . . 1-14
PARKING BRAKE AND EQUIPMENT LOCKS . . . 1-14
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE . . . . 1-15
WHEN STANDING UP FROM OPERATOR'S SEAT . . . 1-15
WHEN LEAVING MACHINE . . . . 1-15
MOUNTING AND DISMOUNTING . . . . 1-16
CRUSH OR PINCH POINT DANGERS . . . 1-16
FIRE EXTINGUISHER AND FIRST AID KIT . . . . 1-16
INSIDE OPERATOR’S COMPARTMENT . . . 1-17
PRECAUTIONS WHEN USING ROPS . . . . 1-17
PRECAUTIONS FOR OPERATION . . . .
IN COLD AREAS . . . .
PRECAUTIONS FOR BLADE AUTOMATIC CONTROL . . . .
PRECAUTIONS BEFORE STARTING OPERATIONS . . . .
PRE-OPERATIONAL CHECKS . . .
STARTING YOUR WORK OPERATIONS . . . .
WORK SITE HAZARDS . . .
AVOIDING DANGEROUS SITUATIONS . . .
HIGH VOLTAGE LINES . . .
RULES FOR ROAD TRAVEL . . . .
PRECAUTIONS WHEN TRAVELING . . . .
USING BRAKES . . . .
RULES FOR TRAVELING IN REVERSE . . .
TRAVELING ON ICY OR SNOW-COVERED SURFACES . . .
WORKING ON LOOSE OR UNSTABLE GROUND . . .
TRAVEL ON SLOPES . . .
PARKING THE MACHINE . . .
PRECAUTIONS DURING MAINTENANCE OPERATIONS . . .
WARNING TAGS . . .
EQUIPMENT STORAGE . . .
WORKING UNDER THE MACHINE . . .
USING DROP LAMPS . . .
KEEPING THE MACHINE CLEAN . . . .
KEEP WORKPLACE CLEAN AND TIDY . . .
APPOINT LEADER WHEN WORKING WITH OTHERS . . .
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE . . . .
RUNNING THE MACHINE DURING MAINTENANCE . . .
RULES FOR REFUELING THE MACHINE . . .
COOLING SYSTEM PRECAUTIONS . . . .
WORK UNDER THE MACHINE . . . .
PRECAUTIONS WHEN USING HAMMER . . . .
TURN THE BATTERY DISCONNECT SWITCH TO THE OFF POSITION . . . .
REPAIR WELDING . . .
ENGINE SYSTEM HIGH VOLTAGE . . .
BATTERY PRECAUTIONS . . . .
STARTING THE MACHINE . . . .
HIGH PRESSURE HOSES . . . .
HANDLING HIGH-PRESSURE HOSES . . . .
PRECAUTION FOR HIGH FUEL PRESSURE . . . .
HIGH TEMPERATURE AREAS . . .
ROTATING PARTS . . .
DISPOSAL OF WASTE MATERIALS . . . .
MERCURY CONTAINING COMPONENT(S) . . . .
USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION . . . .
DO NOT DISASSEMBLE RECOIL SPRING . . .
ACCUMULATOR AND GAS SPRING . . . .
CRITICAL PARTS . . . .
PRECAUTIONS FOR CHECK AND MAINTENANCE . . .
PRECAUTIONS FOR iB GNSS ANTENNA . . . .
TRANSPORTING THE MACHINE . . . . 1-37
LOADING AND SECURING THE MACHINE . . . 1-37
TOWING THE MACHINE . . . . 1-38
OPERATION
GENERAL VIEWS . . . . 2-2
VIEW OF MACHINE . . . 2-2
VIEW OF CONTROLS AND GAUGES . . . . 2-4
MACHINE MONITOR SYSTEM . . . . 2-6
MONITOR LAYOUT . . . 2-6
BASIC OPERATION OF MONITOR PANEL . . . 2-7
CHECK MONITOR SYSTEM . . . . 2-8
MONITOR CHECK ITEMS . . . 2-9
EMERGENCY ALERTS . . . . 2-9
ENGINE OIL PRESSURE CAUTION LAMP . . . 2-9
ENGINE COOLANT TEMPERATURE CAUTION LAMP . . . 2-10
HYDRAULIC OIL TEMPERATURE CAUTION LAMP . . . 2-10
HST CHARGE PRESSURE CAUTION LAMP . . . 2-10
CHARGE FILTER CLOG CAUTION LAMP . . . . 2-10
WARNING ALERTS . . . . 2-11
BATTERY CHARGE CAUTION LAMP . . . 2-11
AIR CLEANER CLOGGING CAUTION LAMP . . . 2-12
WATER IN FUEL LAMP . . . . 2-12
MAINTENANCE CAUTION LAMP . . . 2-12
CONSOLE CONTROL SWITCHES . . . 2-13
SWITCH LAYOUT VIEW . . . . 2-13
LAMP SWITCH . . . 2-13
BUZZER CANCEL SWITCH . . . 2-14
INFORMATION SWITCH . . . 2-14
HEATER SWITCH . . . 2-14
IGNITION SWITCH . . . . 2-15
HORN SWITCH . . . 2-16
WIPER SWITCH . . . 2-16
CAB LAMP SWITCH . . . 2-17
CIGARETTE LIGHTER . . . 2-17
ACCESSORY SOCKET . . . 2-17
METER DISPLAY . . . . 2-18
ENGINE COOLANT TEMPERATURE GAUGE . . . 2-18
HYDRAULIC OIL TEMPERATURE GAUGE . . . 2-19
DISPLAY PANEL (A) . . . . 2-19
FUEL LEVEL GAUGE . . . . 2-23
REVERSE TRAVEL SPEED SET SWITCH . . . 2-23
SHIFT MODE SWITCH . . . 2-23
ENGINE INTAKE AIR PRE-HEAT PILOT LAMP . . . 2-23
DISPLAY PANEL (B) . . . . 2-24
FAN ROTATION SELECTOR SWITCH . . . 2-25
FLOAT MODE MONITOR . . . . 2-25
WARNING LAMP VIEW . . . 2-26
WARNING LAMP (1) . . . .
USING FAILURE CODE DISPLAY . . .
USING MAINTENANCE MODE . . .
METHOD OF SELECTING EACH MODE . . . .
USING OIL AND FILTER MAINTENANCE MODE . . .
USING ADJUSTMENT MODE . . .
CONTROL LEVERS AND PEDALS . . .
LEVER LAYOUT VIEW . . . .
LOCK LEVERS . . .
JOYSTICK (STEERING, DIRECTIONAL AND GEAR . . .
SHIFT LEVER) . . . .
BLADE CONTROL LEVER . . .
ANGLING CONTROL . . . .
WORK EQUIPMENT LOCK LEVER . . . .
FUEL CONTROL DIAL . . .
DECELERATOR PEDAL . . . .
BRAKE PEDAL . . .
PARKING BRAKE LEVER . . . .
DOOR AND WINDOW SYSTEM . . .
DOOR - OPEN LOCK . . .
SASH GLASS INTERMEDIATE LOCK . . .
SAFETY LOCKS AND SECURITY . . .
DOOR LOCK . . . .
CAP, COVER WITH LOCK . . .
METHOD OF OPENING OR CLOSING HYDRAULIC TANK CAP . . . .
OPEN AND CLOSE FUEL FILLER PORT CAP . . . .
OPEN . . . .
CLOSE . . .
METHOD OF OPENING AND CLOSING COVER WITH LOCK . . . .
TO OPEN THE COVER (LOCKED COVER) . . . .
TO LOCK THE COVER . . .
LOCKABLE AREAS . . . .
SEAT POCKET . . . .
ADDITIONAL FEATURES AND ACCESSORIES . . .
AIR CONDITIONER AND FEET HEATER . . . .
GENERAL DESCRIPTION OF CONTROL PANEL . . . .
MODE SELECTOR SWITCH . . . .
BLOWER SPEED SELECTOR SWITCH . . .
TEMPERATURE CONTROL SWITCH . . . .
PRECAUTIONS WHEN USING AIR CONDITIONER . . . .
FEET HEATER . . . .
RADIO . . . .
EXPLANATION OF FEATURES . . .
POWER SWITCH/VOLUME . . .
AUTO-STORE/PRESET SCAN BUTTON . . . .
BASS CONTROL KNOB . . . .
TREBLE CONTROL KNOB . . .
LOUDNESS BUTTON . . . .
TIME/RADIO DISPLAY SELECTOR BUTTON . . .
TAPE EJECT BUTTON . . . 2-54
CASSETTE DOOR . . . 2-54
FAST FORWARD, REWIND BUTTONS . . . 2-54
PRESET BUTTONS . . . . 2-54
METAL TAPE BUTTON . . . . 2-55
MANUAL TUNING BUTTONS . . . . 2-55
SEEK TUNING BUTTONS . . . . 2-55
BAND SELECTOR BUTTON . . . . 2-55
METHOD OF OPERATION . . . . 2-56
LISTENING TO RADIO . . . 2-57
LISTENING TO A CASSETTE TAPE . . . . 2-57
REVERSING TAPE . . . . 2-58
PRECAUTION WHEN USING . . . 2-58
ASHTRAY . . . 2-59
LUNCH BOX HOLDER STRAP . . . 2-59
CUP HOLDER . . . 2-59
TOOL BOX . . . . 2-59
GREASE PUMP HOLDER . . . . 2-60
ELECTRICAL POWER ADAPTER . . . 2-60
BATTERY DISCONNECT SWITCH . . . . 2-61
FUSES . . . 2-62
FUSES . . . . 2-62
FUSE CAPACITIES AND CIRCUIT NAMES . . . 2-62
PRECAUTIONS BEFORE STARTING WORK OPERATIONS . . . 2-65
PRE-OPERATIONAL CHECKS . . . 2-65
WALK-AROUND CHECKS . . . 2-65
CHECKS BEFORE STARTING . . . 2-66
ADJUSTMENTS BEFORE OPERATION . . . 2-80
ADJUST ARMREST . . . . 2-81
FASTENING AND REMOVING SEAT BELT . . . 2-81
ADJUSTING MIRROR . . . . 2-82
OPERATIONS AND CHECKS BEFORE . . . 2-82
STARTING ENGINE . . . 2-82
STARTING THE ENGINE . . . . 2-84
NORMAL OR COLD START PROCEDURES . . . 2-84
COLD WEATHER STARTS . . . 2-85
OPERATIONS AND CHECKS AFTER STARTING ENGINE . . . . 2-89
BREAKING IN THE MACHINE . . . 2-89
WARMING UP ENGINE . . . . 2-89
STARTING IN COLD WEATHER . . . . 2-90
STOPPING THE ENGINE . . . . 2-92
MOVING, STEERING, STOPPING AND PARKING THE MACHINE . . . 2-93
PREPARATIONS FOR MOVING THE MACHINE . . . . 2-93
MOVING MACHINE FORWARD OR REVERSE . . . . 2-94
CHANGING SPEED RANGES . . . 2-96
STEERING THE MACHINE . . . . 2-98
NORMAL TURN . . . . 2-98
MAKING A LEFT OR RIGHT TURN . . . . 2-98
MAKING A PIVOT TURN . . . . 2-99
TURNING WHILE DESCENDING A SLOPE . . . 2-99
COUNTER-ROTATION TURN . . . 2-99
STOPPING THE MACHINE . . . 2-100
PARKING MACHINE . . . . 2-102
CHECK AFTER FINISHING WORK . . . 2-103
CHECK AFTER SHUTTING OFF ENGINE . . . . 2-103
STARTING YOUR WORK OPERATIONS . . . . 2-104
AVOIDING DANGEROUS SITUATIONS . . . . 2-104
HIGH VOLTAGE LINES . . . . 2-106
OPERATING THE MACHINE . . . 2-107
PAY ATTENTION TO GAUGES . . . . 2-107
PERMISSIBLE WATER DEPTH . . . 2-107
METHOD OF USING BRAKES . . . 2-107
WHEN TRAVELING UP OR DOWN HILLS . . . 2-107
PRECAUTIONS ON SLOPES . . . . 2-108
BE AWARE OF FUEL LEVEL . . . . 2-108
PRECAUTIONS WHEN ENGINE STOPS ON A SLOPES . . . . 2-108
ALWAYS KEEP THE DOORS CLOSED DURING OPERATIONS . . . 2-108
DO NOT MODIFY THE CAB GLASS IN ANY WAY . . . . 2-108
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAYS . . . 2-108
CUTTING A GRADE . . . 2-109
DOZING . . . . 2-109
BACK GRADING A SURFACE . . . 2-109
CUTTING HARD OR FROZEN GROUND OR DITCHING . . . 2-110
FELLING TREES, REMOVING STUMPS . . . 2-110
SIDE-CUTTING OPERATIONS . . . 2-110
UNDERCARRIAGE CARE . . . . 2-111
OPERATION METHOD . . . . 2-111
INSPECTION AND ADJUSTMENT . . . . 2-111
INSPECTION AND REPAIR . . . 2-112
MEASURING LINK PITCH . . . 2-112
MEASURING HEIGHT OF GROUSER . . . 2-112
MEASURING OUTSIDE DIAMETER OF TRACK ROLLER . . . . 2-113
TRANSPORTING THE MACHINE . . . 2-114
LOADING OR UNLOADING A TRAILER . . . 2-114
PRE-TRANSPORTATION PROCEDURES . . . . 2-115
SECURING MACHINE . . . . 2-116
UNLOADING THE MACHINE . . . . 2-119
LIFTING THE MACHINE . . . 2-120
FOR BASE MACHINE . . . 2-120
FOR MACHINE EQUIPPED WITH RIPPER . . . 2-121
COLD WEATHER OPERATION . . . . 2-122
FUEL AND LUBRICANTS . . . . 2-122
COOLING SYSTEM COOLANT . . . . 2-122
BATTERY . . . . 2-123
PRECAUTIONS ON PARTICULAR JOBSITES . . . 2-124
DISCHARGED BATTERY . . . . 2-124
REMOVE AND INSTALL BATTERY . . . . 2-125
BATTERY CHARGES . . . 2-125
STARTING ENGINE WITH BOOSTER CABLES . . . 2-126
GENERAL TROUBLESHOOTING . . . 2-128
AFTER RUNNING OUT OF FUEL . . . . 2-128
TOWING THE MACHINE . . . 2-128
WHEN IT IS POSSIBLE TO START ENGINE . . . 2-129
WHEN ENGINE DOES NOT START . . . . 2-129
RELEASING THE BRAKES . . . . 2-129
CONNECTING PUMP TO MACHINE . . . . 2-130
AFTER TOWING MACHINE . . . . 2-132
ELECTRICAL SYSTEM PROBLEMS . . . 2-134
MONITOR PANEL . . . 2-135
CHASSIS PROBLEMS . . . . 2-136
ENGINE PROBLEMS . . . . 2-137
LONG TERM STORAGE . . . 2-138
BEFORE STORAGE . . . . 2-138
DURING STORAGE . . . 2-138
AFTER STORAGE . . . 2-138
MACHINES EQUIPPED WITH KOMTRAX SYSTEMS . . . . 2-139
BASIC PRECAUTIONS . . . 2-139
MAINTENANCE
MAINTENANCE INFORMATION . . .
SERVICE METER READING . . . .
KOMATSU GENUINE REPLACEMENT PARTS . . . .
KOMATSU GENUINE LUBRICANTS . . .
WINDSHIELD WASHER FLUID . . .
FRESH AND CLEAN LUBRICANTS . . . .
CHECK DRAINED OIL AND USED FILTER . . .
FUEL STRAINER . . . .
WELDING INSTRUCTIONS . . .
DO NOT DROP THINGS INSIDE MACHINE . . .
DUSTY JOBSITE . . . .
AVOID MIXING LUBRICANTS . . . .
HYDRAULIC SYSTEM - AIR BLEEDING . . .
HYDRAULIC HOSE INSTALLATION . . . .
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS . . . .
LOCKING THE INSPECTION COVER . . . .
OPENING OR CLOSING RADIATOR GRILL . . .
LUBRICANTS, COOLANT AND FILTERS . . . .
OUTLINE OF SERVICE . . . .
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC . . . .
OIL . . .
FUEL . . .
COOLING SYSTEM COOLANT . . .
GREASE . . . .
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS) . . . .
OIL AND FUEL STORAGE . . .
FILTERS . . . .
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