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.
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
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 . . . .
KEAM019300 – Crawler Dozer D51EXi-22, D51PXi-22 Operation & Maintenance Manual (SN-B13500&up)….2
FOREWORD….5
BEFORE READING THIS MANUAL….5
SAFETY INFORMATION….6
INTRODUCTION….7
USE OF MACHINE….7
DIRECTIONS OF MACHINE….7
PRODUCT IDENTIFICATION….8
PRODUCT IDENTIFICATION PLATE….8
ENGINE SERIAL NUMBER AND EMISSION LABEL….9
SERIAL NUMBERS AND DEALER INFORMATION….10
MODEL: D51EXi/PXi-22….10
INTRODUCTION….11
MACHINE FEATURES….11
CONTENTS….12
SAFETY….26
SAFETY AND WARNING DECALS….27
LOCATION OF THE SAFETY DECALS….28
GENERAL SAFETY RULES AND PRECAUTIONS….33
GENERAL SAFETY RULES….33
UNAUTHORIZED MODIFICATIONS….34
GENERAL SAFETY AT JOB SITE….34
WORKING ON LOOSE GROUND….34
SAFETY FEATURES….35
PERSONAL PROTECTIVE EQUIPMENT….35
FIRE AND EXPLOSION PREVENTION….36
FIRE CAUSED BY FUEL OR OIL….36
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL….36
FIRE FROM ELECTRICAL SYSTEM….37
FIRE FROM HYDRAULIC LINE….37
WINDSHIELD WASHER FLUID….37
ACTION IF FIRE OCCURS….37
DUST HAZARDS….37
BLAST ZONE HAZARD….38
KEEP OPERATOR'S CAB CLEAN….38
UNAUTHORIZED MODIFICATIONS….38
LEAVING OPERATOR’S COMPARTMENT….39
PARKING BRAKE AND EQUIPMENT LOCKS….39
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….40
WHEN STANDING UP FROM OPERATOR'S SEAT….40
WHEN LEAVING MACHINE….40
MOUNTING AND DISMOUNTING….41
CRUSH OR PINCH POINT DANGERS….41
FIRE EXTINGUISHER AND FIRST AID KIT….41
INSIDE OPERATOR’S COMPARTMENT….42
PRECAUTIONS WHEN USING ROPS….42
PRECAUTIONS FOR OPERATION….42
IN COLD AREAS….42
PRECAUTIONS FOR BLADE AUTOMATIC CONTROL….43
PRECAUTIONS BEFORE STARTING OPERATIONS….44
PRE-OPERATIONAL CHECKS….44
STARTING YOUR WORK OPERATIONS….44
WORK SITE HAZARDS….44
AVOIDING DANGEROUS SITUATIONS….45
HIGH VOLTAGE LINES….47
RULES FOR ROAD TRAVEL….48
PRECAUTIONS WHEN TRAVELING….48
USING BRAKES….48
RULES FOR TRAVELING IN REVERSE….49
TRAVELING ON ICY OR SNOW-COVERED SURFACES….49
WORKING ON LOOSE OR UNSTABLE GROUND….49
TRAVEL ON SLOPES….49
PARKING THE MACHINE….50
PRECAUTIONS DURING MAINTENANCE OPERATIONS….51
WARNING TAGS….51
EQUIPMENT STORAGE….51
WORKING UNDER THE MACHINE….52
USING DROP LAMPS….52
KEEPING THE MACHINE CLEAN….52
KEEP WORKPLACE CLEAN AND TIDY….52
APPOINT LEADER WHEN WORKING WITH OTHERS….52
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….53
RUNNING THE MACHINE DURING MAINTENANCE….54
RULES FOR REFUELING THE MACHINE….54
COOLING SYSTEM PRECAUTIONS….54
WORK UNDER THE MACHINE….54
PRECAUTIONS WHEN USING HAMMER….55
TURN THE BATTERY DISCONNECT SWITCH TO THE OFF POSITION….55
REPAIR WELDING….55
ENGINE SYSTEM HIGH VOLTAGE….55
BATTERY PRECAUTIONS….56
STARTING THE MACHINE….57
HIGH PRESSURE HOSES….57
HANDLING HIGH-PRESSURE HOSES….57
PRECAUTION FOR HIGH FUEL PRESSURE….58
HIGH TEMPERATURE AREAS….58
ROTATING PARTS….58
DISPOSAL OF WASTE MATERIALS….58
MERCURY CONTAINING COMPONENT(S)….58
USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….59
DO NOT DISASSEMBLE RECOIL SPRING….59
ACCUMULATOR AND GAS SPRING….59
CRITICAL PARTS….60
PRECAUTIONS FOR CHECK AND MAINTENANCE….61
PRECAUTIONS FOR iB GNSS ANTENNA….61
TRANSPORTING THE MACHINE….62
LOADING AND SECURING THE MACHINE….62
TOWING THE MACHINE….63
OPERATION….66
GENERAL VIEWS….67
VIEW OF MACHINE….67
VIEW OF CONTROLS AND GAUGES….69
MACHINE MONITOR SYSTEM….71
MONITOR LAYOUT….71
BASIC OPERATION OF MONITOR PANEL….72
CHECK MONITOR SYSTEM….73
MONITOR CHECK ITEMS….74
EMERGENCY ALERTS….74
ENGINE OIL PRESSURE CAUTION LAMP….74
ENGINE COOLANT TEMPERATURE CAUTION LAMP….75
HYDRAULIC OIL TEMPERATURE CAUTION LAMP….75
HST CHARGE PRESSURE CAUTION LAMP….75
CHARGE FILTER CLOG CAUTION LAMP….75
WARNING ALERTS….76
BATTERY CHARGE CAUTION LAMP….76
AIR CLEANER CLOGGING CAUTION LAMP….77
WATER IN FUEL LAMP….77
MAINTENANCE CAUTION LAMP….77
CONSOLE CONTROL SWITCHES….78
SWITCH LAYOUT VIEW….78
LAMP SWITCH….78
BUZZER CANCEL SWITCH….79
INFORMATION SWITCH….79
HEATER SWITCH….79
IGNITION SWITCH….80
HORN SWITCH….81
WIPER SWITCH….81
CAB LAMP SWITCH….82
CIGARETTE LIGHTER….82
ACCESSORY SOCKET….82
METER DISPLAY….83
ENGINE COOLANT TEMPERATURE GAUGE….83
HYDRAULIC OIL TEMPERATURE GAUGE….84
DISPLAY PANEL (A)….84
FUEL LEVEL GAUGE….88
REVERSE TRAVEL SPEED SET SWITCH….88
SHIFT MODE SWITCH….88
ENGINE INTAKE AIR PRE-HEAT PILOT LAMP….88
DISPLAY PANEL (B)….89
FAN ROTATION SELECTOR SWITCH….90
FLOAT MODE MONITOR….90
WARNING LAMP VIEW….91
WARNING LAMP (1)….91
USING FAILURE CODE DISPLAY….92
USING MAINTENANCE MODE….93
METHOD OF SELECTING EACH MODE….94
USING OIL AND FILTER MAINTENANCE MODE….95
USING ADJUSTMENT MODE….96
CONTROL LEVERS AND PEDALS….99
LEVER LAYOUT VIEW….99
LOCK LEVERS….99
JOYSTICK (STEERING, DIRECTIONAL AND GEAR….100
SHIFT LEVER)….100
BLADE CONTROL LEVER….101
ANGLING CONTROL….102
WORK EQUIPMENT LOCK LEVER….103
FUEL CONTROL DIAL….104
DECELERATOR PEDAL….105
BRAKE PEDAL….105
PARKING BRAKE LEVER….106
DOOR AND WINDOW SYSTEM….107
DOOR – OPEN LOCK….107
SASH GLASS INTERMEDIATE LOCK….107
SAFETY LOCKS AND SECURITY….108
DOOR LOCK….108
CAP, COVER WITH LOCK….108
METHOD OF OPENING OR CLOSING HYDRAULIC TANK CAP….109
OPEN AND CLOSE FUEL FILLER PORT CAP….110
OPEN….110
CLOSE….110
METHOD OF OPENING AND CLOSING COVER WITH LOCK….110
TO OPEN THE COVER (LOCKED COVER)….110
TO LOCK THE COVER….110
LOCKABLE AREAS….111
SEAT POCKET….111
ADDITIONAL FEATURES AND ACCESSORIES….112
AIR CONDITIONER AND FEET HEATER….112
GENERAL DESCRIPTION OF CONTROL PANEL….112
MODE SELECTOR SWITCH….112
BLOWER SPEED SELECTOR SWITCH….113
TEMPERATURE CONTROL SWITCH….113
PRECAUTIONS WHEN USING AIR CONDITIONER….114
FEET HEATER….115
RADIO….116
EXPLANATION OF FEATURES….116
POWER SWITCH/VOLUME….117
AUTO-STORE/PRESET SCAN BUTTON….117
BASS CONTROL KNOB….117
TREBLE CONTROL KNOB….118
LOUDNESS BUTTON….118
TIME/RADIO DISPLAY SELECTOR BUTTON….118
TAPE EJECT BUTTON….119
CASSETTE DOOR….119
FAST FORWARD, REWIND BUTTONS….119
PRESET BUTTONS….119
METAL TAPE BUTTON….120
MANUAL TUNING BUTTONS….120
SEEK TUNING BUTTONS….120
BAND SELECTOR BUTTON….120
METHOD OF OPERATION….121
LISTENING TO RADIO….122
LISTENING TO A CASSETTE TAPE….122
REVERSING TAPE….123
PRECAUTION WHEN USING….123
ASHTRAY….124
LUNCH BOX HOLDER STRAP….124
CUP HOLDER….124
TOOL BOX….124
GREASE PUMP HOLDER….125
ELECTRICAL POWER ADAPTER….125
BATTERY DISCONNECT SWITCH….126
FUSES….127
FUSES….127
FUSE CAPACITIES AND CIRCUIT NAMES….127
PRECAUTIONS BEFORE STARTING WORK OPERATIONS….130
PRE-OPERATIONAL CHECKS….130
WALK-AROUND CHECKS….130
CHECKS BEFORE STARTING….131
ADJUSTMENTS BEFORE OPERATION….145
ADJUST ARMREST….146
FASTENING AND REMOVING SEAT BELT….146
ADJUSTING MIRROR….147
OPERATIONS AND CHECKS BEFORE….147
STARTING ENGINE….147
STARTING THE ENGINE….149
NORMAL OR COLD START PROCEDURES….149
COLD WEATHER STARTS….150
OPERATIONS AND CHECKS AFTER STARTING ENGINE….154
BREAKING IN THE MACHINE….154
WARMING UP ENGINE….154
STARTING IN COLD WEATHER….155
STOPPING THE ENGINE….157
MOVING, STEERING, STOPPING AND PARKING THE MACHINE….158
PREPARATIONS FOR MOVING THE MACHINE….158
MOVING MACHINE FORWARD OR REVERSE….159
CHANGING SPEED RANGES….161
STEERING THE MACHINE….163
NORMAL TURN….163
MAKING A LEFT OR RIGHT TURN….163
MAKING A PIVOT TURN….164
TURNING WHILE DESCENDING A SLOPE….164
COUNTER-ROTATION TURN….164
STOPPING THE MACHINE….165
PARKING MACHINE….167
CHECK AFTER FINISHING WORK….168
CHECK AFTER SHUTTING OFF ENGINE….168
STARTING YOUR WORK OPERATIONS….169
AVOIDING DANGEROUS SITUATIONS….169
HIGH VOLTAGE LINES….171
OPERATING THE MACHINE….172
PAY ATTENTION TO GAUGES….172
PERMISSIBLE WATER DEPTH….172
METHOD OF USING BRAKES….172
WHEN TRAVELING UP OR DOWN HILLS….172
PRECAUTIONS ON SLOPES….173
BE AWARE OF FUEL LEVEL….173
PRECAUTIONS WHEN ENGINE STOPS ON A SLOPES….173
ALWAYS KEEP THE DOORS CLOSED DURING OPERATIONS….173
DO NOT MODIFY THE CAB GLASS IN ANY WAY….173
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAYS….173
CUTTING A GRADE….174
DOZING….174
BACK GRADING A SURFACE….174
CUTTING HARD OR FROZEN GROUND OR DITCHING….175
FELLING TREES, REMOVING STUMPS….175
SIDE-CUTTING OPERATIONS….175
UNDERCARRIAGE CARE….176
OPERATION METHOD….176
INSPECTION AND ADJUSTMENT….176
INSPECTION AND REPAIR….177
MEASURING LINK PITCH….177
MEASURING HEIGHT OF GROUSER….177
MEASURING OUTSIDE DIAMETER OF TRACK ROLLER….178
TRANSPORTING THE MACHINE….179
LOADING OR UNLOADING A TRAILER….179
PRE-TRANSPORTATION PROCEDURES….180
SECURING MACHINE….181
UNLOADING THE MACHINE….184
LIFTING THE MACHINE….185
FOR BASE MACHINE….185
FOR MACHINE EQUIPPED WITH RIPPER….186
COLD WEATHER OPERATION….187
FUEL AND LUBRICANTS….187
COOLING SYSTEM COOLANT….187
BATTERY….188
PRECAUTIONS ON PARTICULAR JOBSITES….189
DISCHARGED BATTERY….189
REMOVE AND INSTALL BATTERY….190
BATTERY CHARGES….190
STARTING ENGINE WITH BOOSTER CABLES….191
GENERAL TROUBLESHOOTING….193
AFTER RUNNING OUT OF FUEL….193
TOWING THE MACHINE….193
WHEN IT IS POSSIBLE TO START ENGINE….194
WHEN ENGINE DOES NOT START….194
RELEASING THE BRAKES….194
CONNECTING PUMP TO MACHINE….195
AFTER TOWING MACHINE….197
ELECTRICAL SYSTEM PROBLEMS….199
MONITOR PANEL….200
CHASSIS PROBLEMS….201
ENGINE PROBLEMS….202
LONG TERM STORAGE….203
BEFORE STORAGE….203
DURING STORAGE….203
AFTER STORAGE….203
MACHINES EQUIPPED WITH KOMTRAX SYSTEMS….204
BASIC PRECAUTIONS….204
MAINTENANCE….206
MAINTENANCE INFORMATION….207
SERVICE METER READING….207
KOMATSU GENUINE REPLACEMENT PARTS….207
KOMATSU GENUINE LUBRICANTS….207
WINDSHIELD WASHER FLUID….207
FRESH AND CLEAN LUBRICANTS….207
CHECK DRAINED OIL AND USED FILTER….207
FUEL STRAINER….207
WELDING INSTRUCTIONS….207
DO NOT DROP THINGS INSIDE MACHINE….208
DUSTY JOBSITE….208
AVOID MIXING LUBRICANTS….208
HYDRAULIC SYSTEM – AIR BLEEDING….208
HYDRAULIC HOSE INSTALLATION….208
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS….208
LOCKING THE INSPECTION COVER….209
OPENING OR CLOSING RADIATOR GRILL….209
LUBRICANTS, COOLANT AND FILTERS….211
OUTLINE OF SERVICE….211
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….211
OIL….211
FUEL….211
COOLING SYSTEM COOLANT….212
GREASE….212
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)….212
OIL AND FUEL STORAGE….213
FILTERS….213
ELECTRIC SYSTEM MAINTENANCE….214
HANDLING HYDRAULIC SYSTEM….214
WEAR PARTS LIST….215
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….216
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS….218
LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS….219
TIGHTENING TORQUE SPECIFICATIONS….221
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….222
SAFETY RELATED CRITICAL PARTS….222
MAINTENANCE SCHEDULE….223
MAINTENANCE SCHEDULE CHART….223
WHEN REQUIRED….226
CLEANING THE MACHINE….226
CLEAN TIPS….226
CLEANING THROUGH ACCESS AREAS….226
CHECK ELECTRICAL INTAKE AIR HEATER….229
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….229
CLEANING OR REPLACING OUTER ELEMENT….229
REPLACING INNER ELEMENT….231
CLEAN COOLING SYSTEM….233
FLUSHING THE COOLING SYSTEM….234
TRACK SYSTEM MAINTENANCE….237
CHECK AND TIGHTEN TRACK SHOE BOLTS….237
CHECKING AND ADJUSTING TRACK TENSION….237
IDLER GUIDE CLEARANCE….239
REVERSING OR REPLACING END BITS AND CUTTING EDGES….241
CHECKING IDLER OIL LEVEL….241
ADJUST PLAY IN CENTER BALL….242
ADJUST PLAY IN PITCH BALL….242
MECHANICAL PITCH ROD (ADJUSTABLE)….243
ADJUSTMENT….243
SPECIFICATIONS….243
ADJUSTMENT OF PITCH ANGLE….243
DOOR HINGES….244
CHECKING WINDOW WASHER FLUID LEVEL….245
MIXTURE RATIO OF PURE WASHER FLUID AND WATER….245
CHECKING AIR CONDITIONER….246
CHECK LEVEL OF REFRIGERANT….246
OPERATING AIR CONDITIONER OFF-SEASON….246
REPLACE WIPER BLADE….247
REPLACEMENT….247
RELEASING INTERNAL PRESSURE ON HYDRAULIC SYSTEM….248
BLEEDING AIR FROM HYDRAULIC SYSTEM….249
BLEEDING AIR FROM PUMP….249
BLEEDING AIR FROM CYLINDERS….249
CLEAN, CHECK RADIATOR FINS….250
CLEANING BY ROTATING COOLING FAN IN REVERSE DIRECTION….250
CLEANING WITH COMPRESSED AIR….252
CLEAN HYDRAULIC TANK BREATHER….254
CLEAN FUEL TANK BREATHER….254
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….255
REPLACE FUEL PRE-FILTER CARTRIDGE….255
INITIAL 500 HOURS SERVICE (ONLY AFTER THE FIRST 500 HOURS)….257
REPLACE MAIN FUEL FILTER CARTRIDGE….257
EVERY 50 HOURS MAINTENANCE….259
LUBRICATE….259
DRAINING SEDIMENT FROM FUEL TANK….261
EVERY 250 HOURS MAINTENANCE….262
CHECK OIL LEVEL IN FINAL DRIVE CASE….262
CHECKING FINAL DRIVE OIL LEVEL….262
LUBRICATING….262
CHECK LEVEL OF BATTERY ELECTROLYTE….264
CHECK BRAKE PERFORMANCE….265
AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)….267
EVERY 500 HOURS MAINTENANCE….268
REPLACE FUEL PRE-FILTER CARTRIDGE….268
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….271
EVERY 1000 HOURS MAINTENANCE….273
CHANGE OIL IN FINAL DRIVE CASE….273
CHECK ALTERNATOR BELT TENSION….273
CHECK ALL TIGHTENING POINTS OF ENGINE INTAKE & EXHAUST PIPE CLAMPS….273
CHECK FOR LOOSE ROPS MOUNT BOLTS….274
REPLACE PRE AND MAIN FUEL FILTER CARTRIDGES….275
REPLACE BREATHER ELEMENT IN FUEL TANK….281
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK….281
EVERY 2000 HOURS MAINTENANCE….282
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE….282
CHECK ALTERNATOR, STARTING MOTOR….284
CHECK ENGINE VALVE CLEARANCE, ADJUST….284
CHECK CHARGE PRESSURE ACCUMULATOR (CONTROL CIRCUIT)….284
FUNCTION OF ACCUMULATOR….284
CHECKING FUNCTION OF ACCUMULATOR….285
RELEASING PRESSURE IN HYDRAULIC CIRCUIT….285
CHECKING PIVOT SHAFT OIL LEVEL….286
EVERY 4000 HOURS MAINTENANCE….287
CHECK WATER PUMP….287
CHECK VIBRATION DAMPER….287
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)….287
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER….288
CHECK FOR MISSING FUEL SPRAY CAP, HARDENING OF RUBBER….289
SPECIFICATIONS….292
SPECIFICATIONS….293
OPERATING WEIGHT….293
MACHINE DIMENSIONS AND WEIGHTS….294
MACHINE SYSTEMS SPECIFICATIONS….295
ENGINE….295
TRANSMISSION….296
STEERING SYSTEM….296
SERVICE REFILL CAPACITIES….296
UNDERCARRIAGE….296
OPTIONAL ATTACHMENTS….298
AUTHORIZED OPTIONAL EQUIPMENT….299
BASIC PRECAUTIONS….299
AIR SUSPENSION SEAT….300
FORESTRY KIT….302
CABIN POLYCARBONATE PANEL FRONT….303
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT….304
HANDLING HYDRAULIC RIPPER….305
GENERAL VIEW….305
EXPLANATION OF COMPONENTS….306
RIPPER CONTROL LEVER….306
MAINTENANCE….310
EVERY 250 HOURS SERVICE….310
OPERATION….307
CHECK BEFORE STARTING ENGINE, ADJUST….307
PRECAUTIONS WHEN OPERATING….307
ADJUSTING POSTURE OF WORK EQUIPMENT….307
REPLACEMENT OF POINT….308
TROUBLESHOOTING….309
OTHER TROUBLE….309
iB OPERATION….312
HANDLING iB MONITOR….374
iB INDEX….440
SEAM01341703 – Bulldozer D53A,P-17 Operation & Maintenance Manual (SN80001&up)….444
COVER….444
FOREWORD….445
BREAKING IN YOUR NEW MACHINE….446
CONTENTS….447
SAFETY HINTS….448
GENERAL LOCATIONS AND SPECIFICATIONS….455
OPERATOR'S COMPARTMENT….456
INSTRUMENTS AND CONTROLS….458
CHECK BEFORE STARTING….469
OPERATING YOUR MACHINE….473
COLD WEATHER OPERATION….485
BULLDOZER'S WORK….490
BLADE OPERATION….492
BLADE ADJUSTMENT….495
REVERSING OF CUTTING EDGE AND REPLACEMENT OF END BIT….498
TIPS FOR LONGER UNDERCARRIAGE LIFE….499
HANDLING OF BATTERY….500
TRANSPORTATION….503
PERIODIC MAINTENANCE….504
PRECAUTIONS FOR MAINTENANCE….505
MAINTENANCE TABLE….508
EVERY 50 HOURS SERVICE….511
EVERY 250 HOURS SERVICE….512
EVERY 500 HOURS SERVICE….517
EVERY 1000 HOURS SERVICE….522
EVERY 2000 HOURS SERVICE….526
EVERY 4000 HOURS SERVICE….531
WHEN REQUIRED….532
ADJUSTMENT….542
TROUBLE SHOOTING GUIDE….546
STORAGE….549
SERVICE METER….551
MACHINE AND ENGINE SERIAL NUMBERS….552
FUEL,COOLANT AND LUBRICANTS….553
SEAM026300P – Bulldozer D53A,P-17 Operation & Maintenance Manual (SN82727&up)….558
COVER….558
FOREWORD….559
BREAKING IN YOUR NEW MACHINE….560
CONTENTS….561
SAFETY HINTS….562
POSITION FOR ATTACHING SAFETY LABELS….569
GENERAL LOCATIONS AND SPECIFICATIONS….573
OPERATOR'S COMPARTMENT….574
INSTRUMENTS AND CONTROLS….576
CHECK BEFORE STARTING….587
OPERATING YOUR MACHINE….591
COLD WEATHER OPERATION….603
BULLDOZER'S WORK….608
BLADE OPERATION….610
BLADE ADJUSTMENT….613
REVERSING OF CUTTING EDGE AND REPLACEMENT OF END BIT….616
TIPS FOR LONGER UNDERCARRIAGE LIFE….617
HANDLING OF BATTERY….618
TRANSPORTATION….621
PERIODIC MAINTENANCE….622
PRECAUTIONS FOR MAINTENANCE….623
MAINTENANCE TABLE….626
EVERY 50 HOURS SERVICE ….629
EVERY 250 HOURS SERVICE ….630
EVERY 500 HOURS SERVICE ….636
EVERY 1000 HOURS SERVICE ….641
EVERY 2000 HOURS SERVICE ….645
EVERY 4000 HOURS SERVICE ….650
WHEN REQUIRED….651
ADJUSTMENT….661
TROUBLE SHOOTING GUIDE….665
STORAGE….668
SERVICE METER….670
MACHINE AND ENGINE SERIAL NUMBERS….671
FUEL,COOLANT AND LUBRICANTS….672
SEAM13FC00 – Bulldozer D50P,PL-16 Operation & Maintenance Manual (SN68001&up)….677
COVER….677
FOREWORD….678
BREAKING IN YOUR NEW MACHINE….679
CONTENTS….680
SAFETY HINTS….681
GENERAL LOCATIONS….694
OPERATOR'S COMPARTMENT….696
INSTRUMENTS AND CONTROLS….698
CHECK BEFORE STARTING….705
OPERATING YOUR MACHINE….711
COLD WEATHER OPERATION….723
BULLDOZER'S WORK….728
BLADE OPERATION….730
BLADE ADJUSTMENT….732
REVERSING OF CUTTING EDGE AND REPLACEMENT OF END BIT….733
TIPS FOR LONGER UNDERCARRIAGE LIFE….734
TRANSPORTATION….735
MAINTENANCE….737
PERIODIC MAINTENANCE….738
PRECAUTIONS FOR MAINTENANCE….739
MAINTENANCE TABLE….745
EVERY 50 HOURS SERVICE….750
EVERY 250 HOURS SERVICE….751
EVERY 500 HOURS SERVICE….757
EVERY 1000 HOURS SERVICE….760
EVERY 2000 HOURS SERVICE….765
WHEN REQUIRED….772
ADJUSTMENT….776
TROUBLE SHOOTING GUIDE….782
STORAGE….786
SERVICE METER….788
MACHINE AND ENGINE SERIAL NUMBERS….789
WEAR PARTS….790
SPECIFICATIONS….791
FUEL AND LUBRICANTS….793
Komatsu Crawler Dozers D50-, D51-, D53- Operation Maintenance Manuals