Komatsu D375A-5 Galeo Bulldozer Operation & Maintenance Manual - SEAM061500T

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the D375A-5 Galeo Komatsu Bulldozer. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu D375A-5 Galeo Bulldozer
Serial Numbers : 18200 and up


TABLE OF CONTENTS :

- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- OPTIONS, ATTACHMENTS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEAM061500T
Total Pages : 215


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.

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COVER
1. FOREWORD
2. SAFETY INFORMATION
3. INTRODUCTION
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
5. CONTENTS

SAFETY
SAFETY
6. GENERAL PRECAUTIONS
SAFETY RULES
IF ABNORMALITIES ARE FOUND
CLOTHING AND PERSONAL PROTECTIVE ITEMS
FIRE EXTINGUISHER AND FIRST AID KIT
SAFETY FEATURES
KEEP MACHINE CLEAN
INSIDE OPERATOR'S COMPARTMENT
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT
HANDRAILS AND STEPS
MOUNTING AND DISMOUNTING
NO PEOPLE ON ATTACHMENTS
PREVENTIONS OF BURNS
FIRE PREVENTION
ACTION IF FIRE OCCURS
WINDOW WASHER LIQUID
PRECAUTIONS WHEN USING ROPS
PRECAUTIONS FOR ATTACHMENTS
UNAUTHORIZED MODIFICATION
SAFETY AT WORKSITE
WORKING ON LOOSE GROUND
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES
ENSURE GOOD VISIBILITY
VENTILATION FOR ENCLOSED AREAS
CHECKING SIGNALMAN'S SIGNALS AND SIGNS
BE CAREFUL ABOUT ASBESTOS DUST
7. PRECAUTIONS FOR OPERATION
7.1 STARTING ENGINE
CHECKS BEFORE STARTING ENGINE
PRECAUTIONS WHEN STARTING
PRECAUTIONS IN COLD AREAS
7.2 OPERATION
CHECKS BEFORE OPERATION
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE
PRECAUTIONS WHEN TRAVELING
TRAVELING ON SLOPES
PROHIBITION OF DANGEROUS WORK
USING BRAKES
OPERATE CAREFULLY ON SNOW
PARKING MACHINE
7.3 TRANSPORTATION
SHIPPING
7.4 BATTERY
BATTERY HAZARD PREVENTION
STARTING WITH BOOSTER CABLE
7.5 TOWING
WHEN TOWING
8. PRECAUTIONS FOR MAINTENANCE
WARNING TAG
KEEP WORK PLACE CLEAN AND TIDY
APPOINT LEADER WHEN WORKING WITH OTHERS
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
PROPER TOOLS
HANDLING ACCUMULATOR
NO UNAUTHORIZED PERSONNEL INTO AREA
ATTACHMENTS
PRECAUTIONS FOR WORK UNDER MACHINE AND WORK EQUIPMENT
NOISE
PRECAUTIONS WHEN USING HAMMER
REPAIR WELDING
REMOVING BATTERY TERMINAL
PRECAUTIONS WHEN USING HIGH PRESSURE GREASE TO ADJUST TRACK TENSION
DO NOT DISASSEMBLY RECOIL SPRING
PRECAUTION WITH HIGH PRESSURE OIL
PRECAUTIONS WITH HIGH PRESSURE FUEL
HANDLING HIGH PRESSURE HOSES
PRECAUTIONS WITH HIGH VOLTAGE
WASTE MATERIAL
MAINTENANCE FOR AIR CONDITIONER
COMPRESSED AIR
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
9. POSITION FOR ATTACHING SAFETY LABELS
9.1 POSITION FOR ATTACHING SAFETY LABELS
9.2 CONTENT AND USE OF WARNING PLATES

OPERATION
10. GENERAL VIEW
10.1 GENERAL VIEW OF MACHINE
10.2 GENERAL VIEW OF CONTROLS AND GAUGES
11. EXPLANATION OF COMPONENTS
11.1 FRONT PANEL
11.2 SWITCHES
11.3 CONTROL LEVERS AND PEDALS
11.4 DUST INDICATOR
11.5 POWER SOURCE
11.6 FUSE BOX
11.7 DOOR OPEN LOCK
11.8 SASH GLASS INTERMEDIATE LOCK
11.9 DOOR POCKET
11.10 ASHTRAY
11.11 TOOL BOX
11.12 HANDLING ADDITIONAL HEATER
11.13 HANDLING AIR CONDITIONER
11.14 HANDLING ACCUMULATOR
11.15 REVERSING REVERSIBLE FAN
11.16 HANDLING ENGINE SIDE COVER, ENGINE ROOM QUILTING (IF EQUIPPED)
11.17 HANDLING INSPECTION LAMP
12. OPERATION
12.1 CHECK BEFORE STARTING ENGINE
12.2 STARTING ENGINE
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE
12.4 MOVING MACHINE
12.5 SHIFTING GEAR
12.6 SHIFTING BETWEEN FORWARD AND REVERSE
12.7 STEERING MACHINE
12.8 STOPPING MACHINE
12.9 PRECAUTIONS FOR OPERATION
12.10 WORK POSSIBLE USING BULLDOZER
12.11 RIPPER OPERATION
12.12 ADJUSTMENT OF WORK EQUIPMENT
12.13 PARKING MACHINE
12.14 CHECK AFTER FINISHING WORK
12.15 STOPPING ENGINE
12.16 CHECK AFTER STOPPING ENGINE
12.17 LOCKING
12.18 TIPS FOR LONGER UNDERCARRIAGE LIFE
13. TRANSPORTATION
13.1 LOADING, UNLOADING WORK
13.2 PRECAUTIONS FOR LOADING
13.3 METHOD OF LIFTING MACHINE
13.4 PRECAUTIONS FOR TRANSPORTATION
13.5 REMOVAL OF CAB (MACHINES EQUIPPED WITH CAB)
13.6 INSTALLATION OF CAB (MACHINES EQUIPPED WITH CAB)
14. COLD WEATHER OPERATION
14.1 PRECAUTIONS FOR LOW TEMPERATURE
14.2 AFTER COMPLETION OF WORK
14.3 AFTER COLD WEATHER
15. LONG TERM STORAGE
15.1 BEFORE STORAGE
15.2 DURING STORAGE
15.3 AFTER STORAGE
16. TROUBLESHOOTING
16.1 AFTER RUNNING OUT OF FUEL
16.2 METHOD OF TOWING MACHINE
16.3 IF BATTERY IS DISCHARGED
16.4 OTHER TROUBLE

MAINTENANCE
17. GUIDES TO MAINTENANCE
18. OUTLINES OF SERVICE
18.1 OUTLINE OF OIL, FUEL, COOLANT
18.2 RELATING TO ELECTRIC SYSTEM
18.3 OUTLINE OF HYDRAULIC SYSTEM
18.4 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)
19. WEAR PARTS LIST
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
21. STANDARD TIGHTING TORQUES FOR BOLTS AND NUTS
21.1 TORQUE LIST
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
23. MAINTENANCE SCHEDULE CHART
24. SERVICE PROCEDURE
24.1 INITIAL 250 HOURS SERVICE
REPLACE FUEL FILTER CARTRIDGE
REPLACE TRANSMISSION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINER (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE, AND BEVEL GEAR CASE)
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT
CHANGE OIL IN FINAL DRIVE CASE
CHANGE ENGINE VALVE CLEARANCE, ADJUST
24.2 WHEN REQUIRED
24.2.1 CLEAN INSIDE OF COOLING SYSTEM
24.2.2 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
24.2.3 CHECK TRACK TENSION
24.2.4 CHECK AND TIGHTEN TRACK SHOE BOLTS
24.2.5 CHECK ELECTRICAL INTAKE AIR HEATER
24.2.6 ADJUST IDLER CLEARANCE
24.2.7 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES
24.2.8 CHECK AND CLEAN RADIATOR FIN
24.2.9 CLEAN FUEL TANK STRAINER
24.2.10 DRAIN WATER AND SEDIMENT IN FUEL TANK
24.2.11 REPLACE AIR CONDITIONER BELT
24.2.12 CHECK UNDERCARRIAGE OIL
24.2.13 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)
24.2.14 CHECK, ADJUST AIR CONDITIONER
24.2.15 GREASE DOOR HINGE
24.2.16 CHECK DOOR LOCK STRIKER
24.2.17 REPLACE DOOR DAMPER
24.2.18 REPLACE WIPER BLADE
24.2.19 CHECK APS (AUTOMATIC PRIMING SYSTEM)
24.2.20 LUBRICATING
24.2.21 DRAIN WATER FROM WATER SEPARATOR
24.3 CHECK BEFORE STARTING
CHECK MACHINE MONITOR
CHECK COOLANT LEVEL, ADD WATER
CHECK FUEL LEVEL, ADD FUEL
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
CHECK OIL LEVEL IN POWER TRAIN CASE (INCL. TRANSMISSION CASE, TORQUE CONVERTER AND BEVEL GEAR CASES), ADD OIL
CHECK DAMPER CASE OIL LEVEL, ADD OIL
CHECK BRAKE PEDAL TRAVEL
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
CHECK DUST INDICATOR
CHECK ELECTRIC WIRINGS
CHECK THAT LAMPS LIGHT UP
CHECK HORN SOUND
CHECK BACKUP ALARM SOUND
CHECK WATER SEPARATOR
24.4 EVERY 250 HOURS SERVICE
24.4.1 LUBRICATING
24.4.2 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
24.4.3 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
24.4.4 CHECK, ADJUST ALTERNATOR DRIVE BELT TENSION
24.4.5 CHECK LEVEL OF BATTERY ELECTROLYTE
24.4.6 CHECK BRAKE PERFORMANCE
24.5 EVERY 500 HOURS SERVICE
24.5.1 REPLACE FUEL FILTER CARTRIDGE
24.5.2 REPLACE TRANSMISSION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT
24.5.3 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
24.5.4 CHECK, REPLACE FAN BELT
24.6 EVERY 1000 HOURS SERVICE
24.6.1 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)
24.6.2 CHECK, CLEAN FUEL STRAINER
24.6.3 CLEAN STEERING CLUTCH CASE BREATHER
24.6.4 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL
24.6.5 GREASE TENSION PULLEY ASSEMBLY
24.6.6 CHECK FOR LOOSE ROPS MOUNT BOLTS
24.6.7 REPLACE CORROSION RESISTOR CARTRIDGE
24.6.8 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER
24.7 EVERY 2000 HOURS SERVICE
24.7.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT
24.7.2 CHANGE OIL IN FINAL DRIVE CASE
24.7.3 CHANGE OIL IN DAMPER CASE, CLEAN AIR HOLE AND BREATHER
24.7.4 CHECK PIVOT BEARING OIL LEVEL, ADD OIL
24.7.5 CLEAN ENGINE BREATHER ELEMENT
24.7.6 CLEAN, CHECK TURBOCHARGER
24.7.7 CHECK PLAY OF TURBOCHARGER ROTOR
24.7.8 CHECK ALTERNATOR, STARTING MOTOR
24.7.9 CHECK ENGINE VALVE CLEARANCE, ADJUST
24.8 EVERY 4000 HOURS SERVICE
24.8.1 CHECK WATER PUMP
24.8.2 CHECK VIBRATION DAMPER
24.8.3 CHECK FAN PULLEY AND TENSION PULLEY
24.8.4 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)

SPECIFICATIONS
25. SPECIFICATIONS

OPTIONS, ATTACHMENTS
26. GENERAL PRECAUTIONS
26.1 PRECAUTIONS RELATED TO SAFETY
27. USING SEAT BELT
27.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER
28. SELECTION OF TRACK SHOE
28.1 SELECTION OF TRACK SHOES
29. PROCEDURE FOR SELECTING RIPPER POINT
29.1 PROCEDURE FOR SELECTING RIPPER POINT
30. HANDLING CAP WITH LOCK
30.1 OPENING AND CLOSING LOCKABLE CAP

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