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Komatsu Bulldozer Galeo D375A-5EO Operation & Maintenance Manual SN 50001 and up – PDF DOWNLOAD
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Komatsu Bulldozer Galeo D375A-5EO Operation & Maintenance Manual
Book Code :TEN00140-00
SERIAL NUMBERS D375A-5E0 50001 and up
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Description
Komatsu Bulldozer Galeo D375A-5EO Operation & Maintenance Manual
FILE DETAILS:
Komatsu Bulldozer Galeo D375A-5EO_50001 and up Operation & Maintenance Manual_EN TEN00140-00
Size : 8.65 MB
Format : PDF
Language : English
Number of Pages : 334 Pages
Brand: Komatsu
Type of machine: Bulldozer
Type of document: Operation & Maintenance Manual
Model: Galeo D375A-5EO
Serial: 50001 and up
KOMATSU BULLDOZER GALEO D375A-5EO OPERATION & MAINTENANCE MANUAL SN 50001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Bulldozer Galeo D375A-5EO 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 Galeo D375A-5EO Operation & Maintenance Manual
MAIN MENU.......................................................................................................... 0 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 ROPS, FOPS NO. PLATE POSITION.............................................................................. 13 POSITION OF SERVICE METER.................................................................................. 13 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................................. 14 CONTENTS........................................................................................................... 15 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........................................................................................ 27 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................................................................................ 31 PRECAUTIONS FOR ATTACHMENTS................................................................................ 31 CAB WINDOW GLASSES......................................................................................... 31 UNAUTHORIZED MODIFICATION.................................................................................. 31 SAFETY AT WORKSITE......................................................................................... 31 WORKING ON LOOSE GROUND.................................................................................... 32 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES..................................................................... 32 ENSURE GOOD VISIBILITY..................................................................................... 33 VENTILATION FOR ENCLOSED AREAS............................................................................. 33 CHECKING SIGNALMAN'S SIGNALS AND SIGNS..................................................................... 33 BE CAREFUL ABOUT ASBESTOS DUST............................................................................. 33 PRECAUTIONS FOR OPERATION...................................................................................... 34 BEFORE STARTING ENGINE..................................................................................... 34 CHECKS BEFORE STARTING ENGINE.......................................................................... 34 PRECAUTIONS WHEN STARTING.............................................................................. 34 PRECAUTIONS IN COLD AREAS.............................................................................. 35 OPERATION.................................................................................................. 36 CHECKS BEFORE OPERATION................................................................................ 36 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE................................................... 36 PRECAUTIONS WHEN TRAVELING............................................................................. 37 TRAVELING ON SLOPES.................................................................................... 38 PROHIBITED OPERATIONS.................................................................................. 38 USING BRAKES........................................................................................... 38 OPERATE CAREFULLY ON SNOW.............................................................................. 38 PARKING MACHINE........................................................................................ 39 TRANSPORTATION............................................................................................. 40 LOADING AND UNLOADING.................................................................................. 40 SHIPPING............................................................................................... 40 BATTERY.................................................................................................... 41 BATTERY HAZARD PREVENTION.............................................................................. 41 STARTING WITH BOOSTER CABLE............................................................................ 42 TOWING..................................................................................................... 43 WHEN TOWING............................................................................................ 43 PRECAUTIONS FOR MAINTENANCE.................................................................................... 44 WARNING TAG................................................................................................ 44 KEEP WORK PLACE CLEAN AND TIDY............................................................................. 44 APPOINT LEADER WHEN WORKING WITH OTHERS.................................................................... 44 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE................................................. 45 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING......................................................... 46 PROPER TOOLS............................................................................................... 46 HANDLING ACCUMULATOR....................................................................................... 47 PERSONNEL.................................................................................................. 47 ATTACHMENTS................................................................................................ 47 WORK UNDER THE MACHINE..................................................................................... 47 NOISE...................................................................................................... 48 PRECAUTIONS WHEN USING HAMMER.............................................................................. 48 REPAIR WELDING............................................................................................. 48 REMOVING BATTERY TERMINAL.................................................................................. 48 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION........................................ 48 DO NOT DISASSEMBLE RECOIL SPRING........................................................................... 49 PRECAUTION WITH HIGH-PRESSURE OIL.......................................................................... 50 PRECAUTION FOR HIGH FUEL PRESSURE.......................................................................... 50 HANDLING HIGH-PRESSURE HOSES............................................................................... 50 PRECAUTION FOR HIGH VOLTAGE................................................................................ 50 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................................................................................................... 85 CONTROL LEVERS, PEDALS..................................................................................... 89 DUST INDICATOR............................................................................................. 99 POWER SOURCE............................................................................................... 99 FUSE BOX...................................................................................................100 DOOR OPEN LOCK.............................................................................................104 SASH GLASS INTERMEDIATE LOCK...............................................................................105 DOOR POCKET................................................................................................105 ASHTRAY....................................................................................................105 TOOL BOX...................................................................................................106 CAR STEREO, HANDLING.......................................................................................107 AIR CONDITIONER, HANDLING..................................................................................116 OPERATION......................................................................................................122 CHECK BEFORE STARTING ENGINE, ADJUST.......................................................................122 STARTING ENGINE............................................................................................144 OPERATIONS AND CHECKS AFTER STARTING ENGINE................................................................152 STOPPING ENGINE............................................................................................155 MOVING MACHINE.............................................................................................156 STOPPING MACHINE...........................................................................................158 SHIFTING GEAR..............................................................................................159 SHIFTING BETWEEN FORWARD AND REVERSE.......................................................................162 STEERING MACHINE...........................................................................................164 PRECAUTIONS FOR OPERATION..................................................................................167 PARKING MACHINE............................................................................................169 CHECK AFTER STOPPING ENGINE................................................................................171 CHECK AFTER FINISHING WORK.................................................................................171 LOCKING....................................................................................................171 WORK POSSIBLE USING BULLDOZER..............................................................................172 EFFECTIVE USE OF MODE SELECTION SYSTEM.....................................................................174 RIPPER OPERATION...........................................................................................179 OPERATING METHOD FOR RIPPING OPERATIONS....................................................................182 ADJUSTING POSTURE OF WORK EQUIPMENT........................................................................187 TIPS FOR LONGER UNDERCARRIAGE LIFE.........................................................................191 TRANSPORTATION.................................................................................................193 TRANSPORTATION PROCEDURE...................................................................................193 LOADING, UNLOADING WORK....................................................................................194 METHOD OF LIFTING MACHINE..................................................................................198 TRAVELING ON ROADS.........................................................................................199 REMOVAL OF CAB.............................................................................................200 INSTALLATION OF CAB........................................................................................202 INSTALLATION OF ROPS.......................................................................................203 COLD WEATHER OPERATION.........................................................................................204 PRECAUTIONS FOR LOW TEMPERATURE............................................................................204 AFTER COMPLETION OF WORK...................................................................................205 AFTER COLD WEATHER.........................................................................................206 LONG-TERM STORAGE..............................................................................................207 BEFORE STORAGE.............................................................................................207 DURING STORAGE.............................................................................................207 AFTER STORAGE..............................................................................................207 TROUBLESHOOTING................................................................................................208 AFTER RUNNING OUT OF FUEL..................................................................................208 METHOD OF TOWING MACHINE...................................................................................208 IF BATTERY IS DISCHARGED...................................................................................210 OTHER TROUBLE..............................................................................................213 WHEN MODE SELECTION SYSTEM FLASHES.........................................................................218 MAINTENANCE........................................................................................................219 GUIDES TO MAINTENANCE..........................................................................................220 OUTLINES OF SERVICE............................................................................................223 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....................................................223 OUTLINE OF ELECTRIC SYSTEM.................................................................................226 HANDLING HYDRAULIC RELATED EQUIPMENT.......................................................................226 WEAR PARTS LIST................................................................................................228 WEAR PARTS LIST............................................................................................228 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.......................................................................230 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL......................232 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.................................................................233 TORQUE LIST................................................................................................233 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..................................................................234 SAFETY CRITICAL PARTS......................................................................................234 MAINTENANCE SCHEDULE CHART.....................................................................................236 MAINTENANCE SCHEDULE CHART.................................................................................236 SERVICE PROCEDURE..............................................................................................238 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).................................................238 WHEN REQUIRED..............................................................................................239 CLEAN INSIDE OF COOLING SYSTEM.........................................................................239 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...........................................................243 CHECK AND ADJUST TRACK TENSION.........................................................................248 CHECK AND TIGHTEN TRACK SHOE BOLTS.....................................................................250 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES.....................................................251 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS.....................................252 CLEAN FUEL TANK STRAINER...............................................................................254 DRAIN WATER AND SEDIMENT IN FUEL TANK..................................................................255 REPLACE ALTERNATOR DRIVE BELT..........................................................................255 CHECK UNDERCARRIAGE OIL................................................................................256 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER).................................................257 CHECK AND ADJUST AIR CONDITIONER.......................................................................258 LUBRICATE DOOR HINGE...................................................................................259 CHECK DOOR LATCH.......................................................................................259 CHECK DOOR LOCK STRIKER................................................................................260 REPLACE DOOR DAMPER....................................................................................260 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................................260 REPLACE WIPER BLADE....................................................................................260 BLEED AIR FROM HEAD END OF RIGHT PITCH CYLINDER (DUAL TILT DOZER ONLY)...............................261 BLEEDING AIR IN HYDRAULIC SYSTEM.......................................................................262 BLEED AIR FROM FUEL CIRCUIT............................................................................263 LUBRICATING............................................................................................265 CHECK BEFORE STARTING......................................................................................267 EVERY 250 HOURS SERVICE....................................................................................268 LUBRICATING............................................................................................268 CHECK LEVEL OF BATTERY ELECTROLYTE.....................................................................270 CHECK BRAKE PERFORMANCE................................................................................273 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL................................................................274 EVERY 500 HOURS SERVICE....................................................................................275 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......................................275 REPLACE FUEL PRE-FILTER CARTRIDGE......................................................................277 REPLACE FUEL FILTER CARTRIDGE..........................................................................279 REPLACE TRANSMISSION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT............................281 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...........................................................282 REPLACE HYDRAULIC TANK BREATHER ELEMENT................................................................282 CHECK, REPLACE DRIVE BELT FOR ALTERNATOR, AIR CONDITIONER COMPRESSOR...................................283 EVERY 1000 HOURS SERVICE...................................................................................284 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS.........................................................284 CHECK, CLEAN FUEL STRAINER.............................................................................286 CLEAN STEERING CLUTCH CASE BREATHER....................................................................287 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL........................................287 CHECK FOR LOOSE ROPS MOUNT BOLTS.......................................................................288 REPLACE CORROSION RESISTOR CARTRIDGE...................................................................289 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS..............................................289 CHECK, GREASE DRIVE BELT TENSION PULLEY ASSEMBLY FOR ALTERNATOR, AIR CONDITIONER COMPRESSOR..........290 EVERY 2000 HOURS SERVICE...................................................................................291 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER....291 CHANGE OIL IN FINAL DRIVE CASE.........................................................................293 CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER.......................................................294 CHECK PIVOT BEARING OIL LEVEL, ADD OIL.................................................................295 CHECK ENGINE VALVE CLEARANCE, ADJUST...................................................................295 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)..........................296 EVERY 4000 HOURS SERVICE...................................................................................300 REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)..............................................................300 CHECK WATER PUMP.......................................................................................300 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER).......................................................301 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.....................................303 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER....................................304 EVERY 8000 HOURS SERVICE...................................................................................305 REPLACE INJECTOR NOZZLE TIP............................................................................305 REPLACE HIGH-PRESSURE PIPING CLAMPS....................................................................305 REPLACE FUEL SPLAY PREVENTION CAPS.....................................................................305 SPECIFICATIONS.....................................................................................................306 SPECIFICATIONS.................................................................................................307 ATTACHMENTS, OPTIONS...............................................................................................308 GENERAL PRECAUTIONS............................................................................................309 PRECAUTIONS RELATED TO SAFETY..............................................................................309 SELECTION OF TRACK SHOE........................................................................................310 SELECTION OF TRACK SHOES...................................................................................310 PROCEDURE FOR SELECTING RIPPER POINT...........................................................................311 PROCEDURE FOR SELECTING RIPPER POINT.......................................................................311 CAP WITH LOCK, HANDLING........................................................................................312 METHOD OF OPENING AND CLOSING CAP WITH LOCK................................................................312 EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER..............................................................313 BLADE CONDITION............................................................................................313 DOZING WORK................................................................................................315 LEVELING (SPREADING) OPERATION.............................................................................317 DITCHING OPERATION.........................................................................................318 BOULDER RAISING OPERATION..................................................................................318 SIDE-CUTTING OPERATIONS....................................................................................319 HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)................................................319 SHOE SLIP CONTROL..............................................................................................320 MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)............................................................320 EFFECTIVE USE OF MODE SELECTION SYSTEM.....................................................................322 IF MODE SELECTION SYSTEM FLASHES...........................................................................328 HANDLING MACHINES EQUIPPED WITH VHMS...........................................................................329 VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED......................................................329 VHMS AND COMMUNICATIONS TERMINAL INSTALLED.................................................................329 INDEX..............................................................................................................331
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