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KOMATSU D375A-5E0 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:50065 & UP) KOMATSU D375A-5E0 – PDF DOWNLOAD
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- KOMATSU D375A-5E0 BULLDOZER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:50065 & UP
- PUBLICATION NUMBER:TEN00272-00
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KOMATSU D375A-5E0 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:50065 & UP) KOMATSU D375A-5E0
KOMATSU D375A-5E0 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:50065 & UP) KOMATSU D375A-5E0 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D375A-5E0 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:50065 & UP) KOMATSU D375A-5E0
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 for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance
TABLE OF CONTENTS:
KOMATSU D375A-5E0 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:50065 & UP) KOMATSU D375A-5E0
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...................................................................................... 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.............................................................................. 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.................................................................................................... 48 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 DOOR OPEN LOCK...........................................................................................106 SASH GLASS INTERMEDIATE LOCK.............................................................................106 CAP WITH LOCK............................................................................................107 DOOR POCKET..............................................................................................108 ASHTRAY..................................................................................................109 TOOL BOX.................................................................................................109 CAR STEREO, HANDLING.....................................................................................111 AIR CONDITIONER, HANDLING................................................................................120 OPERATION....................................................................................................126 CHECK BEFORE STARTING ENGINE, ADJUST.....................................................................126 STARTING ENGINE..........................................................................................149 OPERATIONS AND CHECKS AFTER STARTING ENGINE..............................................................157 STOPPING ENGINE..........................................................................................160 MOVING MACHINE...........................................................................................161 STOPPING MACHINE.........................................................................................163 SHIFTING GEAR............................................................................................164 SHIFTING BETWEEN FORWARD AND REVERSE.....................................................................168 STEERING MACHINE.........................................................................................170 PRECAUTIONS FOR OPERATION................................................................................173 PARKING MACHINE..........................................................................................175 CHECK AFTER STOPPING ENGINE..............................................................................176 CHECK AFTER FINISHING WORK...............................................................................177 LOCKING..................................................................................................177 WORK POSSIBLE USING BULLDOZER............................................................................178 EFFECTIVE USE OF MODE SELECTION SYSTEM...................................................................180 RIPPER OPERATION.........................................................................................185 OPERATING METHOD FOR RIPPING OPERATIONS..................................................................188 ADJUSTING POSTURE OF WORK EQUIPMENT......................................................................193 TIPS FOR LONGER UNDERCARRIAGE LIFE.......................................................................196 TRANSPORTATION...............................................................................................198 TRANSPORTATION PROCEDURE.................................................................................198 LOADING, UNLOADING WORK..................................................................................198 METHOD OF LIFTING MACHINE................................................................................203 TRAVELING ON ROADS.......................................................................................204 REMOVAL OF CAB...........................................................................................205 INSTALLATION OF CAB......................................................................................207 INSTALLATION OF ROPS.....................................................................................208 COLD WEATHER OPERATION.......................................................................................209 PRECAUTIONS FOR LOW TEMPERATURE..........................................................................209 AFTER COMPLETION OF WORK.................................................................................211 AFTER COLD WEATHER.......................................................................................211 LONG-TERM STORAGE............................................................................................212 BEFORE STORAGE...........................................................................................212 DURING STORAGE...........................................................................................212 AFTER STORAGE............................................................................................212 STARTING MACHINE AFTER LONG-TERM STORAGE.................................................................212 TROUBLESHOOTING..............................................................................................213 AFTER RUNNING OUT OF FUEL................................................................................213 METHOD OF TOWING MACHINE.................................................................................214 IF BATTERY IS DISCHARGED.................................................................................215 OTHER TROUBLE............................................................................................219 WHEN MODE SELECTION SYSTEM FLASHES.......................................................................224 MAINTENANCE......................................................................................................226 GUIDES TO MAINTENANCE........................................................................................227 OUTLINES OF SERVICE..........................................................................................230 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...................................................230 OUTLINE OF ELECTRIC SYSTEM...............................................................................233 HANDLING HYDRAULIC RELATED EQUIPMENT.....................................................................234 WEAR PARTS...................................................................................................235 WEAR PARTS LIST..........................................................................................236 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.....................................................................237 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL......................239 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................................240 TORQUE LIST..............................................................................................240 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................241 SAFETY CRITICAL PARTS....................................................................................242 MAINTENANCE SCHEDULE CHART...................................................................................243 MAINTENANCE SCHEDULE CHART...............................................................................243 SERVICE PROCEDURE............................................................................................245 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)...............................................245 WHEN REQUIRED............................................................................................246 CLEAN INSIDE OF COOLING SYSTEM.......................................................................246 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.........................................................250 CHECK AND ADJUST TRACK TENSION.......................................................................255 CHECK AND TIGHTEN TRACK SHOE BOLTS...................................................................257 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES...................................................258 CLEAN AND CHECK RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS.....................................259 CLEAN FUEL TANK STRAINER.............................................................................261 CLEAN HYDRAULIC TANK BREATHER........................................................................262 CLEAN FUEL TANK BREATHER.............................................................................262 REPLACE ALTERNATOR DRIVE BELT........................................................................262 CHECK UNDERCARRIAGE OIL..............................................................................263 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)...............................................264 CHECK AND ADJUST AIR CONDITIONER.....................................................................265 LUBRICATE DOOR HINGE.................................................................................266 CHECK DOOR LATCH.....................................................................................266 CHECK DOOR LOCK STRIKER..............................................................................267 REPLACE DOOR DAMPER..................................................................................267 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...........................................................267 REPLACE WIPER BLADE..................................................................................267 BLEED AIR FROM HEAD END OF RIGHT PITCH CYLINDER (DUAL TILT DOZER ONLY)...............................269 BLEEDING AIR IN HYDRAULIC SYSTEM.....................................................................270 BLEED AIR FROM FUEL CIRCUIT..........................................................................271 LUBRICATING..........................................................................................274 CHECK BEFORE STARTING....................................................................................276 EVERY 250 HOURS SERVICE..................................................................................277 LUBRICATING..........................................................................................277 CHECK LEVEL OF BATTERY ELECTROLYTE...................................................................279 CHECK BRAKE PERFORMANCE..............................................................................281 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL..............................................................282 EVERY 500 HOURS SERVICE..................................................................................283 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....................................283 REPLACE FUEL PRE-FILTER CARTRIDGE....................................................................285 REPLACE FUEL MAIN FILTER CARTRIDGE...................................................................287 REPLACE TRANSMISSION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT..........................289 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.........................................................290 CHECK, REPLACE DRIVE BELT FOR ALTERNATOR, AIR CONDITIONER COMPRESSOR.................................290 EVERY 1000 HOURS SERVICE.................................................................................292 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS......................................................292 CHECK, CLEAN FUEL STRAINER...........................................................................294 CLEAN STEERING CLUTCH CASE BREATHER..................................................................294 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL......................................295 CHECK FOR LOOSE ROPS MOUNT BOLTS.....................................................................295 REPLACE HYDRAULIC TANK BREATHER ELEMENT..............................................................296 REPLACE FUEL TANK BREATHER ELEMENT...................................................................297 REPLACE CORROSION RESISTOR CARTRIDGE.................................................................298 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS............................................298 CHECK, GREASE DRIVE BELT TENSION PULLEY ASSEMBLY FOR ALTERNATOR, AIR CONDITIONER COMPRESSOR..........299 EVERY 2000 HOURS SERVICE.................................................................................300 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER....300 CHANGE OIL IN FINAL DRIVE CASE.......................................................................302 CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER.....................................................303 CHECK PIVOT BEARING OIL LEVEL, ADD OIL...............................................................304 CHECK ENGINE VALVE CLEARANCE, ADJUST.................................................................304 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)........................305 EVERY 4000 HOURS SERVICE.................................................................................309 REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)............................................................309 CHECK WATER PUMP.....................................................................................309 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER).....................................................310 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER...................................312 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER..................................313 EVERY 8000 HOURS SERVICE.................................................................................314 REPLACE HIGH-PRESSURE PIPING CLAMPS..................................................................314 REPLACE FUEL SPLAY PREVENTION CAPS...................................................................314 SPECIFICATIONS...................................................................................................316 SPECIFICATIONS...............................................................................................317 ATTACHMENTS, OPTIONS.............................................................................................318 GENERAL PRECAUTIONS..........................................................................................319 PRECAUTIONS RELATED TO SAFETY............................................................................319 SELECTION OF TRACK SHOE......................................................................................320 SELECTION OF TRACK SHOES.................................................................................320 PROCEDURE FOR SELECTING RIPPER POINT.........................................................................321 PROCEDURE FOR SELECTING RIPPER POINT.....................................................................321 EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER............................................................322 BLADE CONDITION..........................................................................................322 DOZING WORK..............................................................................................324 LEVELING (SPREADING) OPERATION...........................................................................327 DITCHING OPERATION.......................................................................................327 BOULDER RAISING OPERATION................................................................................327 SIDE-CUTTING OPERATIONS..................................................................................328 HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)..............................................328 SHOE SLIP CONTROL............................................................................................329 MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)..........................................................329 EFFECTIVE USE OF MODE SELECTION SYSTEM...................................................................331 IF MODE SELECTION SYSTEM FLASHES.........................................................................337 HANDLING MACHINES EQUIPPED WITH VHMS.........................................................................338 VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED....................................................338 VHMS AND COMMUNICATIONS TERMINAL INSTALLED...............................................................338 INDEX............................................................................................................340
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