PDF Operation & Maintenance Manual Komatsu D75S-5 Crawler Loader - 758 KB
Learn the proper procedures for operating and maintaining your Komatsu D75S-5 Crawler Loader.
This comprehensive manual details all operator controls, safety guidelines, and scheduled maintenance tasks.
Following the manufacturer's recommendations is the best way to ensure the machine's longevity, reliability, and safe performance.
It's a must-read for every operator.
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¤ WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.
SAFETY RULES
‡ Only trained and authorized personnel can operate and maintain the machine.
‡ Follow all safety rules, precautions and instructions when operating or performing maintenance
on the machine.
‡ Do not operate the machine if you are not feeling well, or if you are taking medicine which will
make you sleepy, or if you have been drinking. Operating in such a condition will adversely affect
your judgement and may lead to an accident.
‡ When working with another operator or with a person on worksite traffic duty, be sure that all
personnel understand all hand signals that are to be used.
‡ Always follow all rules related to safety.
SAFETY FEATURES
‡ Be sure that all guards and covers are in their proper position. Have guards and covers repaired
if damaged.
Proper position of all guards and covers ➞ See “12.1.1 WALK-AROUND CHECK”.
‡ Use safety features such as safety lock levers and the seat belt properly.
‡ Never remove any safety features. Always keep them in good operating condition.
Safety lock lever ➞ See “12.12 PARKING MACHINE”.
Seat belt ➞ See “12.1.4 USING SEAT BELT”.
‡ Improper use of safety features could result in serious bodily
injury or death.
CLOTHING AND PERSONAL PROTECTIVE ITEMS
‡ Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts
and cause serious injury or death.
‡ Also, do not wear oily clothes, because they are flammable.
‡ Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the
machine. Always wear safety goggles, hard hat and heavy gloves if your job involves scattering
metal chips or minute materials particularly when driving pins with a hammer and when cleaning
the air cleaner element with compressed air. Check also that there is no one near the machine.
‡ Check that all protective equipment functions properly before using.
Cleaning element ➞ See “24.2 WHEN REQUIRED”.
UNAUTHORIZED MODIFICATION
Any modification made without authorization from Komatsu can create hazards. Before making a
modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or
damage caused by any unauthorized modification.
1-2
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¤ WARNING: For reasons of safety, always
7. PRECAUTIONS DURING OPERATION follow these safety precautions.
TRAVELING ON SLOPES
‡ Traveling on slopes could result in the machine tipping over or slipping to the side.
‡ When traveling on slopes, keep the blade approximately 20 to 30 cm above the ground. In case
of emergency, quickly lower the blade to the ground to help the machine to stop.
‡ Do not turn on slopes or travel across slopes. Always go down to a flat place to perform these
operations.
‡ Do not travel on grass, fallen leaves, or wet steel plates. Even slight slopes may cause the machine
to slip to the side, so travel at low speed and make sure that the machine is always traveling
directly up or down the slope.
‡ When traveling downhill, use the braking force of the engine and travel slowly.
‡ Be careful when allowing the machine to travel downhill under its own weight. It may steer in the
opposite direction.
Reverse steering when traveling downhill ➞
See “12.7.2 TURNING WHILE DESCENDING A SLOPE”.
INCORRECT CORRECT
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SECURING ENOUGH VISIBILITY
‡ When working in a dark place, turn on the head lamp and rear lamp of the machine, and use
additional lighting equipment, if necessary.
‡ If visibility is lowered by fog, snow, rain, etc., stop working and wait until sufficient visibility for
the work is restored.
OPERATE CAREFULLY ON SNOW
‡ When working on snow or icy roads, even a slight slope may cause the machine to slip to the side,
so always travel at low speed and avoid sudden starting, stopping, or turning. There is danger
of slipping particularly on uphill or downhill slopes.
‡ With frozen road surfaces, the ground becomes soft when the temperature rises, so the travel
conditions become unstable. In such cases be extremely careful when traveling.
‡ When there has been heavy snow, the road shoulder and objects placed beside the road are buried
in the snow and cannot be seen, so always carry out operations carefully.
When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and
use the engine as a brake while applying the foot brake intermittently (depress the brake
intermittently several times). If necessary, lower the blade to the ground to stop the machine.
‡ The load varies greatly according to the characteristics of the snow, so adjust the load accordingly
and be careful not to let the machine slip.
1-12
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¤ WARNING: For reasons of safety, always
8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions.
USE OF LIGHTING
‡ When checking fuel, oil, or battery electrolyte, always use lighting with anti-explosion specifica-
tions.
If such lighting equipment is not used, there is danger of explosion.
‡ If work is carried out in dark places without installing lighting, there is danger of injury, so always
install proper lighting.
‡ Even if it is dark, do not use a lighter or flame instead of lighting. There is danger of starting a
fire, and if the battery gas ignites, it may cause an explosion.
‡ When using the machine as the power supply for the lighting, follow the instructions in this
Operation and Maintenance Manual.
A0055160
PREVENTION OF FIRE
There is danger of the fuel and battery gas catching fire during maintenance, so always follow the
precautions below when carrying out maintenance.
‡ Store fuel, oil, grease, and other flammable materials away from flame.
‡ Use non-flammable materials as the flushing oil for cleaning parts. Do not use diesel oil or
gasoline. There is danger that they will catch fire.
‡ Never smoke when carrying out inspection or maintenance. Always smoke in the prescribed place.
‡ When checking fuel, oil, or battery electrolyte, always use lighting with anti-explosion specifica-
tions. Never use lighters or matches as lighting.
‡ When carrying out grinding or welding operations on the chassis, remove any flammable
materials to a safe place.
‡ Be sure that a fire extinguisher is present at the inspection and maintenance point.
A0055020
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9. POSITION FOR ATTACHING SAFETY LABELS 9. POSITION FOR ATTACHING SAFETY LABELS
13. Warning for battery (09664-30081)
Safety label is attached on the battery.
DANGER EXPLOSIVE GASES
Cigarettes flames or sparks could cause battery to explode. Always
shield eyes and face from battery. Do not charge or use booster cables
or adjust post connections without proper instruction and training.
KEEP VENT CAPS TIGHT AND LEVEL
POISON CAUSES SEVERE BURNS
Contains sulfuric acid. Avoid contact with skin eyes or clothing. In
event of accident flush with water and call a phisician immediately.
KEEP OUT OF REACH OF CHILDREN
09664-30081
Safety label is attached on the battery.
1-32
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11. EXPLANATION OF COMPONENTS 11. EXPLANATION OF COMPONENTS
6. DECELERATION PEDAL
¤ WARNING
When the machine climbs to the top of a slope or it dumps soil
from a cliff, the load reduces and the travel speed rises sud-
denly, and that is dangerous. To prevent this, press the
decelerator pedal to lower the travel speed.
This pedal is used to lower the engine speed from the level set
with the fuel control lever to the low idling level.
If this pedal is pressed, the engine speed lowers.
7. SAFETY LOCK LEVER (For bucket control lever)
¤ WARNING
‡ When leaving the operator’s compartment, set the safety lock
lever securely to the LOCK position. If the control lever is not
locked, and it is touched by mistake, this may lead to a
serious accident.
‡ If the safety lock lever is not placed securely in the LOCK
position, the control lever may not be properly locked.
‡ When parking or servicing the machine, be sure to lower the
bucket and set the safety lock in the LOCK position.
This is the locking device of bucket control lever.
LOCK position: Raising, lowering, dumping, and tilting operations
are locked.
FREE position: Raising, lowering, dumping, and tilting operations
can be performed.
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12. OPERATION 12. OPERATION
CHECK OIL LEVEL IN TRANSMISSION CASE (INCLUDING TORQUE
CONVERTER CASE), ADD OIL
1. Open the cover, remove dipstick G, and wipe the oil off with a
cloth.
2. Insert dipstick G fully in the oil filler pipe, then take it out again.
3. The oil level should be between the H and L marks on dipstick
G.
If the oil level is below the L mark, add engine oil through oil filler
F.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
H
4. If the oil is above the H mark, drain the excess engine oil from L
drain plug P, and check the oil level again.
AD052340
5. If the oil level is correct, tighten the oil filler cap securely and
close the cover.
REMARK
‡ When stopping the engine, check the oil level.
‡ When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking.
If the machine is at an angle, make it horizontal before checking.
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12. OPERATION 12. OPERATION
1. When the engine starts, release the key in starting switch 2. The
key will return automatically to the ON position.
2-30
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12. OPERATION 12. OPERATION
12.9 PRECAUTIONS FOR OPERATION
12.9.1 METHOD OF USING STEERING CLUTCH
If the steering clutch one side is used frequently or if many
gradual turns are made with steering clutch half-engaged, the steering
clutch will wear out in a short time. Design the travel road well and
steer the machine properly.
12.9.2 PERMISSIBLE WATER DEPTH
When operating in water, always keep the bottom of the carrier
roller above the surface of the water.
Also, be careful that the engine cooling fan will not come in
contact with water. The fan can be damaged.
12.9.3 PRECAUTIONS WHEN TRAVELING UP
OR DOWN HILLS
Use engine as a brake
When going downhill, shift gear shift lever into low speed to run
engine at slow speed and travel down slope using the engine as a
brake.
Never coast down slope with the gear shift lever in the N
(neutral) position or with the inching pedal depressed.
Braking when traveling downhill
While descending a slope using the engine as a brake, also apply
the brakes.
Failure to brake may result in overrunning, causing engine
trouble.
12.9.4 PRECAUTIONS ON SLOPES
Be careful of fuel level
If the fuel level in the fuel tank becomes low when working on
slopes, the engine may suck in air because of the angle of the
machine or the swaying of the machine. If this makes the engine
stop, so be careful not to let the fuel level in the fuel tank become
too low.
Precautions when engine stops on slopes
If the engine stops while working or traveling on a hill, immedi-
ately depress the brake pedal, lower the bucket to the ground to stop
the machine, then lock the brake pedal with the brake lock lever.
Thereafter, move the gear shift lever to the N (neutral) position,
lock the lever, then restart the engine.
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12. OPERATION 12. OPERATION
12.15 CHECK AFTER STOPPING ENGINE
1. Walk around the machine and check the work equipment, paint-
work, and undercarriage, and check also for leakage of oil or
water. If any abnormalities are found, repair them.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out
any paper and debris to avoid a fire hazard.
4. Remove any mud stuck to the undercarriage.
2-50
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14. COLD WEATHER OPERATION
14.1 PRECAUTIONS FOR LOW TEMPERATURE
If the temperature becomes low, it becomes difficult to start the
engine, and the coolant may freeze, so do as follows.
14.1.1 FUEL AND LUBRICANTS
Change to fuel and oil with low viscosity for all components.
For details of the specified viscosity, see “20. USE OF FUEL,
COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE”.
14.1.2 COOLANT
¤ WARNING
Keep antifreeze fluid away from an open flame. Never smoke
when using antifreeze.
NOTICE
Never use methanol, ethanol or propanol based antifreeze.
Where no permanent antifreeze is available, an ethylene glycol
antifreeze without corrosion inhibitor may be used only for the cold
season. In this case, clean the cooling system twice a year (in spring
and autumn). When refilling the cooling system, add antifreeze in
autumn, but do not add any in spring.
Absolutely avoid using any water leak preventing agent irrespec-
tive of whether it is used independently or mixed with an antifreeze.
Do not mix one antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant,
see “24.1 WHEN REQUIRED”.
Use a Permanent Antifreeze (ethylene glycol mixed with corro-
sion inhibitor, antifoam agent, etc.) meeting the standard require-
ments as shown below. With permanent antifreeze, no change of
coolant is required for a year. If it is doubtful that an available
antifreeze meets the standard requirements, ask the supplier of that
antifreeze for information.
Standard requirements for permanent antifreeze.
‡ SAE ........................................................................................ J1034
‡ FEDERAL STANDARD .................................................. O-A-548D
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--- Page 15 ---
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
Engine Oil
Anti-freeze
[CD or CE]
Coolant
SAE10W, 30, 40 Gear Oil Grease
No. Supplier [Ethylene Glycol
10W30, 15W40 [GL-4 or GL-5] [Lithium-Base]
Base]
(The 15W40 oil SAE80, 90, 140 NLGI No. 2
Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT (Winter, one
EO15-40CD season type)
Diesel sigma S
Super dieselmulti-
2 AGIP Rotra MP GR MU/EP –
grade
*Sigma turbo
Multi-purpose gear RYKON prenium
3 AMOCO *Amoco 300 –
oil grease
Litholine HEP 2
4 ARCO *Arcofleet S3 plus Arco HD gear oil –
Arco EP moly D
Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP
*RPM delo 400 Universal thuban Marfak all purpose 2
6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 –
Universal gear
9 CONOCO *Fleet motor oil Super-sta grease –
lubricant
Multiperformance 3C Tranself EP
10 ELF – Glacelf
Performance 3C Tranself EP type 2
Essolube D3
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifreeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
Delvac 1300 Mobilux EP2
Mobilube GX
13 MOBIL *Delvac super Mobilgrease 77 –
Mobilube HD
10W-30, 15W-40 Mobilgrease special
3-10
--- Page 16 ---
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE
‡ Use a permanent type of antifreeze.
If, for some reason, it is impossible to use permanent type
antifreeze, use an antifreeze containing ethylene glycol.
‡ Stop the machine on level ground when cleaning or changing
the coolant.
‡ When deciding the ratio of antifreeze to water, check the lowest
temperature in the past, and decide from the mixing rate table
given below.
It is actually better to estimate a temperature about 10°C (50°F)
lower when deciding the mixing rate.
Mixing rate of water and antifreeze
Min. °C -5 –10 –15 –20 –25 –30
atmospheric
temperature °F 23 14 5 –4 –13 –22
¬ 15.0 19.5 23.5 26.5 30.0 32.5
Amount of US gal 3.9 5.07 6.21 6.89 7.8 8.45
antifreeze
UK gal 3.3 4.29 5.17 5.83 6.6 7.15
¬ 50.0 45.5 41.5 38.5 35.0 32.5
Amount of
US gal 13 11.83 10.79 10.01 9.1 8.45
water
UK gal 11 10.01 9.13 8.47 7.7 7.15
‡ We recommend use of an antifreeze density gauge to control the
mixing proportions.
‡ Use city water for the cooling water.
If river water, well water or other such water supply must be
used, contact your Komatsu distributor.
1. Stop the engine and close corrosion resistor levers 1 (2 places).
3-20
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24. SERVICE PROCEDURE 24. SERVICE PROCEDURE
24.3.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
1. Open the upper cover at the front of the machine.
2. Remove dipstick G and wipe the oil off with a cloth.
3. Insert dipstick G fully in the oil filler pipe, then take it out again.
4. The oil level should be between the H and L marks on dipstick
G.
If the oil level is below the L mark, take out the dispstick and add
engine oil through oil filler F.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
5. If the oil is above the H mark, drain the excess engine oil from H
drain plug, and check the oil level again. L
AD052340
6. If the oil level is correct, tighten the oil filler cap securely, insert
oil level gauge G fully into the dipstick guide, then close the
upper cover.
REMARK
‡ When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking.
‡ If the machine is at an angle, make it horizontal before checking.
‡ When adding oil, remove the oil level gauge from the gauge
guide so that the air in the crank case will be released.
3-30
--- Page 18 ---
24. SERVICE PROCEDURE 24. SERVICE PROCEDURE
24.5.4 REPLACE OIL IN ENGINE OIL PAN AND ENGINE
OIL FILTER CARTRIDGE
¤ WARNING
Do not replace the oil just after stopping the engine, since each
part is still hot. Wait until the oil is cooled.
‡ Container to receive used oil: 26 ¬ (6.7 US gal, 5.7 UK gal)
minimum
‡ Replacement oil: 26 ¬ (6.7 US gal, 5.7 UK gal)
‡ Prepare socket wrench and filter wrench.
1. Remove the undercover of the machine body and place a con-
tainer to receive used oil just under the drain plug.
2. Remove drain plug P slowly, taking care not to get soaked with
oil, and loosen valve 1 to drain oil.
3. Check the drained oil. If it contains metal chips and foreign
matter, please contact your Komatsu distributor.
4. Install drain plug P.
5. Turn filter cartridge 2 to the left with the filter wrench to remove
it. If the engine has been operated, wait about 10 minutes, since
much oil flows out.
6. Clean the filter stand and fill the new cartridge with engine oil.
Apply engine oil (or grease) to the packing of the new filter
cartridge and install it.
7. After the packing surface touches the filter stand, turn the
cartridge further by 3/4 – 1 turn.
8. After replacing the filter cartridge, supply engine oil through oil
filler F up to between H and L marks of the oil level gauge.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
When supplying oil, take care not to splash it over the alternator.
9. Run the engine idle at a low speed for a while, then stop it.
Referring to “24.3 CHECK BEFORE STARTING”, confirm that the
oil level is between the H and L marks of the oil level gauge.
Even if the machine has not been operated for 500 hours, the oil
and filter cartridge must be replaced when the machine has been
operated for 6 months.
In the same way, even if the machine has not been operated for 6
months, the oil and filter cartridge must be replaced when the
machine has been operated for 500 hours.
3-40
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24. SERVICE PROCEDURE 24. SERVICE PROCEDURE
7. After installing the strainer, supply engine oil through oil filler F
up to the specified level.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
8. After supplying the oil, confirm its level according to “24.3
CHECK BEFORE STARTING”.
3-50
--- Page 20 ---
25. SPECIFICATIONS
D75S-5
WEIGHT
‡ Operating weight 21130
(kg)
(Excluding operator) (46592 lb)
PERFORMANCE
‡ Bucket capacity (m3) 2.2
‡ Maximum load capacity (kg) 4,400 (9702 lb)
‡ Travel speed Forward 1st gear 0 – 3.3
Forward 2nd gear (km/h) 0 – 5.8
Forward 3rd gear (km/h) 0 – 9.6
Reverse 1st gear (km/h) 0 – 4.3
Reverse 2nd gear (km/h) 0 – 7.5
Reverse 3rd gear (km/h) 0 – 12.1
‡ Maximum traction force (N {kgf}) 250360 {25530}
‡ Ground pressure (kPa {kgf/cm2}) 82.37 {0.84}
ENGINE
‡ Model Komatsu S6D125E-2 diesel engine
‡ Rated output 151.51 kW {206 PS}/2000 rpm
‡ Maximum torque 922 N·m {94 kgf·m}/1500 rpm
‡ Starting motor 24 V 7.5 kW
‡ Alternator 24 V 35 A
‡ Battery 12 V 170 Ah x 2 pieces
4-2