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Komatsu Bulldozer D475A-3 Operator & Maintenance Manual SN 10685 and up – PDF DOWNLOAD
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Komatsu Bulldozer D475A-3 Operator & Maintenance Manual
SERIAL NUMBERS D475A-10685 and up
Book Code : SEAM022005T
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Description
Komatsu Bulldozer D475A-3 Operator & Maintenance Manual
FILE DETAILS:
Komatsu Bulldozer D475A-3 Operator & Maintenance Manual
Size: 6.46 MB
Fomat: PDF
language: English
Brand: Komatsu
Type of machine:Bulldozer
Type of document: Operator & Maintenance Manual
Model: D475A-3
Serial: 10685 and up
Number of Page: 224
KOMATSU BULLDOZER D475A-3 OPERATOR & MAINTENANCE MANUAL SN 10685 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Bulldozer D475A-3 Operator & 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 D475A-3 Operator & Maintenance Manual
COVER.............................................................................................................................. 1 FOREWORD........................................................................................................................... 2 FOREWORD....................................................................................................................... 3 SAFETY INFORMATION............................................................................................................. 6 INTRODUCTION................................................................................................................... 8 FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHINE................................................................................ 8 NECESSARY INFORMATION.......................................................................................................... 9 MACHINE SERIAL NO.PLATE AND POSITION....................................................................................... 9 ENGINE SERIAL NO.PLATE AND POSITION........................................................................................ 9 BLADE SERIAL NO.PLATE POSITION............................................................................................. 10 POSITION OF SERVICE METER.................................................................................................. 10 TABLE OF ENTER SERIAL NO.AND DISTRIBUTORN.................................................................................. 11 CONTENTS........................................................................................................................... 12 SAFETY............................................................................................................................. 15 SAFETY......................................................................................................................... 16 SAFETY LABELS.................................................................................................................. 18 POSITIONS OF SAFETY PICTOGRAMS............................................................................................. 18 SAFETY LABELS.............................................................................................................. 19 GENERAL PRECAUTIONS............................................................................................................ 23 SAFETY RULES............................................................................................................... 23 IF ABNORMALITIES ARE FOUND................................................................................................. 23 CLOTHING AND PERSONAL PROTECTIVE ITEMS..................................................................................... 23 FIRE EXTINGUISHER AND FIRST AID KIT........................................................................................ 23 SAFETY FEATURES............................................................................................................ 23 KEEP MACHINE CLEAN......................................................................................................... 24 INSIDE OPERATOR'S COMPARTMENT.............................................................................................. 24 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT............................................................................. 24 HANDRAILS AND STEPS........................................................................................................ 25 MOUNTING AND DISMOUNTING................................................................................................... 25 NO PEOPLE ON ATTACHMENTS................................................................................................... 25 PREVENTION OF BURNS........................................................................................................ 26 FIRE PREVENTION............................................................................................................ 26 ACTION IF FIRE OCCURS...................................................................................................... 27 WINDOW WASHER LIQUID....................................................................................................... 27 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)............................................................... 27 PRECAUTIONS FOR ATTACHMENTS................................................................................................ 28 ACCUMULATOR................................................................................................................ 28 UNAUTHORIZED MODIFICATION.................................................................................................. 28 SAFETY AT WORKSITE......................................................................................................... 28 WORKING ON LOOSE GROUND.................................................................................................... 29 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES..................................................................................... 29 ENSURE GOOD VISIBILITY..................................................................................................... 29 VENTILATION FOR ENCLOSED AREAS............................................................................................. 30 CHECKING SIGNALMAN'S SIGNALS AND SIGNS..................................................................................... 30 BE CAREFUL ABOUT ASBESTOS DUST............................................................................................. 30 PRECAUTIONS FOR OPERATION...................................................................................................... 31 BEFORE STARTING ENGINE..................................................................................................... 31 CHECKS BEFORE STARTING ENGINE.......................................................................................... 31 PRECAUTIONS WHEN STARTING.............................................................................................. 31 PRECAUTIONS IN COLD AREAS.............................................................................................. 32 OPERATION.................................................................................................................. 33 CHECKS BEFORE OPERATION................................................................................................ 33 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE................................................................... 33 PRECAUTIONS WHEN TRAVELING............................................................................................. 34 TRAVELING ON SLOPES.................................................................................................... 35 PROHIBITED OPERATIONS.................................................................................................. 35 USING BRAKES........................................................................................................... 35 OPERATE CAREFULLY ON SNOW.............................................................................................. 35 PARKING MACHINE........................................................................................................ 36 TRANSPORTATION............................................................................................................. 37 SHIPPING............................................................................................................... 37 BATTERY.................................................................................................................... 38 BATTERY HAZARD PREVENTION.............................................................................................. 38 STARTING WITH BOOSTER CABLE............................................................................................ 39 TOWING..................................................................................................................... 40 WHEN TOWING............................................................................................................ 40 PRECAUTIONS FOR MAINTENANCE.................................................................................................... 41 WARNING TAG................................................................................................................ 41 KEEP WORK PLACE CLEAN AND TIDY............................................................................................. 41 APPOINT LEADER WHEN WORKING WITH OTHERS.................................................................................... 41 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ................................................................ 42 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING......................................................................... 43 PROPER TOOLS............................................................................................................... 43 PERSONNEL.................................................................................................................. 43 ATTACHMENTS................................................................................................................ 44 WORK UNDER THE MACHINE..................................................................................................... 44 NOISE...................................................................................................................... 44 PRECAUTIONS WHEN USING HAMMER.............................................................................................. 44 REPAIR WELDING............................................................................................................. 44 REMOVING BATTERY TERMINAL.................................................................................................. 45 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION........................................................ 45 DO NOT DISASSEMBLE RECOIL SPRING........................................................................................... 45 PRECAUTION WITH HIGH-PRESSURE OIL.......................................................................................... 45 HANDLING HIGH-PRESSURE HOSES............................................................................................... 46 WASTE MATERIAL............................................................................................................. 46 MAINTENANCE FOR AIR CONDITIONER............................................................................................ 46 COMPRESSED AIR............................................................................................................. 46 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.............................................................................. 46 OPERATION.......................................................................................................................... 47 GENERAL VIEW................................................................................................................... 48 GENERAL VIEW OF MACHINE.................................................................................................... 48 GENERAL VIEW OF CONTROLS AND GAUGES........................................................................................ 49 EXPLANATION OF COMPONENTS...................................................................................................... 51 FRONT PANEL................................................................................................................ 51 SWITCH..................................................................................................................... 68 CONTROL LEVERS,PEDALS...................................................................................................... 72 CONTROLLER................................................................................................................. 77 DUST INDICATOR............................................................................................................. 78 POWER SOURSE............................................................................................................... 78 FUSE BOX................................................................................................................... 79 DOOR OPEN LOCK............................................................................................................. 81 SASH GLASS INTERMEDIATE LOCK............................................................................................... 82 DOOR POCKET................................................................................................................ 82 ASHTRAY.................................................................................................................... 82 TOOL BOX................................................................................................................... 83 AIR CONDITIONER,HANDLING................................................................................................... 84 ACCUMULATOR,HANDLING....................................................................................................... 90 OPERATION...................................................................................................................... 91 CHECK BEFORE STARTING ENGINE,ADJUST........................................................................................ 91 STARTING ENGINE............................................................................................................108 OPERATIONS AND CHECKS AFTER STARTING ENGINE................................................................................112 STOPPING ENGINE............................................................................................................115 CHECK AFTER STOPPING ENGINE................................................................................................115 MOVING MACHINE OFF.........................................................................................................116 STOPPING MACHINE...........................................................................................................118 SHIFTING GEAR..............................................................................................................119 SHIFTING BETWEEN FORWARD AND REVERSE.......................................................................................120 STEERING MACHINE...........................................................................................................122 PRECAUTIONS FOR OPERATION..................................................................................................126 PROHIBITED WORK OF SUPER DOZER.............................................................................................128 EFECTIVE USE OF SUPER DOZER................................................................................................130 EFECTIVE USE OF MODE SELECTION SYSTEM......................................................................................133 PARKING MACHINE............................................................................................................136 CHECK AFTER FINISHING WORK.................................................................................................138 LOCKING....................................................................................................................138 ADJUSTING POSTURE OF WORK EQUIPMENT........................................................................................139 TIPS FOR LONGER UNDERCARRIAGE LIFE.........................................................................................140 TRANSPORTATION.................................................................................................................142 TRANSPORTATION PROCEDURE...................................................................................................142 LOADING,UNLOADING WORK.....................................................................................................142 PRECAUTIONS FOR LOADING....................................................................................................143 PRECAUTIONS FOR TRANSPORTATION.............................................................................................143 TRAVELING ON ROADS.........................................................................................................143 COLD WEATHER OPERATION.........................................................................................................144 PRECAUTIONS FOR LOW TEMPERATURE............................................................................................144 AFTER COMPLETION OF WORK...................................................................................................145 AFTER COLD WEATHER.........................................................................................................146 LONG-TERM STORAGE..............................................................................................................147 BEFORE STORAGE.............................................................................................................147 DURING STORAGE.............................................................................................................147 AFTER STORAGE..............................................................................................................147 TROUBLESHOOTING................................................................................................................148 AFTER RUNNING OUT OF FUEL..................................................................................................148 METHOD OF TOWING MACHINE...................................................................................................148 IF BATTERY IS DISCHARGED...................................................................................................149 OTHER TROUBLE..............................................................................................................152 MAINTENANCE........................................................................................................................157 GUIDES TO MAINTENANCE..........................................................................................................158 OUTLINES OF SERVICE............................................................................................................161 HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC........................................................................161 OUTLINE OF ELECTRIC SYSTEM.................................................................................................163 WEAR PARTS LIST................................................................................................................164 WEAR PARTS LIST............................................................................................................164 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...........................................................165 PROPER SELECTION OF FUEL,COOLANT AND LUBRICANTS............................................................................165 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.................................................................................169 TORQUE LIST................................................................................................................169 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..................................................................................170 SAFETY CRITICAL PARTS......................................................................................................171 MAINTENANCE SCHEDULE CHART.....................................................................................................172 MAINTENANCE SCHEDULE CHART.................................................................................................172 SERVICE PROCEDURE..............................................................................................................174 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).................................................................174 WHEN REQUIRED..............................................................................................................175 CLEAN INSIDE OF COOLING SYSTEM.........................................................................................175 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...........................................................................178 CHECK TRACK TENSION....................................................................................................180 CHECK AND TIGHTEN TRACK SHOE BOLTS.....................................................................................183 ADJUST IDLER CLEARANCE.................................................................................................184 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES.....................................................................185 CLEAN AND CHECK RADIATOR FIN...........................................................................................186 CLEAN FUEL TANK STRAINER...............................................................................................187 DRAIN WATER AND SEDIMENT IN FUEL TANK..................................................................................187 CLEAN STEERING CLUTCH CASE BREATHER....................................................................................187 REPLACE AIR CONDITIONER BELT...........................................................................................188 CLEAN, CHECK HYDRAULIC COOLER FINS.....................................................................................188 CHECK UNDERCARRIAGE OIL................................................................................................189 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER).................................................................190 CHECK, ADJUST AIR CONDITIONER..........................................................................................191 LUBRICATE DOOR HINGE...................................................................................................192 CHECK DOOR LOCK STRIKER................................................................................................192 REPLACE DOOR DAMPER....................................................................................................192 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................................................192 REPLACE WIPER BLADE....................................................................................................193 LUBRICATING............................................................................................................195 CHECK BEFORE STARTING......................................................................................................197 EVERY 250 HOURS SERVICE....................................................................................................198 LUBRICATING............................................................................................................198 CHECK ALTERNATOR DRIVE BELT TENSION,ADJUST.............................................................................200 CHECK LEVEL OF BATTERY ELECTROLYTE.....................................................................................201 CHECK BRAKE PERFORMANCE................................................................................................202 EVERY 500 HOURS SERVICE....................................................................................................203 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS FILTER CARTRIDGE..........................203 REPLACE FUEL FILTER CARTRIDGE..........................................................................................205 REPLACE TRANSMISSION FILTER ELEMENT,TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT....206 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...........................................................................207 CHECK REPLACE FAN BELT.................................................................................................207 EVERY 1000 HOURS SERVICE...................................................................................................208 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE,TORQUE CONVERTER CASE AND BEVEL GEAR CASE)....208 CHECK, CLEAN FUEL STRAINER.............................................................................................210 LUBRICATE TENSION PULLEY ASSEMBLY......................................................................................210 CHECK FOR LOOSE ROPS MOUNT BOLTS.......................................................................................210 REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE.........................................211 CHANGE OIL IN HYDRAULIC TANK,REPLACE HYDRAULIC OIL FILTER ELEMENT AND HYDRAULIC TANK BREATHER ELEMENT..................212 CHECK TIGHTENING PARTS OF TURBOCHARGER.................................................................................212 EVERY 2000 HOURS SERVICE...................................................................................................213 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT.....................................................213 CHANGE OIL IN FINAL DRIVE CASE.........................................................................................214 CHANGE OIL IN DAMPER CASE..............................................................................................215 CHECK PIVOT BEARING OIL LEVEL, ADD OIL.................................................................................216 CHECK OIL LEVEL IN RECOIL SPRING,ASSIST CYLINDER CASE,ADD OIL..........................................................216 CLEAN ENGINE BREATHER ELEMENT..........................................................................................217 CHECK ALTERNATOR,STARTING MOTOR........................................................................................217 CHECK ENGINE VALVE CLEARANCE,ADJUST....................................................................................217 EVERY 4000 HOURS SERVICE...................................................................................................218 CHECK WATER PUMP.......................................................................................................218 CHECK VIBRATION DAMPER.................................................................................................218 CHECK FAN PULLEY AND TENSION PULLEY....................................................................................218 CLEAN,CHECK TURBOCHARGER...............................................................................................218 CHECK PLAY OF TURBOCHARGER ROTOR.......................................................................................218 CHECK MAIN FRAME,WORK EQUIPMENT (BLADE)................................................................................219 SPECIFICATIONS.....................................................................................................................220 SPECIFICATIONS.................................................................................................................221 INDEX..............................................................................................................................222
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