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Komatsu Bulldozer D475A-3 Operator & Maintenance Manual SN 10695 and up – PDF DOWNLOAD
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Komatsu Bulldozer D475A-3 Operator & Maintenance Manual
Book Code: SEAM046800T
SERIAL NUMBERS D475A -10695 and up
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Description
Komatsu Bulldozer D475A-3 Operator & Maintenance Manual
FILE DETAILS:
Komatsu Bulldozer D475A-3 Operator & Maintenance Manual
Size: 8.28 MB
Fomat: PDF
language: English
Brand: Komatsu
Type of machine: Bulldozer with Palm Command Control System
Type of document: Operator & Maintenance Manual
Model: D475_A-3
Serial: 10695 and up
Number of Page: 293
KOMATSU BULLDOZER D475A-3 OPERATOR & MAINTENANCE MANUAL SN 10695 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
MAIN MENU........................................................................................................................... 0 COVER............................................................................................................................... 1 CONTENTS............................................................................................................................ 12 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 AND POSITION......................................................................................... 10 RIPPER SERIAL NO. PLATE AND POSITION........................................................................................ 10 POSITION OF SERVICE METER................................................................................................... 10 TABLE OF ENTER SERIAL NO. AND DISTRIBUTION ................................................................................. 11 SAFETY.............................................................................................................................. 16 SAFETY.......................................................................................................................... 17 SAFETY LABELS................................................................................................................... 19 POSITION FOR ATTACHING SAFETY PICTOGRAMS.................................................................................... 19 SAFETY LABELS............................................................................................................... 20 GENERAL PRECAUTIONS............................................................................................................. 24 SAFETY RULES................................................................................................................ 24 IF ABNORMALITIES ARE FOUND.................................................................................................. 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................................................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT......................................................................................... 24 SAFETY FEATURES............................................................................................................. 24 KEEP MACHINE CLEAN.......................................................................................................... 25 INSIDE OPERATOR'S COMPARTMENT............................................................................................... 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.............................................................................. 25 HANDRAILS AND STEPS......................................................................................................... 26 MOUNTING AND DISMOUNTING.................................................................................................... 26 NO PEOPLE ON ATTACHMENTS.................................................................................................... 26 PREVENTION OF BURNS......................................................................................................... 27 FIRE PREVENTION ............................................................................................................ 27 ACTION IF OCCURS............................................................................................................ 28 WINSHIELD WASHER LIQUID..................................................................................................... 28 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................................................................ 28 PRECAUTIONS FOR ATTACHMENTS................................................................................................. 29 CAB WINDOW GLASSES.......................................................................................................... 29 UNAUTHORIZED MODIFICATION................................................................................................... 29 SAFETY AT WORKSITE.......................................................................................................... 29 WORKING ON LOOSE GROUND..................................................................................................... 29 DO NOT GO CLOSE TO HIGH VOLTAGE CABLES...................................................................................... 30 ENSURE GOOD VISIBILITY...................................................................................................... 30 VENTILATION FOR ENCLOSED AREAS.............................................................................................. 30 CHECKING SIGNALMAN'S SIGNAL AND SIGNS....................................................................................... 31 BE CAREFUL ABOUT ASBESTOS DUST.............................................................................................. 31 PRECAUTIONS FOR OPERATION....................................................................................................... 32 STARTING ENGINE............................................................................................................. 32 CHECKS BEFORE STARTING ENGINE........................................................................................... 32 PRECAUTIONS WHEN STARTING............................................................................................... 32 PRECAUTIONS IN COLD AREAS............................................................................................... 33 OPERATION................................................................................................................... 34 CHECKS BEFORE OPERATION................................................................................................. 34 PRECAUTIONS WHEN MOVING MACHINE FORWARD OR IN REVERSE................................................................... 34 PRECAUTIONS WHEN TRAVELING ............................................................................................. 35 TRAVELING ON SLOPES..................................................................................................... 36 PROHIBITED OPERATIONS................................................................................................... 36 USING BRAKES............................................................................................................ 36 OPERATE CAREFULLY ON SNOW............................................................................................... 36 PARKING MACHINE......................................................................................................... 37 TRANSPORTATION.............................................................................................................. 38 SHIPPING................................................................................................................ 38 BATTERY..................................................................................................................... 39 BATTERY HAZARD PREVENTION............................................................................................... 39 STARTING ENGINE WITH BOOSTER CABLES..................................................................................... 40 TOWING...................................................................................................................... 41 WHEN TOWING............................................................................................................. 41 PRECAUTIONS FOR MAINTENANCE..................................................................................................... 42 WARNING TAG................................................................................................................. 42 KEEP WORK PLACE CLEAN AND TIDY.............................................................................................. 42 APPOINT LEADER WHEN WORKING WITH OTHERS..................................................................................... 42 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE................................................................................. 43 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.......................................................................... 44 PROPER TOOLS................................................................................................................ 44 HANDLING ACCUMULATOR........................................................................................................ 45 PERSONNEL................................................................................................................... 45 ATTACHMENTS................................................................................................................. 45 WORK UNDER THE MACHINE...................................................................................................... 46 NOISE ...................................................................................................................... 46 PRECAUTIONS WHEN USING HAMMER............................................................................................... 46 REPAIR WELDING.............................................................................................................. 46 REMOVING BATTERY TERMINAL................................................................................................... 46 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......................................................... 47 DO NOT DISASSEMBLE RECOIL SPRING............................................................................................ 47 PRECAUTIONS WITH HIGH-PRESSURE FUEL......................................................................................... 47 HANDLING HIGH-PRESSURE HOSES................................................................................................ 48 PRECAUTION FOR HIGH VOLTAGE................................................................................................. 48 WASTE MATERIAL.............................................................................................................. 48 MAINTENANCE OF AIR CONDITIONER ............................................................................................. 48 COMPRESSED AIR.............................................................................................................. 48 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................................................... 49 OPERATION........................................................................................................................... 50 GENERAL VIEW ................................................................................................................... 51 GENERAL VIEW OF MACHINE..................................................................................................... 51 GENERAL VIEW OF CONTROLS AND GAUGES......................................................................................... 52 EXPLANATION OF COMPONENTS....................................................................................................... 54 FRONT PANEL................................................................................................................. 54 SWITCH...................................................................................................................... 84 CONTROL LEVERS AND PEDALS................................................................................................... 88 DUST INDICATOR.............................................................................................................. 97 POWER SOURSE................................................................................................................ 97 FUSE BOX.................................................................................................................... 98 FUSIBLE LINK................................................................................................................101 DOOR OPEN LOCK..............................................................................................................102 SASH GLASS INTERMEDIATE LOCK................................................................................................102 DOOR POCKET.................................................................................................................103 ASHTRAY.....................................................................................................................103 TOOL BOX....................................................................................................................103 CAR STEREO, HANDLING........................................................................................................104 AIR CONDITIONER, HANDLING...................................................................................................112 ACCUMULATOR, HANDLING.......................................................................................................117 OPERATION.......................................................................................................................118 CHECK BEFORE STARTING ENGINE................................................................................................118 STARTING ENGINE.............................................................................................................136 OPERATIONS, CHECKS AFTER STARTING ENGINE....................................................................................140 STOPPING ENGINE.............................................................................................................143 CHECK AFTER STOPPING ENGINE.................................................................................................143 MOVING MACHINE OFF..........................................................................................................144 STOPPING MACHINE............................................................................................................146 SHIFTING GEAR...............................................................................................................147 SHIFTING BETWEEN FOREWORD AND REVERSE.......................................................................................150 STEERING MACHINE............................................................................................................152 PRECAUTIONS FOR OPERATION...................................................................................................155 PARKING MACHINE.............................................................................................................157 CHECKS AFTER FINISHING WORK.................................................................................................159 LOCKING.....................................................................................................................159 WORK POSSIBLE USING BULLDOZER...............................................................................................160 EFFECTIVE USE OF MODE SELECTION SYSTEM......................................................................................162 RIPPER OPERATION............................................................................................................167 OPERATING METHOD FOR RIPPING OPERATIONS.....................................................................................170 ADJUSTING POSTURE OF WORK EQUIPMENT.........................................................................................174 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................................................................178 TRANSPORATION...................................................................................................................180 TRANSPORTATION PROCEDURE....................................................................................................180 LOADING, UNLOADING WORK.....................................................................................................180 PRECAUTIONS WHEN LOADING....................................................................................................180 METHOD OF LIFTING MACHINE...................................................................................................181 PRECAUTIONS FOR TRANSPORATION...............................................................................................182 TRAVELING ON ROADS..........................................................................................................182 REMOVAL OF CAB..............................................................................................................182 INSTALLATION OF CAB.........................................................................................................183 COLD WEATHER OPERATION..........................................................................................................184 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................................184 AFTER COMPLETION OF WORK....................................................................................................185 AFTER COLD WEATHER..........................................................................................................186 LONG TERM STORAGE...............................................................................................................187 BEFORE STORAGE..............................................................................................................187 DURING STORAGE..............................................................................................................187 AFTER STORAGE...............................................................................................................187 TROUBLESHOOTING.................................................................................................................188 AFTER RUNNING OUT OF FUEL...................................................................................................188 METHOD OF TOWING THE MACHINE................................................................................................188 IF BATTERY IS DISCHARGED....................................................................................................189 OTHER TROUBLE...............................................................................................................192 WHEN MODE SELECTION SYSTEM FLASHES..........................................................................................197 MAINTENANCE.........................................................................................................................198 GUIDES TO MAINTENANCE...........................................................................................................199 OUTLINE OF SERVICE..............................................................................................................202 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................................202 OUTLINE OF ELECTRIC SYSTEM..................................................................................................205 WEAR PARTS .....................................................................................................................206 WEAR PARTS LIST.............................................................................................................206 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............................................................207 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................................211 TORQUE LIST.................................................................................................................211 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................................212 SAFETY CRITICAL PARTS.......................................................................................................213 MAINTENANCE SCHEDULE CHART......................................................................................................214 MAINTENANCE SCHEDULE CHART..................................................................................................214 SERVICE PROCEDURE...............................................................................................................216 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..................................................................216 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS FILTER CARTRIDGE...........................249 REPLACE FUEL FILTER CARTRIDGE...........................................................................................251 REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE OIL FILTER ELEMENT..............252 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)....216 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT AND HYDRAULIC TANK BREATHER ELEMENT..................258 CHANGE OIL FINAL DRIVE CASE.............................................................................................260 WHEN REQUIRED...............................................................................................................217 CHECK INSIDE OF COOLING SYSTEM..........................................................................................217 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................................221 CHECK TRACK TENSION.....................................................................................................223 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................................................225 ADJUST IDLER CLEARENCE..................................................................................................226 CLEAN, CHECK RADIATOR FINS..............................................................................................229 CLEAN FUEL TANK STRAINER................................................................................................230 DRAIN WATER AND SEDIMENT IN FUEL TANK...................................................................................230 CLEAN STEERING CLUTCH CASE BREATHER.....................................................................................230 REPLACE AIR CONDITIONER BELT............................................................................................231 CLEAN, CHECK HYDRAULIC COOLER FINS......................................................................................231 CHECK UNDERCARRIAGE OIL.................................................................................................232 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..................................................................233 CHECK, ADJUST AIR CONDITIONER...........................................................................................234 LUBRICATE DOOR HINGE....................................................................................................235 CHECK DOOR LATCH........................................................................................................235 CHECK DOOR LOCK STRIKER.................................................................................................236 REPLACE DOOR DAMPER.....................................................................................................236 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................................236 REPLACE WIPER BLADE.....................................................................................................237 BLEED AIR FROM HEAD END OF RIGHT PITCH CYLINDER.........................................................................238 BLEED AIR IN HYDRAULIC SYSTEM...........................................................................................238 CHECK ELECTRICAL INTAKE AIR HEATER......................................................................................239 LUBRICATING.............................................................................................................239 CHECK BEFORE STARTING.......................................................................................................241 EVERY 250 HOURS MAINTENANCE.................................................................................................242 LUBRICATING.............................................................................................................242 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.............................................................................244 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................................245 CHECK BRAKE PERFORMANCE.................................................................................................248 EVERY 500 HOURS MAINTENANCE.................................................................................................249 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ......................................................249 REPLACE FUEL FILTER CARTRIDGE...........................................................................................251 REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT....252 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................................................253 CHECK REPLACE FAN BELT..................................................................................................253 EVERY 1000 HOURS MAINTENANCE................................................................................................254 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE).....254 CHECK, CLEAN FUEL STRAINER..............................................................................................256 LUBRICATE TENSION PULLEY ASSEMBLY....................................................................................... 0 CHECK FOR LOSSE ROPS MOUNT BOLTS........................................................................................256 REPLACE MAIN AND SUB CORROSION RESISTER CARTRIDGES......................................................................257 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................................................................258 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER..............................................................................258 EVERY 2000 HOURS MAINTENANCE................................................................................................259 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT......................................................259 CHANGE OIL IN FINAL DRIVE CASE..........................................................................................260 CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER........................................................................261 CHECK PIVOT BEARING OIL LEVEL, ADD OIL..................................................................................262 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL.........................................................262 CLEAN ENGINE BREATHER ELEMENT...........................................................................................263 CHECK ALTERNATOR, STARTING MOTOR........................................................................................263 CHECK ENGINE VALVE CLEARENCE, ADJUST....................................................................................263 EVERY 4000 HOURS MAINTENANCE................................................................................................264 CHECK WATER PUMP........................................................................................................264 CHECK VIBRATION DAMPER..................................................................................................264 CHECK FAN PULLEY AND TENSION PULLEY.....................................................................................264 CLEAN, CHECK TURBOCHARGER...............................................................................................264 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................................264 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)........................................................................265 SPECIFICATIONS......................................................................................................................266 SPECIFICATIONS..................................................................................................................267 ATTACHMENTS, OPTIONS................................................................................................................268 GENERAL PRECAUTIONS.............................................................................................................269 PRECAUTIONS RELATED TO SAFETY...............................................................................................269 SELECTION OF TRACK SHOE.........................................................................................................270 SELECTION OF TRACK SHOES....................................................................................................270 PROCEDURE FOR SELECTING RIPPER POINT............................................................................................271 PROCEDURE FOR SELECTING RIPPER POINT........................................................................................271 CAP WITH LOCK, HANDLING ........................................................................................................272 METHOD OF OPENING AND CLOSING CAP WITH LOCK.................................................................................272 EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER...............................................................................273 BLADE CONDITION.............................................................................................................273 DOZING WORK ................................................................................................................275 LEVELING (SPREADING) OPERATION..............................................................................................278 DITCHING OPERATION..........................................................................................................278 BOULDER RAISING OPERATION...................................................................................................278 SIDE-CUTTING OPERATIONS.....................................................................................................279 HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND).................................................................279 SHOE SLIP CONTROL...............................................................................................................280 MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL).............................................................................280 EFFECTIVE USE OF MODE SELECTION SYSTEM......................................................................................282 IF MODE SELECTION SYSTEM FLASHES............................................................................................288 INDEX...............................................................................................................................290
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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