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Komatsu Bulldozer D475A-5 Operation & Maintenance Manual SN 20001 and up – PDF DOWNLOAD
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Komatsu Bulldozer D475A-5 Operation & Maintenance Manual
Book Code : TEN00025-04
SERIAL NUMBERS 20001 and up
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Description
Komatsu Bulldozer D475A-5 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Bulldozer D475A-5 Operation & Maintenance Manual
Size : 8.62 MB
Format : PDF
Language : English
Number of Pages : 339 pages
Brand: Komatsu
Type of machine: Bulldozer
Type of document: Operation & Maintenance Manual
Model: D475A-5
Serial: 20001 and up
KOMATSU BULLDOZER D475A-5 OPERATION & MAINTENANCE MANUAL SN 20001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Bulldozer D475A-5 Operation & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu Bulldozer D475A-5 Operation & Maintenance Manual
COVER............................................................................................................................... 1 FOREWORD............................................................................................................................ 2 FOREWORD........................................................................................................................ 3 SAFETY INFORMATION.............................................................................................................. 6 INTRODUCTION.................................................................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................................................................................ 8 BREAKING IN THE MACHINE..................................................................................................... 8 NECESSARY INFORMATION........................................................................................................... 9 PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE............................................................... 9 EPA REGULATIONS, ENGINE NUMBER PLATE........................................................................................ 9 BLADE SERIAL NO. PLATE POSITION............................................................................................. 10 RIPPER SERIAL NO. PLATE POSITION............................................................................................ 10 POSITION OF SERVICE METER................................................................................................... 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................................................... 11 CONTENTS............................................................................................................................ 12 SAFETY.............................................................................................................................. 16 SAFETY.......................................................................................................................... 17 SAFETY LABELS................................................................................................................... 19 POSITIONS OF SAFETY PICTOGRAMS.............................................................................................. 19 SAFETY LABELS............................................................................................................... 20 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 PRECAUTIONS WHEN WORKING IN HIGH PLACES..................................................................................... 25 MOUNTING AND DISMOUNTING.................................................................................................... 25 NO PEOPLE ON ATTACHMENTS.................................................................................................... 25 CRUSHING OR CUTTING PREVENTION.............................................................................................. 26 PREVENTION OF BURNS......................................................................................................... 26 FIRE PREVENTION............................................................................................................. 27 ACTION IF FIRE OCCURS....................................................................................................... 28 WINDOW WASHER LIQUID........................................................................................................ 28 PRECAUTIONS WHEN USING ROPS................................................................................................. 28 PRECAUTIONS FOR ATTACHMENTS................................................................................................. 28 CAB WINDOW GLASSES.......................................................................................................... 28 UNAUTHORIZED MODIFICATION................................................................................................... 28 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.............................................................................................. 31 CHECKING SIGNALMAN'S SIGNALS AND SIGNS...................................................................................... 31 BE CAREFUL ABOUT ASBESTOS DUST.............................................................................................. 31 PRECAUTIONS FOR OPERATION....................................................................................................... 32 BEFORE STARTING ENGINE...................................................................................................... 32 CHECKS BEFORE STARTING ENGINE........................................................................................... 32 PRECAUTIONS WHEN STARTING............................................................................................... 33 PRECAUTIONS IN COLD AREAS............................................................................................... 33 OPERATION................................................................................................................... 34 CHECKS BEFORE OPERATION................................................................................................. 34 PRECAUTIONS FOR 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 LOADING AND UNLOADING................................................................................................... 38 SHIPPING................................................................................................................ 38 BATTERY..................................................................................................................... 39 BATTERY HAZARD PREVENTION............................................................................................... 39 STARTING WITH BOOSTER CABLE............................................................................................. 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 INSPECTION AND 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 PRECAUTION WITH HIGH-PRESSURE OIL........................................................................................... 48 PRECAUTION FOR HIGH FUEL PRESSURE........................................................................................... 48 HANDLING HIGH-PRESSURE HOSES................................................................................................ 48 PRECAUTION FOR HIGH VOLTAGE................................................................................................. 48 WASTE MATERIAL.............................................................................................................. 49 MAINTENANCE FOR AIR CONDITIONER............................................................................................. 49 COMPRESSED AIR.............................................................................................................. 49 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 SWITCHES.................................................................................................................... 85 CONTROL LEVERS, PEDALS...................................................................................................... 90 DUST INDICATOR.............................................................................................................. 99 POWER SOURCE................................................................................................................ 99 FUSE BOX....................................................................................................................100 DOOR OPEN LOCK..............................................................................................................104 SASH GLASS INTERMEDIATE LOCK................................................................................................104 DOOR POCKET.................................................................................................................105 ASHTRAY.....................................................................................................................105 TOOL BOX....................................................................................................................105 CLEAN INTERIOR OF CAB.......................................................................................................105 CAR STEREO, HANDLING........................................................................................................106 AIR CONDITIONER, HANDLING...................................................................................................115 ACCUMULATOR, HANDLING.......................................................................................................132 EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER.........................................................................133 HANDLING MACHINES EQUIPPED WITH VHMS........................................................................................140 OPERATION.......................................................................................................................142 CHECK BEFORE STARTING ENGINE, ADJUST........................................................................................142 STARTING ENGINE.............................................................................................................163 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................................171 STOPPING ENGINE.............................................................................................................174 CHECK AFTER STOPPING ENGINE.................................................................................................174 MOVING MACHINE..............................................................................................................175 STOPPING MACHINE............................................................................................................177 SHIFTING GEAR...............................................................................................................178 SHIFTING BETWEEN FORWARD AND REVERSE........................................................................................183 STEERING MACHINE............................................................................................................185 PRECAUTIONS FOR OPERATION...................................................................................................189 PARKING MACHINE.............................................................................................................191 CHECK AFTER FINISHING WORK..................................................................................................193 LOCKING.....................................................................................................................193 WORK POSSIBLE USING BULLDOZER...............................................................................................194 EFFECTIVE USE OF MODE SELECTION SYSTEM......................................................................................196 RIPPER OPERATION............................................................................................................201 OPERATING METHOD FOR RIPPING OPERATIONS.....................................................................................204 ADJUSTING POSTURE OF WORK EQUIPMENT.........................................................................................208 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................................................................211 TRANSPORTATION..................................................................................................................213 TRANSPORTATION PROCEDURE....................................................................................................213 LOADING, UNLOADING WORK.....................................................................................................213 METHOD OF LIFTING MACHINE...................................................................................................216 PRECAUTIONS FOR TRANSPORTATION..............................................................................................217 TRAVELING ON ROADS..........................................................................................................217 REMOVAL OF CAB..............................................................................................................218 INSTALLATION OF CAB.........................................................................................................221 INSTALLATION OF ROPS........................................................................................................222 COLD WEATHER OPERATION..........................................................................................................223 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................................223 AFTER COMPLETION OF WORK....................................................................................................225 AFTER COLD WEATHER..........................................................................................................225 LONG-TERM STORAGE...............................................................................................................226 BEFORE STORAGE..............................................................................................................226 DURING STORAGE..............................................................................................................226 AFTER STORAGE...............................................................................................................226 STARTING MACHINE AFTER LONG-TERM STORAGE....................................................................................226 TROUBLESHOOTING.................................................................................................................227 AFTER RUNNING OUT OF FUEL...................................................................................................227 METHOD OF TOWING MACHINE....................................................................................................229 IF BATTERY IS DISCHARGED....................................................................................................230 OTHER TROUBLE...............................................................................................................234 WHEN MODE SELECTION SYSTEM FLASHES..........................................................................................239 MAINTENANCE.........................................................................................................................240 GUIDES TO MAINTENANCE...........................................................................................................241 OUTLINES OF SERVICE.............................................................................................................244 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................................244 OUTLINE OF ELECTRIC SYSTEM..................................................................................................247 HANDLING HYDRAULIC RELATED EQUIPMENT........................................................................................248 WEAR PARTS......................................................................................................................249 WEAR PARTS LIST.............................................................................................................249 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............................................................251 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................................255 TORQUE LIST.................................................................................................................255 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................................256 SAFETY CRITICAL PARTS.......................................................................................................257 MAINTENANCE SCHEDULE CHART......................................................................................................259 MAINTENANCE SCHEDULE CHART..................................................................................................259 SERVICE PROCEDURE...............................................................................................................261 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..................................................................261 WHEN REQUIRED...............................................................................................................262 CLEAN INSIDE OF COOLING SYSTEM..........................................................................................262 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................................266 CHECK AND ADJUST TRACK TENSION..........................................................................................268 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................................................271 ADJUST IDLER CLEARANCE..................................................................................................272 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES......................................................................273 CLEAN AND CHECK RADIATOR FINS...........................................................................................275 CLEAN FUEL TANK STRAINER................................................................................................276 DRAIN WATER AND SEDIMENT IN FUEL TANK...................................................................................276 CLEAN STEERING CLUTCH CASE BREATHER.....................................................................................276 CHECK UNDERCARRIAGE OIL.................................................................................................277 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..................................................................278 REPLACE AIR CONDITIONER BELT............................................................................................278 CLEAN AND CHECK HYDRAULIC COOLER FINS...................................................................................278 CHECK AND ADJUST AIR CONDITIONER........................................................................................279 LUBRICATE DOOR HINGE....................................................................................................280 CHECK DOOR LATCH........................................................................................................280 CHECK DOOR LOCK STRIKER.................................................................................................281 REPLACE DOOR DAMPER.....................................................................................................281 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................................281 REPLACE WIPER BLADE.....................................................................................................282 BLEEDING AIR IN HYDRAULIC SYSTEM........................................................................................283 CHECK ELECTRICAL INTAKE AIR HEATER......................................................................................284 LUBRICATING.............................................................................................................284 CHECK BEFORE STARTING.......................................................................................................287 EVERY 250 HOURS SERVICE.....................................................................................................288 LUBRICATING.............................................................................................................288 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.............................................................................290 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................................291 CHECK BRAKE PERFORMANCE.................................................................................................294 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.................................................................................295 EVERY 500 HOURS SERVICE.....................................................................................................296 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......................................................296 REPLACE FUEL FILTER CARTRIDGE...........................................................................................297 REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT....299 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................................................300 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................................................................300 EVERY 1000 HOURS SERVICE....................................................................................................301 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)....301 CHECK, CLEAN FUEL STRAINER..............................................................................................303 CHECK FOR LOOSE ROPS MOUNT BOLTS........................................................................................303 REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE .........................................304 REPLACE AIR CONDITIONER AIR FILTER (FRESH, RECIRC FILTER)...............................................................305 CHECK TIGHTENING PARTS OF TURBOCHARGER..................................................................................305 EVERY 2000 HOURS SERVICE....................................................................................................306 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER.......................306 CHANGE OIL IN FINAL DRIVE CASE..........................................................................................308 CHANGE OIL IN DAMPER CASE AND BREATHER FILTER, CLEAN DAMPER BREATHER....................................................309 CHECK PIVOT BEARING OIL LEVEL, ADD OIL..................................................................................310 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL.........................................................310 CLEAN ENGINE BREATHER ELEMENT...........................................................................................311 CHECK ALTERNATOR, STARTING MOTOR........................................................................................311 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................................................................311 EVERY 4000 HOURS SERVICE....................................................................................................312 CHECK WATER PUMP........................................................................................................312 CHECK VIBRATION DAMPER..................................................................................................312 CLEAN, CHECK TURBOCHARGER...............................................................................................312 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................................312 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)........................................................................313 SPECIFICATIONS......................................................................................................................314 SPECIFICATIONS..................................................................................................................315 ATTACHMENTS, OPTIONS................................................................................................................316 GENERAL PRECAUTIONS.............................................................................................................317 PRECAUTIONS RELATED TO SAFETY...............................................................................................317 SELECTION OF TRACK SHOE.........................................................................................................318 SELECTION OF TRACK SHOES....................................................................................................318 PROCEDURE FOR SELECTING RIPPER POINT............................................................................................319 CAP WITH LOCK, HANDLING.........................................................................................................320 METHOD OF OPENING AND CLOSING CAP WITH LOCK.................................................................................320 EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER...............................................................................321 BLADE CONDITION.............................................................................................................321 DOZING WORK.................................................................................................................323 LEVELING (SPREADING) OPERATION..............................................................................................326 DITCHING OPERATION..........................................................................................................326 BOULDER RAISING OPERATION...................................................................................................326 SIDE-CUTTING OPERATIONS.....................................................................................................327 HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND).................................................................327 SHOE SLIP CONTROL...............................................................................................................328 MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL).............................................................................328 EFFECTIVE USE OF MODE SELECTION SYSTEM......................................................................................329 IF MODE SELECTION SYSTEM FLASHES............................................................................................335 INDEX...............................................................................................................................336
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