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Komatsu Bulldozer D475A-5_20001 and up Operation & Maintenance Manual TEN00018-05 – PDF DOWNLOAD
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Komatsu Bulldozer D475A-5_20001 and up Operation & Maintenance Manual
SERIAL NUMBERS 20001 and up
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Description
Komatsu Bulldozer D475A-5_20001 and up Operation & Maintenance Manual
FILE DETAILS:
Komatsu Bulldozer D475A-5_20001 and up Operation & Maintenance Manual
Size : 8.51 MB
Format : PDF
Language : English
Number of Pages : 333 ages
Brand: Komatsu
Type of machine: Bulldozer
Type of document: Operation & Maintenance Manual
Model: D475A-5
Serial: 20001 and up
KOMATSU BULLDOZER D475A-5_20001 AND UP OPERATION & MAINTENANCE MANUAL TEN00018-05 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Bulldozer D475A-5_20001 and up 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_20001 and up 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............................................................................................... 32 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.............................................................................................................. 98 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 HANDLING MACHINES EQUIPPED WITH VHMS........................................................................................133 OPERATION.......................................................................................................................135 CHECK BEFORE STARTING ENGINE, ADJUST........................................................................................135 STARTING ENGINE.............................................................................................................156 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................................164 STOPPING ENGINE.............................................................................................................167 CHECK AFTER STOPPING ENGINE.................................................................................................167 MOVING MACHINE..............................................................................................................168 STOPPING MACHINE............................................................................................................170 SHIFTING GEAR...............................................................................................................171 SHIFTING BETWEEN FORWARD AND REVERSE........................................................................................176 STEERING MACHINE............................................................................................................178 PRECAUTIONS FOR OPERATION...................................................................................................182 PARKING MACHINE.............................................................................................................184 CHECK AFTER FINISHING WORK..................................................................................................186 LOCKING.....................................................................................................................186 WORK POSSIBLE USING BULLDOZER...............................................................................................187 EFFECTIVE USE OF MODE SELECTION SYSTEM......................................................................................189 RIPPER OPERATION............................................................................................................194 OPERATING METHOD FOR RIPPING OPERATIONS.....................................................................................197 ADJUSTING POSTURE OF WORK EQUIPMENT.........................................................................................201 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................................................................204 TRANSPORTATION..................................................................................................................206 TRANSPORTATION PROCEDURE....................................................................................................206 LOADING, UNLOADING WORK.....................................................................................................206 METHOD OF LIFTING MACHINE...................................................................................................209 PRECAUTIONS FOR TRANSPORTATION..............................................................................................210 TRAVELING ON ROADS..........................................................................................................210 REMOVAL OF CAB..............................................................................................................211 INSTALLATION OF CAB.........................................................................................................214 INSTALLATION OF ROPS........................................................................................................215 COLD WEATHER OPERATION..........................................................................................................216 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................................216 AFTER COMPLETION OF WORK....................................................................................................218 AFTER COLD WEATHER..........................................................................................................218 LONG-TERM STORAGE...............................................................................................................219 BEFORE STORAGE..............................................................................................................219 DURING STORAGE..............................................................................................................219 AFTER STORAGE...............................................................................................................219 STARTING MACHINE AFTER LONG-TERM STORAGE....................................................................................219 TROUBLESHOOTING.................................................................................................................220 AFTER RUNNING OUT OF FUEL...................................................................................................220 METHOD OF TOWING MACHINE....................................................................................................222 IF BATTERY IS DISCHARGED....................................................................................................223 OTHER TROUBLE...............................................................................................................227 WHEN MODE SELECTION SYSTEM FLASHES..........................................................................................232 MAINTENANCE.........................................................................................................................234 GUIDES TO MAINTENANCE...........................................................................................................235 OUTLINES OF SERVICE.............................................................................................................238 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................................238 OUTLINE OF ELECTRIC SYSTEM..................................................................................................241 HANDLING HYDRAULIC RELATED EQUIPMENT........................................................................................242 WEAR PARTS......................................................................................................................243 WEAR PARTS LIST.............................................................................................................243 RECOMMENDED FUEL, COOLANT, AND LUBRICANT........................................................................................245 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.........................................247 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................................248 TORQUE LIST.................................................................................................................248 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................................249 SAFETY CRITICAL PARTS.......................................................................................................250 MAINTENANCE SCHEDULE CHART......................................................................................................252 MAINTENANCE SCHEDULE CHART..................................................................................................252 SERVICE PROCEDURE...............................................................................................................254 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..................................................................254 WHEN REQUIRED...............................................................................................................255 CLEAN INSIDE OF COOLING SYSTEM..........................................................................................255 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................................259 CHECK AND ADJUST TRACK TENSION..........................................................................................261 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................................................264 ADJUST IDLER CLEARANCE..................................................................................................265 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES......................................................................266 CLEAN AND CHECK RADIATOR FINS...........................................................................................268 CLEAN FUEL TANK STRAINER................................................................................................269 DRAIN WATER AND SEDIMENT IN FUEL TANK...................................................................................269 CLEAN STEERING CLUTCH CASE BREATHER.....................................................................................269 CHECK UNDERCARRIAGE OIL.................................................................................................270 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..................................................................271 REPLACE AIR CONDITIONER BELT............................................................................................271 CLEAN AND CHECK HYDRAULIC COOLER FINS...................................................................................271 CHECK AND ADJUST AIR CONDITIONER........................................................................................272 LUBRICATE DOOR HINGE....................................................................................................273 CHECK DOOR LATCH........................................................................................................273 CHECK DOOR LOCK STRIKER.................................................................................................274 REPLACE DOOR DAMPER.....................................................................................................274 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................................274 REPLACE WIPER BLADE.....................................................................................................275 BLEEDING AIR IN HYDRAULIC SYSTEM........................................................................................276 CHECK ELECTRICAL INTAKE AIR HEATER......................................................................................277 LUBRICATING.............................................................................................................277 CHECK BEFORE STARTING.......................................................................................................280 EVERY 250 HOURS SERVICE.....................................................................................................281 LUBRICATING.............................................................................................................281 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.............................................................................283 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................................284 CHECK BRAKE PERFORMANCE.................................................................................................287 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.................................................................................288 EVERY 500 HOURS SERVICE.....................................................................................................289 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......................................................289 REPLACE FUEL FILTER CARTRIDGE...........................................................................................290 REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT....292 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................................................293 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................................................................293 EVERY 1000 HOURS SERVICE....................................................................................................294 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)....294 CHECK, CLEAN FUEL STRAINER..............................................................................................296 CHECK FOR LOOSE ROPS MOUNT BOLTS........................................................................................296 REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE..........................................297 REPLACE AIR CONDITIONER AIR FILTER (FRESH, RECIRC FILTER)...............................................................297 CHECK TIGHTENING PARTS OF TURBOCHARGER..................................................................................298 EVERY 2000 HOURS SERVICE....................................................................................................299 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER.......................299 CHANGE OIL IN FINAL DRIVE CASE..........................................................................................301 CHANGE OIL IN DAMPER CASE AND BREATHER FILTER, CLEAN DAMPER BREATHER....................................................302 CHECK PIVOT BEARING OIL LEVEL, ADD OIL..................................................................................303 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL.........................................................303 CLEAN ENGINE BREATHER ELEMENT...........................................................................................304 CHECK ALTERNATOR, STARTING MOTOR........................................................................................304 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................................................................304 EVERY 4000 HOURS SERVICE....................................................................................................305 CHECK WATER PUMP........................................................................................................305 CHECK VIBRATION DAMPER..................................................................................................305 CLEAN, CHECK TURBOCHARGER...............................................................................................305 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................................305 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)........................................................................306 SPECIFICATIONS......................................................................................................................308 SPECIFICATIONS..................................................................................................................309 ATTACHMENTS, OPTIONS................................................................................................................310 GENERAL PRECAUTIONS.............................................................................................................311 PRECAUTIONS RELATED TO SAFETY...............................................................................................311 SELECTION OF TRACK SHOE.........................................................................................................312 SELECTION OF TRACK SHOES....................................................................................................312 PROCEDURE FOR SELECTING RIPPER POINT............................................................................................313 CAP WITH LOCK, HANDLING.........................................................................................................314 METHOD OF OPENING AND CLOSING CAP WITH LOCK.................................................................................314 EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER...............................................................................315 BLADE CONDITION.............................................................................................................315 DOZING WORK.................................................................................................................317 LEVELING (SPREADING) OPERATION..............................................................................................320 DITCHING OPERATION..........................................................................................................320 BOULDER RAISING OPERATION...................................................................................................320 SIDE-CUTTING OPERATIONS.....................................................................................................321 HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND).................................................................321 SHOE SLIP CONTROL...............................................................................................................322 MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL).............................................................................322 EFFECTIVE USE OF MODE SELECTION SYSTEM......................................................................................323 IF MODE SELECTION SYSTEM FLASHES............................................................................................329 INDEX...............................................................................................................................330
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- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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