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KOMATSU D475A-3 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:10685 & UP) KOMATSU D475A 3 – PDF DOWNLOAD
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- KOMATSU D475A-3 BULLDOZER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:10685 & UP
- PUBLICATION NUMBER:SEAM025105T
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KOMATSU D475A-3 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:10685 & UP) KOMATSU D475A 3
KOMATSU D475A-3 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:10685 & UP) KOMATSU D475A 3 – PDF DOWNLOAD:
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KOMATSU D475A-3 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:10685 & UP) KOMATSU D475A 3
- Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points. Read this manual thoroughly and understand its contents fully. Read the safety messages and safety labels given in this manual carefully so that they should be understood fully. Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved in working on the machine can consult it periodically.
- In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy. When you sell the machine, make sure that this manual should be provided to the new owner together with the machine. in this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in the past are also displayed in {}.
TABLE OF CONTENTS:
KOMATSU D475A-3 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:10685 & UP) KOMATSU D475A 3
COVER............................................................................................................................... 1 FOREWORD............................................................................................................................ 2 FOREWORD........................................................................................................................ 3 SAFETY INFORMATION.............................................................................................................. 6 INTRODUCTION.................................................................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................................................................................ 8 NECESSARY INFORMATION........................................................................................................... 9 MACHINE SERIAL NO. PLATE AND POSITION....................................................................................... 9 ENGINE SERIAL NO. PLATE AND POSITION........................................................................................ 9 BLADE SERIAL NO. PLATE POSITION............................................................................................. 10 RIPPER SERIAL NO. PLATE POSITION............................................................................................ 10 POSITION OF SERVICE METER................................................................................................... 10 TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN.................................................................................. 11 CONTENTS............................................................................................................................ 12 SAFETY.............................................................................................................................. 15 SAFETY.......................................................................................................................... 16 SAFETY LABELS................................................................................................................... 18 POSITIONS OF SAFETY PICTOGRAMS.............................................................................................. 18 SAFETY LABELS............................................................................................................... 19 GENERAL PRECAUTIONS............................................................................................................. 23 SAFETY RULES................................................................................................................ 23 IF ABNORMALITIES ARE FOUND.................................................................................................. 23 CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................................................................... 23 FIRE EXTINGUISHER AND FIRST AID KIT......................................................................................... 23 SAFETY FEATURES............................................................................................................. 23 KEEP MACHINE CLEAN.......................................................................................................... 24 INSIDE OPERATOR'S COMPARTMENT............................................................................................... 24 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.............................................................................. 24 HANDRAILS AND STEPS......................................................................................................... 25 MOUNTING AND DISMOUNTING.................................................................................................... 25 NO PEOPLE ON ATTACHMENTS.................................................................................................... 25 PREVENTION OF BURNS......................................................................................................... 26 FIRE PREVENTION............................................................................................................. 26 ACTION IF FIRE OCCURS....................................................................................................... 27 WINDOW WASHER LIQUID........................................................................................................ 27 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................................................................ 27 PRECAUTIONS FOR ATTACHMENTS................................................................................................. 28 ACCUMULATOR................................................................................................................. 28 UNAUTHORIZED MODIFICATION................................................................................................... 28 SAFETY AT WORKSITE.......................................................................................................... 28 WORKING ON LOOSE GROUND..................................................................................................... 29 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...................................................................................... 29 ENSURE GOOD VISIBILITY...................................................................................................... 29 VENTILATION FOR ENCLOSED AREAS.............................................................................................. 30 CHECKING SIGNALMAN'S SIGNALS AND SIGNS...................................................................................... 30 BE CAREFUL ABOUT ASBESTOS DUST.............................................................................................. 30 PRECAUTIONS FOR OPERATION....................................................................................................... 31 BEFORE STARTING ENGINE...................................................................................................... 31 CHECKS BEFORE STARTING ENGINE........................................................................................... 31 PRECAUTIONS WHEN STARTING............................................................................................... 31 PRECAUTIONS IN COLD AREAS............................................................................................... 32 OPERATION................................................................................................................... 33 CHECKS BEFORE OPERATION................................................................................................. 33 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE.................................................................... 33 PRECAUTIONS WHEN TRAVELING.............................................................................................. 34 TRAVELING ON SLOPES..................................................................................................... 35 PROHIBITED OPERATIONS................................................................................................... 35 USING BRAKES............................................................................................................ 35 OPERATE CAREFULLY ON SNOW............................................................................................... 35 PARKING MACHINE......................................................................................................... 36 TRANSPORTATION.............................................................................................................. 37 SHIPPING................................................................................................................ 37 BATTERY..................................................................................................................... 38 BATTERY HAZARD PREVENTION............................................................................................... 38 STARTING WITH BOOSTER CABLE............................................................................................. 39 TOWING...................................................................................................................... 40 WHEN TOWING............................................................................................................. 40 PRECAUTIONS FOR MAINTENANCE..................................................................................................... 41 WARNING TAG................................................................................................................. 41 KEEP WORK PLACE CLEAN AND TIDY.............................................................................................. 41 APPOINT LEADER WHEN WORKING WITH OTHERS..................................................................................... 41 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE ................................................................. 42 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.......................................................................... 43 PROPER TOOLS................................................................................................................ 43 PERSONNEL................................................................................................................... 43 ATTACHMENTS................................................................................................................. 44 WORK UNDER THE MACHINE...................................................................................................... 44 NOISE....................................................................................................................... 44 PRECAUTIONS WHEN USING HAMMER............................................................................................... 44 REPAIR WELDING.............................................................................................................. 44 REMOVING BATTERY TERMINAL................................................................................................... 45 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......................................................... 45 DO NOT DISASSEMBLE RECOIL SPRING............................................................................................ 45 PRECAUTION WITH HIGH-PRESSURE OIL........................................................................................... 45 HANDLING HIGH-PRESSURE HOSES................................................................................................ 46 WASTE MATERIAL.............................................................................................................. 46 MAINTENANCE FOR AIR CONDITIONER............................................................................................. 46 COMPRESSED AIR.............................................................................................................. 46 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................................................... 46 OPERATION........................................................................................................................... 47 GENERAL VIEW.................................................................................................................... 48 GENERAL VIEW OF MACHINE..................................................................................................... 48 GENERAL VIEW OF CONTROLS AND GAUGES......................................................................................... 49 EXPLANATION OF COMPONENTS....................................................................................................... 51 FRONT PANEL................................................................................................................. 51 SWITCH...................................................................................................................... 67 CONTROL LEVERS, PEDALS...................................................................................................... 71 CONTROLLER.................................................................................................................. 79 DUST INDICATOR.............................................................................................................. 80 POWER SOURSE................................................................................................................ 80 FUSE BOX.................................................................................................................... 81 DOOR OPEN LOCK.............................................................................................................. 83 SASH GLASS INTERMEDIATE LOCK................................................................................................ 84 DOOR POCKET................................................................................................................. 84 ASHTRAY..................................................................................................................... 84 TOOL BOX.................................................................................................................... 85 AIR CONDITIONER, HANDLING................................................................................................... 86 ACCUMULATOR, HANDLING....................................................................................................... 91 OPERATION....................................................................................................................... 92 CHECK BEFORE STARTING ENGINE, ADJUST........................................................................................ 92 STARTING ENGINE.............................................................................................................107 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................................111 STOPPING ENGINE.............................................................................................................113 CHECK AFTER STOPPING ENGINE.................................................................................................113 MOVING MACHINE OFF..........................................................................................................114 STOPPING MACHINE............................................................................................................116 SHIFTING GEAR...............................................................................................................117 SHIFTING BETWEEN FOEWARD AND REVERSE........................................................................................118 STEERING MACHINE............................................................................................................120 PRECAUTIONS FOR OPERATION...................................................................................................124 PARKING MACHINE.............................................................................................................126 CHECK AFTER FINISHING WORK..................................................................................................128 LOCKING.....................................................................................................................128 WORK POSSIBLE USING BULLDOZER...............................................................................................129 RIPPER OPERATION............................................................................................................131 ADJUSTING POSTURE OF WORK EQUIPMENT.........................................................................................134 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................................................................138 TRANSPORTATION..................................................................................................................140 TRANSPORTATION PROCEDURE....................................................................................................140 LOADING, UNLOADING WORK.....................................................................................................140 PRECAUTIONS FOR LOADING.....................................................................................................140 METHOD OF LIFTING MACHINE...................................................................................................141 PRECAUTIONS FOR TRANSPORTATION..............................................................................................142 REMOVAL OF CAB..............................................................................................................142 INSTALLATION OF CAB.........................................................................................................143 COLD WEATHER OPERATION..........................................................................................................144 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................................144 AFTER COMPLETION OF WORK....................................................................................................145 AFTER COLD WEATHER..........................................................................................................146 LONG-TERM STORAGE...............................................................................................................147 BEFORE STORAGE..............................................................................................................147 DURING STORAGE..............................................................................................................147 AFTER STORAGE...............................................................................................................147 TROUBLESHOOTING.................................................................................................................148 AFTER RUNNING OUT OF FUEL...................................................................................................148 METHOD OF TOWING MACHINE....................................................................................................148 IF BATTERY IS DISCHARGED....................................................................................................149 OTHER TROUBLE...............................................................................................................152 MAINTENANCE.........................................................................................................................157 GUIDES TO MAINTENANCE...........................................................................................................158 OUTLINES OF SERVICE.............................................................................................................161 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................................161 OUTLINE OF ELECTRIC SYSTEM..................................................................................................163 WEAR PARTS LIST.................................................................................................................164 WEAR PARTS LIST.............................................................................................................164 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............................................................165 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................................169 TORQUE LIST.................................................................................................................169 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................................170 SAFETY CRITICAL PARTS.......................................................................................................171 MAINTENANCE SCHEDULE CHART......................................................................................................172 MAINTENANCE SCHEDULE CHART..................................................................................................172 SERVICE PROCEDURE...............................................................................................................174 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..................................................................174 WHEN REQUIRED...............................................................................................................175 CLEAN INSIDE OF COOLING SYSTEM..........................................................................................175 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................................178 CHECK TRACK TENSION.....................................................................................................180 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................................................182 ADJUST IDLER CLEARANCE..................................................................................................183 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES......................................................................184 CHECK AND CLEAN RADIATOR FINS...........................................................................................185 CLEAN FUEL TANK STRAINER................................................................................................186 DRAIN WATER AND SEDIMENT IN FUEL TANK...................................................................................186 CLEAN STEERING CLUTCH CASE BREATHER.....................................................................................186 REPLACE AIE CONDITIONER BELT............................................................................................187 CLEAN, CHECK HYDRAULIC COOLER FINS......................................................................................187 CHECK UNDERCARRIAGE OIL.................................................................................................188 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..................................................................189 CHECK, ADJUST AIR CONDITIONER...........................................................................................190 LUBRICATE DOOR HINGE....................................................................................................191 CHECK DOOR LOCK STRIKER.................................................................................................191 REPLACE DOOR DAMPER.....................................................................................................191 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................................191 REPLACE WIPER BLADE.....................................................................................................192 CHECK ELECTRICAL INTAKE AIR HEATER......................................................................................193 LUBRICATING.............................................................................................................193 CHECK BEFORE STARTING.......................................................................................................195 EVERY 250 HOURS SERVICE.....................................................................................................196 LUBRICATING.............................................................................................................196 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.............................................................................198 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................................199 CHECK BRAKE PERFORMANCE.................................................................................................200 EVERY 500 HOURS SERVICE.....................................................................................................201 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS FILTER CARTRIDGE...........................201 REPLACE FUEL FILTER CARTRIDGE...........................................................................................202 REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT....203 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................................................204 CHECK REPLACE FAN BELT..................................................................................................204 EVERY 1000 HOURS SERVICE....................................................................................................205 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)....205 CHECK, CLEAN FUEL STRAINER..............................................................................................207 LUBRICATE TENSION PULLEY ASSEMBLY.......................................................................................207 CHECK FOR LOOSE ROPS MOUNT BOLTS........................................................................................207 REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE..........................................208 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT AND HYDRAULIC TANK BREATHER ELEMENT..................209 CHECK TIGHTENING PARTS OF TURBOCHARGER..................................................................................209 EVERY 2000 HOURS SERVICE....................................................................................................210 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT......................................................210 CHANGE OIL IN FINAL DRIVE CASE..........................................................................................211 CHANGE OIL IN DAMPER CASE...............................................................................................212 CHECK PIVOT BEARING OIL LEVEL, ADD OIL..................................................................................213 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL.........................................................213 CLEAN ENGINE BREATHER ELEMENT...........................................................................................214 CHECK ALTERNATOR,STARTING MOTOR.........................................................................................214 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................................................................214 EVERY 4000 HOURS SERVICE....................................................................................................215 CHECK WATER PUMP........................................................................................................215 CHECK VIBRATION DAMPER..................................................................................................215 CHECK FAN PULLEY AND TENSION PULLEY.....................................................................................215 CLEAN, CHECK TURBOCHARGER...............................................................................................215 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................................215 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)........................................................................216 SPECIFICATIONS......................................................................................................................217 SPECIFICATIONS..................................................................................................................218 ATTACHMENTS, OPTIONS................................................................................................................219 GENERAL PRECAURIONS.............................................................................................................220 PRECAUTIONS RELATED TO SAFETY...............................................................................................220 USING SEAT BELT.................................................................................................................221 HANDLING SEAT BELT..........................................................................................................221 SELECTION OF TRACK SHOE.........................................................................................................222 SELECTION OF TRACK SHOES....................................................................................................222 PROCEDURE FOR SELECTING RIPPER POINT............................................................................................223 PROCEDURE FOR SELECTING RIPPER POINT........................................................................................223 CAP WITH LOCK, HANDLING.........................................................................................................224 METHOD OF OPENING AND CLOSING CAP WITH LOCK.................................................................................224 EFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER................................................................................225 BLADE CONDITION.............................................................................................................225 DOZING WORK.................................................................................................................228 LEVELING (SPREADING) OPERATION..............................................................................................231 DITCHING OPERATION..........................................................................................................231 BOULDER RAISING OPERATION...................................................................................................231 SIDE-CUTTING OPERATIONS.....................................................................................................232 HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND).................................................................232 SHOE SLIP CONTROL...............................................................................................................233 MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL).............................................................................233 EFECTIVE USE OF MODE SELECTION SYSTEM.......................................................................................236 IF MODE SELECTION SYSTEM FLASHES............................................................................................240 INDEX...............................................................................................................................241
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