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KOMATSU D475A-5 SUPERDOZER OPERATION & MAINTENANCE MANUAL (SN:20001 & UP) KOMATSU D475A-5 – PDF DOWNLOAD
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- KOMATSU D475A-5 SUPERDOZER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:20001 & UP
- PUBLICATION NUMBER:TEN00094-03
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KOMATSU D475A-5 SUPERDOZER OPERATION & MAINTENANCE MANUAL (SN:20001 & UP) KOMATSU D475A-5
KOMATSU D475A-5 SUPERDOZER OPERATION & MAINTENANCE MANUAL (SN:20001 & UP) KOMATSU D475A-5 – PDF DOWNLOAD:
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KOMATSU D475A-5 SUPERDOZER OPERATION & MAINTENANCE MANUAL (SN:20001 & UP) KOMATSU D475A-5
- 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 for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
- Operators and maintenance personnel must always do as follows before beginning operation or maintenance. Always be sure to read and understand this manual thoroughly before performing operation and maintenance. Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully.
- Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners together with the machine.
TABLE OF CONTENTS:
KOMATSU D475A-5 SUPERDOZER OPERATION & MAINTENANCE MANUAL (SN:20001 & UP) KOMATSU D475A-5
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 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.............................................................................................................. 96 POWER SOURCE................................................................................................................ 96 FUSE BOX.................................................................................................................... 97 DOOR OPEN LOCK..............................................................................................................101 SASH GLASS INTERMEDIATE LOCK................................................................................................101 DOOR POCKET.................................................................................................................102 ASHTRAY.....................................................................................................................102 TOOL BOX....................................................................................................................102 CLEAN INTERIOR OF CAB.......................................................................................................102 CAR STEREO, HANDLING........................................................................................................103 AIR CONDITIONER, HANDLING...................................................................................................112 ACCUMULATOR, HANDLING.......................................................................................................129 HANDLING MACHINES EQUIPPED WITH VHMS........................................................................................130 OPERATION.......................................................................................................................132 CHECK BEFORE STARTING ENGINE, ADJUST........................................................................................132 STARTING ENGINE.............................................................................................................153 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................................161 STOPPING ENGINE.............................................................................................................164 CHECK AFTER STOPPING ENGINE.................................................................................................164 MOVING MACHINE..............................................................................................................165 STOPPING MACHINE............................................................................................................167 SHIFTING GEAR...............................................................................................................168 SHIFTING BETWEEN FORWARD AND REVERSE........................................................................................174 STEERING MACHINE............................................................................................................176 PRECAUTIONS FOR OPERATION...................................................................................................180 PARKING MACHINE.............................................................................................................182 CHECK AFTER FINISHING WORK..................................................................................................184 LOCKING.....................................................................................................................184 PROHIBITED WORK OF SUPER DOZER..............................................................................................185 EFFECTIVE USE OF SUPER DOZER................................................................................................187 EFFECTIVE USE OF MODE SELECTION SYSTEM......................................................................................190 ADJUSTING POSTURE OF WORK EQUIPMENT.........................................................................................195 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................................................................196 TRANSPORTATION..................................................................................................................198 TRANSPORTATION PROCEDURE....................................................................................................198 LOADING, UNLOADING WORK.....................................................................................................198 METHOD OF LIFTING MACHINE...................................................................................................201 PRECAUTIONS FOR TRANSPORTATION..............................................................................................202 TRAVELING ON ROADS..........................................................................................................202 REMOVAL OF CAB..............................................................................................................203 INSTALLATION OF CAB.........................................................................................................206 INSTALLATION OF ROPS........................................................................................................207 COLD WEATHER OPERATION..........................................................................................................208 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................................208 AFTER COMPLETION OF WORK....................................................................................................210 AFTER COLD WEATHER..........................................................................................................210 LONG-TERM STORAGE...............................................................................................................211 BEFORE STORAGE..............................................................................................................211 DURING STORAGE..............................................................................................................211 AFTER STORAGE...............................................................................................................211 STARTING MACHINE AFTER LONG-TERM STORAGE....................................................................................211 TROUBLESHOOTING.................................................................................................................212 AFTER RUNNING OUT OF FUEL...................................................................................................212 METHOD OF TOWING MACHINE....................................................................................................214 IF BATTERY IS DISCHARGED....................................................................................................215 OTHER TROUBLE...............................................................................................................219 WHEN MODE SELECTION SYSTEM FLASHES..........................................................................................223 MAINTENANCE.........................................................................................................................224 GUIDES TO MAINTENANCE...........................................................................................................225 OUTLINES OF SERVICE.............................................................................................................228 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................................228 OUTLINE OF ELECTRIC SYSTEM..................................................................................................231 HANDLING HYDRAULIC RELATED EQUIPMENT........................................................................................232 WEAR PARTS......................................................................................................................233 WEAR PARTS LIST.............................................................................................................233 RECOMMENDED FUEL, COOLANT, AND LUBRICANT........................................................................................234 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.........................................236 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................................237 TORQUE LIST.................................................................................................................237 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................................238 SAFETY CRITICAL PARTS.......................................................................................................239 MAINTENANCE SCHEDULE CHART......................................................................................................241 MAINTENANCE SCHEDULE CHART..................................................................................................241 SERVICE PROCEDURE...............................................................................................................243 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..................................................................243 WHEN REQUIRED...............................................................................................................244 CLEAN INSIDE OF COOLING SYSTEM..........................................................................................244 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................................248 CHECK AND ADJUST TRACK TENSION..........................................................................................250 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................................................253 ADJUST IDLER CLEARANCE..................................................................................................254 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES......................................................................255 CLEAN AND CHECK RADIATOR FINS...........................................................................................257 CLEAN FUEL TANK STRAINER................................................................................................258 DRAIN WATER AND SEDIMENT IN FUEL TANK...................................................................................258 CLEAN STEERING CLUTCH CASE BREATHER.....................................................................................258 CHECK UNDERCARRIAGE OIL.................................................................................................259 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..................................................................260 REPLACE AIR CONDITIONER BELT............................................................................................260 CLEAN AND CHECK HYDRAULIC COOLER FINS...................................................................................260 CHECK AND ADJUST AIR CONDITIONER........................................................................................261 LUBRICATE DOOR HINGE....................................................................................................262 CHECK DOOR LATCH........................................................................................................262 CHECK DOOR LOCK STRIKER.................................................................................................263 REPLACE DOOR DAMPER.....................................................................................................263 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................................263 REPLACE WIPER BLADE.....................................................................................................264 BLEEDING AIR IN HYDRAULIC SYSTEM........................................................................................265 CHECK ELECTRICAL INTAKE AIR HEATER......................................................................................265 LUBRICATING.............................................................................................................265 CHECK BEFORE STARTING.......................................................................................................268 EVERY 250 HOURS SERVICE.....................................................................................................269 LUBRICATING.............................................................................................................269 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.............................................................................271 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................................272 CHECK BRAKE PERFORMANCE.................................................................................................275 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.................................................................................276 EVERY 500 HOURS SERVICE.....................................................................................................277 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......................................................277 REPLACE FUEL FILTER CARTRIDGE...........................................................................................278 REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT....280 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................................................281 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................................................................281 EVERY 1000 HOURS SERVICE....................................................................................................282 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)....282 CHECK, CLEAN FUEL STRAINER..............................................................................................284 CHECK FOR LOOSE ROPS MOUNT BOLTS........................................................................................284 REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE..........................................284 REPLACE AIR CONDITIONER AIR FILTER (FRESH, RECIRC FILTER)...............................................................285 CHECK TIGHTENING PARTS OF TURBOCHARGER..................................................................................285 EVERY 2000 HOURS SERVICE....................................................................................................286 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER.......................286 CHANGE OIL IN FINAL DRIVE CASE..........................................................................................288 CHANGE OIL IN DAMPER CASE AND BREATHER FILTER, CLEAN DAMPER BREATHER....................................................289 CHECK PIVOT BEARING OIL LEVEL, ADD OIL..................................................................................290 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL.........................................................290 CLEAN ENGINE BREATHER ELEMENT...........................................................................................291 CHECK ALTERNATOR, STARTING MOTOR........................................................................................291 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................................................................291 EVERY 4000 HOURS SERVICE....................................................................................................292 CHECK WATER PUMP........................................................................................................292 CHECK VIBRATION DAMPER..................................................................................................292 CLEAN, CHECK TURBOCHARGER...............................................................................................292 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................................292 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE)................................................................................293 SPECIFICATIONS......................................................................................................................294 SPECIFICATIONS..................................................................................................................295 ATTACHMENTS, OPTIONS................................................................................................................296 GENERAL PRECAUTIONS.............................................................................................................297 PRECAUTIONS RELATED TO SAFETY...............................................................................................297 SELECTION OF TRACK SHOE.........................................................................................................298 SELECTION OF TRACK SHOES....................................................................................................298 CAP WITH LOCK, HANDLING.........................................................................................................299 METHOD OF OPENING AND CLOSING CAP WITH LOCK.................................................................................299 INDEX...............................................................................................................................300
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