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Komatsu Superdozer D575A-3 Operation & Maintenance Manual SN 10101 and up – PDF DOWNLOAD
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Komatsu Superdozer D575A-3 Operation & Maintenance Manual
Book Code : TEN00237-01
SERIAL NUMBERS 10101 and up
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Description
Komatsu Superdozer D575A-3 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Superdozer D575A-3 Operation & Maintenance Manual
Size :6.47 MB
Format : PDF
Language : English
Number of Pages: 267 Pages
Brand: Komatsu
Type of machine: Superdozer
Type of document: Operation & Maintenance Manual
Model: D575A-3
Serial: 10101 and up
KOMATSU SUPERDOZER D575A-3 OPERATION & MAINTENANCE MANUAL SN 10101 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Superdozer D575A-3 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 Superdozer D575A-3 Operation & Maintenance Manual
COVER............................................................................................................................... 1 FOREWORD............................................................................................................................ 2 FOREWORD........................................................................................................................ 3 SAFETY INFORMATION.............................................................................................................. 6 INTRODUCTION.................................................................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................................................................................ 8 VISIBILITY FROM OPERATOR'S SEAT............................................................................................. 9 BREAKING IN THE MACHINE..................................................................................................... 10 NECESSARY INFORMATION........................................................................................................... 11 PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE............................................................... 11 ENGINE SERIAL NO. PLATE AND POSITION........................................................................................ 11 BLADE SERIAL NO. PLATE POSITION............................................................................................. 12 POSITION OF SERVICE METER................................................................................................... 12 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................................................... 13 CONTENTS............................................................................................................................ 14 SAFETY.............................................................................................................................. 18 SAFETY.......................................................................................................................... 19 SAFETY LABELS................................................................................................................... 21 POSITIONS OF SAFETY PICTOGRAMS.............................................................................................. 22 SAFETY LABELS............................................................................................................... 23 GENERAL PRECAUTIONS............................................................................................................. 27 SAFETY RULES................................................................................................................ 27 IF ABNORMALITIES ARE FOUND.................................................................................................. 27 CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................................................................... 27 FIRE EXTINGUISHER AND FIRST AID KIT......................................................................................... 27 SAFETY FEATURES............................................................................................................. 27 KEEP MACHINE CLEAN.......................................................................................................... 28 INSIDE OPERATOR'S COMPARTMENT............................................................................................... 28 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.............................................................................. 28 HANDRAILS AND STEPS......................................................................................................... 29 PRECAUTIONS WHEN WORKING IN HIGH PLACES..................................................................................... 29 MOUNTING AND DISMOUNTING.................................................................................................... 29 NO PEOPLE ON ATTACHMENTS.................................................................................................... 29 CRUSHING OR CUTTING PREVENTION.............................................................................................. 30 PREVENTION OF BURNS......................................................................................................... 30 FIRE PREVENTION............................................................................................................. 31 ACTION IF FIRE OCCURS....................................................................................................... 32 WINDOW WASHER LIQUID........................................................................................................ 32 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................................................................ 32 PRECAUTIONS FOR ATTACHMENTS................................................................................................. 32 CAB WINDOW GLASSES.......................................................................................................... 32 UNAUTHORIZED MODIFICATION................................................................................................... 32 SAFETY AT WORKSITE.......................................................................................................... 33 WORKING ON LOOSE GROUND..................................................................................................... 33 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...................................................................................... 34 ENSURE GOOD VISIBILITY...................................................................................................... 34 VENTILATION FOR ENCLOSED AREAS.............................................................................................. 35 CHECKING SIGNALMAN'S SIGNALS AND SIGNS...................................................................................... 35 BE CAREFUL ABOUT ASBESTOS DUST.............................................................................................. 35 PRECAUTIONS FOR OPERATION....................................................................................................... 36 BEFORE STARTING ENGINE...................................................................................................... 36 CHECKS BEFORE STARTING ENGINE........................................................................................... 36 PRECAUTIONS WHEN STARTING............................................................................................... 37 PRECAUTIONS IN COLD AREAS............................................................................................... 37 OPERATION................................................................................................................... 38 CHECKS BEFORE OPERATION................................................................................................. 38 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE.................................................................... 38 PRECAUTIONS WHEN TRAVELING.............................................................................................. 39 TRAVELING ON SLOPES..................................................................................................... 40 PROHIBITED OPERATIONS................................................................................................... 40 USING BRAKES............................................................................................................ 40 OPERATE CAREFULLY ON SNOW............................................................................................... 40 PARKING MACHINE......................................................................................................... 41 TRANSPORTATION.............................................................................................................. 42 LOADING AND UNLOADING................................................................................................... 42 SHIPPING................................................................................................................ 42 BATTERY..................................................................................................................... 43 BATTERY HAZARD PREVENTION............................................................................................... 43 STARTING WITH BOOSTER CABLE............................................................................................. 44 TOWING...................................................................................................................... 45 WHEN TOWING............................................................................................................. 45 PRECAUTIONS FOR MAINTENANCE..................................................................................................... 46 WARNING TAG................................................................................................................. 46 KEEP WORK PLACE CLEAN AND TIDY.............................................................................................. 46 APPOINT LEADER WHEN WORKING WITH OTHERS..................................................................................... 46 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.................................................................. 47 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.......................................................................... 48 PROPER TOOLS................................................................................................................ 48 HANDLING ACCUMULATOR........................................................................................................ 49 PERSONNEL................................................................................................................... 49 ATTACHMENTS................................................................................................................. 49 WORK UNDER THE MACHINE...................................................................................................... 49 NOISE....................................................................................................................... 50 PRECAUTIONS WHEN USING HAMMER............................................................................................... 50 REPAIR WELDING.............................................................................................................. 50 REMOVING BATTERY TERMINAL................................................................................................... 50 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......................................................... 50 DO NOT DISASSEMBLE RECOIL SPRING............................................................................................ 51 PRECAUTION WITH HIGH-PRESSURE OIL........................................................................................... 51 PRECAUTION FOR HIGH FUEL PRESSURE........................................................................................... 51 HANDLING HIGH-PRESSURE HOSES................................................................................................ 51 PRECAUTION FOR HIGH VOLTAGE................................................................................................. 52 WASTE MATERIAL.............................................................................................................. 52 MAINTENANCE FOR AIR CONDITIONER............................................................................................. 52 COMPRESSED AIR.............................................................................................................. 52 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................................................... 52 OPERATION........................................................................................................................... 54 GENERAL VIEW.................................................................................................................... 55 GENERAL VIEW OF MACHINE..................................................................................................... 55 GENERAL VIEW OF CONTROLS AND GAUGES......................................................................................... 56 EXPLANATION OF COMPONENTS....................................................................................................... 58 MONITOR PANEL............................................................................................................... 58 LAMPS....................................................................................................................... 75 SWITCHES.................................................................................................................... 77 CONTROL LEVERS, PEDALS...................................................................................................... 80 CONTROLLER.................................................................................................................. 85 DUST INDICATOR.............................................................................................................. 86 FUSE BOX.................................................................................................................... 87 FUSIBLE LINK................................................................................................................ 90 CAP WITH LOCK............................................................................................................... 91 DOOR OPEN LOCK.............................................................................................................. 92 SASH GLASS INTERMEDIATE LOCK................................................................................................ 92 NET POCKET.................................................................................................................. 93 ASHTRAY..................................................................................................................... 93 TOOL BOX.................................................................................................................... 93 ENGINE OIL FILLER CAP....................................................................................................... 94 CAR STEREO, HANDLING........................................................................................................ 95 AIR CONDITIONER, HANDLING...................................................................................................104 ACCUMULATOR, HANDLING.......................................................................................................111 OPERATION.......................................................................................................................113 CHECK BEFORE STARTING ENGINE, ADJUST........................................................................................113 STARTING ENGINE.............................................................................................................131 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................................135 STOPPING ENGINE.............................................................................................................137 MOVING MACHINE..............................................................................................................138 STOPPING MACHINE............................................................................................................140 SHIFTING GEAR...............................................................................................................141 SHIFTING BETWEEN FORWARD AND REVERSE........................................................................................145 STEERING MACHINE............................................................................................................147 PRECAUTIONS FOR OPERATION...................................................................................................150 PARKING MACHINE.............................................................................................................152 CHECK AFTER STOPPING ENGINE.................................................................................................154 CHECK AFTER FINISHING WORK..................................................................................................154 LOCKING.....................................................................................................................154 PROHIBITED WORK OF SUPER DOZER..............................................................................................155 EFFECTIVE USE OF SUPER DOZER................................................................................................157 EFFECTIVE USE OF MODE SELECTION SYSTEM......................................................................................160 ADJUSTING POSTURE OF WORK EQUIPMENT.........................................................................................165 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................................................................167 TRANSPORTATION..................................................................................................................169 TRANSPORTATION PROCEDURE....................................................................................................169 METHOD OF LIFTING MACHINE...................................................................................................169 TRAVELING ON ROADS..........................................................................................................170 COLD WEATHER OPERATION..........................................................................................................171 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................................171 AFTER COMPLETION OF WORK....................................................................................................173 AFTER COLD WEATHER..........................................................................................................173 LONG-TERM STORAGE...............................................................................................................174 BEFORE STORAGE..............................................................................................................174 DURING STORAGE..............................................................................................................174 AFTER STORAGE...............................................................................................................174 STARTING MACHINE AFTER LONG-TERM STORAGE....................................................................................174 TROUBLESHOOTING.................................................................................................................175 AFTER RUNNING OUT OF FUEL...................................................................................................175 METHOD OF TOWING MACHINE....................................................................................................175 IF BATTERY IS DISCHARGED....................................................................................................176 OTHER TROUBLE...............................................................................................................179 WHEN MODE SELECTION SYSTEM FLASHES..........................................................................................184 MAINTENANCE.........................................................................................................................186 GUIDES TO MAINTENANCE...........................................................................................................187 OUTLINES OF SERVICE.............................................................................................................190 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................................190 OUTLINE OF ELECTRIC SYSTEM..................................................................................................193 HANDLING HYDRAULIC RELATED EQUIPMENT........................................................................................194 WEAR PARTS......................................................................................................................195 WEAR PARTS LIST.............................................................................................................195 RECOMMENDED FUEL, COOLANT, AND LUBRICANT........................................................................................196 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.........................................198 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................................199 TORQUE LIST.................................................................................................................199 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................................200 SAFETY CRITICAL PARTS.......................................................................................................201 MAINTENANCE SCHEDULE CHART......................................................................................................202 MAINTENANCE SCHEDULE CHART..................................................................................................202 SERVICE PROCEDURE...............................................................................................................204 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..................................................................204 WHEN REQUIRED...............................................................................................................205 CLEAN INSIDE OF COOLING SYSTEM..........................................................................................205 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................................208 CHECK AND ADJUST TRACK TENSION..........................................................................................211 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................................................213 ADJUST IDLER CLEARANCE..................................................................................................216 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES......................................................................217 CHECK, REPLACE FAN BELT.................................................................................................218 CLEAN AND CHECK RADIATOR FINS...........................................................................................219 CLEAN FUEL TANK STRAINER................................................................................................219 CHECK ETHER SPRAY, REPLACE ETHER CYLINDER...............................................................................220 DRAIN WATER AND SEDIMENT IN FUEL TANK...................................................................................220 CHECK AND ADJUST AIR CONDITIONER........................................................................................221 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..................................................................222 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................................222 CLEAN STEERING CLUTCH CASE BREATHER.....................................................................................222 CHECK UNDERCARRIAGE OIL.................................................................................................223 LUBRICATE DOOR HINGE....................................................................................................224 REPLACE WIPER BLADE.....................................................................................................224 BLEEDING AIR IN HYDRAULIC SYSTEM........................................................................................225 LUBRICATING.............................................................................................................226 CHECK BEFORE STARTING.......................................................................................................227 EVERY 250 HOURS SERVICE.....................................................................................................228 LUBRICATING.............................................................................................................228 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.............................................................................230 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................................231 CHECK BRAKE PERFORMANCE.................................................................................................234 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..............................................................................235 EVERY 500 HOURS SERVICE.....................................................................................................236 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......................................................236 REPLACE FUEL FILTER CARTRIDGE...........................................................................................238 REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT....239 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................................................240 EVERY 1000 HOURS SERVICE....................................................................................................241 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS.........................................................................241 CHECK, CLEAN FUEL STRAINER..............................................................................................242 CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL.........................................................243 LUBRICATE UNIVERSAL JOINT...............................................................................................243 CHECK TIGHTENING PARTS OF TURBOCHARGER..................................................................................243 REPLACE CORROSION RESISTOR CARTRIDGE....................................................................................244 CHECK FOR LOOSE ROPS MOUNT BOLTS........................................................................................244 EVERY 2000 HOURS SERVICE....................................................................................................245 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT......................................................245 CHANGE OIL IN FINAL DRIVE CASE..........................................................................................247 CHANGE OIL IN DAMPER CASE, CLEAN DAMPER.................................................................................248 CLEAN PPC STRAINER......................................................................................................248 CHECK PIVOT BEARING OIL LEVEL, ADD OIL..................................................................................250 CLEAN ENGINE BREATHER ELEMENT...........................................................................................251 CHECK FOR LEAKAGE OF OIL FROM GEAR COUPLING.............................................................................251 CHECK ALTERNATOR, STARTING MOTOR........................................................................................251 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................................................................251 LUBRICATE FAN ROTATION SHAFT SPLINE.....................................................................................251 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................................................................252 EVERY 4000 HOURS SERVICE....................................................................................................253 CHECK WATER PUMP........................................................................................................253 CHECK VIBRATION DAMPER..................................................................................................253 CLEAN, CHECK TURBOCHARGER...............................................................................................253 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................................253 CHECK FAN PULLEY AND TENSION PULLEY.....................................................................................253 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE)................................................................................254 SPECIFICATIONS......................................................................................................................256 SPECIFICATIONS..................................................................................................................257 ATTACHMENTS, OPTIONS................................................................................................................258 GENERAL PRECAUTIONS.............................................................................................................259 PRECAUTIONS RELATED TO SAFETY...............................................................................................259 SELECTION OF TRACK SHOE.........................................................................................................260 SELECTION OF TRACK SHOES....................................................................................................260 HANDLING MACHINES EQUIPPED WITH VHMS............................................................................................261 VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED.......................................................................261 VHMS AND COMMUNICATIONS TERMINAL INSTALLED..................................................................................262 INDEX...............................................................................................................................264
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