Komatsu D475A-3 Manual

SEAM046800T
Operation & Maintenance
Operation & MaintenanceOperation & Maintenance
Operation & Maintenance
Manual
ManualManual
Manual
D475A
-3
BULLDOZER
With Palm Command Control System
SERIAL NUMBERS D475A -10695 and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is out policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on
products sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It
is recommended that customers contact their distributor for information on the latest revision.
Copyright 2002 Komatsu
DataKom Publishing Division
March 2002

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FOREWORD
FOREWORD
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 for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing
operation and maintenance.
WARNING
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
at
the
storage
location
for
the
Operation
and
aintenance
anual
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.
Komatsu
delivers
machines
that
comply
with
all
applicable
regulations
and
standards
of
the
country
to
which
it
has
been
shipped.
If
this
machine
has
been
purchased
in
another
country
or
purchased
from
someone
in
another
country,
it
may
lack
certain
safety
devices
and
specifications
that
are
necessary
for
use
in
your
country.
If
there
is
any
question
about
whether
your
product
complies
with
the
applicable
standards
and
regulations
of
your
country,
consult
Komatsu
or
your
Komatsu
distributor
before
operating
the
machine.
Location to Keep Operation Maintenance Manual
In Door Pocket Inside of Cab Door
1 - 2

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FOREWORD
FOREWORD
1 - 3

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FOREWORD
FOREWORD
1 - 4

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FOREWORD
SAFETY INFOR ATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal
words
The following signal words are used to inform you that there is apotential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates apotentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates apotentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example
of
safety
message
using
signal
word
WARNING
When
standing
up
from
the
operator's
seat,
always
place
the
safety
lock
lever
in
the
LOCK
position.
If
you
accidentally
touch
the
control
levers
when
they
are
not
locked,
this
may
cause
a
serious
injury
or
death.
Other
signal
words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD
SAFETY INFOR ATION
Safety
labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example
of
safety
label
using
words
Safety
labels
using
pictogram
Safety pictograms use apicture to express alevel of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous condition
is displayed inside atriangle and the method of avoiding the
hazardous condition is shown inside acircle.
Komatsu cannot predict every circumstance that might involve apotential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( )in the text. (For example: j -> (1))
1 - 6

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FOREWORD
INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Dozing
Cutting into hard or frozen ground or ditching
Felling trees, removing stumps
Pushing
Ripping
For further details, see "WORK POSSIBLE USING BULLDOZER (PAGE 3-111)" and "RIPPER OPERATION
(PAGE 3-118)".
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's cab when
the operator's cab is facing the front and the sprocket is at the rear of the machine.
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FOREWORD
NECESSARY INFOR ATION
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NO. PLATE AND POSITION
Under the front of the console box on the right side of the operator's seat.
ENGINE SERIAL NO. PLATE AND POSITION
On the upper left side of the engine cylinder block, when seen from the fan.
The EPA nameplate and engine number plate are combined into one plate.
EPA: Environmental Protection Agency, U.S.A.
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FOREWORD
NECESSARY INFOR ATION
BLADE SERIAL NO. PLATE POSITION
This is located at the upper right of blade back surface.
RIPPER SERIAL NO. PLATE POSITION
This is located at the left side surface of ripper beam.
POSITION OF SERVICE METER
On top of the machine monitor
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FOREWORD
NECESSARY INFOR ATION
TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN
Machine serial No.
Engine serial No.
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD
CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTRODUCTION 1- 7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 7
NECESSARY INFORMATION 1- 8
MACHINE SERIAL NO. PLATE AND POSITION 1- 8
ENGINE SERIAL NO. PLATE AND POSITION 1- 8
BLADE SERIAL NO. PLATE POSITION 1- 9
RIPPER SERIAL NO. PLATE POSITION 1- 9
POSITION OF SERVICE METER 1- 9
TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN 1- 10
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 4
POSITIONS OF SAFETY PICTOGRAMS 2- 4
SAFETY LABELS 2- 5
GENERAL PRECAUTIONS 2- 9
PRECAUTIONS FOR OPERATION 2- 17
BEFORE STARTING ENGINE 2- 17
OPERATION 2- 19
TRANSPORTATION 2- 23
BATTERY 2- 24
TOWING 2- 26
PRECAUTIONS FOR MAINTENENCE 2- 27
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 5
FRONT PANEL 3- 5
SWITCH 3- 35
CONTROL LEVERS, PEDALS 3- 39
DUST INDICATOR 3- 48
POWER SOURSE 3- 48
FUSE BOX 3- 49
FUSIBLE LINK 3- 52
DOOR OPEN LOCK 3- 53
SASH GLASS INTERMEDIATE LOCK 3- 53
DOOR POCKET 3- 54
ASHTRAY 3- 54
TOOL BOX 3- 54
CAR STEREO, HANDLING 3- 55
AIR CONDITIONER, HANDLING 3- 63
ACCUMULATOR, HANDLING 3- 68
OPERATION 3- 69
CHECK BEFORE STARTING ENGINE, ADJUST 3- 69
STARTING ENGINE 3- 87
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3- 91
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FOREWORD
CONTENTS
STOPPING ENGINE 3- 94
CHECK AFTER STOPPING ENGINE 3- 94
MOVING MACHINE OFF 3- 95
STOPPING MACHINE 3- 97
SHIFTING GEAR 3- 98
SHIFTING BETWEEN FOEWARD AND REVERSE 3-101
STEERING MACHINE 3-103
PRECAUTIONS FOR OPERATION 3-106
PARKING MACHINE 3-108
CHECK AFTER FINISHING WORK 3-110
LOCKING 3-110
WORK POSSIBLE USING BULLDOZER 3-111
EFECTIVE USE OF MODE SELECTION SYSTEM 3-113
RIPPER OPERATION 3-118
OPERATING METHOD FOR RIPPING OPERATIONS 3-121
ADJUSTING POSTURE OF WORK EQUIPMENT 3-125
TIPS FOR LONGER UNDERCARRIAGE LIFE 3-129
TRANSPORTATION 3-131
TRANSPORTATION PROCEDURE 3-131
LOADING, UNLOADING WORK 3-131
PRECAUTIONS FOR LOADING 3-131
METHOD OF LIFTING MACHINE 3-132
PRECAUTIONS FOR TRANSPORTATION 3-133
TRAVELING ON ROADS 3-133
REMOVAL OF CAB 3-133
INSTALLATION OF CAB 3-134
COLD WEATHER OPERATION 3-135
PRECAUTIONS FOR LOW TEMPERATURE 3-135
AFTER COMPLETION OF WORK 3-136
AFTER COLD WEATHER 3-137
LONG-TERM STORAGE 3-138
BEFORE STORAGE 3-138
DURING STORAGE 3-138
AFTER STORAGE 3-138
TROUBLESHOOTING 3-139
AFTER RUNNING OUT OF FUEL 3-139
METHOD OF TOWING MACHINE 3-139
IF BATTERY IS DISCHARGED 3-140
OTHER TROUBLE 3-143
WHEN MODE SELECTION SYSTEM FLASHES 3-148
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 5
OUTLINE OF ELECTRIC SYSTEM 4- 8
WEAR PARTS LIST 4- 9
WEAR PARTS LIST 4- 9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS 4- 10
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 14
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FOREWORD
CONTENTS
TORQUE LIST 4- 14
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 15
SAFETY CRITICAL PARTS 4- 16
MAINTENANCE SCHEDULE CHART 4- 17
MAINTENANCE SCHEDULE CHART 4- 17
SERVICE PROCEDURE 4- 19
INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS) 4- 19
WHEN REQUIRED 4- 20
CHECK BEFORE STARTING 4- 44
EVERY 250 HOURS SERVICE 4- 45
EVERY 500 HOURS SERVICE 4- 52
EVERY 1000 HOURS SERVICE 4- 57
EVERY 2000 HOURS SERVICE 4- 62
EVERY 4000 HOURS SERVICE 4- 67
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAURIONS 6- 2
PRECAUTIONS RELATED TO SAFETY 6- 2
SELECTION OF TRACK SHOE 6- 3
SELECTION OF TRACK SHOES 6- 3
PROCEDURE FOR SELECTING RIPPER POINT 6- 4
PROCEDURE FOR SELECTING RIPPER POINT 6- 4
CAP WITH LOCK, HANDLING 6- 5
METHOD OF OPENING AND CLOSING CAP WITH LOCK 6- 5
EFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER 6- 6
BLADE CONDITION 6- 6
DOZING WORK 6- 8
LEVELING (SPREADING) OPERATION 6- 11
DITCHING OPERATION 6- 11
BOULDER RAISING OPERATION 6- 11
SIDE-CUTTING OPERATIONS 6- 12
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND) 6- 12
SHOE SLIP CONTROL 6- 13
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL) 6- 13
EFECTIVE USE OF MODE SELECTION SYSTEM 6- 15
IF MODE SELECTION SYSTEM FLASHES 6- 21
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
Safety Labels 2- 4
Positions of Safety Pictograms 2- 4
Safety Labels 2- 5
General Precautions
Safety Rules 2- 9
If Abnormalities Are Found 2- 9
Clothing and Personal Protective Items 2- 9
Fire Extinguisher and First Aid Kit 2- 9
Fafety Features 2- 9
Keep Machine Clean 2- 10
Inside Operator's Compartment 2- 10
Always Apply Lock When Leaving Operator's Seat 2- 10
Handrails and Steps 2- 11
Mounting and Dismounting 2- 11
No People on Attachments 2- 11
Prevention of Burns 2- 12
Fire Prevention 2- 12
Action If Fire Occurs 2- 13
Window Washer Liquid 2- 13
Pecautions for ROPS 2- 13
Precautions for Attachments 2- 14
Cab Window Glasses 2- 14
Unauthorized Modification 2- 14
Safety at Worksite 2- 14
Working on Loose Ground 2- 14
Do Not Go Close to High-Voltage Cables 2- 15
Ensure Good Visivility 2- 15
Ventilation for Enclosed Areas 2- 15
Checking Signalman's Signals and Signs 2- 16
Be Careful About Asbestos Dust 2- 16
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SAFETY
SAFETY
Precautions for Operation 2- 17
Before Starting Engine 2- 17
Checks Before Starting Engine 2- 17
Precautions When Starting 2- 17
Precautions in Cold Areas 2- 18
Operation 2- 19
Checks Before Operation 2- 19
Precautions When Moving Machine Forward or in Reverse 2- 19
Precautions When Traveling 2- 20
Traveling on Slopes 2- 21
Prohibited Operations 2- 21
Useing Brakes 2- 21
Operate Carefully on Snow 2- 21
Parking Machine 2- 22
Transportation 2- 23
Shipping 2- 23
Battery 2- 24
Battery Hazard Prevention 2- 24
Starting with Booster Cable 2- 25
Towing 2- 26
When Towing 2- 26
Precautions for Maintenance 2- 27
Warning Tag 2- 27
Keep Work Place Clean and Tidy 2- 27
Appoint Leader When Working with Others 2- 27
Stop Engine Before Carrrying Out Inspection and Maintenance 2- 28
Two Workers for Maintenance when Engine is Running 2- 29
Proper Tools 2- 29
Handling Accumulator 2- 30
Personnel 2- 30
Attachments 2- 30
Work Under the Machine 2- 31
Noise 2- 31
Precautions When Using Hammer 2- 31
Repair Welding 2- 31
Removing Battery Terminal 2- 31
Precautions When Using High-Pressure Grease to Adjust Track Tension 2- 32
Do Not Disassemble Recoil Spring 2- 32
Precaution with High-Pressure Oil 2- 32
Handing High-Pressure Hoses 2- 33
Waste Material 2- 33
Maintenance for Air Conditioner 2- 33
Compressed Air 2- 33
Periodic Replacement of Safety Critical Parts 2- 34
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following warning signes and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signes and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
POSITIONS OF SAFETY PICTOGRAMS
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SAFETY
SAFETY LABELS
SAFETY LABELS
(1) Precautions for operation, inspection and
maintenance (09651-03001)
(2) Precautions when traveling in reverse
(09802-13000)
(3) Precautions for leaving operator's seat
(09654-33001)
(4) Precautions for high-temperature cooling water
(09668-03001)
2 - 5