Komatsu D475A-5E0 Manual

BULLDOZER
PEN00537-05
D475A
-5E0
SERIAL NUMBERS
30134
and up
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
NOTICE
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
WARNING

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FOREWORD
READ THIS MANUAL
READ THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety
rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you
or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance
of the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the
location shown on the right so that all relevant personnel can read
it at any time.
Location to keep operation & maintenance manual
In door pocket inside of cab door
If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details
regarding the machine serial No. you will need to provide your Komatsu distributor, see "TABLE TO ENTER SERIAL
NO. AND DISTRIBUTOR (PAGE 1-8)".
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have
been used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For example: →(1))
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, 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.
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use the machine safely, and to prevent injury or death to operators, service personnel or
bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be followed.
To identify important safety messages in the manual and on the machine labels, the following signal words are used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
This signal word indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
This signal word indicates a potentially hazardous situation exists which, if not avoided,
may result in minor or moderate injury.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
This precaution is given where the machine may be damaged or the service life reduced if
the precaution is not followed.
This word is used for information that is useful to know.
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FOREWORD
INTRODUCTION
INTRODUCTION
USE OF MACHINE
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 3-144)" and "RIPPER OPERATION
(PAGE 3-151)".
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
(1)
(A)
(B)
Operator's seat
Front
Rear
(C)
(D)
Left
Right
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when
the operator's seat is facing the front.
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FOREWORD INTRODUCTION
VISIBILITY FROM OPERATOR'S SEAT
The visibility standards (ISO 5006) for this machine require a view shown in the following figure.
PROXIMITY VISIBILITY
The visibility of this machine in the area 1 m (3 ft 3 in) from the outside surface of the machine at a height of 1.5 m
(4 ft 11 in) is shown in the following figure. The hatched area (A) shows the area where the view is blocked by part
of the machine when mirrors or other aids to visibility are installed as standard. Be fully aware that there are places
that cannot be seen when operating the machine.
12M CIRCUMFERENCE VISIBILITY
The visibility at a radius of 12 m (39 ft 4 in) from the machine is as shown in the diagram below. The hatched areas
(B) show the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Be
fully aware that there are places that cannot be seen when operating the machine.
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FOREWORD
NECESSARY INFORMATION
NECESSARY INFORMATION
When requesting service or ordering replacement parts, contact your Komatsu distributor of the following items.
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE
This is inside the console box on the left side of the operator's seat.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NUMBER PLATE
The normal nameplate is on the common rail cover at the bottom of the fuel prefilter on the left side of the engine.
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FOREWORD NECESSARY INFORMATION
BLADE SERIAL NO. PLATE POSITION
This is located on the upper right of blade back surface.
RIPPER SERIAL NO. PLATE POSITION
This is located on the left side surface of ripper beam.
POSITION OF SERVICE METER
On top of the machine monitor
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FOREWORD
NECESSARY INFORMATION
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD CONTENTS
CONTENTS
FOREWORD 1- 1
READ THIS MANUAL 1- 2
SAFETY INFORMATION 1- 3
INTRODUCTION 1- 4
USE OF MACHINE 1- 4
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 4
VISIBILITY FROM OPERATOR'S SEAT 1- 5
NECESSARY INFORMATION 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE 1- 6
ENGINE SERIAL NUMBER PLATE 1- 6
BLADE SERIAL NO. PLATE POSITION 1- 7
RIPPER SERIAL NO. PLATE POSITION 1- 7
POSITION OF SERVICE METER 1- 7
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 8
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
POSITIONS OF SAFETY PICTOGRAMS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 11
PRECAUTIONS BEFORE STARTING OPERATION 2- 11
PREPARATIONS FOR SAFE OPERATION 2- 11
FIRE PREVENTION 2- 13
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 14
DO NOT GET CAUGHT IN WORK EQUIPMENT 2- 16
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 16
UNAUTHORIZED MODIFICATION 2- 16
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 16
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 17
PRECAUTIONS FOR OPERATION 2- 18
PRECAUTIONS FOR JOBSITE 2- 18
STARTING ENGINE 2- 20
OPERATION 2- 23
TRANSPORTATION 2- 27
TOWING 2- 28
PRECAUTIONS FOR MAINTENANCE 2- 29
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 29
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 34
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
SWITCHES 3- 35
CONTROL LEVERS, PEDALS 3- 40
DUST INDICATOR 3- 49
POWER SOURCE 3- 49
FUSE BOX 3- 50
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FOREWORD
CONTENTS
DOOR OPEN LOCK 3- 54
SASH GLASS INTERMEDIATE LOCK 3- 54
CAP WITH LOCK 3- 55
DOOR POCKET 3- 56
ASHTRAY 3- 57
TOOL BOX 3- 57
CLEAN INTERIOR OF CAB 3- 57
CAR STEREO, HANDLING 3- 58
AIR CONDITIONER, HANDLING 3- 67
BATTERY DISCONNECT SWITCH 3- 84
OPERATION 3- 85
CHECK BEFORE STARTING ENGINE, ADJUST 3- 85
STARTING ENGINE 3-114
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-122
STOPPING ENGINE 3-125
MOVING MACHINE 3-126
STOPPING MACHINE 3-128
SHIFTING GEAR 3-129
SHIFTING BETWEEN FORWARD AND REVERSE 3-134
STEERING MACHINE 3-136
PRECAUTIONS FOR OPERATION 3-138
PARKING MACHINE 3-141
CHECK AFTER STOPPING ENGINE 3-142
CHECK AFTER FINISHING WORK 3-143
LOCKING 3-143
WORK POSSIBLE USING BULLDOZER 3-144
EFFECTIVE USE OF MODE SELECTION SYSTEM 3-146
RIPPER OPERATION 3-151
OPERATING METHOD FOR RIPPING OPERATIONS 3-154
ADJUSTING POSTURE OF WORK EQUIPMENT 3-159
TIPS FOR LONGER UNDERCARRIAGE LIFE 3-162
TRANSPORTATION 3-164
TRANSPORTATION PROCEDURE 3-164
LOADING, UNLOADING WORK 3-164
METHOD OF LIFTING MACHINE 3-167
TRAVELING ON ROADS 3-168
REMOVAL OF CAB 3-169
INSTALLATION OF CAB 3-172
INSTALLATION OF ROPS 3-173
COLD WEATHER OPERATION 3-174
PRECAUTIONS FOR LOW TEMPERATURE 3-174
AFTER COMPLETION OF WORK 3-176
AFTER COLD WEATHER 3-176
LONG-TERM STORAGE 3-177
BEFORE STORAGE 3-177
DURING STORAGE 3-177
AFTER STORAGE 3-177
STARTING MACHINE AFTER LONG-TERM STORAGE 3-177
TROUBLESHOOTING 3-178
AFTER RUNNING OUT OF FUEL 3-178
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FOREWORD CONTENTS
METHOD OF TOWING MACHINE 3-178
IF BATTERY IS DISCHARGED 3-180
OTHER TROUBLE 3-184
WHEN MODE SELECTION SYSTEM FLASHES 3-189
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- 9
HANDLING HYDRAULIC RELATED EQUIPMENT 4- 9
WEAR PARTS 4- 10
WEAR PARTS LIST 4- 10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 12
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 14
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 15
TORQUE LIST 4- 15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 16
SAFETY CRITICAL PARTS 4- 17
MAINTENANCE SCHEDULE CHART 4- 19
MAINTENANCE SCHEDULE CHART 4- 19
SERVICE PROCEDURE 4- 21
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 21
WHEN REQUIRED 4- 22
CHECK BEFORE STARTING 4- 59
EVERY 250 HOURS SERVICE 4- 60
EVERY 500 HOURS SERVICE 4- 68
EVERY 1000 HOURS SERVICE 4- 74
EVERY 2000 HOURS SERVICE 4- 81
EVERY 4000 HOURS SERVICE 4- 90
EVERY 8000 HOURS SERVICE 4- 94
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAUTIONS 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
STARTING IN COLD AREAS 6- 5
EXTERNAL POWER SOURCE TYPE PREHEATER 6- 5
EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER 6- 13
BLADE CONDITION 6- 13
DOZING WORK 6- 15
LEVELING (SPREADING) OPERATION 6- 17
DITCHING OPERATION 6- 17
BOULDER RAISING OPERATION 6- 17
SIDE-CUTTING OPERATIONS 6- 18
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND) 6- 18
SHOE SLIP CONTROL 6- 19
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FOREWORD
CONTENTS
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL) 6- 19
EFFECTIVE USE OF MODE SELECTION SYSTEM 6- 20
IF MODE SELECTION SYSTEM FLASHES 6- 27
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus 6- 28
KOMTRAX Plus INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED 6- 28
KOMTRAX Plus AND COMMUNICATIONS TERMINAL INSTALLED 6- 29
MINING SPECIFICATION MACHINE 6- 30
FRONT PANEL 6- 30
SWITCH 6- 31
FUSE BOX 6- 37
CIRCUIT BREAKER FOR MAIN POWER SUPPLY 6- 38
BATTERY ISOLATOR SWITCH, STARTING MOTOR ISOLATOR SWITCH 6- 39
TOOL BOX 6- 39
CAR STEREO, HANDLING 6- 40
OPERATIONS AND CHECKS BEFORE STARTING ENGINE 6- 41
STARTING WITH BOOSTER CABLES 6- 42
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) 6- 43
WEAR PARTS 6- 44
WHEN REQUIRED 6- 46
EVERY 250 HOURS SERVICE 6- 50
EVERY 500 HOURS SERVICE 6- 52
EVERY 1000 HOURS SERVICE 6- 54
EVERY 2000 HOURS SERVICE 6- 58
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
SAFETY LABEL 2- 5
POSITIONS OF SAFETY PICTOGRAMS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 11
PRECAUTIONS BEFORE STARTING OPERATION 2- 11
ENSURING SAFE OPERATION 2- 11
UNDERSTANDING THE MACHINE 2- 11
PREPARATIONS FOR SAFE OPERATION 2- 11
PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 11
INSPECTING MACHINE 2- 11
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2- 11
KEEP MACHINE CLEAN 2- 12
PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT 2- 12
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2- 12
IF ANY PROBLEM IS FOUND 2- 12
FIRE PREVENTION 2- 13
ACTION IF FIRE OCCURS 2- 13
PRECAUTIONS TO PREVENT FIRE 2- 13
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 14
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE 2- 14
NO JUMPING ON OR OFF MACHINE 2- 15
NO PEOPLE ON ATTACHMENTS 2- 15
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT 2- 15
PRECAUTIONS WHEN LEAVING MACHINE 2- 15
EMERGENCY EXIT FROM OPERATOR'S CAB 2- 15
DO NOT GET CAUGHT IN WORK EQUIPMENT 2- 16
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 16
UNAUTHORIZED MODIFICATION 2- 16
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 16
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 17
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SAFETY SAFETY
PRECAUTIONS FOR OPERATION 2- 18
PRECAUTIONS FOR JOBSITE 2- 18
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 18
WORKING ON LOOSE GROUND 2- 18
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 19
ENSURE GOOD VISIBILITY 2- 19
CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 20
BEWARE OF ASBESTOS DUST 2- 20
STARTING ENGINE 2- 20
USE WARNING TAGS 2- 20
INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE 2- 21
PRECAUTIONS WHEN STARTING ENGINE 2- 21
PRECAUTIONS IN COLD AREAS 2- 21
STARTING WITH BOOSTER CABLES 2- 22
OPERATION 2- 23
CHECKS BEFORE OPERATION 2- 23
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 23
PRECAUTIONS WHEN TRAVELING 2- 24
TRAVELING ON SLOPES 2- 24
PRECAUTIONS WHEN OPERATING 2- 25
PROHIBITED OPERATIONS 2- 25
METHOD OF USING BRAKES 2- 25
TRAVELING ON SNOW-COVERED OR FROZEN SURFACES 2- 25
PARKING MACHINE 2- 26
TRANSPORTATION 2- 27
LOADING AND UNLOADING 2- 27
TOWING 2- 28
PRECAUTIONS WHEN TOWING 2- 28
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SAFETY
SAFETY
PRECAUTIONS FOR MAINTENANCE 2- 29
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 29
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 29
KEEP WORKPLACE CLEAN AND TIDY 2- 29
SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 29
ONLY AUTHORIZED PERSONNE 2- 29
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 29
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 30
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 31
INSTALLING, REMOVING, OR STORING ATTACHMENTS 2- 31
PRECAUTIONS WHEN WORKING AT HIGH PLACES 2- 32
PRECAUTIONS WHEN WORKING ON TOP OF MACHINE 2- 32
PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT 2- 32
PROPER TOOLS 2- 33
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 34
PRECAUTIONS WHEN WELDING 2- 34
HANDLING BATTERY 2- 34
PRECAUTIONS WHEN USING HAMMER 2- 35
PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT 2- 35
PRECAUTIONS WITH HIGH-TEMPERATURE OIL 2- 35
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 36
PRECAUTIONS WITH HIGH-PRESSURE FUEL 2- 36
HANDLING HIGH-PRESSURE HOSES AND PIPING 2- 36
NOISE 2- 36
PRECAUTIONS WITH HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION 2- 37
DO NOT DISASSEMBLE RECOIL SPRING 2- 37
HANDLING ACCUMULATOR AND GAS SPRING 2- 38
PRECAUTIONS WITH COMPRESSED AIR 2- 38
MAINTENANCE OF AIR CONDITIONER 2- 38
DISPOSING OF WASTE MATERIALS 2- 38
MERCURY CONTAINING COMPONENT(S) 2- 38
METHOD OF SELECTING WINDOW WASHER FLUID 2- 38
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2- 39
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SAFETY SAFETY LABELS
SAFETY LABELS
The following warning signs 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.
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.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
POSITIONS OF SAFETY PICTOGRAMS
: if equipped
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SAFETY
SAFETY LABELS
SAFETY LABELS
(1) Caution before operating machine (09651-A0641)
(2) Caution before moving in reverse (09802-B0750)
(3) Caution for leaving operator's seat (09654-B0641)
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SAFETY SAFETY LABELS
SAFETY SAFETY LABELS
(4) Caution for hot water hazard (09653-A0481)
(5) Caution for hot oil hazard (09653-A0481)
(6) Caution for adjusting track tension (195-98-22931)
Safety label is attached to the back side of the
inspection cover of the track frame.
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