Month: June 2025

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INSTANT DOWNLOAD

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Complete service repair manual for Komatsu/DEMAG Hydraulic Shovels, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

DEMAG Hydraulic Shovels workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

DEMAG Hydraulic Shovel Repair Manual (serial numbers DEMAG ALL).pdf
H285S78139OMM – DEMAG Komatsu Hydraulic Mining Shovels Parts & Service.pdf

Total Pages: 2,827 + 498 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
1. CYLINDER
2. HYDRAULIC PUMP
3. HYDRAULIC MOTOR
4. VALVES
5. PUMP DISTRIBUTOR GEAR & DRIVE SHAFT
6. SLEWING GEAR
7. TRAVEL GEAR
8. SLEW RING
9. ROTARY JOINT
10. BOTTOM ROLLER/TRACK ROLLER
11. TOP ROLLER
12. IDLER
13. SPROCKET
14. WELDING INSTRUCTIONS FOR STEEL STRUCTUREAL PARTS AND STEEL CASTINGS

DEMAG Hydraulic Shovel Repair Manual…2
COVER…2
CONTENTS…6
1. CYLINDER…8
1-1 CYLINDERS H 241…11
1. TABLE OF SERVICEABLE CYLINDER…12
2. TABLE OF DRAWINGS…13
3. CYLINDER FEATURES AND DATA…14
4. WORK AIDS…15
5. SEALING…28
6. WEAR AND TEAR LIMITS…40
7. TORQUING REQUIREMENTS…66
8. SPACE MEASUREMENT OF GUIDE RINGS…68
9. MEASURE TABLES REBUILDING OF CYLINDERS…72
10. DRAWINGS, ORIGINAL PARTS, PISTON AND FLANGE BUSHING…79
11. REBUILDING OF CYLINDER PISTON ROD BY GRINDING OFF AND CHROMIUM PLATING…111
1-2 CYLINDERS H 185…116
1. TABLE OF SERVICEABLE CYLINDERS…118
2. TABLE OF DRAWINGS…13
3. CYLINDER MARKINGS…14
4. WORK AIDS…120
5. SEALING…28
6. WEAR AND TEAR LIMIT…140
7. TORQUES…144
1-3 CYLINDERS H 121…148
1. TABLE OF SERVICEABLE CYLINDERS…150
2. TABLE OF DRAWINGS…13
3. CYLINDER MARKING…14
4. WORK AIDS…152
5. SEALING…28
6. WEAR AND TEAR LIMIT…163
7. TORQUES…167
1-4 CYLINDERS H 285…170
1. TABLE OF SERVICEABLE CYLINDERS…172
2. TABLE OF DRAWINGS…13
3. CYLINDER MARKING…14
4. WORK AIDS…174
5. SEALING…28
6. WEAR AND TEAR LIMITS…194
7. TORQUES…197
8. REWORK BY HONING…200
1-5 CYLINDER H485…202
1-5.1 CYLINDER H485/655 AND PC8000…203
1. TABLE OF SERVICEABLE CYLINDERS…205
2. CYLINDER WEIGHT…211
3. DESIGN, CUT VIEW…217
4. WORK AIDS…225
5. WEAR AND TEAR LIMITS…269
6. ASSEMBLY…307
7. TIGHTENING TORQUES…315
1-6 CYLINDERS H 185 S FROM SERIAL NO. 06078 – UP…321
1. TABLE OF SERVICEABLE CYLINDERS…322
2. DESIGN, CUT VIEW…323
3. WORK AIDS…327
4. WEAR AND TEAR LIMITS…348
5. ASSEMBLY…359
6. BOLT TIGHTENING TORQUES…361
1-6.1 CYLINDERS H 185 S…363
1. TABLE OF SERVICEABLE CYLINDERS…365
2. TABLE OF DRAWINGS…366
3. CYLINDER MARKING…371
4. WORK AIDS…373
5. WEAR AND TEAR LIMIT…397
6. TIGHTENING TORQUES FOR MOUNTING BOLTS…415
7. ASSEMBLY…417
1-7 CYLINDERS H 95…419
1. TABLE OF SERVICEABLE CYLINDERS…421
2. DESIGN, CUT VIEW…422
3. WORK AIDS…429
4. WEAR AND TEAR LIMITS…444
5. ASSEMBLY…461
6. TIGHTENING TORQUES…463
1-8 MACHINING OF THE FLANGE BUSHING AFTER FREEZING IN THE BUSHING (ALL CYLINDERS)…465
1-9 CYLINDERS H 135…471
1. TABLE OF SERVICEABLE CYLINDERS…473
2. DESIGN, CUT VIEW…474
3. WORK AIDS…479
4. WEAR AND TEAR LIMITS…494
5. ASSEMBLY…506
6. TIGHTENING TORQUES…508
1-10 HOOK WRENCH FOR PISTN NUT…511
1-11 CYLINDERS H 285 S…515
1. TABLE OF SERVICEABLE CYLINDERS…517
2. DESIGN, CUT VIEW…521
3. WORK AIDS…527
4. WEAR AND TEAR LIMITS…555
5. SEALING OF THE CYLINDER…581
6. ASSEMBLY…583
7. TIGHTENING TORQUES…591
1-12 CYLINDER H 255 S…595
1. TABLE OF SERVICEABLE CYLINDERS…597
2. DESIGN, SECTIONAL DRAWING…599
3. WORK AIDS…605
4. WEAR AND TEAR LIMITS…629
5. ASSEMBLY…649
6. TIGHTENING TORQUES…653
1-12.1 CYLINDER PC3000…655
1. TABLE OF SERVICEABLE CYLINDERS…657
2. DESIGN, SECTIONAL DRAWING…659
3. WORK AIDS…665
4. WEAR AND TEAR LIMITS…693
5. ASSEMBLY…711
6. TIGHTENING TORQUES…715
1-13 CYLINDERS H 455 S…716
1. TABLE OF SERVICEABLE CYLINDERS…718
2. DESIGN, CUT VIEW…720
3. WORK AIDS…734
4. WEAR AND TEAR LIMITS…758
5. SEALING OF THE CYLINDER…780
6. TIGHTENING TORQUES…782
1-14 CYLINDER PC1800…786
1. TABLE OF SERVICEABLE CYLINDERS…788
2. DESIGN, SECTIONAL VIEW…790
3. WORK AIDS…794
4. WEAR AND TEAR LIMITS…808
5. ASSEMBLY…826
6. DISASSEMBLY OF CYLINDER DAMPING SYSTEM…832
7. INSTALLATION OF ROD SEAL AND DUST SEAL…834
8. MOUNTING OF DAMPING PISTION AND SEAL…838
9. TIGHTENING TORQUES…846
1-15 CYLINDER (CYLINDER, BARREL AND ROD)…848
1-16 CYLINDER – GENERAL REBUILD PROCEDURES…850
2. HYDRAULIC PUMP…852
2-1 HYDRAULIC PUMP…858
MANNESMANN REXROTH RDE 92210-04R…858
SLIPPER BEARING …920
CONTENTS…922
TECHNICAL DESCRIPTION…924
ADJUSTING OF ASSEMBLY DIMENSIONS…936
ASSEMBLY-DISASSEMBLY…940
MOBILE ADJUSTMENT…948
MAIN PUMP CATALOGE PAGE ON 90-1560…962
MAIN PUMP CATALOGUE PAGE NO. 90-1490…966
2-2 LUBE OIL PUMP…970
2-3 GEAR LUBE OIL PUMP…976
2-4 MEASURING AND CONTROL OIL PUMP…982
2-5 FAN PUMP…990
2-6 SLEWING PUMP…996
2-7 COOLING CIRCUIT PUMP…1000
3. HYDRAULIC MOTOR…1006
3-1 HYDRAULIC MOTOR…1010
3-2 SLEW MOTOR…1037
SLEWING MOTOR CATALOGUE PAGE NO. 90-1363…1038
SLEWING MOTOR CATALOGUE PAGE NO. 90-1370…1040
SLEWING MOTOR TRAVEL MOTOR CATALOG PAGE NO. 90-1349…1042
3-3 FAN MOTOR DRIVE…1045
4. VALVES…1009
5. PUMP DISTRIBUTOR GEAR & DRIVE SHAFT…1053
5-1 PUMP DISTRIBUTOR GEAR H 241…1056
1. GENERAL VIEW…1057
2. DISASSEMBLING…1060
3. DETERMINATION OF WEAR AND TEAR…1076
4. ASSEMBLING…1102
5. PREASSEMBLING OF DRIVE SHAFT ASSY…1112
5-2 DRIVE SHAFT…1126
5-3 PUMP DISTRIBUTOR GEAR H 285 CONDITION MONITORING GATALOGUE PAGE NO. 90-2060A…1167
1. DESIGN…1168
2.DISASSEMBLY…1187
3. WEAR AND TEAR DETERMINATION…1206
4. PREASSEMBLY OF INPUT SHAFT AND MOUNTING IT IN THE GEAR…1219
5. ASSEMBLY OF THE OTHER SHAFT SETS…1239
5-4 PUMP DISTRIBUTOR GEAR H 85…1257
1. GENERAL VIEW…1259
2. DISASSEMBLY…1268
3. DETERMINATION OF WEAR AND TEAR…1280
4. ASSEMBLY AND ADJUSTMENT OF AXIAL PLAY…1306
5. CONDITION MONITORING PUMP DISTRIBUTOR GEAR…1324
5-5 PUMP DISTRIBUTOR GEAR H 285 CONDITION MONITORING CATALOGUE PAGE NO. 90-2079B …1328
5-6 PUMP DISTRIBUTOR GEAR H 485…1338
ASSEMBLY DRAWING…1340
CONDITION MONITORING CATALOGUE PAGE NO. 90-2076…1344
CONDITION MONITORING CATALOGUE PAGE NO. 90-0558…1352
5-6.1 PUMP DISTRIBUTOR GEAR H 485 CONDITION MONITORING…1357
5-6.2 PUMP DISTRIBUTOR GEAR H 485 DETERMINATION OF WEAR AND TEAR …1364
5-7 PUMP DISTRIBUTOR GEAR H 285…1378
5-8 PUMP DISTRIBUTOR GEAR H 685 SP…1468
1. GENERAL VIEW…1469
2. DISASSEMBLY…1483
3. DETERMINATION OF WEAR AND TEAR…1486
4. ASSEMBLY…1491
5-9 PUMP DISTRIBUTOR GEAR H 285 S…1528
1. GENERAL VIEW…1528
2. DISASSEMBLY…1546
3. DETERMINATION OF WEAR AND TEAR…1562
4. ASSEMBLY…1564
5-10 PUMP DISTRIBUTOR GEAR H 455…1612
1. GENERAL VIEW…1612
2. DISASSEMBLY…1627
3. DETERMINATION OF WEAR AND TEAR…1638
4. ASSEMBLY…1639
5-10.1 PUMP DISTRIBUTOR GEAR H 455 (PC5500) WEAR DIMENSIONS…1686
5-11 PUMP DISTRIBUTOR GEAR H 158 E + H225 E…1695
1. GENERAL VIEW…1695
2. DISASSEMBLY…1707
3. DETERMINATION OF WEAR AND TEAR…1712
4. ASSEMBLY…1715
5-12 PUMP DISTRIBUTOR GEAR H 655 WEAR DIMENSIONS…1771
6. SLEWING GEAR…1774
6-1 SLEWING GEAR H 241…1777
GENERAL VIEW…1778
DISASSEMBLING…1782
DETERMINATION OF WEAR AND TEAR…1829
ASSEMBLING…1847
TORQUES…1869
6-2 SLEWING GEAR H 285…1871
1. GENERAL VIEW…1872
2. DISASSEMBLING…1879
3. DETERMINATION OF WEAR AND TEAR…1897
4. ASSEMBLY…1921
CONDITION MONITORING SLEWING GEAR…1953
6-3 SLEWING GEAR CONDITION MONITORING H 485…1958
1. ASSEMBLY DRAWING SLEWING GEAR …1960
2. CONDITION MONITORING SLEWING GEAR …1962
3. ASSEMBLY MONITORING SLEWING GEAR…1968
6-3.1 SLEWING GEAR H 485 CONDITION MONITORING CATALOGUE PAGE NO. 90-0910…1970
6-3.2 SLEWING GEAR H 485 WEAR AND TEAR DETERMINATION CATALOGUE PAGE NO. 90-0910…1972
6-3.3 SLEWING GEAR H 485 CONDITION MONITORING CATALOGUE PAGE NO. 90-0560…1976
6-3.4 SLEWING GEAR H 485/H 655 WEAR AND TEAR DETERMINATION…1978
6-4 SLEWING GEAR H 85…1985
6-5 SLEWING GEAR H 455…1989
1. GENERAL VIEW…1991
2. DISASSEMBLY…1997
3. DETEMINATION OF WEAR AND TEAR…2001
4. ASSEMBLY…2005
5. TORQUES…2048
6-6 SLEWING GEAR H 285 S CATALOGUE NO. 90-1978D…2050
1. GENERAL VIEW …2051
2. DISASSEMBLY…2064
3. DETERMINATION OF WEAR AND TEAR…2065
4. ASSEMBLY…2067
5. TORQUES…2108
6-6.1 SLEWING GEAR H 285 S CONDITION MONITORING CATALOGUE PAGE NO. 90-1978 & 90-1978B…2110
6-7 SLEWING GEAR H 255 CATALOGUE PAGE NO. 991-0119…2120
1. GENERAL VIEW…2121
2. DISASSEMBLY…2131
3. DETERMINATION OF WEAR AND TEAR…2137
4. ASSEMBLY…2139
5. TORQUES…2184
6-8 SLEWING GEAR PC4000…2186
1. GENERAL VIEW…2187
2. DISASSEMBLY…2193
3. DETERMINATION OF WEAR AND TEAR…2201
4. ASSEMBLY…2203
6-10 SLEWING GEAR DISC BRAKE PC3000/4000/5500/8000…2288
1. PARTS REQUIRED FOR REPAIR…2289
2. DISASSEMBLY…2291
3. ASSEMBLY…2303
7. TRAVEL GEAR…2324
7-7.1 TRAVEL GEAR H 455/PC5500 EXCHANGE OF: PLANETARY CARRIER…2325
5. DISASSEMBLY OF PLANETARY GEARBOX, EXCHANGE OF PLANETARY CARRIER…2327
7-10 TRAVEL GEAR H 255/PC3000…2329
1. GENERAL VIEW…2330
2. DISASSMELBY…2337
3. DETERMINATION OF WEAR AND TEAR…2358
4. ASSEMBLY…2360
8. SLEW RING…2493
9. ROTARY JOINT…2494
10. BOTTOM ROLLER/TRACK ROLLER…2495
11. TOP ROLLER…2496
12. IDLER…2497
13. SPROCKET…2498
14. WELDING INSTRUCTIONS FOR STEEL STRUCTURAL PARTS AND STEEL CASTINGS…2501
14-4 WELDING INSTRUCTIONS, REBUILD OF TRACK PADS, BOTTOM ROLLERS, SPROCKETS AND IDLERS OF CASTING STEEL…2503
1. COMPONENTS SUITABLE FOR REBUILD…2505
1.1 TRACK PADS…2505
1.2 BOTTOM ROLLERS…2507
1.3 SPROCKET…2509
1.4 IDLERS…2511
2. DETERMINATION OF WEAR…2519
3. WELDING PROCESS…2523
4. RE-MACHINING THE ORIGINAL CONTOUR…2527
H285S78139OMM – DEMAG Komatsu Hydraulic Mining Shovels Parts & Service…2529

Komatsu/DEMAG Hydraulic Shovels H285S Repair Service Manuals

---

INSTANT DOWNLOAD

---

---

INSTANT DOWNLOAD

---

Complete service repair manual for Komatsu/DEMAG Hydraulic Shovels H285S, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

DEMAG Hydraulic Shovels H285S workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

H285S78067OMM – Hydraulic Shovel H285S Operation & Maintenance Manual.pdf
H285S78067SM – Hydraulic Shovel H285S Shop Manual.pdf
H285S78094OMM – Hydraulic Shovel H285S Operation & Maintenance Manual.pdf
H285S78094SM – Hydraulic Shovel H285S Shop Manual.pdf
H285S78115SM – Hydraulic Shovel H285S Operation & Maintenance Manual.pdf
H285S78135SM – Hydraulic Shovel H285S Electrical Diagram.pdf

Total Pages: 2,461 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
DIVISION OF MACHINE
SUPERSTRUCTURE
UNDERCARRIAGE
EQUIPMENT
SPECIAL EQUIPMENT
TOOTH SYSTEMS
LUBRICATION
REFILLING UNIT
HYDRAULIC SYSTEM
CONTROL
CONTROL UNITS
FILTERS OF THE HYDRAULIC OIL
ASSEMBLING THE EXCAVATOR
SHORT INFORMATION
HINTS FOR THE USER
HINTS FOR THE HYDRAULIC CIURCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM
HINTS FOR THE ELECTRIC CIRCUIT DIAGRAMS
HINTS FOR CHECK AND ADJUSTMENTS
PROPULSION
PUMP DISTRIBUTOR GEAR
HYDRAULIC PUMPS
PUMP BEARING LUBRICATION
PUMP REGULATION
HYDRAULIC OIL COOLING
HYDRAULIC OIL TANK
PILOT PRESSURE CIRCUITS
SERVICE LINE CIRCUITS
APPENDIX
ELECTRICAL DIAGRAMS

H285S78067OMM – Hydraulic Shovel H285S Operation & Maintenance Manual….2
COVER….2
INTRODUCTION….4
GENERAL CONTENT….10
PART 1: OPERATION MANUAL….14
1. FOREWORD….16
2. CONSTRUCTION OF EXCAVATOR….18
2.1 SUPERSTRUCTURE….20
2.2 UNDERCARRIAGE….22
2.3 EQUIPMENT….24
3. SAFETY INSTRUCTIONS….38
4. OPERATOR'S CAB – CONTROL ELEMENTS….46
5. OPERATOR'S CAB – MONITORING ELEMENTS….50
5.1 POWER COMPARTMENT, ENGINE SHUT-OFF SWITCH….54
5.2 MONITORING ELEMENTS OF THE CENTRAL – AND SLEWING RING TOOTHING LUBRICATION SYSTEM….56
6. OPERATING INSTRUCTIONS….58
6.1 BEFORE STARTING THE ENGINE….58
6.2 STARTING….62
6.3 STOPPING….70
6.4 MOVING THE EXCAVATOR….72
6.5 SLEWING AND BRAKING THE SUPERSTRUCTURE….80
6.6 WORKING WITH THE ATTACHMENT….82
6.7 COMBINED OPERATION CYCLES….88
6.8 OPERATING THE HEATER, VENTILATION AND AIR-CONDITIONING….90
6.9 NOT USED….90
6.10 NOT USED….90
6.11 OPERATING THE LUBRICATION SYSTEM….94
6.13 FIRE DETECTION AND SUPPRESSION SYSTEM….100
7. WORKING HINTS….104
8. PARKING THE EXCAVATOR….108
9. REFUELLING THE EXCAVATOR….110
10. CHANGING EQUIPMENT AND/OR COMPONENTS….112
10.1 NOT USED….114
10.2 REMOVING BACKHOE EQUIPMENT….114
10.3 FITTING LOADING EQUIPMENT….118
10.4 NOT USED….118
10.5 NOT USED….118
10.6 NOT USED….118
10.9 REMOVING THE STICK WITH BULLCLAM BUCKET (LOADING EQUIPMENT)….122
10.10 REMOVING THE LOADER OR BULLCLAM BUCKET….124
PART 2: LUBRICATION-AND MAINTENANCE MANUAL….126
1. FOREWORD….128
2. SAFETY INSTRUCTIONS….138
3. FUEL AND LUBRICANTS….142
4. FILLING CAPACITIES….145
5. LUBRICATION AND MAINTENANCE SCHEDULE….147
5.1 INITIAL SERVICING….147
5.2 PERIODIC SERVICING INTERVALS….147
5.3 MAINTENANCE OF ENGINE….161
6. LUBRICATION AND MAINTENANCE WORK….163
6.1 EVERY 10 HOURS OF OPERATION OR DAILY….163
6.2 EVERY 50 HOURS OF OPERATION OR WEEKLY….183
6.3 NOT USED….198
6.4 NOT USED….198
6.5 NOT USED….198
6.6 EVERY 250 HOURS OF OPERATION OR MONTHLY….199
6.7 NOT USED….211
6.8 EVERY 500 HOURS OF OPERATION OR EVERY 3 MONTHS….211
6.9 EVERY 1000 HOURS OF OPERATION OR EVERY 6 MONTHS….241
6.10 EVERY 1500 HOURS OF OPERATION BUT AT LEASE ONCE A YEAR….271
6.11 EVERY 2000 HOURS OF OPERATION OR ANUALLY….279
6.12 WHEN NECESSARY….297
6.13 NOT USED….297
6.14 NOT USED….297
6.15 EXCAVATOR STORAGE….317
6.16 TROUBLESHOOTING….323
H285S78067SM – Hydraulic Shovel H285S Shop Manual….331
COVER….331
FOREWORD….333
LIST OF CONTENTS….337
PART 1….343
DIVISION OF MACHINE….343
SUPERSTRUCTURE….345
UNDERCARRIAGE….347
EQUIPMENT….349
SPECIAL EQUIPMENT….351
TOOTH SYSTEMS….355
LUBRICATION….357
REFILLING UNIT….367
HYDRAULIC SYSTEM….369
CONTROL….373
CONTROL UNITS….375
FILTERS OF THE HYDRAULIC OIL….377
ASSEMBLING THE EXCAVATOR….379
PART 2….407
LIST OF CONTENTS….407
HINTS FOR THE HYDRAULIC CIRCUIT DIAGRAM….415
ELECTRIC CIRCUIT DIAGRAM….431
HINTS FOR THE ELECTRIC CIRCUIT DIAGRAM….437
HINTS FOR CHECK AND ADJUSTMENTS….449
PROPULSION….451
CUMMINS ENGINE….453
SWITCHES, SENSORS AND FILTERS….455
RPM ADJUSTMENTS….459
FAN/FAN DRIVE….465
AIR FILTER….467
COUPLING….469
PUMP DISTRIBUTOR GEAR….471
GEAR LUBRICATION….473
HYDRAULIC PUMPS….477
PUMP BEARING LUBRICATION….479
PUMP REGULATION….481
LOAD LIMIT REGULATION….485
PRESSURE CUT-OFF….495
SETTING OF THE LOAD LIMIT VALVE….497
MEASURING AND SETTING OF THE PRESSURE OF THE PRESSURE CUT-OFF VALVE….499
MEASURING AND SETTING OF THE BEGINNING OF REGULATION WITHOUT A TEST BOLT….501
CHECKING WITH TEST SCREW….503
HYDRAULIC OIL COOLING….505
MEASURING AND SETTING OF THE FAN SPEED….511
COOLING CIRCUIT….515
MEASURING AND SETTING OF THE BACK PRESSURE VALVE….517
CHECKS TO BE PERFORMED IF HYDRAULIC TEMPERATURE IS TOO HIGH….519
HYDRAULIC OIL TANK….521
PILOT PRESSURE CIRCUITS….523
CONTROL OIL SUPPLY….525
CHECKS AND ADJUSTMENTS….529
CONTROL OIL FLOW FROM THE 4 FUNCTIONS PILOT CONTROL UNIT TO THE CONTROL BLOCKS….531
CONTROL OIL FLOW FROM PEDAL TO THE CONTROL BLOCK….537
CONTROL OIL FLOW FROM THE 2 FUNCTION CONTROL UNIT TO CONTROL BLOCK….539
TRAVEL PARKING BRAKE….541
SLEW PARKING BRAKE….543
SERVICE LINE CIRCUITS….545
MEASUREMENTS AND PRESSURE ADJUSTMENTS/SLEW CIRCUIT….555
TRAVEL MOTORS….563
MEASUREMENTS AND PRESSURE ADJUSTMENTS/TRAVEL MOTORS….565
BUCKET CYLINDER….569
MEASUREMENTS AND PRESSURE ADJUSTMENTS/BUCKET CYLINDER….571
CLAM CYLINDER….579
MEASURINGS AND PRESSURE ADJUSTMENTS/CLAM CYLINDER….581
STICK CYLINDER/LOADER ATTACHMENT….591
MEASURINGS AND PRESSURE ADJUSTMENTS/STICK CYLINDER/LOADER ATTACHMENT….593
BOOM CYLINDER/LOADER ATTACHMENT….601
MEASURINGS AND PRESSURE ADJUSTMENTS/BOOM CYLINDERS/LOADER ATTACHMENTS….603
BUCKET CYLINDER (BACK HOE ATTACHMENT)….611
MEASUREMENTS AND PRESSURE ADJUSTMENTS/BUCKET CYLINDER….613
STICK CYLINDER/BACK HOE ATTACHMENT….621
MEASURINGS AND ADJUSTMENTS/STICK CYLINDER/BACK HOE ATTACHMENT….623
BOOM CYLINDER/BACK HOE ATTACHMENT….631
MEASURINGS AND PRESSURE ADJUSTMENTS/BOOM CYLINDERS/BACK HOE ATTACHMENT….633
AIR CONDITION DRIVE….639
MEASUREMENT AND ADJUSTMENT/AIR CONDITION DRIVE….641
LUBRICATION SYSTEM….643
SINGLE CIRCUIT CENTRAL LUBRICATION SYSTEM WITH PROGRESSIVE DISTIBUTORS….645
ELECTRICAL FUNCTION….651
MEASUREMENT AND PRESSURE ADJUSTMENT/COMPRESSED AIR SYSTEM….655
SLEW RING TOOTHING MIST LUBRICATION….661
ELECTRICAL FUNCTION….665
MEASUREMENT AND PRESSURE ADJUSTMENT/COMPRESSED AIR SYSTEM….669
GENERATOR DRIVE….675
MEASUREMENTS AND ADJUSTMENTS/GENERATOR DRIVE….677
PART 3….683
LIST OF CONTENTS….683
PLATFORM….693
DIESEL MOTOR….695
COMPUSAVE ENGINE MOTOR….697
COUPLING….737
UNIVERSAL SHAFT….739
PUMP DISTRIBUTOR GEAR….741
HYDRAULIC PUMPS….747
MAIN PUMPS, A7V HDD….747
GEARED PUMPS….761
HYDRAULIC PUMP A2F….767
HYDRAULIC PUMP A10V 0….771
HYDRAULIC PUMP A7F 0/107….775
DIESEL FUEL TANK….777
ELECTRONIC SET-UP….779
HYDRAULIC OIL TANK….783
HYDRAULIC OIL FILTERS….793
FILTERS IN THE PUMP LINE TO THE CONTROL BLOCKS….793
IN-LINE FILTER….797
RETURN OIL/CASE DRAIN FILTER IN THE HYDRAULIC RESERVOIR….799
BREATHER FILTER ON THE HYDRAULIC OIL RESERVOIR….801
CONTROL BLOCKS AND VALVES….803
4 FOLD CONTROL BLOCK M0 52….803
PRESSURE RELIEF VALVE, PILOT OPERATED….809
SECONDARY VALVE: PRE-CONTROLLED….813
ANTI-CAVITATION VALVE (MAKE-UP VALVE)….815
LOAD HOLDING VALVES INSIDE THE SPOOLS….817
SINGLE CONTROL BLOCK M0 40….819
PRESSURE INCREASING VALVE….825
PRESSURE RELIEF VALVE, PILOT OPERATED….829
CHECK VALVE….833
SHUTTLE VALVE….835
PRESSURE RELIEF VALVE, PRE-CONTROLLED….837
PRESSURE RELIEF VALVE, PILOT OPERATED….839
PRESSURE RELIEF VALVE, PILOT OPERATED….841
PRESSURE RELIEF VALVES TYPE DB/DBW….843
MAGNET VALVE….845
PRESSURE RELIEF VALVE, REMOTE CONTROLLED….847
LOAD LIMIT VALVE….849
NOZZLE BLOCK/PUMP REGULATING….855
PRESSURE SEQUENCE VALVE (PRESSURE CUT OFF VALVE)….857
RESTRICTOR BLOCK….859
PILOT CONTROL UNITS, 4 BOLT UNITS….861
PILOT CONTROL UNITS, 1 BOLT UNITS….865
TRAVEL BRAKE VALVE….867
PRESSURE ACCUMULATOR….871
TESTING THE PRECHARGE PRESSURE AND REFILLING….875
SLEW GEAR….879
REPLACEMENT OF THE DISKS….883
REPLACEMENT OF THE QUAD-RINGS….885
AXIAL PISTON MOTOR….887
SLEW RING….891
UNDERCARRIAGE….893
IDLER WHEEL ASSEMBLY….893
ALTERING THE TRACK TENSION….895
BOTTOM ROLLER….897
TOP ROLLER….899
CRAWLER DRIVE ASS'Y….901
TRAVEL GEAR….905
REPLACEMENT OF THE DISKS….909
REPLACEMENT OF THE QUAD-RINGS….911
DRIVE SPROCKET….913
CRAWLER CHAIN….915
AXIAL PISTON MOTOR….917
ROTARY DISTRIBUTOR….925
HYDRAULIC CYLINDERS….931
AIR CONDITIONING EQUIPMENT….935
MAINTENANCE SCHEDULE….947
PRESSURE MONITORING….965
COMPRESSED AIR SYSTEM….969
COMPRESSOR AT CU ENGINE….969
AIR DRYER….973
AUTOMATIC DRAIN VALVE….979
AIR EQUIPMENT – SERVICE UNIT….981
SOLENOID VALVE….987
VENT VALVE ASSEMBLY….989
LUBE SYSTEM….991
METERING VALVE….991
PROGRESSIVE LUBE DISTRIBUTOR….999
PRESSURE CONTROL UNIT….1003
TROUBLESHOOTING LUBRICATION SYSTEM….1005
SHORT INFORMATION….1021
REVOLUTIONS/PRESSURES….1021
FILLING CAPACITIES….1023
HYDRAULIC OIL….1025
TORQUE CHART….1027
TORQUE CHART – NM….1027
TORQUE CHART – FT LBF….1029
CONVERSION METRIC/INCH….1031
TROUBLESHOOTING H285….1033
GENERAL ….1035
MALFUNCTION WHEN EXTENDING OR RETRACTING CYLINDERS….1037
TROUBLESHOOTING SLEW CIRCUIT….1039
TROUBLESHOOTING SLEW BRAKE CIRCUIT….1041
TROUBLESHOOTING SLEW HOUSE BRAKE CIRCUIT….1043
TROUBLESHOOTING TRAVEL CIRCUIT….1045
TROUBLESHOOTING THE TRAVEL BRAKE CIRCUIT….1047
TROUBLESHOOTING PUMP REGULATION CIRCUIT….1049
TROUBLESHOOTING OIL COOLER CIRCUIT….1051
HYDRAULIC/ELECTRICAL DIAGRAM….1053
CONTENTS….1053
HYDRAULIC DIAGRAM….1054
ELECTRICAL DIAGRAM….1057
H285S78094OMM – Hydraulic Shovel H285S Operation & Maintenance Manual….1083
COVER….1083
INTRODUCTION….1085
GENERAL CONTENTS….1091
PART 1 OPERATION MANUAL….1093
CONTENTS….1093
1 FOREWARD….1095
2 CONSTRUCTION OF THE EXCAVATOR….1097
2.1 SUPERSTRUCTURE….1099
2.2 UNDERCARRIAGE….1101
2.3 EQUIPMENT….1103
3 SAFETY INSTRUCTIONS….1107
4 OPERATOR'S CAB – CONTROLS….1117
5 OPERATOR'S CAB – MONITORS….1121
5.1 POWER HOUSE….1127
5.2 NOT USED….1093
5.3 HEATING SYSTEMS (SPECIAL EQUIPMENT)….1131
6 OPERATION INSTRUCTIONS….1135
6.1 BEFORE STARTING THE ENGINE….1135
6.2 STARTING THE ENGINE….1139
6.3 STOPPING THE ENGINE….1147
6.4 MOVING THE EXCAVATOR….1149
6.5 SLEWING AND BRAKING THE SUPERSTRUCTURE….1157
6.6 WORKING WITH THE ATTACHMENT….1161
6.7 COMBINED OPERATION CYCLES….1167
6.8 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING….1169
6.11 OPERATION OF THE LUBRICATION SYSTEMS….1173
6.13 FIRE DETECTION AND SUPPRESSION SYSTEM (SPECIAL EQUIPMENT)….1183
7 WORKING INSTRUCTIONS….1187
8 PARKING THE EXCAVATOR….1191
9 REFILLING OF FLUIDS….1193
9.1 SERVICE CRANE FOR GREASE BARRELS (SPECIAL EQUIPMENT)….1195
10 CHANGING EQUIPMENT AND/OR COMPONENTS….1201
10.2 REMOVING THE BACKHOE EQUIPMENT (Z 0065)….1205
10.3 MOUNTING OF THE BULLCLAM BUCKET EQUIPMENT (Z 10353/Z 10355)….1209
10.9 REMOVING STICK WITH BULLCLAM BUCKET (LOADING EQUIPMENT) ILLUS. (Z 19256)….1213
10.10 REMOVING THE LOADER OR BULLCLAM BUCKET….1215
PART 2 LUBRICATION AND MAINTENANCE MANUAL….1217
CONTENTS….1217
1 FOREWARD….1219
1.1 FIRE PREVENTION….1223
1.2 REPAIR WELDINGS….1227
2 SAFETY INSTRUCTIONS….1229
3 FUEL AND LUBRICANTS….1235
4 FILLING CAPACITIES….1239
5 LUBRICATION AND MAINTENANCE SCHEDULE….1241
5.1 INITIAL SERVICING….1241
5.2 PERIODIC SERVICING SCHEDULE….1243
5.3 MAINTENANCE OF ENGINE….1255
6 LUBRICATION AND MAINTENANCE WORK….1259
6.1 EVERY 10 OPERATING HOURS OR DAILY….1259
6.2 EVERY 50 HOURS OF OPERATION OR WEEKLY….1277
6.6 EVERY 250 OPERATING HOURS OR MONTHLY….1287
6.8 EVERY 500 OPERATING HOURS OR EVERY 3 MONTHS….1307
6.9 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS….1349
6.11 EVERY 2000 OPERATING HOURS OR YEARLY….1383
6.12 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR….1395
6.15 WHEN NECESSARY….1407
7 EXCAVATOR STORAGE….1423
8 TROUBLE SHOOTING….1429
H285S78094SM – Hydraulic Shovel H285S Shop Manual….1437
COVER….1437
FOREWORD….1439
CONTENTS….1443
PART 1….1445
DIVISION OF MACHINE….1446
SUPERSTRUCTURE….1448
UNDERCARRIAGE….1450
EQUIPMENT….1452
SPECIAL EQUIPMENT….1454
TOOTH SYSTEMS….1456
LUBRICATION….1458
REFILLING UNIT….1468
HYDRAULIC SYSTEM….1470
CONTROL….1474
CONTROL UNITS….1476
FILTERS OF THE HYDRAULIC OIL….1478
ASSEMBLING THE EXCAVATOR….1480
PART 2….1510
LIST OF CONTENTS….1510
SHORT INFORMATION….1518
HINTS FOR THE USER….1520
HINTS FOR THE HYDRAULIC CIRCUIT DIAGRAM….1522
ELECTRIC CIRCUIT DIAGRAM….1541
HINTS FOR THE ELECTRIC CIRCUIT DIAGRAM….1544
HINTS FOR CHECK AND ADJUSTMENTS….1550
PROPULSION….1551
OVERVIEW DIESEL ENGINE….1551
OVERVIEW ELECTRIC MOTOR….1552
ENGINE MOUNTINGS….1553
SWITCHES, SENSORS AND FILTERS….1554
RPM ADJUSTMENTS….1556
FAN DRIVE….1561
AIR FILTER….1562
COUPLING FOR DIESEL ENGINE DRIVEN MACHINES….1563
COUPLING FOR ELECTRIC MOTOR DRIVEN MACHINES….1564
PUMP DISTRIBUTOR GEAR….1566
GEAR LUBRICATION….1567
HYDRAULIC PUMPS….1569
PUMP BEARING LUBRICATION….1570
PUMP REGULATION….1572
FOR MACHINES WITH DIESEL ENGINE ONLY….1572
LOAD LIMIT REGULATION….1573
PRESSURE CUT OFF VALVE….1579
SETTING OF THE LOAD LIMIT VALVE….1580
MEASURING AND SETTING OF THE PRESSURE OF THE PRESSURE CUT OFF VALVES….1582
MEASURING AND SETTING OF THE START OF DESTROKING OF THE MAIN PUMPS….1584
CHECKING WITH TEST BOLT….1585
FOR MACHINES WITH ELECTRONIC MOTOR DRIVE….1586
BRIEF DESCRIPTION OF THE ELECTRONIC PARTS OF THE EGL….1588
HYDRAULIC REGULATION….1589
ADJUSTMENTS….1596
ADJUSTING WORKS FOR THE ELECTRONIC PUMP REGULATION….1604
TROUBLESHOOTING/ELECTRONIC CONTROLLING….1609
MEASURING AND SETTING OF THE PRESSURE CUT OFF VALVES….1612
MEASURING AND SETTING OF THE START OF DESTROKING OF THE MAIN PUMPS….1614
CHECKING WITH TEST BOLT….1615
HYDRAULIC OIL COOLING….1616
FAN DRIVE….1617
MEASURING AND SETTING OF THE FAN SPEED….1619
COOLING CIRCUIT….1622
MEASURING AND SETTING OF THE BACK PRESSURE VALVE….1623
CHECKS TO BE PERFORMED IF HYDRAULIC TEMPERATURE IS TOO HIGH….1624
HYDRAULIC OIL TANK….1625
PILOT PRESSURE CIRCUITS….1626
OVERVIEW….1626
CONTROL OIL SUPPLY….1627
CHECKING AND ADJUSTMENTS….1629
TRAVEL PARKING BRAKE….1630
SLEW BRAKE HOUSE BRAKE….1632
TRAVEL MOTION CONTROL WHEN USING A CABLE REEL….1634
PILOT PRESSURE CUT OFF FOR "BUCKET FILLING" AT TOO HOT HYDRAULIC OIL….1635
PRIORITY FOR STICK OR BOOM IN R.H. CONTROL BLOCK WITH A BHA….1636
SERVICE LINE CIRCUITS….1637
SLEW CIRCUIT….1637
CHECKS AND ADJUSTMENTS….1642
TRAVEL MOTORS….1645
CHECKS AND ADJUSTMENTS….1646
BUCKET CYLINDER….1647
CHECKS AND ADJUSTMENTS….1648
CLAM CYLINDER….1650
CHECKS AND ADJUSTMENTS….1651
STICK CYLINDER/LOADER ATTACHMENT….1655
CHECKS AND ADJUSTMENTS….1656
BOOM CYLINDER/LOADER ATTACHMENT….1659
CHECKS AND ADJUSTMENTS….1660
BUCKET CYLINDER/BACK HOE ATTACHMENT….1663
CHECKS AND ADJUSTMENTS….1664
STICK CYLINDER/BACK HOE ATTACHMNET….1667
CHECKS AND ADJUSTMENTS….1668
BOOM CYLINDER/BACK HOE ATTACHMENT….1671
CHECKS AND ADJUSTMENTS….1672
HYDRAULIC TRACK ADJUSTING SYSTEM….1675
LEGEND….1675
FUNCTION….1676
APPENDIX….1683
HYDRAULIC AIR CONDITION DRIVE….1685
CHECKS AND ADJUSTMENTS….1686
SERVICE MANUAL….1688
GENERATOR DRIVE….1722
CHECKS AND ADJUSTMENTS….1728
LUBRICATION….1736
COMPRESSED AIR SYSTEM….1736
SINGLE LINE CENTRALIZED LUBE SYSTEM….1740
ELECTRICAL FUNCTION….1744
CHECKS AND ADJUSTMENTS….1748
SLEW RING TOOTHING MIST LUBRICATION….1752
ELECTRICAL FUNCTION….1756
CHECKS AND ADJUSTMENTS….1760
SLEW RING TOOTHING DRIP LUBRICATION….1762
ELECTRICAL FUNCTION….1766
CHECKS AND ADJUSTMENTS….1770
CENTRAL LUBRICATION SYSTEM WITH ELECTRIC MOTOR DRIVE PUMPS….1772
DESIGN….1772
SINGLE LINE CENTRALIZED LUBE SYSTEM….1774
ELECTRICAL FUNCTION….1778
CHECKS AND ADJUSTMENTS….1782
SLEW RING DRIP LUBRICATION….1784
ELECTRICAL FUNCTION….1788
CHECKS AND ADJUSTMENTS….1792
SL-1 AND SL-11 INJECTOR….1794
DIFFERENT TIME RELAYS….1798
CABLE REEL/ELECTRIC MACHINE….1804
ELECTRICAL FUNCTION….1806
TRAVEL MOTION CONTROL….1808
SWITCHING MECHANISM WITH SWITCHES 5S4….1810
REQUIRED ADJUSTMENTS/CHECKS….1812
PART 3….1814
CONTENTS….1814
ELECTRICAL DIAGRAM….1815
H285S78115SM – Hydraulic Shovel H285S Operation & Maintenance Manual….1847
Hydraulic Diagram.pdf….0
Electrical Diagram.pdf….0
H285S78135SM – Hydraulic Shovel H285S Electrical Diagram….2391
COVER….2391
CONTENTS….2392
ELECTRICAL DIAGRAM….2393

Komatsu/DEMAG Hydraulic Shovels H285S Repair Service Manuals + Operation & Maintenance Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual for Komatsu/DEMAG Hydraulic Shovels H185S, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

DEMAG Hydraulic Shovels H185S workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

H185S06081OMM – Hydraulic Shovel H185S Operation & Maintenance Manual.pdf
H185S06081SM – Hydraulic Shovel H185S Shop Manual.pdf
H185S06108OMM – Mining Shovel H185S Operation & Maintenance Manual.pdf
H185S06108SM – Hydraulic Shovel H185S Electrical & Hydraulic Diagrams.pdf
H185S06111OMM – Hydraulic Shovel H185S Operation & Maintenance Manual.pdf
H185S06111SM – Hydraulic Shovel H185S Shop Manual.pdf

Total Pages: 2,132 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
TECHNICAL SUMMARY
ASSEMBLING THE EXCAVATOR
FOREWORD
INTRODUCTION
DRIVE
HYDRAULIC OIL TANK
DYDRAULIC OIL COOLING
CONTROL
MAIN HYDRAULIC PUMPS AND PUMP REGULATION
OPERATING HYDRAULIC
HYDRAULIC TRACK TENSION SYSTEM
HYDRAULIC DRIVE FOR AIR CONDITION COMPRESSOR
GENERATOR DRIVE
HINTS FOR THE HYDRAULIC CIRCUIT DIAGRAM
HINTS FOR THE ELECTRIC CIRCUIT DIAGRAMS
APPENDIX

H185S06081OMM – Hydraulic Shovel H185S Operation & Maintenance Manual…2
  COVER…2
  INTRODUCTION…3
  GENERAL CONTENT…9
  PART 1 OPERATION MANUAL…11
    CONTENTS…11
    FOREWARD…13
    CONSTRUCTION OF THE EXCAVATOR…15
      2.0 OVERALL VIEW…15
      2.1 SUPERSTRUCTURE…17
      2.2 UNDERCARRIAGE…19
      2.3 ATTACHMENT…21
    SAFETY PRECAUTIONS…23
      3.0 SAFETY INSTRUCTIONS…23
      3.1 LADDER, WALKWAYS AND ACCESS DOORS…31
    OPERATOR'S CAB – CONTROLS…33
      4.0 OPERATOR'S CAB – CONTROLS…33
    OPERATOR'S CAB – MONITORS…39
      5.0 OPERATOR'S CAB – MONITORS…39
      5.1 POWER HOUSE CONTROLS…45
      5.2 INDEPENDENT CAB HEATER (SPECIAL EQUIPMENT)…49
    OPERATION INSTRUCTIONS…51
      6.1 BEFORE STARTING THE ENGINE…51
      6.2 STARTING THE ENGINE…53
      6.3 STOPPING THE ENGINE…63
      6.4 MOVING THE EXCAVATOR…65
      6.5 SLEWING AND BRAKING THE SUPERSTRUCTURE…73
      6.6 WORKING WITH THE ATTACHMENT…77
      6.7 COMBINED OPERATION CYCLES…83
      6.8 OPERATING THE HEATER, VENTIALTION AND AIR CONDITIONING…85
      6.11 OPERATION OF THE LUBRICATION SYSTEMS…89
      6.13 FIRE DETECTION AND SUPRESSION SYSTEM (SPECIAL EQUIPMENT)…99
    WORKING INSTRUCTIONS…105
      7.0 WORKING INSTRUCTIONS…105
    PARKING THE EXCAVATOR…109
      8.0 PARKING THE EXCAVATOR…109
    REFUELLING THE EXCAVATOR…111
      9.0 REFUELLING THE EXCAVATOR…111
      9.1 SERVICE CRANE FOR GREASE BARRELS (SPECIAL EQUIPMENT)…115
    EXCHANGE OF ATTACHMENT…121
      10. CHANGING EQUIPMENT AND/OR COMPONENTS…121
      10.2 REMOVING THE BACKHOE EQUIPMENT…123
      10.3 MOUNTING THE LOADER…127
      10.7 REMOVING THE STICK WITH BUCKET (BACKHOE EQUIPMENT)…129
      10.8 REMOVING THE BUCKET…129
      10.9 REMOVING STICK WITH BULLCLAM BUCKET…131
      10.10 REMOVING THE LOADER OR BULLCLAM BUCKET…133
  PART 2 LUBRICATION AND MAINTENANCE MANUAL…135
    CONTENTS…135
    FOREWARD…137
      1.0 FOREWARD…137
      1.1 FIRE PREVENTION…141
      1.2 REPAIR WELDINGS…145
    SAFETY PRECAUTIONS…147
      2.0 SAFETY INSTRUCTIONS…147
      2.1 LADDER, WALKWAYS AND ACCESS DOORS…151
    FUELS AND LUBRICANTS…153
      3.0 FUEL AND LUBRICANTS…153
    FILLIING CAPACITIES…157
      4.0 FILLING CAPACITIES…157
    LUBRICATION AND MAINTENANCE SCHEDULE…159
      5.1 INITIAL SERVICING…159
      5.2 PERIODIC SERVICING INTERVALS…159
      5.3 MAINTENANCE OF ENGINE…171
    LUBRICATION AND MAINTENANCE WORK…177
      6.0 LUBRICATION AND MAINTENANCE CHART…177
      6.1 EVERY 10 OPERATING HOURS OR DAILY…179
      6.2 EVERY 50 OPERATING HOURS OR WEEKLY…199
      6.6 EVERY 250 OPERATING HOURS OR MONTHLY…207
      6.8 EVERY 500 OPERATING HOURS OR EVERY 3 MONTHS…223
      6.9 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS…245
      6.11 EVERY 2000 OPERATING HOURS OR YEARLY…275
      6.12 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…287
      6.15 WHEN NECESSARY…293
    EXCAVATOR STORAGE…307
      7.0 EXCAVATOR STORAGE…307
    TROUBLESHOOTING…313
      8.0 TROUBLESHOOTING…313
H185S06081SM – Hydraulic Shovel H185S Shop Manual…321
  COVER…321
  FOREWORD…322
  PART 1…324
    CONTENTS…324
    TECHNICAL SUMMARY…326
    ASSEMBLING THE EXCAVATOR…346
  PART 2…372
    CONTENTS…372
    FOREWARD…374
    INTRODUCTION…376
    DRIVE…378
      GENERAL…380
      ENGINE MOUNTS…382
        FAN DRIVE AND COOLER ASSY…384
        COUPLING…386
        AIR FILTER…388
      RPM ADJUSTMENTS (CUMMINS ENGINE KTA 38C)…390
      ELECTRIC MOTOR…392
        COUPLING…394
      PUMP DISTRIBUTOR GEAR…398
        LUBRICATION…400
      LOCATION OF THE PUMPS AT THE DISTRIBUTOR GEAR…406
    HYDRAULIC OIL TANK…408
      HYDRAULIC OIL TANK…410
    HYDRAULIC OIL COOLING…416
      GENERAL…418
      HYDRAULIC OIL COOLING CIRCUIT…420
      FAN DRIVE…424
        AXIAL PISTON PUMP…428
        MEASURING AND SETTING OF THE FAN SPEED…430
        FUNCTION CHECK FOR RPM CONTROL…434
    CONTROL…436
      PILOT PRESSURE SUPPLY…438
      OVERVIEW FOR PILOT PRESSURE LINES…442
      ELECTRO PROPORTIONAL CONTROL…444
        GENERAL FUNCTION…444
        DETAILED EXPLANATION…446
        POTENTIOMETER CONTROL (LEVER)…448
      ADJUSTMENTS…456
    MAIN HYDRAULIC PUMPS AND PUMP REGULATION…466
      HYDRAULIC PUMP A7V/HD D…468
        DESCRIPTION OF THE SL BEARING…472
        FUNCTION OF THE GOVERNOR…474
        PUMP BEARING LUBRICATION…480
        MEASURING AND SETTING OF THE PRESSURE CUT-OFF VALVES…484
      PUMP REGULATION SYSTEM…494
        DIESEL ENGINE…494
          DETAILED EXPLANATION FOR THE HYDRAULIC REGULATION…498
          FUNCTION OF THE REGULATION CARTRIDGE…500
        ELECTRIC MOTOR…502
          DETAILED EXPLANATION FOR THE HYDRAULIC REGULATION…506
          BASIC EXPLANATION OF THE POWER CONTROL VALVE…508
      PUMP REGULATION SYSTEM…512
        FOR MACHINES WITH A CUMMINS ENGINE ONLY)…512
        FOR MACHINES WITH A CATERPILLAR ENGINE…520
        FOR MACHINES WITH AN ELECTRIC MOTOR…527
      DETAILED EXPLANATION FOR THE ELECTRONIC REGULATION FOR MACHINES WITH DIESEL ENGINE DRIVE…541
        NORMAL ADJUSTMENTS/CHECKS FOR THE ELECTRONIC REGULATION…543
        FIELD ADJUSTMENTS/CHECKS FOR THE ELECTRONIC REGULATION…551
      DETAILED EXPLANATION FOR THE ELECTRONIC REGULATION FOR ELECTRIC MOTOR POWERED MACHINES…569
        NORMAL ADJUSTMENTS/CHECKS FOR THE ELECTRONIC REGULATION…571
        FIELD ADJUSTMENTS/CHECKS FOR THE ELECTRONIC REGULATION…583
    OPERATING HYDRAULIC…599
      REMOTE CONTROL, CONTROL BLOCKS AND DISTRIBUTOR MANIFOLD ARRANGEMENT…601
        CONTROL BLOCKS…603
        LOAD HOLDING VALVES…605
        TRAVEL BRAKE VALVES…607
        CONTROL BLOCK VALVES…609
        PILOT OPERATED PRESSURE RELIEF VALVE…611
      RESTRICTOR BLOCK…613
        ANTI CAVITATION VALVE BLOCK…615
        REMOTE CONTROL MANIFOLD…617
        DIRECTIONAL SOLENOID VALVES…619
        PROPORTIONAL SOLENOID VALVE…621
        HIGH PRESSURE FILTER…623
        HYDRAULIC CYLINDER…625
      HYDRAULIC FOR ATTACHMENT CYLINDER…627
        VALVES AND PRESSURE CHECK POINTS…631
        EXEMPLARY EXPLANATION FOR ONE CIRCUIT…635
      ADJUSTMENTS FOR THE ATTACHMENT CYLINDER HYDRAULIC…645
      SLEW CIRCUIT…661
        SLEW MOTOR (AXIAL PISTON MOTOR A2FM)…665
        SLEW GEAR…669
        SLEW GEAR HOUSE BRAKE…671
        SLEW BRAKE VALVE…673
        DETAILED EXPLANATION FOR RIGHT HAND SLEWING (EURO CONTROL)…679
        DETAILED EXPLANATION FOR LEFT HAND SLEWING (EURO CONTROL)…683
        SLEWING DOWN PATH…685
        ANTICAVITATION CIRCUIT…687
        ADJUSTMENTS FOR THE SLEW CIRCUIT…689
      TRAVEL CIRCUIT…693
        ROTARY DISTRIBUTOR…697
        TRAVEL MOTOR (AXIAL PISTON MOTOR A2FM)…699
        DRIVE ASSY…703
        TRAVEL GEAR…705
        TRAVEL GEAR HOUSE BRAKE…707
        DETAILED EXPLANATION FOR TRAVELLING FORWARD…711
        DETAILED EXPLANATION FOR TRAVELLING BACKWARD…717
        ADJUSTMENTS FOR THE TRAVEL CIRCUIT…721
    HYDRAULIC TRACK TENSION SYSTEM…725
      LEGEND…727
        GENERAL…727
      LEGEND…729
        FUNCTION…729
      PRESSURE RELIEF VALVE, PILOT OPERATED TYPE: DBD S…733
      ADJUSTMENTS…735
    HYDRAULIC DRIVE FOR AIR CONDITION COMPRESSOR…741
      HYDRAULIC DRIVE FOR AIR CONDITION COMPRESSOR…743
      ADJUSTMENTS FOR THE HYDRAULIC AIR CONDITION DRIVE…745
      SOLENOID VALVE…747
      PRESSURE RELIEF VALVE, PILOT OPERATED TYPE: DBD S…749
    GENERATOR DRIVE…751
      FUNCTION…753
      ELECTRICAL FUNCTION…755
      BASIC ADJUSTMENT…759
      PRESSURE RELIEF VALVE WITH SOLENOID VALVE…765
      AXIAL PISTON PUMP A10V 0…767
    HINTS FOR THE HYDRAULIC CIRCUIT DIAGRAM…771
      HINTS FOR READING THE CIRCUIT DIAGRAM…775
        LEGEND TO THE HYDRAULIC CIRCUIT DIAGRAM H185 WITH DIESEL ENGINE…777
        HOW TO READ THE CIRCUIT DIAGRAM…783
    HINTS FOR THE ELECTRIC CIRCUIT DIAGRAM…785
      MARKINGS OF ELECTRICAL COMPONENTS IN THE CIRCUIT DIAGRAMS…787
      SYMBOLS…789
      DEMAG CIRCUIT DIAGRAMS – GENERAL INFORMATION…793
      EXPLANATION OF THE DRAWING CONCEPT…795
      LOCATION OF THE MAIN TERMINAL BOXES AND SOME IMPORTANT COMPONENTS…797
      READING A CIRCUIT DIAGRAM…799
  APPENDIX (PART 3)…805
    CONTENTS…807
    ELECTRICAL DIAGRAM…808
    HYDRAULIC DIAGRAM…860
H185S06108OMM – Mining Shovel H185S Operation & Maintenance Manual…863
  COVER…863
  CONTENTS…864
  PART 1 OPERATION MANUAL…865
    GENERAL CONTENTS…874
    PART 1 CONTENTS…876
    1.0 FOREWORD…878
    2.0 CONSTRUCTION OF EXCAVATOR…880
      2.1 SUPERSTRUCTURE…882
      2.2 UNDERCARRIAGE…884
      2.3 ATTACHMENT…886
    3.0 SAFETY PRECAUTIONS…888
      3.1 LADDER, WALKWAYS AND ACCESS DOORS…896
    4.0 OPERATOR'S CAB, CONTROLS…898
    5.0 OPERATOR'S CAB, MONITORS…904
      5.1 POWER HOUSE CONTROLS…910
      5.2 INDEPENDANT CAB HEATER…914
    6.0 OPERATION INSTRUCTIONS…916
      6.1 BEFORE STARTING THE ENGINE…916
      6.2 STARTING THE TNINE…920
      6.3 STOPPING THE ENGINE…928
      6.4 MOVING THE EXCAVATOR…930
      6.5 SLEWING AND BRAKING THE SUPERSTRUCTURE…938
      6.6 WORKING WITH THE ATTACHMENT…943
      6.7 COMBINED OPERATION CYCLES…948
      6.8 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…950
      6.11 OPERATION OF THE LUBRICATION SYSTEMS…954
      6.13 FIRE DETECTION AND SUPPRESSION SYSTEM…974
    7.0 WORKING INSTRUCTIONS (HINTS)…980
    8.0 PARKING THE EXCAVATOR…984
    9.0 REFUELLING THE EXCAVATOR, CENTRAL RIFILLING SYSTEM…986
      9.1 SERVICE CRANE FOR GREASE BARRELS…994
    10.0 EXCHANGE OF ATTACHMENT AND/OR COMPONENTS…1000
      10.2 REMOVING BACKHOE ATTACHMENT…1002
      10.3 MOUNTING THE LOADER…1006
      10.7 REMOVING DIPPERSTICK WITH BUCKET…1008
      10.8 REMOVING THE BUCKET…1008
      10.9 REMOVING THE STICK WITH BULLCLAM BUCKET…1010
      10.10 REMOVING THE LOADER OR BULLCLAM BUCKET …1012
  PART 2 LUBRICATION AND MAINTENANCE MANUAL…1014
    PART 2 CONTENTS…1015
    1.0 FOREWORD…1017
      1.1 FIRE PREVENTION…1021
      1.2 REPAIR WELDINGS…1025
    2.0 SAFETY PRECAUTIONS…1027
    3.0 FUELS AND LUBRICANTS…1033
    4.0 FILLING CAPACITIES…1037
    5.0 LUBRICATION AND MAINTENANCE SCHEDULE…1039
      5.1 INITIAL SERVICING…1039
      5.2 PERIODIC SERVICING SCHEDULE…1041
      5.3 MAINTENACE OF THE ENGINE…1053
    6.0 LUBRICATION AND MAINTENANCE WORK…1061
      6.1 EVERY 10 HOURS OF OPERATION OR DAILY…1061
      6.2 EVERY 50 HOURS OF OPERATION OR WEEKLY…1081
      6.6 EVERY 250 OPERATING HOURS OR MONTHLY…1089
      6.8 EVERY 500 HOURS OF PERATION OR EVERY 3 MONTHS…1107
      6.9 EVERY 1000 HOURS OF OPERATION OR EVERY 6 MONTHS…1141
      6.11 EVERY 2000 HOURS OF OPERATION OR YEARLY…1173
      6.12 EVERY 3000 HOURS OF OPERATION BUT AT LEAST ONCE A YEAR…1185
      6.15 WHEN NECESSARY…1193
    7.0 EXCAVATOR STORAGE…1207
    8.0 TROUBLESHOOTING…1213
H185S06108SM – Hydraulic Shovel H185S Electrical & Hydraulic Diagrams…1221
  COVER…1221
  CONTENTS…1222
  ELECTRICAL DIAGRAM…1223
  HYDRAULIC DIAGRAM…1276
H185S06111OMM – Hydraulic Shovel H185S Operation & Maintenance Manual…1278
  COVER…1278
  INTRODUCTION…1279
  GENERAL CONTENT…1285
  PART 1 OPERATION MANUAL…1287
    CONTENTS…1287
    FOREWORD…1289
      1.0 FORWORD…1289
    CONSTRUCTION OF THE EXCAVATOR…1291
      2.0 OVERALL VIEW…1291
      2.1 SUPERSTRUCTURE…1293
      2.2 UNDERCARRIAGE…1295
      2.3 ATTACHMENT…1297
    SAFETY INSTRUCTIONS…1299
      3.0 SAFETY INSTRUCTIONS…1299
      3.1 LADDER, WALKWAYS AND ACCESS DOORS…1307
    OPERATOR'S CAB – CONTROLS…1309
      4.0 OPERATOR'S CAB – CONTROLS…1309
    OPERATOR'S CAB – MONITORS…1315
      5.0 OPERATOR'S CAB – MONITORS…1315
      5.1 POWER HOUSE CONTROLS…1321
      5.2 INDEPENENT CAB HEATER (SPECIAL EQUIPMENT)…1325
    OPERATION INSTRUCTIONS…1327
      6.1 BEFORE STARTING THE ENGINE…1327
      6.2 STARTING THE ENGINE…1331
      6.3 STOPPING THE ENGINE…1339
      6.4 MOVING THE EXCAVATOR…1341
      6.5 SLEWING AND BRAKING THE SUPERSTRUCTURE…1349
      6.6 WORKING WITH THE ATTACHMENT…1353
      6.7 COMBINED OPERATION CYCLES…1359
      6.8 OPERATING THE HEATER, VENTILATION AND AIR CONDITIONING…1361
      6.11 OPERATION OF THE LUBRICATION SYSTEMS…1365
      6.13 FIRE DETECTION AND SUPRESSION SYSTEM (SPECIAL EQUIPMENT)…1375
    WORKING INSTRUCTIONS…1381
      7.0 WORKING INSTRUCTIONS…1381
    PARKING THE EXCAVATOR…1385
      8.0 PARKING THE EXCAVATOR…1385
    REFUELLING THE EXCAVATOR…1387
      9.0 REFUELLING THE EXCAVATOR…1387
      9.1 SERVICE CRANE FOR GREASE BARRELS (SPECIAL EQUIPMENT)…1391
    EXCHANGE OF EQUIPMENT…1397
      10.0 CHANGING EQUIPMENT AND/OR COMPONENTS…1397
      10.2 REMOVING THE BACKHOE EQUIPMENT…1399
      10.3 MOUNTING THE LOADER…1403
      10.7 REMOVING THE STICK WITH BUCKET (BACKHOE EQUIPMENT)…1405
      10.8 REMOVING THE BUCKET…1405
      10.9 REMOVING STICK WITH BULLCLAM BUCKET (LOADING EQUIPMENT)…1407
      10.10 REMOVING THE LOADER OR BULLCLAM BUCKET…1409
  PART 2 LUBRICATION AND MAINTENANCE MANUAL…1411
    CONTENTS…1411
    FOREWARD…1413
      1.0 FOREWARD…1413
      1.1 FIRE PREVENTION…1417
      1.2 REPAIR WELDINGS…1421
    SAFETY PRECAUTIONS…1423
      2. SAFETY INSTRUCTIONS…1423
      2.1 LADDER, WALKWAYS AND ACCESS DOORS…1427
    FUELS AND LUBRICANTS…1429
      3.0 FUEL AND LUBRICANTS…1429
    FILLING CAPACITIES…1433
      4.0 FILLING CAPACITIES…1433
    LUBRICATION AND MAINTENANCE SCHEDULE…1435
      5.0 LUBRICATION AND MAINTENANCE SCHEDULE…1435
      5.1 INITIAL SERVICING…1435
      5.2 PERIODIC SERVICING INTERVALS…1435
      5.3 MAINTENANCE OF THE ENGINE…1447
    LUBRICATION AND MAINTENANCE WORK…1453
      6.0 LUBRICATION AND MAINTENANCE CHART…1453
      6.1 EVERY 10 OPERATING OR DAILY…1455
      6.2 EVERY 50 OPERATING HOURS OR WEEKLY…1475
      6.6 EVERY 250 OPERATING HOURS OR MONTHLY…1483
      6.8 EVERY 500 OPERATING HOURS OR EVERY 3 MONTHS…1499
      6.9 EVERY 1000 OPERATING HOURS OR EVERY 6 MONTHS…1521
      6.11 EVERY 2000 OPERATING HOURS OR YEARLY…1551
      6.12 EVERY 3000 OPERATING HOURS HOWEVER AT LEAST ONCE A YEAR…1563
      6.15 WHEN NECESSARY…1569
    EXCAVATOR STORAGE…1583
      7.0 EXCAVATOR STORAGE…1583
    TROUBLESHOOTING…1589
      8.0 TROUBLESHOOTING…1589
H185S06111SM – Hydraulic Shovel H185S Shop Manual…1597
  COVER…1597
  FOREWARD…1598
  PART 1…1602
    TECHNICAL SUMMARY…1604
    ASSEMBLIING THE EXCAVATOR…1624
  PART 2…1650
    FOREWARD…1652
    INTRODUCTION…1654
    DRIVE…1656
      GENERAL…1658
      ENGINE MOUNTS…1660
        FAN DRIVE AND COOLER ASSY…1662
        COUPLING…1664
        AIR FILTER…1666
      RPM ADJUSTMENTS (CUMMINS ENGINE KTA 38C)…1668
      ELECTRIC MOTOR…1670
        COUPLING…1672
      PUMP DISTRIBUTOR GEAR…1676
        LUBRICATION…1678
      LOCATION OF THE PUMPS AT THE DISTRIBUTOR GEAR…1684
    HYDRAULIC OIL TANK…1686
      HYDRAULIC OIL TANK…1688
    HYDRAULIC OIL COOLING…1694
      GENERAL…1696
      HYDRAULIC OIL COOLING CIRCUIT…1698
      FAN DRIVE…1702
        AXIAL PISTON PUMP…1706
        MEASURING AND SETTING OF THE FAN SPEED…1708
        FUNCTION CHECK FOR RPM CONTROL…1712
    CONTROL…1714
      PILOT PRESSURE SUPPLY…1716
      OVERVIEW FOR PILOT PRESSURE LINES…1720
      ELECTRO PROPORTIONAL CONTROL…1722
        GENERAL FUNCTION…1722
        DETAILED EXPLANATION …1722
        POTENTIOMETER CONTROL (LEVER)…1724
      ADJUSTMENTS…1734
    MAIN HYDRAULIC PUMPS AND PUMP REGULATION…1744
      HYDRAULIC PUMP A7V…1746
        DESCRIPTION OF THE SL BEARING…1750
        FUNCTION OF THE GOVERNOR…1752
        PUMP BEARING LUBRICATION…1758
        MEASURING AND SETTING OF THE PRESSURE OF THE PRESSURE CUT-OFF VALVES…1762
      PUMP REGULATION SYSTEM …1772
        GENERAL FOR DIESEL ENGINE DRIVEN MACHINES…1772
          DETAILED EXPLANATION FOR THE HYDRAULIC REGULATION…1776
          FUNCTION OF THE REGULATION CARTRIDGE…1778
        GENERAL FOR ELECTRIC MOTOR DRIVEN MACHINES…1780
      SETTING/ADJUSTING THE HYDRAULIC PUMP REGULATION …1784
        (FOR MACHINES WITH A CUMMINS ENGINE ONLY)…1784
        (FOR MACHINES WITH A CAT ENGINE)…1792
        ADJUSTING THE CONTSTANT X1 PRESSURE FOR THE STOP GAP OPERATION (ONLY FOR MACHINES WITH AN ELECTRIC MOTOR)…1802
      DETAILED EXPLANATION FOR THE ELECTRONIC REGULATION FOR MACHINES WITH DIESEL ENGINE DRIVE…1806
        ADJUSTMENTS/CHECKS FOR THE ELECTRONIC REGULATION – NORMAL…1808
        ADJUSTMENTS/CHECKS FOR THE ELECTRONIC REGULATION – CHECKS/FUNCTION TEST/FAULTFINDING AT JOBSITE…1816
      DETAILED EXPLANATION FOR THE ELECTRONIC REGULATION FOR ELECTRIC MOTOR POWERED MACHINES…1834
        ADJUSTMENTS/CHECKS FOR THE ELECTRONIC REGULATION – NORMAL…1836
        ADJUSTMENTS/CHECKS FOR THE ELECTRONIC REGULATION – CHECKS/FUNCTION TEST/FAULTFINING AT THE JOBSITE…1848
    OPERATING HYDRAULIC…1864
      REMOTE CONTROL, CONTROL BLOCKS AND DISTRIBUTOR MANIFOLD ARRANGEMENT…1866
        CONTROL BLOCKS…1868
        LOAD HOLDING VALVES…1870
        TRAVEL BRAKE VALVES…1872
        CONTROL BLOCK VALVES…1874
        PILOT OPERATED PRESSURE RELIEF VALVE…1876
      RESTRICTOR BLOCK…1878
        ANTI CAVITATION VALVE BLOCK…1880
        REMOTE CONTROL MANIFOLD…1882
        DIRECTIONAL SOLENOID VALVES…1884
        PROPORTIONAL SOLENOID VALVE…1886
        HIGH PRESSURE FILTER…1888
        HYDRAULIC CYLINDER…1890
      HYDRAULIC FOR ATTACHMENT CYLINDER…1892
        VALVES AND PRESSURE CHECK POINTS FOR LBA…1896
        REMOTE CONTROL SOLENOIDS VALVES LOCATION…1900
        EXEMPLARY EXPLANATION FOR ONE CIRCUIT…1904
      ADJUSTMENTS FOR THE ATTACHMENT CYLINDER HYDRAULIC…1914
      SLEW CIRCUIT…1932
        SLEW MOTOR (AXIAL PISTON MOTOR A2FM)…1936
        SLEW GEAR…1940
        SLEW GEAR HOUSE BRAKE…1942
        SLEW BRAKE VALVE…1944
        DETAILED EXPLANATION FOR RIGHT HAND SLEWING (EURO-CONTROL)…1950
        DETAILED EXPLANATION FOR LEFT HAND SLEWING (EURO-CONTROL)…1954
        SLEWING DOWN PATH…1956
        ANTICAVITATION CIRCUIT…1958
        ADJUSTMENTS FOR THE SLEW CIRCUIT…1960
      TRAVEL CIRCUIT…1964
        ROTARY DISTRIBUTOR…1968
        TRAVEL MOTOR (AXIAL PISTON MOTOR A2FM)…1970
        DRIVE ASSY…1974
        TRAVEL GEAR…1976
        TRAVEL GEAR HOUSE BRAKE…1978
        DETAILED EXPLANATION FOR "TRAVELLING FORWARD"…1982
        DETAILED EXPLANATION FOR "TRAVELLING BACKWARD"…1988
        ADJUSTMENTS FOR THE TRAVEL CIRCUIT…1992
    HYDRAULIC TRACK TENSION SYSTEM…1996
      GENERAL…1998
      FUNCTION…2000
      PRESSURE INCREASING VALVE TYPE: MO 7010…2004
      PRESSURE RELIEF VALVE, PILOT OPERATED TYPE: DBD S…2006
      ADJUSTMENTS…2008
    HYDRAULIC DRIVE FOR AIR CONDITION COMPRESSOR…2014
      HYDRAULIC DRIVE FOR AIR CONDITION COMPRESSOR…2016
        ADJUSTMENTS FOR THE HYDRAULIC AIR CONDITION DRIVE…2018
        SOLENOID VALVE…2020
        PRESSURE RELIEF VALVE, PILOT OPERATED TYPE: DBD S…2022
    GENERATOR DRIVE…2024
      FUNCTION…2026
      ELECTRICAL FUNCTION…2028
      BASIC ADJUSTMENTS…2032
      PRESSURE RELIEF VALVE WITH SOLENOID VALVE…2038
      AXIAL PISTON PUMP A10V 0…2040
    HINTS FOR THE HYDRAULIC CIRCUIT DIAGRAM…2044
      HINTS FOR READING THE CIRCUIT DIAGRAM…2048
      LEGEND TO THE HYDRAULIC CIRCUIT DIAGRAM H185 WITH DIESEL ENGINE…2050
      HOW TO READ THE CIRCUIT DIAGRAM…2056
    HINTS FOR THE ELECTRIC CIRCUIT DIAGRAM…2058
      MARKINGS OF ELECTRICAL COMPONENTS IN THE CIRCUIT DIAGRAMS (DIN 40719 PART 2)…2060
        SYMBOLS…2062
        DEMAG CIRCUIT DIAGRAMS…2066
        EXPLANATION OF THE DRAWING CONCEPT…2068
        LOCATION OF THE MAIN TERMINAL BOXES AND SOME IMPORTANT COMPONENTS…2070
        READING A CIRCUIT DIAGRAM…2072
  PART 3 APPENDIX…2078
    CONTENTS…2079
    ELECTRICAL DIAGRAM…2080
    HYDRAULIC DIAGRAM…2131

Komatsu/DEMAG Hydraulic Shovels H185S Repair Service Manuals + Operation & Maintenance Manual

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete Operation & Maintenance Manuals for Komatsu Bullozers D575, with all the technical information to maintain & operate.

SEAD000202 – Bullozer D575A-2 Operation & Maintenance Manual (SN10002&up).pdf
SEAD007901 – Super Dozer D575A-2 Operation & Maintenance Manual (SN10012&up).pdf
SEAD021800 – Bullozer D575A-2 Operation & Maintenance Manual (SN10035&up).pdf
SEAM007905T – Super Dozer D575A-2 Operation & Maintenance Manual (SN10042&up).pdf
SEAWD00500 – Super Dozer D575A-2 Field Assembly Manual (SN10012&up).pdf
SEAWD02700 – Super Dozer D575A-3 Field Assembly Manual (SN10101&up).pdf
TEN00237-01 – Super Dozer D575A-3 Operation & Maintenance Manual (SN10101&up).pdf

Total Pages: 1,205 pages
File Format: PDF
Language: English

MAIN SECTIONS
FOREWAORD
SAFETY INFORMATION
INTRODUCTION
LOCATION OF PLATES
OPERATION
MAINTENANCE
SPECIFICATIONS
OPTIONS, ATTACHMENTS
INDEX

SEAD000202 – Bullozer D575A-2 Operation & Maintenance Manual (SN10002&up)….2
1. FOREWORD….3
2. SAFETY INFORMATION….4
3. INTRODUCTION….5
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….6
5. CONTENTS….7
SAFETY ….10
6. GENERAL PRECAUTIONS ….11
7. PRECAUTIONS DURING OPERATION ….18
7.1 BEFORE STARTING ENGINE ….18
7.2 OPERATING MACHINE ….20
7.3 BATTERY ….23
8. PRECAUTIONS FOR MAINTENANCE ….24
8.1 BEFORE CARRYING OUT MAINTENANCE ….24
8.2 DURING MAINTENANCE ….26
9. POSITION FOR ATTACHING SAFETY LABELS ….31
OPERATION….34
10. GENERAL VIEW ….35
10.1 GENERAL VIEW OF MACHINE ….35
10.2 GENERAL VIEW OF CONTROLS AND GAUGES ….36
11. EXPLANATION OF COMPONENTS ….37
11.1 MONITOR PANEL ….37
11.2 SWITCHES….47
11.3 CONTROL LEVERS AND PEDALS….49
11.4 FUSE BOX….55
11.5 DOOR LOCK….56
11.6 CAP WITH LOCK….57
11.7 OPERATING THE CAR STEREO….58
11.8 OPERATING THE AIR CONDITIONER….61
12. OPERATION….67
12.1 CHECK BEFORE STARTING ENGINE….67
12.2 STARTING ENGINE….77
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….81
12.4 MOVING MACHINE….82
12.5 SHIFTING GEAR….83
12.6 SHIFTING BETWEEN FORWARD AND REVERSE….84
12.7 STEERING MACHINE….85
12.8 STOPPING MACHINE….87
12.9 PRECAUTIONS FOR OPERATION….88
12.10 WORK POSSIBLE USING BULLDOZER….90
12.11 EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER….91
12.12 OPERATING RIPPER….96
12.13 ADJUSTMENT QF WORK EQUIPMENT….99
12.14 PARKING MACHINE….102
12.15 CHECK AFTER FINISHING WORK….103
12.16 STOPPING ENGINE….104
12.17 CHECK AFTER STOPPING ENGINE….105
12.18 LOCKING….105
12.19 TIPS FOR LONGER UNDERCARRIAGE LIFE….106
13. HANDLING ACCUMULATOR….108
14. COLD WEATHER OPERATION….109
14.1 PRECAUTIONS FOR LOW TEMPERATURE….109
14.2 AFTER COMPLETION OF WORK….111
14.3 AFTER COLD WEATHER….111
15. LONG-TERM STORAGE (MORE THAN ONE MONTH)….112
15.1 BEFORE STORAGE….112
15.2 DURING STORAGE….113
15.3 AFTER STORAGE….113
16. TROUBLESHOOTING….114
16.1 AFTER RUNNING OUT OF FUEL….114
16.2 IF BATTERY IS DISCHARGED….114
16.3 OTHER TROUBLE….118
MAINTENANCE….121
17. GUIDES TO MAINTENANCE….122
18. OUTLINES OF SERVICE….125
18.1 OUTLINE OF OIL, FUEL, COOLANT….125
18.2 RELATING TO ELECTRIC SYSTEM….128
19. WEAR PARTS LIST….129
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….130
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….134
21.1 INTRODUCTION OF NECESSARY TOOLS….134
21.2 TORQUE LIST….135
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….136
23. MAINTENANCE SCHEDULE CHART….139
24. SERVICE PROCEDURE….142
24.1 INITIAL 250 HOURS SERVICE….142
24.2 WHEN REQUIRED….143
24.3 CHECK BEFORE STARTING….160
24.4 EVERY 250 HOURS SERVICE….165
24.5 EVERY 500 HOURS SERVICE….174
24.6 EVERY 1000 HOURS SERVICE….178
24.7 EVERY 2000 HOURS SERVICE….182
24.8 EVERY 4000 HOURS SERVICE….189
SPECIFICATIONS….190
25. SPECIFICATIONS….191
OPTIONS, ATTACHMENTS….193
26. GENERAL PRECAUTIONS….194
26.1 PRECAUTIONS RELATED TO SAFETY….194
27. USING SEAT BELT….195
27.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER….195
SEAD007901 – Super Dozer D575A-2 Operation & Maintenance Manual (SN10012&up)….197
1. FOREWORD….198
2. SAFETY INFORMATION….199
3. INTRODUCTION….200
3.1 INTENDED USE….200
3.2 FEATURES….200
3.3 BREAKING IN THE MACHINE….200
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….201
4.1 MACHINE SERIAL NO. PLATE POSITION….201
4.2 ENGINE SERIAL NO. PLATE POSITION….201
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….201
5. CONTENTS….202
SAFETY….205
6. GENERAL PRECAUTIONS….206
7. PRECAUTIONS DURING OPERATION….212
7.1 BEFORE STARTING ENGINE….212
7.2 AFTER STARTING ENGINE….214
7.3 BATTERY….220
8. PRECAUTIONS FOR MAINTENANCE….222
8.1 BEFORE CARRYING OUT MAINTENANCE….222
8.2 DURING MAINTENANCE….226
9. POSITION FOR ATTACHING SAFETY LABELS….231
9.1 POSITION FOR ATTACHING SAFETY LABELS….231
OPERATION….235
10. GENERAL VIEW….236
10.1 GENERAL VIEW OF MACHINE….236
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….237
11. EXPLANATION OF COMPONENTS….238
11.1 MONITOR PANEL….238
11.2 SWITCHES….249
11.3 CONTROL LEVERS AND PEDALS….251
11.4 FUSE BOX….255
11.5 DOOR LOCK….256
11.6 CAP WITH LOCK….257
11.7 HANDLING OF ENGINE OIL FILLER CAP….258
11.8 OPERATING THE CAR STEREO (MACHINES EQUIPPED WITH CAB, CAR RADIO)….259
11.9 OPERATING THE AIR CONDITIONER….266
12. OPERATION….272
12.1 CHECK BEFORE STARTING ENGINE….272
12.2 STARTING ENGINE….282
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….286
12.4 MOVING MACHINE….287
12.5 SHIFTING GEAR….288
12.6 SHIFTING BETWEEN FORWARD AND REVERSE….289
12.7 STEERING MACHINE….290
12.8 STOPPING MACHINE….292
12.9 PRECAUTIONS FOR OPERATION….293
12.10 PROHIBITED OPERATIONS WITH A SUPER-DOZER….295
12.11 EFFICIENT OPERATIONS OF A SUPER-DOZER….296
12.12 ADJUSTMENT OF WORK EQUIPMENT….298
12.13 PARKING MACHINE….299
12.14 CHECK AFTER FINISHING WORK….300
12.15 STOPPING ENGINE….301
12.16 CHECK AFTER STOPPING ENGINE….302
12.17 LOCKING….302
12.18 TIPS FOR LONGER UNDERCARRIAGE LIFE….303
13. HANDLING ACCUMULATOR….305
13.1 RELEASING REMAINING PRESSURE IN ACCUMULATOR CIRCUIT….305
14. COLD WEATHER OPERATION….306
14.1 PRECAUTIONS FOR LOW TEMPERATURE….306
14.2 AFTER COMPLETION OF WORK….308
14.3 AFTER COLD WEATHER….308
15. LONG-TERM STORAGE….309
15.1 BEFORE STORAGE….309
15.2 DURING STORAGE….309
15.3 AFTER STORAGE….309
16. TROUBLESHOOTING….310
16.1 AFTER RUNNING OUT OF FUEL….310
16.2 IF BATTERY IS DISCHARGED….310
16.3 OTHER TROUBLE….313
MAINTENANCE….316
17. GUIDES TO MAINTENANCE….317
18. OUTLINES OF SERVICE….319
18.1 OUTLINE OF OIL, FUEL, COOLANT….319
18.2 RELATING TO ELECTRIC SYSTEM….321
19. WEAR PARTS LIST….322
20. USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….323
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….327
21.1 INTRODUCTION OF NECESSARY TOOLS….327
21.2 TORQUE LIST….328
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….329
23. MAINTENANCE SCHEDULE CHART….332
23.1 MAINTENANCE SCHEDULE CHART….332
24. SERVICE PROCEDURE….335
24.1 INITIAL 250 HOURS SERVICE….335
24.2 WHEN REQUIRED….336
24.3 CHECK BEFORE STARTING….352
24.4 EVERY 250 HOURS SERVICE….357
24.5 EVERY 500 HOURS SERVICE….365
24.6 EVERY 1000 HOURS SERVICE….368
24.7 EVERY 2000 HOURS SERVICE….370
24.8 EVERY 4000 HOURS SERVICE….377
SPECIFICATIONS….378
25. SPECIFICATIONS….379
OPTIONS, ATTACHMENTS….381
26. GENERAL PRECAUTIONS….382
26.1 PRECAUTIONS RELATED TO SAFETY….382
27. USING SEAT BELT….383
27.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER….383
SEAD021800 – Bullozer D575A-2 Operation & Maintenance Manual (SN10035&up)….384
1. FOREWORD….385
2. SAFETY INFORMATION ….386
3. INTRODUCTION ….387
3.1 INTENDED USE ….387
3.2 FEATURES ….387
3.3 BREAKING IN THE MACHINE ….387
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ….388
4.1 MACHINE SERIAL NO. PLATE ….388
4.2 ENGINE SERIAL NO. PLATE POSITION….388
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ….388
5. CONTENTS….389
SAFETY….393
6. GENERAL PRECAUTIONS ….394
7. PRECAUTIONS DURING OPERATION….400
7.1 BEFORE STARTING ENGINE ….400
7.2 AFTER STARTING ENGINE….402
8. PRECAUTIONS FOR MAINTENANCE ….410
8.1 BEFORE CARRYING OUT MAINTENANCE….410
8.2 DURING MAINTENANCE ….414
9. POSITION FOR ATTACHING SAFETY LABELS ….419
OPERATION….423
10. GENERAL VIEW ….424
10.1 GENERAL VIEW OF MACHINE ….424
10.2 GENERAL VIEW OF CONTROLS AND GAUGES ….425
11. EXPLANATION OF COMPONENTS ….426
11.1 MONITOR PANEL ….426
11.2 SWITCHES ….439
11.3 CONTROL LEVERS AND PEDALS….442
11.4 FUSE BOX ….446
11.5 DOOR LOCK ….447
11.6 CAP WITH LOCK ….448
11.7 HANDLING OF ENGINE OIL FILLER CAP ….449
11.8 OPERATING THE CAR STEREO (MACHINES EQUIPPED WITH CAB, CAR RADIO) ….450
11.9 OPERATING THE AIR CONDITIONER….457
11.10 CONTROLLER ….463
12. OPERATION ….465
12.1 CHECK BEFORE STARTING ENGINE ….465
12.2 STARTING ENGINE….474
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE ….478
12.4 MOVING MACHINE ….480
12.5 SHIFTING GEAR ….481
12.6 SHIFTING BETWEEN FORWARD AND REVERSE ….482
12.7 STEERING MACHINE ….483
12.8 STOPPING MACHINE ….486
12.9 PRECAUTIONS FOR OPERATION ….487
12.10 WORK POSSIBLE USING BULLDOZER….489
12.11 OPERATING RIPPER ….490
12.12 ADJUSTMENT OF WORK EQUIPMENT ….494
12.13 PARKING MACHINE ….497
12.14 CHECK AFTER FINISHING WORK ….498
12.15 STOPPING ENGINE ….499
12.16 CHECK AFTER STOPPING ENGINE ….500
12.17 LOCKING….500
12.18 TIPS FOR LONGER UNDERCARRIAGE LIFE ….501
13. HANDLING ACCUMULATOR ….507
13.1 RELEASING REMAINING PRESSURE IN ACCUMULATOR CIRCUIT….507
14. COLD WEATHER OPERATION ….508
14.1 PRECAUTIONS FOR LOW TEMPERATURE ….508
14.2 AFTER COMPLETION OF WORK ….510
14.3 AFTER COLD WEATHER ….510
15. LONG-TERM STORAGE (MORE THAN ONE MONTH) ….511
15.1 BEFORE STORAGE ….511
15.2 DURING STORAGE ….512
15.3 AFTER STORAGE ….512
16. TROUBLESHOOTING ….513
16.1 AFTER RUNNING OUT OF FUEL ….513
16.2 IF BATTERY IS DISCHARGED ….513
16.3 OTHER TROUBLE….517
16.4 WHEN MODE SELECTION SYSTEM CAUTION LAMP FLASHES….520
MAINTENANCE….523
17. GUIDES TO MAINTENANCE ….524
18. OUTLINES OF SERVICE ….527
18.1 OUTLINE OF OIL, FUEL, COOLANT ….527
18.2 RELATING TO ELECTRIC SYSTEM ….530
19. WEAR PARTS LIST ….531
20. USE OF FUEL, COOLANT AND LUBRICANTS….532
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS ….536
21.1 INTRODUCTION OF NECESSARY TOOLS ….536
21.2 TORQUE LIST ….537
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ….538
23. MAINTENANCE SCHEDULE CHART ….541
23.1 MAINTENANCE SCHEDULE CHART ….541
24. SERVICE PROCEDURE ….544
24.1 INITIAL 250 HOURS SERVICE….544
24.2 WHEN REQUIRED ….545
24.3 CHECK BEFORE STARTING ….562
24.4 EVERY 250 HOURS SERVICE ….567
24.5 EVERY 500 HOURS SERVICE ….576
24.6 EVERY 1000 HOURS SERVICE ….580
24.7 EVERY 2000 HOURS SERVICE….584
24.8 EVERY 4000 HOURS SERVICE ….591
SPECIFICATIONS….593
25. SPECIFICATIOIUS ….594
OPTIONS, ATTACHMENTS….597
26. GENERAL PRECAUTIONS ….598
26.1 PRECAUTIONS RELATED TO SAFETY ….598
27. USING SEAT BELT ….599
27.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER ….599
SEAM007905T – Super Dozer D575A-2 Operation & Maintenance Manual (SN10042&up)….602
COVER….602
1. FOREWORD….603
2. SAFETY INFORMATION….606
3. INTRODUCTION….607
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….608
5. CONTENTS….609
SAFETY….612
6. GENERAL PRECAUTIONS….613
7. PRECAUTIONS DURING OPERATION….619
7.1 BEFORE STARTING ENGINE….619
7.2 AFTER STARTING ENGINE….621
7.3 BATTERY….627
8. PRECAUTIONS FOR MAINTENANCE ….629
8.1 BEFORE CARRYING OUT MAINTENANCE….629
8.2 DURING MAINTENANCE….633
9. POSITION FOR ATTACHING SAFETY LABELS….638
9.1 POSITION FOR ATTACHING SAFETY LABELS….638
9.2 CONTENT AND USE OF WARNING PLATES….642
OPERATION….643
10. GENERAL VIEW….644
10.1 GENERAL VIEW OF MACHINE….644
10.2 GENERAL VIEW OF CONTROLS AND GAUGES….645
11. EXPLANATION OF COMPONENTS….646
11.1 MONITOR PANEL….646
11.2 SWITCHES….657
11.3 CONTROL LEVERS AND PEDALS….659
11.4 FUSE BOX….663
11.5 DOOR LOCK….664
11.6 CAP WITH LOCK….665
11.7 HANDLING OF ENGINE OIL FILLER CAP….666
11.8 OPERATING THE CAR STEREO ….667
11.9 OPERATING THE AIR CONDITIONER….674
12. OPERATION….680
12.1 CHECK BEFORE STARTING ENGINE….680
12.2 STARTING ENGINE….690
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE….694
12.4 MOVING MACHINE….695
12.5 SHIFTING GEAR….696
12.6 SHIFTING BETWEEN FORWARD AND REVERSE….697
12.7 STEERING MACHINE….698
12.8 STOPPING MACHINE….700
12.9 PRECAUTIONS FOR OPERATION….701
12.10 PROHIBITED OPERATIONS WITH A SUPER-DOZER….703
12.11 EFFICIENT OPERATIONS OF A SUPER-DOZER….704
12.12 ADJUSTMENT OF WORK EQUIPMENT….706
12.13 PARKING MACHINE….707
12.14 CHECK AFTER FINISHING WORK….708
12.15 STOPPING ENGINE….709
12.16 CHECK AFTER STOPPING ENGINE….710
12.17 LOCKING….710
12.18 TIPS FOR LONGER UNDERCARRIAGE LIFE….711
13. HANDLING ACCUMULATOR….713
13.1 RELEASING REMAINING PRESSURE IN ACCUMULATOR CIRCUIT….713
14. COLD WEATHER OPERATION….714
14.1 PRECAUTIONS FOR LOW TEMPERATURE….714
14.2 AFTER COMPLETION OF WORK….716
14.3 AFTER COLD WEATHER….716
15. LONG-TERM STORAGE….717
15.1 BEFORE STORAGE….717
15.2 DURING STORAGE….717
15.3 AFTER STORAGE….717
16. TROUBLESHOOTING….718
16.1 AFTER RUNNING OUT OF FUEL….718
16.2 IF BATTERY IS DISCHARGED….718
16.3 OTHER TROUBLE….721
MAINTENANCE….724
17. GUIDES TO MAINTENANCE….725
18. OUTLINES OF SERVICE….727
18.1 OUTLINE OF OIL,FUEL,COOLANT….727
18.2 RELATING TO ELECTRIC SYSTEM….729
19. WEAR PARTS LIST….730
20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….731
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….735
21.1 INTRODUCTION OF NECESSARY TOOLS….735
21.2 TORQUE LIST….736
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….737
23. MAINTENANCE SCHEDULE CHART….740
24. SERVICE PROCEDURE….743
24.1 INITIAL 250 HOURS SERVICE….743
24.2 WHEN REQUIRED….744
24.3 CHECK BEFORE STARTING….760
24.4 EVERY 250 HOURS SERVICE….765
24.5 EVERY 500 HOURS SERVICE….773
24.6 EVERY 1000 HOURS SERVICE….776
24.7 EVERY 2000 HOURS SERVICE….778
24.8 EVERY 4000 HOURS SERVICE….785
SPECIFICATIONS….786
25. SPECIFICATIONS….787
OPTIONS,ATTACHMENTS….789
26. GENERAL PRECAUTIONS….790
26.1 PRECAUTIONS RELATED TO SAFETY….790
27. USING SEAT BELT ….791
27.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER….791
SEAWD00500 – Super Dozer D575A-2 Field Assembly Manual (SN10012&up)….793
COVER….793
CONTENTS….796
ASSEMBLY PROCEDURE &TIME SCHEDULE (TRANSPORTED DISASSEMBLED-WEIGHTS LESS THAN 50 TONS)….797
EQUIPMENT AND TOOLS TO BE USED….798
TRANSPORTATION POSTURE….800
INSTALLATION PROCEDURE….802
1. Installation of main unit….802
2. Installation of final drive Assembly….803
3. Installation of pivot shaft….804
4. Installation of cylinder support….805
5. Installation of cylinder stay….806
6. Installation of undercarriage….806
7. Installation of track shoe Assembly….808
8. Installation of counterweight….812
9. Installation of blade lift cylinder….813
10. Assembly of super blade Assembly….814
Bleeding air from hydraulic cylinders….819
Standard tightening torque….820
Coating materials….822
11. Installation of cab….823
Electrical circuit diagram….830
12. Installation of ROPS….832
13. Installation of external components….833
Exhaust pipes and hoods….833
Head lamp….834
ROPS light….835
External cover….836
Hand rail….837
ASSEMBLY JIG DRAWING….839
SEAWD02700 – Super Dozer D575A-3 Field Assembly Manual (SN10101&up)….846
COVER….846
CONTENTS….847
1. ASSEMBLY PROCEDURE & TIME SCHEDULE(TRANSPORTED DISASSEMBLED – WEIGHTS LESS THAN 50 TONS)….848
2. EQUIPMENT AND TOOLS TO BE USED….849
3. ASSEMBLY MAP FOR TOOLS TO USED….850
4. TRANSPORTATION POSTURE….851
5. INSTALLATION PROCEDURE….852
(1) UNLOADING BARE MACHINE….852
(2) INSTALLATION OF OPERATING CABIN….853
(3) INSTALLATION OF FOODS & EXHAUST PIPE….861
(4) INSTALLATION OF PIVOT SHAFT….862
(5) INSTALLATION OF FINAL DRIVE….863
(6) INSTALLATION & REMOVAL OF CYLINDER SUPPORT….867
(7) INSTALLATION OF UNDERCARRIAGE….869
(8) INSTALLATION OF TRACK SHOE ASSEMBLY & TRUNNION….873
(9) INSTALLATION OF BLADE CYLINDER & STAY….875
(10) ASSEMBLE OF BLADE ASSEMBLY….876
(11) INSTALLATION OF COUNTER WEIGHT….878
(12) INSTALLATION OF ROPS….879
(13) INSTALLATION OF HEAD LAMP….883
(14) INSTALLATION OF HANDRAILS….884
(15) INSTALLATION OF BLADE ASSEMBLY….889
(16) INSTALLATION OF POTENTIOMETER….893
(17) ADJUSTMENT OF TRACK TENSION & ALIGNMENT FOR CARRIER ROLLER….894
(18) LUBRICATING ITEMS….895
6. PROCEDURE MANUAL FOR INITIAL SETTING TILT LIMIT….898
7. HOW TO CHECK AUTOMATIC RESETTING TO SYSTEMS….901
8. BLEDDING AIR FROM HYDRAULIC CYLINDER….902
9. TABLE OF FUEL COOLANT AND LUBRICANTS….903
10. COATING MATERIALS….906
11. STANDARD TIGHENING TORQUE….908
12. WEAR PARTS LIST….911
13. HOW TO CHECK ERROR CODE….912
14. ERROR CODE LIST….913
ANNEX DATE 1. ASSEMBLY JIG DRAWING….918
ANNEX DATE 2. INSTALLATION OF SPILL GUARD TO THE SUPPER BLADE….924
CHECK SHEET….930
TEN00237-01 – Super Dozer D575A-3 Operation & Maintenance Manual (SN10101&up)….939
COVER….939
FOREWORD….940
FOREWORD….941
SAFETY INFORMATION….944
INTRODUCTION….946
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE….946
VISIBILITY FROM OPERATOR'S SEAT….947
BREAKING IN THE MACHINE….948
NECESSARY INFORMATION….949
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE….949
ENGINE SERIAL NO. PLATE AND POSITION….949
BLADE SERIAL NO. PLATE POSITION….950
POSITION OF SERVICE METER….950
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….951
CONTENTS….952
SAFETY….956
SAFETY….957
SAFETY LABELS….959
POSITIONS OF SAFETY PICTOGRAMS….960
SAFETY LABELS….961
GENERAL PRECAUTIONS….965
SAFETY RULES….965
IF ABNORMALITIES ARE FOUND….965
CLOTHING AND PERSONAL PROTECTIVE ITEMS….965
FIRE EXTINGUISHER AND FIRST AID KIT….965
SAFETY FEATURES….965
KEEP MACHINE CLEAN….966
INSIDE OPERATOR'S COMPARTMENT….966
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT….966
HANDRAILS AND STEPS….967
PRECAUTIONS WHEN WORKING IN HIGH PLACES….967
MOUNTING AND DISMOUNTING….967
NO PEOPLE ON ATTACHMENTS….967
CRUSHING OR CUTTING PREVENTION….968
PREVENTION OF BURNS….968
FIRE PREVENTION….969
ACTION IF FIRE OCCURS….970
WINDOW WASHER LIQUID….970
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)….970
PRECAUTIONS FOR ATTACHMENTS….970
CAB WINDOW GLASSES….970
UNAUTHORIZED MODIFICATION….970
SAFETY AT WORKSITE….971
WORKING ON LOOSE GROUND….971
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES….972
ENSURE GOOD VISIBILITY….972
VENTILATION FOR ENCLOSED AREAS….973
CHECKING SIGNALMAN'S SIGNALS AND SIGNS….973
BE CAREFUL ABOUT ASBESTOS DUST….973
PRECAUTIONS FOR OPERATION….974
BEFORE STARTING ENGINE….974
CHECKS BEFORE STARTING ENGINE….974
PRECAUTIONS WHEN STARTING….975
PRECAUTIONS IN COLD AREAS….975
OPERATION….976
CHECKS BEFORE OPERATION….976
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE….976
PRECAUTIONS WHEN TRAVELING….977
TRAVELING ON SLOPES….978
PROHIBITED OPERATIONS….978
USING BRAKES….978
OPERATE CAREFULLY ON SNOW….978
PARKING MACHINE….979
TRANSPORTATION….980
LOADING AND UNLOADING….980
SHIPPING….980
BATTERY….981
BATTERY HAZARD PREVENTION….981
STARTING WITH BOOSTER CABLE….982
TOWING….983
WHEN TOWING….983
PRECAUTIONS FOR MAINTENANCE….984
WARNING TAG….984
KEEP WORK PLACE CLEAN AND TIDY….984
APPOINT LEADER WHEN WORKING WITH OTHERS….984
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE….985
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….986
PROPER TOOLS….986
HANDLING ACCUMULATOR….987
PERSONNEL….987
ATTACHMENTS….987
WORK UNDER THE MACHINE….987
NOISE….988
PRECAUTIONS WHEN USING HAMMER….988
REPAIR WELDING….988
REMOVING BATTERY TERMINAL….988
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….988
DO NOT DISASSEMBLE RECOIL SPRING….989
PRECAUTION WITH HIGH-PRESSURE OIL….989
PRECAUTION FOR HIGH FUEL PRESSURE….989
HANDLING HIGH-PRESSURE HOSES….989
PRECAUTION FOR HIGH VOLTAGE….990
WASTE MATERIAL….990
MAINTENANCE FOR AIR CONDITIONER….990
COMPRESSED AIR….990
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….990
OPERATION….992
GENERAL VIEW….993
GENERAL VIEW OF MACHINE….993
GENERAL VIEW OF CONTROLS AND GAUGES….994
EXPLANATION OF COMPONENTS….996
MONITOR PANEL….996
LAMPS….1013
SWITCHES….1015
CONTROL LEVERS, PEDALS….1018
CONTROLLER….1023
DUST INDICATOR….1024
FUSE BOX….1025
FUSIBLE LINK….1028
CAP WITH LOCK….1029
DOOR OPEN LOCK….1030
SASH GLASS INTERMEDIATE LOCK….1030
NET POCKET….1031
ASHTRAY….1031
TOOL BOX….1031
ENGINE OIL FILLER CAP….1032
CAR STEREO, HANDLING….1033
AIR CONDITIONER, HANDLING….1042
ACCUMULATOR, HANDLING….1049
OPERATION….1051
CHECK BEFORE STARTING ENGINE, ADJUST….1051
STARTING ENGINE….1069
OPERATIONS AND CHECKS AFTER STARTING ENGINE….1073
STOPPING ENGINE….1075
MOVING MACHINE….1076
STOPPING MACHINE….1078
SHIFTING GEAR….1079
SHIFTING BETWEEN FORWARD AND REVERSE….1083
STEERING MACHINE….1085
PRECAUTIONS FOR OPERATION….1088
PARKING MACHINE….1090
CHECK AFTER STOPPING ENGINE….1092
CHECK AFTER FINISHING WORK….1092
LOCKING….1092
PROHIBITED WORK OF SUPER DOZER….1093
EFFECTIVE USE OF SUPER DOZER….1095
EFFECTIVE USE OF MODE SELECTION SYSTEM….1098
ADJUSTING POSTURE OF WORK EQUIPMENT….1103
TIPS FOR LONGER UNDERCARRIAGE LIFE….1105
TRANSPORTATION….1107
TRANSPORTATION PROCEDURE….1107
METHOD OF LIFTING MACHINE….1107
TRAVELING ON ROADS….1108
COLD WEATHER OPERATION….1109
PRECAUTIONS FOR LOW TEMPERATURE….1109
AFTER COMPLETION OF WORK….1111
AFTER COLD WEATHER….1111
LONG-TERM STORAGE….1112
BEFORE STORAGE….1112
DURING STORAGE….1112
AFTER STORAGE….1112
STARTING MACHINE AFTER LONG-TERM STORAGE….1112
TROUBLESHOOTING….1113
AFTER RUNNING OUT OF FUEL….1113
METHOD OF TOWING MACHINE….1113
IF BATTERY IS DISCHARGED….1114
OTHER TROUBLE….1117
WHEN MODE SELECTION SYSTEM FLASHES….1122
MAINTENANCE….1124
GUIDES TO MAINTENANCE….1125
OUTLINES OF SERVICE….1128
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1128
OUTLINE OF ELECTRIC SYSTEM….1131
HANDLING HYDRAULIC RELATED EQUIPMENT….1132
WEAR PARTS….1133
WEAR PARTS LIST….1133
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….1134
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….1136
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….1137
TORQUE LIST….1137
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….1138
SAFETY CRITICAL PARTS….1139
MAINTENANCE SCHEDULE CHART….1140
MAINTENANCE SCHEDULE CHART….1140
SERVICE PROCEDURE….1142
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….1142
WHEN REQUIRED….1143
CLEAN INSIDE OF COOLING SYSTEM….1143
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1146
CHECK AND ADJUST TRACK TENSION….1149
CHECK AND TIGHTEN TRACK SHOE BOLTS….1151
ADJUST IDLER CLEARANCE….1154
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES….1155
CHECK, REPLACE FAN BELT….1156
CLEAN AND CHECK RADIATOR FINS….1157
CLEAN FUEL TANK STRAINER….1157
CHECK ETHER SPRAY, REPLACE ETHER CYLINDER….1158
DRAIN WATER AND SEDIMENT IN FUEL TANK….1158
CHECK AND ADJUST AIR CONDITIONER….1159
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)….1160
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….1160
CLEAN STEERING CLUTCH CASE BREATHER….1160
CHECK UNDERCARRIAGE OIL….1161
LUBRICATE DOOR HINGE….1162
REPLACE WIPER BLADE….1162
BLEEDING AIR IN HYDRAULIC SYSTEM….1163
LUBRICATING….1164
CHECK BEFORE STARTING….1165
EVERY 250 HOURS SERVICE….1166
LUBRICATING….1166
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST….1168
CHECK LEVEL OF BATTERY ELECTROLYTE….1169
CHECK BRAKE PERFORMANCE….1172
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….1173
EVERY 500 HOURS SERVICE….1174
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1174
REPLACE FUEL FILTER CARTRIDGE….1176
REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT….1177
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1178
EVERY 1000 HOURS SERVICE….1179
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS….1179
CHECK, CLEAN FUEL STRAINER….1180
CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL….1181
LUBRICATE UNIVERSAL JOINT….1181
CHECK TIGHTENING PARTS OF TURBOCHARGER….1181
REPLACE CORROSION RESISTOR CARTRIDGE….1182
CHECK FOR LOOSE ROPS MOUNT BOLTS….1182
EVERY 2000 HOURS SERVICE….1183
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT….1183
CHANGE OIL IN FINAL DRIVE CASE….1185
CHANGE OIL IN DAMPER CASE, CLEAN DAMPER….1186
CLEAN PPC STRAINER….1186
CHECK PIVOT BEARING OIL LEVEL, ADD OIL….1188
CLEAN ENGINE BREATHER ELEMENT….1189
CHECK FOR LEAKAGE OF OIL FROM GEAR COUPLING….1189
CHECK ALTERNATOR, STARTING MOTOR….1189
CHECK ENGINE VALVE CLEARANCE, ADJUST….1189
LUBRICATE FAN ROTATION SHAFT SPLINE….1189
REPLACE HYDRAULIC TANK BREATHER ELEMENT….1190
EVERY 4000 HOURS SERVICE….1191
CHECK WATER PUMP….1191
CHECK VIBRATION DAMPER….1191
CLEAN, CHECK TURBOCHARGER….1191
CHECK PLAY OF TURBOCHARGER ROTOR….1191
CHECK FAN PULLEY AND TENSION PULLEY….1191
CHECK MAIN FRAME, WORK EQUIPMENT (BLADE)….1192
SPECIFICATIONS….1194
SPECIFICATIONS….1195
ATTACHMENTS, OPTIONS….1196
GENERAL PRECAUTIONS….1197
PRECAUTIONS RELATED TO SAFETY….1197
SELECTION OF TRACK SHOE….1198
SELECTION OF TRACK SHOES….1198
HANDLING MACHINES EQUIPPED WITH VHMS….1199
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED….1199
VHMS AND COMMUNICATIONS TERMINAL INSTALLED….1200
INDEX….1202

Komatsu Bullozers D575 Operation & Maintenance Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete Operation & Maintenance Manuals for Komatsu Bulldozers D455-series, with all the technical information to maintain & operate.

D455A.1-AE1 – Bulldozer D455A-1 Operation & Maintenance Manual.pdf
GEN00012-00 (Replaces SEAW005000) – Bulldozer GALEO D475A-5 Field Assembly Manual (SN20001&up).pdf
GEN00051-05 – Bulldozer D475A-5E0, D475ASD-5E0 Field Assembly Manual (SN30001&up).pdf
SEAD019M0202 – Bulldozer D475A-2 Operation & Maintenance Manual (SN10201&up).pdf
SEAD019M0203 – Bulldozer D475A-2 Operation & Maintenance Manual (SN10282&up).pdf
SEAD046800 – D475A-3 (Palm Control Specification) Operation & Maintenance Manual (SN10695&up).pdf
SEAM198A05 – Bulldozer D455A-1 Operation & Maintenance Manual.pdf
SEAM007603T – Bulldozer D475A-2 Operation & Maintenance Manual (SN10365&up).pdf
SEAM022005T – Super Dozer D475A-3 Operation & Maintenance Manual (SN10685&up).pdf
SEAM025103T – Bulldozer D475A-3 Operation & Maintenance Manual (SN10601&up).pdf
SEAM025105T – Bulldozer D475A-3 Operation & Maintenance Manual (SN10685&up).pdf
SEAWD02302 – Super Dozer D475A-3 Operation & Maintenance Manual (SN10601&up).pdf
TEN00018-05 – Bulldozer D475A-5 Operation & Maintenance Manual (SN20001&up).pdf
TEN00025-04 – Bulldozer D475A-5 Operation & Maintenance Manual (SN20001&up).pdf
TEN00094-03 – Bulldozer D475A-5 Operation & Maintenance Manual (SN20001&up).pdf
TEN00132-05 – Bulldozer D475A-5E0 Operation & Maintenance Manual (SN30001&up).pdf
TEN00136-05 – Bulldozer D475ASD-5E0 Operation & Maintenance Manual (SN30001&up).pdf
TEN00282-03 – Bulldozer D475A-5E0 Operation & Maintenance Manual (SN30071&up).pdf
TEN00283-03 – Bulldozer D475ASD-5E0 Operation & Maintenance Manual (SN30071&up).pdf
TEN00374-00 – Bulldozer D475A-5E0 Operation & Maintenance Manual (SN30126&up).pdf
TEN00483-02 – Bulldozer D475A-5E0 Operation & Maintenance Manual (SN30134&up).pdf

PRODUCT DETAILS:
Total Pages: 5,522 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
FOERWORD
CONTENTS
SAFETY
OPERATION
MAINTENANCE
SPECIFICATIONS
ATTACHMENTS, OPTIONS
INDEX

D455A.1-AE1 – Bulldozer D455A-1 Operation & Maintenance Manual…2
COVER…2
FOREWORD…3
BREAKING IN YOUR NEW MACHINE…4
CONTENTS…5
GENERAL LOCATIONS…6
SOME SAFETY HINTS…8
PUTTING YOUR BULLDOZER TO WORK…14
OPERATOR'S COMPARTMENT…16
INSTRUMENTS AND CONTROLS…20
CHECKS BEFORE STARTING…33
STARTING AND STOPPING THE ENGINE…39
OPERATING THE MACHINE…43
BLADE OPERATION…47
RIPPER OPERATION…49
PERIODICAL MAINTENANCE…54
GENERAL PRECAUTIONS FOR MAINTENANCE…55
EXCHANGE OF COOLING WATER…57
EVERY 250 HOUR SERVICE OPERATION…58
EVERY 500 HOUR SERVICE OPERATION…77
EVERY 1000 HOUR SERVICE OPERATION…78
EVERY 2000 HOUR SERVICE OPERATION…87
EVERY 4000 HOUR SERVICE OPERATION…94
ADJUSTMENT…95
LIST OF PERIODICAL MAINTENANCE…103
TROUBLE SHOOTING GUIDE…108
COLD WEATHER OPERATION…112
STORAGE…116
SERVICE METER…118
MACHINE AND ENGINE SERIAL NUMBERS…119
SPECIFICATIONS…120
FUEL AND LUBRICANTS…123
GEN00012-00 (Replaces SEAW005000) – Bulldozer GALEO D475A-5 Field Assembly Manual (SN20001&up)…125
COVER…125
CONTENTS…127
SPECIFICATIONS…128
PRECAUTIONS FOR FIELD ASSEMBLY…130
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE…131
LAYOUT OF KIT…132
STYLE FOR TRANSPORTATION…133
TOOLS LIST FOR FIELD ASSEMBLY…138
TIGHTENING TORQUE…145
COATING MATERIALS…149
A. ASSEMBLY PROCEDURE…152
A-1 INSTALLATION OF UNDERCARRIAGE…153
A-2 INSTALLATION OF RIPPER…160
A-3 INSTALLATION OF TRACKS…164
A-4 ADDING OIL TO PIVOT CHAMBER…166
A-5 INSTALLATION OF RIPPER SHANK…167
A-6 INSTALLATION OF BLAD LIFT CYLINDER…168
A-7 INSTALLATION OF TRUNNION…170
A-8 ASSEMBLY OF BLADE…171
A-9 ADJUSTMENT OF ARM JOINT (U-BLADE)…177
A-10 INSTALLATION OF BLADE…178
A-11 INSTALLATION OF COUNTERWEIGHT…180
A-12 INSTALLATION OF OPERATOR'S CAB…181
A-13 INSTALLATION OF ROPS…197
A-14 ADJUSTMENT OF POTENTIOMETER ROD…198
A-15 PROCEDURE FOR ADJUSTING BLADE TILT ANGLE LIMIT …199
A-16 METHOD OF CHECKING AUTOR-RESET SYSTEM (SUPERDOZER…208
A-17 CHECK TRACK TENSION…209
A-18 CHECKING FUEL, COOLANT AND LUBRICANTS…211
A-19 GREASING OF GREASING POINT…213
A-20 INSTALLATION OF ORTBOCMM ANTENNA AND WIRING HARNESS…216
A-21 REPLACEMENT OF RETURN FILTER (REPLACEMENT OF STANDARD FILTER WITH FLUSHING FILTER)…217
A-22 INSTALLING DIRECTION OF EXHAUST PIPE…220
A-23 BLEEDING AIR FROM HYDRAULIC CYLINDERS…221
A-24 INSTALLING LUNCHBOX BAND (IF EQUIPPED)…222
M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY…224
M-1 CHECK AND ADJUSTMENT OF OPERATOR'S CAB…225
M-2 ERROR CODE…232
M-3 FLUSHING OF HYDRAULIC CIRCUIT…241
APPENDIX 1…242
INSTALLATION OF SPILL GUARDS…242
APPENDIX 2…256
PRECAUTIONS FOR INITIALIZATION PROCEDURES FOR VHMS CONTROLLER…256
FIELD ASSEMBLY INSPECTION REPORT (U-DOZER SPECIFICATION)…284
FIELD ASSEMBLY INSPECTION REPORT (SUPERDOZER SPECIFICATION)…294
GEN00051-05 – Bulldozer D475A-5E0, D475ASD-5E0 Field Assembly Manual (SN30001&up)…304
Cover…304
Preface…305
CONTENTS…307
SPECIFICATIONS…309
PRECAUTIONS FOR FIELD ASSEMBLY…311
DISPOSAL OF REMOVED PARTS…312
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE…313
KIT LAYOUT DIAGRAM…314
STYLE FOR TRANSPORTATION…315
TOOLS LIST FOR FIELD ASSEMBLY…321
SKETCH OF TOOLS…324
TIGHTENING TORQUE…333
COATING MATERIALS…337
A. Assembly…339
A- 1. Setting of track shoe…340
A- 2. Setting of the machine…341
A- 3. Installation of blade lift hydraulic cylinder…344
A- 4. Installation of undercarriage…350
A- 5. Adding oil to pivot chamber…366
A- 6. Check of oil and coolant levels…367
A- 7. Installation of ripper…369
A- 8. Installation of trunnion…374
A- 9. Installation of track shoe…375
A-10. Check track tension…378
A-11. Assembly of blade…380
A-12. Installation of blade…400
A-13. Installation of operator's cab…408
A-14. Installation of ROPS…428
A-15. Installing direction of exhaust pipe…429
A-16. Installation of giant ripper shank…430
A-17. Adjustment of arm joint (U-blade)…431
A-18. Installation of counterweight…432
A-19. Procedure for adjusting blade tilt angle limit…433
A-20. Method of checking auto-reset system (Superdozer)…442
A-21. Installation of ORBCOMM antenna and wiring harness…443
A-22. Installing lunchbox band (if equipped)…444
A-23. Greasing each part of work equipment…446
A-24. Bleeding air from hydraulic cylinders…449
A-25. Air bleeding from work equipment pump and fan pump…450
M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY…451
M- 1. Check and adjustment of operator’s cab…452
M- 2. Inspection of machine monitor…459
M- 3. No-injection cranking of engine…472
M- 4. Setting procedure of user adjust mode…475
M- 5. Replacement of return filter (Replacement of standard filter -> special flushing parts)…478
M- 6. Flushing of hydraulic circuit, and bleeding air from hydraulic cylinders (Part 1)…480
M- 7. Replacement of return filter (Replacement of special flushing parts -> standard filter)…481
M- 8. Bleeding air from hydraulic cylinders (Part 2)…483
APPENDIX 1. …485
APPENDIX 2. PRECAUTIONS FOR INITIALIZATION PROCEDURES FOR VHMS CONTROLLER…499
FIELD ASSEMBLY INSPECTION REPORT (U-DOZER SPECIFICATION)…521
FIELD ASSEMBLY INSPECTION REPORT (SUPERDOZER SPECIFICATION)…535
SEAD019M0202 – Bulldozer D475A-2 Operation & Maintenance Manual (SN10201&up)…548
CONTENTS…551
OPERATION…552
GENERAL LOCATIONS AND SPECIFICATIONS…552
INSTRUMENTS AND CONTROLS…554
CHECK BEFORE STARTING…592
OPERATING YOUR MACHINE…598
COLD WEATHER OPERATION…618
OPERATING RIPPER…624
SELECTION OF RIPPER POINT…628
BULLDOZER'S WORK…630
TIPS FOR LONGER UNDERCARRIAGE LIFE…632
ADJUSTMENT OF WORK EQUIPMENT…634
MAINTENANCE…639
PERIODIC MAINTENANCE…639
PERIODICAL REPLACEMENT OF SAFETY PARTS…640
MAINTENANCE TABLE…643
OIL FILLER AND LEVEL GAUGE POSITIONS…647
EVERY 250 HOURS SERVICE…649
EVERY 500 HOURS SERVICE…657
EVERY 1000 HOURS SERVICE…659
EVERY 2000 HOURS SERVICE…663
EVERY 4000 HOURS SERVICE…668
WHEN REQUIRED…669
ADJUSTMENT…682
TROUBLESHOOTING GUIDE…686
SERVICE METER…690
MACHINE AND ENGINE SERIAL NUMBERS…692
FUEL, COOLANT AND LUBRICANTS…694
SAFETY AND OPERATION…696
CONTENTS…697
SAFETY HINTS…698
PRECAUTIONS FOR MAINTENANCE…712
CAR STEREO…718
AIR CONDITIONER…722
LOCKING CAP…728
HANDLING OF BATTERY…730
STORAGE…733
COOLANT AND LUBRICANTS…734
SEAD019M0203 – Bulldozer D475A-2 Operation & Maintenance Manual (SN10282&up)…736
CONTENTS…739
OPERATION…740
GENERAL LOCATIONS AND SPECIFICATIONS…740
INSTRUMENTS AND CONTROLS…742
CHECK BEFORE STARTING…778
OPERATING YOUR MACHINE …784
COLD WEATHER OPERATION …804
OPERATING RIPPER …810
SELECTION OF RIPPER POINT …814
BULLDOZER’S WORK …816
TIPS FOR LONGER UNDERCARRIAGE LIFE …818
ADJUSTMENT OF WORK EQUIPMENT …820
MAINTENANCE…825
PERIODIC MAINTENANCE …825
PERIODICAL REPLACEMENT OF SAFETY PARTS …826
MAINTENANCE TABLE…829
OIL FILLER AND LEVEL GAUGE POSITIONS …833
EVERY 250 HOURS SERVICE…835
EVERY 500 HOURS SERVICE…843
EVERY 1000 HOURS SERVICE…845
EVERY 2000 HOURS SERVICE…849
EVERY 4000 HOURS SERVICE…853
WHEN REQUIRED…855
ADJUSTMENT …869
TROUBLE SHOOTING GUIDE …873
SERVICE METER …877
MACHINE AND ENGINE SERIAL …879
FUEL, COOLANT AND LUBRICANTS …881
SAFETY AND OPERATION…883
CONTENTS …884
SAFETY HINTS …885
PRECAUTIONS FOR MAINTENANCE…899
CAR STEREO…905
AIR CONDITIONER …909
LOCKING CAP …917
HANDLING OF BATTERY …919
STORAGE …922
COOLANT AND LUBRICANTS …923
SEAD046800 – D475A-3 (Palm Control Specification) Operation & Maintenance Manual (SN10695&up)…926
COVER…926
CONTENTS…937
FOREWORD…927
FOREWORD…928
SAFETY INFORMATION…931
INTRODUCTION…933
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…933
NECESSARY INFORMATION…934
MACHINE SERIAL NO. PLATE AND POSITION…934
ENGINE SERIAL NO. PLATE AND POSITION…934
BLADE SERIAL NO. PLATE AND POSITION…935
RIPPER SERIAL NO. PLATE AND POSITION…935
POSITION OF SERVICE METER…935
TABLE OF ENTER SERIAL NO. AND DISTRIBUTION …936
SAFETY…941
SAFETY…942
SAFETY LABELS…944
POSITION FOR ATTACHING SAFETY PICTOGRAMS…944
SAFETY LABELS…945
GENERAL PRECAUTIONS…949
SAFETY RULES…949
IF ABNORMALITIES ARE FOUND…949
CLOTHING AND PERSONAL PROTECTIVE ITEMS…949
FIRE EXTINGUISHER AND FIRST AID KIT…949
SAFETY FEATURES…949
KEEP MACHINE CLEAN…950
INSIDE OPERATOR'S COMPARTMENT…950
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…950
HANDRAILS AND STEPS…951
MOUNTING AND DISMOUNTING…951
NO PEOPLE ON ATTACHMENTS…951
PREVENTION OF BURNS…952
FIRE PREVENTION …952
ACTION IF OCCURS…953
WINSHIELD WASHER LIQUID…953
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…953
PRECAUTIONS FOR ATTACHMENTS…954
CAB WINDOW GLASSES…954
UNAUTHORIZED MODIFICATION…954
SAFETY AT WORKSITE…954
WORKING ON LOOSE GROUND…954
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES…955
ENSURE GOOD VISIBILITY…955
VENTILATION FOR ENCLOSED AREAS…955
CHECKING SIGNALMAN'S SIGNAL AND SIGNS…956
BE CAREFUL ABOUT ASBESTOS DUST…956
PRECAUTIONS FOR OPERATION…957
STARTING ENGINE…957
CHECKS BEFORE STARTING ENGINE…957
PRECAUTIONS WHEN STARTING…957
PRECAUTIONS IN COLD AREAS…958
OPERATION…959
CHECKS BEFORE OPERATION…959
PRECAUTIONS WHEN MOVING MACHINE FORWARD OR IN REVERSE…959
PRECAUTIONS WHEN TRAVELING …960
TRAVELING ON SLOPES…961
PROHIBITED OPERATIONS…961
USING BRAKES…961
OPERATE CAREFULLY ON SNOW…961
PARKING MACHINE…962
TRANSPORTATION…963
SHIPPING…963
BATTERY…964
BATTERY HAZARD PREVENTION…964
STARTING ENGINE WITH BOOSTER CABLES…965
TOWING…966
WHEN TOWING…966
PRECAUTIONS FOR MAINTENANCE…967
WARNING TAG…967
KEEP WORK PLACE CLEAN AND TIDY…967
APPOINT LEADER WHEN WORKING WITH OTHERS…967
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…968
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…969
PROPER TOOLS…969
HANDLING ACCUMULATOR…970
PERSONNEL…970
ATTACHMENTS…970
WORK UNDER THE MACHINE…971
NOISE …971
PRECAUTIONS WHEN USING HAMMER…971
REPAIR WELDING…971
REMOVING BATTERY TERMINAL…971
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…972
DO NOT DISASSEMBLE RECOIL SPRING…972
PRECAUTIONS WITH HIGH-PRESSURE FUEL…972
HANDLING HIGH-PRESSURE HOSES…973
PRECAUTION FOR HIGH VOLTAGE…973
WASTE MATERIAL…973
MAINTENANCE OF AIR CONDITIONER …973
COMPRESSED AIR…973
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…974
OPERATION…975
GENERAL VIEW …976
GENERAL VIEW OF MACHINE…976
GENERAL VIEW OF CONTROLS AND GAUGES…977
EXPLANATION OF COMPONENTS…979
FRONT PANEL…979
SWITCH…1009
CONTROL LEVERS AND PEDALS…1013
DUST INDICATOR…1022
POWER SOURSE…1022
FUSE BOX…1023
FUSIBLE LINK…1026
DOOR OPEN LOCK…1027
SASH GLASS INTERMEDIATE LOCK…1027
DOOR POCKET…1028
ASHTRAY…1028
TOOL BOX…1028
CAR STEREO, HANDLING…1029
AIR CONDITIONER, HANDLING…1037
ACCUMULATOR, HANDLING…1042
OPERATION…1043
CHECK BEFORE STARTING ENGINE…1043
STARTING ENGINE…1061
OPERATIONS, CHECKS AFTER STARTING ENGINE…1065
STOPPING ENGINE…1068
CHECK AFTER STOPPING ENGINE…1068
MOVING MACHINE OFF…1069
STOPPING MACHINE…1071
SHIFTING GEAR…1072
SHIFTING BETWEEN FOREWORD AND REVERSE…1075
STEERING MACHINE…1077
PRECAUTIONS FOR OPERATION…1080
PARKING MACHINE…1082
CHECKS AFTER FINISHING WORK…1084
LOCKING…1084
WORK POSSIBLE USING BULLDOZER…1085
EFFECTIVE USE OF MODE SELECTION SYSTEM…1087
RIPPER OPERATION…1092
OPERATING METHOD FOR RIPPING OPERATIONS…1095
ADJUSTING POSTURE OF WORK EQUIPMENT…1099
TIPS FOR LONGER UNDERCARRIAGE LIFE…1103
TRANSPORATION…1105
TRANSPORTATION PROCEDURE…1105
LOADING, UNLOADING WORK…1105
PRECAUTIONS WHEN LOADING…1105
METHOD OF LIFTING MACHINE…1106
PRECAUTIONS FOR TRANSPORATION…1107
TRAVELING ON ROADS…1107
REMOVAL OF CAB…1107
INSTALLATION OF CAB…1108
COLD WEATHER OPERATION…1109
PRECAUTIONS FOR LOW TEMPERATURE…1109
AFTER COMPLETION OF WORK…1110
AFTER COLD WEATHER…1111
LONG TERM STORAGE…1112
BEFORE STORAGE…1112
DURING STORAGE…1112
AFTER STORAGE…1112
TROUBLESHOOTING…1113
AFTER RUNNING OUT OF FUEL…1113
METHOD OF TOWING THE MACHINE…1113
IF BATTERY IS DISCHARGED…1114
OTHER TROUBLE…1117
WHEN MODE SELECTION SYSTEM FLASHES…1122
MAINTENANCE…1123
GUIDES TO MAINTENANCE…1124
OUTLINE OF SERVICE…1127
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1127
OUTLINE OF ELECTRIC SYSTEM…1130
WEAR PARTS …1131
WEAR PARTS LIST…1131
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1132
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1136
TORQUE LIST…1136
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1137
SAFETY CRITICAL PARTS…1138
MAINTENANCE SCHEDULE CHART…1139
MAINTENANCE SCHEDULE CHART…1139
SERVICE PROCEDURE…1141
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…1141
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS FILTER CARTRIDGE…1174
REPLACE FUEL FILTER CARTRIDGE…1176
REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE OIL FILTER ELEMENT…1177
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)…1141
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT AND HYDRAULIC TANK BREATHER ELEMENT…1183
CHANGE OIL FINAL DRIVE CASE…1185
WHEN REQUIRED…1142
CHECK INSIDE OF COOLING SYSTEM…1142
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…1146
CHECK TRACK TENSION…1148
CHECK AND TIGHTEN TRACK SHOE BOLTS…1150
ADJUST IDLER CLEARENCE…1151
CLEAN, CHECK RADIATOR FINS…1154
CLEAN FUEL TANK STRAINER…1155
DRAIN WATER AND SEDIMENT IN FUEL TANK…1155
CLEAN STEERING CLUTCH CASE BREATHER…1155
REPLACE AIR CONDITIONER BELT…1156
CLEAN, CHECK HYDRAULIC COOLER FINS…1156
CHECK UNDERCARRIAGE OIL…1157
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)…1158
CHECK, ADJUST AIR CONDITIONER…1159
LUBRICATE DOOR HINGE…1160
CHECK DOOR LATCH…1160
CHECK DOOR LOCK STRIKER…1161
REPLACE DOOR DAMPER…1161
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1161
REPLACE WIPER BLADE…1162
BLEED AIR FROM HEAD END OF RIGHT PITCH CYLINDER…1163
BLEED AIR IN HYDRAULIC SYSTEM…1163
CHECK ELECTRICAL INTAKE AIR HEATER…1164
LUBRICATING…1164
CHECK BEFORE STARTING…1166
EVERY 250 HOURS MAINTENANCE…1167
LUBRICATING…1167
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST…1169
CHECK LEVEL OF BATTERY ELECTROLYTE…1170
CHECK BRAKE PERFORMANCE…1173
EVERY 500 HOURS MAINTENANCE…1174
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE …1174
REPLACE FUEL FILTER CARTRIDGE…1176
REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT…1177
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…1178
CHECK REPLACE FAN BELT…1178
EVERY 1000 HOURS MAINTENANCE…1179
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)…1179
CHECK, CLEAN FUEL STRAINER…1181
CHECK FOR LOSSE ROPS MOUNT BOLTS…1181
REPLACE MAIN AND SUB CORROSION RESISTER CARTRIDGES…1182
REPLACE HYDRAULIC TANK BREATHER ELEMENT…1183
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…1183
EVERY 2000 HOURS MAINTENANCE…1184
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT…1184
CHANGE OIL IN FINAL DRIVE CASE…1185
CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER…1186
CHECK PIVOT BEARING OIL LEVEL, ADD OIL…1187
CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL…1187
CLEAN ENGINE BREATHER ELEMENT…1188
CHECK ALTERNATOR, STARTING MOTOR…1188
CHECK ENGINE VALVE CLEARENCE, ADJUST…1188
EVERY 4000 HOURS MAINTENANCE…1189
CHECK WATER PUMP…1189
CHECK VIBRATION DAMPER…1189
CHECK FAN PULLEY AND TENSION PULLEY…1189
CLEAN, CHECK TURBOCHARGER…1189
CHECK PLAY OF TURBOCHARGER ROTOR…1189
CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)…1190
SPECIFICATIONS…1191
SPECIFICATIONS…1192
ATTACHMENTS, OPTIONS…1193
GENERAL PRECAUTIONS…1194
PRECAUTIONS RELATED TO SAFETY…1194
SELECTION OF TRACK SHOE…1195
SELECTION OF TRACK SHOES…1195
PROCEDURE FOR SELECTING RIPPER POINT…1196
PROCEDURE FOR SELECTING RIPPER POINT…1196
CAP WITH LOCK, HANDLING …1197
METHOD OF OPENING AND CLOSING CAP WITH LOCK…1197
EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER…1198
BLADE CONDITION…1198
DOZING WORK …1200
LEVELING (SPREADING) OPERATION…1203
DITCHING OPERATION…1203
BOULDER RAISING OPERATION…1203
SIDE-CUTTING OPERATIONS…1204
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)…1204
SHOE SLIP CONTROL…1205
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)…1205
EFFECTIVE USE OF MODE SELECTION SYSTEM…1207
IF MODE SELECTION SYSTEM FLASHES…1213
INDEX…1215
SEAM007603T – Bulldozer D475A-2 Operation & Maintenance Manual (SN10365&up)…1219
COVER…1219
1. FOREWORD…1220
2. SAFETY INFORMATION…1223
3. INTRODUCTION…1224
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1225
5. CONTENTS…1226
SAFETY…1229
6. GENERAL PRECAUTIONS…1230
7. PRECAUTIONS DURING OPERATION…1236
7.1 BEFORE STARTING ENGINE…1236
7.2 OPERATING MACHINE…1238
7.3 TRANSPORTATION…1241
7.4 BATTERY…1242
7.5 TOWING…1243
8. PRECAUTIONS FOR MAINTENANCE …1244
8.1 BEFORE CARRYING OUT MAINTENANCE…1244
8.2 DURING MAINTENANCE…1246
9. POSITION FOR ATTACHING SAFETY LABELS…1251
9.1 POSITION FOR ATTACHING SAFETY LABELS…1251
9.2 CONTENT AND USE OF WARNING PLATES…1254
OPERATION…1255
10. GENERAL VIEW…1256
10.1 GENERAL VIEW OF MACHINE…1256
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…1257
11. EXPLANATION OF COMPONENTS…1258
11.1 MONITOR PANEL…1258
11.2 LAMPS…1268
11.3 SWITCHES…1269
11.4 CONTROL LEVERS AND PEDALS…1271
11.5 DUST INDICATOR…1276
11.6 FUSE BOX…1276
11.7 DOOR LOCK…1277
11.8 CAR STEREO…1278
11.9 OPERATING THE AIR CONDITIONER…1284
12. OPERATION…1290
12.1 CHECK BEFORE STARTING ENGINE…1290
12.2 STARTING ENGINE…1303
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…1306
12.4 MOVING MACHINE…1307
12.5 SHIFTING GEAR…1308
12.6 SHIFTING BETWEEN FORWARD AND REVERSE…1309
12.7 STEERING MACHINE…1310
12.8 STOPPING MACHINE…1312
12.9 PRECAUTIONS FOR OPERATION…1313
12.10 WORK POSSIBLE USING BULLDOZER…1315
12.11 RIPPER OPERATION…1316
12.12 ADJUSTMENT OF WORK EQUIPMENT…1318
12.13 PARKING MACHINE…1321
12.14 CHECK AFTER FINISHING WORK…1322
12.15 STOPPING ENGINE…1323
12.16 CHECK AFTER STOPPING ENGINE…1324
12.17 LOCKING…1324
12.18 TIPS FOR LONGER UNDERCARRIAGE LIFE…1325
13. TRANSPORTATION…1327
13.1 LOADING,UNLOADING WORK…1327
13.2 PRECAUTIONS FOR LOADING…1328
13.3 LIFTING POSITION…1328
13.4 PRECAUTIONS FOR TRANSPORTATION…1329
13.5 REMOVAL AND INSTALLATION OF CAB…1329
14. COLD WEATHER OPERATION…1332
14.1 PRECAUTIONS FOR LOW TEMPERATURE…1332
14.2 AFTER COMPLETION OF WORK…1334
14.3 AFTER COLD WEATHER…1334
15. LONG-TERM STORAGE…1335
15.1 BEFORE STORAGE…1335
15.2 DURING STORAGE…1335
15.3 AFTER STORAGE…1336
16. TROUBLESHOOTING…1337
16.1 AFTER RUNNING OUT OF FUEL…1337
16.2 METHOD OF TOWING MACHINE…1337
16.3 IF BATTERY IS DISCHARGED…1337
16.4 OTHER TROUBLE…1340
MAINTENANCE…1343
17. GUIDES TO MAINTENANCE…1344
18. OUTLINES OF SERVICE…1347
18.1 OUTLINE OF OIL,FUEL,COOLANT…1347
18.2 RELATING TO ELECTRIC SYSTEM…1349
19. WEAR PARTS LIST…1350
20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1351
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1355
21.1 INTRODUCTION OF NECESSARY TOOLS…1355
21.2 TORQUE LIST…1356
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1357
23. MAINTENANCE SCHEDULE CHART…1361
24. SERVICE PROCEDURE…1364
24.1 INITIAL 250 HOURS SERVICE…1364
24.2 WHEN REQUIRED…1365
24.3 CHECK BEFORE STARTING…1382
24.4 EVERY 250 HOURS SERVICE…1389
24.5 EVERY 500 HOURS SERVICE…1397
24.6 EVERY 1000 HOURS SERVICE…1399
24.7 EVERY 2000 HOURS SERVICE…1403
24.8 EVERY 4000 HOURS SERVICE…1407
SPECIFICATIONS…1408
25. SPECIFICATIONS…1409
OPTIONS,ATTACHMENTS…1411
26. GENERAL PRECAUTIONS…1412
26.1 PRECAUTIONS RELATED TO SAFETY…1412
27. USING SEAT BELT …1413
27.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER…1413
28. PROCEDURE FOR SELECTING RIPPER POINT…1414
28.1 PROCEDURE FOR SELECTING RIPPER POINT…1414
29. HANDLING CAP WITH LOCK…1415
29.1 OPENING AND CLOSING LOCKABLE CAP…1415
SEAM022005T – Super Dozer D475A-3 Operation & Maintenance Manual (SN10685&up)…1417
COVER…1417
FOREWORD…1418
FOREWORD…1419
SAFETY INFORMATION…1422
INTRODUCTION…1424
FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHINE…1424
NECESSARY INFORMATION…1425
MACHINE SERIAL NO.PLATE AND POSITION…1425
ENGINE SERIAL NO.PLATE AND POSITION…1425
BLADE SERIAL NO.PLATE POSITION…1426
POSITION OF SERVICE METER…1426
TABLE OF ENTER SERIAL NO.AND DISTRIBUTORN…1427
CONTENTS…1428
SAFETY…1431
SAFETY…1432
SAFETY LABELS…1434
POSITIONS OF SAFETY PICTOGRAMS…1434
SAFETY LABELS…1435
GENERAL PRECAUTIONS…1439
SAFETY RULES…1439
IF ABNORMALITIES ARE FOUND…1439
CLOTHING AND PERSONAL PROTECTIVE ITEMS…1439
FIRE EXTINGUISHER AND FIRST AID KIT…1439
SAFETY FEATURES…1439
KEEP MACHINE CLEAN…1440
INSIDE OPERATOR'S COMPARTMENT…1440
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…1440
HANDRAILS AND STEPS…1441
MOUNTING AND DISMOUNTING…1441
NO PEOPLE ON ATTACHMENTS…1441
PREVENTION OF BURNS…1442
FIRE PREVENTION…1442
ACTION IF FIRE OCCURS…1443
WINDOW WASHER LIQUID…1443
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…1443
PRECAUTIONS FOR ATTACHMENTS…1444
ACCUMULATOR…1444
UNAUTHORIZED MODIFICATION…1444
SAFETY AT WORKSITE…1444
WORKING ON LOOSE GROUND…1445
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…1445
ENSURE GOOD VISIBILITY…1445
VENTILATION FOR ENCLOSED AREAS…1446
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…1446
BE CAREFUL ABOUT ASBESTOS DUST…1446
PRECAUTIONS FOR OPERATION…1447
BEFORE STARTING ENGINE…1447
CHECKS BEFORE STARTING ENGINE…1447
PRECAUTIONS WHEN STARTING…1447
PRECAUTIONS IN COLD AREAS…1448
OPERATION…1449
CHECKS BEFORE OPERATION…1449
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE…1449
PRECAUTIONS WHEN TRAVELING…1450
TRAVELING ON SLOPES…1451
PROHIBITED OPERATIONS…1451
USING BRAKES…1451
OPERATE CAREFULLY ON SNOW…1451
PARKING MACHINE…1452
TRANSPORTATION…1453
SHIPPING…1453
BATTERY…1454
BATTERY HAZARD PREVENTION…1454
STARTING WITH BOOSTER CABLE…1455
TOWING…1456
WHEN TOWING…1456
PRECAUTIONS FOR MAINTENANCE…1457
WARNING TAG…1457
KEEP WORK PLACE CLEAN AND TIDY…1457
APPOINT LEADER WHEN WORKING WITH OTHERS…1457
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE …1458
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…1459
PROPER TOOLS…1459
PERSONNEL…1459
ATTACHMENTS…1460
WORK UNDER THE MACHINE…1460
NOISE…1460
PRECAUTIONS WHEN USING HAMMER…1460
REPAIR WELDING…1460
REMOVING BATTERY TERMINAL…1461
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…1461
DO NOT DISASSEMBLE RECOIL SPRING…1461
PRECAUTION WITH HIGH-PRESSURE OIL…1461
HANDLING HIGH-PRESSURE HOSES…1462
WASTE MATERIAL…1462
MAINTENANCE FOR AIR CONDITIONER…1462
COMPRESSED AIR…1462
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1462
OPERATION…1463
GENERAL VIEW…1464
GENERAL VIEW OF MACHINE…1464
GENERAL VIEW OF CONTROLS AND GAUGES…1465
EXPLANATION OF COMPONENTS…1467
FRONT PANEL…1467
SWITCH…1484
CONTROL LEVERS,PEDALS…1488
CONTROLLER…1493
DUST INDICATOR…1494
POWER SOURSE…1494
FUSE BOX…1495
DOOR OPEN LOCK…1497
SASH GLASS INTERMEDIATE LOCK…1498
DOOR POCKET…1498
ASHTRAY…1498
TOOL BOX…1499
AIR CONDITIONER,HANDLING…1500
ACCUMULATOR,HANDLING…1506
OPERATION…1507
CHECK BEFORE STARTING ENGINE,ADJUST…1507
STARTING ENGINE…1524
OPERATIONS AND CHECKS AFTER STARTING ENGINE…1528
STOPPING ENGINE…1531
CHECK AFTER STOPPING ENGINE…1531
MOVING MACHINE OFF…1532
STOPPING MACHINE…1534
SHIFTING GEAR…1535
SHIFTING BETWEEN FORWARD AND REVERSE…1536
STEERING MACHINE…1538
PRECAUTIONS FOR OPERATION…1542
PROHIBITED WORK OF SUPER DOZER…1544
EFECTIVE USE OF SUPER DOZER…1546
EFECTIVE USE OF MODE SELECTION SYSTEM…1549
PARKING MACHINE…1552
CHECK AFTER FINISHING WORK…1554
LOCKING…1554
ADJUSTING POSTURE OF WORK EQUIPMENT…1555
TIPS FOR LONGER UNDERCARRIAGE LIFE…1556
TRANSPORTATION…1558
TRANSPORTATION PROCEDURE…1558
LOADING,UNLOADING WORK…1558
PRECAUTIONS FOR LOADING…1559
PRECAUTIONS FOR TRANSPORTATION…1559
TRAVELING ON ROADS…1559
COLD WEATHER OPERATION…1560
PRECAUTIONS FOR LOW TEMPERATURE…1560
AFTER COMPLETION OF WORK…1561
AFTER COLD WEATHER…1562
LONG-TERM STORAGE…1563
BEFORE STORAGE…1563
DURING STORAGE…1563
AFTER STORAGE…1563
TROUBLESHOOTING…1564
AFTER RUNNING OUT OF FUEL…1564
METHOD OF TOWING MACHINE…1564
IF BATTERY IS DISCHARGED…1565
OTHER TROUBLE…1568
MAINTENANCE…1573
GUIDES TO MAINTENANCE…1574
OUTLINES OF SERVICE…1577
HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC…1577
OUTLINE OF ELECTRIC SYSTEM…1579
WEAR PARTS LIST…1580
WEAR PARTS LIST…1580
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1581
PROPER SELECTION OF FUEL,COOLANT AND LUBRICANTS…1581
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1585
TORQUE LIST…1585
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1586
SAFETY CRITICAL PARTS…1587
MAINTENANCE SCHEDULE CHART…1588
MAINTENANCE SCHEDULE CHART…1588
SERVICE PROCEDURE…1590
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…1590
WHEN REQUIRED…1591
CLEAN INSIDE OF COOLING SYSTEM…1591
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…1594
CHECK TRACK TENSION…1596
CHECK AND TIGHTEN TRACK SHOE BOLTS…1599
ADJUST IDLER CLEARANCE…1600
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES…1601
CLEAN AND CHECK RADIATOR FIN…1602
CLEAN FUEL TANK STRAINER…1603
DRAIN WATER AND SEDIMENT IN FUEL TANK…1603
CLEAN STEERING CLUTCH CASE BREATHER…1603
REPLACE AIR CONDITIONER BELT…1604
CLEAN, CHECK HYDRAULIC COOLER FINS…1604
CHECK UNDERCARRIAGE OIL…1605
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)…1606
CHECK, ADJUST AIR CONDITIONER…1607
LUBRICATE DOOR HINGE…1608
CHECK DOOR LOCK STRIKER…1608
REPLACE DOOR DAMPER…1608
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1608
REPLACE WIPER BLADE…1609
LUBRICATING…1611
CHECK BEFORE STARTING…1613
EVERY 250 HOURS SERVICE…1614
LUBRICATING…1614
CHECK ALTERNATOR DRIVE BELT TENSION,ADJUST…1616
CHECK LEVEL OF BATTERY ELECTROLYTE…1617
CHECK BRAKE PERFORMANCE…1618
EVERY 500 HOURS SERVICE…1619
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS FILTER CARTRIDGE…1619
REPLACE FUEL FILTER CARTRIDGE…1621
REPLACE TRANSMISSION FILTER ELEMENT,TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT…1622
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…1623
CHECK REPLACE FAN BELT…1623
EVERY 1000 HOURS SERVICE…1624
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE,TORQUE CONVERTER CASE AND BEVEL GEAR CASE)…1624
CHECK, CLEAN FUEL STRAINER…1626
LUBRICATE TENSION PULLEY ASSEMBLY…1626
CHECK FOR LOOSE ROPS MOUNT BOLTS…1626
REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE…1627
CHANGE OIL IN HYDRAULIC TANK,REPLACE HYDRAULIC OIL FILTER ELEMENT AND HYDRAULIC TANK BREATHER ELEMENT…1628
CHECK TIGHTENING PARTS OF TURBOCHARGER…1628
EVERY 2000 HOURS SERVICE…1629
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT…1629
CHANGE OIL IN FINAL DRIVE CASE…1630
CHANGE OIL IN DAMPER CASE…1631
CHECK PIVOT BEARING OIL LEVEL, ADD OIL…1632
CHECK OIL LEVEL IN RECOIL SPRING,ASSIST CYLINDER CASE,ADD OIL…1632
CLEAN ENGINE BREATHER ELEMENT…1633
CHECK ALTERNATOR,STARTING MOTOR…1633
CHECK ENGINE VALVE CLEARANCE,ADJUST…1633
EVERY 4000 HOURS SERVICE…1634
CHECK WATER PUMP…1634
CHECK VIBRATION DAMPER…1634
CHECK FAN PULLEY AND TENSION PULLEY…1634
CLEAN,CHECK TURBOCHARGER…1634
CHECK PLAY OF TURBOCHARGER ROTOR…1634
CHECK MAIN FRAME,WORK EQUIPMENT (BLADE)…1635
SPECIFICATIONS…1636
SPECIFICATIONS…1637
INDEX…1638
SEAM025103T – Bulldozer D475A-3 Operation & Maintenance Manual (SN10601&up)…1641
COVER…1641
1.FOREWORD…1642
2.SAFETY INFORMATION…1645
3.INTRODUCTION…1646
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR…1647
5.CONTENTS…1649
SAFETY…1653
6.GENERAL PRECAUTIONS…1654
7.PRECAUTIONS DURING OPERATION…1660
7.1 BEFORE STARTING ENGINE…1660
7.2 AFTER STARTING ENGINE…1662
7.3 TRANSPORTATION…1668
7.4 BATTERY…1669
7.5 TOWING…1671
8.PRECAUTIONS FOR MAINTENANCE…1672
8.1 BEFORE CARRYING OUT MAINTENANCE…1672
8.2 DURING MAINTENANCE…1676
9.POSITION FOR ATTACHING SAFETY LABELS…1682
9.1 POSITION FOR ATTACHING SAFETY LABELS…1682
9.2 CONTENT AND USE OF WARNING PLATES…1686
OPERATION…1687
10.GENERAL VIEW…1688
10.1 GENERAL VIEW OF MACHINE…1688
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…1689
11.EXPLANATION OF COMPONENTS…1691
11.1 FRONT PANEL…1691
11.2 SWITCHES…1705
11.3 CONTROL LEVERS AND PEDALS…1708
11.4 CONTROLLER…1715
11.5 DUST INDICATOR…1716
11.6 POWER SOURCE…1716
11.7 FUSE BOX…1716
11.8 DOOR-OPEN LOCK…1718
11.9 SASH GLASS INTERMEDIATE LOCK…1718
11.10 DOOR POCKET…1718
11.11 ASHTRAY…1718
11.12 TOOL BOX…1719
11.13 HANDLING AIR CONDITIONER…1720
11.14 HANDLING ACCUMULATOR…1726
12.OPERATION…1727
12.1 CHECK BEFORE STARTING ENGINE…1727
12.2 STARTING ENGINE…1743
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…1746
12.4 MOVING MACHINE…1748
12.5 SHIFTING GEAR…1750
12.6 SHIFTING BETWEEN FORWARD AND REVERSE…1751
12.7 STEERING MACHINE…1752
12.8 STOPPING MACHINE…1754
12.9 PRECAUTIONS FOR OPERATION…1755
12.10 WORK POSSIBLE USING BULLDOZER…1758
12.11 RIPPER OPERATION…1760
12.12 ADJUSTMENT OF WORK EQUIPMENT…1763
12.13 PARKING MACHINE…1767
12.14 CHECK AFTER FINISHING WORK…1768
12.15 STOPPING ENGINE…1769
12.16 CHECK AFTER STOPPING ENGINE…1770
12.17 LOCKING…1770
12.18 TIPS LONGER UNDERCARRIAGE LIFE…1771
13.TRANSPORTATION…1773
13.1 LOADING,UNLOADING WORK…1773
13.2 PRECAUTIONS FOR LOADING…1774
13.3 METHOD OF LIFTING MACHINE…1774
13.4 PRECAUTIONS FOR TRANSPORTATION…1775
13.5 REMOVAL OF CAB…1775
13.6 INSTALLATION OF CAB…1776
14.COLD WEATHER OPERATION…1777
14.1 PRECAUTIONS FOR LOW TEMPERATURE…1777
14.2 AFTER COMPLETION OF WORK…1779
14.3 AFTER COLD WEATHER…1779
15.LONG-TERM STORAGE…1780
15.1 BEFORE STORAGE…1780
15.2 DURING STORAGE…1780
15.3 AFTER STORAGE…1781
16.TROUBLESHOOTING…1782
16.1 AFTER RUNNING OUT OF FUEL…1782
16.2 METHOD OF TOWING MACHINE…1782
16.3 IF BATTERY IS DISCHARGED…1782
16.4 OTHER TROUBLE…1785
MAINTENANCE …1788
17.GUIDES TO MAINTENANCE…1789
18.OUTLINES OF SERVICE…1792
18.1 OUTLINE OF OIL,FUEL,COOLANT…1792
18.2 RELATING TO ELECTRIC SYSTEM…1794
18.3 OUTLINE OF HYDRAULIC SYSTEM…1795
19.WEAR PARTS LIST…1796
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1797
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1801
21.1 INTRODUCTION OF NECESSARY TOOLS…1801
21.2 TORQUE LIST…1802
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1803
23.MAINTENANCE SCHEDULE CHART…1806
24.SERVICE PROCEDURE…1810
24.1 INITIAL 250 HOURS SERVICE…1810
24.2 WHEN REQUIRED…1811
24.3 CHECK BEFORE STARTING…1832
24.4 EVERY 250 HOURS SERVICE…1833
24.5 EVERY 500 HOURS SERVICE…1839
24.6 EVERY 1000 HOURS SERVICE…1845
24.7 EVERY 2000 HOURS SERVICE…1849
24.8 EVERY 4000 HOURS SERVICE…1854
SPECIFICATIONS…1856
25.SPECIFICATIONS…1857
OPTIONS,ATTACHMENTS…1859
26.GENERAL PRECAUTIONS…1860
26.1 PRECAUTIONS RELATED TO SAFETY…1860
27.USING SEAT BELT…1861
27.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER…1861
28.SELECTION OF TRACK SHOE…1863
28.1 SELECTION OF TRACK SHOES…1863
29.PROCEDURE FOR SELECTING RIPPER POINT…1864
29.1 PROCEDURE FOR SELECTING RIPPER POINT…1864
30.HANDLING CAP WITH LOCK…1865
30.1 OPENING AND CLOSING LOCKABLE CAP…1865
31.EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER…1866
31.1 BLADE CONDITION…1866
31.2 DOZING WORK…1867
31.3 LEVELING (SPREADING) OPERATIONS…1870
31.4 DITCHING OPERATIONS…1870
31.5 BOULDER RAISING OPERATIONS…1870
31.6 SIDE-CUTTING OPERATIONS…1870
31.7 HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)…1871
32.SHOE SLIP CONTROL…1872
32.1 MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)…1872
32.2 EFFECTIVE USE OF MODE SELECTION SYSTEM…1874
32.3 IF MODE SELECTION SYSTEM FLASHES…1878
SEAM025105T – Bulldozer D475A-3 Operation & Maintenance Manual (SN10685&up)…1880
COVER…1880
FOREWORD…1881
FOREWORD…1882
SAFETY INFORMATION…1885
INTRODUCTION…1887
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…1887
NECESSARY INFORMATION…1888
MACHINE SERIAL NO. PLATE AND POSITION…1888
ENGINE SERIAL NO. PLATE AND POSITION…1888
BLADE SERIAL NO. PLATE POSITION…1889
RIPPER SERIAL NO. PLATE POSITION…1889
POSITION OF SERVICE METER…1889
TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN…1890
CONTENTS…1891
SAFETY…1894
SAFETY…1895
SAFETY LABELS…1897
POSITIONS OF SAFETY PICTOGRAMS…1897
SAFETY LABELS…1898
GENERAL PRECAUTIONS…1902
SAFETY RULES…1902
IF ABNORMALITIES ARE FOUND…1902
CLOTHING AND PERSONAL PROTECTIVE ITEMS…1902
FIRE EXTINGUISHER AND FIRST AID KIT…1902
SAFETY FEATURES…1902
KEEP MACHINE CLEAN…1903
INSIDE OPERATOR'S COMPARTMENT…1903
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…1903
HANDRAILS AND STEPS…1904
MOUNTING AND DISMOUNTING…1904
NO PEOPLE ON ATTACHMENTS…1904
PREVENTION OF BURNS…1905
FIRE PREVENTION…1905
ACTION IF FIRE OCCURS…1906
WINDOW WASHER LIQUID…1906
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…1906
PRECAUTIONS FOR ATTACHMENTS…1907
ACCUMULATOR…1907
UNAUTHORIZED MODIFICATION…1907
SAFETY AT WORKSITE…1907
WORKING ON LOOSE GROUND…1908
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…1908
ENSURE GOOD VISIBILITY…1908
VENTILATION FOR ENCLOSED AREAS…1909
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…1909
BE CAREFUL ABOUT ASBESTOS DUST…1909
PRECAUTIONS FOR OPERATION…1910
BEFORE STARTING ENGINE…1910
CHECKS BEFORE STARTING ENGINE…1910
PRECAUTIONS WHEN STARTING…1910
PRECAUTIONS IN COLD AREAS…1911
OPERATION…1912
CHECKS BEFORE OPERATION…1912
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE…1912
PRECAUTIONS WHEN TRAVELING…1913
TRAVELING ON SLOPES…1914
PROHIBITED OPERATIONS…1914
USING BRAKES…1914
OPERATE CAREFULLY ON SNOW…1914
PARKING MACHINE…1915
TRANSPORTATION…1916
SHIPPING…1916
BATTERY…1917
BATTERY HAZARD PREVENTION…1917
STARTING WITH BOOSTER CABLE…1918
TOWING…1919
WHEN TOWING…1919
PRECAUTIONS FOR MAINTENANCE…1920
WARNING TAG…1920
KEEP WORK PLACE CLEAN AND TIDY…1920
APPOINT LEADER WHEN WORKING WITH OTHERS…1920
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE …1921
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…1922
PROPER TOOLS…1922
PERSONNEL…1922
ATTACHMENTS…1923
WORK UNDER THE MACHINE…1923
NOISE…1923
PRECAUTIONS WHEN USING HAMMER…1923
REPAIR WELDING…1923
REMOVING BATTERY TERMINAL…1924
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…1924
DO NOT DISASSEMBLE RECOIL SPRING…1924
PRECAUTION WITH HIGH-PRESSURE OIL…1924
HANDLING HIGH-PRESSURE HOSES…1925
WASTE MATERIAL…1925
MAINTENANCE FOR AIR CONDITIONER…1925
COMPRESSED AIR…1925
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1925
OPERATION…1926
GENERAL VIEW…1927
GENERAL VIEW OF MACHINE…1927
GENERAL VIEW OF CONTROLS AND GAUGES…1928
EXPLANATION OF COMPONENTS…1930
FRONT PANEL…1930
SWITCH…1946
CONTROL LEVERS, PEDALS…1950
CONTROLLER…1958
DUST INDICATOR…1959
POWER SOURSE…1959
FUSE BOX…1960
DOOR OPEN LOCK…1962
SASH GLASS INTERMEDIATE LOCK…1963
DOOR POCKET…1963
ASHTRAY…1963
TOOL BOX…1964
AIR CONDITIONER, HANDLING…1965
ACCUMULATOR, HANDLING…1970
OPERATION…1971
CHECK BEFORE STARTING ENGINE, ADJUST…1971
STARTING ENGINE…1986
OPERATIONS AND CHECKS AFTER STARTING ENGINE…1990
STOPPING ENGINE…1992
CHECK AFTER STOPPING ENGINE…1992
MOVING MACHINE OFF…1993
STOPPING MACHINE…1995
SHIFTING GEAR…1996
SHIFTING BETWEEN FOEWARD AND REVERSE…1997
STEERING MACHINE…1999
PRECAUTIONS FOR OPERATION…2003
PARKING MACHINE…2005
CHECK AFTER FINISHING WORK…2007
LOCKING…2007
WORK POSSIBLE USING BULLDOZER…2008
RIPPER OPERATION…2010
ADJUSTING POSTURE OF WORK EQUIPMENT…2013
TIPS FOR LONGER UNDERCARRIAGE LIFE…2017
TRANSPORTATION…2019
TRANSPORTATION PROCEDURE…2019
LOADING, UNLOADING WORK…2019
PRECAUTIONS FOR LOADING…2019
METHOD OF LIFTING MACHINE…2020
PRECAUTIONS FOR TRANSPORTATION…2021
REMOVAL OF CAB…2021
INSTALLATION OF CAB…2022
COLD WEATHER OPERATION…2023
PRECAUTIONS FOR LOW TEMPERATURE…2023
AFTER COMPLETION OF WORK…2024
AFTER COLD WEATHER…2025
LONG-TERM STORAGE…2026
BEFORE STORAGE…2026
DURING STORAGE…2026
AFTER STORAGE…2026
TROUBLESHOOTING…2027
AFTER RUNNING OUT OF FUEL…2027
METHOD OF TOWING MACHINE…2027
IF BATTERY IS DISCHARGED…2028
OTHER TROUBLE…2031
MAINTENANCE…2036
GUIDES TO MAINTENANCE…2037
OUTLINES OF SERVICE…2040
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2040
OUTLINE OF ELECTRIC SYSTEM…2042
WEAR PARTS LIST…2043
WEAR PARTS LIST…2043
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…2044
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…2048
TORQUE LIST…2048
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2049
SAFETY CRITICAL PARTS…2050
MAINTENANCE SCHEDULE CHART…2051
MAINTENANCE SCHEDULE CHART…2051
SERVICE PROCEDURE…2053
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…2053
WHEN REQUIRED…2054
CLEAN INSIDE OF COOLING SYSTEM…2054
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…2057
CHECK TRACK TENSION…2059
CHECK AND TIGHTEN TRACK SHOE BOLTS…2061
ADJUST IDLER CLEARANCE…2062
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES…2063
CHECK AND CLEAN RADIATOR FINS…2064
CLEAN FUEL TANK STRAINER…2065
DRAIN WATER AND SEDIMENT IN FUEL TANK…2065
CLEAN STEERING CLUTCH CASE BREATHER…2065
REPLACE AIE CONDITIONER BELT…2066
CLEAN, CHECK HYDRAULIC COOLER FINS…2066
CHECK UNDERCARRIAGE OIL…2067
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)…2068
CHECK, ADJUST AIR CONDITIONER…2069
LUBRICATE DOOR HINGE…2070
CHECK DOOR LOCK STRIKER…2070
REPLACE DOOR DAMPER…2070
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2070
REPLACE WIPER BLADE…2071
CHECK ELECTRICAL INTAKE AIR HEATER…2072
LUBRICATING…2072
CHECK BEFORE STARTING…2074
EVERY 250 HOURS SERVICE…2075
LUBRICATING…2075
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST…2077
CHECK LEVEL OF BATTERY ELECTROLYTE…2078
CHECK BRAKE PERFORMANCE…2079
EVERY 500 HOURS SERVICE…2080
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS FILTER CARTRIDGE…2080
REPLACE FUEL FILTER CARTRIDGE…2081
REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT…2082
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…2083
CHECK REPLACE FAN BELT…2083
EVERY 1000 HOURS SERVICE…2084
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)…2084
CHECK, CLEAN FUEL STRAINER…2086
LUBRICATE TENSION PULLEY ASSEMBLY…2086
CHECK FOR LOOSE ROPS MOUNT BOLTS…2086
REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE…2087
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT AND HYDRAULIC TANK BREATHER ELEMENT…2088
CHECK TIGHTENING PARTS OF TURBOCHARGER…2088
EVERY 2000 HOURS SERVICE…2089
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT…2089
CHANGE OIL IN FINAL DRIVE CASE…2090
CHANGE OIL IN DAMPER CASE…2091
CHECK PIVOT BEARING OIL LEVEL, ADD OIL…2092
CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL…2092
CLEAN ENGINE BREATHER ELEMENT…2093
CHECK ALTERNATOR,STARTING MOTOR…2093
CHECK ENGINE VALVE CLEARANCE, ADJUST…2093
EVERY 4000 HOURS SERVICE…2094
CHECK WATER PUMP…2094
CHECK VIBRATION DAMPER…2094
CHECK FAN PULLEY AND TENSION PULLEY…2094
CLEAN, CHECK TURBOCHARGER…2094
CHECK PLAY OF TURBOCHARGER ROTOR…2094
CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)…2095
SPECIFICATIONS…2096
SPECIFICATIONS…2097
ATTACHMENTS, OPTIONS…2098
GENERAL PRECAURIONS…2099
PRECAUTIONS RELATED TO SAFETY…2099
USING SEAT BELT…2100
HANDLING SEAT BELT…2100
SELECTION OF TRACK SHOE…2101
SELECTION OF TRACK SHOES…2101
PROCEDURE FOR SELECTING RIPPER POINT…2102
PROCEDURE FOR SELECTING RIPPER POINT…2102
CAP WITH LOCK, HANDLING…2103
METHOD OF OPENING AND CLOSING CAP WITH LOCK…2103
EFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER…2104
BLADE CONDITION…2104
DOZING WORK…2107
LEVELING (SPREADING) OPERATION…2110
DITCHING OPERATION…2110
BOULDER RAISING OPERATION…2110
SIDE-CUTTING OPERATIONS…2111
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)…2111
SHOE SLIP CONTROL…2112
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)…2112
EFECTIVE USE OF MODE SELECTION SYSTEM…2115
IF MODE SELECTION SYSTEM FLASHES…2119
INDEX…2120
SEAM198A05 – Bulldozer D455A-1 Operation & Maintenance Manual…2123
COVER…2123
FOREWORD…2124
BREAKING IN YOUR NEW MACHINE…2125
CONTENTS…2126
SAFETY HINTS…2127
GENERAL LOCATIONS…2140
OPERATOR'S COMPARTMENT…2142
INSTRUMENTS AND CONTROLS…2146
AIR CONDITIONER…2160
CHECK BEFORE STARTING…2170
OPERATING YOUR MACHINE…2174
COLD WEATHER OPERATION…2186
BULLDOZER'S WORK…2191
BLADE OPERATION…2193
RIPPER OPERATION…2196
TIPS FOR LONGER UNDERCARRIAGE LIFE…2201
HANDLING OF BATTERY…2202
OPENING AND CLOSING OF A LOCKING CAP…2205
PERIODIC MAINTENANCE…2206
PRECAUTIONS FOR MAINTENANCE…2207
MAINTENANCE TABLE…2213
INITIAL 250 HOURS SERVICE…2217
EVERY 250 HOURS SERVICE…2218
EVERY 500 HOURS SERVICE…2232
EVERY 1000 HOURS SERVICE…2234
EVERY 1500 HOURS SERVICE…2238
EVERY 2000 HOURS SERVICE…2239
EVERY 4000 HOURS SERVICE…2241
WHEN REQUIRED…2243
ADJUSTMENT…2249
TROUBLE SHOOTING GUIDE…2259
STORAGE…2263
SERVICE METER…2265
MACHINE AND ENGINE SERIAL NUMBERS…2266
WEAR PARTS…2267
SPECIFICATIONS…2268
FUEL,COOLANT AND LUBRICANTS…2270
SEAWD02302 – Super Dozer D475A-3 Operation & Maintenance Manual (SN10601&up)…2273
COVER…2273
CONTENTS…2276
SPECIFICATIONS…2278
PRECAUTIONS FOR FIELD ASSEMBLY…2281
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE…2282
LAYOUT OF KIT…2283
STYLE FOR TRANSPORTATION…2284
TOOLS LIST FOR FIELD ASSEMBLY…2289
TIGHTENING TORQUE…2296
COATING MATERIALS…2300
A. ASSEMBLY PROCEDURE…2302
A-1 INSTALLATION OF UNDERCARRIAGE…2303
A-2 INSTALLATION OF RIPPER…2315
A-3 INSTALLATION OF TRACKS…2318
A-4 ADDING OIL TO PIVOT CHAMBER…2320
A-5 INSTALLATION OF RIPPER SHANK…2321
A-6 INSTALLATION OF BLADE LIFT CYLINDER…2322
A-7 INSTALLATION OF TILT HOSES AND TRUNNION…2324
A-8 ASSEMBLY OF BLADE…2327
A-9 ADJUSTMENT OF ARM JOINT (U-BLADE)…2339
A-10 INSTALLATION OF BLADE…2340
A-11 INSTALLATION OF COUNTERWEIGHT…2342
A-12 INSTALLATION OF OPERATOR'S CAB…2343
A-13 INSTALLATION OF ROPS…2353
A-14 ADJUSTMENT OF POTENTIOMETER ROD…2354
A-15 PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE…2355
A-16 METHOD OF CHECKING AUTO-RESET SYSTEM (SUPERDOZER)…2364
A-17 CHECK TRACK TENSION…2365
A-18 CHECK OF OIL/COOLANT LEVEL IN EACH PART…2367
A-19 GREASING OF GREASING POINT…2369
A-20 INSTALLATION OF ORBCOMM ANTENNA AND WIRING HARNESS…2372
A-21 REPLACEMENT OF RETURN FILTER (REPLACEMENT OF STANDARD FILTER WITH FLUSHING FILTER)…2373
A-22 INSTALLING DIRECTION OF EXHAUST PIPE…2376
A-23 BLEEDING AIR FROM HYDRAULIC CYLINDERS…2377
M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY…2378
M-1 TESTING AND ADJUSTING OPERATOR'S CAB…2379
M-2 ERROR CODE…2385
M-3 FLUSHING HYDRAULIC CIRCUIT…2391
INSTALLATION OF SPILL GUARD…2392
1. INTRODUCTION…2392
2. ADDITIONAL PARTS…2392
3. MANUFACUTURE DRAWING FOR SPILL GUARD…2393
3-1. FOR SEMI-U-BLADE…2393
3-2. FOR FULL-U-BLADE…2396
4. INSTALLATION PROCEDURE…2399
FIELD ASSEMBLY INSPECTION REPORT [FOR U OR SEMI U TILT DOZER]…2400
FIELD ASSEMBLY INSPECTION REPORT [FOR SUPER DOZER]…2414
TEN00018-05 – Bulldozer D475A-5 Operation & Maintenance Manual (SN20001&up)…2428
COVER…2428
FOREWORD…2429
FOREWORD…2430
SAFETY INFORMATION…2433
INTRODUCTION…2435
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…2435
BREAKING IN THE MACHINE…2435
NECESSARY INFORMATION…2436
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE…2436
EPA REGULATIONS, ENGINE NUMBER PLATE…2436
BLADE SERIAL NO. PLATE POSITION…2437
RIPPER SERIAL NO. PLATE POSITION…2437
POSITION OF SERVICE METER…2437
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…2438
CONTENTS…2439
SAFETY…2443
SAFETY…2444
SAFETY LABELS…2446
POSITIONS OF SAFETY PICTOGRAMS…2446
SAFETY LABELS…2447
GENERAL PRECAUTIONS…2450
SAFETY RULES…2450
IF ABNORMALITIES ARE FOUND…2450
CLOTHING AND PERSONAL PROTECTIVE ITEMS…2450
FIRE EXTINGUISHER AND FIRST AID KIT…2450
SAFETY FEATURES…2450
KEEP MACHINE CLEAN…2451
INSIDE OPERATOR'S COMPARTMENT…2451
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…2451
HANDRAILS AND STEPS…2452
PRECAUTIONS WHEN WORKING IN HIGH PLACES…2452
MOUNTING AND DISMOUNTING…2452
NO PEOPLE ON ATTACHMENTS…2452
CRUSHING OR CUTTING PREVENTION…2453
PREVENTION OF BURNS…2453
FIRE PREVENTION…2454
ACTION IF FIRE OCCURS…2455
WINDOW WASHER LIQUID…2455
PRECAUTIONS WHEN USING ROPS…2455
PRECAUTIONS FOR ATTACHMENTS…2455
CAB WINDOW GLASSES…2455
UNAUTHORIZED MODIFICATION…2455
SAFETY AT WORKSITE…2456
WORKING ON LOOSE GROUND…2456
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…2457
ENSURE GOOD VISIBILITY…2457
VENTILATION FOR ENCLOSED AREAS…2458
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…2458
BE CAREFUL ABOUT ASBESTOS DUST…2458
PRECAUTIONS FOR OPERATION…2459
BEFORE STARTING ENGINE…2459
CHECKS BEFORE STARTING ENGINE…2459
PRECAUTIONS WHEN STARTING…2459
PRECAUTIONS IN COLD AREAS…2460
OPERATION…2461
CHECKS BEFORE OPERATION…2461
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE…2461
PRECAUTIONS WHEN TRAVELING…2462
TRAVELING ON SLOPES…2463
PROHIBITED OPERATIONS…2463
USING BRAKES…2463
OPERATE CAREFULLY ON SNOW…2463
PARKING MACHINE…2464
TRANSPORTATION…2465
LOADING AND UNLOADING…2465
SHIPPING…2465
BATTERY…2466
BATTERY HAZARD PREVENTION…2466
STARTING WITH BOOSTER CABLE…2467
TOWING…2468
WHEN TOWING…2468
PRECAUTIONS FOR MAINTENANCE…2469
WARNING TAG…2469
KEEP WORK PLACE CLEAN AND TIDY…2469
APPOINT LEADER WHEN WORKING WITH OTHERS…2469
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…2470
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…2471
PROPER TOOLS…2471
HANDLING ACCUMULATOR…2472
PERSONNEL…2472
ATTACHMENTS…2472
WORK UNDER THE MACHINE…2473
NOISE…2473
PRECAUTIONS WHEN USING HAMMER…2473
REPAIR WELDING…2473
REMOVING BATTERY TERMINAL…2473
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…2474
DO NOT DISASSEMBLE RECOIL SPRING…2474
PRECAUTION WITH HIGH-PRESSURE OIL…2475
PRECAUTION FOR HIGH FUEL PRESSURE…2475
HANDLING HIGH-PRESSURE HOSES…2475
PRECAUTION FOR HIGH VOLTAGE…2475
WASTE MATERIAL…2476
MAINTENANCE FOR AIR CONDITIONER…2476
COMPRESSED AIR…2476
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2476
OPERATION…2477
GENERAL VIEW…2478
GENERAL VIEW OF MACHINE…2478
GENERAL VIEW OF CONTROLS AND GAUGES…2479
EXPLANATION OF COMPONENTS…2481
FRONT PANEL…2481
SWITCHES…2512
CONTROL LEVERS, PEDALS…2517
DUST INDICATOR…2525
POWER SOURCE…2526
FUSE BOX…2527
DOOR OPEN LOCK…2531
SASH GLASS INTERMEDIATE LOCK…2531
DOOR POCKET…2532
ASHTRAY…2532
TOOL BOX…2532
CLEAN INTERIOR OF CAB…2532
CAR STEREO, HANDLING…2533
AIR CONDITIONER, HANDLING…2542
ACCUMULATOR, HANDLING…2559
HANDLING MACHINES EQUIPPED WITH VHMS…2560
OPERATION…2562
CHECK BEFORE STARTING ENGINE, ADJUST…2562
STARTING ENGINE…2583
OPERATIONS AND CHECKS AFTER STARTING ENGINE…2591
STOPPING ENGINE…2594
CHECK AFTER STOPPING ENGINE…2594
MOVING MACHINE…2595
STOPPING MACHINE…2597
SHIFTING GEAR…2598
SHIFTING BETWEEN FORWARD AND REVERSE…2603
STEERING MACHINE…2605
PRECAUTIONS FOR OPERATION…2609
PARKING MACHINE…2611
CHECK AFTER FINISHING WORK…2613
LOCKING…2613
WORK POSSIBLE USING BULLDOZER…2614
EFFECTIVE USE OF MODE SELECTION SYSTEM…2616
RIPPER OPERATION…2621
OPERATING METHOD FOR RIPPING OPERATIONS…2624
ADJUSTING POSTURE OF WORK EQUIPMENT…2628
TIPS FOR LONGER UNDERCARRIAGE LIFE…2631
TRANSPORTATION…2633
TRANSPORTATION PROCEDURE…2633
LOADING, UNLOADING WORK…2633
METHOD OF LIFTING MACHINE…2636
PRECAUTIONS FOR TRANSPORTATION…2637
TRAVELING ON ROADS…2637
REMOVAL OF CAB…2638
INSTALLATION OF CAB…2641
INSTALLATION OF ROPS…2642
COLD WEATHER OPERATION…2643
PRECAUTIONS FOR LOW TEMPERATURE…2643
AFTER COMPLETION OF WORK…2645
AFTER COLD WEATHER…2645
LONG-TERM STORAGE…2646
BEFORE STORAGE…2646
DURING STORAGE…2646
AFTER STORAGE…2646
STARTING MACHINE AFTER LONG-TERM STORAGE…2646
TROUBLESHOOTING…2647
AFTER RUNNING OUT OF FUEL…2647
METHOD OF TOWING MACHINE…2649
IF BATTERY IS DISCHARGED…2650
OTHER TROUBLE…2654
WHEN MODE SELECTION SYSTEM FLASHES…2659
MAINTENANCE…2661
GUIDES TO MAINTENANCE…2662
OUTLINES OF SERVICE…2665
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2665
OUTLINE OF ELECTRIC SYSTEM…2668
HANDLING HYDRAULIC RELATED EQUIPMENT…2669
WEAR PARTS…2670
WEAR PARTS LIST…2670
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…2672
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…2674
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…2675
TORQUE LIST…2675
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2676
SAFETY CRITICAL PARTS…2677
MAINTENANCE SCHEDULE CHART…2679
MAINTENANCE SCHEDULE CHART…2679
SERVICE PROCEDURE…2681
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…2681
WHEN REQUIRED…2682
CLEAN INSIDE OF COOLING SYSTEM…2682
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…2686
CHECK AND ADJUST TRACK TENSION…2688
CHECK AND TIGHTEN TRACK SHOE BOLTS…2691
ADJUST IDLER CLEARANCE…2692
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES…2693
CLEAN AND CHECK RADIATOR FINS…2695
CLEAN FUEL TANK STRAINER…2696
DRAIN WATER AND SEDIMENT IN FUEL TANK…2696
CLEAN STEERING CLUTCH CASE BREATHER…2696
CHECK UNDERCARRIAGE OIL…2697
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)…2698
REPLACE AIR CONDITIONER BELT…2698
CLEAN AND CHECK HYDRAULIC COOLER FINS…2698
CHECK AND ADJUST AIR CONDITIONER…2699
LUBRICATE DOOR HINGE…2700
CHECK DOOR LATCH…2700
CHECK DOOR LOCK STRIKER…2701
REPLACE DOOR DAMPER…2701
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…2701
REPLACE WIPER BLADE…2702
BLEEDING AIR IN HYDRAULIC SYSTEM…2703
CHECK ELECTRICAL INTAKE AIR HEATER…2704
LUBRICATING…2704
CHECK BEFORE STARTING…2707
EVERY 250 HOURS SERVICE…2708
LUBRICATING…2708
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST…2710
CHECK LEVEL OF BATTERY ELECTROLYTE…2711
CHECK BRAKE PERFORMANCE…2714
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…2715
EVERY 500 HOURS SERVICE…2716
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…2716
REPLACE FUEL FILTER CARTRIDGE…2717
REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT…2719
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…2720
REPLACE HYDRAULIC TANK BREATHER ELEMENT…2720
EVERY 1000 HOURS SERVICE…2721
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)…2721
CHECK, CLEAN FUEL STRAINER…2723
CHECK FOR LOOSE ROPS MOUNT BOLTS…2723
REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE…2724
REPLACE AIR CONDITIONER AIR FILTER (FRESH, RECIRC FILTER)…2724
CHECK TIGHTENING PARTS OF TURBOCHARGER…2725
EVERY 2000 HOURS SERVICE…2726
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER…2726
CHANGE OIL IN FINAL DRIVE CASE…2728
CHANGE OIL IN DAMPER CASE AND BREATHER FILTER, CLEAN DAMPER BREATHER…2729
CHECK PIVOT BEARING OIL LEVEL, ADD OIL…2730
CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL…2730
CLEAN ENGINE BREATHER ELEMENT…2731
CHECK ALTERNATOR, STARTING MOTOR…2731
CHECK ENGINE VALVE CLEARANCE, ADJUST…2731
EVERY 4000 HOURS SERVICE…2732
CHECK WATER PUMP…2732
CHECK VIBRATION DAMPER…2732
CLEAN, CHECK TURBOCHARGER…2732
CHECK PLAY OF TURBOCHARGER ROTOR…2732
CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)…2733
SPECIFICATIONS…2735
SPECIFICATIONS…2736
ATTACHMENTS, OPTIONS…2737
GENERAL PRECAUTIONS…2738
PRECAUTIONS RELATED TO SAFETY…2738
SELECTION OF TRACK SHOE…2739
SELECTION OF TRACK SHOES…2739
PROCEDURE FOR SELECTING RIPPER POINT…2740
CAP WITH LOCK, HANDLING…2741
METHOD OF OPENING AND CLOSING CAP WITH LOCK…2741
EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER…2742
BLADE CONDITION…2742
DOZING WORK…2744
LEVELING (SPREADING) OPERATION…2747
DITCHING OPERATION…2747
BOULDER RAISING OPERATION…2747
SIDE-CUTTING OPERATIONS…2748
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)…2748
SHOE SLIP CONTROL…2749
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)…2749
EFFECTIVE USE OF MODE SELECTION SYSTEM…2750
IF MODE SELECTION SYSTEM FLASHES…2756
INDEX…2757
TEN00025-04 – Bulldozer D475A-5 Operation & Maintenance Manual (SN20001&up)…2761
COVER…2761
FOREWORD…2762
FOREWORD…2763
SAFETY INFORMATION…2766
INTRODUCTION…2768
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…2768
BREAKING IN THE MACHINE…2768
NECESSARY INFORMATION…2769
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE…2769
EPA REGULATIONS, ENGINE NUMBER PLATE…2769
BLADE SERIAL NO. PLATE POSITION…2770
RIPPER SERIAL NO. PLATE POSITION…2770
POSITION OF SERVICE METER…2770
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…2771
CONTENTS…2772
SAFETY…2776
SAFETY…2777
SAFETY LABELS…2779
POSITIONS OF SAFETY PICTOGRAMS…2779
SAFETY LABELS…2780
GENERAL PRECAUTIONS…2783
SAFETY RULES…2783
IF ABNORMALITIES ARE FOUND…2783
CLOTHING AND PERSONAL PROTECTIVE ITEMS…2783
FIRE EXTINGUISHER AND FIRST AID KIT…2783
SAFETY FEATURES…2783
KEEP MACHINE CLEAN…2784
INSIDE OPERATOR'S COMPARTMENT…2784
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…2784
HANDRAILS AND STEPS…2785
PRECAUTIONS WHEN WORKING IN HIGH PLACES…2785
MOUNTING AND DISMOUNTING…2785
NO PEOPLE ON ATTACHMENTS…2785
CRUSHING OR CUTTING PREVENTION…2786
PREVENTION OF BURNS…2786
FIRE PREVENTION…2787
ACTION IF FIRE OCCURS…2788
WINDOW WASHER LIQUID…2788
PRECAUTIONS WHEN USING ROPS…2788
PRECAUTIONS FOR ATTACHMENTS…2788
CAB WINDOW GLASSES…2788
UNAUTHORIZED MODIFICATION…2788
SAFETY AT WORKSITE…2789
WORKING ON LOOSE GROUND…2789
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…2790
ENSURE GOOD VISIBILITY…2790
VENTILATION FOR ENCLOSED AREAS…2791
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…2791
BE CAREFUL ABOUT ASBESTOS DUST…2791
PRECAUTIONS FOR OPERATION…2792
BEFORE STARTING ENGINE…2792
CHECKS BEFORE STARTING ENGINE…2792
PRECAUTIONS WHEN STARTING…2793
PRECAUTIONS IN COLD AREAS…2793
OPERATION…2794
CHECKS BEFORE OPERATION…2794
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE…2794
PRECAUTIONS WHEN TRAVELING…2795
TRAVELING ON SLOPES…2796
PROHIBITED OPERATIONS…2796
USING BRAKES…2796
OPERATE CAREFULLY ON SNOW…2796
PARKING MACHINE…2797
TRANSPORTATION…2798
LOADING AND UNLOADING…2798
SHIPPING…2798
BATTERY…2799
BATTERY HAZARD PREVENTION…2799
STARTING WITH BOOSTER CABLE…2800
TOWING…2801
WHEN TOWING…2801
PRECAUTIONS FOR MAINTENANCE…2802
WARNING TAG…2802
KEEP WORK PLACE CLEAN AND TIDY…2802
APPOINT LEADER WHEN WORKING WITH OTHERS…2802
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…2803
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…2804
PROPER TOOLS…2804
HANDLING ACCUMULATOR…2805
PERSONNEL…2805
ATTACHMENTS…2805
WORK UNDER THE MACHINE…2806
NOISE…2806
PRECAUTIONS WHEN USING HAMMER…2806
REPAIR WELDING…2806
REMOVING BATTERY TERMINAL…2806
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…2807
DO NOT DISASSEMBLE RECOIL SPRING…2807
PRECAUTION WITH HIGH-PRESSURE OIL…2808
PRECAUTION FOR HIGH FUEL PRESSURE…2808
HANDLING HIGH-PRESSURE HOSES…2808
PRECAUTION FOR HIGH VOLTAGE…2808
WASTE MATERIAL…2809
MAINTENANCE FOR AIR CONDITIONER…2809
COMPRESSED AIR…2809
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2809
OPERATION…2810
GENERAL VIEW…2811
GENERAL VIEW OF MACHINE…2811
GENERAL VIEW OF CONTROLS AND GAUGES…2812
EXPLANATION OF COMPONENTS…2814
FRONT PANEL…2814
SWITCHES…2845
CONTROL LEVERS, PEDALS…2850
DUST INDICATOR…2859
POWER SOURCE…2859
FUSE BOX…2860
DOOR OPEN LOCK…2864
SASH GLASS INTERMEDIATE LOCK…2864
DOOR POCKET…2865
ASHTRAY…2865
TOOL BOX…2865
CLEAN INTERIOR OF CAB…2865
CAR STEREO, HANDLING…2866
AIR CONDITIONER, HANDLING…2875
ACCUMULATOR, HANDLING…2892
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER…2893
HANDLING MACHINES EQUIPPED WITH VHMS…2900
OPERATION…2902
CHECK BEFORE STARTING ENGINE, ADJUST…2902
STARTING ENGINE…2923
OPERATIONS AND CHECKS AFTER STARTING ENGINE…2931
STOPPING ENGINE…2934
CHECK AFTER STOPPING ENGINE…2934
MOVING MACHINE…2935
STOPPING MACHINE…2937
SHIFTING GEAR…2938
SHIFTING BETWEEN FORWARD AND REVERSE…2943
STEERING MACHINE…2945
PRECAUTIONS FOR OPERATION…2949
PARKING MACHINE…2951
CHECK AFTER FINISHING WORK…2953
LOCKING…2953
WORK POSSIBLE USING BULLDOZER…2954
EFFECTIVE USE OF MODE SELECTION SYSTEM…2956
RIPPER OPERATION…2961
OPERATING METHOD FOR RIPPING OPERATIONS…2964
ADJUSTING POSTURE OF WORK EQUIPMENT…2968
TIPS FOR LONGER UNDERCARRIAGE LIFE…2971
TRANSPORTATION…2973
TRANSPORTATION PROCEDURE…2973
LOADING, UNLOADING WORK…2973
METHOD OF LIFTING MACHINE…2976
PRECAUTIONS FOR TRANSPORTATION…2977
TRAVELING ON ROADS…2977
REMOVAL OF CAB…2978
INSTALLATION OF CAB…2981
INSTALLATION OF ROPS…2982
COLD WEATHER OPERATION…2983
PRECAUTIONS FOR LOW TEMPERATURE…2983
AFTER COMPLETION OF WORK…2985
AFTER COLD WEATHER…2985
LONG-TERM STORAGE…2986
BEFORE STORAGE…2986
DURING STORAGE…2986
AFTER STORAGE…2986
STARTING MACHINE AFTER LONG-TERM STORAGE…2986
TROUBLESHOOTING…2987
AFTER RUNNING OUT OF FUEL…2987
METHOD OF TOWING MACHINE…2989
IF BATTERY IS DISCHARGED…2990
OTHER TROUBLE…2994
WHEN MODE SELECTION SYSTEM FLASHES…2999
MAINTENANCE…3000
GUIDES TO MAINTENANCE…3001
OUTLINES OF SERVICE…3004
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3004
OUTLINE OF ELECTRIC SYSTEM…3007
HANDLING HYDRAULIC RELATED EQUIPMENT…3008
WEAR PARTS…3009
WEAR PARTS LIST…3009
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…3011
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…3015
TORQUE LIST…3015
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…3016
SAFETY CRITICAL PARTS…3017
MAINTENANCE SCHEDULE CHART…3019
MAINTENANCE SCHEDULE CHART…3019
SERVICE PROCEDURE…3021
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…3021
WHEN REQUIRED…3022
CLEAN INSIDE OF COOLING SYSTEM…3022
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…3026
CHECK AND ADJUST TRACK TENSION…3028
CHECK AND TIGHTEN TRACK SHOE BOLTS…3031
ADJUST IDLER CLEARANCE…3032
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES…3033
CLEAN AND CHECK RADIATOR FINS…3035
CLEAN FUEL TANK STRAINER…3036
DRAIN WATER AND SEDIMENT IN FUEL TANK…3036
CLEAN STEERING CLUTCH CASE BREATHER…3036
CHECK UNDERCARRIAGE OIL…3037
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)…3038
REPLACE AIR CONDITIONER BELT…3038
CLEAN AND CHECK HYDRAULIC COOLER FINS…3038
CHECK AND ADJUST AIR CONDITIONER…3039
LUBRICATE DOOR HINGE…3040
CHECK DOOR LATCH…3040
CHECK DOOR LOCK STRIKER…3041
REPLACE DOOR DAMPER…3041
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…3041
REPLACE WIPER BLADE…3042
BLEEDING AIR IN HYDRAULIC SYSTEM…3043
CHECK ELECTRICAL INTAKE AIR HEATER…3044
LUBRICATING…3044
CHECK BEFORE STARTING…3047
EVERY 250 HOURS SERVICE…3048
LUBRICATING…3048
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST…3050
CHECK LEVEL OF BATTERY ELECTROLYTE…3051
CHECK BRAKE PERFORMANCE…3054
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…3055
EVERY 500 HOURS SERVICE…3056
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…3056
REPLACE FUEL FILTER CARTRIDGE…3057
REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT…3059
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…3060
REPLACE HYDRAULIC TANK BREATHER ELEMENT…3060
EVERY 1000 HOURS SERVICE…3061
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)…3061
CHECK, CLEAN FUEL STRAINER…3063
CHECK FOR LOOSE ROPS MOUNT BOLTS…3063
REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE …3064
REPLACE AIR CONDITIONER AIR FILTER (FRESH, RECIRC FILTER)…3065
CHECK TIGHTENING PARTS OF TURBOCHARGER…3065
EVERY 2000 HOURS SERVICE…3066
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER…3066
CHANGE OIL IN FINAL DRIVE CASE…3068
CHANGE OIL IN DAMPER CASE AND BREATHER FILTER, CLEAN DAMPER BREATHER…3069
CHECK PIVOT BEARING OIL LEVEL, ADD OIL…3070
CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL…3070
CLEAN ENGINE BREATHER ELEMENT…3071
CHECK ALTERNATOR, STARTING MOTOR…3071
CHECK ENGINE VALVE CLEARANCE, ADJUST…3071
EVERY 4000 HOURS SERVICE…3072
CHECK WATER PUMP…3072
CHECK VIBRATION DAMPER…3072
CLEAN, CHECK TURBOCHARGER…3072
CHECK PLAY OF TURBOCHARGER ROTOR…3072
CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)…3073
SPECIFICATIONS…3074
SPECIFICATIONS…3075
ATTACHMENTS, OPTIONS…3076
GENERAL PRECAUTIONS…3077
PRECAUTIONS RELATED TO SAFETY…3077
SELECTION OF TRACK SHOE…3078
SELECTION OF TRACK SHOES…3078
PROCEDURE FOR SELECTING RIPPER POINT…3079
CAP WITH LOCK, HANDLING…3080
METHOD OF OPENING AND CLOSING CAP WITH LOCK…3080
EFFECTIVE METHOD OF OPERATION FOR DUAL TILT DOZER…3081
BLADE CONDITION…3081
DOZING WORK…3083
LEVELING (SPREADING) OPERATION…3086
DITCHING OPERATION…3086
BOULDER RAISING OPERATION…3086
SIDE-CUTTING OPERATIONS…3087
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)…3087
SHOE SLIP CONTROL…3088
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)…3088
EFFECTIVE USE OF MODE SELECTION SYSTEM…3089
IF MODE SELECTION SYSTEM FLASHES…3095
INDEX…3096
TEN00094-03 – Bulldozer D475A-5 Operation & Maintenance Manual (SN20001&up)…3100
COVER…3100
FOREWORD…3101
FOREWORD…3102
SAFETY INFORMATION…3105
INTRODUCTION…3107
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…3107
BREAKING IN THE MACHINE…3107
NECESSARY INFORMATION…3108
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE…3108
EPA REGULATIONS, ENGINE NUMBER PLATE…3108
BLADE SERIAL NO. PLATE POSITION…3109
POSITION OF SERVICE METER…3109
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…3110
CONTENTS…3111
SAFETY…3115
SAFETY…3116
SAFETY LABELS…3118
POSITIONS OF SAFETY PICTOGRAMS…3118
SAFETY LABELS…3119
GENERAL PRECAUTIONS…3122
SAFETY RULES…3122
IF ABNORMALITIES ARE FOUND…3122
CLOTHING AND PERSONAL PROTECTIVE ITEMS…3122
FIRE EXTINGUISHER AND FIRST AID KIT…3122
SAFETY FEATURES…3122
KEEP MACHINE CLEAN…3123
INSIDE OPERATOR'S COMPARTMENT…3123
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…3123
HANDRAILS AND STEPS…3124
PRECAUTIONS WHEN WORKING IN HIGH PLACES…3124
MOUNTING AND DISMOUNTING…3124
NO PEOPLE ON ATTACHMENTS…3124
CRUSHING OR CUTTING PREVENTION…3125
PREVENTION OF BURNS…3125
FIRE PREVENTION…3126
ACTION IF FIRE OCCURS…3127
WINDOW WASHER LIQUID…3127
PRECAUTIONS WHEN USING ROPS…3127
PRECAUTIONS FOR ATTACHMENTS…3127
CAB WINDOW GLASSES…3127
UNAUTHORIZED MODIFICATION…3127
SAFETY AT WORKSITE…3128
WORKING ON LOOSE GROUND…3128
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…3129
ENSURE GOOD VISIBILITY…3129
VENTILATION FOR ENCLOSED AREAS…3130
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…3130
BE CAREFUL ABOUT ASBESTOS DUST…3130
PRECAUTIONS FOR OPERATION…3131
BEFORE STARTING ENGINE…3131
CHECKS BEFORE STARTING ENGINE…3131
PRECAUTIONS WHEN STARTING…3132
PRECAUTIONS IN COLD AREAS…3132
OPERATION…3133
CHECKS BEFORE OPERATION…3133
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE…3133
PRECAUTIONS WHEN TRAVELING…3134
TRAVELING ON SLOPES…3135
PROHIBITED OPERATIONS…3135
USING BRAKES…3135
OPERATE CAREFULLY ON SNOW…3135
PARKING MACHINE…3136
TRANSPORTATION…3137
LOADING AND UNLOADING…3137
SHIPPING…3137
BATTERY…3138
BATTERY HAZARD PREVENTION…3138
STARTING WITH BOOSTER CABLE…3139
TOWING…3140
WHEN TOWING…3140
PRECAUTIONS FOR MAINTENANCE…3141
WARNING TAG…3141
KEEP WORK PLACE CLEAN AND TIDY…3141
APPOINT LEADER WHEN WORKING WITH OTHERS…3141
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…3142
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…3143
PROPER TOOLS…3143
HANDLING ACCUMULATOR…3144
PERSONNEL…3144
ATTACHMENTS…3144
WORK UNDER THE MACHINE…3145
NOISE…3145
PRECAUTIONS WHEN USING HAMMER…3145
REPAIR WELDING…3145
REMOVING BATTERY TERMINAL…3145
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…3146
DO NOT DISASSEMBLE RECOIL SPRING…3146
PRECAUTION WITH HIGH-PRESSURE OIL…3147
PRECAUTION FOR HIGH FUEL PRESSURE…3147
HANDLING HIGH-PRESSURE HOSES…3147
PRECAUTION FOR HIGH VOLTAGE…3147
WASTE MATERIAL…3148
MAINTENANCE FOR AIR CONDITIONER…3148
COMPRESSED AIR…3148
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…3148
OPERATION…3149
GENERAL VIEW…3150
GENERAL VIEW OF MACHINE…3150
GENERAL VIEW OF CONTROLS AND GAUGES…3151
EXPLANATION OF COMPONENTS…3153
FRONT PANEL…3153
SWITCHES…3184
CONTROL LEVERS, PEDALS…3189
DUST INDICATOR…3195
POWER SOURCE…3195
FUSE BOX…3196
DOOR OPEN LOCK…3200
SASH GLASS INTERMEDIATE LOCK…3200
DOOR POCKET…3201
ASHTRAY…3201
TOOL BOX…3201
CLEAN INTERIOR OF CAB…3201
CAR STEREO, HANDLING…3202
AIR CONDITIONER, HANDLING…3211
ACCUMULATOR, HANDLING…3228
HANDLING MACHINES EQUIPPED WITH VHMS…3229
OPERATION…3231
CHECK BEFORE STARTING ENGINE, ADJUST…3231
STARTING ENGINE…3252
OPERATIONS AND CHECKS AFTER STARTING ENGINE…3260
STOPPING ENGINE…3263
CHECK AFTER STOPPING ENGINE…3263
MOVING MACHINE…3264
STOPPING MACHINE…3266
SHIFTING GEAR…3267
SHIFTING BETWEEN FORWARD AND REVERSE…3273
STEERING MACHINE…3275
PRECAUTIONS FOR OPERATION…3279
PARKING MACHINE…3281
CHECK AFTER FINISHING WORK…3283
LOCKING…3283
PROHIBITED WORK OF SUPER DOZER…3284
EFFECTIVE USE OF SUPER DOZER…3286
EFFECTIVE USE OF MODE SELECTION SYSTEM…3289
ADJUSTING POSTURE OF WORK EQUIPMENT…3294
TIPS FOR LONGER UNDERCARRIAGE LIFE…3295
TRANSPORTATION…3297
TRANSPORTATION PROCEDURE…3297
LOADING, UNLOADING WORK…3297
METHOD OF LIFTING MACHINE…3300
PRECAUTIONS FOR TRANSPORTATION…3301
TRAVELING ON ROADS…3301
REMOVAL OF CAB…3302
INSTALLATION OF CAB…3305
INSTALLATION OF ROPS…3306
COLD WEATHER OPERATION…3307
PRECAUTIONS FOR LOW TEMPERATURE…3307
AFTER COMPLETION OF WORK…3309
AFTER COLD WEATHER…3309
LONG-TERM STORAGE…3310
BEFORE STORAGE…3310
DURING STORAGE…3310
AFTER STORAGE…3310
STARTING MACHINE AFTER LONG-TERM STORAGE…3310
TROUBLESHOOTING…3311
AFTER RUNNING OUT OF FUEL…3311
METHOD OF TOWING MACHINE…3313
IF BATTERY IS DISCHARGED…3314
OTHER TROUBLE…3318
WHEN MODE SELECTION SYSTEM FLASHES…3322
MAINTENANCE…3323
GUIDES TO MAINTENANCE…3324
OUTLINES OF SERVICE…3327
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3327
OUTLINE OF ELECTRIC SYSTEM…3330
HANDLING HYDRAULIC RELATED EQUIPMENT…3331
WEAR PARTS…3332
WEAR PARTS LIST…3332
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…3333
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…3335
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…3336
TORQUE LIST…3336
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…3337
SAFETY CRITICAL PARTS…3338
MAINTENANCE SCHEDULE CHART…3340
MAINTENANCE SCHEDULE CHART…3340
SERVICE PROCEDURE…3342
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…3342
WHEN REQUIRED…3343
CLEAN INSIDE OF COOLING SYSTEM…3343
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…3347
CHECK AND ADJUST TRACK TENSION…3349
CHECK AND TIGHTEN TRACK SHOE BOLTS…3352
ADJUST IDLER CLEARANCE…3353
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES…3354
CLEAN AND CHECK RADIATOR FINS…3356
CLEAN FUEL TANK STRAINER…3357
DRAIN WATER AND SEDIMENT IN FUEL TANK…3357
CLEAN STEERING CLUTCH CASE BREATHER…3357
CHECK UNDERCARRIAGE OIL…3358
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)…3359
REPLACE AIR CONDITIONER BELT…3359
CLEAN AND CHECK HYDRAULIC COOLER FINS…3359
CHECK AND ADJUST AIR CONDITIONER…3360
LUBRICATE DOOR HINGE…3361
CHECK DOOR LATCH…3361
CHECK DOOR LOCK STRIKER…3362
REPLACE DOOR DAMPER…3362
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…3362
REPLACE WIPER BLADE…3363
BLEEDING AIR IN HYDRAULIC SYSTEM…3364
CHECK ELECTRICAL INTAKE AIR HEATER…3364
LUBRICATING…3364
CHECK BEFORE STARTING…3367
EVERY 250 HOURS SERVICE…3368
LUBRICATING…3368
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST…3370
CHECK LEVEL OF BATTERY ELECTROLYTE…3371
CHECK BRAKE PERFORMANCE…3374
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…3375
EVERY 500 HOURS SERVICE…3376
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…3376
REPLACE FUEL FILTER CARTRIDGE…3377
REPLACE TRANSMISSION FILTER ELEMENT, TRANSMISSION LUBRICATION FILTER ELEMENT AND TORQUE CONVERTER OIL FILTER ELEMENT…3379
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…3380
REPLACE HYDRAULIC TANK BREATHER ELEMENT…3380
EVERY 1000 HOURS SERVICE…3381
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (INCL. TRANSMISSION CASE, TORQUE CONVERTER CASE AND BEVEL GEAR CASE)…3381
CHECK, CLEAN FUEL STRAINER…3383
CHECK FOR LOOSE ROPS MOUNT BOLTS…3383
REPLACE MAIN CORROSION RESISTOR CARTRIDGE AND SUB CORROSION RESISTOR CARTRIDGE…3383
REPLACE AIR CONDITIONER AIR FILTER (FRESH, RECIRC FILTER)…3384
CHECK TIGHTENING PARTS OF TURBOCHARGER…3384
EVERY 2000 HOURS SERVICE…3385
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER…3385
CHANGE OIL IN FINAL DRIVE CASE…3387
CHANGE OIL IN DAMPER CASE AND BREATHER FILTER, CLEAN DAMPER BREATHER…3388
CHECK PIVOT BEARING OIL LEVEL, ADD OIL…3389
CHECK OIL LEVEL IN RECOIL SPRING, ASSIST CYLINDER CASE, ADD OIL…3389
CLEAN ENGINE BREATHER ELEMENT…3390
CHECK ALTERNATOR, STARTING MOTOR…3390
CHECK ENGINE VALVE CLEARANCE, ADJUST…3390
EVERY 4000 HOURS SERVICE…3391
CHECK WATER PUMP…3391
CHECK VIBRATION DAMPER…3391
CLEAN, CHECK TURBOCHARGER…3391
CHECK PLAY OF TURBOCHARGER ROTOR…3391
CHECK MAIN FRAME, WORK EQUIPMENT (BLADE)…3392
SPECIFICATIONS…3393
SPECIFICATIONS…3394
ATTACHMENTS, OPTIONS…3395
GENERAL PRECAUTIONS…3396
PRECAUTIONS RELATED TO SAFETY…3396
SELECTION OF TRACK SHOE…3397
SELECTION OF TRACK SHOES…3397
CAP WITH LOCK, HANDLING…3398
METHOD OF OPENING AND CLOSING CAP WITH LOCK…3398
INDEX…3399
TEN00132-05 – Bulldozer D475A-5E0 Operation & Maintenance Manual (SN30001&up)…3403
COVER…3403
FOREWORD…3404
FOREWORD…3405
SAFETY INFORMATION…3408
INTRODUCTION…3410
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…3410
VISIBILITY FROM OPERATOR'S SEAT…3411
BREAKING IN THE MACHINE…3412
NECESSARY INFORMATION…3413
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE…3413
EPA REGULATIONS, ENGINE NUMBER PLATE…3413
BLADE SERIAL NO. PLATE POSITION…3414
RIPPER SERIAL NO. PLATE POSITION…3414
POSITION OF SERVICE METER…3414
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…3415
CONTENTS…3416
SAFETY…3420
SAFETY…3421
SAFETY LABELS…3423
POSITIONS OF SAFETY PICTOGRAMS…3423
SAFETY LABELS…3424
GENERAL PRECAUTIONS…3428
PRECAUTIONS FOR OPERATION…3437
BEFORE STARTING ENGINE…3437
OPERATION…3439
TRANSPORTATION…3443
BATTERY…3444
TOWING…3446
PRECAUTIONS FOR MAINTENANCE…3447
OPERATION…3456
GENERAL VIEW…3457
GENERAL VIEW OF MACHINE…3457
GENERAL VIEW OF CONTROLS AND GAUGES…3458
EXPLANATION OF COMPONENTS…3460
FRONT PANEL…3460
SWITCHES…3491
CONTROL LEVERS, PEDALS…3496
DUST INDICATOR…3505
POWER SOURCE…3505
FUSE BOX…3506
DOOR OPEN LOCK…3510
SASH GLASS INTERMEDIATE LOCK…3510
CAP WITH LOCK…3511
DOOR POCKET…3513
ASHTRAY…3513
TOOL BOX…3513
CLEAN INTERIOR OF CAB…3513
CAR STEREO, HANDLING…3514
AIR CONDITIONER, HANDLING…3523
OPERATION…3540
CHECK BEFORE STARTING ENGINE, ADJUST…3540
STARTING ENGINE…3561
OPERATIONS AND CHECKS AFTER STARTING ENGINE…3569
STOPPING ENGINE…3572
MOVING MACHINE…3573
STOPPING MACHINE…3575
SHIFTING GEAR…3576
SHIFTING BETWEEN FORWARD AND REVERSE…3581
STEERING MACHINE…3583
PRECAUTIONS FOR OPERATION…3585
PARKING MACHINE…3588
CHECK AFTER STOPPING ENGINE…3589
CHECK AFTER FINISHING WORK…3590
LOCKING…3590
WORK POSSIBLE USING BULLDOZER…3591
EFFECTIVE USE OF MODE SELECTION SYSTEM…3593
RIPPER OPERATION…3598
OPERATING METHOD FOR RIPPING OPERATIONS…3601
ADJUSTING POSTURE OF WORK EQUIPMENT…3606
TIPS FOR LONGER UNDERCARRIAGE LIFE…3609
TRANSPORTATION…3611
TRANSPORTATION PROCEDURE…3611
LOADING, UNLOADING WORK…3611
METHOD OF LIFTING MACHINE…3614
TRAVELING ON ROADS…3615
REMOVAL OF CAB…3616
INSTALLATION OF CAB…3619
INSTALLATION OF ROPS…3620
COLD WEATHER OPERATION…3621
PRECAUTIONS FOR LOW TEMPERATURE…3621
AFTER COMPLETION OF WORK…3623
AFTER COLD WEATHER…3623
LONG-TERM STORAGE…3624
BEFORE STORAGE…3624
DURING STORAGE…3624
AFTER STORAGE…3624
STARTING MACHINE AFTER LONG-TERM STORAGE…3624
TROUBLESHOOTING…3625
AFTER RUNNING OUT OF FUEL…3625
METHOD OF TOWING MACHINE…3626
IF BATTERY IS DISCHARGED…3627
OTHER TROUBLE…3631
WHEN MODE SELECTION SYSTEM FLASHES…3636
MAINTENANCE…3638
GUIDES TO MAINTENANCE…3639
OUTLINES OF SERVICE…3642
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3642
OUTLINE OF ELECTRIC SYSTEM…3645
HANDLING HYDRAULIC RELATED EQUIPMENT…3646
WEAR PARTS…3647
WEAR PARTS LIST…3647
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…3649
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…3651
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…3652
TORQUE LIST…3652
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…3653
SAFETY CRITICAL PARTS…3654
MAINTENANCE SCHEDULE CHART…3656
MAINTENANCE SCHEDULE CHART…3656
SERVICE PROCEDURE…3658
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…3658
WHEN REQUIRED…3659
CHECK BEFORE STARTING…3690
EVERY 250 HOURS SERVICE…3691
EVERY 500 HOURS SERVICE…3699
EVERY 1000 HOURS SERVICE…3705
EVERY 2000 HOURS SERVICE…3714
EVERY 4000 HOURS SERVICE…3723
EVERY 8000 HOURS SERVICE…3727
SPECIFICATIONS…3728
SPECIFICATIONS…3729
ATTACHMENTS, OPTIONS…3730
GENERAL PRECAUTIONS…3731
PRECAUTIONS RELATED TO SAFETY…3731
SELECTION OF TRACK SHOE…3732
SELECTION OF TRACK SHOES…3732
PROCEDURE FOR SELECTING RIPPER POINT…3733
EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER…3734
BLADE CONDITION…3734
DOZING WORK…3736
LEVELING (SPREADING) OPERATION…3738
DITCHING OPERATION…3738
BOULDER RAISING OPERATION…3738
SIDE-CUTTING OPERATIONS…3739
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)…3739
SHOE SLIP CONTROL…3740
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)…3740
EFFECTIVE USE OF MODE SELECTION SYSTEM…3741
IF MODE SELECTION SYSTEM FLASHES…3748
HANDLING MACHINES EQUIPPED WITH VHMS…3749
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED…3749
VHMS AND COMMUNICATIONS TERMINAL INSTALLED…3750
INDEX…3752
TEN00136-05 – Bulldozer D475ASD-5E0 Operation & Maintenance Manual (SN30001&up)…3756
COVER…3756
FOREWORD…3757
FOREWORD…3758
SAFETY INFORMATION…3761
INTRODUCTION…3763
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…3763
VISIBILITY FROM OPERATOR'S SEAT…3764
BREAKING IN THE MACHINE…3765
NECESSARY INFORMATION…3766
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE…3766
EPA REGULATIONS, ENGINE NUMBER PLATE…3766
BLADE SERIAL NO. PLATE POSITION…3767
POSITION OF SERVICE METER…3767
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…3767
CONTENTS…3768
SAFETY…3771
SAFETY…3772
SAFETY LABELS…3774
POSITIONS OF SAFETY PICTOGRAMS…3774
SAFETY LABELS…3775
GENERAL PRECAUTIONS…3779
PRECAUTIONS FOR OPERATION…3788
BEFORE STARTING ENGINE…3788
OPERATION…3790
TRANSPORTATION…3794
BATTERY…3795
TOWING…3797
PRECAUTIONS FOR MAINTENANCE…3798
OPERATION…3807
GENERAL VIEW…3808
GENERAL VIEW OF MACHINE…3808
GENERAL VIEW OF CONTROLS AND GAUGES…3809
EXPLANATION OF COMPONENTS…3811
FRONT PANEL…3811
SWITCHES…3841
CONTROL LEVERS, PEDALS…3846
DUST INDICATOR…3852
POWER SOURCE…3852
FUSE BOX…3853
DOOR OPEN LOCK…3857
SASH GLASS INTERMEDIATE LOCK…3857
CAP WITH LOCK…3858
DOOR POCKET…3860
ASHTRAY…3860
TOOL BOX…3860
CLEAN INTERIOR OF CAB…3860
CAR STEREO, HANDLING…3861
AIR CONDITIONER, HANDLING…3870
OPERATION…3887
CHECK BEFORE STARTING ENGINE, ADJUST…3887
STARTING ENGINE…3908
OPERATIONS AND CHECKS AFTER STARTING ENGINE…3916
STOPPING ENGINE…3919
MOVING MACHINE…3920
STOPPING MACHINE…3922
SHIFTING GEAR…3923
SHIFTING BETWEEN FORWARD AND REVERSE…3928
STEERING MACHINE…3930
PRECAUTIONS FOR OPERATION…3933
PARKING MACHINE…3936
CHECK AFTER STOPPING ENGINE…3937
CHECK AFTER FINISHING WORK…3938
LOCKING…3938
PROHIBITED WORK OF SUPER DOZER…3939
EFFECTIVE USE OF SUPER DOZER…3941
EFFECTIVE USE OF MODE SELECTION SYSTEM…3944
ADJUSTING POSTURE OF WORK EQUIPMENT…3949
TIPS FOR LONGER UNDERCARRIAGE LIFE…3950
TRANSPORTATION…3952
TRANSPORTATION PROCEDURE…3952
LOADING, UNLOADING WORK…3952
METHOD OF LIFTING MACHINE…3955
TRAVELING ON ROADS…3956
REMOVAL OF CAB…3957
INSTALLATION OF CAB…3960
INSTALLATION OF ROPS…3961
COLD WEATHER OPERATION…3962
PRECAUTIONS FOR LOW TEMPERATURE…3962
AFTER COMPLETION OF WORK…3964
AFTER COLD WEATHER…3964
LONG-TERM STORAGE…3965
BEFORE STORAGE…3965
DURING STORAGE…3965
AFTER STORAGE…3965
STARTING MACHINE AFTER LONG-TERM STORAGE…3965
TROUBLESHOOTING…3966
AFTER RUNNING OUT OF FUEL…3966
METHOD OF TOWING MACHINE…3967
IF BATTERY IS DISCHARGED…3968
OTHER TROUBLE…3972
WHEN MODE SELECTION SYSTEM FLASHES…3976
MAINTENANCE…3977
GUIDES TO MAINTENANCE…3978
OUTLINES OF SERVICE…3981
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3981
OUTLINE OF ELECTRIC SYSTEM…3984
HANDLING HYDRAULIC RELATED EQUIPMENT…3985
WEAR PARTS…3986
WEAR PARTS LIST…3986
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…3987
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…3989
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…3990
TORQUE LIST…3990
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…3991
SAFETY CRITICAL PARTS…3992
MAINTENANCE SCHEDULE CHART…3994
MAINTENANCE SCHEDULE CHART…3994
SERVICE PROCEDURE…3996
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…3996
WHEN REQUIRED…3997
CHECK BEFORE STARTING…4029
EVERY 250 HOURS SERVICE…4030
EVERY 500 HOURS SERVICE…4038
EVERY 1000 HOURS SERVICE…4044
EVERY 2000 HOURS SERVICE…4052
EVERY 4000 HOURS SERVICE…4061
EVERY 8000 HOURS SERVICE…4065
SPECIFICATIONS…4067
SPECIFICATIONS…4068
ATTACHMENTS, OPTIONS…4069
GENERAL PRECAUTIONS…4070
PRECAUTIONS RELATED TO SAFETY…4070
SELECTION OF TRACK SHOE…4071
SELECTION OF TRACK SHOES…4071
HANDLING MACHINES EQUIPPED WITH VHMS…4072
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED…4072
VHMS AND COMMUNICATIONS TERMINAL INSTALLED…4073
INDEX…4075
TEN00282-03 – Bulldozer D475A-5E0 Operation & Maintenance Manual (SN30071&up)…4079
COVER…4079
FOREWORD…4080
BEFORE READING THIS MANUAL…4081
SAFETY INFORMATION…4082
INTRODUCTION…4083
USE OF MACHINE…4083
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…4083
VISIBILITY FROM OPERATOR'S SEAT…4084
NECESSARY INFORMATION…4085
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE…4085
EPA REGULATIONS, ENGINE NUMBER PLATE…4085
BLADE SERIAL NO. PLATE POSITION…4086
RIPPER SERIAL NO. PLATE POSITION…4086
POSITION OF SERVICE METER…4086
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…4087
CONTENTS…4088
SAFETY…4092
SAFETY…4093
SAFETY LABELS…4096
POSITIONS OF SAFETY PICTOGRAMS…4096
SAFETY LABELS…4097
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…4101
PRECAUTIONS BEFORE STARTING OPERATION…4101
PREPARATIONS FOR SAFE OPERATION…4101
FIRE PREVENTION…4103
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…4104
DO NOT GET CAUGHT IN WORK EQUIPMENT…4106
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4106
UNAUTHORIZED MODIFICATION…4106
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4106
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…4107
PRECAUTIONS FOR OPERATION…4108
PRECAUTIONS FOR JOBSITE…4108
STARTING ENGINE…4110
OPERATION…4113
TRANSPORTATION…4117
TOWING…4118
PRECAUTIONS FOR MAINTENANCE…4119
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…4119
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4123
OPERATION…4130
GENERAL VIEW…4131
GENERAL VIEW OF MACHINE…4131
GENERAL VIEW OF CONTROLS AND GAUGES…4132
EXPLANATION OF COMPONENTS…4134
FRONT PANEL…4134
SWITCHES…4164
CONTROL LEVERS, PEDALS…4173
DUST INDICATOR…4182
POWER SOURCE…4182
FUSE BOX…4183
DOOR OPEN LOCK…4188
SASH GLASS INTERMEDIATE LOCK…4188
CAP WITH LOCK…4189
DOOR POCKET…4190
ASHTRAY…4191
TOOL BOX…4191
CLEAN INTERIOR OF CAB…4191
CAR STEREO, HANDLING…4192
AIR CONDITIONER, HANDLING…4201
OPERATION…4218
CHECK BEFORE STARTING ENGINE, ADJUST…4218
STARTING ENGINE…4239
OPERATIONS AND CHECKS AFTER STARTING ENGINE…4247
STOPPING ENGINE…4250
MOVING MACHINE…4251
STOPPING MACHINE…4253
SHIFTING GEAR…4254
SHIFTING BETWEEN FORWARD AND REVERSE…4259
STEERING MACHINE…4261
PRECAUTIONS FOR OPERATION…4263
PARKING MACHINE…4266
CHECK AFTER STOPPING ENGINE…4267
CHECK AFTER FINISHING WORK…4268
LOCKING…4268
WORK POSSIBLE USING BULLDOZER…4269
EFFECTIVE USE OF MODE SELECTION SYSTEM…4271
RIPPER OPERATION…4276
OPERATING METHOD FOR RIPPING OPERATIONS…4279
ADJUSTING POSTURE OF WORK EQUIPMENT…4284
TIPS FOR LONGER UNDERCARRIAGE LIFE…4287
TRANSPORTATION…4289
TRANSPORTATION PROCEDURE…4289
LOADING, UNLOADING WORK…4289
METHOD OF LIFTING MACHINE…4292
TRAVELING ON ROADS…4293
REMOVAL OF CAB…4294
INSTALLATION OF CAB…4297
INSTALLATION OF ROPS…4298
COLD WEATHER OPERATION…4299
PRECAUTIONS FOR LOW TEMPERATURE…4299
AFTER COMPLETION OF WORK…4301
AFTER COLD WEATHER…4301
LONG-TERM STORAGE…4302
BEFORE STORAGE…4302
DURING STORAGE…4302
AFTER STORAGE…4302
STARTING MACHINE AFTER LONG-TERM STORAGE…4302
TROUBLESHOOTING…4303
AFTER RUNNING OUT OF FUEL…4303
METHOD OF TOWING MACHINE…4303
IF BATTERY IS DISCHARGED…4305
OTHER TROUBLE…4310
WHEN MODE SELECTION SYSTEM FLASHES…4315
MAINTENANCE…4316
GUIDES TO MAINTENANCE…4317
OUTLINES OF SERVICE…4320
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…4320
OUTLINE OF ELECTRIC SYSTEM…4324
HANDLING HYDRAULIC RELATED EQUIPMENT…4324
WEAR PARTS…4325
WEAR PARTS LIST…4325
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…4327
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…4329
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…4330
TORQUE LIST…4330
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…4331
SAFETY CRITICAL PARTS…4332
MAINTENANCE SCHEDULE CHART…4334
MAINTENANCE SCHEDULE CHART…4334
SERVICE PROCEDURE…4336
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…4336
WHEN REQUIRED…4337
CHECK BEFORE STARTING…4368
EVERY 250 HOURS SERVICE…4369
EVERY 500 HOURS SERVICE…4377
EVERY 1000 HOURS SERVICE…4383
EVERY 2000 HOURS SERVICE…4392
EVERY 4000 HOURS SERVICE…4402
EVERY 8000 HOURS SERVICE…4406
SPECIFICATIONS…4408
SPECIFICATIONS…4409
ATTACHMENTS, OPTIONS…4410
GENERAL PRECAUTIONS…4411
PRECAUTIONS RELATED TO SAFETY…4411
SELECTION OF TRACK SHOE…4412
SELECTION OF TRACK SHOES…4412
PROCEDURE FOR SELECTING RIPPER POINT…4413
EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER…4414
BLADE CONDITION…4414
DOZING WORK…4416
LEVELING (SPREADING) OPERATION…4418
DITCHING OPERATION…4418
BOULDER RAISING OPERATION…4418
SIDE-CUTTING OPERATIONS…4419
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)…4419
SHOE SLIP CONTROL…4420
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)…4420
EFFECTIVE USE OF MODE SELECTION SYSTEM…4421
IF MODE SELECTION SYSTEM FLASHES…4428
HANDLING MACHINES EQUIPPED WITH VHMS…4429
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED…4429
VHMS AND COMMUNICATIONS TERMINAL INSTALLED…4430
INDEX…4432
TEN00283-03 – Bulldozer D475ASD-5E0 Operation & Maintenance Manual (SN30071&up)…4436
COVER…4436
FOREWORD…4437
BEFORE READING THIS MANUAL…4438
SAFETY INFORMATION…4439
INTRODUCTION…4440
USE OF MACHINE…4440
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…4440
VISIBILITY FROM OPERATOR'S SEAT…4441
NECESSARY INFORMATION…4442
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE…4442
EPA REGULATIONS, ENGINE NUMBER PLATE…4442
BLADE SERIAL NO. PLATE POSITION…4443
POSITION OF SERVICE METER…4443
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…4443
CONTENTS…4444
SAFETY…4447
SAFETY…4448
SAFETY LABELS…4451
POSITIONS OF SAFETY PICTOGRAMS…4451
SAFETY LABELS…4452
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…4456
PRECAUTIONS BEFORE STARTING OPERATION…4456
PREPARATIONS FOR SAFE OPERATION…4456
FIRE PREVENTION…4458
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…4459
DO NOT GET CAUGHT IN WORK EQUIPMENT…4461
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4461
UNAUTHORIZED MODIFICATION…4461
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4461
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…4462
PRECAUTIONS FOR OPERATION…4463
PRECAUTIONS FOR JOBSITE…4463
STARTING ENGINE…4465
OPERATION…4468
TRANSPORTATION…4472
TOWING…4473
PRECAUTIONS FOR MAINTENANCE…4474
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…4474
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4478
OPERATION…4485
GENERAL VIEW…4486
GENERAL VIEW OF MACHINE…4486
GENERAL VIEW OF CONTROLS AND GAUGES…4487
EXPLANATION OF COMPONENTS…4489
FRONT PANEL…4489
SWITCHES…4520
CONTROL LEVERS, PEDALS…4529
DUST INDICATOR…4535
POWER SOURCE…4535
FUSE BOX…4536
DOOR OPEN LOCK…4541
SASH GLASS INTERMEDIATE LOCK…4541
CAP WITH LOCK…4542
DOOR POCKET…4543
ASHTRAY…4544
TOOL BOX…4544
CLEAN INTERIOR OF CAB…4544
CAR STEREO, HANDLING…4545
AIR CONDITIONER, HANDLING…4554
OPERATION…4571
CHECK BEFORE STARTING ENGINE, ADJUST…4571
STARTING ENGINE…4592
OPERATIONS AND CHECKS AFTER STARTING ENGINE…4600
STOPPING ENGINE…4603
MOVING MACHINE…4604
STOPPING MACHINE…4606
SHIFTING GEAR…4607
SHIFTING BETWEEN FORWARD AND REVERSE…4612
STEERING MACHINE…4614
PRECAUTIONS FOR OPERATION…4617
PARKING MACHINE…4620
CHECK AFTER STOPPING ENGINE…4621
CHECK AFTER FINISHING WORK…4622
LOCKING…4622
PROHIBITED WORK OF SUPER DOZER…4623
EFFECTIVE USE OF SUPER DOZER…4625
EFFECTIVE USE OF MODE SELECTION SYSTEM…4628
ADJUSTING POSTURE OF WORK EQUIPMENT…4633
TIPS FOR LONGER UNDERCARRIAGE LIFE…4634
TRANSPORTATION…4636
TRANSPORTATION PROCEDURE…4636
LOADING, UNLOADING WORK…4636
METHOD OF LIFTING MACHINE…4639
TRAVELING ON ROADS…4640
REMOVAL OF CAB…4641
INSTALLATION OF CAB…4644
INSTALLATION OF ROPS…4645
COLD WEATHER OPERATION…4646
PRECAUTIONS FOR LOW TEMPERATURE…4646
AFTER COMPLETION OF WORK…4648
AFTER COLD WEATHER…4648
LONG-TERM STORAGE…4649
BEFORE STORAGE…4649
DURING STORAGE…4649
AFTER STORAGE…4649
STARTING MACHINE AFTER LONG-TERM STORAGE…4649
TROUBLESHOOTING…4650
AFTER RUNNING OUT OF FUEL…4650
METHOD OF TOWING MACHINE…4650
IF BATTERY IS DISCHARGED…4651
OTHER TROUBLE…4657
WHEN MODE SELECTION SYSTEM FLASHES…4661
MAINTENANCE…4663
GUIDES TO MAINTENANCE…4664
OUTLINES OF SERVICE…4667
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…4667
OUTLINE OF ELECTRIC SYSTEM…4671
HANDLING HYDRAULIC RELATED EQUIPMENT…4671
WEAR PARTS…4672
WEAR PARTS LIST…4672
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…4673
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…4675
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…4676
TORQUE LIST…4676
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…4677
SAFETY CRITICAL PARTS…4678
MAINTENANCE SCHEDULE CHART…4680
MAINTENANCE SCHEDULE CHART…4680
SERVICE PROCEDURE…4682
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…4682
WHEN REQUIRED…4683
CHECK BEFORE STARTING…4714
EVERY 250 HOURS SERVICE…4715
EVERY 500 HOURS SERVICE…4723
EVERY 1000 HOURS SERVICE…4729
EVERY 2000 HOURS SERVICE…4739
EVERY 4000 HOURS SERVICE…4749
EVERY 8000 HOURS SERVICE…4753
SPECIFICATIONS…4755
SPECIFICATIONS…4756
ATTACHMENTS, OPTIONS…4757
GENERAL PRECAUTIONS…4758
PRECAUTIONS RELATED TO SAFETY…4758
SELECTION OF TRACK SHOE…4759
SELECTION OF TRACK SHOES…4759
HANDLING MACHINES EQUIPPED WITH VHMS…4760
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED…4760
VHMS AND COMMUNICATIONS TERMINAL INSTALLED…4761
INDEX…4763
TEN00374-00 – Bulldozer D475A-5E0 Operation & Maintenance Manual (SN30126&up)…4767
COVER…4767
FOREWORD…4768
BEFORE READING THIS MANUAL…4769
SAFETY INFORMATION…4770
INTRODUCTION…4771
USE OF MACHINE…4771
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…4771
VISIBILITY FROM OPERATOR'S SEAT…4772
NECESSARY INFORMATION…4773
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE…4773
EPA REGULATIONS, ENGINE NUMBER PLATE…4773
BLADE SERIAL NO. PLATE POSITION…4774
RIPPER SERIAL NO. PLATE POSITION…4774
POSITION OF SERVICE METER…4774
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…4775
CONTENTS…4776
SAFETY…4780
SAFETY…4781
SAFETY LABELS…4784
POSITIONS OF SAFETY PICTOGRAMS…4784
SAFETY LABELS…4785
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…4789
PRECAUTIONS BEFORE STARTING OPERATION…4789
PREPARATIONS FOR SAFE OPERATION…4789
FIRE PREVENTION…4791
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…4792
DO NOT GET CAUGHT IN WORK EQUIPMENT…4794
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…4794
UNAUTHORIZED MODIFICATION…4794
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…4794
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…4795
PRECAUTIONS FOR OPERATION…4796
PRECAUTIONS FOR JOBSITE…4796
STARTING ENGINE…4798
OPERATION…4801
TRANSPORTATION…4805
TOWING…4806
PRECAUTIONS FOR MAINTENANCE…4807
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…4807
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…4811
OPERATION…4818
GENERAL VIEW…4819
GENERAL VIEW OF MACHINE…4819
GENERAL VIEW OF CONTROLS AND GAUGES…4820
EXPLANATION OF COMPONENTS…4822
FRONT PANEL…4822
SWITCHES…4852
CONTROL LEVERS, PEDALS…4861
DUST INDICATOR…4870
POWER SOURCE…4870
FUSE BOX…4871
DOOR OPEN LOCK…4876
SASH GLASS INTERMEDIATE LOCK…4876
CAP WITH LOCK…4877
DOOR POCKET…4878
ASHTRAY…4879
TOOL BOX…4879
CLEAN INTERIOR OF CAB…4879
CAR STEREO, HANDLING…4880
AIR CONDITIONER, HANDLING…4889
OPERATION…4906
CHECK BEFORE STARTING ENGINE, ADJUST…4906
STARTING ENGINE…4928
OPERATIONS AND CHECKS AFTER STARTING ENGINE…4936
STOPPING ENGINE…4939
MOVING MACHINE…4940
STOPPING MACHINE…4942
SHIFTING GEAR…4943
SHIFTING BETWEEN FORWARD AND REVERSE…4948
STEERING MACHINE…4950
PRECAUTIONS FOR OPERATION…4952
PARKING MACHINE…4955
CHECK AFTER STOPPING ENGINE…4956
CHECK AFTER FINISHING WORK…4957
LOCKING…4957
WORK POSSIBLE USING BULLDOZER…4958
EFFECTIVE USE OF MODE SELECTION SYSTEM…4960
RIPPER OPERATION…4965
OPERATING METHOD FOR RIPPING OPERATIONS…4968
ADJUSTING POSTURE OF WORK EQUIPMENT…4973
TIPS FOR LONGER UNDERCARRIAGE LIFE…4976
TRANSPORTATION…4978
TRANSPORTATION PROCEDURE…4978
LOADING, UNLOADING WORK…4978
METHOD OF LIFTING MACHINE…4981
TRAVELING ON ROADS…4982
REMOVAL OF CAB…4983
INSTALLATION OF CAB…4986
INSTALLATION OF ROPS…4987
COLD WEATHER OPERATION…4988
PRECAUTIONS FOR LOW TEMPERATURE…4988
AFTER COMPLETION OF WORK…4990
AFTER COLD WEATHER…4990
LONG-TERM STORAGE…4991
BEFORE STORAGE…4991
DURING STORAGE…4991
AFTER STORAGE…4991
STARTING MACHINE AFTER LONG-TERM STORAGE…4991
TROUBLESHOOTING…4992
AFTER RUNNING OUT OF FUEL…4992
METHOD OF TOWING MACHINE…4992
IF BATTERY IS DISCHARGED…4994
OTHER TROUBLE…4999
WHEN MODE SELECTION SYSTEM FLASHES…5004
MAINTENANCE…5006
GUIDES TO MAINTENANCE…5007
OUTLINES OF SERVICE…5010
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…5010
OUTLINE OF ELECTRIC SYSTEM…5014
HANDLING HYDRAULIC RELATED EQUIPMENT…5014
WEAR PARTS…5015
WEAR PARTS LIST…5015
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…5017
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…5019
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…5020
TORQUE LIST…5020
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…5021
SAFETY CRITICAL PARTS…5022
MAINTENANCE SCHEDULE CHART…5024
MAINTENANCE SCHEDULE CHART…5024
SERVICE PROCEDURE…5026
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…5026
WHEN REQUIRED…5027
CHECK BEFORE STARTING…5058
EVERY 250 HOURS SERVICE…5059
EVERY 500 HOURS SERVICE…5067
EVERY 1000 HOURS SERVICE…5073
EVERY 2000 HOURS SERVICE…5081
EVERY 4000 HOURS SERVICE…5091
EVERY 8000 HOURS SERVICE…5095
SPECIFICATIONS…5096
SPECIFICATIONS…5097
ATTACHMENTS, OPTIONS…5098
GENERAL PRECAUTIONS…5099
PRECAUTIONS RELATED TO SAFETY…5099
SELECTION OF TRACK SHOE…5100
SELECTION OF TRACK SHOES…5100
PROCEDURE FOR SELECTING RIPPER POINT…5101
EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER…5102
BLADE CONDITION…5102
DOZING WORK…5104
LEVELING (SPREADING) OPERATION…5106
DITCHING OPERATION…5106
BOULDER RAISING OPERATION…5106
SIDE-CUTTING OPERATIONS…5107
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)…5107
SHOE SLIP CONTROL…5108
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)…5108
EFFECTIVE USE OF MODE SELECTION SYSTEM…5109
IF MODE SELECTION SYSTEM FLASHES…5116
HANDLING MACHINES EQUIPPED WITH VHMS…5117
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED…5117
VHMS AND COMMUNICATIONS TERMINAL INSTALLED…5118
INDEX…5120
TEN00483-02 – Bulldozer D475A-5E0 Operation & Maintenance Manual (SN30134&up)…5124
COVER…5124
FOREWORD…5125
BEFORE READING THIS MANUAL…5126
SAFETY INFORMATION…5127
INTRODUCTION…5128
USE OF MACHINE…5128
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…5128
VISIBILITY FROM OPERATOR'S SEAT…5129
NECESSARY INFORMATION…5130
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE…5130
EPA REGULATIONS, ENGINE NUMBER PLATE…5130
BLADE SERIAL NO. PLATE POSITION…5131
RIPPER SERIAL NO. PLATE POSITION…5131
POSITION OF SERVICE METER…5131
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…5132
CONTENTS…5133
SAFETY…5137
SAFETY…5138
SAFETY LABELS…5141
POSITIONS OF SAFETY PICTOGRAMS…5141
SAFETY LABELS…5142
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…5146
PRECAUTIONS BEFORE STARTING OPERATION…5146
PREPARATIONS FOR SAFE OPERATION…5146
FIRE PREVENTION…5148
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…5149
DO NOT GET CAUGHT IN WORK EQUIPMENT…5151
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…5151
UNAUTHORIZED MODIFICATION…5151
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…5151
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…5152
PRECAUTIONS FOR OPERATION…5153
PRECAUTIONS FOR JOBSITE…5153
STARTING ENGINE…5155
OPERATION…5158
TRANSPORTATION…5162
TOWING…5163
PRECAUTIONS FOR MAINTENANCE…5164
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…5164
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…5168
OPERATION…5175
GENERAL VIEW…5176
GENERAL VIEW OF MACHINE…5176
GENERAL VIEW OF CONTROLS AND GAUGES…5177
EXPLANATION OF COMPONENTS…5179
FRONT PANEL…5179
SWITCHES…5209
CONTROL LEVERS, PEDALS…5216
DUST INDICATOR…5225
POWER SOURCE…5225
FUSE BOX…5226
DOOR OPEN LOCK…5230
SASH GLASS INTERMEDIATE LOCK…5230
CAP WITH LOCK…5231
DOOR POCKET…5232
ASHTRAY…5233
TOOL BOX…5233
CLEAN INTERIOR OF CAB…5233
CAR STEREO, HANDLING…5234
AIR CONDITIONER, HANDLING…5243
BATTERY DISCONNECT SWITCH…5260
OPERATION…5261
CHECK BEFORE STARTING ENGINE, ADJUST…5261
STARTING ENGINE…5284
OPERATIONS AND CHECKS AFTER STARTING ENGINE…5292
STOPPING ENGINE…5295
MOVING MACHINE…5296
STOPPING MACHINE…5298
SHIFTING GEAR…5299
SHIFTING BETWEEN FORWARD AND REVERSE…5304
STEERING MACHINE…5306
PRECAUTIONS FOR OPERATION…5308
PARKING MACHINE…5311
CHECK AFTER STOPPING ENGINE…5312
CHECK AFTER FINISHING WORK…5313
LOCKING…5313
WORK POSSIBLE USING BULLDOZER…5314
EFFECTIVE USE OF MODE SELECTION SYSTEM…5316
RIPPER OPERATION…5321
OPERATING METHOD FOR RIPPING OPERATIONS…5324
ADJUSTING POSTURE OF WORK EQUIPMENT…5329
TIPS FOR LONGER UNDERCARRIAGE LIFE…5332
TRANSPORTATION…5334
TRANSPORTATION PROCEDURE…5334
LOADING, UNLOADING WORK…5334
METHOD OF LIFTING MACHINE…5337
TRAVELING ON ROADS…5338
REMOVAL OF CAB…5339
INSTALLATION OF CAB…5342
INSTALLATION OF ROPS…5343
COLD WEATHER OPERATION…5344
PRECAUTIONS FOR LOW TEMPERATURE…5344
AFTER COMPLETION OF WORK…5346
AFTER COLD WEATHER…5346
LONG-TERM STORAGE…5347
BEFORE STORAGE…5347
DURING STORAGE…5347
AFTER STORAGE…5347
STARTING MACHINE AFTER LONG-TERM STORAGE…5347
TROUBLESHOOTING…5348
AFTER RUNNING OUT OF FUEL…5348
METHOD OF TOWING MACHINE…5348
IF BATTERY IS DISCHARGED…5350
OTHER TROUBLE…5354
WHEN MODE SELECTION SYSTEM FLASHES…5359
MAINTENANCE…5361
GUIDES TO MAINTENANCE…5362
OUTLINES OF SERVICE…5365
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…5365
OUTLINE OF ELECTRIC SYSTEM…5369
HANDLING HYDRAULIC RELATED EQUIPMENT…5369
WEAR PARTS…5370
WEAR PARTS LIST…5370
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…5372
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…5374
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…5375
TORQUE LIST…5375
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…5376
SAFETY CRITICAL PARTS…5377
MAINTENANCE SCHEDULE CHART…5379
MAINTENANCE SCHEDULE CHART…5379
SERVICE PROCEDURE…5381
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…5381
WHEN REQUIRED…5382
CHECK BEFORE STARTING…5419
EVERY 250 HOURS SERVICE…5420
EVERY 500 HOURS SERVICE…5428
EVERY 1000 HOURS SERVICE…5434
EVERY 2000 HOURS SERVICE…5441
EVERY 4000 HOURS SERVICE…5450
EVERY 8000 HOURS SERVICE…5454
SPECIFICATIONS…5455
SPECIFICATIONS…5456
ATTACHMENTS, OPTIONS…5457
GENERAL PRECAUTIONS…5458
PRECAUTIONS RELATED TO SAFETY…5458
SELECTION OF TRACK SHOE…5459
SELECTION OF TRACK SHOES…5459
PROCEDURE FOR SELECTING RIPPER POINT…5460
STARTING IN COLD AREAS…5461
EXTERNAL POWER SOURCE TYPE PREHEATER…5461
EFFECTIVE METHOD OF OPERATION FOR DUAL TILTDOZER…5469
BLADE CONDITION…5469
DOZING WORK…5471
LEVELING (SPREADING) OPERATION…5473
DITCHING OPERATION…5473
BOULDER RAISING OPERATION…5473
SIDE-CUTTING OPERATIONS…5474
HORIZONTAL DOZING OPERATIONS FROM SIDE SLOPE (ROUGH GROUND)…5474
SHOE SLIP CONTROL…5475
MODE SELECTION SWITCH PANEL (SHOE SLIP CONTROL)…5475
EFFECTIVE USE OF MODE SELECTION SYSTEM…5476
IF MODE SELECTION SYSTEM FLASHES…5483
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus…5484
KOMTRAX Plus INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED…5484
KOMTRAX Plus AND COMMUNICATIONS TERMINAL INSTALLED…5485
MINING SPECIFICATION MACHINE…5486
FRONT PANEL…5486
SWITCH…5487
FUSE BOX…5493
CIRCUIT BREAKER FOR MAIN POWER SUPPLY…5494
BATTERY ISOLATOR SWITCH, STARTING MOTOR ISOLATOR SWITCH…5495
TOOL BOX…5495
CAR STEREO, HANDLING…5496
OPERATIONS AND CHECKS BEFORE STARTING ENGINE…5497
STARTING WITH BOOSTER CABLES…5498
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…5499
WEAR PARTS…5500
WHEN REQUIRED…5502
EVERY 250 HOURS SERVICE…5506
EVERY 500 HOURS SERVICE…5508
EVERY 1000 HOURS SERVICE…5510
EVERY 2000 HOURS SERVICE…5514
INDEX…5519

Komatsu Bulldozers D455-series Operation & Maintenance Manual

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