Komatsu D475A-8 Bulldozer Operation and Maintenance Manual (EENAM03950)

On a D475A-8 working in hard push, ripping, or stockpile work, this Operation and Maintenance Manual is what I lean on to keep the machine reliable shift after shift. It lays out how to run the dozer without abusing it, then shows you how to schedule and carry out routine checks so you catch problems before they park the machine. If, for example, the operator reports sluggish blade response after a long push on a hot day, I use this manual to verify the basic operating steps, trace the issue through the daily/periodic checks, and decide what needs a closer shop inspection.

Applications & Use Cases

Set up a realistic service rhythm so the dozer comes in for planned checks, not surprise breakdowns.
Walk operators through start/stop and warm-up routines that reduce shock loads and premature wear.
Standardize daily inspections for leaks, loose hardware, and undercarriage wear before each shift.
Use the recommended check points to isolate early signs of overheating, vibration, or steering issues.
Plan parts and consumables ahead of time by knowing what’s due at upcoming service intervals.

FAQ

Q: Can I keep this manual on a tablet in the service truck?

A: Yes, it’s practical to use digitally; just make sure the file is easy to search so you can pull up procedures at the machine.

Q: Is it worth printing sections of this manual?

A: I’d print the inspection and service-interval pages you use most and keep them in a binder that can live in the site office or service truck.

Safety Note

Always follow the manual’s safety instructions and lockout procedures before inspecting, adjusting, or servicing the dozer.

📘 Show Index

Komatsu D475A-8 Bulldozer Index:

FOREWORD
- READ THIS MANUAL
- KOMATSU MACHINE OPERATOR PRIVACY POLICY
- SAFETY INFORMATION
- SAFETY LABELS
- NOISE
- VIBRATION LEVELS
  - VIBRATION – OPERATING CONDITION
  - GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE
- INTRODUCTION
  - MAIN APPLICATION OF MACHINE
  - DIRECTIONS OF MACHINE
  - VISIBILITY FROM OPERATOR’S SEAT
- ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION
- PRODUCT INFORMATION
  - LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN) AND MACHINE SERIAL NO. PLATE
  - LOCATION OF ENGINE NUMBER PLATE
  - LOCATION OF BLADE SERIAL NO. PLATE
  - FLUORINATED GREENHOUSE GASES
  - LOCATION OF RIPPER SERIAL NO. PLATE
  - LOCATION OF ROPS AND FOPS PLATE
  - SERVICE METER LOCATION
  - YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
- SERIAL PLATE
- DECLARATION OF CONFORMITY
- CONTENTS
- ABBREVIATION LIST
SAFETY
- SAFETY LABELS
- GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
  - PRECAUTIONS BEFORE STARTING OPERATION
  - PREPARATIONS FOR SAFE OPERATION
  - PRECAUTIONS TO PREVENT FIRE
  - PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
  - PRECAUTIONS FOR MACHINE AND JOBSITE
- PRECAUTIONS FOR OPERATION
  - PRECAUTIONS FOR JOBSITE
  - START ENGINE
  - PRECAUTIONS FOR OPERATION
  - PRECAUTIONS FOR TRANSPORTATION
  - PRECAUTIONS FOR TOWING
- PRECAUTIONS FOR MAINTENANCE
  - PRECAUTIONS BEFORE YOU START INSPECTION AND MAINTENANCE
  - PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
  - PRECAUTIONS FOR CHECK AND MAINTENANCE
OPERATION
- GENERAL VIEW
  - MACHINE EQUIPMENT NAME
  - CONTROLS AND GAUGES NAMES
- EXPLANATION OF COMPONENTS
  - MACHINE MONITOR EQUIPMENT
  - SWITCHES
  - CONTROL LEVERS AND PEDALS
  - OTHER EQUIPMENT
- MACHINE OPERATIONS AND CONTROLS
  - CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE
  - METHOD FOR STARTING ENGINE
  - METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE
  - STOP ENGINE
  - METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE
  - SHIFT GEARS
  - SWITCH BETWEEN FORWARD AND REVERSE
  - METHOD FOR STEERING MACHINE
  - RECOMMENDED WORKING MODES FOR WORKS
  - PRECAUTIONS FOR OPERATION
  - PRECAUTIONS WHEN YOU WORK ON SLOPE
  - PRECAUTIONS FOR USING BRAKE
  - DO NOT OPEN DOOR WHILE OPERATING MACHINE
  - DO NOT MODIFY CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
  - PRECAUTIONS FOR FLOATING OPERATION
  - PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES
  - RECOMMENDED APPLICATIONS
  - EFFECTIVE USE OF RIPPER
  - OPERATING METHOD FOR RIPPING WORK
  - METHOD FOR ADJUSTING WORK EQUIPMENT
  - TIPS FOR LONGER UNDERCARRIAGE LIFE
  - PARK MACHINE
  - METHOD FOR CHECKING AFTER FINISHING WORK
  - LOCK
- AIR CONDITIONER
  - AIR CONDITIONER EQUIPMENT
  - METHOD FOR OPERATING AIR CONDITIONER
- RADIO
  - RADIO EQUIPMENT
  - OPERATE RADIO
  - RADIO SETTING
- ANTENNA
- TRANSPORTATION
  - TRAVEL ON ROAD
  - PRECAUTIONS FOR TRANSPORTING MACHINE
  - TRANSPORTATION PROCEDURE
  - REMOVE CAB
  - LOADING AND UNLOADING WITH TRAILER
  - LIFT MACHINE
- COLD WEATHER OPERATION
  - COLD WEATHER OPERATION INFORMATION
  - PRECAUTIONS AFTER DAILY WORK COMPLETION
  - AFTER COLD WEATHER SEASON
- PRECAUTIONS FOR LONG-TERM STORAGE
  - PREPARATION FOR LONG-TERM STORAGE
  - MAINTENANCE DURING LONG-TERM STORAGE
  - START MACHINE AFTER LONG-TERM STORAGE
- TROUBLES AND ACTIONS
  - ACTIONS WHEN YOU RUN OUT OF FUEL
  - PRECAUTIONS FOR TOWING MACHINE
  - PRECAUTIONS FOR DISCHARGED BATTERY
  - OTHER TROUBLE
MAINTENANCE
- PRECAUTIONS FOR MAINTENANCE
  - CHECK SERVICE METER READING
  - KOMATSU GENUINE REPLACEMENT PARTS
  - KOMATSU GENUINE LUBRICANTS
  - ALWAYS USE CLEAN WASHER FLUID
  - FRESH AND CLEAN LUBRICANTS
  - CHECK DRAINED OIL AND USED FILTER
  - PRECAUTIONS FOR REFILLING OIL OR FUEL
  - PRECAUTIONS FOR WELDING
  - DO NOT DROP THINGS INSIDE MACHINE
  - PRECAUTIONS FOR KDPF
  - DUSTY JOBSITES
  - AVOID MIXING OIL
  - LOCK INSPECTION COVERS
  - PRECAUTIONS WHEN YOU OPEN AND CLOSE ENGINE SIDE COVER
  - BLEED AIR FROM HYDRAULIC CIRCUIT
  - PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES
  - CHECKS AFTER INSPECTION AND MAINTENANCE
  - FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE
- OUTLINE OF MAINTENANCE
  - HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
  - ELECTRICAL COMPONENTS
  - HANDLE HYDRAULIC COMPONENTS
- STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS
- MAINTENANCE SCHEDULE
  - MAINTENANCE SCHEDULE TABLE
  - MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED
- MAINTENANCE PROCEDURE
  - INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)
  - WHEN REQUIRED
  - CHECK BEFORE YOU START OPERATION
  - EVERY 250 HOURS MAINTENANCE
  - EVERY 500 HOURS MAINTENANCE
  - EVERY 1000 HOURS MAINTENANCE
  - EVERY 2000 HOURS MAINTENANCE
  - EVERY 4000 HOURS MAINTENANCE
  - EVERY 4500 HOURS MAINTENANCE
  - EVERY 8000 HOURS MAINTENANCE
  - EVERY 9000 HOURS MAINTENANCE
SPECIFICATIONS
- SPECIFICATIONS
ATTACHMENTS AND OPTIONS
- GENERAL PRECAUTIONS
  - PRECAUTIONS FOR SAFETY
- ATTACHMENTS AND OPTIONS
  - TRACK SHOES SELECTION
- SELECT RIPPER POINT
- HANDLE EXTERNAL POWER SUPPLY ENGINE PREHEATER
  - INSTALL EXTERNAL POWER SUPPLY SYSTEM FOR EXTERNAL POWER SUPPLY ENGINE PREHEATER
  - MAKE EXTERNAL POWER SUPPLY CABLE
  - INSTALL EXTERNAL POWER SUPPLY SYSTEM
  - START ENGINE IN COLD WEATHER
- METHOD FOR USING DUAL TILT DOZER EFFECTIVELY
  - BLADE STATE
  - DOZING WORK
- HANDLE HYDRAULIC TYPE LADDER
  - OPERATE HYDRAULIC TYPE LADDER
  - ACTIONS IF MACHINE DOES NOT MOVE BY FAILURE
  - WHEN REQUIRED
  - EVERY 1000 HOURS MAINTENANCE
  - EVERY 4000 HOURS MAINTENANCE
- MACHINE WITH MINING SPECIFICATION
  - GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
  - SWITCHES
  - SYSTEM OPERATING LAMP
  - CHECKS BEFORE STARTING
  - KOWA (Komatsu Oil Wear Analysis)
  - WHEN REQUIRED
  - EVERY 250 HOURS MAINTENANCE
  - EVERY 500 HOURS MAINTENANCE
  - EVERY 1000 HOURS MAINTENANCE
  - EVERY 2000 HOURS MAINTENANCE
  - CONSUMABLE PARTS
REPLACEMENT PARTS
- PERIODIC REPLACEMENT OF DEFINED LIFE PARTS
  - DEFINED LIFE PARTS LIST
- CONSUMABLE PARTS
  - CONSUMABLE PARTS LIST
- RECOMMENDED FUEL, COOLANT, AND LUBRICANT
  - LUBRICATION CHART
  - USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
  - RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS
INDEX