Komatsu Bulldozer Galeo D475A-5E0 D475ASD-5E0 Shop Manual SEN00203-02 PDF

Description

Komatsu Bulldozer Galeo D475A-5E0 D475ASD-5E0 Shop Manual SEN00203-02 – PDF DOWNLOAD

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Komatsu Bulldozer Galeo D475A-5E0 D475ASD-5E0 Shop Manual SEN00203-02 – PDF DOWNLOAD

Language : English
Pages :348
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Bulldozer Galeo D475A-5E0 D475ASD-5E0 Shop Manual SEN00203-02 – PDF DOWNLOAD

SERIAL NUMBERS D475A- 30001 and up D475ASD-30001

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine.

TABLE OF CONTENTS:

Komatsu Bulldozer Galeo D475A-5E0 D475ASD-5E0 Shop Manual SEN00203-02 – PDF DOWNLOAD

SERIAL NUMBERS D475A- 30001 and up D475ASD-30001

Table of contents 1
00 Index and foreword
Index SEN00205-02
Composition of shop manual 2
Table of contents 4
Foreword and general information SEN00206-01
Safety notice 2
How to read the shop manual 7
Explanation of terms for maintenance standard 9
Handling electric equipment and hydraulic component 11
How to read electric wire code 23
Precautions when carrying out operation 26
Method of disassembling and connecting push-pull type coupler 29
Standard tightening torque table 32
Conversion table 36
01 Specification
Specification and technical data SEN00208-00
Specification and technical data 2
Specification drawings 2
Specifications 3
Weight table 12
Fuel, coolant and lubricants 16
10 Structure, function and maintenance standard
Engine and cooling system SEN00210-00
Engine and cooling system 2
Radiator and oil cooler 2
Engine mount 3
Cooling fan pump 4
Cooling fan motor 26
Power train, Part 1 SEN00211-00
Power train, Part 1 2
Power train 2
Power train hydraulic equipment arrangement diagram 4
Damper and universal joint 6
Power train system 8
General view of power train unit 8
Torque converter, PTO 10
Torque converter valve 18
Torque converter lockup control system 28
Scavenging pump 29
Transmission control 31
Transmission 32
Power train, Part 2 SEN00212-00
Power train, Part 2 2
Transmission control valve 2
Transmission clutch ECMV 4
Priority valve 8
Lubricating oil relief valve 10
Torque converter, power train, lubricating oil pump 11
Steering, brake control 12
Final drive 14
00 Index and foreword SEN00205-02
D475A, D475ASD-5E0 5
Sprocket 18
Steering unit 21
Steering control valve 32
Steering clutch ECMV, Steering brake ECMV 34
Parking brake valve 40
Sudden stop prevention valve 42
Undercarriage and frame SEN00213-00
Undercarriage and frame 2
Track frame 2
Recoil spring 4
Idler 6
Track roller 8
Carrier roller 12
Track roller bogie 13
Track shoe 14
Main frame 18
Suspension 20
Hydraulic system, Part 1 SEN00214-00
Hydraulic system, Part 1 2
Work equipment hydraulic equipment arrangement diagram 2
PPC control piping diagram 6
Work equipment control 8
Work equipment pump 10
PPC valve 27
PCCS lever 38
Hydraulic system, Part 2 SEN00215-00
Hydraulic system, Part 2 2
Control valve 2
CLSS 17
Unload valve 20
Introduction of LS pressure 21
LS bypass plug 22
Pressure compensation valve 23
Blade lift valve 26
Merge-divider valve 34
Self pressure reducing valve 36
Pilot solenoid valve 40
Hydraulic system, Part 3 SEN00216-00
Hydraulic system, Part 3 2
Hydraulic tank, hydraulic filter 2
Accumulator 4
Work equipment cylinder 6
Piston valve 8
Quick drop valve 10
Blade control knob (Dual tilt specification) 12
Blade control knob (Superdozer specification) 13
Pitch and dual solenoid valve 14
Pin puller hydraulic circuit diagram 15
Pin puller solenoid valve 16
Work equipment SEN00217-00
Work equipment 2
Cylinder stay 2
Blade 4
Ripper equipment 8
SEN00205-02 00 Index and foreword
6 D475A, D475ASD-5E0
Cab and its attachments SEN00218-00
Cab and its attachments 2
Cab mount 2
Cab 3
Air conditioner 6
Electrical system SEN00219-00
Electrical system 2
Engine control 2
Engine control system 3
Deceleration potentiometer 4
CRI engine control system 6
Monitor system 8
Monitor panel 11
Sensors 15
Mode selection system 18
Electrical equipment 24
Steering electronic control system 27
VHMS controller 29
Communication (ORB: ORBCOMM) controller/antenna 35
20 Standard value table
Standard service value table SEN01816-00
Standard service value table 2
Standard value table for engine 2
Standard value table for chassis 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN01817-00
Testing and adjusting, Part 1 3
Tools for testing, adjusting, and troubleshooting 3
Measuring engine speed 6
Measuring intake air pressure (boost pressure) 9
Measuring exhaust temperature 11
Measuring exhaust gas color 13
Adjusting valve clearance 15
Testing compression pressure 17
Measuring blow-by pressure 19
Measuring engine oil pressure 21
Handling of fuel system devices 22
Releasing residual pressure from fuel system 22
Testing fuel pressure 23
Handling of reduced cylinder mode operation 24
Handling of no injection cranking operation 24
Testing fuel return and leak amount 25
Bleeding air from fuel circuit 28
Testing fuel circuit for leakage 30
Testing and adjusting alternator belt tension 31
Testing and adjusting belt tension for air conditioner compressor 32
Adjusting fuel control dial and decelerator pedal 33
Testing and adjusting, Part 2 SEN01818-00
Testing and adjusting, Part 2 3
Measuring power train oil pressure 3
Adjusting transmission speed sensor 12
Simple method to test brake performance 13
Adjusting brake pedal and parking brake lever 14
Adjusting PCCS lever console position 17
00 Index and foreword SEN00205-02
D475A, D475ASD-5E0 7
Emergency escape method when power train has trouble 18
Inspecting wear of sprocket 20
Testing and adjusting track shoe tension 21
Testing and adjusting work equipment oil pressure 22
Testing and adjusting control circuit basic pressure 33
Measuring PPC valve output pressure and solenoid valve output pressure 34
Adjusting play of PPC valve 40
Measuring outlet pressure of ripper pin puller solenoid valve 41
Checking parts which caused hydraulic drift of blade and ripper 42
Measuring internal leakage of work equipment cylinder 43
Releasing residual pressure from work equipment cylinder 44
Bleeding air from work equipment cylinder 44
Adjusting ripper lever position 45
Adjusting work equipment lock lever 46
Measuring fan circuit oil pressure 48
Bleeding air from fan pump 49
Measurement procedure for blade tilt control angle (Dual tiltdozer specification) 50
Measurement procedure for blade tilt control angle (Superdozer specification) 53
Testing and adjusting operator’s cab 55
Adjusting blade 59
Testing and adjusting, Part 3 SEN01819-00
Testing and adjusting, Part 3 2
Special functions of monitor panel (EMMS) 2
Testing and adjusting, Part 4 SEN01820-00
Testing and adjusting, Part 4 2
Adjustment method when controller has been replaced 2
Preparation work for troubleshooting for electrical equipment system 4
Inspection procedure of diode 8
Handling of optional devices 9
Initialization procedures for VHMS controller 10
Precautions for replacing VHMS controller 31
Pm Clinic service 36
40 Troubleshooting
Failure code table and fuse locations SEN01821-00
Failure code table and fuse locations 2
Failure code table 2
Fuse locations 12
General information on troubleshooting SEN01822-00
General information on troubleshooting 2
Points to remember when troubleshooting 2
Sequence of events in troubleshooting 3
Checks before troubleshooting 4
Classification and procedures of troubleshooting 5
Contents of troubleshooting table 8
Wiring table for connector pin numbers 10
T-adapter box and T-adapter table 39
Troubleshooting by failure code (Display of code), Part 1 SEN01823-00
Troubleshooting by failure code (Display of code), Part 1 3
Failure code [1500L0] Transmission clutch: Dual engagement 3
Failure code [15SAL1] Forward clutch oil pressure:
Command current OFF and fill signal ON 4
Failure code [15SALH] Forward clutch oil pressure:
Command current ON and fill signal OFF 5
Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON 6
SEN00205-02 00 Index and foreword
8 D475A, D475ASD-5E0
Failure code [15SBLH] Reverse clutch oil pressure:
Command current ON and fill signal OFF 7
Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON 8
Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF 9
Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON 10
Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF 11
Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON 12
Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF 13
Failure code [1800MW] Power train clutch: Slip 14
Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON 15
Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF 16
Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON 17
Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF 18
Failure code [2300NR] Brake thermal load: Abnormal heating 19
Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON 20
Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF 21
Failure code [2301NR] Right steering brake thermal load: Abnormal heating 22
Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON 23
Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF 24
Failure code [2302NR] Left steering brake thermal load: Abnormal heating 25
Failure code [AA10NX] Air cleaner: Clogging 26
Failure code [AB00MA] Battery charge abnormality: Malfunction 27
Failure code [B@BAZG] Engine oil: Oil pressure too low 28
Failure code [B@BAZK] Engine oil: Oil level reduction 29
Failure code [B@BCNS] Radiator coolant: Overheat 30
Failure code [B@BCZK] Radiator coolant: Level too low 31
Failure code [B@CENS] Power train oil: Overheat 32
Failure code [B@CHZG] Power train oil: Low oil pressure 33
Failure code [B@HANS] Hydraulic oil: Overheat 34
Failure code [B@HAZK] Hydraulic oil: Level reduction 35
Troubleshooting by failure code (Display of code), Part 2 SEN01824-00
Troubleshooting by failure code (Display of code), Part 2 4
Failure code [CA111] Engine controller (Left bank): Internal abnormality 4
Failure code [CB111] Engine controller (Right bank): Internal abnormality 6
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank):
Abnormal speed sensor signal 8
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank):
Abnormal speed sensor signal 9
Failure code [CA122] Charge pressure sensor too high (At left bank only):
Excessively high voltage detected 10
Failure code [CA123] Charge pressure sensor too low (At left bank only):
Excessively low voltage detected 12
Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank):
High voltage detection 13
Failure code [CA132] Decelerator pedal sensor too low (At left bank only):
Excessively low voltage detected 15
Failure code [CA135] Oil pressure sensor too high (At left bank only):
Excessively high voltage detected 16
Failure code [CA141] Oil pressure sensor too low (At left bank only):
Excessively low voltage detected 18
Failure code [CA144] Coolant temperature sensor too high:
Excessively high voltage detected 20
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Excessively low voltage detected 22
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Excessively high voltage detected 24
Failure code [CA154] Charge temperature sensor too low (At left bank only):
Excessively low voltage detected 26
00 Index and foreword SEN00205-02
D475A, D475ASD-5E0 9
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank):
Low voltage detection 28
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank):
Low voltage detection 29
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank):
High voltage detection 30
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank):
Low voltage detection 31
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Excessively high voltage detected 32
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Excessively low voltage detected 34
Failure code [CA227] Sensor power source (2) too high (At left bank):
Excessively high voltage detected 36
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank):
High voltage detection 38
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed 40
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Excessively low voltage detected 42
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Excessively low voltage detected 44
Failure code [CA263] Fuel temperature sensor too high (At left bank):
Excessively high voltage detected 46
Failure code [CB263] Fuel temperature sensor too high (At right bank):
Excessively high voltage detected 48
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
Low voltage detection 49
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Low voltage detection 49
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit 50
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit 51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection 52
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection 53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit 54
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit 55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection 56
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection 57
Troubleshooting by failure code (Display of code), Part 3 SEN01825-00
Troubleshooting by failure code (Display of code), Part 3 4
Failure code [CA322] Injector No 1 (L/B No1) system disconnection or short circuit
(At left bank): Disconnection, short circuit 4
Failure code [CA323] Injector No 5 (L/B No5) system disconnection or short circuit
(At left bank): Disconnection, short circuit 6
Failure code [CA324] Injector No 3 (L/B No3) system disconnection or short circuit
(At left bank): Disconnection, short circuit 8
Failure code [CA325] Injector No 6 (L/B No6) system disconnection or short circuit
(At left bank): Disconnection, short circuit 10
Failure code [CA331] Injector No 2 (L/B No2) system disconnection or short circuit
(At left bank): Disconnection, short circuit 12
Failure code [CA332] Injector No 4 (L/B No4) system disconnection or short circuit
(At left bank): Disconnection, short circuit 14
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch 16
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch 17
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit 18
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality 20
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank):
Low voltage detection 22

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24