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KOMATSU D475A-2 SERVICE REPAIR MANUAL (SN:D475A-2 10201 and up) – PDF DOWNLOAD
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- KOMATSU D475A-2 SERVICE REPAIR MANUAL
- SERIAL NUMBER:D475A-2 10201 and up
- PUBLICATION NUMBER:SEBM019M0207
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Description
KOMATSU D475A-2 SERVICE REPAIR MANUAL (SN:D475A-2 10201 and up)
KOMATSU D475A-2 SERVICE REPAIR MANUAL (SN:D475A-2 10201 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D475A-2 SERVICE REPAIR MANUAL (SN:D475A-2 10201 and up)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts
TABLE OF CONTENTS:
KOMATSU D475A-2 SERVICE REPAIR MANUAL (SN:D475A-2 10201 and up)
MAIN MENU......................................................................................................................................................... 0 CONTENTS.......................................................................................................................................................... 2 10 STRUCTURE AND FUNCTION......................................................................................................................................... 28 ENGINE........................................................................................................................................................ 30 ENGINE MOUNT.............................................................................................................................................. 30 RADIATOR, OIL COOLER...................................................................................................................................... 31 FAN DRIVE HYDRAULIC PIPING DIAGRAM........................................................................................................................ 35 FAN DRIVE HYDRAULIC SYSTEM DIAGRAM........................................................................................................................ 36 FAN DRIVE HYDRAULIC CIRCUIT DIAGRAM....................................................................................................................... 36 FAN DRIVE PUMP (SAR63 +40)................................................................................................................................ 37 FAN DRIVE MOTOR (SAL140).................................................................................................................................. 38 FAN HIGH-LOW SPEED SELECTOR SOLENOID VALVE, CHECK VALVE................................................................................................... 39 FAN DRIVE CIRCUIT MAIN RELIEF VALVE....................................................................................................................... 42 IN-LINE SERVO VALVE....................................................................................................................................... 43 ENGINE CONTROL............................................................................................................................................ 44 POWER TRAIN................................................................................................................................................... 47 POWER TRAIN............................................................................................................................................... 47 POWER TRAIN UNIT.......................................................................................................................................... 49 POWER TRAIN PIPING........................................................................................................................................ 50 POWER TRAIN HYDRAULIC SYSTEM.............................................................................................................................. 51 POWER TRAIN HYDRAULIC CIRCUIT............................................................................................................................. 52 DAMPER AND UNIVERSAL JOINT................................................................................................................................ 53 TORQUE CONVERTER AND PTO.................................................................................................................................. 55 TORQUE CONVERTER VALVE.................................................................................................................................... 59 TRANSMISSION.............................................................................................................................................. 67 SCAVENGING PUMP........................................................................................................................................... 85 POWER TRAIN PUMP AND LUBRICATION PUMP..................................................................................................................... 86 STRAINERS................................................................................................................................................. 87 POWER TRAIN OIL FILTER AND LUBRICATION OIL FILTER......................................................................................................... 88 TRANSFER, BEVEL PINION, BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE ............................................................................... 89 TRANSFER, BEVEL PINION.................................................................................................................................... 90 BEVEL GEAR, STEERING CLUTCH AND STEERING BRAKE............................................................................................................ 91 STEERING CLUTCH AND STEERING BRAKE CONTROL ............................................................................................................... 95 STEERING CLUTCH, BRAKE HYDRCUALIC CIRCUIT DIAGRAM ........................................................................................................ 98 STEERING CONTROL VALVE ................................................................................................................................... 99 FINAL DRIVE ..............................................................................................................................................105 POWER TRAIN UNIT MOUNT ...................................................................................................................................108 UNDERCARRIAGE.................................................................................................................................................110 TRACK (LUBRICATED TRACK LINK) ............................................................................................................................110 TRACK FRAME AND RECOIL SPRING ............................................................................................................................111 IDLER.....................................................................................................................................................112 TRACK ROLLER .............................................................................................................................................113 CARRIER ROLLER ...........................................................................................................................................113 SUSPENSION................................................................................................................................................114 HYDRAULIC SYSTEM..............................................................................................................................................117 HYDRAULIC PIPING DIAGRAM .................................................................................................................................117 HYDRAULIC CONTROL ........................................................................................................................................119 HYDRAULIC CIRCUIT SYSTEM .................................................................................................................................121 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................122 HYDRAULIC TANK ...........................................................................................................................................123 HYDRAULIC PUMP ...........................................................................................................................................124 BLADE LIFT VALVE .........................................................................................................................................125 MAIN RELIEF, SHUTTLE VALVE ...............................................................................................................................127 BLADE TILT, RIPPER LOW VALVE .............................................................................................................................129 RIPPER HIGH VALVE ........................................................................................................................................131 HYDRAULIC LEVER OPERATION ................................................................................................................................133 CYLINDER .................................................................................................................................................139 RIPPER CYLINDER ..........................................................................................................................................143 PIN-PULLER HYDRAULIC SYSTEM DRAWING ......................................................................................................................144 PIN-PULLER HYDRAULIC CIRCUIT DRAWING .....................................................................................................................144 PIN-PULLER SOLENOID VALVE ................................................................................................................................145 WORK EQUIPMENT................................................................................................................................................147 DOZER EQUIPMENT ..........................................................................................................................................147 RIPPER EQUIPMENT .........................................................................................................................................151 CYLINDER STAY.............................................................................................................................................154 ELECTRIC AND ELECTRONIC SYSTEM................................................................................................................................155 ELECTRICAL WIRING DIAGRAM.................................................................................................................................155 CAB WIRING DIAGRAM........................................................................................................................................157 AIR CONDITIONER CIRCUIT DIAGRAM...........................................................................................................................157 EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM) ............................................................................................................159 ELECTRICAL CONTROL .......................................................................................................................................168 SENSOR....................................................................................................................................................177 PIN-PULLER CONTROL .......................................................................................................................................179 OTHERS........................................................................................................................................................181 ROPS CANOPY ..............................................................................................................................................181 CAB.......................................................................................................................................................182 AIR CONDITIONER ..........................................................................................................................................183 20 TESTING AND ADJUSTING..........................................................................................................................................185 TABLE OF STANDARD VALUES FOR ENGINE...........................................................................................................................186 TABLE OF STANDARD VALUES FOR CHASSIS..........................................................................................................................187 TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE..................................................................................................................193 TESTING AND ADJUSTING.........................................................................................................................................196 TESTING AND ADJUSTING TOOL LIST...........................................................................................................................197 ADJUSTING VALVE CLEARANCE.................................................................................................................................198 MEASURING COMPRESSION PRESSURE............................................................................................................................199 CHECKING AND ADJUSTING FUEL INJECTION TIMING..............................................................................................................200 MEASURING TORQUE CONVERTER STALL SPEED....................................................................................................................201 BLEEDING AIR FROM HYDRAULIC CYLINDER......................................................................................................................202 MEASURING OIL PRESSURE....................................................................................................................................203 ADJUSTING FUEL CONTROL LINKAGE............................................................................................................................207 ADJUSTING GEAR SHIFT LEVER LINKAGE........................................................................................................................209 ADJUSTING STEERING CLUTCH LINKAGE.........................................................................................................................211 ADJUSTING BRAKE PEDAL LINKAGE.............................................................................................................................213 ADJUSTING BLADE CONTROL LINKAGE...........................................................................................................................215 ADJUSTING RIPPER CONTROL LINKAGE..........................................................................................................................217 TROUBLESHOOTING...............................................................................................................................................219 POINTS TO REMEMBER WHEN TROUBLESHOOTING ..................................................................................................................220 SEQUENCE OF EVENTS IN TROUBLESHOOTING ....................................................................................................................221 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE ................................................................................................................222 HANDLING CONNECTORS ......................................................................................................................................229 PREVENTING RECURRENCE OF THE SAME TROUBLE ................................................................................................................230 CHECKS BEFORE TROUBLESHOOTING ............................................................................................................................231 METHOD OF USING TROUBLESHOOTING CHARTS ...................................................................................................................232 RELATED ELECTRICAL CIRCUIT ...............................................................................................................................234 MONITOR SYSTEM........................................................................................................................................234 TORQUE CONVERTER LOCK-UP SYSTEM.......................................................................................................................236 FAN CONTROLLER SYSTEM.................................................................................................................................237 RELAY BOX CIRCUIT.....................................................................................................................................238 LOCATION OF CONNECTORS FOR TROUBLESHOOTING ...............................................................................................................239 LOCATION OF CONNECTORS ...................................................................................................................................242 CONNECTION TABLE FOR CONNECTOR............................................................................................................................243 TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL, HYDRAULIC, MECHANICAL SYSTEMS) ...........................................................................251 TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR) .....................................................................................................252 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM ..................................................................................................253 H-1. Brakes do not work. .............................................................................................................................254 H-2. Machine does not turn. (Machine can travel only in a straight line.) ............................................................................255 H-3. Machine does not turn properly. ................................................................................................................256 H-4. Gear shifting is slow. ..........................................................................................................................257 H-5. Machine travels only in one direction (forward or in reverse) ...................................................................................257 H-6. Machine does not move. (2nd. 3rd, engine running) ...............................................................................................258 H-7. Machine does not move in any speed range. .......................................................................................................260 H-8. Torque converter overheats (power train overheats). .............................................................................................262 H-9. Machine turns in one direction (when lever operated) ............................................................................................264 H-10. Abnormal noise from around hydraulic pump. .....................................................................................................265 H-11. Blade RAISE speed slow or lacks power. .........................................................................................................265 H-12. Ripper lift speed slow. ........................................................................................................................267 H-13. Excessive hydraulic drift of blade .............................................................................................................269 H-14. Excessive hydraulic drift of ripper ............................................................................................................269 H-15. Torque converter lock-up does not work..........................................................................................................270 H-16. Pin puller cylinder does not work...............................................................................................................270 H-17. Even when water temperature or oil temperature rises, cooling fan speed does not increase......................................................271 H-18. Water temperature and oil temperature have dropped, but fan speed does not drop (still rotates at high speed)..................................271 TROUBLESHOOTING OF ELECTRICAL SYSTEM ....................................................................................................................272 E-1. Torque converter lockup does not work. (Lockup pilot lamp does not light up.) ...................................................................273 E-2. Abnormality in torque converter lockup display ..................................................................................................276 a) Lockup display lamp does not go out ...........................................................................................................276 b) Lockup display lights up but torque converter does not lockup. ................................................................................276 E-3. Fuse No. 8 inside torque converter lockup relay box is blown. ...................................................................................277 E-4. Pin puller cylinder does not work. ..............................................................................................................278 E-5. Preheating fuse 11 is blown. ...................................................................................................................279 E-6. When preheating switch on the panel is pressed, the preheating pilot lamp on the monitor panel does not light up. ...............................280 E-7. Even when water temperature or oil temperature rises, cooling fan speed does not increase. ......................................................282 E-8. Water temperature and oil temperature have both dropped, but fan speed does not drop. (still rotates at high speed) ............................283 E-9. Panel switch does not work. (red lamps in the switch do not light up when any of the switch are pressed) .......................................286 a) When fuse 9 broken.............................................................................................................................286 b) When fuse 15 broken............................................................................................................................286 c) When starting switch is turned to START, panel switch does not work; or red lamp goes out. ...................................................286 d) Panel switch does not work when engine is running; or red lamp goes out. .....................................................................286 e) When monitor panel is working (fuse g normal) .................................................................................................287 f) When monitor panel is not working (fuse 15 normal).............................................................................................289 E-10. When one of panel switch is pushed ON, all panel switches stop working. ........................................................................291 a) When head lamp switch is pressed...............................................................................................................291 b) When rear lamp switch m is pressed. ...........................................................................................................291 c) When working lamp switch is pressed............................................................................................................292 d) When PREHEAT switch is pressed.................................................................................................................292 e) When lockup switch is pressed..................................................................................................................292 TROUBLESHOTING OF MONITOR SYSTEM .........................................................................................................................294 M-1. Monitor panel shows no display with starting switch ON ..........................................................................................295 M-2. When starting switch is turned ON, all monitor panel lamps stay lighted up and do not go out. ..................................................295 M-3. When starting switch is turned ON (engine stopped), CHECK items flash (light up). (Oil, water, and fuel levels for CHECK items are correct.)....296 M-4. Preheating indicator is defective. ..............................................................................................................299 M-5. When starting switch is turned ON and engine is started, CHECK items flash.......................................................................300 M-6. When starting switch is turned ON (engine stopped), CAUTION items flash. ........................................................................301 M-7. When starting switch is turned ON and engine is started, CAUTION items flash. (When there is no abnormality in CHECK items or engine)...........302 M-8 When starting switch is turned ON (engine stopped), buzzer does not sound for 1 sec...............................................................305 M-9 When starting switch is turned ON (engine stopped), lamp does not flash for 2 sec.................................................................306 M-10 Panel lighting for monitor panel does not light up. (liquid crystal display normal)..............................................................307 M-11 After engine is started, service meter does not move.............................................................................................308 M-12 Coolant temperature gauge shows abnormally low temperature.......................................................................................308 M-13 Coolant temperature gauge does not give display..................................................................................................309 M-14 Torque converter oil temperature gauge shows abnormally low temperature..........................................................................309 M-15 Torque converter oil temperature gauge does not give display.....................................................................................310 M-16 Fuel gauge always shows FULL display.............................................................................................................310 M-17 Fuel gauge does not give display.................................................................................................................311 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................312 METHOD OF USING MANUAL........................................................................................................................................314 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................................................315 SPECIAL TOOL LIST.............................................................................................................................................317 WEIGHT TABLE..................................................................................................................................................323 LUBRICANT AND COOLANT TABLE...................................................................................................................................326 TIGHTENING TORQUES AND STANDARD VALUES TABLE..................................................................................................................327 ENGINE........................................................................................................................................................335 STARTING MOTOR............................................................................................................................................335 ALTERNATOR................................................................................................................................................335 ENGINE OIL COOLER.........................................................................................................................................335 TORQUE CONVERTER COOLER...................................................................................................................................337 FUEL INJECTION PUMP.......................................................................................................................................337 WATER PUMP................................................................................................................................................339 TURBOCHARGER..............................................................................................................................................339 AFTERCOOLER CORE..........................................................................................................................................341 NOZZLE HOLDER.............................................................................................................................................341 CYLINDER HEAD.............................................................................................................................................343 FUEL TANK.................................................................................................................................................345 RADIATOR..................................................................................................................................................347 RADIATOR GUARD............................................................................................................................................349 FAN DRIVE PUMP............................................................................................................................................351 FAN MOTOR.................................................................................................................................................351 ENGINE....................................................................................................................................................353 REMOVAL...............................................................................................................................................353 INSTALLATION..........................................................................................................................................355 POWER TRAIN...................................................................................................................................................357 DAMPER....................................................................................................................................................357 REMOVAL & INSTALLATION................................................................................................................................357 DISASSEMBLY & ASSEMBLY................................................................................................................................361 POWER TRAIN UNIT..........................................................................................................................................365 REMOVAL...............................................................................................................................................365 INSTALLATION..........................................................................................................................................367 PTO, TORQUE CONVERTER.....................................................................................................................................369 REMOVAL & INSTALLATION................................................................................................................................369 DISCONNECTION & CONNECTION............................................................................................................................371 TORQUE CONVERTER..........................................................................................................................................373 DISASSEMBLY...........................................................................................................................................373 ASSEMBLY..............................................................................................................................................379 PTO.......................................................................................................................................................385 DISASSEMBLY...........................................................................................................................................385 ASSEMBLY..............................................................................................................................................389 TORQFLOW TRANSMISSION.....................................................................................................................................393 REMOVAL & INSTALLATION................................................................................................................................393 DISASSEMBLY...........................................................................................................................................395 ASSEMBLY..............................................................................................................................................405 STEERING CASE.............................................................................................................................................415 DISASSEMBLY...........................................................................................................................................415 ASSEMBLY..............................................................................................................................................417 STEERING CLUTCH, BRAKE....................................................................................................................................423 DISASSEMBLY...........................................................................................................................................423 ASSEMBLY..............................................................................................................................................427 TRANSFER GEAR HOUSING.....................................................................................................................................433 DISASSEMBLY...........................................................................................................................................433 ASSEMBLY..............................................................................................................................................435 TORQUE CONVERTER VALVE....................................................................................................................................437 REMOVAL & INSTALLATION................................................................................................................................437 DISASSEMBLY...........................................................................................................................................439 ASSEMBLY..............................................................................................................................................441 TRANSMISSION CONTROL VALVE................................................................................................................................443 REMOVAL & INSTALLATION................................................................................................................................443 DISASSEMBLY...........................................................................................................................................445 ASSEMBLY..............................................................................................................................................447 STEERING CONTROL VALVE....................................................................................................................................451 REMOVAL & INSTALLATION................................................................................................................................451 DISASSEMBLY & ASSSEMBLY...............................................................................................................................453 POWER TRAIN PUMP..........................................................................................................................................455 SCAVENGING PUMP...........................................................................................................................................455 FINAL DRIVE...............................................................................................................................................455 REMOVAL & INSTALLATION................................................................................................................................455 DISASSEMBLY...........................................................................................................................................457 ASSEMBLY..............................................................................................................................................463 UNDERCARRIAGE.................................................................................................................................................469 TRACK FRAME...............................................................................................................................................469 RECOIL SPRING.............................................................................................................................................471 REMOVAL...............................................................................................................................................471 INSTALLATION..........................................................................................................................................475 DISASSEMBLY & ASSEMBLY................................................................................................................................476 IDLER.....................................................................................................................................................478 TRACK ROLLER..............................................................................................................................................478 CARRIER ROLLER............................................................................................................................................480 TRACK SHOE................................................................................................................................................482 CHECKING BEFORE REMOVAL...............................................................................................................................482 REMOVAL (NORMAL)......................................................................................................................................482 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)................................................................................................483 INSTALLATION..........................................................................................................................................484 OVERALL DISASSEMBLY...................................................................................................................................486 OVERALL ASSEMBLY......................................................................................................................................491 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS......................................................................................................505 FIELD DISASSEMBLY OF ONE LINK.........................................................................................................................506 FIELD ASSEMBLY OF ONE LINK............................................................................................................................508 DISASSEMBLY OF MASTER LINK............................................................................................................................510 ASSEMBLY OF MASTER LINK...............................................................................................................................512 PIVOT SHAFT...............................................................................................................................................515 EQUALIZER BAR.............................................................................................................................................517 REMOVAL...............................................................................................................................................517 INSTALLATION..........................................................................................................................................519 EQUALIZER BAR BUSHING.....................................................................................................................................525 IDLER YOKE CARTRIDGE......................................................................................................................................527 IDLER PAD.................................................................................................................................................527 HYDRAULIC SYSTEM..............................................................................................................................................529 HYDRAULIC PUMP............................................................................................................................................529 BLADE LIFT VALVE..........................................................................................................................................529 REMOVAL & INSTALLATION................................................................................................................................529 DISASSEMBLY...........................................................................................................................................531 ASSEMBLY..............................................................................................................................................533 BLADE TILT, RIPPER Lo VALVE...............................................................................................................................535 REMOVAL & INSTALLATION................................................................................................................................535 DISASSEMBLY...........................................................................................................................................537 ASSEMBLY..............................................................................................................................................539 RIPPER Hi VALVE...........................................................................................................................................541 REMOVAL & INSTALLATION................................................................................................................................541 DISASSEMBLY...........................................................................................................................................543 ASSEMBLY..............................................................................................................................................545 BLADE LIFT CYLINDER.......................................................................................................................................547 BLADE TILT CYLINDER.......................................................................................................................................547 RIPPER LIFT CYLINDER......................................................................................................................................549 RIPPER TILT CYLINDER......................................................................................................................................549 HYDRAULIC CYLINDER........................................................................................................................................551 DISASSEMBLY...........................................................................................................................................551 ASSEMBLY..............................................................................................................................................553 PIN PULLER CYLINDER.......................................................................................................................................555 REMOVAL & INSTALLATION................................................................................................................................555 DISASSEMBLY & ASSEMBLY................................................................................................................................557 WORK EQUIPMENT................................................................................................................................................559 WORK EQUIPMENT............................................................................................................................................559 REMOVAL & INSTALLATION................................................................................................................................559 DISASSEMBLY & ASSEMBLY................................................................................................................................561 RIPPER....................................................................................................................................................563 ROPS CAB..................................................................................................................................................565 40 MAINTENANCE STANDARD...........................................................................................................................................567 ENGINE........................................................................................................................................................568 ENGINE MOUNT .............................................................................................................................................568 FAN DRIVE PUMP (SAR63 + 40) ..............................................................................................................................569 FAN DRIVE MOTOR (SAL140) .................................................................................................................................570 IN-LINE SERVO VALVE ......................................................................................................................................571 POWER TRAIN...................................................................................................................................................572 DAMPER....................................................................................................................................................572 TORQUE CONVERTER (TCS52-1 D) .............................................................................................................................574 TORQUE CONVERTER VALVE ...................................................................................................................................576 TORQFLOW TRANSMISSION ....................................................................................................................................578 TRANSMISSION CONTROL VALVE ...............................................................................................................................580 POWER TRAIN LUBRICATION PUMP (BAL 160 + 224) .............................................................................................................583 TRANSFER, BEVEL PINION ...................................................................................................................................584 BEVEL GEAR, STEERING CLUTCH, BRAKE........................................................................................................................585 STEERING CONTROL VALVE....................................................................................................................................588 FINAL DRIVE ..............................................................................................................................................590 MAIN FRAME................................................................................................................................................592 UNDERCARRIAGE.................................................................................................................................................594 TRACK FRAME ..............................................................................................................................................594 RECOIL SPRING ............................................................................................................................................595 IDLER ....................................................................................................................................................596 TRACK ROLLER .............................................................................................................................................598 CARRIER ROLLER ...........................................................................................................................................600 TRACK (LUBRICATED TRACK LINK) ............................................................................................................................602 EQUALIZER BAR ............................................................................................................................................604 PIVOT SHAFT ..............................................................................................................................................605 HYDRAULIC SYSTEM..............................................................................................................................................606 WORK EQUIPMENT PUMP (SARZOO + 100) .......................................................................................................................606 BLADE LIFT VALVE .........................................................................................................................................607 MAIN RELIEF, SHUTTLE VALVE ...............................................................................................................................608 BLADE TILT, RIPPER LOW VALVE .............................................................................................................................609 RIPPER HIGH VALVE ........................................................................................................................................610 HYDRAULIC CYLINDER .......................................................................................................................................611 CYLINDER STAY ............................................................................................................................................613 WORK EQUIPMENT................................................................................................................................................614 DOZER EQUIPMENT...........................................................................................................................................614 CUTTING EDGES AND END BITS ...............................................................................................................................618 RIPPER EQUIPMENT .........................................................................................................................................619
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