Komatsu D475A-3 Bulldozer Shop Manual SEBM027503 – PDF DOWNLOAD 

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Komatsu D475A-3 Bulldozer Shop Manual SEBM027503 – PDF DOWNLOAD

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Komatsu D475A-3 Bulldozer Shop Manual SEBM027503 – PDF DOWNLOAD 

Language : English
Pages : 777
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D475A-3 Bulldozer Shop Manual SEBM027503 – PDF DOWNLOAD 

MACHINE MODEL       SERIAL No.
D475A-3                         10695 and up

COVER 1
CONTENTS 2
LIST OF REVISED PAGES 3
SAFETY 9
SAFETY NOTICE 9
FOREWORD 11
GENERAL 11
HOW TO READ THE SHOP MANUAL 12
HOISTING INSTRUCTIONS 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 14
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE 18
ELECTRIC WIRE CODE 21
CONVERSION TABLE 22
UNITS 28
01 GENERAL 29
SPECIFICATION DIMENSION DRAWINGS 30
SPECIFICATIONS 32
WEIGHT TABLE 41
TABLE OF FUEL, COOLANT AND LUBRICANTS 45
10 STRUCTURE AND FUNCTION 47
ENGINE, POWER TRAIN COOLING SYSTEM DRAWING 48
POWER TRAIN 49
POWER TRAIN SKELETON 50
POWER TRAIN HYDRAULIC PIPING DIAGRAM 51
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 52
TORQUE CONVERTER AND PTO 55
TORQUE CONVERTER VALVE 62
TRANSMISSION 71
TRANSMISSION CONTROL 78
TRANSMISSION ECMV 80
TRANSMISSION CLUTCH ECMV 82
TRANSMISSION LUBRICATION RELIEF VALVE 86
PRIORITY VALVE 87
STEERING, BRAKE CONTROL 88
TRANSFER, BEVEL GEAR SHAFT, STEERING 90
TRANSFER, BEVEL PINION 91
STEERING ECMV 94
STEERING CLUTCH, STEERING BRAKE ECMV 96
SUDDEN STOP PREVENTION VALVE 103
FINAL DRIVE 104
TRACK FRAME 108
HYDRAULIC TANK 111
PPC VALVE 112
MAIN CONTROL VALVE 124
PIN-PULLER HYDRAULIC SYSTEM DRAWING 132
PIN-PULLER HYDRAULIC CIRCUIT DRAWING 132
PIN-PULLER SOLENOID VALVE 133
AIR CONDITIONER 135
ENGINE CONTROL 136
ENGINE CONTROL SYSTEM 137
DECELERATION POTENTIOMETER 138
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER 140
MONITOR SYSTEM 142
MONITOR PANEL 144
MODE SELECTION SYSTEM 152
ELECTRICAL EQUIPMENT 158
STEERING ELECTRONIC CONTROL 162
20 TESTING AND ADJUSTING 165
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 166
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 167
TESTING AND ADJUSTING 175
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 176
MEASURING ENGINE SPEED 177
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 180
MEASURING EXHAUST TEMPERATURE 181
MEASURING EXHAUST COLOR 182
ADJUSTING VALVE CLEARANCE 183
MEASURING COMPRESSION PRESSURE 184
MEASURING BLOW-BY PRESSURE 185
MEASURING ENGINE OIL PRESSURE 186
TESTING AND ADJUSTING FUEL INJECTION TIMING 187
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 188
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 188
ADJUSTING ENGINE SPEED SENSOR 189
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL 190
MEASURING POWER TRAIN OIL PRESSURE 192
SIMPLE METHOD FOR TESTING BRAKE PERFORMANCE 201
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER 202
ADJUSTING PCCS LEVER CONSOLE POSITION 205
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE 206
ADJUSTING CLEARANCE OF IDLER 209
TESTING AND ADJUSTING TRACK SHOE TENSION 210
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE 211
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE 216
MEASURING PPC VALVE AND PITCH, TILT CONTROL VALVE OUTPUT PRESSURE 218
ADJUSTING PPC VALVE 222
MEASURING OUTPUT PRESSURE OF DEMAND SOLENOID VALVE 223
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE 224
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER 225
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER 226
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 227
BLEEDING AIR FROM HYDRAULIC CYLINDERS 227
ADJUSTING WORK EQUIPMENT SAFETY LEVER 228
ADJUSTING RIPPER LEVER POSITION 229
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (DUAL TILT DOZER SPECIFICATION) 230
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 232
ADJUSTING METHOD OF REPLACED CONTROLLER 276
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM 278
HANDLING OF OPTIONAL DEVICES 280
PM CLINIC SERVICE 281
UNDERCARRIAGE TROUBLESHOOTING REPORT 289
TROUBLESHOOTING 291
POINTS TO REMEMBER WHEN TROUBLESHOOTING 292
SEQUENCE OF EVENTS IN TROUBLESHOOTING 293
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 294
CHECKS BEFORE TROUBLESHOOTING 302
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 303
TABLE OF CONNECTORS 304
CONNECTOR ARRANGEMENT DRAWING 308
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 316
T-BRANCH BOX AND T-BRANCH TABLE 338
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE) 341
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 345
TROUBLE CODE TABLE 346
ERROR CODE [1500L0] (TRANSMISSION CLUTCH: SEE THE LIST (L0)) 347
ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST (L1)) 348
ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST (LH)) 349
ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST (L1)) 350
ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST (LH)) 351
ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST (L1)) 352
ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST (LH)) 353
ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST (L1)) 354
ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST (LH)) 355
ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST (L1)) 356
ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST (LH)) 357
ERROR CODE [1800MW] (POWER TRAIN CLUTCH: SLIP (MW)) 358
ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST (L1)) 359
ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST (LH)) 360
ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST (L1)) 361
ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST (LH)) 362
ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST (L1)) 363
ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST (LH)) 364
ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST (L1)) 365
ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST (LH)) 366
ERROR CODE [A70XLK] (GOVERNOR SERVO SYSTEM RIGHT: * REFER TO TABLE (LK)) 367
ERROR CODE [A70YLK] (GOVERNOR SERVO SYSTEM LEFT: * REFER TO TABLE (LK)) 368
ERROR CODE [AA1ANX] (AIR CLEANER: CLOGGING (NX)) 371
ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA)) 372
ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)) 373
ERROR CODE [B@BAZK] (ENGINE OIL: OIL LEVEL REDUCTION (ZK)) 373
ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS)) 374
ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK)) 375
ERROR CODE [B@CENS] (POWER TRAIN OIL: OVERHEAT (NS)) 375
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS)) 376
ERROR CODE [B@HAZK] (HYDRAULIC OIL: LEVEL REDUCTION (ZK)) 376
ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA)) 377
ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB)) 378
ERROR CODE [D130KA] (NEUTRAL RELAY: DISCONNECTION (KA)) 379
ERROR CODE [D130KB] (NEUTRAL RELAY: SHORT CIRCUIT (KB)) 381
ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA)) 382
ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB)) 384
ERROR CODE [D1D0KA] (GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION (KA)) 386
ERROR CODE [D1D0KB] (GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT (KB)) 387
ERROR CODE [D1D1KA] (GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION (KA)) 389
ERROR CODE [D1D1KB] (GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT (KB)) 391
ERROR CODE [D5ZFKA] (NEUTRAL SIGNAL 1: DISCONNECTION (KA)) 394
ERROR CODE [D5ZFKB] (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB)) 395
ERROR CODE [D5ZFL4] (ENGINE CONTROLLER NEUTRAL SIGNAL: ON AND OFF SIGNALS DO NOT AGREE (L4)) 396
ERROR CODE [D5ZGKA] (NEUTRAL SIGNAL 2: DISCONNECTION (KA)) 398
ERROR CODE [D5ZGKB] (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB)) 399
ERROR CODE [D5ZKKX] (CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL RANGE (KX)) 400
ERROR CODE [DAFRKR] (MONITOR PANEL “CAN” COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 402
ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 404
ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 405
ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 406
ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 408
ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 409
ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 410
ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 412
ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 414
ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 415
ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 416
ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 418
ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 419
ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 420
ERROR CODE [DB3SKR] (STEERING CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 422
ERROR CODE [DB40KK] (ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK)) 423
ERROR CODE [DB41KK] (SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)) 424
ERROR CODE [DB42KK] (SOLENOID POWER SUPPLY 1: LOWERING OF SOURCE VOLTAGE (KK)) 426
ERROR CODE [DB43KK] (BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)) 428
ERROR CODE [DB44KK] (SOLENOID POWER SUPPLY 2: LOWERING OF SOURCE VOLTAGE (KK)) 430
ERROR CODE [DB45KP] (RACK SENSOR POWER SUPPLY: LOWERING OF OUTPUT VOLTAGE (KP)) 432
ERROR CODE [DB49KM] (WRONG CONNECTION OF CONNECTOR: MISTAKE IN OPERATION OR SETTING (KM)) 434
ERROR CODE [DB49KQ] (ENGINE CONTROLLER SPECIFICATION: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)) 435
ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)) 438
ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) 440
ERROR CODE [DDB9KA] (REVERSE SWITCH: DISCONNECTION (KA)) 442
ERROR CODE [DDB9KB] (REVERSE SWITCH: SHORT CIRCUIT (KB)) 444
ERROR CODE [DDK3KA] (FORWARD SWITCH: DISCONNECTION (KA)) 446
ERROR CODE [DDK3KB] (FORWARD SWITCH: SHORT CIRCUIT (KB)) 448
ERROR CODE [DDK5KA] (SHIFT SWITCH: DISCONNECTION (KA)) 450
ERROR CODE [DDK5KB] (SHIFT SWITCH: SHORT CIRCUIT (KB)) 452
ERROR CODE [DDN2LD] (SEE TABLE (LD) BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM) 453
ERROR CODE [DDN3LD] (SEE TABLE (LD) BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM) 454
ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA)) 456
ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB)) 458
ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA)) 460
ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB)) 462
ERROR CODE [DDNALD] (BLADE LIFT UP FULL PRESSURE SWITCH: REFER TO TABLE (LD)) 464
ERROR CODE [DDNBLD] (RIPPER LIFT UP PRESSURE SWITCH: REFER TO TABLE (LD)) 465
ERROR CODE [DDNCLD] (RIPPER LOWER PRESSURE SWITCH: REFER TO TABLE (LD)) 466
ERROR CODE [DDNDLD] (RIPPER TILT IN PRESSURE SWITCH: REFER TO TABLE (LD)) 467
ERROR CODE [DDNELD] (RIPPER TILT BACK PRESSURE SWITCH: REFER TO TABLE (LD)) 468
ERROR CODE [DDNFLD] (BLADE LOWER FULL PRESSURE SWITCH: REFER TO TABLE (LD)) 469
ERROR CODE [DDQ2KA] (PARKING BRAKE LEVER SWITCH: DISCONNECTION (KA)) 470
ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB)) 472
ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4)) 474
ERROR CODE [DDT5KA] (NEUTRAL SWITCH: DISCONNECTION (KA)) 476
ERROR CODE [DDT5KB] (NEUTRAL SWITCH: SHORT CIRCUIT (KB)) 478
ERROR CODE [DDT5KQ] (PCCS LEVER SPECIFICATION SIGNAL INCONSISTENCY (KQ)) 480
ERROR CODE [DGE2KX] (COOLANT TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)) 481
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 483
ERROR CODE [DH22KA] (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA)) 484
ERROR CODE [DH22KB] (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) 485
ERROR CODE [DH23KA] (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA)) 486
ERROR CODE [DH23KB] (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) 487
ERROR CODE [DK01KA] (LEFT YOKE ANGEL SENSOR: DISCONNECTION (KA)) 488
ERROR CODE [DK01KB] (LEFT YOKE ANGEL SENSOR: SHORT CIRCUIT (KB)) 489
ERROR CODE [DK03KA] (RIGHT YOKE ANGEL SENSOR: DISCONNECTION (KA)) 490
ERROR CODE [DK03KB] (RIGHT YOKE ANGEL SENSOR: SHORT CIRCUIT (KB)) 491
ERROR CODE [DK10KX] (FUEL DIAL: OUT OF NORMAL SIGNAL RANGE (KX)) 492
ERROR CODE [DK11KA] (DECELERATION POTENTIOMETER: DISCONNECTION (KA)) 494
ERROR CODE [DK11KB] (DECELERATION POTENTIOMETER: SHORT CIRCUIT (KB)) 496
ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER: OUT OF INPUT SIGNAL RANGE (KX)) 498
ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA)) 500
ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)) 502
ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 503
ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ)) 503
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8)) 504
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA)) 506
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB)) 508
ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA)) 509
ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB)) 510
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 511
ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ)) 511
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8)) 512
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA)) 513
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB)) 514
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA)) 516
ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB)) 518
ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA)) 519
ERROR CODE [DK60KB] (ACCELERATION SENSOR: SHORT CIRCUIT (KB)) 520
ERROR CODE [DKF1KX] (RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE (KX)) 521
ERROR CODE [DKF2KX] (RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE (KX)) 523
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA)) 525
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB)) 526
ERROR CODE [DLE1KA] (ENGINE NE SPEED SENSOR: DISCONNECTION (KA)) 528
ERROR CODE [DLE4LC] (ENGINE SPEED SENSOR A: * REFER TO TABLE (LC)) 530
ERROR CODE [DLE5LC] (ENGINE SPEED SENSOR B: * REFER TO TABLE (LC)) 532
ERROR CODE [DLF1KA] (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION (KA)) 534
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB)) 535
ERROR CODE [DW55KA] (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA)) 536
ERROR CODE [DW55KB] (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB)) 537
ERROR CODE [DW56KA] (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA)) 538
ERROR CODE [DW56KB] (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB)) 539
ERROR CODE [DW57KA] (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA)) 540
ERROR CODE [DW57KB] (LEFT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB)) 541
ERROR CODE [DW58KA] (RIGHT TILT LIMIT SOLENOID: DISCONNECTION (KA)) 542
ERROR CODE [DW58KB] (RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB)) 543
ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA)) 544
ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB)) 545
ERROR CODE [DW5JKA] (BLADE PITCH SOLENOID: DISCONNECTION (KA)) 546
ERROR CODE [DW5JKB] (BLADE PITCH SOLENOID: SHORT CIRCUIT (KB)) 547
ERROR CODE [DW5LKA] (BLADE PITCH DUMP ASSIST SOLENOID: DISCONNECTION (KA)) 548
ERROR CODE [DW5LKB] (BLADE PITCH DUMP ASSIST SOLENOID: SHORT CIRCUIT (KB)) 549
ERROR CODE [DW98KA] (UNLOAD SOLENOID: DISCONNECTION (KA)) 550
ERROR CODE [DW98KB] (UNLOAD SOLENOID: SHORT CIRCUIT (KB)) 551
ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA)) 552
ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB)) 553
ERROR CODE [DXH1KA] (LOCK-UP SOLENOID: DISCONNECTION (KA)) 554
ERROR CODE [DXH1KB] (LOCK-UP SOLENOID: SHORT CIRCUIT (KB)) 555
ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA)) 556
ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)) 557
ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA)) 558
ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB)) 559
ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA)) 560
ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB)) 561
ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA)) 562
ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB)) 563
ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA)) 564
ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB)) 565
ERROR CODE [DXH9KA] (RIGHT STEERING CLUTCH ECMV: DISCONNECTION (KA)) 566
ERROR CODE [DXH9KB] (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) 567
ERROR CODE [DXHAKA] (LEFT STEERING CLUTCH ECMV: DISCONNECTION (KA)) 568
ERROR CODE [DXHAKB] (LEFT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) 569
ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA)) 570
ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB)) 571
ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA)) 572
ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB)) 573
ERROR CODE [DXHDKA] (GOVERNOR SOLNOID RIGHT: DISCONNECTION (KA)) 574
ERROR CODE [DXHDKB] (GOVERNOR SOLNOID RIGHT: SHORT CIRCUIT (KB)) 576
ERROR CODE [DXHEKA] (GOVERNOR SOLNOID LEFT: DISCONNECTION (KA)) 577
ERROR CODE [DXHEKB] (GOVERNOR SOLNOID LEFT: SHORT CIRCUIT (KB)) 579
ERROR CODE [DXHFKA] (PRE-STROKE SOLENOID RIGHT: DISCONNECTION (KA)) 580
ERROR CODE [DXHFKB] (PRE-STORKE SOLENOID RIGHT: SHORT CIRCUIT (KB)) 581
ERROR CODE [DXHGKA] (PRE-STROKE SOLENOID LEFT: DISCONNECTION (KA)) 582
ERROR CODE [DXHGKB] (PRE-STORKE SOLENOID LEFT: SHORT CIRCUIT (KB)) 583
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 585
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 586
E-1 THE ENGINE DOES NOT START 588
E-2 THE PREHEATER DOES NOT OPERATE (MANUAL PREHEATING FUNCTION) 590
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE 592
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON 593
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT 594
E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH (THE RADIATOR WATER LEVEL CAUTION LAMP FLASHES) 595
E-7 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH (THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP FLASHES) 596
E-8 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH (THE ENGINE OIL LEVEL CAUTION LAMP FLASHES) 597
E-9 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES 598
E-10 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES 600
E-11 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON 604
E-12 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON (DUAL TILT-MOUNTED MACHINE) 606
E-13 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON 606
E-14 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 607
E-15 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL 608
E-16 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 609
E-17 INDICATION OF THE FUEL GAUGE IS ABNORMAL 610
E-18 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL 611
E-19 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL 611
E-20 THE SWITCH MODULE CANNOT BE OPERATED 612
E-21 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT 613
E-22 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP 614
E-23 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED 615
E-24 THE ALARM BUZZER CANNOT BE CANCELLED 616
E-25 THE OPERATOR MODE CANNOT BE OPERATED 617
E-26 THE SERVICE MODE CANNOT BE OPERATED 618
E-27 THE BACK-UP ALARM DOES NOT SOUND 620
E-28 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON 621
E-29 THE AIR CONDITIONER DOES NOT OPERATE 626
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 631
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 632
H-1 NO TRAVEL POWER (NO DRAWBAR PULL) 633
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED) 634
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE 635
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE 636
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED,LARGE TIME LAG IS MADE 637
H-6 STEERING IS NOT POSSIBLE 638
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE 638
H-8 STEERING OVERRUN OCCURS 639
H-9 BRAKE DOES NOT WORK 639
H-10 TORQUE CONVERTER IS NOT LOCK-UP 640
H-11 OVERHEAT OF POWER TRAIN OIL TEMPERATURE 641
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY 642
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE 643
H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER 644
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER 644
H-16 RIPPER TILT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER 645
H-17 RIPPER TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER 645
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT 646
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT 647
H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT 647
H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE) 648
H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE) 648
H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP 650
30 DISASSEMBLY AND ASSEMBLY 651
POWER TRAIN UNIT ASSEMBLY 654
REMOVAL AND INSTALLATION 654
PTO,TORQUE CONVERTER ASSEMBLY 658
REMOVAL AND INSTALLATION 658
TORQFLOW TRANSMISSION ASSEMBLY 662
DISASSEMBLY AND ASSEMBLY 662
STEERING CASE ASSEMBLY 682
DISASSEMBLY AND ASSEMBLY 682
TRANSMISSION CONTROL VALVE ASSEMBLY 691
REMOVAL AND INSTALLATION 691
STEERING CONTROL VALVE ASSEMBLY 693
REMOVAL AND INSTALLATION 693
FLOOR FRAME ASSEMBLY 695
REMOVAL AND INSTALLATION 695
DASHBOARD ASSEMBLY 700
REMOVAL AND INSTALLATION 700
CONTROLLER ASSEMBLY 702
REMOVAL AND INSTALLATION 702
AIR CONDITIONER UNIT ASSEMBLY 704
REMOVAL AND INSTALLATION 704
40 MAINTENANCE STANDARD 709
ENGINE MOUNT 710
DAMPER, UNIVERSAL JOINT 711
TORQUE CONVERTER 712
TORQUE CONVERTER VALVE 714
TORQFLOW TRANSMISSION 716
POWER TRAIN, HYDRAULIC, LUBRICATION PUMP 718
TRANSFER, BEVEL PINION 719
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE 720
PARKING BRAKE VALVE 722
FINAL DRIVE 724
MAIN FRAME 726
TRACK FRAME 728
RECOIL SPRING 729
IDLER 730
TRACK ROLLER 732
CARRIER ROLLER 734
TRACK SHOE 736
EQUALIZER BAR 740
PIVOT SHAFT 742
HYDRAULIC PUMP 743
WORK EQUIPMENT CONTROL PUMP 744
MAIN CONTROL VALVE 745
PPC VALVE 749
WORK EQUIPMENT CYLINDER 752
CYLINDER STAY 754
BLADE 756
RIPPER EQUIPMENT 762
90 OTHERS 765
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 767
SINGLE TILT SPECIFICATION 767
DUAL TILT SPECIFICATION 768
SUPER DOZER SPECIFICATION 769
ELECTRICAL CIRCUIT DIAGRAM 770
SINGLE TILT AND DUAL TILT SPECIFICATIONS 770
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/4) 770
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/4) 771
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/4) 772
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (4/4) 773
SUPER DOZER SPECIFICATION 774
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/3) 774
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/3) 775
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/3) 776
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB 777

DESCRIPTION:

Komatsu D475A-3 Bulldozer Shop Manual SEBM027503 – PDF DOWNLOAD 

MACHINE MODEL       SERIAL No.
D475A-3                         10695 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

S.V 24/12/24