Komatsu D475A-3 (Palm Control Specification) Bulldozer Shop Manual SEBM029001

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Komatsu D475A-3 (Palm Control Specification) Bulldozer Shop Manual SEBM029001 – PDF DOWNLOAD

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Komatsu D475A-3 (Palm Control Specification) Bulldozer Shop Manual SEBM029001 – PDF DOWNLOAD 

Language : English
Pages : 727
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu D475A-3 (Palm Control Specification) Bulldozer Shop Manual SEBM029001 – PDF DOWNLOAD 

MACHINE MODEL       SERIAL No.
D475A-3                        10727 and up

COVER 1
CONTENTS 2
Notice of revision 3
SAFETY7
SAFETY NOTICE 7
FOREWORD 9
GENERAL 9
HOW TO READ THE SHOP MANUAL 10
HOISTING INSTRUCTIONS 11
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 12
COATING MATERIALS 14
STANDARD TIGHTENING TORQUE 16
ELECTRIC WIRE CODE 19
CONVERSION TABLE 20
UNITS 26
01 GENERAL 27
SPECIFICATION DIMENSION DRAWINGS 28
SPECIFICATIONS 30
WEIGHT TABLE 39
TABLE OF FUEL, COOLANT AND LUBRICANTS 43
10 STRUCTURE AND FUNCTION 45
ENGINE, POWER TRAIN COOLING SYSTEM DRAWING 46
POWER TRAIN 47
POWER TRAIN SKELETON 48
POWER TRAIN HYDRAULIC PIPING DIAGRAM 49
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 50
TORQUE CONVERTER AND PTO 53
TORQUE CONVERTER VALVE 60
TRANSMISSION 69
TRANSMISSION CONTROL 76
TRANSMISSION ECMV 78
TRANSMISSION CLUTCH ECMV 80
TRANSMISSION LUBRICATION RELIEF VALVE 84
PRIORITY VALVE 85
STEERING, BRAKE CONTROL 86
TRANSFER, BEVEL GEAR SHAFT , STEERING 88
TRANSFER, BEVEL PINION 89
STEERING ECMV 92
STEERING CLUTCH ECMV, STEERING BRAKE ECMV 94
SUDDEN STOP PREVENTION VALVE 101
FINAL DRIVE 102
TRACK FRAME 106
HYDRAULIC TANK 109
PPC VALVE 110
MAIN CONTROL VALVE 122
PIN-PULLER HYDRAULIC SYSTEM DRAWING 130
PIN-PULLER HYDRAULIC CIRCUIT DRAWING 130
PIN-PULLER SOLENOID VALVE 131
AIR CONDITIONER 133
ENGINE CONTROL 134
ENGINE CONTROL SYSTEM 135
DECELERATION POTENTIOMETER 136
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER 138
MONITOR SYSTEM 140
MONITOR PANEL 142
MODE SELECTION SYSTEM 150
ELECTRICAL EQUIPMENT 156
STEERING ELECTRONIC CONTROL 160
20 TESTING AND ADJUSTING 163
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 164
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 165
TESTING AND ADJUSTING 173
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 174
MEASURING ENGINE SPEED 175
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 178
MEASURING EXHAUST TEMPERATURE 179
MEASURING EXHAUST COLOR 180
ADJUSTING VALVE CLEARANCE 181
MEASURING COMPRESSION PRESSURE 182
MEASURING BLOW-BY PRESSURE 183
MEASURING ENGINE OIL PRESSURE 184
TESTING AND ADJUSTING FUEL INJECTION TIMING 185
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 186
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 186
ADJUSTING ENGINE SPEED SENSOR 187
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL 188
MEASURING POWER TRAIN OIL PRESSURE 190
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE 199
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER 200
ADJUSTING PCCS LEVER CONSOLE POSITION 203
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE 204
ADJUSTING CLEARANCE OF IDLER 207
TESTING AND ADJUSTING TRACK SHOE TENSION 208
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE 209
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE 214
MEASURING PPC VALVE AND PITCH, TILT CONTROL VALVE OUTPUT PRESSURE 216
ADJUSTING PPC VALVE 220
MEASURING OUTPUT PRESSURE OF DEMAND SOLENOID VALVE 221
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE 222
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER 223
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER 224
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 225
BLEEDING AIR FROM HYDRAULIC CYLINDERS 225
ADJUSTING WORK EQUIPMENT SAFETY LEVER 226
ADJUSTING RIPPER LEVER POSITION 227
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (DUAL TILT DOZER SPECIFICATION) 228
SPECIAL FUNCTION OF MONITOR PANEL (EMMS) 230
ADJUSTMENT METHOD OF REPLACED CONTROLLER 274
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM 276
HANDLING OF OPTIONAL DEVICES 278
PM CLINIC SERVICE 279
UNDERCARRIAGE TROUBLESHOOTING REPORT 287
TROUBLESHOOTING 289
POINTS TO REMEMBER WHEN TROUBLESHOOTING 290
SEQUENCE OF EVENTS IN TROUBLESHOOTING 291
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 292
CHECKS BEFORE TROUBLESHOOTING 300
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 301
TABLE OF CONNECTORS 302
CONNECTOR ARRANGEMENT DRAWING 306
CONNECTION TABLE FOR CONNECTOR PIN NUMNERS 314
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE) 337
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 341
TROUBLE CODE TABLE 342
ERROR CODE [1500LO] (TRANSMISSION CLUTCH: SEE THE LIST (LO)) 343
ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST (L1)) 344
ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST (LH)) 345
ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST (L1)) 346
ERROR CODE [15SELH] (REVERSE CLUTCH: SEE THE LIST (LH)) 347
ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST (L1)) 348
ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST (LH)) 349
ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST (L1)) 350
ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST (LH)) 351
ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST (L1)) 352
ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST (LH)) 353
ERROR CODE [1800MW] (POWER TRAIN CLUTCH: SLIP (MW)) 354
ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST (L1)) 355
ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST (LH)) 356
ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST (L1)) 357
ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST (LH)) 358
ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST (L1)) 359
ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST (LH)) 360
ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST (L1)) 361
ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST (LH)) 362
ERROR CODE [AA1ANX] (AIR CLEANER: CLOGGING (NX)) 363
ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA)) 364
ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)) 365
ERROR CODE [B@BAZK] (ENGINE OIL: LEVEL REDUCTION (ZK)) 365
ERROR CODE [B@BCNS] (RADIATOR COOLANT:OVERHEAT (NS)) 366
ERROR CODE [B@BCZK] (RADIATOR COOLANT:LEVERL REDUCTION (ZK)) 367
ERROR CODE [B@CENS] (POWER TRAIN OIL: OVERHEAT (NS)) 367
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS)) 368
ERROR CODE [B@HAZK] (HYDRAULIC OIL: LEVEL REDUCTION (ZK)) 368
ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA)) 369
ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB)) 370
ERROR CODE [D130KA] (NEUTRAL RELAY: DISCONNECTION (KA)) 371
ERROR CODE [D130KB] (ENUTRAL RELAY: SHORT CIRCUIT (KB)) 373
ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA)) 374
ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB)) 376
ERROR CODE [D52FKA] (NEUTRAL SIGNAL 1: DISCONNECTION (KA)) 378
ERROR CODE [D52FKB] (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB)) 379
ERROR CODE [D52GKA] (NEUTRAL SIGNAL 2: DISCONNECTION (KA)) 380
ERROR CODE [D52GKB] (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB)) 381
ERROR CODE [DAFRKR] (MONITOR PANEL “CAN” COMMUNICTION: DEFECTIVE COMMUNICATION (KR)) 382
ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 384
ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT) 385
ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 386
ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 388
ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 389
ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 390
ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 392
ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 394
ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 395
ERROR CODE [DB35KK] (STEERING CONTROLLER: POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 396
ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 398
ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 399
ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 400
ERROR CODE [DB3SKR] (STEERING CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 402
ERROR CODE [DD12KA] (SHIFT UP SWITCH: DISCONNECTION (KA)) 404
ERROR CODE [DD12KB] (SHIFT UP SWITCH: SHORT CIRCUIT (KB)) 406
ERROR CODE [DD13KA] (SHIFT DOWN SWITCH: DISCONNECTION (KA)) 408
ERROR CODE [DD13KB] (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB)) 410
ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)) 412
ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) 414
ERROR CODE [DDB9KA] (REVERSE SWITCH: DISCONNECTION (KA)) 416
ERROR CODE [DDB9KB] (REVERSE SWITCH: SHORT CIRCUIT (KB)) 418
ERROR CODE [DDK3KA] (FORWARD SWITCH: DISCONNECTION (KA)) 420
ERROR CODE [DDK3KB] (REVERSE SWITCH: SHORT CIRCUIT (KB)) 422
ERROR CODE [DDK5KA] (SHIFT SWITCH: DISCONNECTION (KA)) 424
ERROR CODE [DDK5KB] (SHIFT SWITCH: SHORT CIRCUIT (KB)) 426
ERROR CODE [DDN2LD] (SEE TABLE (LD) BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM) 427
ERROR CODE [DDN3LD] (SEE TABLE (LD) BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM) 428
ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA)) 430
ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB)) 432
ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA)) 434
ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB)) 436
ERROR CODE [DDNALD] (BLADE LIFT UP FULL PRESSURE SWITCH: REFER TO TABLE (LD)) 438
ERROR CODE [DDNBLD] (RIPPER LIFT UP PRESSURE SWITCH: REFTER TO TABLE (LD)) 439
ERROR CODE [DDNCLD] (RIPPER LOWER PRESSURE SWITCH: REFTER TO TABLE (LD)) 440
ERROR CODE [DDNDLD] (RIPPER TILT IN PRESSURE SWITCH: REFTER TO TABLE (LD)) 441
ERROR CODE [DDNELD] (RIPPER TILT BACK PRESSURE SWITCH: REFTER TO TABLE (LD)) 442
ERROR CODE [DDNFLD] (BLADE LOWER FULL PRESSURE SWITCH: REFTER TO TABLE (LD)) 443
ERROR CODE [DDQ2KA] (PARKING BRADE LEVER SWITCH: DISCONNECTION (KA)) 444
ERROR CODE [DDQ2KB] (PARKING BRADE LEVER SWITCH: SHORT CIRCUIT (KB)) 446
ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4)) 448
ERROR CODE [DDT5KA] (NEUTRAL SWITCH: DISCONNECTION (KA)) 450
ERROR CODE [DDT5KB] (NEUTRAL SWITCH: SHORT CIRCUIT (KB)) 452
ERROR CODE [DDT5KQ] (PCCS LEVER SPECIFICATION SIGNAL INCONSISTENCY (KQ)) 454
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 455
ERROR CODE [DH22KA] (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA)) 456
ERROR CODE [DH22KB] (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) 457
ERROR CODE [DH23KA] (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA)) 458
ERROR CODE [DH23KB] (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) 459
ERROR CODE [DK01KA] (LEFT YOKE ANGLE SENSOR: DISCONNECTION (KA)) 460
ERROR CODE [DK01KB] (LEFT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB)) 461
ERROR CODE [DK03KA] (RIGHT YOKE ANGLE SENSOR: DISCONNECTION (KA)) 462
ERROR CODE [DK03KB] (RIGHT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB)) 463
ERROR CODE [DK11KA] (DECELERATION POTENTIOMETER: DISCONNECTION (KA)) 464
ERROR CODE [DK11KB] (DECELERATION POTENTIOMETER: SHORT CIRCUIT (KB)) 466
ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA)) 468
ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)) 470
ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 471
ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ)) 471
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8)) 472
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA)) 474
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB)) 476
ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA)) 477
ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB)) 478
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX) 479
ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ)) 479
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8)) 480
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA)) 481
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB)) 482
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA)) 484
ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB)) 486
ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA)) 487
ERROR CODE [DK60KB] (ACCELERATION SENSOR: SHORT CIRCUIT (KB)) 488
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA)) 489
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB)) 490
ERROR CODE [DLE1KIA] (ENGINE NE SPEED SENSOR: DISCONNECTION (KA)) 492
ERROR CODE [DLF1KA] (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION (KA)) 494
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB)) 495
ERROR CODE [DW55KA] (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA)) 496
ERROR CODE [DW55KB] (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB)) 497
ERROR CODE [DW56KA] (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA)) 498
ERROR CODE [DW56KB] (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB)) 499
ERROR CODE [DW57KA] (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA)) 500
ERROR CODE [DW57KB] (LEFT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB)) 501
ERROR CODE [DW58KA] (RIGHT TILT LIMIT SOLENOID: DISCONNECTION (KA)) 502
ERROR CODE [DW58KB] (RIGHT TILT SOLENOID: SHORT CIRCUIT (KB)) 503
ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA)) 504
ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB)) 505
ERROR CODE [DW5JKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA)) 506
ERROR CODE [DW5JKB] (BLADE PITCH SOLENOID: SHORT CIRCUIT (KB)) 507
ERROR CODE [DW5LKA] (BLADE PITCH DUMP ASSIST SOLENOID: DISCONNECTION (KA)) 508
ERROR CODE [DW5LKB] (BLADE PITCH DUMP ASSIST SOLENOID: SHORT CIRCUIT (KB)) 509
ERROR CODE [DW98KA] (UNLOAD SOLENOID: DISCONNECTION (KA)) 510
ERROR CODE [DW98KB] (UNLOAD SOLENOID: SHORT CIRCUIT (KB)) 511
ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA)) 512
ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB)) 513
ERROR CODE [DXH1KA] (LOCK-UP SOLENOID: DISCONNECTION (KA)) 514
ERROR CODE [DXH1KB] (LOCK-UP SOLENOID: SHORT CIRCUIT (KB)) 515
ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA)) 516
ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)) 517
ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA)) 518
ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB)) 519
ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA)) 520
ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB)) 521
ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA)) 522
ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB)) 523
ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA)) 524
ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB)) 525
ERROR CODE [DXH9KA] (RIGHT STEERING CLUTCH ECMV SYSTEM: DISCONNECTION (KA)) 526
ERROR CODE [DXH9KB] (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) 527
ERROR CODE [DXHAKA] (LEFT STEERING CLUTCH ECMV: DISCONNECTION (KA)) 528
ERROR CODE [DXHAKB] (LEFT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) 529
ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA)) 530
ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB)) 531
ERROR CODE [DXHCKA] (LEFT BACK ECMV: DISCONNECTION (KA)) 532
ERROR CODE [DXHCKB] (LEFT BACK ECMV: SHORT CIRCUIT (KB)) 533
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 535
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 536
E- 1 THE ENGINE DOES NOT START 538
E- 2 THE PREHEATER DOES NOT OPERATE (MANUAL PREHEATING FUNCTION) 540
E- 3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE 542
E- 4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON 543
E- 5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT 544
E- 6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH (THE RADIATOR WATER LEVEL CAUTION LAMP FLASHES) 545
E- 7 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH (THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP FLASHES) 546
E- 8 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH (THE ENGINE OIL LEVEL CAUTION LAMP FLASHES) 547
E- 9 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES 548
E-10 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES 550
E-11 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON 554
E-12 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR TILT SELECTOR LAMP DOES NOT COME ON (DUAL TILT-MOUNTED MACHINE) 556
E-13 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON 556
E-14 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 557
E-15 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL 558
E-16 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 559
E-17 INDICATION OF THE FUEL GAUGE IS ABNORMAL 560
E-18 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL 561
E-19 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL 561
E-20 THE SWITCH MODULE CANNOT BE OPERATED 562
E-21 THE WAMING LAMP DOES NOT FLASH OR DOES NOT GO OUT 563
E-22 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP 564
E-23 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED 565
E-24 THE ALARM BUZZER CANNOT BE CANCELLED 566
E-25 THE OPERATOR MODE CANNOT BE OPERATED 567
E-26 THE SERVICE MODE CANNOT BE OPERATED 568
E-27 THE BACK-UP ALARM DOES NOT SOUND 570
E-28 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON 571
E-29 THE AIR CONDITIONER DOES NOT OPERATE 576
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 581
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 582
H-1 NO TRAVEL POWER (NO DRAWBAR PULL) 583
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED) 584
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE 585
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION IN FORWARD OR IN REVERSE 586
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE 587
H-6 STEERING IS NOT POSSIBLE 588
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE 588
H-8 STEERING OVERRUN OCCURS 589
H-9 BRAKE DOES NOT WORK 589
H-10 TORQUE CONVERTER DOES NOT LOCK-UP 590
H-11 OVERHEAT OF POWER TRAIN OIL TEMPERATURE 591
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY 592
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE 593
H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER 594
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER 594
H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER 595
H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER 595
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT 596
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT 597
H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT 597
H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE ) 598
H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE) 598
H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP 600
30 DISASSEMBLY AND ASSEMBLY 601
POWER TRAIN UNIT ASSEMBLY 604
REMOVAL 604
INSTALLATION 607
PTO, TORQUE CONVERTER ASSEMBLY 608
REMOVAL 608
INSTALLATION 610
TORQFLOW TRANSMISSION ASSEMBLY 612
DISASSEMBLY 612
ASSEMBLY 621
STEERING CASE ASSEMBLY 632
DISASSEMBLY 632
ASSEMBLY 634
TRANSMISSION CONTROL VALVE ASSEMBLY 641
REMOVAL 641
INSTALLATION 642
STEERING CONTROL VALVE ASSEMBLY 643
REMOVAL 643
INSTALLATION 643
FLOOR FRAME ASSEMBLY 645
REMOVAL 645
INSTALLATION 649
DASHBOARD ASSEMBLY 650
REMOVAL 650
INSTALLATION 651
CONTROLLER ASSEMBLY 652
REMOVAL 652
INSTALLATION 652
AIR CONDITIONER UNIT ASSEMBLY 654
REMOVAL 654
INSTALLATION 657
40 MAINTENANCE STANDARD 659
ENGINE MOUNT 660
DAMPER,UNIVERSAL JOINT 661
TORQUE CONVERTER 662
TORQUE CONVERTER VALVE 664
TORQFLOW TRANSMISSION 666
POWER TRAIN, HYDRAULIC, LUBRICATION PUMP 668
TRANSFER,BEVEL PINION 669
BEVEL GEAR SHAFT, STEERING CLUTCH,BRAKE 670
PARKING BRAKE VALVE 672
FINAL DRIVE 674
MAIN FRAME 676
TRACK FRAME 678
RECOIL SPRING 679
IDLER 680
TRACK ROLLER 682
CARRIER ROLLER 684
TRACK SHOE 686
EQUALIZE BAR 690
PIVOT SHAFT 692
HYDRAULIC PUMP 693
WORK EQUIPMENT CONTROL PUMP 694
MAIN CONTROL VALVE 695
PPC VALVE 699
WORK EQUIPMENT CYLINDER 702
CYLINDER STAY 704
BLADE 706
RIPPER EQUIPMENT 712
90 OTHERS 715
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 717
SINGLE TILT SPECIFTICATION 717
DUAL TILT SPECFICATION 718
SUPER DOZER SPECFICATION 719
ELECTRICAL CIRCUIT DIAGRAM 720
SINGLE TILT AND DUAL TILT SPECIFICATIONS 720
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/4) 720
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/4) 721
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/4) 722
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (4/4) 723
SUPER DOZER SPECFICATION 724
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/3) 724
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/3) 725
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/3) 726
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB 727

DESCRIPTION:

Komatsu D475A-3 (Palm Control Specification) Bulldozer Shop Manual SEBM029001 – PDF DOWNLOAD 

MACHINE MODEL       SERIAL No.
D475A-3                        10727 and up

FOREWORD
GENERAL
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 chapters; these chapters are further
divided into the each main group of components.
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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

IMAGES PREVIEW OF THE MANUAL:

S.V 22/12/24