Komatsu D475A-5 Bulldozer Shop Manual SEBM033717 PDF DOWNLOAD

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Komatsu D475A-5 Bulldozer Shop Manual SEBM033717  – PDF DOWNLOAD

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Komatsu D475A-5 Bulldozer Shop Manual SEBM033717  – PDF DOWNLOAD

Language : English
Pages : 1306
Downloadable : Yes
File Type : PDF

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Komatsu D475A-5 Bulldozer Shop Manual SEBM033717  – PDF DOWNLOAD

• MACHINE MODEL             SERIAL No.
  D475A-5                               20001 and up

COVER 1
CONTENTS . 2
01 GENERAL . 23
SPECIFICATION DRAWINGS . 24
SPECIFICATIONS . 25
WEIGHT TABLE . 34
FUEL, COOLANT AND LUBRICANTS . 38
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 41
RADIATOR AND OIL COOLER 44
ENGINE MOUNT . 45
POWER TRAIN 46
POWER TRAIN HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM 48
DAMPER AND UNIVERSAL JOINT . 50
POWER TRAIN UNIT . 52
TORQUE CONVERTER AND PTO . 54
TORQUE CONVERTER VALVE . 64
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM 74
SCAVENGING PUMP 75
TRANSMISSION CONTROL . 76
TRANSMISSION . 78
TRANSMISSION ECMV 90
TRANSMISSION CLUTCH ECMV . 92
PRIORITY VALVE . 96
LUBRICATING OIL RELIEF VALVE . 97
POWER TRAIN, LUBRICATION PUMP 98
STEERING, BRAKE CONTROL 100
FINAL DRIVE 103
STEERING UNIT 108
STEERING ECMV 120
STEERING CLUTCH ECMV, STEERING BRAKE ECMV 122
PARKING BRAKE VALVE 128
SUDDEN STOP PREVENTION VALVE . 130
SPROCKET . 132
TRACK FRAME 134
RECOIL SPRING 138
IDLER 140
TRACK ROLLER . 142
CARRIER ROLLER . 145
TRACK ROLLER BOGIE . 146
TRACK SHOE . 148
MAIN FRAME . 152
SUSPENSION . 155
WORK EQUIPMENT HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM . 158
PPC CONTROL PIPING DIAGRAM . 162
WORK EQUIPMENT CONTROL . 164
WORK EQUIPMENT PUMP 166
COOLING FAN PUMP . 183
COOLING FAN MOTOR 204
PPC VALVE 212
ELECTRIC LEVER (STEERING) 222
CONTROL VALVE 226
MAIN RELIEF VALVE 240
CLSS . 241
UNLOAD VALVE . 244
INTRODUCTION OF LS PRESSURE (LS SHUTTLE VALVE) . 245
LS BYPASS PLUG . 246
PRESSURE COMPENSATION VALVE 247
BLADE LIFT VALVE . 250
MERGE DIVIDER VALVE 258
SELF PRESSURE REDUCING VALVE . 260
PILOT SOLENOID VALVE . 264
HYDRAULIC TANK . 266
ACCUMULATOR 268
WORK EQUIPMENT CYLINDER 270
PISTON VALVE . 272
QUICK DROP VALVE . 273
BLADE CONTROL KNOB . 276
PITCH AND DUAL SOLENOID VALVE 278
PIN PULLER HYDRAULIC CIRCUIT DIAGRAM . 279
PIN PULLER SOLENOID VALVE 280
CYLINDER STAY 282
BLADE 284
RIPPER EQUIPMENT . 288
CAB MOUNT 292
CAB 293
AIR CONDITIONER 296
ENGINE CONTROL . 298
ENGINE CONTROL SYSTEM 299
DECELERATION POTENTIOMETER . 300
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER . 301
FULE INJECTION PUMP WITH ELECTRONIC GOVERNOR . 302
MONITOR SYSTEM . 303
MONITOR PANEL 305
SENSORS 313
MODE SELECTION SYSTEM 317
ELECTRICAL EQUIPMENT . 323
STEERING ELECTRONIC CONTROL SYSTEM . 326
VHMS CONTROLLER 328
SENSORS 331
COMMUNICATION (ORB: ORBCOMM) CONTROLLER/ANTENNA 334
20 TESTING AND ADJUSTING . 335
STANDARD VALUE TABLE FOR ENGINE 336
STANDARD VALUE TABLE FOR CHASSIS . 337
TESTING AND ADJUSTING 349
TESTING, ADJUSTING, AND TROUBLESHOOTING DEVICES TABLE . 351
MEASURING ENGINE SPEED . 353
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) . 356
MEASURING EXHAUST TEMPERATURE 357
MEASURING EXHAUST GAS COLOR 359
ADJUSTING VALVE CLEARANCE 360
MEASURING COMPRESSION PRESSURE . 361
MEASURING BLOW-BY PRESSURE . 362
MEASURING ENGINE OIL PRESSURE 363
TESTING AND ADJUSTING FUEL INJECTION TIMING . 364
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 366
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 367
ADJUSTING ENGINE SPEED SENSOR 367
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL 368
MEASURING POWER TRAIN OIL PRESSURE . 370
ADJUSTING TRANSMISSION SPEED SENSOR 378
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE . 379
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER 380
ADJUSTING PCCS LEVER CONSOLE POSITION 383
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE . 384
ADJUSTING CLEARANCE OF IDLER . 386
INSPECTING WEAR OF SPROCKET 386
TESTING AND ADJUSTING TRACK SHOE TENSION . 387
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE 388
TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE . 399
MEASURING PPC VALVE OUTPUT PRESSURE AND SOLENOID VALVE OUTPUT PRESSURE . 400
ADJUSTING PLAY OF PPC VALVE 407
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE 408
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER 409
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER 410
RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CIRCUIT 411
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER 411
ADJUSTING BLADE LEVER TILTING STROKE . 412
ADJUSTING RIPPER LEVER POSITION 413
ADJUSTING LOCK LEVER . 414
MEASURING FAN MOTOR SPEED 415
MEASURING FAN CIRCUIT OIL PRESSURE 416
BLEEDING AIR FROM FAN PUMP . 417
MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE (DUAL TILTDOZER SPECIFICATION) 418
MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE (SUPERDOZER SPECIFICATION) 420
TESTING AND ADJUSTING OPERATOR’S CAB . 422
ADJUSTING BLADE 426
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) . 428
ADJUSTING METHOD OF REPLACED CONTROLLER 491
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM . 493
HANDLING OF OPTIONAL DEVICES . 496
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER 497
PROCEDURES FOR EXECUTING QUICK PM 502
PRECAUTIONS FOR REPLACING VHMS CONTROLLER 512
PM CLINIC SERVICE 513
TROUBLESHOOTING 523
POINTS TO REMEMBER WHEN TROUBLESHOOTING . 524
SEQUENCE OF EVENTS IN TROUBLESHOOTING 525
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE . 526
CHECKS BEFORE TROUBLESHOOTING 534
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING . 535
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM 538
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . 576
T-BRANCH BOX AND T-BRANCH TABLE 600
TROUBLESHOOTING WHEN SERVICE CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE INDICATED . 603
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE . 609
ERROR CODE [1500L0] (TRANSMISSION CLUTCH: SEE THE LIST. (L0)) 611
ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST. (L1)) . 612
ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST. (LH)) . 613
ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST. (L1)) . 614
ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST. (LH)) . 615
ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST. (L1)) . 616
ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST. (LH)) . 617
ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST. (L1)) . 618
ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST. (LH)) . 619
ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST. (L1)) . 620
ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST. (LH)) . 621
ERROR CODE [1800MW] (POWER TRAIN CLUTCH: SLIP (MW)) 622
ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST. (L1)) . 623
ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST. (LH)) . 624
ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST. (L1)) 625
ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST. (LH)) 626
ERROR CODE [2300NR] (BRAKE THERMAL LOAD: ABNORMAL HEATING (NR)) 627
ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST. (L1)) 628
ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST. (LH)) 629
ERROR CODE [2301NR] (RIGHT STEERING BRAKE THERMAL LOAD: ABNORMAL HEATING (NR)) . 630
ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST. (L1)) . 631
ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST. (LH)) . 632
ERROR CODE [2302NR] (LEFT STEERING BRAKE THERMAL LOAD: ABNORMAL HEATING (NR)) 633
ERROR CODE [A000N1] (OR VHMS_LED IS DISPLAYED “n2″ →”01”) ENGINE OVERRUN . 633
ERROR CODE [A70XLK] (GOVERNOR SERVO SYSTEM RIGHT: *REFER TO TABLE (LK)) 634
ERROR CODE [A70YLK] (GOVERNOR SERVO SYSTEM LEFT: *REFER TO TABLE (LK)) . 635
ERROR CODE [AA1ANX] (AIR CLEANER: CLOGGING (NX)) . 636
ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA)) . 636
ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)) 637
ERROR CODE [B@BAZK] (ENGINE OIL: OIL LEVEL REDUCTION (ZK)) . 637
ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS)) 638
ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK)) . 638
ERROR CODE [B@CENS] (POWER TRAIN OIL: OVERHEAT (NS)) . 639
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS)) . 639
ERROR CODE [B@HAZK] (HYDRAULIC OIL: LEVEL REDUCTION (ZK)) 640
ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA)) 641
ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB)) 642
ERROR CODE [D130KA] (NEUTRAL SAFETY RELAY: DISCONNECTION (KA)) . 643
ERROR CODE [D130KB] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB)) . 645
ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA)) 646
ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB)) 648
ERROR CODE [D182KZ] (PREHEATER RELAY: LOWERING OF LEVEL (KZ)) 650
ERROR CODE [D1D0KA] (GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION (KA)) 652
ERROR CODE [D1D0KB] (GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT (KB)) 654
ERROR CODE [D1D1KA] (GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION (KA)) . 656
ERROR CODE [D1D1KB] (GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT (KB)) . 658
ERROR CODE [D5ZFKA] (NEUTRAL SIGNAL 1: DISCONNECTION (KA)) . 660
ERROR CODE [D5ZFKB] (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB)) . 661
ERROR CODE [D5ZFL4] (ENGINE CONTROLLER NEUTRAL SIGNAL: ON AND OFF SIGNAL DO NOT AGREE (L4)) 662
ERROR CODE [D5ZGKA] (NEUTRAL SIGNAL 2: DISCONNECTION (KA)) . 664
ERROR CODE [D5ZGKB] (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB)) . 665
ERROR CODE [D5ZKKX] (CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL RANGE (KX)) 666
ERROR CODE [D5ZRKA] (SNAP SHOT SWITCH: DISCONNECTION (KA)) . 667
ERROR CODE [D5ZRKB] (SNAP SHOT SWITCH: SHORT CIRCUIT (KB)) . 668
ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 670
ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) . 672
ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 673
ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) 674
ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) . 675
ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 676
ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR)) 678
ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR)) 680
ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) . 682
ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 683
ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) 684
ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) . 686
ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 687
ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR)) 688
ERROR CODE [DB3SKR] (STEERING CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR)) 690
ERROR CODE [DB40KK] (ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK)) . 692
ERROR CODE [DB41KK] (SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)) . 692
ERROR CODE [DB42KK] (SOLENOID POWER SUPPLY 1: LOWERING OF SOURCE VOLTAGE (KK)) . 694
ERROR CODE [DB43KK] (BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)) . 696
ERROR CODE [DB44KK] (SOLENOID POWER SUPPLY 2: LOWERING OF SOURCE VOLTAGE (KK)) . 698
ERROR CODE [DB45KP] (RACK SENSOR POWER SUPPLY: LOWERING OF OUTPUT VOLTAGE (KP)) 700
ERROR CODE [DB49KM] (WRONG CONNECTION OF CONNECTOR: MISTAKE IN OPERATION OR SETTING (KM)) 702
ERROR CODE [DB49KQ] (ENGINE CONTROLLER SPECIFICATION: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)) 703
ERROR CODE [DBB0KK] (OR LED OF VHMS CONTROLLER INDICATES “n9″”→01”) (VHMS CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK)) . 704
ERROR CODE [DBB0KQ] (OR LED OF VHMS CONTROLLER INDICATES “nF”→”11”) (CHECK OF VHMS CONTROLLER MODEL: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)) . 706
ERROR CODE [DBB3KK] (OR LED OF VHMS CONTROLLER INDICATES “n9″→”02”) (VHMS CONTROLLER: LOWERING OF BATTERY DIRECT SOURCE VOLTAGE (KK)) 707
ERROR CODE [DBB5KP] (OR LED OF VHMS CONTROLLER INDICATES “n9″→”04”) (SENSOR POWER SUPPLY (5V): LOWERING OF OUTPUT VOLTAGE (KP)) 708
ERROR CODE [DBB6KP] (OR LED OF VHMS CONTROLLER INDICATES “n9″→”02”) (SENSOR POWER SUPPLY (24V): LOWERING OF OUTPUT VOLTAGE (KP)) . 709
ERROR CODE [DBB7KP] (OR LED OF VHMS CONTROLLER INDICATES “n9″→”03”) (SENSOR POWER SUPPLY (12V): LOWERING OF OUTPUT VOLTAGE (KP)) . 710
ERROR CODE [DBBQKR] (OR LED OF VHMS CONTROLLER INDICATES “n8″→”02”) (VHMS KOM-NET: DEFECTIVE COMMUNICATION (KR)) . 712
ERROR CODE [DD12KA] (SHIFT UP SWITCH: DISCONNECTION (KA)) 714
ERROR CODE [DD12KB] (SHIFT UP SWITCH: SHORT CIRCUIT (KB)) 716
ERROR CODE [DD13KA] (SHIFT DOWN SWITCH: DISCONNECTION (KA)) 718
ERROR CODE [DD13KB] (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB)) 720
ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)) . 722
ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) . 724
ERROR CODE [DDN2LD] (BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM: REFER TO TABLE (LD)) . 726
ERROR CODE [DDN3LD] (BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM: REFER TO TABLE (LD)) 727
ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA)) . 728
ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB)) . 730
ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA)) 732
ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB)) 734
ERROR CODE [DDNALD] (BLADE LEFT RAISE FULL OIL PRESSURE SWITCH: REFER TO TABLE (LD)) . 736
ERROR CODE [DDNBLD] (RIPPER LEFT RAISE OIL PRESSURE SWITCH: REFER TO TABLE (LD)) . 737
ERROR CODE [DDNCLD] (RIPPER LEFT LOWER OIL PRESSURE SWITCH: REFER TO TABLE (LD)) . 738
ERROR CODE [DDNDLD] (RIPPER TILT IN OIL PRESSURE SWITCH: REFER TO TABLE (LD)) 739
ERROR CODE [DDNELD] (RIPPER TILT BACK OIL PRESSURE SWITCH: REFER TO TABLE (LD)) 740
ERROR CODE [DDNFLD] (BLADE LEFT LOWER FULL OIL PRESSURE SWITCH: REFER TO TABLE (LD)) . 741
ERROR CODE [DDQ2KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)) . 742
ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB)) . 744
ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4)) . 746
ERROR CODE [DGE1KB] (OR LED OF VHMS CONTROLLER INDICATES “n2″→”42”) (ENGINE OIL TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB)) (30 MINUTES AFTER ENGINE IS STARTED (ABOVE 500 RPM)) 747
ERROR CODE [DGE1KY] (OR LED OF VHMS CONTROLLER INDICATES “n2″→”41”) (ENGINE OIL TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KY)) . 748
ERROR CODE [DGE2KX] (COOLANT TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)) . 750
ERROR CODE [DGE3KA] (ENGINE COOLANT TEMPERATURE SENSOR GAUGE) (FOR LOW TEMPERATURE): DISCONNECTION(KA)) 752
ERROR CODE [DGE5KB] (OR LED OF VHMS CONTROLLER INDICATES “n4″→”01”) (ATMOSPHEREIC TEMPERATURE SENSOR SYSTEM: DISCONNECTION OR SHORT CIRCUIT (KY OR KB)) 753
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) . 754
ERROR CODE [DGT5KA] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”22”) (LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KA)) 756
ERROR CODE [DGT5KB] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”21”) (LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB)) 758
ERROR CODE [DGT6KA] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”12”) (RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KA)) . 760
ERROR CODE [DGT6KB] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”11”) (RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB)) . 762
ERROR CODE [DH22KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (F): DISCONNECTION (KA)) 764
ERROR CODE [DH22KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (F): SHORT CIRCUIT (KB)) 765
ERROR CODE [DH23KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (R): DISCONNECTION (KA)) 766
ERROR CODE [DH23KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (R): SHORT CIRCUIT (KB)) 767
ERROR CODE [DHE4KA] (ENGINE OIL PRESSURE SENSOR: DISCONNECTION (KA)) . 768
ERROR CODE [DHE4KB] (ENGINE OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) . 769
ERROR CODE [DHE5KB] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”32”) (ENGINE BLOW-BY PRESSURE SENSOR SYSTEM: DISCONNECTION (KB)) 770
ERROR CODE [DHE5KY] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”31”) (ENGINE BLOW-BY PRESSURE SENSOR SYSTEM: SHORT CIRCUIT WITH POWER SUPPLY LINE (KY)) . 771
ERROR CODE [DHT3KX] (OR LED OF VHMS CONTROLLER INDICATES “n6″→”14”) (TRANSMISSION OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE(KX)) . 772
ERROR CODE [DK01KA] (LEFT YOKE ANGEL SENSOR: DISCONNECTION (KA)) . 774
ERROR CODE [DK01KB] (LEFT YOKE ANGEL SENSOR: SHORT CIRCUIT (KB)) . 776
ERROR CODE [DK03KA] (RIGHT YOKE ANGEL SENSOR: DISCONNECTION (KA)) 777
ERROR CODE [DK03KB] (RIGHT YOKE ANGEL SENSOR: SHORT CIRCUIT (KB)) 779
ERROR CODE [DK10KX] (FUEL DIAL: OUT OF NORMAL RANGE (KX)) 780
ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER: OUT OF INPUT SIGNAL RANGE (KX)) 782
ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA)) . 784
ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)) . 785
ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) . 786
ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ)) 786
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8)) . 787
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA)) . 788
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB)) . 789
ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA)) 790
ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB)) 792
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 793
ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ)) . 793
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8)) 794
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA)) 795
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB)) 796
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA)) 797
ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB)) 798
ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA)) 799
ERROR CODE [DK60KB] (ACCELERATION SENSOR: SHORT CIRCUIT (KB)) 800
ERROR CODE [DKFOKX] (OR LED OF VHMS CONTROLLER INDICATES “n2″→”62”) (INJECTION PUMP RACK SENSOR: OUT OF INPUT SIGNAL RANGE (KX)) . 801
ERROR CODE [DKF1KX] (RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE (KX)) 802
ERROR CODE [DKF2KX] (RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE (KX)) . 804
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA)) . 806
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB)) . 807
ERROR CODE [DLE1KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA)) 808
ERROR CODE [DLE4LC] (ENGINE SPEED SENSOR A: *REFER TO TABLE (LC)) 810
ERROR CODE [DLE5LC] (ENGINE SPEED SENSOR B: *REFER TO TABLE (LC)) 812
ERROR CODE [DLF1KA] (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION (KA)) . 814
ERROR CODE [DLT3KA] (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION (KA)) . 815
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB)) . 816
ERROR CODE [DW55KA] (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA)) 817
ERROR CODE [DW55KB] (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB)) 818
ERROR CODE [DW56KA] (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA)) 819
ERROR CODE [DW56KB] (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB)) 820
ERROR CODE [DW57KA] (LEFT TILT LIMT SOLENOID: DISCONNECTION (KA)) 821
ERROR CODE [DW57KB] (LEFT TILT LIMT SOLENOID: SHORT CIRCUIT (KB)) 822
ERROR CODE [DW58KA] (RIGHT TILT LIMT SOLENOID: DISCONNECTION (KA)) . 823
ERROR CODE [DW58KB] (RIGHT TILT LIMT SOLENOID: SHORT CIRCUIT (KB)) . 824
ERROR CODE [DW59KA] (BLADE DUAL SELECTOR SOLENOID: DISCONNECTION (KA)) . 825
ERROR CODE [DW59KB] (BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT (KB)) . 826
ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA)) 827
ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB)) 828
ERROR CODE [DW5DKA] (BLADE PITCH DUMP SOLENOID (SUPERDOZER SPECIFICATION): DISCONNECTION (KA)) . 829
ERROR CODE [DW5DKB] (BLADE PITCH DUMP SOLENOID (SUPERDOZER SPECIFICATION): SHORT CIRCUIT (KB)) . 830
ERROR CODE [DW7BKA] (FAN REVERSE SOLENOID: DISCONNECTION (KA)) . 831
ERROR CODE [DW7BKB] (FAN REVERSE SOLENOID: SHORT CIRCUIT (KB)) . 832
ERROR CODE [DWJ0KA] (PUMP MERGE-DIVIDER SOLENOID: DISCONNECTION (KA)) 833
ERROR CODE [DWJ0KB] (PUMP MERGE-DIVIDER SOLENOID: SHORT CIRCUIT (KB)) 834
ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA)) 835
ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB)) 836
ERROR CODE [DWN5KA] (FAN PUMP SOLENOID 1: DISCONNECTION (KA)) 837
ERROR CODE [DWN5KB] (FAN PUMP SOLENOID 1: SHORT CIRCUIT (KB)) 838
ERROR CODE [DWNCKA] (FAN PUMP SOLENOID 2: DISCONNECTION (KA)) 839
ERROR CODE [DWNCKB] (FAN PUMP SOLENOID 2: SHORT CIRCUIT (KB)) 840
ERROR CODE [DXE0KA] (LS SET SOLENOID: DISCONNECTION (KA)) 841
ERROR CODE [DXE0KB] (LS SET SOLENOID: SHORT CIRCUIT (KB)) 842
ERROR CODE [DXH1KA] (LOCK-UP SOLENOID: DISCONNECTION (KA)) . 843
ERROR CODE [DXH1KB] (LOCK-UP SOLENOID: SHORT CIRCUIT (KB)) . 844
ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA)) 845
ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)) 846
ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA)) 847
ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB)) 848
ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA)) 849
ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB)) 850
ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA)) 851
ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB)) 852
ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA)) 853
ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB)) 854
ERROR CODE [DXH9KA] (RIGHT STEERING CLUTCH ECMV: DISCONNECTION (KA)) . 855
ERROR CODE [DXH9KB] (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) . 856
ERROR CODE [DXHAKA] (LEFT STEERING CLUTCH ECMV: DISCONNECTION (KA)) 857
ERROR CODE [DXHAKB] (LEFT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) 858
ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA)) . 859
ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB)) . 860
ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA)) 861
ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB)) 862
ERROR CODE [DXHDKA] (GOVERNOR SOLNOID RIGHT: DISCONNECTION (KA)) . 863
ERROR CODE [DXHDKB] (GOVERNOR SOLNOID RIGHT: SHORT CIRCUIT (KB)) . 866
ERROR CODE [DXHEKA] (GOVERNOR SOLNOID LEFT: DISCONNECTION (KA)) 867
ERROR CODE [DXHEKB] (GOVERNOR SOLNOID LEFT: SHORT CIRCUIT (KB)) 870
ERROR CODE [DXHFKA] (PRE-STROKE SOLENOID RIGHT: DISCONNECTION (KA)) 871
ERROR CODE [DXHFKB] (PRE-STORKE SOLENOID RIGHT: SHORT CIRCUIT (KB)) 872
ERROR CODE [DXHGKA] (PRE-STROKE SOLENOID LEFT: DISCONNECTION (KA)) . 873
ERROR CODE [DXHGKB] (PRE-STORKE SOLENOID LEFT: SHORT CIRCUIT (KB)) . 874
ERROR CODE [F@BBZL] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”38”) (ENGINE BLOW-BY PRESSURE: OVERPRESSURE (ZL)) . 875
ERROR CODE [F@BYNR] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”62”) (LEFT BANK EXHAUST TEMPERATURE (2): ABNORMAL HEATING (NR)) . 876
ERROR CODE [F@BYNS] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”61”) (LEFT BANK EXHAUST TEMPERATURE (1): OVERHEATING (NS)) 877
ERROR CODE [F@BZNR] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”72”) (RIGHT BANK EXHAUST TEMPERATURE (2): ABNORMAL HEATING (NR)) 878
ERROR CODE [F@BZNS] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”71”) (RIGHT BANK EXHAUST TEMPERATURE (1): OVERHEATING (NS)) . 879
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 881
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 882
E-1 THE ENGINE DOES NOT START 883
E-2 THE PREHEATER DOES NOT OPERATE. (MANUAL PREHEATING FUNCTION) . 886
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE 888
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON 889
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT 890
E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH . 891
E-7 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES 892
E-8 AN EMERGENCY CAUTION ITEM FLASHES WHILE ENGINE IS RUNNING 895
E-9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON . 901
E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE) 903
E-11 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON . 903
E-12 THE ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY . 904
E-13 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL . 905
E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 906
E-15 INDICATION OF THE FUEL GAUGE IS ABNORMAL 907
E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL . 908
E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL 908
E-18 THE SWITCH MODULE CANNOT BE OPERATED 909
E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT 910
E-20 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP 911
E-21 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED 912
E-22 THE AUTOMATIC PITCH BACK SYSTEM DOES NOT OPERATE (ONLY SUPERDOZER SPECIFICATION) 913
E-23 THE ALARM BUZZER CANNOT BE CANCELLED 914
E-24 THE OPERATOR MODE CANNOT BE OPERATED 915
E-25 THE SERVICE MODE CANNOT BE OPERATED . 916
E-26 THE BACK-UP ALARM DOES NOT SOUND 918
E-27 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON . 919
E-28 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM 924
E-29 ORBCOMM TERMINAL DOES NOT OPERATE NORMALLY (DATA ARE NOT TRANSMITTED) . 939
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) . 941
INFORMATION IN TROUBLESHOOTING TABLE . 942
H-1 NO FORCE (NO DRAWBAR PULL) . 943
H-2 NO TRAVEL (AT 2ND OR 3RD SPEED) 944
H-3 NO TRAVEL AT ALL GEAR SPEEDS . 945
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE 946
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING 947
H-6 STEERING IS NOT POSSIBLE . 948
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE 948
H-8 STEERING OVERRUN OCCURS 949
H-9 BRAKE DOES NOT WORK 949
H-10 TORQUE CONVERTER IS NOT LOCK-UP . 950
H-11 TORQUE CONVERTER OIL IS OVERHEATED 950
H-12 ALL WORK EQUIPMENT SPEEDS ARE SLOW 951
H-13 WORK EQUIPMENT DOES NOT MOVE 952
H-14 BLADE LIFT SPEED IS SLOW OR LACKS POWER . 952
H-15 BLADE TILT SPEED IS SLOW OR LACKS POWER . 953
H-16 RIPPER LIFT SPEED IS SLOW OR LACKS POWER 953
H-17 RIPPER TILT SPEED IS SLOW OR LACKS POWER 954
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT . 954
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT . 955
H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT 955
H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE) 956
H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE) 956
H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP 956
TROUBLESHOOTING OF ENGINE BODY (S MODE) 957
POINTS TO REMEMBER WHEN TROUBLESHOOTING 958
METHOD OF USING TROUBLESHOOTING CHARTS . 959
S-1 STARTING PERFORMANCE IS POOR (STARTING ALAWYS TAKES TIME) 962
S-2 ENGING DOES NOT START 963
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) . 966
S-4 ENGINE STOPS DURING OPERATIONS . 967
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 968
S-6 ENGINE LACKS OUTPUT (NO POWER) . 969
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) . 970
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 971
S-9 OIL BECOMES CONTAMINATED QUICKLY . 972
S-10 FUEL CONSUMPTION IS EXCESSIVE . 973
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN . 974
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 975
S-13 OIL LEVEL RISES . 976
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 977
S-15 ABNORMAL NOISE IS MADE 978
S-16 VIBRATION IS EXCESSIVE 979
30 DISASSEMBLY AND ASSEMBLY 981
METHOD OF USING MANUAL . 983
PRECAUTIONS WHEN CARRYING OUT OPERATION 985
SPECIAL TOOL LIST 987
SKETCHES OF SPECIAL TOOLS 997
REMOVAL AND INSTALLATION OF ENGINE OIL COOLER ASSEMBLY .1008
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 1008
REMOVAL AND INSTALLATION OF AFTER-COOLER CORE ASSEMBLY .1010
REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY .1012
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL 1013
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL .1014
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY .1016
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY .1020
REMOVAL AND INSTALLATION OF MAIN RADIATOR ASSEMBLY .1021
REMOVAL AND INSTALLATION OF SUB RADIATOR ASSEMBLY 1022
REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY 1024
REMOVAL AND INSTALLATION OF FAN MOTOR PUMP .1027
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY 1028
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY 1031
DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY 1032
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY 1034
REMOVAL AND INSTALLATION OF PTO, TORQUE CONVERTER ASSEMBLY .1041
DISCONNECTION AND CONNECTION OF PTO, TORQUE CONVERTER ASSEMBLY .1043
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY 1045
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY .1053
REMOVAL AND INSTALLATION OF TORQFLOW TRANSMISSION ASSEMBLY .1058
DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY .1059
DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY .1073
DISASSEMBLY AND ASSEMBLY OF STEERING CLUTCH, BRAKE ASSEMBLY 1086
DISASSEMBLY AND ASSEMBLY OF TRANSFER GEAR HOUSING ASSEMBLY .1093
REMOVAL AND INSTALLATION OF POWER TRAIN PUMP ASSEMBLY 1096
REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY .1096
REMOVAL AND INSTALLATION OF TORQUE CONVERTER OIL COOLER 1097
REMOVAL AND INSTALLATION OF TORQUE CONVERTER VALVE ASSEMBLY 1098
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER VALVE ASSEMBLY 1099
REMOVAL AND INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY 1103
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY (ECMV ASSEMBLY) 1104
REMOVAL AND INSTALLATION OF STEERING CONTROL VALVE ASSEMBLY 1107
DISASSEMBLY AND ASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY 1108
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY .1110
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY .1111
REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY .1143
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY .1145
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY .1148
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY .1169
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY 1171
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY 1174
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY 1176
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY 1176
REMOVAL AND INSTALLATION OF BOGIE ASSEMBLY .1179
DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY .1184
REMOVAL AND INSTALLATION OF NO.1 BOGIE ASSEMBLY 1186
EXPANSIO AND INSTALLATION OF TRACK SHOE ASSEMBLY .1195
OVERALL DISASSEMBLY AND OVERALL ASSEMBLY OF TRACK SHOE .1198
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS .1211
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK .1212
DISASSEMBLY AND ASSEMBLY OF MASTER LINK 1216
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY .1220
REMOVAL AND INSTALLATION OF EQUALIZER BAR 1222
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING 1225
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY 1228
REMOVAL AND INSTALLATION OF HYDRAULIC VALVE ASSEMBLY .1229
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE 1230
DISASSEMBLY AND ASSEMBLY OF MERGE DIVIDER VALVE AND SELF PRESSURE REDUCING VALVE ASSEMBLY 1234
REMOVAL AND INSTALLATION OF PPC RELIEF VALVE ASSEMBLY 1236
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1237
DISASSEMBLY AND ASSEMBLY OF RIPPER PIN PULLER CYLINDER ASSEMBLY 1243
REMOVE AND INSTALL BLADE LIFT CYLINDER ASSEMBLY 1246
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY .1258
DISASSEMBLY AND ASSEMBLY OF GIANT RIPPER ASSEMBLY 1260
REMOVAL AND INSTALLATION OF ROPS GUARD .1263
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY 1264
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY .1265
REMOVAL AND INSTALLATION OF CONTROLLER ASSEMBLY 1268
REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY .1269
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY 1270
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT .1272
REMOVAL AND INSTALLATION OF HOOD ASSEMBLY 1274
REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY .1275
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY .1276
90 OTHERS 1279
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1281
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/3) .1283
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (2/3) .1285
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (3/3) .1287
ELECTRICAL CIRCUIT DIAGRAM (1/8) .1289
ELECTRICAL CIRCUIT DIAGRAM (2/8) .1291
ELECTRICAL CIRCUIT DIAGRAM (3/8) .1293
ELECTRICAL CIRCUIT DIAGRAM (4/8) .1295
ELECTRICAL CIRCUIT DIAGRAM (5/8) .1297
ELECTRICAL CIRCUIT DIAGRAM (6/8) .1299
ELECTRICAL CIRCUIT DIAGRAM (7/8) .1301
ELECTRICAL CIRCUIT DIAGRAM (8/8) .1303
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE CAB .1305

DESCRIPTION:

Komatsu D475A-5 Bulldozer Shop Manual SEBM033717  – PDF DOWNLOAD

• MACHINE MODEL             SERIAL No.
  D475A-5                               20001 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.

G.B 26/12/24