Komatsu D475A-5 Serial 20001 and Up Shop Manual SEBM033701 PDF

Description

Komatsu D475A-5 Serial 20001 and Up Shop Manual SEBM033701 PDF

The Komatsu D475A-5 Serial 20001 and Up Shop Manual SEBM033701 PDF is a detailed technical reference for D475A-5 machines with serial number 20001 and up. This volume combines machine specifications, structure and function explanations, maintenance standards, testing and adjusting procedures, troubleshooting information, and hydraulic and electrical circuit diagrams. It covers the chassis and work-equipment systems in substantial depth, including the power train, steering and brakes, undercarriage, work equipment hydraulics, controls, cab systems, monitoring, and electronic control systems.

File Details

• Manual type: Shop Manual
• Brand / model: Komatsu D475A-5
• Serial coverage: 20001 and up
• Engine fitted: SDA12V140E-1
• Language: English
• Page count: 971 pages
• File format: PDF
• Document number: SEBM033701
• Publication marking: © 2003; Printed in Japan 11-03 (01)

The manual identifies the D475A-5 as mounting the SDA12V140E-1 engine and directs the reader to the separate 12V140-1 Series Engine Shop Manual for detailed engine information. Engine standard values, measurements, adjustments, and engine-body troubleshooting are nevertheless included in this D475A-5 volume where they relate to machine testing and diagnosis.

Machine Coverage and Technical Reference

This Komatsu D475A-5 shop manual covers the machine in Semi-U tiltdozer, Full-U tiltdozer, and Superdozer configurations shown in the specification section, together with ripper-related equipment described in the manual. General data includes specification drawings, machine dimensions, weights, travel performance, engine data, power-train construction, undercarriage details, work-equipment hydraulic data, blade and ripper specifications, component weight tables, and fuel, coolant, and lubricant information.

The specification pages identify the SDA12V140E-1 as a water-cooled V-type direct-injection engine with turbocharger and aftercooler. The manual also details the torque converter with lock-up clutch, planetary transmission with three forward and three reverse speeds, wet multiple-disc steering clutch and brake arrangements, final drives, suspension, rollers, track shoes, hydraulic pumps, control valves, cylinders, and related control systems. These reference sections are paired with maintenance-standard tables containing inspection dimensions, clearances, backlash values, wear criteria, repair limits, spring data, pressures, torque information, and other decision points used during service evaluation.

Chapters Covered

• 01 General
  • Specification drawings and dimensions
  • Specifications for Semi-U tiltdozer, Full-U tiltdozer, and Superdozer configurations
  • Weight tables for major machine components and work equipment
  • Fuel, coolant, lubricants, specified capacities, and refill capacities
  Complete PDF Bookmark Tree

  Complete Bookmarks

  The complete bookmarks in the “Komatsu D475A-5 Serial 20001 and Up Shop Manual SEBM033701 PDF” are as follows:

  +D475A-5.pdf

  +SAFETYp. 9

  SAFETY NOTICEp. 9

  00- 4p. 10

  00- 5p. 11

  +FOREWORDp. 11

  GENERALp. 11

  00- 12 STANDARD TIGHTENING TORQUEp. 18

  00- 16 CONVERSION TABLEp. 22

  SPECIFICATION DRAWINGSp. 30

  SPECIFICATIONSp. 31

  WEIGHT TABLEp. 40

  WEIGHT TABLEp. 40

  RADIATOR AND OIL COOLERp. 50

  ENGINE MOUNTp. 51

  POWER TRAINp. 52

  POWER TRAIN HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAMp. 54

  DAMPER AND UNIVERSAL JOINTp. 56

  POWER TRAIN UNITp. 58

  TORQUE CONVERTER AND PTOp. 60

  TORQUE CONVERTER VALVEp. 70

  TORQUE CONVERTER LOCK- UP CONTROL SYSTEMp. 80

  SCAVENGING PUMPp. 81

  TRANSMISSION CONTROLp. 82

  TRANSMISSION TRANSMISSION ECMVp. 96

  TRANSMISSION CLUTCH ECMVp. 98

  LUBRICATING OIL RELIEF VALVEp. 103

  POWER TRAIN, LUBRICATION PUMPp. 104

  FINAL DRIVEp. 109

  POWER TRAINp. 114

  STEERING ECMVp. 126

  STEERING CLUTCH ECMV, STEERING BRAKE ECMVp. 128

  PARKING BRAKE VALVEp. 134

  SUDDEN STOP PREVENTION VALVEp. 136

  SPROCKETp. 138

  TRACK FRAMEp. 140

  RECOIL SPRINGp. 142

  IDLER TRACK ROLLER CARRIER ROLLERp. 148

  TRACK ROLLER BOGIEp. 149

  TRACK SHOEp. 150

  MAIN FRAME SUSPENSION WORK EQUIPMENT HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAMp. 160

  PPC CONTROL PIPING DIAGRAMp. 164

  WORK EQUIPMENT CONTROLp. 166

  WORK EQUIPMENT PUMPp. 168

  COOLING FAN PUMPp. 185

  COOLING FAN MOTORp. 206

  PPC VALVEp. 212

  ELECTRIC LEVER ( STEERING)p. 222

  CONTROL VALVEp. 226

  MAIN RELIEF VALVEp. 240

  CLSSp. 241

  UNLOAD VALVEp. 244

  INTRODUCTION OF LS PRESSURE ( LS SHUTTLE VALVE)p. 245

  LS BYPASS PLUGp. 246

  PRESSURE COMPENSATION VALVEp. 247

  BLADE LIFT VALVEp. 250

  MERGE- DIVIDER VALVEp. 258

  SELF- REDUCING PRESSURE VALVEp. 260

  PILOT SOLENOID VALVEp. 264

  HYDRAULIC TANKp. 266

  ACCUMULATORp. 268

  WORK EQUIPMENT CYLINDERp. 270

  PISTON VALVEp. 272

  QUICK DROP VALVEp. 274

  BLADE CONTROL KNOBp. 276

  PITCH AND DUAL SOLENOID VALVEp. 278

  PIN- PULLER HYDRAULIC CIRCUIT DRAWINGp. 279

  PIN- PULLER SOLENOID VALVEp. 280

  CYLINDER STAYp. 282

  BLADEp. 284

  RIPPER EQUIPMENTp. 288

  CAB MOUNTp. 290

  CABp. 291

  AIR CONDITIONERp. 294

  ENGINE CONTROLp. 296

  ENGINE CONTROL SYSTEMp. 297

  DECELERATION POTENTIOMETERp. 298

  ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLERp. 299

  FUEL INJECTION PUMP WITH ELECTRONIC GOVERNORp. 300

  MONITOR SYSTEMp. 301

  MONITOR PANELp. 303

  SENSORSp. 307

  MODE SELECTION SYSTEMp. 311

  ELECTRICAL EQUIPMENTp. 317

  STEERING ELECTRONIC CONTROL SYSTEMp. 320

  VHMS CONTROLLER SENSORSp. 325

  COMMUNICATION ( ORB: ORBCOMM) CONTROLLER/ ANTENNAp. 328

  STANDARD VALUE TABLE FOR ENGINEp. 330

  STANDARD VALUE TABLE FOR CHASSISp. 331

  TESTING, ADJUSTING, AND TROUBLESHOOTING DEVICES TABLEp. 345

  MEASURING ENGINE SPEEDp. 347

  MEASURING INTAKE AIR PRESSURE ( BOOST PRESSURE)p. 350

  MEASURING EXHAUST TEMPERATUREp. 351

  MEASURING EXHAUST GAS COLORp. 353

  ADJUSTING VALVE CLEARANCEp. 354

  MEASURING COMPRESSION PRESSUREp. 355

  MEASURING BLOW- BY PRESSUREp. 356

  MEASURING ENGINE OIL PRESSUREp. 357

  TESTING AND ADJUSTING FUEL INJECTION TIMINGp. 358

  TESTING AND ADJUSTING ALTERNATOR BELT TENSIONp. 360

  TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSORp. 361

  ADJUSTING ENGINE SPEED SENSORp. 361

  ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDALp. 362

  MEASURING POWER TRAIN OIL PRESSUREp. 364

  ADJUSTING TRANSMISSION SPEED SENSORp. 372

  SIMPLE METHOD OF TESTING BRAKE PERFORMANCEp. 373

  ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVERp. 374

  ADJUSTING PCCS LEVER CONSOLE POSITIONp. 377

  EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLEp. 378

  ADJUSTING CLEARANCE OF IDLERp. 380

  INSPECTING WEAR OF SPROCKETp. 380

  TESTING AND ADJUSTING TRACK SHOE TENSIONp. 381

  TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSUREp. 382

  TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSUREp. 391

  MEASURING PPC VALVE OUTPUT PRESSURE AND SOLENOID VALVE OUTPUT PRESSUREp. 392

  ADJUSTING PLAY OF PPC VALVEp. 399

  MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVEp. 400

  TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPERp. 401

  MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDERp. 402

  RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDERp. 403

  BLEEDING AIR FROM WORK EQUIPMENT CYLINDERp. 403

  ADJUSTING BLADE LEVER TILTING STROKEp. 404

  ADJUSTING RIPPER LEVER POSITIONp. 405

  ADJUSTING SAFETY LOCK LEVERp. 406

  MEASURING FAN MOTOR SPEEDp. 407

  MEASURING FAN CIRCUIT OIL PRESSUREp. 408

  BLEEDING AIR FROM FAN PUMPp. 409

  MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE ( DUAL TILTDOZER SPECIFICATION)p. 410

  MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE ( SUPERDOZER SPECIFICATION)p. 412

  TESTING AND ADJUSTING OPERATOR'S CABp. 414

  ADJUSTING BLADEp. 418

  SPECIAL FUNCTIONS OF MONITOR PANEL ( EMMS)p. 420

  ADJUSTMENT METHOD OF REPLACED CONTROLLERp. 475

  PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEMp. 477

  HANDLING OF OPTIONAL DEVICESp. 480

  INITIALIZATION PROCEDURES FOR VHMS CONTROLLERp. 481

  PROCEDURES FOR EXECUTING QUICK PMp. 486

  PRECAUTIONS FOR REPLACING VHMS CONTROLLERp. 496

  POINTS TO REMEMBER WHEN TROUBLESHOOTINGp. 508

  SEQUENCE OF EVENTS IN TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCEp. 510

  CHECKS BEFORE TROUBLESHOOTINGp. 518

  CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTINGp. 519

  CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEMp. 522

  CONNECTION TABLE FOR CONNECTOR PIN NUMBERSp. 560

  T- BRANCH BOX AND T- BRANCH TABLEp. 582

  INFORMATION CONTAINED IN TROUBLESHOOTING TABLEp. 591

  SERVICE CODE LISTp. 585

  ERROR CODE [ 1500L0] ( TRANSMISSION CLUTCH: SEE THE LIST. ( L0))p. 593

  ERROR CODE [ 15SAL1] ( FORWARD CLUTCH: SEE THE LIST. ( L1))p. 594

  ERROR CODE [ 15SALH] ( FORWARD CLUTCH: SEE THE LIST. ( LH))p. 595

  ERROR CODE [ 15SBL1] ( REVERSE CLUTCH: SEE THE LIST. ( L1))p. 596

  ERROR CODE [ 15SBLH] ( REVERSE CLUTCH: SEE THE LIST. ( LH))p. 597

  ERROR CODE [ 15SEL1] ( 1ST CLUTCH: SEE THE LIST. ( L1))p. 598

  ERROR CODE [ 15SELH] ( 1ST CLUTCH: SEE THE LIST. ( LH))p. 599

  ERROR CODE [ 15SFL1] ( 2ND CLUTCH: SEE THE LIST. ( L1))p. 600

  ERROR CODE [ 15SFLH] ( 2ND CLUTCH: SEE THE LIST. ( LH))p. 601

  ERROR CODE [ 15SGL1] ( 3RD CLUTCH: SEE THE LIST. ( L1))p. 602

  ERROR CODE [ 15SGLH] ( 3RD CLUTCH: SEE THE LIST. ( LH))p. 603

  ERROR CODE [ 1800MW] ( POWER TRAIN CLUTCH: SLIP ( MW))p. 604

  ERROR CODE [ 2201L1] ( RIGHT CLUTCH: SEE THE LIST. ( L1))p. 605

  ERROR CODE [ 2201LH] ( RIGHT CLUTCH: SEE THE LIST. ( LH))p. 606

  ERROR CODE [ 2202L1] ( LEFT CLUTCH: SEE THE LIST. ( L1))p. 607

  ERROR CODE [ 2202LH] ( LEFT CLUTCH: SEE THE LIST. ( LH))p. 608

  ERROR CODE [ 2300NR] ( BRAKE THERMAL LOAD: ABNORMAL HEATING ( NR))p. 609

  ERROR CODE [ 2301L1] ( RIGHT BRAKE: SEE THE LIST. ( L1))p. 610

  ERROR CODE [ 2301LH] ( RIGHT BRAKE: SEE THE LIST. ( LH))p. 611

  ERROR CODE [ 2301NR] ( RIGHT STEERING BRAKE THERMAL LOAD: ABNORMAL HEATING ( NR))p. 612

  ERROR CODE [ 2302L1] ( LEFT BRAKE: SEE THE LIST. ( L1))p. 613

  ERROR CODE [ 2302LH] ( LEFT BRAKE: SEE THE LIST. ( LH))p. 614

  ERROR CODE [ 2302NR] ( LEFT STEERING BRAKE THERMAL LOAD: ABNORMAL HEATING ( NR)) ERROR CODE [ A000N1] ( or VHMS_ LED IS DISPLAYED " n2"p. 615

  01") ENGINE OVERRUNp. 615

  ERROR CODE [ A70XLK] ( GOVERNOR SERVO SYSTEM RIGHT: * REFER TO TABLE ( LK))p. 616

  ERROR CODE [ A70YLK] ( GOVERNOR SERVO SYSTEM LEFT: * REFER TO TABLE ( LK))p. 617

  ERROR CODE [ AA1ANX] ( AIR CLEANER: CLOGGING ( NX)) ERROR CODE [ AB00MA] ( ALTERNATOR: MALFUNCTION ( MA))p. 618

  ERROR CODE [ B@ BAZG] ( ENGINE OIL: OIL PRESSURE REDUCTION ( ZG)) ERROR CODE [ B@ BAZK] ( ENGINE OIL: OIL LEVEL REDUCTION ( ZK))p. 619

  ERROR CODE [ B@ BCNS] ( RADIATOR COOLANT: OVERHEAT ( NS)) ERROR CODE [ B@ BCZK] ( RADIATOR COOLANT: LEVEL REDUCTION ( ZK))p. 620

  ERROR CODE [ B@ CENS] ( POWER TRAIN OIL: OVERHEAT ( NS)) ERROR CODE [ B@ HANS] ( HYDRAULIC OIL: OVERHEAT ( NS))p. 621

  ERROR CODE [ B@ HAZK] ( HYDRAULIC OIL: LEVEL REDUCTION ( ZK))p. 622

  ERROR CODE [ D110KA] ( BATTERY RELAY: DISCONNECTION ( KA))p. 623

  ERROR CODE [ D110KB] ( BATTERY RELAY: SHORT CIRCUIT ( KB))p. 624

  ERROR CODE [ D130KA] ( NEUTRAL SAFETY RELAY: DISCONNECTION ( KA))p. 625

  ERROR CODE [ D130KB] ( NEUTRAL SAFETY RELAY: SHORT CIRCUIT ( KB))p. 627

  ERROR CODE [ D161KA] ( BACK- UP ALARM RELAY: DISCONNECTION ( KA))p. 628

  ERROR CODE [ D161KB] ( BACK- UP ALARM RELAY: SHORT CIRCUIT ( KB))p. 630

  ERROR CODE [ D182KZ] ( PREHEATER RELAY: LOWERING OF LEVEL ( KZ))p. 632

  ERROR CODE [ D1D0KA] ( GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION ( KA))p. 634

  ERROR CODE [ D1D0KB] ( GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT ( KB))p. 636

  ERROR CODE [ D1D1KA] ( GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION ( KA))p. 638

  ERROR CODE [ D1D1KB] ( GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT ( KB))p. 640

  ERROR CODE [ D5ZFKA] ( NEUTRAL SIGNAL 1: DISCONNECTION ( KA))p. 642

  ERROR CODE [ D5ZFKB] ( NEUTRAL SIGNAL 1: SHORT CIRCUIT ( KB))p. 643

  ERROR CODE [ D5ZFL4] ( ENGINE CONTROLLER NEUTRAL SIGNAL: ON AND OFF SIGNALS DO NOT AGREE ( L4))p. 644

  ERROR CODE [ D5ZGKA] ( NEUTRAL SIGNAL 2: DISCONNECTION ( KA))p. 646

  ERROR CODE [ D5ZGKB] ( NEUTRAL SIGNAL 2: SHORT CIRCUIT ( KB))p. 647

  ERROR CODE [ D5ZKKX] ( CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL RANGE ( KX))p. 648

  ERROR CODE [ D5ZRKA] ( SNAP SHOT SWITCH: DISCONNECTION ( KA))p. 649

  ERROR CODE [ D5ZRKB] ( SNAP SHOT SWITCH: SHORT CIRCUIT ( KB))p. 650

  ERROR CODE [ DAFRKR] ( MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION ( KR))p. 652

  ERROR CODE [ DAQ0KK] ( TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION ( INPUT) ( KK))p. 654

  ERROR CODE [ DAQ0KT] ( TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER ( KT))p. 655

  ERROR CODE [ DAQ5KK] ( TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION ( INPUT) ( KK))p. 656

  ERROR CODE [ DAQ6KK] ( TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION ( INPUT) ( KK))p. 657

  ERROR CODE [ DAQ9KQ] ( TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY ( KQ))p. 658

  ERROR CODE [ DAQRKR] ( TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION ( ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) ( KR))p. 660

  ERROR CODE [ DAQSKR] ( TRANSMISSION CONTROLLER S- NET COMMUNICATION: DEFECTIVE COMMUNICATION ( ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) ( KR))p. 662

  ERROR CODE [ DB30KK] ( STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION ( INPUT) ( KK))p. 664

  ERROR CODE [ DB30KT] ( STEERING CONTROLLER: ABNORMALITY IN CONTROLLER ( KT))p. 665

  ERROR CODE [ DB35KK] ( STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION ( INPUT) ( KK))p. 666

  ERROR CODE [ DB36KK] ( STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION ( INPUT) ( KK))p. 668

  ERROR CODE [ DB39KQ] ( STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY ( KQ))p. 669

  ERROR CODE [ DB3RKR] ( STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION ( ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) ( KR))p. 670

  ERROR CODE [ DB3SKR] ( STEERING CONTROLLER S- NET COMMUNICATION: DEFECTIVE COMMUNICATION ( ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) ( KR))p. 672

  ERROR CODE [ DB40KK] ( ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE ( KK)) ERROR CODE [ DB41KK] ( SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLTAGE ( KK))p. 674

  ERROR CODE [ DB42KK] ( SOLENOID POWER SUPPLY 1: LOWERING OF SOURCE VOLTAGE ( KK))p. 676

  ERROR CODE [ DB43KK] ( BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLTAGE ( KK))p. 678

  ERROR CODE [ DB44KK] ( SOLENOID POWER SUPPLY 2: LOWERING OF SOURCE VOLTAGE ( KK))p. 680

  ERROR CODE [ DB45KP] ( RACK SENSOR POWER SUPPLY: LOWERING OF OUTPUT VOLTAGE ( KP))p. 682

  ERROR CODE [ DB49KM] ( WRONG CONNECTION OF CONNECTOR: MISTAKE IN OPERATION OR SETTING ( KM))p. 684

  ERROR CODE [ DB49KQ] ( ENGINE CONTROLLER SPECIFICATION: DISAGREEMENT OF MODEL SELECTION SIGNALS ( KQ))p. 685

  ERROR CODE [ DBB0KK] ( OR LED OF VHMS CONTROLLER INDICATES " n9"p. 686

  " 01") ( VHMS CONTROLLER: LOWERING OF SOURCE VOLTAGE ( KK))p. 686

  ERROR CODE [ DBB0KQ] ( OR LED OF VHMS CONTROLLER INDICATES " nF"p. 688

  " 11") ( CHECK OF VHMS CONTROLLER MODEL: DISAGREEMENT OF MODEL SELECTION SIGNALS ( KQ))p. 688

  ERROR CODE [ DBB3KK] ( OR LED OF VHMS CONTROLLER INDICATES " n9"p. 689

  " 02") ( VHMS CONTROLLER: LOWERING OF BATTERY DIRECT SOURCE VOLTAGE ( KK))p. 689

  ERROR CODE [ DBB5KP] ( OR LED OF VHMS CONTROLLER INDICATES " n9"p. 690

  " 04") ( SENSOR POWER SUPPLY ( 5 V): LOWERING OF OUTPUT VOLTAGE ( KP))p. 690

  ERROR CODE [ DBB6KP] ( OR LED OF VHMS CONTROLLER INDICATES " n9"p. 691

  " 02") ( SENSOR POWER SUPPLY ( 24 V): LOWERING OF OUTPUT VOLTAGE ( KP))p. 691

  ERROR CODE [ DBB7KP] ( OR LED OF VHMS CONTROLLER INDICATES " n9"p. 692

  " 03") ( SENSOR POWER SUPPLY ( 12 V): LOWERING OF OUTPUT VOLTAGE ( KP))p. 692

  ERROR CODE [ DBBQKR] ( OR LED OF VHMS CONTROLLER INDICATES " n8"p. 694

  " 02") ( VHMS KOM- NET: DEFECTIVE COMMUNICATION ( KR))p. 694

  ERROR CODE [ DD12KA] ( SHIFT UP SWITCH: DISCONNECTION ( KA))p. 696

  ERROR CODE [ DD12KB] ( SHIFT UP SWITCH: SHORT CIRCUIT ( KB))p. 698

  ERROR CODE [ DD13KA] ( SHIFT DOWN SWITCH: DISCONNECTION ( KA))p. 700

  ERROR CODE [ DD13KB] ( SHIFT DOWN SWITCH: SHORT CIRCUIT ( KB))p. 702

  ERROR CODE [ DD14KA] ( PARKING LEVER SWITCH: DISCONNECTION ( KA))p. 704

  ERROR CODE [ DD14KB] ( PARKING LEVER SWITCH: SHORT CIRCUIT ( KB))p. 706

  ERROR CODE [ DDN2LD] ( BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM: REFER TO TABLE ( LD))p. 708

  ERROR CODE [ DDN3LD] ( BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM: REFER TO TABLE ( LD))p. 709

  ERROR CODE [ DDN7KA] ( BLADE PITCH SWITCH: DISCONNECTION ( KA))p. 710

  ERROR CODE [ DDN7KB] ( BLADE PITCH SWITCH: SHORT CIRCUIT ( KB))p. 712

  ERROR CODE [ DDN9KA] ( BLADE TILT SWITCH: DISCONNECTION ( KA))p. 714

  ERROR CODE [ DDN9KB] ( BLADE TILT SWITCH: SHORT CIRCUIT ( KB))p. 716

  ERROR CODE [ DDNALD] ( BLADE LIFT RAISE FULL OIL PRESSURE SWITCH: REFER TO TABLE ( LD))p. 718

  ERROR CODE [ DDNBLD] ( RIPPER LIFT RAISE OIL PRESSURE SWITCH: REFER TO TABLE ( LD))p. 719

  ERROR CODE [ DDNCLD] ( RIPPER LIFT LOWER OIL PRESSURE SWITCH: REFER TO TABLE ( LD))p. 720

  ERROR CODE [ DDNDLD] ( RIPPER TILT IN OIL PRESSURE SWITCH: REFER TO TABLE ( LD))p. 721

  ERROR CODE [ DDNELD] ( RIPPER TILT BACK OIL PRESSURE SWITCH: REFER TO TABLE ( LD))p. 722

  ERROR CODE [ DDNFLD] ( BLADE LIFT LOWER FULL OIL PRESSURE SWITCH: REFER TO TABLE ( LD))p. 723

  ERROR CODE [ DDQ2KA] ( PARKING LEVER SWITCH: DISCONNECTION ( KA))p. 724

  ERROR CODE [ DDQ2KB] ( PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT ( KB))p. 726

  ERROR CODE [ DDQ2L4] ( PARKING BRAKE LEVER SWITCH: SEE TABLE ( L4))p. 728

  ERROR CODE [ DGE1KB] ( OR LED OF VHMS CONTROLLER INDICATES " n2"p. 729

  " 42") ( ENGINE OIL TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT ( KB)) ( 30 MINUTES AFTER ENGINE IS STARTED ( ABOVE 500 RPM))p. 729

  ERROR CODE [ DGE1KY] ( OR LED OF VHMS CONTROLLER INDICATES " n2"p. 730

  " 41") ( ENGINE OIL TEMPERATURE SENSOR SYSTEM: DISCONNECTION ( KY))p. 730

  ERROR CODE [ DGE2KX] ( COOLANT TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE ( KX))p. 732

  ERROR CODE [ DGE3KA] ( ENGINE COOLANT TEMPERATURE SENSOR GAUGE) ( FOR LOW TEMPERATURE): DISCONNECTION ( KA))p. 734

  ERROR CODE [ DGE5KB] ( OR LED OF VHMS CONTROLLER INDICATES " n4"p. 735

  " 01") ( ATMOSPHEREIC TEMPERATURE SENSOR SYSTEM: DISCONNECTION OR SHORT CIRCUIT ( KY OR KB))p. 735

  ERROR CODE [ DGS1KX] ( HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE ( KX))p. 736

  ERROR CODE [ DGT5KA] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 738

  " 22") ( LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION ( KA))p. 738

  ERROR CODE [ DGT5KB] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 740

  " 21") ( LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT ( KB))p. 740

  ERROR CODE [ DGT6KA] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 742

  " 12") ( RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION ( KA))p. 742

  ERROR CODE [ DGT6KB] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 744

  " 11") ( RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT ( KB))p. 744

  ERROR CODE [ DH22KA] ( WORK EQUIPMENT PUMP OIL PRESSURE SENSOR ( F): DISCONNECTION ( KA))p. 746

  ERROR CODE [ DH22KB] ( WORK EQUIPMENT PUMP OIL PRESSURE SENSOR ( F): SHORT CIRCUIT ( KB))p. 747

  ERROR CODE [ DH23KA] ( WORK EQUIPMENT PUMP OIL PRESSURE SENSOR ( R): DISCONNECTION ( KA))p. 748

  ERROR CODE [ DH23KB] ( WORK EQUIPMENT PUMP OIL PRESSURE SENSOR ( R): SHORT CIRCUIT ( KB))p. 749

  ERROR CODE [ DHE4KA] ( ENGINE OIL PRESSURE SENSOR: DISCONNECTION ( KA))p. 750

  ERROR CODE [ DHE4KB] ( ENGINE OIL PRESSURE SENSOR: SHORT CIRCUIT ( KB))p. 751

  ERROR CODE [ DHE5KB] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 752

  32") ( ENGINE BLOW- BY PRESSURE SENSOR SYSTEM: DISCONNECTION ( KB))p. 752

  ERROR CODE [ DHE5KY] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 753

  31") ( ENGINE BLOW- BY PRESSURE SENSOR SYSTEM: SHORT CIRCUIT WITH POWER SUPPLY LINE ( KY))p. 753

  ERROR CODE [ DHT3KX] ( OR LED OF VHMS CONTROLLER INDICATES " n6"p. 754

  " 14") ( TRANSMISSION OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE ( KX))p. 754

  ERROR CODE [ DK01KA] ( LEFT YOKE ANGLE SENSOR: DISCONNECTION ( KA))p. 756

  ERROR CODE [ DK01KB] ( LEFT YOKE ANGLE SENSOR: SHORT CIRCUIT ( KB))p. 758

  ERROR CODE [ DK03KA] ( RIGHT YOKE ANGLE SENSOR: DISCONNECTION ( KA))p. 759

  ERROR CODE [ DK03KB] ( RIGHT YOKE ANGLE SENSOR: SHORT CIRCUIT ( KB))p. 761

  ERROR CODE [ DK10KX] ( FUEL DIAL: OUT OF INPUT SIGNAL RANGE ( KX))p. 762

  ERROR CODE [ DK12KX] ( DECELERATOR POTENTIOMETER: OUT OF INPUT SIGNAL RANGE ( KX))p. 764

  ERROR CODE [ DK30KA] ( STEERING POTENTIOMETER 1: DISCONNECTION ( KA))p. 766

  ERROR CODE [ DK30KB] ( STEERING POTENTIOMETER 1: SHORT CIRCUIT ( KB))p. 767

  ERROR CODE [ DK30KX] ( STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE ( KX)) ERROR CODE [ DK30KZ] ( STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT ( KZ))p. 768

  ERROR CODE [ DK30L8] ( STEERING POTENTIOMETER 1: SEE TABLE ( L8))p. 769

  ERROR CODE [ DK31KA] ( STEERING POTENTIOMETER 2: DISCONNECTION ( KA))p. 770

  ERROR CODE [ DK31KB] ( STEERING POTENTIOMETER 2: SHORT CIRCUIT ( KB))p. 771

  ERROR CODE [ DK40KA] ( BRAKE POTENTIOMETER: DISCONNECTION ( KA))p. 772

  ERROR CODE [ DK40KB] ( BRAKE POTENTIOMETER: SHORT CIRCUIT ( KB))p. 774

  ERROR CODE [ DK55KX] ( FORWARD- REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE ( KX)) ERROR CODE [ DK55KZ] ( FORWARD- REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT ( KZ))p. 775

  ERROR CODE [ DK55L8] ( FORWARD- REVERSE POTENTIOMETER: SEE TABLE ( L8))p. 776

  ERROR CODE [ DK56KA] ( FORWARD- REVERSE POTENTIOMETER 1: DISCONNECTION ( KA))p. 777

  ERROR CODE [ DK56KB] ( FORWARD- REVERSE POTENTIOMETER 1: SHORT CIRCUIT ( KB))p. 778

  ERROR CODE [ DK57KA] ( FORWARD- REVERSE POTENTIOMETER 2: DISCONNECTION ( KA))p. 779

  ERROR CODE [ DK57KB] ( FORWARD- REVERSE POTENTIOMETER 2: SHORT CIRCUIT ( KB))p. 780

  ERROR CODE [ DK60KA] ( ACCELERATION SENSOR: DISCONNECTION ( KA))p. 781

  ERROR CODE [ DK60KB] ( ACCELERATION SENSOR: SHORT CIRCUIT ( KB))p. 782

  ERROR CODE [ DKF0KX] ( OR LED OF VHMS CONTROLLER INDICATES " n2"p. 783

  " 62") ( INJECTION PUMP RACK SENSOR: OUT OF INPUT SIGNAL RANGE ( KX))p. 783

  ERROR CODE [ DKF1KX] ( RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE ( KX))p. 784

  ERROR CODE [ DKF2KX] ( RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE ( KX))p. 786

  ERROR CODE [ DKH1KA] ( PITCH ANGLE SENSOR: DISCONNECTION ( KA))p. 788

  ERROR CODE [ DKH1KB] ( PITCH ANGLE SENSOR: SHORT CIRCUIT ( KB))p. 789

  ERROR CODE [ DLE1KA] ( ENGINE SPEED SENSOR: DISCONNECTION ( KA))p. 790

  ERROR CODE [ DLE4LC] ( ENGINE SPEED SENSOR A: * REFER TO TABLE ( LC))p. 792

  ERROR CODE [ DLE5LC] ( ENGINE SPEED SENSOR B: * REFER TO TABLE ( LC))p. 794

  ERROR CODE [ DLF1KA] ( TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION ( KA))p. 796

  ERROR CODE [ DLT3KA] ( TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION ( KA))p. 797

  ERROR CODE [ DV00KB] ( CAUTION BUZZER: SHORT CIRCUIT ( KB))p. 798

  ERROR CODE [ DW55KA] ( BLADE PITCH BACK SOLENOID: DISCONNECTION ( KA))p. 799

  ERROR CODE [ DW55KB] ( BLADE PITCH BACK SOLENOID: SHORT CIRCUIT ( KB))p. 800

  ERROR CODE [ DW56KA] ( BLADE PITCH DUMP SOLENOID: DISCONNECTION ( KA))p. 801

  ERROR CODE [ DW56KB] ( BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT ( KB))p. 802

  ERROR CODE [ DW57KA] ( LEFT TILT LIMIT SOLENOID: DISCONNECTION ( KA))p. 803

  ERROR CODE [ DW57KB] ( LEFT TILT LIMIT SOLENOID: SHORT CIRCUIT ( KB))p. 804

  ERROR CODE [ DW58KA] ( RIGHT TILT LIMIT SOLENOID: DISCONNECTION ( KA))p. 805

  ERROR CODE [ DW58KB] ( RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT ( KB))p. 806

  ERROR CODE [ DW59KA] ( BLADE DUAL SELECTOR SOLENOID: DISCONNECTION ( KA))p. 807

  ERROR CODE [ DW59KB] ( BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT ( KB))p. 808

  ERROR CODE [ DW5AKA] ( BLADE PITCH SELECTOR SOLENOID: DISCONNECTION ( KA))p. 809

  ERROR CODE [ DW5AKB] ( BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT ( KB))p. 810

  ERROR CODE [ DW5DKA] ( BLADE PITCH DUMP SOLENOID ( SUPERDOZER SPECIFICATION): DISCONNECTION ( KA))p. 811

  ERROR CODE [ DW5DKB] ( BLADE PITCH DUMP SOLENOID ( SUPERDOZER SPECIFICATION): SHORT CIRCUIT ( KB))p. 812

  ERROR CODE [ DW7BKA] ( FAN REVERSE SOLENOID: DISCONNECTION ( KA))p. 813

  ERROR CODE [ DW7BKB] ( FAN REVERSE SOLENOID: SHORT CIRCUIT ( KB))p. 814

  ERROR CODE [ DWJ0KA] ( PUMP MERGE- DIVIDER SOLENOID: DISCONNECTION ( KA))p. 815

  ERROR CODE [ DWJ0KB] ( PUMP MERGE- DIVIDER SOLENOID: SHORT CIRCUIT ( KB))p. 816

  ERROR CODE [ DWN3KA] ( SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION ( KA))p. 817

  ERROR CODE [ DWN3KB] ( SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT ( KB))p. 818

  ERROR CODE [ DWN5KA] ( FAN PUMP SOLENOID 1: DISCONNECTION ( KA))p. 819

  ERROR CODE [ DWN5KB] ( FAN PUMP SOLENOID 1: SHORT CIRCUIT ( KB))p. 820

  ERROR CODE [ DWNCKA] ( FAN PUMP SOLENOID 2: DISCONNECTION ( KA))p. 821

  ERROR CODE [ DWNCKB] ( FAN PUMP SOLENOID 2: SHORT CIRCUIT ( KB))p. 822

  ERROR CODE [ DXE0KA] ( LS SET SOLENOID: DISCONNECTION ( KA))p. 823

  ERROR CODE [ DXE0KB] ( LS SET SOLENOID: SHORT CIRCUIT ( KB))p. 824

  ERROR CODE [ DXH1KA] ( LOCK- UP SOLENOID: DISCONNECTION ( KA))p. 825

  ERROR CODE [ DXH1KB] ( LOCK- UP SOLENOID: SHORT CIRCUIT ( KB))p. 826

  ERROR CODE [ DXH4KA] ( 1ST CLUTCH ECMV: DISCONNECTION ( KA))p. 827

  ERROR CODE [ DXH4KB] ( 1ST CLUTCH ECMV: SHORT CIRCUIT ( KB))p. 828

  ERROR CODE [ DXH5KA] ( 2ND CLUTCH ECMV: DISCONNECTION ( KA))p. 829

  ERROR CODE [ DXH5KB] ( 2ND CLUTCH ECMV: SHORT CIRCUIT ( KB))p. 830

  ERROR CODE [ DXH6KA] ( 3RD CLUTCH ECMV: DISCONNECTION ( KA))p. 831

  ERROR CODE [ DXH6KB] ( 3RD CLUTCH ECMV: SHORT CIRCUIT ( KB))p. 832

  ERROR CODE [ DXH7KA] ( REVERSE CLUTCH ECMV: DISCONNECTION ( KA))p. 833

  ERROR CODE [ DXH7KB] ( REVERSE CLUTCH ECMV: SHORT CIRCUIT ( KB))p. 834

  ERROR CODE [ DXH8KA] ( FORWARD CLUTCH ECMV: DISCONNECTION ( KA))p. 835

  ERROR CODE [ DXH8KB] ( FORWARD CLUTCH ECMV: SHORT CIRCUIT ( KB))p. 836

  ERROR CODE [ DXH9KA] ( RIGHT STEERING CLUTCH ECMV: DISCONNECTION ( KA))p. 837

  ERROR CODE [ DXH9KB] ( RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT ( KB))p. 838

  ERROR CODE [ DXHAKA] ( LEFT STEERING CLUTCH ECMV: DISCONNECTION ( KA))p. 839

  ERROR CODE [ DXHAKB] ( LEFT STEERING CLUTCH ECMV: SHORT CIRCUIT ( KB))p. 840

  ERROR CODE [ DXHBKA] ( RIGHT BRAKE ECMV: DISCONNECTION ( KA))p. 841

  ERROR CODE [ DXHBKB] ( RIGHT BRAKE ECMV: SHORT CIRCUIT ( KB))p. 842

  ERROR CODE [ DXHCKA] ( LEFT BRAKE ECMV: DISCONNECTION ( KA))p. 843

  ERROR CODE [ DXHCKB] ( LEFT BRAKE ECMV: SHORT CIRCUIT ( KB))p. 844

  ERROR CODE [ DXHDKA] ( GOVERNOR SOLNOID RIGHT: DISCONNECTION ( KA))p. 845

  ERROR CODE [ DXHDKB] ( GOVERNOR SOLNOID RIGHT: SHORT CIRCUIT ( KB))p. 846

  ERROR CODE [ DXHEKA] ( GOVERNOR SOLNOID LEFT: DISCONNECTION ( KA))p. 847

  ERROR CODE [ DXHEKB] ( GOVERNOR SOLNOID LEFT: SHORT CIRCUIT ( KB))p. 848

  ERROR CODE [ DXHFKA] ( PRE- STROKE SOLENOID RIGHT: DISCONNECTION ( KA))p. 849

  ERROR CODE [ DXHFKB] ( PRE- STROKE SOLENOID RIGHT: SHORT CIRCUIT ( KB))p. 850

  ERROR CODE [ DXHGKA] ( PRE- STROKE SOLENOID LEFT: DISCONNECTION ( KA))p. 851

  ERROR CODE [ DXHGKB] ( PRE- STROKE SOLENOID LEFT: SHORT CIRCUIT ( KB))p. 852

  ERROR CODE [ F@ BBZL] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 853

  " 38") ( ENGINE BLOW- BY PRESSURE: OVERPRESSURE ( ZL))p. 853

  ERROR CODE [ F@ BYNR] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 854

  " 62") ( LEFT BANK EXHAUST TEMPERATURE ( 2): ABNORMAL HEATING ( NR))p. 854

  ERROR CODE [ F@ BYNS] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 855

  " 61") ( LEFT BANK EXHAUST TEMPERATURE ( 1): OVERHEATING ( NS))p. 855

  ERROR CODE [ F@ BZNR] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 856

  " 72") ( RIGHT BANK EXHAUST TEMPERATURE ( 2): ABNORMAL HEATING ( NR))p. 856

  ERROR CODE [ F@ BZNS] ( OR LED OF VHMS CONTROLLER INDICATES " n3"p. 857

  " 71") ( RIGHT BANK EXHAUST TEMPERATURE ( 1): OVERHEATING ( NS))p. 857

  INFORMATION DESCRIBED IN TROUBLESHOOTING LISTp. 860

  E- 1 THE ENGINE DOES NOT START.p. 861

  E- 2 THE PREHEATER DOES NOT OPERATE. ( MANUAL PREHEATING FUNCTION)p. 864

  E- 3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE.p. 866

  E- 4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON.p. 867

  E- 5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.p. 868

  E- 6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH.p. 869

  E- 7 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES.p. 870

  E- 8 AN EMERGENCY CAUTION ITEM FLASHES WHILE THE ENGINE IS RUNNING.p. 873

  E- 9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON.p. 877

  E- 10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/ SINGLE TILT SELECTOR LAMP DOES NOT COME ON. ( DUAL TILT- MOUNTED MACHINE) E- 11 AT THE LOCKING- UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK- UP DISPLAY LAMP DOES NOT COME ON.p. 879

  E- 12 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.p. 880

  E- 13 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL.p. 881

  E- 14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.p. 882

  E- 15 INDICATION OF THE FUEL GAUGE IS ABNORMAL.p. 883

  E- 16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL. E- 17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL.p. 884

  E- 18 THE SWITCH MODULE CANNOT BE OPERATED.p. 885

  E- 19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT.p. 886

  E- 20 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP.p. 887

  E- 21 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED.p. 888

  E- 22 THE AUTOMATIC PITCH BACK SYSTEM DOES NOT OPERATE ( ONLY SUPERDOZER SPECIFICATION).p. 889

  E- 23 THE ALARM BUZZER CANNOT BE CANCELLED.p. 890

  E- 24 THE OPERATOR MODE CANNOT BE OPERATED.p. 891

  E- 25 THE SERVICE MODE CANNOT BE OPERATED.p. 892

  E- 26 THE BACK- UP ALARM DOES NOT SOUND.p. 894

  E- 27 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON.p. 895

  E- 28 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEMp. 900

  E- 29 ORBCOMM TERMINAL DOES NOT OPERATE NORMALLY ( DATA ARE NOT TRANSMITTED).p. 915

  INFORMATION IN TROUBLESHOOTING TABLEp. 918

  H- 1 NO FORCE ( NO DRAWBAR PULL)p. 919

  H- 2 NO TRAVEL ( AT 2ND OR 3RD SPEED)p. 920

  H- 3 NO TRAVEL AT ALL GEAR SPEEDSp. 921

  H- 4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSEp. 922

  H- 5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD- REVERSE SHIFTINGp. 923

  H- 6 STEERING IS NOT POSSIBLE H- 7 STEERING IS POSSIBLE ONLY ON ONE SIDEp. 924

  H- 8 STEERING OVERRUN OCCURS H- 9 BRAKE DOES NOT WORKp. 925

  H- 10 TORQUE CONVERTER IS NOT LOCK- UP H- 11 TORQUE CONVERTER OIL IS OVERHEATEDp. 926

  H- 12 ALL WORK EQUIPMENT SPEEDS ARE SLOWp. 927

  H- 13 WORK EQUIPMENT DOES NOT MOVE H- 14 BLADE LIFT SPEED IS SLOW OR LACKS POWERp. 928

  H- 15 BLADE TILT SPEED IS SLOW OR LACKS POWER H- 16 RIPPER LIFT SPEED IS SLOW OR LACKS POWERp. 929

  H- 17 RIPPER TILT SPEED IS SLOW OR LACKS POWER H- 18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFTp. 930

  H- 19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT H- 20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFTp. 931

  H- 21 RIPPER PIN PULLER CYLINDER DOES NOT WORK ( GIANT RIPPER ATTACHMENT MACHINE) H- 22 BLADE PITCH DOES NOT WORK ( DUAL TILT ATTACHMENT MACHINE) H- 23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMPp. 932

  S- 7 Exhaust gas is black ( incomplete combustion)p. 936

  S- 1 STARTING PERFORMANCE IS POOR ( STARTING ALWAYS TAKES TIME)p. 938

  S- 2 ENGINE DOES NOT STARTp. 939

  S- 3 ENGINE DOES NOT PICK UP SMOOTHLY ( FOLLOW- UP IS POOR)p. 942

  S- 4 ENGINE STOPS DURING OPERATIONS ( Including cases with V- type engine where there is fuel injection for the bank on only one side)p. 943

  S- 5 ENGINE DOES NOT ROTATE SMOOTHLY ( HUNTING)p. 944

  S- 6 ENGINE LACKS OUTPUT( NO POWER) ( With V- type engine, for cases where there is injection for only one bank, go to troubleshooting S- 2- 2) or S- 4.)p. 945

  S- 7 EXHAUST GAS IS BLACK ( INCOMPLETE COMBUSTION)p. 946

  S- 8 OIL CONSUMPTION IS EXCESSIVE ( OR EXHAUST GAS IS BLUE)p. 947

  S- 9 OIL BECOMES CONTAMINATED QUICKLYp. 948

  S- 10 FUEL CONSUMPTION IS EXCESSIVEp. 949

  S- 11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWNp. 950

  S- 12 OIL PRESSURE LAMP LIGHTS UP ( DROP IN OIL PRESSURE)p. 951

  S- 13 OIL LEVEL RISESp. 952

  S- 14 WATER TEMPERATURE BECOMES TOO HIGH ( OVERHEATING)p. 953

  S- 15 ABNORMAL NOISE IS MADEp. 954

  S- 16 VIBRATION IS EXCESSIVEp. 955

• 10 Structure, Function and Maintenance Standard
  • Radiator, oil cooler, engine mount, damper, and universal joint
  • Power train layout, hydraulic arrangement, power train unit, torque converter and PTO
  • Torque converter valve and lock-up control system
  • Scavenging pump, transmission control, transmission, transmission ECMV, and clutch ECMV
  • Priority valve, lubricating oil relief valve, and power train lubrication pump
  • Steering and brake control, steering unit, steering ECMV, clutch ECMV, brake ECMV, parking brake, and sudden-stop prevention valve
  • Final drive, sprocket, track frame, recoil spring, idler, track roller, carrier roller, bogie, and track shoe
  • Main frame and suspension
  • Work-equipment hydraulic arrangement for dozer and ripper configurations
  • PPC control piping and work-equipment control
  • Work-equipment pump, cooling fan pump, cooling fan motor, PPC valve, and electric steering lever
  • Control valve, main relief valve, CLSS, unload valve, LS pressure circuits, LS bypass plug, and pressure compensation valve
  • Blade lift valve, merge-divider valve, self-reducing pressure valve, and pilot solenoid valve
  • Hydraulic tank, accumulator, work-equipment cylinder, piston valve, and quick-drop valve
  • Blade control knob, pitch and dual solenoid valve, and pin-puller hydraulic circuit
  • Cylinder stay, blade, and ripper equipment
  • Cab mount, cab, and air conditioner
  • Engine control, deceleration potentiometer, electronic engine throttle controller, and electronic-governor fuel injection pump
  • Monitor system, monitor panel, sensors, and mode selection system
  • Electrical equipment and steering electronic control system
  • VHMS controller, sensors, and communication controller / antenna
• 20 Testing and Adjusting
  • Standard value tables for engine and chassis
  • Testing, adjusting, and troubleshooting devices table
  • Engine speed, boost pressure, exhaust temperature, exhaust gas color, valve clearance, compression, blow-by, engine oil pressure, and fuel injection timing
  • Alternator and air-conditioner compressor belt checks and engine speed sensor adjustment
  • Fuel control dial and decelerator pedal adjustment
  • Power train oil pressure measurement and transmission speed sensor adjustment
  • Brake performance, brake pedal, parking brake lever, and PCCS lever adjustments
  • Emergency escape method when the power train has trouble
  • Idler clearance, sprocket wear, and track shoe tension checks
  • Work-equipment oil pressure and control-circuit basic pressure testing
  • PPC valve and solenoid-valve output pressure measurement
  • Hydraulic drift checks, work-equipment cylinder internal leakage, residual-pressure release, and air bleeding
  • Blade and ripper control adjustments
  • Fan motor speed and fan-circuit oil pressure measurement
  • Blade tilt control-angle measurement for dual tiltdozer and Superdozer specifications
  • Operator cab testing and blade adjustment
  • Monitor-panel special functions, replacement-controller adjustment, optional devices, VHMS initialization, Quick PM, and PM Clinic service
  • Troubleshooting preparation, connector arrangements, connector pin tables, and T-branch information
  • Electrical-system troubleshooting, hydraulic/mechanical troubleshooting, and engine-body troubleshooting
• 30 Disassembly and Assembly
  • This contents entry is marked “To be issued next time” in this edition and is not included as a completed chapter in the PDF.
• 90 Others
  • Power train hydraulic circuit diagram
  • Work-equipment hydraulic circuit diagrams, 3 sheets
  • Electrical circuit diagrams, 8 sheets
  • Electrical circuit diagram of inside cab

Taken together, these chapters give a technician both a systems-level explanation of how the D475A-5 works and the measurement data needed to evaluate its condition. The structure-and-function material is particularly useful when tracing power flow, hydraulic operation, steering and braking behavior, electronic modulation, work-equipment control, and undercarriage wear. The testing section then links those systems to practical checks, pressures, speeds, adjustments, service limits, connector information, and troubleshooting paths.

Testing, Adjustment and Troubleshooting Depth

The Komatsu D475A-5 Serial 20001 and Up Shop Manual SEBM033701 PDF contains extensive procedures for checking machine condition before replacing parts. Engine-related checks include speed, intake-air pressure, exhaust temperature and color, compression, blow-by, oil pressure, injection timing, and valve clearance. Chassis testing extends to power-train pressures, transmission and steering controls, brake operation, track tension, work-equipment pressure, PPC and solenoid pressure, cylinder leakage, fan-system pressure, control angles, and cab-related checks.

Troubleshooting is organized around preparatory checks, connector and circuit information, service and failure codes, and dedicated diagnostic paths for electrical, hydraulic/mechanical, and engine-body problems. This makes the manual useful for identifying likely causes from symptoms and measurements instead of relying only on component replacement. The document also includes standard values and service-limit criteria intended to help judge wear and machine condition during repair work.

Hydraulic, Electrical and Control-System Diagrams

Hydraulic and electrical information is distributed throughout the manual rather than confined to a single chapter. Structure-and-function pages show component arrangements and operating circuits for the power train, torque converter, transmission, steering, brakes, work equipment, blade and ripper controls, pumps, valves, and electronic modulation systems. The final Others section adds a complete power-train hydraulic circuit diagram, three work-equipment hydraulic circuit sheets, eight electrical circuit sheets, and an inside-cab electrical circuit diagram.

For fault tracing, the manual also provides electrical connector arrangement drawings, connector pin-number tables, troubleshooting preparation, monitoring functions, sensors, controller information, VHMS-related procedures, and system-specific diagnostic material. This combination helps connect a reported symptom to the appropriate circuit, test point, component, adjustment, or standard value.

Get the D475A-5 Service Information Ready for the Job

The Komatsu D475A-5 Serial 20001 and Up Shop Manual SEBM033701 PDF supports a wide range of inspection, testing, adjustment, troubleshooting, maintenance-standard, hydraulic, electrical, power-train, steering, brake, undercarriage, blade, ripper, and control-system work on covered D475A-5 machines. Correct pressures, dimensions, clearances, service limits, circuit layouts, and test procedures matter when diagnosing faults and deciding whether components are within usable limits.

IMAGES PREVIEW

This edition does not include the Disassembly and Assembly chapter shown in the contents; that entry is specifically marked as being issued next time. Detailed engine service is also referred to the separate 12V140-1 Series Engine Shop Manual. For the extensive chassis, systems, testing, troubleshooting, and circuit information contained here, the manual is supplied as an instant PDF download after payment, with no shipping required. Open it on a compatible phone, tablet, laptop, or desktop, and print the pages you need for workshop reference.