KOMATSU D475A-5EO D475ASD-5EO DOZER Service Shop Manual

BULLDOZER SEN00203-16 D475A -5E0 D475ASD -5E0 SERIAL NUMBERS D475A- 30001 D475ASD- 30001 and up

D475A, D475ASD-5E0 1 SEN00205-16 BULLDOZER 1SHOP MANUAL D475A-5E0 D475ASD-5E0 Machine model Serial number D475A-5E0 30001 and up D475ASD-5E0 30001 and up 00 Index and foreword 1 Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4

SEN00205-16 00 Index and foreword 2 D475A, D475ASD-5E0 Composition of shop manual 1 The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title Form Number Shop Manual, contents binder, binder label and tabs ............................................................ SEN00203-16 00 Index and foreword ......................................................................................................... SEN00204-16 Index ............................................................................................................................... SEN00205-16 q Foreword and general information .................................................................................. SEN00206-05 01 Specification.................................................................................................................... SEN00207-01 Specification and technical data...................................................................................... SEN00208-01 10 Structure, function and maintenance standard ............................................................... SEN00209-03 Engine and cooling system ............................................................................................. SEN00210-00 Power train, Part 1 ........................................................................................................... SEN00211-01 Power train, Part 2 .......................................................................................................... SEN00212-02 Undercarriage and frame ................................................................................................ SEN00213-01 Hydraulic system, Part 1 ................................................................................................. SEN00214-00 Hydraulic system, Part 2 ................................................................................................. SEN00215-00 Hydraulic system, Part 3 ................................................................................................. SEN00216-01 Work equipment .............................................................................................................. SEN00217-00 Cab and its attachments ................................................................................................. SEN00218-00 Electrical system ............................................................................................................. SEN00219-02 20 Standard value table ....................................................................................................... SEN00220-01 Standard service value table ........................................................................................... SEN01816-01 30 Testing and adjusting ...................................................................................................... SEN00221-06 Testing and adjusting, Part 1........................................................................................... SEN01817-03 Testing and adjusting, Part 2........................................................................................... SEN01818-03 Testing and adjusting, Part 3........................................................................................... SEN01819-04 Testing and adjusting, Part 4........................................................................................... SEN01820-03 40 Troubleshooting .............................................................................................................. SEN00222-05 Failure code table and fuse locations ............................................................................. SEN01821-04 General information on troubleshooting .......................................................................... SEN01822-03 Troubleshooting by failure code, Part 1 .......................................................................... SEN01823-02 Troubleshooting by failure code, Part 2 .......................................................................... SEN01824-01 Troubleshooting by failure code, Part 3 .......................................................................... SEN01825-03

00 Index and foreword SEN00205-16 D475A, D475ASD-5E0 3 Troubleshooting by failure code, Part 4 .......................................................................... SEN01826-01 Troubleshooting by failure code, Part 5 .......................................................................... SEN01827-03 Troubleshooting by failure code, Part 6 .......................................................................... SEN01828-03 Troubleshooting by failure code (Display of code), Part 7 .............................................. SEN01829-02 Troubleshooting by failure code (Display of code), Part 8 .............................................. SEN01830-01 Troubleshooting of electrical system (E-mode)............................................................... SEN01831-02 Troubleshooting of hydraulic and mechanical system (H-mode) .................................... SEN01832-02 Troubleshooting of engine (S-mode) .............................................................................. SEN01833-01 50 Disassembly and assembly ............................................................................................ SEN00223-08 General information on disassembly and assembly ....................................................... SEN02013-06 q Engine and cooling system (SAA12V140E-3) ................................................................ SEN02014-01 Engine (SAA12V140E-3) ................................................................................................ SEN02338-03 Power train, Part 1 .......................................................................................................... SEN02015-01 q Power train, Part 2 .......................................................................................................... SEN02016-03 q Undercarriage and frame, Part 1 .................................................................................... SEN02017-03 Undercarriage and frame, Part 2 .................................................................................... SEN02018-02 Hydraulic system ............................................................................................................ SEN02019-01 Work equipment .............................................................................................................. SEN02020-00 Cab and its attachments ................................................................................................. SEN02021-01 Electrical system ............................................................................................................. SEN02339-02 90 Diagrams and drawings .................................................................................................. SEN00224-03 Hydraulic diagrams and drawings................................................................................... SEN00225-00 Electrical diagrams and drawings ................................................................................... SEN00226-03

SEN00205-16 00 Index and foreword 4 D475A, D475ASD-5E0 Table of contents 1 00 Index and foreword Index ............................................................................................................................... SEN00205-16 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 Foreword and general information .................................................................................. SEN00206-05 Safety notice ............................................................................................................................ 2 How to read the shop manual .................................................................................................. 7 Explanation of terms for maintenance standard ...................................................................... 9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 How to read electric wire code................................................................................................. 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table .............................................................................................. 32 Conversion table ...................................................................................................................... 36 01 Specification Specification and technical data...................................................................................... SEN00208-01 Specification drawings ............................................................................................................. 2 Specifications ........................................................................................................................... 3 Weight table ............................................................................................................................. 12 Fuel, coolant and lubricants ..................................................................................................... 16 10 Structure, function and maintenance standard Engine and cooling system ............................................................................................. SEN00210-00 Radiator and oil cooler ............................................................................................................. 2 Engine mount........................................................................................................................... 3 Cooling fan pump..................................................................................................................... 4 Cooling fan motor .................................................................................................................... 26 Power train, Part 1 ........................................................................................................... SEN00211-01 Power train............................................................................................................................... 2 Power train hydraulic equipment arrangement diagram .......................................................... 4 Damper and universal joint ...................................................................................................... 6 Power train system .................................................................................................................. 8 General view of power train unit .............................................................................................. 8 Torque converter, PTO............................................................................................................. 10 Torque converter valve ............................................................................................................ 18 Torque converter lockup control system .................................................................................. 28 Scavenging pump .................................................................................................................... 29 Transmission control ................................................................................................................ 31 Transmission............................................................................................................................ 32 Power train, Part 2 .......................................................................................................... SEN00212-02 Transmission control valve ...................................................................................................... 2 Transmission clutch ECMV...................................................................................................... 4 Priority valve ............................................................................................................................ 8 Lubricating oil relief valve ........................................................................................................ 10 Torque converter, power train, lubricating oil pump ................................................................. 11 Steering, brake control ............................................................................................................. 12 Final drive ................................................................................................................................ 14 Sprocket ................................................................................................................................... 18 Steering unit ............................................................................................................................. 21 Steering control valve .............................................................................................................. 32 Steering clutch ECMV, Steering brake ECMV ......................................................................... 34 Parking brake valve ................................................................................................................. 40 Sudden stop prevention valve ................................................................................................. 42

00 Index and foreword SEN00205-16 D475A, D475ASD-5E0 5 Undercarriage and frame ................................................................................................ SEN00213-01 Track frame.............................................................................................................................. 2 Recoil spring ............................................................................................................................ 4 Idler .......................................................................................................................................... 6 Track roller ............................................................................................................................... 8 Carrier roller ............................................................................................................................. 12 Track roller bogie ..................................................................................................................... 13 Track shoe ............................................................................................................................... 14 Main frame............................................................................................................................... 18 Suspension .............................................................................................................................. 20 Hydraulic system, Part 1 ................................................................................................. SEN00214-00 Work equipment hydraulic equipment arrangement diagram .................................................. 2 PPC control piping diagram ..................................................................................................... 6 Work equipment control ........................................................................................................... 8 Work equipment pump ............................................................................................................ 10 PPC valve ................................................................................................................................ 27 PCCS lever .............................................................................................................................. 38 Hydraulic system, Part 2 ................................................................................................. SEN00215-00 Control valve............................................................................................................................ 2 CLSS ....................................................................................................................................... 17 Unload valve ............................................................................................................................ 20 Introduction of LS pressure ..................................................................................................... 21 LS bypass plug ........................................................................................................................ 22 Pressure compensation valve ................................................................................................. 23 Blade lift valve ......................................................................................................................... 26 Merge-divider valve ................................................................................................................. 34 Self pressure reducing valve ................................................................................................... 36 Pilot solenoid valve .................................................................................................................. 40 Hydraulic system, Part 3 ................................................................................................. SEN00216-01 Hydraulic tank, hydraulic filter .................................................................................................. 2 Accumulator ............................................................................................................................. 4 Work equipment cylinder ......................................................................................................... 6 Piston valve ............................................................................................................................. 8 Quick drop valve ...................................................................................................................... 10 Blade control knob (Dual tilt specification) ............................................................................... 12 Blade control knob (Superdozer specification) ........................................................................ 13 Pitch and dual solenoid valve .................................................................................................. 14 Pin puller hydraulic circuit diagram .......................................................................................... 15 Pin puller solenoid valve .......................................................................................................... 16 Work equipment .............................................................................................................. SEN00217-00 Cylinder stay ............................................................................................................................ 2 Blade ....................................................................................................................................... 4 Ripper equipment .................................................................................................................... 8 Cab and its attachments ................................................................................................. SEN00218-00 Cab mount ............................................................................................................................... 2 Cab .......................................................................................................................................... 3 Air conditioner .......................................................................................................................... 6 Electrical system ............................................................................................................. SEN00219-02 Engine control system ............................................................................................................. 2 CRI engine control system ...................................................................................................... 6 Monitor system ........................................................................................................................ 10 Machine monitor ...................................................................................................................... 12 Mode selection system ............................................................................................................ 30 Electrical equipment ................................................................................................................ 34 Palm command control system (PCCS) .................................................................................. 36 Sensors ................................................................................................................................... 38 Vehicle health monitoring system (VHMS) .............................................................................. 45

SEN00205-16 00 Index and foreword 6 D475A, D475ASD-5E0 ORBCOMM terminal ................................................................................................................ 51 20 Standard value table Standard service value table ........................................................................................... SEN01816-01 Standard value table for engine ............................................................................................... 2 Standard value table for chassis .............................................................................................. 3 30 Testing and adjusting Testing and adjusting, Part 1........................................................................................... SEN01817-03 Tools for testing, adjusting, and troubleshooting...................................................................... 3 Measuring engine speed ......................................................................................................... 6 Measuring intake air pressure (boost pressure) ...................................................................... 10 Measuring exhaust temperature .............................................................................................. 12 Measuring exhaust gas color ................................................................................................... 14 Adjusting valve clearance ........................................................................................................ 16 Testing compression pressure ................................................................................................. 18 Measuring blow-by pressure.................................................................................................... 20 Measuring engine oil pressure................................................................................................. 22 Handling of fuel system devices .............................................................................................. 23 Releasing residual pressure from fuel system ......................................................................... 23 Testing fuel pressure................................................................................................................ 24 Handling of reduced cylinder mode operation ......................................................................... 25 Handling of no injection cranking operation ............................................................................. 25 Testing fuel return and leak amount......................................................................................... 26 Bleeding air from fuel circuit .................................................................................................... 29 Bleeding air from fuel circuit (Low-grade fuel specification) .................................................... 31 Testing fuel circuit for leakage ................................................................................................. 33 Testing and adjusting alternator belt tension ........................................................................... 34 Testing and adjusting belt tension for air conditioner compressor ........................................... 35 Adjusting fuel control dial and decelerator pedal ..................................................................... 36 Testing and adjusting, Part 2........................................................................................... SEN01818-03 Measuring power train oil pressure.......................................................................................... 3 Adjusting transmission speed sensor ...................................................................................... 12 Simple method to test brake performance ............................................................................... 13 Adjusting brake pedal and parking brake lever ........................................................................ 14 Adjusting PCCS lever console position ................................................................................... 17 Emergency escape method when power train has trouble ...................................................... 18 Inspecting wear of sprocket ..................................................................................................... 20 Testing and adjusting track shoe tension ................................................................................. 21 Testing and adjusting work equipment oil pressure ................................................................. 22 Testing and adjusting control circuit basic pressure ................................................................ 33 Measuring PPC valve output pressure and solenoid valve output pressure ........................... 34 Adjusting play of PPC valve..................................................................................................... 40 Measuring outlet pressure of ripper pin puller solenoid valve.................................................. 41 Checking parts which caused hydraulic drift of blade and ripper ............................................. 42 Measuring internal leakage of work equipment cylinder .......................................................... 43 Releasing residual pressure from work equipment cylinder .................................................... 44 Bleeding air from work equipment cylinder .............................................................................. 44 Adjusting ripper lever position.................................................................................................. 45 Adjusting work equipment lock lever ....................................................................................... 46 Measuring fan motor speed ..................................................................................................... 47 Measuring fan circuit oil pressure ............................................................................................ 48 Bleeding air from fan pump...................................................................................................... 49 Measurement procedure for blade tilt control angle (Dual tiltdozer specification) ................... 50 Measurement procedure for blade tilt control angle (Superdozer specification) ...................... 53 Testing and adjusting operator's cab ....................................................................................... 55 Adjusting blade ........................................................................................................................ 59

00 Index and foreword SEN00205-16 D475A, D475ASD-5E0 7 Testing and adjusting operator's seat isolator.......................................................................... 61 Testing and adjusting, Part 3 .......................................................................................... SEN01819-04 Special functions of monitor panel (EMMS) ............................................................................. 2 Testing and adjusting, Part 4 .......................................................................................... SEN01820-03 Adjustment method when controller has been replaced.......................................................... 2 Preparation work for troubleshooting for electrical equipment system .................................... 4 Inspection procedure of diode ................................................................................................. 8 Handling of optional devices.................................................................................................... 9 Initialization procedures for VHMS controller .......................................................................... 10 Precautions for replacing VHMS controller .............................................................................. 31 Pm Clinic service ..................................................................................................................... 36 40 Troubleshooting Failure code table and fuse locations ............................................................................. SEN01821-04 Failure code table .................................................................................................................... 2 Fuse locations ......................................................................................................................... 12 General information on troubleshooting.......................................................................... SEN01822-03 Points to remember when troubleshooting .............................................................................. 2 Sequence of events in troubleshooting ................................................................................... 3 Checks before troubleshooting ................................................................................................ 4 Classification and procedures of troubleshooting .................................................................... 5 Contents of troubleshooting table ............................................................................................ 8 Connection table for connector pin numbers ........................................................................... 10 T- branch box and T- branch adapter table ............................................................................. 46 Troubleshooting by failure code, Part 1 .......................................................................... SEN01823-02 Failure code [1380MW] Lockup clutch: Clutch slip .................................................................. 3 Failure code [1500L0] Transmission clutch: Dual engagement ............................................... 4 Failure code [15E0MW] Transmission clutch: Clutch slip ........................................................ 5 Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON ............................................................................ 6 Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF ............................................................................ 7 Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON ................. 8 Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF ............................................................................ 9 Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON ...... 10 Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF ..... 11 Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON ..... 12 Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF .... 13 Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON ..... 14 Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF..... 15 Failure code [1800MW] Power train clutch: Slip ...................................................................... 16 Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON ... 17 Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF... 18 Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON...... 19 Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF ..... 20 Failure code [2300NR] Brake thermal load: Abnormal heating ............................................... 21 Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON.... 22 Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF ... 23 Failure code [2301NR] Right steering brake thermal load: Abnormal heating ........................ 24 Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON ...... 25 Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF...... 26 Failure code [2302NR] Left steering brake thermal load: Abnormal heating ........................... 27 Failure code [6001ZK] Failure code for design........................................................................ 28 Failure code [A000NS] Engine: Overheat ............................................................................... 29 Failure code [AA10NX] Air cleaner: Clogging.......................................................................... 30 Failure code [AB00MA] Battery charge abnormality: Malfunction ........................................... 31

SEN00205-16 00 Index and foreword 8 D475A, D475ASD-5E0 Failure code [B@BAZG] Engine oil: Oil pressure too low........................................................ 32 Failure code [B@BAZK] Engine oil: Oil level reduction ........................................................... 33 Failure code [B@BCNS] Engine coolant: Overheat ................................................................ 34 Failure code [B@BCZK] Engine coolant: Level too low........................................................... 35 Failure code [B@BEBF] Fuel: Water in fuel ............................................................................ 36 Failure code [B@BFZK] Fuel level: Reduction ........................................................................ 37 Failure code [B@CENS] Power train oil: Overheat ................................................................. 38 Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure...................................... 39 Failure code [B@CHZK] Power train oil: Oil level reduction .................................................... 39 Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction ......................... 40 Failure code [B@HANS] Hydraulic oil: Overheat..................................................................... 40 Failure code [B@HAZK] Hydraulic oil: Level reduction ........................................................... 41 Troubleshooting by failure code, Part 2 .......................................................................... SEN01824-01 Failure code [CA111] Engine controller (Left bank): Internal abnormality ................................ 4 Failure code [CB111] Engine controller (Right bank): Internal abnormality ............................. 6 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal ............................................................................................. 8 Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal ............................................................................................. 9 Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 10 Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 12 Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank): High voltage detection.......................................................................................................... 13 Failure code [CA132] Decelerator pedal sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 15 Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 16 Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 18 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ....................................................................................... 20 Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 22 Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 24 Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 26 Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection .......................................................................................................... 28 Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection .......................................................................................................... 29 Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection.......................................................................................................... 30 Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection .......................................................................................................... 31 Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 32 Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 34 Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected ....................................................................................... 36 Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection.......................................................................................................... 38 Failure code [CA234] Engine over speed (At left bank only): Excessively high speed............ 40 Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected......................................................................................... 42

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KOMATSU D475A-5EO D475ASD-5EO DOZER Service Shop Manual

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