Komatsu Bulldozer D475A-8 service & repair manual

Description Komatsu Bulldozer D475A-8 service & repair manual

Komatsu Bulldozer D475A-8 pdf workshop service manual

Serial number 50001 and up

Specifications, testing, adjusting, troubleshooting, technical documentation, electrical wiring diagrams, hydraulic schematics, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and Foreword
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Discard Waste Materials
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
Disconnect and Connect Connector with Lock to Pull
Disconnect and Connect Connector with Lock to Push
Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table

Specification
Specification Drawing
Weight Table
Fuel, Coolant, Lubricant

Structure and Function
Boot-up System
Layout Drawing of Boot-up System
System Operating Lamp System
Battery Isolator
Engine System
Layout Drawing of Engine System
Engine Control System
Automatic Idle Stop System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Specifications of Cooling System
Component Parts of Cooling System
Control System
Layout Drawing of Control System
Machine Monitor System
KOMTRAX Plus System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Transmission, Steering, and Brake Control System
Palm Command Control System
Function of Gear Shift Mode
Centralized Pressure Pickup Port
Component Parts of Power Train System
Work Equipment System
Layout Drawing of Work Equipment System
Function of Work Equipment System
Component Parts of Work Equipment System
ICT System
Layout Drawing of ICT System
System Diagram of ICT Control System
Blade Control System
Smooth Start System
Slip Control System
Assist Control System
Straight Travel Correction System
Smooth Carry System
Component Parts of ICT System
Lifting System
Power Ladder System
Component Parts of Lifting System
Undercarriage and Frame
Main Frame
Suspension
Track Frame and Idler Cushion
Work Equipment
Structure of Front Work Equipment
Structure of Cylinder Stay
Structure of Variable Giant Ripper
Structure of Variable Multi-Shank Ripper
CAB Related Parts
ROPS
CAB
CAB Mount

Standard Value Table
Standard Value Table for Engine
Standard Value Table for Machine
Machine Posture and Procedures to Measure Performance

Testing and Adjusting
Precautions Before Work
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine Mass Air Flow and Temperature Sensor
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine EGR Valve and VGT Oil Pressure
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Examine Low Pressure Circuit Devices
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Examine KDPF and Muffler for Looseness and Damage
Examine Installation of Cylinder Head Cover and Manifolds
Examine Engine Piping for Damage and Looseness
Clean Fuel Doser
Write Injector Compensation Value to Engine Controller
Write Correction for Ash in Soot Accumulation to Engine Controller
Examine Alternator, Air Conditioner Compressor Belt
Adjust Decelerator Pedal
Power Train
Examine Power Train Oil Pressure
Adjust Transmission Output Shaft Speed Sensor
Examine Brake Performance Simply
Examine and Adjust Brake Pedal
Release Parking Brake and Move Machine
Undercarriage and Frame
Examine and Adjust Track Tension
Hydraulic System
Release Remained Pressure in Hydraulic Circuit
Examine and Adjust Work Equipment Oil Pressure
Examine EPC Valve Outlet Pressure
Examine and Adjust Oil Pressure in Pump LS Control Circuit
Examine Oil Pressure of Control Circuit
Examine Work Equipment Lock Solenoid Valve Outlet Pressure
Examine Ripper Pin Puller Solenoid Valve Outlet Pressure
Bleed Air from Work Equipment Pump
Examine Cooling Fan Speed
Examine Cooling Fan Circuit Oil Pressure
Bleed Air in Cooling Fan Pump
Examine Parts Which Cause Hydraulic Drift of Work Equipment
Examine Oil Leakage from Work Equipment Cylinder
Bleed Air from Work Equipment Cylinders
Operation When Work Equipment is Disabled
Work Equipment
Examine and Adjust Play of Blade Electric Lever
Power Ladder
Bleed Air from Power Ladder Cylinder
Examine and Adjust Power Ladder Limit Switch
CAB Related Parts
Examine and Adjust Operator Cab
Adjust Play of Operator's Seat
Examine the Seating Switch
Examine Work Equipment Lock Switch
Examine Parking Brake Switch
Electrical System
Set and Operate Machine Monitor
How to Start Up KOMTRAX Terminal
How to Stop Use of KOMTRAX Terminal
Default Setting of KOMTRAX Plus Controller
Default Setting of Wireless LAN Modem
Download Data from KOMTRAX Plus Controller
Adjust After Replacement of KOMTRAX Plus Controller
Adjust After Replacement of Wireless LAN Modem
Adjust Rearview Camera Angle
Set Region of Bluetooth® Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Isolator and Starting Motor Isolator
Examine Diodes
ICT System
Set and Operate Control Box
Calibrate Blade Edge Position
Calibrate IMU Sensor
Reset Cylinder Stroke End
Set Standard Angle of Blade Edge
How to Input Wear Volume of Blade Edge and Track Shoes
Examine and Adjust Blade Elevation
Examine Stroke Sensor for Lift Cylinder
Examine and Adjust Reset Sensor for Lift Cylinder
Adjust When Work Equipment Controller is Replaced
How to Adjust When ICT Related Devices are Repaired or Replaced
Pm Clinic
Pm Clinic Service
Perform Quick Pm

Troubleshooting
Precautions Before Work
Related Information to Troubleshooting
Precautions for Troubleshooting
Sequence of Events in Troubleshooting
Troubleshooting Points for Aftertreatment System
Troubleshooting for Radio Control System
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Connect Adapter for Troubleshooting Controller
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness
Connector and Wiring Harness Identification Table
Connector Layout
Connector and Wiring Harness Identification Table
Connector Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Troubleshooting of Engine (S-Mode)

Disassembly and Assembly
Precautions Before Work
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Prepare
Drain and Add Coolant
Drain and Add Hydraulic Oil
Drain and Add Fuel
Collect and Refill Refrigerant
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Fuel Doser Assembly
Remove and Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
Remove and Install Starter Assembly
Remove and Install Alternator Belt
Remove and Install Alternator Assembly
Remove and Install Radiator Guard Assembly
Remove and Install Radiator Assembly
Remove and Install Radiator Tube
Remove and Install Hydraulic Oil Cooler Assembly
Remove and Install Aftercooler Assembly
How to Swing Radiator Fan Drive Assembly
Remove and Install Cooling Fan Drive Assembly
Remove and Install Cooling Fan Motor Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Engine Assembly
Remove and Install Engine Hood Assembly
Remove and Install Fuel Tank Assembly
Remove and Install KDPF Assembly
Remove and Install KCCV Assembly
Remove and Install VGT Assembly
Remove and Install Air Cleaner Assembly 
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Power Train
Remove and Install Damper Assembly
Disassemble and Assemble Damper Assembly
Remove and Install Power Train Unit Assembly
Disconnect and Connect Power Train Unit Assembly
Disassemble and Assemble PTO Assembly
Disassemble and Assemble Torque Converter Assembly
Disassemble and Assemble Transmission Assembly
Disassemble and Assemble Steering Case Assembly
Remove and Install Final Drive Assembly
Disassemble and Assemble Final Drive Assembly
Undercarriage and Frame
Remove and Install Track Frame Assembly
Remove and Install Recoil Spring Assembly
Disassemble and Assemble Recoil Spring Assembly
Remove and Install Track Roller Assembly
Disassemble and Assemble Track Roller Assembly
Remove and Install No. 1 Bogie Assembly
Remove and Install Bogie Assembly
Disassemble and Assemble Bogie Assembly
Remove and Install Idler Assembly
Disassemble and Assemble Idler Assembly
Remove and Install Carrier Roller Assembly
Disassemble and Assemble Carrier Roller Assembly
Remove and Install Pivot Shaft Assembly
Separate and Connect Track Assembly
Disassemble and Assemble Track Assembly Generally
Disassemble and Assemble One Track Link Assembly in Field
Disassemble and Assemble Master Link
Remove and Install Equalizer Bar Assembly
Disassemble and Assemble Equalizer Bar Bushing
Remove and Install Segment Teeth
Remove and Install Power Ladder Assembly
Open and Close Underguard Assembly
Remove and Install Under Guard Assembly
Hydraulic System
Remove and Install Hydraulic Tank Assembly
Remove and Install Work Equipment Pump Assembly
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly
Remove and Install Control Valve Assembly
Remove and Install Cooling Fan Pump Assembly
Remove and Install Scavenging Pump Assembly
Work Equipment
Remove and Install Blade Assembly
Disassemble and Assemble Blade Assembly (U dozer and Semi-U dozer spec)
Disassemble and Assemble Blade Assembly (Super dozer spec)
Disassemble and Assemble Giant Ripper Assembly
Remove and Install Blade Lift Cylinder Assembly
Disassemble and Assemble Blade Lift Cylinder Assembly
Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly
Disassemble and Assemble Blade Tilt Cylinder Assembly (U dozer and Semi-U dozer spec)
Disassemble and Assemble Blade Tilt Cylinder Assembly (Super dozer spec)
Disassemble and Assemble Ripper Lift Cylinder Assembly
Disassemble and Assemble Ripper Tilt Cylinder Assembly
Disassemble and Assemble Ripper Pin Puller Cylinder Assembly
CAB Related Parts
Remove and Install ROPS Guard
Remove and Install Operator Cab Assembly
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator's Seat Assembly
How to Remove and Install Seat Belt
Electrical System
Remove and Install Engine Controller Assembly
Remove and Install Power Train Controller Assembly
Remove and Install Work Equipment Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Mass Air Flow and Temperature Sensor
Remove and Install KCCV Crankcase Pressure Sensor
Remove and Install KDPF Differential Pressure Sensor
Remove and Install KDPF Temperature Sensor
Remove and Install KOMTRAX Terminal Assembly
Remove And Install KOMTRAX Plus Controller Assembly
Remove and Install Option Controller Assembly
Remove and Install Wireless LAN Unit Assembly
Remove and Install Stroke Sensor Wiring Harness
Remove and Install ICT Wiring Harness
Remove and Install Offset Switch
Remove and Install Control Box
Remove and Install Navigation Controller Assembly
Remove and Install AUX BOX
Remove and Install IMU Sensor

Maintenance Standard
Explanation of Terms for Maintenance Standard
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Maintenance Standard for Cooling System
Maintenance Standard for Cooling Fan Pump
Maintenance Standard for Servo Valve (Cooling Fan Pump)
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Universal Joint
Maintenance Standard for Power Train Mount
Maintenance Standard for Torque Converter and PTO
Maintenance Standard for Torque Converter Control Valve
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve
Maintenance Standard for ECMV (Lockup Clutch)
Maintenance Standard for ECMV (Stator Clutch)
Maintenance Standard for Transmission
Maintenance Standard for Triplex Pump (Lubrication, Power Train, Torque Converter)
Maintenance Standard for Transmission Control Valve
Maintenance Standard for ECMV (Directional Operation Clutch, Gear Speed Clutch)
Maintenance Standard for Priority Valve
Maintenance Standard for Transmission Lubrication Relief Valve
Maintenance Standard for Transfer, Bevel Gear Shaft, and Steering
Maintenance Standard for Solenoid Valve (Brake)
Maintenance Standard for Sudden Stop Prevention Valve
Maintenance Standard for Final Drive
Maintenance Standard for Sprocket
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing
Undercarriage and Frame
Maintenance Standard for Main Frame
Maintenance Standard for Suspension
Maintenance Standard for Track Frame and Idler Cushion
Maintenance Standard for Idler
Maintenance Standard for Track Roller Bogie
Maintenance Standard for Track Roller
Maintenance Standard for Carrier Roller
Maintenance Standard for Track Shoes
Maintenance Standard for Single Shoes and Heavy Duty Shoes
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Duplex Pump (Work Equipment)
Maintenance Standard for Scavenging Pump
Maintenance Standard for Control Valve
Maintenance Standard for Self-Pressure Reducing Valve
Maintenance Standard for Quick Drop Valve
Work Equipment
Maintenance Standard for Cylinder Stay
Maintenance Standard for Front Work Equipment
Maintenance Standard for Cutting Edge and End Bit
Maintenance Standard for Variable Multi-Shank Ripper
Maintenance Standard for Variable Giant Ripper
Maintenance Standard for Blade Lift Cylinder
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder
Maintenance Standard for Blade Tilt Cylinder
Maintenance Standard for Ripper Lift Cylinder
Maintenance Standard for Ripper Tilt Cylinder
Maintenance Standard for Pin Puller Cylinder
CAB Related Parts
Maintenance Standard for CAB Mount
Maintenance Standard for ROPS Mount

Appendix
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Receiver Drier
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with Self-Diagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
How to Examine Sunlight Sensor
Examine Refrigerant (Triple) Pressure Switch
How to Examine Refrigerant (Triple) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown in Troubleshooting Table
A-1 Air Conditioner Does Not Operate
A-2 Defective Cooling
A-3 Heater Does Not Operate
A-4 Cool Air Does Not Come Out
A-5 No Air Comes Out or Air Flow is Abnormal
A-6 Fresh/Recirc Air Changeover Does Not Work
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil

Circuit Diagrams
How to Read the Codes for Electric Cable
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Power Train Hydraulic Circuit Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram
Inside Cab Electrical Circuit Diagram

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