Komatsu D475A-5E0, D475ASD-5E0 Crawler Bulldozer Shop Manual SEN00203-16 - PDF DOWNLOAD

SEN00203-16

BULLDOZER

-5E0 D475A D475ASD -5E0 SERIAL NUMBERS

D475A30001 and up D475ASD- 30001

SEN00205-16

BULLDOZER 1SHOP MANUAL

D475A-5E0 D475ASD-5E0

Machine model

Serial number

D475A-5E0 D475ASD-5E0

30001 and up 30001 and up

00 Index and foreword

1

Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4

D475A, D475ASD-5E0

1

SEN00205-16

00 Index and foreword

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

2

D475A, D475ASD-5E0

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00 Index and foreword

SEN00205-16

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

D475A, D475ASD-5E0

3

SEN00205-16

00 Index and foreword

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

4

D475A, D475ASD-5E0

00 Index and foreword

SEN00205-16

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 D475A, D475ASD-5E0

5

SEN00205-16

00 Index and foreword

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

6

D475A, D475ASD-5E0

00 Index and foreword

SEN00205-16

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 D475A, D475ASD-5E0

7

SEN00205-16

00 Index and foreword

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

8

D475A, D475ASD-5E0

00 Index and foreword

SEN00205-16

Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected ........................................................................................ 44 Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected ....................................................................................... 46 Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected ....................................................................................... 48 Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection .......................................................................................................... 49 Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection .......................................................................................................... 49 Failure code [CA271] PCV1 short circuit (Left bank): Short circuit .......................................... 50 Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ....................................... 51 Failure code [CA272] PCV1 disconnection (Left bank): Disconnection................................... 52 Failure code [CB272] PCV1 disconnection (Right bank): Disconnection ................................ 53 Failure code [CA273] PCV2 short circuit (Left bank): Short circuit .......................................... 54 Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ....................................... 55 Failure code [CA274] PCV2 disconnection (Left bank): Disconnection................................... 56 Failure code [CB274] PCV2 disconnection (Right bank): Disconnection ................................ 57 Troubleshooting by failure code, Part 3 .......................................................................... SEN01825-03 Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................

4 Failure code [CA323] Injector #5 (L/B #5) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................

6 Failure code [CA324] Injector #3 (L/B #3) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................

8 Failure code [CA325] Injector #6 (L/B #6) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 10 Failure code [CA331] Injector #2 (L/B #2) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 12 Failure code [CA332] Injector #4 (L/B #4) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 14 Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch ....................... 16 Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch..................... 17 Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit.............. 18 Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality ....... 20 Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection .......................................................................................................... 22 Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection .......................................................................................................... 23 Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection ......................................................................................................... 24 Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection ......................................................................................................... 26 Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection .......................................................................................................... 28 Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection .......................................................................................................... 28 Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection ......................................................................................................... 29 Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection ......................................................................................................... 29 Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence ................................................................................. 30 Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence ................................................................................. 30 Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected ....................................................................................... 32

D475A, D475ASD-5E0

9

SEN00205-16

00 Index and foreword

Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection.......................................................................................................... 34 Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection......................................................................................... 36 Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection......................................................................................... 36 Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected..................................................................................... 37 Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected..................................................................................... 38 Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error ....................................................................................................................... 39 Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error ....................................................................................................................... 39 Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected............................................................................................ 40 Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected (Low-grade fuel specification)............................................ 44 Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected............................................................................................ 48 Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal ..... 52 Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal ... 54 Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection ............................................................................... 56 Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection ................................................................................ 58 Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase ................................................................................................................... 59 Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase ................................................................................................................... 59 Troubleshooting by failure code, Part 4 .......................................................................... SEN01826-01 Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data...........

3 Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data.........

3 Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal ..........................................................................................................

4 Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error ..................................................................................................................

6 Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error............................................................................................................ 8 Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error............................................................................................................ 10 Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error .................................................................................................................... 11 Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error .................................................................................................................... 12 Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 14 Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 16 Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 18 Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 20 Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 22 Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit ............................................................................. 24 Failure code [CA1633] KOMNET abnormality (Left bank): Communication error ................... 26

10

D475A, D475ASD-5E0

00 Index and foreword

SEN00205-16

Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level (Only left bank): High voltage detection ............................................................................... 28 Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only): Excessively low voltage detected........................................................... 30 Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected............................................................................................ 31 Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected............................................................................................ 31 Failure code [D110KA] Battery relay: Disconnection ............................................................... 32 Failure code [D110KB] Battery relay: Short circuit .................................................................. 34 Failure code [D130KA] Neutral safety relay: Disconnection.................................................... 36 Failure code [D130KB] Neutral safety relay: Short circuit ....................................................... 38 Failure code [D161KA] Back-up alarm relay: Disconnection ................................................... 40 Failure code [D161KB] Back-up alarm relay: Short circuit ...................................................... 42 Failure code [D182KZ] Preheater relay: Disconnection or short circuit ................................... 44 Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection ................. 46 Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit ..................... 48 Failure code [D5ZRKA] Snap shot switch: Disconnection....................................................... 50 Failure code [D5ZRKB] Snap shot switch: Short circuit .......................................................... 51 Failure code [DAFRKR] Monitor panel CAN communication: Communication error ............... 52 Failure code [dAFRKR] Monitor panel CAN communication: Communication error................ 54 Failure code [daFRKR] Monitor panel CAN communication: Communication error ................ 56 Failure code [DAQ0KT] Transmission controller: Abnormality in controller............................. 58 Failure code [DAQ1KK] Transmission controller main power supply: Power supply voltage reduction (Input)................................................................................ 60 Failure code [DAQ2KK] Transmission controller load power supply: Power supply voltage reduction (Input)................................................................................ 62 Failure code [DAQ5KK] Transmission controller potentiometer power supply: Source voltage reduction (input) .......................................................................................... 64 Failure code [DAQ6KK] Transmission controller sensor power supply: Source voltage reduction (input) .......................................................................................... 65 Failure code [DAQ7KK] Transmission controller sensor power supply: Power supply voltage reduction (Input)................................................................................ 66 Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency.......................................................................................... 67 Failure code [DAQRKR] Transmission controller sensor CAN communication: Communication error (Objective component system abnormality) ...................................... 68 Failure code [DAQSKR] Transmission controller S-NET communication: Defective communication (Abnormality in objective component system) ............................ 70 Troubleshooting by failure code, Part 5 .......................................................................... SEN01827-03 Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error ...........................................................................................................

4 Failure code [dB2RKR] Engine controller (Left bank) CAN communication: Communication error ...........................................................................................................

6 Failure code [db2RKR] Engine controller (Right bank) CAN communication: Communication error ...........................................................................................................

8 Failure code [DB30KT] Steering controller: Abnormality in controller...................................... 10 Failure code [DB31KK] Steering controller main power supply: Power supply voltage reduction (Input)................................................................................ 12 Failure code [DB32KK] Steering controller load power supply: Power supply voltage reduction (Input)................................................................................ 14 Failure code [DB35KK] Steering controller potentiometer power supply: Power supply voltage reduction (Input)................................................................................ 16 Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input) .......................................................................................... 18 Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input) .......................................................................................... 19

D475A, D475ASD-5E0

11

SEN00205-16

00 Index and foreword

Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency .......................................................................................... 20 Failure code [dB3RKR] Steering controller CAN communication: Communication error......... 22 Failure code [DB3SKR] Steering controller S-NET communication: Defective communication (Abnormality in objective component system) ............................ 24 Failure code [DBB0KK] (or LED of VHMS controller indicates "n9" o "01") VHMS controller: Lowering of source voltage ...................................................................... 26 Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o "11") Check of VHMS controller model: Disagreement of model selection................................... 27 Failure code [DBB3KK] (or LED of VHMS controller indicates "n9" o "05") VHMS controller: Lowering of direct source voltage ............................................................ 28 Failure code [DBB5KP] (or LED of VHMS controller indicates "n9" o "04") VHMS sensor power supply (5 V): Lowering of output voltage............................................ 29 Failure code [DBB6KP] (or LED of VHMS controller indicates "n9" o "02") VHMS sensor power supply (24 V): Lowering of output voltage.......................................... 30 Failure code [DBB7KP] (or LED of VHMS controller indicates "n9" o "03") VHMS sensor power supply (12 V): Lowering of output voltage.......................................... 32 Failure code [DBBQKR] (or VHMS_LED display "n8" o "02") VHMS KOM-NET: Communication error .............................................................................. 34 Failure code [dbBRKR] VHMS controller CAN communication: Communication error ........... 36 Failure code [DD12KA] Shift up switch: Disconnection ........................................................... 38 Failure code [DD12KB] Shift up switch: Short circuit............................................................... 40 Failure code [DD13KA] Shift down switch: Disconnection....................................................... 42 Failure code [DD13KB] Shift down switch: Short circuit .......................................................... 44 Failure code [DD14KA] Parking brake lever switch: Disconnection ........................................ 46 Failure code [DD14KB] Parking brake lever switch: Short circuit ............................................ 48 Failure code [DDB9L4] Reverse switch: Signal disagreement ................................................ 50 Failure code [DDK3L4] Forward switch: Signal disagreement ................................................ 52 Failure code [DDK5KA] Gearshift switch: Disconnection ........................................................ 54 Failure code [DDK5KB] Gearshift switch: Short circuit ............................................................ 56 Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time.................................................................................................... 58 Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time .. 59 Failure code [DDN7KA] Blade pitch switch: Disconnection ..................................................... 60 Failure code [DDN7KB] Blade pitch switch: Short circuit......................................................... 62 Failure code [DDN9KA] Blade tilt switch: Disconnection ......................................................... 64 Failure code [DDN9KB] Blade tilt switch: Short circuit............................................................. 66 Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time ... 68 Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time ........ 69 Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time ....... 70 Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time ............. 71 Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time ....... 72 Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time ... 73 Troubleshooting by failure code, Part 6 .......................................................................... SEN01828-03 Failure code [DDQ2KA] Parking brake lever switch: Disconnection........................................

4 Failure code [DDQ2KB] Parking brake lever switch: Short circuit ...........................................

6 Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals ........................

8 Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals .........................

9 Failure code [DDT5KA] Neutral switch: Disconnection............................................................ 10 Failure code [DDT5KB] Neutral switch: Short circuit ............................................................... 12 Failure code [DDT5KQ] Lever specification selection: Model selection signal disagreement ................................................................................... 14 Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range ....................................................................................... 15 Failure code [DGT1KA] Power train oil temperature sensor: Disconnection ........................... 16 Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range ....................................................................................... 17

12

D475A, D475ASD-5E0

00 Index and foreword

SEN00205-16

Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front): Disconnection (or LED of VHMS controller indicates "n3" o "12") ...................................... 18 Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear): Disconnection (or LED of VHMS controller indicates "n3" o "22") ...................................... 20 Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front): Short circuit (or LED of VHMS controller indicates "n3" o "11") .......................................... 22 Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" o "21") Left bank exhaust temperature sensor system (Rear): Short circuit .................................... 24 Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o "24") Right bank exhaust temperature sensor system (Front): Disconnection ............................. 26 Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o "26") Right bank exhaust temperature sensor system (Rear): Disconnection.............................. 28 Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o "23") Right bank exhaust temperature sensor system (Front): Short circuit................................. 30 Failure code [dGT6KB] (or LED of VHMS controller indicates "n3" o "25") Right bank exhaust temperature sensor system (Rear): Short circuit ................................. 32 Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection ......... 34 Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit............. 35 Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection......... 36 Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit ............ 37 Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o "32") Blow-by pressure sensor system: Disconnection ................................................................ 38 Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o "31") Blow-by pressure sensor system: Hot short ........................................................................ 39 Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o "14") Transmission oil pressure sensor: Out of input signal range ............................................... 40 Failure code [DK01KA] Left yoke angle sensor: Disconnection .............................................. 41 Failure code [DK01KB] Left yoke angle sensor: Short circuit .................................................. 42 Failure code [DK03KA] Right yoke angle sensor: Disconnection ............................................ 43 Failure code [DK03KB] Right yoke angle sensor: Short circuit ............................................... 44 Failure code [DK10KA] Fuel dial: Disconnection ..................................................................... 45 Failure code [DK10KB] Fuel dial: Short circuit ........................................................................ 46 Failure code [DK30KA] Steering potentiometer (1): Disconnection......................................... 48 Failure code [DK30KB] Steering potentiometer (1): Short circuit ............................................ 50 Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range ......... 52 Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit ................. 52 Failure code [DK30L8] Steering potentiometer (1): See table ................................................. 53 Failure code [DK31KA] Steering potentiometer (2): Disconnection......................................... 54 Failure code [DK31KB] Steering potentiometer (2): Short circuit ............................................ 56 Troubleshooting by failure code (Display of code), Part 7 .............................................. SEN01829-02 3 Failure code [DK40KA] Brake potentiometer: Disconnection ..................................................

Failure code [DK40KB] Brake potentiometer: Short circuit......................................................

4 Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range...

5 Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit..........

6 Failure code [DK55L8] Forward-reverse potentiometer: See table .........................................

7 Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection............................

8 Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit .............................. 10 Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection............................ 12 Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit .............................. 14 Failure code [DK60KA] Acceleration sensor: Disconnection................................................... 16 Failure code [DK60KB] Acceleration sensor: Short circuit ...................................................... 18 Failure code [DKH1KA] Pitch angle sensor: disconnection..................................................... 19 Failure code [DKH1KB] Pitch angle sensor: Short circuit........................................................ 20 Failure code [DKH1KX] Pitch angle sensor: Out of input signal range.................................... 21 Failure code [DLF1KA] Torque converter output speed sensor: Disconnection ...................... 22 Failure code [DLT3KA] Transmission output speed sensor: Disconnection ............................ 23 Failure code [dLT3KA] Transmission output speed sensor: Disconnection............................. 24 Failure code [DLT3KB] Transmission output speed sensor: Short circuit................................ 26 D475A, D475ASD-5E0

13

SEN00205-16

00 Index and foreword

Failure code [DV00KB] Caution buzzer: Short circuit .............................................................. 27 Failure code [DW55KA] Blade pitch back solenoid: Disconnection......................................... 28 Failure code [DW55KB] Blade pitch back solenoid: Short circuit ............................................ 29 Failure code [DW56KA] Blade pitch dump solenoid: Disconnection ....................................... 30 Failure code [DW56KB] Blade pitch dump solenoid: Short circuit ........................................... 31 Failure code [DW56KY] Blade pitch dump solenoid: Hot short ............................................... 32 Failure code [DW57KA] Left tilt limit solenoid: Disconnection ................................................. 33 Failure code [DW57KB] Left tilt limit solenoid: Short circuit ..................................................... 34 Failure code [DW57KY] Left tilt limit solenoid: Hot short ......................................................... 35 Failure code [DW58KA] Right tilt limit solenoid: Disconnection............................................... 36 Failure code [DW58KB] Right tilt limit solenoid: Short circuit .................................................. 37 Failure code [DW58KY] Right tilt limit solenoid: Hot short....................................................... 38 Failure code [DW59KA] Dual tilt selector solenoid: Disconnection.......................................... 39 Failure code [DW59KB] Dual tilt selector solenoid: Short circuit ............................................. 40 Failure code [DW59KY] Dual tilt selector solenoid: Hot short.................................................. 41 Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection ................................... 42 Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit ....................................... 43 Failure code [DW5AKY] Blade pitch selector solenoid: Hot short ........................................... 44 Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification): Disconnection....................................................................................................................... 45 Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification): Short circuit .......................................................................................................................... 46 Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification): Hot short............................................................................................................................... 47 Failure code [DW7BKA] Fan reverse solenoid: Disconnection................................................ 48 Failure code [DW7BKB] Fan reverse solenoid: Short circuit ................................................... 49 Failure code [DW7BKY] Fan reverse solenoid: Hot short........................................................ 50 Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection ................................... 51 Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit....................................... 52 Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short ........................................... 53 Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection............................. 54 Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit ................................ 55 Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short..................................... 56 Failure code [DWN5KA] Fan pump solenoid 1: Disconnection ............................................... 57 Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ................................................... 58 Failure code [DWN5KY] Fan pump solenoid 1: Hot short ....................................................... 59 Failure code [DWNCKA] Fan pump solenoid 2: Disconnection............................................... 60 Failure code [DWNCKB] Fan pump solenoid 2: Short circuit .................................................. 61 Failure code [DWNCKY] Fan pump solenoid 2: Hot short....................................................... 62 Troubleshooting by failure code (Display of code), Part 8 .............................................. SEN01830-01 Failure code [DXE0KA] LS set solenoid: Disconnection..........................................................

3 Failure code [DXE0KB] LS set solenoid: Short circuit .............................................................

4 Failure code [DXE0KY] LS set solenoid: Hot short..................................................................

5 Failure code [DXH1KA] Lock-up solenoid: Disconnection.......................................................

6 7 Failure code [DXH1KB] Lock-up solenoid: Short circuit ..........................................................

Failure code [DXH1KY] Lockup solenoid: Hot short ................................................................

8 Failure code [DXH4KA] 1st clutch ECMV: Disconnection........................................................

9 Failure code [DXH4KB] 1st clutch ECMV: Short circuit ........................................................... 10 Failure code [DXH4KY] 1st clutch ECMV: Hot short................................................................ 11 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ...................................................... 12 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit .......................................................... 13 Failure code [DXH5KY] 2nd clutch ECMV: Hot short .............................................................. 14 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ....................................................... 15 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit........................................................... 16 Failure code [DXH6KY] 3rd clutch ECMV: Hot short ............................................................... 17 Failure code [DXH7KA] Reverse clutch ECMV: Disconnection ............................................... 18 Failure code [DXH7KB] Reverse clutch ECMV: Short circuit................................................... 19 Failure code [DXH7KY] Reverse clutch ECMV: Hot short ....................................................... 20

14

D475A, D475ASD-5E0

00 Index and foreword

SEN00205-16

Failure code [DXH8KA] Forward clutch ECMV: Disconnection ............................................... 21 Failure code [DXH8KB] Forward clutch ECMV: Short circuit................................................... 22 Failure code [DXH8KY] Forward clutch ECMV: Hot short ....................................................... 23 Failure code [DXH9KA] Right steering clutch ECMV: Disconnection ...................................... 24 Failure code [DXH9KB] Right steering clutch ECMV: Short circuit.......................................... 25 Failure code [DXH9KY] Right steering clutch ECMV: Hot short .............................................. 26 Failure code [DXHAKA] Left steering clutch ECMV: Disconnection ........................................ 27 Failure code [DXHAKB] Left steering clutch ECMV: Short circuit............................................ 28 Failure code [DXHAKY] Left steering clutch ECMV: Hot short ................................................ 29 Failure code [DXHBKA] Right brake ECMV: Disconnection.................................................... 30 Failure code [DXHBKB] Right brake ECMV: Short circuit ....................................................... 31 Failure code [DXHBKY] Right brake ECMV: Hot short............................................................ 32 Failure code [DXHCKA] Left brake ECMV: Disconnection ...................................................... 33 Failure code [DXHCKB] Left brake ECMV: Short circuit.......................................................... 34 Failure code [DXHCKY] Left brake ECMV: Hot short .............................................................. 35 Failure code [F@BBZL] (or VHMS_LED display "n3" o "38") Engine blow-by pressure sensor: Abnormally high pressure occurrence ............................ 36 Failure code [F@BYNS] (or VHMS_LED display "n3" o "61") Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise ................. 38 Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise .................. 40 Failure code [F@BZNS] (or VHMS_LED display "n3" o "38") Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise ............... 42 Failure code [f@BZNS] (or VHMS_LED display "n3" o "39") Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise ................ 44 Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise ................. 46 Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise .................. 48 Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise ............... 50 Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise ................ 52 Troubleshooting of electrical system (E-mode)............................................................... SEN01831-02 Contents of troubleshooting table ............................................................................................

3 E-1 The engine does not start .................................................................................................

4 E-2 The preheater does not operate .......................................................................................

8 E-3 The ripper pin puller cylinder does not operate................................................................. 12 E-4 The monitor panel does not come on at all when the starting switch is turned on............ 14 E-5 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out.......................................................................................................... 16 E-6 When the starting switch is turned on, the basic check items flash .................................. 17 E-7 While the engine is operating, any caution item flashes ................................................... 18 E-8 An emergency caution item flashes while the engine is running ...................................... 21 E-9 While the preheater is operating, the preheating pilot lamp does not come on ................ 24 E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)............................................................................................ 26 E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on ........................................................................................................... 26 E-12 The engine coolant temperature gauge does not indicate normally ............................... 27 E-13 Indication of the power train (torque converter) temperature gauge is abnormal ........... 28 E-14 The hydraulic oil temperature gauge does not indicate normally.................................... 30 E-15 Indication of the fuel gauge is abnormal ......................................................................... 31 E-16 Indications of gear speed and engine speed are abnormal ............................................ 32 E-17 Indication of the shift mode service meter is abnormal ................................................... 32 E-18 The switch module cannot be operated .......................................................................... 33 E-19 The warning lamp does not flash or does not go out ...................................................... 34 E-20 The alarm buzzer does not sound or does not stop........................................................ 35 D475A, D475ASD-5E0

15

SEN00205-16

00 Index and foreword

E-21 Auto shift down is not possible or is not released ........................................................... 36 E-22 The automatic pitch back system does not operate (only superdozer specification) ...... 37 E-23 The alarm buzzer cannot be cancelled ........................................................................... 38 E-24 The operator mode cannot be operated.......................................................................... 39 E-25 The service mode cannot be operated............................................................................ 40 E-26 The back-up alarm does not sound................................................................................. 42 E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on ............................................................................................................... 44 E-28 Troubleshooting for air conditioner system ..................................................................... 50 E-29 Orbcomm terminal does not operate normally (Data are not transmitted) ...................... 65 E-30 Fan does not reverse ...................................................................................................... 67 E-31 Gear cannot be shifted.................................................................................................... 69 E-32 Electric priming pump does not operate or does not stop automatically......................... 70 Troubleshooting of hydraulic and mechanical system (H-mode) .................................... SEN01832-02 Information in troubleshooting table.........................................................................................

3 H-1 No force (no drawbar pull) ................................................................................................

4 H-2 No travel (at 2nd or 3rd speed) .........................................................................................

6 H-3 No travel at all gear speeds ..............................................................................................

7 H-4 Machine travels only in one direction forward or in reverse..............................................

8 H-5 Large time lag at gear speed shifting or forward-reverse shifting .....................................

9 H-6 Steering is not possible ..................................................................................................... 10 H-7 Steering is possible only on one side................................................................................ 11 H-8 Steering overrun occurs .................................................................................................... 12 H-9 Brake does not work ......................................................................................................... 13 H-10 Torque converter is not lock-up....................................................................................... 14 H-11 Power train oil is overheated ........................................................................................... 15 H-12 All work equipment speeds are slow............................................................................... 16 H-13 Work equipment does not move ..................................................................................... 17 H-14 Blade lift speed is slow or lacks power ........................................................................... 18 H-15 Blade tilt speed is slow or lacks power ........................................................................... 19 H-16 Ripper lift speed is slow or lacks power .......................................................................... 20 H-17 Ripper tilt speed is slow or lacks power .......................................................................... 21 H-18 Excessive hydraulic drift of blade lift ............................................................................... 22 H-19 Excessive hydraulic drift of blade tilt ............................................................................... 23 H-20 Excessive hydraulic drift of ripper lift............................................................................... 24 H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine) .................. 24 H-22 Blade pitch does not work (dual tilt attachment machine)............................................... 25 H-23 Abnormal sound comes out from around work equipment pump ................................... 25 H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats) ........................................................................................................... 26 H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator)................................................................................................... 27 Troubleshooting of engine (S-mode)............................................................................... SEN01833-01 Method of using troubleshooting chart.....................................................................................

3 S-1 Starting performance is poor .............................................................................................

6 S-2 Engine does not start ........................................................................................................

7 S-3 Engine does not pick up smoothly .................................................................................... 10 S-4 Engine stops during operations......................................................................................... 11 S-5 Engine does not rotate smoothly....................................................................................... 12 S-6 Engine lacks output (or lacks power) ................................................................................ 13 S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 15 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 16 S-9 Oil becomes contaminated quickly.................................................................................... 17 S-10 Fuel consumption is excessive ....................................................................................... 18 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 19 S-12 Oil pressure drops........................................................................................................... 20 S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 21 S-14 Coolant temperature becomes too high (overheating).................................................... 22

16

D475A, D475ASD-5E0

00 Index and foreword

SEN00205-16

S-15 Abnormal noise is made ................................................................................................. 23 S-16 Vibration is excessive ..................................................................................................... 24 50 Disassembly and assembly General information on disassembly and assembly ....................................................... SEN02013-06 How to read this manual..........................................................................................................

2 Coating materials list ...............................................................................................................

4 Special tools list .......................................................................................................................

7 Sketches of special tools ......................................................................................................... 14 Engine and cooling system (SAA12V140E-3) ................................................................ SEN02014-01 Removal and installation of engine assembly .........................................................................

2 Removal and installation of radiator assembly ........................................................................

6 Removal and installation of aftercooler assembly ...................................................................

8 Removal and installation of radiator guard assembly .............................................................. 10 Removal and installation of fuel tank assembly....................................................................... 12 Removal and installation of engine hood assembly ................................................................ 13 Removal and installation of fan drive assembly ...................................................................... 15 Removal and installation of fan motor assembly ..................................................................... 16 Engine (SAA12V140E-3) ................................................................................................ SEN02338-03 Removal and installation of fuel supply pump assembly .........................................................

2 Removal and installation of cylinder head assembly ...............................................................

8 Removal and installation of fuel injector assembly .................................................................. 19 Removal and installation of engine front seal .......................................................................... 25 Removal and installation of engine rear seal........................................................................... 27 Power train, Part 1 .......................................................................................................... SEN02015-01 Removal and installation of damper assembly ........................................................................

2 Disassembly and assembly of damper assembly....................................................................

4 Removal and installation of power train unit assembly............................................................

7 Removal and installation of PTO, torque converter assembly................................................. 10 Disconnection and connection of PTO, torque converter assembly ........................................ 12 Disassembly and assembly of torque converter assembly...................................................... 14 Disassembly and assembly of PTO assembly......................................................................... 24 Removal and installation of TORQFLOW transmission assembly .......................................... 31 Disassembly and assembly of TORQFLOW transmission assembly ...................................... 32 Power train, Part 2 .......................................................................................................... SEN02016-03 Disassembly and assembly of steering case assembly ..........................................................

2 Disassembly and assembly of steering clutch, brake assembly.............................................. 15 Disassembly and assembly of transfer gear housing assembly.............................................. 23 Removal and installation of power train pump assembly ........................................................ 27 Removal and installation of scavenging pump assembly ........................................................ 27 Removal and installation of torque converter oil cooler ........................................................... 28 Removal and installation of torque converter valve assembly................................................. 29 Disassembly and assembly of torque converter valve assembly ............................................ 30 Removal and installation of transmission control valve assembly ........................................... 34 Disassembly and assembly of transmission control valve assembly (ECMV assembly) ........ 35 Removal and installation of steering control valve assembly .................................................. 38 Disassembly and assembly of steering control valve assembly .............................................. 39 Removal and installation of final drive assembly ..................................................................... 41 Disassembly and assembly of final drive assembly ................................................................ 43 Undercarriage and frame, Part 1 .................................................................................... SEN02017-03 Removal and installation of track frame assembly ..................................................................

2 Disassembly and assembly of idler assembly .........................................................................

4 Removal and installation of recoil spring assembly .................................................................

7 Disassembly and assembly of recoil spring assembly ............................................................ 11 Removal and installation of track roller assembly ................................................................... 13 Disassembly and assembly of track roller assembly ............................................................... 15 Removal and installation of carrier roller assembly ................................................................. 17 Disassembly and assembly of carrier roller assembly............................................................. 18 D475A, D475ASD-5E0

17

SEN00205-16

00 Index and foreword

Removal and installation of bogie assembly............................................................................ 21 Disassembly and assembly of bogie assembly ....................................................................... 25 Removal and installation of No.1 bogie assembly ................................................................... 27 Removal and installation of operator's seat isolator ................................................................ 32 Disassembly and assembly of operator's seat isolator ............................................................ 33 Undercarriage and frame, Part 2 .................................................................................... SEN02018-02 Expansion and installation of track shoe assembly .................................................................

2 Overall disassembly and overall assembly of track shoe ........................................................

5 Press-fitting jig dimension table for link press.......................................................................... 21 Field disassembly and assembly of one link............................................................................ 22 Disassembly and assembly of master link............................................................................... 27 Removal and installation of pivot shaft assembly .................................................................... 31 Removal and installation of equalizer bar................................................................................ 32 Disassembly and assembly of equalizer bar bushing.............................................................. 35 Hydraulic system............................................................................................................. SEN02019-01 Removal and installation of hydraulic pump assembly ............................................................

2 Removal and installation of hydraulic valve assembly.............................................................

4 Disassembly and assembly of control valve ............................................................................

5 Disassembly and assembly of merge divider valve and self pressure reducing valve assembly 9 Removal and installation of PPC relief valve assembly ........................................................... 11 Disassembly and assembly of hydraulic cylinder assembly .................................................... 12 Disassembly and assembly of ripper pin puller cylinder assembly.......................................... 17 Work equipment.............................................................................................................. SEN02020-00 Removal and installation of blade assembly............................................................................

2 Disassembly and assembly of giant ripper assembly ..............................................................

4 Cab and its attachments ................................................................................................. SEN02021-01 Removal and installation of ROPS guard ................................................................................

2 Removal and installation of operator’s cab assembly..............................................................

3 Removal and installation of floor frame assembly ...................................................................

4 Electrical system ............................................................................................................. SEN02339-02 Removal and installation of controller assembly......................................................................

2 Removal and installation of engine controller assembly (left)..................................................

3 Removal and installation of air conditioner condenser assembly ............................................

4 Removal and installation of air conditioner compressor assembly ..........................................

5 Removal and installation of air conditioner unit .......................................................................

7 90 Diagrams and drawings Hydraulic diagrams and drawings................................................................................... SEN00225-00 Power train hydraulic circuit diagram.......................................................................................

3 Hydraulic circuit diagram (1/3) .................................................................................................

5 Hydraulic circuit diagram (2/3) .................................................................................................

7 Hydraulic circuit diagram (3/3) .................................................................................................

9 Electrical diagrams and drawings ................................................................................... SEN00226-03 Electrical circuit diagram (1/13) ...............................................................................................

3 Electrical circuit diagram (2/13) ...............................................................................................

5 Electrical circuit diagram (3/13) ...............................................................................................

7 Electrical circuit diagram (4/13) ...............................................................................................

9 Electrical circuit diagram (5/13) ............................................................................................... 11 Electrical circuit diagram (6/13) ............................................................................................... 13 Electrical circuit diagram (7/13) ............................................................................................... 15 Electrical circuit diagram (8/13) ............................................................................................... 17 Electrical circuit diagram (9/13) ............................................................................................... 19 Electrical circuit diagram (10/13) ............................................................................................. 21 Electrical circuit diagram (11/13).............................................................................................. 23 Electrical circuit diagram (12/13) ............................................................................................. 25 Electrical circuit diagram (13/13) ............................................................................................. 27 Electrical circuit diagram of inside cab..................................................................................... 29 Connector arrangement diagram............................................................................................. 31

18

D475A, D475ASD-5E0

00 Index and foreword

D475A, D475ASD-5E0

SEN00205-16

19

SEN00205-16

D475A, D475ASD-5E0 Bulldozer Form No. SEN00205-16

© 2013 KOMATSU All Rights Reserved Printed in Japan 01-13(02)

20

SEN00206-05

BULLDOZER 1SHOP MANUAL

D475A-5E0 D475ASD-5E0

Machine model

Serial number

D475A-5E0 D475ASD-5E0

30001 and up 30001 and up

00 Index and foreword

1

Foreword and general information 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

D475A, D475ASD-5E0

1

SEN00206-05

00 Index and foreword

Safety notice

1

Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe.

Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

1.

2

General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.

2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc.

4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment.

5) Only qualified workers must carry out work and operation which require license or qualification.

6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7)

8)

9)

If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out w elding work, alw ays wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.

Before starting work, warm up your body thoroughly to start work under good condition.

Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.

Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5

Prohibition of operation and handling by unlicensed workers

6 Safety check before starting work 7

Wearing protective goggles (for cleaning or grinding work)

8

Wearing shielding goggles and protectors (for welding work)

9 Good physical condition and preparation 10

Precautions against work which you are not used to or you are used to too much

D475A, D475ASD-5E0

00 Index and foreword

2.

3.

Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving.

2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work.

4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out.

2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits.

3) Before starting work, stop the engine.

When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts.

4) For the machine equipped with a battery disconnct switch, turn the battery disconnect switch to the OFF (O) position and pull the switch key out, before starting the work. For machines without a battery disconnct switch, remove the cable from the battery , before starting the work. Always remove the cable from the negative (-) terminal first.

D475A, D475ASD-5E0

SEN00206-05

5)

When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover.

7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.

8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires.

9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular.

10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated.

11) When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed.

3

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