Komatsu D475A-3 Bull Dozer Shop Manual SEBM029001

Description

• Model List:
  • D475A-3 Bull Dozer

• 1. COVER
• 2. CONTENTS
• 3. Notice of revision
• 4. SAFETY
• 4.1. SAFETY NOTICE
• 5. FOREWORD
• 5.1. GENERAL
• 5.2. HOW TO READ THE SHOP MANUAL
• 5.3. HOISTING INSTRUCTIONS
• 5.4. METHOD OF DISASSEMBLING, CONNECTING PUSHPULL TYPE COUPLER
• 5.5. COATING MATERIALS
• 5.6. STANDARD TIGHTENING TORQUE
• 5.7. ELECTRIC WIRE CODE
• 5.8. CONVERSION TABLE
• 5.9. UNITS
• 6. GENERAL
• 6.1. SPECIFICATION DIMENSION DRAWINGS
• 6.2. SPECIFICATIONS
• 6.3. WEIGHT TABLE
• 6.4. TABLE OF FUEL, COOLANT AND LUBRICANTS
• 7. STRUCTURE AND FUNCTION
• 7.1. ENGINE, POWER TRAIN COOLING SYSTEM DRAWING
• 7.2. POWER TRAIN
• 7.3. POWER TRAIN SKELETON
• 7.4. POWER TRAIN HYDRAULIC PIPING DIAGRAM
• 7.5. POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
• 7.6. TORQUE CONVERTER AND PTO
• 7.7. TORQUE CONVERTER VALVE
• 7.8. TRANSMISSION
• 7.9. TRANSMISSION CONTROL
• 7.10. TRANSMISSION ECMV
• 7.11. TRANSMISSION CLUTCH ECMV
• 7.12. TRANSMISSION LUBRICATION RELIEF VALVE
• 7.13. PRIORITY VALVE
• 7.14. STEERING, BRAKE CONTROL
• 7.15. TRANSFER, BEVEL GEAR SHAFT , STEERING
• 7.16. TRANSFER, BEVEL PINION
• 7.17. STEERING ECMV
• 7.18. STEERING CLUTCH ECMV, STEERING BRAKE ECMV
• 7.19. SUDDEN STOP PREVENTION VALVE
• 7.20. FINAL DRIVE
• 7.21. TRACK FRAME
• 7.22. HYDRAULIC TANK
• 7.23. PPC VALVE
• 7.24. MAIN CONTROL VALVE
• 7.25. PINPULLER HYDRAULIC SYSTEM DRAWING
• 7.26. PINPULLER HYDRAULIC CIRCUIT DRAWING
• 7.27. PINPULLER SOLENOID VALVE
• 7.28. AIR CONDITIONER
• 7.29. ENGINE CONTROL
• 7.30. ENGINE CONTROL SYSTEM
• 7.31. DECELERATION POTENTIOMETER
• 7.32. ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER
• 7.33. MONITOR SYSTEM
• 7.34. MONITOR PANEL
• 7.35. MODE SELECTION SYSTEM
• 7.36. ELECTRICAL EQUIPMENT
• 7.37. STEERING ELECTRONIC CONTROL
• 8. TESTING AND ADJUSTING
• 8.1. STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
• 8.2. STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
• 8.3. TESTING AND ADJUSTING
• 8.3.1. TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 8.3.2. MEASURING ENGINE SPEED
• 8.3.3. MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
• 8.3.4. MEASURING EXHAUST TEMPERATURE
• 8.3.5. MEASURING EXHAUST COLOR
• 8.3.6. ADJUSTING VALVE CLEARANCE
• 8.3.7. MEASURING COMPRESSION PRESSURE
• 8.3.8. MEASURING BLOWBY PRESSURE
• 8.3.9. MEASURING ENGINE OIL PRESSURE
• 8.3.10. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 8.3.11. TESTING AND ADJUSTING ALTERNATOR BELT TENSION
• 8.3.12. TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
• 8.3.13. ADJUSTING ENGINE SPEED SENSOR
• 8.3.14. ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
• 8.3.15. MEASURING POWER TRAIN OIL PRESSURE
• 8.3.16. SIMPLE METHOD OF TESTING BRAKE PERFORMANCE
• 8.3.17. ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
• 8.3.18. ADJUSTING PCCS LEVER CONSOLE POSITION
• 8.3.19. EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
• 8.3.20. ADJUSTING CLEARANCE OF IDLER
• 8.3.21. TESTING AND ADJUSTING TRACK SHOE TENSION
• 8.3.22. MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
• 8.3.23. TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE
• 8.3.24. MEASURING PPC VALVE AND PITCH, TILT CONTROL VALVE OUTPUT PRESSURE
• 8.3.25. ADJUSTING PPC VALVE
• 8.3.26. MEASURING OUTPUT PRESSURE OF DEMAND SOLENOID VALVE
• 8.3.27. MEASURING OUTPUT PRESSURE OF RIPPER PINPULLER SOLENOID VALVE
• 8.3.28. CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER
• 8.3.29. MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER
• 8.3.30. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
• 8.3.31. BLEEDING AIR FROM HYDRAULIC CYLINDERS
• 8.3.32. ADJUSTING WORK EQUIPMENT SAFETY LEVER
• 8.3.33. ADJUSTING RIPPER LEVER POSITION
• 8.3.34. PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (DUAL TILT DOZER SPECIFICATION)
• 8.3.35. SPECIAL FUNCTION OF MONITOR PANEL (EMMS)
• 8.3.36. ADJUSTMENT METHOD OF REPLACED CONTROLLER
• 8.3.37. PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM
• 8.3.38. HANDLING OF OPTIONAL DEVICES
• 8.3.39. PM CLINIC SERVICE
• 8.3.40. UNDERCARRIAGE TROUBLESHOOTING REPORT
• 8.3.41. TROUBLESHOOTING
• 8.3.41.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 8.3.41.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 8.3.41.3. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 8.3.41.4. CHECKS BEFORE TROUBLESHOOTING
• 8.3.41.5. CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
• 8.3.41.6. TABLE OF CONNECTORS
• 8.3.41.7. CONNECTOR ARRANGEMENT DRAWING
• 8.3.41.8. CONNECTION TABLE FOR CONNECTOR PIN NUMNERS
• 8.3.41.9. TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE)
• 8.3.41.10. TROUBLESHOOTING OF ELECTRICAL SYSTEM (EMODE)
• 8.3.41.11. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (HMODE)
• 9. DISASSEMBLY AND ASSEMBLY
• 9.1. POWER TRAIN UNIT ASSEMBLY
• 9.1.1. REMOVAL
• 9.1.2. INSTALLATION
• 9.2. PTO, TORQUE CONVERTER ASSEMBLY
• 9.2.1. REMOVAL
• 9.2.2. INSTALLATION
• 9.3. TORQFLOW TRANSMISSION ASSEMBLY
• 9.3.1. DISASSEMBLY
• 9.3.2. ASSEMBLY
• 9.4. STEERING CASE ASSEMBLY
• 9.4.1. DISASSEMBLY
• 9.4.2. ASSEMBLY
• 9.5. TRANSMISSION CONTROL VALVE ASSEMBLY
• 9.5.1. REMOVAL
• 9.5.2. INSTALLATION
• 9.6. STEERING CONTROL VALVE ASSEMBLY
• 9.6.1. REMOVAL
• 9.6.2. INSTALLATION
• 9.7. FLOOR FRAME ASSEMBLY
• 9.7.1. REMOVAL
• 9.7.2. INSTALLATION
• 9.8. DASHBOARD ASSEMBLY
• 9.8.1. REMOVAL
• 9.8.2. INSTALLATION
• 9.9. CONTROLLER ASSEMBLY
• 9.9.1. REMOVAL
• 9.9.2. INSTALLATION
• 9.10. AIR CONDITIONER UNIT ASSEMBLY
• 9.10.1. REMOVAL
• 9.10.2. INSTALLATION
• 10. MAINTENANCE STANDARD
• 10.1. ENGINE MOUNT
• 10.2. DAMPER,UNIVERSAL JOINT
• 10.3. TORQUE CONVERTER
• 10.4. TORQUE CONVERTER VALVE
• 10.5. TORQFLOW TRANSMISSION
• 10.6. POWER TRAIN, HYDRAULIC, LUBRICATION PUMP
• 10.7. TRANSFER,BEVEL PINION
• 10.8. BEVEL GEAR SHAFT, STEERING CLUTCH,BRAKE
• 10.9. PARKING BRAKE VALVE
• 10.10. WORK EQUIPMENT CONTROL PUMP
• 10.11. MAIN CONTROL VALVE
• 10.12. PPC VALVE
• 10.13. WORK EQUIPMENT CYLINDER
• 10.14. CYLINDER STAY
• 10.15. BLADE
• 10.16. RIPPER EQUIPMENT
• 11. OTHERS
• 11.1. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
• 11.1.1. SINGLE TILT SPECIFTICATION
• 11.1.2. DUAL TILT SPECFICATION
• 11.1.3. SUPER DOZER SPECFICATION
• 11.2. ELECTRICAL CIRCUIT DIAGRAM
• 11.2.1. SINGLE TILT AND DUAL TILT SPECIFICATIONS
• 11.2.1.1. CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/4)
• 11.2.1.2. CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/4)
• 11.2.1.3. CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/4)
• 11.2.1.4. CHASSIS ELECTRICAL CIRCUIT DIAGRAM (4/4)
• 11.2.2. SUPER DOZER SPECFICATION
• 11.2.2.1. CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/3)
• 11.2.2.2. CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/3)
• 11.2.2.3. CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/3)
• 11.2.3. ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB