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D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00205-18 00 Index and foreword
Shop Manual, contents binder, binder label and tabs ............................................................ SEN00203-18
01 Specification.................................................................................................................... SEN00207-01
Specification and technical data...................................................................................... SEN00208-01
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D475A, D475ASD-5E0 3
SEN00205-18 00 Index and foreword
Table of contents 1
00 Index and foreword
Index ............................................................................................................................... SEN00205-18
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
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ORBCOMM terminal................................................................................................................ 51
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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 .......................................................................... SEN01823-03
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
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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
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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
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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
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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
Failure code [DK40KA] Brake potentiometer: Disconnection .................................................. 3
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
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SEN00205-18
2016 KOMATSU
All Rights Reserved
Printed in Japan 02-16 (01)
20
SEN00206-05
D475A-5E0
D475ASD-5E0
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 situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
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12) When assembling or installing parts, 7) Limit the hanging angle to 60, as a rule.
always tighten them to the specified Do not sling a heavy load with ropes form-
torques. When installing protective parts ing a wide hanging angle from the hook.
such as guards, or parts which vibrate vio- When hoisting a load with 2 or more
lently or rotate at high speed, be particu- ropes, the force subjected to each rope
l ar l y c a r e f u l t o c h e c k t h a t t h e y a r e will increase with the hanging angle. The
installed correctly. table below shows the variation of allow-
13) When aligning 2 holes, never insert your able load in kN {kg} when hoisting is made
fingers or hand. Be careful not to get your with 2 ropes, each of which is allowed to
fingers caught in a hole. sling up to 9.8 kN {1,000 kg} vertically, at
14) When measuring hydraulic pressure, various hanging angles. When the 2 ropes
check that the measuring tools are cor- sling a load vertically, up to 19.6 kN {2,000
rectly assembled. kg} of total weight can be suspended.
15) Take care when removing or installing the This weight is reduced to 9.8 kN {1,000
tracks of track-type machines. When kg} when the 2 ropes make a hanging
removing the track, the track separates angle of 120. If the 2 ropes sling a 19.6
suddenly, so never let anyone stand at kN {2,000 kg} load at a lifting angle of
either end of the track. 150, each of them is subjected to a force
16) If the engine is operated for a long time in as large as 39.2 kN {4,000 kg}.
a place which is not ventilated well, you
may suffer from gas poisoning. Accord-
ingly, open the windows and doors to ven-
tilate well.
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q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
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3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
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Example:
Standard size Tolerance
0.022
120
0.126
Example:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0
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3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
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2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
D475A, D475ASD-5E0 15
SEN00206-05 00 Index and foreword
16 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
D475A, D475ASD-5E0 17
SEN00206-05 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D475A, D475ASD-5E0 19
SEN00206-05 00 Index and foreword
20 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
q 114 engine
q 107 engine
D475A, D475ASD-5E0 21
SEN00206-05 00 Index and foreword
q 95, 125 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- 30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
D475A, D475ASD-5E0 23
SEN00206-05 00 Index and foreword
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6
Cov-
AV Standard 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
24 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch
D475A, D475ASD-5E0 25
SEN00206-05 00 Index and foreword
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
D475A, D475ASD-5E0 27
SEN00206-05 00 Index and foreword
28 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D475A, D475ASD-5E0 29
SEN00206-05 00 Index and foreword
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
D475A, D475ASD-5E0 31
SEN00206-05 00 Index and foreword
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
D475A, D475ASD-5E0 33
SEN00206-05 00 Index and foreword
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14
34 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 2 1.53 0.20 51 0.51 0.10
1/8 20 2 2.04 0.20 15 2 1.53 0.20
1/4 25 3 2.55 0.31 20 2 2.04 0.20
3/8 35 4 3.57 0.41 25 3 2.55 0.31
1/2 55 6 5.61 0.61 35 4 3.57 0.41
3/4 75 8 7.65 0.82 45 5 4.59 0.51
D475A, D475ASD-5E0 35
SEN00206-05 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
D475A, D475ASD-5E0 37
SEN00206-05 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D475A, D475ASD-5E0 39
SEN00206-05 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 D475A, D475ASD-5E0
00 Index and foreword SEN00206-05
D475A, D475ASD-5E0 41
SEN00206-05
2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
42
SEN00208-01
D475A-5E0
D475ASD-5E0
01 Specification 1
Specification and technical data
Specification drawings .................................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................. 12
Fuel, coolant and lubricants .......................................................................................................................... 16
D475A, D475ASD-5E0 1
SEN00208-01 01 Specification
Specification drawings 1
Dimensions
2 D475A, D475ASD-5E0
01 Specification SEN00208-01
Specifications 1
Semi-U tiltdozer and full-U tiltdozer specifications
Machine weight
Tractor 83,510
Weight
3rd 0 10.9
Gear
Performance
1st 0 4.7
Reverse
2
Semi-U dozer + Variable giant ripper kPa {kg/cm } 163.9 {1.67}
Above + ROPS cab + Air conditioner 165.3 {1.69}
+ Perforated side cover
Tractor 6,680
Overall
length
D475A, D475ASD-5E0 3
SEN00208-01 01 Specification
Power train + Lubricating oil pump (Tandem) Gear type (BAL 160 + 160 + 112)
4 D475A, D475ASD-5E0
01 Specification SEN00208-01
2
MPa {kg/cm } Max. using pressure: 17.5 {178}
Type
Work equipment
D475A, D475ASD-5E0 5
SEN00208-01 01 Specification
6 D475A, D475ASD-5E0
01 Specification SEN00208-01
Performance
D475A, D475ASD-5E0 7
SEN00208-01 01 Specification
Superdozer specification
Machine weight
Weight
Tractor 84,430
kg
Superdozer + ROPS cab + Air conditioner 113,120
+ Counterweight
Min. turning radius m 4.6
Gradeability deg. 30
Stability (Front, Rear, Left, Right) deg. 35
1st 0 3.5
Forward
Gear speeds
3rd 0 10.9
1st 0 4.7
Reverse
2
Superdozer + ROPS cab + kPa {kg/cm } 151.4 {1.54}
Air conditioner + Counterweight
Overall
length
Tractor 6,680
mm
Superdozer + Counterweight 10,525
Overall
Tractor 3,620
width
mm
Superdozer 6,465
Dimensions
8 D475A, D475ASD-5E0
01 Specification SEN00208-01
D475A, D475ASD-5E0 9
SEN00208-01 01 Specification
Type
For blade lift
valve
10 D475A, D475ASD-5E0
01 Specification SEN00208-01
D475A, D475ASD-5E0 11
SEN00208-01 01 Specification
Weight table 1
k This weight table is a reference for handling and transportation of components.
Unit: kg
12 D475A, D475ASD-5E0
01 Specification SEN00208-01
Unit: kg
D475A, D475ASD-5E0 13
SEN00208-01 01 Specification
Superdozer specification
Unit: kg
14 D475A, D475ASD-5E0
01 Specification SEN00208-01
Unit: kg
D475A, D475ASD-5E0 15
SEN00208-01 01 Specification
16 D475A, D475ASD-5E0
01 Specification SEN00208-01
Unit: l
D475A, D475ASD-5E0
Refilling points
Specified capacity Refill capacity
Engine oil pan 126 121
Damper case 2.2 2.2
Power train case 410 210
Final drive case (each) 75 75
Hydraulic system
420 170
(with blade, without ripper)
Cooling system
210
(including reservoir tank)
Fuel tank 1670
D475A, D475ASD-5E0 17
SEN00208-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 08-07 (01)
18
SEN00210-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00210-00 10 Structure, function and maintenance standard
1. Main radiator
2. Sub radiator
3. Turbocharger
4. Engine
5. Power train oil cooler
6. Water pump
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
Engine mount 1
Unit: mm
D475A, D475ASD-5E0 3
SEN00210-00 10 Structure, function and maintenance standard
4 D475A, D475ASD-5E0
SEN00210-00 10 Structure, function and maintenance standard
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
D475A, D475ASD-5E0 7
SEN00210-00 10 Structure, function and maintenance standard
Function Structure
q The rotation and torque of the engine are q Cylinder block (7) is supported on shaft (1)
transmitted to the shaft of this pump. Then, through spline (C). Shaft (1) is supported on
this pump converts the rotation and torque into the front and rear bearings.
hydraulic energy and discharges hydraulic oil q The end of piston (6) has a spherical hollow
according to the load. which is combined with shoe (5). Piston (6)
q The discharge of this pump can be changed by and shoe (5) form a spherical bearing.
changing the swash plate angle in it. q Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly. Rocker cam
(4) receives high-pressure oil and forms a
static pressure bearing and slides on cylindri-
cal surface B of cradle (2).
q Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
q Cylinder block (7) rotates relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic balance on the valve plate is main-
tained properly.
q The oil in each cylinder of cylinder block (7)
can be sucked and discharged through valve
plate (8).
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
D475A, D475ASD-5E0 9
SEN00210-00 10 Structure, function and maintenance standard
2) Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (1).
q Servo piston (1) reciprocates straight accord-
ing to the signal pressure of the PC valve. This
straight motion is transmitted to rocker cam
(4). Then, rocker cam (4) supported on the
cylindrical surface of cradle (2) slides in the
rotating direction.
q The pressure receiving area of the top of servo
piston (1) is different from that of the bottom.
Main pump discharge pressure (self-pressure)
(PA) is kept led in the pressure chamber on the
small-diameter piston side (upper side).
q PC valve output pressure (PEN) is led in the
pressure chamber on the large-diameter piston
side (lower side).
q The movement of servo piston (1) is controlled
according to the difference between pressure
(PA) on the small-diameter piston side and
pressure (PEN) on the large-diameter piston
side and the ratio of the pressure receiving
area of the small-diameter piston to that of the
large-diameter piston.
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
D475A, D475ASD-5E0 11
SEN00210-00 10 Structure, function and maintenance standard
Function
q The PC valve works so the relationship
between the current input to the EPC valve
and pump swash plate angle (a) will be as
shown in the figure below.
12 D475A, D475ASD-5E0
SEN00210-00 10 Structure, function and maintenance standard
(1) When EPC output pressure is high [When EPC current (i) is large]
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
Operation
q The relationship between the EPC valve input
current (i) and EPC valve output pressure (F)
is as shown in the figure below.
D475A, D475ASD-5E0 15
SEN00210-00 10 Structure, function and maintenance standard
(2) When EPC output pressure is low [When EPC current (i) is small]
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
Operation
q If EPC current (i) reduces and the EPC output
pressure lowers, spool (7) is pushed to the
right by the force of spring (6).
q Accordingly, port (g) is disconnected from port
(f) and port (f) is connected to the drain circuit.
q At this time, the oil in chamber (X) on the large
diameter side of servo piston (1) flows through
port (f) of the PC valve to the drain circuit.
q As a result, servo piston (1) is moved toward
the maximum swash plate angle side (lower
side) by the pressure of chamber (Y) on the
small diameter side.
D475A, D475ASD-5E0 17
SEN00210-00 10 Structure, function and maintenance standard
18 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball
D475A, D475ASD-5E0 19
SEN00210-00 10 Structure, function and maintenance standard
Function
q The rotation and torque of the engine are
transmitted to the shaft of this pump. Then,
this pump converts the rotation and torque into
hydraulic energy and discharges hydraulic oil
according to the load.
q The discharge of this pump can be changed by
changing the swash plate angle in it.
Structure
q Cylinder block (7) is supported on shaft (1)
through spline (B). Shaft (1) is supported on
the front and rear bearings.
q The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6)
and shoe (5) form a spherical bearing.
q Shoe (5) is kept pressed against plane (A) of
rocket cam (4) and slid circularly. Rocker cam
(4) slides around ball (11).
q Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
q Cylinder block (7) rotates relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic balance on the valve plate is main-
tained properly.
q The oil in each cylinder of cylinder block (7)
can be sucked and discharged through valve
plate (8).
20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
D475A, D475ASD-5E0 21
SEN00210-00 10 Structure, function and maintenance standard
2) Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (10).
q Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the servo valve.
This straight motion is transmitted to rocker
cam (4). Then, rocker cam (4) supported on
ball (11) rocks around ball (11).
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
3) Servo valve
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
D475A, D475ASD-5E0 23
SEN00210-00 10 Structure, function and maintenance standard
Function
q The servo valve works so the relationship
between the current input to the EPC valve
and pump swash plate angle (a) will be as
shown in the figure below.
24 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
Operation
q The output oil of the EPC valve flows in the pis-
ton chamber (C) to push piston (6). Piston (6)
pushes spool (5) until it is balanced with the
spring.
q Then, land (PE) of the servo piston pressure
passage is connected to the pump discharge
passage by the cut of spool (5) and the dis-
charge pressure is led to the servo piston.
q The servo piston is raised by the rocker cam.
The position feedback is applied and the lever
moves to compress the spring.
q If spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
shut off. The pressure in the servo piston
chamber lowers and the rocker cam returns
toward the maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with the spring force.
q Accordingly, as the EPC output pressure is
heightened, the swash plate angle is
decreased. As the EPC output pressure is
lowered, the swash plate angle is increased.
D475A, D475ASD-5E0 25
SEN00210-00 10 Structure, function and maintenance standard
Specifications
Type : LMF180
Capacity : 180 cc/rev
Rated speed : 982 rpm
Rated flow : 178 l/min
Check valve cracking pressure:
0.07 MPa {0.7 kg/cm2}
26 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Center spring
10. Safety-suction valve
D475A, D475ASD-5E0 27
SEN00210-00 10 Structure, function and maintenance standard
1. Hydraulic motor
Function
q This hydraulic motor is a swash plate type axial
piston motor, which converts the pressure of
the hydraulic oil sent from the hydraulic pump
into revolution.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses pistons (4) (4 or 5 pieces) and gener-
ates force (F1) (F1 kg = P kg/cm2 x x/4D2 cm2).
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a)
degrees to the output shaft (1), the force is
divided into components (F2) and (F3).
q Radial component (F3) generates torque
against the (Y Y) line connecting the top
dead center and bottom dead center (T = F3 x
ri).
q The resultant of this torque [T = s (F3 x ri)]
rotates cylinder block (5) through the piston.
q Since cylinder block (5) is coupled with the out-
put shaft by means of spline, the output shaft
revolves to transmit the torque.
28 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
2. Safety-suction valve
1. Piston
2. Main valve
3. Piston spring
4. Valve seat
5. Poppet
6. Poppet spring
7. Suction valve
8. Suction valve spring
9. Adjustment screw
Function
q When the pressure in port (P) of the motor
rises at the starting time of the engine, this
valve protects the fan system circuit. (Safety
valve)
q When the fan pump stops, the hydraulic oil
does not flow into the motor. Since the motor
continues revolution because of the force of
inertia, however, the pressure on the outlet
side of the motor rises.
q When the oil stops flowing in from inlet port (P),
the safety-suction valve sucks in the oil on the
outlet side and supplies it to port (MA) where
there is not sufficient oil to prevent cavitation.
(Suction valve)
D475A, D475ASD-5E0 29
SEN00210-00 10 Structure, function and maintenance standard
30 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
D475A, D475ASD-5E0 31
SEN00210-00 10 Structure, function and maintenance standard
32 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00210-00
D475A, D475ASD-5E0 33
SEN00211-01
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00211-01 10 Structure, function and maintenance standard
Power train 1
Outline
q The power generated by engine (1) has its tor- tive steering clutches (9). The power transmit-
sional vibration dampened by damper (2), and ted from the bevel gear shaft to the final drive
then passes through universal joint (3), and is is used to steer the machine by engaging or
transmitted to torque converter (7). disengaging steering clutch (9).
The power from the engine is transmitted The steering lever is operated to disengage
through oil by torque converter (7) to the input the steering clutch on the side to which the
shaft (turbine shaft) of transmission (8) in machine is to be steered in order to change the
accordance with the change in the load. direction of travel. The size of the turning
There is a lockup clutch assembled to the radius is controlled by steering brake (10)
torque converter, and when the rotating speed installed to the outside of the steering clutch.
beyond the torque converter becomes higher, Steering brake (10) uses the same disc system
the lockup clutch is engaged. When this hap- that is used for the steering clutch.
pens, the drive case and turbine form one unit, The power output from the steering clutch
so the power from the engine is transmitted enters final drive (11), where it is reduced, and
directly to the transmission input shaft. rotates sprocket (12).
Transmission (8) uses a combination of a plan- Final drive is a double reduction type consist-
etary gear system and hydraulic equipment to ing of a single stage spur gear and single stage
reduce the speed and shift the gears (forward: planetary gear system.
3 gears, reverse: 3 gears). It connects two sets It rotates the sprocket to drive track shoe (13)
of clutches selected with the gear shift lever and moves the machine.
according to the change in the load, and trans-
mits the power from the transmission to trans-
fer (14) from output shaft.
The power entering transfer (14) has its speed
reduced. Its speed is further reduced by the
bevel pinion and bevel gear of the bevel gear
shaft, and it is then divided at right angles to
the left and right and transmitted to the respec-
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
D475A, D475ASD-5E0 3
SEN00211-01 10 Structure, function and maintenance standard
1. Torque converter oil filter A. Transmission main relief pressure pickup port (TM)
2. Transmission lubricating oil filter B. Transmission R clutch pressure pickup port (REV)
3. Transmission oil filter C. Transmission F clutch pressure pickup port (FWD)
4. Torque converter valve D. Torque converter inlet pressure pickup port (IN)
5. Transmission control valve E. Lockup clutch pressure pickup port (LU)
6. Steering control valve F. Left clutch pressure pickup port (LC)
7. Power train oil strainer G. Left brake pressure pickup port (LB)
8. Oil tank H. Right brake pressure pickup port (RB)
9. Power train, lubrication pump J. Right clutch pressure pickup port (RC)
(BAL160+160+112) K. Stator clutch pressure pickup port (SC)
10. Scavenging pump L. Torque converter outlet pressure pickup port (OUT)
11. Power train oil cooler M. Transmission 1st clutch pressure pickup port (1ST)
N. Transmission 2nd clutch pressure pickup port (2ND)
P. Transmission 3rd clutch pressure pickup port (3RD)
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
D475A, D475ASD-5E0 5
SEN00211-01 10 Structure, function and maintenance standard
Operation
q The power from the engine is transmitted
through flywheel (2) to outer body (3). The
tensional vibration of the engine is absorbed in
rubber coupling (10) and the power is transmit-
ted to output shaft (1), and then transmitted
through universal joint (9) to the torque con-
verter and transmission.
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
Unit: mm
D475A, D475ASD-5E0 7
SEN00211-01 10 Structure, function and maintenance standard
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
Outline
q The power train unit broadly consists of torque
converter and PTO (4), transmission (7), and
steering unit (9). Therefore, after the power
train unit is removed, it can be divided into
torque converter and PTO (4), transmission
(7), and steering unit (9).
q Steering unit (9) consists of the transfer, bevel
gear shaft, steering clutch, and the steering
brake.
D475A, D475ASD-5E0 9
SEN00211-01 10 Structure, function and maintenance standard
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
D475A, D475ASD-5E0 11
SEN00211-01 10 Structure, function and maintenance standard
12 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
Outline Structure
q The torque converter is a 3-element, 1-stage, q Pump (17) is integral with coupling (6), input
and 1-phase type, which is integral with the shaft (8), lockup clutch housing (12), and drive
transmission. case (13), and rotated by the engine power.
q The torque converter is equipped with a wet q Turbine (14) is integral with turbine boss (29)
multiple disc clutch type torque converter and transmission input shaft (22), and rotated
lockup device and a wet double disc clutch by the oil from pump (17).
type stator clutch in order to reduce fuel con- q Stator (16) is integral with stator shaft (18) and
sumption, to increase the operability, and to stator clutch hub gear (23), and fixed to rear
reduce the horsepower consumption by the housing (15) through the stator clutch unit.
engine. q The lockup clutch unit consists of clutch plate
q For higher efficiency of continuous light dozing (30) meshed with drive case (13), clutch disc
and leveling operation, the torque converter is (31) meshed with turbine boss (29), and clutch
locked up and the engine power is transferred piston (32) which slides inside clutch housing
directly to the transmissions input shaft. (12) integral with drive case (13).
q When the torque converter is locked up (the q The stator clutch unit consists of clutch hub
pump and turbine is integrated into 1 unit), the gear (23) attached to stator shaft (18) with
oil is still supplied to the torque converter. spline, clutch disc (27) meshed with clutch hub
Accordingly, the oil flowing from the pump gear (23), clutch plate (26) supported by the
through the turbine to the stator is obstructed pins on clutch housing (24) and rear housing
by the stator blades and cannot flow in any (15), and clutch piston (28) which slides inside
direction. As a result, this oil resists the rotation rear housing (15).
of the pump and turbine (it is agitated). q The PTO unit consists of input shaft (8), PTO
q To reduce the rotating resistance of the pump idler gear (10), and pump drive gears (33), (36)
and turbine, the stator clutch is disengaged and (40).
simultaneously with lockup of the torque con-
verter so that the stator can rotate freely.
As the stator is dragged and turned by the
pump and turbine, the oil returns from the tur-
bine to the pump smoothly against less resis-
tance.
D475A, D475ASD-5E0 13
SEN00211-01 10 Structure, function and maintenance standard
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Outside diameter of oil seal contact
surface of input coupling 125 0 124.8
0.063
Inside diameter of seal ring con- +0.035 Repair by hard
2 tact surface of sleeve 115 0 115.1 chrome plating
or replace
3 Inside diameter of seal ring contact 190 +0.046 190.5
surface of retainer 0
D475A, D475ASD-5E0 15
SEN00211-01 10 Structure, function and maintenance standard
When lockup clutch is disengaged and stator When lockup clutch is engaged and stator
clutch is engaged clutch is disengaged
q If lockup clutch (3) is disengaged, drive case q If lockup clutch (3) is engaged, drive case (5)
(5) and turbine (7) are disconnected from each and turbine (7) are connected to each other.
other. If stator clutch (9) is disengaged at this time,
If stator clutch (9) is engaged at this time, rear housing (10) and stator shaft (11) are dis-
rear housing (10) and stator shaft (11) are con- connected from each other, and stator (8) is
nected to each other to fix stator (8). dragged and turned by pump (6) and turbine
Therefore, the torque converter works as an (7).
ordinary torque converter. Therefore, the torque converter works as a
q The power from the engine is transmitted to lockup torque converter.
coupling (1) through the damper and the uni- q The power from the engine is transmitted to
versal joint. coupling (1) through the damper and the uni-
q The power transmitted to coupling (1) rotates versal joint.
input shaft (2), clutch housing (4), drive case q The power transmitted to coupling (1) rotates
(5) and pump (6) integrally. input shaft (2), clutch housing (4), drive case
q The power transmitted to pump (6) rotates tur- (5) and pump (6) integrally.
bine (7) through the medium of oil and is trans- q The power transmitted to drive case (5) rotates
ferred to transmission input shaft (12) attached turbine (7) directly since lockup clutch (3) is
to turbine (7) with spline. fixed, and is transferred to transmission input
shaft (12) attached to turbine (7) with spline.
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
Oil flow
D475A, D475ASD-5E0 17
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18 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 19
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20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
Unit: mm
No. Check item Criteria Remedy
D475A, D475ASD-5E0 21
SEN00211-01 10 Structure, function and maintenance standard
Outline
q The torque converter valve is installed at the
top of the rear housing of the toque converter,
and consists of the following 6 types of valves.
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
q The oil from the hydraulic pump flows through q The oil from the main relief valve flows through
the filter, port (A) of the torque converter valve, port (C) to the torque converter, and at the
and orifice (a) of torque converter relief valve same time, also flows through orifice (b) of
(1) to chamber (B). torque converter relief valve (3) to chamber
(D).
q When the oil pressure on the torque converter
exceeds the set pressure, the oil in chamber
(D) pushes piston (4), the reaction force of
which moves torque converter relief valve (3)
to the right to open port (C) and port (E).
Then the oil in port (C) is drained from port (E)
to the oil tank.
D475A, D475ASD-5E0 23
SEN00211-01 10 Structure, function and maintenance standard
q While the machine is in the torque converter q The oil from the pump flows through port (D)
range, the lockup solenoid valve is de-ener- into port (E) and applies back pressure to sta-
gized and therefore plunger (1) is pushed tor clutch piston (7). It turns engaged the sta-
back upward by the oil pressure from the tor clutch as the oil pressure in the circuit is
pump. raised.
q As the seats of valve (2) and ball (3) are At the same time, the oil which applied back
opened, the drain circuit of port (B) is opened pressure to lockup clutch piston (8) is drained
and the oil in port (A) and port (C) is drained. through port (F) into port (H) to turn the lockup
q Lockup selector valve (5) is pushed back to the clutch disengaged.
right by the tension of spring (6). As a result, q The oil from the pump flows into port (A) and
the passages between port (D) and port (F) port (D). The oil in port (A) is drained as the
and between port (E) and port (G) are closed, lockup solenoid valve is de-energized, while
while the passages between port (D) and port the oil pressure in port (D) is secured by orifice
(E) and between port (F) and port (H) are (a) and adjusted by modulating valve (9).
opened.
24 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
q While the machine is in the direct range, the q The oil from the pump flows through port (D)
lockup solenoid valve is energized and there- into port (F) and applies back pressure to sta-
fore plunger (1) moves downward. tor clutch piston (8). It turns the lockup clutch
q As the seats of valve (2) and ball (3) are engaged as the oil pressure in the circuit is
closed, the drain circuit of port (B) is closed raised.
and the oil in port (A) flows to port (C) At the same time, the oil which had applied
q The oil from port (C) pushes piston (4) to move back pressure to stator clutch piston (7) is
lockup selector valve (5) to the left. As a drained through port (E) into port (G) to turn
result, the passages between port (D) and port the stator clutch disengaged.
(E) and between port (F) and port (H) are q The pressure of the oil which flows from the
closed, while the passages between port (D) pump into port (D) is adjusted by modulating
and port (F) and between port (E) and port (G) valve (10).
are opened.
D475A, D475ASD-5E0 25
SEN00211-01 10 Structure, function and maintenance standard
Modulating valve
Outline
q The modulating valve is located between the
lockup selector valve and the inlet of each
clutch.
q When each clutch is turned engaged, it
raises the oil pressure applied to the piston
gradually to the set pressure to engage the
clutch smoothly and to reduce the shock given
to the torque converter and transmission.
a Though the following explanation on operation
takes the modulating valve for the stator clutch
as an example, the modulating valve for the
lockup clutch also operates in a similar way.
However, please note that the oil flow into the
clutches in the torque converter range and in
the direct range is opposite in direction.
Operation
When traveling in torque converter range
q While the machine is in the torque converter
range, lockup solenoid valve (1) is de-ener-
gized and the oil from the pump and the oil in
port (B) are drained.
q Lockup selector valve (2) is pushed back to the
right by the tension of spring (3). Then the pas-
sages between port (A) and port (E) and
between port (D) and port (G) are closed, while
the passage between port (A) and port (D) is
opened. As a result, the circuit is connected
through modulating valve (5) to stator clutch
(9).
q The oil from the pump flows through port (A)
into stator clutch (9), and the oil pressure in the
circuit starts rising.
q If the oil pressure in the circuit rises, the oil
flowing through orifice (a) of modulating valve
(5) pushes piston (6), the reaction force of
which moves modulating valve (5) to the left to
throttle part (C).
q Port (D) is connected to port (F) which applies
back pressure to load piston (7). Load piston
(7) is pushed to the right to retract spring (8),
the tension of which opens part (C).
q By repeating the above operation intermit-
tently, load on spring (8) increases and the oil
pressure rises gradually.
Ultimately, modulating valve (5) stops at the
position where it closed part (C). Rise in the oil
pressure is completed and stator clutch (9) is
completely turned engaged.
26 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
D475A, D475ASD-5E0 27
SEN00211-01 10 Structure, function and maintenance standard
Operation
q The torque converter lockup control system
controls the lockup operation of the torque
converter automatically with a sensor signal
and the controller in it according to the load on
the machine. When the torque converter is
locked up, the pilot lamp on the machine moni-
tor lights up.
q The signal of the transmission outlet speed
sensor is input to the transmission controller.
q The lockup mode is set with the mode selec-
tion panel.
q The machine controller receives the gear
speed information from the transmission con-
troller and the transmission outlet speed sen-
sor signal from the shoe slip controller and
turns ON and OFF the lockup system by con-
necting and disconnecting the lockup solenoid
and pilot lamp to and from the chassis ground.
a As for the details of the valve, refer to section
Torque converter valve.
28 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
Scavenging pump 1
Type: BAR(3)63+320
Specifications
D475A, D475ASD-5E0 29
SEN00211-01 10 Structure, function and maintenance standard
30 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
Transmission control 1
a PCCS: Abbreviation for Palm Command Control System
a For steering operation concerned to operation of the Palm Command Control System lever (PCCS
lever), see Steering and brake control.
D475A, D475ASD-5E0 31
SEN00211-01 10 Structure, function and maintenance standard
Transmission 1
32 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
D475A, D475ASD-5E0 33
SEN00211-01 10 Structure, function and maintenance standard
34 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
D475A, D475ASD-5E0 35
SEN00211-01 10 Structure, function and maintenance standard
36 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length Free length
1 R clutch spring (12 pcs.) length load load
140.5 N 119.6 N
100.0 90.0 94.0
{14.3 kg} {12.2 kg}
84.3 N 70.6 N
2 F clutch spring (12 pcs.) 100.0 94.0 94.0
{8.5 kg} {7.2 kg}
150.5 N 128.5 N
3 3rd clutch spring (12 pcs.) 84.0 72.0 79.0
{15.4 kg} {13.1 kg}
119.1 N 102.0 N
4 2nd clutch spring (12 pcs.) 81.7 63.0 76.8
{12.2 kg} {10.4 kg}
238.7 N 203.0 N
5 1st clutch spring (12 pcs.) 103.5 76.0 97.3
{24.4 kg} {20.7 kg}
Total assembled thickness of Standard size Tolerance Repair limit
6
7 discs and 6 plates of R clutch 72.6 0.36 68.9
Total assembled thickness of
7 72.6 0.36 68.9
7 discs and 6 plates of F clutch
Total assembled thickness of
8 50.2 0.30 47.5
5 discs and 4 plates of 3rd clutch
Total assembled thickness of
9 39.0 0.26 36.9
4 discs and 3 plates of 2nd clutch
Total assembled thickness of
10 61.4 0.43 58.2
6 discs and 5 plates of 1st clutch
F, R,
5.4 0.1 4.9
11 Thickness of clutch disc 2nd, 3rd Replace
1st 5.4 0.15 4.9
12 Thickness of clutch plate 5.8 0.1 5.2
0.01
Wear of seal ring Width 3.0 2.70
13 0.03
(1 place)
Thickness 4.0 0.12 3.85
0.01
Wear of seal ring Width 4.0 3.60
14 0.03
(4 places)
Thickness 5.0 0.15 4.85
0.01
Wear of seal ring Width 4.0 3.60
15 0.03
(2 places)
Thickness 5.0 0.15 4.85
0.01
Wear of seal ring Width 6.0 5.50
16 0.03
(2 places)
Thickness 6.8 0.15 6.65
0.01
Wear of seal ring Width 4.0 3.60
17 0.04
(1 place)
Thickness 5.0 0.15 4.85
0.01
Wear of seal ring Width 4.0 3.60
18 0.04
(3 places)
Thickness 4.0 0.15 3.85
Backlash between
19 0.16 0.35
sun gear and planetary pinion
Backlash between
20 0.18 0.38
planetary pinion and ring gear
D475A, D475ASD-5E0 37
SEN00211-01 10 Structure, function and maintenance standard
Disc clutch
Structure Operation
When clutch is engaged (fixed)
q The disc clutch consists of piston (2), plates q The oil from ECMV is sent with pressure to the
(3), discs (4), pin (5), return spring (6) etc. to fix rear side of piston (2) through the oil passage
ring gear (1). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
38 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
q When the transmission is set to the forward 1st q The rotation of F and 3rd carrier (10) is trans-
speed, the F clutch and 1st clutch are mitted through 3rd planetary pinion (11) to 3rd
engaged. The power transmitted from the ring gear (12).
torque converter to input shaft (1) is then trans- q 3rd ring gear (12) and 2nd carrier (13) are
mitted to output shaft (20). meshed with each other and rotate integrally.
q The F clutch is actuated by the oil pressure Accordingly, the rotation of 3rd ring gear (12) is
applied to the F clutch piston, and fixes F ring transmitted through 2nd carrier (13) to 1st
gear (4). The 1st clutch is actuated by the oil clutch piston housing (14).
pressure applied to the 1st clutch piston, and q As 1st clutch inner drum (16) is fixed by the 1st
fixes 1st clutch inner drum (16). clutch, the power transmitted to 1st clutch pis-
q The power from the torque converter is trans- ton housing (14) is transmitted through 1st
mitted to F planetary pinion (3) through input clutch inner drum (16) to output shaft (20).
shaft (1) and F sun gear (2).
q As F ring gear (4) is fixed by the F clutch, the
power transmitted to F planetary pinion (3)
rotates F and 3rd carrier (10) located inside of
F ring gear (4).
D475A, D475ASD-5E0 39
SEN00211-01 10 Structure, function and maintenance standard
q When the transmission is set to the forward q The rotation of F and 3rd carrier (10) is trans-
2nd speed, the F clutch and 2nd clutch are mitted through 3rd planetary pinion (11) to 3rd
engaged.The power transmitted from the ring gear (12).
torque converter to input shaft (1) is then trans- q 3rd ring gear (12) and 2nd carrier (13) are
mitted to output shaft (20). meshed with each other and rotate integrally.
q The F clutch is actuated by the oil pressure Accordingly, the rotation of 2nd carrier (13) is
applied to the F clutch piston, and fixes F ring transmitted to 2nd planetary pinion (15).
gear (4). The 2nd clutch is actuated by the oil q As 2nd ring gear (17) is fixed by the 2nd clutch,
pressure applied to the 2nd clutch piston, and the power transmitted to 2nd planetary pinion
fixes 2nd ring gear (17). (15) is transmitted through 2nd sun gear (18)
q The power from the torque converter is trans- to output shaft (20).
mitted to F planetary pinion (3) through input
shaft (1) and F sun gear (2).
q As F ring gear (4) is fixed by the F clutch, the
power transmitted to F planetary pinion (3)
rotates F and 3rd carrier (10) located inside of
F ring gear (4).
40 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
q When the transmission is set to the forward 3rd q As 3rd ring gear (12) is fixed by the 3rd clutch,
s p e ed , t h e F c l u t c h a n d 3 r d c lu t c h ar e the power transmitted to F and 3rd carrier (10)
engaged. The power transmitted from the is transmitted through 3rd planetary pinion (11)
torque converter to input shaft (1) is then trans- and 3rd sun gear (19) to output shaft (20).
mitted to output shaft (20).
q The F clutch is actuated by the oil pressure
applied to the F clutch piston, and fixes F ring
gear (4). The 3rd clutch is actuated by the oil
pressure applied to the 3rd clutch piston, and
fixes 3rd ring gear (12).
q The power from the torque converter is trans-
mitted to F planetary pinion (3) through input
shaft (1) and F sun gear (2).
q As F ring gear (4) is fixed by the F clutch, the
power transmitted to F planetary pinion (3)
rotates F and 3rd carrier (10) located inside of
F ring gear (4).
D475A, D475ASD-5E0 41
SEN00211-01 10 Structure, function and maintenance standard
q When the transmission is set to the reverse 1st q The rotation of F and 3rd carrier (10) is trans-
s p e e d , t h e R c l u t c h a n d 1 s t c lu t c h a r e mitted through 3rd planetary pinion (11) to 3rd
engaged. The power transmitted from the ring gear (12).
torque converter to input shaft (1) is then trans- q 3rd ring gear (12) and 2nd carrier (13) are
mitted to output shaft (20). meshed with each other and rotate integrally.
q The R clutch is actuated by the oil pressure Accordingly, the rotation of 3rd ring gear (12) is
applied to the R clutch piston, and fixes ring transmitted through 2nd carrier (13) to 1st
gear (7). The 1st clutch is actuated by the oil clutch piston housing (14).
pressure applied to the 1st clutch piston, and q As 1st clutch inner drum (16) is fixed by the 1st
fixes 1st clutch inner drum (16). clutch, the power transmitted to 1st clutch pis-
q The power from the torque converter is trans- ton housing (14) is transmitted through 1st
mitted to R planetary pinion (6) through input clutch inner drum (16) to output shaft (20).
shaft (1) and R sun gear (5).
q Ring gear (7) and R carrier (8) are meshed
with each other and fixed by the R clutch.
Accordingly, the rotation of R planetary pinion
(6) rotates R ring gear (9). The rotation of R
ring gear (9), the direction of which is opposite
to that of input shaft (1), rotates F and 3rd car-
rier (10).
42 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00211-01
D475A, D475ASD-5E0 43
SEN00211-01
2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)
44
SEN00212-02
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00212-02 10 Structure, function and maintenance standard
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
PF: F clutch oil pressure pickup port (FWD) Operation table of ECMV
PR: R clutch oil pressure pickup port (REV)
P1: 1st clutch pressure pickup port (1ST) ECMV
P2: 2nd clutch pressure pickup port (2ND) F R 1st 2nd 3rd
Gear speed
P3: 3rd clutch pressure pickup port (3RD)
Forward 1st Q Q
PV: To priority valve
LV: To lubricating oil relief valve Forward 2nd Q Q
LD: Drain (from lubricating oil relief valve) Forward 3rd Q Q
CF: To F clutch Reverse 1st Q Q
CR: To R clutch
Reverse 2nd Q Q
C1: To 1st clutch
C2: To 2nd clutch Reverse 3rd Q Q
C3: To 3rd clutch * Neutral Q
dr: Drain *: Filled with oil at low pressure.
(Except for low temperature and abnormal conditions.)
1. Filter
2. Priority valve
3. Lubricating oil relief valve
4. 1st clutch ECMV
5. 2nd clutch ECMV
6. 3rd clutch ECMV
7. F clutch ECMV
8. R clutch ECMV
9. Valve seat
D475A, D475ASD-5E0 3
SEN00212-02 10 Structure, function and maintenance standard
A: To clutch
P: From pump *1:
T: Drain
Stamp of the
Dr: Drain Clutch used
nameplate
P1: Clutch oil pressure pickup port
F, R, 1st, 2nd, 3rd A*******
1. Fill switch connector
2. Proportional solenoid connector
3. Flow rate pickup valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
D475A, D475ASD-5E0 5
SEN00212-02 10 Structure, function and maintenance standard
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
q If current is applied to proportional solenoid (1) q If current flows in proportional solenoid (1), the
with no oil in the clutch, the oil pressure force solenoid generates thrust in proportion to the
balanced with the solenoid force is applied to current. This thrust of the solenoid is balanced
chamber (B) and pushes pressure control with the sum of the thrust generated by the oil
valve (3) to the left. This opens pump port (P) pressure in clutch port and the tension of pres-
and clutch port (A) to feed oil in the clutch. sure control valve spring (2), and then the
When the clutch is filled with oil, pressure pressure is settled.
detection valve (4) actuates to turn ON fill
switch (5).
D475A, D475ASD-5E0 7
SEN00212-02 10 Structure, function and maintenance standard
Priority valve 1
Unit: mm
No. Check item Criteria Remedy
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
Operation from start to finish of gear shifting Operation right after finishing of gear shifting
q The oil from the pump flows through port (A) q If the gear shift lever is operated, the oil pres-
and orifice (a) to chamber (C). sure in port (B) decreases sharply nearing 0
q If the oil flow from the pump increases and the MPa {0 kg/cm2} as a result of the ECMV opera-
oil pressure rises, the oil in chamber (C) tion.
pushes piston (1). Then, the reaction force of q Then, the oil pressure in port (A) also
piston (1) compresses spring (2) and moves decreases, but valve (3) is pushed back to the
valve (3) to the left. right by the tension of spring (2).
q If valve (3) moves, port (A) and port (B) are q As a result, the oil pressure in port (A) (pilot
connected and the oil from the pump flows pressure) is kept to the set pressure.
through port (B) to the ECMV. The oil pressure
at this time is the set pressure of the priority
valve.
q Then, the oil pressure transmitted from port (B)
to the ECMV rises to the set pressure of the
clutch.
D475A, D475ASD-5E0 9
SEN00212-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
Unit: mm
No. Check item Criteria Remedy
Type Standard clearance Clearance limit
1 Side clearance BAL(4)160
0.04 0.10 0.13
BAL(4)112
Clearance between plain bearing BAL(4)160
2 0.060 0.145 0.20 Replace
inner diameter and gear shaft BAL(4)112
Type Standard size Tolerance Repair limit
3 Depth to knock in pin BAL(4)160 0
14
BAL(4)112 0.5
D475A, D475ASD-5E0 11
SEN00212-02 10 Structure, function and maintenance standard
12 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
D475A, D475ASD-5E0 13
SEN00212-02 10 Structure, function and maintenance standard
Final drive 1
Outline
q The final drive is a single stage spur gear, sin-
gle stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears.
The final drive can be removed and installed
as a single unit.
q Floating seal (1) is installed to the rotating slid-
ing portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubri-
cating oil.
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
D475A, D475ASD-5E0 15
SEN00212-02 10 Structure, function and maintenance standard
Unit: mm
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
q The power from the bevel gear shaft and steer- Then, the rotating force of sun gear (2) forms
ing clutch is transmitted to No. 1 pinion (15). It the rotating force of carrier (3), which supports
then passes through No. 1 gear (13), which is the planetary pinion, and is transmitted to
meshed with the No. 1 pinion, and is transmit- sprocket hub (6).
ted to sun gear (2) to rotate it. The rotation direction of carrier (3) is the same
The rotation of sun gear (2) is transmitted to as sun gear (2).
planetary pinion (10), but ring gear (11), which The rotating force transmitted to sprocket hub
is meshed with the planetary pinion, is fixed to (6) is transmitted to sprocket teeth (7).
cover (9), so the planetary pinion rotates on its
own axis and moves around the sun gear
along the ring gear.
D475A, D475ASD-5E0 17
SEN00212-02 10 Structure, function and maintenance standard
Sprocket 1
Unit: mm
18 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
D475A, D475ASD-5E0 19
SEN00212-02 10 Structure, function and maintenance standard
20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
Steering unit 1
D475A, D475ASD-5E0 21
SEN00212-02 10 Structure, function and maintenance standard
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
D475A, D475ASD-5E0 23
SEN00212-02 10 Structure, function and maintenance standard
Outline
24 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
D475A, D475ASD-5E0 25
SEN00212-02 10 Structure, function and maintenance standard
26 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Replace
1 Brake plate Thickness 4.2 0.1 3.8
Strain Max. 0.3 0.4 Repair or replace
Thickness 5.4 0.1 4.3 Replace
2 Brake disc
Strain Max. 0.3 0.4 Repair or replace
Total assembled thickness of
3 82.2 0.41 72.6
8 brake plates and 9 discs Replace
Thickness 4.2 0.1 3.8
4 Clutch plate
Strain Max. 0.3 0.4 Repair or replace
Thickness 5.4 0.1 4.5 Replace
5 Clutch disc
Strain Max. 0.4 0.5 Repair or replace
Total assembled thickness of
6 76.8 0.40 69.3
8 clutch plates and 8 discs
Inside diameter of seal ring +0.046
7 190 190.5
contact surface of sleeve 0
Large
+0.089
diameter 350 350.1
Inside diameter 0
parts
8 of seal ring contact
surface of brake piston Small
+0.052
diameter 300 300.1
0
parts
Large
+0.089
diameter 350 350.1
Inside diameter 0
parts
9 of seal ring contact
face of clutch piston Small
+0.052
diameter 300 300.1
0
parts
Replace
Standard size Repair limit
Installed Installed Installed
Free length Free length
10 Brake spring length load load
46.97 kN 44.62 kN
19.7 12.9 19.1
{4,790 kg} {4,550 kg}
55.7 kN 52.96 kN
11 Clutch spring 20.4 12.9 20.0
{5,680 kg} {5,400 kg}
D475A, D475ASD-5E0 27
SEN00212-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
18 Backlash between transfer gears Adjust or replace
0.26 0.67 0.75
28 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
When steering clutch is turned engaged When steering clutch is turned disengaged
q When the PCCS lever is in the neutral posi- q If the PCCS lever is operated to the left or
tion, the oil in the back side of clutch piston (1) right, the oil pressure is applied to the back of
is drained by the steering control valve. clutch piston (1) by the steering control valve.
q At this time, clutch piston (1) is pushed back to q As the oil pressure rises, clutch piston (1) com-
the right by the tension of clutch spring (2) to press clutch spring (2) and moves to the left to
press discs (3) and plates (4) against stopper eliminate the pressing force between discs (3)
(5). and plates (4).
q The power from steering shaft (6) is transmit- q The power from steering shaft (6) is not trans-
ted through clutch hub (7), pressed discs (3) mitted after housing (8) and accordingly is not
and plates (4) to housing (8). transmitted to the final drive.
q Since housing (8) is connected to brake hub q If the PCCS lever is released, the oil in the
(9) and output shaft (10), the power is transmit- back side of clutch piston (1) is drained by the
ted through output shaft (10) to the final drive. steering control valve, thus the steering clutch
is turned engaged.
q If the L.H. steering clutch is turned disen-
gaged, the power is transmitted only to the
R.H. steering clutch, and consequently the
machine turns to the left.
D475A, D475ASD-5E0 29
SEN00212-02 10 Structure, function and maintenance standard
q When the PCCS lever is in the neutral posi- q If the PCCS lever is operated to the left or
tion and the brake pedal is released, the steer- right, the steering control valve turns the steer-
ing control valve only sets the brake pressure ing clutch disengaged and the oil in the back
to the maximum. Accordingly, the steering side of piston (1) starts to be drained.
clutch is turned engaged and the oil pressure q At this time, brake piston (1) is pushed back to
is applied to the back of brake piston (1). the right by the tension of brake spring (2) to
q As the oil pressure rises, brake piston (1) com- press discs (3) and plates (4) against stopper
presses brake spring (2) and moves to the left (5).
to eliminate the pressing force between discs q Brake piston (1) and stopper (5) are fixed to
(3) and plates (4). the steering case by the pin.
q The power transmitted from the steering shaft q Brake hub (7) and output shaft (8), which tend
(6) through the steering clutch to brake hub (7) to rotate by the inertia force even after the
is further transmitted through output shaft (8) steering clutch is turned disengaged, can be
to the final drive. stopped by pressing discs (3) and plates (4) to
each other.
q The turning radius and speed can be adjusted
by the brake force controlled by the oil pres-
sure in the back side of piston (1) according to
the stroke of the PCCS lever to the left and
right.
30 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
D475A, D475ASD-5E0 31
SEN00212-02 10 Structure, function and maintenance standard
32 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
D475A, D475ASD-5E0 33
SEN00212-02 10 Structure, function and maintenance standard
A: To clutch or brake
P: From pump *1:
T: Drain
Clutch used Stamp of the nameplate
Dr: Drain
P1: To clutch or brake pressure pickup port Steering clutch,
R*******
Steering brake
1. Fill switch connector
2. Proportional solenoid connector Outline
3. Pressure detection valve q Each ECMV keeps the steering clutch oil pres-
4. Fill switch sure and steering brake oil pressure to the set
5. Proportional solenoid pressure and furthermore changes the circuit
6. Pressure control valve to the piston chamber of the steering clutch
7. Nameplate (*1) and steering brake.
34 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
Outline of ECMV
q The ECMV consists of 1 pressure control valve
and 1 fill switch.
q Pressure control valve
A proportional solenoid in this valve receives a
current sent from the steering controller and
this valve converts it to an oil pressure.
q Fill switch
This is a switch to detect that a clutch or brake
is filled with oil and has the following functions.
1. At the moment when the clutch or brake is
filled with oil, the fill switch outputs the sig-
nal (fill signal) to the controller to notify the
finishing of filling.
2. While the oil pressure is applied to the
clutch or brake, the fill switch outputs the
signal (fill signal) to the controller to notify
the presence of the oil pressure.
Operation of ECMV
q The ECMV is controlled by the command
current from the controller to the propor-
tional solenoid and the fill switch output
signal.
D475A, D475ASD-5E0 35
SEN00212-02 10 Structure, function and maintenance standard
When PCCS lever is in neutral position, brake pedal is released, and parking brake lever is in
free position: Straight travel
(L.H. and R.H. clutches are turned engaged, L.H. and R.H. brakes are released, and parking brake is
released.)
q When the PCCS lever is in neutral position q Proportional solenoid (5) of the brake ECMV is
and the brake pedal is released, proportional energized and pushes ball (6) to the left and
solenoid (1) of the clutch ECMV is de-ener- closes the sealing part.
gized and the sealing part of ball (2) is opened. q The oil in port (Pb) of the brake ECMV flows in
q The oil from the power train pump flows port (E) and pushes valve (7) to the left to con-
through port (Pc) of the clutch ECMV to orifice nect port (Pb) with port (B) and disconnect port
(a), then it is drained through the sealing part (B) from port (Dr). At this time, the oil flows in
of ball (2). the back pressure port of the brake piston. As
q Valve (3) is moved to the right by the tension of the oil pressure rises, the brake piston is
spring (4) to disconnect port (Pc) from port (C), pushed to the left to compress the brake
and connect port (C) with port (Dr). At this spring, then the brake is released.
time, the oil from the back pressure port of the q When the parking brake lever is in free posi-
clutch piston is drained through port (C) and tion, as the parking brake valve is closed, the
the clutch is turned engaged by the tension of oil in the brake circuit is not drained.
the clutch spring.
q The oil pressure in the brake circuit, etc. is
secured by orifice (a).
36 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
When PCCS lever is operated to the left halfway, brake pedal is released, and parking brake lever
is in free position: Gradual left turn
(L.H. clutch is turned disengaged, L.H. brake is semi-released, R.H. clutch is turned engaged, R.H.
brake is released, and parking brake is released.)
q When the PCCS lever is operated to left half- q Proportional solenoid (5) generates the propul-
way and the brake pedal is released, propor- sion force in proportion to the command cur-
tional solenoid (1) of the L.H. clutch ECMV is rent. This propulsion force is balanced with the
energized and the sealing part of ball (2) is sum of the propulsion force generated by the
closed. oil pressure in the back pressure port of the
q The oil from the power train pump flows brake piston and the tension of spring (8), then
through port (Pc) of the clutch EMCV and ori- the brake pressure is set up to adjust the brake
fice (a) to port (F) and pushes valve (3) to the force.
left to connect port (Pc) with port (C) and dis- q Accordingly, if the stroke of the PCCS lever is
connect port (C) from port (Dr). At this time, the short, the oil pressure after port (B) is set high
oil flows in the back pressure port of the clutch and the brake is turned from released to
piston. As the oil pressure rises, the clutch pis- semi-released. If the stroke of the PCCS
ton is pushed to the left to compress the clutch lever is long, the oil pressure after port (B) is
spring, then the clutch is turned disengaged. set low and the brake is turned from semi-
q Proportional solenoid (5) of the brake ECMV is released to applied.
energized and pushes ball (6) to the left and q When the parking brake lever is in free posi-
closes the sealing part. tion, as the parking brake valve is closed, the
q The oil in port (Pb) of the brake ECMV flows in oil in the brake circuit is not drained.
port (E) and pushes valve (7) to the left. As for
the oil pressure after port (B), the controller
outputs the command current to proportional
solenoid (5) according to the stroke of the
PCCS lever.
D475A, D475ASD-5E0 37
SEN00212-02 10 Structure, function and maintenance standard
When PCCS lever is operated fully to the left, brake pedal is released, and parking brake lever is
in free position: Sharp left turn
(L.H. clutch is turned disengaged, L.H. brake is applied, R.H. clutch is turned engaged, R.H. brake is
released, and parking brake is released.)
q When the PCCS lever is shifted from operated q When the parking brake lever is in free posi-
to left halfway to operated to left fully, pro- tion, as the parking brake valve is closed, the
portional solenoid (5) of the L.H. brake ECMV oil in the brake circuit is not drained.
is de-energized and the sealing part of ball (6)
is fully opened.
q Since the oil in port (E) is drained through the
sealing part, valve (7) is moved to the right by
the tension of spring (8) to disconnect port (Pb)
from (B) and connect port (B) with port (Dr). At
this time, the oil from the back pressure port of
the brake piston is drained through port (B)
and the brake is turned applied by the tension
of the brake spring.
q The oil from the power train pump flows
through port (Pb) of the brake ECMV and ori-
fice (b), then it is drained through sealing part
of ball (6).
q The oil pressure in the clutch circuit, etc. is
secured by orifice (b).
38 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
When PCCS lever is in neutral, brake pedal is depressed, and parking brake lever is in free
position: Stop
(L.H. and R.H. clutches are turned engaged, L.H. and R.H. brakes are applied, and parking brake is
released.)
q When the brake pedal is depressed fully, pro- q If the brake pedal is depressed, the parking
portional solenoids (5) of L.H. and R.H. brake brake valve connected by the linkage operates
ECMV are de-energized to open the sealing to open the brake circuit and drain the oil.
part of ball (6).
q The controller outputs the command current to
proportional solenoid (5) according to the
brake pedal stroke.
q Proportional solenoid (5) generates the propul-
sion force in proportion to the command cur-
rent. This propulsion force is balanced with the
sum of the propulsion force generated by the
oil pressure in the back pressure port of the
brake piston and the tension of spring (8), then
the brake pressure is set up to adjust the brake
force.
q Since the PCCS lever is in neutral position,
proportional solenoids (1) of L.H. and R.H.
clutch ECMV are de-energized and L.H. and
R.H. clutch are turned engaged.
D475A, D475ASD-5E0 39
SEN00212-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
4. Spool Outline
5. Valve body q The parking brake valve is installed to the
steering control valve, and spool (4) operates
with the parking brake lever.
q When the parking brake lever is in lock posi-
tion, the brake operates by draining the operat-
ing pressure of the L.H. and R.H. steering
brake.
40 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
When PCCS lever is in neutral position, brake pedal is released, and parking brake lever is in
lock position : Parking
(L.H. and R.H. clutches are turned engaged, L.H. and R.H. brakes are applied, and parking brake is
applied.)
D475A, D475ASD-5E0 41
SEN00212-02 10 Structure, function and maintenance standard
Outline
q The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly
when an abnormality takes place in the electri-
cal system.
q Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
sudden oil pressure drop of port (DR) when
brake ECMV coil (2) is de-energized, and con-
sequently the sudden brake can be avoided.
q If an abnormality takes place in the electrical
system, also solenoid (3) of sudden stop pre-
vention valve (1) is de-energized. Then, the oil
of port (DR) is drained through orifice (a) so
that the brake is applied gradually.
42 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00212-02
D475A, D475ASD-5E0 43
SEN00212-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)
44
SEN00213-02
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00213-02 10 Structure, function and maintenance standard
Track frame 1
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
Outline
q The track roller uses K-shape bogie mount to
increase the ground contact area between the
track shoe and ground surface on rough sur-
faces, thereby increasing the drawbar pull.
q The K-shape bogie is fitted with rubber pads to
absorb the shock from the ground surface.
Unit: mm
D475A, D475ASD-5E0 3
SEN00213-02 10 Structure, function and maintenance standard
Recoil spring 1
1. Yoke Outline
2. Nut q Recoil spring (10) damps sudden shocks
3. Retainer applied to the idler.
4. Rod q The recoil spring is also used to adjust the
5. Spring cylinder track shoe tension by supplying or discharging
6. Retainer grease through lubricator (8) and moving rod
7. Piston (4) forward or in reverse.
8. Lubricator
(for supplying and discharging grease)
9. Grease chamber cylinder
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
Unit: mm
D475A, D475ASD-5E0 5
SEN00213-02 10 Structure, function and maintenance standard
Idler 1
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
Unit: mm
D475A, D475ASD-5E0 7
SEN00213-02 10 Structure, function and maintenance standard
Track roller 1
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
D475A, D475ASD-5E0 9
SEN00213-02 10 Structure, function and maintenance standard
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
D475A, D475ASD-5E0 11
SEN00213-02 10 Structure, function and maintenance standard
Carrier roller 1
Unit: mm
12 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
Outline 1. Guide
q The track rollers are installed to small bogie 2. Cap
(6). The track rollers and track shoes are 3. Track roller assembly (double)
always in contact. 4. Large bogie
q The vibration of the machine from the ground 5. Rubber mount
surface is absorbed by rubber mount (5). 6. Small bogie
7. Track roller assembly (single)
8. Cover
9. Cartridge pin
D475A, D475ASD-5E0 13
SEN00213-02 10 Structure, function and maintenance standard
Track shoe 1
a Portion P shows the link on the side where the bushing is pressed fitted.
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
Unit: mm
Turning
Standard size
2 Outside diameter of bushing Load Heavy load Turn or
116 107.5 110 replace
*1: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit
is 183 mm.
*2: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit
is 37.5 mm.
D475A, D475ASD-5E0 15
SEN00213-02 10 Structure, function and maintenance standard
Unit: mm
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
D475A, D475ASD-5E0 17
SEN00213-02 10 Structure, function and maintenance standard
Main frame 1
18 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
Unit: mm
D475A, D475ASD-5E0 19
SEN00213-02 10 Structure, function and maintenance standard
Suspension 1
20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
D475A, D475ASD-5E0 21
SEN00213-02 10 Structure, function and maintenance standard
Unit: mm
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00213-02
D475A, D475ASD-5E0 23
SEN00213-02
2016 KOMATSU
All Rights Reserved
Printed in Japan 02-16 (01)
24
SEN00214-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00214-00 10 Structure, function and maintenance standard
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 3
SEN00214-00 10 Structure, function and maintenance standard
Multi-shank ripper
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Giant ripper
q The diagram shows a machine equipped with a pin puller cylinder
D475A, D475ASD-5E0 5
SEN00214-00 10 Structure, function and maintenance standard
6 D475A, D475ASD-5E0
SEN00214-00 10 Structure, function and maintenance standard
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Outline
q The work equipment control employs a PPC
method which uses a PPC valve to move each
control valve spool.
q Work equipment lock lever (1) is intercon-
nected with PPC lock valve (7), and at the
LOCK position (N), the oil in the PPC circuit is
stopped.
D475A, D475ASD-5E0 9
SEN00214-00 10 Structure, function and maintenance standard
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
A PBF : Front pump pressure input port L PLSR : Load pressure input port
B PAF : Front pump discharge port M PLSRC: Load pressure pickup port
C PLSC : LS set selector pressure pickup port N PLSFC : Load pressure pickup port
D PBR : Rear pump pressure input port P PLSF : Load pressure input port
E PENR : Control pressure pickup port Q PEPC : EPC basic pressure port
F PAR : Rear pump discharge port R PFC : Front pump discharge pressure pickup
G PENF : Control pressure pickup port port
H PD1F : Case drain port S PD2F : Drain plug
J PEPB : EPC basic pressure pickup port T ISIG : LS set selector current
K PRC : Rear pump discharge pressure pickup U PS : Pump suction port
port V PD2R : Air breather mounting port
D475A, D475ASD-5E0 11
SEN00214-00 10 Structure, function and maintenance standard
Function Structure
q The rotation and torque transmitted to the q Cylinder block (7) is supported to shaft (1) by a
pump shaft are converted into hydraulic pres- spline, and shaft (1) is supported by the front
sure, and pressurized oil is discharged accord- and rear bearings.
ing to the load. q The tip of piston (6) is a concave ball, and shoe
q It is possible to change the discharge amount (5) is caulked to it to form one unit. Piston (6)
by changing the swash plate angle. and shoe (5) form a spherical bearing.
q Shoe (5) is always pressed against flat surface
(A) of rocker cam (4) while sliding in a circular
movement.
q Rocker cam (4) brings high pressure oil at cyl-
inder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q The cylinder block (7) seals the pressure oil to
valve plate (8) and carries out relative rotation.
This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
The oil inside each cylinder chamber of cylin-
der block (7) is sucked in and discharged
through valve plate (8).
12 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 13
SEN00214-00 10 Structure, function and maintenance standard
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
3. LS valve
4. CO valve
D475A, D475ASD-5E0 15
SEN00214-00 10 Structure, function and maintenance standard
Function 2) CO valve
1) LS valve q When the pump pressure in the hydraulic cir-
q The LS (Load Sensing) valve detects the load cuit becomes maximum, the CO (Cut-OFF)
and controls the discharge amount. valve minimizes the pump swash plate angle
q This valve controls main pump delivery amount to limit the pressure and protect the circuit.
(Q) according to differential pressure (dPLS) q Since the pump swash plate angle is mini-
between main pump pressure (PP) and con- mized, the pump absorption torque is reduced
trol valve outlet port pressure (PLS) (= PP and the fuel consumption is reduced.
PLS) [called the LS differential pressure].
q Main pump pressure (PP), pressure (PLS)
[called the LS pressure] from the control valve
output, and pressure (PSIG) from the propor-
tional solenoid valve [called the LS selector
pressure] enter this valve.
q The relationship between differential pressure
(dPLS) between main pump pressure (PP) and
LS pressure (PLS) (= PP PLS) and delivery
amount (Q) changes according to LS selector
current (ISIG) of the LS-EPC valve as shown in
the figure below.
q As (ISIG) changes from 0 to 0.9 A, the set
force of the spring changes. As a result, the
median of the standard changing point of the
pump delivery amount changes from 2.5 to
0.98 MPa {from 25 to 10 kg/cm2}.
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Operation
1) LS valve
(1) When control valve is at neutral position
q The LS valve is a three-way selector valve, q At this point, spool (6) is pushed to the right,
with pressure (PLS) (LS pressure) from the and port (C) and port (D) are connected. Pump
inlet port of the control valve brought to spring pressure (PP) enters the large diameter end of
chamber (B), and main pump discharge pres- the piston from port (K) and the same pump
sure (PP) brought to port (H) of sleeve (8). The pressure (PP) also enters port (J) at the small
size of this LS pressure (PLS) + force of spring diameter end of the piston, so the swash plate
(4) and the main pump pressure (self pres- is moved to the minimum angle by the differ-
sure) (PP) determines the position of spool (6). ence in the area of piston (12).
q However, the size of the output pressure
(PSIG) (the LS selection pressure) of the EPC
valve for the LS valve entering port (G) also
changes the position of spool (6). (The set
pressure of the spring changes).
q Before the engine is started, servo piston (12)
is pushed to the right. (See the diagram on the
right)
q When the engine is started and the control
lever is at the neutral position, LS pressure
(PLS) is 0 MPa {0 kg/cm2}. (It is interconnected
with the drain circuit through the control valve
spool.)
D475A, D475ASD-5E0 17
SEN00214-00 10 Structure, function and maintenance standard
q When the difference between main pump pres- q If the output pressure of the EPC valve for the
sure (PP) and LS pressure (PLS), or LS differ- LS valve is applied to port (G) at this time, it
ential pressure (dPLS), becomes smaller (for pushes piston (7) to the left.
example, when the area of opening of the con- q If piston (7) is pushed to the left, the set force
trol valve becomes larger and LS pressure of spring (4) is reduced and LS differential
(PLS) increases), the combined force of LS pressure (dPLS) [the difference between oil
pressure (PLS) and force of spring (4) pushes pressures (PLS) and (PP)] changes when
spool (6) to the right. ports (D) and (E) of spool (6) are connected.
q As spool (6) moves, ports (D) and (E) are con-
nected to each other and to the CO valve.
q At this time, the CO valve is connected to the
drain port and the pressure in circuit (D) (K)
becomes drain pressure (PT). (Operation of
the CO valve will be explained later.)
q Accordingly, the pressure on the large diame-
ter end of servo piston (12) becomes drain
pressure (PT). Since pump pressure (PP) is
constantly applied to port (J) on the small
diameter end, servo piston (12) is pushed to
the left and the swash plate is moved in the
direction for increasing the delivery amount.
18 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 19
SEN00214-00 10 Structure, function and maintenance standard
q Let us take the area receiving the pressure at q At this time, the relationship between the areas
the large diameter end of the piston as (A1), receiving the pressure at both ends of servo
the area receiving the pressure at the small piston (12) is (A0) : (A1) = 1 : 2. Accordingly,
diameter end as (A0), and the pressure flowing the relationship between the pressures applied
into the large diameter end of the piston as to both ends of the piston when the piston is
(PEN). balanced becomes (PP) : (PEN) C 2 : 1.
q When main pump pressure (PP) of the LS q The position where spool (6) is balanced and
valve is balanced with the combined force of stopped is the standard center. The force of
LS pressure (PLS) and the force of spring (4) spring (4) is so adjusted that the standard cen-
and their relationship is (A0) (PP) = (A1) ter will be decided when (PP) (PLS) = 2.5
(PEN), servo piston (12) stops in the current MPa {25 kg/cm2}.
position. q When the input current to the LS-EPC valve
q Then, swash plate is kept at an intermediate changes from 0 to 0.9A and (PSIG) (the output
position. [It stops at a position where the pressure of the LS-EPC valve varying from 0 to
opening between ports (D) and (E) of spool (6) 2.9 MPa {0 to 30 kg/cm2}) is applied to port (G),
and that between ports (C) and (D) are approx- however, the balancing and stopping position
imately the same.] changes in proportion to the (PSIG) pressure
in the range from (PP) (PLS) = 2.5 to 0.98
MPa {25 to 10 kg/cm2}.
20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Left tilt q q q
Left tilt limit q
Single tilt
Right tilt q q q
Right tilt limit q
Blade
Left tilt q
Left tilt limit q
Dual tilt
Right tilt q
Right tilt limit q
Rear pitch q
Pitch
Forward pitch q
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
D475A, D475ASD-5E0 21
SEN00214-00 10 Structure, function and maintenance standard
2) CO valve
(1) When actuator load is small and pump pressure (PP) is low
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
(2) When actuator load is large and pump discharge pressure reaches maximum
D475A, D475ASD-5E0 23
SEN00214-00 10 Structure, function and maintenance standard
5. LS-EPC valve
24 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Function Operation
q The EPC valve consists of the solenoid portion 1) When signal current is 0
and the hydraulic valve portion. (coil de-energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
pump controller, it generates the EPC output the controller to coil (1), coil (1) is de-energized.
pressure in proportion to the size of the signal, q For this reason, spool (4) is pushed to the right
and outputs it to the LS valve. in the direction of the arrow by spring (3).
q As a result, port (C) (PEPC) closes and the
pressurized oil from the main pump does not
flow to the LS valve.
q At the same time, the pressurized oil from the
LS valve passes from port (A) (PSIG) through
port (B) (PT) and is drained to the tank.
D475A, D475ASD-5E0 25
SEN00214-00 10 Structure, function and maintenance standard
2) When signal current is small (Coil is ener- 3) When signal current is maximum (Coil is
gized) energized)
q If a small signal current flows in coil (1), coil (1) q If the signal current flows in coil (1), coil (1) is
is energized and a thrust to the right is gener- energized.
ated in plunger (6). q Since the signal current is at the maximum, the
q Rod (5) pushes spool (2) to the right and the oil thrust in plunger (6) becomes maximum.
from port (C) (PEPC) flows in port (A) (PSIG). q Accordingly, rod (5) presses spool (2) to the
q The pressure in port (A) (PSIG) rises. If the right.
total of the force applied to spool (2) and the q As a result, the maximum oil flows from port
load of spring (3) exceeds the thrust of plunger (C) (PEPC) to port (A) (PSIG) and the pressure
(6), spool (2) is pushed to the left. Then, port in the circuit between the EPC valve and LS
(C) (PEPC) and port (A) (PSIG) are discon- valve becomes highest.
nected and port (A) (PSIG) and port (B) (PT) q At this time, port (C) (PT) is closed and the oil
are connected simultaneously. does not flow in the tank.
q As a result, spool (2) moves up and down until
the thrust of plunger (6) is balanced with the
total of the pressure in port (A) (PSIG) and the
load of spring (3).
q Accordingly, the pressure in the circuit
between the EPC valve and LS valve is con-
trolled in proportion to the signal current.
26 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
PPC valve 1
1. Blade PPC valve
P : From self pressure reducing valve P3 : To blade tilt valve (LEFT TILT) PPC port
P1 : To blade lift valve (LOWER) PPC port P4 : To blade tilt valve (RIGHT TILT) PPC port
P2 : To blade lift valve (RAISE) PPC port T : To hydraulic tank
D475A, D475ASD-5E0 27
SEN00214-00 10 Structure, function and maintenance standard
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connecting lever)
28 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Unit: mm
D475A, D475ASD-5E0 29
SEN00214-00 10 Structure, function and maintenance standard
Operation
1) When in neutral
(1) For lifting blade (2) For tilting blade
q Ports (A) and (B) of the blade lift valve of the q Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P1) and (P2) of the control valve and ports (P3) and (P4) of the
PPC valve are connected through fine control PPC valve are connected through fine control
hole (f) of spool (1) to drain chamber (D). hole (f) of spool (1) to drain chamber (D).
30 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 31
SEN00214-00 10 Structure, function and maintenance standard
32 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 33
SEN00214-00 10 Structure, function and maintenance standard
34 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Unit: mm
D475A, D475ASD-5E0 35
SEN00214-00 10 Structure, function and maintenance standard
36 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
D475A, D475ASD-5E0 37
SEN00214-00 10 Structure, function and maintenance standard
PCCS lever 1
Travel and steering PCCS lever
a Do not disassemble the PCCS lever. If it is disassembled, the output voltage characteristics and operat-
ing effort characteristics will need to be adjusted.
1. Bellows 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
38 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00214-00
Function
1. Operating effort characteristics
1) Operation for forward and reverse travel 2) Operation for steering
q The control lever is held at 3 positions of For- q Free return.
ward, Neutral, and Reverse.
D475A, D475ASD-5E0 39
SEN00214-00 10 Structure, function and maintenance standard
40 D475A, D475ASD-5E0
SEN00214-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)
42
SEN00215-01
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00215-01 10 Structure, function and maintenance standard
Control valve 1
Outline
q This control valve consists of a 6-spool valve
and a merge-divider valve.
q Since the 6-spool valve and the merge-divider
valve are assembled into 1 unit by connecting
bolts and each passage is connected inside,
the whole unit is compact and easy to main-
tain.
A1 : To ripper lift cylinder head P10 : From blade tilt PPC valve
A2 : To blade tilt right cylinder head P11 : From ripper tilt PPC valve
A3 : To blade lift cylinder head P12 : From ripper tilt PPC valve
A4 : To blade lift cylinder head PLS1 : To front pump control
A5 : To blade tilt left cylinder head PLS2 : To rear pump control
A6 : To ripper tilt cylinder head PP1 : From rear main pump
B1 : To ripper lift cylinder bottom PP2 : From front main pump
B2 : To blade tilt right cylinder bottom PPS1: To front pump control
B3 : To blade lift cylinder bottom PPS2: To rear pump control
B4 : To blade lift cylinder bottom PR : To solenoid valve, PPC valve, and EPC valve
B5 : To blade tilt left cylinder bottom PS : From merge-divider solenoid valve
B6 : To ripper tilt cylinder bottom PST : From port PR
P1 : From ripper lift PPC valve SA : Pressure sensor mounting port
P2 : From ripper lift PPC valve SB : Pressure sensor mounting port
P3 : From blade tilt PPC valve T : To tank
P4 : From blade tilt PPC valve TS : To tank
P7 : From blade lift PPC valve
P8 : From blade lift PPC valve
P9 : From blade tilt PPC valve
1. 6-spool valve
2. Cover 1
3. Cover 2
4. Merge-divider valve
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
6-spool valve
(1/8)
D475A, D475ASD-5E0 3
SEN00215-01 10 Structure, function and maintenance standard
(2/8)
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
(3/8)
D475A, D475ASD-5E0 5
SEN00215-01 10 Structure, function and maintenance standard
(4/8)
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
D475A, D475ASD-5E0 7
SEN00215-01 10 Structure, function and maintenance standard
(5/8)
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
D475A, D475ASD-5E0 9
SEN00215-01 10 Structure, function and maintenance standard
(6/8)
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
1. Unload valve
2. Main relief valve
D475A, D475ASD-5E0 11
SEN00215-01 10 Structure, function and maintenance standard
(7/8)
12 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
D475A, D475ASD-5E0 13
SEN00215-01 10 Structure, function and maintenance standard
(8/8)
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
1. Unload valve
2. Main relief valve
3. Merge-divider valve (For main)
4. Spool return spring
5. Merge-divider valve (For LS)
6. Spool return spring
7. Valve (Sequence valve)
8. Spring (Sequence valve)
9. LS bypass plug
10. Spring (Safety valve)
11. Ball
12. Valve (Pressure reducing valve)
13. Spring (Main pressure reducing valve)
14. Spring (Pilot pressure reducing valve)
15. Poppet
16. Screw
17. Spring (Safety valve)
18. Ball
Unit: mm
D475A, D475ASD-5E0 15
SEN00215-01 10 Structure, function and maintenance standard
1. Spring
2. Poppet
Function
q The main relief valve sets the maximum pump
pressure of the main valve.
Operation
q The set pressure of the relief valve depends on
the installed load of spring (1).
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
CLSS 1
1. Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q The CLSS consists of a main pump (2 pumps),
tem, and has the following features. control valve, and actuators for the work equip-
q Fine control not influenced by load ment.
q Control enabling digging even with fine control q The work equipment pump body consists of
q Ease of compound operation ensured by flow the pump itself, CO valve and LS valve.
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
D475A, D475ASD-5E0 17
SEN00215-01 10 Structure, function and maintenance standard
2. Basic principle
1) Control of pump swash plate
q The pump swash plate angle (pump delivery q If LS differential pressure (dPLS) becomes
amount) is controlled so that LS differential lower than the set pressure of the LS valve
pressure (dPLS) [the difference between pump (when the actuator load pressure is high), the
pressure (PP) and control valve outlet port LS pump swash plate moves towards the maxi-
pressure (PLS)] (load pressure of actuator) is mum position; if it becomes higher than the set
constant. pressure of the LS valve (when the actuator
[LS pressure (dPLS) = Pump discharge pres- load pressure is low), the pump swash plate
sure (PP) LS pressure (PLS)] moves towards the minimum position.
18 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
2) Pressure compensation
q A pressure compensation valve is installed to
the outlet port side of the control valve to bal-
ance the load.
q When two actuators are operated together, this
valve acts to make pressure difference (dP)
between the upstream (inlet port) and down-
stream (outlet port) of the spool of each valve
the same regardless of the size of the load
(pressure).
q In this way, the flow of oil from the pump is
divided (compensated) in proportion to the
area of openings (S1) and (S2) of each valve.
D475A, D475ASD-5E0 19
SEN00215-01 10 Structure, function and maintenance standard
Unload valve 1
Function
q When the pump flow is merged and the control
valve group on one side is actuated (with the
remaining control valve group at neutral), the
sub-unload valve drains the pump flow to the
group that is at neutral.
Operation
q The pressure in pump passages (A) is
received at the end portion of valve (1). The
control valve is at neutral, so the pressure in
LS circuit (B) is 0 MPa {0 kg/cm2}.
q The pressurized oil in pump passage (A) is
stopped by valve (1) and cannot escape, so
the pr essur e r ises . When this pr essur e
becomes larger than the force of spring (2),
valve (1) moves to the left, ports (C) and (D)
are interconnected, and the pump pressure
flows to tank passsage (E). In addition, the
pressurized oil in LS circuit (B) passes from
orifice (f) through port (D) and is drained to
tank passage (E). Therefore, in this operation,
LS pressure C tank pressure.
q In this unload operation, pump discharge pres-
sure LS circuit pressure is greater than the
pump LS control pressure, so a signal is sent
to set the pump swash plate to the minimum
angle.
20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
Introduction of LS pressure 1
(LS shuttle valve)
Function Operation
q LS pressure (PLS) is the actuator load pres- q When main spool (2) is operated, pump dis-
sure at the output side of the control valve. charge pressure (PP) starts to flow to actuator
q The upstream pressure (= spool meter-in circuit (A).
downstream pressure) of pressure compensa- q First, this pump discharge pressure (PP)
tion valve (3) is taken inside main spool (2) and passes through introduction hole (a) of main
goes to LS shuttle valve (5). spool (2), and is taken to LS circuit (PLS).
q When this happens, it connects actuator circuit q When actuator circuit pressure (A) rises to the
(A) and LS circcuit (PLS) through check valve necessary pressure, pump pressure (PP) rises
(4), and sets so that LS pressure (PLS) C actu- and check valve (4) inside main spool (2)
ator load pressure. opens. The high pressure of LS circuit (PLS)
q Introduction hole (a) inside main spool (2) has then flows to actuator circuit (A).
a small diameter, so it also acts as a throttle. q In this way, LS pressure (PLS) becomes
almost the same as actuator circuit pressure
(A).
D475A, D475ASD-5E0 21
SEN00215-01 10 Structure, function and maintenance standard
LS bypass plug 1
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
Operation
q If pump pressure (PP) and LS pressure (PLS)
are lower than actuator circuit (B), shuttle valve
(3) inside the pressure compensation valve
moves to the left in the direction of the arrow to
interconnect spring chamber (C).
q When this happens, piston (4) is pushed to the
right by spring (5), so pump outlet circuit (A)
closes. This prevents the oil from flowing back
from actuator circuit (B) to pump outlet circuit
(A).
D475A, D475ASD-5E0 23
SEN00215-01 10 Structure, function and maintenance standard
Function Operation
q During compound operations, if the load pres- q During compound operations, if the load pres-
sure is lower than the other actuators and the sure for the other actuators rises, the oil flow in
flow of oil starts to increase, the pressure com- actuator circuit (B) tries to increase.
pensation valve carries out compensation. In q When this happens, LS pressure (PLS) for the
this case, it tries to make the load pressure for other actuator also increases, so this LS pres-
the other actuators greater and reduce the flow sure (PLS) pushes shuttle valve (3) of the
of oil. pressure compensation valve to the right in the
direction of the arrow, passes through the pas-
sage inside piston (4), and flows to spring
chamber (C).
q As a results, piston (4) is pushed to the right in
the direction of the arrow, and the outlet side of
pump circuit (PP) is closed, so outlet port pres-
sure (A) (spool meter-in downstream pressure)
becomes the same as the outlet port pressure
of the other actuators.
q Pump pressure (PP) (spool meter-in upstream
pressure) is the same between all actuators,
so pump pressure (PP) and outlet port pres-
sure (A) become the same between all spools
that are being operated. Therefore, the pump
flow is divided in proportion to the area of the
opening of each valve.
24 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
D475A, D475ASD-5E0 25
SEN00215-01 10 Structure, function and maintenance standard
26 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
Operation
q When the blade lift lever is in NEUTRAL, spool
(3) is held in the neutral position by springs (1)
and (6) through retainers (2) and (4).
q At this time, the oil does not flow in either of the
head and bottom of the blade lift cylinder.
D475A, D475ASD-5E0 27
SEN00215-01 10 Structure, function and maintenance standard
28 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
Operation
q If the blade lift lever is set in the RAISE posi-
tion, the pilot pressure is applied through the
blade PPC valve to chamber (E) and spool (3)
moves to the left.
q The oil from the main pump flows through
notch (11) of spool (3) and cylinder port (A) to
the cylinder head.
q The oil returning from the cylinder bottom flows
through cylinder port (B) and notch (9) of spool
(3) to drain port (D).
D475A, D475ASD-5E0 29
SEN00215-01 10 Structure, function and maintenance standard
30 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
Operation
q If the blade lift lever is set in the LOWER posi-
tion, the pilot pressure is applied through the
blade PPC valve to chamber (F) and spool (3)
moves to the right.
q If the blade lift lever is set to the LOWER
stroke end, retainer (4) moves to retainer (5)
and the load of spring (7) is added to the load
of spring (6) and spool (3) stops moving.
q At this time, the oil from the main pump flows
through notch (10) of spool (3) and cylinder
port (B) to the cylinder bottom.
q The oil returning from the cylinder head flows
through cylinder port (A) and notch (12) of
spool (3) to drain port (C).
D475A, D475ASD-5E0 31
SEN00215-01 10 Structure, function and maintenance standard
32 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
Operation
q If the blade lift lever is moved from the LOWER
position to the FLOAT position, the pilot pres-
sure is applied through the blade PPC valve to
chamber (F) and spool (3) moves further to the
right.
q At this time, retainer (5) moves against the
total load of springs (6) and (7) until its right
end touches plug (8).
q Since cylinder ports (A) and (B) are connected
to drain ports (C) and (D) respectively, both
head and bottom of the blade lift cylinder are
connected to the drain port and the blade is
FLOATED.
D475A, D475ASD-5E0 33
SEN00215-01 10 Structure, function and maintenance standard
Merge-divider valve 1
34 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
D475A, D475ASD-5E0 35
SEN00215-01 10 Structure, function and maintenance standard
36 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
Operation
q Valve (7) is pressed by spring (8) and (PR) q Accordingly, differential pressure is generated
pressure (which is 0 MPa {0 kg/cm2} while the over orifice (a) in spool (14), and spool (14)
engine is stopped) to close the passage moves in the direction to close the passage
between ports (P2) and (A2). If hydraulic oil between ports (P2) and (PR). The P2 pressure
flows in through port (P2), however, (d area x is lowered and controlled to a constant pres-
pressure P2) = force of spring (8) + (d area x sure (set pressure) by the opening ratio of the
PR pressure), and they are balanced. Then, passage at this time and supplied as the PR
the passage between ports (P2) and (A2) is so pressure.
adjusted that the P2 pressure will be kept at a
certain value higher than the PR pressure.
q If the PR pressure rises higher than the set
level, poppet (11) opens and the hydraulic oil
flows from port (PR) through orifice (a) in spool
(14) and opening of poppet (11) into seal drain
port (TS).
D475A, D475ASD-5E0 37
SEN00215-01 10 Structure, function and maintenance standard
Operation
q If load pressure (A2) is heightened and the q Accordingly, differential pressure is generated
pump delivery amount is increased because of over orifice (a) in spool (14) and spool (14)
digging operation, etc., the P2 pressure rises moves in the direction to close the passage
{(d area P2 pressure) > force of spring (8) + between ports (P2) and (PR). The P2 pressure
(d area PR pressure)}, then valve (7) is lowered and controlled to a constant pres-
moves to the right stroke end. sure (set pressure) by the opening ratio of the
q As a result, the opening ratio of the passage passage at this time and supplied as the PR
between ports (P2) and (A2) is increased and pressure.
the passage resistance is reduced. Conse-
quently, the loss of the engine horsepower is
reduced.
q If the PR pressure rises higher than the set
level, poppet (11) opens and the hydraulic oil
flows from port (PR) through orifice (a) in spool
(14) and opening of poppet (11) into seal drain
port (TS).
38 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
Operation
q If the PR pressure of the self pressure reduc-
ing valve is raised abnormally, ball (16) sepa-
rates from the seat against the force of spring
(15). As a result, the hydraulic oil flows from
output port (PR) to (TS) and the PR pressure
lowers. Accordingly, the devices receiving the
oil pressure (PPC valves, solenoid valves, etc.)
are protected from abnormally high pressure.
D475A, D475ASD-5E0 39
SEN00215-01 10 Structure, function and maintenance standard
40 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00215-01
q The operation of the pilot solenoid valve is shown in the following table.
D475A, D475ASD-5E0 41
SEN00215-01
2016 KOMATSU
All Rights Reserved
Printed in Japan 02-16 (01)
42
SEN00216-01
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00216-01 10 Structure, function and maintenance standard
1. Cover 7. Spring
2. Sight gauge 8. Suction valve
3. Cover 9. Strainer
4. Hydraulic tank 10. Drain plug
5. Oil filler cap 11. Drain valve
6. Hydraulic filter element 12. Breather, with valve function
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-01
Specified value
Tank capacity (l) 310
Specified value
Cracking pressure 150 30
(kPa {kg/cm2}) {1.53 0.3}
Hydraulic Mesh size (m) 30/8
filter
2
Filtering area (cm ) 17,600
Filtering oil flow (l/min) 703
Mesh size (m) 105
Strainer 2
Filtering area (cm ) 3,600
D475A, D475ASD-5E0 3
SEN00216-01 10 Structure, function and maintenance standard
Accumulator 1
For PPC valve Operation
q After the engine is stopped, when the PPC
valve is at neutral, chamber (A) inside the blad-
der is compressed by the oil pressure in cham-
ber (B).
q When the PPC valve is operated, the oil pres-
sure in chamber (B) goes below 2.9 MPa {30
kg/cm2}, and the pressure of the nitrogen gas
in chamber (A) expands the bladder, so the oil
in chamber (B) acts as the pilot pressure and
actuates the main control valve.
1. Glass plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas:Nitrogen
Gas volume:300 cc
Max. actuation pressure:3.1 MPa {32 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
Function
q The accumulator is installed between the pres-
sure reducing valve and the PPC valve. Even if
the engine is stopped with the work equipment
still raised, the pressure of the nitrogen gas
compressed inside the accumulator sends the
pilot pressure to the main control valve to actu-
ate it and enable the work equipment to move
down under its own weight.
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-01
D475A, D475ASD-5E0 5
SEN00216-01 10 Structure, function and maintenance standard
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-01
Unit: mm
D475A, D475ASD-5E0 7
SEN00216-01 10 Structure, function and maintenance standard
Piston valve 1
For blade lift cylinder
Operation
1. When piston valve is closed
The oil from the work equipment pump acts on
piston (2) and piston valve (3).
Then, piston valve (3) is pushed to the right to
seal the tapered part of piston valve seat (4).
As a result, the oil pressure in the cylinder
rises to move piston (2) to the right.
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-01
D475A, D475ASD-5E0 9
SEN00216-01 10 Structure, function and maintenance standard
Operation
1. Start of lowering blade
If the blade control lever is set in the LOWER
position, the oil from the control valve flows
through port (A) to the cylinder bottom side and
pushes the piston.
The oil on the cylinder head side is pushed out
by the piston into port (B), and then flows
through port (C) and control valve to the
hydraulic tank.
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-01
Unit: mm
D475A, D475ASD-5E0 11
SEN00216-01 10 Structure, function and maintenance standard
1. Switch (dual-single selector switch) q If switch (2) is pressed and the lever is oper-
2. Switch (pitch) ated, the blade is pitched. If the lever is tilted to
3. Cover the left, the blade is pitched back. If the former
4. Connector (male) is tilted to the right, the latter is pitched for-
5. Connector (female) ward.
q If switch (1) is set to the DUAL position and
Outline the lever is operated, blade carries out dual tilt
q If the blade control knob is tilted forward, back- operation. If the lever is tilted to the left, the
ward, to the right, or to the left, the blade is blade carries out left dual tilt operation. If the
raised, lowered, tilted to the right, or tilted to the lever is tilted to the right, the blade carries out
left. If switch (1) is set to the DUAL position right dual tilt operation.
and the lever is tilted to the right or left, dual tilt q If switch (1) is set in either DUAL or
operation is carried out. If the lever is tilted to SINGLE position and the lever is tilted to the
the right or left while switch (2) is pressed and right or left while switch (2) is pressed and
held, pitching operation is carried out. held, the blade is pitched.
12 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-01
D475A, D475ASD-5E0 13
SEN00216-01 10 Structure, function and maintenance standard
1. Connector Outline
2. Solenoid (a) q The pitch and dual solenoid valve is installed
3. Valve between the PPC valve and main control valve
4. Solenoid (b) and used to select the PPC pilot pressure.
5. Manual push pin q Operation of the pitch switch of the blade con-
trol lever (or the rear pitch switch or forward
A: Port A pitch switch of the superdozer specification),
B: Port B pilot pressure can be applied so the right and
P: Port P left pitch cylinders will move similarly and the
T: Port T tilt operation can be changed to the pitch oper-
ation.
q If the dual tilt specification is installed and the
toggle switch of the blade control lever is set in
the "dual" position, the pilot pressure is applied
to both right and left tilt cylinder spools to
change the single tilt operation to the dual tilt
operation.
q The pitch and dual tilt solenoid valve is oper-
ated by the controller.
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-01
D475A, D475ASD-5E0 15
SEN00216-01 10 Structure, function and maintenance standard
16 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00216-01
Operation
1. Pin puller switch at PUSH IN position 2. Pin-puller switch at PULL OUT position
When the pin-puller switch is turned to the When the pin puller switch is turned to the
PUSH IN position, no current flows to solenoid PULL OUT position, current flows to solenoid
(9) and it is deactivated. (9) and it is excited.
When this happens, spool (5) opens ports (A) When this happens, the solenoid pushes out
and (B) and ports (C) and (D), and the oil from push pin (8), and spool (5) moves to the left in
the power train pump flows from port (A) to the direction of the arrow.
port (B) and enters the bottom of pin puller cyl- Ports (A) and (B) and ports (C) and (D) close,
inder (10). and ports (A) and (C) and ports (B) and (D)
The oil entering the bottom end of the cylinder open. The oil from the power train pump flows
increases the hydraulic pressure in the circuit from port (A) to port (C) and enters the head of
and extends the cylinder. Shank mounting pin pin puller cylinder (10).
(11) is pushed into shank (12). The oil entering the head end of the cylinder
increases the hydraulic pressure in the circuit
and retracts the cylinder. Shank mounting pin
(11) is pulled out of shank (12).
D475A, D475ASD-5E0 17
SEN00216-01
2008 KOMATSU
All Rights Reserved
Printed in Japan 04-08 (01)
18
SEN00217-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00217-00 10 Structure, function and maintenance standard
Work equipment 1
Cylinder stay 1
Unit: mm
2 D475A, D475ASD-5E0
SEN00217-00 10 Structure, function and maintenance standard
Blade 1
Full U-dozer, Semi U-dozer, Superdozer
Unit: mm
4 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00217-00
D475A, D475ASD-5E0 5
SEN00217-00 10 Structure, function and maintenance standard
Unit: mm
6 D475A, D475ASD-5E0
SEN00217-00 10 Structure, function and maintenance standard
Ripper equipment 1
Variable giant ripper
8 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00217-00
Unit: mm
D475A, D475ASD-5E0 9
SEN00217-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)
10
SEN00218-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00218-00 10 Structure, function and maintenance standard
1. Support Outline
2. Damper mount (front) q Mounts are installed at two places at the front
3. Damper mount (rear) and two places at the rear to secure the floor
frame and cab.
q An oil-filled damper mount is used to absorb
the vibration.
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00218-00
Cab 1
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D475A, D475ASD-5E0 3
SEN00218-00 10 Structure, function and maintenance standard
ROPS guard
1. ROPS guard
4 D475A, D475ASD-5E0
SEN00218-00 10 Structure, function and maintenance standard
Air conditioner 1
Air conditioner piping
6 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00218-00
1. Condenser
2. Air conditioner compressor
3. Refrigerant piping
4. Window defroster
5. Side defroster
6. Vent
7. Hot water pickup piping
8. Valve (hot water outlet)
9. Receiver tank
10. Hot water return piping
11. Valve (hot water inlet)
12. Air conditioner unit
13. Additional blower motor
A. Fresh air
B. Recirculated air
C. Hot air/cold air
D475A, D475ASD-5E0 7
SEN00218-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)
8
SEN00219-02
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00219-02 10 Structure, function and maintenance standard
2 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
System diagram
Note
The design of the machine monitor differs by a q The steering controller sends the most suitable
machine. For details, see section Machine moni- for engine speed from informations 1) and 2)
tor. and transmits it as the 3rd throttle to the engine
throttle controller.
Outline q Information of the engine throttle controller is
q The engine throttle controller receives the commonly used by all the controllers through-
manual signals of the 1st throttle, 2nd throttle out the network, for optimum control of the
and the 3rd throttle signals which is the control engine and machine body.
signals from the machine body, then selects q The automatic deceleration function sets the
the lower engine speed and controls the fuel engine speed to 1,000 rpm temporarily when
supply pump. the travel direction is changed from F3, R3, or
The 3rd throttle control signals contain the fol- R2 (to protect the transmission clutch).
lowing.
1) High idle speed control
2) SSC (Shoe Slip Control)
3) Automatic deceleration (F3, R3, R2)
D475A, D475ASD-5E0 3
SEN00219-02 10 Structure, function and maintenance standard
Deceleration potentiometer
1. Connector Outline
2. Lever q The deceleration potentiometer is installed to
3. Body the front lower part of the operators cab and
4. Potentiometer connected to the decelerator pedal by linkage.
5. Coupling q If the decelerator pedal is pressed, the throttle
6. Shaft potentiometer shaft rotates by the linkage and
7. Stopper the potentiometer resistance changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and an electric
signal is sent through pin (B) to the engine
throttle controller according to the position of
the decelerator pedal.
4 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 5
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6 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 7
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8 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 9
SEN00219-02 10 Structure, function and maintenance standard
Monitor system 1
Note
The design of the machine monitor differs by a torque converter oil temperature, fuel
machine. For details, see section Machine moni- level, hydraulic oil level, etc.) on the
tor. gauge.
3) Function of displaying error codes.
Outline 4) Function of monitoring the current and
q The monitor system monitors the machine con- voltage of the sensors and solenoids.
dition with sensors installed to various parts of q In the monitor panel, there are various mode
the machine, and quickly processes and dis- selector switches of the SSC (Shoe Slip Con-
plays obtained information on the monitor trol), which are used to operate the machine
panel, to notify the operator of machine condi- control system (with SSC).
tion. q The monitor panel has the functions of display-
The function of the monitor system is as fol- ing data and selecting the SSC mode (with
lows. SSC).
1) Function which turns on the alarm when q The CPU (Central Processing Unit) in it pro-
the machine has a trouble on the monitor. cesses, displays, and outputs the information.
2) Function which constantly displays the The display unit is LCD (Liquid Crystal Display)
machine condition (coolant temperature, and the switches are seat switches.
10 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
2) Display of engine speed in gauge number. CAN Engine speed sensor o Steering
The number of pulses the engine rotation is controller o Machine monitor
converted into a gauge number and notified to the
monitor panel by CAN signals.
3) Display of failure
When the machine has a failure, the corresponding CAN Engine sensor/solenoid o Steering
failure code is notified to the monitor panel by CAN controller or transmission controller
signals. o Machine monitor
Which one should be turned on, the buzzer or the
caution lamp, is notified, too.
i) In normal state
User code Sensors and solenoids o Engine
ii) In fault history display mode throttle controller o Steering
The service code (6-digit code) and the controller o Machine monitor
following items are displayed
1. Time after first occurrence
2. Time after latest occurrence
3. Number of past occurrence
The machine monitor displays code on the multi-
information section.
Other items
Contents and conditions of processing Method Flow of signals
1) Function selection mode (Displayed each time CAN Steering controller o Machine
cancel switch is turned to left) monitor
i) Replacement periods of oil filter and oil are
displayed.
ii) Engine speed, oil pressure in work equipment
circuit, etc. are displayed.
iii) Failure codes related to electronic control are
displayed.
iv) Brightness of display, etc. are adjusted.
2) Mode to change replacement periods of
maintenance mode
3) Mode to display failure codes related to the Note
machine such as overheating, abnormal coolant CAN is abbreviation for Controller
temperature, etc. Area Network, which is a
4) Mode to display service meter and information communication standard name
related to load on machine provided by ISO etc.
D475A, D475ASD-5E0 11
SEN00219-02 10 Structure, function and maintenance standard
Machine monitor 1
Monitor portion
Serial No.: 30001 30070
12 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 13
SEN00219-02 10 Structure, function and maintenance standard
Outline 3. Indicators
q The monitor section is an LCD screen which The necessary timings of the operations of the
consists of the gauges that constantly indicate machine are indicated by the indicator lamps in
the machine condition, character screen that the monitor section.
displays the current travel condition of the Indication items (type of the indicator lamps),
machine (travel direction and gear speed), their operations, and their indication methods
caution lamps that indicate abnormalities of the are shown in the List of display of cautions
machine, indicator lamps that show the opera- and indicators which will appear later.
tion guide, and multi-information unit that dis- a The blinking intervals of the indicator lamps
plays the service meter and maintenance are the same with the caution lamps.
information.
The CPU in the machine monitor processes
the signals from the sensors at various places
of the machine and indicates the results on the
screen.
Operation
1. Operation check (Check before starting)
While the engine is stopped (five or more sec-
onds after the engine is stopped), if the power
is turned ON (the starting switch is turned to
the ON position), all items of the gauges, indi-
cator lamps and caution lamps of the monitor
section operate as follows to indicate that each
of them operates normally.
1) All items of the gauges, indicator lamps
and caution lamps light for about 3 sec-
onds and then go off.
2) The alarm buzzer sounds for about 1 sec-
ond, synchronizing with 1) above.
2. Cautions
If the machine has any trouble, the caution
lamp corresponding to the trouble part in the
monitor section blinks or lights and the alarm
buzzer sounds as required.
The caution items (types of the caution lamps),
caution lamps corresponding to the caution
items, and operation of the alarm buzzer are
shown in the List of display of cautions and
indicators which will appear later.
All the items, except the items of indication cat-
egory Check before starting in List of display
of cautions and indicators shown later, are
monitored while the engine is running, from the
start to the stop of the engine.
a The items of display category Check before
starting are monitored from when the starting
switch is turned ON while the engine is
stopped.
a The blinking intervals of the caution lamps and
the sounding intervals of the alarm buzzer are
set to about 0.8 seconds, which fluctuates
more or less when the ambient temperature is
low (below about 10C), but that does not
indicate trouble.
14 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
D475A, D475ASD-5E0 15
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16 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 17
SEN00219-02 10 Structure, function and maintenance standard
Display
Symbol Indicated item Indication range Indication method
category
Displayed when abnormality oc-
curs while engine is running.
When power train oil temp. 120C 130C (1st red segment):
Power train oil temp. gauge is in red range (above Blinking
120C) Above 130C (2nd red segment):
Blinking. Warning lamp blinks and
alarm buzzer sounds, too.
Displayed when abnormality oc-
curs while engine is running.
When hydraulic oil temperature 100C 110C (1st red segment):
Hydraulic oil temp. gauge is in red range (above Blinking
100C) Above 110C (2nd red segment):
Blinking. Warning lamp blinks and
alarm buzzer sounds, too.
Cautions
18 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
Display
Symbol Indicated item Indication range Indication method
category
ON: Turned ON when fan rotation
selector switch is turned to CLN
position.
Indication that engine
can be started with
Blinking: Blinks for 3 seconds to
cooling fan in reserve
ON: When cooling fan rotation notify that cooling fan rotation
direction for cleaning
direction is in reverse rotation direction cannot be changed
cooling device such as
mode when fan rotation selector switch
radiator and that
is operated while engine is
cooling fan rotation
Blinking: When cooling fan running.
direction cannot be
rotation direction cannot be
changed while engine
changed OFF: Turned OFF when fan
is running regardless of
Orange rotation selector switch is
current cooling fan
Non-symbol operated again while this lamp is
rotation direction
ON (At this time, cooling fan
Indicators
D475A, D475ASD-5E0 19
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20 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
Display
Symbol Indicated item Indication range Indication method
category
Displayed when abnormality oc-
curs while engine is running.
120C 130C (1st red segment
When power train oil temperature and all segments under it): Blink-
Power train oil temp. gauge is in red range (above ing
120C) Above 130C (2nd red segment
and all segments under it): Blink-
ing. Warning lamp blinks and
alarm buzzer sounds, too.
Displayed when abnormality oc-
curs while engine is running.
100C 110C (1st red segment
When hydraulic oil temperature and all segments under it): Blink-
Hydraulic oil temp. gauge is in red range (above ing
100C) Above 110C (2nd red segment
and all segments under it): Blink-
ing. Warning lamp blinks and
Cautions
D475A, D475ASD-5E0 21
SEN00219-02 10 Structure, function and maintenance standard
Display
Symbol Indicated item Indication range Indication method
category
ON: Turned ON when fan rotation
selector switch is turned to CLN
Indication that cooling position.
fan rotation direction is
When cooling fan rotation
in reserve rotation OFF: Turned OFF when fan
direction is in reserve rotation
mode when cooling rotation selector switch is
mode
device such as radiator operated again while this lamp is
is being cleaned ON (At this time, cooling fan
rotation direction is set in forward
rotation mode).
Indication that cooling
Blinking: Blinks for 3 seconds to
fan rotation direction
notify that cooling fan rotation
cannot be changed
Indicators
22 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
Engine coolant
temperature
Hydraulic oil
temperature
Gauges
Fuel level
D475A, D475ASD-5E0 23
SEN00219-02 10 Structure, function and maintenance standard
Engine coolant
temperature
Hydraulic oil
Gauges
Fuel level
Engine speed
24 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
2) Special display
(Service mode display)
Selected service mode symbol
when display section B is changed
For details of selection of normal dis-
to special display
play and special display, see 30 Test-
ing and adjusting of this manual.
1) Normal display Display unit displays 2 16-alphanu-
(Operation mode display) meric lines.
Preset forward gear speed and Preset gear speed is displayed by ver-
reverse gear speed. tically enlarged letters, however.
Service meter (Integrated oper- For details of selection of this display
ating hours of machine) and normal display, see 30 Testing
and adjusting of this manual.
Display section B (Multi-information)
D475A, D475ASD-5E0 25
SEN00219-02 10 Structure, function and maintenance standard
Display
Form and position Indicated item Indication method
section
4) Special display (Service mode dis- 4) Example of special display
play)
Machine information necessary to
Display section B (Multi-information)
26 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
D475A, D475ASD-5E0 27
SEN00219-02 10 Structure, function and maintenance standard
1. Switch functions
q Option
The machine with SSC (Shoe slip control)
fu nc t io n pu t on o pt io na l ly ha s t he n ex t
switches.
2. Operation
For the operation, see Mode selection sys-
tem.
28 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
D475A, D475ASD-5E0 29
SEN00219-02 10 Structure, function and maintenance standard
Note
The design of the machine monitor differs by a
machine. For details, see section Machine moni-
tor.
30 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
D475A, D475ASD-5E0 31
SEN00219-02 10 Structure, function and maintenance standard
a When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the
engine output control is performed in accordance with the command having the smallest value among
the control command, throttle command, and decelerator command.
a Note 1: When the lock-up mode is not selected, the other Economy, Reverse slow, SSC, and Rock-bed
selection modes can be selected simultaneously.
Note 2: When the lock-up mode is selected, Reverse slow mode can be selected simultaneously, but
Economy, SSC, and Rock-bed selection modes cannot be selected simultaneously.
32 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
D475A, D475ASD-5E0 33
SEN00219-02 10 Structure, function and maintenance standard
Electrical equipment 1
Operation of lamp system
34 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
Preheating circuit
D475A, D475ASD-5E0 35
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36 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
Manual mode
Shift mode 1
Shift mode 2
Display
The selected shift mode is displayed on the Multi-
information.
For the Multi-information, see Machine monitor.
D475A, D475ASD-5E0 37
SEN00219-02 10 Structure, function and maintenance standard
Sensors 1
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine coolant temperature Resistance
Torque converter oil temperature Resistance
Hydraulic oil temperature Resistance
Radiator coolant level Contact ON OFF
Fuel level Resistance
Engine oil level Contact ON OFF
Air cleaner clogging Contact ON OFF
Transmission output shaft speed sensor Resistance
Torque converter speed sensor Resistance
Acceleration sensor Resistance
Pitch angle sensor Resistance
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
38 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
D475A, D475ASD-5E0 39
SEN00219-02 10 Structure, function and maintenance standard
1. Connector Function
2. Float q The fuel level sensor is installed to the side
3. Arm face of the fuel tank. The float moves up and
4. Body down according to the fuel level. This move-
5. Spring ment of the float is transmitted by the arm and
6. Contact actuates a variable resistance. This sends a
7. Spacer signal to the monitor panel to indicate the
remaining fuel level. When the display on the
monitor panel reaches a certain level, a warn-
ing lamp flashes.
40 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
1. Boss 4. Wire
2. Switch 5. Connector
3. Conduit
D475A, D475ASD-5E0 41
SEN00219-02 10 Structure, function and maintenance standard
1. Magnet 4. Boots
2. Terminal 5. Connector
3. Case
1. Connector
2. Flange
3. Sensor
42 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
D475A, D475ASD-5E0 43
SEN00219-02 10 Structure, function and maintenance standard
1. Body
2. Tube
3. Wire
4. Connector
44 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
VHMS controller
D475A, D475ASD-5E0 45
SEN00219-02 10 Structure, function and maintenance standard
46 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
CN3-A12 NC Input/
CN4-A12 CAN (1) L (KOM-NET/c)
Output
CN3-A13 GND Input
CN4-A13 CAN (1) SH (KOM-NET/c) Input
CN3-A14 NC
Input/
CN3-A15 NC CN4-A14 CAN (0) L CGC
Output
CN3-A16 NC CN4-B1 NC
CN3-A17 NC Input CN4-B2 NC
CN3-A18 NC CN4-B3 RS232C GND Input
CN3-B1 NC CN4-B4 RS232C TX1 (Orbcomm) Output
CN3-B2 NC CN4-B5 NC
CN3-B3 NC CN4-B6 NC
CN3-B4 NC CN4-B7 NC
CN3-B5 NC CN4-B8 NC
CN3-B6 Snap shot Sw Input CN4-B9 GND Input
CN3-B7 NC CN4-B10 RS232C RX1 (Orbcomm) Input
CN3-B8 NC
CN5
CN3-B9 GND Input
Input/
CN3-B10 NC Pin No. Signal name
Output
CN3-B11 NC
1 TX + Output
CONNECTOR SELECTION 3 2 TX Output
CN3-B12 Input
(OPEN)
3 RX + Input
4 RT 3 Input
5 RT 4 Input
6 RX Input
7 RT 1 Input
8 RT 2 Input
9 NC
10 GND
11 5 V POWER SUPPLY Output
12 GND Input
D475A, D475ASD-5E0 47
SEN00219-02 10 Structure, function and maintenance standard
Sensors
Engine oil temperature sensor Exhaust temperature sensor/amplifier
Specifications Specifications
Type of sensor: Thermistor Rated voltage: DC 24 V
Measurement range: 40 130C Sensed temperature range: 100 1,000C
80 130C 300 800C
(Assured accuracy: 2C) (Assured accuracy: 10C)
Max. power consumption: 0.5 mW Output voltage characteristics
Pressure resistance: 4.9 MPa {50 kg/cm} (Ambient temperature: 20C)
Reference values
Using temperature: 30C to +140C
Sensed
Performance table
temperature 50 100 400 700 800
Temper- Resis- Temper- Resis- Temper- Resis- (C)
ature tance ature tance ature tance
Output voltage
(C) (kz) (C) (kz) (C) (kz) 1.191 1.397 2.626 3.899 4.316
(V)
30 35.27 80 6.571 110 2.887
40 24.28 85 5.682 115 2.544 Operating temperature range: 40 to +110C
Current consumption: Max. 30 mA
50 17.05 90 4.931 120 2.248
a: Heat sensing part of sensor Outside diame-
60 12.20 95 4.293 125 1.992
ter of mounting part: R1/8
70 8.884 100 3.750 130 1.769 b: Amplifier
a: Heat sensing part of sensor Outside diame- c: Connector (Power supply side)
ter of mounting part: R1/4 d: Connector (Sensor side)
Function Function
The exhaust temperature sensor/amplifier is a ther-
The engine oil temperature sensor is installed to
mocouple-type temperature sensor, which is
the engine oil filter. It inputs the change of the tem-
installed to the turbocharger inlet. It outputs the
perature as the change of the thermistor resistance
exhaust temperature data to the VHMS controller.
to the VHMS controller.
48 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
Function
The atmospheric temperature sensor inputs the
change of the atmospheric temperature as the
change of the thermistor resistance to the VHMS
controller.
D475A, D475ASD-5E0 49
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50 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
ORBCOMM terminal 1
Outline
q The ORBCOMM terminal obtains various kinds of machine information recorded in the VHMS controller
and transmits them via the wireless communication antenna. It has a CPU (Central Processing Unit)
and wireless communication function.
q This terminal has an LED lamp and a 7-segment display lamp used for inspection and troubleshooting.
Input/Output signals
q DRC connector
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
1 NC 16 NC
2 NC 17 NC
3 NC 18 NC
4 COMM 232C RXD Input 19 PWR_CTR_EXT Output
5 COMM 232C TXD Output 20 NC
6 NC 21 NC
7 NC 22 NC
8 NC 23 NC
9 NC 24 NC
10 NC 25 NC
11 GND_RS232C 26 NC
12 NC 27 NC
13 NC 28 NC
14 NC 29 DOUT (GND) Output
15 NC 30 GND
31 NC
32 NC
33 NC
34 NC
35 NC
36 PWR_CTR_KEY Input
37 GND_PWR
38 GND_PWR
39 PWR_IN_BATT Input
40 PWR_IN_BATT Input
D475A, D475ASD-5E0 51
SEN00219-02 10 Structure, function and maintenance standard
Antenna
Specifications
Type: Helical whip antenna (1)
Impedance: 50 z
Input terminal: N-P type
Length: 165 20 mm
a. Communication antenna mounting part
Function
The communication controller transmits the data
collected and stored by the VHMS controller to the
computer center via the communication satellite.
52 D475A, D475ASD-5E0
10 Structure, function and maintenance standard SEN00219-02
D475A, D475ASD-5E0 53
SEN00219-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)
54
SEN01816-01
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN01816-01 20 Standard value table
(*1): Refer to the item 3. of Measuring engine speed in Testing and adjusting, Part 1.
2 D475A, D475ASD-5E0
20 Standard value table SEN01816-01
Standard value
Service limit
Measurement item Measurement conditions Unit for new
value
machine
Deceleration low idle Engine coolant temperature: Within operating
range 900 50 900 50
speed
Power train oil temperature: Within operating
Deceleration high idle range
Hydraulic oil temperature: Within operating 2,000 50 2,000 50
speed
Engine speed
range
Deceleration low idle: Press decelerator pedal
Torque converter stall Deceleration high idle: Set forward-reverse rpm
lever in neutral + Set work equipment control 1,690 50 Min. 1,590
speed lever in neutral
Torque converter stall: Stall at F3
Torque converter stall + Torque converter stall + Work equipment relief
Work equipment relief speed: Stall at F3 + Raise ripper or relieve 1,615 75 Min. 1,450
speed pitch back circuit
Steering
40 5 40 5
Neutral o Right
(Play: Max. 3) (Play: Max. 3)
Full stroke 78 10 78 10
Brake pedal Run engine at low idle mm
Press pedal to center Stroke to oil pres-
58 10 58 10
sure of 0
Neutral o Float 90 10 90 10
Run engine at low idle
Hydraulic oil tempera- Neutral o
60 10 60 10
Blade control lever ture: Raise/Lower mm
Within operating range
Set lever to center Neutral o
60 10 60 10
Left/Right tilt
Run engine at low idle Neutral o
78 10 78 10
Hydraulic oil tempera- Raise/Lower
Ripper control lever ture: mm
Within operating range Neutral o
81 10 81 10
Set lever to center Tilt in/out
Control lever and pedal operating effort
D475A, D475ASD-5E0 3
SEN01816-01 20 Standard value table
Standard value
Service limit
Measurement item Measurement conditions Unit for new
value
machine
4 D475A, D475ASD-5E0
20 Standard value table SEN01816-01
Standard value
Service limit
Measurement item Measurement conditions Unit for new
value
machine
Transmission 3rd clutch 2.35 2.74 2.25 2.74
Low idle
pressure {24.0 28.0} {23.0 28.0}
Transmission lubricating 0.15 0.29 0.15 0.29
High idle
pressure {1.5 3.0} {1.5 3.0}
2.65 2.98 Min. 2.45
High idle
{27.0 30.4} Min. {25}
Steering left clutch pressure
2.35 2.89 2.26 2.89
Low idle
{24.0 29.5} {23.0 29.5}
Power train oil pressure
flat and level place Forward 3rd 11.2 0.6 11.2 0.6
Run engine at high
idle Reverse 1st 4.2 0.3 4.2 0.3
Engine coolant Reverse 2nd 8.0 0.4 8.0 0.4
Power train
temperature: Within
operating range Reverse 3rd 14.0 0.7 14.0 0.7
Travel speed Economy mode: km/h
OFF Forward 1st 3.4 0.3 3.4 0.3
When lockup switch
Reverse slow
mode: OFF Forward 2nd 6.3 0.3 6.3 0.3
Run-up distance: Forward 3rd 11.6 0.6 11.6 0.6
is ON
10 30 m
Measuring dis- Reverse 1st 4.4 0.3 4.4 0.3
tance: 20 m
Reverse 2nd 8.4 0.4 8.4 0.4
Reverse 3rd 14.3 0.7 14.3 0.7
D475A, D475ASD-5E0 5
SEN01816-01 20 Standard value table
Engine speed
Specification
conditions
Work (Refer-
Relieving ence) Work equipment pump Work equipment pump
equip-
method outlet pressure (F) outlet pressure (R)
ment
tilt oil temper- 21.1 1.4 21.1 1.4 27.4 1.4 27.4 1.4
ature: Low
Dual tilt
45 55C MPa {215 14} {215 14} {280 14} {280 14}
Relieve {kg/cm2} 27.4 1.4 27.4 1.4 24.0 1.4 24.0 1.4
only circuit High
Right dual to be mea- {280 14} {280 14} {245 14} {245 14}
Divide
tilt sured 27.4 1.4 27.4 1.4 21.1 1.4 21.1 1.4
Low
Blade {280 14} {280 14} {215 14} {215 14}
dual tilt 24.5 1.4 24.5 1.4 24.5 1.4 24.5 1.4
High
Pitch {250 14} {250 14} {250 14} {250 14}
Divide
dump 21.1 1.4 21.1 1.4 21.1 1.4 21.1 1.4
Low
{215 14} {215 14} {215 14} {215 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Pitch {280 14} {280 14} {280 14} {280 14}
Divide
back 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Raise {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
Ripper
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Lower {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
6 D475A, D475ASD-5E0
20 Standard value table SEN01816-01
Engine speed
Specification
conditions
Work (Refer-
Relieving ence) Work equipment pump Work equipment pump
equip-
method outlet pressure (F) outlet pressure (R)
ment
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Raise {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Lower {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
Ripper
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
{280 14} {280 14} {280 14} {280 14}
Tilt in Merge
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
{280 14} {280 14} {280 14} {280 14}
Tilt back Merge
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
D475A, D475ASD-5E0 7
SEN01816-01 20 Standard value table
Engine speed
Specification
conditions
Work (Refer-
Relieving ence) Work equipment pump Work equipment pump
equip-
method outlet pressure (F) outlet pressure (R)
ment
dump oil temper- 21.1 1.4 21.1 1.4 21.1 1.4 21.1 1.4
ature: Low
{215 14} {215 14} {215 14} {215 14}
Super
8 D475A, D475ASD-5E0
20 Standard value table SEN01816-01
Specification
Work Standard value for
Relieving Measurement conditions Unit Service limit value
equip- new machine
method
ment
Raise relief
{25 2} {25 2}
Lower 2.45 0.2 2.45 0.2
relief Hydraulic oil temperature: MPa {25 2} {25 2}
Ripper Within operating range
Run engine at high idle {kg/cm2} 2.45 0.2 2.45 0.2
Tilt in
{25 2} {25 2}
2.45 0.2 2.45 0.2
Tilt back
{25 2} {25 2}
2.45 0.2 2.45 0.2
Raise relief
{25 2} {25 2}
Blade
Lower 2.45 0.2 2.45 0.2
relief {25 2} {25 2}
Left steer- 1.76 0.2 1.76 0.2
Blade ing tilt {18 2} {18 2}
single tilt Right 1.76 0.2 1.76 0.2
Single tilt
D475A, D475ASD-5E0 9
SEN01816-01 20 Standard value table
Specification
Blade
Within operating range
dual tilt Run engine at high idle 1.76 0.2 1.76 0.2
Pitch back
Work equipment oil pressure
{18 2} {18 2}
2.45 0.2 2.45 0.2
Raise relief
{25 2} {25 2}
Lower MPa 2.45 0.2 2.45 0.2
relief {kg/cm2} {25 2} {25 2}
Ripper
2.45 0.2 2.45 0.2
Tilt in
{25 2} {25 2}
2.45 0.2 2.45 0.2
Tilt back
{25 2} {25 2}
Hydraulic oil temperature:
45 55 C 2.94 4.9 2.94 4.9
Unload pressure
Set all work equipment {30 50} {30 50}
control levers in neutral
Hydraulic oil temperature:
Work equipment control oil Within operating range 3.92 4.51 Min. 3.72
Set all work equipment
pressure control levers in neutral {40 46} {Min. 38}
Engine at high idle
Hydraulic oil temperature:
Within operating range 3.92 4.51 Min. 3.72
PPC valve output pressure Set lever at stroke end {40 46} {Min. 38}
Engine at high idle
Work equipment
10 D475A, D475ASD-5E0
20 Standard value table SEN01816-01
Standard
Service limit
Measurement item Measurement conditions Unit value for new
value
machine
Measuring posture
Low
14 3.5 Max. 20.0
idle
Raise
Blade lift High
5.0 0.5 Max. 6.0
(Single tiltdozer idle
specification) sec
(Dual tiltdozer Low
specification) 1.8 0.3 Max. 2.5
idle
Hydraulic oil temperature:
Within operating range Lower
Apply no load on blade. High
Between blade on ground and rais- 1.8 0.3 Max. 2.5
idle
ing stroke end
Measuring posture
Low
15.8 3.5 Max. 22.0
idle
Raise
High
5.1 0.5 Max. 7.0
Blade lift idle
(Superdozer sec
specification) Low
1.7 0.3 Max. 3.0
idle
Hydraulic oil temperature:
Within operating range Lower
Work equipment
D475A, D475ASD-5E0 11
SEN01816-01 20 Standard value table
Standard
Service limit
Measurement item Measurement conditions Unit value for new
value
machine
Measuring posture
Low
4.0 1.5 Max. 6.0
idle
Left tilt
High +0.5
3.3 Max. 6.0
Blade tilt idle -0.8
(Superdozer sec
specification) Low
4.4 1.5 Max. 6.5
idle
Hydraulic oil temperature:
Within operating range Right tilt
Apply no load on blade. High +0.5
Between left tilt end and right tilt 3.6 Max. 6.0
idle -0.8
end
12 D475A, D475ASD-5E0
20 Standard value table SEN01816-01
Standard
Service limit
Measurement item Measurement conditions Unit value for new
value
machine
Blade
range idle
(Superdozer Lower blade from max. rising position and
specification) measure time after blade comes in contact High
with ground until idler is lifted. Max. 2.7 3.5
idle
Work equipment
Hydraulic drift of
mm/
machine tilted by Max. 50/5 Max. 100/5
min
blade
Hydraulic oil temperature: Within operating range
Stop engine.
Tilt blade to maximum to push up shoe on either side
and then measure reduction of shoe height (h) in 5
minutes.
D475A, D475ASD-5E0 13
SEN01816-01 20 Standard value table
Standard
Service limit
Measurement item Measurement conditions Unit value for new
value
machine
Measuring posture
Hydraulic drift of
mm/
machine lifted by Max. 50/5 Max. 100/5
min
blade
Hydraulic oil temperature: Within operating range
Stop engine.
Push up front part of machine with blade and then
measure reduction of idler center height (h) in 5 min-
utes.
Measuring posture
Work equipment
Hydraulic drift
Hydraulic drift of
mm/
machine lifted by Max. 30/5 Max. 60/5
min
ripper
Hydraulic oil temperature: Within operating range
Stop engine.
Push up rear part of machine with ripper and then
measure reduction of sprocket center height (h) in 5
minutes.
14 D475A, D475ASD-5E0
20 Standard value table SEN01816-01
D475A, D475ASD-5E0 15
SEN01816-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 08-07 (01)
16
SEN01817-03
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN01817-03 30 Testing and adjusting
2 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
Quantity
Symbol
Testing or adjusting
Part No. Part name Remarks
item
Air boost pressure 799-201-2202 Boost gauge kit 1 101 200 kPa {760 1,500 mmHg}
A
(boost pressure) 799-401-2220 Hose 1
Coolant temperature,
oil temperature and B 799-101-1502 Digital temperature gauge 1 99.9 1,299C
exhaust temperature
1 799-201-9001 Handy smoke checker 1
Exhaust gas color C Commercial Bosch index: 0 9
2 Smoke meter 1
item
Commercial
Valve clearance D Thickness gauge 1
item
0 7 MPa {0 70 kg/cm2}
1 795-502-1590 Compression gauge 1
KIT Part No.: 795-502-1205
Compression pressure E
2 795-471-1310 Adapter 1
3 6217-71-6150 Gasket 1
Blow-by pressure F 799-201-1504 Blow-by checker 1 0 5 kPa {0 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Engine oil pressure G
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester 1
1 *As common as G1
790-261-1204 Digital hydraulic tester 1
Testing fuel pressure H 2 799-401-2320 Hydraulic tester 1 *As common as G2
3 795-471-1450 Adapter 1
4 07005-00812 Gasket 1
1 6151-51-8490 Spacer 1
2 6141-71-1710 Joint 1
Commercial
3 Hose 1
item
Commercial
Testing fuel return and 4 Hose 1
J item
leak amount
Commercial
5 Measuring cylinder 1
item
Commercial
6 Stopwatch 1
item
7 07376-70315 Plug 1
799-101-5002 Hydraulic tester 1
1 *As common as G1
790-261-1204 Digital hydraulic tester 1
Power train oil pressure K 2 799-401-2320 Hydraulic tester 1 *As common as G2
799-101-5220 Nipple (10 x 1.25 mm) 1
3
07002-11023 O-ring 1
D475A, D475ASD-5E0 3
SEN01817-03 30 Testing and adjusting
Quantity
Symbol
Testing or adjusting
Part No. Part name Remarks
item
4 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
Quantity
Symbol
Testing or adjusting
Part No. Part name Remarks
item
D475A, D475ASD-5E0 5
SEN01817-03 30 Testing and adjusting
6 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
D475A, D475ASD-5E0 7
SEN01817-03 30 Testing and adjusting
8 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
D475A, D475ASD-5E0 9
SEN01817-03 30 Testing and adjusting
Measuring intake air pressure 2. Remove air intake connector boost pressure
(boost pressure) 1 pickup plugs (2) and (3) (R1/8).
a If nipple [1] is installed as standard to the
a Measuring instruments for intake air pressure intake air pressure (boost pressure) mea-
(boost pressure) suring port, install gauge [2] without
installing anything to the port.
Symbol Part No. Part name
q Plug (2): For left bank
799-201-2202 Boost gauge kit q Plug (3): For right bank
A
799-401-2220 Hose
10 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
5. Measure the intake air pressure (boost pres- Serial numbers: 30071 and up
sure) while the engine is running at high idle
and the torque converter is stalling.
a For the procedure for stalling the torque
converter, see Measuring engine speed.
a Normally, the intake air pressure (boost
pressure) should be measured while the
engine is running at the rated output. In
the field, however, an approximate value
can be obtained by stalling the torque con-
verter.
D475A, D475ASD-5E0 11
SEN01817-03 30 Testing and adjusting
12 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
4. Procedure for measuring maximum exhaust 2) Stop relieving the ripper or pitch back, and
temperature for troubleshooting. lower the exhaust temperature by only
Operate the machine and measure the maxi- stalling the torque converter (Condition (b)
mum exhaust temperature. in the figure).
a Use the PEAK mode of the digital ther- a If the temperature does not lower but
mometer. rises, set the temperature to high in
a The exhaust temperature largely depends step 1).
on the outside air temperature (intake air 3) After the temperature lowers and is stabi-
temperature of the engine). Accordingly, if lized, measure it (Condition (c) in the fig-
any abnormal value is obtained, correct it ure).
by the following calculation. k Just after the power train oil tempera-
q Corrected value [C] = Measured ture gauge reads the red range, return
value + 2 x (20 Outside air tempera- the direction of the PCCS lever into
ture) neutral and lower the power train oil
temperature.
D475A, D475ASD-5E0 13
SEN01817-03 30 Testing and adjusting
14 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
D475A, D475ASD-5E0 15
SEN01817-03 30 Testing and adjusting
16 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
D475A, D475ASD-5E0 17
SEN01817-03 30 Testing and adjusting
18 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
D475A, D475ASD-5E0 19
SEN01817-03 30 Testing and adjusting
20 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
D475A, D475ASD-5E0 21
SEN01817-03 30 Testing and adjusting
Measuring engine oil pressure 1 3) Install nipple [1] and joint (M14 1.5 mm)
of hydraulic tester G1 and connect them to
hydraulic tester G2.
a Measuring instruments for engine oil pressure 4) Run the engine at low idle and high idle
Symbol Part No. Name and measure the engine oil pressure at
each speed.
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
22 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
D475A, D475ASD-5E0 23
SEN01817-03 30 Testing and adjusting
Testing fuel pressure 1 4. Start the engine and inspect the fuel pressure
with the engine running at high idle or at the
a Measuring tools for fuel pressure equivalent of rated output speed (stall load).
a If the fuel pressure is in the following
Symbol Part No. Part name
range, it is normal.
799-101-5002 Hydraulic tester
1 Engine speed Fuel pressure
790-261-1204 Digital hydraulic tester
At high idle or
H 2 799-401-2320 Hydraulic tester 0.15 0.3 MPa
at the equivalent of rated
{1.5 3 kg/cm2}
3 795-471-1450 Adapter output speed
4 07005-00812 Gasket
24 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
D475A, D475ASD-5E0 25
SEN01817-03 30 Testing and adjusting
a Testing tools for fuel return and leak amount 1. Preparation work (example for left bank)
1) Remove tube (3) between common rail (1)
Symbol Part No. Part name and supply pump (2).
1 6151-51-8490 Spacer 2) Insert spacer J1 to supply pump (2) side
2 6141-71-1710 Joint and retighten it with the currently removed
joint bolt.
Commercially
3 Hose a Be sure to fit the gaskets to both ends
available
of the spacer.
Commercially 3) Connect the return piping to the fuel tank
4 Hose
J available
side again.
5
Commercially
Measuring cylinder a Be sure to fit the gaskets to both ends
available of the spacer.
Commercially
6 Stopwatch
available
7 07376-70315 Plug
26 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
D475A, D475ASD-5E0 27
SEN01817-03 30 Testing and adjusting
28 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
a If fuel is used up or if a fuel circuit part is a Don't fill fuel directly after removing main
removed and installed, bleed air from the fuel filter (2).
circuit according to the following procedure.
D475A, D475ASD-5E0 29
SEN01817-03 30 Testing and adjusting
30 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
q Left bank
D475A, D475ASD-5E0 31
SEN01817-03 30 Testing and adjusting
a The buit-in timer of this switch automati- 9. Start the engine with the starting motor.
cally starts or stops operation of the elec- a The air in the high-pressure circuit is bled
tric priming pump. (See the figure below) automatically if the engine is cranked.
a Operation of the electric priming pump is a If the engine does not start, the air in the
stopped as long as flashing of the lamp is low-pressure circuit may have not been
continued. It is not an error. bled. In this case, start the engine accord-
a Shifting the switch to OFF while the lamp ing to the following procedure.
is flashing turns off the lamp and stops the 1) Turn electric priming pump switch (2) to
electric priming pump, too. the ON position.
k Pressure is constantly applied to the 2) While the electric priming pump is operat-
fuel circuit as long as operation of the ing, crank the engine to start with the start-
electric priming pump is continued. ing motor. If the engine still does not start,
Loosening the air bleeding plug from wait for about 2 minutes and repeat steps
this state might allow fuel to burst out. 1) and 2).
Thus, dont try to loosen the plug while 3) After the engine starts, keep it running for
the pump is in operation. at least 5 minutes to bleed all air from the
fuel circuit.
a Do not operate the starting motor continu-
ously for more than 20 seconds.
a For the filter replacement procedure, see
the standard specification.
32 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
Testing fuel circuit for leakage 1 9. Inspect the fuel piping and the devices for fuel
k
leakage.
Very high pressure is generated in the high- a Inspect the high-pressure circuit parts
pressure circuit of the fuel system. If fuel concentration on the areas coated with the
leaks while the engine is running, it is dan- color checker, for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
and installing its components, check for a If any fuel leakage is not detected, inspec-
fuel leakage according to the following pro- tion is completed.
cedure.
a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
D475A, D475ASD-5E0 33
SEN01817-03 30 Testing and adjusting
34 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
Testing
q Measure deflection (a) of the belt when it is
p ushed with a finge r a t a p oint midway
between the compressor pulley and the engine
drive pulley.
q Pushing force: Approx. 59 N {approx. 6 kg}
q Deflection (a) of belt: 20 2 mm
Adjusting
a If the belt deflection is outside the standard
value, adjust as follows.
D475A, D475ASD-5E0 35
SEN01817-03 30 Testing and adjusting
1. Outline of fuel control system [1] Fuel control dial (2nd throttle signal)
q The following signals are inputted as rota- [2] Engine controller
tion command signals to the engine con- [3] Steering controller
troller. [4] Decelerator pedal (1st throttle signal)
q Decelerator pedal potentiometer signal [5] Decelerator potentiometer
q 3rd throttle signal [6] Engine (CRI system)
The engine controller controls the fuel [7] Machine control signal
control system of the engine (CRI system) (3rd throttle signal)
according to the lowest engine speed sig- [8] Rod
nal among those input signals. [9] Stopper bolt
q Adjust the deceleration slow speed by
adjusting the decelerator pedal linkage.
36 D475A, D475ASD-5E0
30 Testing and adjusting SEN01817-03
D475A, D475ASD-5E0 37
SEN01817-03
2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
38
SEN01818-03
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN01818-03 30 Testing and adjusting
2 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-03
D475A, D475ASD-5E0 3
SEN01818-03 30 Testing and adjusting
1. Measuring torque converter inlet pressure 2. Measuring torque converter outlet pressure
(IN) (OUT)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect hydraulic tester K2 to oil pres-
lic tester K1 to oil pressure pick-up nipple sure pick-up nipple (2).
(1). a Use an oil pressure gauge of 1.0 MPa
a Use an oil pressure gauge of 2.5 MPa {10 kg/cm2}.
{25 kg/cm2}.
4) After finishing measurement, remove the 4) After finishing measurement, remove the
measuring instrument and return the measuring instrument and return the
removed parts. removed parts.
4 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-03
3. Measuring torque converter stator clutch 4. Measuring torque converter lock-up clutch
pressure (SC) pressure (LU)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester K1 to oil pressure pick-up nipple lic tester K1 to oil pressure pick-up nipple
(3). (4).
a Use an oil pressure gauge of 6 MPa a Use an oil pressure gauge of 2.5 MPa
{60 kg/cm2}. {25 kg/cm2}.
2) Run the engine and set the PCCS lever in 2) Start the engine and set the monitor panel
the full neutral position. in the Adjustment mode and disengage
3) Measure the oil pressure while the engine both steering clutches.
is running at low idle and high idle. a For the operating method, see Spe-
cial functions of monitor panel
(EMMS).
a Adjustment code: 5535 (Disengage-
ment of both steering clutches)
a The transmission speed is displayed
on the lower display section (Unit: 1
rpm).
D475A, D475ASD-5E0 5
SEN01818-03 30 Testing and adjusting
6 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-03
2) Run the engine, set the monitor panel in 2) Run the engine, set the monitor panel in
the Adjustment mode, and disengage the Adjustment mode, and disengage
both steering clutches. both steering clutches.
a For the operating method, see Spe- a For the operating method, see Spe-
cial functions of monitor panel cial functions of monitor panel
(EMMS). (EMMS).
a Adjustment code: 5535 (Both steering a Adjustment code: 5535 (Both steering
clutches disengagement) clutches disengagement)
a The lower message display displays a The lower message display displays
the transmission speed (in rpm). the transmission speed (Unit: 1 rpm).
3) Set the parking brake lever in the FREE 3) Set the parking brake lever in the FREE
position. position.
4) Set the PCCS lever in the REVERSE 3rd 4) Set the PCCS lever in the FORWARD 1st
gear speed position, and run the transmis- gear speed position, and run the transmis-
sion idle. sion idle.
k Keep ready to press the brake k Keep ready to press the brake
pedal at any time for safety. pedal at any time for safety.
5) Measure the oil pressure while the engine 5) Measure the oil pressure while the engine
is running at low idle. is running at low idle.
6) After finishing measurement, remove the 6) After finishing measurement, remove the
measuring instrument and return the measuring instrument and return the
removed parts. removed parts.
D475A, D475ASD-5E0 7
SEN01818-03 30 Testing and adjusting
9. Measuring transmission 2nd clutch pres- 10. Measuring transmission 3rd clutch pres-
sure (2ND) sure (3RD)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester K1 to oil pressure pickup nipple lic tester K1 to oil pressure pickup nipple
(9). (10).
a Use an oil pressure gauge of 6 MPa a Use an oil pressure gauge of 6 MPa
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine, set the monitor panel in 2) Run the engine, set the monitor panel in
the Adjustment mode, and disengage the Adjustment mode, and disengage
both steering clutches. both steering clutches.
a For the operating method, see Spe- a For the operating method, see Spe-
cial functions of monitor panel cial functions of monitor panel
(EMMS). (EMMS).
a Adjustment code: 5535 (Both steering a Adjustment code: 5535 (Both steering
clutches disengagement) clutches disengagement)
a The lower message display displays a The message display displays the
the transmission speed (in rpm). transmission speed (in rpm).
3) Set the parking brake lever in the FREE 3) Set the parking brake lever in the FREE
position. position.
4) Set the PCCS lever in the FORWARD 2nd 4) Set the PCCS lever in the FORWARD 3rd
gear speed position, and run the transmis- gear speed position, and run the transmis-
sion idle. sion idle.
k Keep ready to press the brake k Keep ready to press the brake
pedal at any time for safety. pedal at any time for safety.
5) Measure the oil pressure while the engine 5) Measure the oil pressure while the engine
is running at low idle. is running at low idle.
6) After finishing measurement, remove the 6) After finishing measurement, remove the
measuring instrument and return the measuring instrument and return the
removed parts. removed parts.
8 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-03
11. Measuring steering left brake pressure (LB) 12. Measuring steering right brake pressure
1) Connect oil pressure gauge [1] of hydrau- (RB)
lic tester K1 to oil pressure pickup nipple 1) Connect oil pressure gauge [1] of hydrau-
(11). lic tester K1 to oil pressure pickup nipple
a Use an oil pressure gauge of 6 MPa (12).
{60 kg/cm2}. a Use an oil pressure gauge of 6 MPa
{60 kg/cm2}.
D475A, D475ASD-5E0 9
SEN01818-03 30 Testing and adjusting
13. Measuring steering left clutch pressure 14. Measuring steering right clutch pressure
(LC) (RC)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester K1 to oil pressure pickup nipple lic tester K1 to oil pressure pickup nipple
(13). (14).
a Use an oil pressure gauge of 6 MPa a Use an oil pressure gauge of 6 MPa
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the parking brake 2) Run the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) Set the PCCS lever to the steering left 3) Set the PCCS lever to the steering right
stroke end. stroke end.
a Set the direction of the PCCS lever in a Set the direction of the PCCS lever in
neutral. neutral.
4) Measure the oil pressure while the engine 4) Measure the oil pressure while the engine
is running at low idle and high idle. is running at low idle and high idle.
a Check that the oil pressure becomes a Check that the oil pressure becomes
0 when the steering of the PCCS 0 when the steering of the PCCS
lever is returned to the neutral posi- lever is returned to the neutral posi-
tion. tion.
5) After finishing measurement, remove the 5) After finishing measurement, remove the
measuring instrument and return the measuring instrument and return the
removed parts. removed parts.
10 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-03
D475A, D475ASD-5E0 11
SEN01818-03 30 Testing and adjusting
Adjusting transmission speed 6. Remove sensor (1) and flange (2) together and
sensor 1 secure them with nut (3).
a Take care that the adjustment angle of the
sensor will not change.
a The torque converter output speed sensor for 3 Nut: 49.0 68.6 Nm {5 7 kgm}
the VHMS is not adjustable.
7. Install flange (2) and the sensor together to the
1. Remove the fuel tank undercover, and then steering case.
remove transmission output speed sensor (1) 2 Flange and mounting bolt:
and the flange together. Gasket sealant (LG-6)
a Before adjusting transmission speed sen- 3 Mounting bolt:
sor (1), remove it temporarily and check 59 74 Nm {6 7.5 kgm}
that its tip is free from a steel chip and a
flaw.
a Before installing the transmission speed
sensor, separate sensor (1), flange (2),
and nut (3).
12 D475A, D475ASD-5E0
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Testing and adjusting work 3) Install nipples M2, M3, and connect them
equipment oil pressure 1 to oil pressure gauge [1] of hydraulic
tester M1.
a Use an oil pressure gauge of 6 MPa
a Testing and adjusting instruments for work {60 kg/cm2}.
equipment oil pressure
Measuring
k Stop the machine on a level place, lower
the work equipment to the ground, and set 4) Run the engine at high idle and set the
the parking brake lever and work equip- blade lever and ripper lever in neutral, and
ment lock lever in the LOCK position. measure the oil pressure.
a Measure the work equipment oil pressure
under the following condition.
q Hydraulic oil temperature: Within operat-
ing range
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30 Testing and adjusting SEN01818-03
2. Measuring main relief pressure (Single tilt Serial numbers: 30001 30070
specification)
a Measure the main relief pressure at the
same point as the unload pressure.
a Use an oil pressure gauge of 40 MPa {400
kg/cm2}.
a Since the oils from the 2 pumps are
merged in the work equipment circuit of
the single tilt specification, the oil pressure
of the divided oil cannot be measured.
1) Start the engine and set the work equip-
ment lock lever in the FREE position.
2) Run the engine at high idle, raise or tilt the
ripper to relieve the cylinder at a stroke
end, and measure the oil pressure.
Serial numbers: 30071 and up
D475A, D475ASD-5E0 23
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3. Measuring main relief pressure (Dual tilt Serial numbers: 30001 30070
specification and superdozer specification)
a Measure the main relief pressure at the
same point as the unload pressure.
a Use an oil pressure gauge of 40 MPa {400
kg/cm2}.
a The oil pressure of the divided oil can be
measured by measuring while pitching
back the ripper.
1) Start the engine and set the work equip-
ment lock lever in the FREE position.
2) Run the engine at high idle, raise or pitch
back the ripper to relieve the cylinder at a
stroke end, and measure the oil pressure.
24 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-03
4. Measuring blade tilt relief pressure (Single Serial numbers: 30001 30070
tilt specification)
a Measure the blade tilt relief pressure at
the same point as the unload pressure.
a Use an oil pressure gauge of 40 MPa {400
kg/cm2}.
a Since all of the oils from the 2 pumps are
merged in the work equipment circuit of
the single tilt specification, the oil pressure
of the divided oil cannot be measured.
1) Start the engine and set the work equip-
ment lock lever in the FREE position.
2) Run the engine at high idle, tilt the blade
to the left to relieve the cylinder at a stroke
end, and measure the oil pressure.
Serial numbers: 30071 and up
D475A, D475ASD-5E0 25
SEN01818-03 30 Testing and adjusting
5. Measuring blade pitch relief pressure (Dual Serial numbers: 30001 30070
tilt specification and superdozer specifica-
tion)
a Measure the blade pitch dump relief pres-
sure at the same point as the unload pres-
sure.
a Use an oil pressure gauge of 40 MPa {400
kg/cm2}.
a Measure the pressure of the divided oil
from the 2 pumps during pitch dump oper-
ation.
1) Start the engine and set the work equip-
ment lock lever in the FREE position.
2) Run the engine at high idle, pitch dump
the blade to relieve the cylinder at a stroke
end, and measure the oil pressure. Serial numbers: 30071 and up
26 D475A, D475ASD-5E0
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D475A, D475ASD-5E0 27
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30 Testing and adjusting SEN01818-03
a When using oil pressure gauge: 8. Measuring LS valve output pressure (servo
Use the oil pressure gauge of 40 MPa piston inlet pressure)
{400 kg/cm2}. 1) Open the inspection cover of the cross bar
Since the differential pressure is about 3.9 front undercover.
MPa {40 kg/cm2} at maximum, measure it 2) Remove oil pressure pickup plugs (5) and
by installing the same gauge to the pickup (6) from the work equipment pump.
plugs alternately. q (5):For front pump LS valve output
pressure
q (6):For rear pump LS valve output
pressure
D475A, D475ASD-5E0 29
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30 D475A, D475ASD-5E0
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30 Testing and adjusting SEN01818-03
Testing and adjusting control 3. Run the engine at high idle, set the blade lever
circuit basic pressure 1 and ripper lever in neutral, and measure the oil
pressure.
Measuring
k Stop the machine on a level place, lower 4. After finishing measurement, remove the mea-
the work equipment to the ground, and set suring instrument and return the removed
the parking brake lever and work equip- parts.
ment lock lever in the LOCK position.
a Measure the control circuit basic pressure Adjusting
under the following condition. a The self-pressure reducing valve cannot be
q Hydraulic oil temperature: Within operat- adjusted.
ing range
D475A, D475ASD-5E0 33
SEN01818-03 30 Testing and adjusting
Measuring PPC valve output a The PPC valve output pressure of the
pressure and solenoid valve following circuits is the basic pressure
of the solenoid valve (Dual tilt specifi-
output pressure 1 cation and superdozer specification).
q Blade right tilt/left tilt:
a Measuring instruments for PPC valve output Pitch/Tilt solenoid valve basic pres-
pressure and solenoid valve output pressure sure
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30 Testing and adjusting SEN01818-03
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30 Testing and adjusting SEN01818-03
Measuring internal leakage of 3. Run the engine at high idle and apply the relief
work equipment cylinder 1 pressure to the cylinder bottom side.
q Blade tilt cylinder:
Operate to extend the cylinder to
a Measuring instruments for internal leakage of be measured.
work equipment cylinder q Ripper lift cylinder:
Operate to lower ripper.
Symbol Part No. Name
q Ripper Tilt cylinder:
L Purchased Measuring cylinder Operate to tilt ripper forward.
a Measure the internal leakage of work equip- 4. After 30 seconds, measure leakage for 1
ment cylinder under the following condition. minute.
q Hydraulic oil temperature: 45 55C
a Since the blade lift cylinder is equipped with a 5. After finishing measurement, return the
piston valve, its internal leakage cannot be removed parts.
measured.
D475A, D475ASD-5E0 43
SEN01818-03 30 Testing and adjusting
a When disconnecting the piping between the a If the work equipment cylinder is removed and
control valve and work equipment cylinder, installed or its piping is disconnected and con-
release the residual pressure from the circuit nected, bleed air from its circuit according to
according to the following procedure. the following procedure.
1. Loosen the hydraulic tank oil filler cap gradu- 1. Run the engine at low idle for about 5 minutes.
ally to release the residual pressure from the
tank. 2. Running the engine at low idle, extend and
retract the cylinder to be bled 4 5 times.
2. Set the work equipment lock lever in the FREE a Move the piston rod to about 100mm
position and operate the work equipment con- before the stroke end and never relieve
trol lever to each direction. the oil.
a If the work equipment control lever is
operated 2 3 times, the residual pres- 3. Running the engine at high idle and carry out
sure in the accumulator is released. the operation in 2.
3. Run the engine at low idle for about 5 seconds, 4. Running the engine at low idle, move the cylin-
then stop it. der to the stroke end to relieve the oil.
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D475A, D475ASD-5E0 45
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Measuring fan motor speed 1 4. Insert probe [2] of tachometer kit S through the
radiator mask and set it out of the fan net with
stand [3] and connect it to multi-tachometer [4].
a Measuring instruments for fan motor speed a The probe tip cannot be inserted in an
opening of the fan net, but it can measure
Symbol Part No. Name
the fan motor speed. Remove all obsta-
S 799-205-1100 Tachometer kit
cles between the lighting part of the probe
and the reflecting tape.
1. Open the radiator mask and remove the
mounting bolts of fan net (1) under the fan
motor.
a Fan net (1) cannot be removed since the
fan motor piping is installed.
D475A, D475ASD-5E0 47
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D475A, D475ASD-5E0 49
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Measurement procedure for blade 2. Run the engine at low idle, set the toggle
tilt control angle switch of the blade lever to the dual tilt posi-
tion, and set the blade in the following standard
(Dual tiltdozer specification) 1 posture.
1) Set the blade horizontally (Set it to 0).
a Measuring instrument for blade tilt control 2) Pitch back the blade to the maximum.
angle 3) Raise the blade at 100 mm above the
ground.
Symbol Part No. Name
U 799-402-3800 Angle gauge
50 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-03
6. Operate information switches [<] and [>] to 10. Operate the blade lever to tilt the blade to the
select the tilt limit setting screen. left and set the left tilting angle to 12.
a Since the tilt limiting function does not
work at this time, operate the lever slowly
and take care not to increase the tilting
angle too much.
a Adjust the tilting angle accurately with
angle gauge U.
D475A, D475ASD-5E0 51
SEN01818-03 30 Testing and adjusting
19. Start the engine again, tilt the blade to the right
and left, and check that the blade does not
interfere with the track shoe at any height.
52 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-03
2. Run the engine at low idle and set the blade in 6. Operate information switches [<] and [>] to
the following standard posture. select the tilt limit setting screen.
1) Set the blade horizontally (Set it to 0).
2) Pitch back the blade to the maximum.
3) Raise the blade at 100 mm above the
ground.
D475A, D475ASD-5E0 53
SEN01818-03 30 Testing and adjusting
7. Set the buzzer cancel switch in the select posi- 13. Press the pitch dump button (upper button),
tion [U] to select the tilt limit adjustment mode. and the buzzer sounds and the left limit posi-
tion is saved.
8. Press the pitch back button (lower button) of a Since the tilt limiting function does not
the work equipment lever, and the buzzer work at this time, operate the lever slowly
sounds and the work equipment position in the and take care not to increase the tilting
standard posture is saved. angle too much.
a Adjust the tilting angle accurately with
9. Set the buzzer cancel switch in the cancel angle gauge U.
position [t] once to cancel the tilt limit adjust-
ment mode temporarily. 14. Tilt the work equipment to the right by 7.
18. Start the engine again, tilt the blade to the right
and left, and check that the blade stops auto-
matically in the following range at any height.
q Automatic tilt stopping angle: 7 1
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4. Testing open lock ii) Check the installed height of the stop-
Lock the door open and check the relationship per rubbers.
between the operator's cab and door. If there is (Check both sides, 4 pieces on each.)
any fault, repair it. q Lock the door open and shake it in
1) Check of condition the forward and reverse directions to
1] Check the relationship between open see if it has any play.
lock latch (9) and striker (10) from the q Check that the operating effort of the
direction of B. unlock lever is not heavy.
2) Adjusting
1] Adjusting latch and striker
q Loosen the adjustment nut of striker
(10) and adjust striker (10) so that it
will not interfere with or ride over
open latch (9), then tighten the nut.
q If interference cannot be eliminated
by adjusting striker (10), loosen the
mounting bolt of open latch (9) and
adjust open latch (9).
q Push the door. If it moves until clear-
ance (b) between striker (7) and open
latch (9) is reduced to 0, loosen
mounting nut (12) of stopper rubber
a Open the door and check the engag- (11) and extend stopper rubber (11) in
ing condition of the open latch and the pushing direction to adjust.
striker.
q Check that the claw of open latch (9)
does not ride over the bent part of
striker (10).
q Check that the body of open latch (9)
does not interfere with striker (10).
58 D475A, D475ASD-5E0
30 Testing and adjusting SEN01818-03
Adjusting blade 1
a If the blade is removed and installed or disas- 2) Adjust the shim of trunnion (2) (shim
sembled and reassemble, adjust it according adjustment type).
to the following procedure.
Adjusted Standard
Adjusted Standard clear-
1. Adjusting shims for assembly clear- shim thick-
point ance
ance ness
1) Adjust the shim of center (1).
1.56 0.65 mm
Adjusted Adjusted Standard Standard shim 2 c (Total thickness 12 mm
point clearance clearance thickness clearance)
1 a See note 4.5 mm
D475A, D475ASD-5E0 59
SEN01818-03 30 Testing and adjusting
Blade U Semi-U
Right tilt distance Approx. 900 Approx. 750
(e1) mm mm
Left tilt distance Approx. 900 Approx. 750
(e2) mm mm
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a Machine with operator's seat isolator 3) Stand backrest (4) of the operator's seat
upright.
1. Breakage of rubber
q Criterion: When the operator's seat is
pressed with the hand, it must not touch
the stopper of operator's seat isolator.
a When the criterion is not satisfied.
q Remove and disassemble the operator's
seat isolator and check the rubber for
breakage.
q If the rubber is broken, replace the opera-
tor's seat isolator assembly.
1) Pull slide (1) and move the operator's seat
to the forward end.
D475A, D475ASD-5E0 61
SEN01818-03 30 Testing and adjusting
5) Press the seat surface through the win- 1) Remove bolts (7) of front cover (6) of the
dow. operator's seat and remove the front
cover.
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D475A, D475ASD-5E0 63
SEN01818-03
2011 KOMATSU
All Rights Reserved
Printed in Japan 06-11
64
SEN01819-04
D475A-5E0
D475ASD-5E0
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3) Contrast of display
This mode is to adjust contrast of the liquid
crystal at the multi-information section.
(See Operation and maintenance man-
ual.)
D475A, D475ASD-5E0 7
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Action
Indication method of fault Contents of fault Remedy
code
Automatic function stops or normal
Torque converter is not locked up. function stops partially but machine
Only action code is dis-
E01 Blade dual tilt mechanism does not can work.
played.
work. Call your Komatsu distributor for
repair.
Stop engine and start it again, and
Gear is not shifted up or down. you can operate machine without lim-
Action code is displayed.
Blade tilt is not limited. iting function. You must take care,
E02 Caution lamp flashes.
Blade pitch mechanism does not however.
Caution buzzer sounds.
work. Call your Komatsu distributor for
repair.
Engine boost pressure is defective.
Action code is displayed. Usable gear speeds are limited. Move machine to safe place.
CALL E03 Caution lamp flashes. Engine speed does not rise fully. Call your Komatsu distributor for
Caution buzzer sounds. Gear shifting shocks become large. repair.
Steering performance lowers.
Action code is displayed. Engine cannot be controlled. Stop machine immediately.
CALL E04 Caution lamp flashes. Machine cannot travel. Call your Komatsu distributor for
Caution buzzer sounds. Machine stops. repair.
D475A, D475ASD-5E0 9
SEN01819-04 30 Testing and adjusting
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4) Changing replacement interval time 2] If the input time is correct, enter the
1] Change the set time by operating change of setting by operating buzzer
information switch (5), shift-up switch cancel switch (4).
(6), and shift-down switch (7). q [U]: Enter change.
q [ > ]: Move cursor to right. a If the change is finished normally,
q [ < ]: Move cursor to left. the information display screen
q [UP]: Increase number. appears after the screen shown
q [DOWN]: Decrease number. below.
a If you do not use the mainte- a If the change does not finish nor-
nance function, set the all times mally, above message SET-
to 0. TING NOW!! is not displayed
but the replacement interval
change screen is kept displayed.
(The screen does not return to
the information display screen.)
12 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
a The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that
the first maintenance has been finished in the maintenance mode of the operator mode, then change
the 2nd and after interval times.
D475A, D475ASD-5E0 13
SEN01819-04 30 Testing and adjusting
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a Condition for detecting and keeping 7. Mechanical system failure code display
failure code mode
If a failure code of any item other than (7-MACHINE CHECK CODE MODE)
communication and engine is output, In this mode, you can check the past mechani-
it keeps flashing until the starting cal system error codes.
switch is turned off. After the starting a Refer to the item Failure code list in
switch is turn on or the engine is Troubleshooting, General.
started again, the failure code keeps
lighting until the same fault is 1) Selecting and executing mode
detected. 1] Select Mechanical system failure
A failure codes of communication and code display mode on the mode
engine start lighting when the fault is selection screen.
solved, even if the starting switch is a If the mode is selected, code
not turned off. (bE) is displayed on gear speed
display section (1) and the title is
4) Operation to take when multiple codes are displayed on multi-information
recorded. section (2).
When multiple codes are recorded, they 2] Display the failure code display
can be displayed one by one by operating screen by operating buzzer cancel
information switch (5). switch (4).
q [ > ]: Next code q [U]: Execute mode.
q [ < ]: Previous code Serial numbers: 30001 30070
a The failure codes are displayed from
the oldest one in order of length of
time after they were output.
D475A, D475ASD-5E0 15
SEN01819-04 30 Testing and adjusting
2) Display in the case where no codes are a Flashing and lighting of failure code
recorded Flashing: Code is being output cur-
If no failure codes have been output up to rently.
now, the information section displays as Lighting: Code is not being output
shown below. currently.
a Condition for detecting and keeping
failure code
A failure code of mechanical system
starts lighting when the fault is solved,
even if the starting switch is not
turned off.
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30 Testing and adjusting SEN01819-04
Disassembly Sending
No. Code Adjustment item Related information
and assembly in order
[1] 0001 INP TEL NO. Phone No. input mode Numerals and symbols
[2] 0002 S/T S. CODE Steering controller specification set Code q 1
Transmission controller specification
[3] 0003 T/M S. CODE Code q 2
set
[4] 0004 BODY TYPE Machine specification set Code q 3
Brake potentiometer zero point adjust-
[5] 0005 BRAKE BASE Voltage q 4
ment
[6] 0007 ENG. FULL CH Engine deceleration cut mode Engine speed 5
Speed/Fuel injection
[7] 0008 INT-> 123456 Common rail reduced cylinder mode
rate
[8] 0009 PITCH SENS. Pitch angle sensor initialization set Voltage q 6
[9] 0010 FAN 70%MODE Fan speed 70% speed mode (Adjustment amount) 8
[10] 0022 VHMS INST VHMS specification set Set state 7
[11] 0530 STALL CHECK Stall speed check mode Engine speed
(Date of adjustment in
[12] 1005 FAN 100%MODE Fan speed 100% mode 9
factory)
[13] 1012 S/T N-SET Steering lever neutral set Voltage
[14] 1013 S/T M. L-SET Steering lever left set Voltage
[15] 1014 S/T M. R-SET Steering lever right set Voltage
[16] 1015 BRKLH. OFST Left brake oil pressure offset (set) Oil pressure
[17] 1016 BRKRH. OFST Right brake oil pressure offset (set) Oil pressure
[18] 1112 PRE LUB SEL Pre-lubrication set Set state
[19] 2223 R SLOW CUT Reverse slow stop set Set state
[20] 5535 CLUTCH OPEN Clutch disengagement mode Transmission speed
[21] 5537 CLT LH. OFST Left clutch oil pressure offset (set) Oil pressure
[22] 5538 CLT RH. OFST Right clutch oil pressure offset (set) Oil pressure
Engine oil level display mode
[23] 9801 ENG. LEVEL Set state
(if equipped)
Hydraulic oil level display mode
[24] 9993 HYD. LEVEL Set state
(if equipped)
[25] 9995 LOCK BRAKE Electrical brake constantly ON mode Voltage
[26] 9996 MECHA BRAKE Electrical brake release mode Voltage
[27] 9997 HI IDLE SET High idle limit mode Revolving speed
[28] 9998 SFT INHIBIT 3rd speed cut set Permit
a After assembling the machine or replacing each controller, be sure to adjust the items marked with q in
the Disassembly and assembly column of the above table. (For the adjustment procedure, see
Adjustment procedure after replacement of controller.)
a The numbers in Sending in order column can be displayed in order by setting the information switch in
[>] or [<] position.
D475A, D475ASD-5E0 19
SEN01819-04 30 Testing and adjusting
[1] 0001: Phone number input mode [2] 0002: Steering controller specification set
q This code inputs or changes a phone number q This code is used to initialize the specification
to be displayed simultaneously when the user codes recognized by the steering controller
code is displayed. and the set values of the memory in the con-
q The lower part displays a phone number and troller.
symbols. q The specification code is displayed on the
q Available characters: lower line.
0123456789:;<=>? q Adjustment method
q Instructions for use: 1) Set buzzer cancel switch (4) in the [U]
1) By operating the information switch (5), position and check that the caution buzzer
shift up switch (6), and shift down switch sounds.
(7), input a phone number and symbols. 2) Check that the displayed specification
q [ > ]: Moves the cursor rightward. code has changed from [2*2] to [222].
q [ < ]: Moves the cursor leftward. a If specification code [222] is not displayed,
q [UP]: Advance the numeric character or the controller wiring harness or the con-
character (in the order of available charac- troller unit may be defective.
ters). a Even if this code is turned off, the setting
q [DOMN]: Reverse the numeric character is effective.
or character (in the reverse order of avail-
able characters).
2) Set buzzer cancel switch (4) in the [U]
position and check that the alarm buzzer
sounds.
a Sixteen digits of numeric characters are
provided. To avoid confusion, input sym-
bols other than numeric characters at dig-
its you will not use.
a 0 (zero) is input at all places of the lower
part before shipment from our factory. (No
phone number is displayed under this con-
dition.)
a The setting is enabled even after ending
this code.
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30 Testing and adjusting SEN01819-04
D475A, D475ASD-5E0 21
SEN01819-04 30 Testing and adjusting
[5] 0005: Brake potentiometer zero-point adjust- [6] 0007: Engine deceleration-cut mode
ment q This code is used to stop the auto-deceleration
q This code is used to adjust the zero point of the function of the engine and check the high idle
brake pedal potentiometer. speed of the engine singly.
q The deviation from the standard value is indi- q The engine speed is displayed on the lower
cated by voltage on the lower line (Indication line (Display range: 0 3000 rpm).
range: -2500 to 2500 mV). q Using method:
q Adjustment method: q While this code is displayed, its function is
1) Check that the brake pedal is in neutral (it turned on and the auto-deceleration function is
is not pressed). turned off.
2) Set buzzer cancel switch (4) in the [U] a If this code is turned off, its function is
position and check that the alarm buzzer turned off.
sounds.
a This adjustment is performed to have the
zero point of the potentiometer recognized
by the controller. It is not performed to
adjust the effect of the brake.
a Even if this adjustment is performed, the
indication on the lower line does not
change.
a Even if this code is turned off, the setting
is effective.
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30 Testing and adjusting SEN01819-04
[7] 0008: Common rail reduced cylinder mode [8] 0009: Pitch angle sensor initial set
a When the engine common rail system seems q This code is used to adjust the zero point and
to be defective, this code is used to stop inject- installation error of the pitch angle sensor.
ing fuel into 1 or more cylinders (reduce the q The deviation from the standard neutral posi-
number of effective cylinders) while the engine tion is displayed by voltage on the lower line
is running and find out a defective cylinder (Display range: -2500 to 2500 mV).
from the change of the engine speed and the q Adjustment method:
fuel injection rate. Set buzzer cancel switch (4) in the [U] position
a Since this function diagnoses a failure based and check that the caution buzzer sounds.
on the differences of the engine speed and the a Even if this code is turned off, the setting
fuel injection rate in the reduced cylinder mode is effective.
operation from that in the normal mode opera-
tion, use this function while the engine is run-
ning.
q Engine speed (A) and fuel injection rate (B) are
displayed on the lower line.
q How to use:
Select the cylinders to be turned off for the
reduced cylinder mode operation by operating
information switch (5) and buzzer cancel
switch (4).
Use this method to turn on the selected cylin-
ders again, too.
q [>]: Moves cursor rightward.
q [<]: Moves cursor leftward.
q [U]: Executes or stops reduced cylinder
mode operation. [9] 0010: Fan 70% speed mode
q This code forcedly sets the rpm of cooling fan
at 70% of the maximum rotation.
q The lower part displays data for factory adjust-
ment.
q Instructions for use:
q The function is enabled with this code dis-
played to control the rpm of cooling fan to
approximately 70% of the maximum rotation.
a Ending this code disables the function.
D475A, D475ASD-5E0 23
SEN01819-04 30 Testing and adjusting
[10] 0022: Setting of VHMS specification [11] 0530: Stall speed check mode
q This code is used to set the installation of q This code is the function to make the cooling
VHMS terminal. If the installation is not set, the fan speed maximum to check the torque con-
VHMS operation data is not set normally and verter stall speed.
the data related to the VHMS cannot be moni- k In this machine the cooling fan speed con-
tored. trol function is installed in order to protect
q The installation condition of the terminal is dis- the radiator when the engine is not yet
played on the lower line. warmed up enough. However, in case that
q ACTIVE: Setting of installation of VHMS this mode is in use, the protecting function
q DEACTIVE: Setting of non-installation of does not work. So use the machine after
VHMS carrying out enough warming up.
q Setting method q The engine speed is displayed on the lower line.
1) Select an installation condition of the (Display range: 0 3000)
VHMS terminal with shift-up switch (6) and q How to use
shift-down switch (7). While this code is displayed, its function is
2) After selecting the condition of the termi- enabled and the cooling fan speed becomes
nal, set buzzer cancel switch (4) in the [?] maximum.
position. a If this code is turned off, its function is disabled.
3) The buzzer sounds and the set condition
is saved.
a The setting is effective even after this
code is finished.
a After the control is replaced, be sure to set
(check) the condition.
24 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
[12] 1005: Fan 100% mode [13] 1012: Steering lever neutral set
q This code forcedly sets the speed of cooling q This code is used to adjust the steering neutral
fan at approximately 100% of the maximum position of the PCCS lever.
speed. q The deviation of the steering potentiometer
Also by this code, the adjustment value for the from the standard neutral position is displayed
maximum speed can be set. by voltage on the lower line (Display range:
q The adjustment data is displayed on the lower -2500 2500 mV).
line. q Adjustment method:
q How to use: 1) Set the PCCS lever to the neutral position.
a The function is effective with this code dis- 2) Set buzzer cancel switch (4) in the [U]
played to control the speed of cooling fan position and check that the caution buzzer
to approximately 100% of the maximum sounds.
speed. a Even if adjustment is carried out, the dis-
i) When changing the adjustment value, play on the lower line does not change.
operate shift up switch (6) and shift down a Even if this code is turned off, the setting
switch (7) to set the adjustment value for is effective.
the maximum speed. a This code is not for adjusting the steering
q [UP]: Adjustment value increases. performance.
q [DOWN]: Adjustment value decreases.
ii) For confirming the adjustment value, set
buzzer cancel switch (4) in the [U] posi-
tion and check that the alarm buzzer
sounds.
a If this code is turned off, its function is dis-
abled. However, the adjustment value
once set is still effective.
D475A, D475ASD-5E0 25
SEN01819-04 30 Testing and adjusting
26 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
2) Operate the buzzer cancel switch to [U] [19] 2223: Reverse slow stop set
side and check that the caution buzzer q This code is used to turn off the reverse slow
sounds. function forcibly, regardless of the operation of
a Even if this code is turned off, the setting the switches on the monitor panel.
is effective. q The state of the reverse slow function is dis-
played on the lower line by letters.
q Adjustment method:
Operate information switch (5) to change the
setting.
q [ < ] [ > ]: Change display
q [DEACTIVE]: Turn reverse slow function
OFF
q [ACTIVE]: Turn reverse slow function ON
a Once the reverse slow function is turned
OFF, the reverse speed is not lowered,
even if the reverse slow mode switch on
the monitor panel is turned ON.
a Even if this code is turned off, the setting
is effective.
D475A, D475ASD-5E0 27
SEN01819-04 30 Testing and adjusting
[20] 5535: Both steering clutches disengagement [21] 5537: Left steering clutch oil pressure offset
q This code is used to engage the transmission q This code is used to adjust the left clutch oil
clutch without driving the machine for testing, pressure manually.
adjusting, troubleshooting, Pm Clinic, etc. q The offset oil pressure (Unit: MPa) is displayed
q The transmission speed (Unit: rpm) is dis- on the lower line (If it has been adjusted, its
played on the lower line. value is displayed. It can be adjusted further
q Using method: within the allowable range).
While this code is displayed, the function is q Adjustment method:
effective and steering clutches on both sides a The allowable adjustment range is 0.3
are disengaged. Accordingly, the machine MPa {3 kg/cm2} (Displayed value: 0.3)
does not travel even if the PCCS lever is oper- 1) Operate the shift switch to set the offset oil
ated. pressure.
a If this code is turned off, the function q Shiftup switch (6): Increase oil pres-
becomes ineffective. sure
q Shiftdown switch (7): Decrease oil
pressure
a The offset pressure is increased or
decreased by 0.05 MPa {0.5 kg/cm2}
(Displayed value: 0.05).
2) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
a Even if this code is turned off, the setting
is effective.
28 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
[22] 5538: Right steering clutch oil pressure offset [23] 9801: Engine oil level set (if equipped)
q This code is used to adjust the right clutch oil q This code is used to set the machine equipped
pressure manually. with the engine oil level switch.
q The offset oil pressure (Unit: MPa) is displayed q Installation or non-installation of the engine oil
on the lower line (If it has been adjusted, its level switch is displayed on the lower line by
value is displayed. It can be adjusted further letters.
within the allowable range). q Adjustment method:
q Adjustment method: Operate information switch (5) to change the
a The allowable adjustment range is 0.3 setting.
MPa {3 kg/cm2} (Displayed value: 0.3) q [ < ] [ > ]: Change display
1) Operate the shift switch to set the offset oil q [ACTIVE]: Machine is equipped with
pressure. engine oil level switch
q Shiftup switch (6): Increase oil pres- q [DEACTIVE]: Machine is not equipped
sure with engine oil level switch
q Shiftdown switch (7): Decrease oil a To use this function, the engine oil level switch
pressure must be installed.
a The offset pressure is increased or a If [ACTIVE] is selected while the engine oil
decreased by 0.05 MPa {0.5 kg/cm2} level switch is not installed, the caution buzzer
(Displayed value: 0.05). sounds. Take care.
2) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer
sounds.
a Even if this code is turned off, the setting
is effective.
D475A, D475ASD-5E0 29
SEN01819-04 30 Testing and adjusting
[24] 9993: Hydraulic oil level set (if equipped) [25] 9995: Electric brake constantly ON mode
q This code is used to set the hydraulic oil level q This code is used to see if the sudden stop
caution. prevent valve operates normally.
q The setting of the hydraulic oil level caution is q The voltage of the brake potentiometer is dis-
displayed on the lower line by letters. played on the lower line.
q Adjustment method: q Using method:
Operate information switch (5) to change the While this code is displayed, the function is
setting. effective and the electric brake is constantly
q [ < ] [ > ]: Change display turned on.
q [ACTIVE]: Turn hydraulic oil level caution a If this code is turned off, the function
function ON becomes ineffective.
q [DEACTIVE]: Turn hydraulic oil level cau-
tion function OFF
a To use this function, the hydraulic oil level
switch must be installed.
a If [ACTIVE] is selected while the hydraulic oil
level switch is not installed, the caution buzzer
sounds. Take care.
a Even if this code is turned off, the setting is
effective.
30 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
[27] 9997: High idle limit mode [28] 9998: 3rd speed cut set
q This code is used to limit the high idle speed. q This code is used to prevent the gear from
q The engine speed (set value) is displayed on shifting up to the 3rd gear speed.
the lower line. q Available gear speeds are displayed on the
q Possible limiting range: High idle speed 400 lower line by bits (in the order of the 3rd, 2nd,
rpm and 1st from the left).
q Using method: q Using method:
1) Set information switch (5) in the [ > ] or [ < ] Operate information switch (5) and buzzer can-
position to select the limit speed. cel switch (4) to limit or reset the maximum
2) Set buzzer cancel switch (4) in the [U] gear speed.
position and check that the caution buzzer q [ > ]: Move cursor to right
sounds. q [ < ]: Move cursor to left
a Once the high idle speed is limited, the q [U] Change setting
engine speed does not reach the original q Display of lower line [o]: Gear speed is
high idle speed, even if the fuel control dial effective
is operated. q Display of lower line [_]: Gear speed is
a Even if this code is turned off, the setting ineffective
is effective. a Once a gear speed is limited, the gear
does not shift up to that gear speed, even
if the shiftup switch is operated.
a Even if this code is turned off, the setting
is effective.
D475A, D475ASD-5E0 31
SEN01819-04 30 Testing and adjusting
32 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
D475A, D475ASD-5E0 33
SEN01819-04 30 Testing and adjusting
10) Display of R2 odometer (08) 12) Moving machine with saved load dis-
On this screen, the integrated R2 played
(Reverse 2nd gear) travel distance is dis- If the parking brake lever is set in the
played. FREE position, gear speed display unit (1)
a The data cannot be reset. is set in the normal display mode again
and the machine can operate normally.
a At this time, even if the shift up or shift
down switch is pressed with the
PCCS lever in the neutral position,
the shift cannot be changed.
(The displayed number is the code of
load saving display mode.)
To change the shift, shift the PCCS
lever to the forward or reverse
position and press the shift up or shift
down switch while the machine is
traveling.
a To select another screen, return the
parking brake lever to the LOCK posi-
tion temporarily, and then start the
11) Display of R3 odometer (09) operation.
On this screen, the integrated R3 Serial numbers: 30001 30070
(Reverse 3rd gear) travel distance is dis-
played.
a The data cannot be reset.
34 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
D475A, D475ASD-5E0 35
SEN01819-04 30 Testing and adjusting
36 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
D475A, D475ASD-5E0 37
SEN01819-04 30 Testing and adjusting
Auto-
No. Code Monitoring item Unit Remarks matic
selection
1 00201 ENG M ID L Engine controller model selection name, left bank Letter
2 00203 ENG M ID R Engine controller model selection name, right bank Letter
3 01002 ENG REV L Engine speed, left bank rpm 1
4 01004 ENG REV R Engine speed, right bank rpm 2
5 01603 Remote Th 2nd throttle position %
6 03000 FUEL DIAL Fuel control dial voltage mV 25
7 03200 BATTERY Battery voltage mV 39
8 03201 S/T ACC Steering controller ACC input voltage mV
9 03202 S/T PWR2 Steering controller load power supply voltage mV
10 03203 E-ECM PW L Engine controller power supply voltage, left bank mV
11 03206 E-ECM PW R Engine controller power supply voltage, right bank mV
12 03207 S/T PWR1 Steering controller unswitched power supply voltage mV
Transmission controller unswitched power supply volt-
13 03208 T/M PWR1 mV
age
14 03212 T/M ACC Transmission controller ACC input voltage mV
15 03216 T/M PWR2 Transmission controller load power supply voltage mV
16 04104 COOLANT TP Engine coolant temperature C 6
17 04105 COOLANT TP Engine coolant temperature sensor voltage mV
18 04200 FUEL SENS Fuel level sensor voltage mV 37
19 04401 HYD.TEMP Hydraulic oil temperature C 7
20 08100 HSI BREAK HSI line break point rpm
21 08200 TQ Sel Torque curve selection Letter
22 08300 Droop Type Droop type selection Letter
23 08400 Droop SW Droop switch selection Letter
24 08500 Droop Trim Droop trim selection Letter
25 10500 S/T 5V PW1 Steering controller sensor 5V power supply voltage 1 mV
Transmission controller sensor 5V power supply voltage
26 10501 T/M 5V PW1 mV
1
27 10505 S/T 5V PW2 Steering controller sensor 5V power supply voltage 2 mV
Transmission controller sensor 5V power supply voltage
28 10506 T/M 5V PW2 mV
2
29 10700 S/T 24V PW Steering controller sensor 24V power supply voltage mV
Transmission controller sensor 24V power supply volt-
30 10701 T/M 24V PW mV
age
31 14200 FUEL TMP L Fuel temperature, left bank C
32 14201 FUEL TMP L Fuel temperature sensor voltage, left bank mV
33 14202 FUEL TMP R Fuel temperature, right bank C
34 14203 FUEL TMP R Fuel temperature sensor voltage, right bank mV
35 17201 PCV TMG L PCV closing timing, left bank CA
36 17202 PCV TMG R PCV closing timing, right bank CA
37 17500 ENG MODE Engine controller mode selection Letter
(See detailed
38 18300 ENG IVSW 1 Engine controller idle validation switch 1 bit
information)
(See detailed
39 18301 ENG IVSW 1 Engine controller idle validation switch 2 bit
information)
38 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
Auto-
No. Code Monitoring item Unit Remarks matic
selection
40 18400 INTAKE TEMP Intake air temperature C
41 18401 INTAKE TEMP Intake air temperature sensor voltage mV
42 18500 BOOST TEMP Boost temperature C
43 18501 BOOST TEMP Boost temperature sensor voltage mV
44 18600 INJECT CMD Final injection rate command mg/st
45 18700 ENG TRUQUE Engine output torque Nm
46 18900 E-ECM TP L Engine controller ECM inside temperature, left bank C
47 18902 E-ECM TP R Engine controller ECM inside temperature, right bank C
48 20201 T/M. PROGRM Transmission controller program version Letter
49 20202 S/T. PROGRM Steering controller program version Letter
50 20216 ENG BLD L Engine controller build version, left bank Letter
51 20217 ENG CAL L Engine controller calibration data version, left bank Letter
52 20218 ENG CAL R Engine controller calibration data version, right bank Letter
53 20219 ENG BLD R Engine controller build version, right bank Letter
54 20301 VHMS VHMS LED monitor LED 40
55 20400 E-ECM SN L Engine controller ECM serial No., left bank Letter
56 20401 E-ECM SN R Engine controller ECM serial No., right bank Letter
57 30100 T/C TEMP. Torque converter oil temperature C 8
58 31200 T/M IN Transmission input speed rpm
59 31400 T/M OUT Transmission output speed rpm 3
(See detailed
60 31520 T/M-FILL Transmission-related fill switch input state bit
information)
(See detailed
61 31521 S/T FILL Steering-related fill switch input state bit
information)
62 31602 1st CLUTCH 1st clutch ECMV current command value mA
63 31603 2nd CLUTCH 2nd clutch ECMV current command value mA
64 31604 3rd CLUTCH 3rd clutch ECMV current command value mA
65 31606 Rev CLUTCH Reverse clutch ECMV current command value mA
66 31608 Frd CLUTCH Forward clutch ECMV current command value mA
67 31612 1 CLUTCH F 1st clutch ECMV output feedback current mA 33
68 31613 2 CLUTCH F 2nd clutch ECMV output feedback current mA 34
69 31614 3 CLUTCH F 3rd clutch ECMV output feedback current mA 35
70 31616 R CLUTCH F Reverse clutch ECMV output feedback current mA 32
71 31618 BRAKE R.H. Right brake ECMV output feedback current mA 27
72 31619 BRAKE L.H. Left brake ECMV output feedback current mA 26
73 31620 BRAKE R.H. Right brake ECMV current command value mA
74 31621 BRAKE L.H. Left brake ECMV current command value mA
75 31622 F CLUTCH F Forward clutch ECMV output feedback current mA 31
76 31623 FAN PUMP. O Cooling fan pump solenoid output command current mA
77 31624 FAN PUMP. F Cooling fan pump solenoid output feedback current mA
78 31625 PITCH SOL. Blade pitch solenoid output feedback current mA
Torque converter lockup solenoid output feedback cur-
79 31627 L/U SOL mA 36
rent
Sudden stop prevention solenoid output feedback cur-
80 31628 E. BRAKE SL mA 28
rent
81 31633 FAN PMP2. O Cooling fan pump 2 solenoid output command current mA
D475A, D475ASD-5E0 39
SEN01819-04 30 Testing and adjusting
Auto-
No. Code Monitoring item Unit Remarks matic
selection
82 31634 FAN PMP2. F Cooling fan pump 2 solenoid output feedback current mA
83 31701 DECEL Decelerator position % 9
84 31703 DECEL Decelerator pedal potentiometer voltage mV 24
85 31706 F THROTTLE Final accelerator position % 10
86 32900 BODY ANGLE Machine pitch angle 18
87 36001 Accel Adj Throttle correction value data %
88 36200 PRESS CMD Final common rail pressure command MPa
89 36300 INJECT CMD Final injection timing command CA
90 36400 RAIL PR L Common rail pressure, left bank MPa 12
91 36401 RAIL PR L Common rail pressure sensor voltage, left bank mV
92 36403 RAIL PR R Common rail pressure, right bank MPa 13
93 36404 RAIL PR R Common rail pressure sensor voltage, right bank mV
(Absolute
94 36500 BOOST PRS Boost pressure kPa 14
pressure)
95 36501 BOOST PRS Boost pressure sensor voltage mV
96 36700 ENG TORQUE Engine converted torque % 15
97 37200 ENG OIL PRS Engine oil pressure kPa 11
98 37201 ENG OIL PRS Engine oil pressure sensor voltage mV
99 37301 FUEL RATE Fuel injection rate L/h
(Absolute
100 37400 ABM PRESS Ambient pressure kPa
pressure)
101 37401 ABM PRESS Ambient pressure sensor voltage mV
102 37500 ATM TEMP Ambient temperature C
103 40001 VEHICLE SP Travel speed (Theoretical value) km/h 4
(See detailed
104 40905 T/M-SW1 Transmission-related controller input signal 1 bit
information)
(See detailed
105 40906 T/M-SW2 Transmission-related controller input signal 2 bit
information)
(See detailed
106 40907 T/M OP SIG Transmission-related controller operation input signal bit
information)
(See detailed
107 40908 T/M HYD SW Blade lever oil pressure switch input signal bit
information)
(See detailed
108 40909 T/M SOL. 2 Transmission-related controller ON/OFF output 2 bit
information)
(See detailed
109 40910 S/T-SW1 Steering-related controller switch input signal 1 bit
information)
(See detailed
110 40911 S/T-SW2 Steering-related controller switch input signal 2 bit
information)
(See detailed
111 40913 S/T-SW5 Steering-related controller switch input signal 5 bit
information)
(See detailed
112 40914 S/T SOL. 1 Transmission-related controller ON/OFF output 1 bit
information)
(See detailed
113 40915 S/T SOL. 2 Steering-related controller output signal 2 bit
information)
114 42600 EXH TEMP LF Exhaust temperature, left front C
115 42601 EXH TEMP RR Exhaust temperature, right rear C
116 42602 EXH TEMP RF Exhaust temperature, right front C
117 42603 EXH TEMP RF Exhaust temperature sensor voltage, right front mV
40 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
Auto-
No. Code Monitoring item Unit Remarks matic
selection
118 42604 EXH TEMP LF Exhaust temperature sensor voltage, left front mV
119 42605 EXH TEMP RR Exhaust temperature sensor voltage, right rear mV
120 42606 EXH TEMP LR Exhaust temperature, left rear C
121 42607 EXH TEMP LR Exhaust temperature sensor voltage, left rear mV
122 42700 ENG OIL TMP Engine oil temperature C
123 42701 ENG OIL TMP Engine oil pressure sensor voltage mV
124 42800 BLOWBY PRS Blow-by pressure kPa
125 43000 T/M PRESS Transmission main relief pressure MPa
(See detailed
126 43502 IdleCancel Warm-up operation cancel flag bit
information)
127 44202 Accel Up Throttle upper limit value data %
128 44203 Accel low Throttle lower limit value data %
129 50200 T/M LEVR 1 Directional lever potentiometer 1 voltage mV 19
130 50201 T/M LEVR 2 Directional lever potentiometer 2 voltage mV 20
131 50300 S/T LEVR 1 Steering potentiometer 1 voltage mV 21
132 50301 S/T LEVR 2 Steering potentiometer 2 voltage mV 22
133 50400 BRAKE PEDL Brake pedal potentiometer voltage mV 23
134 50900 N-SAFTY Neutral safety relay drive voltage mV 38
135 51000 ENG REG Regulation command speed rpm
136 51100 FUEL DIAL Fuel control dial command speed rpm
137 60000 TRACTION Traction force (Theoretical value) W 5
138 60100 BODY ANGLE Machine pitch angle sensor voltage mV
139 60200 ACCELERATN Acceleration sensor voltage mV
140 60300 SSC ORDER SSC command speed rpm
(See detailed
141 60400 S/T-SW6 Steering-related controller input signal 6 bit
information)
142 60500 ENG.CON. PW Engine controller drive voltage mV
143 60600 BR HOLD Battery relay drive voltage mV
144 60700 S/T MODE Steering state code Letter
145 60800 FILL MODE Fill condition setting variable Letter
146 60909 MOD MODE Modulation condition setting variable Letter
147 70000 CHG.P. MODE Gearshift point condition setting variable Letter
148 70200 T/M OUT Transmission speed sensor voltage mV
(See detailed
149 70300 B. KNOB SW Blade lever knob switch input signal bit
information)
(See detailed
150 70305 T/M RIPER2 Ripper lever oil pressure switch input signal bit
information)
151 70400 BACK ALARM Backup alarm relay drive voltage mV
152 70600 DUAL SOL. Dual tilt solenoid drive current mA
153 70700 HYD. PUMP 1 Work equipment pump oil pressure 1 MPa 16
154 70701 HYD. PUMP 1 Work equipment oil pressure sensor 1 voltage mV
155 70702 HYD. PUMP 2 Work equipment pump oil pressure 2 MPa 17
156 70703 HYD. PUMP 2 Work equipment oil pressure sensor 2 voltage mV
(See detailed
157 90000 T/M SOL. 3 Tilt and pitch solenoid output 3 bit output signal bit
information)
(See detailed
158 90001 T/M SOL. 4 Dual tilt and pitch solenoid output 4 bit output signal bit
information)
D475A, D475ASD-5E0 41
SEN01819-04 30 Testing and adjusting
Auto-
No. Code Monitoring item Unit Remarks matic
selection
159 90002 BL YOKE L Left yoke angle sensor voltage mV
160 90003 BL YOKE R Right yoke angle sensor voltage mV
161 90600 S/T CLT LH Left clutch ECMV output feedback current mA 29
162 90601 S/T CLT RH Right clutch ECMV output feedback current mA 30
163 90602 S/T CLT LH Left clutch ECMV output current mA
164 90603 S/T CLT RH Right clutch ECMV output current mA
165 92100 F1 SMR F1 integrated travel hours h
166 92101 F2 SMR F2 integrated travel hours h
167 92102 F3 SMR F3 integrated travel hours h
168 92200 R1 SMR R1 integrated travel hours h
169 92201 R2 SMR R2 integrated travel hours h
170 92202 R3 SMR R3 integrated travel hours h
171 99901 TRIG T F Trigger time F msec
172 99902 TRIG T R Trigger time R msec
173 99903 TRIG T 1 Trigger time 1 msec
174 99904 TRIG T 2 Trigger time 2 msec
175 99905 TRIG T 3 Trigger time 3 msec
176 99906 TM SFT Transmission shift Letter
(See detailed
177 99907 LU Lockup state bit
information)
178 99908 TM IN TRQ Transmission input torque Nm
179 99909 DOZING h Dozing hours h
180 99910 RIPPING h Ripping hours h
181 99911 PATH NUM Number of path path
182 99913 TC IN TRQ Torque converter input torque Nm
183 99914 H. P 1 TRQ Work equipment pump 1 input torque Nm
184 99915 H. P 2 TRQ Work equipment pump 2 input torque Nm
185 99917 BR L PRESS Left brake oil pressure MPa
186 99918 BR R PRESS Right brake oil pressure MPa
187 99919 CL L PRESS Left clutch oil pressure MPa
188 99920 CL R PRESS Right clutch oil pressure MPa
a The numbers in the Automatic selection column can be displayed in numeric order by setting the infor-
mation switch in the > or < position.
42 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
Detailed information on bit display 18301: Engine controller idle validation switch 2
codes 1: Idle validation switch 2: ON
2: (Unused)
Examples of display of bit information 3: (Unused)
a The display position of the bit information in the 4: (Unused)
Real-time monitoring mode (Display of only 1 5: (Unused)
item) is different from that in the Dual display 6: (Unused)
monitoring mode (Simultaneous display of 2 7: (Unused)
items). 8: (Unused)
a The bit information is displayed by [ ] for OFF
and [o] for ON in the places 1 8.
a The state of each item shown below is the con-
dition for turning on the bit.
D475A, D475ASD-5E0 43
SEN01819-04 30 Testing and adjusting
31521: Input state of steering related fill switch 40906: Transmission related controller input signal 2
1: Left brake fill switch: ON 1: Automatic gear shift-down switch: ON
2: Left clutch fill switch: ON 2: Neutral switch (OPT-type travel lever): OFF
3: (Unused) 3: Neutral switch (OPT-type travel lever): ON
4: (Unused) 4: Neutral switch (OPT-type travel lever): OFF
5: Right clutch fill switch: ON 5: Neutral switch (OPT-type travel lever): ON
6: Right brake fill switch: ON 6: Automatic pitch back switch: ON
7: (Unused) 7: (Unused)
8: (Unused) 8: (Unused)
40905: Transmission related controller input signal 1 40907: Transmission related controller function
1: Shift-up switch: OFF input signal
2: Shift-up switch: ON 1: ACC signal switch: ON
3: Shift-down switch: OFF 2: (Unused)
4: Shift-down switch: ON 3: R signal: ON
5: Parking brake switch: FREE 4: (Unused)
6: Parking brake switch: LOCK 5: (Unused)
7: (Unused) 6: (Unused)
8: (Unused) 7: (Unused)
8: (Unused)
44 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
40908: Blade lever oil pressure switch input signal 40910: Steering related controller input signal 1
1: Blade lift raise oil pressure switch: ON 1: (Unused)
2: Blade lift lower oil pressure switch: ON 2: (Unused)
3: (Unused) 3: (Unused)
4: (Unused) 4: (Unused)
5: Blade left tilt oil pressure switch: ON 5: Parking brake lever switch: FREE
6: Blade right tilt oil pressure switch: ON 6: Parking brake lever switch: LOCK
7: (Unused) 7: (Unused)
8: (Unused) 8: (Unused)
40909: Transmission related controller output 40911: Steering related controller input signal 2
signal 2 1: Buzzer cancel switch: t position
1: (Unused) 2: Buzzer cancel switch: U position
2: (Unused) 3: Information switch: > position
3: (Unused) 4: Information switch: < position
4: Backup alarm relay: ON 5: Service switch: ON
5: Neutral safety relay: ON 6: (Unused)
6: Lockup: ON 7: (Unused)
7: (Unused) 8: (Unused)
8: (Unused)
D475A, D475ASD-5E0 45
SEN01819-04 30 Testing and adjusting
40913: Steering related controller input signal 5 40915: Steering related controller ON-OFF output
1: ACC signal: ON signal 2
2: Pre-lubrication oil pressure switch: ON 1: Pre-lubrication motor relay: ON
3: R signal: ON 2: Engine stop relay: ON
4: (Unused) 3: (Unused)
5: Fan reverse switch: ON 4: (Unused)
6: Fan cleaning switch: ON 5: (Unused)
7: (Unused) 6: (Unused)
8: (Unused) 7: (Unused)
8: (Unused)
46 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
60400: Steering related controller input signal 6 70305: Ripper lever oil pressure switch input signal
1: (Unused) 1: (Unused)
2: C signal: ON 2: Ripper lift raise oil pressure switch:
3: Engine low idle signal: ON ON (Operated)
4: Engine stop command signal: ON 3: Ripper lift lower oil pressure switch:
5: Hydraulic oil level switch signal: ON ON (Operated)
6: Pre-lubrication motor drive signal: ON 4: Ripper tilt in oil pressure switch: ON (Operated)
7: (Unused) 5: Ripper tilt out oil pressure switch: ON (Oper-
8: (Unused) ated)
6: (Unused)
7: (Unused)
8: (Unused)
D475A, D475ASD-5E0 47
SEN01819-04 30 Testing and adjusting
90000: Dual/Pitch dump solenoid output 4 bit out- 99907: Lockup state
put signal (Other than superdozer specification) 1: Forward clutch output: ON
1: Left tilt limit solenoid: ON 2: Reverse clutch output: ON
2: Right tilt limit solenoid: ON 3: 1st clutch output: ON
3: (Unused) 4: 2nd clutch output: ON
4: (Unused) 5: 3rd clutch output: ON
5: (Unused) 6: Clutch modulation: Modulating
6: (Unused) 7: Lockup clutch output: ON
7: (Unused) 8: Clutch state: Neutral
8: (Unused)
48 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
11. Dual display monitoring mode 2) Selecting and entering monitored items
(11-DUAL DISPLAY MONITORING MODE) 1] On the code input screen, input the 5-
In this mode, 2 monitored items can be dis- digit codes of the items to be moni-
played simultaneously. tored to the upper and lower lines by
a Note that only codes and monitoring infor- operating information switch (5), shift-
mation are displayed in this mode since up switch (6), and shift-down switch
the usable display columns are limited. (7).
(Item names and units cannot be dis- q [ > ]: Move cursor to right.
played.) q [ < ]: Move cursor to left.
q [UP]: Increase number.
1) Selecting and executing mode q [DOWN]: Decrease number.
1] Select Dual display monitoring 2] After inputting the codes, display the
mode on the mode selection screen. m on ito ring scree n by op erating
a If the mode is selected, code buzzer cancel switch (4).
(dR) is displayed on gear speed q [U]: Enter input code.
display section (1) and the title is
displayed on multi-information
section (2).
2] Display the monitoring code input
screen by operating buzzer cancel
switch (4).
q [U]: Execute mode.
Serial numbers: 30001 30070
D475A, D475ASD-5E0 49
SEN01819-04 30 Testing and adjusting
50 D475A, D475ASD-5E0
30 Testing and adjusting SEN01819-04
12. Snap shot mode (12-SNAPSHOT MODE) Serial numbers: 30001 30070
The VHMS specification has the manual snap
shot function and automatic snap shot func-
tion.
While the manual snap shot function is turned
ON, various data in 7 minutes 30 seconds for
the Pm clinic, testing, and adjusting can be
saved in the VHMS controller.
1) Select Snap shot mode on the mode
selection screen.
a If the mode is selected, code (55) is dis-
played on gear speed display unit (1) and
the title is displayed on multi-information
unit (2).
For details of the operating method in the
snap shot mode, see Execution method Serial numbers: 30071 and up
of quick PM.
(1) Manual snap shot function
q To collect data periodically for the Pm
clinic, the machine must be operated
as specified by the Quick Pm. When
data is required and collected for test-
ing, adjusting, etc., the operations of
the machine are not limited.
q To use the data saved with the man-
ual snap shot function, a personal
computer must be connected. For the
procedure for connecting the per-
sonal computer, see Initialization
procedure for VHMS controller. (The
personal computer may be connected
either before or after the snap shot
operation.)
(2) Automatic snap shot function
q While the automatic snap shot func-
tion is turned ON, if an item which the
VHMS controller monitors constantly
becomes abnormal (if the corre-
sponding failure code is displayed),
the snap shot data of that item in 7
minutes 30 seconds are saved in the
VHMS controller automatically.
q Since the VHMS controller automati-
cally performs the automatic snap
shot function according to the moni-
toring item data, the operator does
not need to operate the monitor.
q How to collect snap shot data
If the value of a monitoring item data
becomes abnormal, that data is
recorded and saved for 7 minutes 30
seconds from 5 minutes 30 seconds
ago.
a The data is recorded at 10 second
intervals for the first 5 minutes, and at
1 second intervals for 2 minutes 30
seconds after the first 5 minutes.
D475A, D475ASD-5E0 51
SEN01819-04
2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
52
SEN01820-03
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN01820-03 30 Testing and adjusting
2 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 3
SEN01820-03 30 Testing and adjusting
1. Monitor panel
1) Remove cover (1).
2) Remove the 2 mounting bolts and pull out
monitor panel (2) toward the operators
seat.
Serial numbers: 30001 30070
2. Engine controller
1) Open left and right side covers (1) and
remove side covers (2) and (3).
4 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 5
SEN01820-03 30 Testing and adjusting
6 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
2) Remove amplifier mounting cover (2). 2) Referring to 5 above, remove VHMS con-
troller (3).
3) Insert or connect T-adapters in or to con-
nectors KOM1 of ORBCOMM terminal (4).
a If it is difficult to remove and install the
connectors, remove the terminal for
the ease of work.
D475A, D475ASD-5E0 7
SEN01820-03 30 Testing and adjusting
8 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 9
SEN01820-03 30 Testing and adjusting
10 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 11
SEN01820-03 30 Testing and adjusting
Right decimal
Display
point
Power is not supplied to ORB-
COMM controller.
OFF
Communication line to VHMS
controller is abnormal.
Satellite is not captured.
Power is supplied to ORB-
ON COMM controller.
Communication line to VHMS
controller is normal.
Power is supplied to ORB-
4. Startup of VHMS initialization tool
COMM controller.
a This step is a work performed in the oper-
Blinking Communication line to VHMS
controller is normal. ator's cab (on the personal computer).
Satellite is captured. 1) Turn on the personal computer and start
the OS.
2) Click the icon of [VHMS Initialization Tool]
8) Check the controller for normal operation on the personal computer screen to start
referencing 7-segment LED of VHMS con- the VHMS initialization tool.
troller. a The setting screen varies with the
a VHMS controller is fed with switch version No. of the VHMS setting tool.
power supply. Thus, its operation is a When using a tool before Ver. 3.5.2.1
judged normal if its 7-segment LED (CD-ROM), set the VHMS in step 5.
starts flashing while rotating as the a When using an updated tool (Ver.
starting switch is turned on and then if 3.5.2.1 or after), set the VHMS in step
the controller starts counting in the 6.
ascending order. a It is recommended to download the
latest VHMS setting tool from the
WebCARE and update your tool.
(Related material: Servicemate SMP-
623)
3) Input the 10-digit service ID in [Service
ID].
a Service ID: 7826146000
4) Select [Data clear and Set up] in the
[Select Function] column.
5) Press the [OK] button to go to the setup
screen.
12 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 13
SEN01820-03 30 Testing and adjusting
14 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
9) To change setting in [SHORT TREND 11) After checking/changing all the data in
ANALYSIS], follow the procedures below: [Communication Setting], press [Apply]
1] Select [SHORT TREND ANALYSIS] button to settle the setting.
on the screen and press [Edit] button a If the [Apply] button is pressed, the
on the left lower part of the [File s c r e e n f o r c h e c k in g t h e s e t t i n g
Transfer Setting] block to display the appears. Check the setting again and
setting screen. press the [OK] button if the setting is
2] Change the setting and then press correct.
the [OK] button.
a At initialization, input [20h] to
[SMR] and set the function to
[ON].
D475A, D475ASD-5E0 15
SEN01820-03 30 Testing and adjusting
6. Initialization of VHMS controller (Ver. 3.5.2.1 3) Check the machine information. If it does
or after) not need to be corrected, press the Next
a This step is a work performed in the oper- button.
ator's cab (on the personal computer).
a When initializing, do not change the data
of service meter [SMR].
1) Select [VHMS Setting] and press the
Next button.
16 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
4) Select the time zone. 8) The contents of the setting are displayed
5) Input the local time. finally. If there is not a problem, press the
6) If the DST (Daylight Saving Time) is used Apply button.
now, select it and press the Next button.
a If the DST is selected, the clock is
advanced 1 hour automatically, thus
the time must be corrected again.
D475A, D475ASD-5E0 17
SEN01820-03 30 Testing and adjusting
7. Procedures for executing Quick Pm 2] Set the buzzer cancel switch in the
a The Quick Pm means the Pm Clinic exe- [U] position.
cuted with the manual snap shot function 3] READY is displayed and the system
of the monitor panel. is ready to start.
a Data in 7 minutes 30 seconds are saved in a On the lower line, 15 pieces of -
the VHMS controller. are displayed.
k Stop the machine on a flat place.
18 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 19
SEN01820-03 30 Testing and adjusting
Fuel
No.
(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.
(Note 2): Keep running the engine at low idle until the oil temperature is lowered to the normal level.
a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine
speed to high idle.
a After stalling the torque converter, watch the power train oil temperature gauge and take care not to
overheat the power train oil.
(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature
gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the
engine at high idle to lower the oil temperature.)
20 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 21
SEN01820-03 30 Testing and adjusting
22 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 23
SEN01820-03 30 Testing and adjusting
Measurement items
24 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 25
SEN01820-03 30 Testing and adjusting
26 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
E-mail: webcare@komatsu.co.jp
D475A, D475ASD-5E0 27
SEN01820-03 30 Testing and adjusting
28 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 29
SEN01820-03 30 Testing and adjusting
30 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 31
SEN01820-03 30 Testing and adjusting
5) Check the information again and press the 3) Select [Load] from [File] in the menu.
OK button to save it.
32 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
7) After setting the time, press the OK but- 9) The system asks you if you will save the
ton. previous data. Press the NO button.
a Usually, you do not need to save the
previous data.
D475A, D475ASD-5E0 33
SEN01820-03 30 Testing and adjusting
3) Select [Save Current Setting before 3-2. Writing of set information in new VHMS con-
replacement of VHMS controller] and troller
press the Next button. 1) Connect the personal computer again and
start the VHMS technical analysis tool.
a See Initialization procedures for
VHMS controller.
2) Select [When VHMS needs to be
replaced] and press the Next button.
34 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
4) The saved information is displayed. Press 7) The above completes modification of the
the Next button. setting. Press [OK] button to end the
VHMS initial setting tool.
D475A, D475ASD-5E0 35
SEN01820-03 30 Testing and adjusting
Pm Clinic service 1
Model Serial No. Service meter
T D475A-5E0
h
T D475ASD-5E0
Specifications
Blade Attachment Shoe width
T Semi U blade T Variable Multi-shank ripper T 710 mm %
T U blade T Variable giant ripper T 810 mm %
T Super blade T Counterweight ( kg) T 910 mm %
T T T %
Operating conditions
Quarry, mine Construction Type of soil (specific gravity) Type of work
T Construction, civil engi-
T Coal T Rock T Dozing
neering
T Gold T Roads T Gravel T Side cutting
T Limestone T Tunnels T Sand T Ripping
T T T Clay T Travel
Existence of abnormalities
Oil, coolant level check
T Engine coolant level When necessary
T Engine oil level T Power train T Damper case
T Hydraulic oil level T Final drive T( )
Operator's opinion
a Engine coolant temperature: Max. range a Power train oil temperature: Max. range
Serial numbers: 30001 30070 Serial numbers: 30071 and up Serial numbers: 30001 30070 Serial numbers: 30071 and up
36 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 37
SEN01820-03 30 Testing and adjusting
38 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
D475A, D475ASD-5E0 39
SEN01820-03 30 Testing and adjusting
Low idle
High idle
Low idle
Transmission: Neutral
Oil temperature:
Within operating range
High idle
Low idle
High idle
Transmission: F3
(Adjustment code: 5535) Low idle
Transmission: R3
(Adjustment code: 5535) Low idle
Transmission: F1
(Adjustment code: 5535) Low idle
Transmission: F2
(Adjustment code: 5535) Low idle
Transmission: F3
(Adjustment code: 5535) Low idle
40 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
Low idle
High idle
Transmission: Neutral
Low idle
High idle
Low idle
High idle
Low idle
High idle
High idle
Low idle
High idle
High idle
D475A, D475ASD-5E0 41
SEN01820-03 30 Testing and adjusting
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
High idle
Low idle
High idle
42 D475A, D475ASD-5E0
30 Testing and adjusting SEN01820-03
Pm clinic T D475A-5E0 #
Serial number
Undercarriage check sheet T D475ASD-5E0 #
a Measurement results
Pass Fail
Left side of
machine
Right side of
machine
D475A, D475ASD-5E0 43
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
(Program form No.: SELA195001)
44 D475A, D475ASD-5E0
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
(Program form No.: SELA195001)
IMPACT
D475A, D475ASD-5E0 45
SEN01820-03
2010 KOMATSU
All Rights Reserved
Printed in Japan 04-10
46
SEN01821-04
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2
Fuse locations............................................................................................................................................... 12
D475A, D475ASD-5E0 1
SEN01821-04 40 Troubleshooting
1500L0 Transmission clutch Double engagement T/M CALL E03 Electrical system
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-04
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
B@BFZK Fuel level Reduction MON Mechanical system
B@CHZG HSS charge oil pressure Low oil pressure MON Mechanical system Troubleshoot-
ing by failure
B@CHZK Power train Oil level reduction MON Mechanical system code, Part 1
B@GAZK Battery electrolyte level Electrolyte level reduction MON Mechanical system SEN01823-02
CA111 Engine controller (Left bank) Internal abnormality ENG CALL E04 Electrical system
CB111 Engine controller (Right bank) Internal abnormality ENG CALL E04 Electrical system
Engine NE/Bkup speed sensor
CA115 Speed sensor signal error ENG CALL E04 Electrical system
abnormality (Left bank)
Engine NE/Bkup speed sensor
CB115 Speed sensor signal error ENG CALL E04 Electrical system
abnormality (Right bank)
Charge pressure sensor abnormally
CA122 High voltage detection ENG CALL E03 Electrical system
high level (Only left bank)
Charge pressure sensor abnormally
CA123 Low voltage detection ENG CALL E03 Electrical system
low level (Only left bank)
Decelerator pedal sensor abnormally
CA131 High voltage detection ENG CALL E03 Electrical system
high level (Only left bank)
Decelerator pedal sensor abnormally
CA132 Low voltage detection ENG CALL E03 Electrical system
low level (Only left bank)
Oil pressure sensor abnormally high
CA135 High voltage detection ENG CALL E02 Electrical system
level (Only left bank)
Oil pressure sensor abnormally low
CA141 Low voltage detection ENG CALL E02 Electrical system
level (Only left bank)
Coolant temperature sensor abnor-
CA144 High voltage detection ENG CALL E02 Electrical system
mally high level (Only left bank)
Coolant temperature sensor abnor-
CA145 Low voltage detection ENG CALL E02 Electrical system
mally low level (Only left bank)
Charge temperature sensor abnor-
CA153 High voltage detection ENG CALL E01 Electrical system
mally high level (Only left bank)
Charge temperature sensor abnor- Troubleshoot-
CA154 Low voltage detection ENG CALL E01 Electrical system ing by failure
mally low level (Only left bank)
code, Part 2
Sensor power supply (2) abnormally
CA187 Low voltage detection ENG CALL E03 Electrical system
low level (Left bank) SEN01824-01
Sensor power supply (2) abnormally
CB187 Low voltage detection ENG CALL E03 Electrical system
low level (Right bank)
Engine oil temperature sensor
CA212 High voltage detection ENG CALL E01 Electrical system
abnormally high level (Only left bank)
Engine oil temperature sensor
CA213 Low voltage detection ENG CALL E01 Electrical system
abnormally low level (Only left bank)
Ambient temperature sensor abnor-
CA221 High voltage detection ENG CALL E03 Electrical system
mally high level (Only left bank)
Ambient temperature sensor abnor-
CA222 Low voltage detection ENG CALL E03 Electrical system
mally low level (Only left bank)
Sensor power supply (2) abnormally
CA227 High voltage detection ENG CALL E03 Electrical system
high level (Left bank)
Sensor power supply (2) abnormally
CB227 High voltage detection ENG CALL E03 Electrical system
high level (Right bank)
CA234 Engine overspeed (Only left bank) Abnormally high speed ENG Mechanical system
Ne speed sensor power supply
CA238 Low voltage detection ENG CALL E03 Electrical system
abnormality (Left bank)
Ne speed sensor power supply
CB238 Low voltage detection ENG CALL E03 Electrical system
abnormality (Right bank)
Fuel temperature sensor abnormally
CA263 Abnormally high speed ENG CALL E01 Electrical system
high level (Left bank)
Fuel temperature sensor abnormally
CB263 Abnormally high speed ENG CALL E01 Electrical system
high level (Right bank)
Fuel temperature sensor abnormally
CA265 Low voltage detection ENG CALL E01 Electrical system
low level (Left bank)
D475A, D475ASD-5E0 3
SEN01821-04 40 Troubleshooting
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
Fuel temperature sensor abnormally
CB265 Low voltage detection ENG CALL E01 Electrical system
low level (Right bank)
CA271 PCV1 short circuit (Left bank) Short circuit ENG CALL E03 Electrical system
CB271 PCV1 short circuit (Right bank) Short circuit ENG CALL E03 Electrical system
CA272 PCV1 disconnection (Left bank) Disconnection ENG CALL E03 Electrical system Troubleshoot-
ing by failure
CB272 PCV1 disconnection (Right bank) Disconnection ENG CALL E03 Electrical system code, Part 2
CA273 PCV2 short circuit (Left bank) Short circuit ENG CALL E03 Electrical system SEN01824-01
CB273 PCV2 short circuit (Right bank) Short circuit ENG CALL E03 Electrical system
CA274 PCV2 disconnection (Left bank) Disconnection ENG CALL E03 Electrical system
CB274 PCV2 disconnection (Right bank) Disconnection ENG CALL E03 Electrical system
Injector #1 (L/B#1) system discon-
CA322 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Injector #5 (L/B#5) system discon-
CA323 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Injector #3 (L/B#3) system discon-
CA324 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Injector #6 (L/B#6) system discon-
CA325 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Injector #2 (L/B#2) system discon-
CA331 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Injector #4 (L/B#4) system discon-
CA332 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Engine controller data mismatch
CA342 Mismatch ENG CALL E03 Electrical system
(Left bank)
Engine controller data mismatch
CB342 Mismatch ENG CALL E03 Electrical system
(Right bank)
Injector drive circuit abnormality
CA351 Circuit abnormality ENG CALL E03 Electrical system
(Left bank)
Injector drive circuit abnormality
CB351 Circuit abnormality ENG CALL E03 Electrical system
(Right bank)
Sensor power supply (1) abnormally
CA352 Low voltage detection ENG CALL E03 Electrical system
low level (Left bank)
Sensor power supply (1) abnormally
CB352 Low voltage detection ENG CALL E03 Electrical system
low level (Right bank)
Sensor power supply (1) abnormally Troubleshoot-
CA386 High voltage detection ENG CALL E03 Electrical system ing by failure
high level (Left bank)
code, Part 3
Sensor power supply (1) abnormally
CB386 High voltage detection ENG CALL E03 Electrical system
high level (Right bank) SEN01825-03
Power supply voltage abnormally low
CA441 Low voltage detection ENG CALL E04 Electrical system
level (Left bank)
Power supply voltage abnormally low
CB441 Low voltage detection ENG CALL E04 Electrical system
level (Right bank)
Power supply voltage abnormally
CA442 High voltage detection ENG CALL E04 Electrical system
high level (Left bank)
Power supply voltage abnormally
CB442 High voltage detection ENG CALL E04 Electrical system
high level (Right bank)
Common rail abnormally high pres- Abnormally high pressure
CA449 ENG CALL E03 Electrical system
sure (2) (Left bank) occurrence
Common rail abnormally high pres- Abnormally high pressure
CB449 ENG CALL E03 Electrical system
sure (2) (Right bank) occurrence
Common rail pressure sensor abnor-
CA451 High voltage detection ENG CALL E03 Electrical system
mally high level (Left bank)
Common rail pressure sensor abnor-
CB451 High voltage detection ENG CALL E03 Electrical system
mally high level (Right bank)
Common rail pressure sensor abnor-
CA452 Low voltage detection ENG CALL E03 Electrical system
mally low level (Left bank)
Common rail pressure sensor abnor-
CB452 Low voltage detection ENG CALL E03 Electrical system
mally low level (Right bank)
Common rail abnormally high pres- Abnormally high pressure
CA553 ENG E02 Electrical system
sure (1) (Left bank) occurrence
Common rail abnormally high pres- Abnormally high pressure
CB553 ENG E02 Electrical system
sure (1) (Right bank) occurrence
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-04
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
Common rail pressure sensor in-
CA554 In-range error occurrence ENG CALL E03 Electrical system
range error (Left bank)
Common rail pressure sensor in-
CB554 In-range error occurrence ENG CALL E03 Electrical system
range error (Right bank)
Supply pump low pressure (1)
CA559 Low pressure occurrence ENG E02 Electrical system
(Left bank)
Supply pump low pressure (1)
CB559 Low pressure occurrence ENG E02 Electrical system
(Right bank)
Engine Ne speed sensor abnormality Troubleshoot-
CA689 Signal error ENG CALL E03 Electrical system ing by failure
(Left bank)
code, Part 3
Engine Ne speed sensor abnormality
CB689 Signal error ENG CALL E03 Electrical system
(Right bank) SEN01825-03
Intake air temperature sensor abnor-
CA691 High voltage detection ENG E01 Electrical system
mally high level (Only left bank)
Intake air temperature sensor abnor-
CA692 Low voltage detection ENG E01 Electrical system
mally low level (Only left bank)
Engine Bkup speed sensor abnormal
CA731 Phase error ENG CALL E03 Electrical system
phase (Left bank)
Engine Bkup speed sensor abnormal
CB731 Phase error ENG CALL E03 Electrical system
phase (Right bank)
Engine controller all data loss
CA757 All data loss ENG CALL E04 Electrical system
(Left bank)
Engine controller all data loss
CB757 All data loss ENG CALL E04 Electrical system
(Right bank)
Engine Bkup speed sensor abnor-
CA778 Bkup signal error ENG CALL E03 Electrical system
mality (Left bank)
Engine Bkup speed sensor abnor-
CB778 Bkup signal error ENG CALL E03 Electrical system
mality (Right bank)
Inter-multicontroller communication
CA781 Communication error ENG CALL E03 Electrical system
error (Left bank)
Inter-multicontroller communication
CB781 Communication error ENG CALL E03 Electrical system
error (Right bank)
Multicontroller distinction wiring har-
CA1257 Distinction error ENG CALL E03 Electrical system
ness key error (Left bank)
Multicontroller distinction wiring har-
CB1257 Distinction error ENG CALL E03 Electrical system
ness key error (Right bank)
Injector #7 (R/B#1) system discon-
CB1548 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Right bank)
Injector #8 (R/B#2) system discon-
CB1549 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Right bank)
Injector #10 (R/B#4) system discon-
CB1551 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Right bank)
Injector #11 (R/B#5) system discon-
CB1552 Disconnection/Short circuit ENG CALL E03 Electrical system Troubleshoot-
nection/short circuit (Right bank)
ing by failure
Injector #12 (R/B#6) system discon-
CB1553 Disconnection/Short circuit ENG CALL E03 Electrical system code, Part 4
nection/short circuit (Right bank)
Injector #19 (R/B#3) system discon-
CB1622 Disconnection/Short circuit ENG CALL E03 Electrical system SEN01826-01
nection/short circuit (Right bank)
CA1633 KOMNET abnormality (Left bank) Communication error ENG CALL E03 Electrical system
Decelerator pedal sensor power sup-
CA2185 ply abnormally high level (Only left High voltage detection ENG CALL E03 Electrical system
bank)
Decelerator pedal sensor power sup-
CA2186 ply abnormally low level (Only left Low voltage detection ENG CALL E03 Electrical system
bank)
Supply pump low pressure (2)
CA2249 Low pressure occurrence ENG CALL E03 Electrical system
(Left bank)
Supply pump low pressure (2)
CB2249 Low pressure occurrence ENG CALL E03 Electrical system
(Right bank)
D110KA Battery relay Disconnection S/T Electrical system
D130KB Neutral safety relay Short circuit T/M E02 Electrical system
D475A, D475ASD-5E0 5
SEN01821-04 40 Troubleshooting
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
D161KB Backup alarm relay Short circuit T/M E01 Electrical system
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-04
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
DBB7KP
VHMS sensor power supply (12 V) Output voltage reduction VHMS
[n9 o 03]
DBBQKR
VHMS KOM-NET Communication error VHMS
[n8 o 02]
VHMS controller CAN communica-
dbBRKR Communication error S/T Electrical system
tion
DD12KA Shift-up switch Disconnection T/M E02 Electrical system
DD14KA Parking brake lever switch Disconnection T/M CALL E03 Electrical system
DD14KB Parking brake lever switch Short circuit T/M CALL E03 Electrical system
DDN7KB Blade pitch switch Short circuit T/M E02 Electrical system
DDN9KB Blade tilt switch Short circuit T/M E01 Electrical system
DDNALD Blade lift raise full oil pressure switch Switch ON for long time T/M Electrical system
DDNBLD Ripper lift raise oil pressure switch Switch ON for long time T/M Electrical system
DDNCLD Ripper lift lower oil pressure switch Switch ON for long time T/M Electrical system
DDNDLD Ripper tilt in oil pressure switch Switch ON for long time T/M Electrical system
DDNELD Ripper tilt back oil pressure switch Switch ON for long time T/M Electrical system
Ripper lift lower full oil pressure
DDNFLD Switch ON for long time T/M Electrical system
switch
DDQ2KA Parking brake lever switch Disconnection S/T CALL E03 Electrical system
DDQ2KB Parking brake lever switch Short circuit S/T CALL E03 Electrical system
DDQ2L4 Parking brake lever switch (S/T) Signal disagreement S/T CALL E03 Electrical system
dDQ2L4 Parking brake lever switch (T/M) Signal disagreement T/M CALL E03 Electrical system
Troubleshoot-
DDT5KA Neutral switch Disconnection T/M CALL E04 Electrical system ing by failure
code, Part 6
DDT5KB Neutral switch Short circuit T/M CALL E04 Electrical system
SEN01828-03
Model selection signal dis-
DDT5KQ Lever specification selection error T/M CALL E04 Electrical system
agreement
DGS1KX Hydraulic oil temperature sensor Out of input signal range T/M Electrical system
DGT1KA Power train oil temperature sensor Disconnection MON E01 Electrical system
DGT1KX Power train oil temperature sensor Out of input signal range MON E01 Electrical system
D475A, D475ASD-5E0 7
SEN01821-04 40 Troubleshooting
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
DGT5KA Left bank exhaust temperature sen-
Disconnection VHMS
[n3 o 12] sor system (Front)
dGT5KA Left bank exhaust temperature sen-
Disconnection VHMS
[n3 o 22] sor system (Rear)
DGT5KB Left bank exhaust temperature sen-
Short circuit VHMS
[n3 o 11] sor system (Front)
dGT5KB Left bank exhaust temperature sen-
Short circuit VHMS
[n3 o 21] sor system (Rear)
DGT6KA Right bank exhaust temperature sen-
Disconnection VHMS
[n3 o 24] sor system (Front)
dGT6KA Right bank exhaust temperature sen-
Disconnection VHMS
[n3 o 26] sor system (Rear)
DGT6KB Right bank exhaust temperature sen-
Short circuit VHMS
[n3 o 23] sor system (Front)
dGT6KB Right bank exhaust temperature sen-
Short circuit VHMS
[n3 o 25] sor system (Rear)
Work equipment pump oil pressure
DH22KA Disconnection T/M Electrical system
sensor (F)
Work equipment pump oil pressure
DH22KB Short circuit T/M Electrical system
sensor (F)
Work equipment pump oil pressure
DH23KA Disconnection T/M Electrical system
sensor (R)
Work equipment pump oil pressure
DH23KB Short circuit T/M Electrical system
sensor (R)
DHE5KB
Blow-by pressure sensor system Disconnection VHMS
[n3 o 32]
DHE5KY Troubleshoot-
Blow-by pressure sensor system Hot short VHMS ing by failure
[n3 o 31]
code, Part 6
DHT3KX
Transmission oil pressure sensor Out of input signal range VHMS
[n6 o 14] SEN01828-03
DK01KA Left yoke angle sensor Disconnection T/M E02 Electrical system
DK01KB Left yoke angle sensor Short circuit T/M E02 Electrical system
DK03KA Right yoke angle sensor Disconnection T/M E02 Electrical system
DK03KB Right yoke angle sensor Short circuit T/M E02 Electrical system
DK10KA Fuel control dial Disconnection S/T CALL E03 Electrical system
DK10KB Fuel control dial Short circuit S/T CALL E03 Electrical system
DK30KA Steering potentiometer (1) Disconnection S/T CALL E03 Electrical system
DK30KB Steering potentiometer (1) Short circuit S/T CALL E03 Electrical system
DK30KX Steering potentiometer (1) Out of input signal range S/T CALL E04 Electrical system
DK30KZ Steering potentiometer (1) Disconnection or short circuit S/T CALL E04 Electrical system
DK30L8 Steering potentiometer (1) Analog signal disagreement S/T CALL E03 Electrical system
DK31KA Steering potentiometer (2) Disconnection S/T CALL E03 Electrical system
DK31KB Steering potentiometer (2) Short circuit S/T CALL E03 Electrical system
DK40KB Brake potentiometer Short circuit S/T CALL E03 Electrical system
DK55KX Forward-reverse potentiometer Out of input signal range T/M CALL E04 Electrical system Troubleshoot-
ing by failure
code (Display
DK55KZ Forward-reverse potentiometer Disconnection or short circuit T/M CALL E04 Electrical system
of code), Part 7
DK55L8 Forward-reverse potentiometer Analog signal disagreement T/M CALL E03 Electrical system SEN01829-02
DK56KA Forward-reverse potentiometer (1) Disconnection T/M CALL E03 Electrical system
DK56KB Forward-reverse potentiometer (1) Short circuit T/M CALL E03 Electrical system
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-04
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
DK57KA Forward-reverse potentiometer (2) Disconnection T/M CALL E03 Electrical system
DK57KB Forward-reverse potentiometer (2) Short circuit T/M CALL E03 Electrical system
DKH1KA Pitch angle sensor Disconnection S/T CALL E03 Electrical system
DKH1KB Pitch angle sensor Short circuit S/T CALL E03 Electrical system
DKH1KX Pitch angle sensor Out of input signal range S/T E01 Electrical system
Torque converter output speed sen-
DLF1KA Disconnection T/M Electrical system
sor
DLT3KA Transmission output speed sensor Disconnection T/M E01 Electrical system
dLT3KA Transmission output speed sensor Disconnection T/M E01 Electrical system
DLT3KB Transmission output speed sensor Short circuit T/M E01 Electrical system
DW55KA Blade pitch back solenoid Disconnection T/M CALL E03 Electrical system
DW55KB Blade pitch back solenoid Short circuit T/M CALL E03 Electrical system
DW56KA Blade pitch dump solenoid Disconnection T/M CALL E03 Electrical system
DW56KB Blade pitch dump solenoid Short circuit T/M CALL E03 Electrical system
DW56KY Blade pitch dump solenoid Hot short T/M CALL E03 Electrical system Troubleshoot-
ing by failure
code (Display
DW57KA Left tilt limit solenoid Disconnection T/M E02 Electrical system
of code), Part 7
DW57KB Left tilt limit solenoid Short circuit T/M E02 Electrical system SEN01829-02
DW57KY Left tilt limit solenoid Hot short T/M E02 Electrical system
DW58KA Right tilt limit solenoid Disconnection T/M E02 Electrical system
DW58KB Right tilt limit solenoid Short circuit T/M E02 Electrical system
DW58KY Right tilt limit solenoid Hot short T/M E02 Electrical system
DW59KA Dual tilt selector solenoid Disconnection T/M E01 Electrical system
DW59KB Dual tilt selector solenoid Short circuit T/M E01 Electrical system
DW59KY Dual tilt selector solenoid Hot short T/M E01 Electrical system
DW5AKA Blade pitch selector solenoid Disconnection T/M E02 Electrical system
DW5AKB Blade pitch selector solenoid Short circuit T/M E02 Electrical system
DW5AKY Blade pitch selector solenoid Hot short T/M E02 Electrical system
Blade pitch dump solenoid
DW5DKA Disconnection T/M CALL E03 Electrical system
(Superdozer specification)
Blade pitch dump solenoid
DW5DKB Short circuit T/M CALL E03 Electrical system
(Superdozer specification)
Blade pitch dump solenoid
DW5DKY Hot short T/M CALL E03 Electrical system
(Superdozer specification)
DW7BKA Fan reverse solenoid Disconnection T/M E01 Electrical system
DW7BKB Fan reverse solenoid Short circuit T/M E01 Electrical system
DW7BKY Fan reverse solenoid Hot short T/M E01 Electrical system
D475A, D475ASD-5E0 9
SEN01821-04 40 Troubleshooting
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
DWJ0KA Pump merge-divider solenoid Disconnection S/T E02 Electrical system
DWJ0KB Pump merge-divider solenoid Short circuit S/T E02 Electrical system
DWJ0KY Pump merge-divider solenoid Hot short S/T E02 Electrical system
DWN3KA Sudden stop prevention solenoid Disconnection S/T CALL E04 Electrical system
DWN3KB Sudden stop prevention solenoid Short circuit S/T CALL E04 Electrical system
Troubleshoot-
DWN3KY Sudden stop prevention solenoid Hot short S/T CALL E04 Electrical system ing by failure
code (Display
of code), Part 7
DWN5KA Fan pump solenoid (1) Disconnection T/M E01 Electrical system
SEN01829-02
DWN5KB Fan pump solenoid (1) Short circuit T/M E01 Electrical system
DWN5KY Fan pump solenoid (1) Hot short T/M E02 Electrical system
DWNCKA Fan pump solenoid (2) Disconnection T/M E01 Electrical system
DWNCKB Fan pump solenoid (2) Short circuit T/M E01 Electrical system
DWNCKY Fan pump solenoid (2) Hot short T/M E02 Electrical system
DXH1KY Lockup solenoid Hot short T/M CALL E03 Electrical system
DXH4KA 1st clutch ECMV Disconnection T/M CALL E03 Electrical system
DXH4KB 1st clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH4KY 1st clutch ECMV Hot short T/M CALL E03 Electrical system
DXH5KA 2nd clutch ECMV Disconnection T/M CALL E03 Electrical system
DXH5KB 2nd clutch ECMV Short circuit T/M CALL E03 Electrical system Troubleshoot-
ing by failure
code (Display
DXH5KY 2nd clutch ECMV Hot short T/M CALL E03 Electrical system
of code), Part 8
DXH6KA 3rd clutch ECMV Disconnection T/M CALL E03 Electrical system SEN01830-01
DXH6KB 3rd clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH6KY 3rd clutch ECMV Hot short T/M CALL E03 Electrical system
DXH7KA Reverse clutch ECMV Disconnection T/M CALL E03 Electrical system
DXH7KB Reverse clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH7KY Reverse clutch ECMV Hot short T/M CALL E03 Electrical system
DXH8KA Forward clutch ECMV Disconnection T/M CALL E03 Electrical system
DXH8KB Forward clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH8KY Forward clutch ECMV Hot short T/M CALL E03 Electrical system
DXH9KA Right steering clutch ECMV Disconnection S/T CALL E03 Electrical system
DXH9KB Right steering clutch ECMV Short circuit S/T CALL E03 Electrical system
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-04
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
DXH9KY Right steering clutch ECMV Hot short S/T CALL E04 Electrical system
DXHAKA Left steering clutch ECMV Disconnection S/T CALL E03 Electrical system
DXHAKB Left steering clutch ECMV Short circuit S/T CALL E03 Electrical system
DXHAKY Left steering clutch ECMV Hot short S/T CALL E04 Electrical system
DXHBKA Right brake ECMV Disconnection S/T CALL E04 Electrical system
DXHBKB Right brake ECMV Short circuit S/T CALL E04 Electrical system
DXHBKY Right brake ECMV Hot short S/T CALL E04 Electrical system
DXHCKA Left brake ECMV Disconnection S/T CALL E04 Electrical system
DXHCKB Left brake ECMV Short circuit S/T CALL E04 Electrical system Troubleshoot-
ing by failure
code (Display
DXHCKY Left brake ECMV Hot short S/T CALL E04 Electrical system
of code), Part 8
F@BBZL Abnormality high pressure
Engine blow-by pressure sensor VHMS
[n3 o 38] occurrence SEN01830-01
F@BYNS Left front exhaust temperature sen- Exhaust temperature abnor-
VHMS
[n3 o 61] sor (1) mal rise
f@BYNS Left rear exhaust temperature sensor Exhaust temperature abnor-
VHMS
[n3 o 71] (1) mal rise
F@BZNS Right front exhaust temperature sen- Exhaust temperature abnor-
VHMS
[n3 o 81] sor (1) mal rise
f@BZNS Right rear exhaust temperature sen- Exhaust temperature abnor-
VHMS
[n3 o 91] sor (1) mal rise
F@BYNR Left front exhaust temperature sen- Exhaust temperature abnor-
VHMS
[n3 o 62] sor (2) mal rise
f@BYNR Left rear exhaust temperature sensor Exhaust temperature abnor-
VHMS
[n3 o 72] (2) mal rise
F@BZNR Right front exhaust temperature sen- Exhaust temperature abnor-
VHMS
[n3 o 82] sor (2) mal rise
f@BZNR Right rear exhaust temperature sen- Exhaust temperature abnor-
VHMS
[n3 o 92] sor (2) mal rise
a The items in this table are arranged in the order of the failure codes.
a A component in charge is a controller or the monitor panel in charge of the system check.
MON : Monitor panel
ENG : Engine controller
T/M : Transmission controller
S/T : Steering controller
VHMS : VHMS controller
a The failure codes having no numbers in the action code column are not displayed on the ordinary
screen when abnormality related to them occurs. They are simply recorded in the fault history of the
service menu (Electrical equipment system or mechanical equipment system).
a The history classification column shows in which system each failure is classified, the electrical equip-
ment system or mechanical equipment system, when it is recorded in the failure history.
Since the failure codes of VHMS are special to the VHMS specification and saved only in the VHMS
controller, however, they are not recorded in the fault history. The 4-letter codes in [ ] among the VHMS
codes are the failure codes displayed on the 7-segment LED of the VHMS controller (They are divided
into 2 2-letter codes).
a Blinking and lighting of failure code
q Blinking : The trouble has not been repaired.
q Lighting : The trouble has been repaired.
D475A, D475ASD-5E0 11
SEN01821-04 40 Troubleshooting
Fuse locations 1
Connection table of fuse boxes
a This connection table shows the devices to which each power supply of the fuse box supplies power (An
accessory power supply is a device which supplies power while the starting switch is in the ON position
and an unswitched power supply is a device which supplies power while the starting switch is in the OFF
and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-04
D475A, D475ASD-5E0 13
SEN01821-04 40 Troubleshooting
Circuit breaker
No Connector No. Capacity (A) Circuit Remarks
1 F30 30 Cab unswitched power supply
2 F96 105 Main power supply
Electrical intake air heater main power supply
3 B105H2L 105 Installed in battery box at
(Right bank)
left of operator's seat
4 B105H1L 105 Electrical intake air heater main power supply
6 B7L 30 Engine controller unswitched power supply
7 B8L 30 Engine controller unswitched power supply
8 CB1 20 Steering controller
9 CB2 20 Monitor panel
10 CB3 20 Transmission controller Installed in console box at
11 CB4 20 Air conditioner left of operator's seat
12 CB5 20 Headlamp
13 CB6 20 Starting switch unswitched power supply
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01821-04
D475A, D475ASD-5E0 15
SEN01821-04
2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
16
SEN01822-03
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
General information on troubleshooting
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
D475A, D475ASD-5E0 1
SEN01822-03 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a shortcut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 3
SEN01822-03 40 Troubleshooting
Judgement
Item Action
Value
1. Check fuel level Add fuel
2. Check for impurities in fuel Clean, drain
Checks before starting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code flashes when the trouble corresponding to it is detected. Even if a failure code
lights up when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of Phenomena looking like troubles and troubleshooting Nos., and then carry out trouble-
shooting related to that phenomenon in the E-mode, H-mode, or S-mode.
D475A, D475ASD-5E0 5
SEN01822-03 40 Troubleshooting
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
38 Ripper tilting speed or power is low H-17
39 Hydraulic drift of blade lifting is large H-18
40 Hydraulic drift of blade tilting is large H-19
41 Hydraulic drift of ripper lifting is large H-20
The ripper pin puller cylinder does not operate (if the giant ripper is
42 H-21
installed)
43 The blade does not pitch (if the dual tilt system installed) H-22
44 Abnormal sound comes out from around hydraulic pump H-23
Phenomena related to monitor panel (Operator mode: Ordinary screen)
When the starting switch is turned ON, no items are displayed on
45 E-4
monitor panel
When the starting switch is turned ON, all items are kept displayed on
46 E-5
monitor panel
47 When the starting switch is turned ON, the basic check items flash E-6
48 Caution items flash while the engine is running E-7
49 Emergency warning items flash while the engine is started E-8
When the preheater is operated, the preheater pilot lamp does not
50 E-9
light up
When the dual tilt is selected, the dual/single tilt selector lamp does
51 E-10
not light up (if the dual tilt system is equipped)
When the torque converter is locked up, the torque converter lockup
52 E-11
pilot lamp does not light up
53 Display of the engine coolant temperature gauge is abnormal E-12
54 Display of the power train oil temperature gauge is abnormal E-13
55 Display of the hydraulic oil temperature gauge is abnormal E-14
56 Display of the fuel level gauge is abnormal E-15
57 Display of the gear speed and engine speed is abnormal E-16
58 Display of the shift mode and service meter is abnormal E-17
59 The switch module cannot be operated E-18
60 The caution lamp does not flash or go off E-19
61 The caution buzzer does not sound or go off E-20
62 The auto shift-down system does not operate or reset E-21
63 The auto pitch-back system does not operate or reset E-22
64 The caution buzzer cannot be canceled E-23
65 The operator mode does not operate E-24
Phenomena related to monitor panel (Service mode: Special function screen)
66 The service mode does not operate E-25
Other phenomena
67 The backup alarm does not sound E-26
The night lamp of the panel, headlamp, working lamp, and rear lamp
68 E-27
do not light up
69 The air conditioner does not operate E-28
70 The ORBCOMM terminal does not operate normally E-29
71 Fan does not reverse E-30
72 Gear cannot be shifted E-31
73 Electric priming pump does not operate or does not stop E-32
D475A, D475ASD-5E0 7
SEN01822-03 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 9
SEN01822-03 40 Troubleshooting
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 11
SEN01822-03 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 13
SEN01822-03 40 Troubleshooting
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 15
SEN01822-03 40 Troubleshooting
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 17
SEN01822-03 40 Troubleshooting
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 19
SEN01822-03 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 21
SEN01822-03 40 Troubleshooting
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 23
SEN01822-03 40 Troubleshooting
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 25
SEN01822-03 40 Troubleshooting
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 27
SEN01822-03 40 Troubleshooting
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 29
SEN01822-03 40 Troubleshooting
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 31
SEN01822-03 40 Troubleshooting
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 33
SEN01822-03 40 Troubleshooting
34 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 35
SEN01822-03 40 Troubleshooting
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 37
SEN01822-03 40 Troubleshooting
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 39
SEN01822-03 40 Troubleshooting
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 41
SEN01822-03 40 Troubleshooting
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 43
SEN01822-03 40 Troubleshooting
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 45
SEN01822-03 40 Troubleshooting
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
D475A, D475ASD-5E0 47
SEN01822-03 40 Troubleshooting
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 q
795-799-5470 Cable for engine (HPI-T2) 3 q
795-799-5480 Cable for engine (HPI-T2) 3 q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1,2,3L q q
Commonrail pressure
Socket for engine (CRI-T3)
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
Socket for engine (CRI-T3)
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 q
799-601-4280* Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, q
DT2 4 and DTM2
4,
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01822-03
D475A, D475ASD-5E0 49
SEN01822-03
2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
50
SEN01823-03
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code, Part 1
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
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SEN01823-03 40 Troubleshooting
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
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
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Failure code [15SBL1] Reverse clutch: Command current OFF and fill
signal ON
Action code Failure code Symptom of Reverse clutch: Command current OFF and fill signal ON
CALL E03 15SBL1 failure (Transmission controller system)
Failure content The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.
Flashes caution lamp and turns on caution buzzer.
Controller's
Becomes neutral (N) at forward operation.
action
Limits operation of engine and transmission.
Symptoms that
Once machine is stopped, engine speed is limited to medium (half).
appear on
Once machine is stopped, running is limited to R1.
machine
The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
General
(Code 31520: Transmission fill switch input state)
information
Method of reproducing failure code: Engine start + Neutral running
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Failure code [15SEL1] 1st clutch oil pressure: Command current OFF
and fill signal ON
Action code Failure code Symptom of 1st clutch oil pressure: Command current OFF and fill signal ON
CALL E03 15SEL1 failure (Transmission controller system)
Failure content The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit.
Controller's Flashes caution lamp and turns on caution buzzer.
action Limits operation of engine and transmission.
Symptoms that
Once machine is stopped, engine speed is limited to medium (half).
appear on
Once machine is stopped, running is limited to F1 and R1.
machine
The input state (ON/OFF) from the level 1 clutch fill switch can be checked in monitoring mode.
General
(Code 31520: Transmission fill switch input state)
information
Method of reproducing failure code: Engine start + F1 or R1 o Neutral running
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Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF
and fill signal ON
Action code Failure code Symptom of 2nd clutch oil pressure: Command current OFF and fill signal ON
CALL E03 15SFL1 failure (Transmission controller system)
Failure content The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit.
Controller's Flashes caution lamp and turns on caution buzzer.
action Limits operation of engine and transmission.
Symptoms that
Once machine is stopped, engine speed is limited to medium (half).
appear on
Once machine is stopped, running is limited to F2 and R2.
machine
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
General
(Code 31520: Transmission fill switch input state)
information
Method of reproducing failure code: Engine start + F2 or R2 running o Neutral running
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40 Troubleshooting SEN01823-03
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Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF
and fill signal ON
Action code Failure code Symptom of 3rd clutch oil pressure: Command current OFF and fill signal ON
CALL E03 15SGL1 failure (Transmission controller system)
Failure content The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit.
Controller's Flashes caution lamp and turns on caution buzzer.
action Limits operation of engine and transmission.
Symptoms that
Once machine is stopped, engine speed is limited to medium (half).
appear on
Once machine is stopped, running is limited to F3 and R3.
machine
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
General
(Code 31520: Transmission fill switch input state)
information
Method of reproducing failure code: Engine start + F3 or R3 running o Neutral running
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Failure code [2201L1] Right clutch oil pressure: Command current OFF
and fill signal ON
Action code Failure code Symptom of Right clutch oil pressure: Command current OFF and fill signal OFF
CALL E04 2201L1 failure (Steering controller system)
Failure content The fill switch signal is not set off at output stop of the right steering clutch solenoid circuit.
Controller's Flashes caution lamp and turns on caution buzzer.
action Limits operation of engine, transmission, and brake.
Symptoms that
Once machine is stopped, engine speed is limited to medium (half).
appear on
Once machine is stopped, it never runs.
machine
The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring
General mode.
information (Code 31521: Steering fill switch input state)
Method of reproducing failure code: Engine start
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Failure code [2202L1] Left clutch oil pressure: Command current OFF
and fill signal ON
Action code Failure code Symptom of Left clutch oil pressure: Command current OFF and fill signal ON
CALL E04 2202L1 failure (Steering controller system)
Failure content The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit.
Controller's Flashes caution lamp and turns on caution buzzer.
action Limits operation of engine, transmission, and brake.
Symptoms that
Once machine is stopped, engine speed is limited to medium (half).
appear on
Once machine is stopped, it never runs.
machine
The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring
General
mode. (Code 31521: Steering fill switch input state)
information
Method of reproducing failure code: Engine start
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Possible Cause Standard values when normal and remarks for troubleshooting
causes and the 1 Improper braking during downslope travel (Machine traveled down with brake pedal pressed)
standard values Defective steering control-
when normal 2 When the operation in cause 1 is not performed
ler
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Failure code [2301L1] Right brake oil pressure: Command current OFF
and fill signal ON
Action code Failure code Symptom of Right brake oil pressure: Command current OFF and fill signal ON
CALL E04 2301L1 failure (Steering controller system)
Failure content The fill switch signal is not set off at output stop of the right steering brake solenoid circuit.
Controller's Flashes caution lamp and turns on caution buzzer.
action Limits operation of engine, transmission, and brake.
Symptoms that
Once machine is stopped, engine speed is limited to medium (half).
appear on
Once machine is stopped, it never runs.
machine
The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring
General mode.
information (Code 31521: Steering fill switch input state)
Method of reproducing failure code: Engine start
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Failure code [2302L1] Left brake oil pressure: Command current OFF
and fill signal ON
Action code Failure code Symptom of Left brake oil pressure: Command current OFF and fill signal ON
CALL E04 2302L1 failure (Steering controller system)
Failure content The fill switch signal is not set off at output stop of the left steering brake solenoid circuit.
Controller's Flashes caution lamp and turns on caution buzzer.
action Limits operation of engine, transmission, and brake.
Symptoms that
Once machine is stopped, engine speed is limited to medium (half).
appear on
Once machine is stopped, it never runs.
machine
The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring
General
mode. (Code 31521: Steering fill switch input state)
information
Method of reproducing failure code: Engine start
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Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure
Action code Failure code Symptom of HSS charge oil pressure: Low oil pressure
B@CHZG failure (Mechanical system)
Failure content HSS charge oil pressure is reduced and HSS charge oil pressure caution lamp lights up.
Controller's
None in particular.
action
Symptoms that
appear on None in particular.
machine
General Since above caution lamp is not set on this machine, above failure code not occur. Above failure
information code is listed up in mechanical system failure code table, however.
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D475A, D475ASD-5E0 41
SEN01823-03
2015 KOMATSU
All Rights Reserved
Printed in Japan 06-15 (02)
42
SEN01824-01
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code, Part 2
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
D475A, D475ASD-5E0 1
SEN01824-01 40 Troubleshooting
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
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
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Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At
left bank): Abnormal speed sensor signal
Action code Failure code Symptom of Abnormal engine Ne and Bkup speed sensors (At left bank): Abnor-
CALL E04 CA115 failure mal speed sensor signal (Engine controller system)
Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
Failure content
cuit.
Controller's
Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
Engine does not start (during engine stop).
appear on
Engine stops (during engine running).
machine
General
information
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Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At
right bank): Abnormal speed sensor signal
Action code Failure code Symptom of Abnormal engine Ne and Bkup speed sensors (At right bank): Abnor-
CALL E04 CB115 failure mal speed sensor signal (Engine controller system)
Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
Failure content
cuit.
Controller's
Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
Engine does not start (during engine stop).
appear on
Engine stops (during engine running).
machine
General
information
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SEN01824-01 40 Troubleshooting
Failure code [CA122] Charge pressure sensor too high (At left bank
only): Excessively high voltage detected
Action code Failure code Symptom of Charge pressure sensor too high (At left bank only): Excessively high
CALL E03 CA122 failure voltage detected (Engine controller system)
Failure content Excessively high voltage is detected at circuit of charge pressure (boost pressure) sensor.
Controller's Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Acceleration performance of engine deteriorates.
machine
The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
General
function. (Code: 36501 Boost pressure sensor voltage)
information
Duplication of failure code: turn ON the starting switch.
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Failure code [CA123] Charge pressure sensor too low (At left bank
only): Excessively low voltage detected
Action code Failure code Symptom of Charge pressure sensor too low (At left bank only): Excessively low
CALL E03 CA123 failure voltage detected (Engine controller system)
Failure content Excessively low voltage is detected at circuit of charge pressure (boost pressure) sensor.
Controller's Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Acceleration performance of engine deteriorates.
machine
The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
General
function. (Code: 36501 Boost pressure sensor voltage)
information
Duplication of failure code: turn ON the starting switch.
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
Defective sensor power If failure code [CA187] is displayed at the same time, carry out trou-
standard values 1
source circuit bleshooting for it first.
when normal
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Failure code [CA132] Decelerator pedal sensor too low (At left bank
only): Excessively low voltage detected
Action code Failure code Symptom of Decelerator pedal sensor too low: excessively low voltage detected
CALL E03 CA132 failure (At left bank only) (Engine controller system)
Failure content Excessively low voltage is detected at signal circuit of decelerator pedal.
Operates with the fixed value that is same as the value just before the abnormality is detected, if
abnormality occurs with the starting switch in the ON position.
Controller's
If the starting switch is turned to the ON position in as-is abnormal condition, the controller oper-
action
ates with 100% value.
Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Engine speed cannot be controlled by decelerator pedal.
machine
The signal voltage of decelerator pedal can be checked in monitoring mode.
General
(Code: 31703 Decelerator voltage)
information
Duplication of failure code: turn ON the starting switch.
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the Defective decelerator
If failure code [CA2186] is displayed at the same time, carry out trou-
standard values 1 pedal sensor power sup-
when normal bleshooting for it first.
ply circuit
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Failure code [CA135] Oil pressure sensor too high (At left bank only):
Excessively high voltage detected
Action code Failure code Symptom of Oil pressure sensor too high (At left bank only): Excessively high volt-
CALL E02 CA135 failure age detected (Engine controller system)
Failure content Excessively high voltage is detected at oil pressure sensor circuit.
Controller's Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on
machine
The signal voltage of engine oil pressure sensor can be checked in monitoring function.
General
(Code: 37201 Engine oil pressure sensor voltage)
information
Duplication of failure code: turn ON the starting switch.
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 17
SEN01824-01 40 Troubleshooting
Failure code [CA141] Oil pressure sensor too low (At left bank only):
Excessively low voltage detected
Action code Failure code Symptom of Oil pressure sensor too low (At left bank only): Excessively low volt-
CALL E03 CA132 failure age detected (At left bank only) (Engine controller system)
Failure content Excessively low voltage is detected at oil pressure sensor circuit.
Controller's Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on
machine
The signal voltage of engine oil pressure sensor can be checked in monitoring function.
General
(Code: 37201 Engine oil pressure sensor voltage)
information
Duplication of failure code: turn ON the starting switch.
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
Defective sensor power If failure code [CA187] is displayed at the same time, carry out trou-
standard values 1
source circuit bleshooting for it first.
when normal
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 19
SEN01824-01 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 21
SEN01824-01 40 Troubleshooting
Failure code [CA145] Coolant temperature sensor too low (At left bank
only): Excessively low voltage detected
Action code Failure code Symptom of Coolant temperature sensor too low (At left bank only): Excessively
E01 CA145 failure low voltage detected (Engine controller system)
Failure content Excessively low voltage is detected at signal circuit of coolant temperature sensor.
Controller's Operates with a fixed coolant temperature (90C).
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Exhaust gas color becomes white.
machine
General The signal voltage of coolant temperature sensor can be checked in monitoring function.
information (Code: 04105 Coolant temperature sensor voltage)
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 23
SEN01824-01 40 Troubleshooting
Failure code [CA153] Charge temperature sensor too high (At left bank
only): Excessively high voltage detected
Action code Failure code Symptom of Charge temperature sensor too high (At left bank only): Excessively
E01 CA153 failure high voltage detected. (Engine controller system)
Excessively high voltage is detected at signal circuit of charge temperature (boost temperature)
Failure content
sensor.
Controller's
Operates with a fixed charge temperature (boost temperature) (70C).
action
Symptoms that
appear on Exhaust gas color becomes white.
machine
The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
General
monitoring function. (Code: 18501 Boost temperature sensor voltage)
information
Duplication of failure code: turn ON the starting switch.
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 25
SEN01824-01 40 Troubleshooting
Failure code [CA154] Charge temperature sensor too low (At left bank
only): Excessively low voltage detected
Action code Failure code Symptom of Charge temperature sensor too low (At left bank only): Excessively
E01 CA154 failure low voltage detected (Engine controller system)
Excessively low voltage is detected at signal circuit of charge temperature (boost temperature)
Failure content
sensor.
Controller's
Operates with a fixed charge temperature (boost temperature) (70C).
action
Symptoms that
appear on Exhaust gas color becomes white.
machine
The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
General
monitoring function. (Code: 18501 Boost temperature sensor voltage)
information
Duplication of failure code: turn ON the starting switch.
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 27
SEN01824-01 40 Troubleshooting
Failure code [CA187] Sensor power supply (2) abnormally low level
(Left bank): Low voltage detection
Action code Failure code Symptom of Sensor power supply (2) abnormally low level (Left bank): Low voltage
CALL E03 CA187 failure detection (Engine controller system)
Failure content Low voltage was detected in sensor power supply (2) (5 V) circuit.
Ambient pressure sensor sets ambient temperature to default value (52.44 kPa {0.5 kg/cm2}) and
continues operation.
Oil pressure sensor sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues opera-
Controller's
tion.
action
Charge pressure sensor fixes charge pressure to (400 kPa {4.1 kg/cm2}) and continues operation.
Bkup sensor operates with Ne speed sensor signal.
Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA227].
when normal
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
Failure code [CB187] Sensor power supply (2) abnormally low level
(Right bank): Low voltage detection
Action code Failure code Symptom of Sensor power supply (2) abnormally low level (Right bank): Low volt-
CALL E03 CA187 failure age detection (Engine controller system)
Failure content Low voltage was detected in sensor power supply (2) (5 V) circuit.
Controller's Bkup sensor operates with Ne speed sensor signal.
action Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB227].
when normal
D475A, D475ASD-5E0 29
SEN01824-01 40 Troubleshooting
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA212].
when normal
D475A, D475ASD-5E0 31
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Failure code [CA221] Atmospheric pressure sensor too high (At left
bank only): Excessively high voltage detected
Action code Failure code Symptom of Atmospheric pressure sensor too high (At left bank only): Excessively
CALL E03 CA213 failure high voltage detected (Engine controller system)
Failure content Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
Controller's Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Output decreases.
machine
The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
General
(Code: 37401 Atmospheric pressure sensor voltage)
information
Duplication of failure code: turn ON the starting switch.
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 33
SEN01824-01 40 Troubleshooting
Failure code [CA222] Atmospheric pressure sensor too low (At left bank
only): Excessively low voltage detected
Action code Failure code Symptom of Atmospheric pressure sensor too low (At left bank only): Excessively
CALL E03 CA222 failure low voltage detected (Engine controller system)
Failure content Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
Controller's Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Output decreases.
machine
The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
General
(Code: 37401 Atmospheric pressure sensor voltage)
information
Duplication of failure code: turn ON the starting switch.
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting of failure code [CA221].
when normal
34 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 35
SEN01824-01 40 Troubleshooting
Failure code [CA227] Sensor power source (2) too high (At left bank):
Excessively high voltage detected
Action code Failure code Symptom of Sensor power source (2) too high (At left bank): Excessively high volt-
CALL E03 CA227 failure age detected (Engine controller system)
Failure content Excessively high voltage is detected in sensor power source (2) (5V) circuit.
Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm2})
Controller's
Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2})
action
Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}).
Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Output decreases.
machine
General
information
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 37
SEN01824-01 40 Troubleshooting
Failure code [CB227] Sensor power supply (2) abnormally high level
(Right bank): High voltage detection
Action code Failure code Symptom of Sensor power supply (2) abnormally high level (Right bank): High volt-
CALL E03 CB227 failure age detection (Engine controller system)
Failure content High voltage was detected in sensor power supply (2) (5 V) circuit.
Controller's
Bkup speed sensor operates with Ne speed sensor signal.
action
Symptoms that
appear on Output lowers.
machine
General
information
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
Circuit diagram related to sensor power source (2) (At right bank)
D475A, D475ASD-5E0 39
SEN01824-01 40 Troubleshooting
Failure code [CA234] Engine over speed (At left bank only): Excessively
high speed
Action code Failure code Symptom of Engine over speed (At left bank only): Excessively high speed
CA234 failure (Engine controller system)
The engine speed exceeds upper control limit speed.
Failure content
Flashes warning lamp and turns on alarm buzzer.
Controller's
Stops operation of injector until the engine speed drops to the normal speed.
action
Symptoms that
appear on Engine speed fluctuates.
machine
The engine speed can be checked in monitoring function.
General
(Code: 01000 Engine speed)
information
Duplication of failure code: Start engine and operate at high idle.
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 41
SEN01824-01 40 Troubleshooting
Failure code [CA238] Abnormal power source for Ne speed sensor (At
left bank only): Excessively low voltage detected
Action code Failure code Symptom of Abnormal power source for Ne speed sensor (At left bank only):
CALL E03 CA238 failure Excessively low voltage detected (Engine controller system)
Failure content Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controller's Controls using Bkup speed sensor signal.
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 43
SEN01824-01 40 Troubleshooting
Failure code [CB238] Abnormal power source for Ne speed sensor (At
right bank only): Excessively low voltage detected
Action code Failure code Symptom of Abnormal power source for Ne speed sensor (At right bank only):
CALL E03 CB238 failure Excessively low voltage detected (Engine controller system)
Failure content Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controller's Controls using Bkup speed sensor signal.
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 45
SEN01824-01 40 Troubleshooting
Failure code [CA263] Fuel temperature sensor too high (At left bank):
Excessively high voltage detected
Action code Failure code Symptom of Fuel temperature sensor too high (At left bank): Excessively high volt-
E01 CA263 failure age detected (Engine controller system)
Failure content Excessively high voltage is detected at fuel temperature sensor circuit.
Controller's
Operates with a fixed fuel temperature (95C).
action
Symptoms that
appear on
machine
General The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
information (Code: 14201 Engine fuel temperature sensor voltage)
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 47
SEN01824-01 40 Troubleshooting
Failure code [CB263] Fuel temperature sensor too high (At right bank):
Excessively high voltage detected
Action code Failure code Symptom of Fuel temperature sensor too high (At right bank): Excessively high
E01 CB263 failure voltage detected (Engine controller system)
Failure content Excessively high voltage is detected at fuel temperature sensor circuit.
Controller's
Operates with a fixed fuel temperature (95C).
action
Symptoms that
appear on
machine
General The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
information (Code: 14201 Engine fuel temperature sensor voltage)
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA263].
when normal
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB263].
when normal
D475A, D475ASD-5E0 49
SEN01824-01 40 Troubleshooting
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit
Action code Failure code Symptom of PCV1 short circuit (Left bank): Short circuit
CALL E03 CA271 failure (Engine controller system)
Failure content Short circuit occurred in supply pump PCV1 circuit.
Controller's
Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
appear on
machine
General While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse
information voltage cannot be measured with circuit tester.
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit
Action code Failure code Symptom of PCV1 short circuit (Right bank): Short circuit
CALL E03 CB271 failure (Engine controller system)
Failure content Short circuit occurred in supply pump PCV1 circuit.
Controller's
Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
appear on
machine
General While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse
information voltage cannot be measured with circuit tester.
D475A, D475ASD-5E0 51
SEN01824-01 40 Troubleshooting
52 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 53
SEN01824-01 40 Troubleshooting
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit
Action code Failure code Symptom of PCV2 short circuit (Left bank): Short circuit
CALL E03 CA273 failure (Engine controller system)
Failure content Short circuit occurred in supply pump PCV2 circuit.
Controller's
Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
appear on
machine
General While engine is running normally, pulse voltage of about 24 V is applied to PCV2 (1). This pulse
information voltage cannot be measured with circuit tester.
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit
Action code Failure code Symptom of PCV2 short circuit (Right bank): Short circuit
CALL E03 CB273 failure (Engine controller system)
Failure content Short circuit occurred in supply pump PCV2 circuit.
Controller's
Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
appear on
machine
General While engine is running normally, pulse voltage of about 24 V is applied to PCV2 (1). This pulse
information voltage cannot be measured with circuit tester.
D475A, D475ASD-5E0 55
SEN01824-01 40 Troubleshooting
56 D475A, D475ASD-5E0
40 Troubleshooting SEN01824-01
D475A, D475ASD-5E0 57
SEN01824-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 08-07 (01)
58
SEN01825-03
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code, Part 3
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
D475A, D475ASD-5E0 1
SEN01825-03 40 Troubleshooting
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
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
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 3
SEN01825-03 40 Troubleshooting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 5
SEN01825-03 40 Troubleshooting
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 7
SEN01825-03 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 9
SEN01825-03 40 Troubleshooting
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 11
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12 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 13
SEN01825-03 40 Troubleshooting
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 15
SEN01825-03 40 Troubleshooting
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA111].
when normal
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB111].
when normal
D475A, D475ASD-5E0 17
SEN01825-03 40 Troubleshooting
Failure code [CA351] Abnormal injector drive circuit (At left bank):
Abnormal circuit
Action code Failure code Symptom of Abnormal injector drive circuit (At left bank): Abnormal circuit
CALL E03 CA351 failure (Engine controller system)
Failure content Abnormality has occurred in injector drive circuit.
Controller's Operates with limited output. (Limits common rail pressure.)
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Output decreases.
machine
General
information
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 19
SEN01825-03 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 21
SEN01825-03 40 Troubleshooting
Failure code [CA352] Sensor power supply (1) abnormally low level
(Left bank): Low voltage detection
Action code Failure code Symptom of Sensor power supply (1) abnormally low level (Left bank): Low volt-
CALL E03 CA352 failure age detection (Engine controller system)
Failure content Low voltage was detected in sensor power supply (1) (5 V) circuit.
Controller's Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
action Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA386].
when normal
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
Failure code [CB352] Sensor power supply (1) abnormally low level
(Right bank): Low voltage detection
Action code Failure code Sensor power supply (1) abnormally low level (Right bank): Low volt-
Symptom of
age detection
CALL E03 CB352 failure
(Engine controller system)
Failure content Low voltage was detected in sensor power supply (1) (5 V) circuit.
Controller's Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
action Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB386].
when normal
D475A, D475ASD-5E0 23
SEN01825-03 40 Troubleshooting
Failure code [CA386] Sensor power supply (1) abnormally high level
(Left bank): High voltage detection
Action code Failure code Symptom of Sensor power supply (1) abnormally high level (Left bank): High volt-
CALL E03 CA386 failure age detection (Engine controller system)
Failure content High voltage was detected in sensor power supply (1) (5 V) circuit.
Controller's Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
action Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on Output lowers.
machine
General
information
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 25
SEN01825-03 40 Troubleshooting
Failure code [CB386] Sensor power supply (1) abnormally high level
(Right bank): High voltage detection
Action code Failure code Sensor power supply (1) abnormally high level (Right bank): High
Symptom of
voltage detection
CALL E03 CB386 failure
(Engine controller system)
Failure content High voltage was detected in sensor power supply (1) (5 V) circuit.
Controller's Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
action Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on Output lowers.
machine
General
information
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 27
SEN01825-03 40 Troubleshooting
Failure code [CA441] Power supply voltage abnormally low level (Left
bank): Low voltage detection
Action code Failure code Symptom of Power supply voltage abnormally low level (Left bank): Low voltage
CALL E04 CA441 failure detection (Engine controller system)
Failure content Low voltage was detected in power supply voltage circuit.
Controller's
Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
Machine continues operation normally but may stop suddenly or may not able to start again once
appear on
it stops.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA111].
when normal
Failure code [CB441] Power supply voltage abnormally low level (Right
bank): Low voltage detection
Action code Failure code Symptom of Power supply voltage abnormally low level (Right bank): Low voltage
CALL E04 CB441 failure detection (Engine controller system)
Failure content Low voltage was detected in power supply voltage circuit.
Controller's
Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
Machine continues operation normally but may stop suddenly or may not able to start again once
appear on
it stops.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB111].
when normal
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
Failure code [CA442] Power supply voltage abnormally high level (Left
bank): High voltage detection
Action code Failure code Symptom of Power supply voltage abnormally high level (Left bank): High voltage
CALL E04 CA442 failure detection (Engine controller system)
Failure content High voltage was detected in power supply voltage circuit.
Controller's
Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
Machine continues operation normally but may stop suddenly or may not able to start again once
appear on
it stops.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA111].
when normal
Failure code [CB442] Power supply voltage abnormally high level (Right
bank): High voltage detection
Action code Failure code Symptom of Power supply voltage abnormally high level (Right bank): High volt-
CALL E04 CB442 failure age detection (Engine controller system)
Failure content High voltage was detected in power supply voltage circuit.
Controller's
Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
Machine continues operation normally but may stop suddenly or may not able to start again once
appear on
it stops.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB111].
when normal
D475A, D475ASD-5E0 29
SEN01825-03 40 Troubleshooting
Failure code [CA449] Common rail abnormally high pressure (2) (Left
bank): Abnormally high pressure occurrence
Action code Failure code Symptom of Common rail abnormally high pressure (2) (Left bank): Abnormally
CALL E03 CA449 failure high pressure occurrence (Engine controller system)
Failure content Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
Controller's Limits output and continues operation (Limits common rail pressure).
action Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA2249].
when normal
Failure code [CB449] Common rail abnormally high pressure (2) (Right
bank): Abnormally high pressure occurrence
Action code Failure code Symptom of Common rail abnormally high pressure (2) (Right bank): Abnormally
CALL E03 CB449 failure high pressure occurrence (Engine controller system)
Failure content Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
Controller's Limits output and continues operation (Limits common rail pressure).
action Blinks warning lamp and sounds alarm buzzer.
Symptoms that
appear on Output lowers.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA2249].
when normal
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 31
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Failure code [CA451] Common rail pressure sensor too high (At left
bank): Excessively high voltage detected
Action code Failure code Symptom of Common rail pressure sensor too high (At left bank): Excessively
CALL E03 CA451 failure high voltage detected (Engine controller system)
Failure content Excessively high voltage has occurred in the common rail pressure sensor circuit.
Controller's Operates with limited output.(Limits common rail pressure.)
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Output decreases.
machine
General The signal voltage of the common rail pressure sensor can be checked with the monitoring func-
information tion. (Code: 36401 Common rail pressure sensor voltage)
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40 Troubleshooting SEN01825-03
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34 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 35
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Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA451].
when normal
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CB451].
when normal
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
Failure code [CA553] Common rail pressure too high (1) (At left bank):
Excessively high pressure detected
Action code Failure code Symptom of Common rail pressure high trouble (1) (At left bank): Excessively
CALL E03 CA553 failure high pressure trouble occurred (Engine controller system)
Failure content Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
Controller's
Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
appear on Output decreases.
machine
General Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)
D475A, D475ASD-5E0 37
SEN01825-03 40 Troubleshooting
Failure code [CB553] Common rail pressure too high (1) (At right bank):
Excessively high pressure detected
Action code Failure code Symptom of Common rail pressure high trouble (1) (At right bank): Excessively
CALL E03 CB553 failure high pressure trouble occurred (Engine controller system)
Failure content Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
Controller's
Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
appear on Output decreases.
machine
General Common rail pressure can be checked with the monitoring function.
information (Code: 36403 Common rail pressure)
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40 Troubleshooting SEN01825-03
Failure code [CA554] In-range error in common rail pressure sensor (At
left bank): In-range error
Action code Failure code Symptom of In-range error in common rail pressure sensor (At left bank): In-
CALL E03 CA554 failure range error occurred (Engine controller system)
Failure content In-range error has occurred in common rail pressure sensor circuit.
Controller's Operates with limited output.(Limits common rail pressure.)
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Output decreases.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting of [CA451].
when normal
Failure code [CB554] In-range error in common rail pressure sensor (At
right bank): In-range error
Action code Failure code Symptom of In-range error in common rail pressure sensor (At right bank): In-
CALL E03 CB554 failure range error occurred (Engine controller system)
Failure content In-range error has occurred in common rail pressure sensor circuit.
Controller's Operates with limited output.(Limits common rail pressure.)
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Output decreases.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting of [CB451].
when normal
D475A, D475ASD-5E0 39
SEN01825-03 40 Troubleshooting
Failure code [CA559] Loss of pressure feed from supply pump (1) (At
left bank): Loss of pressure feed detected
Action code Failure code Symptom of Loss of pressure feed from supply pump (1) (At left bank): Loss of
E02 CA559 failure pressure feed detected (Engine controller system)
Failure content Loss of pressure feed (level 1) from supply pump has occurred.
Controller's Limits common rail pressure.
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Output decreases.
machine
General
information
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D475A, D475ASD-5E0 41
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B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 600 700
*1 Engine speed High idle rpm 2,100 2,200
Equivalent to rating rpm 2,000
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3
tion rate
Command for common
*4 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
*5 Equivalent to rating MPa
common rail
Low idle CA
Command for
*6 High idle CA
fuel injection timing
Equivalent to rating CA
*7 Boost pressure Equivalent to rating kPa
Coolant temperature
*8 Low idle C
(high temperature)
Coolant temperature
*9 Low idle C
(low temperature)
*10 Fuel temperature Low idle C
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
Cylinder No. 1 Low idle rpm
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa 0.15 0.3
6
cuit lent to rating (stalling) {kg/cm2} {1.5 3.0}
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40 Troubleshooting SEN01825-03
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Failure code [CA559] Loss of pressure feed from supply pump (1) (At
left bank): Loss of pressure feed detected (Low-grade fuel specification)
Action code Failure code Loss of pressure feed from supply pump (1) (At left bank): Loss of
Symptom of
pressure feed detected (Low-grade fuel specification)
E02 CA559 failure
(Engine controller system)
Failure content Loss of pressure feed (level 1) from supply pump has occurred.
Controller's
Limits common rail pressure.
action
Symptoms that
Output decreases.
appear on
Flashes warning lamp and turns on alarm buzzer.
machine
General
information
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40 Troubleshooting SEN01825-03
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
D475A, D475ASD-5E0 45
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B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 600 700
*1 Engine speed High idle rpm 2,100 2,200
Equivalent to rating rpm 2,000
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3
tion rate
Command for common
*4 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
*5 Equivalent to rating MPa
common rail
Low idle CA
Command for
*6 High idle CA
fuel injection timing
Equivalent to rating CA
*7 Boost pressure Equivalent to rating kPa
Coolant temperature
*8 Low idle C
(high temperature)
Coolant temperature
*9 Low idle C
(low temperature)
*10 Fuel temperature Low idle C
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
Cylinder No. 1 Low idle rpm
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa 0.15 0.3
6
cuit lent to rating (stalling) {kg/cm2} {1.5 3.0}
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40 Troubleshooting SEN01825-03
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Failure code [CB559] Loss of pressure feed from supply pump (1) (At
right bank): Loss of pressure feed detected
Action code Failure code Symptom of Loss of pressure feed from supply pump (1) (At right bank): Loss of
E02 CB559 failure pressure feed detected (Engine controller system)
Failure content Loss of pressure feed (level 1) from supply pump has occurred.
Controller's
Limits common rail pressure.
action
Symptoms that
Output decreases.
appear on
Flashes warning lamp and turns on alarm buzzer.
machine
General
information
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D475A, D475ASD-5E0 49
SEN01825-03 40 Troubleshooting
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 600 700
*1 Engine speed High idle rpm 2,100 2,200
Equivalent to rating rpm 2,000
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3
tion rate
Command for common
*4 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
*5 Equivalent to rating MPa
common rail
Low idle CA
Command for
*6 High idle CA
fuel injection timing
Equivalent to rating CA
*7 Boost pressure Equivalent to rating kPa
Coolant temperature
*8 Low idle C
(high temperature)
Coolant temperature
*9 Low idle C
(low temperature)
*10 Fuel temperature Low idle C
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
Cylinder No. 1 Low idle rpm
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa 0.15 0.3
6
cuit lent to rating (stalling) {kg/cm2} {1.5 3.0}
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40 Troubleshooting SEN01825-03
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SEN01825-03 40 Troubleshooting
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank):
Abnormal signal
Action code Failure code Symptom of Abnormal engine Ne speed sensor (At left bank): Abnormal signal
CALL E03 CA689 failure (Engine controller system)
Failure content Abnormal signal of the engine Ne speed sensor has been detected.
Controller's Operates using Bkup speed sensor signal.
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information
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40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 53
SEN01825-03 40 Troubleshooting
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank):
Abnormal signal
Action code Failure code Symptom of Abnormal engine Ne speed sensor (At right bank): Abnormal signal
CALL E03 CB689 failure (Engine controller system)
Failure content Abnormal signal of the engine Ne speed sensor has been detected.
Controller's Operates using Bkup speed sensor signal.
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
D475A, D475ASD-5E0 55
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Failure code [CA692] Intake air temperature sensor abnormally low level
(Only left bank): Low voltage detection
Action code Failure code Symptom of Intake air temperature sensor abnormally low level (Only left bank):
E01 CA692 failure Low voltage detection (Engine controller system)
Failure content Intake air temperature sensor circuit detected low voltage.
Controller's
Fixes intake air temperature (25C) and continues operation.
action
Symptoms that
appear on
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA691].
when normal
58 D475A, D475ASD-5E0
40 Troubleshooting SEN01825-03
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At
left bank): Abnormal phase
Action code Failure code Symptom of Abnormal engine Bkup speed sensor phase (At left bank): Abnormal
CALL E03 CA731 failure phase (Engine controller system)
Failure content Abnormal phase has been detected in the engine Bkup sensor circuit.
Controller's Operates using engine Ne speed sensor signal.
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
Engine stops during operation (when Ne speed sensor is defective at the same time).
appear on
Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
General
information
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At
right bank): Abnormal phase
Action code Failure code Symptom of Abnormal engine Bkup speed sensor phase (At right bank): Abnor-
CALL E03 CB731 failure mal phase (Engine controller system)
Failure content Abnormal phase has been detected in the engine Bkup sensor circuit.
Controller's Operates using engine Ne speed sensor signal.
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
Engine stops during operation (when Ne speed sensor is defective at the same time).
appear on
Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
General
information
D475A, D475ASD-5E0 59
SEN01825-03
2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
60
SEN01826-01
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code, Part 4
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
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SEN01826-01 40 Troubleshooting
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
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
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40 Troubleshooting SEN01826-01
Failure code [CA757] Loss of all engine controller data (At left bank):
Loss of all data 1
Action code Failure code Symptom of Loss of all engine controller data (At left bank): Loss of all data
CALL E04 CA757 failure (Engine controller system)
Failure content Loss of all data in engine controller has been detected.
Controller's
Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
appear on The engine cannot be started, or cannot be operated.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting of [CA111].
when normal
Failure code [CB757] Loss of all engine controller data (At right bank):
Loss of all data 1
Action code Failure code Symptom of Loss of all engine controller data (At right bank): Loss of all data
CALL E04 CB757 failure (Engine controller system)
Failure content Loss of all data in engine controller has been detected.
Controller's
Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
appear on The engine cannot be started, or cannot be operated.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting of [CB111].
when normal
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Failure code [CA778] Abnormal engine Bkup speed sensor (At left
bank): Abnormal Bkup signal 1
Action code Failure code Symptom of Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup
CALL E03 CA778 failure signal (Engine controller system)
Failure content Abnormal engine Bkup speed sensor signal has been detected.
Controller's Operates using Ne speed sensor signal.
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that
Engine stops during operation (when Ne speed sensor is defective at the same time).
appear on
Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
General
information
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40 Troubleshooting SEN01826-01
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Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure code [CA781].
when normal
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24 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
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26 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
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28 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 29
SEN01826-01 40 Troubleshooting
Failure code [CA2186] Decelerator pedal sensor power source too low
(At left bank only): Excessively low voltage detected 1
Action code Failure code Symptom of Decelerator pedal sensor power source too low (At left bank only):
CALL E03 CA2186 failure Excessively low voltage detected (Engine controller system)
Failure content Excessively low voltage is detected in the decelerator pedal sensor (5V) power source circuit.
Operates with the fixed value that is same as the value just before the abnormality is detected, if
abnormality occurs with the starting switch in the ON position.
Controller's
If the starting switch is turned to the ON position in as-is abnormal condition, the controller oper-
action
ates with 100% value.
Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on Engine speed cannot be controlled by decelerator pedal.
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values 1 Carry out troubleshooting for failure code [CA2185].
when normal
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
Failure code [CA2249] Loss of pressure feed from supply pump (2) (At
left bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (2) (At left bank): Loss of
CALL E03 CA2249 failure pressure feed detected (Engine controller system)
Failure content Loss of pressure feed (level 2) occurred in the common rail circuit.
Controller's Operates with limited output.
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that Engine is hard to start.
appear on Exhaust gas color becomes black.
machine Output decreases.
General Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values 1 Carry out troubleshooting of [CA559].
when normal
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At
right bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (2) (At right bank): Loss of
CALL E03 CB2249 failure pressure feed detected (Engine controller system)
Failure content Loss of pressure feed (level 2) occurred in the common rail circuit.
Controller's Operates with limited output.
action Flashes warning lamp and turns on alarm buzzer.
Symptoms that Engine is hard to start.
appear on Exhaust gas color becomes black.
machine Output decreases.
General Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values 1 Carry out troubleshooting of [CB559].
when normal
D475A, D475ASD-5E0 31
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32 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
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34 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
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SEN01826-01 40 Troubleshooting
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
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SEN01826-01 40 Troubleshooting
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 39
SEN01826-01 40 Troubleshooting
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 41
SEN01826-01 40 Troubleshooting
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 43
SEN01826-01 40 Troubleshooting
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 45
SEN01826-01 40 Troubleshooting
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 47
SEN01826-01 40 Troubleshooting
Failure code [D190KB] Engine controller ACC signal cutout relay: Short
circuit 1
Action code Failure code Symptom of Engine controller ACC signal cutout relay: Short circuit
D190KA failure (Steering controller system)
Failure content When signal was output to engine controller ACC cut relay, abnormal current flowed.
Controller's
Stops outputting signal to engine controller ACC cut relay.
action
Symptoms that
appear on Engine stop function of steering controller does not work.
machine
Output state (voltage) to engine controller ACC cut relay can be checked in real-time monitoring
mode (Code 60500: Engine controller ACC cut relay voltage).
General
Method of reproducing failure code: Turn starting switch ON.
information
a This failure code detects abnormality on primary side (coil side) of engine controller ACC cut relay
but does not detect abnormality on secondary side (contact side).
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 49
SEN01826-01 40 Troubleshooting
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 51
SEN01826-01 40 Troubleshooting
52 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 53
SEN01826-01 40 Troubleshooting
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 55
SEN01826-01 40 Troubleshooting
56 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 57
SEN01826-01 40 Troubleshooting
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the Troubleshooting cannot be carried out since it is internal defect.
Defective transmission
standard values 1 (It is no problem even if you use controller unless no visible problem
when normal controller
appears on machine.)
58 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 59
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60 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
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62 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
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64 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
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66 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
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68 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
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SEN01826-01 40 Troubleshooting
70 D475A, D475ASD-5E0
40 Troubleshooting SEN01826-01
D475A, D475ASD-5E0 71
SEN01826-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 08-07 (01)
72
SEN01827-03
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code, Part 5
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
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
D475A, D475ASD-5E0 1
SEN01827-03 40 Troubleshooting
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
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 3
SEN01827-03 40 Troubleshooting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 5
SEN01827-03 40 Troubleshooting
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 7
SEN01827-03 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 9
SEN01827-03 40 Troubleshooting
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the Troubleshooting cannot be carried out since it is internal defect.
Defective steering
standard values 1 (It is no problem even if you use controller unless no visible problem
controller
when normal appears on machine.)
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 11
SEN01827-03 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 13
SEN01827-03 40 Troubleshooting
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 15
SEN01827-03 40 Troubleshooting
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 17
SEN01827-03 40 Troubleshooting
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 19
SEN01827-03 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 21
SEN01827-03 40 Troubleshooting
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
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SEN01827-03 40 Troubleshooting
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
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SEN01827-03 40 Troubleshooting
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
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SEN01827-03 40 Troubleshooting
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 29
SEN01827-03 40 Troubleshooting
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
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SEN01827-03 40 Troubleshooting
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
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SEN01827-03 40 Troubleshooting
34 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 35
SEN01827-03 40 Troubleshooting
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 37
SEN01827-03 40 Troubleshooting
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 39
SEN01827-03 40 Troubleshooting
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 41
SEN01827-03 40 Troubleshooting
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 43
SEN01827-03 40 Troubleshooting
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
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SEN01827-03 40 Troubleshooting
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Cause Standard values when normal and remarks for troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Parking brake lever switch Parking brake lever
1 NSW (male)
(Internal disconnection) Free position Lock position
Between (A) (B) Max. 1 z Min. 1 Mz
Possible
causes and the Between (A) (B) Min. 1 Mz Max. 1 z
standard values a Prepare with starting switch OFF, then carry out troubleshooting
when normal without turning starting switch ON.
Disconnection in wiring Wiring harness between NSW (female) (B) Resis-
Max. 1 z
harness (Disconnection in TMC1 (female) (18), STCN2 (female) (5) tance
2
wiring or defective contact Wiring harness between NSW (female) (C) Resis-
in connector) Max. 1 z
TMC1 (female) (12), STCN2 (female) (15) tance
Wiring harness between NSW (female) (A) Resis-
Max. 1 z
chassis ground tance
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Cause Standard values when normal and remarks for troubleshooting
a Prepare with starting switch OFF, turn starting switch ON and
carry out troubleshooting.
Possible
causes and the Short circuit of wiring harness between NSW
standard values Hot short in wiring harness (female) (B) TMC1 (female) (18), STCN2 Voltage Max. 1 V
3
when normal (Contact with 24 V circuit) (female) (5) with chassis ground
Short circuit of wiring harness between NSW
(female) (C) TMC1 (female) (12), STCN2 Voltage Max. 1 V
(female) (15) with chassis ground
D475A, D475ASD-5E0 47
SEN01827-03 40 Troubleshooting
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 49
SEN01827-03 40 Troubleshooting
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 51
SEN01827-03 40 Troubleshooting
52 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 53
SEN01827-03 40 Troubleshooting
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 55
SEN01827-03 40 Troubleshooting
56 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
D475A, D475ASD-5E0 57
SEN01827-03 40 Troubleshooting
Failure code [DDN2LD] (Blade tilt right oil pressure switch system:
Switch is ON for long time 1
Action code Failure code Symptom of Blade tilt right oil pressure switch system: Switch is ON for long time
E02 DDN2LD failure (Transmission controller system)
Failure content The signal of the blade tilt right oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's Flashes the caution lamp and turns on the caution buzzer.
action Recognizes that the oil pressure switch is turned OFF.
Symptoms that During right dual tilt operation, tilting is not limited.
appear on Blade tilt right operation becomes slow.
machine VHMS data is not always correct.
The input state (ON/OFF) from the blade tilt right oil pressure switch can be checked in the moni-
General toring mode. (Code 40908: Blade lever oil pressure switch input state)
information Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
58 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch
is ON for long time 1
Action code Failure code Symptom of Blade tilt left oil pressure switch system: Switch is ON for long time
E02 DDN3LD failure (Transmission controller system)
Failure content The signal of the blade tilt left oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's Flashes the caution lamp and turns on the caution buzzer.
action Recognizes that the oil pressure switch is turned OFF.
Symptoms that During left dual tilt operation, tilting is not limited.
appear on Blade tilt left operation becomes slow.
machine VHMS data is not always correct.
The input state (ON/OFF) from the blade tilt left oil pressure switch can be checked in the monitor-
General ing mode. (Code 40908: Blade lever oil pressure switch input state)
information Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
D475A, D475ASD-5E0 59
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60 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
Circuit diagram related to blade pitch switch and blade tilt switch
D475A, D475ASD-5E0 61
SEN01827-03 40 Troubleshooting
62 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0 63
SEN01827-03 40 Troubleshooting
64 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0 65
SEN01827-03 40 Troubleshooting
66 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0 67
SEN01827-03 40 Troubleshooting
Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch
is ON for long time 1
Action code Failure code Symptom of Blade lift raise full oil pressure switch: Switch is ON for long time
DDNALD failure (Transmission controller system)
Failure content The signal of the blade lift raise full oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that
The data of the VHMS may become abnormal.
appear on
Blade lift raise operation becomes slow.
machine
The input state (ON/OFF) from the blade lift raise full oil pressure switch can be checked in the
General monitoring mode. (Code 40908: Ripper lever oil pressure switch input signal)
information Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
Circuit diagram related to blade lift raise full oil pressure switch
68 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is
ON for long time 1
Action code Failure code Symptom of Ripper lift raise oil pressure switch: Switch is ON for long time
DDNBLD failure (Transmission controller system)
Failure content The signal of the ripper lift raise oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that The shoe slip control (SSC) function does not operate normally.
appear on Ripper lift raise operation becomes slow.
machine The data of the VHMS may become abnormal.
The input state (ON/OFF) from the ripper lift raise oil pressure switch can be checked in the moni-
General toring mode. (Code 70305: Steering controller input signal 3)
information Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
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Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is
ON for long time 1
Action code Failure code Symptom of Ripper lift lower oil pressure switch: Switch is ON for long time
DDNCLD failure (Transmission controller system)
Failure content The signal of the ripper lift lower oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that The shoe slip control (SSC) function does not operate normally.
appear on The data of the VHMS may become abnormal.
machine Ripper lift lower operation becomes slow.
The input state (ON/OFF) from the ripper lift lower oil pressure switch can be checked in the moni-
General toring mode. (Code 70305: Steering controller input signal 3)
information Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
70 D475A, D475ASD-5E0
40 Troubleshooting SEN01827-03
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SEN01827-03 40 Troubleshooting
Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is
ON for long time 1
Action code Failure code Symptom of Ripper tilt back oil pressure switch: Switch is ON for long time
DDNELD failure (Transmission controller system)
Failure content The signal of the ripper tilt back oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that The shoe slip control (SSC) function does not operate normally.
appear on The tilt back speed of the ripper lowers.
machine The data of the VHMS may become abnormal.
The input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked in the moni-
General toring mode. (Code 70305: Ripper lever oil pressure switch input signal)
information Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).
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40 Troubleshooting SEN01827-03
Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch
is ON for long time 1
Action code Failure code Symptom of Blade lift lower full pressure switch: Switch is ON for long time
DDNFLD failure (Transmission controller system)
Failure content The signal of the blade lift lower full oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that
The lift lower speed of the blade lowers.
appear on
The data of the VHMS may become abnormal.
machine
The input state (ON/OFF) from the blade lift lower full oil pressure switch can be checked in the mon-
General itoring mode. (Code 40908: Ripper lever oil pressure switch input signal)
information Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 180 sec-
onds).
Circuit diagram related to blade lift lower full oil pressure switch
D475A, D475ASD-5E0 73
SEN01827-03
2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
74
SEN01828-03
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code, Part 6
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
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
D475A, D475ASD-5E0 1
SEN01828-03 40 Troubleshooting
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
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 3
SEN01828-03 40 Troubleshooting
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time
Cause Standard values when normal and remarks for troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Parking brake lever Parking brake lever
1 switch NSW
Free position Lock position
(Internal disconnection)
Between (A) (B) Max. 1 z Min. 1 Mz
Possible
Between (A) (B) Min. 1 Mz Max. 1 z
causes and the
standard values a Prepare with starting switch OFF, then carry out troubleshooting
when normal without turning starting switch ON.
Disconnection in wiring Wiring harness between NSW (female) (B) Resis-
Max. 1 z
harness (Disconnection TMC1 (female) (18), STCN2 (female) (5) tance
2
in wiring or defective con- Wiring harness between NSW (female) (C) Resis-
tact in connector) Max. 1 z
TMC1 (female) (12), STCN2 (female) (15) tance
Wiring harness between NSW (female) (A) Resis-
Max. 1 z
chassis ground tance
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time
Cause Standard values when normal and remarks for troubleshooting
a Prepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Possible
causes and the Short circuit of wiring harness between NSW
Hot short in wiring har-
standard values (female) (B) TMC1 (female) (18) STCN2 Voltage Max. 1 V
3 ness (Contact with 24 V
when normal (female) (5) with chassis ground
circuit)
Short circuit of wiring harness between NSW
(female) (C) TMC1 (female) (12) STCN2 Voltage Max. 1 V
(female) (15) with chassis ground
D475A, D475ASD-5E0 5
SEN01828-03 40 Troubleshooting
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 7
SEN01828-03 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 9
SEN01828-03 40 Troubleshooting
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 11
SEN01828-03 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 13
SEN01828-03 40 Troubleshooting
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 15
SEN01828-03 40 Troubleshooting
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
Failure code [DGT1KX] Power train oil temperature sensor: Input signal
is out of normal range 1
Action code Failure code Symptom of Power train oil temperature sensor: Input signal out of range
E01 DGT1KX failure (Machine monitor system)
Failure content Power train temperature sensor signal is out of normal range.
Controller's
Nothing particular.
action
Symptoms that Power train oil temperature on machine monitor is not displayed properly.
appear on Fan speed is limited to half.
machine Gear shift shock of transmission is large.
Power train temperature state (temperature) can be checked in monitoring mode.
General
(Code 30100: Power train oil temperature)
information
Duplication of failure code: Turn starting switch ON or start engine.
D475A, D475ASD-5E0 17
SEN01828-03 40 Troubleshooting
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 19
SEN01828-03 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 21
SEN01828-03 40 Troubleshooting
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 23
SEN01828-03 40 Troubleshooting
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 25
SEN01828-03 40 Troubleshooting
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 27
SEN01828-03 40 Troubleshooting
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 29
SEN01828-03 40 Troubleshooting
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 31
SEN01828-03 40 Troubleshooting
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 33
SEN01828-03 40 Troubleshooting
Failure code [DH22KA] Work equipment pump oil pressure sensor (F):
Disconnection 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (F): Disconnection
DH22KA failure (Transmission controller system)
Failure content Signal voltage of work equipment pump oil pressure sensor (F) circuit is below 0.2 V.
Controller's
Recognizes hydraulic pump (F) oil pressure to be 0.
action
Symptoms that
appear on Work equipment pump (F) oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment pump oil pressure sensor (F) can be checked in monitoring
General
mode. (Code 70701: Voltage of work equipment pump oil sensor (F))
information
Method of reproducing failure code: Turn starting switch ON.
Circuit diagram related to work equipment pump oil pressure sensor (F)
34 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
Failure code [DH22KB] Work equipment pump oil pressure sensor (F):
Short circuit 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (F): Short circuit
DH22KB failure (Transmission controller system)
Failure content Signal voltage of work equipment pump oil pressure sensor (F) circuit is above 4.8 V
Controller's
Recognizes hydraulic pump (F) oil pressure to be 0.
action
Symptoms that
appear on Work equipment pump (F) oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment pump oil pressure sensor (F) can be checked in monitoring
General mode.
information (Code 70701: Voltage of work equipment pump oil pressure sensor (F))
Method of reproducing failure code: Turn starting switch ON.
Circuit diagram related to work equipment pump oil pressure sensor (F)
D475A, D475ASD-5E0 35
SEN01828-03 40 Troubleshooting
Failure code [DH23KA] Work equipment pump oil pressure sensor (R):
Disconnection 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (R): Disconnection
DH23KA failure (Transmission controller system)
Failure content Signal voltage of work equipment pump oil pressure sensor (R) circuit is below 0.2 V.
Controller's
Recognizes hydraulic pump (R) oil pressure to be 0.
action
Symptoms that
appear on Work equipment pump (R) oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment pump oil pressure sensor (R) can be checked in monitoring
General
mode. (Code 70703: Voltage of work equipment pump oil sensor (R))
information
Method of reproducing failure code: Turn starting switch ON.
Circuit diagram related to work equipment pump oil pressure sensor (R)
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
Failure code [DH23KB] Work equipment pump oil pressure sensor (R):
Short circuit 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (R): Short circuit
DH23KB failure (Transmission controller system)
Failure content Signal voltage of work equipment pump oil pressure sensor (R) circuit is above 4.8 V
Controller's
Recognizes hydraulic pump (R) oil pressure to be 0.
action
Symptoms that
appear on Work equipment pump (R) oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment pump oil pressure sensor (R) can be checked in monitoring
General mode.
information (Code 70703: Voltage of work equipment pump oil pressure sensor (R))
Method of reproducing failure code: Turn starting switch ON.
Circuit diagram related to work equipment pump oil pressure sensor (R)
D475A, D475ASD-5E0 37
SEN01828-03 40 Troubleshooting
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 39
SEN01828-03 40 Troubleshooting
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 41
SEN01828-03 40 Troubleshooting
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 43
SEN01828-03 40 Troubleshooting
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 45
SEN01828-03 40 Troubleshooting
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 47
SEN01828-03 40 Troubleshooting
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 49
SEN01828-03 40 Troubleshooting
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 51
SEN01828-03 40 Troubleshooting
Possible Causes Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
when normal
Possible Causes Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
when normal
52 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
Possible Causes Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
when normal
D475A, D475ASD-5E0 53
SEN01828-03 40 Troubleshooting
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 55
SEN01828-03 40 Troubleshooting
56 D475A, D475ASD-5E0
40 Troubleshooting SEN01828-03
D475A, D475ASD-5E0 57
SEN01828-03
2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
58
SEN01829-02
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 7
Failure code [DK40KA] Brake potentiometer: Disconnection ......................................................................... 3
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
D475A, D475ASD-5E0 1
SEN01829-02 40 Troubleshooting
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 3
SEN01829-02 40 Troubleshooting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
when normal
D475A, D475ASD-5E0 5
SEN01829-02 40 Troubleshooting
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
when normal
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
when normal
D475A, D475ASD-5E0 7
SEN01829-02 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 9
SEN01829-02 40 Troubleshooting
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 11
SEN01829-02 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 13
SEN01829-02 40 Troubleshooting
Action code Failure code Symptom of Forward-Reverse potentiometer (2): Short circuit
CALL E03 DK57KB failure (Transmission controller system)
Signal voltage of forward-reverse potentiometer (2) system (F) circuit is higher than specified
Failure content
value.
Blinks warning lamp and sounds alarm buzzer.
Controller's
Continues control with signal of forward-reverse potentiometer (1) system (R).
action
Limits operations of engine and transmission.
Symptoms that
Once machine is stopped, engine speed is limited to medium (half).
appear on
Once machine is stopped, gear speed is limited to F1 and R1.
machine
Input state (Voltage) from forward-reverse potentiometer (2) (F) can be checked in monitoring
General mode (Code 50201: Forward-Reverse potentiometer (2) voltage).
information Method of reproducing failure code: Turn starting switch ON (+ Operate PCCS lever (Forward and
reverse)).
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 15
SEN01829-02 40 Troubleshooting
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 17
SEN01829-02 40 Troubleshooting
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 19
SEN01829-02 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range 1
Action code Failure code Symptom of Pitch angle sensor: Out of input signal range
E01 DKH1KX failure (Steering controller system)
Either of pitch angle sensor errors [DKH1KA] and [DKH1KB] occurred or steering controller CAN
Failure content
communication error [DB3RKR] occurred.
Controller's
Cannot recognize pitch angle.
action
Symptoms that
appear on Gear speed is not changed automatically.
machine
Input state (Voltage) from pitch angle sensor can be checked in monitoring mode
General
(Code 60100: Pitch angle sensor voltage).
information
Method of reproducing failure code: Turn starting switch ON.
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
Carry out troubleshooting for disconnection [DKH1KA] and short circuit [DKH1KB] in pitch angle
standard values
sensor and steering controller CAN communication [DB3RKR].
when normal
D475A, D475ASD-5E0 21
SEN01829-02 40 Troubleshooting
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for disconnection [dLT3KA] and transmission CAN communication error
when normal [DAQRKR].
D475A, D475ASD-5E0 23
SEN01829-02 40 Troubleshooting
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 25
SEN01829-02 40 Troubleshooting
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 27
SEN01829-02 40 Troubleshooting
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 29
SEN01829-02 40 Troubleshooting
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 31
SEN01829-02 40 Troubleshooting
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 33
SEN01829-02 40 Troubleshooting
34 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 35
SEN01829-02 40 Troubleshooting
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 37
SEN01829-02 40 Troubleshooting
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 39
SEN01829-02 40 Troubleshooting
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 41
SEN01829-02 40 Troubleshooting
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 43
SEN01829-02 40 Troubleshooting
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 45
SEN01829-02 40 Troubleshooting
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 47
SEN01829-02 40 Troubleshooting
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 49
SEN01829-02 40 Troubleshooting
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 51
SEN01829-02 40 Troubleshooting
52 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 53
SEN01829-02 40 Troubleshooting
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 55
SEN01829-02 40 Troubleshooting
56 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 57
SEN01829-02 40 Troubleshooting
58 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 59
SEN01829-02 40 Troubleshooting
60 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 61
SEN01829-02 40 Troubleshooting
62 D475A, D475ASD-5E0
40 Troubleshooting SEN01829-02
D475A, D475ASD-5E0 63
SEN01829-02
2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
64
SEN01830-01
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 8
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
Failure code [DXH1KB] Lock-up solenoid: Short circuit.................................................................................. 7
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
D475A, D475ASD-5E0 1
SEN01830-01 40 Troubleshooting
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 3
SEN01830-01 40 Troubleshooting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 5
SEN01830-01 40 Troubleshooting
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 7
SEN01830-01 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 9
SEN01830-01 40 Troubleshooting
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 11
SEN01830-01 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 13
SEN01830-01 40 Troubleshooting
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28 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
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SEN01830-01 40 Troubleshooting
30 D475A, D475ASD-5E0
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32 D475A, D475ASD-5E0
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34 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
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SEN01830-01 40 Troubleshooting
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 37
SEN01830-01 40 Troubleshooting
Failure code [F@BYNS] (or VHMS_LED display "n3" o "61") Left front
exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure code Left front exhaust temperature sensor (1): Exhaust temperature
Symptom of
abnormal rise
F@BYNS failure
(VHMS controller system)
Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Failure content perature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700C
in range above rated output speed and 750C in range below maximum torque speed)
Controller's
None in particular.
action
Symptoms that
appear on If machine is used as it is, engine may be broken.
machine
Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
"n3" on VHMS controller LED changes to "61".
38 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 39
SEN01830-01 40 Troubleshooting
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear
exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Left rear exhaust temperature sensor (1): Exhaust temperature
f@BYNS failure abnormal rise (VHMS controller system)
Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Failure content perature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700C
in range above rated output speed and 750C in range below maximum torque speed)
Controller's
None in particular.
action
Symptoms that
appear on If machine is used as it is, engine may be broken.
machine
Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
"n3" on VHMS controller LED changes to "71".
40 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 41
SEN01830-01 40 Troubleshooting
Failure code [F@BZNS] (or VHMS_LED display "n3" o "38") Right front
exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Right front exhaust temperature sensor (1): Exhaust temperature
F@BZNS failure abnormal rise (VHMS controller system)
Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust
Failure content temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between
700C in range above rated output speed and 750C in range below maximum torque speed)
Controller's
None in particular.
action
Symptoms that
appear on If machine is used as it is, engine may be broken.
machine
Failure code is not displayed on machine monitor (It can be checked, however, by downloading
General
data saved in VHMS controller into personal computer).
information
"n3" on VHMS controller LED changes to "38".
42 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 43
SEN01830-01 40 Troubleshooting
Failure code [f@BZNS] (or VHMS_LED display "n3" o "39") Right rear
exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure code Right rear exhaust temperature sensor (1): Exhaust temperature
Symptom of
abnormal rise
f@BZNS failure
(VHMS controller system)
Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust
Failure content temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between
700C in range above rated output speed and 750C in range below maximum torque speed)
Controller's
None in particular.
action
Symptoms that
appear on If machine is used as it is, engine may be broken.
machine
Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
"n3" on VHMS controller LED changes to "39".
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 45
SEN01830-01 40 Troubleshooting
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front
exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Left front exhaust temperature sensor (2): Exhaust temperature
F@BYNR failure abnormal rise (VHMS controller system)
Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Failure content perature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750C
in range above rated output speed and 800C in range below maximum torque speed)
Controller's
None in particular.
action
Symptoms that
appear on If machine is used as it is, engine may be broken.
machine
Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
"n3" on VHMS controller LED changes to "62".
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 47
SEN01830-01 40 Troubleshooting
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear
exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Left rear exhaust temperature sensor (2): Exhaust temperature
f@BYNR failure abnormal rise (VHMS controller system)
Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Failure content perature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750C
in range above rated output speed and 800C in range below maximum torque speed)
Controller's
None in particular.
action
Symptoms that
appear on If machine is used as it is, engine may be broken.
machine
Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
"n3" on VHMS controller LED changes to "72".
48 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 49
SEN01830-01 40 Troubleshooting
Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front
exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Right front exhaust temperature sensor (2): Exhaust temperature
F@BZNR failure abnormal rise (VHMS controller system)
Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust
Failure content temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between
750C in range above rated output speed and 800C in range below maximum torque speed)
Controller's
None in particular.
action
Symptoms that
appear on If machine is used as it is, engine may be broken.
machine
Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
"n3" on VHMS controller LED changes to "82".
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01830-01
D475A, D475ASD-5E0 51
SEN01830-01 40 Troubleshooting
Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear
exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure code Symptom of Right rear exhaust temperature sensor (2): Exhaust temperature
f@BZNR failure abnormal rise (VHMS controller system)
Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust
Failure content temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between
750C in range above rated output speed and 800C in range below maximum torque speed)
Controller's
None in particular.
action
Symptoms that
appear on If machine is used as it is, engine may be broken.
machine
Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
"n3" on VHMS controller LED changes to "92".
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D475A, D475ASD-5E0 53
SEN01830-01
2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
54
SEN01831-02
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
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
D475A, D475ASD-5E0 1
SEN01831-02 40 Troubleshooting
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
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
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40 Troubleshooting SEN01831-02
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Symptom of (2) Trouble (1) is not detected but the engine does not start (When the machine is equipped with pre-
failure lubricator).
"PE" is displayed on the gear speed display unit and "E" on the right side flashes.
After the engine is started, if "Po" is displayed on the gear speed display unit and "o" on the right
General
side flashes, the engine oil pressure is not heightened. (In this case, the pre-lubrication motor and
information
the engine oil pressure switch for pre-lubrication may be defective. Accordingly, carry out the fol-
lowing troubleshooting.)
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40 Troubleshooting SEN01831-02
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40 Troubleshooting SEN01831-02
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E-4 The monitor panel does not come on at all when the starting switch
is turned on
Symptom of
The monitor panel does not come on at all when the starting switch is turned ON.
failure
General When the starting switch is turned ON, the gear speed indicator, the multi information section, the
information gauge section and the lamp section come on for 2 sec.
Possible a Prepare with the starting switch OFF, then carry out troubleshoot-
causes and the ing without turning the starting switch ON.
Short circuit with chassis
standard values Between wiring harness CB2 (outlet side)
ground in wiring harness Resis-
when normal 3 and S03 (female) (2) and S01 (female) (1) Min. 1 Mz
(Contact with ground cir- tance
and ground
cuit)
Between wiring harness CB6 (outlet side) Resis-
Min. 1 Mz
and S03 (female) (5) (6) and ground tance
a Prepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
S03 Voltage
Between (1), (2) and (3), (4) 20 30 V
Defective monitor panel S01 Voltage
4
(Gauge/lamp module) Between (1) and (2) 20 30 V
a Prepare with the starting switch OFF, then carry out troubleshoot-
ing without turning the starting switch ON and OFF.
S03 Voltage
Between (5) (6) and (3) (4) 20 30 V
If failure code [DAFRKR] of CAN communication error is displayed,
5 CAN communication error
carry out troubleshooting for it.
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E-5 When the starting switch is turned on, the monitor panel completely
remains lighted and does not go out
Symptom of When the starting switch is turned ON, the monitor panel completely remains lighted and does not
failure go out.
General When the starting switch is turned ON, the gear speed indicator, the multi information section, the
information gauge section and the lamp section come on for 2 sec. and go out.
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40 Troubleshooting SEN01831-02
E-6 When the starting switch is turned on, the basic check items flash
Trouble The radiator coolant level caution lamp flashes.
Related
When any basic check items are detected to be abnormal before the engine starts, they will flash.
information
D475A, D475ASD-5E0 17
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18 D475A, D475ASD-5E0
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Symptom of
(2) The air cleaner clogging caution lamp flashes.
failure
General
If abnormality is detected while the engine is running, the caution item lamp flashes.
information
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40 Troubleshooting SEN01831-02
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SEN01831-02 40 Troubleshooting
Symptom of
(2) The engine coolant temperature caution lamp flashes.
failure
When any abnormality is detected during engine operation, the relevant emergency warning item
will sound the alarm buzzer.
General The engine coolant temperature caution lamp flashes or goes out as it links with indication on the
information engine coolant temperature gauge.
The engine controller checks the engine coolant temperature for abnormality.
Failure code [B@BCNS] may be displayed, too.
Symptom of
(3) The power train oil temperature caution lamp flashes.
failure
When any abnormality is detected during engine operation, the relevant emergency warning item
will sound the alarm buzzer.
General
The power train oil temperature caution lamp flashes or goes out as it links with indication on the
information
power train oil temperature gauge.
Failure code [B@CENS] may be displayed, too.
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
Symptom of
(4) The hydraulic oil temperature caution lamp flashes.
failure
When any abnormality is detected during engine operation, the relevant emergency warning item
will sound the alarm buzzer.
General
The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the
information
hydraulic oil temperature gauge.
Failure code [B@HANS] may be displayed, too.
D475A, D475ASD-5E0 23
SEN01831-02 40 Troubleshooting
E-9 While the preheater is operating, the preheating pilot lamp does not
come on
Symptom of
While the preheater is operating, the preheating pilot lamp does not come on.
failure
a This troubleshooting describes the procedures to be followed when the preheating lamp does not
come on. (When the preheater mounting section is not heated, carry out the troubleshooting of
General
"The preheater does not work.")
information
For preheating, both the "Automatic Preheating Function" and the "Manual Preheating Function"
are available. Even when either function is performed, the preheating lamp comes on.
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
D475A, D475ASD-5E0 25
SEN01831-02 40 Troubleshooting
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp
does not come on (Dual tilt-mounted machine)
Symptom of At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tilt-
failure mounted machine)
Before troubleshooting the blade, make sure that the dual tilt can operate. (When the blade does
General
not operate normally, the electrical system on the machine side or the hydraulic/mechanical system
information
is supposed to be out of order. So, troubleshoot the relevant system.)
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
E-12 The engine coolant temperature gauge does not indicate normally
Symptom of
The engine coolant temperature gauge does not indicate normally.
failure
Information of the engine coolant temperature sensor is received from the engine controller by CAN
General communication.
information When any abnormality occurs in the engine coolant temperature sensor system, failure code
[CA144] or [CA145] may be displayed.
D475A, D475ASD-5E0 27
SEN01831-02 40 Troubleshooting
28 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
D475A, D475ASD-5E0 29
SEN01831-02 40 Troubleshooting
E-14 The hydraulic oil temperature gauge does not indicate normally
Symptom of
The hydraulic oil temperature gauge does not indicate normally.
failure
Signals of the hydraulic oil temperature sensor are received from the transmission controller
General through communication.
information When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
[DGS1KX] is displayed sometimes.
30 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
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SEN01831-02 40 Troubleshooting
Symptom of
(2) Shift mode and service meter are not displayed at all.
failure
General
information
32 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
Symptom of
(2) Though the switch is used, the system setting does not change.
failure
General
Switch module signals are transmitted to each controller through communication.
information
D475A, D475ASD-5E0 33
SEN01831-02 40 Troubleshooting
E-19 The warning lamp does not flash or does not go out
Symptom of
The warning lamp does not flash or does not go out.
failure
General
information
34 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
E-20 The alarm buzzer does not sound or does not stop
Symptom of
The alarm buzzer does not sound or does not stop.
failure
General When a short circuit occurs in the alarm buzzer system, the failure code is displayed but no other
information failure codes are displayed.
D475A, D475ASD-5E0 35
SEN01831-02 40 Troubleshooting
36 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
E-22 The automatic pitch back system does not operate (only superdozer
specification)
Symptom of
The machine cannot start or stop a pivot turn.
failure
General
information
D475A, D475ASD-5E0 37
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38 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
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40 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
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SEN01831-02 40 Troubleshooting
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E-27 The night light, the headlamp, the working lamp and the rear lamp
on the panel do not come on 1
Symptom of
(1) None of the night light, the headlamp and the working lamp on the panel comes on.
failure
General Headlamp and working lamp are operated with 1 switch.
information If headlamp switch is operated, panel lighting is changed for night.
44 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
Symptom of
(2) Only the night light on the panel does not comes on. (Whole or part)
failure
General
If headlamp switch is operated, panel lighting is changed for night.
information
D475A, D475ASD-5E0 45
SEN01831-02 40 Troubleshooting
Symptom of
(3) Only the headlamp does not comes on. (Both right and left, or one side only)
failure
General
information
46 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
Symptom of
(4) Only the working lamp does not comes on. (Both right and left, or one side only)
failure
General
information
D475A, D475ASD-5E0 47
SEN01831-02 40 Troubleshooting
Symptom of
(5) Only the rear lamp does not comes on. (Both right and left, or one side only)
failure
General
information
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40 Troubleshooting SEN01831-02
D475A, D475ASD-5E0 49
SEN01831-02 40 Troubleshooting
50 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
Self-diagnosis
notice Symptom of
Disconnection in recirculated air sensor
failure
E11
Contents of
Disconnection in the recirculated air sensor system is detected.
trouble
Fixes the recirculated air temperature for control.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General
information
Self-diagnosis
notice Symptom of
Short circuit in recirculated air sensor
failure
E12
Contents of
Disconnection in the recirculated air sensor system is detected.
trouble
Fixes the recirculated air temperature for control.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General
information
D475A, D475ASD-5E0 51
SEN01831-02 40 Troubleshooting
Self-diagnosis
notice Symptom of
Disconnection in fresh air sensor
failure
E13
Contents of
Disconnection in the fresh air sensor system is detected.
trouble
Assumes that the fresh air sensor is not installed for control.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General
information
Self-diagnosis
notice Symptom of
Short circuit in fresh air sensor
failure
E14
Contents of
Short circuit in the fresh air sensor system is detected.
trouble
Assumes that the fresh air sensor is not installed for control.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General
information
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40 Troubleshooting SEN01831-02
Self-diagnosis
notice Symptom of
Disconnection in coolant temperature sensor
failure
E15
Contents of
Disconnection in the coolant temperature sensor system is detected.
trouble
Ignores the warm-up control and fixes the engine coolant temperature at 60C for control.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General
information
Self-diagnosis
notice Symptom of
Short circuit in coolant temperature sensor
failure
E16
Contents of
Short circuit in the coolant temperature sensor system is detected.
trouble
Ignores the warm-up control and fixes the engine coolant temperature at 60C for control.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General
information
D475A, D475ASD-5E0 53
SEN01831-02 40 Troubleshooting
Self-diagnosis
notice Symptom of
Short circuit in daylight sensor
failure
E18
Contents of
Short circuit in the daylight sensor system is detected.
trouble
Assumes that the daylight sensor is not installed for control.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General
information
54 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
Self-diagnosis
notice Symptom of
Disconnection in air blow sensor
failure
E21
Contents of
Disconnection in the air blow sensor (frost sensor) system is detected.
trouble
Fixes the evaporator temperature at 10C for control.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General
information
Self-diagnosis
notice Symptom of
Short circuit in air blow sensor
failure
E22
Contents of
Short circuit in the air blow sensor (frost sensor) system is detected.
trouble
Fixes the evaporator temperature at 10C for control.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General
information
D475A, D475ASD-5E0 55
SEN01831-02 40 Troubleshooting
Self-diagnosis
notice Symptom of
Abnormality in air outlet damper
failure
E43
Contents of
Abnormality in air outlet servomotor system or front air outlet servomotor system is detected.
trouble
Stops the air outlet servomotor and front air outlet servomotor.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can
information damage the motor output shaft and break the motor coils.
56 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
Self-diagnosis
notice Symptom of
Abnormality in air mix damper
failure
E44
Contents of
Abnormality in air mix servomotor system is detected.
trouble
Stops the air mix servomotor.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can
information damage the motor output shaft and break the motor coils.
D475A, D475ASD-5E0 57
SEN01831-02 40 Troubleshooting
Self-diagnosis
notice Symptom of
Abnormality in recirculated and fresh air damper
failure
E45
Contents of
Abnormality in recirculated and fresh air servomotor system is detected.
trouble
Stops the recirculated and fresh air servomotor.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can
information damage the motor output shaft and break the motor coils.
58 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
Self-diagnosis
notice Symptom of
Abnormality in refrigerant pressure
failure
E51
Contents of
Abnormality in refrigerant pressure circuit is detected.
trouble
Turns the compressor clutch OFF.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch
OFF and ON> + <Starting air conditioner>
General
information
D475A, D475ASD-5E0 59
SEN01831-02 40 Troubleshooting
60 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
D475A, D475ASD-5E0 61
SEN01831-02 40 Troubleshooting
Symptom of
The air conditioner does not operate. (2) Air does not come out (Air flow is insufficient).
failure
General
information
62 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
Symptom of
The air conditioner does not operate. (3) Air is not cooled (Cooling capacity is low).
failure
General
information
D475A, D475ASD-5E0 63
SEN01831-02 40 Troubleshooting
64 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
E-29 Orbcomm terminal does not operate normally (Data are not
transmitted)
Symptom of
The ORBCOMM terminal does not operate normally (Data are not transmitted).
failure
General
Even if the ORBCOMM terminal is abnormal, it does not cause a trouble in the machine.
information
D475A, D475ASD-5E0 65
SEN01831-02 40 Troubleshooting
66 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
D475A, D475ASD-5E0 67
SEN01831-02 40 Troubleshooting
68 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
D475A, D475ASD-5E0 69
SEN01831-02 40 Troubleshooting
E-32 Electric priming pump does not operate or does not stop
automatically
Symptom of
Electric priming pump does not operate or does not stop automatically.
failure
General
information
70 D475A, D475ASD-5E0
40 Troubleshooting SEN01831-02
D475A, D475ASD-5E0 71
SEN01831-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 06-08 (01)
72
SEN01832-02
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
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
D475A, D475ASD-5E0 1
SEN01832-02 40 Troubleshooting
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
Possible causes 2
and standard Possible causes of trouble
<Contents of description>
value in normal (Given numbers are refer-
Standard value in normal state to judge possible causes
state ence numbers, which do not
Remarks on judgment
indicate priority)
3
D475A, D475ASD-5E0 3
SEN01832-02 40 Troubleshooting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 5
SEN01832-02 40 Troubleshooting
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 7
SEN01832-02 40 Troubleshooting
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 9
SEN01832-02 40 Troubleshooting
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 11
SEN01832-02 40 Troubleshooting
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 13
SEN01832-02 40 Troubleshooting
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 15
SEN01832-02 40 Troubleshooting
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 17
SEN01832-02 40 Troubleshooting
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 19
SEN01832-02 40 Troubleshooting
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 21
SEN01832-02 40 Troubleshooting
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 23
SEN01832-02 40 Troubleshooting
H-21 Ripper pin puller cylinder does not work (giant ripper attachment
machine) 1
Symptom of
The ripper pin puller cylinder does not work.
failure
General
Confirm that the main relief pressure for transmission is normal before troubleshooting.
information
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
H-22 Blade pitch does not work (dual tilt attachment machine) 1
Symptom of
The blade pitch does not work.
failure
General
information
H-23 Abnormal sound comes out from around work equipment pump 1
Symptom of
Abnormal noise from around work equipment pump.
failure
General
Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information
D475A, D475ASD-5E0 25
SEN01832-02 40 Troubleshooting
26 D475A, D475ASD-5E0
40 Troubleshooting SEN01832-02
D475A, D475ASD-5E0 27
SEN01832-02
2011 KOMATSU
All Rights Reserved
Printed in Japan 06-11
28
SEN01833-01
D475A-5E0
D475ASD-5E0
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
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
S-15 Abnormal noise is made....................................................................................................................... 23
D475A, D475ASD-5E0 1
SEN01833-01 40 Troubleshooting
2 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
Questions:
Information to be obtained by questioning the user
or operator, and which corresponds to the sections
A and B in the right chart.
Section A includes basic information, and section B
contains items which can be obtained depending
on the level of the user or operator.
Check items:
Items checked by the serviceman in order to nar-
row down the causes, section C of the right chart is
corresponding to them.
Causes:
Items to be narrowed down by the questions and
check items.
The serviceman narrows down the causes to highly
probable causes according to the information from
A, B and C.
Troubleshooting:
Items to be verified at the end in order to check if
the narrowed down causes are the true factors
causing the failure. The verification is carried out
by applying diagnostic tools or implementing direct
inspection in the order of probability.
D475A, D475ASD-5E0 3
SEN01833-01 40 Troubleshooting
4 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
If we look for the linkage of these three phenomena to possible causes, we find that they have causal rela-
tionship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
D475A, D475ASD-5E0 5
SEN01833-01 40 Troubleshooting
Defective injector
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
Carry out troubleshooting of the failure code for "No-pressure feed by supply pump
(*1)" q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change on some cylinders q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Is voltage 20 30 V between alternator terminal B and terminal E with Yes q
engine at low idle? None q
When specific gravity of electrolyte and voltage of battery are measured, they are
low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
6 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
in E-mode
switch ON and carry out When terminal B and terminal C at safety relay outlet are connected,
troubleshooting engine starts q
When terminal B and terminal C at safety relay outlet are connected,
engine does not start q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
D475A, D475ASD-5E0 7
SEN01833-01 40 Troubleshooting
Defective injector
Confirm recent repair history
Degree of
Operated for long period E E E
Questions
machine operation
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Non-specified fuel is being used w
Replacement of filters not carried out according to Operation and Maintenance
w w E E Q
Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is no fuel in it w Q w
w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
*2: Failure code [CA271], [CB271] and failure code [CA272], [CB272]
*3: Failure code [CA273], [CB273] and failure code [CA274], [CB274]
8 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Fuel does not flow out if air bleeding plug of fuel filter is
While engine is
removed Q Q w w
cranked with start-
ing motor, If spill hose from injector is disconnected, little fuel spills Q Q w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
D475A, D475ASD-5E0 9
SEN01833-01 40 Troubleshooting
gas is Black w Q w w
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is emitted from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
10 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
D475A, D475ASD-5E0 11
SEN01833-01 40 Troubleshooting
Correct
Correct
Correct
Clean
Remedy
Add
12 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation and Mainte-
nance Manual w Q
Engine oil replenished more frequently Q Q Q
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low w
w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Remedy
D475A, D475ASD-5E0 13
SEN01833-01 40 Troubleshooting
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
*2: Failure code [CA122] and failure code[CA123]
*3: Failure code [CA263], [CB263] and failure code [CA265], [CB265]
14 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
*2: Failure code [CA144] and failure code[CA145]
D475A, D475ASD-5E0 15
SEN01833-01 40 Troubleshooting
Turbocharger
ation
Oil consumption suddenly increased w Q
Oil replenished more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is contaminated with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
16 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
D475A, D475ASD-5E0 17
SEN01833-01 40 Troubleshooting
Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
change on some cylinders q
If spill hose from injector is disconnected and measured, much fuel spills q
Carry out troubleshooting of failure code for "Abnormality in coolant temperature sensor (*2)" q
Confirm with monitoring function of machine monitor q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
*2: Failure code [CA144] and failure code[CA145]
18 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant Causes
q Internal leakage in lubrication system
operation
Suddenly increased Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Remedy
D475A, D475ASD-5E0 19
SEN01833-01 40 Troubleshooting
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
Add
20 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
Clogged water pump drain hole (breather hole) and/or defective seal
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in cool-
Degree of
machine operation
Operated for long period E E E E
Fuel consumption increasing w w
Coolant replenished more frequently Q w
There is oil mixed in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appears, or coolant spurts back w Q
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
D475A, D475ASD-5E0 21
SEN01833-01 40 Troubleshooting
Sudden overheated Q w Q
Condition for
Persistent overheating Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator and coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged with
dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature gauge enters red range faster than engine coolant tem-
perature gauge (if oil temperature gauge and coolant temperature gauge are w
installed) on the installed machine side
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt and pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
22 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
machine operation
Condition of Gradually increased Q Q
abnormal noise Suddenly increased Q Q Q
Non-specified fuel is being used Q
Oil replenished more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is emitted from around turbocharger w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is emitted around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
D475A, D475ASD-5E0 23
SEN01833-01 40 Troubleshooting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
24 D475A, D475ASD-5E0
40 Troubleshooting SEN01833-01
D475A, D475ASD-5E0 25
SEN01833-01
2008 KOMATSU
All Rights Reserved
Printed in Japan 06-08 (01)
26
SEN02013-06
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN02013-06 50 Disassembly and assembly
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in Removal section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2] etc. and their
sented in the section of Sketches of part numbers, part names and quantities are
special tools. not described.
q Part No. of special tools starting with q Marks shown in the Installation section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
D475A, D475ASD-5E0 3
SEN02013-06 50 Disassembly and assembly
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
Used for plastic (except polyethylene, poly-
propylene, tetrafluoroethylene and vinyl chlo-
20 g Polyethylene
LT-1B 790-129-9050 ride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube Heat-resistant seal used to repair engines.
Quick-setting adhesive.
ThreeBond Polyethylene Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
Used mainly to stick rubbers, plastics, and
metals.
Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc Used for fitted portions used at high tempera-
648-50 container
tures.
Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
Used to seal transfer case, etc.
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
Can be coated with paint.
Gasket sealant
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
09995-00250 190 g Can
ing each other.
Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
Feature: Seizure and scuffing prevention com-
compound
prevention
Seizure
LM-G (G2-M) SYGA-16CNM 16 kg Can The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
D475A, D475ASD-5E0 5
SEN02013-06 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
facture)
SUNSTAR Ecocart Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
Sketches of special tools).
Necessity
remodel
Sketch
New/
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
790-431-1120 Adapter t 1
791-520-4140 Screw t 1
791-181-1020 Sleeve t 1
Removal and instal- 791-765-1150 Plate t 1
Pulling out pin or radiator
lation of radiator 1 791-112-1180 Nut t 1 guard
guard assembly
790-101-2540 Washer t 1
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Removal, installation
Tightening of cylinder
of cylinder head 2 790-331-1110 Wrench q 1
head bolt
assembly
A
Seal puller assem-
3 795-931-1100 t 1 Extraction of oil seal
bly
795T-621-1430 Plate t 1 N Q
Removal, installation 795T-621-1441 Push tool t 1 N Q
of engine front seal
4 01050-32280 Bolt t 3 Press fitting of oil seal
01582-02218 Nut t 3
01640-22232 Washer t 3
Seal puller assem-
3 795-931-1100 t 1 Extraction of oil seal
bly
Removal, installation 795T-621-1531 Push tool t 1 N Q
of engine rear seal
5 01050-32050 Bolt t 5 Press fitting of oil seal
01640-02032 Washer t 5
Disassembly and 790-413-1010 Bracket t 1
Disassembly, assembly of
assembly of torque 1
converter 790-501-5000 Repair stand t 1 torque converter
D475A, D475ASD-5E0 7
SEN02013-06 50 Disassembly and assembly
Necessity
remodel
Sketch
New/
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
8 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
Necessity
remodel
Sketch
New/
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
791-830-1760 Plate t 1 N
791-830-1320 Rod t 2
790-101-2510 Block t 1
790-101-2570 Plate t 2
Press fitting of idler bush-
1 01580-01613 Nut t 2 ing
01643-31645 Washer t 2
Assembly of Idler
Puller
790-101-2102 t 2
(294 kN {30 ton})
790-101-1102 Pump t 1
2 791-560-1520 Installer t 1 Installation of floating seal
3 791-830-1480 Push tool t 1 Press fitting of seal guide
4 791-601-1000 Oil pump t 1 Filling with oil
5 791-515-1520 Installer t 1 Installation of floating seal
Disassembly and Press fitting of floating seal
6 791-830-1770 Push tool t 1 N
assembly of carrier collar
roller Removal, installation of
7 791-630-1270 Wrench t 1
round nut
8 791-830-1740 Plate t 1 N Press fitting of bushing
9 791-515-1520 Installer t 1 Installation of floating seal
10 791-830-1730 Push tool t 1 N Press fitting of seal ring
Assembly of track 11 791-601-1000 Oil pump t 1 Filling with oil
roller 790-401-1700 Lifting tool t 1
L
790-401-1761 Adapter t 1 Removal, installation of
12
790-401-1540 Shackle t 2 track roller assembly
790-401-1770 T-bolt t 2
D475A, D475ASD-5E0 9
SEN02013-06 50 Disassembly and assembly
Necessity
remodel
Sketch
New/
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
1 791-830-1620 Plate t 1 N
2 791-830-1640 Screw t 3 N
3 01580-12722 Nut t 3
16 4 01643-32780 Washer t 3 Press fitting of pin assem-
Puller bly
5 790-101-4000 t 1
(490 kN {50 ton})
6 790-101-1102 Pump t 1
17 791T-830-1670 Guide t 2 N Q
18 791-530-1510 Installer t 1 Installation of floating seal
19 791-601-1000 Oil pump t 1 Filling with oil
Disassembly and
L 791-630-1860 Bracket t 1
assembly of bogie
791-630-1870 Bracket t 1
Removal of No. 1 bogie
20 791T-830-1510 Spacer t 2 Q
assembly
19M-09-12850 Bolt t 2
01643-33380 Washer t 2
791T-830-1700 Lifting tool t 1 N Q
791T-830-1710 Bar 1 N Q
791T-830-1720 Plate 1 N Q
Removal of No. 1 bogie
21 07283-31079 Grip 1
track roller
01582-01210 Nut 2
01643-31232 Washer 2
04530-11628 Eye bolt 1
790-434-1401 Remover assembly t 1
Puller Pulling out idler cushion
1 790-101-2102 t 1
(294 kN {30 ton}) guide pin
790-101-1102 Pump t 1
791-685-8502 Compressor t 1
10 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
Necessity
remodel
Sketch
New/
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
Puller
790-101-2102 t 1 Pulling out center pin
1 (294 kN {30 ton})
790-101-1102 Pump t 1
791T-850-1160 Bracket t 1 Q
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
791T-850-1180 Sleeve t 1 Q
791T-850-1190 Plate t 1 Q
791-730-1130 Bolt t 2
Disassembly and 791-101-3310 Plate t 1
assembly of pivot P Press fitting of seal
shaft 01643-32060 Washer t 2
01580-02016 Nut t 2
790-105-2300 Jack assembly t 1
790-101-1102 Pump t 1
1 791-646-7531 Plug remover t 1 Knocking out small plug
2 791-660-7460 Pin brush t 1 Cleaning of pin
3 791-646-7900 Push tool t 1 Knocking in large plug
4 791-932-1110 Push tool t 1 Knocking in all plugs
790-701-3000 Seal checker
Filling with oil and check-
5 and t 1
ing air tightness
791-601-1000 Oil pump
6 791-632-1010 Installer t 1 Replacing of link seal
1 791-832-1610 Plate t 1
2 791-832-1270 Bracket t 1
3 01010-81495 Bolt t 1
4 791-832-1250 Bracket t 1
Disassembly and
assembly of track R 5 01010-62050 Bolt t 2
shoe 6 791-832-1220 Plate t 1
7 791-832-1230 Shaft t 2
8 791-832-1210 Frame t 1
Pulling out and press fit-
8 9 791-832-1240 Nut t 2
ting of pin and bush
10 04530-11628 Eye bolt t 2
11 791-832-1310 Adapter t 1
12 791-832-1280 Adapter t 1
13 791-832-1320 Guide t 1
14 01310-21032 Screw t 5
15 791-832-1640 Pusher t 1
16 791-832-1340 Extension t 2
17 791-832-1650 Adapter t 1 N
D475A, D475ASD-5E0 11
SEN02013-06 50 Disassembly and assembly
Necessity
remodel
Sketch
New/
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
18 791-832-1480 Adapter t 1
19 791-832-1670 Guide t 1
20 791-832-1330 Guide t 1
21 791-832-1660 Adapter t 1 Pulling out and press fit-
ting of pin and bush
22 791-832-1630 Guide t 1 N
23 791-832-1470 Guide t 1
24 791-832-1410 Extension t 1
8 25 791-832-1350 Pusher t 1
26 791-832-1620 Guide t 1
27 04530-11018 Eye bolt t 1
Cylinder
28 790-101-4500 t 1
(1960 kN {200 ton}) Pulling out and press fit-
29 790-101-1102 Pump t 1 ting of pin and bush
Puller
30 790-101-4200 t 1
(294 kN {30 ton})
31 791-685-9230 Spacer t 1
1 791-685-5600 Push tool assembly t 1 N
2 791-685-5640 Adapter 1 N
3 791-685-5660 Ring 1 N
4 791-685-5670 Plate 1 N
Disassembly and 5 791-685-5680 Ring 1 N
assembly of track Press fitting ring
R 9 6 791-685-5690 Push tool 1 N
shoe (For large plug)
7 791-685-5710 Adapter 1 N
8 791-685-5720 Spring 1 N
9 791-685-5730 Bar 1 N
10 01252-30655 Bolt 1
11 01580-01210 Nut 1
10 791-685-5740 Push tool t 1 N Press fitting ring
1 791-832-1490 Push tool t 1 N
11 Press fitting ring
2 791-832-1510 Push tool t 1 N
1 791-685-5700 Push tool assembly 1 N
2 791-685-5650 Adapter 1 N
3 791-685-5660 Ring 1 N Press fitting ring
4 791-685-5670 Plate 1 N (For small plug)
5 791-685-5680 Ring 1 N
6 791-685-5690 Push tool 1 N
12
7 791-685-5710 Adapter 1 N
8 791-685-5720 Spring 1 N Press fitting ring
9 791-685-5730 Bar 1 N (For small plug)
10 01252-30655 Bolt 1
Press fitting ring
11 01580-01210 Nut 1
(For small plug)
13 791-685-5750 Push tool t 1 N Press fitting ring
12 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
Necessity
remodel
Sketch
New/
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
D475A, D475ASD-5E0 13
SEN02013-06 50 Disassembly and assembly
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A4 Plate
A4 Push tool
14 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A5 Push tool
C2 Push tool
D475A, D475ASD-5E0 15
SEN02013-06 50 Disassembly and assembly
C2 Plate
E2 Push tool
16 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
E2 Push tool
L13 Plate
D475A, D475ASD-5E0 17
SEN02013-06 50 Disassembly and assembly
L17 Guide
L20 Spacer
18 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
L21 Bar
D475A, D475ASD-5E0 19
SEN02013-06 50 Disassembly and assembly
L-21 Plate
N1 Plate
20 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
N2 Bracket
N2 Bracket
D475A, D475ASD-5E0 21
SEN02013-06 50 Disassembly and assembly
P Sleeve
P Plate
22 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02013-06
D475A, D475ASD-5E0 23
SEN02013-06
2013 KOMATSU
All Rights Reserved
Printed in Japan 01-13(02)
24
SEN02014-01
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN02014-01 50 Disassembly and assembly
Removal
k Lower the work equipment to the ground
and stop the engine.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Disconnect the cable from the negative ()
terminal of the battery.
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02014-01
7. Remove undercovers (1st, 2nd and 3rd ones 10. Disconnect radiator outlet tube (11).
from the front) (33).
11. Disconnect torque converter oil cooler tubes
(12) and (13).
13. Lift off the right and left aftercooler outlet piping
assemblies.
a Loosen hose clamp (15).
a Remove pipe mounting bolt (16).
a Remove piping fixing bracket (17).
D475A, D475ASD-5E0 3
SEN02014-01 50 Disassembly and assembly
14. Disconnect air conditioner hose (15) and 17. Disconnect engine rear-side air conditioner
remove the compressor assembly. hoses (23) and wiring connectors (24).
a Cover the hoses so that dirt, water, etc.
will not enter them.
a Disconnect all the clamps of hose (11).
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02014-01
D475A, D475ASD-5E0 5
SEN02014-01 50 Disassembly and assembly
Removal and installation of 4. Disconnect radiator inlet hoses (3) (right and
radiator assembly 1 left) and aeration hoses (4) (right and left).
3. Lift off radiator upper cover (2). 7. Remove isolator bolts (7) (2 each on the right
4
and left sides).
Radiator upper cover assembly: 85 kg
8. Remove wind breaker panels (8) (upper, lower,
right and left).
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02014-01
10. Disconnect radiator upper wiring harness (10) 13. Remove tube (15).
and radiator coolant level sensor connector
(11). 14. Lift off lower mounting bolts (16) (right and left).
11. Sling radiator assembly (12) and remove upper 15. Lift off radiator assembly (12).
mounting bolts (13) (2 each on the right and a When removing the radiator assembly,
left sides). take care not to damage its core.
4 Radiator assembly: 485 kg
Installation
q Carry out installation in the reverse order to
removal.
D475A, D475ASD-5E0 7
SEN02014-01 50 Disassembly and assembly
Removal and installation of 3. Disconnect radiator upper clamp (3) and after-
aftercooler assembly 1 cooler upper clamp (4).
8 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02014-01
Installation
q Carry out installation in the reverse order to
removal.
D475A, D475ASD-5E0 9
SEN02014-01 50 Disassembly and assembly
Removal and installation of 3. Sling blade lift cylinder assembly (4), then fit
radiator guard assembly 1 cylinder holder tool and secure to radiator
guard.
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-431-1120 Adapter t 1
791-520-4140 Screw t 1
791-181-1020 Sleeve t 1
791-765-1150 Plate t 1
A 1 791-112-1180 Nut t 1
790-101-2540 Washer t 1
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
5. Disconnect radiator inlet and outlet hoses, aer-
ation hose, and wiring harness clip.
Removal For details, see "Removal and installation of
1. Remove lock plate (1) of the lift cylinder rod radiator assembly".
pin, then remove pin (2). [*1]
a Start the engine and retract the piston rod 6. Disconnect hydraulic cooler hose (5).
Disconnect fan motor hose (6).
k Release the remaining pressure from
fully, then tie the piston rod with wire to
prevent it from coming out.
a Tie the piston rod on the opposite side in the hydraulic circuit.
the same way. For details, see Testing and adjusting,
Releasing residual pressure from work
equipment circuit.
a Fit a cover to prevent dirt from entering the
piping.
10 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02014-01
D475A, D475ASD-5E0 11
SEN02014-01 50 Disassembly and assembly
Removal and installation of fuel 6. Remove fuel tank mounting bolt (9).
tank assembly 1
Removal
1. Disconnect hose (1).
a Before disconnecting the hose, close the
fuel valve.
Installation
q Carry out installation in the reverse order to
removal.
12 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02014-01
D475A, D475ASD-5E0 13
SEN02014-01 50 Disassembly and assembly
7. Loosen clamps (9) and disconnect air cleaner 11. Remove hood mounting bolts (16) and (17).
hoses (10). [*1]
Installation
q Carry out installation in the reverse order to
removal.
[*1]
Hose inserted length: Min. 40 mm
3 Hose clamp:
8.83 0.5 Nm {0.9 0.05 kgm}
14 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02014-01
Removal and installation of fan 5. Remove wiring harness clamp (5) and discon-
drive assembly 1 nect connector (6).
6. Bracket (7).
Removal
1. Drain the hydraulic oil.
6 Hydraulic tank: Approx. 340 l
Installation
q Carry out installation in the reverse order to
removal.
D475A, D475ASD-5E0 15
SEN02014-01 50 Disassembly and assembly
Removal
1. Remove the fan drive assembly. For details,
see "Removal and installation of fan drive 3. Remove nut (2). [*2]
assembly".
4. Remove fan (3).
2. Remove the mounting bolt and lock plate (1).
[*1] 5. Remove the 4 mounting bolts and fan motor
assembly (4). [*3]
4 Fan motor assembly: 65 kg
16 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02014-01
Installation
q Carry out installation in the reverse order to
removal.
[*1]
Be sure to adjust the hole of lock plate (1) by
turning nut (2) in the tightening direction.
[*2]
3 Mounting nut (2):
1,080 1,275 Nm {110 130 kgm}
a After tightening the nut, check dimension
(d) shown below.
q MIN: 2.0 mm
q MAX: 4.0 mm
[*3]
a When fitting the fan motor and fan, clean
and degrease them thoroughly.
D475A, D475ASD-5E0 17
SEN02014-01
2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
18
SEN02338-03
D475A-5E0
D475ASD-5E0
Engine (SAA12V140E-3)
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
D475A, D475ASD-5E0 1
SEN02338-03 50 Disassembly and assembly
Removal and installation of fuel 4. Remove fuel hose clamp (4) and bracket (5).
supply pump assembly 1
5. Remove high-pressure pipe clamp (6) and
high-pressure pipe (7).
Removal of fuel supply pump on left bank
side 6. Remove clamp (8) and fuel tube (9). [*1]
k Lower the work equipment to the ground
and stop the engine. 7. Remove lubrication tube (10).
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Disconnect the cable from the negative ()
terminal of the battery.
a Do not remove the undercover.
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
9. Disconnect wiring connectors (12). Removal of fuel supply pump on right bank
a Connectors: PCV1, PCV2 and G
side
k Lower the work equipment to the ground
and stop the engine.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Disconnect the cable from the negative ()
terminal of the battery.
a Do not remove the undercover.
D475A, D475ASD-5E0 3
SEN02338-03 50 Disassembly and assembly
5. Disconnect wiring clamp (5) and fuel hose 7) Disconnect 6 upper high-pressure pipes
clamps (6). (13) of the common rail and high-pressure
pipes (14) on this side.
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
8. Remove brackets (18) and (19). 13. If necessary, remove nut (25), coupling (26)
and key (27) from supply pump assembly (24).
D475A, D475ASD-5E0 5
SEN02338-03 50 Disassembly and assembly
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
3 Bracket mounting bolt (14): q Carry out the following installation in the
19.6 29.4 Nm {2.0 3.0 kgm} reverse order to removal.
4) Install lubrication tube (10).
3 Lubrication tube joint bolt: [*1]
9.8 12.7 Nm {1.0 1.3 kgm} 3 Joint bolt on main fuel filter (upper) side:
5) Install high-pressure pipe clamp (6) 24.5 34.3 Nm {2.5 3.5 kgm}
according to the following procedure. 3 Joint bolt on fuel supply pump side:
1] Finger tighten all the mounting bolts 14.8 19.6 Nm {1.5 2.0 kgm}
of high-pressure pipe clamp (6) and
bracket (16). k Check that each high-pressure pipe is at
2] Tighten the high-pressure pipe clamp least 10 mm apart from the wiring harness
(6) mounting bolts permanently. around it.
a When tightening the high-pres-
sure pipe clamp mounting bolts,
ta ke care ex tremely that an
excessive force will not be
applied to the mounting area on
the supply pump side.
3 Clamp bolt:
9.8 1 Nm {1 0.1 kgm}
3] Tighten bracket (16) mounting bolts
permanently.
6) Install 4 rubber covers (15) to the high-
pressure pipe sleeve nuts.
a Install the rubber covers so that their
slits will be directed as follows.
q Supply pump side: Down
q Common rail side: Inward (Fac-
ing each other)
D475A, D475ASD-5E0 7
SEN02338-03 50 Disassembly and assembly
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
A 2 790-331-1110 Wrench q 1
Removal
k Lower the work equipment to the ground
and stop the engine.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Disconnect the cable from the negative ()
terminal of the battery. 5. Remove the piping and then remove the corro-
sion resistor, air bleeding valve and mounting
1. Close the fuel valve under the fuel tank. bracket (5) together.
2. Remove the engine hood. For details, see 4 Corrosion resistor, air bleeding valve
"Removal and installation of engine hood". and mounting bracket: Approx. 35 kg
8 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
D475A, D475ASD-5E0 9
SEN02338-03 50 Disassembly and assembly
18. Remove each tube of the turbocharger. 19. Remove heat insulation cover (25).
q Lubrication tube (21)
q Lubricating oil drain tube (22)
q Coolant tube (23) [*4]
q Coolant drain tube (24) [*4]
10 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
21. Removal of injector external wiring 25. Removal of rocker arm assembly
1) Remove cover plate (27). 1) Loosen locknuts (34) and then loosen
2) Disconnect connector (28) from each cyl- adjustment screws (35) fully.
inder head and disconnect wiring harness a Check that the rocker arm is not
(29). affected by the valve tension but it is
free.
22. Remove air vent tubes (30) and (31). [*6] 2) Remove rocker arm assembly (36).
a Put a location tag to each rocker arm
23. Remove spill tube (32). assembly before storing.
D475A, D475ASD-5E0 11
SEN02338-03 50 Disassembly and assembly
12 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
Crosshead
7. Install crossheads (38).
Fuel injector 2 Sliding parts of crosshead:
a Check that there is no dirt in the injector Engine oil (EO30)
sleeve.
2 O-ring: Engine oil (EO30)
D475A, D475ASD-5E0 13
SEN02338-03 50 Disassembly and assembly
8. Adjust the crosshead according to the follow- 10. Install push rods (37).
ing procedure. a Check that each push rod end is fitted in
1) Loosen locknut (102) and then loosen the receiving area of the cam follower.
adjustment screw (103) to a position 2 Both ends of push rod:
where it will not touch valve stem (104). Engine oil (EO30)
2) Hold the contact face to the rocker arm
with the finger to keep crosshead in con-
tact with valve stem (105) on the push rod
side.
3) Tighten adjustment screw (103) slowly
and check the point at which adjustment
screw (103) touches valve stem (104).
4) Tighten adjustment screw (103) further by
20 30 from the above point.
5) While holding adjustment screw (103),
tighten locknut (102).
3 Locknut:
58.8 5.9 Nm {6.0 0.6 kgm}
14 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
3 Tightening torque for locknut: 14. Fuel injector and high-pressure pipe (between
52.9 64.7 Nm {5.4 6.6 kgm} common rail and fuel injector)
a After tightening the locknut, check the k When handling the high-pressure pipe
valve clearance again. and clamp, observe the following.
q Never bend the high-pressure pipe to
correct before installing or use it for
another section.
q Install the specified clamp to the
specified position securely and
tighten it to the specified torque.
q Do not apply lubricant to the high-
pressure pipe sleeve nut and the
threads of the mating part.
a If lubricant is applied, the axial ten-
sion is increased too much and the
high-pressure pipe may be broken
when the sleeve nut is tightened.
k Before installing the high-pressure
pipe, check it. If it has any defect,
replace it since fuel may leak.
12. Install spill tube (32). q Check the taper seal of the connect-
3 Joint bolt: ing part (Part "a": Part of 2 mm from
9.8 12.7 Nm {1.0 1.3 kgm} the end) for visible lengthwise slit "b"
and dent "c".
13. Place cylinder head cover (33). (Place it to q Check part "d" (End of the taper seal:
prevent dirt from entering. It will need to be Part at 2 mm from the end) for
removed again.) stepped-type wear (fatigue) which
your nail can feel.
D475A, D475ASD-5E0 15
SEN02338-03 50 Disassembly and assembly
1) Fit O-ring (52) to the high-pressure pipe 6) Install the cylinder head cover.
sleeve nut (51). 3 Cylinder head cover mounting bolt:
2 O-ring: Engine oil (EO30) 14.7 34.3 Nm {1.5 3.5 kgm}
2) Tighten sleeve nut (51) temporarily into 7) Install rubber covers (17) and (18) to the
fuel injector (44). sleeve nuts of high-pressure pipes (19).
a If sleeve nut (51) does not catch the a Install the rubber covers so that their
threads, press its end with a small slits will be directed as follows.
rod, etc. toward the injector and turn q Injector side (17): Down
the spanner. q Common rail side (18):
3) Tighten sleeve nut (53) on the common Cylinder block side
rail side temporarily, too.
4) Tighten injector holder (49) permanently.
3 Injector holder mounting bolt (43):
58.9 73.5 Nm {6.0 7.5 kgm}
5) Tighten the sleeve nut to the specified
torque.
a Using a spanner-type torque wrench
(commercially available), control the
tightening torque.
3 High-pressure pipe (19) sleeve nut
(Injector side):
39.2 49 Nm {4 5 kgm}
3 High-pressure pipe (19) sleeve nut
(Common rail side):
39.2 49 Nm {4 5 kgm}
a After tightening each sleeve nut (51), 15. Air intake manifold assembly
check that O-rings (46) and (52) are 1) Install the gasket.
not projected from the sleeve nut. a Direct the side having the mark of
"UP" up and direct it toward the air
intake manifold.
2 Threaded part and seat of mount-
ing bolt:
Molybdenum disulfide grease (LM-P)
a Tighten the mounting bolts according
to the following procedure.
3 Air intake manifold mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
16 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
D475A, D475ASD-5E0 17
SEN02338-03 50 Disassembly and assembly
Reference
Turbocharger assembly
2 Turbocharger assembly mounting bolt and
nut: Molybdenum disulfide grease (LM-P)
3 Turbocharger assembly mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
[*6]
3 Air vent tube mounting bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
18 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
Removal
k Lower the work equipment to the ground
and stop the engine.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Disconnect the cable from the negative ()
terminal of the battery.
1. Close the fuel valve under the fuel tank.
D475A, D475ASD-5E0 19
SEN02338-03 50 Disassembly and assembly
20 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
20. Removal of rocker arm assembly 5) Insert small L-bar [B] under the fuel con-
1) Loosen locknuts (34) and then loosen nector and pry out fuel injector (44) slowly.
adjustment screws (35) fully. a Do not grip the solenoid valve at the
a Check that the rocker arm is not top of the injector with pliers to pull
affected by the valve tension but it is out the injector.
free.
2) Remove rocker arm assembly (36).
a Put a location tag to each rocker arm
assembly before storing.
Installation
Fuel injector
a Check that there is no dirt in the injector
21. Removal of fuel injector sleeve.
1) Remove injector terminal mounting nuts 2 O-ring: Engine oil (EO30)
(39).
2) Remove clamp mounting bolt (40). 1. Fit O-rings (46) and (47) to fuel injector (44).
3) Push connector (41) into the cylinder head a Take care not to fit O-ring (47) to center
and remove injector wiring harness (42). groove (A).
4) Remove holder mounting bolt (43).
2. Install gasket (48) to fuel injector (44).
D475A, D475ASD-5E0 21
SEN02338-03 50 Disassembly and assembly
4. Install spherical washer (50) to injector holder 6. Install rocker arm assembly (36).
mounting bolt (43) and tighten injector holder 2 Rocker shaft: Engine oil (EO30)
(49) temporarily. 2 Threaded part and seat of rocker arm
2 Spherical washer: Engine oil (EO30) assembly mounting bolt:
a Tighten injector holder (49) permanently Engine oil (EO30)
after tightening the high-pressure pipe a Check that the ball of adjustment screw
temporarily. (35) is fitted in the push rod socket.
a When tightening the mounting bolt, check
that adjustment screw (35) does not press
the push rod.
3 Rocker arm assembly mounting bolt:
93 103 Nm {9.5 10.5 kgm}
a Tighten locknut (34) after adjusting the
valve clearance.
a Adjust the valve clearance. For details,
see Testing and adjusting, "Testing and
adjusting valve clearance".
22 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
7. Place the cylinder head cover. (Place it to pre- 1) Fit O-ring (52) to the high-pressure pipe
vent dirt from entering. It will need to be sleeve nut (51).
removed again.) 2 O-ring: Engine oil (EO30)
2) Tighten sleeve nut (51) temporarily into
8. Fuel injector and high-pressure pipe (between fuel injector (44).
common rail and fuel injector) a If sleeve nut (51) does not catch the
k When handling the high-pressure pipe threads, press its end with a small
and clamp, observe the following. rod, etc. toward the injector and turn
q Never bend the high-pressure pipe to the spanner.
correct before installing or use it for 3) Tighten sleeve nut (53) on the common
another section. rail side temporarily, too.
q Install the specified clamp to the 4) Tighten injector holder (49) permanently.
specified position securely and 3 Injector holder mounting bolt (43):
tighten it to the specified torque. 58.9 73.5 Nm {6.0 7.5 kgm}
q Do not apply lubricant to the high- 5) Tighten the sleeve nut to the specified
pressure pipe sleeve nut and the torque.
threads of the mating part. a Using a spanner-type torque wrench
a If lubricant is applied, the axial ten- (commercially available), control the
sion is increased too much and the tightening torque.
high-pressure pipe may be broken 3 High-pressure pipe (19) sleeve nut
when the sleeve nut is tightened. (Injector side):
k Before installing the high-pressure 39.2 49 Nm {4 5 kgm}
pipe, check it. If it has any defect, 3 High-pressure pipe (19) sleeve nut
replace it since fuel may leak. (Common rail side):
q Check the taper seal of the connect- 39.2 49 Nm {4 5 kgm}
ing part (Part "a": Part of 2 mm from a After tightening each sleeve nut (51),
the end) for visible lengthwise slit "b" check that O-rings (46) and (52) are
and dent "c". not projected from the sleeve nut.
q Check part "d" (End of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.
D475A, D475ASD-5E0 23
SEN02338-03 50 Disassembly and assembly
[*2]
3 Air intake connector mounting bolt:
49 68.6 Nm {5.0 7.0 kgm}
[*3]
3 Fuel tube joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
24 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
Removal and installation of a Remove front seal (2) in the following proce-
engine front seal 1
dure.
1) Replace the tip of tool A3 with the hook
type one.
Special tools 2) Hitch the hook to the hoop of front seal
(2).
New/remodel
Necessity
3) Remove front seal with impact of slide
Symbol
Sketch
Q'ty
Part No. Part Name hammer (SH).
q Tool A3
3 795-931-1100 Seal puller t 1
795T-621-1430 Plate t 1 N Q
795T-621-1441 Push tool t 1 N Q
A
4 01050-32280 Bolt t 3
01582-02218 Nut t 3
01640-22232 Washer t 3
Removal
1. Remove radiator guard assembly.
For details, see "Removal and installation of
radiator guard assembly".
a CS: Crankshaft
2. Remove crankshaft pulley (1). [*1]
D475A, D475ASD-5E0 25
SEN02338-03 50 Disassembly and assembly
[*1]
a Align the dowel pin when installing the crank-
shaft pulley.
a Tighten the mounting bolts in the order shown
in the diagram below.
2 Threaded part and seat of bolt:
Engine oil (EO30)
3 Crankshaft pulley mounting bolt:
1st time: 73.5 19.6 Nm {7.5 2.0 kgm}
2nd time: 245 19.6 Nm {25 2.0 kgm}
3rd time: 744.8 19.6 Nm {76 2.0 kgm}
26 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
New/remodel
Necessity
1) Replace the tip of tool A3 with the
Symbol
Sketch
Q'ty
Part No. Part Name hook type one.
2) Hitch the hook to the hoop of rear
seal (3).
3 795-931-1100 Seal puller t 1 3) Remove rear seal with impact of slide
hammer (SH).
795T-621-1531 Plate t 1 N Q
A q Tool A3
5 01050-32050 Bolt t 5
01640-02032 Washer t 5
Removal
1. Remove damper assembly.
For details, see "Removal and installation of
damper assembly".
D475A, D475ASD-5E0 27
SEN02338-03 50 Disassembly and assembly
3. When installing rear oil seal (3), do not apply 5. Secure flywheel (2) and housing with plate [3].
oil or grease to the shaft and seal lip. Wipe off
the oil from the shaft.
2 Inner circumference of rear oil seal:
Gasket sealant (LG-7 or equivalent)
1) The surface having the parts number (PN)
marking must face to the outside of
engine.
28 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02338-03
D475A, D475ASD-5E0 29
SEN02338-03
2011 KOMATSU
All Rights Reserved
Printed in Japan 02-11
30
SEN02015-01
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN02015-01 50 Disassembly and assembly
Removal and installation of 6. Remove holder (4) and coupling (5). [*2]
damper assembly
7. Remove retainer (6).
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Universal joint mounting bolt:
156.8 196 Nm {16 20 kgm}
[*2]
2 Holder mounting bolt thread:
Thread tightener (LT-2)
3 Holder mounting bolt:
490 607.6 Nm {50 62 kgm}
D475A, D475ASD-5E0 3
SEN02015-01 50 Disassembly and assembly
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
D475A, D475ASD-5E0 5
SEN02015-01 50 Disassembly and assembly
10. Using push tool [1], press fit oil seal (11) to
cover (12).
2 Oil seal press-fitting surface:
Gasket sealant (LG-1)
a Coat the inside surface of the cover thinly
with gasket sealant and wipe off any seal-
ant that is forced out.
2 Lip of oil seal: Grease (G2-LI)
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
Removal and installation of power 8. Remove hydraulic pump inlet tube coupling (5)
train unit assembly and hydraulic tank side coupling (6), and
remove tube (7).
7. Disconnect fan motor pump tube coupling (4). 13. Remove hydraulic pump inlet tube (14).
D475A, D475ASD-5E0 7
SEN02015-01 50 Disassembly and assembly
15. Disconnect hydraulic pump outlet hoses (17) 19. Remove universal joint (23). [*1]
4
and (18).
Universal joint: 65 kg
16. Disconnect hydraulic PPC hoses (19) and (20).
8 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
[*2]
3 Front mount bolt:
1,519 1,911 Nm {155 195 kgm}
[*3]
3 Rear mount bolt:
823.2 1,029 Nm {84 105 kgm}
[*4]
a Check that the housing clip is fitted
securely in the flange.
3 Housing clip:
4.9 8.8 Nm {0.5 0.9 kgm}
25. Lift off power train unit assembly (31). [*5]
4
[*5]
Power train unit assembly: 5,500 kg
a When installing the power train unit
assembly, pay attention to the mating sur-
face of the coupling, and be careful not to
damage the seal of the rear mount cou-
pling.
D475A, D475ASD-5E0 9
SEN02015-01 50 Disassembly and assembly
Removal and installation of PTO, 6. Sling filter assembly (6), then remove.
torque converter assembly 4 Transmission filter assembly: 40 kg
4 Torque converter, transmission lubrica-
Removal tion filter assembly: Approx. 80 kg
1. Remove power train unit assembly.
For details, see "Removal and installation of
power train unit assembly".
10 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
10. Remove hose (12). 14. Remove PTO and torque converter assembly
(19). [*3]
11. Remove gauge guide (13). k Sling the PTO and torque converter
assembly, then remove the mounting
bolts.
a Using a lever block, lift off the PTO and
torque converter assembly horizontally.
4 PTO, torque converter assembly:
830 kg
Installation
q Carry out installation in the reverse order to
removal.
[*1]
k Bend the cotter pin securely.
[*2]
2 PTO boss rotating portion:
Grease (G2-LI)
[*3]
a Using a lever block, raise the PTO and
13. Remove oil pan (18). torque converter assembly horizontally,
a Remove the block under the oil pan, sling align it with the spline of the shaft at the
the oil pan, then remove the mounting steering case end, then install.
bolts and disconnect the oil pan.
4 Oil pan: 120 kg
D475A, D475ASD-5E0 11
SEN02015-01 50 Disassembly and assembly
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-413-1010 Bracket t 1
C 1
790-501-5000 Repair stand t 1
Disconnection
1. Set PTO and torque converter assembly (1) to
tool C1.
12 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
a Apply liquid gasket (LG-5) to the oil 58.8 73.5 Nm {6 7.5 kgm}
seal press-fitting face. a Assemble the shim as shown in the dia-
a Apply liquid gasket (LG-5) thinly to gram below so that it does not come at
the inside of the retainer hole and position (b) of the retainer removal tap.
wipe off any part forced out.
a Install the oil seal without slanting it.
a Apply grease (G2-LI) to the oil seal lip
part
2) Using a clearance gauge, measure clear-
ance (a) between the retainer and the
housing.
a Measure clearance (a) at four points
(A, B, C, D) around the circumfer-
ence, and take the average as clear-
ance (a).
D475A, D475ASD-5E0 13
SEN02015-01 50 Disassembly and assembly
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-413-1010 Bracket t 1
C 1
790-501-5000 Repair stand t 1
Disassembly
q Set the torque converter assembly to tool C1.
2. Draining oil
Remove 2 drain plugs (2), and drain oil from
pump case.
a After draining the oil, tighten the plugs.
14 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
4] Set clutch housing at top, then using 9] Remove 3 discs (16) and 2 plates
eyebolts [4], remove housing and pis- (17) from drive case (18).
ton assembly (10). a After removing the discs and
a When the assembly is removed, plates, keep them in a flat place
the piston will fall out, so support to prevent them from becoming
it by hand when removing. distorted.
5] Remove piston (11) from housing
(12).
4. Stator assembly
1) Remove snap ring (19), then remove sta-
6] Remove seal ring (13) from piston. tor assembly (20).
7] Remove seal ring (14) from housing. 2) Disassemble stator assembly as follows.
1] Remove snap ring (21), then remove
race (22) from stator (23).
D475A, D475ASD-5E0 15
SEN02015-01 50 Disassembly and assembly
11. Piston
3] Remove bearing outer race (30) from 1) Remove piston (40) from case (41).
guide (31).
7. Spring
Remove spring (33).
16 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
12. Stator shaft assembly 5] Using push tool [7], remove bearing
1) Tap stator shaft assembly (44) with a plas- (55), then remove plate (56).
tic hammer, and remove from case (45).
2) Disassemble stator shaft assembly as fol-
lows.
1] Using push tool [6], remove shaft
assem bly (4 6) from stator sha ft
assembly.
D475A, D475ASD-5E0 17
SEN02015-01 50 Disassembly and assembly
18 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
4. Pin
Install pin (37).
6. Dowel pins
Install dowel pins (34A).
7. Spring
Install spring (33).
D475A, D475ASD-5E0 19
SEN02015-01 50 Disassembly and assembly
20 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
D475A, D475ASD-5E0 21
SEN02015-01 50 Disassembly and assembly
3] Install seal ring (14) to housing. 5] Install piston (11) to housing (12).
Be careful to assemble the seal ring 2 Contact surface of seal ring:
facing in the direction shown in the Grease (G2-LI)
diagram below. a When installing, be careful not to
2 Outer circumference of seal damage the seal ring.
ring: Grease (G2-LI) 6] Using eyebolts [4], install housing and
4] Install seal ring (13) to piston. piston assembly (10).
Install the seal rings in the correct a Support the piston assembly by
directions with their grooves (b) in the hand to prevent it from falling out
directions shown in the figure. when installing.
2 Outer circumference of seal 2 Mounting bolt:
ring: Grease (G2-LI) Thread tightener (LT-2)
3 Mounting bolt:
98 122.5 Nm {10 12.5 kgm}
22 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
2) Using eyebolt [1], install lock-up clutch 12. Torque converter valve assembly
and drive case assembly (4). Install torque converter valve assembly (1).
a Align the positions of the turbine oil a Tighten the mounting bolts uniformly in
groove ( mark) and drain plug (2) turn and be careful not to tighten them
when installing. unevenly.
3 Mounting bolt:
43.1 53.9 Nm {4.4 5.5 kgm}
D475A, D475ASD-5E0 23
SEN02015-01 50 Disassembly and assembly
Disassembly and assembly of 3) Using puller [2], remove bearings (5) and
PTO assembly (6) from gear (7).
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Disassembly
1. PTO lubrication tube
Sling PTO assembly and remove lubrication 3. Power train and PPC pump gear assembly
tube (1). 1) Using forcing screw [1], pull out cover
a Remove the 3 lubrication tubes on the assembly (8) and lift off.
opposite side also, set the torque con- 2) Using puller [2], remove bearing (9).
verter end at the bottom, then lower. 3) Remove gear (10).
2. Hydraulic pump gear assembly 4) Using push tool [3], remove boss (11) and
1) Using forcing screws [1], pull out cover bearing (12) from cover.
assembly (2) and lift off. 5) Using forcing screw [4], remove bearing
2) Using puller [2], remove gear assembly (3) (12) from boss (11).
from cover (4).
24 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
7. PTO case
1) Remove race assembly (24) together with
2) Turn over PTO case, then using forcing bearing outer race (25).
screw [1], remove shaft assembly (16).
a The bearing outer race and key
assembly will come out from the bot-
tom of the PTO case, so place a
wooden block in position and be care-
ful not to damage the assembly.
3) Remove plug (17), then using forcing
screw, push out bearing (18).
a After removing the bearing, assemble
the plug again in the correct position.
D475A, D475ASD-5E0 25
SEN02015-01 50 Disassembly and assembly
8. Bearing
1) Remove snap ring (22).
2) Remove bearing (23).
26 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
Assembly 3. Bearing
a Clean all parts, and check for dirt or damage. 1) Turn over PTO case, and press fit bearing
a Check that the snap ring is fitted securely in spacer (31) and bearing inner race (20) to
the groove. shaft, then tighten mounting bolts of shaft
assembly.
1. Idler gear 3 Mounting bolt:
1) Using push tool [5], press fit bearing outer 98 123 Nm {10 12.5 kgm}
race (21) to gear (19). a Drop power train oil TO30 or TO10 to
2) Position idler gear to PTO case. the bearing by at least 6 cc and rotate
it 10 turns.
2. Shaft assembly
1) Using push tool [6], press fit bearing inner 2) Install plate (15).
race (18) to shaft. 2 Mounting bolt:
2) Fit O-ring, align shaft assembly (16) with Thread tightener (LT-2)
idler gear, then insert. 3 Mounting bolt:
D475A, D475ASD-5E0 27
SEN02015-01 50 Disassembly and assembly
28 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
4) Using push tool [7], press fit bearing (9) to 2) Using push tool [8], press fit gear assem-
gear (10). bly (3) to cover (4).
a Drop power train oil TO30 or TO10 to a Expand fit the bearing.
the bearing by at least 6 cc and rotate a Set the end where the bearing end
it 10 turns. face and gear end face are level so
5) Raise cover assembly (8) and install. that it faces the cover.
3 Mounting bolt: 2 Gear spline portion:
98 123 Nm {10 12.5 kgm} Grease (G2-LI)
a If the cover assembly is stiff and does 3) Fit O-ring, then raise cover assembly (2)
not enter the case, use a plastic ham- and install to case.
mer and tap evenly on the side face 3 Mounting bolt:
to install. 98 123 Nm {10 12.5 kgm}
a If the cover assembly is stiff and does
not enter the case, use a plastic ham-
mer and tap evenly on the side face
to install.
D475A, D475ASD-5E0 29
SEN02015-01 50 Disassembly and assembly
8. Install sleeve (30) to the PTO case. 2) Using push tool, press fit bearing inner
a Install the sleeve with the chamfered races (27) and (26) to race (28).
inside circumference facing down.
a Expand-fit the sleeve.
30 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Using a lever block, sling transmission
assembly (1) horizontally, align with spline
of shaft at steering case end, then install.
D475A, D475ASD-5E0 31
SEN02015-01 50 Disassembly and assembly
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-413-1010 Bracket t 1
D 790-501-5000 Repair stand t 1
799-301-1600 Oil leak tester t 1
Disassembly
4. Housing
q Set the transmission assembly on the block.
1) Remove 17 tie bolts (12).
2) Using eyebolts, remove housing (13).
1. Control valve assembly
3) Remove seal ring (14) from housing.
1) Remove cover (1).
2) Remove control valve assembly (2)
together with seat.
2. Sleeve
1) Remove plug (8).
2) Using eyebolts [1], pull out sleeve (9).
32 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
D475A, D475ASD-5E0 33
SEN02015-01 50 Disassembly and assembly
2) Disassemble the shaft and No. 1 carrier 3) Disassemble the No. 2, No.3 carrier
assembly as follows. assembly as follows.
1] Raise the assembly, then using forc- 1] Remove sun gear (48).
ing screw [2], remove shaft and cage 2] Using eyebolts, remove plate and
assembly (33). gear assembly (49).
2] Using plastic hammer, remove cage
assembly (34), spacer (35), and bear-
ing (36).
3] Remove seal ring (37) from cage
assembly.
4] Remove seal ring (38) from cage.
5] Remove seal ring (40) from shaft
(39).
34 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
18. Seat
Remove seat (76).
21. Spring
Remove spring (79).
D475A, D475ASD-5E0 35
SEN02015-01 50 Disassembly and assembly
36 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
29. Shaft
Remove shaft (115).
D475A, D475ASD-5E0 37
SEN02015-01 50 Disassembly and assembly
38 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
3) Install cover(123).
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
4) Install seal ring (122) to cage (133).
2 Periphery of seal ring:
Grease (G2-LI)
5) Install the outer race of bearing (121) to
cage (133) and fix it with snap ring (134).
D475A, D475ASD-5E0 39
SEN02015-01 50 Disassembly and assembly
2. No. 4 carrier and No. 5 clutch assembly 5) Install seal ring (110)to inner gear (109).
1) Install the dowel pin (1piece) for 2 Periphery of seal ring:
spacer(113) to No. 5 housing (111). Grease (G2-LI)
2) By using the push tool, install spacer (113) 6) Install inner gear (109).
to No. 5 housing (111). 7) Install guide pin (108).
3) Install seal ring (114). 8) Install springs (107) (6 pieces), plates
2 Periphery of seal ring: (106) (5 pieces), and discs (105) (6
Grease (G2-LI) pieces) alternately.
4) Install the seal rings to piston (112)and 9) Install pins (104) and springs (103).
housing (111). a Free length of spring: 103.5 mm
2 Periphery of seal ring:
Grease (G2-LI)
a Install the seal rings in the correct
directions with their grooves (d) in the
directions shown in the figure.
40 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
D475A, D475ASD-5E0 41
SEN02015-01 50 Disassembly and assembly
9. Springs
Install springs (79).
a Free length of spring: 81.7 mm
42 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
12. Springs
Install springs (72).
a Free length of spring: 84 mm
D475A, D475ASD-5E0 43
SEN02015-01 50 Disassembly and assembly
3) Install bearing (60) to gear (59), fit thrust 20. Ring gear
washers (58) to both sides, and set them 1) Install cover and snap ring (50) to ring
to the carrier. gear (52).
4) Install ball (57) to shaft (56) and push the 2) Engage the internal teeth of the ring gear
shaft into the carrier. assembly with the external teeth of carrier
5) By using eyebolts, install carrier assembly assembly (53).
(53). 3) Install the cover to carrier assembly (53)
and fix the ring gear assembly.
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
17. Guide pin and sleeve 21. No. 1 housing and No. 1piston
1) Install guide pin (28). 1) Install the seal rings to No. 1 piston (22)
a Guide pin length: 270 mm and No. 1 housing (21).
2) Install sleeve (27). a Install the seal rings in the correct direc-
tions with their grooves (h) in the direc-
18. Discs, plates, and springs tions shown in the figure.
Install springs (26) (7 pieces each), plate (25) 2 Periphery of seal ring:
(6 pieces), discs (24) (7 pieces) alternately. Grease (G2-LI)
2) Install No. 1 piston (22) to No. 1 housing
19. Springs (21).
Install springs (23).
a Free length of spring: 100 mm
44 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
D475A, D475ASD-5E0 45
SEN02015-01 50 Disassembly and assembly
46 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
Unit: mm
Piston Standard stroke
No. 1 (R) 7.4
No. 2 (F) 8.4
No. 3 (3) 4.8
No. 4 (2) 5.0
No. 5 (1) 7.1
D475A, D475ASD-5E0 47
SEN02015-01 50 Disassembly and assembly
48 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02015-01
D475A, D475ASD-5E0 49
SEN02015-01
2013 KOMATSU
All Rights Reserved
Printed in Japan 01-13 (02)
50
SEN02016-03
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN02016-03 50 Disassembly and assembly
New/remodel
Necessity
When pulling out the clutch and brake
Symbol
Sketch
Q'ty
Part No. Part Name assembly, be careful not to damage the
discs and plates.
791-622-1110 Bracket t 1
1 01016-51690 Bolt t 1
E 01011-81600 Bolt t 1
791T-822-1810 Push tool t 1 Q
2
791T-822-1820 Push tool t 1 Q
Disassembly
1. Steering rod bracket
1) Remove cover (1).
2) Remove tube (2).
3) Remove brake rod bracket (20).
3. Shafts
Remove left and right shafts (4).
4. Lubrication tube
Remove lubrication tubes (5).
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
D475A, D475ASD-5E0 3
SEN02016-03 50 Disassembly and assembly
3] Reverse the transfer and gear hous- 7] Push pinion shaft (60) out of pinion
ing assembly and remove lubrication housing assembly (57) with a press.
tube (56). 8] Remove the holder. Using puller [12],
4] Using eyebolts [11], remove pinion remove bearing inner race (61) from
housing assembly (57). pinion shaft (60).
a Check the quantity and thickness 9] Remove cage and bearing assembly
of the inserted shims and then (62).
keep them.
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
12] Remove the bolts and remove hous- 16] Remove bearing outer race (70) from
ing (76) from case (78). housing (76).
13] Remove drive gear and bearing 17] Remove snap ring (83), and then
assembly (77). remove bearing outer race (71) from
housing (76).
D475A, D475ASD-5E0 5
SEN02016-03 50 Disassembly and assembly
1. Cage
1) Using push tool, press fit outer race (19).
2) Assemble shim, and install bearing cage
(18).
q Standard shim thickness: 2 mm
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
2. Bevel gear, shaft assembly 2) Assemble shim, and install bearing cage
1) Assemble bevel gear and shaft as follows. (11).
1] Using tool E2, press fit bearings (17) q Standard shim thickness: 2 mm
and (16). 3 Mounting bolt:
2] Set bevel gear (14) to shaft (15), and 245 308.7 Nm {25 31.5 kgm}
tighten reamer bolt.
3 Reamer bolt: 4. Adjusting preload
490 607.6 Nm {50 62 kgm} Rotate bevel gear 10 20 turns, and fit push-
pull scale [4] to tip of teeth, then measure rotat-
ing torque of bevel gear shaft.
a Measure while the bevel pinion is not
engaged.
a Standard rotating torque:
9.8 11.8 Nm {1.0 1.2 kgm}
q Rotating force at outside of bevel gear:
51.0 61.8 Nm {5.2 6.3 kgm}
3. Cage
1) Using eyebolts [2], install cage (12).
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
D475A, D475ASD-5E0 7
SEN02016-03 50 Disassembly and assembly
3] Using the push tool, press fit bearing 7] Using push tool [18], press fit inner
inner races (81) and (82). race (61) to pinion shaft (60).
8] Install the holder.
2 Holder mounting bolt:
Adhesive (LT-2)
3 Holder mounting bolt:
276.85 31.85 Nm
{28.25 3.25 kgm}
9] Install pinion gear (64) and collar (63)
to the pinion shaft.
8 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
12] Tighten the mounting bolts of cover 17] Tighten the mounting bolts of cover
(58) temporarily in the following order. (58) permanently in the following
3 Mounting bolt: 49 Nm {5 kgm} order.
3 Mounting bolt:
66.15 7.35 Nm
{6.75 0.75 kgm}
D475A, D475ASD-5E0 9
SEN02016-03 50 Disassembly and assembly
20] Install lubrication tube (51) and block 6. Adjusting tooth contact, backlash
as a unit. 1) Adjusting backlash
Put the probe of dial gauge [6] in contact
with the tip of the bevel gear teeth at right
angles. Hold the bevel pinion in position,
and read the measurement when the
bevel gear is moved forward and back-
ward.
a Standard value for backlash:
0.3 0.4 mm
a Measure at a minimum of 3 points on
diagonally opposite sides.
10 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
D475A, D475ASD-5E0 11
SEN02016-03 50 Disassembly and assembly
Adjusting
If the result of the inspection shows that
the correct tooth contact is not being
obtained, adjust again as follows.
1] If bevel pinion is too far from center
line of bevel gear.
Contact is at the small end of the con-
vex tooth face of the bevel gear and
at the big end of the concave tooth
face.
[Correct the tooth contact as follows.]
Adjust the thickness of the shims at
the bevel pinion to move the bevel
pinion in direction (A).
Or adjust the thickness of the shims
at the bearing cage of the bevel gear
shaft to move the bevel gear in direc-
tion (B), then check the tooth contact
pattern and backlash again.
2] If bevel pinion is too close to center
line of bevel gear.
Contact is at the big end of the convex
tooth face of the bevel gear and the
small end of the concave tooth face.
[Correct the tooth contact as follows.]
Adjust the thickness of the shims at
the bevel pinion to move the bevel
pinion in direction (A) (the opposite
direction from (A) above).
7. Transmission output shaft and input shaft
Or adjust the thickness of the shims
1) Install the speed sensor and flange
at the bearing cage of the bevel gear
according to the following procedure.
shaft to move the bevel gear in direc-
1] Install flange (76).
tion (B) (the opposite direction from
a Remove the speed sensor.
(B) above), then check the tooth con-
2] Looking at transfer gear (85) through
tact pattern and backlash again.
the hole of the flange, check that a
a When adjusting the movement in or
tooth of the gear is at the center of the
out of the bevel gear, do not change
hole.
the preload of the bearing. Adjust by
a If a tooth is not seen, turn the
moving shims between the bearing
transfer gear to bring a tooth to
cage and the bevel pinion. Always
the center of the hole.
keep the same total thickness of
3] Remove locknut (84) from speed sen-
shims.
sor (75). Apply gasket sealant to the
threaded portion of speed sensor (75)
and install speed sensor (75) to
flange (76).
a Tighten the speed sensor until its
tip touches the transfer gear, and
then return it by 1/2 1 turn.
2 Threaded portion of speed
sensor: Gasket sealant (LG-6)
12 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
4] Remove the speed sensor and flange 8. Steering valve and pipe
as a unit and tighten locknut (84). 1) Install steering valve assembly (21) and
a Take care that the speed sensor seat as unit.
will not turn when the locknut is
tightened.
2 Threaded portion of locknut
and its contact surface against
flange: Gasket sealant (LG-6)
3 Locknut:
49 68.6 Nm {5 7 kgm}
5] Install speed sensor (75) and flange
(76) as a unit.
2 Flange mounting bolt hole and
flange mounting surface:
Gasket sealant (LG-6)
6] After installing the speed sensor,
rotate the transfer gear slowly and
check that the speed sensor does not 2) Install pipe (7).
interfere with the gear. 3) Install left and right pipes (6).
a Coat the O-rings thinly with grease (G2-
LI), and be careful not to damage them
when installing.
9. Lubrication tube
Install lubrication tubes (5).
D475A, D475ASD-5E0 13
SEN02016-03 50 Disassembly and assembly
11. Shafts
Install left and right shafts (4).
a If it is difficult to insert the shafts with the
bevel locked, release the steering brake
before inserting.
1) When removing plugs (20) and using bolts
(21), set 5 washers under each bolt head
to shorten the bolt stem length to 64 mm.
If these washers are not used, the bolts
break the plate when they are tightened.
Remove bolts (21) and tighten them into
the plug holes to compress the clutch
springs and set the brake free.
14 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
E 3 791-822-1830 Wrench t 1
Disassembly
D475A, D475ASD-5E0 15
SEN02016-03 50 Disassembly and assembly
9. Belleville springs
2) Remove outer race (15) from flange. Remove Belleville springs (26).
6. Bearing cage
1) Remove bearing cage assembly (16).
16 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
6. Belleville springs
Remove Belleville springs (39).
3. Brake cage
1) Using eyebolts [6], remove brake cage
(33).
2) Remove outer race (34) and seal ring (35)
from brake cage.
D475A, D475ASD-5E0 17
SEN02016-03 50 Disassembly and assembly
Assembly 2. Piston
Install piston (37).
Assembly of brake assembly 3. Torque pin
a Clean each part, and check for dirt or damage. Install torque pin (36).
a After installing the bearing, drip power train oil
TO30 or TO10 to it by at least 6 cc and rotate it
10 turns.
1. Disc springs
Install disc springs (39).
a Install the disc springs back to back by the
set (of the same number).
4. Brake cage
1) Using push tool, install outer race (34) to
brake cage.
2) Install seal ring (35).
3) Using eyebolts [6], install brake cage (33).
2 Mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt:
q Install the seal rings to the piston and 245 308.7 Nm {25 31.5 kgm}
brake cage.
Install the seal rings in the correct direc-
tions with their grooves (j) in the directions
shown in the figure.
2 Periphery of seal ring:
Grease(G2-LI)
q Install and fit the piston to the housing
(Remove after fitting).
18 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
6. Stopper
Install stopper (29).
q Remove brake hub.
3 Mounting bolt:
245 308.7 Nm {35 31.5 kgm}
q After Installing the stopper, remove
the brake hub.
D475A, D475ASD-5E0 19
SEN02016-03 50 Disassembly and assembly
6. Plate
1) Using push tool, press fit outer race (15) to
flange.
20 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
7. Clutch hub
Set guide bolts to housing, and using eyebolts,
install clutch hub (13).
2 Mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
8. Torque pin
Install torque pin (12).
2. Sleeve
1) Install O-ring (6A)and seal ring (6B)to the
sleeve. Apply grease (G2-LI) to each part.
D475A, D475ASD-5E0 21
SEN02016-03 50 Disassembly and assembly
3. Collar
Fit collar (2) and install plate (1).
22 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
1. Lubrication tube
Remove lubrication tube (1) together with
block.
2. Bearing cage
1) Remove bearing cage (2).
2) Using push tool, remove bearing (3).
3) Remove snap ring, and using push tool,
remove bearing (4)
5. Pinion assembly
1) Using forcing screws, remove cover (9).
2) Remove holder (10).
3) Push pinion shaft with press, then pull out
pinion gear (11).
4) Remove holder, and using puller [3],
remove inner race (12) from pinion gear
(11).
3. Transfer gear
1) Remove transfer gear (5).
2) Using puller [1], remove inner races (6) on
both sides.
D475A, D475ASD-5E0 23
SEN02016-03 50 Disassembly and assembly
24 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
6) Using push tool [6], press fit cage, bearing 2. Pinion housing
assembly (13). 1) Assemble shim, and using eyebolts [2],
7) Install holder (10). install pinion housing assembly (8).
3 Holder mounting bolt: a Standard shim thickness: 2 mm
245 308.7 Nm {25 31.5 kgm} 2) Install lubrication tube (7).
D475A, D475ASD-5E0 25
SEN02016-03 50 Disassembly and assembly
4. Bearing cage
1) Using push tool, press fit bearing (4), and
secure with snap ring.
2) Using push tool, press fit bearing (3).
3) Install bearing cage assembly (2) to case.
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
5. Lubrication tube
Install lubrication tube (1) together with block.
26 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
Removal Removal
1. Remove oil strainer inspection cover at front 1. Open undercover. (3rd from front of machine).
left of operators platform.
2. Disconnect inlet tube (1).
2. Open undercover. (3rd from front of machine). a Oil will leak out from inside the piping, so
prepare a container to catch the oil.
3. Remove oil strainer (1).
a Disconnect coupling (2) and remove 3. Disconnect outlet tube (2).
strainer mounting bolts.
4. Remove scavenging pump assembly (3).
4. Disconnect hose (3). 4 Scavenging pump assembly: 25 kg
Installation
q Carry out installation in the reverse order to
removal.
Installation
q Carry out installation in the reverse order to q Refilling with oil (power train case)
removal. Add oil through the oil filler to the specified
level, and run the engine to circulate the oil
through the system. Then check the oil level
again.
D475A, D475ASD-5E0 27
SEN02016-03 50 Disassembly and assembly
Removal and installation of 7. Sling torque converter oil cooler assembly (8),
torque converter oil cooler then lower assembly to remove.
4 Torque converter oil cooler assembly:
170 kg
Removal
1. Remove engine undercover.
2. Drain coolant.
Installation
q Carry out installation in the reverse order to
removal.
28 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Adjust the brake pedal linkage.
3. Disconnect connector of solenoid valve (2). For details, see Testing and adjusting,
Adjusting brake pedal and parking brake
4. Disconnect hose clamp (3). lever.
3 Turnbuckle locknut:
5. Disconnect central pressure detection hose 34.3 58.8 Nm {3.5 6 kgm}
(4).
a Before removing the pressure detection [*2]
3
hoses, mark them with tags to prevent any Torque converter valve assembly
mistake in the mounting position when mounting bolt:
installing. 43.1 53.9 Nm {4.4 5.5 kgm}
6. Disconnect hose (5).
D475A, D475ASD-5E0 29
SEN02016-03 50 Disassembly and assembly
3. Remove cover (7), then remove piston (10). 3. Assemble spring (5), then fit O-ring and install
plug (3).
4. Pull out spool (6).
4. Fit O-ring (17) to plug (19), then assemble.
30 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
D475A, D475ASD-5E0 31
SEN02016-03 50 Disassembly and assembly
32 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
D475A, D475ASD-5E0 33
SEN02016-03 50 Disassembly and assembly
2. Remove operators seat and floor frame cover. 7. Remove transmission control valve assembly
a Use turnbuckle (1) when disconnecting (6). (4 places)
the brake rod. Check the mounting dimen-
sions of the rod before disconnecting. [*1]
Installation
3. Disconnect hose clamp (2). q Carry out installation in the reverse order to
removal.
4. Remove valve cover (3).
[*1]
a Adjust the brake pedal linkage.
For details, see Testing and adjusting,
Adjusting brake pedal and parking brake
lever.
3 Turnbuckle locknut:
34.3 58.8 Nm {3.5 6 kgm}
34 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
D475A, D475ASD-5E0 35
SEN02016-03 50 Disassembly and assembly
Assembly of ECMV assembly a Install the shim securely and do not drop it
a If the pressure control valve was disassembled in the valve.
or any part of it was replaced, be sure to check a After adjusting the shim, test the oil pres-
the oil pressure. sure again.
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with
engine oil before installing.
Quantity of adjustment
0.06 MPa
per shim (0.5 mm thick)
{Approx. 0.65 kg/cm2}
714-23-15580
Quantity of adjustment
0.025 MPa
per shim (0.2 mm thick)
{Approx. 0.26 kg/cm2}
714-28-15590
36 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
2. Remove shim (4) and spring (3). 4. Install spring (7) and shim (4). Fit O-ring (9) to
a Check the quantity of shim (4). plug (8) and install them to body (1).
3 Plug: 58.8 78.4 Nm {6 8 kgm}
3. Remove spool (2).
a When removing the spool, check that it Quantity of adjustment
52 kPa {0.53 kg/cm2}
per shim (0.5 mm thick)
moves smoothly.
4. Remove plug (10) from valve body (1). a If the shim is increased, the oil pressure is
heightened. If the former is decreased, the
5. Remove sleeve (5), spring (7), and valve (6). latter is lowered.
a After adjusting the shim, test the oil pres-
sure again.
D475A, D475ASD-5E0 37
SEN02016-03 50 Disassembly and assembly
Removal
1. Remove fuel tank assembly.
For details, see Removal and installation of
fuel tank assembly.
Installation
q Carry out installation in the reverse order to
removal.
38 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
D475A, D475ASD-5E0 39
SEN02016-03 50 Disassembly and assembly
Quantity of adjustment
0.06 MPa
per shim (0.5 mm thick)
{Approx. 0.65 kg/cm2}
714-23-15580
Quantity of adjustment
0.025 MPa
per shim (0.2 mm thick)
{Approx. 0.26 kg/cm2}
714-23-15590
40 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
Removal and installation of final 4. Remove cover (3), then using forcing screw,
drive assembly pull out drive shaft (4). [*1]
a If the shaft will not come out, set a jack on
the ground and push the shoe grouser up,
Special tools then move the sprocket to the front or rear
to a position where the shaft will come out,
New/remodel
Necessity
and remove the shaft.
Symbol
Sketch
a Pull the shaft out to a position where it
Q'ty
Part No. Part Name
contacts the sprocket.
Removal
1. Remove track shoe assembly.
For details, see "Expansion and installation of
track shoe assembly".
3. Remove covers (1) and (2). 5. Remove 3 bolts of final drive and install tool J1.
D475A, D475ASD-5E0 41
SEN02016-03 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
q Installed position of gear hole cover button
(6): 72 0.8 mm
a If the installed position is higher than the
specified position, the button may be
driven defectively. In this case, pull out the
button, check for foreign matter and scuff-
ing, and then driving it again.
.
[*2]
2 Final drive assembly mounting bolt:
Thread tightener (LT-2)
3 Final drive assembly mounting bolt:
1,960 2,450 Nm (200 250 kgm)
42 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name 2. Sprocket
1) Set final drive assembly to block (height:
approx. 50 mm).
790-431-1081 Guide t 1 2) Remove sprocket (1).
790-431-1031 Block t 1
790-101-2350 Leg t 2
790-101-2430 Adapter t 2
2 790-101-2360 Plate t 4
02215-11622 Nut t 2
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
790-431-1101 Installer assembly t 1
Puller
3 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1 3. Cover
t 1 Using eyebolts [1], remove cover (2).
J 4 791-585-1510 Installer
790-431-1220 Remover assembly t 1
Puller
5 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
790-431-1210 Installer assembly t 1
Puller
6 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Remover &
790-431-1230 t 1
installer
7 Puller
790-101-2102 t 1
(294 kN {30 ton})
4. Hub
790-101-1102 Pump t 1 1) Remove plate (3).
8 790-431-1240 Guide t 1 2) Using eyebolts [2], lift off hub (4).
D475A, D475ASD-5E0 43
SEN02016-03 50 Disassembly and assembly
6. Wear guard
Lift off wear guard (13).
7. Cover assembly
1) Using eyebolts, lift off cover assembly
(14).
44 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
3] Remove spacer (17) and bearing 4] Remove planet gear (23), bearing
inner race (18). inner races (24A) and (24B), and
spacer (24C).
8. Carrier assembly
1) Using eyebolts [5], remove carrier assem-
bly (20).
D475A, D475ASD-5E0 45
SEN02016-03 50 Disassembly and assembly
9. Sun gear 2) Using tool J5, pull out hub assembly (29)
1) Remove plate (25). and bearing inner race (30) from shaft
2) Remove holder (26). assembly (31).
3) Pull out sun gear shaft assembly (27).
46 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
D475A, D475ASD-5E0 47
SEN02016-03 50 Disassembly and assembly
2. Carrier assembly
2] Set gear (32) to hub (33). 1) Assemble carrier assembly as follows.
2 Mounting bolt: a The planetary gear bearing forms a
Thread tightener (LT-2) set, so align the mating marks on the
3 Mounting bolt: inner race, outer race, and spacer
823 1,029 Nm {84 105 kgm} when assembling.
4) Set shaft assembly (31) and hub assem-
bly (29) in position, then using tool J6,
press fit bearing (30) portion.
48 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
D475A, D475ASD-5E0 49
SEN02016-03 50 Disassembly and assembly
5. Cover assembly
1) Assemble cover assembly as follows.
1] Using push tools [11] and [12], install
oil seals (50) and (49).
a Install the bottom oil seal with the part
receiving the pressure at the bottom;
install the top oil seal with the part
receiving the pressure at the top.
2 Lip of oil seal: Grease (G2-LI)
2 Oil seal press-fitting surface:
Gasket sealant (LG-5)
a Coat the inside surface of the case
thinly with gasket sealant and wipe off
any sealant that is forced out.
6] Using tool J4, press fit floating seal
(16) to floating seal cover.
a Remove all oil and grease from
the O-ring and O-ring contact
surface, and dry before installing.
a After installing the floating seal,
check that the angle of the seal is
less than 1 mm.
50 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
6. Wear guard
1) Raise wear guard (13) and install.
2) Install wear guard plate (13a).
3 Mounting bolt:
823 1,029 Nm {84 105 kgm}
4) Set bearing (8) to sprocket hub assembly.
D475A, D475ASD-5E0 51
SEN02016-03 50 Disassembly and assembly
8. Hub
1) Using eyebolts [2], raise hub (4) and
install.
2) Install plate (3).
2 Mounting bolt:
6) Using tool J3, press fit bearing (7) portion. Thread tightener (LT-2)
a Rotate the sprocket hub assembly 3 Mounting bolt:
when press fitting. 245 309 Nm {25 31.5 kgm}
52 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
D475A, D475ASD-5E0 53
SEN02016-03 50 Disassembly and assembly
54 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02016-03
Table 1
a + b (mm) Number of shim to use Total shim
More than Less than t = 0.15 t = 0.5 t = 1.0 thickness c (mm)
3.05 3.15 9 1 1.85
3.15 3.25 6 1 1.90
3.25 3.35 3 1 1 1.95
3.35 3.45 2 2.00
3.45 3.55 7 1 2.05
3.55 3.65 4 1 1 2.10
3.65 3.75 1 2 2.15
3.75 3.85 8 1 2.20
3.85 3.95 5 1 1 2.25
3.95 4.05 2 2 2.30
4.05 4.15 9 1 2.35
4.15 4.25 6 1 1 2.40
4.25 4.35 3 2 2.45
4.35 4.45 1 2 2.50
4.45 4.55 7 1 1 2.55
4.55 4.65 4 2 2.60
4.65 4.75 1 1 2 2.65
4.75 4.85 8 1 1 2.70
4.85 4.95 5 2 2.75
4.95 5.05 2 1 2 2.80
5.05 5.15 9 1 1 2.85
5.15 5.25 6 2 2.90
5.25 5.35 3 1 2 2.95
5.35 5.45 3 3.00
5.45 5.55 7 2 3.05
5.55 5.65 4 1 2 3.10
5.65 5.75 1 3 3.15
5.75 5.85 8 2 3.20
5.85 5.95 5 1 2 3.25
5.95 6.05 2 3 3.30
6.05 6.15 9 3 3.35
6.15 6.25 6 1 2 3.40
6.25 6.35 3 3 3.45
6.35 6.45 1 3 3.50
6.45 6.55 7 1 2 3.55
6.55 6.65 4 3 3.60
6.65 6.75 1 1 3 3.65
6.75 6.85 8 1 2 3.70
6.85 6.95 5 3 3.75
6.95 7.05 2 1 3 3.80
7.05 7.15 9 1 2 3.85
7.15 7.25 6 3 3.90
7.25 7.35 3 1 3 3.95
D475A, D475ASD-5E0 55
SEN02016-03
2013 KOMATSU
All Rights Reserved
Printed in Japan 01-13 (02)
56
SEN02017-04
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN02017-04 50 Disassembly and assembly
Removal and installation of track 7. Using eyebolts [3], pull out pin (3). [*1]
frame assembly 1
a It is difficult to remove the pin if the centers
of the equalizer bar hole and track frame
hole are not aligned, so adjust the height
Removal of the track frame before removing.
1. Remove track shoe assembly.
For details, see "Expansion and installation of
track shoe assembly".
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
[*2]
a After removing the grease from the press-
fitting surface of the seal, coat with gasket
sealant (LG-6).
a Be careful not to install with the seal dis-
placed in the direction of twisting.
[*3]
a Be careful not to install the track frame
with seal (11) displaced in the direction of
twisting.
D475A, D475ASD-5E0 3
SEN02017-04 50 Disassembly and assembly
Disassembly and assembly of 6. Using puller [4], remove seal guide (6) and
idler assembly retainer (7) and plate (8).
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791-830-1760 Plate t 1 N
791-830-1320 Rod t 2
790-101-2510 Block t 1
790-101-2570 Plate t 2
1 01580-01613 Nut t 2
7. Remove seal guides (2) and (6) from retainers
01643-31645 Washer t 2 (3) and (7).
L
Puller
790-101-2102 t 2
(294 kN {30 ton})
790-101-1102 Pump t 1
2 791-560-1520 Installer t 1
3 791-830-1480 Push tool t 1
4 791-601-1000 Oil pump t 1
Disassembly
1. Remove oil filler plug and drain oil.
6 Idler: 1.4 1.5 l (GO140)
2. Set idler assembly (1) on block [1]. 8. Remove floating seal (9) from seal guides (2)
and (6).
3. Remove mounting bolts, then using forcing a Keep the floating seal in a safe place to
screws [2], remove seal guide (2) together with protect it from damage.
retainer (3) and plate (4).
9. Remove floating seal (10) from seal guides (3)
and (7).
a Keep the floating seal in a safe place to
protect it from damage.
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
10. Remove bushings (11) from idler (12). 2. Using tool L2, install floating seal (10) to retain-
ers (3) and (7).
Assembly
a Clean all parts, and check for dirt or damage.
1. Set bushing (11) and tool L1 to idler (12), and
press fit bushing (11).
a First, center the bushing with a plastic
hammer, then press fit with a puller. 4. Using eyebolts [3], set idler (12) to shaft (5).
a Press fit so that press-fitting dimension (a) a Set block (height: approx. 200 mm) under
from the end face of the idler to the top the idler.
surface of the bushing is the dimension
given below. 5. Turn over idler assembly.
q Press-fitting dimension (a): 17 0.5 a Tie with wire to prevent the shaft from fall-
mm ing out.
D475A, D475ASD-5E0 5
SEN02017-04 50 Disassembly and assembly
7. Using tool L2, install floating seal (9) to seal 9. Using tool L4, fill with oil to specified level, then
guides (2) and (6). tighten oil filler plug.
5 Idler: 1.4 1.5 l (GO140)
3 Oil filler plug:
156.8 254.8 Nm {16 26 kgm}
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
D475A, D475ASD-5E0 7
SEN02017-04 50 Disassembly and assembly
8. Lift off idler and recoil spring assembly (6). [*2] 2) Loosen idler yoke mounting bolts (9) grad-
a Using a lever block, keep the assembly ually in turn on diagonally opposite sides.
horizontal, and be careful not to damage [*4]
the oil seal at the track frame end.
4 Idler, recoil spring assembly: 3,500 kg
8 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
D475A, D475ASD-5E0 9
SEN02017-04 50 Disassembly and assembly
11. Pump in grease through lubricator (13), and 14. Remove holder (20) from recoil spring assem-
remove cylinder (14) and piston assembly (15). bly.
[*5]
[*2]
a Using a lever block, keep horizontal and
be careful not to damage the oil seal at the
track frame end when installing.
a Adjust the clearance.
For details, see Testing and adjusting,
Adjusting clearance of idler.
[*4]
2 Idler yoke assembly mounting bolt:
Thread tightener (LT-2)
3 Idler yoke assembly mounting bolt:
2,205 2,695 Nm {225 275 kgm}
[*5]
a To prevent air from accumulating inside
the cylinder, fill with grease as follows.
1] Fill the inside of the cylinder with
approx. 2.0 l of grease.
2] Set with the cylinder drain hole facing
up, then loosen the lubricator.
3] Push the piston until it contacts the
stopper. This will push out the air and
any extra grease.
10 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
New/Remodel
Necessity
Symbol
Sketch
Qty
Part No. Part Name
791-685-8502 Compressor t 1
791-635-3160 Extension t 1
790-201-2790 Spacer t 1
M 2
Cylinder (980 kN
790-101-1300 t 1
{100 ton})
790-101-1102 Pump t 1
Disassembly
1. Remove recoil spring assembly (1) with tool
4. Remove rear pilot (5), spacer (6), bolt (7), and
M2.
k The spring is under high installed load,
front pilot (8) from spring (4).
so be careful to set it correctly.
a Installed load of spring:
Approx. 788 kN {approx. 81 ton}
D475A, D475ASD-5E0 11
SEN02017-04 50 Disassembly and assembly
Assembly
1. Assemble front pilot (8), bolt (7), spacer (6),
and rear pilot (5) to spring (4), then set in tool
M2.
k The spring is under high installed load,
so be careful to set all parts correctly.
12 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
Special tools
New/Remodel
Necessity
Symbol
Sketch
Qty
Part No. Part Name
D475A, D475ASD-5E0 13
SEN02017-04 50 Disassembly and assembly
[*3]
[*2] When using the assembling tool
Install S to the first and last track rollers and Set tool L12 under the track roller assem-
install D to the other track rollers. bly (2) and lift up and set track roller
S: Single flange assembly (2) to the track frame.
D: Double flange
14 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
Disassembly and assembly of 6. Using press, remove seal guide (6) together
track roller assembly with retainer (7) and plate (8) from shaft.
New/Remodel
Necessity
Symbol
Sketch
Qty
Part No. Part Name
8 791-830-1740 Plate t 1 N
9 791-515-1520 Installer t 1
L
10 791-830-1730 Push tool t 1 N
11 791-601-1000 Oil pump t 1
Disassembly
1. Remove oil filler plug and drain oil.
6 Track roller: 1.4 1.5 l 8. Remove floating seal (9) from seal guides (2)
and (6).
2. Set track roller assembly (1) on block [1]. a Keep the floating seal in a safe place to
protect it from damage.
3. Remove mounting bolts, then using forcing
screws [2], remove seal guide (2) together with 9. Remove floating seal (10) from retainers (3)
retainer (3) and plate (4). and (7).
a Keep the floating seal in a safe place to
4. Turn over track roller assembly. protect it from damage.
D475A, D475ASD-5E0 15
SEN02017-04 50 Disassembly and assembly
Assembly
a Clean all parts, and check for dirt or damage.
1. Set roller (12) to press, then using tool L8,
press fit bushing (11).
a First, center the bushing with a plastic
hammer, then press fit with a press.
a Press fit so that press-fitting dimension (a)
from the end face of the roller to the top
surface of the bushing is the dimension
given below.
q Press-fitting dimension (a):
17 0.5 mm
16 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
Removal
1. Loosen the track shoe. For details, see
Expanding track shoe assembly.
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Make a clearance (a) of 5 mm between
the carrier roller and support as shown
below.
2 Carrier roller assembly mounting bolt:
Adhesive (LT-2)
3 Carrier roller assembly mounting bolt:
744.8 83.3 Nm {76 8.5 kgm}
D475A, D475ASD-5E0 17
SEN02017-04 50 Disassembly and assembly
New/Remodel
Necessity
Symbol
Sketch
Qty
Part No. Part Name
Disassembly
1. Remove the oil filler plug and drain the oil.
a Drain the oil, turning the shaft.
7. Remove bearing outer race (7) from the roller.
6 Carrier roller: Approx. 13 l
8. Remove seal guide (8) and bearing inner race
2. Set carrier roller assembly (1) to block [1]. (9) as one unit with puller [3].
18 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
10. Remove seal guide (11) with push tool [4]. a Press fit the bearing inner race, turning
the roller, until the roller becomes a little
11. Remove floating seal (12) from seal guide (11). hard to turn.
a Clean the all parts and check them for dirt. a After the nut is tightened, if its hole is not
matched to the hole of the shaft, match its
1. Press fit bearing inner race (9) with push tool hole by loosening the nut.
[5].
6. Install ring (3).
2. Press fit bearing outer race (7) with push tool
[6].
D475A, D475ASD-5E0 19
SEN02017-04 50 Disassembly and assembly
8. Install floating seal (10) to seal guide (8) with 12. Supply specified quantity of oil by using tool L4
tool L5. and tighten the oil filler plug.
5 Carrier roller: 1.25 1.35 l (GO140)
9. Fit the O-ring to seal guide (8) and install them, 3 Oil filler plug:
matching them to the dowel pin. 157 255 Nm {16 26 kgm}
20 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
New/Remodel
Necessity
Symbol
Sketch
Qty
Part No. Part Name
791T-830-
Plate t 3 N Q
1780
13
01011-62700 Bolt t 6
01673-32780 Washer t 6
1 791-830-1620 Plate t 1 N
2 791-830-1630 Spacer t 1 N
3 791-830-1640 Screw t 3 N
4 01580-12722 Nut t 3
14
5 01630-32780 Washer t 3 3. Operate the blade and ripper to lift the machine
Puller body until the track roller assembly separates
6 790-101-4000 t 1 from the track link.
(490 kN {50 ton})
7 790-101-1102 Pump t 1 k Set a block between the track roller and
track link so that the machine body will
1 791-830-1650 Plate t 1 N
not lower.
2 791-830-1660 Spacer t 1 N
3 796-670-1120 Plate t 1 4. Set block [1] out of the track shoe, matching it
4 790-434-1070 Screw t 1 N to the height of the track link.
L
15 5 01580-13629 Nut t 2
6 01643-33690 Washer t 1 5. Set steel plate [2] on the track shoe and block
[1].
Puller
7 790-101-4000 t 1
(490 kN {50 ton})
6. Operate the blade and ripper to lower the
8 790-101-1102 Pump t 1
machine body until the track roller of bogie
1 791-830-1620 Plate t 1 N assembly (1) comes in contact with steel plate
2 791-830-1640 Screw t 3 N [2].
3 01580-12722 Nut t 3 a Operate the blade and ripper slowly, run-
16 4 01643-32780 Washer t 3 ning the engine at the low idling speed.
Puller
5 790-101-4000 t 1
(490 kN {50 ton})
6 790-101-1102 Pump t 1
791T-830-
17 Guide t 2 N Q
1670
18 791-530-1510 Installer t 1
19 791-601-1000 Oil pump t 1
D475A, D475ASD-5E0 21
SEN02017-04 50 Disassembly and assembly
22 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
12. Sling bogie assembly (1) and pull it out, sliding 2) Press fit shaft (3) to ring (8).
it on steel plate [2]. 3) Install spacer (9).
4 Bogie assembly: 1,200 kg 4) Press fit ring (7) to shaft (3).
5) Install spacer (6).
6) Press fit ring (4) to shaft (3).
2 Apply lubricant (LM-P) to parts (a)
(about 10 mm) of rings (8) and (4).
Installation
1. Assembly of pin assembly
1) Using tool L18, install floating seals (5) to
2. Apply lever block [3] between the guard of
rings (4) and (7) and install floating seals
bogie assembly (1) and the bogie assembly on
(10) to the opposite side of ring (7) and
the opposite side. Slide bogie assembly (1) on
ring (8).
the steel plate to set it to the mounting position.
a When installing the floating seals,
completely degrease the O-rings and
O-ring contacting surfaces.
a Check that each floating seal is not
inclined more than 1 mm.
D475A, D475ASD-5E0 23
SEN02017-04 50 Disassembly and assembly
24 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
New/Remodel
Necessity
Symbol
Sketch
Qty
Part No. Part Name
1 791-830-1620 Plate t 1 N
2 791-830-1640 Screw t 3 N
3 01580-12722 Nut t 3
16 4 01643-32780 Washer t 3
L
Puller
5 790-101-4000 t 1
(490 kN {50 ton})
6 790-101-1102 Pump t 1
19 791-601-1000 Oil pump t 1
Disassembly
Assembly
1. Track roller assembly
1. Assembly of pin assembly
Turn over bogie assembly (1) and lift off 2 track
Assemble the pin assembly according to
roller assemblies (2).
Removal and installation of bogie assembly
(Steps 3 5 of Installation).
D475A, D475ASD-5E0 25
SEN02017-04 50 Disassembly and assembly
2) Press fit the pin assembly. 5. Press fit the pin assembly on the opposite side
a Direct arrow (a) on the end face of the of the bogie according to above steps 3 and 4.
pin assembly up (when the pin a After press fitting the pin assembly, rock
assembly is installed to the machine). the small bogie so that it can be moved
a Push in the pin assembly with cover with light force.
(3).
a Push in the pin assembly to the 6. Tighten the mounting bolts of pin assembly
machined face (b) of the bogie and cover (3) (2 places on inside and outside).
secure the level difference of 5 mm 3 Cover mounting bolt:
between the bogie and pin assembly. 883 1,470 Nm {90 150 kgm}
2 Apply lubricant (LM-P) all over
the side of the pin assembly. 7. Track roller assembly
a Total press fitting force of pin assem- Sling and install 2 track roller assemblies (2) to
bly: bogie assembly (1).
294.2 490.5 kN {30 50 tons} 2 Track roller mounting bolt:
Adhesive (LT-2)
3 Track roller mounting bolt:
2,205 2,695 Nm {225 275 kgm}
26 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
New/Remodel
a position where track roller of No. 2 bogie
Necessity
Symbol
Sketch
assembly is separated from track link.
Qty
Part No. Part Name
k Set a block between the track roller and
the track link to prevent the chassis
1 791-830-1620 Plate t 1 N from coming down.
2 791-830-1630 Spacer t 1 N
3. Fit eyebolts to holes of pad mounting bolt (M12
3 791-830-1640 Screw t 3 N
x 2) portion at rear of No. 1 bogie assembly,
4 01580-12722 Nut t 3 and raise No. 1 bogie assembly (1).
14
5 01630-32780 Washer t 3
Puller
6 790-101-4000 t 1
(490 kN {50 ton})
7 790-101-1102 Pump t 1
1 791-830-1650 Plate t 1 N
2 791-830-1660 Spacer t 1 N
3 796-670-1120 Plate t 1
4 790-434-1070 Screw t 1 N
15 5 01580-13629 Nut t 2
6 01643-33960 Washer t 1
Puller
7 790-101-4000 t 1
(490 kN {50 ton})
8 790-101-1102 Pump t 1
1 791-830-1620 Plate t 1 N 4. Put steel plate between track shoe and roller,
then loosen roller cap bolts (2) approx. 20 mm.
2 791-830-1640 Screw t 3 N
(Both inside and outside)
L 3 01580-12722 Nut t 3
16 4 01643-32780 Washer t 3 5. Tap end face of shaft (3) with hammer and
5 790-101-4000
Puller
t 1
remove track roller assembly (4).
(490 kN {50 ton}) q There is a dowel pin on the near side of
6 790-101-1102 Pump t 1 the track roller assembly, so be careful not
17 791T-830-1670 Guide t 2 N Q to break it.
18 791-530-1510 Installer t 1 (Dowel pin insertion tolerance: 5 6 mm)
19 791-601-1000 Oil pump t 1
6. Remove roller cap bolt (2), then put track roller
791-630-1860 Bracket t 1 assembly (4) on steel plate, and pull out.
4
791-630-1870 Bracket t 1
Track roller assembly: 240 kg
20 791T-830-1510 Spacer t 2 Q
19M-09-12850 Bolt t 2
01643-33380 Washer t 2
791T-830-1700 Lifting tool t 1 N Q
791T-830-1710 Bar 1 N Q
791T-830-1720 Plate 1 N Q
21 07283-31079 Grip 1
01582-01210 Nut 2
01643-31232 Washer 2
04530-11628 Eye bolt 1
D475A, D475ASD-5E0 27
SEN02017-04 50 Disassembly and assembly
7. Raise No. 1 bogie (5) with tool L20 and hold in 3) Remove floating seals (9) from the end
position. faces of rings (8) and (12).
a Store the floating seals so that they
8. Remove cover (6). will not be damaged.
28 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
10. Lower bogie (5) on the steel plate and pull it 2) Press fit shaft (7) to ring (13).
out. 3) Install spacer (14).
4 Bogie assembly: 180 kg 4) Press fit ring (12) to shaft (7).
5) Install spacer (11).
6) Press fit ring (8) to shaft (7).
2 Apply lubricant (LM-P) to parts (a)
(about 10 mm) of rings (13) and (8).
Installation
1. Assembly of pin assembly
1) Using tool L18, install floating seals (9) to
2. Slide bogie (5) on steel plate [1] to the center.
rings (8) and (12) and install floating seals
(10) to the opposite side of ring (12) and
3. Set bogie (5) to the mounting position with tool
ring (13).
L20.
a When installing the floating seals,
completely degrease the O-rings and
O-ring contacting surfaces.
a Check that each floating seal is not
inclined more than 1 mm.
D475A, D475ASD-5E0 29
SEN02017-04 50 Disassembly and assembly
30 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
D475A, D475ASD-5E0 31
SEN02017-04 50 Disassembly and assembly
Removal
1. Disconnect power connector (2) of operator's
seat (1).
Installation
q Perform installation in the reverse order to
removal.
32 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
Disassembly
q Perform disassembly in the reverse order to
assembly.
Assembly
1. Install stopper rubbers (3) to two stopper
bosses (2) of base plate (1).
a Hitch one side of stopper rubber (3) to the
groove of the boss and press it with a
round bar to install it to the boss. 2. Install four laminated rubbers (4) to base plate
(1) with eight M10 bolts (5).
3 Laminated rubber mounting bolt:
40 Nm {4.08 kgm}
D475A, D475ASD-5E0 33
SEN02017-04 50 Disassembly and assembly
4. Install protection tube (9) side of damper (8) to 7. Insert the top plate mounting pin into free side
the mounting pin of the base plate. (15) of the damper installed to the top plate
and remove the tape.
10. Turn over the top plate, install slotted head nut
(10) to the mounting pin, and pass cotter pin
(11) and bend it to secure. (Two places)
34 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02017-04
D475A, D475ASD-5E0 35
SEN02017-04
2016 KOMATSU
All Rights Reserved
Printed in Japan 02-16 (01)
36
SEN02018-02
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN02018-02 50 Disassembly and assembly
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
D475A, D475ASD-5E0 3
SEN02018-02 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
expansion (normal).
[*1]
a For details of the track shoe tension, see
Testing and adjusting, Testing and adjust-
ing of track shoe tension.
a Tighten all of the 4 bolts with the fingers
until the master link contacting faces are
fitted to each other.
a If a bolt is tightened forcibly before the
master link contacting faces are fitted to
each other, the threads of that bolt and the
master link may be damaged.
[*2]
a Tighten the master link shoe mounting
bolts in the order shown in the diagram
below.
2 Shoe mounting bolt:
Seizure prevention compound
(Maruzen Molymax No. 2 or
equivalent)
3 Shoe mounting bolt:
1st step:
980 98 Nm {100 10 kgm}
2nd step:
Tighten a further 180 10
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
New/remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
D475A, D475ASD-5E0 5
SEN02018-02 50 Disassembly and assembly
2. Disassembly of link
1) Set the link assembly on the link press
and hit it with a hammer so that the bush-
ing will be fitted to the jaw.
a If the link tread, outside of the bush-
ing, etc. are worn, adjust the height of
the jaw or guide plate to align the dis-
assembly jig with the pin and bushing
so that the link hole will not be dam-
aged during disassembly.
a If the above parts are not aligned per-
fectly, the link hole may be damaged
and the pin and bushing may be bro-
ken during disassembly.
a The track press operator and other workers a Drive the small plug of the pin inward
must put on helmets, safety glasses and ear- with tool R1 after disassembly to
plugs. avoid making the workshop dirty.
1. Removal of shoe
Sling the shoe assembly and set it on a floor
with the shoe up. Remove the shoe with a
shoe bolt impact wrench.
a If a shoe bolt is still hard (If its torque is not
lowered to 0) after it is unscrewed by 1
turn, loosen the other bolts, and it can be
removed easily.
a If a bolt is unscrewed forcibly while its
torque is not 0, it will stick to the link and
will need to be repaired.
a When moving the shoe assembly, take
care not to damage the master link.
a If it is obliged to cut a shoe nut with gas,
keep the temperature of the sealing parts
below 80C and prevent the spatters from
entering the clearance of the link so that
the sealing parts will not be deteriorated
by the heat.
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
2) Operate the left cylinder to pull out the fit- 4) Return the right cylinder and take out the
ted parts of the left link, pin, and bushing links, pins, bushings, and spacers on both
simultaneously. sides, then send the next link assembly to
a Check the pulling out force of the pin the jaw.
and bushing to see if the necessary a If the end faces of the bushings and
fitting force of the pin and bushing is sealing surfaces are damaged, oil will
obtained when they are turned over leak. Accordingly, handle them with
and assembled. care.
a When the wedge link is cut, it bangs. a Take care not to scratch your hands
This phenomenon is normal. with the sharp edges of a cut wedge
link.
D475A, D475ASD-5E0 7
SEN02018-02 50 Disassembly and assembly
8 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
2) When reusing the pin, chamfer the cor- 1] Insert the plug in the hole of the guide
ners of its end smoothly with a grinder. through the plug inserting hole.
Remove the projections of the fitting parts 2] Push the bar with the hand and insert
with the grinder. the plug until it stops.
a If the corners of the pin end are worn 3] Push the plug with the bar to press
and sharpened, they may scuff the fit- the guide against the pin.
ting parts to cause oil leakage. 4] Drive the bar with a hammer.
a Driving distance (a) from pin end:
10 1 mm
a If the edge of the pin hole is worn
and sharpened, chamfer it with a
small grinder (wheel tip angle: 45
60) so that the plug will not be
damaged.
a Coat the plug with GO90 and
drive it with the smaller end
ahead.
D475A, D475ASD-5E0 9
SEN02018-02 50 Disassembly and assembly
10 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
4) Turn over the master links and check that 7) Apply gasket sealant (198-32-19890) to
they are press fitted in parallel. the pin fitting hole of the link to prevent oil
from oozing through the scuffs of the pin
fitting parts.
D475A, D475ASD-5E0 11
SEN02018-02 50 Disassembly and assembly
9) Set the right jig on the receiving side and 11) Set the left link and install the spacer to
the left jig on the pushing side and press the pin.
fit the pin and bushing simultaneously. a Apply oil similarly to the right link.
a If the jigs shake while the pin and
bushing are press fitted, the seal may
come off the link. Accordingly, press
fit smoothly. If the seal comes off the
link, stop press fitting and install the
seal to the link correctly, then start
press fitting again.
a Press fitting force of pin and bushing:
578 833 kN {59 85 tons}
12 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
13) Press fit until the link, spacer, and bushing 15) Install the ring to jig R12.
are fitted to each other.
a Actually, you cannot see from outside
if the above parts are fitted. Accord-
ingly, control the hydraulic pressure of
the link press. Set the relief pressure
to a proper level and heighten the
hydraulic pressure to that level.
For setting of the relief pressure, see
Preparation work.
a Check that adjacent 2 links can turn
around each other.
D475A, D475ASD-5E0 13
SEN02018-02 50 Disassembly and assembly
18) Push in the ring with jig R13. 20) Supply oil (GO90) with tool R5 until the oil
Pushing force of ring: supply pressure rises to 196 294 kPa {2
392 490 kN {40 50 tons} 3 kg/cm2}.
a In a cold or very cold district, supply
Komatsu genuine oil (150-09-19270
or 195-32-61990) having better low-
temperature characteristics instead of
GO90.
a If the oil pressure is heightened too
much, it has bad effects on the seal.
Take care.
14 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
21) After supplying oil, drive in the small plug 2) When installing a double track, place the
to the specified position with tool R4. assembled double shoes on a level place
a Apply GO90 around the small plug. in 1 line with the shoe side up. Pull pin-
a Drive in the plug to the following side master link (1) and bushing-side mas-
depth. ter link (2) together and set them to each
Driving depth from end: 7.5 1 mm other by the mating faces. Place shoe (3)
22) Assemble the master link on the pin side on the links and check that master bolts
at last. (4) can be tightened easily by hands until
a Check that the master links on both the mating faces of the links are fitted
sides are press fitted in parallel. together, and then connect the master
links.
3. Installation of shoe
1) Set the link assembly on the bed and 2 Shoe bolt:
install the shoe with a shoe bolt impact Lubricant containing molybde-
wrench and a torque wrench. num disulfide (LM-P)
2 Shoe bolt: 3 Shoe bolt (Master link)
Lubricant containing Initial torque:
molybdenum disulfide (LM-P) 980 98 Nm {100 10 kgm}
3 Shoe bolt (Regular link) Retightening angle: 180 10
Initial torque: a Tighten the bolts in the order of [1]
784 78 Nm {80 8 kgm} [4].
Retightening angle: 180 10
D475A, D475ASD-5E0 15
SEN02018-02 50 Disassembly and assembly
When recycling for grease lubricated track 4) Clean the outside of the pin, surfaces of
1. Preparation work the spacer, and end faces and inside of
1) Cleaning of seal assembly the bushing, if they are dirty.
Take the seal assembly out of the link and 5) Apply grease to the outside of the pin and
divide it into the seal ring and load ring, surfaces of the spacer.
then clean them.
a Since the seal ring and load ring are
deteriorated easily by cleaning liquid,
clean them quickly. After cleaning
them, wipe off the cleaning liquid.
16 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
7) Adjust the dimensions of the fitting jig of 2) Press fit both bushing-side master links to
the link press to keep the projection dis- the bushings with the shoe fitting faces up.
tance of the pin and bushing constant and a At this time, use the pin-side master
keep the fitting dimensions of the seal links as supports.
within the limits when those parts are a Fitting force of bushing:
assembled. 245 382 kN {25 39 tons}
a For the standard dimensions, see
Press-fitting jig dimension table for
link press.
a If the pin end (Part P) and link sides
(Parts Q and R) are worn, count in the
quantity of the wear when adjusting
the dimensions of the fitting jig so that
the pin and bushing will be projected
by the same distance on both sides.
D475A, D475ASD-5E0 17
SEN02018-02 50 Disassembly and assembly
18 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
9) Install the ring to jig R12. 12) Assemble the master link on the pin side
at last.
a Check that the master links on both
sides are press fitted in parallel.
D475A, D475ASD-5E0 19
SEN02018-02 50 Disassembly and assembly
20 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
D475A, D475ASD-5E0 21
SEN02018-02 50 Disassembly and assembly
Special tools
New/Remodel
New/Remodel
Necessity
Necessity
Symbol
Symbol
Sketch
Sketch
Qty
Qty
Part No. Part Name Part No. Part Name
22 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
D475A, D475ASD-5E0 23
SEN02018-02 50 Disassembly and assembly
24 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
3. Set link (10) on the opposite side and support it 6. Similarly to the disassembly procedure, push
with tool R8-19. open link (11) to be connected by using tools
R8-30 and R8-31.
D475A, D475ASD-5E0 25
SEN02018-02 50 Disassembly and assembly
26 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
Special tools
New/Remodel
New/Remodel
Necessity
Necessity
Symbol
Symbol
Sketch
Sketch
Qty
Qty
Part No. Part Name Part No. Part Name
D475A, D475ASD-5E0 27
SEN02018-02 50 Disassembly and assembly
28 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
D475A, D475ASD-5E0 29
SEN02018-02 50 Disassembly and assembly
5) Install ring (6) with tools R8, R9, R11, R12, 2) Pass pin (10) through bushing (9) and set
and R13. and press fit pin-side master links (11)
6) Install the shoe to the link of the connect- from both sides with tool R8.
ing part. 3) Install the ring with tools R8, R9, R11,
7) Drive large plug (7) with tool R3 and sup- R12, and R13.
ply oil with tool R5, then drive small plug 4) Drive large plug (13) with tool R3 and sup-
(8) with tool R4. ply oil with tool R5, then drive small plug
a When press fitting both master links, (14) with tool R4.
take care that they will be in parallel
with each other (Bushing side and pin
side).
a Do not damage the mating surfaces
of the master links and end faces of
the bushing.
a Take care that dirt and sand will not
stick to the seal, spacer, end of bush-
ing, and tap-hole mating face of the
master link.
30 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
Removal and installation of pivot 3. Remove seal (2), then remove cover (3). [*2]
shaft assembly
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791T-850-1180 Sleeve t 1 Q
791T-850-1190 Plate t 1 Q
791-730-1130 Bolt t 2
791-101-3310 Plate t 1
P
01643-32060 Washer t 2
Installation
01580-02016 Nut t 2
q Carry out installation in the reverse order to
790-105-2300 Jack assembly t 1 removal.
790-101-1102 Pump t 1
[*1]
2 Pivot shaft press-fitting surface:
Removal
Anti-friction compound (LM-P)
2
1. Remove track frame assembly. Pivot shaft mounting bolt:
For details, see "Removal of track frame Adhesive (LT-2)
3
assembly". Pivot shaft mounting bolt:
1,519 1,911 Nm {155 195 kgm2}
2. Sling pivot shaft assembly (1) and remove
mounting bolts, then using forcing screw [1], [*2]
pull out pivot shaft assembly. [*1] a Using tool P, press fit seal (2) to the pivot
4 Pivot shaft assembly: 390 kg shaft.
2 Seal press-fitting surface:
Gasket sealant (LG-6)
a Check that press-fitting dimension (a) of
the seal from the end face of the shaft is
the specified dimension.
q Press-fitting dimension (a): 665 1.0 mm
q Press-fitting surface:
20.6 32.4 kN {2.1 3.3 ton}
D475A, D475ASD-5E0 31
SEN02018-02 50 Disassembly and assembly
Removal and installation of 5. Set stand and hydraulic jack [1] (294 kN {30
equalizer bar ton}) under radiator guard.
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
792-900-1610 Adapter t 1
792-900-1530 Screw t 1
791-775-1110 Sleeve t 1
791T-850-1150 Plate t 1 Q
N 1 01582-53024 Nut t 1
6. Remove cover (6).
01643-33080 Washer t 1
Puller 7. Remove cover (7).
790-101-2102 t 1
(294 kN {30t on})
790-101-1102 Pump t 1 8. Remove main bolt (8) of side pin.
Removal
1. Remove engine underguard and power train
underguard (front).
4 Engine underguard: 330 kg
4 Power train underguard (front): 340 kg
32 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
10. Operate hydraulic jack [1] slowly and lower 14. Operate blade and raise front of chassis, and
chassis to point where equalizer bar contacts set hydraulic jack under radiator guard.
left and right track frames.
15. Raise equalizer bar (13), move it past main
11. Disconnect lubrication tube (10). frame and track frame, and remove.
k After removing the equalizer bar, do
12. Remove lock plate (11). [*4] not lower the chassis.
4 Equalizer bar assembly: 600 kg
[*2]
3 Main mounting bolt of side pin:
2,450 2,695 Nm {250 275 kgm}
a After tightening main mounting bolts (8) of
the side pin, tighten the mounting bolts of
covers (6) and (7).
a Take care of the tightening order of main
mounting bolts (8) of the side pin and the
mounting bolts of covers (6) and (7).
D475A, D475ASD-5E0 33
SEN02018-02 50 Disassembly and assembly
[*3]
2 Inside surface of bushing:
Grease (G2-LI)
a Before installing the pin, operate hydraulic
jack [1] to adjust the height of the main
frame and align the center of the equalizer
bar hole and track frame hole.
a Set the pin with the grease hole facing the
outside of the machine.
[*4]
2 Lock plate mounting bolt:
Tread tightener (LT-2)
3 Lock plate mounting bolt:
1,519 1,911 Nm {155 195 kgm}
[*5]
2 Equalizer bar bushing and main frame
bushing: Grease (G2-LI)
a Before installing the pin, operate the crane
to align the center of the main frame hole
and the equalizer bar hole.
34 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791T-850-1160 Bracket t 1 Q
791T-850-1170 Bracket t 1 Q
790-438-1110 Screw t 1
790-101-2540 Washer t 2
N 2
791-112-1180 Nut t 2
Puller Assembly
790-101-2102 t 1
(294 kN {30 ton})
1. Side bushing
790-101-1102 Pump t 1 1) Set side bushing (4) and tool N2 in posi-
tion, then press fit side bushing (4) to
Disassembly equalizer bar (5).
1. Center bushing 2 Outer circumference of bushing:
2. Side bushing
1) Remove seals (2).
2) Remove snap ring (3).
D475A, D475ASD-5E0 35
SEN02018-02 50 Disassembly and assembly
36 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02018-02
D475A, D475ASD-5E0 37
SEN02018-02
2010 KOMATSU
All Rights Reserved
Printed in Japan 04-10
38
SEN02019-01
D475A-5E0
D475ASD-5E0
Hydraulic system
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
D475A, D475ASD-5E0 1
SEN02019-01 50 Disassembly and assembly
Removal
k Lower the work equipment to the ground
and stop the engine. Release the remaining
pressure in the hydraulic piping.
For details, see Testing and adjusting,
" R e l e a s i n g r e m a i n i n g p re s s u re f r o m
hydraulic circuit".
Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic
tank.
k Disconnect the cable from the negative ()
terminal of the battery. 6. Remove tube coupling (6).
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02019-01
Installation
q Carry out installation in the reverse order to
removal.
D475A, D475ASD-5E0 3
SEN02019-01 50 Disassembly and assembly
Removal and installation of 6. Disconnect 5 PPC hoses (5) from bottom side.
hydraulic valve assembly a PPC hoses are distinguished by color
bands.
3. Remove hose (1). 10. Disconnect wiring connectors (11) and (12),
and clamp (13).
4. Disconnect 5 PPC hoses (2) from upper side.
11. Sling control valve assembly (14), and then
remove.
4 Main control valve assembly: 195 kg
Installation
q Carry out installation in the reverse order to
removal.
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02019-01
D475A, D475ASD-5E0 5
SEN02019-01 50 Disassembly and assembly
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02019-01
Disassembly Assembly
1. Ripper lift valve q Coat the sliding surface of each part with
1) Remove case (1), spring (12), and retainer engine oil before installing.
(9).
2) Remove lower case (1), spring (12), and 1. Ripper tilt valve
retainer (9). 1) Install spool (2) to the valve body.
3) Remove spool (2). 2) Install lower retainer (9) and spring (12).
a Do not disassemble spool assembly Fit the O-ring to case (1) and install them.
(2). 3) Install retainer (9) and spring (12). Fit the
O-ring to case (1) and install them.
2. Blade right tilt valve 3 Case mounting bolt:
1) Remove case (1), spring (15), and retainer 27.5 34.3 Nm {2.8 3.5 kgm}
(9).
2) Remove lower case (1), spring (15), and 2. Blade left tilt valve
retainer (9). 1) Install spool (3) to the valve body.
3) Remove spool (3). 2) Install lower retainer (9) and spring (15).
a Do not disassemble spool assembly Fit the O-ring to case (1) and install them.
(3). 3) Install retainer (9) and spring (15). Fit the
O-ring to case (1) and install them.
3. Blade lift valve 3 Case mounting bolt:
1) Remove case (3), loosen bolt (8), and 27.5 34.3 Nm {2.8 3.5 kgm}
remove retainer (7) and spring (6).
2) Remove plate (2), spring (13), and 3. Blade lift valve
retainer (10). 1) Install spool (4) to the valve body.
3) Remove lower case (1), plate (2), spring 2) Install lower retainer (11), spring (14), and
(14), and retainer (11). plate (2). Fit the O-ring to case (1) and
4) Remove spool (4). install them.
a Do not disassemble spool assembly 3) Install retainer (10), spring (13), and plate
(4). (2).
4) Install spring (6) and retainer (7) to case
4. Blade lift valve (3) and secure them with bolt (8). Fit the
1) Remove case (3), loosen bolt (8), and O-ring to case (3) and install them.
remove retainer (7) and spring (6). 3 Retainer mounting bolt:
2) Remove plate (2), spring (13), and 11.8 14.6 Nm {1.2 1.5 kgm}
retainer (10). 3 Case mounting bolt:
3) Remove lower case (1), plate (2), spring 27.5 34.3 Nm {2.8 3.5 kgm}
(14), and retainer (11).
4) Remove spool (4). 4. Blade lift valve
a Do not disassemble spool assembly 1) Install spool (4) to the valve body.
(4). 2) Install lower retainer (11), spring (14), and
plate (2). Fit the O-ring to case (1) and
5. Blade left tilt valve install them.
1) Remove case (1), spring (15), and retainer 3) Install retainer (10), spring (13), and plate
(9). (2).
2) Remove lower case (1), spring (15), and 4) Install spring (6) and retainer (7) to case
retainer (9). (3) and secure them with bolt (8). Fit the
3) Remove spool (3). O-ring to case (3) and install them.
a Do not disassemble spool assembly 3 Retainer mounting bolt:
(3). 11.8 14.6 Nm {1.2 1.5 kgm}
3 Case mounting bolt:
6. Ripper tilt valve 27.5 34.3 Nm {2.8 3.5 kgm}
1) Remove case (1), spring (12), and retainer
(9).
2) Remove lower case (1), spring (12), and
retainer (9).
3) Remove spool (2).
a Do not disassemble spool assembly
(2).
D475A, D475ASD-5E0 7
SEN02019-01 50 Disassembly and assembly
8 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02019-01
D475A, D475ASD-5E0 9
SEN02019-01 50 Disassembly and assembly
Disassembly Assembly
1. Remove case (7) from valve body (1). Loosen q Coat the sliding surface of each part with
bolt (6) and remove retainer (8), spring (5), engine oil before installing.
retainer (4), plug (3), and spool (2).
1. Fit the O-ring and install ball (37), spring (36),
2. Remove plug (14), spring (12), and spool (11). and seat (35) to block (30).
3 Seat: 9.8 12.7 Nm {1.0 1.3 kgm}
3. Remove plug (18), spring (17), and spool (16).
2. Fit the O-ring and install valve assembly (20) to
4. Remove plug (33), spring (32), and spool (31) block (30).
from block (30). 3 Valve assembly:
24.5 34.3 Nm {2.5 3.5 kgm}
5. Remove valve assembly (20) from block (30).
3. Install spool (31) and spring (32). Fit the O-ring
6. Remove seat (35), spring (36), and ball (37) and install plug (33).
from block (30). 3 Plug assembly:
a After disassembling, if any of body (1) and 19.6 24.5 Nm {2 2.5 kgm}
spools (2), (11), and (16) is defective,
replace the whole merge divider valve 4. Install spool (16) and spring (17). Fit the O-ring
assembly. to plug (18) and install them to valve body (1).
3 Plug assembly:
147.1 186.3 Nm {15 19 kgm}
10 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02019-01
Removal
k Lower the work equipment to the ground
and stop the engine. Release the remaining
pressure in the hydraulic piping.
For details, see Testing and adjusting,
Releasing remaining pressure from hydrau-
lic circuit.
Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic
tank.
Installation
q Carry out installation in the reverse order to
removal.
D475A, D475ASD-5E0 11
SEN02019-01 50 Disassembly and assembly
New/remodel
Necessity
1) Remove quick drop valve assembly (1).
Symbol
Sketch
Q'ty
Part No. Part Name
Cylinder repair
1 790-502-1003 q 1
stand
790-201-1702 Push tool kit t 1
790-201-1881 Push tool 1
790-201-1871 Push tool 1
2
790-201-1721 Push tool 1
790-101-5021 Grid 1
01010-50816 Bolt 1
790-201-1500 Push tool kit t 1
790-201-1670 Plate 1 2) Disassemble quick drop valve assembly
as follows.
790-201-1680 Plate 1 1] Remove elbow (2).
3 790-201-1690 Plate 1 2] Remove spring (3), washer (4), and
790-201-1530 Plate 1 valves (5) and (6), and pull out collar
U
(7).
790-101-5021 Grip 1
01010-50816 Bolt 1
4 790-720-1000 Expander t 1
796-720-1690 Ring t 1
07281-01919 Clamp t 1
796-720-1690 Ring t 1
07281-02169 Clamp t 1
5
796-720-1710 Ring t 1
07281-02709 Clamp t 1
796-720-1630 Ring t 1
07281-00709 Clamp t 1
6 790-102-2304 Wrench t 1
12 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02019-01
5. Head assembly
1) Remove head assembly (19) from piston
rod.
4. Piston assembly
1) Set piston rod assembly (10) to tool U1.
D475A, D475ASD-5E0 13
SEN02019-01 50 Disassembly and assembly
Assembly
a Coat the sliding surfaces of all parts with
engine oil before installing. Be careful not to
damage the packings, dust seals, and O-rings
when installing.
1. Head assembly
1) Assemble head assembly as follows.
1] Using tool U2, press fit bushing (25)
to head.
2] Install packing (24).
3] Using tool U3, press fit seal (23). 2) Install head assembly (19) to piston rod.
4] Install snap ring (22).
14 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02019-01
D475A, D475ASD-5E0 15
SEN02019-01 50 Disassembly and assembly
2) Assemble piston rod (10) to cylinder (8). 2) Install quick drop valve assembly (1).
a Coat the seal portion of the piston
with grease.
a Push in the piston rod fully.
3) Push head assembly to cylinder and
tighten mounting bolts.
a Coat the backup ring with grease.
3 Mounting bolt:
Blade lift:
490 49 Nm {50 5 kgm}
Blade tilt, ripper lift, ripper tilt:
1,320 140 Nm {135 15 kgm}
5. Cylinder tube
Install cylinder tube.
16 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02019-01
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Cylinder repair
1 790-502-1003 q 1
stand
790-201-1702 Push tool kit t 1
790-201-1881 Push tool 1
790-201-1871 Push tool 1 2. Cylinder head assembly
2 1) Remove cylinder head assembly (2) from
790-201-1721 Push tool 1
piston rod (3).
790-101-5021 Grid 1
01010-50816 Bolt 1
790-201-1500 Push tool kit t 1
790-201-1670 Plate 1
790-201-1680 Plate 1
3 790-201-1690 Plate 1
U 790-201-1530 Plate 1
790-101-5021 Grip 1
01010-50816 Bolt 1
4 790-720-1000 Expander t 1
796-720-1690 Ring t 1
07281-01919 Clamp t 1 2) Remove O-ring (5) and backup ring (6).
3) Remove O-ring (7).
796-720-1690 Ring t 1
4) Remove snap ring (8), then remove dust
07281-02169 Clamp t 1 seal (9).
5
796-720-1710 Ring t 1 5) Remove rod packing (10), then remove
bushing (11).
07281-02709 Clamp t 1
796-720-1630 Ring t 1
07281-00709 Clamp t 1
6 790-102-2304 Wrench t 1
Disassembly
1. Cylinder assembly
1) Set pin puller cylinder assembly (1) to tool
U1.
2) Using tool U6, loosen cylinder head
assembly (2).
3) Remove piston rod (3) together with cylin-
der head assembly (2).
D475A, D475ASD-5E0 17
SEN02019-01 50 Disassembly and assembly
18 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02019-01
3) Install snap ring (8) and rod packing (10). 3. Cylinder assembly
4) Install O-ring (7). 1) Set cylinder to tool U1 and support with
5) Install backup ring (6) and O-ring (4). block [1].
2) Install piston rod (3) together with cylinder
head assembly (2).
a Coat the seal portion of the piston
with grease.
a Coat the backup ring with grease.
a Push in the piston fully.
3) Using tool U6, tighten cylinder head
assembly (2).
3 Cylinder head assembly:
441 44.1 Nm {45 4.5 kgm}
D475A, D475ASD-5E0 19
SEN02019-01
2008 KOMATSU
All Rights Reserved
Printed in Japan 06-08 (01)
20
SEN02020-00
D475A-5E0
D475ASD-5E0
Work equipment
Work equipment .............................................................................................................................................. 2
Removal and installation of blade assembly ........................................................................................ 2
Disassembly and assembly of giant ripper assembly .......................................................................... 4
D475A, D475ASD-5E0 1
SEN02020-00 50 Disassembly and assembly
Work equipment 1
Removal and installation of blade k Release the remaining pressure from the
assembly 1
hydraulic circuit.
For details, see Testing and adjusting,
" R e l e a s i n g re m a i ni n g pr e s s ur e f ro m
Removal hydraulic circuit".
k Lower the work equipment to the ground in Then loosen the oil filler cap slowly to
a horizontal place, and set blocks [1] release the pressure inside the hydraulic
securely under the left and right straight tank.
frames.
3. Remove left and right covers (4).
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02020-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Adjust with block [1] so that height (b) and
width (c) of the left and right straight frames are
the dimensions given below.
q Height (b) of trunnion portion:
Approx. 981 mm
q Brace width (c): Approx. 3,840 mm
D475A, D475ASD-5E0 3
SEN02020-00 50 Disassembly and assembly
Disassembly and assembly of 7. Disconnect 4 lift cylinder hoses (4), 4 tilt cylin-
giant ripper assembly der hoses (5), and 2 pin-puller cylinder hoses
(6).
Disassembly
1. Mount machine on block [1] and lower blade to
ground.
k Lock the brake securely.
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02020-00
10. Sling beam (11), then remove left and right 2. Sling beam (11) and set in mounting position,
pins (12) and lift off beam (11). then fit left and right pins (12) and secure with
4 Beam: 2,450 kg lock plate.
4 Arm: 2,450 kg
a Set a stand under the beam.
11. Sling arm (13), then remove left and right pins
(14) and lift off arm (13).
4 Arm: 1,800 kg 3. Sling lift cylinder assembly (9) and set in
mounting position, then fit pin (10) and secure
with lock plate.
4 Lift cylinder assembly: 400 kg
Assembly
1. Sling arm (13) and set in mounting position,
then fit left and right pins (14) and secure with 4. Sling tilt cylinder assembly (7) and set in
lock plate. mounting position, then fit pin (8) and secure
4
with lock plate.
Arm: 1,800 kg
a Set a stand under the arm. 4 Tilt cylinder assembly: 410 kg
D475A, D475ASD-5E0 5
SEN02020-00 50 Disassembly and assembly
5. Connect 2 pin-puller cylinder hoses (6), 4 tilt 8. Mount machine on block [1] and lower blade to
cylinder hoses (5), and 4 lift cylinder hoses (4). ground.
k Lock the brake securely.
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02020-00
D475A, D475ASD-5E0 7
SEN02020-00
2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (01)
8
SEN02021-01
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN02021-01 50 Disassembly and assembly
Removal
1. Sling ROPS guard (1) and remove 16 mount-
ing bolts (2). [*1]
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 ROPS guard mounting bolt:
1,960 2,450 Nm {200 250 kgm}
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02021-01
Removal and installation of 6. Remove front covers (8), (9) and (10).
operators cab assembly
7. Remove 3 mounting bolts (11), 6 bolts (12) and
15 bolts (13).
Removal
k Disconnect the cable from the negative ()
terminal of the battery.
D475A, D475ASD-5E0 3
SEN02021-01 50 Disassembly and assembly
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02021-01
6. Disconnect wiring harness connectors (7) 11. Remove brake rod (17).
(VF1-CA1-VF2), (8) (PL1-PL2-PL3), (9) (FD5-
BWR1-PWR2-USB-12V-20-21), and (10) (TCI- 12. Disconnect parking brake cable (18). [*3]
V12-BSW), and then disconnect the wiring
clamp. 13. Disconnect air conditioner hose (19). [*1]
Disconnect washer hose (11) and the clamp. a Collect the refrigerant (R134a) from the air
conditioner circuit.
8. Disconnect wiring connector (13) (995-111- 15. Disconnect wiring connector (21) and clamp
VFD) and remove the connector bracket. (22).
D475A, D475ASD-5E0 5
SEN02021-01 50 Disassembly and assembly
[*1]
a Install the hoses without twisting or inter-
ference.
a Install the air conditioner circuit hoses
carefully to prevent dirt, dust, or water
from getting inside the hoses.
a Check that there are O-rings at the piping
connection of the air conditioner hoses
before installing.
Coat the O-rings thoroughly with compres-
sor oil (Shell Suniso 4G or 5G).
20. Lift off floor frame assembly (27).
4 Floor frame assembly: 500 kg
a Use a chain block to adjust the balance in all
directions (front, rear, left, and right), and lift off
slowly.
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02021-01
[*2]
a The connecting positions of the PPC
hoses are indicated by the band colors on
their quick couplers. When connecting
them, confirm them by the band colors.
[*3]
a Adjust installed length of parking brake
cable. For details, see Testing and adjust-
ing, Adjusting brake pedal and parking
brake lever.
[*4]
a Adjust installed length of brake rod.
For details, see Testing and adjusting,
"Adjusting brake pedal and parking brake
lever".
3 Brake pedal linkage turnbuckle:
34.3 58.8 Nm {3.5 6 kgm}
D475A, D475ASD-5E0 7
SEN02021-01
2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
8
SEN02339-02
D475A-5E0
D475ASD-5E0
Electrical system
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
D475A, D475ASD-5E0 1
SEN02339-02 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
2 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02339-02
Removal
k Disconnect the cable from the negative ()
terminal of the battery.
Installation
q Carry out installation in the reverse order to
removal.
D475A, D475ASD-5E0 3
SEN02339-02 50 Disassembly and assembly
Removal
1. Open engine right side cover (1) and remove
side covers (2) and (3).
Installation
q Carry out installation in the reverse order to
removal.
4 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02339-02
D475A, D475ASD-5E0 5
SEN02339-02 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Install the air conditioner circuit hoses
carefully to prevent dirt, dust, or water
from getting inside the hoses.
a Check that there are O-rings at the piping
connection of the air conditioner hoses
before installing.
a Check that there is no defect or deteriora-
tion on the O-ring.
a When connecting the refrigerant piping,
coat the O-ring with compressor oil for
new refrigerant (R134a) (Denso: ND-
O I L 8 , Va l e o t h e r m a l s y s t e m s :
ZXL100PG (PAG 46 or equivalent)).
3 Air conditioner hose mounting bolt:
10 2 Nm {1.0 0.2 kgm}
[*2]
a Adjust the belt tension.
For details, see Testing and adjusting,
"Testing and adjusting tension of air condi-
tioner compressor belt".
6 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02339-02
D475A, D475ASD-5E0 7
SEN02339-02 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Install the hoses without twisting or inter-
ference.
a Install the air conditioner circuit hoses
carefully to prevent dirt, dust, or water
from getting inside the hoses.
a Check that there are O-rings at the piping
connection of the air conditioner hoses
before installing.
a Check that there is no defect or deteriora-
tion on the O-ring.
a When connecting the refrigerant piping,
coat the O-ring with compressor oil for
new refrigerant (R134a) (Denso: ND-
O I L 8 , Va l e o t h e r m a l s y s t e m s :
ZXL100PG (PAG 46 or equivalent)).
8 D475A, D475ASD-5E0
50 Disassembly and assembly SEN02339-02
D475A, D475ASD-5E0 9
SEN02339-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
10
SEN00225-00
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
90 Diagrams and drawings SEN00225-00
D475A, D475ASD-5E0 3
Hydraulic circuit diagram (1/3) Hydraulic circuit diagram (1/3)
D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0 5
Hydraulic circuit diagram (2/3) Hydraulic circuit diagram (2/3)
D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0 7
Hydraulic circuit diagram (3/3) Hydraulic circuit diagram (3/3)
D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0 9
SEN00225-00
2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)
12
SEN00226-03
D475A-5E0
D475ASD-5E0
D475A, D475ASD-5E0 1
SEN00226-03 90 Diagrams and drawings
2 D475A, D475ASD-5E0
Electrical circuit diagram (1/13) Electrical circuit diagram (1/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 3
Electrical circuit diagram (2/13) Electrical circuit diagram (2/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 5
Electrical circuit diagram (3/13) Electrical circuit diagram (3/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 7
Electrical circuit diagram (4/13) Electrical circuit diagram (4/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 9
Electrical circuit diagram (5/13) Electrical circuit diagram (5/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 11
Electrical circuit diagram (6/13) Electrical circuit diagram (6/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 13
Electrical circuit diagram (7/13) Electrical circuit diagram (7/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 15
Electrical circuit diagram (8/13) Electrical circuit diagram (8/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 17
Electrical circuit diagram (9/13) Electrical circuit diagram (9/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 19
Electrical circuit diagram (10/13) Electrical circuit diagram (10/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 21
Electrical circuit diagram (11/13) Electrical circuit diagram (11/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 23
Electrical circuit diagram (12/13) Electrical circuit diagram (12/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 25
Electrical circuit diagram (13/13) Electrical circuit diagram (13/13)
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0 27
90 Diagrams and drawings SEN00226-03
Electrical circuit diagram of inside cab Electrical circuit diagram of inside cab
D475A, D475ASD-5E0
D475A, D475ASD-5E0 29
Connector arrangement diagram
D475A, D475ASD-5E0
Connector arrangement diagram D475A, D475ASD-5E0
Connector Number Address of Connector Number Address of Connector Number Address of Connector Number Address of
Model Component name Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram No. of pins stereogram
1 Giboshi 1 Lamp outlet connector (Cab) J-9 BRE Terninal 1 Battery relay (Right) (Terminal E) E-8 GND4 Terninal 1 Ground (Engine) AT-3 SFTU 3 PCCS lever shift-up switch V-9
2 Terninal 1 Rear left speaker (Cab) J-9 BRE Terninal 1 Battery relay (Left) (Terminal E) I-2 H01 Giboshi 1 Additional heater switch (If equipped) Y-2 SL81 DT 2 Left brake ECMV (Solenoid) BB-6
3 Terninal 1 Rear left speaker (Cab) J-9 BRK DT 3 Brake potentiometer U-2 H02 Giboshi 1 Additional heater switch (If equipped) Y-2 SLC5 DT 2 Left clutch ECMV (Solenoid) BA-6
4 4 Rear wiper motor (Cab) I-9 BSW HD-18 14 Intermediate connector (BULGA specification) X-2 HLS DT 2 Hydraulic oil level switch (If equipped) H-9 SLS 2 Daylight sensor AF-8
5 Terninal 1 Rear right speaker (Cab) I-9 BUA DT 2 Backup alarm I-9 HP1 DT 3 Work equipment pump oil pressure (F) F-9 SR83 DT 2 Right brake ECMV (Solenoid) BB-6
6 Terninal 1 Rear right speaker (Cab) I-9 BUZ KES-1 3 Buzzer switch AH-7 HP2 DT 3 Work equipment pump oil pressure (R) F-9 SRC7 DT 2 Right clutch ECMV (Solenoid) BA-7
9 6 Front wiper motor (Cab) G-9 CB1 Terninal 1 Circuit breaker (20 A) (Steering controller) AK-4 HR1 DT-B 12 Intermediate connector (Hood) P-4 SRT1 DT 2 Reverse clutch ECMV (Solenoid) AX-5
10 9 Radio (Cab) K-9 CB2 Terninal 1 Circuit breaker (20 A) (Monitor panel) AK-4 HR2 DT-A 12 Intermediate connector (Hood) P-4 SRV DT-A 12 Service connector AH-2
11 KES1 6 Left wiper switch (Cab) J-1 CB3 Terninal 1 Circuit breaker (20 A) (Transmission controller) AK-4 HRN1 Terninal 1 Horn (415 Hz) D-1 SSA DT 4 Acceleration sensor (SSC model) R-1
12 KES1 6 Front wiper switch (Cab) J-2 CB4 Terninal 1 Circuit breaker (20 A) (Air conditioner) AK-3 HRN2 Terninal 1 Horn (350 Hz) C-7 ST/B2 Terninal 1 Safety relay (Terminal B) AV-4
13 KES1 6 Right wiper switch (Cab) K-2 CB5 Terninal 1 Circuit breaker (20 A) (Headlamp) AK-3 HT1 Terninal 1 Electrical intake air heater (Left bank) AV-6 ST1 DT 3 Intermediate connector (Starting motor A) AV-5
14 KES1 6 Rear wiper switch (Cab) K-2 CB6 Terninal 1 Circuit breaker (20 A) (Starting switch terminal B) AK-3 HT2 Terninal 1 Electrical intake air heater (Right bank) AR-8 ST2 DT 2 Intermediate connector (Starting motor B) AV-5
15 M 2 Lamp switch (Cab) K-2 CM29 AMP070 10 ORBCOMM terminal AK-9 HTR1A Terninal 1 Preheater relay (Left) AR-1 ST8 DT 2 Emergency stop valve BB-6
17 YAZAKI 4 Right door wiper motor (Cab) G-9 CM30 AMP070 14 ORBCOMM terminal AJ-8 HTR1C Terninal 1 Preheater relay (Left) AR-1 STB Terninal 1 Safety relay (Terminal B) AV-5
18 YAZAKI 4 Left door wiper motor (Cab) L-4 CN1 DT 2 Injector #1 (Left bank) AS-9 HTR2A Terninal 1 Preheater relay (Right) AQ-1 STCN1 DRC26 24 Steering controller AD-2
19 DT 4 Intermediate connector (Window washer) K-3 CN1 DT 2 Injector #1 (Right bank) AQ-7 HTR2C Terninal 1 Preheater relay (Right) AQ-2 STCN2 DRC26 40 Steering controller AE-2
20 DTHD#8 1 Cab power supply Z-4 CN2 DT 2 Injector #2 (Left bank) AV-4 J1939 DT-A 8 Intermediate connector AU-2 STCN3 DRC26 40 Steering controller AE-1
21 DTHD#12 1 Cab unswitched power supply Z-3 CN2 DT 2 Injector #2 (Right bank) AR-8 KEY DT 6 Starting switch AH-8 STF X 4 Steering controller write connector AD-4
22 Terninal 1 Cigarette lighter (Cab) L-9 CN3 DT 2 Injector #3 (Left bank) AV-5 L.P. HD-18 14 Intermediate connector (Injector left bank) AS-2 SW Terninal 1 Battery relay (Right) (Terminal BR) F-9
25 Giboshi 1 Rotary lamp outlet connector (Cab) K-9 CN3 DT 2 Injector #3 (Right bank) AR-8 L.S. HD-18 14 Intermediate connector (Injector left bank) AS-2 SW Terninal 1 Battery relay (Left) (Terminal BR) I-1
26 M 2 Rotary lamp switch (Cab) K-2 CN4 DT 2 Injector #4 (Left bank) AV-5 LMFL Relay 5 Front lamp relay (Left) AK-1 SX8 Terninal 1 Ground L-4
81 2 Room lamp (Cab) H-9 CN4 DT 2 Injector #4 (Right bank) AS-8 LMFR Relay 5 Front lamp relay (Right) AL-1 TAM1 PACKARD 2 Intake air temperature sensor AV-8
101 DT-B 12 Intermediate connector (Bulkhead wiring harness) P-3 CN5 DT 2 Injector #5 (Left bank) AV-6 LMRP Relay 5 Ripper point lamp relay AL-1 TC1 DT 2 Torque converter outlet speed sensor BB-5
102 DT-A 12 Intermediate connector (Bulkhead wiring harness) P-3 CN5 DT 2 Injector #5 (Right bank) AS-9 LMW Relay 5 Working lamp relay AL-1 TFUEL PACKARD 2 Fuel temperature sensor (Left bank) AU-4
201 DT-B 12 Intermediate connector (Yoke angle sensor) D-7 CN6 DT 2 Injector #6 (Left bank) AV-6 LSV DT 2 Pump LS selector solenoid AW-5 TFUEL PACKARD 2 Fuel temperature sensor (Right bank) AQ-6
203 DT 2 Right headlamp C-7 CN6 DT 2 Injector #6 (Right bank) AU-9 MFD DT 2 Merge-divider solenoid valve R-7 TIM PACKARD 2 Intake air temperature sensor AQ-4
204 DT 2 Left headlamp C-7 CONV DT 6 Converter X-8 MMS DT-C 12 Intermediate connector AO-6 TL1 HD-24 23 Intermediate connector (PCCS lever) Y-2
207 DT 2 Left headlamp D-7 CSL DT 3 Left yoke angle sensor E-1 NE SUMITOMO 3 Ne sensor AV-8 TL2 DT-B 8 PCCS lever potentiometer W-8
208 DT 2 Right headlamp C-7 CSR DT 3 Right yoke angle sensor B-3 NSF Relay 5 Neutral safety relay AM-1 TL3 DT 6 Intermediate connector (Console) W-9
209 DT-A 12 Intermediate connector (Small hood) E-1 CT1 DT 3 CAN terminal resistor AF-8 NSW DT 3 Parking brake switch AM-4 TLL DT 2 Left tilt limit solenoid valve Q-7
217 DT 2 Caution buzzer AE-6 CTV DT 3 CAN terminal resistor AN-6 OEM HD-24 21 Intermediate connector AR-3 TLR DT 2 Right tilt limit solenoid valve Q-7
221 DT 2 Left working lamp H-1 CUR KES-1 3 Cursor switch AI-7 OEM L DRC-50 50 Engine controller (Left bank) AV-1 TLS DT 2 Blade tilt left oil pressure switch Q-8
223 DT 2 Ripper point lamp (If equipped) L-6 DEC DT 3 Decelerator pedal T-2 OEM R DRC-50 50 Engine controller (Right bank) AU-2 TM1 DT 2 Transmission outlet speed sensor BB-5
226 DT 2 Left rear working lamp L-7 DIAL M 3 Fuel control dial W-9 OLLV DT 2 Engine oil level switch AR-3 TMC1 DRC26 24 Transmission controller AI-5
241 DT-A 12 Intermediate connector (Right fender) G-9, P-6 DL1 BENDIX 5 Download connector (ORBCOM specification) M-3 OLV1 DT 2 Intermediate connector (Engine oil level) AU-9 TMC2 DRC26 40 Transmission controller AI-5
242 DT 2 Right working lamp D-8 DLT DT 2 Download right (ORBCOM specification) L-2 OLV2 2 Intermediate connector (Engine oil level) AS-8 TMC3 DRC26 40 Transmission controller AI-4
243 DT 2 Right rear working lamp H-9 DPNL DT 2 Diode AX-8 P03 DT 6 Intermediate connector (Work equipment knob switch) Q-9 TMF X 4 Transmission write connector AD-4
244 DT 2 Pin puller solenoid L-5 DUL DT 2 Dual tilt selector solenoid valve R-8 PAMB AMP 3 Ambient pressure sensor AV-6 TMMD DT 3 Transmission main oil pressure AW-5
250 Terninal 1 Starting switch (Terminal B) AI-9 EG1 DTP 4 Intermediate connector (Engine) AQ-1 PCV1 SUMITOMO 2 Supply pump #1 (Left bank) AU-3 TOIL PACKARD 2 Engine oil temperature sensor AV-4
255 Terninal 1 Starting switch (Terminal R1) AI-8 EG2 HD-24 23 Intermediate connector (Engine) AV-7 PCV1 SUMITOMO 2 Supply pump #1 (Right bank) AQ-5 TRS DT 2 Blade tilt right oil pressure switch P-8
256 Terninal 1 Starting switch (Terminal R2) AI-8 EHL Relay 5 Engine hold relay AK-1 PCV2 SUMITOMO 2 Supply pump #2 (Left bank) AU-4 TS1 DT-C 12 Intermediate connector (Monitor panel) AI-3
260 Terninal 1 Starting switch (Terminal BR) AH-8 ENBP DT 3 Blow-by pressure AQ-3 PCV2 SUMITOMO 2 Supply pump #2 (Right bank) AQ-5 TS1F DT-C 12 Intermediate connector (Steering controller) AI-3
262 X 2 Intermediate connector (Horn switch) S-9 ENG DRC-60 60 Engine controller (Left bank) AV-1 PFUEL AMP 3 Common rail pressure sensor (Left bank) AU-4 TS2 DT-D 12 Intermediate connector (Monitor panel) AD-3
263 X 2 Pin puller switch U-9 ENG DRC-60 60 Engine controller (Right bank) AU-2 PFUEL AMP 3 Common rail pressure sensor (Right bank) AU-9 TS2F DT-D 12 Intermediate connector (Steering controller) AD-3
265 Terninal 1 Horn switch T-9 ENGL HD-18 21 Intermediate connector (Engine sensor) AS-2 PHR Relay 5 Preheater relay AM-1 TTM DT-B 12 Intermediate connector (Monitor panel) AD-5
266 Terninal 1 Horn switch T-9 ESD DT 3 Intermediate connector (Fuse box) AN-1 PIM SUMITOMO 3 Boost pressure sensor AR-3 TTMF DT-B 12 Intermediate connector (Transmission controller) AD-5
270 Terninal 1 Starting switch (Terminal ACC) AH-9 EXA1 DT 3 Exhaust temperature sensor amplifier (Left 1) AN-6 PL1 HD-24 23 Intermediate connector (Power train) BB-4 TWTR PACKARD 2 Coolant temperature sensor AR-3
280 Terninal 1 Starting switch (Terminal C) AI-9 EXA2 DT 3 Exhaust temperature sensor amplifier (Left 2) AL-5 PL1F HD-24 23 Intermediate connector (Emergency escape device) (If equipped) AY-8 USB DTHD#8 1 Intermediate connector (Fuse) Z-4
360 DT 6 Washing tank motor K-3 EXA3 DT 3 Exhaust temperature sensor amplifier (Right 1) AN-8 PL1M HD-24 23 Intermediate connector (Emergency escape device) (If equipped) AY-8 V1 AMP070 20 VHMS controller AK-6
369 DT 6 Washing tank motor L-3 EXA4 DT 3 Exhaust temperature sensor amplifier (Right 2) AJ-7 PL2 HD-24 31 Intermediate connector (Power train) AY-8, BB-4 V2A AMP070 18 VHMS controller AL-9
422 DT 2 Fuel level gauge L-5 EXTLF DT 2 Exhaust temperature sensor (Left front) AU-9 PL3 HD-18 14 Intermediate connector (Power train) BB-4 V2B AMP070 12 VHMS controller AM-9
453 DT 2 Torque converter oil temperature sensor AZ-2 EXTLR DT 2 Exhaust temperature sensor (Left rear) AT-9 PLUB Relay 5 Pre-lubricator relay AK-3 V3A AMP070 18 VHMS controller AM-5
599 DT-A 12 Intermediate connector (Left fender) Z-4 EXTRF DT 2 Exhaust temperature sensor (Right front) AT-9 PM1 Terninal 1 Pre-lubricator motor (If equipped) F-1 V3B AMP070 12 VHMS controller AL-5
653 DT 2 Lockup solenoid AX-5 EXTRR DT 2 Exhaust temperature sensor (Right rear) AT-9 PNL HD-24 31 Intermediate connector (Emergency escape device) (If equipped) AW-9 V4A AMP070 14 VHMS controller AO-8
800 Giboshi 1 Intermediate connector (Spare power supply 1) AN-2 EXT1 DT 2 Exhaust temperature sensor amplifier (Left 1) AM-5 POIL FRAMATOME 3 Engine oil pressure sensor AV-4 V4B AMP070 10 VHMS controller AO-7
801 Giboshi 1 Intermediate connector (Spare power supply 2) AN-2 EXT2 DT 2 Exhaust temperature sensor amplifier (Left 2) AN-9 POP Terninal 1 Pre-lubricator pressure switch (If equipped) AV-5 VDA HD-18 14 Intermediate connector (Download) M-3
810 Giboshi 1 Spare power supply 1 Z-5 EXT3 DT 2 Exhaust temperature sensor amplifier (Right 1) AJ-7 PPB DT 2 Pitch back solenoid valve R-8 VDB DT-A 8 Intermediate connector (Left fender) Z-4
811 Giboshi 1 Spare power supply 2 Z-5 EXT4 DT 2 Exhaust temperature sensor amplifier (Right 2) AN-9 PPD DT 2 Pitch dump solenoid valve R-8 VDW BENDIX 5 VHMS download (ORBCOM specification) Y-8
12S1 YAZAKI 2 Accessory socket X-8 F1T8 DT 2 1st clutch ECMV (Fill switch) AY-6 PPV DT 2 Pitch priority solenoid valve S-8 VEG HD-24 21 Intermediate connector (Engine) AV-7
12S2 YAZAKI 2 Accessory socket X-8 F2T6 DT 2 2nd clutch ECMV (Fill switch) AY-6 PR1 Terninal 1 Pre-lubricator relay (If equipped) E-8 VF1 HD-24 21 Intermediate connector (Floor) AJ-6
12V DT 3 Intermediate connector (Cab) Z-3 F3T4 DT 2 3rd clutch ECMV (Fill switch) AZ-6 PR2 Terninal 1 Pre-lubricator relay (If equipped) E-8 VF2 HD-24 23 Intermediate connector (Floor) AK-5
AC DT 2 Air conditioner compressor AQ-7 F30 1 Circuit breaker (30 A) B-9 PR3 Terninal 1 Pre-lubricator relay (If equipped) F-1 WLD DT 2 Coolant level sensor C-2
AC1 DT-A 12 Intermediate connector (Air conditioner) W-8 F96 1 Circuit breaker (105 A) B-9 PR4 Terninal 1 Pre-lubricator relay (If equipped) G-1 a The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles, 12 poles) are as follows.
AC2 HD-24 31 Intermediate connector (Air conditioner) Z-6 FA1 DT 2 Fun pump solenoid AZ-2 PRE DT 2 Pre-lubricator AN-3 DT-A = Gray, DT-B = Black, DT-C = Green, DT-D = Brown
ACT DT 2 Air conditioner external air sensor E-8 FA2 DT 2 Fun pump solenoid BA-3 PRS DT 2 Pre-lubricator AN-4
ACT Relay 5 ACC cut relay AK-2 FAN1 KES1 3 Fan clean mode switch AI-7 PT1 DT 3 Pitch angle sensor R-1
ACU S 12 Air conditioner unit Z-7 FAN2 KES1 4 Fan reverse mode switch AI-6 PTH DT 2 Pitch selector solenoid valve R-8
ADH KES1 4 Additional heater switch AI-6 FAR DT 2 Fan reverse solenoid D-2 PW L DTP 4 Engine controller (Left bank) AV-1
AF1 DT 2 Air cleaner clogging sensor G-1 FD5 DT-B 12 Fuse wiring harness W-1 PW R DTP 4 Engine controller (Right bank) AT-2
AF2 DT 2 Air cleaner clogging sensor H-1 FFT2 DT 2 Forward clutch ECMV (Fill switch) AZ-6 PWR1 DTHD#4 1 Intermediate connector (fuse) Z-5
ANB Terninal 1 Alternator (Terminal B) AQ-7 FL82 DT 2 Left brake ECMV (Fill switch) BB-6 PWR2 DTHD#4 1 Intermediate connector (fuse) Z-5
ANR Terninal 1 Alternator (Terminal R) AQ-7 FLC6 DT 2 Left clutch ECMV (Fill switch) BA-7 R.P. HD-18 14 Intermediate connector AQ-5
AP1 AMP040 16 Air conditioner control panel U-2 FR84 DT 2 Right brake ECMV (Fill switch) BA-6 R.S. HD-18 14 Intermediate connector (Injector right bank) AQ-5
AP2 AMP040 20 Air conditioner control panel U-2 FRC8 DT 2 Right clutch ECMV (Fill switch) BA-7 REL1 Terninal 1 Preheater relay (Left) AR-2
AP3 SWP 12 Air conditioner unit Y-7 FRT2 DT 2 Reverse clutch ECMV (Fill switch) AY-6 REL2 Terninal 1 Preheater relay (Right) AQ-2
AP4 SWP 16 Air conditioner unit Z-7 FS11 Fuse box AL-4 RES DT 2 Left bank resistor (Pull-up) AT-3
AP5 SWP 8 Air conditioner unit Y-7 FS12 Fuse box AL-4 RES DT 2 Right bank resistor (Pull-up) AQ-4
ASD KES1 4 Auto shift-down switch AH-8 FS21 Fuse box AL-4 RES L DT 3 CAN terminal resistor (Left bank) AU-1
ASUS DT 2 Intermediate connector (Air suspension seat) U-9 FS22 Fuse box AL-4 RES R DT 3 CAN terminal resistor (Right bank) AQ-3
B7L 1 Circuit breaker (30 A) C-9 FS31 Fuse box AM-4 RPD DT 2 Ripper lower oil pressure switch P-9
B7S 1 Circuit breaker (30 A) C-8 FS32 Fuse box AM-4 RPNL X 2 Resistor AY-9
B8L 1 Circuit breaker (30 A) C-8 FSB HD-24 31 Intermediate connector (Fuse box) W-1 RPU DT 2 Ripper raise oil pressure switch Q-9
B8S 1 Circuit breaker (30 A) C-8 FTU KES-1 4 Auto pitch back switch AH-8 RSD DT 2 Diode P-6
B30S 1 Circuit breaker (30 A) B-9 FWL KES-1 4 Front working lamp switch AI-6 RTB DT 2 Ripper tilt back oil pressure switch Q-8
B105H1L 1 Circuit breaker (105 A) C-9 G SUMITOMO 3 G sensor (Left bank) AU-3 RTI DT 2 Ripper tilt in oil pressure switch P-9
B105H1S 1 Circuit breaker (105 A) C-9 G SUMITOMO 3 G sensor (Right bank) AQ-5 RWL KES-1 4 Rear working lamp switch AI-7
B105H2L 1 Circuit breaker (105 A) B-9 GND Terninal 1 Ground (Engine) AT-3 S01 AMP040 12 Monitor panel AG-8
B105H2S 1 Circuit breaker (105 A) B-9 GND01 Terninal 1 Ground (Floor) X-1 S02 M 2 Monitor panel AF-8
B105S 1 Circuit breaker (105 A) B-9 GND02 Terninal 1 Ground (Floor) X-1 S03 AMP070 20 Monitor panel AG-8
BKA Relay 5 Backup alarm relay AK-2 GND03 Terninal 1 Ground (Left fender) J-2 S04 AMP070 12 Monitor panel AG-8
BLD DT 2 Blade lower oil pressure switch Q-8 GND04 Terninal 1 Ground (Right fender) E-8 S1T7 DT 2 1st clutch ECMV (Solenoid) AY-6
BLMT YAZAKI 2 Air conditioner additional blower X-8 GND05 Terninal 1 Ground (Bulkhead) P-3 S21 DT 3 Intermediate connector (Monitor) AG-8
BLSW KES1 4 Additional blower motor switch AI-6 GND06 Terninal 1 Ground (Heater relay) AQ-2 S24 Service switch AD-6
BLU DT 2 Blade raise oil pressure switch Q-8 GND07 Terninal 1 Ground (Floor) AG-1 S2T5 DT 2 2nd clutch ECMV (Solenoid) AY-6
BRB Terninal 1 Battery relay (Right) (Terminal B) F-9 GND09 Terninal 1 Ground (Left fender) J-2 S3T3 DT 2 3rd clutch ECMV (Solenoid) AZ-6
BRB Terninal 1 Battery relay (Left) (Terminal B) J-2 GND1 Terninal 1 Ground (Engine) AS-2 SDS DT 2 Hydraulic oil temperature sensor AZ-2
BRC Terninal 1 Battery relay (Right) (Terminal M) F-8 GND2 Terninal 1 Ground (Engine) AS-2 SFT1 DT 2 Forward clutch ECMV (Solenoid) AZ-6
BRC Terninal 1 Battery relay (Left) (Terminal M) H-1 GND3 Terninal 1 Ground (Engine) AT-3 SFTD 3 PCCS lever shift-down switch V-9
SEN00226-03
D475A, D475ASD-5E0 31
90 Diagrams and drawings SEN00226-03
D475A, D475ASD-5E0 33
SEN00226-03
2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)
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