Komatsu D475A-2 Bulldozer (10201 and up) Service Repair Shop Manual - SEBM019M0207

This complete service repair workshop manual PDF download for the D475A-2 Komatsu Bulldozer (SN: 10201 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : D475A-2
Serial Numbers : 10201 and up
Engine : SA12V140-1


TABLE OF CONTENTS :

- GENERAL
- STRUCTURE AND FUNCTION
- MAINTENANCE STANDARD
- TESTING AND ADJUSTING
- DISASSEMBLY AND ASSEMBLY
- OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM019M0207
Total Pages : 621


This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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TABLE OF CONTENTS :

10 STRUCTURE AND FUNCTION
ENGINE
ENGINE MOUNT
RADIATOR, OIL COOLER
FAN DRIVE HYDRAULIC PIPING DIAGRAM
FAN DRIVE HYDRAULIC SYSTEM DIAGRAM
FAN DRIVE HYDRAULIC CIRCUIT DIAGRAM
FAN DRIVE PUMP (SAR63 +40)
FAN DRIVE MOTOR (SAL140)
FAN HIGH-LOW SPEED SELECTOR SOLENOID VALVE, CHECK VALVE
FAN DRIVE CIRCUIT MAIN RELIEF VALVE
IN-LINE SERVO VALVE
ENGINE CONTROL
POWER TRAIN
POWER TRAIN
POWER TRAIN UNIT
POWER TRAIN PIPING
POWER TRAIN HYDRAULIC SYSTEM
POWER TRAIN HYDRAULIC CIRCUIT
DAMPER AND UNIVERSAL JOINT
TORQUE CONVERTER AND PTO
TORQUE CONVERTER VALVE
TRANSMISSION
SCAVENGING PUMP
POWER TRAIN PUMP AND LUBRICATION PUMP
STRAINERS
POWER TRAIN OIL FILTER AND LUBRICATION OIL FILTER
TRANSFER, BEVEL PINION, BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
TRANSFER, BEVEL PINION
BEVEL GEAR, STEERING CLUTCH AND STEERING BRAKE
STEERING CLUTCH AND STEERING BRAKE CONTROL
STEERING CLUTCH, BRAKE HYDRCUALIC CIRCUIT DIAGRAM
STEERING CONTROL VALVE
FINAL DRIVE
POWER TRAIN UNIT MOUNT
UNDERCARRIAGE
TRACK (LUBRICATED TRACK LINK)
TRACK FRAME AND RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
SUSPENSION
HYDRAULIC SYSTEM
HYDRAULIC PIPING DIAGRAM
HYDRAULIC CONTROL
HYDRAULIC CIRCUIT SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK
HYDRAULIC PUMP
BLADE LIFT VALVE
MAIN RELIEF, SHUTTLE VALVE
BLADE TILT, RIPPER LOW VALVE
RIPPER HIGH VALVE
HYDRAULIC LEVER OPERATION
CYLINDER
RIPPER CYLINDER
PIN-PULLER HYDRAULIC SYSTEM DRAWING
PIN-PULLER HYDRAULIC CIRCUIT DRAWING
PIN-PULLER SOLENOID VALVE
WORK EQUIPMENT
DOZER EQUIPMENT
RIPPER EQUIPMENT
CYLINDER STAY
ELECTRIC AND ELECTRONIC SYSTEM
ELECTRICAL WIRING DIAGRAM
CAB WIRING DIAGRAM
AIR CONDITIONER CIRCUIT DIAGRAM
EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM)
ELECTRICAL CONTROL
SENSOR
PIN-PULLER CONTROL
OTHERS
ROPS CANOPY
CAB
AIR CONDITIONER

20 TESTING AND ADJUSTING
TABLE OF STANDARD VALUES FOR ENGINE
TABLE OF STANDARD VALUES FOR CHASSIS
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE
TESTING AND ADJUSTING
TESTING AND ADJUSTING TOOL LIST
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
CHECKING AND ADJUSTING FUEL INJECTION TIMING
MEASURING TORQUE CONVERTER STALL SPEED
BLEEDING AIR FROM HYDRAULIC CYLINDER
MEASURING OIL PRESSURE
ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING GEAR SHIFT LEVER LINKAGE
ADJUSTING STEERING CLUTCH LINKAGE
ADJUSTING BRAKE PEDAL LINKAGE
ADJUSTING BLADE CONTROL LINKAGE
ADJUSTING RIPPER CONTROL LINKAGE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
HANDLING CONNECTORS
PREVENTING RECURRENCE OF THE SAME TROUBLE
CHECKS BEFORE TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
RELATED ELECTRICAL CIRCUIT
MONITOR SYSTEM
TORQUE CONVERTER LOCK-UP SYSTEM
FAN CONTROLLER SYSTEM
RELAY BOX CIRCUIT
LOCATION OF CONNECTORS FOR TROUBLESHOOTING
LOCATION OF CONNECTORS
CONNECTION TABLE FOR CONNECTOR
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL, HYDRAULIC, MECHANICAL SYSTEMS)
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM
H-1. Brakes do not work.
H-2. Machine does not turn. (Machine can travel only in a straight line.)
H-3. Machine does not turn properly.
H-4. Gear shifting is slow.
H-5. Machine travels only in one direction (forward or in reverse)
H-6. Machine does not move. (2nd. 3rd, engine running)
H-7. Machine does not move in any speed range.
H-8. Torque converter overheats (power train overheats).
H-9. Machine turns in one direction (when lever operated)
H-10. Abnormal noise from around hydraulic pump.
H-11. Blade RAISE speed slow or lacks power.
H-12. Ripper lift speed slow.
H-13. Excessive hydraulic drift of blade
H-14. Excessive hydraulic drift of ripper
H-15. Torque converter lock-up does not work
H-16. Pin puller cylinder does not work.
H-17. Even when water temperature or oil temperature rises, cooling fan speed does not increase.
H-18. Water temperature and oil temperature have dropped, but fan speed does not drop (still rotates at high speed)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
E-1. Torque converter lockup does not work. (Lockup pilot lamp does not light up.)
E-2. Abnormality in torque converter lockup display
a) Lockup display lamp does not go out
b) Lockup display lights up but torque converter does not lockup.
E-3. Fuse No. 8 inside torque converter lockup relay box is blown.
E-4. Pin puller cylinder does not work.
E-5. Preheating fuse 11 is blown.
E-6. When preheating switch on the panel is pressed, the preheating pilot lamp on the monitor panel does not light up.
E-7. Even when water temperature or oil temperature rises, cooling fan speed does not increase.
E-8. Water temperature and oil temperature have both dropped, but fan speed does not drop. (still rotates at high speed)
E-9. Panel switch does not work. (red lamps in the switch do not light up when any of the switch are pressed)
a) When fuse 9 broken
b) When fuse 15 broken
c) When starting switch is turned to START, panel switch does not work; or red lamp goes out.
d) Panel switch does not work when engine is running; or red lamp goes out.
e) When monitor panel is working (fuse g normal)
f) When monitor panel is not working (fuse 15 normal)
E-10. When one of panel switch is pushed ON, all panel switches stop working.
a) When head lamp switch is pressed.
b) When rear lamp switch m is pressed.
c) When working lamp switch is pressed.
d) When PREHEAT switch is pressed
e) When lockup switch is pressed
TROUBLESHOTING OF MONITOR SYSTEM
M-1. Monitor panel shows no display with starting switch ON
M-2. When starting switch is turned ON, all monitor panel lamps stay lighted up and do not go out.
M-3. When starting switch is turned ON (engine stopped), CHECK items flash (light up). (Oil, water, and fuel levels for CHECK items are correct.)
M-4. Preheating indicator is defective.
M-5. When starting switch is turned ON and engine is started, CHECK items flash.
M-6. When starting switch is turned ON (engine stopped), CAUTION items flash.
M-7. When starting switch is turned ON and engine is started, CAUTION items flash. (When there is no abnormality in CHECK items or engine)
M-8 When starting switch is turned ON (engine stopped), buzzer does not sound for 1 sec.
M-9 When starting switch is turned ON (engine stopped), lamp does not flash for 2 sec.
M-10 Panel lighting for monitor panel does not light up. (liquid crystal display normal)
M-11 After engine is started, service meter does not move.
M-12 Coolant temperature gauge shows abnormally low temperature
M-13 Coolant temperature gauge does not give display.
M-14 Torque converter oil temperature gauge shows abnormally low temperature
M-15 Torque converter oil temperature gauge does not give display
M-16 Fuel gauge always shows FULL display
M-17 Fuel gauge does not give display

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
WEIGHT TABLE
LUBRICANT AND COOLANT TABLE
TIGHTENING TORQUES AND STANDARD VALUES TABLE
ENGINE
STARTING MOTOR
ALTERNATOR
ENGINE OIL COOLER
TORQUE CONVERTER COOLER
FUEL INJECTION PUMP
WATER PUMP
TURBOCHARGER
AFTERCOOLER CORE
NOZZLE HOLDER
CYLINDER HEAD
FUEL TANK
RADIATOR
RADIATOR GUARD
FAN DRIVE PUMP
FAN MOTOR
ENGINE
REMOVAL
INSTALLATION
POWER TRAIN
DAMPER
REMOVAL & INSTALLATION
DISASSEMBLY & ASSEMBLY
POWER TRAIN UNIT
REMOVAL
INSTALLATION
PTO, TORQUE CONVERTER
REMOVAL & INSTALLATION
DISCONNECTION & CONNECTION
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
PTO
DISASSEMBLY
ASSEMBLY
TORQFLOW TRANSMISSION
REMOVAL & INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING CASE
DISASSEMBLY
ASSEMBLY
STEERING CLUTCH, BRAKE
DISASSEMBLY
ASSEMBLY
TRANSFER GEAR HOUSING
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER VALVE
REMOVAL & INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL & INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING CONTROL VALVE
REMOVAL & INSTALLATION
DISASSEMBLY & ASSSEMBLY
POWER TRAIN PUMP
SCAVENGING PUMP
FINAL DRIVE
REMOVAL & INSTALLATION
DISASSEMBLY
ASSEMBLY
UNDERCARRIAGE
TRACK FRAME
RECOIL SPRING
REMOVAL
INSTALLATION
DISASSEMBLY & ASSEMBLY
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
CHECKING BEFORE REMOVAL
REMOVAL (NORMAL)
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)
INSTALLATION
OVERALL DISASSEMBLY
OVERALL ASSEMBLY
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
FIELD DISASSEMBLY OF ONE LINK
FIELD ASSEMBLY OF ONE LINK
DISASSEMBLY OF MASTER LINK
ASSEMBLY OF MASTER LINK
PIVOT SHAFT
EQUALIZER BAR
REMOVAL
INSTALLATION
EQUALIZER BAR BUSHING
IDLER YOKE CARTRIDGE
IDLER PAD
HYDRAULIC SYSTEM
HYDRAULIC PUMP
BLADE LIFT VALVE
REMOVAL & INSTALLATION
DISASSEMBLY
ASSEMBLY
BLADE TILT, RIPPER Lo VALVE
REMOVAL & INSTALLATION
DISASSEMBLY
ASSEMBLY
RIPPER Hi VALVE
REMOVAL & INSTALLATION
DISASSEMBLY
ASSEMBLY
BLADE LIFT CYLINDER
BLADE TILT CYLINDER
RIPPER LIFT CYLINDER
RIPPER TILT CYLINDER
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
PIN PULLER CYLINDER
REMOVAL & INSTALLATION
DISASSEMBLY & ASSEMBLY
WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL & INSTALLATION
DISASSEMBLY & ASSEMBLY
RIPPER
ROPS CAB

40 MAINTENANCE STANDARD
ENGINE
ENGINE MOUNT
FAN DRIVE PUMP (SAR63 + 40)
FAN DRIVE MOTOR (SAL140)
IN-LINE SERVO VALVE
POWER TRAIN
DAMPER
TORQUE CONVERTER (TCS52-1 D)
TORQUE CONVERTER VALVE
TORQFLOW TRANSMISSION
TRANSMISSION CONTROL VALVE
POWER TRAIN LUBRICATION PUMP (BAL 160 + 224)
TRANSFER, BEVEL PINION
BEVEL GEAR, STEERING CLUTCH, BRAKE
STEERING CONTROL VALVE
FINAL DRIVE
MAIN FRAME
UNDERCARRIAGE
TRACK FRAME
RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK (LUBRICATED TRACK LINK)
EQUALIZER BAR
PIVOT SHAFT
HYDRAULIC SYSTEM
WORK EQUIPMENT PUMP (SARZOO + 100)
BLADE LIFT VALVE
MAIN RELIEF, SHUTTLE VALVE
BLADE TILT, RIPPER LOW VALVE
RIPPER HIGH VALVE
HYDRAULIC CYLINDER
CYLINDER STAY
WORK EQUIPMENT
DOZER EQUIPMENT
CUTTING EDGES AND END BITS
RIPPER EQUIPMENT

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