Komatsu D475A-5E0, D475ASD-5E0 Bulldozer Service Manual
1,618 pages · Publication SEN00203-18
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- Models
- D475A-5E0, D475ASD-5E0
- Serial coverage
- 30001 and up
- Manual type
- Service Manual
- Pages
- 1,618
- Publication
- SEN00203-18
- Condition
- Brand new
What's inside
From the manual's own table of contents: 324 sections, 602 entries. See sample pages (PDF, 1590 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification drawings
Specifications
Weight table
Fuel, coolant and lubricants
Radiator and oil cooler
Engine mount
Cooling fan pump
Cooling fan motor
Power train
Power train hydraulic equipment arrangement diagram
Damper and universal joint
Power train system
General view of power train unit
Show all 324 sections
Torque converter, PTO
Torque converter valve
Torque converter lockup control system
Scavenging pump
Transmission control
Transmission
Transmission control valve
Transmission clutch ECMV
Priority valve
Lubricating oil relief valve
Torque converter, power train, lubricating oil pump
Steering, brake control
Final drive
Sprocket
Steering unit
Steering control valve
Steering clutch ECMV, Steering brake ECMV
Parking brake valve
Sudden stop prevention valve49 topics
- Track frame
- Recoil spring
- Idler
- Track roller
- Carrier roller
- Track roller bogie
- Track shoe
- Main frame
- Suspension
- Work equipment hydraulic equipment arrangement diagram
- PPC control piping diagram
- Work equipment control
- Work equipment pump
- PPC valve
- PCCS lever
- Control valve
- CLSS
- Unload valve
- Introduction of LS pressure
- LS bypass plug
- Pressure compensation valve
- Blade lift valve
- Merge-divider valve
- Self pressure reducing valve
- Pilot solenoid valve
- Hydraulic tank, hydraulic filter
- Accumulator
- Work equipment cylinder
- Piston valve
- Quick drop valve
- Blade control knob (Dual tilt specification)
- Blade control knob (Superdozer specification)
- Pitch and dual solenoid valve
- Pin puller hydraulic circuit diagram
- Pin puller solenoid valve
- Cylinder stay
- Blade
- Ripper equipment
- Cab mount
- Air conditioner
- Engine control system
- CRI engine control system
- Monitor system
- Machine monitor
- Mode selection system
- Electrical equipment
- Palm command control system (PCCS)
- Sensors
- Vehicle health monitoring system (VHMS)
ORBCOMM terminal
Standard value table for engine
Standard value table for chassis
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Measuring exhaust temperature
Measuring exhaust gas color
Adjusting valve clearance
Testing compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Handling of reduced cylinder mode operation
Handling of no injection cranking operation
Testing fuel return and leak amount
Bleeding air from fuel circuit
Bleeding air from fuel circuit (Low-grade fuel specification)
Testing fuel circuit for leakage
Testing and adjusting alternator belt tension
Testing and adjusting belt tension for air conditioner compressor
Adjusting fuel control dial and decelerator pedal
Measuring power train oil pressure
Adjusting transmission speed sensor
Simple method to test brake performance
Adjusting brake pedal and parking brake lever
Adjusting PCCS lever console position
Emergency escape method when power train has trouble
Inspecting wear of sprocket
Testing and adjusting track shoe tension
Testing and adjusting work equipment oil pressure
Testing and adjusting control circuit basic pressure
Measuring PPC valve output pressure and solenoid valve output pressure
Adjusting play of PPC valve
Measuring outlet pressure of ripper pin puller solenoid valve
Checking parts which caused hydraulic drift of blade and ripper
Measuring internal leakage of work equipment cylinder
Releasing residual pressure from work equipment cylinder
Bleeding air from work equipment cylinder
Adjusting ripper lever position
Adjusting work equipment lock lever
Measuring fan motor speed
Measuring fan circuit oil pressure
Bleeding air from fan pump
Measurement procedure for blade tilt control angle (Dual tiltdozer specification)
Measurement procedure for blade tilt control angle (Superdozer specification)
Testing and adjusting operator's cab
Adjusting blade46 topics
- Testing and adjusting operator's seat isolator
- Special functions of monitor panel (EMMS)
- Adjustment method when controller has been replaced
- Preparation work for troubleshooting for electrical equipment system
- Inspection procedure of diode
- Handling of optional devices
- Initialization procedures for VHMS controller
- Precautions for replacing VHMS controller
- Pm Clinic service
- Failure code table
- Fuse locations
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Checks before troubleshooting
- Classification and procedures of troubleshooting
- Contents of troubleshooting table
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- Failure code [1380MW] Lockup clutch: Clutch slip
- Failure code [1500L0] Transmission clutch: Dual engagement
- Failure code [15E0MW] Transmission clutch: Clutch slip
- Command current OFF and fill signal ON
- Command current ON and fill signal OFF
- Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON
- Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON
- Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF
- Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON
- Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF
- Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON
- Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF
- Failure code [1800MW] Power train clutch: Slip
- Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON
- Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF
- Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON
- Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF
- Failure code [2300NR] Brake thermal load: Abnormal heating
- Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON
- Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF
- Failure code [2301NR] Right steering brake thermal load: Abnormal heating
- Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON
- Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF
- Failure code [2302NR] Left steering brake thermal load: Abnormal heating
- Failure code [6001ZK] Failure code for design
- Failure code [A000NS] Engine: Overheat
- Failure code [AA10NX] Air cleaner: Clogging
- Failure code [AB00MA] Battery charge abnormality: Malfunction
Failure code [B@BAZG] Engine oil: Oil pressure too low
Failure code [B@BAZK] Engine oil: Oil level reduction
Failure code [B@BCNS] Engine coolant: Overheat
Failure code [B@BCZK] Engine coolant: Level too low
Failure code [B@BEBF] Fuel: Water in fuel
Failure code [B@BFZK] Fuel level: Reduction
Failure code [B@CENS] Power train oil: Overheat
Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure
Failure code [B@CHZK] Power train oil: Oil level reduction
Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction
Failure code [B@HANS] Hydraulic oil: Overheat
Failure code [B@HAZK] Hydraulic oil: Level reduction
Failure code [CA111] Engine controller (Left bank): Internal abnormality
Failure code [CB111] Engine controller (Right bank): Internal abnormality
Abnormal speed sensor signal
Excessively high voltage detected
Excessively low voltage detected
High voltage detection
Low voltage detection
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed18 topics
- Excessively low voltage detected
- Excessively high voltage detected
- Low voltage detection
- Failure code [CA271] PCV1 short circuit (Left bank): Short circuit
- Failure code [CB271] PCV1 short circuit (Right bank): Short circuit
- Failure code [CA272] PCV1 disconnection (Left bank): Disconnection
- Failure code [CB272] PCV1 disconnection (Right bank): Disconnection
- Failure code [CA273] PCV2 short circuit (Left bank): Short circuit
- Failure code [CB273] PCV2 short circuit (Right bank): Short circuit
- Failure code [CA274] PCV2 disconnection (Left bank): Disconnection
- Failure code [CB274] PCV2 disconnection (Right bank): Disconnection
- (At left bank): Disconnection, short circuit
- Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch
- Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch
- Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit
- Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality
- High voltage detection
- Abnormally high pressure occurrence
Abnormally low voltage detection
Excessively high pressure detected
In-range error
Loss of pressure feed detected
Loss of pressure feed detected (Low-grade fuel specification)
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal
(Only left bank): High voltage detection
(Only left bank): Low voltage detection
Abnormal phase
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data
Abnormal Bkup signal
Bkup signal error
Communication error
Distinction error
(Right bank): Disconnection/Short circuit
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error23 topics
- (Only left bank): High voltage detection
- (At left bank only): Excessively low voltage detected
- Loss of pressure feed detected
- Failure code [D110KA] Battery relay: Disconnection
- Failure code [D110KB] Battery relay: Short circuit
- Failure code [D130KA] Neutral safety relay: Disconnection
- Failure code [D130KB] Neutral safety relay: Short circuit
- Failure code [D161KA] Back-up alarm relay: Disconnection
- Failure code [D161KB] Back-up alarm relay: Short circuit
- Failure code [D182KZ] Preheater relay: Disconnection or short circuit
- Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection
- Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit
- Failure code [D5ZRKA] Snap shot switch: Disconnection
- Failure code [D5ZRKB] Snap shot switch: Short circuit
- Failure code [DAFRKR] Monitor panel CAN communication: Communication error
- Failure code [DAQ0KT] Transmission controller: Abnormality in controller
- Power supply voltage reduction (Input)
- Source voltage reduction (input)
- Type select signal inconsistency
- Communication error (Objective component system abnormality)
- Defective communication (Abnormality in objective component system)
- Communication error
- Failure code [DB30KT] Steering controller: Abnormality in controller
Type select signal inconsistency
Failure code [dB3RKR] Steering controller CAN communication: Communication error
Defective communication (Abnormality in objective component system)
VHMS controller: Lowering of source voltage
Check of VHMS controller model: Disagreement of model selection
VHMS controller: Lowering of direct source voltage
VHMS sensor power supply (5 V): Lowering of output voltage
VHMS sensor power supply (24 V): Lowering of output voltage
VHMS sensor power supply (12 V): Lowering of output voltage
VHMS KOM-NET: Communication error
Failure code [dbBRKR] VHMS controller CAN communication: Communication error
Failure code [DD12KA] Shift up switch: Disconnection
Failure code [DD12KB] Shift up switch: Short circuit
Failure code [DD13KA] Shift down switch: Disconnection
Failure code [DD13KB] Shift down switch: Short circuit
Failure code [DD14KA] Parking brake lever switch: Disconnection
Failure code [DD14KB] Parking brake lever switch: Short circuit
Failure code [DDB9L4] Reverse switch: Signal disagreement
Failure code [DDK3L4] Forward switch: Signal disagreement
Failure code [DDK5KA] Gearshift switch: Disconnection
Failure code [DDK5KB] Gearshift switch: Short circuit
Switch is ON for long time
Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time
Failure code [DDN7KA] Blade pitch switch: Disconnection
Failure code [DDN7KB] Blade pitch switch: Short circuit
Failure code [DDN9KA] Blade tilt switch: Disconnection
Failure code [DDN9KB] Blade tilt switch: Short circuit
Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time
Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time
Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time
Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time
Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time
Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time
Failure code [DDQ2KA] Parking brake lever switch: Disconnection
Failure code [DDQ2KB] Parking brake lever switch: Short circuit
Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals
Failure code [DDT5KA] Neutral switch: Disconnection
Failure code [DDT5KB] Neutral switch: Short circuit
Model selection signal disagreement
Input signal is out of normal range
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection45 topics
- Disconnection (or LED of VHMS controller indicates "n3" o "12")
- Disconnection (or LED of VHMS controller indicates "n3" o "22")
- Short circuit (or LED of VHMS controller indicates "n3" o "11")
- Left bank exhaust temperature sensor system (Rear): Short circuit
- Right bank exhaust temperature sensor system (Front): Disconnection
- Right bank exhaust temperature sensor system (Rear): Disconnection
- Right bank exhaust temperature sensor system (Front): Short circuit
- Right bank exhaust temperature sensor system (Rear): Short circuit
- Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection
- Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit
- Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection
- Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit
- Blow-by pressure sensor system: Disconnection
- Blow-by pressure sensor system: Hot short
- Transmission oil pressure sensor: Out of input signal range
- Failure code [DK01KA] Left yoke angle sensor: Disconnection
- Failure code [DK01KB] Left yoke angle sensor: Short circuit
- Failure code [DK03KA] Right yoke angle sensor: Disconnection
- Failure code [DK03KB] Right yoke angle sensor: Short circuit
- Failure code [DK10KA] Fuel dial: Disconnection
- Failure code [DK10KB] Fuel dial: Short circuit
- Failure code [DK30KA] Steering potentiometer (1): Disconnection
- Failure code [DK30KB] Steering potentiometer (1): Short circuit
- Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range
- Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit
- Failure code [DK30L8] Steering potentiometer (1): See table
- Failure code [DK31KA] Steering potentiometer (2): Disconnection
- Failure code [DK31KB] Steering potentiometer (2): Short circuit
- Failure code [DK40KA] Brake potentiometer: Disconnection
- Failure code [DK40KB] Brake potentiometer: Short circuit
- Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range
- Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit
- Failure code [DK55L8] Forward-reverse potentiometer: See table
- Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection
- Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit
- Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection
- Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit
- Failure code [DK60KA] Acceleration sensor: Disconnection
- Failure code [DK60KB] Acceleration sensor: Short circuit
- Failure code [DKH1KA] Pitch angle sensor: disconnection
- Failure code [DKH1KB] Pitch angle sensor: Short circuit
- Failure code [DKH1KX] Pitch angle sensor: Out of input signal range
- Failure code [DLF1KA] Torque converter output speed sensor: Disconnection
- Failure code [DLT3KA] Transmission output speed sensor: Disconnection
- Failure code [DLT3KB] Transmission output speed sensor: Short circuit
Failure code [DV00KB] Caution buzzer: Short circuit
Failure code [DW55KA] Blade pitch back solenoid: Disconnection
Failure code [DW55KB] Blade pitch back solenoid: Short circuit
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit
Failure code [DW56KY] Blade pitch dump solenoid: Hot short
Failure code [DW57KA] Left tilt limit solenoid: Disconnection
Failure code [DW57KB] Left tilt limit solenoid: Short circuit
Failure code [DW57KY] Left tilt limit solenoid: Hot short
Failure code [DW58KA] Right tilt limit solenoid: Disconnection
Failure code [DW58KB] Right tilt limit solenoid: Short circuit
Failure code [DW58KY] Right tilt limit solenoid: Hot short
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit
Failure code [DW59KY] Dual tilt selector solenoid: Hot short
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short
Disconnection
Short circuit
Hot short
Failure code [DW7BKA] Fan reverse solenoid: Disconnection
Failure code [DW7BKB] Fan reverse solenoid: Short circuit
Failure code [DW7BKY] Fan reverse solenoid: Hot short
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short
Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit
Failure code [DWN5KY] Fan pump solenoid 1: Hot short
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit
Failure code [DWNCKY] Fan pump solenoid 2: Hot short
Failure code [DXE0KA] LS set solenoid: Disconnection
Failure code [DXE0KB] LS set solenoid: Short circuit
Failure code [DXE0KY] LS set solenoid: Hot short
Failure code [DXH1KA] Lock-up solenoid: Disconnection
Failure code [DXH1KB] Lock-up solenoid: Short circuit
Failure code [DXH1KY] Lockup solenoid: Hot short
Failure code [DXH4KA] 1st clutch ECMV: Disconnection
Failure code [DXH4KB] 1st clutch ECMV: Short circuit
Failure code [DXH4KY] 1st clutch ECMV: Hot short
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
Failure code [DXH5KY] 2nd clutch ECMV: Hot short
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit
Failure code [DXH6KY] 3rd clutch ECMV: Hot short
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit
Failure code [DXH7KY] Reverse clutch ECMV: Hot short44 topics
- Failure code [DXH8KA] Forward clutch ECMV: Disconnection
- Failure code [DXH8KB] Forward clutch ECMV: Short circuit
- Failure code [DXH8KY] Forward clutch ECMV: Hot short
- Failure code [DXH9KA] Right steering clutch ECMV: Disconnection
- Failure code [DXH9KB] Right steering clutch ECMV: Short circuit
- Failure code [DXH9KY] Right steering clutch ECMV: Hot short
- Failure code [DXHAKA] Left steering clutch ECMV: Disconnection
- Failure code [DXHAKB] Left steering clutch ECMV: Short circuit
- Failure code [DXHAKY] Left steering clutch ECMV: Hot short
- Failure code [DXHBKA] Right brake ECMV: Disconnection
- Failure code [DXHBKB] Right brake ECMV: Short circuit
- Failure code [DXHBKY] Right brake ECMV: Hot short
- Failure code [DXHCKA] Left brake ECMV: Disconnection
- Failure code [DXHCKB] Left brake ECMV: Short circuit
- Failure code [DXHCKY] Left brake ECMV: Hot short
- Engine blow-by pressure sensor: Abnormally high pressure occurrence
- Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise
- Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise
- Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise
- Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise
- Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise
- Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise
- Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise
- Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise
- The engine does not start
- The preheater does not operate
- The ripper pin puller cylinder does not operate
- The monitor panel does not come on at all when the starting switch is turned on
- and does not go out
- When the starting switch is turned on, the basic check items flash
- While the engine is operating, any caution item flashes
- An emergency caution item flashes while the engine is running
- While the preheater is operating, the preheating pilot lamp does not come on
- (Dual tilt-mounted machine)
- does not come on
- The engine coolant temperature gauge does not indicate normally
- Indication of the power train (torque converter) temperature gauge is abnormal
- The hydraulic oil temperature gauge does not indicate normally
- Indication of the fuel gauge is abnormal
- Indications of gear speed and engine speed are abnormal
- Indication of the shift mode service meter is abnormal
- The switch module cannot be operated
- The warning lamp does not flash or does not go out
- The alarm buzzer does not sound or does not stop
Auto shift down is not possible or is not released
The automatic pitch back system does not operate (only superdozer specification)
The alarm buzzer cannot be cancelled
The operator mode cannot be operated
The service mode cannot be operated
The back-up alarm does not sound1 topic
- do not come on
Troubleshooting for air conditioner system
Orbcomm terminal does not operate normally (Data are not transmitted)
Fan does not reverse
Gear cannot be shifted
Electric priming pump does not operate or does not stop automatically
Information in troubleshooting table
No force (no drawbar pull)
No travel (at 2nd or 3rd speed)
No travel at all gear speeds
Machine travels only in one direction forward or in reverse
Large time lag at gear speed shifting or forward-reverse shifting
Steering is not possible
Steering is possible only on one side
Steering overrun occurs
Brake does not work
Torque converter is not lock-up
Power train oil is overheated
All work equipment speeds are slow
Work equipment does not move
Blade lift speed is slow or lacks power
Blade tilt speed is slow or lacks power
Ripper lift speed is slow or lacks power
Ripper tilt speed is slow or lacks power
Excessive hydraulic drift of blade lift
Excessive hydraulic drift of blade tilt
Excessive hydraulic drift of ripper lift
Ripper pin puller cylinder does not work (giant ripper attachment machine)
Blade pitch does not work (dual tilt attachment machine)
Abnormal sound comes out from around work equipment pump2 topics
- engine overheats)
- operator's seat isolator)
Method of using troubleshooting chart
Starting performance is poor
Engine does not start
Engine does not pick up smoothly
Engine stops during operations
Engine does not rotate smoothly
Engine lacks output (or lacks power)
Exhaust smoke is black (incomplete combustion)
Oil consumption is excessive (or exhaust smoke is blue)
Oil becomes contaminated quickly
Fuel consumption is excessive
Oil is in coolant (or coolant spurts back or coolant level goes down)
Oil pressure drops
Oil level rises (Entry of coolant or fuel)
Coolant temperature becomes too high (overheating)50 topics
- Abnormal noise is made
- Vibration is excessive
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- Removal and installation of engine assembly
- Removal and installation of radiator assembly
- Removal and installation of aftercooler assembly
- Removal and installation of radiator guard assembly
- Removal and installation of fuel tank assembly
- Removal and installation of engine hood assembly
- Removal and installation of fan drive assembly
- Removal and installation of fan motor assembly
- Removal and installation of fuel supply pump assembly
- Removal and installation of cylinder head assembly
- Removal and installation of fuel injector assembly
- Removal and installation of engine front seal
- Removal and installation of engine rear seal
- Removal and installation of damper assembly
- Disassembly and assembly of damper assembly
- Removal and installation of power train unit assembly
- Removal and installation of PTO, torque converter assembly
- Disconnection and connection of PTO, torque converter assembly
- Disassembly and assembly of torque converter assembly
- Disassembly and assembly of PTO assembly
- Removal and installation of TORQFLOW transmission assembly
- Disassembly and assembly of TORQFLOW transmission assembly
- Disassembly and assembly of steering case assembly
- Disassembly and assembly of steering clutch, brake assembly
- Disassembly and assembly of transfer gear housing assembly
- Removal and installation of power train pump assembly
- Removal and installation of scavenging pump assembly
- Removal and installation of torque converter oil cooler
- Removal and installation of torque converter valve assembly
- Disassembly and assembly of torque converter valve assembly
- Removal and installation of transmission control valve assembly
- Disassembly and assembly of transmission control valve assembly (ECMV assembly)
- Removal and installation of steering control valve assembly
- Disassembly and assembly of steering control valve assembly
- Removal and installation of final drive assembly
- Disassembly and assembly of final drive assembly
- Removal and installation of track frame assembly
- Disassembly and assembly of idler assembly
- Removal and installation of recoil spring assembly
- Disassembly and assembly of recoil spring assembly
- Removal and installation of track roller assembly
- Disassembly and assembly of track roller assembly
- Removal and installation of carrier roller assembly
- Disassembly and assembly of carrier roller assembly
Removal and installation of bogie assembly
Disassembly and assembly of bogie assembly
Removal and installation of No.1 bogie assembly
Removal and installation of operator's seat isolator
Disassembly and assembly of operator's seat isolator
Expansion and installation of track shoe assembly
Overall disassembly and overall assembly of track shoe
Press-fitting jig dimension table for link press
Field disassembly and assembly of one link
Disassembly and assembly of master link
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar
Disassembly and assembly of equalizer bar bushing
Removal and installation of hydraulic pump assembly
Removal and installation of hydraulic valve assembly
Disassembly and assembly of control valve
Removal and installation of PPC relief valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of ripper pin puller cylinder assembly
Removal and installation of blade assembly
Disassembly and assembly of giant ripper assembly
Removal and installation of ROPS guard
Removal and installation of operator’s cab assembly
Removal and installation of floor frame assembly
Removal and installation of controller assembly
Removal and installation of engine controller assembly (left)
Removal and installation of air conditioner condenser assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner unit
Power train hydraulic circuit diagram
Hydraulic circuit diagram (1/3)
Hydraulic circuit diagram (2/3)
Hydraulic circuit diagram (3/3)
Electrical circuit diagram (1/13)
Electrical circuit diagram (2/13)
Electrical circuit diagram (3/13)
Electrical circuit diagram (4/13)
Electrical circuit diagram (5/13)
Electrical circuit diagram (6/13)
Electrical circuit diagram (7/13)
Electrical circuit diagram (8/13)
Electrical circuit diagram (9/13)
Electrical circuit diagram (10/13)
Electrical circuit diagram (11/13)
Electrical circuit diagram (12/13)
Electrical circuit diagram (13/13)
Electrical circuit diagram of inside cab
Connector arrangement diagram
Inside this manual
Real pages from this service manual (1,618 pages). Open the sample pages (PDF, 1588 KB)
- Specifications, page 542: 30 Testing and adjusting
- Troubleshooting, page 1,067: Failure code [DK60KB] Acceleration sensor: Short circuit
- Diagram, page 1,142: Failure code [DXHAKY] Left steering clutch ECMV: Hot short
- Color page, page 617: D475A, D475ASD-5E0
- Foldout diagram, page 1,616: Connector arrangement diagram
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Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,618 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).