Komatsu Bulldozer D475A-3 Shop Manual SEBM017209 – PDF DOWNLAD

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Komatsu Bulldozer D475A-3 Shop Manual SEBM017209 – PDF DOWNLAD

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Komatsu Bulldozer D475A-3 Shop Manual SEBM017209 – PDF DOWNLAD

Language : English
Pages :957
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu Bulldozer D475A-3 Shop Manual SEBM017209 – PDF DOWNLAD

MACHINE MODEL SERIAL No.
D475A-3 10601 and up

FOREWORD
GENERAL
This shop manual 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 shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu Bulldozer D475A-3 Shop Manual SEBM017209 – PDF DOWNLAD

MACHINE MODEL SERIAL No.
D475A-3 10601 and up

COVER 1
CONTENTS 2
01 GENERAL 29
SPECIFICATION DIMENSION DRAWINGS 30
SPECIFICATIONS 32
WEIGHT TABLE 41
TABLE OF FUEL, COOLANT AND LUBRICANTS 45
10 STRUCTURE AND FUNCTION 48
ENGINE, POWER TRAIN COOLING SYSTEM DRAWING 49
POWER TRAIN 50
POWER TRAIN SKELETON 51
POWER TRAIN HYDRAULIC PIPING DIAGRAM 52
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 53
TORQUE CONVERTER AND PTO 55
TORQUE CONVERTER VALVE 61
TRANSMISSION 69
TRANSMISSION CONTROL VALVE 76
STEERING, BRAKE CONTROL 91
TRANSFER, BEVEL GEAR SHAFT, STEERING 95
TRANSFER, BEVEL PINION 96
STEERING CONTROL VALVE 99
FINAL DRIVE107
TRACK FRAME111
TRACK ROLLER BOGIE115
PPC VALVE117
MAIN CONTROL VALVE128
PIN-PULLER HYDRAULIC SYSTEM DRAWING136
PIN-PULLER HYDRAULIC CIRCUIT DRAWING136
PIN-PULLER SOLENOID VALVE137
AIR CONDITIONER139
ENGINE CONTROL140
ENGINE CONTROL SYSTEM141
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER144
MACHINE MONITOR SYSTEM146
MODE SELECTION SYSTEM155
ELECTRICAL EQUIPMENT161
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM165
20 TESTING AND ADJUSTING166
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS167
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS168
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS175
TESTING AND ADJUSTING194
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING195
MEASURING ENGINE SPEED196
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)198
MEASURING EXHAUST TEMPERATURE199
MEASURING EXHAUST COLOR200
ADJUSTING VALVE CLEARANCE201
MEASURING COMPRESSION PRESSURE202
MEASURING BLOW-BY PRESSURE203
MEASURING ENGINE OIL PRESSURE204
TESTING AND ADJUSTING FUEL INJECTION TIMING 205
TESTING AND ADJUSTING ALTERNATOR BELT TENSION206
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR206
ADJUSTING ENGINE SPEED SENSOR207
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL208
MEASURING TORQUE CONVERTER STALL SPEED210
MEASURING TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL) SPEED211
MEASURING POWER TRAIN OIL PRESSURE212
SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE217
ADJUSTING FULL MONOLEVER AND PARKING LEVER218
ADJUSTING BRAKE PEDAL LINKAGE222
ADJUSTING CLEARANCE OF IDLER224
TESTING AND ADJUSTING TRACK SHOE TENSION225
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE226
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE232
MEASURING PPC VALVE AND PITCH, TILT CONTROL VALVE OUTPUT PRESSURE234
ADJUSTING PPC VALVE238
MEASURING OUTPUT PRESSURE OF DEMAND SOLENOID VALVE239
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE240
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER241
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER242
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT243
BLEEDING AIR FROM HYDRAULIC CYLINDERS243
ADJUSTING WORK EQUIPMENT SAFETY LEVER244
PROCEDURE FOR SELECTING MODEL245
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (DUAL TILT DOZER SPECIFICATION)248
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (SUPER DOZER SPECIFICATION)250
TROUBLESHOOTING252
POINTS TO REMEMBER WHEN TROUBLESHOOTING 253
SEQUENCE OF EVENTS IN TROUBLESHOOTING254
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE255
CHECKS BEFORE TROUBLESHOOTING263
CONNECTION TYPES AND MOUNTING LOCATIONS264
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS272
T-BRANCH BOX AND T-BRANCH TABLE294
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM296
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL300
METHOD OF USING TROUBLESHOOTING CHARTS313
TROUBLESHOOTING OF NETWORK SYSTEM (N MODE)315
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE316
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM318
SERVICE CODES OF NETWORK SYSTEM319
N-1 [E0101] ABNORMALITY IN NETWORK SYSTEM (ENGINE CONTROLLER SYSTEM) IS DISPLAYED320
N-2 [E0104] ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL SYSTEM) IS DISPLAYED321
N-3 [E0105] ABNORMALITY IN NETWORK SYSTEM (MACHINE CONTROLLER SYSTEM) IS DISPLAYED322
N-4 [E0101], [E0104], AND [E0105] ARE DISPLAYED AT SAME TIME (ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED)323
N-5 [E0152] ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED324
N-5 [E0436] ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED324
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE)325
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE326
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM332
E-1 [E0401] ABNORMALITY IN ENGINE CONTROLLER POWER SOURCE VOLTAGE IS DISPLAYED334
E-2 [E0402] ABNORMALITY IN ENGINE CONTROLLER IS DISPLAYED334
E-3 [E0403] MISTAKEN CONNECTION IN ENGINE CONTROLLER IS DISPLAYED335
E-4 [E0405] ABNORMALITY IN FUEL CONTROL DIAL SYSTEM IS DISPLAYED336
E-5 [E0406] ABNORMALITY IN DECELERATION POTENTIOMETER IS DISPLAYED337
E-6 [E0407] ABNORMALITY IN SHOE SLIP CONTROL COMMAND VALUE IS DISPLAYED338
E-7 [E0409] ABNORMALITY IN ENGINE SPEED SENSOR A SYSTEM IS DISPLAYED339
E-8 [E0410] ABNORMALITY IN ENGINE SPEED SENSOR B SYSTEM IS DISPLAYED340
E-9 [E0411] ABNORMALITY IN RIGHT RACK SENSOR SYSTEM IS DISPLAYED341
E-10 [E0412] ABNORMALITY IN LEFT RACK SENSOR SYSTEM IS DISPLAYED342
E-11 [E0413] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM IS DISPLAYED343
E-12 [E0421] SHORT CIRCUIT IN RIGHT GOVERNOR SOLENOID SYSTEM IS DISPLAYED344
E-13 [E0422] DISCONNECTION IN RIGHT GOVERNOR SOLENOID SYSTEM IS DISPLAYED345
E-14 [E0423] SHORT CIRCUIT IN LEFT GOVERNOR SOLENOID SYSTEM IS DISPLAYED347
E-15 [E0424] DISCONNECTION IN LEFT GOVERNOR SOLENOID SYSTEM IS DISPLAYED348
E-16 [E0425] SHORT CIRCUIT IN RIGHT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED350
E-17 [E0426] DISCONNECTION IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED351
E-18 [E0427] SHORT CIRCUIT IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED352
E-19 [E0428] DISCONNECTION IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED353
E-20 [E0433] SHORT CIRCUIT IN LEFT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED354
E-21 [E0434] DISCONNECTION IN LEFT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED355
E-22 [E0435] ABNORMALITY IN ENGINE WATER TEMPERATURE SENSOR SYSTEM IS DISPLAYED356
E-23 [E0437] ABNORMALITY IN RIGHT GOVERNOR SERVO IS DISPLAYED357
E-24 [E0438] ABNORMALITY IN LEFT GOVERNOR SERVO IS DISPLAYED358
E-25 [E0440] DISCONNECTION SOLENOID POWER SOURCE 1 SYSTEM IS DISPLAYED359
E-26 [E0441] DISCONNECTION IN POWER SUPPLY SYSTEM 2 OF SOLENOID IS DISPLAYED359
E-27 [E0442] ABNORMALITY IN ENGINE CONTROLLER BACKUP POWER SOURCE SYSTEM IS DISPLAYED360
E-28 [E0443] ABNORMALITY IN ENGINE CONTROLLER SWITCH POWER SOURCE SYSTEM IS DISPLAYED361
E-29 [E0455] ENGINE OVERHEATING IS DISPLAYED362
E-30 [E0456] SHORT CIRCUIT IN RIGHT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED363
E-31 [E0457] DISCONNECTION IN RIGHT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED364
E-32 ENGINE DOES NOT REVOLVE WHEN STARTING SWITCH IS TURNED TO ON POSITION365
E-33 ENGINE DOES NOT STOP WHEN STARTING SWITCH IS TURNED TO OFF POSITION368
TROUBLESHOOTING OF MACHINE CONTROLLER SYSTEM (C MODE)369
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE371
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM383
C-1 [E0111] ABNORMALITY IN MACHINE CONTROLLER POWER SOURCE VOLTAGE IS DISPLAYED389
C-2 [E0150] ABNORMALITY IN MACHINE CONTROLLER E2ROM IS DISPLAYED390
C-3 [E0151] ABNORMALITY IN SPECIFICATION SELECTION IS DISPLAYED390
C-4 [E0201] DISCONNECTION IN TORQUE CONVERTER SPEED SENSOR SYSTEM IS DISPLAYED391
C-5 [E0202] SHORT CIRCUIT IN TORQUE CONVERTER SPEED SENSOR SYSTEM IS DISPLAYED392
C-6 [E0203] DISCONNECTION IN TRANSMISSION FORWARD CLUTCH OIL PRESSURE SWITCH SYSTEM & REVERSE OIL PRESSURE SWITCH SYSTEM IS DISPLAYED393
C-7 [E0204] SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH OIL PRESSURE SWITCH SYSTEM IS DISPLAYED394
C-8 [E0205] SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH OIL PRESSURE SWITCH SYSTEM IS DISPLAYED395
C-9 [E0206] DISCONNECTION IN TRANSMISSION 1ST CLUTCH OIL PRESSURE SWITCH & 2ND OIL PRESSURE SWITCH & 3RD OIL PRESSURE SWITCH SYSTEM IS DISPLAYED396
C-10 [E0207] SHORT CIRCUIT IN TRANSMISSION 1ST OIL CLUTCH PRESSURE SWITCH SYSTEM IS DISPLAYED398
C-11 [E0208] SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH OIL PRESSURE SWITCH SYSTEM IS DISPLAYED399
C-12 [E0209] SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH OIL PRESSURE SWITCH SYSTEM IS DISPLAYED400
C-13 [E0210] DISCONNECTION IN TRANSMISSION MODULATING OIL PRESSURE SENSOR SYSTEM IS DISPLAYED401
C-14 [E0212] SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM IS DISPLAYED402
C-15 [E0213] DISCONNECTION IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM IS DISPLAYED403
C-16 [E0220] SHORT CIRCUIT IN TRANSMISSION MODULATING OIL PRESSURE SENSOR SYSTEM IS DISPLAYED404
C-17 [E0301] SHORT CIRCUIT IN LEFT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED405
C-18 [E0302] DISCONNECTION IN LEFT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED406
C-19 [E0303] SHORT CIRCUIT IN RIGHT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED407
C-20 [E0304] DISCONNECTION IN RIGHT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED408
C-21 [E0305] SHORT CIRCUIT IN BLADE RAISE OIL PRESSURE SWITCH SYSTEM IS DISPLAYED409
C-22 [E0306] SHORT CIRCUIT IN BLADE RIGHT TILT OIL PRESSURE SWITCH SYSTEM IS DISPLAYED410
C-23 [E0307] SHORT CIRCUIT IN BLADE LEFT TILT OIL PRESSURE SWITCH SYSTEM IS DISPLAYED411
C-24 [E0308] SHORT CIRCUIT IN RIPPER RAISE OIL PRESSURE SWITCH SYSTEM IS DISPLAYED412
C-25 [E0309] SHORT CIRCUIT IN RIPPER LOWER OIL PRESSURE SWITCH SYSTEM IS DISPLAYED413
C-26 [E0310] SHORT CIRCUIT IN RIPPER TILT IN OIL PRESSURE SWITCH SYSTEM IS DISPLAYED414
C-27 [E0311] SHORT CIRCUIT IN BLADE LEVER FRONT BUTTON SWITCH SYSTEM IS DISPLAYED415
C-28 [E0312] SHORT CIRCUIT IN BLADE LEVER UPPER BUTTON SWITCH SYSTEM IS DISPLAYED416
C-29 [E0313] SHORT CIRCUIT IN PITCH BACK SOLENOID SYSTEM IS DISPLAYED417
C-30 [E0314] DISCONNECTION IN PITCH BACK SOLENOID SYSTEM IS DISPLAYED418
C-31 [E0315] SHORT CIRCUIT IN PITCH DUMP SOLENOID SYSTEM IS DISPLAYED419
C-32 [E0316] DISCONNECTION IN PITCH DUMP SOLENOID SYSTEM IS DISPLAYED420
C-33 [E0317] SHORT CIRCUIT IN LEFT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED421
C-34 [E0318] DISCONNECTION IN LEFT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED422
C-35 [E0319] SHORT CIRCUIT IN RIGHT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED423
C-36 [E0320] DISCONNECTION IN RIGHT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED424
C-37 [E0321] SHORT CIRCUIT IN DUAL TILT SELECTION SOLENOID SYSTEM IS DISPLAYED425
C-38 [E0322] DISCONNECTION IN DUAL TILT SELECTION SOLENOID SYSTEM IS DISPLAYED426
C-39 [E0323] SHORT CIRCUIT IN PITCH SELECTION SOLENOID SYSTEM IS DISPLAYED427
C-40 [E0324] DISCONNECTION IN PITCH SELECTION SOLENOID SYSTEM IS DISPLAYED428
C-41 [E0325] SHORT CIRCUIT IN PITCH BACK ASSIST SOLENOID SYSTEM IS DISPLAYED429
C-42 [E0326] DISCONNECTION IN PITCH BACK ASSIST SOLENOID SYSTEM IS DISPLAYED430
C-43 [E0327] SHORT CIRCUIT IN PITCH DUMP ASSIST SOLENOID SYSTEM IS DISPLAYED431
C-44 [E0328] DISCONNECTION IN PITCH DUMP ASSIST SOLENOID SYSTEM IS DISPLAYED432
C-45 [E0330] SHORT CIRCUIT IN BLADE LOWER OIL PRESSURE SWITCH SYSTEM IS DISPLAYED433
C-46 [E0332] SHORT CIRCUIT IN UNLOAD VALVE SOLENOID SYSTEM IS DISPLAYED434
C-47 [E0333] DISCONNECTION IN UNLOAD VALVE SOLENOID SYSTEM IS DISPLAYED435
C-48 [E0334] SHORT CIRCUIT IN DEMAND VALVE SOLENOID SYSTEM IS DISPLAYED436
C-49 [E0335] DISCONNECTION IN DEMAND VALVE SOLENOID SYSTEM IS DISPLAYED437
C-50 [E0336] SHORT CIRCUIT IN RIPPER TILT BACK OIL PRESSURE SWITCH SYSTEM IS DISPLAYED438
C-51 [E0337] SHORT CIRCUIT IN PITCH INDEPENDENT SOLENOID SYSTEM IS DISPLAYED439
C-52 [E0338] DISCONNECTION IN PITCH INDEPENDENT SOLENOID SYSTEM IS DISPLAYED440
C-53 [E0339] SHORT CIRCUIT IN LEFT BOTTOM DRAIN SOLENOID SYSTEM IS DISPLAYED441
C-54 [E0340] DISCONNECTION IN LEFT BOTTOM DRAIN SOLENOID SYSTEM IS DISPLAYED442
C-55 [E0351] ABNORMALITY IN STANDARD VALUE OF BLADE TILT ANGLE SENSOR IS DISPLAYED443
C-56 [E0352] ABNORMALITY IN COMPENSATED VALUE OF BLADE TILT ANGLE SENSOR IS DISPLAYED443
C-57 [E0360] SHORT CIRCUIT IN WORK EQUIPMENT OIL PRESSURE SENSOR (140 PUMP) SYSTEM IS DISPLAYED444
C-58 [E0361] DISCONNECTION IN WORK EQUIPMENT OIL PRESSURE SENSOR (140 PUMP) SYSTEM IS DISPLAYED445
C-59 [E0362] SHORT CIRCUIT IN WORK EQUIPMENT OIL PRESSURE SENSOR (100 PUMP) SYSTEM IS DISPLAYED446
C-60 [E0363] DISCONNECTION IN WORK EQUIPMENT OIL PRESSURE SENSOR (100 PUMP) SYSTEM IS DISPLAYED447
C-61 [E0501] SHORT CIRCUIT IN ACCELERATION SENSOR SYSTEM IS DISPLAYED448
C-62 [E0502] DISCONNECTION IN ACCELERATION SENSOR SYSTEM IS DISPLAYED449
C-63 [E0601] SHORT CIRCUIT IN BUZZER CANCEL SWITCH SYSTEM IS DISPLAYED450
C-64 [E0610] SHORT CIRCUIT IN BACKUP ALARM RELAY SYSTEM IS DISPLAYED451
C-65 [E0611] DISCONNECTION IN BACKUP ALARM RELAY SYSTEM IS DISPLAYED452
C-66 [E0632] SHORT CIRCUIT IN ROCKBED SELECTION MODE SWITCH SYSTEM IS DISPLAYED453
C-67 [E0633] DISCONNECTION IN ROCKBED SELECTION MODE SWITCH SYSTEM IS DISPLAYED454
C-68 [E0930] DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED455
C-69 LOCK-UP DEVICE DOES NOT OPERATE WHEN LOCK-UP MODE SWITCH IS TURNED ON456
C-70 ENGINE OUTPUT DOES NOT CHANGE WHEN ECONOMY MODE SWITCH IS TURNED ON457
C-71 REVERSE TRAVEL SPEED DOES NOT CHANGE WHEN REVERSE SLOW MODE SWITCH IS TURNED ON458
C-72 SHOE SLIP CONTROL DEVICE DOES NOT OPERATE WHEN SHOE SLIP CONTROL SWITCH IS TURNED ON OR SHOE SLIP LEVEL DOES NOT CHANGE WHEN ROCKBED SELECTION MODE SWITCH IS CHANGED459
C-73 ANY SOLENOID RELATED TO MACHINE CONTROLLER DOES NOT OPERATE460
C-74 BACKUP ALARM DOES NOT SOUND OR KEEPS SOUNDING461
C-75 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE463
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)465
TABLE OF FAILURE MODES AND CAUSES466
H-1 MACHINE LACKS POWER (LACKS DRAWBAR PULL)467
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD GEAR SPEED)469
H-3 MACHINE DOES NOT MOVE AT ANY GEAR SPEED471
H-4 MACHINE TRAVELS ONLY FORWARD OR IN REVERSE473
H-5 TIME LAG IS EXCESSIVE WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED473
H-6 MACHINE DOES NOT TURN IN EITHER DIRECTION474
H-7 MACHINE TURNS ONLY IN ONE DIRECTION475
H-8 MACHINE TURNS TOO FAR476
H-9 BRAKES DO NOT WORK476
H-10 TORQUE CONVERTER LOCK-UP DOES NOT WORK477
H-11 POWER TRAIN OIL OVERHEATS478
H-12 ALL WORK EQUIPMENT SPEEDS ARE LOW479
H-13 WORK EQUIPMENT DOES NOT MOVE AT ALL480
H-14 BLADE LIFT SPEED IS SLOW OR LACKS POWER480
H-15 BLADE TILT SPEED IS SLOW OR LACKS POWER481
H-16 BLADE PITCH DOES NOT WORK481
H-17 RIPPER LIFT SPEED IS SLOW OR LACKS POWER482
H-18 RIPPER TILT SPEED IS SLOW OR LACKS POWER482
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT483
H-20 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT483
H-21 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT483
H-22 RIPPER PIN-PULLER CYLINDER DOES NOT WORK484
H-23 ABNORMAL NOISE FROM AROUND HYDRAULIC PUMP484
TROUBLESHOOTING OF MONITOR PANEL AND ELECTRICAL SYSTEM (M MODE)485
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE486
ELECTRICAL CIRCUIT DIAGRAM OF M MODE SYSTEM488
M-1 [E0120] SHORT CIRCUIT IN CAUTION LAMP OUTPUT SYSTEM IS DISPLAYED490
M-2 [E0121] SHORT CIRCUIT IN CAUTION BUZZER SYSTEM IS DISPLAYED491
M-3 [E0211] ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER OIL TEMPERATURE IS DISPLAYED492
M-4 [E0329] ABNORMALITY IN HYDRAULIC OIL TEMPERATURE IS DISPLAYED492
M-5 [E0430] ABNORMALITY IN ENGINE OIL PRESSURE IS DISPLAYED493
M-6 [E0431] ABNORMALITY IN RADIATOR WATER LEVEL IS DISPLAYED493
M-7 [E0432] ABNORMALITY IN ENGINE WATER TEMPERATURE IS DISPLAYED494
M-8 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL GIVES NO DISPLAY495
M-9 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT497
M-10 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK BEFORE STARTING ITEMS FLASH498
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH (BUT BATTERY CHARGE, ENGINE OIL PRESSURE CAUTION DO NOT FLASH)500
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH (BUT THERE IS NO ABNORMALITY IN CHECKS BEFORE STARTING ITEMS OR ENGINE)502
M-13 PREHEATING MONITOR DOES NOT LIGHT UP OR GO OUT508
M-14 ABNORMALITY IN CAUTION BUZZER509
M-15 ABNORMALITY IN CAUTION LAMP511
M-16 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE513
M-17 ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE GAUGE515
M-18 ABNORMALITY IN FUEL LEVEL GAUGE517
M-19 SPEED RANGE DISPLAY SHOWS “–“, ENGINE SPEED IS NOT DISPLAYED519
M-20 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING519
M-21 ABNORMALITY IN SERVICE MODE520
M-22 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (FRONT LAMP, WORKING LAMP ARE NORMAL)522
M-23 FRONT LAMPS AND WORKING LAMPS DO NOT LIGHT UP524
M-24 REAR LAMPS DO NOT LIGHT UP527
M-25 AUTOMATIC PREHEATER DOES NOT WORK528
M-26 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK531
TROUBLESHOOTING OF AIR CONDITIONER SYSTEM534
ELECTRICAL CIRCUIT DIAGRAM OF AIR CONDITIONER SYSTEM535
TROUBLESHOOTING OF AIR CONDITIONER WHICH DOES NOT WORK536
30 DISASSEMBLY AND ASSEMBLY541
METHOD OF USING MANUAL543
PRECAUTIONS WHEN CARRYING OUT OPERATION546
SPECIAL TOOL LIST548
SKETCHES OF SPECIAL TOOLS562
ENGINE OIL COOLER ASSEMBLY575
REMOVAL AND INSTALLATION575
FUEL INJECTION PUMP ASSEMBLY576
REMOVAL AND INSTALLATION576
AFTERCOOLER CORE ASSEMBLY577
REMOVAL AND INSTALLATION577
NOZZLE HOLDER ASSEMBLY579
REMOVAL AND INSTALLATION579
ENGINE FRONT SEAL580
REMOVAL AND INSTALLATION580
ENGINE REAR SEAL582
REMOVAL AND INSTALLATION582
CYLINDER HEAD ASSEMBLY585
REMOVAL AND INSTALLATION585
FUEL TANK ASSEMBLY589
REMOVAL AND INSTALLATION589
MAIN RADIATOR ASSEMBLY590
REMOVAL AND INSTALLATION590
SUB RADIATOR ASSEMBLY592
REMOVAL AND INSTALLATION592
RADIATOR GUARD ASSEMBLY593
REMOVAL AND INSTALLATION593
ENGINE ASSEMBLY595
REMOVAL AND INSTALLATION595
DAMPER ASSEMBLY599
REMOVAL AND INSTALLATION599
DISASSEMBLY AND ASSEMBLY601
PAWER TRAIN UNIT ASSEMBLY604
REMOVAL AND INSTALLATION604
PTO, TORQUE CONVERTER ASSEMBLY608
REMOVAL AND INSTALLATION608
DISCONNECTION AND CONNECTION611
TORQUE CONVERTER ASSEMBLY613
DISASSEMBLY AND ASSEMBLY613
PTO ASSEMBLY624
DISASSEMBLY AND ASSEMBLY624
TORQFLOW TRANSMISSION ASSEMBLY631
REMOVAL AND INSTALLATION631
DISASSEMBLY AND ASSEMBLY632
STEERING CASE ASSEMBLY651
DISASSEMBLY AND ASSEMBLY651
STEERING CLUTCH, BRAKE ASSEMBLY659
DISASSEMBLY AND ASSEMBLY659
TRANSFER GEAR HOUSING ASSEMBLY667
DISASSEMBLY AND ASSEMBLY667
POWER TRAIN PUMP ASSEMBLY671
REMOVAL AND INSTALLATION671
SCAVENGING PUMP ASSEMBLY672
REMOVAL AND INSTALLATION672
TORQUE CONVERTER OIL COOLER673
REMOVAL AND INSTALLATION673
TORQUE CONVERTER VALVE ASSEMBLY674
REMOVAL AND INSTALLATION674
DISASSEMBLY AND ASSEMBLY675
TRANSMISSION CONTROL VALVE ASSEMBLY678
REMOVAL AND INSTALLATION678
DISASSEMBLY AND ASSEMBLY680
STEERING CONTROL VALVE ASSEMBLY685
REMOVAL AND INSTALLATION685
DISASSEMBLY AND ASSEMBLY686
FINAL DRIVE ASSEMBLY690
REMOVAL AND INSTALLATION690
DISASSEMBLY AND ASSEMBLY692
TRACK FRAME ASSEMBLY709
REMOVAL AND INSTALLATION709
IDLER ASSEMBLY715
DISASSEMBLY AND ASSEMBLY715
RECOIL SPRING ASSEMBLY723
REMOVAL AND INSTALLATION723
DISASSEMBLY AND ASSEMBLY735
TRACK ROLLER ASSEMBLY739
REMOVAL AND INSTALLATION739
DISASSEMBLY AND ASSEMBLY743
CARRIER ROLLER ASSEMBLY749
REMOVAL AND INSTALLATION749
DISASSEMBLY AND ASSEMBLY750
BOGIE ASSEMBLY754
REMOVAL AND INSTALLATION754
DISASSEMBLY AND ASSEMBLY762
NO1 BOGIE ASSEMBLY774
REMOVAL AND INSTALLATION774
TRACK SHOE ASSEMBLY785
REMOVAL AND INSTALLATION785
OVERALL DISASSEMBLY791
OVERALL ASSEMBLY795
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS810
FIELD DISASSEMBLY OF ONE LINK811
FIELD ASSEMBLY OF ONE LINK814
MASTER LINK817
DISASSEMBLY AND ASSEMBLY817
PIVOT SHAFT ASSEMBLY822
REMOVAL AND INSTALLATION822
EQUALIZER BAR823
REMOVAL AND INSTALLATION823
EQUALIZER BAR BUSHING829
DISASSEMBLY AND ASSEMBLY829
HYDRAULIC PUMP ASSEMBLY831
REMOVAL AND INSTALLATION831
BLADE LIFT VALVE ASSEMBLY832
REMOVAL AND INSTALLATION832
DISASSEMBLY AND ASSEMBLY833
BLADE TILT, RIPPER LO VALVE ASSEMBLY835
REMOVAL AND INSTALLATION835
DISASSEMBLY AND ASSEMBLY836
RIPPER HI VALVE ASSEMBLY838
REMOVAL AND INSTALLATION838
DISASSEMBLY AND ASSEMBLY839
PPC RELIEF VALVE ASSEMBLY841
REMOVAL AND INSTALLATION841
HYDRAULIC CYLINDER ASSEMBLY842
DISASSEMBLY AND ASSEMBLY842
RIPPER PIN-PULLER CYLINDER ASSEMBLY848
DISASSEMBLY AND ASSEMBLY848
BLADE ASSEMBLY851
REMOVAL AND INSTALLATION851
GIANT RIPPER ASSEMBLY853
DISASSEMBLY AND ASSEMBLY853
ROPS GUARD857
REMOVAL AND INSTALLATION857
OPERATOR’S CAB ASSEMBLY858
REMOVAL AND INSTALLATION858
FLOOR FRAME ASSEMBLY860
REMOVAL AND INSTALLATION860
DASHBOARD ASSEMBLY865
REMOVAL AND INSTALLATION865
CONTROLLER ASSEMBLY867
REMOVAL AND INSTALLATION867
AIR CONDITIONER COMPRESSOR ASSEMBLY868
REMOVAL AND INSTALLATION868
AIR CONDITIONER CONDENSER ASSEMBLY870
REMOVAL AND INSTALLATION870
AIR CONDITIONER UNIT ASSEMBLY871
REMOVAL AND INSTALLATION871
HOOD ASSEMBLY875
REMOVAL AND INSTALLATION875
40 MAINTENANCE STANDARD876
ENGINE MOUNT877
DAMPER, UNIVERSAL JOINT878
TORQUE CONVERTER879
TORQUE CONVERTER VALVE881
TORQFLOW TRANSMISSION883
TRANSMISSION CONTROL VALVE885
POWER TRAIN, HYDRAULIC, LUBRICATION PUMP888
TRANSFER, BEVEL PINION889
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE890
STEERING CONTROL VALVE892
FINAL DRIVE894
MAIN FRAME896
TRACK FRAME898
RECOIL SPRING900
IDLER902
TRACK ROLLER BOGIE906
TRACK ROLLER908
CARRIER ROLLER912
TRACK SHOE914
EQUALIZER BAR920
PIVOT SHAFT922
HYDRAULIC PUMP923
WORK EQUIPMENT CONTROL PUMP924
MAIN CONTROL VALVE925
PPC VALVE929
WORK EQUIPMENT CYLINDER932
CYLINDER STAY934
BLADE935
RIPPER EQUIPMENT940
90 OTHERS942
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM943
SINGLE TILT SPECIFICATION943
DUAL TILT SPECIFICATION (SERIAL NO: 10601-10674)944
DUAL TILT SPECIFICATION (TANDEM CIRCUIT SPECIFICATION) (SERIAL NO: 10675 AND UP)945
DUAL TILT SPECIFICATION (PARALLEL CIRCUIT SPECIFICATION) (SERIAL NO: 10675 AND UP)946
SUPER DOZER SPECIFICATION947
ELECTRICAL CIRCUIT DIAGRAM948
SINGLE TILT AND DUAL TILT SPECIFICATIONS948
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/3)948
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/3)949
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/3)950
SUPER DOZER SPECIFICATION951
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/3)951
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/3)952
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/3)953
HEAVY-DUTY SPECIFICATION954
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/3)954
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/3)955
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/3)956
ELECTRICAL CIRCUIT DIAGRAM INSIDE CAB957

S.M 29/12/24