Komatsu BULLDOZER D475A -5E0 D475ASD-5E0 Shop Manual SEN00203-34 PDF

Description

Komatsu BULLDOZER D475A -5E0 D475ASD-5E0 Shop Manual SEN00203-34 – PDF  DOWNLOAD

FILE DETAILS:

Komatsu BULLDOZER D475A -5E0 D475ASD-5E0 Shop Manual SEN00203-34 – PDF  DOWNLOAD

Language : English
Pages :1736
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu BULLDOZER D475A -5E0 D475ASD-5E0 Shop Manual SEN00203-34 – PDF  DOWNLOAD

SERIAL NUMBERS D475A- 30001
D475ASD- 30001 and up

1. General precautions

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu BULLDOZER D475A -5E0 D475ASD-5E0 Shop Manual SEN00203-34 – PDF  DOWNLOAD

SERIAL NUMBERS D475A- 30001
D475ASD- 30001 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 23
Safety notice 24
How to read the shop manual 29
Explanation of terms for maintenance standard 31
Handling of electric equipment and hydraulic component 33
Handling of connectors newly used for engines 42
How to read electric wire code 45
Precautions when carrying out operation 48
Method of disassembling and connecting push-pull type coupler 51
Standard tightening torque table 54
Conversion table 58
01 Specification 65
Specification and technical data 65
Specification drawings 66
Specifications 67
Weight table 76
Fuel, coolant and lubricants 80
10 Structure, function and maintenance standard 83
Engine and cooling system 83
Engine and cooling system 84
Radiator and oil cooler 84
Engine mount 85
Cooling fan pump 86
Cooling fan motor 108
Power train, Part 1 117
Power train 118
Power train hydraulic equipment arrangement diagram 120
Damper and universal joint 122
Power train system 124
General view of power train unit 124
Torque converter, PTO 126
Torque converter valve 134
Torque converter lockup control system 144
Scavenging pump 145
Transmission control 147
Transmission 148
Power train, Part 2 161
Transmission control valve 162
Transmission clutch ECMV 164
Priority valve 168
Lubricating oil relief valve 170
Torque converter, power train, lubricating oil pump 171
Steering, brake control 172
Steering and brake control 174
Final drive 176
Sprocket 180
Steering unit 183
Steering control valve 194
Steering clutch ECMV, Steering brake ECMV 196
Parking brake valve 202
Sudden stop prevention valve 204
Undercarriage and frame 207
Track frame 208
Recoil spring 210
Idler 212
Track roller 214
Carrier roller 218
Track roller bogie 219
Track shoe 220
Main frame 224
Suspension 226
Hydraulic system, Part 1 231
Hydraulic system, Part 1 232
Work equipment hydraulic equipment arrangement diagram 232
PPC control piping diagram 236
Work equipment control 238
Work equipment pump 240
PPC valve 257
PCCS lever 268
Hydraulic system, Part 2 273
Control valve 274
CLSS 289
Unload valve 292
Introduction of LS pressure 293
LS bypass plug 294
Pressure compensation valve 295
Blade lift valve 298
Merge-divider valve 306
Self pressure reducing valve 308
Pilot solenoid valve 312
Hydraulic system, Part 3 315
Hydraulic tank, hydraulic filter 316
Accumulator 318
Work equipment cylinder 320
Piston valve 322
Quick drop valve 324
Blade control knob (Dual tilt specification) 326
Blade control knob (Superdozer specification) 327
Pitch and dual solenoid valve 328
Pin puller hydraulic circuit diagram 329
Pin puller solenoid valve 330
Work equipment 333
Work equipment 334
Cylinder stay 334
Blade 336
Ripper equipment 340
Cab and its attachments 345
Cab and its attachments 346
Cab mount 346
Cab 347
Air conditioner 350
Electrical system 353
Engine control system 354
CRI engine control system 358
Monitor system 362
Machine monitor 364
Mode selection system 382
Electrical equipment 386
Palm command control system (PCCS) 388
Sensors 390
Vehicle health monitoring system (VHMS) 397
ORBCOMM terminal 403
20 Standard value table 407
Standard service value table 407
Standard value table for engine 408
Standard value table for chassis 409
30 Testing and adjusting 423
Testing and adjusting, Part 1 423
Tools for testing, adjusting, and troubleshooting 425
Measuring engine speed 428
Measuring intake air pressure (boost pressure) 432
Measuring exhaust temperature 434
Measuring exhaust gas color 436
Adjusting valve clearance 438
Testing compression pressure 440
Measuring blow-by pressure 442
Measuring engine oil pressure 444
Handling of fuel system devices 445
Releasing residual pressure from fuel system 445
Testing fuel pressure 446
Handling of reduced cylinder mode operation 447
Handling of no injection cranking operation 447
Testing fuel return and leak amount 448
Bleeding air from fuel circuit 451
Bleeding air from fuel circuit (Low-grade fuel specification) 453
Testing fuel circuit for leakage 455
Testing and adjusting alternator belt tension 456
Testing and adjusting belt tension for air conditioner compressor 457
Adjusting fuel control dial and decelerator pedal 458
Testing and adjusting, Part 2 461
Measuring power train oil pressure 463
Adjusting transmission speed sensor 472
Simple method to test brake performance 473
Adjusting brake pedal and parking brake lever 474
Adjusting PCCS lever console position 477
Emergency escape method when power train has trouble 478
Inspecting wear of sprocket 480
Testing and adjusting track shoe tension 481
Testing and adjusting work equipment oil pressure 482
Testing and adjusting control circuit basic pressure 493
Measuring PPC valve output pressure and solenoid valve output pressure 494
Adjusting play of PPC valve 500
Measuring outlet pressure of ripper pin puller solenoid valve 501
Checking parts which caused hydraulic drift of blade and ripper 502
Measuring internal leakage of work equipment cylinder 503
Releasing residual pressure from work equipment cylinder 504
Bleeding air from work equipment cylinder 504
Adjusting ripper lever position 505
Adjusting work equipment lock lever 506
Measuring fan motor speed 507
Measuring fan circuit oil pressure 508
Bleeding air from fan pump 509
Measurement procedure for blade tilt control angle (Dual tiltdozer specification) 510
Measurement procedure for blade tilt control angle (Superdozer specification) 513
Testing and adjusting operator’s cab 515
Adjusting blade 519
Testing and adjusting operator’s seat isolator 521
Testing and adjusting, Part 3 525
Special functions of monitor panel (EMMS) 526
Testing and adjusting, Part 4 579
Adjustment method when controller has been replaced 580
Preparation work for troubleshooting for electrical equipment system 582
Inspection procedure of diode 586
Handling of optional devices 587
Initialization procedures for VHMS controller 588
Precautions for replacing VHMS controller 609
Pm Clinic service 614
40 Troubleshooting 625
Failure code table and fuse locations 625
Failure code table 626
Fuse locations 636
General information on troubleshooting 641
Points to remember when troubleshooting 642
Sequence of events in troubleshooting 643
Checks before troubleshooting 644
Classification and procedures of troubleshooting 645
Contents of troubleshooting table 648
Connection table for connector pin numbers 650
T- branch box and T- branch adapter table 686
Troubleshooting by failure code, Part 1 691
Failure code [1380MW] Lockup clutch: Clutch slip 693
Failure code [1500L0] Transmission clutch: Dual engagement 694
Failure code [15E0MW] Transmission clutch: Clutch slip 695
Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON 696
Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF 697
Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON 698
Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF 699
Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON 700
Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF 701
Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON 702
Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF 703
Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON 704
Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF 705
Failure code [1800MW] Power train clutch: Slip 706
Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON 707
Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF 708
Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON 709
Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF 710
Failure code [2300NR] Brake thermal load: Abnormal heating 711
Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON 712
Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF 713
Failure code [2301NR] Right steering brake thermal load: Abnormal heating 714
Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON 715
Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF 716
Failure code [2302NR] Left steering brake thermal load: Abnormal heating 717
Failure code [6001ZK] Failure code for design 718
Failure code [A000NS] Engine: Overheat 719
Failure code [AA10NX] Air cleaner: Clogging 720
Failure code [AB00MA] Battery charge abnormality: Malfunction 721
Failure code [B@BAZG] Engine oil: Oil pressure too low 722
Failure code [B@BAZK] Engine oil: Oil level reduction 723
Failure code [B@BCNS] Engine coolant: Overheat 724
Failure code [B@BCZK] Engine coolant: Level too low 725
Failure code [B@BEBF] Fuel: Water in fuel 726
Failure code [B@BFZK] Fuel level: Reduction 727
Failure code [B@CENS] Power train oil: Overheat 728
Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure 729
Failure code [B@CHZK] Power train oil: Oil level reduction 729
Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction 730
Failure code [B@HANS] Hydraulic oil: Overheat 730
Failure code [B@HAZK] Hydraulic oil: Level reduction 731
Troubleshooting by failure code, Part 2 733
Failure code [CA111] Engine controller (Left bank): Internal abnormality 736
Failure code [CB111] Engine controller (Right bank): Internal abnormality 738
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal 740
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal 741
Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected 742
Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected 744
Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank): High voltage detection 745
Failure code [CA132] Decelerator pedal sensor too low (At left bank only): Excessively low voltage detected 747
Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected 748
Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected 750
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected 752
Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected 754
Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected 756
Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected 758
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection 760
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection 761
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection 762
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection 763
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected 764
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected 766
Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected 768
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection 770
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed 772
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected 774
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected 776
Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected 778
Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected 780
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection 781
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection 781
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit 782
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit 783
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection 784
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection 785
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit 786
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit 787
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection 788
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection 789
Troubleshooting by failure code, Part 3 791
Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank): Disconnection, short circuit 794
Failure code [CA323] Injector #5 (L/B #5) system disconnection or short circuit (At left bank): Disconnection, short circuit 796
Failure code [CA324] Injector #3 (L/B #3) system disconnection or short circuit (At left bank): Disconnection, short circuit 798
Failure code [CA325] Injector #6 (L/B #6) system disconnection or short circuit (At left bank): Disconnection, short circuit 800
Failure code [CA331] Injector #2 (L/B #2) system disconnection or short circuit (At left bank): Disconnection, short circuit 802
Failure code [CA332] Injector #4 (L/B #4) system disconnection or short circuit (At left bank): Disconnection, short circuit 804
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch 806
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch 807
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit 808
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality 810
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection 812
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection 813
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection 814
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection 816
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection 818
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection 818
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection 819
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection 819
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence 820
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence 820
Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected 822
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection 824
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection 826
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection 826
Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected 827
Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected 828
Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error 829
Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error 829
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected 830
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected (Low-grade fuel specification) 834
Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected 838
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal 842
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal 844
Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection 846
Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection 848
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase 849
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase 849
Troubleshooting by failure code, Part 4 851
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data 853
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data 853
Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal 854
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error 856
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error 858
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error 860
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error 861
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error 862
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit 864
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit 866
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit 868
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit 870
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit 872
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit 874
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error 876
Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level (Only left bank): High voltage detection 878
Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only): Excessively low voltage detected 880
Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected 881
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected 881
Failure code [D110KA] Battery relay: Disconnection 882
Failure code [D110KB] Battery relay: Short circuit 884
Failure code [D130KA] Neutral safety relay: Disconnection 886
Failure code [D130KB] Neutral safety relay: Short circuit 888
Failure code [D161KA] Back-up alarm relay: Disconnection 890
Failure code [D161KB] Back-up alarm relay: Short circuit 892
Failure code [D182KZ] Preheater relay: Disconnection or short circuit 894
Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection 896
Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit 898
Failure code [D5ZRKA] Snap shot switch: Disconnection 900
Failure code [D5ZRKB] Snap shot switch: Short circuit 901
Failure code [DAFRKR] Monitor panel CAN communication: Communication error 902
Failure code [dAFRKR] Monitor panel CAN communication: Communication error 904
Failure code [daFRKR] Monitor panel CAN communication: Communication error 906
Failure code [DAQ0KT] Transmission controller: Abnormality in controller 908
Failure code [DAQ1KK] Transmission controller main power supply: Power supply voltage reduction (Input) 910
Failure code [DAQ2KK] Transmission controller load power supply: Power supply voltage reduction (Input) 912
Failure code [DAQ5KK] Transmission controller potentiometer power supply: Source voltage reduction (input) 914
Failure code [DAQ6KK] Transmission controller sensor power supply: Source voltage reduction (input) 915
Failure code [DAQ7KK] Transmission controller sensor power supply: Power supply voltage reduction (Input) 916
Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency 917
Failure code [DAQRKR] Transmission controller sensor CAN communication: Communication error (Objective component system abnormality) 918
Failure code [DAQSKR] Transmission controller S-NET communication: Defective communication (Abnormality in objective component system) 920
Troubleshooting by failure code, Part 5 923
Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error 926
Failure code [dB2RKR] Engine controller (Left bank) CAN communication: Communication error 928
Failure code [db2RKR] Engine controller (Right bank) CAN communication: Communication error 930
Failure code [DB30KT] Steering controller: Abnormality in controller 932
Failure code [DB31KK] Steering controller main power supply: Power supply voltage reduction (Input) 934
Failure code [DB32KK] Steering controller load power supply: Power supply voltage reduction (Input) 936
Failure code [DB35KK] Steering controller potentiometer power supply: Power supply voltage reduction (Input) 938
Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input) 940
Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input) 941
Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency 942
Failure code [dB3RKR] Steering controller CAN communication: Communication error 944
Failure code [DB3SKR] Steering controller S-NET communication: Defective communication (Abnormality in objective component system) 946
Failure code [DBB0KK] (or LED of VHMS controller indicates “n9” o “01”) VHMS controller: Lowering of source voltage 948
Failure code [DBB0KQ] (or LED of VHMS controller indicates “nF” o “11”) Check of VHMS controller model: Disagreement of model selection 949
Failure code [DBB3KK] (or LED of VHMS controller indicates “n9” o “05”) VHMS controller: Lowering of direct source voltage 950
Failure code [DBB5KP] (or LED of VHMS controller indicates “n9” o “04”) VHMS sensor power supply (5 V): Lowering of output voltage 951
Failure code [DBB6KP] (or LED of VHMS controller indicates “n9” o “02”) VHMS sensor power supply (24 V): Lowering of output voltage 952
Failure code [DBB7KP] (or LED of VHMS controller indicates “n9” o “03”) VHMS sensor power supply (12 V): Lowering of output voltage 954
Failure code [DBBQKR] (or VHMS_LED display “n8” o “02”) VHMS KOM-NET: Communication error 956
Failure code [dbBRKR] VHMS controller CAN communication: Communication error 958
Failure code [DD12KA] Shift up switch: Disconnection 960
Failure code [DD12KB] Shift up switch: Short circuit 962
Failure code [DD13KA] Shift down switch: Disconnection 964
Failure code [DD13KB] Shift down switch: Short circuit 966
Failure code [DD14KA] Parking brake lever switch: Disconnection 968
Failure code [DD14KB] Parking brake lever switch: Short circuit 970
Failure code [DDB9L4] Reverse switch: Signal disagreement 972
Failure code [DDK3L4] Forward switch: Signal disagreement 974
Failure code [DDK4KA] Directional switch open circuit or hot short 976
Failure code [DDK4KB] Directional switch ground fault 0
Failure code [DDK5KA] Gearshift switch: Disconnection 980
Failure code [DDK5KB] Gearshift switch: Short circuit 982
Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time 984
Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time 985
Failure code [DDN7KA] Blade pitch switch: Disconnection 986
Failure code [DDN7KB] Blade pitch switch: Short circuit 988
Failure code [DDN9KA] Blade tilt switch: Disconnection 990
Failure code [DDN9KB] Blade tilt switch: Short circuit 992
Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time 994
Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time 995
Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time 996
Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time 997
Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time 998
Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time 999
Troubleshooting by failure code, Part 61001
Failure code [DDQ2KA] Parking brake lever switch: Disconnection1004
Failure code [DDQ2KB] Parking brake lever switch: Short circuit1006
Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals1008
Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals1009
Failure code [DDT5KA] Neutral switch: Disconnection1010
Failure code [DDT5KB] Neutral switch: Short circuit1012
Failure code [DDT5KQ] Lever specification selection: Model selection signal disagreement1014
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range1015
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection1016
Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range1017
Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front): Disconnection (or LED of VHMS controller indicates “n3” o “12”)1018
Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear): Disconnection (or LED of VHMS controller indicates “n3” o “22”)1020
Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front): Short circuit (or LED of VHMS controller indicates “n3” o “11”)1022
Failure code [dGT5KB] (or LED of VHMS controller indicates “n3” o “21”) Left bank exhaust temperature sensor system (Rear): Short circuit1024
Failure code [DGT6KA] (or LED of VHMS controller indicates “n3” o “24”) Right bank exhaust temperature sensor system (Front): Disconnection1026
Failure code [dGT6KA] (or LED of VHMS controller indicates “n3” o “26”) Right bank exhaust temperature sensor system (Rear): Disconnection1028
Failure code [DGT6KB] (or LED of VHMS controller indicates “n3” o “23”) Right bank exhaust temperature sensor system (Front): Short circuit1030
Failure code [dGT6KB] (or LED of VHMS controller indicates “n3” o “25”) Right bank exhaust temperature sensor system (Rear): Short circuit1032
Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection1034
Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit1035
Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection1036
Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit1037
Failure code [DHE5KB] (or LED of VHMS controller indicates “n3” o “32”) Blow-by pressure sensor system: Disconnection1038
Failure code [DHE5KY] (or LED of VHMS controller indicates “n3” o “31”) Blow-by pressure sensor system: Hot short1039
Failure code [DHT3KX] (or LED of VHMS controller indicates “n6” o “14”) Transmission oil pressure sensor: Out of input signal range1040
Failure code [DK01KA] Left yoke angle sensor: Disconnection1041
Failure code [DK01KB] Left yoke angle sensor: Short circuit1042
Failure code [DK03KA] Right yoke angle sensor: Disconnection1043
Failure code [DK03KB] Right yoke angle sensor: Short circuit1044
Failure code [DK10KA] Fuel dial: Disconnection1045
Failure code [DK10KB] Fuel dial: Short circuit1046
Failure code [DK30KA] Steering potentiometer (1): Disconnection1048
Failure code [DK30KB] Steering potentiometer (1): Short circuit1050
Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range1052
Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit1052
Failure code [DK30L8] Steering potentiometer (1): See table1053
Failure code [DK31KA] Steering potentiometer (2): Disconnection1054
Failure code [DK31KB] Steering potentiometer (2): Short circuit1056
Troubleshooting by failure code (Display of code), Part 71059
Failure code [DK40KA] Brake potentiometer: Disconnection1061
Failure code [DK40KB] Brake potentiometer: Short circuit1062
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range1063
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit1064
Failure code [DK55L8] Forward-reverse potentiometer: See table1065
Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection1066
Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit1068
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection1070
Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit1072
Failure code [DK60KA] Acceleration sensor: Disconnection1074
Failure code [DK60KB] Acceleration sensor: Short circuit1076
Failure code [DKH1KA] Pitch angle sensor: disconnection1077
Failure code [DKH1KB] Pitch angle sensor: Short circuit1078
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range1079
Failure code [DKW0KX] Swing RIGHT lever potentiometer: Out of input signal range1080
Failure code [DKW0KZ] Swing RIGHT lever potentiometer: Open circuit or short circuit1080
Failure code [DKW0L8] Swing RIGHT lever potentiometer: Analog signals are inconsistent1081
Failure code [DKW1KA] Swing RIGHT lever potentiometer 1: Open circuit1082
Failure code [DKW1KB] Swing RIGHT lever potentiometer 1: short circuit1084
Failure code [DKW2KA] Swing RIGHT lever potentiometer 2: Open circuit1086
Failure code [DKW2KB] Swing RIGHT lever potentiometer 2: short circuit1088
Failure code [DKW3KX] Swing LEFT lever potentiometer: Out of input signal range1090
Failure code [DKW3KZ] Swing LEFT lever potentiometer: Open circuit or short circuit1090
Failure code [DKW3L8] Swing LEFT lever potentiometer: Analog signal inconsistency1091
Failure code [DKW4KA] Swing LEFT lever potentiometer 1: Open circuit1092
Failure code [DKW4KB] Swing LEFT lever potentiometer 1: Short circuit1094
Failure code [DKW5KA] Swing LEFT lever potentiometer 2: Open circuit1096
Failure code [DKW5KB] Swing LEFT lever potentiometer 2: Short circuit1098
Failure code [DLF1KA] Torque converter output speed sensor: Disconnection1100
Failure code [DLT3KA] Transmission output speed sensor: Disconnection1101
Failure code [dLT3KA] Transmission output speed sensor: Disconnection1102
Failure code [DLT3KB] Transmission output speed sensor: Short circuit1104
Failure code [DV00KB] Caution buzzer: Short circuit1105
Failure code [DW55KA] Blade pitch back solenoid: Disconnection1106
Failure code [DW55KB] Blade pitch back solenoid: Short circuit1107
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection1108
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit1109
Failure code [DW56KY] Blade pitch dump solenoid: Hot short1110
Failure code [DW57KA] Left tilt limit solenoid: Disconnection1111
Failure code [DW57KB] Left tilt limit solenoid: Short circuit1112
Failure code [DW57KY] Left tilt limit solenoid: Hot short1113
Failure code [DW58KA] Right tilt limit solenoid: Disconnection1114
Failure code [DW58KB] Right tilt limit solenoid: Short circuit1115
Failure code [DW58KY] Right tilt limit solenoid: Hot short1116
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection1117
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit1118
Failure code [DW59KY] Dual tilt selector solenoid: Hot short1119
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection1120
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit1121
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short1122
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification): Disconnection1123
Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification): Short circuit1124
Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification): Hot short1125
Failure code [DW7BKA] Fan reverse solenoid: Disconnection1126
Failure code [DW7BKB] Fan reverse solenoid: Short circuit1127
Failure code [DW7BKY] Fan reverse solenoid: Hot short1128
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection1129
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit1130
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short1131
Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection1132
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit1133
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short1134
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection1135
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit1136
Failure code [DWN5KY] Fan pump solenoid 1: Hot short1137
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection1138
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit1139
Failure code [DWNCKY] Fan pump solenoid 2: Hot short1140
Troubleshooting by failure code (Display of code), Part 81143
Failure code [DXE0KA] LS set solenoid: Disconnection1145
Failure code [DXE0KB] LS set solenoid: Short circuit1146
Failure code [DXE0KY] LS set solenoid: Hot short1147
Failure code [DXH1KA] Lock-up solenoid: Disconnection1148
Failure code [DXH1KB] Lock-up solenoid: Short circuit1149
Failure code [DXH1KY] Lockup solenoid: Hot short1150
Failure code [DXH4KA] 1st clutch ECMV: Disconnection1151
Failure code [DXH4KB] 1st clutch ECMV: Short circuit1152
Failure code [DXH4KY] 1st clutch ECMV: Hot short1153
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection1154
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit1155
Failure code [DXH5KY] 2nd clutch ECMV: Hot short1156
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection1157
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit1158
Failure code [DXH6KY] 3rd clutch ECMV: Hot short1159
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection1160
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit1161
Failure code [DXH7KY] Reverse clutch ECMV: Hot short1162
Failure code [DXH8KA] Forward clutch ECMV: Disconnection1163
Failure code [DXH8KB] Forward clutch ECMV: Short circuit1164
Failure code [DXH8KY] Forward clutch ECMV: Hot short1165
Failure code [DXH9KA] Right steering clutch ECMV: Disconnection1166
Failure code [DXH9KB] Right steering clutch ECMV: Short circuit1167
Failure code [DXH9KY] Right steering clutch ECMV: Hot short1168
Failure code [DXHAKA] Left steering clutch ECMV: Disconnection1169
Failure code [DXHAKB] Left steering clutch ECMV: Short circuit1170
Failure code [DXHAKY] Left steering clutch ECMV: Hot short1171
Failure code [DXHBKA] Right brake ECMV: Disconnection1172
Failure code [DXHBKB] Right brake ECMV: Short circuit1173
Failure code [DXHBKY] Right brake ECMV: Hot short1174
Failure code [DXHCKA] Left brake ECMV: Disconnection1175
Failure code [DXHCKB] Left brake ECMV: Short circuit1176
Failure code [DXHCKY] Left brake ECMV: Hot short1177
Failure code [F@BBZL] (or VHMS_LED display “n3” → “38”) Engine blow-by pressure sensor: Abnormally high pressure occurrence1178
Failure code [F@BYNS] (or VHMS_LED display “n3” → “61”) Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise1180
Failure code [f@BYNS] (or VHMS_LED display “n3” → “71”) Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise1182
Failure code [F@BZNS] (or VHMS_LED display “n3” → “38”) Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise1184
Failure code [f@BZNS] (or VHMS_LED display “n3” → “39”) Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise1186
Failure code [F@BYNR] (or VHMS_LED display “n3” → “62”) Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise1188
Failure code [f@BYNR] (or VHMS_LED display “n3” → “72”) Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise1190
Failure code [F@BZNR] (or VHMS_LED display “n3” → “82”) Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise1192
Failure code [f@BZNR] (or VHMS_LED display “n3” → “92”) Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise1194
Troubleshooting of electrical system (E-mode)1197
Contents of troubleshooting table1199
E-1 The engine does not start1200
E-2 The preheater does not operate1204
E-3 The ripper pin puller cylinder does not operate1208
E-4 The monitor panel does not come on at all when the starting switch is turned on1210
E-5 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out1212
E-6 When the starting switch is turned on, the basic check items flash1213
E-7 While the engine is operating, any caution item flashes1214
E-8 An emergency caution item flashes while the engine is running1217
E-9 While the preheater is operating, the preheating pilot lamp does not come on1220
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)1222
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on1222
E-12 The engine coolant temperature gauge does not indicate normally1223
E-13 Indication of the power train (torque converter) temperature gauge is abnormal1224
E-14 The hydraulic oil temperature gauge does not indicate normally1226
E-15 Indication of the fuel gauge is abnormal1227
E-16 Indications of gear speed and engine speed are abnormal1228
E-17 Indication of the shift mode service meter is abnormal1228
E-18 The switch module cannot be operated1229
E-19 The warning lamp does not flash or does not go out1230
E-20 The alarm buzzer does not sound or does not stop1231
E-21 Auto shift down is not possible or is not released1232
E-22 The automatic pitch back system does not operate (only superdozer specification)1233
E-23 The alarm buzzer cannot be cancelled1234
E-24 The operator mode cannot be operated1235
E-25 The service mode cannot be operated1236
E-26 The back-up alarm does not sound1238
E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on1240
E-28 Troubleshooting for air conditioner system1246
E-29 Orbcomm terminal does not operate normally (Data are not transmitted)1261
E-30 Fan does not reverse1263
E-31 Gear cannot be shifted1265
E-32 Electric priming pump does not operate or does not stop automatically1266
E-33 Engine pre-lube system does not operate1268
Troubleshooting of hydraulic and mechanical system (H-mode)1275
Information in troubleshooting table1277
H-1 No force (no drawbar pull)1278
H-2 No travel (at 2nd or 3rd speed)1280
H-3 No travel at all gear speeds1281
H-4 Machine travels only in one direction forward or in reverse1282
H-5 Large time lag at gear speed shifting or forward-reverse shifting1283
H-6 Steering is not possible1284
H-7 Steering is possible only on one side1285
H-8 Steering overrun occurs1286
H-9 Brake does not work1287
H-10 Torque converter is not lock-up1288
H-11 Power train oil is overheated1289
H-12 All work equipment speeds are slow1290
H-13 Work equipment does not move1291
H-14 Blade lift speed is slow or lacks power1292
H-15 Blade tilt speed is slow or lacks power1293
H-16 Ripper lift speed is slow or lacks power1294
H-17 Ripper tilt speed is slow or lacks power1295
H-18 Excessive hydraulic drift of blade lift1296
H-19 Excessive hydraulic drift of blade tilt1297
H-20 Excessive hydraulic drift of ripper lift1298
H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine)1298
H-22 Blade pitch does not work (dual tilt attachment machine)1299
H-23 Abnormal sound comes out from around work equipment pump1299
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats)1300
Troubleshooting of engine (S-mode)1303
Method of using troubleshooting chart1305
S-1 Starting performance is poor1308
S-2 Engine does not start1309
S-3 Engine does not pick up smoothly1312
S-4 Engine stops during operations1313
S-5 Engine does not rotate smoothly1314
S-6 Engine lacks output (or lacks power)1315
S-7 Exhaust smoke is black (incomplete combustion)1317
S-8 Oil consumption is excessive (or exhaust smoke is blue)1318
S-9 Oil becomes contaminated quickly1319
S-10 Fuel consumption is excessive1320
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1321
S-12 Oil pressure drops1322
S-13 Oil level rises (Entry of coolant or fuel)1323
S-14 Coolant temperature becomes too high (overheating)1324
S-15 Abnormal noise is made1325
S-16 Vibration is excessive1326
50 Disassembly and assembly1329
General information on disassembly and assembly1329
How to read this manual1330
Coating materials list1332
Special tools list1335
Sketches of special tools1346
Engine and cooling system (SAA12V140E-3)1359
Removal and installation of engine assembly1360
Removal and installation of radiator assembly1364
Removal and installation of aftercooler assembly1366
Removal and installation of radiator guard assembly1368
Removal and installation of fuel tank assembly1370
Removal and installation of engine hood assembly1371
Removal and installation of fan drive assembly1373
Removal and installation of fan motor assembly1374
Engine (SAA12V140E-3)1377
Removal and installation of fuel supply pump assembly1378
Removal and installation of cylinder head assembly1384
Removal and installation of fuel injector assembly1395
Removal and installation of engine front seal1401
Removal and installation of engine rear seal1403
Power train, Part 11407
Removal and installation of damper assembly1408
Disassembly and assembly of damper assembly1410
Removal and installation of power train unit assembly1413
Removal and installation of PTO, torque converter assembly1420
Disconnection and connection of PTO, torque converter assembly1422
Disassembly and assembly of torque converter assembly1424
Disassembly and assembly of PTO assembly1434
Removal and installation of TORQFLOW transmission assembly1441
Disassembly and assembly of TORQFLOW transmission assembly1442
Power train, Part 21461
Disassembly and assembly of steering case assembly1462
Disassembly and assembly of steering clutch, brake assembly1474
Disassembly and assembly of transfer gear housing assembly1481
Removal and installation of power train pump assembly1485
Removal and installation of scavenging pump assembly1485
Removal and installation of torque converter oil cooler1486
Removal and installation of torque converter valve assembly1487
Disassembly and assembly of torque converter valve assembly1488
Removal and installation of transmission control valve assembly1492
Disassembly and assembly of transmission control valve assembly (ECMV assembly)1493
Removal and installation of steering control valve assembly1496
Disassembly and assembly of steering control valve assembly1497
Removal and installation of final drive assembly1499
Disassemble and assemble final drive assembly1501
Undercarriage and frame, Part 11533
Removal and installation of track frame assembly1534
Disassembly and assembly of idler assembly1537
Removal and installation of recoil spring assembly1540
Disassembly and assembly of recoil spring assembly1556
Removal and installation of track roller assembly1558
Disassembly and assembly of track roller assembly1560
Removal and installation of carrier roller assembly1562
Disassembly and assembly of carrier roller assembly1563
Removal and installation of bogie assembly1566
Disassembly and assembly of bogie assembly1570
Removal and installation of No1 bogie assembly1572
Removal and installation of operator’s seat isolator1577
Disassembly and assembly of operator’s seat isolator1578
Undercarriage and frame, Part 21581
Expansion and installation of track shoe assembly1582
Overall disassembly and overall assembly of track shoe1585
Press-fitting jig dimension table for link press1600
Field disassembly and assembly of one link1601
Disassembly and assembly of master link1606
Removal and installation of pivot shaft assembly1612
Removal and installation of equalizer bar1614
Disassembly and assembly of equalizer bar bushing1617
Hydraulic system1621
Removal and installation of hydraulic pump assembly1622
Removal and installation of hydraulic valve assembly1624
Disassembly and assembly of control valve1625
Disassembly and assembly of merge divider valve and self pressure reducing valve assembly1629
Removal and installation of PPC relief valve assembly1631
Disassembly and assembly of hydraulic cylinder assembly1632
Disassembly and assembly of ripper pin puller cylinder assembly1637
Remove and install blade lift cylinder assembly1640
Work equipment1653
Removal and installation of blade assembly1654
Disassembly and assembly of giant ripper assembly1656
Cab and its attachments1661
Removal and installation of ROPS guard1662
Removal and installation of operator’s cab assembly1663
Removal and installation of floor frame assembly1664
Electrical system1669
Removal and installation of controller assembly1670
Removal and installation of engine controller assembly (left)1671
Removal and installation of air conditioner condenser assembly1672
Removal and installation of air conditioner compressor assembly1673
Removal and installation of air conditioner unit1675
90 Diagrams and drawings1679
Hydraulic diagrams and drawings1679
Hydraulic diagrams and drawings1681
Power train hydraulic circuit diagram1681
Hydraulic circuit diagram (1/3)1683
Hydraulic circuit diagram (2/3)1685
Hydraulic circuit diagram (3/3)1687
Electrical diagrams and drawings1691
Electrical circuit diagram (1/17)1693
Electrical circuit diagram (2/17)1695
Electrical circuit diagram (3/17)1697
Electrical circuit diagram (4/17)1699
Electrical circuit diagram (5/17)1701
Electrical circuit diagram (6/17)1703
Electrical circuit diagram (7/17)1705
Electrical circuit diagram (8/17)1707
Electrical circuit diagram (9/17)1709
Electrical circuit diagram (10/17)1711
Electrical circuit diagram (11/17)1713
Electrical circuit diagram (12/17)1715
Electrical circuit diagram (13/17)1717
Electrical circuit diagram (14/17)1719
Electrical circuit diagram (15/17)1721
Electrical circuit diagram (16/17)1723
Electrical circuit diagram (17/17)1725
Electrical circuit diagram of inside cab (1/3)1727
Electrical circuit diagram of inside cab (2/3)1729
Electrical circuit diagram of inside cab (3/3)1731
Connector arrangement diagram1733

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24