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KOMATSU D475A-3 PALM CONTROL SPECIFICATION SERVICE REPAIR MANUAL (SN:10695 & UP) KOMATSU D475A 3 – PDF DOWNLOAD
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- KOMATSU D475A-3 PALM CONTROL SPECIFICATION SERVICE REPAIR MANUAL
- SERIAL NUMBER:10695 & UP
- PUBLICATION NUMBER:SEBM027502
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Description
KOMATSU D475A-3 PALM CONTROL SPECIFICATION SERVICE REPAIR MANUAL (SN:10695 & UP) KOMATSU D475A 3
KOMATSU D475A-3 PALM CONTROL SPECIFICATION SERVICE REPAIR MANUAL (SN:10695 & UP) KOMATSU D475A 3 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D475A-3 PALM CONTROL SPECIFICATION SERVICE REPAIR MANUAL (SN:10695 & UP) KOMATSU D475A 3
- 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 D475A-3 PALM CONTROL SPECIFICATION SERVICE REPAIR MANUAL (SN:10695 & UP) KOMATSU D475A 3
COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 01 GENERAL................................................................................................................................... 28 SPECIFICATION DIMENSION DRAWINGS......................................................................................................... 29 SPECIFICATIONS........................................................................................................................... 31 WEIGHT TABLE............................................................................................................................. 40 TABLE OF FUEL, COOLANT AND LUBRICANTS.................................................................................................... 44 10 STRUCTURE AND FUNCTION.................................................................................................................... 46 ENGINE, POWER TRAIN COOLING SYSTEM DRAWING............................................................................................... 47 POWER TRAIN.............................................................................................................................. 48 POWER TRAIN SKELETON..................................................................................................................... 49 POWER TRAIN HYDRAULIC PIPING DIAGRAM..................................................................................................... 50 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.................................................................................................... 51 TORQUE CONVERTER AND PTO................................................................................................................. 53 TORQUE CONVERTER VALVE................................................................................................................... 59 TRANSMISSION............................................................................................................................. 67 TRANSMISSION CONTROL..................................................................................................................... 74 TRANSMISSION ECMV........................................................................................................................ 75 TRANSMISSION CLUTCH ECMV................................................................................................................. 77 TRANSMISSION LUBRICATION RELIEF VALVE.................................................................................................... 81 PRIORITY VALVE........................................................................................................................... 82 STEERING, BRAKE CONTROL.................................................................................................................. 83 TRANSFER, BEVEL GEAR SHAFT, STEERING..................................................................................................... 85 TRANSFER, BEVEL PINION................................................................................................................... 86 STEERING ECMV............................................................................................................................ 89 STEERING CLUTCH, STEERING BRAKE ECMV..................................................................................................... 91 SUDDEN STOP PREVENTION VALVE............................................................................................................. 98 FINAL DRIVE.............................................................................................................................. 99 TRACK FRAME..............................................................................................................................103 HYDRAULIC TANK...........................................................................................................................105 PPC VALVE................................................................................................................................106 MAIN CONTROL VALVE.......................................................................................................................117 PIN-PULLER HYDRAULIC SYSTEM DRAWING......................................................................................................125 PIN-PULLER HYDRAULIC CIRCUIT DRAWING.....................................................................................................125 PIN-PULLER SOLENOID VALVE................................................................................................................126 AIR CONDITIONER..........................................................................................................................128 ENGINE CONTROL...........................................................................................................................129 ENGINE CONTROL SYSTEM....................................................................................................................130 DECELERATION POTENTIOMETER...............................................................................................................131 ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER.........................................................................132 MONITOR SYSTEM...........................................................................................................................134 MONITOR PANEL............................................................................................................................136 MODE SELECTION SYSTEM....................................................................................................................144 ELECTRICAL EQUIPMENT.....................................................................................................................150 STEERING ELECTRONIC CONTROL..............................................................................................................153 20 TESTING AND ADJUSTING.....................................................................................................................155 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS............................................................................................156 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...........................................................................................157 TESTING AND ADJUSTING....................................................................................................................165 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...........................................................................166 MEASURING ENGINE SPEED...............................................................................................................167 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE).......................................................................................170 MEASURING EXHAUST TEMPERATURE........................................................................................................171 MEASURING EXHAUST COLOR..............................................................................................................172 ADJUSTING VALVE CLEARANCE............................................................................................................173 MEASURING COMPRESSION PRESSURE.......................................................................................................174 MEASURING BLOW-BY PRESSURE...........................................................................................................175 MEASURING ENGINE OIL PRESSURE........................................................................................................176 TESTING AND ADJUSTING FUEL INJECTION TIMING .........................................................................................177 TESTING AND ADJUSTING ALTERNATOR BELT TENSION........................................................................................178 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR....................................................................178 ADJUSTING ENGINE SPEED SENSOR........................................................................................................179 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL....................................................................................180 MEASURING POWER TRAIN OIL PRESSURE...................................................................................................182 SIMPLE METHOD FOR TESTING BRAKE PERFORMANCE..........................................................................................191 ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER........................................................................................192 ADJUSTING PCCS LEVER CONSOLE POSITION................................................................................................195 EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE.................................................................................196 ADJUSTING CLEARANCE OF IDLER.........................................................................................................199 TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................................200 MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE..................................................................................201 TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE........................................................................206 MEASURING PPC VALVE AND PITCH, TILT CONTROL VALVE OUTPUT PRESSURE....................................................................208 ADJUSTING PPC VALVE..................................................................................................................212 MEASURING OUTPUT PRESSURE OF DEMAND SOLENOID VALVE...................................................................................213 MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE........................................................................214 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER....................................................................215 MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER..........................................................................................216 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....................................................................................217 BLEEDING AIR FROM HYDRAULIC CYLINDERS................................................................................................217 ADJUSTING WORK EQUIPMENT SAFETY LEVER................................................................................................218 ADJUSTING RIPPER LEVER POSITION......................................................................................................219 PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (DUAL TILT DOZER SPECIFICATION).......................................................220 SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) ...........................................................................................222 ADJUSTING METHOD OF REPLACED CONTROLLER..............................................................................................266 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM.............................................................................268 HANDLING OF OPTIONAL DEVICES.........................................................................................................270 PM CLINIC SERVICE....................................................................................................................271 UNDERCARRIAGE TROUBLESHOOTING REPORT.................................................................................................279 TROUBLESHOOTING..........................................................................................................................281 POINTS TO REMEMBER WHEN TROUBLESHOOTING .............................................................................................282 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................283 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....................................................................................284 CHECKS BEFORE TROUBLESHOOTING........................................................................................................292 CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING.....................................................................................293 TABLE OF CONNECTORS..................................................................................................................294 CONNECTOR ARRANGEMENT DRAWING........................................................................................................297 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................304 T-BRANCH BOX AND T-BRANCH TABLE......................................................................................................326 TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE)............................................................................328 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST....................................................................................332 TROUBLE CODE TABLE...............................................................................................................333 ERROR CODE [1500L0] (TRANSMISSION CLUTCH: SEE THE LIST.(L0)).....................................................................334 ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST.(L1))..........................................................................335 ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST.(LH))..........................................................................336 ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST.(L1))..........................................................................337 ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST.(LH))..........................................................................338 ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST.(L1))..............................................................................339 ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST.(LH))..............................................................................340 ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST.(L1))..............................................................................341 ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST.(LH))..............................................................................342 ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST.(L1))..............................................................................343 ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST.(LH))..............................................................................344 ERROR CODE [1800MW] (POWER TRAIN CLUTCH: SLIP (MW))..............................................................................345 ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST.(L1))............................................................................346 ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST.(LH))............................................................................347 ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST.(L1)).............................................................................348 ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST.(LH)).............................................................................349 ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST.(L1)).............................................................................350 ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST.(LH)).............................................................................351 ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST.(L1))..............................................................................352 ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST.(LH))..............................................................................353 ERROR CODE [A70XLK] (GOVERNOR SERVO SYSTEM RIGHT: * REFER TO TABLE (LK)).........................................................354 ERROR CODE [A70YLK] (GOVERNOR SERVO SYSTEM LEFT: * REFER TO TABLE (LK))..........................................................355 ERROR CODE [AA1ANX] (AIR CLEANER: CLOGGING (NX)).................................................................................357 ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA))...............................................................................358 ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))....................................................................359 ERROR CODE [B@BAZK] (ENGINE OIL: OIL LEVEL REDUCTION (ZK)).......................................................................359 ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))............................................................................360 ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK)).....................................................................361 ERROR CODE [B@CENS] (POWER TRAIN OIL: OVERHEAT (NS)).............................................................................361 ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))...............................................................................362 ERROR CODE [B@HAZK] (HYDRAULIC OIL: LEVEL REDUCTION (ZK))........................................................................362 ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA))..........................................................................363 ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB))..........................................................................364 ERROR CODE [D130KA] (NEUTRAL RELAY: DISCONNECTION (KA))..........................................................................365 ERROR CODE [D130KB] (NEUTRAL RELAY: SHORT CIRCUIT (KB))..........................................................................367 ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA))....................................................................368 ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))....................................................................370 ERROR CODE [D1D0KA] (GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION (KA))............................................................372 ERROR CODE [D1D0KB] (GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT (KB))............................................................373 ERROR CODE [D1D1KA] (GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION (KA)).............................................................375 ERROR CODE [D1D1KB] (GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT (KB)).............................................................377 ERROR CODE [D5ZFKA] (NEUTRAL SIGNAL 1: DISCONNECTION (KA)).......................................................................379 ERROR CODE [D5ZFKB] (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB)).......................................................................380 ERROR CODE [D5ZFL4] (ENGINE CONTROLLER NEUTRAL SIGNAL: ON AND OFF SIGNALS DO NOT AGREE (L4)).....................................381 ERROR CODE [D5ZGKA] (NEUTRAL SIGNAL 2: DISCONNECTION (KA)).......................................................................383 ERROR CODE [D5ZGKB] (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB)).......................................................................384 ERROR CODE [D5ZKKX] (CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL RANGE (KX))....................................................385 ERROR CODE [DAFRKR] (MONITOR PANEL "CAN" COMMUNICATION: DEFECTIVE COMMUNICATION (KR))............................................386 ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))...............................................388 ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT))....................................................389 ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))....................390 ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))...........................392 ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))..............................393 ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))....................................394 ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))..................................396 ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))...................................................398 ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT))........................................................399 ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))........................400 ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))...............................402 ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))..................................403 ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))........................................404 ERROR CODE [DB3SKR] (STEERING CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))......................................406 ERROR CODE [DB40KK] (ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK)).........................................................407 ERROR CODE [DB41KK] (SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)).......................................................408 ERROR CODE [DB42KK] (SOLENOID POWER SUPPLY 1: LOWERING OF SOURCE VOLTAGE (KK))...................................................410 ERROR CODE [DB43KK] (BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)).......................................................412 ERROR CODE [DB44KK] (SOLENOID POWER SUPPLY 2: LOWERING OF SOURCE VOLTAGE (KK))...................................................414 ERROR CODE [DB45KP] (RACK SENSOR POWER SUPPLY: LOWERING OF OUTPUT VOLTAGE (KP))..................................................416 ERROR CODE [DB49KM] (WRONG CONNECTION OF CONNECTOR: MISTAKE IN OPERATION OR SETTING (KM))........................................418 ERROR CODE [DB49KQ] (ENGINE CONTROLLER SPECIFICATION: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ))..............................419 ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA))...................................................................421 ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))...................................................................423 ERROR CODE [DDB9KA] (REVERSE SWITCH: DISCONNECTION (KA)).........................................................................425 ERROR CODE [DDB9KB] (REVERSE SWITCH: SHORT CIRCUIT (KB)).........................................................................427 ERROR CODE [DDK3KA] (FORWARD SWITCH: DISCONNECTION (KA)).........................................................................429 ERROR CODE [DDK3KB] (FORWARD SWITCH: SHORT CIRCUIT (KB)).........................................................................431 ERROR CODE [DDK5KA] (SHIFT SWITCH: DISCONNECTION (KA))...........................................................................433 ERROR CODE [DDK5KB] (SHIFT SWITCH: SHORT CIRCUIT (KB))...........................................................................435 ERROR CODE [DDN2LD] (SEE TABLE (LD) BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM).................................................436 ERROR CODE [DDN3LD] (SEE TABLE (LD) BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM)..................................................437 ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA)).....................................................................438 ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB)).....................................................................440 ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA))......................................................................442 ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB))......................................................................444 ERROR CODE [DDNALD] (BLADE LIFT UP FULL PRESSURE SWITCH: REFER TO TABLE (LD))....................................................446 ERROR CODE [DDNBLD] (RIPPER LIFT UP PRESSURE SWITCH: REFER TO TABLE (LD))........................................................447 ERROR CODE [DDNCLD] (RIPPER LOWER PRESSURE SWITCH: REFER TO TABLE (LD))..........................................................448 ERROR CODE [DDNDLD] (RIPPER TILT IN PRESSURE SWITCH: REFER TO TABLE (LD))........................................................449 ERROR CODE [DDNELD] (RIPPER TILT BACK PRESSURE SWITCH: REFER TO TABLE (LD))......................................................450 ERROR CODE [DDNFLD] (BLADE LOWER FULL PRESSURE SWITCH: REFER TO TABLE (LD))......................................................451 ERROR CODE [DDQ2KA] (PARKING BRAKE LEVER SWITCH: DISCONNECTION (KA)).............................................................452 ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB)).............................................................454 ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4)).................................................................456 ERROR CODE [DDT5KA] (NEUTRAL SWITCH: DISCONNECTION (KA)).........................................................................457 ERROR CODE [DDT5KB] (NEUTRAL SWITCH: SHORT CIRCUIT (KB)).........................................................................459 ERROR CODE [DDT5KQ] (PCCS LEVER SPECIFICATION SIGNAL INCONSISTENCY (KQ)).........................................................461 ERROR CODE [DGE2KX] (COOLANT TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)).................................................462 ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).................................464 ERROR CODE [DH22KA] (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA))..........................................465 ERROR CODE [DH22KB] (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB))..........................................466 ERROR CODE [DH23KA] (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA)).....................................467 ERROR CODE [DH23KB] (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)).....................................468 ERROR CODE [DK01KA] (LEFT YOKE ANGEL SENSOR: DISCONNECTION (KA)).................................................................469 ERROR CODE [DK01KB] (LEFT YOKE ANGEL SENSOR: SHORT CIRCUIT (KB)).................................................................470 ERROR CODE [DK03KA] (RIGHT YOKE ANGEL SENSOR: DISCONNECTION (KA))................................................................471 ERROR CODE [DK03KB] (RIGHT YOKE ANGEL SENSOR: SHORT CIRCUIT (KB))................................................................472 ERROR CODE [DK10KX] (FUEL DIAL: OUT OF NORMAL SIGNAL RANGE (KX)).................................................................473 ERROR CODE [DK11KA] (DECELERATION POTENTIOMETER: DISCONNECTION (KA)).............................................................475 ERROR CODE [DK11KB] (DECELERATION POTENTIOMETER: SHORT CIRCUIT (KB)).............................................................477 ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER: OUT OF INPUT SIGNAL RANGE (KX)).................................................479 ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA))...............................................................481 ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))...............................................................483 ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).........................................484 ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ))..............................................484 ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8))...................................................................485 ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA))...............................................................486 ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB))...............................................................488 ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA))....................................................................489 ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))....................................................................490 ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))....................................491 ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ)).........................................491 ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))..............................................................492 ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA))........................................................493 ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB))........................................................494 ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA))........................................................495 ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB))........................................................497 ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA))....................................................................498 ERROR CODE [DK60KB] (ACCELERATION SENSOR: SHORT CIRCUIT (KB))....................................................................499 ERROR CODE [DKF1KX] (RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE (KX))..........................................................500 ERROR CODE [DKF2KX] (RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE (KX))...........................................................502 ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA)).....................................................................504 ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB)).....................................................................505 ERROR CODE [DLE1KA] (ENGINE NE SPEED SENSOR: DISCONNECTION (KA)).................................................................506 ERROR CODE [DLE4LC] (ENGINE SPEED SENSOR A: * REFER TO TABLE (LC))...............................................................508 ERROR CODE [DLE5LC] (ENGINE SPEED SENSOR B: * REFER TO TABLE (LC))...............................................................510 ERROR CODE [DLF1KA] (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION (KA))...................................................512 ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB)).........................................................................513 ERROR CODE [DW55KA] (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA))..............................................................514 ERROR CODE [DW55KB] (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB))..............................................................515 ERROR CODE [DW56KA] (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA))..............................................................516 ERROR CODE [DW56KB] (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB))..............................................................517 ERROR CODE [DW57KA] (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA))...............................................................518 ERROR CODE [DW57KB] (LEFT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))...............................................................519 ERROR CODE [DW58KA] (RIGHT TILT LIMIT SOLENOID: DISCONNECTION (KA))..............................................................520 ERROR CODE [DW58KB] (RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))..............................................................521 ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA))..........................................................522 ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB))..........................................................523 ERROR CODE [DW5JKA] (BLADE PITCH SOLENOID: DISCONNECTION (KA))...................................................................524 ERROR CODE [DW5JKB] (BLADE PITCH SOLENOID: SHORT CIRCUIT (KB))...................................................................525 ERROR CODE [DW5LKA] (BLADE PITCH DUMP ASSIST SOLENOID: DISCONNECTION (KA)).......................................................526 ERROR CODE [DW5LKB] (BLADE PITCH DUMP ASSIST SOLENOID: SHORT CIRCUIT (KB)).......................................................527 ERROR CODE [DW98KA] (UNLOAD SOLENOID: DISCONNECTION (KA))........................................................................528 ERROR CODE [DW98KB] (UNLOAD SOLENOID: SHORT CIRCUIT (KB))........................................................................529 ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA))........................................................530 ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB))........................................................531 ERROR CODE [DXH1KA] (LOCK-UP SOLENOID: DISCONNECTION (KA)).......................................................................532 ERROR CODE [DXH1KB] (LOCK-UP SOLENOID: SHORT CIRCUIT (KB)).......................................................................533 ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA))........................................................................534 ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))........................................................................535 ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA))........................................................................536 ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))........................................................................537 ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA))........................................................................538 ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))........................................................................539 ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA))....................................................................540 ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))....................................................................541 ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA))....................................................................542 ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))....................................................................543 ERROR CODE [DXH9KA] (RIGHT STEERING CLUTCH ECMV: DISCONNECTION (KA)).............................................................544 ERROR CODE [DXH9KB] (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)).............................................................545 ERROR CODE [DXHAKA] (LEFT STEERING CLUTCH ECMV: DISCONNECTION (KA))..............................................................546 ERROR CODE [DXHAKB] (LEFT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB))..............................................................547 ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA)).......................................................................548 ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB)).......................................................................549 ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA))........................................................................550 ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))........................................................................551 ERROR CODE [DXHDKA] (GOVERNOR SOLNOID RIGHT: DISCONNECTION (KA)).................................................................552 ERROR CODE [DXHDKB] (GOVERNOR SOLNOID RIGHT: SHORT CIRCUIT (KB)).................................................................554 ERROR CODE [DXHEKA] (GOVERNOR SOLNOID LEFT: DISCONNECTION (KA))..................................................................555 ERROR CODE [DXHEKB] (GOVERNOR SOLNOID LEFT: SHORT CIRCUIT (KB))..................................................................557 ERROR CODE [DXHFKA] (PRE-STROKE SOLENOID RIGHT: DISCONNECTION (KA))..............................................................558 ERROR CODE [DXHFKB] (PRE-STORKE SOLENOID RIGHT: SHORT CIRCUIT (KB))..............................................................559 ERROR CODE [DXHGKA] (PRE-STROKE SOLENOID LEFT: DISCONNECTION (KA))...............................................................560 ERROR CODE [DXHGKB] (PRE-STORKE SOLENOID LEFT: SHORT CIRCUIT (KB))...............................................................561 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)........................................................................................562 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST....................................................................................563 E-1 THE ENGINE DOES NOT START....................................................................................................564 E-2 THE PREHEATER DOES NOT OPERATE. (MANUAL PREHEATING FUNCTION).................................................................566 E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE..............................................................................568 E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON..............................................569 E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT......................570 E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH. (THE RADIATOR WATER LEVEL CAUTION LAMP FLASHES)..........571 E-7 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH. (THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP FLASHES)....572 E-8 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH. (THE ENGINE OIL LEVEL CAUTION LAMP FLASHES).............573 E-9 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES......................................................................574 E-10 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES...........................................................576 E-11 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON................................................580 E-12 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE)........582 E-13 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON.......................582 E-14 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY...............................................................583 E-15 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL.................................................................584 E-16 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY..............................................................585 E-17 INDICATION OF THE FUEL GAUGE IS ABNORMAL....................................................................................586 E-18 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL.....................................................................587 E-19 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL......................................................................587 E-20 THE SWITCH MODULE CANNOT BE OPERATED........................................................................................588 E-21 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT..........................................................................589 E-22 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP............................................................................590 E-23 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED..........................................................................591 E-24 THE ALARM BUZZER CANNOT BE CANCELLED........................................................................................592 E-25 THE OPERATOR MODE CANNOT BE OPERATED........................................................................................593 E-26 THE SERVICE MODE CANNOT BE OPERATED.........................................................................................594 E-27 THE BACK-UP ALARM DOES NOT SOUND............................................................................................596 E-28 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON...............................597 E-29 THE AIR CONDITIONER DOES NOT OPERATE........................................................................................601 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)..........................................................................606 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST....................................................................................607 H-1 NO TRAVEL POWER (NO DRAWBAR PULL)............................................................................................608 H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)..................................................................................609 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE.....................................................................................610 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE..................................................................611 H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED,LARGE TIME LAG IS MADE...................................................612 H-6 STEERING IS NOT POSSIBLE.....................................................................................................613 H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE........................................................................................613 H-8 STEERING OVERRUN OCCURS......................................................................................................614 H-9 BRAKE DOES NOT WORK..........................................................................................................614 H-10 TORQUE CONVERTER IS NOT LOCK-UP.............................................................................................615 H-11 OVERHEAT OF POWER TRAIN OIL TEMPERATURE.....................................................................................616 H-12 ALL WORK EQUIPMENT OPERATES SLOWLY..........................................................................................617 H-13 ALL WORK EQUIPMENT DOES NOT OPERATE.........................................................................................618 H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER.............................................................619 H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER.............................................................619 H-16 RIPPER TILT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER...........................................................620 H-17 RIPPER TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER............................................................620 H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT.....................................................................................621 H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT.....................................................................................622 H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT....................................................................................622 H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE)..................................................623 H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE)....................................................................623 H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP....................................................................625 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................626 POWER TRAIN UNIT ASSEMBLY................................................................................................................628 REMOVAL AND INSTALLATION.............................................................................................................628 PTO,TORQUE CONVERTER ASSEMBLY............................................................................................................632 REMOVAL AND INSTALLATION.............................................................................................................632 TORQFLOW TRANSMISSION ASSEMBLY...........................................................................................................635 DISASSEMBLY AND ASSEMBLY.............................................................................................................635 STEERING CASE ASSEMBLY...................................................................................................................655 DISASSEMBLY AND ASSEMBLY.............................................................................................................655 TRANSMISSION CONTROL VALVE ASSEMBLY......................................................................................................663 REMOVAL AND INSTALLATION.............................................................................................................663 STEERING CONTROL VALVE ASSEMBLY..........................................................................................................665 REMOVAL AND INSTALLATION.............................................................................................................665 FLOOR FRAME ASSEMBLY.....................................................................................................................666 REMOVAL AND INSTALLATION.............................................................................................................666 DASHBOARD ASSEMBLY.......................................................................................................................670 REMOVAL AND INSTALLATION.............................................................................................................670 CONTROLLER ASSEMBLY......................................................................................................................672 REMOVAL AND INSTALLATION.............................................................................................................672 AIR CONDITIONER UNIT ASSEMBLY............................................................................................................673 REMOVAL AND INSTALLATION.............................................................................................................673 40 MAINTENANCE STANDARD......................................................................................................................677 ENGINE MOUNT.............................................................................................................................678 DAMPER, UNIVERSAL JOINT..................................................................................................................679 TORQUE CONVERTER.........................................................................................................................680 TORQUE CONVERTER VALVE...................................................................................................................682 TORQFLOW TRANSMISSION....................................................................................................................684 POWER TRAIN, HYDRAULIC, LUBRICATION PUMP.................................................................................................686 TRANSFER, BEVEL PINION...................................................................................................................687 BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE.................................................................................................688 PARKING BRAKE VALVE......................................................................................................................690 FINAL DRIVE..............................................................................................................................691 MAIN FRAME...............................................................................................................................693 TRACK FRAME..............................................................................................................................695 RECOIL SPRING............................................................................................................................696 IDLER....................................................................................................................................697 TRACK ROLLER.............................................................................................................................699 CARRIER ROLLER...........................................................................................................................701 TRACK SHOE...............................................................................................................................702 EQUALIZER BAR............................................................................................................................705 PIVOT SHAFT..............................................................................................................................707 HYDRAULIC PUMP...........................................................................................................................708 WORK EQUIPMENT CONTROL PUMP..............................................................................................................709 MAIN CONTROL VALVE.......................................................................................................................710 PPC VALVE................................................................................................................................714 WORK EQUIPMENT CYLINDER..................................................................................................................717 CYLINDER STAY............................................................................................................................719 BLADE....................................................................................................................................720 RIPPER EQUIPMENT.........................................................................................................................725 90 OTHERS....................................................................................................................................727 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.................................................................................................728 SINGLE TILT SPECIFICATION............................................................................................................728 DUAL TILT SPECIFICATION..............................................................................................................729 SUPER DOZER SPECIFICATION............................................................................................................730 ELECTRICAL CIRCUIT DIAGRAM...............................................................................................................731 SINGLE TILT AND DUAL TILT SPECIFICATIONS.............................................................................................731 CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/4).........................................................................................731 CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/4).........................................................................................732 CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/4).........................................................................................733 CHASSIS ELECTRICAL CIRCUIT DIAGRAM (4/4).........................................................................................734 SUPER DOZER SPECIFICATION............................................................................................................735 CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/3).........................................................................................735 CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/3).........................................................................................736 CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/3).........................................................................................737 ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB............................................................................................738
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