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Komatsu D475A-5 Dozer Service Repair Manual – PDF Download
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Komatsu D475A-5 Dozer Service Repair Manual
KOMATSU D475A-5 DOZER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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Komatsu D475A-5 Dozer Service Repair Manual
MAIN MENU............................................................................................................................................................................................... 0 COVER................................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................................ 2 SAFETY.................................................................................................................................................................................................. 10 SAFETY NOTICE....................................................................................................................................................................................... 10 FOREWORD................................................................................................................................................................................................ 12 GENERAL............................................................................................................................................................................................. 12 HOW TO READ THE SHOP MANUAL......................................................................................................................................................................... 13 HOISTING INSTRUCTIONS............................................................................................................................................................................... 14 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.......................................................................................................................................... 15 COATING MATERIALS................................................................................................................................................................................... 17 STANDARD TIGHTENING TORQUE.......................................................................................................................................................................... 19 ELECTRIC WIRE CODE.................................................................................................................................................................................. 22 CONVERSION TABLE.................................................................................................................................................................................... 23 UNITS............................................................................................................................................................................................... 29 01 GENERAL.............................................................................................................................................................................................. 30 SPECIFICATION DRAWINGS.............................................................................................................................................................................. 31 SPECIFICATIONS...................................................................................................................................................................................... 32 WEIGHT TABLE........................................................................................................................................................................................ 41 FUEL, COOLANT AND LUBRICANTS........................................................................................................................................................................ 45 10 STRUCTURE, FUNCTION AND.............................................................................................................................................................................. 48 RADIATOR AND OIL COOLER............................................................................................................................................................................. 51 ENGINE MOUNT........................................................................................................................................................................................ 52 POWER TRAIN......................................................................................................................................................................................... 53 POWER TRAIN HYDRAULIC EQUIPMENT ARRANGEMENT......................................................................................................................................................... 55 DAMPER AND UNIVERSAL JOINT.......................................................................................................................................................................... 57 POWER TRAIN UNIT.................................................................................................................................................................................... 59 TORQUE CONVERTER AND PTO............................................................................................................................................................................ 61 TORQUE CONVERTER VALVE.............................................................................................................................................................................. 71 TORQUE CONVERTER LOCK-UP CONTROL SYSTEM............................................................................................................................................................. 81 SCAVENGING PUMP..................................................................................................................................................................................... 82 TRANSMISSION CONTROL................................................................................................................................................................................ 83 TRANSMISSION........................................................................................................................................................................................ 85 TRANSMISSION ECMV................................................................................................................................................................................... 97 TRANSMISSION CLUTCH ECMV............................................................................................................................................................................ 99 PRIORITY VALVE...................................................................................................................................................................................... 103 LUBRICATING OIL RELIEF VALVE........................................................................................................................................................................ 104 POWER TRAIN, LUBRICATION PUMP....................................................................................................................................................................... 105 STEERING, BRAKE CONTROL............................................................................................................................................................................. 107 FINAL DRIVE......................................................................................................................................................................................... 110 STEERING UNIT....................................................................................................................................................................................... 115 STEERING ECMV....................................................................................................................................................................................... 127 STEERING CLUTCH ECMV, STEERING BRAKE ECMV........................................................................................................................................................... 129 PARKING BRAKE VALVE................................................................................................................................................................................. 135 SUDDEN STOP PREVENTION VALVE........................................................................................................................................................................ 137 SPROCKET............................................................................................................................................................................................ 139 TRACK FRAME......................................................................................................................................................................................... 141 RECOIL SPRING....................................................................................................................................................................................... 144 IDLER............................................................................................................................................................................................... 146 TRACK ROLLER........................................................................................................................................................................................ 148 CARRIER ROLLER...................................................................................................................................................................................... 151 TRACK ROLLER BOGIE.................................................................................................................................................................................. 152 TRACK SHOE.......................................................................................................................................................................................... 154 MAIN FRAME.......................................................................................................................................................................................... 158 SUSPENSION.......................................................................................................................................................................................... 161 WORK EQUIPMENT HYDRAULIC EQUIPMENT ARRANGEMENT...................................................................................................................................................... 164 PPC CONTROL PIPING DIAGRAM.......................................................................................................................................................................... 168 WORK EQUIPMENT CONTROL.............................................................................................................................................................................. 170 WORK EQUIPMENT PUMP................................................................................................................................................................................. 172 COOLING FAN PUMP.................................................................................................................................................................................... 189 COOLING FAN MOTOR................................................................................................................................................................................... 210 PPC VALVE........................................................................................................................................................................................... 218 ELECTRIC LEVER (STEERING)........................................................................................................................................................................... 228 CONTROL VALVE....................................................................................................................................................................................... 232 MAIN RELIEF VALVE................................................................................................................................................................................... 246 CLSS................................................................................................................................................................................................ 247 UNLOAD VALVE........................................................................................................................................................................................ 250 INTRODUCTION OF LS PRESSURE (LS SHUTTLE VALVE)...................................................................................................................................................... 251 LS BYPASS PLUG...................................................................................................................................................................................... 252 PRESSURE COMPENSATION VALVE......................................................................................................................................................................... 253 BLADE LIFT VALVE.................................................................................................................................................................................... 256 MERGE DIVIDER VALVE................................................................................................................................................................................. 264 SELF PRESSURE REDUCING VALVE........................................................................................................................................................................ 266 PILOT SOLENOID VALVE................................................................................................................................................................................ 270 HYDRAULIC TANK...................................................................................................................................................................................... 272 ACCUMULATOR......................................................................................................................................................................................... 274 WORK EQUIPMENT CYLINDER............................................................................................................................................................................. 276 PISTON VALVE........................................................................................................................................................................................ 278 QUICK DROP VALVE.................................................................................................................................................................................... 280 BLADE CONTROL KNOB.................................................................................................................................................................................. 282 PITCH AND DUAL SOLENOID VALVE....................................................................................................................................................................... 284 PIN PULLER HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................................ 285 PIN PULLER SOLENOID VALVE........................................................................................................................................................................... 286 CYLINDER STAY....................................................................................................................................................................................... 288 BLADE............................................................................................................................................................................................... 290 RIPPER EQUIPMENT.................................................................................................................................................................................... 294 CAB MOUNT........................................................................................................................................................................................... 296 CAB................................................................................................................................................................................................. 297 AIR CONDITIONER..................................................................................................................................................................................... 300 ENGINE CONTROL...................................................................................................................................................................................... 302 ENGINE CONTROL SYSTEM............................................................................................................................................................................... 303 DECELERATION POTENTIOMETER.......................................................................................................................................................................... 304 ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER.................................................................................................................................... 305 FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR........................................................................................................................................................ 306 MONITOR SYSTEM...................................................................................................................................................................................... 307 MONITOR PANEL....................................................................................................................................................................................... 309 SENSORS............................................................................................................................................................................................. 313 MODE SELECTION SYSTEM............................................................................................................................................................................... 317 ELECTRICAL EQUIPMENT................................................................................................................................................................................ 323 STEERING ELECTRONIC CONTROL SYSTEM.................................................................................................................................................................. 326 VHMS CONTROLLER..................................................................................................................................................................................... 328 SENSORS............................................................................................................................................................................................. 331 COMMUNICATION (ORB: ORBCOMM) CONTROLLER/ANTENNA..................................................................................................................................................... 334 20 TESTING AND ADJUSTING................................................................................................................................................................................ 335 STANDARD VALUE TABLE FOR ENGINE..................................................................................................................................................................... 336 STANDARD VALUE TABLE FOR CHASSIS.................................................................................................................................................................... 337 TESTING AND ADJUSTING............................................................................................................................................................................... 349 TESTING, ADJUSTING, AND TROUBLESHOOTING DEVICES TABLE........................................................................................................................................... 351 MEASURING ENGINE SPEED.......................................................................................................................................................................... 353 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).................................................................................................................................................. 356 MEASURING EXHAUST TEMPERATURE................................................................................................................................................................... 357 MEASURING EXHAUST GAS COLOR..................................................................................................................................................................... 359 ADJUSTING VALVE CLEARANCE....................................................................................................................................................................... 360 MEASURING COMPRESSION PRESSURE.................................................................................................................................................................. 361 MEASURING BLOW-BY PRESSURE...................................................................................................................................................................... 362 MEASURING ENGINE OIL PRESSURE................................................................................................................................................................... 363 TESTING AND ADJUSTING FUEL INJECTION TIMING..................................................................................................................................................... 364 TESTING AND ADJUSTING ALTERNATOR BELT TENSION................................................................................................................................................... 366 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR............................................................................................................................... 367 ADJUSTING ENGINE SPEED SENSOR................................................................................................................................................................... 367 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL............................................................................................................................................... 368 MEASURING POWER TRAIN OIL PRESSURE.............................................................................................................................................................. 370 ADJUSTING TRANSMISSION SPEED SENSOR............................................................................................................................................................. 378 SIMPLE METHOD OF TESTING BRAKE PERFORMANCE...................................................................................................................................................... 379 ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER................................................................................................................................................... 380 ADJUSTING PCCS LEVER CONSOLE POSITION........................................................................................................................................................... 383 EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE............................................................................................................................................ 384 ADJUSTING CLEARANCE OF IDLER.................................................................................................................................................................... 386 INSPECTING WEAR OF SPROCKET..................................................................................................................................................................... 386 TESTING AND ADJUSTING TRACK SHOE TENSION........................................................................................................................................................ 387 TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE............................................................................................................................................... 388 TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE............................................................................................................................................ 397 MEASURING PPC VALVE OUTPUT PRESSURE AND SOLENOID VALVE OUTPUT PRESSURE.......................................................................................................................... 398 ADJUSTING PLAY OF PPC VALVE..................................................................................................................................................................... 405 MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE................................................................................................................................... 406 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER................................................................................................................................... 407 MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER........................................................................................................................................... 408 RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CIRCUIT......................................................................................................................................... 409 BLEEDING AIR FROM WORK EQUIPMENT CYLINDER....................................................................................................................................................... 409 ADJUSTING BLADE LEVER TILTING STROKE............................................................................................................................................................ 410 ADJUSTING RIPPER LEVER POSITION................................................................................................................................................................. 411 ADJUSTING LOCK LEVER............................................................................................................................................................................ 412 MEASURING FAN MOTOR SPEED....................................................................................................................................................................... 413 MEASURING FAN CIRCUIT OIL PRESSURE.............................................................................................................................................................. 414 BLEEDING AIR FROM FAN PUMP...................................................................................................................................................................... 415 MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE (DUAL TILT DOZER SPECIFICATION).............................................................................................................. 416 MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE (SUPERDOZER SPECIFICATION)................................................................................................................... 418 TESTING AND ADJUSTING OPERATOR'S CAB............................................................................................................................................................ 420 ADJUSTING BLADE................................................................................................................................................................................. 424 SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)....................................................................................................................................................... 426 ADJUSTMENT METHOD OF REPLACED CONTROLLER........................................................................................................................................................ 481 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM............................................................................................................................ 483 HANDLING OF OPTIONAL DEVICES.................................................................................................................................................................... 486 INITIALIZATION PROCEDURES FOR VHMS CONTROLLER................................................................................................................................................... 487 PROCEDURES FOR EXECUTING QUICK PM............................................................................................................................................................... 492 PRECAUTIONS FOR REPLACING VHMS CONTROLLER....................................................................................................................................................... 502 PM CLINIC SERVICE............................................................................................................................................................................... 503 TROUBLESHOOTING..................................................................................................................................................................................... 513 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................................................................................... 514 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................................................................... 515 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................................................................................................ 516 CHECKS BEFORE TROUBLESHOOTING................................................................................................................................................................... 524 CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING................................................................................................................................................ 525 CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM....................................................................................................................... 528 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...................................................................................................................................................... 566 T-BRANCH BOX AND T-BRANCH TABLE................................................................................................................................................................. 590 TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED........................................................................................ 593 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.............................................................................................................................................. 599 ERROR CODE [1500L0] (TRANSMISSION CLUTCH: SEE THE LIST. (L0))............................................................................................................................... 601 ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST. (L1)).................................................................................................................................... 602 ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST. (LH)).................................................................................................................................... 603 ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST. (L1)).................................................................................................................................... 604 ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST. (LH)).................................................................................................................................... 605 ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST. (L1))........................................................................................................................................ 606 ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST. (LH))........................................................................................................................................ 607 ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST. (L1))........................................................................................................................................ 608 ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST. (LH))........................................................................................................................................ 609 ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST. (L1))....................................................................................................................................... 610 ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST. (LH))........................................................................................................................................ 611 ERROR CODE [1800MW] (POWER TRAIN CLUTCH: SLIP (MW))......................................................................................................................................... 612 ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST. (L1))...................................................................................................................................... 613 ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST. (LH))...................................................................................................................................... 614 ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST. (L1))....................................................................................................................................... 615 ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST. (LH))....................................................................................................................................... 616 ERROR CODE [2300NR] (BRAKE THERMAL LOAD: ABNORMAL HEATING (NR))............................................................................................................................. 617 ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST. (L1))....................................................................................................................................... 618 ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST. (LH))....................................................................................................................................... 619 ERROR CODE [2301NR] (RIGHT STEERING BRAKE THERMAL LOAD: ABNORMAL HEATING (NR)).............................................................................................................. 620 ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST. (L1))........................................................................................................................................ 621 ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST. (LH))........................................................................................................................................ 622 ERROR CODE [2302NR] (LEFT STEERING BRAKE THERMAL LOAD: ABNORMAL HEATING (NR))............................................................................................................... 623 ERROR CODE [A000N1] (OR VHMS_LED IS DISPLAYED "N2" ->"01") ENGINE OVERRUN................................................................................................................... 623 ERROR CODE [A70XLK] (GOVERNOR SERVO SYSTEM RIGHT: *REFER TO TABLE (LK))..................................................................................................................... 624 ERROR CODE [A70YLK] (GOVERNOR SERVO SYSTEM LEFT: *REFER TO TABLE (LK))..................................................................................................................... 625 ERROR CODE [AA1ANX] (AIR CLEANER: CLOGGING (NX))............................................................................................................................................ 626 ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA)).......................................................................................................................................... 626 ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))............................................................................................................................... 627 ERROR CODE [B@BAZK] (ENGINE OIL: OIL LEVEL REDUCTION (ZK)).................................................................................................................................. 627 ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))....................................................................................................................................... 628 ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK))................................................................................................................................ 628 ERROR CODE [B@CENS] (POWER TRAIN OIL: OVERHEAT (NS))........................................................................................................................................ 629 ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS)).......................................................................................................................................... 629 ERROR CODE [B@HAZK] (HYDRAULIC OIL: LEVEL REDUCTION (ZK))................................................................................................................................... 630 ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA))..................................................................................................................................... 631 ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB)).................................................................................................................................... 632 ERROR CODE [D130KA] (NEUTRAL SAFETY RELAY: DISCONNECTION (KA)).............................................................................................................................. 633 ERROR CODE [D130KB] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB)).............................................................................................................................. 635 ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA))............................................................................................................................... 636 ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))............................................................................................................................... 638 ERROR CODE [D182KZ] (PREHEATER RELAY: LOWERING OF LEVEL (KZ))............................................................................................................................... 640 ERROR CODE [D1D0KA] (GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION (KA))....................................................................................................................... 642 ERROR CODE [D1D0KB] (GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT (KB))....................................................................................................................... 644 ERROR CODE [D1D1KA] (GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION (KA))........................................................................................................................ 646 ERROR CODE [D1D1KB] (GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT (KB))........................................................................................................................ 648 ERROR CODE [D5ZFKA] (NEUTRAL SIGNAL 1: DISCONNECTION (KA)).................................................................................................................................. 650 ERROR CODE [D5ZFKB] (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB)).................................................................................................................................. 651 ERROR CODE [D5ZFL4] (ENGINE CONTROLLER NEUTRAL SIGNAL: ON AND OFF SIGNALS DO NOT AGREE (L4))................................................................................................ 652 ERROR CODE [D5ZGKA] (NEUTRAL SIGNAL 2: DISCONNECTION (KA)).................................................................................................................................. 654 ERROR CODE [D5ZGKB] (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB)).................................................................................................................................. 655 ERROR CODE [D5ZKKX] (CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL RANGE (KX))............................................................................................................... 656 ERROR CODE [D5ZRKA] (SNAP SHOT SWITCH: DISCONNECTION (KA)).................................................................................................................................. 657 ERROR CODE [D5ZRKB] (SNAP SHOT SWITCH: SHORT CIRCUIT (KB)).................................................................................................................................. 658 ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICAITONS: DEFECTIVE COMMUNICATION (KR))........................................................................................................ 660 ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION (INPUT) (KK))........................................................................................................ 662 ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT))............................................................................................................... 663 ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK))............................................................................. 664 ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK)).................................................................................... 665 ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))......................................................................................... 666 ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATIONS DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))................................................... 668 ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))................................................. 670 ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION (INPUT) (KK))............................................................................................................ 672 ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT))................................................................................................................... 673 ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK))................................................................................. 674 ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK))........................................................................................ 676 ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) ............................................................................................ 677 ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))....................................................... 678 ERROR CODE [DB3SKR] (STEERING CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))..................................................... 680 ERROR CODE [DB40KK] (ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK)).................................................................................................................... 682 ERROR CODE [DB41KK] (SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)).................................................................................................................. 682 ERROR CODE [DB42KK] (SOLENOID POWER SUPPLY 1: LOWERING OF SOURCE VOLTAGE (KK)) ............................................................................................................. 684 ERROR CODE [DB43KK] (BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)).................................................................................................................. 686 ERROR CODE [DB44KK] (SOLENOID POWER SUPPLY 2: LOWERING OF SOURCE VOLTAGE (KK)).............................................................................................................. 688 ERROR CODE [DB45KP] (RACK SENSOR POWER SUPPLY: LOWERING OF OUTPUT VOLTAGE (KP))............................................................................................................. 690 ERROR CODE [DB49KM] (WRONG CONNECTION OF CONNECTOR: MISTAKE IN OPERATION OR SETTING (KM))................................................................................................... 692 ERROR CODE [DB49KQ] (ENGINE CONTROLLER SPECIFICATION: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ))......................................................................................... 693 ERROR CODE [DBB0KK] (OR LED OF VHMS CONTROLLER INDICATES "N9" ---> "01") (VHMS CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK))................................................................. 694 ERROR CODE [DBB0KQ] (OR LED OF VHMS CONTROLLER INDICATES "NF" ---> "11") (CHECK OF VHMS CONTROLLER MODEL: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)).................................... 696 ERROR CODE [DBB3KK] (OR LED OF VHMS CONTROLLER INDICATES "N9" ---> "02") (VHMS CONTROLLER: LOWERING OF BATTERY DIRECT SOURCE VOLTAGE (KK)).................................................. 697 ERROR CODE [DBB5KP] (OR LED OF VHMS CONTROLLER INDICATES "N9" ---> "04") (SENSOR POWER SUPPLY (5 V): LOWERING OF OUTPUT VOLTAGE (KP))....................................................... 698 ERROR CODE [DBB6KP] (OR LED OF VHMS CONTROLLER INDICATES "N9" ---> "02") (SENSOR POWER SUPPLY (24 V): LOWERING OF OUTPUT VOLTAGE (KP))..................................................... 699 ERROR CODE [DBB7KP] (OR LED OF VHMS CONTROLLER INDICATES "N9" ---> "03") (SENSOR POWER SUPPLY (12 V): LOWERING OF OUTPUT VOLTAGE (KP))...................................................... 700 ERROR CODE [DBBQKR] (OR LED OF VHMS CONTROLLER INDICATES "N8" ---> "02") (VHMS KOM-NET: DEFECTIVE COMMUNICATION (KR))....................................................................... 702 ERROR CODE [DD12KA] (SHIFT UP SWITCH: DISCONNECTION (KA))................................................................................................................................... 704 ERROR CODE [DD12KB] (SHIFT UP SWITCH: SHORT CIRCUIT (KB))................................................................................................................................... 706 ERROR CODE [DD13KA] (SHIFT DOWN SWITCH: DISCONNECTION (KA))................................................................................................................................. 708 ERROR CODE [DD13KB] (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))................................................................................................................................. 710 ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)).............................................................................................................................. 712 ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)).............................................................................................................................. 714 ERROR CODE [DDN2LD] (BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM: REFER TO TABLE (LD))...................................................................................................... 716 ERROR CODE [DDN3LD] (BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM: REFER TO TABLE (LD))....................................................................................................... 717 ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA))................................................................................................................................ 718 ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))................................................................................................................................ 720 ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA))................................................................................................................................. 722 ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB))................................................................................................................................. 724 ERROR CODE [DDNALD] (BLADE LIFT RAISE FULL OIL PRESSURE SWITCH: REFER TO TABLE (LD))........................................................................................................ 726 ERROR CODE [DDNBLD] (RIPPER LIFT RAISE OIL PRESSURE SWITCH: REFER TO TABLE (LD))............................................................................................................ 727 ERROR CODE [DDNCLD] (RIPPER LIFT LOWER OIL PRESSURE SWITCH: REFER TO TABLE (LD))............................................................................................................ 728 ERROR CODE [DDNDLD] (RIPPER TILT IN OIL PRESSURE SWITCH: REFER TO TABLE (LD))............................................................................................................... 729 ERROR CODE [DDNELD] (RIPPER TILT BACK OIL PRESSURE SWITCH: REFER TO TABLE (LD))............................................................................................................. 730 ERROR CODE [DDNFLD] (BLADE LIFT LOWER FULL OIL PRESSURE SWITCH: REFER TO TABLE (LD))........................................................................................................ 731 ERROR CODE [DDQ2KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)).............................................................................................................................. 732 ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB))........................................................................................................................ 734 ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4))............................................................................................................................ 736 ERROR CODE [DGE1KB] (OR LED OF VHMS CONTROLLER INDICATES "N2" ---> "42") (ENGINE OIL TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB)) (30 MINUTES AFTER ENGINE IS STARTED (ABOVE 500 RPM)).... 737 ERROR CODE [DGE1KY] (OR LED OF VHMS CONTROLLER INDICATES "N2" ---> "41") (ENGINE OIL TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KY))......................................................... 738 ERROR CODE [DGE2KX] (COOLANT TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX))............................................................................................................ 740 ERROR CODE [DGE3KA] (ENGINE COOLANT TEMPERATURE SENSOR GAUGE) (FOR LOW TEMPERATURE): DISCONNECTION (KA)).................................................................................... 742 ERROR CODE [DGE5KB] (OR LED OF VHMS CONTROLLER INDICATES "N4" ---> "01") (ATMOSPHEREIC TEMPERATURE SENSOR SYSTEM: DISCONNECTION OR SHORT CIRCUIT (KY OR KB))................................ 743 ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATUER SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))............................................................................................ 744 ERROR CODE [DGT5KA] (OR LED OF VHMS CONTROLLER INDICATES "N3" ---> "22") (LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KA)).................................................. 746 ERROR CODE [DGT5KB] (OR LED OF VHMS CONTROLLER INDICATES "N3" ---> "21" (LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB))................................................... 748 ERROR CODE [DGT6KA] (OR LED OF VHMS CONTROLLER INDICATED "N3" ---> "12") (RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KA))................................................. 750 ERROR CODE [DGT6KB] (OR LED OF VHMS CONTROLLER INDICATES "N3" ---> "11") (RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB))................................................. 752 ERROR CODE [DH22KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (F): DISCONNECTION (KA)) ..................................................................................................... 754 ERROR CODE [DH22KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (F): SHORT CIRCUIT (KB)) ...................................................................................................... 755 ERROR CODE [DH23KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (R): DISCONNECTION (KA)) ...................................................................................................... 756 ERROR CODE [DH23KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (R): SHORT CIRCUIT (KB)) ...................................................................................................... 757 ERROR CODE [DHE4KA] (ENGINE OIL PRESSURE SENSOR: DISCONNECTION (KA))........................................................................................................................ 758 ERROR CODE [DHE4KB] (ENGINE OIL PRESSURE SENSOR: SHORT CIRCUIT (KB))........................................................................................................................ 759 ERROR CODE [DHE5KB] (OR LED OF VHMS CONTROLLER INDICATES "N3" ---> "32") (ENGINE BLOW-BY PRESSURE SENSOR SYSTEM: DISCONNECTION (KB))........................................................ 760 ERROR CODE [DHE5KY] (OR LED OF VHMS CONTROLLER INDICATES "N3" ---> "31") (ENGINE BLOW-BY PRESSURE SENSOR SYSTEM: SHORT CIRCUIT WITH POWER SUPPLY LINE (KY)) ................................ 761 ERROR CODE [DHT3KX] (OR LED OF VHMS CONTROLLER INDICATES "N6" ---> "14") (TRANSMISSION OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX))................................................. 762 ERROR CODE [DK01KA] (LEFT YOKE ANGLE SENSOR: DISCONNECTION (KA))............................................................................................................................ 764 ERROR CODE [DK01KB] (LEFT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB))............................................................................................................................ 766 ERROR CODE [DK03KA] (RIGHT YOKE ANGLE SENSOR: DISCONNECTION (KA))........................................................................................................................... 767 ERROR CODE [DK03KB] (RIGHT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB))........................................................................................................................... 769 ERROR CODE [DK10KX] (FUEL DIAL: OUT OF INPUT SIGNAL RANGE (KX))............................................................................................................................. 770 ERROR CODE [DK12KX] (DECELERATOR POTENTIOMETER: OUT OF INPUT SIGNAL RANGE (KX))............................................................................................................. 772 ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA)).......................................................................................................................... 774 ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)).......................................................................................................................... 775 ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).................................................................................................... 776 ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ))......................................................................................................... 776 ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8)).............................................................................................................................. 777 ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA))......................................................................................................................... 778 ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB)).......................................................................................................................... 779 ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA))............................................................................................................................... 780 ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))............................................................................................................................... 782 ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))............................................................................................... 783 ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ)).................................................................................................... 783 ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))......................................................................................................................... 784 ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA))................................................................................................................... 785 ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB))................................................................................................................... 786 ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA))................................................................................................................... 787 ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTOMETER 2: SHORT CIRCUIT (KB)).................................................................................................................... 788 ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA))............................................................................................................................... 789 ERROR CODE [DK60KB] (ACCELERATION SENSOR: SHORT CIRCUIT (KB))............................................................................................................................... 790 ERROR CODE [DKF0KX] (OR LED OF VHMS CONTROLLER INDICATES "N2" ---> "62" (INJECTION PUMP RACK SENSOR: OUT OF INPUT SIGNAL RANGE (KX))........................................................ 791 ERROR CODE [DKF1KX] (RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE (KX))..................................................................................................................... 792 ERROR CODE [DKF2KX] (RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE (KX))...................................................................................................................... 794 ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA))................................................................................................................................ 796 ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB))................................................................................................................................ 797 ERROR CODE [DLE1KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))............................................................................................................................... 798 ERROR CODE [DLE4LC] (ENGINE SPEED SENSOR A: *REFER TO TABLE (LC))........................................................................................................................... 800 ERROR CODE [DLE5LC] (ENGINE SPEED SENSOR B: *REFER TO TABLE (LC))........................................................................................................................... 802 ERROR CODE [DLF1KA] (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION (KA)).............................................................................................................. 804 ERROR CODE [DLT3KA] (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION (KA)).................................................................................................................. 805 ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB)).................................................................................................................................... 806 ERROR CODE [DW55KA] (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA))......................................................................................................................... 807 ERROR CODE [DW55KB] (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB))......................................................................................................................... 808 ERROR CODE [DW56KA] (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA))......................................................................................................................... 809 ERROR CODE [DW56KB] (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB))......................................................................................................................... 810 ERROR CODE [DW57KA] (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA)).......................................................................................................................... 811 ERROR CODE [DW57KB] (LEFT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB)).......................................................................................................................... 812 ERROR CODE [DW58KA] (RIGHT TILT LIMIT SOLENOID: DISCONNECTION (KA))......................................................................................................................... 813 ERROR CODE [DW58KB] (RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))......................................................................................................................... 814 ERROR CODE [DW59KA] (BLADE DUAL SELECTOR SOLENOID: DISCONNECTION (KA))...................................................................................................................... 815 ERROR CODE [DW59KB] (BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT (KB))...................................................................................................................... 816 ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA))..................................................................................................................... 817 ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB))..................................................................................................................... 818 ERROR CODE [DW5DKA] (BLADE PITCH DUMP SOLENOID (SUPERDOZER SPECIFICATION): DISCONNECTION (KA)).............................................................................................. 819 ERROR CODE [DW5DKB] (BLADE PITCH DUMP SOLENOID (SUPERDOZER SPECIFICATION): SHORT CIRCUIT (KB)).............................................................................................. 820 ERROR CODE [DW7BKA] (FAN REVERSE SOLENOID: DISCONNECTION (KA)).............................................................................................................................. 821 ERROR CODE [DW7BKB] (FAN REVERSE SOLENOID: SHORT CIRCUIT (KB)).............................................................................................................................. 822 ERROR CODE [DWJ0KA] (PUMP MERGE-DIVIDER SOLENOID: DISCONNECTION (KA))....................................................................................................................... 823 ERROR CODE [DWJ0KB] (PUMP MERGE-DIVIDER SOLENOID: SHORT CIRCUIT (KB))....................................................................................................................... 824 ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA))................................................................................................................... 825 ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB))................................................................................................................... 826 ERROR CODE [DWN5KA] (FAN PUMP SOLENOID 1: DISCONNECTION (KA))............................................................................................................................... 827 ERROR CODE [DWN5KB] (FAN PUMP SOLENOID 1: SHORT CIRCUIT (KB))............................................................................................................................... 828 ERROR CODE [DWNCKA] (FAN PUMP SOLENOID 2: DISCONNECTION (KA))............................................................................................................................... 829 ERROR CODE [DWNCKB] (FAN PUMP SOLENOID 2: SHORT CIRCUIT (KB))............................................................................................................................... 830 ERROR CODE [DXE0KA] (LS SET SOLENOID: DISCONNECTION (KA))................................................................................................................................... 831 ERROR CODE [DXE0KB] (LS SET SOLENOID: SHORT CIRCUIT (KB))................................................................................................................................... 832 ERROR CODE [DXH1KA] (LOCK-UP SOLENOID: DISCONNECTION (KA)).................................................................................................................................. 833 ERROR CODE [DXH1KB] (LOCK-UP SOLENOID: SHORT CIRCUIT (KB)).................................................................................................................................. 834 ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA))................................................................................................................................... 835 ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))................................................................................................................................... 836 ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA))................................................................................................................................... 837 ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))................................................................................................................................... 838 ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA))................................................................................................................................... 839 ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))................................................................................................................................... 840 ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA))............................................................................................................................... 841 ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))............................................................................................................................... 842 ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA))............................................................................................................................... 843 ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))............................................................................................................................... 844 ERROR CODE [DXH9KA] (RIGHT STEERING CLUTCH ECMV: DISCONNECTION (KA))........................................................................................................................ 845 ERROR CODE [DXH9KB] (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB))........................................................................................................................ 846 ERROR CODE [DXHAKA] (LEFT STEERING CLUTCH ECMV: DISCONNECTION (KA))......................................................................................................................... 847 ERROR CODE [DXHAKB] (LEFT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB))......................................................................................................................... 848 ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA)).................................................................................................................................. 849 ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB)).................................................................................................................................. 850 ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA))................................................................................................................................... 851 ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))................................................................................................................................... 852 ERROR CODE [DXHDKB] (GOVERNOR SOLENOID RIGHT: SHORT CIRCUIT (KB))........................................................................................................................... 854 ERROR CODE [DXHEKB] (GOVERNOR SOLNOID LEFT: SHORT CIRCUIT (KB))............................................................................................................................. 856 ERROR CODE [DXHFKA] (PRE-STROKE SOLENOID RIGHT: DISCONNECTION (KA))......................................................................................................................... 857 ERROR CODE [DXHFKB] (PRE-STROKE SOLENOID RIGHT: SHORT CIRCUIT (KB))......................................................................................................................... 858 ERROR CODE [DXHGKA] (PRE-STROKE SOLENOID LEFT: DISCONNECTION (KA)).......................................................................................................................... 859 ERROR CODE [DXHGKB] (PRE-STROKE SOLENOID LEFT: SHORT CIRCUIT (KB)).......................................................................................................................... 860 ERROR CODE [F@BBZL] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "38") (ENGINE BLOW-BY PRESSURE: OVERPRESSURE (ZL)).......................................................................... 861 ERROR CODE [F@BYNR] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "62") (LEFT BANK EXHAUST TEMPERATURE (2): ABNORMAL HEATING (NR))............................................................ 862 ERROR CODE [F@BYNS] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "61") (LEFT BANK EXHAUST TEMPERATURE (1): OVERHEATING (NS))................................................................. 863 ERROR CODE [F@BZNR] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "72") (RIGHT BANK EXHAUST TEMPERATURE (2): ABNORMAL HEATING (NR))........................................................... 864 ERROR CODE [F@BZNS] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "71") (RIGHT BANK EXHAUST TEMPERATURE (1): OVERHEATING (NS))................................................................ 865 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)................................................................................................................................................... 867 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST............................................................................................................................................... 868 E-1 THE ENGINE DOES NOT START............................................................................................................................................................... 869 E-2 THE PREHEATER DOES NOT OPERATE. (MANUAL PREHEATING FUNCTION)............................................................................................................................ 872 E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATER........................................................................................................................................ 874 E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON......................................................................................................... 875 E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT................................................................................. 876 E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH...................................................................................................................... 877 E-7 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEMS FLASHES................................................................................................................................ 878 E-8 AN EMERGENCY CAUTION ITEM FLASHES WHILE THE ENGINE IS RUNNING........................................................................................................................... 881 E-9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON............................................................................................................ 885 E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE)................................................................... 887 E-11 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON.................................................................................. 887 E-12 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.......................................................................................................................... 888 E-13 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL............................................................................................................................ 889 E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY......................................................................................................................... 890 E-15 INDICATION OF THE FUEL GAUGE IS ABNORMAL............................................................................................................................................... 891 E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL................................................................................................................................ 892 E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL................................................................................................................................. 892 E-18 THE SWITCH MODULE CANNOT BE OPERATED................................................................................................................................................... 893 E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT..................................................................................................................................... 894 E-20 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP....................................................................................................................................... 895 E-21 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED..................................................................................................................................... 896 E-22 THE AUTOMATIC PITCH BACK SYSTEM DOES NOT OPERATE (ONLY SUPERDOZER SPECIFICATION),...................................................................................................... 897 E-23 THE ALARM BUZZER CANNOT BE CANCELLED................................................................................................................................................... 898 E-24 THE OPERATOR MODE CANNOT BE OPERATED................................................................................................................................................... 899 E-25 THE SERVICE MODE CANNOT BE OPERATED.................................................................................................................................................... 900 E-26 THE BACK-UP ALARM DOES NOT SOUND....................................................................................................................................................... 902 E-27 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REARLAMP ON THE PANEL DO NOT COME ON........................................................................................... 903 E-28 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM............................................................................................................................................. 908 E-29 ORBCOMM TERMINAL DOES NOT OPERATE NORMALLY (DATA ARE NOT TRANSMITTED).................................................................................................................. 923 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)........................................................................................................................................ 925 INFORMATION IN TROUBLESHOOTING TABLE........................................................................................................................................................ 926 H-1 NO FORCE (NO DRAWBAR PULL).............................................................................................................................................................. 927 H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)......................................................................................................................................................... 928 H-3 NO TRAVEL AT ALL GEAR SPEEDS............................................................................................................................................................ 929 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE............................................................................................................................. 930 H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVESE SHIFTING........................................................................................................................ 931 H-6 STEERING IS NOT POSSIBLE................................................................................................................................................................ 932 H-7 STEERING IS POSSIBLE ONLY ON SIDE....................................................................................................................................................... 932 H-8 STEERING OVERRUN OCCURS................................................................................................................................................................. 933 H-9 BRAKE DOES NOT WORK..................................................................................................................................................................... 933 H-10 TORQUE CONVERTER IS NOT LOCK-UP........................................................................................................................................................ 934 H-11 TORQUE CONVERTER OIL IS OVERHEATED..................................................................................................................................................... 934 H-12 ALL WORK EQUIPMENT SPEED ARE SLOW...................................................................................................................................................... 935 H-13 WORK EQUIPMENT DOES NOT MOVE........................................................................................................................................................... 936 H-14 BLADE LIFT SPEED IS SLOW OR LACKS POWER................................................................................................................................................ 936 H-15 BLADE TILT SPEED IS SLOW OR LACKS POWER................................................................................................................................................ 937 H-16 RIPPER LIFT SPEED IS SLOW OR LACKS POWER............................................................................................................................................... 937 H-17 RIPPER TILT SPEED IS SLOW OR LACKS POWER............................................................................................................................................... 938 H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT................................................................................................................................................ 938 H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT................................................................................................................................................ 939 H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT............................................................................................................................................... 939 H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE)............................................................................................................. 940 H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE)............................................................................................................................... 940 H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP............................................................................................................................... 940 TROUBLESHOOTING OF ENGINE BODY (S MODE)......................................................................................................................................................... 941 POINTS TO REMEBER WHEN TROUBLESHOOTING...................................................................................................................................................... 942 METHOD OF USING TROUBLESHOOTING CHARTS...................................................................................................................................................... 943 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)............................................................................................................................... 946 S-2 ENGINE DOES NOT START................................................................................................................................................................... 947 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).................................................................................................................................... 950 S-4 ENGINE STOPS DURING OPERATIONS.......................................................................................................................................................... 951 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)............................................................................................................................................... 952 S-6 ENGINE LACKS OUTPUT (NO POWER).......................................................................................................................................................... 953 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)............................................................................................................................................ 954 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)................................................................................................................................... 955 S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................................................................................................ 956 S-10 FUEL CONSUMPTION IS EXCESSIVE.......................................................................................................................................................... 957 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN................................................................................................................ 958 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)..................................................................................................................................... 959 S-13 OIL LEVEL RISES........................................................................................................................................................................ 960 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....................................................................................................................................... 961 S-15 ABNORMAL NOIS IS MADE.................................................................................................................................................................. 962 S-16 VIBRATION IS EXCESSIVE................................................................................................................................................................. 963 30 DISASSEMBLY AND ASSEMBLY............................................................................................................................................................................. 965 METHOD OF USING MANUAL.............................................................................................................................................................................. 967 PRECAUTIONS WHEN CARRYING OUT OPERATION............................................................................................................................................................. 969 SPECIAL TOOL LIST................................................................................................................................................................................... 971 REMOVAL AND INSTALLATION OF ENGINE OIL COOLER ASSEMBLY.............................................................................................................................................. 986 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY (BOTH LEFT AND RIGHT)...................................................................................................................... 986 REMOVAL AND INSTALLATION OF AFTERCOOLER CORE ASSEMBLY............................................................................................................................................... 988 REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY.................................................................................................................................................. 990 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL....................................................................................................................................................... 991 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL........................................................................................................................................................ 992 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.................................................................................................................................................. 994 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY...................................................................................................................................................... 998 REMOVAL AND INSTALLATION OF MAIN RADIATOR ASSEMBLY.................................................................................................................................................. 999 REMOVAL AND INSTALLATION OF SUB RADIATOR ASSEMBLY...................................................................................................................................................1000 REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY.................................................................................................................................................1002 REMOVAL AND INSTALLATION OF FAN MOTOR PUMP..........................................................................................................................................................1005 REMOVAL AND INSTALLATION ENGINE ASSEMBLY............................................................................................................................................................1006 REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY.........................................................................................................................................................1009 DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY.........................................................................................................................................................1010 REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY...............................................................................................................................................1012 REMOVAL AND INSTALLATION OF PTO, TORQUE CONVERTER ASSEMBLY..........................................................................................................................................1015 DISCONNECTION AND CONNECTION OF PTO, TORQUE CONVERTER...............................................................................................................................................1017 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY...............................................................................................................................................1019 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY............................................................................................................................................................1027 REMOVAL AND INSTALLATION OF TORQFLOW TRANSMISSION ASSEMBLY..........................................................................................................................................1032 DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY..........................................................................................................................................1033 DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY..................................................................................................................................................1047 DISASSEMBLY AND ASSEMBLY OF STEERING CLUTCH, BRAKE ASSEMBLY.........................................................................................................................................1059 DISASSEMBLY AND ASSEMBLY OF TRANSFER GEAR HOUSING ASSEMBLY..........................................................................................................................................1066 REMOVAL AND INSTALLATION OF POWER TRAIN PUMP ASSEMBLY...............................................................................................................................................1069 REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY................................................................................................................................................1069 REMOVAL AND INSTALLATION OF TORQUE CONVERTER OIL COOLER.............................................................................................................................................1070 REMOVAL AND INSTALLATION OF TORQUE CONVERTER VALVE ASSEMBLY.........................................................................................................................................1071 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER VALVE ASSEMBLY.........................................................................................................................................1072 REMOVAL AND INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY.....................................................................................................................................1076 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROLE VALVE ASSEMBLY (ECMV ASSEMBLY)....................................................................................................................1077 REMOVAL AND INSTALLATION OF STEERING CONTROL VALVE ASSEMBLY.........................................................................................................................................1080 DISASSEMBLY AND ASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY.........................................................................................................................................1081 REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY....................................................................................................................................................1083 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY....................................................................................................................................................1084 REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY....................................................................................................................................................1096 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY..........................................................................................................................................................1098 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY..................................................................................................................................................1100 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY..................................................................................................................................................1104 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY...................................................................................................................................................1106 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...................................................................................................................................................1109 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY.................................................................................................................................................1111 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.................................................................................................................................................1111 REMOVAL AND INSTALLATION OF BOGIE ASSEMBLY..........................................................................................................................................................1114 DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY..........................................................................................................................................................1119 REMOVAL AND INSTALLATION OF NO. 1 BOGIE ASSEMBLY....................................................................................................................................................1121 EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY...................................................................................................................................................1130 OVERALL DISASSEMBLY AND OVERALL ASSEMBLY OF TRACK SHOE..............................................................................................................................................1133 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS....................................................................................................................................................1146 FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK..........................................................................................................................................................1147 DISASSEMBLY AND ASSEMBLY OF MASTER LINK.............................................................................................................................................................1151 REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY....................................................................................................................................................1155 REMOVAL AND INSTALLATION OF EQUALIZER BAR...........................................................................................................................................................1157 DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING...................................................................................................................................................1160 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY.................................................................................................................................................1163 REMOVAL AND INSTALLATION OF HYDRAULIC VALVE ASSEMBLY................................................................................................................................................1164 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE...........................................................................................................................................................1165 DISASSEMBLY AND ASSEMBLY OF MERGE-DIVIDER VALVE AND SELF-REDUCING PRESSURE VALVE ASSEMBLY...........................................................................................................1169 REMOVAL AND INSTALLATION OF PPC RELIEF VALVE ASSEMBLY...............................................................................................................................................1171 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.............................................................................................................................................1172 DISASSEMBLY AND ASSEMBLY OF RIPPER PIN-PULLER CYLINDER ASSEMBLY.....................................................................................................................................1176 REMOVAL AND INSTALLATION OF BLADE ASSEMBLY..........................................................................................................................................................1179 DISASSEMBLY AND ASSEMBLY OF GIANT RIPPER ASSEMBLY...................................................................................................................................................1181 REMOVAL AND INSTALLATION OF ROPS GUARD..............................................................................................................................................................1184 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY.................................................................................................................................................1185 REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY....................................................................................................................................................1186 REMOVAL AND INSTALLATION OF CONTROLLER ASSEMBLY.....................................................................................................................................................1189 REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY......................................................................................................................................1190 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................................................................................................1191 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT....................................................................................................................................................1193 REMOVAL AND INSTALLATION OF HOOD ASSEMBLY...........................................................................................................................................................1195 REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY......................................................................................................................................................1196 REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY......................................................................................................................................................1197 90 OTHERS...............................................................................................................................................................................................1200 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...............................................................................................................................................................1202 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/3)......................................................................................................................................................1203 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (2/3)......................................................................................................................................................1204 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (3/3)......................................................................................................................................................1205 ELECTRICAL CIRCUIT DIAGRAM (1/8)....................................................................................................................................................................1206 ELECTRICAL CIRCUIT DIAGRAM (2/8)....................................................................................................................................................................1207 ELECTRICAL CIRCUIT DIAGRAM (3/8)....................................................................................................................................................................1208 ELECTRICAL CIRCUIT DIAGRAM (4/8)....................................................................................................................................................................1209 ELECTRICAL CIRCUIT DIAGRAM (5/8)....................................................................................................................................................................1210 ELECTRICAL CIRCUIT DIAGRAM (6/8)....................................................................................................................................................................1211 ELECTRICAL CIRCUIT DIAGRAM (7/8)....................................................................................................................................................................1212 ELECTRICAL CIRCUIT DIAGRAM (8/8)....................................................................................................................................................................1213 ELECTRICAL CIRCUIT DIAGRAM OF INSIDE CAB............................................................................................................................................................1214
Description:
Komatsu D475A-5 Dozer Service Repair Manual
- 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.
Please Note:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
⦁ You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
⦁ Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
