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Komatsu D475A-5E0, D475ASD-5E0 Crawler Bulldozer Shop Manual SEN00203-16 – PDF DOWNLOAD
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Komatsu D475A-5E0, D475ASD-5E0 Crawler Bulldozer Shop Manual
SERIAL NUMBERS:
D475A- 30001 and up
D475ASD-30001 and up
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Description
Komatsu D475A-5E0, D475ASD-5E0 Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D475A-5E0, D475ASD-5E0 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D475A-5E0, D475ASD-5E0
Serial Number: 30001 and up
Book Code: SEN00203-16
Language: English
Pages: 1606
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D475A-5E0, D475ASD-5E0 Crawler Bulldozer Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu D475A-5E0, D475ASD-5E0 Crawler Bulldozer Shop Manual
COVER ................................................................................................................................................... 1 00 Index and foreword.................................................................................................................................... 0 Index................................................................................................................................................ 3 Composition of shop manual....................................................................................................................... 4 Table of contents................................................................................................................................ 6 Foreword and general information..................................................................................................................... 23 Safety notice.................................................................................................................................... 24 How to read the shop manual...................................................................................................................... 29 Explanation of terms for maintenance standard.................................................................................................... 31 Handling of electric equipment and hydraulic component........................................................................................... 33 Handling of connectors newly used for engines.................................................................................................... 42 How to read electric wire code................................................................................................................... 45 Precautions when carrying out operation.......................................................................................................... 48 Method of disassembling and connecting push-pull type coupler.................................................................................... 51 Standard tightening torque table................................................................................................................. 54 Conversion table................................................................................................................................. 58 01 Specification......................................................................................................................................... 0 Specification and technical data..................................................................................................................... 65 Specification drawings........................................................................................................................... 66 Specifications................................................................................................................................... 67 Weight table..................................................................................................................................... 76 Fuel, coolant and lubricants..................................................................................................................... 80 10 Structure, function and maintenance standard.......................................................................................................... 0 Engine and cooling system............................................................................................................................ 83 Engine and cooling system........................................................................................................................ 84 Radiator and oil cooler...................................................................................................................... 84 Engine mount................................................................................................................................. 85 Cooling fan pump............................................................................................................................. 86 Cooling fan motor............................................................................................................................ 106 Power train, Part 1.................................................................................................................................. 114 Power train...................................................................................................................................... 115 Power train hydraulic equipment arrangement diagram.............................................................................................. 117 Damper and universal joint....................................................................................................................... 119 Power train system............................................................................................................................... 121 General view of power train unit................................................................................................................. 121 Torque converter, PTO............................................................................................................................ 123 Torque converter valve........................................................................................................................... 131 Torque converter lockup control system........................................................................................................... 141 Scavenging pump.................................................................................................................................. 142 Transmission control............................................................................................................................. 144 Transmission..................................................................................................................................... 145 Power train, Part 2.................................................................................................................................. 158 Transmission control valve....................................................................................................................... 159 Transmission clutch ECMV......................................................................................................................... 161 Priority valve................................................................................................................................... 165 Lubricating oil relief valve..................................................................................................................... 167 Torque converter, power train, lubricating oil pump.............................................................................................. 168 Steering, brake control.......................................................................................................................... 169 Final drive...................................................................................................................................... 171 Sprocket......................................................................................................................................... 175 Steering unit.................................................................................................................................... 178 Steering control valve........................................................................................................................... 189 Steering clutch ECMV, Steering brake ECMV........................................................................................................ 191 Parking brake valve.............................................................................................................................. 197 Sudden stop prevention valve..................................................................................................................... 199 Undercarriage and frame.............................................................................................................................. 202 Track frame...................................................................................................................................... 203 Recoil spring.................................................................................................................................... 205 Idler............................................................................................................................................ 207 Track roller..................................................................................................................................... 209 Carrier roller................................................................................................................................... 213 Track roller bogie............................................................................................................................... 214 Track shoe....................................................................................................................................... 215 Main frame....................................................................................................................................... 219 Suspension....................................................................................................................................... 221 Hydraulic system, Part 1............................................................................................................................. 226 Hydraulic system, Part 1......................................................................................................................... 227 Work equipment hydraulic equipment arrangement diagram....................................................................................... 227 PPC control piping diagram................................................................................................................... 231 Work equipment control....................................................................................................................... 232 Work equipment pump.......................................................................................................................... 234 PPC valve.................................................................................................................................... 251 PCCS lever................................................................................................................................... 262 Hydraulic system, Part 2............................................................................................................................. 266 Hydraulic system, Part 2......................................................................................................................... 267 Control valve................................................................................................................................ 267 CLSS......................................................................................................................................... 282 Unload valve................................................................................................................................. 285 Introduction of LS pressure.................................................................................................................. 286 LS bypass plug............................................................................................................................... 287 Pressure compensation valve.................................................................................................................. 288 Blade lift valve............................................................................................................................. 290 Merge-divider valve.......................................................................................................................... 298 Self pressure reducing valve................................................................................................................. 300 Pilot solenoid valve......................................................................................................................... 304 Hydraulic system, Part 3............................................................................................................................. 307 Hydraulic tank, hydraulic filter................................................................................................................. 308 Accumulator...................................................................................................................................... 310 Work equipment cylinder.......................................................................................................................... 312 Piston valve..................................................................................................................................... 314 Quick drop valve................................................................................................................................. 316 Blade control knob (Dual tilt specification)..................................................................................................... 318 Blade control knob (Superdozer specification).................................................................................................... 319 Pitch and dual solenoid valve.................................................................................................................... 320 Pin puller hydraulic circuit diagram............................................................................................................. 321 Pin puller solenoid valve........................................................................................................................ 322 Work equipment....................................................................................................................................... 325 Work equipment................................................................................................................................... 326 Cylinder stay................................................................................................................................ 326 Blade........................................................................................................................................ 327 Ripper equipment............................................................................................................................. 330 Cab and its attachments.............................................................................................................................. 333 Cab and its attachments.......................................................................................................................... 334 Cab mount.................................................................................................................................... 334 Cab.......................................................................................................................................... 335 Air conditioner.............................................................................................................................. 337 Electrical system.................................................................................................................................... 340 Engine control system............................................................................................................................ 341 CRI engine control system........................................................................................................................ 345 Monitor system................................................................................................................................... 349 Machine monitor.................................................................................................................................. 351 Mode selection system............................................................................................................................ 369 Electrical equipment............................................................................................................................. 373 Palm command control system (PCCS)............................................................................................................... 375 Sensors.......................................................................................................................................... 377 Vehicle health monitoring system (VHMS).......................................................................................................... 384 ORBCOMM terminal................................................................................................................................. 390 20 Standard value table.................................................................................................................................. 0 Standard service value table......................................................................................................................... 394 Standard value table for engine.................................................................................................................. 395 Standard value table for chassis................................................................................................................. 396 30 Testing and adjusting................................................................................................................................. 0 Testing and adjusting, Part 1........................................................................................................................ 410 Tools for testing, adjusting, and troubleshooting................................................................................................ 412 Measuring engine speed........................................................................................................................... 415 Measuring intake air pressure (boost pressure)................................................................................................... 419 Measuring exhaust temperature.................................................................................................................... 421 Measuring exhaust gas color...................................................................................................................... 423 Adjusting valve clearance........................................................................................................................ 425 Testing compression pressure..................................................................................................................... 427 Measuring blow-by pressure....................................................................................................................... 429 Measuring engine oil pressure.................................................................................................................... 431 Handling of fuel system devices.................................................................................................................. 432 Releasing residual pressure from fuel system..................................................................................................... 432 Testing fuel pressure............................................................................................................................ 433 Handling of reduced cylinder mode operation...................................................................................................... 434 Handling of no injection cranking operation...................................................................................................... 434 Testing fuel return and leak amount.............................................................................................................. 435 Bleeding air from fuel circuit................................................................................................................... 438 Bleeding air from fuel circuit (Low-grade fuel specification).................................................................................... 440 Testing fuel circuit for leakage................................................................................................................. 442 Testing and adjusting alternator belt tension.................................................................................................... 443 Testing and adjusting belt tension for air conditioner compressor................................................................................ 444 Adjusting fuel control dial and decelerator pedal................................................................................................ 445 Testing and adjusting, Part 2........................................................................................................................ 448 Measuring power train oil pressure............................................................................................................... 450 Adjusting transmission speed sensor.............................................................................................................. 459 Simple method to test brake performance.......................................................................................................... 460 Adjusting brake pedal and parking brake lever.................................................................................................... 461 Adjusting PCCS lever console position............................................................................................................ 464 Emergency escape method when power train has trouble............................................................................................. 465 Inspecting wear of sprocket...................................................................................................................... 467 Testing and adjusting track shoe tension......................................................................................................... 468 Testing and adjusting work equipment oil pressure................................................................................................ 469 Testing and adjusting control circuit basic pressure............................................................................................. 480 Measuring PPC valve output pressure and solenoid valve output pressure........................................................................... 481 Adjusting play of PPC valve...................................................................................................................... 487 Measuring outlet pressure of ripper pin puller solenoid valve.................................................................................... 488 Checking parts which caused hydraulic drift of blade and ripper.................................................................................. 489 Measuring internal leakage of work equipment cylinder............................................................................................ 490 Releasing residual pressure from work equipment cylinder......................................................................................... 491 Bleeding air from work equipment cylinder........................................................................................................ 491 Adjusting ripper lever position.................................................................................................................. 492 Adjusting work equipment lock lever.............................................................................................................. 493 Measuring fan motor speed........................................................................................................................ 494 Measuring fan circuit oil pressure............................................................................................................... 495 Bleeding air from fan pump....................................................................................................................... 496 Measurement procedure for blade tilt control angle (Dual tiltdozer specification)................................................................ 497 Measurement procedure for blade tilt control angle (Superdozer specification).................................................................... 500 Testing and adjusting operator's cab............................................................................................................. 502 Adjusting blade.................................................................................................................................. 506 Testing and adjusting operator's seat isolator................................................................................................... 508 Testing and adjusting, Part 3........................................................................................................................ 512 Special functions of monitor panel (EMMS)........................................................................................................ 513 Testing and adjusting, Part 4........................................................................................................................ 564 Adjustment method when controller has been replaced.............................................................................................. 565 Preparation work for troubleshooting for electrical equipment system............................................................................. 567 Inspection procedure of diode.................................................................................................................... 571 Handling of optional devices..................................................................................................................... 572 Initialization procedures for VHMS controller.................................................................................................... 573 Precautions for replacing VHMS controller........................................................................................................ 594 Pm Clinic service................................................................................................................................ 599 40 Troubleshooting....................................................................................................................................... 0 Failure code table and fuse locations................................................................................................................ 610 Failure code table............................................................................................................................... 611 Fuse locations................................................................................................................................... 621 General information on troubleshooting............................................................................................................... 626 Points to remember when troubleshooting.......................................................................................................... 627 Sequence of events in troubleshooting............................................................................................................ 628 Checks before troubleshooting.................................................................................................................... 629 Classification and procedures of troubleshooting................................................................................................. 630 Contents of troubleshooting table................................................................................................................ 633 Connection table for connector pin numbers....................................................................................................... 635 T- branch box and T- branch adapter table........................................................................................................ 671 Troubleshooting by failure code, Part 1.............................................................................................................. 676 Failure code [1380MW] Lockup clutch: Clutch slip................................................................................................. 678 Failure code [1500L0] Transmission clutch: Dual engagement....................................................................................... 679 Failure code [15E0MW] Transmission clutch: Clutch slip........................................................................................... 680 Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON........................................................ 681 Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF........................................................ 682 Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON..................................................................... 683 Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF........................................................ 684 Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON............................................................ 685 Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF............................................................ 686 Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON............................................................ 687 Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF............................................................ 688 Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON............................................................ 689 Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF............................................................ 690 Failure code [1800MW] Power train clutch: Slip................................................................................................... 691 Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON.......................................................... 692 Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF.......................................................... 693 Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON........................................................... 694 Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF........................................................... 695 Failure code [2300NR] Brake thermal load: Abnormal heating....................................................................................... 696 Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON........................................................... 697 Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF........................................................... 698 Failure code [2301NR] Right steering brake thermal load: Abnormal heating........................................................................ 699 Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON............................................................ 700 Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF............................................................ 701 Failure code [2302NR] Left steering brake thermal load: Abnormal heating......................................................................... 702 Failure code [6001ZK] Failure code for design.................................................................................................... 703 Failure code [A000NS] Engine: Overheat........................................................................................................... 704 Failure code [AA10NX] Air cleaner: Clogging...................................................................................................... 705 Failure code [AB00MA] Battery charge abnormality: Malfunction.................................................................................... 706 Failure code [B@BAZG] Engine oil: Oil pressure too low........................................................................................... 707 Failure code [B@BAZK] Engine oil: Oil level reduction............................................................................................ 708 Failure code [B@BCNS] Engine coolant: Overheat................................................................................................... 709 Failure code [B@BCZK] Engine coolant: Level too low.............................................................................................. 710 Failure code [B@BEBF] Fuel: Water in fuel........................................................................................................ 711 Failure code [B@BFZK] Fuel level: Reduction...................................................................................................... 712 Failure code [B@CENS] Power train oil: Overheat.................................................................................................. 713 Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure.................................................................................. 714 Failure code [B@CHZK] Power train oil: Oil level reduction....................................................................................... 714 Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction..................................................................... 715 Failure code [B@HANS] Hydraulic oil: Overheat.................................................................................................... 715 Failure code [B@HAZK] Hydraulic oil: Level reduction............................................................................................. 716 Troubleshooting by failure code, Part 2.............................................................................................................. 718 Failure code [CA111] Engine controller (Left bank): Internal abnormality......................................................................... 721 Failure code [CB111] Engine controller (Right bank): Internal abnormality........................................................................ 723 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal...................................... 725 Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal..................................... 726 Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected...................................... 727 Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected........................................ 729 Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank): High voltage detection..................................... 730 Failure code [CA132] Decelerator pedal sensor too low (At left bank only): Excessively low voltage detected...................................... 732 Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected......................................... 733 Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected........................................... 735 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected...................................................... 737 Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected.................................... 739 Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected................................... 741 Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected..................................... 743 Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection............................................. 745 Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection............................................ 746 Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection................................ 747 Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection.................................. 748 Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected................................. 749 Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected................................... 751 Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected.......................................... 753 Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection.......................................... 755 Failure code [CA234] Engine over speed (At left bank only): Excessively high speed............................................................... 757 Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected............................. 759 Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected............................ 761 Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected.......................................... 763 Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected......................................... 765 Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection............................................. 766 Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection............................................ 766 Failure code [CA271] PCV1 short circuit (Left bank): Short circuit............................................................................... 767 Failure code [CB271] PCV1 short circuit (Right bank): Short circuit.............................................................................. 768 Failure code [CA272] PCV1 disconnection (Left bank): Disconnection............................................................................... 769 Failure code [CB272] PCV1 disconnection (Right bank): Disconnection.............................................................................. 770 Failure code [CA273] PCV2 short circuit (Left bank): Short circuit............................................................................... 771 Failure code [CB273] PCV2 short circuit (Right bank): Short circuit.............................................................................. 772 Failure code [CA274] PCV2 disconnection (Left bank): Disconnection............................................................................... 773 Failure code [CB274] PCV2 disconnection (Right bank): Disconnection.............................................................................. 774 Troubleshooting by failure code, Part 3.............................................................................................................. 776 Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank): Disconnection, short circuit..................... 779 Failure code [CA323] Injector #5 (L/B #5) system disconnection or short circuit (At left bank): Disconnection, short circuit..................... 781 Failure code [CA324] Injector #3 (L/B #3) system disconnection or short circuit (At left bank): Disconnection, short circuit..................... 783 Failure code [CA325] Injector #6 (L/B #6) system disconnection or short circuit (At left bank): Disconnection, short circuit..................... 785 Failure code [CA331] Injector #2 (L/B #2) system disconnection or short circuit (At left bank): Disconnection, short circuit..................... 787 Failure code [CA332] Injector #4 (L/B #4) system disconnection or short circuit (At left bank): Disconnection, short circuit..................... 789 Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch....................................................................... 791 Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch...................................................................... 792 Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit............................................................ 793 Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality........................................................ 795 Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection............................................. 797 Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection............................................ 798 Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection........................................... 799 Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection.......................................... 801 Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection................................................ 803 Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection............................................... 803 Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection.............................................. 804 Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection............................................. 804 Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence................................... 805 Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence.................................. 805 Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected...................................... 807 Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection...................................... 809 Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection.............................. 811 Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection............................. 811 Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected........................................ 812 Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected....................................... 813 Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error................................................ 814 Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error............................................... 814 Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected................................... 815 Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected (Low-grade fuel specification).... 819 Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected.................................. 823 Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal............................................................. 827 Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal............................................................ 829 Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection................................ 831 Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection.................................. 833 Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase...................................................... 834 Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase..................................................... 834 Troubleshooting by failure code, Part 4.............................................................................................................. 836 Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data......................................................... 838 Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data........................................................ 838 Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal...................................................... 839 Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error........................................................ 841 Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error.................................................. 843 Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error................................................. 845 Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error........................................ 846 Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error....................................... 847 Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit.......................... 849 Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit.......................... 851 Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit......................... 853 Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit......................... 855 Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit......................... 857 Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit.......................... 859 Failure code [CA1633] KOMNET abnormality (Left bank): Communication error........................................................................ 861 Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level (Only left bank): High voltage detection....................... 863 Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only): Excessively low voltage detected........................ 865 Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected.................................. 866 Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected................................. 866 Failure code [D110KA] Battery relay: Disconnection............................................................................................... 867 Failure code [D110KB] Battery relay: Short circuit............................................................................................... 869 Failure code [D130KA] Neutral safety relay: Disconnection........................................................................................ 871 Failure code [D130KB] Neutral safety relay: Short circuit........................................................................................ 873 Failure code [D161KA] Back-up alarm relay: Disconnection......................................................................................... 875 Failure code [D161KB] Back-up alarm relay: Short circuit......................................................................................... 877 Failure code [D182KZ] Preheater relay: Disconnection or short circuit............................................................................ 879 Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection................................................................... 881 Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit................................................................... 883 Failure code [D5ZRKA] Snap shot switch: Disconnection............................................................................................ 885 Failure code [D5ZRKB] Snap shot switch: Short circuit............................................................................................ 886 Failure code [DAFRKR] Monitor panel CAN communication: Communication error....................................................................... 887 Failure code [dAFRKR] Monitor panel CAN communication: Communication error....................................................................... 889 Failure code [daFRKR] Monitor panel CAN communication: Communication error....................................................................... 891 Failure code [DAQ0KT] Transmission controller: Abnormality in controller......................................................................... 893 Failure code [DAQ1KK] Transmission controller main power supply: Power supply voltage reduction (Input).......................................... 895 Failure code [DAQ2KK] Transmission controller load power supply: Power supply voltage reduction (Input).......................................... 897 Failure code [DAQ5KK] Transmission controller potentiometer power supply: Source voltage reduction (input)....................................... 899 Failure code [DAQ6KK] Transmission controller sensor power supply: Source voltage reduction (input).............................................. 900 Failure code [DAQ7KK] Transmission controller sensor power supply: Power supply voltage reduction (Input)........................................ 901 Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency................................................... 902 Failure code [DAQRKR] Transmission controller sensor CAN communication: Communication error (Objective component system abnormality)............. 903 Failure code [DAQSKR] Transmission controller S-NET communication: Defective communication (Abnormality in objective component system)........... 905 Troubleshooting by failure code, Part 5.............................................................................................................. 908 Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error....................................................... 911 Failure code [dB2RKR] Engine controller (Left bank) CAN communication: Communication error....................................................... 913 Failure code [db2RKR] Engine controller (Right bank) CAN communication: Communication error...................................................... 915 Failure code [DB30KT] Steering controller: Abnormality in controller............................................................................. 917 Failure code [DB31KK] Steering controller main power supply: Power supply voltage reduction (Input).............................................. 919 Failure code [DB32KK] Steering controller load power supply: Power supply voltage reduction (Input).............................................. 921 Failure code [DB35KK] Steering controller potentiometer power supply: Power supply voltage reduction (Input)..................................... 923 Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input).................................................. 925 Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input).................................................. 926 Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency....................................................... 927 Failure code [dB3RKR] Steering controller CAN communication: Communication error................................................................. 929 Failure code [DB3SKR] Steering controller S-NET communication: Defective communication (Abnormality in objective component system)............... 931 Failure code [DBB0KK] (or LED of VHMS controller indicates "n9" → "01") VHMS controller: Lowering of source voltage.............................. 933 Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" → "11") Check of VHMS controller model: Disagreement of model selection.......... 934 Failure code [DBB3KK] (or LED of VHMS controller indicates "n9" → "05") VHMS controller: Lowering of direct source voltage....................... 935 Failure code [DBB5KP] (or LED of VHMS controller indicates "n9" → "04") VHMS sensor power supply (5 V): Lowering of output voltage............... 936 Failure code [DBB6KP] (or LED of VHMS controller indicates "n9" → "02") VHMS sensor power supply (24 V): Lowering of output voltage.............. 937 Failure code [DBB7KP] (or LED of VHMS controller indicates "n9" → "03") VHMS sensor power supply (12 V): Lowering of output voltage.............. 939 Failure code [DBBQKR] (or VHMS_LED display "n8" → "02") VHMS KOM-NET: Communication error........................................................ 941 Failure code [dbBRKR] VHMS controller CAN communication: Communication error..................................................................... 943 Failure code [DD12KA] Shift up switch: Disconnection............................................................................................. 945 Failure code [DD12KB] Shift up switch: Short circuit............................................................................................. 947 Failure code [DD13KA] Shift down switch: Disconnection........................................................................................... 949 Failure code [DD13KB] Shift down switch: Short circuit........................................................................................... 951 Failure code [DD14KA] Parking brake lever switch: Disconnection.................................................................................. 953 Failure code [DD14KB] Parking brake lever switch: Short circuit.................................................................................. 955 Failure code [DDB9L4] Reverse switch: Signal disagreement........................................................................................ 957 Failure code [DDK3L4] Forward switch: Signal disagreement........................................................................................ 959 Failure code [DDK5KA] Gearshift switch: Disconnection............................................................................................ 961 Failure code [DDK5KB] Gearshift switch: Short circuit............................................................................................ 963 Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time................................................... 965 Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time..................................................... 966 Failure code [DDN7KA] Blade pitch switch: Disconnection.......................................................................................... 967 Failure code [DDN7KB] Blade pitch switch: Short circuit.......................................................................................... 969 Failure code [DDN9KA] Blade tilt switch: Disconnection........................................................................................... 971 Failure code [DDN9KB] Blade tilt switch: Short circuit........................................................................................... 973 Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time..................................................... 975 Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time.......................................................... 976 Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time.......................................................... 977 Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time............................................................. 978 Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time.......................................................... 979 Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time...................................................... 980 Troubleshooting by failure code, Part 6.............................................................................................................. 982 Failure code [DDQ2KA] Parking brake lever switch: Disconnection.................................................................................. 985 Failure code [DDQ2KB] Parking brake lever switch: Short circuit.................................................................................. 987 Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals........................................................................ 989 Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals........................................................................ 990 Failure code [DDT5KA] Neutral switch: Disconnection.............................................................................................. 991 Failure code [DDT5KB] Neutral switch: Short circuit.............................................................................................. 993 Failure code [DDT5KQ] Lever specification selection: Model selection signal disagreement......................................................... 995 Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range...................................................... 996 Failure code [DGT1KA] Power train oil temperature sensor: Disconnection.......................................................................... 997 Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range.................................................... 998 Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front): Disconnection (or LED of VHMS controller indicates "n3" →"12")........ 999 Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear): Disconnection (or LED of VHMS controller indicates "n3" →"22").........1001 Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front): Short circuit (or LED of VHMS controller indicates "n3" → "11") ......1003 Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" →"21") Left bank exhaust temperature sensor system (Rear): Short circuit1........1005 Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" →"24") Right bank exhaust temperature sensor system (Front): Disconnection.......1007 Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" →"26") Right bank exhaust temperature sensor system (Rear): Disconnection........1009 Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" →"23") Right bank exhaust temperature sensor system (Front): Short circuit.......1011 Failure code [dGT6KB] (or LED of VHMS controller indicates "n3" →"25") Right bank exhaust temperature sensor system (Rear): Short circuit........1013 Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection.................................................................1015 Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit.................................................................1016 Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection.................................................................1017 Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit.................................................................1018 Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" →"32") Blow-by pressure sensor system: Disconnection.............................1019 Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" →"31") Blow-by pressure sensor system: Hot short.................................1020 Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" →"14") Transmission oil pressure sensor: Out of input signal range...............1021 Failure code [DK01KA] Left yoke angle sensor: Disconnection......................................................................................1022 Failure code [DK01KB] Left yoke angle sensor: Short circuit......................................................................................1023 Failure code [DK03KA] Right yoke angle sensor: Disconnection.....................................................................................1024 Failure code [DK03KB] Right yoke angle sensor: Short circuit.....................................................................................1025 Failure code [DK10KA] Fuel dial: Disconnection...................................................................................................1026 Failure code [DK10KB] Fuel dial: Short circuit...................................................................................................1027 Failure code [DK30KA] Steering potentiometer (1): Disconnection..................................................................................1029 Failure code [DK30KB] Steering potentiometer (1): Short circuit..................................................................................1031 Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range............................................................1033 Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit.................................................................1033 Failure code [DK30L8] Steering potentiometer (1): See table......................................................................................1034 Failure code [DK31KA] Steering potentiometer (2): Disconnection..................................................................................1035 Failure code [DK31KB] Steering potentiometer (2): Short circuit..................................................................................1037 Troubleshooting by failure code (Display of code), Part 7............................................................................................1040 Failure code [DK40KA] Brake potentiometer: Disconnection.........................................................................................1042 Failure code [DK40KB] Brake potentiometer: Short circuit.........................................................................................1043 Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range.........................................................1044 Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit..............................................................1045 Failure code [DK55L8] Forward-reverse potentiometer: See table...................................................................................1046 Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection...........................................................................1047 Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit...........................................................................1049 Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection...........................................................................1051 Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit...........................................................................1053 Failure code [DK60KA] Acceleration sensor: Disconnection.........................................................................................1055 Failure code [DK60KB] Acceleration sensor: Short circuit.........................................................................................1057 Failure code [DKH1KA] Pitch angle sensor: disconnection..........................................................................................1058 Failure code [DKH1KB] Pitch angle sensor: Short circuit..........................................................................................1059 Failure code [DKH1KX] Pitch angle sensor: Out of input signal range..............................................................................1060 Failure code [DLF1KA] Torque converter output speed sensor: Disconnection........................................................................1061 Failure code [DLT3KA] Transmission output speed sensor: Disconnection............................................................................1062 Failure code [dLT3KA] Transmission output speed sensor: Disconnection............................................................................1063 Failure code [DLT3KB] Transmission output speed sensor: Short circuit............................................................................1065 Failure code [DV00KB] Caution buzzer: Short circuit..............................................................................................1066 Failure code [DW55KA] Blade pitch back solenoid: Disconnection...................................................................................1067 Failure code [DW55KB] Blade pitch back solenoid: Short circuit...................................................................................1068 Failure code [DW56KA] Blade pitch dump solenoid: Disconnection...................................................................................1069 Failure code [DW56KB] Blade pitch dump solenoid: Short circuit...................................................................................1070 Failure code [DW56KY] Blade pitch dump solenoid: Hot short.......................................................................................1071 Failure code [DW57KA] Left tilt limit solenoid: Disconnection....................................................................................1072 Failure code [DW57KB] Left tilt limit solenoid: Short circuit....................................................................................1073 Failure code [DW57KY] Left tilt limit solenoid: Hot short........................................................................................1074 Failure code [DW58KA] Right tilt limit solenoid: Disconnection...................................................................................1075 Failure code [DW58KB] Right tilt limit solenoid: Short circuit...................................................................................1076 Failure code [DW58KY] Right tilt limit solenoid: Hot short.......................................................................................1077 Failure code [DW59KA] Dual tilt selector solenoid: Disconnection.................................................................................1078 Failure code [DW59KB] Dual tilt selector solenoid: Short circuit.................................................................................1079 Failure code [DW59KY] Dual tilt selector solenoid: Hot short.....................................................................................1080 Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection...............................................................................1081 Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit...............................................................................1082 Failure code [DW5AKY] Blade pitch selector solenoid: Hot short...................................................................................1083 Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification): Disconnection....................................................1084 Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification): Short circuit....................................................1085 Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification): Hot short........................................................1086 Failure code [DW7BKA] Fan reverse solenoid: Disconnection........................................................................................1087 Failure code [DW7BKB] Fan reverse solenoid: Short circuit........................................................................................1088 Failure code [DW7BKY] Fan reverse solenoid: Hot short............................................................................................1089 Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection.................................................................................1090 Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit.................................................................................1091 Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short.....................................................................................1092 Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection.............................................................................1093 Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit.............................................................................1094 Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short.................................................................................1095 Failure code [DWN5KA] Fan pump solenoid 1: Disconnection.........................................................................................1096 Failure code [DWN5KB] Fan pump solenoid 1: Short circuit.........................................................................................1097 Failure code [DWN5KY] Fan pump solenoid 1: Hot short.............................................................................................1098 Failure code [DWNCKA] Fan pump solenoid 2: Disconnection.........................................................................................1099 Failure code [DWNCKB] Fan pump solenoid 2: Short circuit.........................................................................................1100 Failure code [DWNCKY] Fan pump solenoid 2: Hot short.............................................................................................1101 Troubleshooting by failure code (Display of code), Part 8............................................................................................1104 Failure code [DXE0KA] LS set solenoid: Disconnection.............................................................................................1106 Failure code [DXE0KB] LS set solenoid: Short circuit.............................................................................................1107 Failure code [DXE0KY] LS set solenoid: Hot short.................................................................................................1108 Failure code [DXH1KA] Lock-up solenoid: Disconnection............................................................................................1109 Failure code [DXH1KB] Lock-up solenoid: Short circuit............................................................................................1110 Failure code [DXH1KY] Lockup solenoid: Hot short.................................................................................................1111 Failure code [DXH4KA] 1st clutch ECMV: Disconnection.............................................................................................1112 Failure code [DXH4KB] 1st clutch ECMV: Short circuit.............................................................................................1113 Failure code [DXH4KY] 1st clutch ECMV: Hot short.................................................................................................1114 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection.............................................................................................1115 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit.............................................................................................1116 Failure code [DXH5KY] 2nd clutch ECMV: Hot short.................................................................................................1117 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection.............................................................................................1118 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit.............................................................................................1119 Failure code [DXH6KY] 3rd clutch ECMV: Hot short.................................................................................................1120 Failure code [DXH7KA] Reverse clutch ECMV: Disconnection.........................................................................................1121 Failure code [DXH7KB] Reverse clutch ECMV: Short circuit.........................................................................................1122 Failure code [DXH7KY] Reverse clutch ECMV: Hot short.............................................................................................1123 Failure code [DXH8KA] Forward clutch ECMV: Disconnection.........................................................................................1124 Failure code [DXH8KB] Forward clutch ECMV: Short circuit.........................................................................................1125 Failure code [DXH8KY] Forward clutch ECMV: Hot short.............................................................................................1126 Failure code [DXH9KA] Right steering clutch ECMV: Disconnection..................................................................................1127 Failure code [DXH9KB] Right steering clutch ECMV: Short circuit..................................................................................1128 Failure code [DXH9KY] Right steering clutch ECMV: Hot short......................................................................................1129 Failure code [DXHAKA] Left steering clutch ECMV: Disconnection...................................................................................1130 Failure code [DXHAKB] Left steering clutch ECMV: Short circuit...................................................................................1131 Failure code [DXHAKY] Left steering clutch ECMV: Hot short.......................................................................................1132 Failure code [DXHBKA] Right brake ECMV: Disconnection............................................................................................1133 Failure code [DXHBKB] Right brake ECMV: Short circuit............................................................................................1134 Failure code [DXHBKY] Right brake ECMV: Hot short................................................................................................1135 Failure code [DXHCKA] Left brake ECMV: Disconnection.............................................................................................1136 Failure code [DXHCKB] Left brake ECMV: Short circuit.............................................................................................1137 Failure code [DXHCKY] Left brake ECMV: Hot short.................................................................................................1138 Failure code [F@BBZL] (or VHMS_LED display "n3" → "38") Engine blow-by pressure sensor: Abnormally high pressure occurrence......................1139 Failure code [F@BYNS] (or VHMS_LED display "n3" → "61") Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise.............1141 Failure code [f@BYNS] (or VHMS_LED display "n3" → "71") Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise..............1143 Failure code [F@BZNS] (or VHMS_LED display "n3" → "38") Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise............1145 Failure code [f@BZNS] (or VHMS_LED display "n3" → "39") Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise.............1147 Failure code [F@BYNR] (or VHMS_LED display "n3" → "62") Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise.............1149 Failure code [f@BYNR] (or VHMS_LED display "n3" → "72") Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise..............1151 Failure code [F@BZNR] (or VHMS_LED display "n3" → "82") Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise............1153 Failure code [f@BZNR] (or VHMS_LED display "n3" → "92") Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise.............1155 Troubleshooting of electrical system (E-mode)........................................................................................................1158 Contents of troubleshooting table................................................................................................................1160 E-1 The engine does not start....................................................................................................................1161 E-2 The preheater does not operate...............................................................................................................1165 E-3 The ripper pin puller cylinder does not operate..............................................................................................1169 E-4 The monitor panel does not come on at all when the starting switch is turned on..............................................................1171 E-5 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out......................................1173 E-6 When the starting switch is turned on, the basic check items flash...........................................................................1174 E-7 While the engine is operating, any caution item flashes......................................................................................1175 E-8 An emergency caution item flashes while the engine is running................................................................................1178 E-9 While the preheater is operating, the preheating pilot lamp does not come on.................................................................1181 E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine).........................1183 E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on.......................................1183 E-12 The engine coolant temperature gauge does not indicate normally.............................................................................1184 E-13 Indication of the power train (torque converter) temperature gauge is abnormal..............................................................1185 E-14 The hydraulic oil temperature gauge does not indicate normally..............................................................................1187 E-15 Indication of the fuel gauge is abnormal....................................................................................................1188 E-16 Indications of gear speed and engine speed are abnormal.....................................................................................1189 E-17 Indication of the shift mode service meter is abnormal......................................................................................1189 E-18 The switch module cannot be operated........................................................................................................1190 E-19 The warning lamp does not flash or does not go out..........................................................................................1191 E-20 The alarm buzzer does not sound or does not stop............................................................................................1192 E-21 Auto shift down is not possible or is not released..........................................................................................1193 E-22 The automatic pitch back system does not operate (only superdozer specification)............................................................1194 E-23 The alarm buzzer cannot be cancelled........................................................................................................1195 E-24 The operator mode cannot be operated........................................................................................................1196 E-25 The service mode cannot be operated.........................................................................................................1197 E-26 The back-up alarm does not sound............................................................................................................1199 E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on...............................................1201 E-28 Troubleshooting for air conditioner system..................................................................................................1207 E-29 Orbcomm terminal does not operate normally (Data are not transmitted).......................................................................1222 E-30 Fan does not reverse........................................................................................................................1224 E-31 Gear cannot be shifted......................................................................................................................1226 E-32 Electric priming pump does not operate or does not stop automatically.......................................................................1227 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................................................................1230 Information in troubleshooting table.............................................................................................................1232 H-1 No force (no drawbar pull)...................................................................................................................1233 H-2 No travel (at 2nd or 3rd speed)..............................................................................................................1235 H-3 No travel at all gear speeds.................................................................................................................1236 H-4 Machine travels only in one direction forward or in reverse..................................................................................1237 H-5 Large time lag at gear speed shifting or forward-reverse shifting............................................................................1238 H-6 Steering is not possible.....................................................................................................................1239 H-7 Steering is possible only on one side........................................................................................................1240 H-8 Steering overrun occurs......................................................................................................................1241 H-9 Brake does not work..........................................................................................................................1242 H-10 Torque converter is not lock-up.............................................................................................................1243 H-11 Power train oil is overheated...............................................................................................................1244 H-12 All work equipment speeds are slow..........................................................................................................1245 H-13 Work equipment does not move................................................................................................................1246 H-14 Blade lift speed is slow or lacks power.....................................................................................................1247 H-15 Blade tilt speed is slow or lacks power.....................................................................................................1248 H-16 Ripper lift speed is slow or lacks power....................................................................................................1249 H-17 Ripper tilt speed is slow or lacks power....................................................................................................1250 H-18 Excessive hydraulic drift of blade lift.....................................................................................................1251 H-19 Excessive hydraulic drift of blade tilt.....................................................................................................1252 H-20 Excessive hydraulic drift of ripper lift....................................................................................................1253 H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine)..................................................................1253 H-22 Blade pitch does not work (dual tilt attachment machine)....................................................................................1254 H-23 Abnormal sound comes out from around work equipment pump....................................................................................1254 H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats)...........................................1255 Troubleshooting of engine (S-mode)...................................................................................................................1258 Method of using troubleshooting chart............................................................................................................1260 S-1 Starting performance is poor.................................................................................................................1263 S-2 Engine does not start........................................................................................................................1264 S-3 Engine does not pick up smoothly.............................................................................................................1267 S-4 Engine stops during operations...............................................................................................................1268 S-5 Engine does not rotate smoothly..............................................................................................................1269 S-6 Engine lacks output (or lacks power).........................................................................................................1270 S-7 Exhaust smoke is black (incomplete combustion)...............................................................................................1272 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................................................................1273 S-9 Oil becomes contaminated quickly.............................................................................................................1274 S-10 Fuel consumption is excessive...............................................................................................................1275 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).......................................................................1276 S-12 Oil pressure drops..........................................................................................................................1277 S-13 Oil level rises (Entry of coolant or fuel)..................................................................................................1278 S-14 Coolant temperature becomes too high (overheating)..........................................................................................1279 S-15 Abnormal noise is made......................................................................................................................1280 S-16 Vibration is excessive......................................................................................................................1281 50 Disassembly and assembly.............................................................................................................................. 0 General information on disassembly andassembly.......................................................................................................1284 How to read this manual..........................................................................................................................1285 Coating materials list...........................................................................................................................1287 Special tools list...............................................................................................................................1290 Sketches of special tools........................................................................................................................1297 Engine and cooling system (SAA12V140E-3).............................................................................................................1308 Engine and cooling system (SAA12V140E-3).........................................................................................................1309 Removal and installation of engine assembly..................................................................................................1309 Removal and installation of radiator assembly................................................................................................1313 Removal and installation of aftercooler assembly.............................................................................................1315 Removal and installation of radiator guard assembly..........................................................................................1317 Removal and installation of fuel tank assembly...............................................................................................1319 Removal and installation of engine hood assembly.............................................................................................1320 Removal and installation of fan drive assembly...............................................................................................1322 Removal and installation of fan motor assembly...............................................................................................1323 Engine (SAA12V140E-3)................................................................................................................................1326 Removal and installation of fuel supply pump assembly............................................................................................1327 Removal and installation of cylinder head assembly...............................................................................................1333 Removal and installation of fuel injector assembly...............................................................................................1344 Removal and installation of engine front seal....................................................................................................1350 Removal and installation of engine rear seal.....................................................................................................1352 Power train, Part 1..................................................................................................................................1356 Removal and installation of damper assembly......................................................................................................1357 Disassembly and assembly of damper assembly......................................................................................................1359 Removal and installation of powe rtrain unit assembly............................................................................................1362 Removal and installation of PTO, torque converter assembly.......................................................................................1365 Disconnection and connection of PTO, torque converter assembly...................................................................................1367 Disassembly and assembly of torque converter assembly............................................................................................1369 Disassembly and assembly of PTO assembly.........................................................................................................1379 Removal and installation of TORQFLOW transmission assembly.......................................................................................1386 Disassembly and assembly of TORQFLOW transmission assembly.......................................................................................1387 Power train, Part 2..................................................................................................................................1406 Disassembly and assembly of steering case assembly...............................................................................................1407 Disassembly and assembly of steering clutch, brake assembly......................................................................................1420 Disassembly and assembly of transfer gear housing assembly.......................................................................................1428 Removal and installation of power train pump assembly............................................................................................1432 Removal and installation of scavenging pump assembly.............................................................................................1432 Removal and installation of torque converter oil cooler..........................................................................................1433 Removal and installation of torque converter valve assembly......................................................................................1434 Disassembly and assembly of torque converter valve assembly......................................................................................1435 Removal and installation of transmission control valve assembly..................................................................................1439 Disassembly and assembly of transmission control valve assembly (ECMV assembly)..................................................................1440 Removal and installation of steering control valve assembly......................................................................................1443 Disassembly and assembly of steering control valve assembly......................................................................................1444 Removal and installation of final drive assembly.................................................................................................1446 Disassembly and assembly of final drive assembly.................................................................................................1448 Undercarriage and frame, Part 1......................................................................................................................1462 Removal and installation of track frame assembly.................................................................................................1463 Disassembly and assembly of idler assembly.......................................................................................................1465 Removal and installation of recoil spring assembly...............................................................................................1468 Disassembly and assembly of recoil spring assembly...............................................................................................1472 Removal and installation of track roller assembly................................................................................................1474 Disassembly and assembly of track roller assembly................................................................................................1476 Removal and installation of carrier roller assembly..............................................................................................1478 Disassembly and assembly of carrier roller assembly..............................................................................................1479 Removal and installation of bogie assembly.......................................................................................................1482 Disassembly and assembly of bogie assembly.......................................................................................................1486 Removal and installation of No.1 bogie assembly..................................................................................................1488 Removal and installation of operator's seat isolator.............................................................................................1493 Disassembly and assembly of operator's seat isolator.............................................................................................1494 Undercarriage and frame, Part 2......................................................................................................................1498 Expansion and installation of track shoe assembly................................................................................................1499 Overall disassembly and overall assembly of track shoe...........................................................................................1502 Press-fitting jig dimension table for link press.................................................................................................1518 Field disassembly and assembly of one link.......................................................................................................1519 Disassembly and assembly of master link..........................................................................................................1524 Removal and installation of pivot shaft assembly.................................................................................................1528 Removal and installation of equalizer bar........................................................................................................1529 Disassembly and assembly of equalizer bar bushing................................................................................................1532 Hydraulic system.....................................................................................................................................1536 Removal and installation of hydraulic pump assembly..............................................................................................1537 Removal and installation of hydraulic valve assembly.............................................................................................1539 Disassembly and assembly of control valve........................................................................................................1540 Disassembly and assembly of merge divider valve and self pressure reducing valve assembly........................................................1544 Removal and installation of PPC relief valve assembly............................................................................................1546 Disassembly and assembly of hydraulic cylinder assembly..........................................................................................1547 Disassembly and assembly of ripper pin puller cylinder assembly..................................................................................1552 Work equipment.......................................................................................................................................1556 Work equipment...................................................................................................................................1557 Removal and installation of blade assembly...................................................................................................1557 Disassembly and assembly of giant ripper assembly............................................................................................1559 Cab and its attachments..............................................................................................................................1564 Cab and its attachments..........................................................................................................................1565 Removal and installation of ROPS guard.......................................................................................................1565 Removal and installation of operator’s cab assembly..........................................................................................1566 Removal and installation of floor frame assembly.............................................................................................1567 Electrical system....................................................................................................................................1572 Removal and installation of controller assembly..................................................................................................1573 Removal and installation of engine controller assembly (left)....................................................................................1574 Removal and installation of air conditioner condenser assembly...................................................................................1575 Removal and installation of air conditioner compressor assembly..................................................................................1576 Removal and installation of air conditioner unit.................................................................................................1578 90 Diagrams and drawings................................................................................................................................. 0 Hydraulic diagrams and drawings......................................................................................................................1582 Hydraulic diagrams and drawings..................................................................................................................1583 Power train hydraulic circuit diagram........................................................................................................1583 Hydraulic circuit diagram (1/3)..............................................................................................................1584 Hydraulic circuit diagram (2/3)..............................................................................................................1585 Hydraulic circuit diagram (3/3)..............................................................................................................1586 Electrical diagrams and drawings.....................................................................................................................1588 Electrical circuit diagram (1/13)................................................................................................................1590 Electrical circuit diagram (2/13)................................................................................................................1591 Electrical circuit diagram (3/13)................................................................................................................1592 Electrical circuit diagram (4/13)................................................................................................................1593 Electrical circuit diagram (5/13)................................................................................................................1594 Electrical circuit diagram (6/13)................................................................................................................1595 Electrical circuit diagram (7/13)................................................................................................................1596 Electrical circuit diagram (8/13)................................................................................................................1597 Electrical circuit diagram (9/13)................................................................................................................1598 Electrical circuit diagram (10/13)...............................................................................................................1599 Electrical circuit diagram (11/13)...............................................................................................................1600 Electrical circuit diagram (12/13)...............................................................................................................1601 Electrical circuit diagram (13/13)...............................................................................................................1602 Electrical circuit diagram of inside cab.........................................................................................................1603 Connector arrangement diagram....................................................................................................................1604
KOMATSU D475A-5E0, D475ASD-5E0 CRAWLER BULLDOZER SHOP MANUAL SEN00203-16 – PDF DOWNLOAD:
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Ephraim Cedric –