Komatsu D475A-5 Bulldozer Shop Manual SEBM033713 – PDF DOWNLOAD

Komatsu D475A-5 Bulldozer Shop Manual SEBM033713 – PDF DOWNLOAD

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Komatsu D475A-5 Bulldozer Shop Manual SEBM033713 – PDF DOWNLOAD

Language : English
Pages : 1252
Downloadable : Yes
File Type : PDF
Size: 76.3 MB

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Komatsu D475A-5 Bulldozer Shop Manual SEBM033713 – PDF DOWNLOAD

MACHINE MODEL SERIAL No.
D475A-5 20001 and up

GENERAL PRECAUTIONS:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.• Always wear safety glasses when hitting parts with a hammer.• Always wear safety glasses when grinding parts with a grinder, etc.3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work.4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:

• 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
• 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
• 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
• 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

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

TABLE OF CONTENTS:

Komatsu D475A-5 Bulldozer Shop Manual SEBM033713 – PDF DOWNLOAD

COVER 1
CONTENTS 2
LIST OF REVISED PAGES 3
SAFETY 11
SAFETY NOTICE 11
FOREWORD 13
GENERAL 13
HOW TO READ THE SHOP MANUAL 14
HOISTING INSTRUCTIONS 15
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 16
COATING MATERIALS 18
STANDARD TIGHTENING TORQUE 20
ELECTRIC WIRE CODE 23
CONVERSION TABLE 24
UNITS 30
01 GENERAL 31
SPECIFICATION DRAWINGS 32
SPECIFICATIONS 33
WEIGHT TABLE 42
FUEL, COOLANT AND LUBRICANTS 46
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 49
RADIATOR AND OIL COOLER 52
ENGINE MOUNT 53
POWER TRAIN 54
POWER TRAIN HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM 56
DAMPER AND UNIVERSAL JOINT 58
POWER TRAIN UNIT 60
TORQUE CONVERTER AND PTO 62
TORQUE CONVERTER VALVE 72
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM 82
SCAVENGING PUMP 83
TRANSMISSION CONTROL 84
TRANSMISSION 86
TRANSMISSION ECMV 98
TRANSMISSION CLUTCH ECMV 100
PRIORITY VALVE 104
LUBRICATING OIL RELIEF VALVE 105
POWER TRAIN, LUBRICATION PUMP 106
STEERING, BRAKE CONTROL 108
FINAL DRIVE 111
STEERING UNIT 116
STEERING ECMV 128
STEERING CLUTCH ECMV, STEERING BRAKE ECMV 130
PARKING BRAKE VALVE 136
SUDDEN STOP PREVENTION VALVE 138
SPROCKET 140
TRACK FRAME 142
RECOIL SPRING 146
IDLER 148
TRACK ROLLER 150
CARRIER ROLLER 153
TRACK ROLLER BOGIE 154
TRACK SHOE 156
MAIN FRAME 160
SUSPENSION 163
WORK EQUIPMENT HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM 166
PPC CONTROL PIPING DIAGRAM 170
WORK EQUIPMENT CONTROL 172
WORK EQUIPMENT PUMP 174
COOLING FAN PUMP 191
COOLING FAN MOTOR 212
PPC VALVE 220
ELECTRIC LEVER (STEERING) 230
CONTROL VALVE 234
MAIN RELIEF VALVE 248
CLSS 249
UNLOAD VALVE 252
INTRODUCTION OF LS PRESSURE (LS SHUTTLE VALVE) 253
LS BYPASS PLUG 254
PRESSURE COMPENSATION VALVE 255
BLADE LIFT VALVE 258
MERGE DIVIDER VALVE 266
SELF PRESSURE REDUCING VALVE 268
PILOT SOLENOID VALVE 272
HYDRAULIC TANK 274
ACCUMULATOR 276
WORK EQUIPMENT CYLINDER 278
PISTON VALVE 280
QUICK DROP VALVE 281
BLADE CONTROL KNOB 284
PITCH AND DUAL SOLENOID VALVE 286
PIN PULLER HYDRAULIC CIRCUIT DIAGRAM 287
PIN PULLER SOLENOID VALVE 288
CYLINDER STAY 290
BLADE 292
RIPPER EQUIPMENT 296
CAB MOUNT 300
CAB 301
AIR CONDITIONER 304
ENGINE CONTROL 306
ENGINE CONTROL SYSTEM 307
DECELERATION POTENTIOMETER 308
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER 309
FULE INJECTION PUMP WITH ELECTRONIC GOVERNOR 310
MONITOR SYSTEM 311
MONITOR PANEL 313
SENSORS 317
MODE SELECTION SYSTEM 321
ELECTRICAL EQUIPMENT 327
STEERING ELECTRONIC CONTROL SYSTEM 330
VHMS CONTROLLER 332
SENSORS 335
COMMUNICATION (ORB: ORBCOMM) CONTROLLER/ANTENNA 338
20 TESTING AND ADJUSTING 339
STANDARD VALUE TABLE FOR ENGINE 340
STANDARD VALUE TABLE FOR CHASSIS 341
TESTING AND ADJUSTING 353
TESTING, ADJUSTING, AND TROUBLESHOOTING DEVICES TABLE 355
MEASURING ENGINE SPEED 357
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 360
MEASURING EXHAUST TEMPERATURE 361
MEASURING EXHAUST GAS COLOR 363
ADJUSTING VALVE CLEARANCE 364
MEASURING COMPRESSION PRESSURE 365
MEASURING BLOW-BY PRESSURE 366
MEASURING ENGINE OIL PRESSURE 367
TESTING AND ADJUSTING FUEL INJECTION TIMING 368
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 370
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 371
ADJUSTING ENGINE SPEED SENSOR 371
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL 372
MEASURING POWER TRAIN OIL PRESSURE 374
ADJUSTING TRANSMISSION SPEED SENSOR 382
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE 383
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER 384
ADJUSTING PCCS LEVER CONSOLE POSITION 387
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE 388
ADJUSTING CLEARANCE OF IDLER 390
INSPECTING WEAR OF SPROCKET 390
TESTING AND ADJUSTING TRACK SHOE TENSION 391
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE 392
TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE 401
MEASURING PPC VALVE OUTPUT PRESSURE AND SOLENOID VALVE OUTPUT PRESSURE 402
ADJUSTING PLAY OF PPC VALVE 409
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE 410
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER 411
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER 412
RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CIRCUIT 413
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER 413
ADJUSTING BLADE LEVER TILTING STROKE 414
ADJUSTING RIPPER LEVER POSITION 415
ADJUSTING LOCK LEVER 416
MEASURING FAN MOTOR SPEED 417
MEASURING FAN CIRCUIT OIL PRESSURE 418
BLEEDING AIR FROM FAN PUMP 419
MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE (DUAL TILTDOZER SPECIFICATION) 420
MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE (SUPERDOZER SPECIFICATION) 422
TESTING AND ADJUSTING OPERATOR’S CAB 424
ADJUSTING BLADE 428
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 430
ADJUSTING METHOD OF REPLACED CONTROLLER 485
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM 487
HANDLING OF OPTIONAL DEVICES 490
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER 491
PROCEDURES FOR EXECUTING QUICK PM 496
PRECAUTIONS FOR REPLACING VHMS CONTROLLER 506
PM CLINIC SERVICE 507
TROUBLESHOOTING 517
POINTS TO REMEMBER WHEN TROUBLESHOOTING 518
SEQUENCE OF EVENTS IN TROUBLESHOOTING 519
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 520
CHECKS BEFORE TROUBLESHOOTING 528
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 529
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM 532
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 570
T-BRANCH BOX AND T-BRANCH TABLE 594
TROUBLESHOOTING WHEN SERVICE CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE INDICATED 597
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 603
ERROR CODE [1500L0] (TRANSMISSION CLUTCH: SEE THE LIST (L0)) 605
ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST (L1)) 606
ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST (LH)) 607
ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST (L1)) 608
ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST (LH)) 609
ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST (L1)) 610
ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST (LH)) 611
ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST (L1)) 612
ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST (LH)) 613
ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST (L1)) 614
ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST (LH)) 615
ERROR CODE [1800MW] (POWER TRAIN CLUTCH: SLIP (MW)) 616
ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST (L1)) 617
ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST (LH)) 618
ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST (L1)) 619
ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST (LH)) 620
ERROR CODE [2300NR] (BRAKE THERMAL LOAD: ABNORMAL HEATING (NR)) 621
ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST (L1)) 622
ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST (LH)) 623
ERROR CODE [2301NR] (RIGHT STEERING BRAKE THERMAL LOAD: ABNORMAL HEATING (NR)) 624
ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST (L1)) 625
ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST (LH)) 626
ERROR CODE [2302NR] (LEFT STEERING BRAKE THERMAL LOAD: ABNORMAL HEATING (NR)) 627
ERROR CODE [A000N1] (OR VHMS_LED IS DISPLAYED “n2″ →”01”) ENGINE OVERRUN 627
ERROR CODE [A70XLK] (GOVERNOR SERVO SYSTEM RIGHT: *REFER TO TABLE (LK)) 628
ERROR CODE [A70YLK] (GOVERNOR SERVO SYSTEM LEFT: *REFER TO TABLE (LK)) 629
ERROR CODE [AA1ANX] (AIR CLEANER: CLOGGING (NX)) 630
ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA)) 630
ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)) 631
ERROR CODE [B@BAZK] (ENGINE OIL: OIL LEVEL REDUCTION (ZK)) 631
ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS)) 632
ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK)) 632
ERROR CODE [B@CENS] (POWER TRAIN OIL: OVERHEAT (NS)) 633
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS)) 633
ERROR CODE [B@HAZK] (HYDRAULIC OIL: LEVEL REDUCTION (ZK)) 634
ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA)) 635
ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB)) 636
ERROR CODE [D130KA] (NEUTRAL SAFETY RELAY: DISCONNECTION (KA)) 637
ERROR CODE [D130KB] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB)) 639
ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA)) 640
ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB)) 642
ERROR CODE [D182KZ] (PREHEATER RELAY: LOWERING OF LEVEL (KZ)) 644
ERROR CODE [D1D0KA] (GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION (KA)) 646
ERROR CODE [D1D0KB] (GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT (KB)) 648
ERROR CODE [D1D1KA] (GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION (KA)) 650
ERROR CODE [D1D1KB] (GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT (KB)) 652
ERROR CODE [D5ZFKA] (NEUTRAL SIGNAL 1: DISCONNECTION (KA)) 654
ERROR CODE [D5ZFKB] (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB)) 655
ERROR CODE [D5ZFL4] (ENGINE CONTROLLER NEUTRAL SIGNAL: ON AND OFF SIGNAL DO NOT AGREE (L4)) 656
ERROR CODE [D5ZGKA] (NEUTRAL SIGNAL 2: DISCONNECTION (KA)) 658
ERROR CODE [D5ZGKB] (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB)) 659
ERROR CODE [D5ZKKX] (CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL RANGE (KX)) 660
ERROR CODE [D5ZRKA] (SNAP SHOT SWITCH: DISCONNECTION (KA)) 661
ERROR CODE [D5ZRKB] (SNAP SHOT SWITCH: SHORT CIRCUIT (KB)) 662
ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 664
ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) 666
ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 667
ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) 668
ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) 669
ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 670
ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR)) 672
ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR)) 674
ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) 676
ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 677
ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) 678
ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK)) 680
ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 681
ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR)) 682
ERROR CODE [DB3SKR] (STEERING CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR)) 684
ERROR CODE [DB40KK] (ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK)) 686
ERROR CODE [DB41KK] (SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)) 686
ERROR CODE [DB42KK] (SOLENOID POWER SUPPLY 1: LOWERING OF SOURCE VOLTAGE (KK)) 688
ERROR CODE [DB43KK] (BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)) 690
ERROR CODE [DB44KK] (SOLENOID POWER SUPPLY 2: LOWERING OF SOURCE VOLTAGE (KK)) 692
ERROR CODE [DB45KP] (RACK SENSOR POWER SUPPLY: LOWERING OF OUTPUT VOLTAGE (KP)) 694
ERROR CODE [DB49KM] (WRONG CONNECTION OF CONNECTOR: MISTAKE IN OPERATION OR SETTING (KM)) 696
ERROR CODE [DB49KQ] (ENGINE CONTROLLER SPECIFICATION: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)) 697
ERROR CODE [DBB0KK] (OR LED OF VHMS CONTROLLER INDICATES “n9″”→01”) (VHMS CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK)) 698
ERROR CODE [DBB0KQ] (OR LED OF VHMS CONTROLLER INDICATES “nF”→”11”) (CHECK OF VHMS CONTROLLER MODEL: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)) 700
ERROR CODE [DBB3KK] (OR LED OF VHMS CONTROLLER INDICATES “n9″→”02”) (VHMS CONTROLLER: LOWERING OF BATTERY DIRECT SOURCE VOLTAGE (KK)) 701
ERROR CODE [DBB5KP] (OR LED OF VHMS CONTROLLER INDICATES “n9″→”04”) (SENSOR POWER SUPPLY (5V): LOWERING OF OUTPUT VOLTAGE (KP)) 702
ERROR CODE [DBB6KP] (OR LED OF VHMS CONTROLLER INDICATES “n9″→”02”) (SENSOR POWER SUPPLY (24V): LOWERING OF OUTPUT VOLTAGE (KP)) 703
ERROR CODE [DBB7KP] (OR LED OF VHMS CONTROLLER INDICATES “n9″→”03”) (SENSOR POWER SUPPLY (12V): LOWERING OF OUTPUT VOLTAGE (KP)) 704
ERROR CODE [DBBQKR] (OR LED OF VHMS CONTROLLER INDICATES “n8″→”02”) (VHMS KOM-NET: DEFECTIVE COMMUNICATION (KR)) 706
ERROR CODE [DD12KA] (SHIFT UP SWITCH: DISCONNECTION (KA)) 708
ERROR CODE [DD12KB] (SHIFT UP SWITCH: SHORT CIRCUIT (KB)) 710
ERROR CODE [DD13KA] (SHIFT DOWN SWITCH: DISCONNECTION (KA)) 712
ERROR CODE [DD13KB] (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB)) 714
ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)) 716
ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) 718
ERROR CODE [DDN2LD] (BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM: REFER TO TABLE (LD)) 720
ERROR CODE [DDN3LD] (BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM: REFER TO TABLE (LD)) 721
ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA)) 722
ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB)) 724
ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA)) 726
ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB)) 728
ERROR CODE [DDNALD] (BLADE LEFT RAISE FULL OIL PRESSURE SWITCH: REFER TO TABLE (LD)) 730
ERROR CODE [DDNBLD] (RIPPER LEFT RAISE OIL PRESSURE SWITCH: REFER TO TABLE (LD)) 731
ERROR CODE [DDNCLD] (RIPPER LEFT LOWER OIL PRESSURE SWITCH: REFER TO TABLE (LD)) 732
ERROR CODE [DDNDLD] (RIPPER TILT IN OIL PRESSURE SWITCH: REFER TO TABLE (LD)) 733
ERROR CODE [DDNELD] (RIPPER TILT BACK OIL PRESSURE SWITCH: REFER TO TABLE (LD)) 734
ERROR CODE [DDNFLD] (BLADE LEFT LOWER FULL OIL PRESSURE SWITCH: REFER TO TABLE (LD)) 735
ERROR CODE [DDQ2KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)) 736
ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB)) 738
ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4)) 740
ERROR CODE [DGE1KB] (OR LED OF VHMS CONTROLLER INDICATES “n2″→”42”) (ENGINE OIL TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB)) (30 MINUTES AFTER ENGINE IS STARTED (ABOVE 500 RPM)) 741
ERROR CODE [DGE1KY] (OR LED OF VHMS CONTROLLER INDICATES “n2″→”41”) (ENGINE OIL TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KY)) 742
ERROR CODE [DGE2KX] (COOLANT TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)) 744
ERROR CODE [DGE3KA] (ENGINE COOLANT TEMPERATURE SENSOR GAUGE) (FOR LOW TEMPERATURE): DISCONNECTION(KA)) 746
ERROR CODE [DGE5KB] (OR LED OF VHMS CONTROLLER INDICATES “n4″→”01”) (ATMOSPHEREIC TEMPERATURE SENSOR SYSTEM: DISCONNECTION OR SHORT CIRCUIT (KY OR KB)) 747
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 748
ERROR CODE [DGT5KA] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”22”) (LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KA)) 750
ERROR CODE [DGT5KB] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”21”) (LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB)) 752
ERROR CODE [DGT6KA] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”12”) (RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KA)) 754
ERROR CODE [DGT6KB] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”11”) (RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB)) 756
ERROR CODE [DH22KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (F): DISCONNECTION (KA)) 758
ERROR CODE [DH22KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (F): SHORT CIRCUIT (KB)) 759
ERROR CODE [DH23KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (R): DISCONNECTION (KA)) 760
ERROR CODE [DH23KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (R): SHORT CIRCUIT (KB)) 761
ERROR CODE [DHE4KA] (ENGINE OIL PRESSURE SENSOR: DISCONNECTION (KA)) 762
ERROR CODE [DHE4KB] (ENGINE OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) 763
ERROR CODE [DHE5KB] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”32”) (ENGINE BLOW-BY PRESSURE SENSOR SYSTEM: DISCONNECTION (KB)) 764
ERROR CODE [DHE5KY] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”31”) (ENGINE BLOW-BY PRESSURE SENSOR SYSTEM: SHORT CIRCUIT WITH POWER SUPPLY LINE (KY)) 765
ERROR CODE [DHT3KX] (OR LED OF VHMS CONTROLLER INDICATES “n6″→”14”) (TRANSMISSION OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE(KX)) 766
ERROR CODE [DK01KA] (LEFT YOKE ANGEL SENSOR: DISCONNECTION (KA)) 768
ERROR CODE [DK01KB] (LEFT YOKE ANGEL SENSOR: SHORT CIRCUIT (KB)) 770
ERROR CODE [DK03KA] (RIGHT YOKE ANGEL SENSOR: DISCONNECTION (KA)) 771
ERROR CODE [DK03KB] (RIGHT YOKE ANGEL SENSOR: SHORT CIRCUIT (KB)) 773
ERROR CODE [DK10KX] (FUEL DIAL: OUT OF NORMAL RANGE (KX)) 774
ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER: OUT OF INPUT SIGNAL RANGE (KX)) 776
ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA)) 778
ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)) 779
ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 780
ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ)) 780
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8)) 781
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA)) 782
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB)) 783
ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA)) 784
ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB)) 786
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 787
ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ)) 787
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8)) 788
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA)) 789
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB)) 790
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA)) 791
ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB)) 792
ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA)) 793
ERROR CODE [DK60KB] (ACCELERATION SENSOR: SHORT CIRCUIT (KB)) 794
ERROR CODE [DKFOKX] (OR LED OF VHMS CONTROLLER INDICATES “n2″→”62”) (INJECTION PUMP RACK SENSOR: OUT OF INPUT SIGNAL RANGE (KX)) 795
ERROR CODE [DKF1KX] (RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE (KX)) 796
ERROR CODE [DKF2KX] (RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE (KX)) 798
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA)) 800
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB)) 801
ERROR CODE [DLE1KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA)) 802
ERROR CODE [DLE4LC] (ENGINE SPEED SENSOR A: *REFER TO TABLE (LC)) 804
ERROR CODE [DLE5LC] (ENGINE SPEED SENSOR B: *REFER TO TABLE (LC)) 806
ERROR CODE [DLF1KA] (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION (KA)) 808
ERROR CODE [DLT3KA] (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION (KA)) 809
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB)) 810
ERROR CODE [DW55KA] (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA)) 811
ERROR CODE [DW55KB] (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB)) 812
ERROR CODE [DW56KA] (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA)) 813
ERROR CODE [DW56KB] (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB)) 814
ERROR CODE [DW57KA] (LEFT TILT LIMT SOLENOID: DISCONNECTION (KA)) 815
ERROR CODE [DW57KB] (LEFT TILT LIMT SOLENOID: SHORT CIRCUIT (KB)) 816
ERROR CODE [DW58KA] (RIGHT TILT LIMT SOLENOID: DISCONNECTION (KA)) 817
ERROR CODE [DW58KB] (RIGHT TILT LIMT SOLENOID: SHORT CIRCUIT (KB)) 818
ERROR CODE [DW59KA] (BLADE DUAL SELECTOR SOLENOID: DISCONNECTION (KA)) 819
ERROR CODE [DW59KB] (BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT (KB)) 820
ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA)) 821
ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB)) 822
ERROR CODE [DW5DKA] (BLADE PITCH DUMP SOLENOID (SUPERDOZER SPECIFICATION): DISCONNECTION (KA)) 823
ERROR CODE [DW5DKB] (BLADE PITCH DUMP SOLENOID (SUPERDOZER SPECIFICATION): SHORT CIRCUIT (KB)) 824
ERROR CODE [DW7BKA] (FAN REVERSE SOLENOID: DISCONNECTION (KA)) 825
ERROR CODE [DW7BKB] (FAN REVERSE SOLENOID: SHORT CIRCUIT (KB)) 826
ERROR CODE [DWJ0KA] (PUMP MERGE-DIVIDER SOLENOID: DISCONNECTION (KA)) 827
ERROR CODE [DWJ0KB] (PUMP MERGE-DIVIDER SOLENOID: SHORT CIRCUIT (KB)) 828
ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA)) 829
ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB)) 830
ERROR CODE [DWN5KA] (FAN PUMP SOLENOID 1: DISCONNECTION (KA)) 831
ERROR CODE [DWN5KB] (FAN PUMP SOLENOID 1: SHORT CIRCUIT (KB)) 832
ERROR CODE [DWNCKA] (FAN PUMP SOLENOID 2: DISCONNECTION (KA)) 833
ERROR CODE [DWNCKB] (FAN PUMP SOLENOID 2: SHORT CIRCUIT (KB)) 834
ERROR CODE [DXE0KA] (LS SET SOLENOID: DISCONNECTION (KA)) 835
ERROR CODE [DXE0KB] (LS SET SOLENOID: SHORT CIRCUIT (KB)) 836
ERROR CODE [DXH1KA] (LOCK-UP SOLENOID: DISCONNECTION (KA)) 837
ERROR CODE [DXH1KB] (LOCK-UP SOLENOID: SHORT CIRCUIT (KB)) 838
ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA)) 839
ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)) 840
ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA)) 841
ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB)) 842
ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA)) 843
ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB)) 844
ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA)) 845
ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB)) 846
ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA)) 847
ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB)) 848
ERROR CODE [DXH9KA] (RIGHT STEERING CLUTCH ECMV: DISCONNECTION (KA)) 849
ERROR CODE [DXH9KB] (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) 850
ERROR CODE [DXHAKA] (LEFT STEERING CLUTCH ECMV: DISCONNECTION (KA)) 851
ERROR CODE [DXHAKB] (LEFT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) 852
ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA)) 853
ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB)) 854
ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA)) 855
ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB)) 856
ERROR CODE [DXHDKA] (GOVERNOR SOLNOID RIGHT: DISCONNECTION (KA)) 857
ERROR CODE [DXHDKB] (GOVERNOR SOLNOID RIGHT: SHORT CIRCUIT (KB)) 860
ERROR CODE [DXHEKA] (GOVERNOR SOLNOID LEFT: DISCONNECTION (KA)) 861
ERROR CODE [DXHEKB] (GOVERNOR SOLNOID LEFT: SHORT CIRCUIT (KB)) 864
ERROR CODE [DXHFKA] (PRE-STROKE SOLENOID RIGHT: DISCONNECTION (KA)) 865
ERROR CODE [DXHFKB] (PRE-STORKE SOLENOID RIGHT: SHORT CIRCUIT (KB)) 866
ERROR CODE [DXHGKA] (PRE-STROKE SOLENOID LEFT: DISCONNECTION (KA)) 867
ERROR CODE [DXHGKB] (PRE-STORKE SOLENOID LEFT: SHORT CIRCUIT (KB)) 868
ERROR CODE [F@BBZL] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”38”) (ENGINE BLOW-BY PRESSURE: OVERPRESSURE (ZL)) 869
ERROR CODE [F@BYNR] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”62”) (LEFT BANK EXHAUST TEMPERATURE (2): ABNORMAL HEATING (NR)) 870
ERROR CODE [F@BYNS] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”61”) (LEFT BANK EXHAUST TEMPERATURE (1): OVERHEATING (NS)) 871
ERROR CODE [F@BZNR] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”72”) (RIGHT BANK EXHAUST TEMPERATURE (2): ABNORMAL HEATING (NR)) 872
ERROR CODE [F@BZNS] (OR LED OF VHMS CONTROLLER INDICATES “n3″→”71”) (RIGHT BANK EXHAUST TEMPERATURE (1): OVERHEATING (NS)) 873
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 875
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 876
E-1 THE ENGINE DOES NOT START 877
E-2 THE PREHEATER DOES NOT OPERATE (MANUAL PREHEATING FUNCTION) 880
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE 882
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON 883
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT 884
E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH 885
E-7 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES 886
E-8 AN EMERGENCY CAUTION ITEM FLASHES WHILE ENGINE IS RUNNING 889
E-9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON 893
E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON (DUAL TILT-MOUNTED MACHINE) 895
E-11 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON 895
E-12 THE ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 896
E-13 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL 897
E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 898
E-15 INDICATION OF THE FUEL GAUGE IS ABNORMAL 899
E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL 900
E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL 900
E-18 THE SWITCH MODULE CANNOT BE OPERATED 901
E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT 902
E-20 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP 903
E-21 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED 904
E-22 THE AUTOMATIC PITCH BACK SYSTEM DOES NOT OPERATE (ONLY SUPERDOZER SPECIFICATION) 905
E-23 THE ALARM BUZZER CANNOT BE CANCELLED 906
E-24 THE OPERATOR MODE CANNOT BE OPERATED 907
E-25 THE SERVICE MODE CANNOT BE OPERATED 908
E-26 THE BACK-UP ALARM DOES NOT SOUND 910
E-27 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON 911
E-28 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM 916
E-29 ORBCOMM TERMINAL DOES NOT OPERATE NORMALLY (DATA ARE NOT TRANSMITTED) 931
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 933
INFORMATION IN TROUBLESHOOTING TABLE 934
H-1 NO FORCE (NO DRAWBAR PULL) 935
H-2 NO TRAVEL (AT 2ND OR 3RD SPEED) 936
H-3 NO TRAVEL AT ALL GEAR SPEEDS 937
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE 938
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING 939
H-6 STEERING IS NOT POSSIBLE 940
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE 940
H-8 STEERING OVERRUN OCCURS 941
H-9 BRAKE DOES NOT WORK 941
H-10 TORQUE CONVERTER IS NOT LOCK-UP 942
H-11 TORQUE CONVERTER OIL IS OVERHEATED 942
H-12 ALL WORK EQUIPMENT SPEEDS ARE SLOW 943
H-13 WORK EQUIPMENT DOES NOT MOVE 944
H-14 BLADE LIFT SPEED IS SLOW OR LACKS POWER 944
H-15 BLADE TILT SPEED IS SLOW OR LACKS POWER 945
H-16 RIPPER LIFT SPEED IS SLOW OR LACKS POWER 945
H-17 RIPPER TILT SPEED IS SLOW OR LACKS POWER 946
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT 946
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT 947
H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT 947
H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE) 948
H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE) 948
H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP 948
TROUBLESHOOTING OF ENGINE BODY (S MODE) 949
POINTS TO REMEMBER WHEN TROUBLESHOOTING 950
METHOD OF USING TROUBLESHOOTING CHARTS 951
S-1 STARTING PERFORMANCE IS POOR (STARTING ALAWYS TAKES TIME) 954
S-2 ENGING DOES NOT START 955
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 958
S-4 ENGINE STOPS DURING OPERATIONS 959
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 960
S-6 ENGINE LACKS OUTPUT (NO POWER) 961
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 962
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 963
S-9 OIL BECOMES CONTAMINATED QUICKLY 964
S-10 FUEL CONSUMPTION IS EXCESSIVE 965
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 966
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 967
S-13 OIL LEVEL RISES 968
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 969
S-15 ABNORMAL NOISE IS MADE 970
S-16 VIBRATION IS EXCESSIVE 971
30 DISASSEMBLY AND ASSEMBLY 973
METHOD OF USING MANUAL 975
PRECAUTIONS WHEN CARRYING OUT OPERATION 977
SPECIAL TOOL LIST 979
SKETCHES OF SPECIAL TOOLS 988
REMOVAL AND INSTALLATION OF ENGINE OIL COOLER ASSEMBLY 996
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 996
REMOVAL AND INSTALLATION OF AFTER-COOLER CORE ASSEMBLY 998
REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY 1000
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL 1001
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL 1002
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 1004
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY 1008
REMOVAL AND INSTALLATION OF MAIN RADIATOR ASSEMBLY 1009
REMOVAL AND INSTALLATION OF SUB RADIATOR ASSEMBLY 1010
REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY 1012
REMOVAL AND INSTALLATION OF FAN MOTOR PUMP 1015
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY 1016
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY 1019
DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY 1020
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY 1022
REMOVAL AND INSTALLATION OF PTO, TORQUE CONVERTER ASSEMBLY 1025
DISCONNECTION AND CONNECTION OF PTO, TORQUE CONVERTER ASSEMBLY 1027
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY 1029
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY 1037
REMOVAL AND INSTALLATION OF TORQFLOW TRANSMISSION ASSEMBLY 1042
DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY 1043
DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY 1057
DISASSEMBLY AND ASSEMBLY OF STEERING CLUTCH, BRAKE ASSEMBLY 1070
DISASSEMBLY AND ASSEMBLY OF TRANSFER GEAR HOUSING ASSEMBLY 1077
REMOVAL AND INSTALLATION OF POWER TRAIN PUMP ASSEMBLY 1080
REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY 1080
REMOVAL AND INSTALLATION OF TORQUE CONVERTER OIL COOLER 1081
REMOVAL AND INSTALLATION OF TORQUE CONVERTER VALVE ASSEMBLY 1082
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER VALVE ASSEMBLY 1083
REMOVAL AND INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY 1087
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY (ECMV ASSEMBLY) 1088
REMOVAL AND INSTALLATION OF STEERING CONTROL VALVE ASSEMBLY 1091
DISASSEMBLY AND ASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY 1092
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY 1094
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY 1095
REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY 1107
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY 1109
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY 1112
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY 1127
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY 1129
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY 1132
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY 1134
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY 1134
REMOVAL AND INSTALLATION OF BOGIE ASSEMBLY 1137
DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY 1142
REMOVAL AND INSTALLATION OF NO 1 BOGIE ASSEMBLY 1144
EXPANSIO AND INSTALLATION OF TRACK SHOE ASSEMBLY 1153
OVERALL DISASSEMBLY AND OVERALL ASSEMBLY OF TRACK SHOE 1156
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS 1169
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK 1170
DISASSEMBLY AND ASSEMBLY OF MASTER LINK 1174
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY 1178
REMOVAL AND INSTALLATION OF EQUALIZER BAR 1180
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING 1183
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY 1186
REMOVAL AND INSTALLATION OF HYDRAULIC VALVE ASSEMBLY 1187
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE 1188
DISASSEMBLY AND ASSEMBLY OF MERGE DIVIDER VALVE AND SELF PRESSURE REDUCING VALVE ASSEMBLY 1192
REMOVAL AND INSTALLATION OF PPC RELIEF VALVE ASSEMBLY 1194
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1195
DISASSEMBLY AND ASSEMBLY OF RIPPER PIN PULLER CYLINDER ASSEMBLY 1201
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY 1204
DISASSEMBLY AND ASSEMBLY OF GIANT RIPPER ASSEMBLY 1206
REMOVAL AND INSTALLATION OF ROPS GUARD 1209
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY 1210
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY 1211
REMOVAL AND INSTALLATION OF CONTROLLER ASSEMBLY 1214
REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY 1215
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY 1216
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT 1218
REMOVAL AND INSTALLATION OF HOOD ASSEMBLY 1220
REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY 1221
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY 1222
90 OTHERS 1225
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1227
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/3) 1229
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (2/3) 1231
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (3/3) 1233
ELECTRICAL CIRCUIT DIAGRAM (1/8) 1235
ELECTRICAL CIRCUIT DIAGRAM (2/8) 1237
ELECTRICAL CIRCUIT DIAGRAM (3/8) 1239
ELECTRICAL CIRCUIT DIAGRAM (4/8) 1241
ELECTRICAL CIRCUIT DIAGRAM (5/8) 1243
ELECTRICAL CIRCUIT DIAGRAM (6/8) 1245
ELECTRICAL CIRCUIT DIAGRAM (7/8) 1247
ELECTRICAL CIRCUIT DIAGRAM (8/8) 1249
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE CAB 1251

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