Komatsu D275AX-5EO Bulldozer (30001 and up) Service Repair Shop Manual - SEN00919-10

This complete Service Repair Workshop Manual PDF Download for the D275AX-5EO Komatsu Bulldozer (30001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu D275AX-5E0 Bulldozer
Serial Numbers : 30001 and up


TABLE OF CONTENTS :

00 Index and foreword
01 Specification
10 Structure, function and maintenance standard
20 Standard value table
30 Testing and adjusting
40 Troubleshooting
50 Disassembly and assembly
90 Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN00919-10
Total Pages : 1508


This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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COVER

00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

01 Specification
Specification and technical data
Specification and technical data
Specefication dimension drawings
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure, function and maintenance standard
Engine and cooling system
Engine and cooling system
Engine mount
Cooling system
Cooling fan pump
Cooling fan motor
Power train, Part 1
Power train skeleton
HSS system
Overall drawing of power train unit
Power train hydraulic piping drawing
Transmission control
Steering, brake control
Damper, universal joint
Torque converter, PTO
Transmission
Tranmission ECMV
Main relief valve and torque convertor relif valve
Torque converter valve
Lubrication relief valve
Power train system, Part 2
Power train system, Part 2
Bevel gear shaft, HSS, brake
Brake valve
Brake ECMV
Parking brake valve
Sudden brake prevention valve
Final drive
Sprocket
Undercarriage and frame
Track frame
Recoil spring
Idler
Track roller
Track roller bogie
Carrier roller
Track shoe
Main frame
Suspension
Hydraulic system, Part 1
Hydraulic system, Part 1
Work equipment hydraulic piping diagram
PPC control piping diagram
Work equipment control
Hydraulic tank
Scavenging pump
Work equipment pump
Power train pump, steering lubrication pump
HSS pump
HSS motor
PPC, HSS charge filter
Hydraulic system, Part 2
Hydraulic system, Part 2
Control valve
Self pressure reducing valve
Hydraulic system, Part 3
Hydraulic system, Part 3
HSS charge filter bypass
HSS oil cooler bypass valve
PPC valve
PCCS lever
PPC lock valve
Work equipment cylinder
Piston valve
Quick drop valve
Pin puller switch
Pin puller solenoid valve
Blade control knob
Pitch, dual tilt solenoid valve
Accumulator
Work equipment
Cylinder stay
Blade
Ripper
Cab and its attachments
Cab and its attachments
Cab mount
Cab
Air conditioner
Electrical system
Engine control system
CRI engine control system
Monitor system
Machine monitor
Mode selection system
Sensors
Electrical equipment
Palm command control system
KOMTRAX system

20 Standard value table
Standard service value table
Standard value table for engine
Standard value table for machine

30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Testing engine speed
Testing intake air pressure (Boost pressure)
Testing exhaust temperature
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Testing EGR valve and bypass valve drive oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Testing fuel return rate and fuel leakage
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Testing and adjusting alternator belt tension
Handling controller voltage circuit
Testing and adjusting air conditioner compressor belt
Testing fan speed
Testing fan circuit oil pressure
Bleeding air from fan pump
Adjusting fuel control dial and decelerator pedal
Testing and adjusting, Part 2
Testing power train oil pressure
Testing and adjusting HSS oil pressure
Adjusting transmission speed sensor
Bleeding air from HSS pump
Simple method of testing brake performance
Adjusting brake pedal and parking brake lever
Adjusting PCCS lever console position
Emergency escape method when power train has trouble
Adjusting clearance of idler
Inspecting wear of sprocket
Testing and adjusting track shoe tension
Testing and adjusting worke quipment oil pressure
Testing control circuit main pressure
Testing PPC valve output pressure
Adjusting play of PPC valve
Testing outlet pressure of ripper pin puller solenoid valve
Testing parts which cause hydraulic drift of blade and ripper

Testing internal leakage of work equipment cylinder
Releasing residual pressure from work equipment cylinder
Bleeding air from work equipment cylinder
Adjusting ripper lever position
Adjusting work equipment lock lever
Adjusting blade
Testing and adjusting operator’s cab
Testing and adjusting, Part 3
Special functions of machine monitor (EMMS)
Testing and adjusting, Part 4
Adjustment method when controller has been replaced
Method of starting use of KOMTRAX terminal
Indication by KOMTRAX terminal lamps
Preparation work for troubleshooting for electric system
Handling of optional devices
Pm Clinic service

40 Troubleshooting
Failure code table and fuse locations
Failure codes table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Contents of troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure and error codes, Part 1
Failure code [1500L0] Transmission clutch dual engagement
Failure code [15SAL1] Forward clutch oil pressure 1
Failure code [15SALH] Forward clutch oil pressure 2
Failure code [15SBL1] Reverse clutch oil pressure 1
Failure code [15SBLH] Reverse clutch oil pressure 2
Failure code [15SEL1] 1st clutch oil pressure 1
Failure code [15SELH] 1st clutch oil pressure 2
Failure code [15SFL1] 2nd clutch oil pressure 1
Failure code [15SFLH] 2nd clutch oil pressure 2
Failure code [15SGL1] 3rd clutch oil pressure 1
Failure code [15SGLH] 3rd clutch oil pressure 2
Failure code [1800MW] Power train clutch slip
Failure code [2300NR] Brake thermal load
Failure code [2301L1] Right steering brake oil pressure 1
Failure code [2301LH] Right steering brake oil pressure 2
Failure code [2301NR] Right steering brake thermal load
Failure code [2302L1] Left steering brake oil pressure 1
Failure code [2302LH] Left steering brake oil pressure 2
Failure code [2302NR] Left steering brake thermal load
Failure code [6001ZK] Failure code for design
Failure code [A000NS] Engine overheat
Failure code [AA10NX] Air cleaner clogging
Failure code [AB00MA] Battery charge abnormal
Failure code [B@BAZG] Eng oil press low
Failure code [B@BAZK] Eng oil level low
Failure code [B@BCNS] Eng coolant overheat
Failure code [B@BCZK] Radiator coolant level low
Failure code [B@BEBF] Water gets mixed with fuel
Failure code [B@BFZK] Fuel level abnormal reduction
Failure code [B@CENS] Torque converter oil overheat
Failure code [B@CHZG] HSS charge oil pressure reduction
Failure code [B@CHZK] Power train oil oil level reduction
Failure code [B@GAZK] Battery electrolyte level reduction
Failure code [B@HANS] Hyd oil overheat
Failure code [B@HAZK] Hydraulic oil level reduction
Troubleshooting by failure and error codes, Part 2
Failure code [CA111] EMC critical internal failure
Failure code [CA115] Eng Ne and Bkup speed sens error
Failure code [CA122] Chg air press sensor high error
Failure code [CA123] Chg air press sensor low error
Failure code [CA131] Throttle sensor high error
Failure code [CA132] Throttle sensor low error
Failure code [CA135] Eng oil press sensor high error
Failure code [CA141] Eng oil press sensor low error
Failure code [CA144] Coolant temp sens high error
Failure code [CA145] Coolant temp sens low error
Failure code [CA153] Chg air temp sensor high error
Failure code [CA154] Chg air temp sensor low error
Failure code [CA187] Sens supply 2 volt low error
Failure code [CA221] Ambient press sens high error
Failure code [CA222] Ambient press sens low error
Failure code [CA227] Sens supply 2 volt high error
Failure code [CA234] Eng overspeed
Failure code [CA238] Ne speed sens supply volt error
Failure code [CA263] Fuel temp sensor high error
Failure code [CA265] Fuel temp sensor low error
Failure code [CA271] PCV1 short error
Failure code [CA272] PCV1 open error
Failure code [CA273] PCV2 short error
Failure code [CA274] PCV2 open error
Failure code [CA322] Inj #1 (L#1) open/short error
Failure code [CA323] Inj #5 (L#5) open/short error
Failure code [CA324] Inj #3 (L#3) open/short error
Failure code [CA325] Inj #6 (L#6) open/short error
Failure code [CA331] Inj #2 (L#2) open/short error
Failure code [CA332] Inj #4 (L#4) open/short error
Failure code [CA342] Calibration code incompatibility
Failure code [CA351] Injectors drive circuit error
Failure code [CA352] Sens supply 1 volt low error
Failure code [CA386] Sens supply 1 volt high error
Failure code [CA441] Battery voltage low error
Failure code [CA442] Battery voltage high error
Failure code [CA449] Rail press very high error
Failure code [CA451] Rail press sensor high error
Failure code [CA452] Rail press sensor low error
Failure code [CA553] Rail press high error
Failure code [CA554] Rail press sensor in range error
Failure code [CA559] Rail press low error
Failure code [CA689] Eng Ne speed sensor error
Troubleshooting by failure and error codes, Part 3
Failure code [CA731] Eng Bkup speed sens phase error
Failure code [CA757] All continuous data lost error
Failure code [CA778] Eng Bkup speed sensor error
Failure code [CA1228] EGR valve servo error 1
Failure code [CA1625] EGR valve servo error 2
Failure code [CA1626] BP valve sol current high error
Failure code [CA1627] BP valve sol current low error
Failure code [CA1628] Bypass valve servo error 1
Failure code [CA1629] Bypass valve servo error 2
Failure code [CA1631] BP valve pos sens high error
Failure code [CA1632] BP valve pos sens low error
Failure code [CA1633] KOMNET error
Failure code [CA1642] EGR inlet press sens low error
Failure code [CA1653] EGR inlet press sens high error
Failure code [CA2185] Throt sens sup volt high error
Failure code [CA2186] Throt sens sup volt low error
Failure code [CA2249] Rail press very low error
Failure code [CA2271] EGR valve pos sens high error
Failure code [CA2272] EGR valve pos sens low error
Failure code [CA2351] EGR valve sol current high error
Failure code [CA2352] EGR valve sol current low error
Failure code [CA2555] Grid htr relay volt low error
Failure code [CA2556] Grid htr relay volt high error
Failure code [D110KA] Battery relay holding disconnection
Failure code [D110KB] Battery relay drive short circuit
Failure code [D130KA] Neutral safety relay disconnection
Failure code [D130KB] Neutral safety relay short circuit
Failure code [D161KA] Back-up alarm relay disconnection
Failure code [D161KB] Back-up alarm relay short circuit
Failure code [D190KA] Engine controller ACC signal cut relay
Failure code [D190KB] Engine controller ACC signal cut relay short
Failure code [D811KR] KOMTRAX controller CAN defective communication
Failure code [DAFRKR] Machine monitor CAN communication defective communication
Troubleshooting by failure and error codes, Part 4
Failure code [DAQ0KT] Transmission controller internal abnormality
Failure code [DAQ1KK] Transmission controller main source voltage reduction
Failure code [DAQ2KK] Transmission controller load voltage reduction
Failure code [DAQ5KK] Transmission controller sensor 5 V power source (1) power supply source voltage reduction
Failure code [DAQ6KK] Transmission controller sensor 24 V power supply source voltage reduction
Failure code [DAQ7KK] Transmission controller sensor 5 V power supply source (2) power source voltage reduction
Failure code [DAQ9KQ] Transmission controller type collation (Type select signal inconsistency)
Failure code [DAQRKR] Transmission controller CAN defective communication (Abnormality in objective component system)
Failure code [DAQSKR] Transmission controller S-NET defective communication (Abnormality in objective component system)
Failure code [DB2RKR] Engine controller CAN defective communication
Failure code [DB30KT] Steering controller abnormality in controller
Failure code [DB31KK] Steering controller main power supply source voltage reduction
Failure code [DB32KK] Load power source of steering controller power source voltage drop
Failure code [DB35KK] Steering controller sensor 5 V power source (1) power source voltage drop
Failure code [DB36KK] Steering controller sensor 24 V power supply source voltage reduction
Failure code [DB37KK] Steering controller sensor 5 V power source (2) power source voltage drop
Failure code [DB39KQ] Steering controller type collation (Type select signal inconsistency)
Failure code [DB3RKR] Steering controller CAN defective communication (Abnormality in objective component system)
Failure code [DB3SKR] Steering controller S-NET defective communication (Abnormality in objective component system)
Failure code [DD12KA] Shift up switch disconnection
Failure code [DD12KB] Shift up switch short circuit
Failure code [DD13KA] Shift down switch disconnection
Failure code [DD13KB] Shift down switch short circuit
Failure code [DD14KA] Parking brake lever switch disconnection
Failure code [DD14KB] Parking brake lever switch short circuit
Failure code [DDB9L4] Reverse switch disagreement
Failure code [DDK3L4] Forward switch disagreement
Failure code [DDK5KA] Gearshift switch disconnection
Failure code [DDK5KB] Gearshift switch short circuit
Failure code [DDN7KA] Blade pitch switch disconnection
Failure code [DDN7KB] Blade pitch switch short circuit
Failure code [DDN9KA] Blade tilt switch disconnection
Failure code [DDN9KB] Blade tilt switch short circuit
Failure code [DDNBLD] Ripper lift raise oil pressure switch is kept ON for long time
Failure code [DDNCLD] Ripper lift lower oil pressure switch is kept ON for long time
Failure code [DDNDLD] Ripper lift tilt-in oil pressure switch is kept ON for long time
Failure code [DDQ2KA] Parking brake lever switch disconnection
Failure code [DDQ2KB] Parking brake lever switch short circuit
Failure code [DDQ2L4] Parking brake lever switch disagreement
Failure code [DDT5KA] Neutral switch disconnection
Failure code [DDT5KB] Neutral switch short circuit
Failure code [DDT5KQ] Lever specification selection (Model selection signal disagreement)
Failure code [DGS1KX] Hydraulic oil temperature sensor input signal is out of normal range
Troubleshooting by failure and error codes, Part 5
Failure code [DGT1KA] Power train oil temp sensor disconnection
Failure code [DGT1KX] Power train oil temp sensor out of input signal range
Failure code [DH21KB] Work equipment pump oil pressure sensor short circuit
Failure code [DH22KA] Work equipment pump oil pressure sensor disconnection
Failure code [DH22KB] Work equipment pump oil pressure sensor short circuit
Failure code [DHH3KA] HSS pump oil pressure sensor A disconnection
Failure code [DHH3KB] HSS pump oil pressure sensor A short circuit
Failure code [DHH4KA] HSS pump oil pressure sensor B disconnection
Failure code [DHH4KB] HSS pump oil pressure sensor B short circuit
Failure code [DK10KA] Fuel control dial disconnection
Failure code [DK10KB] Fuel control dial short circuit
Failure code [DK30KA] Steering potentiometer (1) disconnection
Failure code [DK30KB] Steering potentiometer (1) short circuit
Failure code [DK30KX] Steering potentiometer (1) out of input signal range
Failure code [DK30KZ] Steering potentiometer (1) disconnection or short circuit
Failure code [DK30L8] Steering potentiometer (1) analog signals do not agree
Failure code [DK31KA] Steering potentiometer (2) disconnection
Failure code [DK31KB] Steering potentiometer (2) short circuit
Failure code [DK40KA] Brake potentiometer disconnection
Failure code [DK40KB] Brake potentiometer short circuit
Failure code [DK55KX] Directional potentiometer out of input signal range
Failure code [DK55KZ] Directional potentiometer disconnection or short circuit
Failure code [DK55L8] Directional potentiometer analog signals do not agree
Failure code [DK56KA] F-R potentiometer (1) disconnection
Failure code [DK56KB] F-R potentiometer (1) short circuit
Failure code [DK57KA] F-R potentiometer (2) disconnection
Failure code [DK57KB] F-R potentiometer (2) short circuit
Failure code [DK60KA] Acceleration sensor disconnection
Failure code [DK60KB] Acceleration sensor short circuit
Failure code [DKH1KA] Pitch angle sensor disconnection
Failure code [DKH1KB] Pitch angle sensor short circuit
Failure code [DKH1KX] Pitch angle sensor out of input signal range
Failure code [DLT3KA] Transmission out-speed sensor disconnection
Failure code [DLT3KB] Transmission out-speed sensor abnormal
Failure code [DV00KB] Caution buzzer short circuit
Failure code [DW59KA] Blade dual selector solenoid disconnection
Failure code [DW59KB] Blade dual selector solenoid short circuit
Failure code [DW59KY] Blade dual selector solenoid hot short
Failure code [DW5AKA] Blade pitch selector solenoid disconnection
Failure code [DW5AKB] Blade pitch selector solenoid short circuit
Failure code [DW5AKY] Blade pitch selection solenoid hot short circuit
Troubleshooting by failure and error codes, Part 6
Failure code [DW7BKA] Fan rev EPC disconnection
Failure code [DW7BKB] Fan rev EPC short circuit
Failure code [DW7BKY] Fan reverse solenoid hot short circuit
Failure code [DWN1KA] HSS pump solenoid right disconnection
Failure code [DWN1KB] HSS pump solenoid right short circuit
Failure code [DWN1KY] HSS pump solenoid right hot short
Failure code [DWN2KA] HSS pump solenoid left disconnection
Failure code [DWN2KB] HSS pump solenoid left short circuit
Failure code [DWN2KY] HSS pump solenoid left short circuit
Failure code [DWN3KA] Sudden stop prevention solenoid disconnection
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit
Failure code [DWN3KY] Sudden stop prevention solenoid hot short circuit
Failure code [DWN4KA] HSS motor free solenoid disconnection
Failure code [DWN4KB] HSS motor free solenoid short circuit
Failure code [DWN5KA] Fan pump solenoid disconnection
Failure code [DWN5KB] Fan pump solenoid short circuit
Failure code [DWN5KY] Fan pump solenoid hot short circuit
Failure code [DXH1KA] Lock-up solenoid disconnection
Failure code [DXH1KB] Lock-up solenoid short circuit
Failure code [DXH1KY] Lock-up solenoid hot short
Failure code [DXH4KA] 1st clutch ECMV disconnection
Failure code [DXH4KB] 1st clutch ECMV short circuit
Failure code [DXH4KY] 1st clutch ECMV hot short circuit
Failure code [DXH5KA] 2nd clutch ECMV disconnection
Failure code [DXH5KB] 2nd clutch ECMV short circuit
Failure code [DXH5KY] 2nd clutch ECMV hot short circuit
Failure code [DXH6KA] 3rd clutch ECMV disconnection
Failure code [DXH6KB] 3rd clutch ECMV short circuit
Failure code [DXH6KY] 3rd clutch ECMV hot short circuit
Failure code [DXH7KA] Reverse clutch ECMV disconnection
Failure code [DXH7KB] Reverse clutch ECMV short circuit
Failure code [DXH7KY] R clutch ECMV hot short circuit
Failure code [DXH8KA] Forward clutch ECMV disconnection
Failure code [DXH8KB] Forward clutch ECMV short circuit
Failure code [DXH8KY] F clutch ECMV hot short circuit
Failure code [DXHBKA] Right brake ECMV disconnection
Failure code [DXHBKB] Right brake ECMV short circuit
Failure code [DXHBKY] Right brake ECMV hot short circuit
Failure code [DXHCKA] Left brake ECMV disconnection
Failure code [DXHCKB] Left brake ECMV short circuit
Failure code [DXHCKY] Left brake ECMV hot short circuit
Troubleshooting of electrical system (E-mode)
Information in troubleshooting table
E-1 The engine does not start
E-2 The preheater does not operate (Manual preheating function)
E-3 The ripper pin puller cylinder does not operate
E-4 The machine monitor does not come on at all when the starting switch is turned ON
E-5 When the starting switch is turned ON, the machine monitor completely remains lighted and does not go out
E-6 When the starting switch is turned ON, the basic check items flash
E-7 While the engine is operating, any caution item flashes
E-8 While the engine is operating, the emergency warning item flashes
E-9 While the preheater is operating, the preheating pilot lamp does not come on
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on
E-12 The engine coolant temperature gauge does not indicate normally
E-13 Indication of the power train (torque converter) temperature gauge is abnormal
E-14 The hydraulic oil temperature gauge does not indicate normally
E-15 Indication of the fuel gauge is abnormal
E-16 Indications of gear speed and engine speed are abnormal
E-17 Indication of the shift mode service meter is abnormal
E-18 The switch module cannot be operated
E-19 The warning lamp does not flash or does not go out
E-20 The alarm buzzer does not sound or does not stop
E-21 Auto shift down is not possible or is not released
E-22 Pivot turn is not possible or is not released
E-23 The alarm buzzer cannot be cancelled
E-24 The operator mode cannot be operated
E-25 The service mode cannot be operated
E-26 The back-up alarm does not sound
E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on
E-28 The air conditioner does not operate
E-29 KOMTRAX system does not operate normally
E-30 Fan does not reverse
E-31 Gear cannot be shifted
Troubleshooting of hydraulic and mechanical system (H-mode)
Information in troubleshooting table
H-1 No travel power (No drawbar pull)
H-2 Machine does not move (At 2nd or 3rd speed)
H-3 Machine does not move in any speed range
H-4 Machine travels only in one direction forward or in reverse
H-5 When gear is shifted or travel direction is changed, large time lag is made
H-6 Machine does not turn (Not turned rightward or leftward)
H-7 Steering speed or power is low
H-8 Brake does not work
H-9 Torque converter does not lock-up
H-10 Overheat of power train oil temperature
H-11 Abnormal sound around HSS pump or HSS motor
H-12 All work equipment speeds are slow
H-13 Work equipment does not move
H-14 Blade lift speed is slow or lacks power
H-15 Blade tilt speed is slow or lacks power
H-16 Ripper lift speed is slow or lacks power
H-17 Ripper tilt speed is slow or lacks power
H-18 Excessive hydraulic drift of blade lift
H-19 Excessive hydraulic drift of blade tilt
H-20 Excessive hydraulic drift of ripper lift
H-21 Ripper pin puller cylinder does not work (Giant ripper attachment machine)
H-22 Blade pitch does not work (Dual tilt attachment machine)
H-23 Abnormal sound comes out from around work equipment pump
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats).
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance of engine is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operation
S-5 Engine does not rotate smoothly
S-6 Engine lack output (or lacks power)
S-7 Exhaust gas is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust gas is blue)
S-9 Oil becomes dirty quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (Overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive

50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketchs of special tools
Engine and cooling system
Removal and installation of engine assembly
Removal and installation of radiator assembly (including hydraulic oil cooler assembly and aftercooler assembly)
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of radiator guard assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Removal and installation of fan drive assembly
Removal and installation of fan motor assembly
Engine
Removal and installation of fuel supply pump assembly
Removal and installation of common rail
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Power train, Part 1
Removal and installation of damper assembly
Disassembly and assembly of damper assembly
Removal and installation of power train unit assembly
Disconnection and connection of power train unit assembly
Disassembly and assembly of PTO assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of torqflow transmission assembly
Power train, Part 2
Removal and installation of scavenging pump
Disassembly and assembly of HSS case assembly
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame, Part 1
Removal and installation of track frame assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of idler assembly
Disassembly and assembly of idler assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of 1st bogie assembly
Removal and installation of 2nd, 3rd and 4th bogie assembly
Disassembly and assembly of bogie assembly
Undercarriage and frame, Part 2
Expanding and installing track shoe assembly
Whole disassembly and whole assembly of track shoe assembly
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar assembly
Disassembly and assembly of equalizer bar bushing
Hydraulic system
Removal and installation of HSS pump assembly
Removal and installation of work equipment and HSS charge pump assembly
Removal and installation of power train and lubricating oil pump assembly
Removal and installation of HSS motor assembly
Removal and installation of fan pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of work equipment control valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of blade assembly
Disassembly and assembly of ripper assembly
Cab and its attachments
Removal and installation of ROPS guard
Removal and installation of operator’s cab assembly
Removal and installation of operator’s cab glass (Stuck glass)
Removal and installation of floor frame assembly
Electrical system
Removal and installation of transmission controller assembly
Removal and installation of steering controller assembly
Removal and installation of engine controller assembly
Removal and installation of air conditioner unit assembly
Removal and installation of monitor panel assembly

90 Diagrams and drawings
Hydraulic circuit diagram
Hydraulic circuit diagram
Hydraulic circuit diagram
Power train hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram (1/13)
Electrical circuit diagram (2/13)
Electrical circuit diagram (3/13)
Electrical circuit diagram (4/13)
Electrical circuit diagram (5/13)
Electrical circuit diagram (6/13)
Electrical circuit diagram (7/13)
Electrical circuit diagram (8/13)
Electrical circuit diagram (9/13)
Electrical circuit diagram (10/13)
Electrical circuit diagram (11/13)
Electrical circuit diagram (12/13)
Electrical circuit diagram (13/13)
Electrical circuit diagram for inside cab
Air conditioner unit electrical circuit diagram
Connectors table and arrangement drawing

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