Komatsu D475A-3 Bulldozer (10695 and up) Service Repair Shop Manual - SEBM027501

This complete service repair workshop manual PDF download for the D475A-3 Komatsu Bulldozer (SN: 10695 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 :

Machine Model : D475A-3
Serial Numbers : 10695 and up
Engine : SDA12V140E-1


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM027501
Total Pages : 769


Komatsu D475A-3 mounts the SDA12V140E-1 engine.
For details of the engine, see the 12V140-1 Series Engine Shop Manual.

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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SAFETY
FOREWORD
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
UNITS

01 GENERAL
SPECIFICATION DIMENSION DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANTS

10 STRUCTURE AND FUNCTION
ENGINE, POWER TRAIN COOLING SYSTEM DRAWING
POWER TRAIN
POWER TRAIN SKELETON
POWER TRAIN HYDRAULIC PIPING DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
TORQUE CONVERTER AND PTO
TORQUE CONVERTER VALVE
TRANSMISSION
TRANSMISSION CONTROL
TRANSMISSION ECMV
TRANSMISSION CLUTCH ECMV
TRANSMISSION LUBRICATION RELIEF VALVE
PRIORITY VALVE
STEERING, BRAKE CONTROL
TRANSFER, BEVEL GEAR SHAFT, STEERING
TRANSFER, BEVEL PINION
STEERING ECMV
STEERING CLUTCH, STEERING BRAKE ECMV
SUDDEN STOP PREVENTION VALVE
FINAL DRIVE
TRACK FRAME
HYDRAULIC TANK
PPC VALVE
MAIN CONTROL VALVE
PIN-PULLER HYDRAULIC SYSTEM DRAWING
PIN-PULLER HYDRAULIC CIRCUIT DRAWING
PIN-PULLER SOLENOID VALVE
AIR CONDITIONER
ENGINE CONTROL
ENGINE CONTROL SYSTEM
DECELERATION POTENTIOMETER
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER
MONITOR SYSTEM
MONITOR PANEL
MODE SELECTOR SYSTEM
ELECTRICAL EQUIPMENT
STEERING ELECTRONIC CONTROL

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
MEASURING POWER TRAIN OIL PRESSURE
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
TESTING AND ADJUSTING TRACK SHOE TENSION
MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE
MEASURING PPC VALVE AND PITCH, TILT CONTROL VALVE OUTPUT PRESSURE
ADJUSTING PPC VALVE
MEASURING OUTPUT PRESSURE OF DEMAND SOLENOID VALVE
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
BLEEDING AIR FROM HYDRAULIC CYLINDERS
ADJUSTING WORK EQUIPMENT SAFETY LEVER
ADJUSTING RIPPER LEVER POSITION
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE (DUAL TILT DOZER SPECIFICATION)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
ADJUSTMENT METHOD OF REPLACED CONTROLLER
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM
HANDLING OF OPTIONAL DEVICES
PM CLINIC SERVICE
POWER TRAIN OIL PRESSURE AND OTHERS
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
TABLE OF CONNECTORS
CONNECTOR ARRANGEMENT DRAWING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
TROUBLE CODE TABLE
ERROR CODE [1500LO] (TRANSMISSION CLUTCH: SEE THE LIST. (L0))
ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST. (L1))
ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST. (LH))
ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST. (L1))
ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST. (LH))
ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST. (L1))
ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST. (LH))
ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST. (L1))
ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST. (LH))
ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST. (L1))
ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST. (LH))
ERROR CODE [1800MW] (POWER TRAIN CLUTCH: SLIP (MW))
ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST. (L1))
ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST. (LH))
ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST. (L1))
ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST. (LH))
ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST. (L1))
ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST. (LH))
ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST. (L1))
ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST. (LH))
ERROR CODE [A70XLK] (GOVERNOR SERVO SYSTEM RIGHT: * REFER TO TABLE (LK))
ERROR CODE [A70YLK] (GOVERNOR SERVO SYSTEM LEFT: * REFER TO TABLE (LK))
ERROR CODE [AA1ANX] (AIR CLEANER:CLOGGING (NX))
ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA))
ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))
ERROR CODE [B@BAZK] (ENGINE OIL: LEVEL REDUCTION (ZK))
ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))
ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK))
ERROR CODE [B@CENS] (POWER TRAIN OIL: OVERHEAT (NS))
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))
ERROR CODE [B@HAZK] (HYDRAULIC OIL: LEVEL REDUCTION (ZK))
ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA))
ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB))
ERROR CODE [D130KA] (NEUTRAL RELAY: DISCONNECTION (KA))
ERROR CODE [D130KB] (NEUTRAL RELAY: SHORT CIRCUIT (KB))
ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA))
ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
ERROR CODE [D1D0KA] (GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION (KA))
ERROR CODE [D1D0KB] (GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT (KB))
ERROR CODE [D1D1KA] (GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION (KA))
ERROR CODE [D1D1KB] (GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT (KB))
ERROR CODE [D52FKA] (NEUTRAL SIGNAL 1: DISCONNECTION (KA))
ERROR CODE [D5ZFKB] (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB))
ERROR CODE [D5ZFL4] (ENGINE CONTROLLER NEUTRAL SIGNAL: ON AND OFF SIGNALS DO NOT AGREE (L4))
ERROR CODE [D5ZGKA] (NEUTRAL SIGNAL 2: DISCONNECTION (KA))
ERROR CODE [D5ZGKB] (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB))
ERROR CODE [D5ZKKX] (CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL RANGE (KX))
ERROR CODE [DAFRKR] (MONITOR PANEL “CAN” COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE DAQ0KT (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT))
ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT))
ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE [DB3SKR] (STEERING CONTROLLER S-NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE [DB40KK] (ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK))
ERROR CODE [DB41KK] (SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK))
ERROR CODE [DB42KK] (SOLENOID POWER SUPPLY 1: LOWERING OF SOURCE VOLTAGE (KK))
ERROR CODE [DB43KK] (BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK))
ERROR CODE [DB44KK] (SOLENOID POWER SUPPLY 2: LOWERING OF SOURCE VOLTAGE (KK))
ERROR CODE [DB45KP] (RACK SENSOR POWER SUPPLY: LOWERING OF OUTPUT VOLTAGE (KP))
ERROR CODE [DB49KM] (WRONG CONNECTION OF CONNECTOR: MISTAKE IN OPERATION OR SETTING (KM))
ERROR CODE [DB49KQ] (ENGINE CONTROLLER SPECIFICATION: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ))
ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA))
ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DDB9KA] (REVERSE SWITCH: DISCONNECTION (KA))
ERROR CODE [DDB9KB] (REVERSE SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DDK3KA] (FORWARD SWITCH: DISCONNECTION (KA))
ERROR CODE [DDK3KB] (FORWARD SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DDK5KA] (SHIFT SWITCH: DISCONNECTION (KA))
ERROR CODE [DDK5KB] (SHIFT SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DDN2LD] (SEE TABLE (LD) BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM)
ERROR CODE [DDN3LD] (SEE TABLE (LD) BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM)
ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA))
ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA))
ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DDNALD] (BLADE LIFT UP FULL PRESSURE SWITCH: REFER TO TABLE (LD)
ERROR CODE [DDNBLD] (RIPPER LIFT UP PRESSURE SWITCH: REFER TO TABLE (LD)
ERROR CODE [DDNCLD] (RIPPER LOWER PRESSURE SWITCH: REFER TO TABLE (LD)
ERROR CODE [DDNDLD] (RIPPER TILT IN PRESSURE SWITCH: REFER TO TABLE (LD))
ERROR CODE [DDNELD] (RIPPER TILT BACK PRESSURE SWITCH: REFER TO TABLE (LD))
ERROR CODE [DDNFLD] (BLADE LOWER FULL PRESSURE SWITCH: REFER TO TABLE (LD))
ERROR CODE [DDQ2KA] (PARKING BRAKE LEVER SWITCH: DISCONNECTION (KA))
ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4))
ERROR CODE [DDT5KA] (NEUTRAL SWITCH: DISCONNECTION (KA))
ERROR CODE [DDT5KB] (NEUTRAL SWITCH: SHORT CIRCUIT (KB))
ERROR CODE [DDT5KQ] (PCCS LEVER SPECIFICATION SIGNAL INCONSISTENCY (KQ))
ERROR CODE [DGE2KX] (COOLANT TEMPERATURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX))
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DH22KA] (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA))
ERROR CODE [DH22KB] (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE [DH23KA] (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA))
ERROR CODE [DH23KB] (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE [DK01KA] (LEFT YOKE ANGLE SENSOR: DISCONNECTION (KA))
ERROR CODE [DK01KB] (LEFT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE [DK03KA] (RIGHT YOKE ANGLE SENSOR: DISCONNECTION (KA))
ERROR CODE [DK03KB] (RIGHT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE [DK10KX] (FUEL DIAL: OUT OF INPUT SIGNAL RANGE (KX))
ERROR CODE [DK11KA] (DECELERATION POTENTIOMETER: DISCONNECTION (KA))
ERROR CODE [DK11KB] (DECELERATION POTENTIOMETER: SHORT CIRCUIT (KB))
ERROR CODE [DK12KX] (DECELERATOR POTENTIOMETER: OUT OF INPUT SIGNAL RANGE (KX))
ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA))
ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))
ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ))
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8))
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA))
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB))
ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA))
ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ))
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA))
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB))
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA))
ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB))
ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA))
ERROR CODE [DK60KB] (ACCELERATION SENSOR: SHORT CIRCUIT (KB))
ERROR CODE [DKF1KX] (RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE (KX))
ERROR CODE [DKF2KX] (RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE (KX))
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA))
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE [DLE1KA] (ENGINE NE SPEED SENSOR: DISCONNECTION (KA))
ERROR CODE [DLE4LC] (ENGINE SPEED SENSOR A: * REFER TO TABLE (LC))
ERROR CODE [DLE5LC] (ENGINE SPEED SENSOR B: * REFER TO TABLE (LC))
ERROR CODE [DLF1KA] (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION (KA))
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB))
ERROR CODE [DW55KA] (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA))
ERROR CODE [DW55KB] (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DW56KA] (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA))
ERROR CODE [DW56KB] (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DW57KA] (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA))
ERROR CODE [DW57KB] (LEFT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DW58KA] (RIGHT TILT LIMIT SOLENOID: DISCONNECTION (KA))
ERROR CODE [DW58KB] (RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA))
ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DW5JKA] (BLADE PITCH SOLENOID: DISCONNECTION (KA))
ERROR CODE [DW5JKB] (BLADE PITCH SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DW5LKA] (BLADE PITCH DUMP ASSIST SOLENOID: DISCONNECTION (KA))
ERROR CODE [DW5LKB] (BLADE PITCH DUMP ASSIST SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DW98KA] (UNLOAD SOLENOID: DISCONNECTION (KA))
ERROR CODE [DW98KB] (UNLOAD SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA))
ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DXH1KA] (LOCK-UP SOLENOID: DISCONNECTION (KA))
ERROR CODE [DXH1KB] (LOCK-UP SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXH9KA] (RIGHT STEERING CLUTCH ECMV : DISCONNECTION (KA))
ERROR CODE [DXH9KB] (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXHAKA] (LEFT STEERING CLUTCH ECMV : DISCONNECTION (KA))
ERROR CODE [DXHAKB] (LEFT STEERING CLUTCH ECMV : SHORT CIRCUIT (KB))
ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA))
ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA))
ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))
ERROR CODE [DXHDKA] (GOVERNOR SOLNOID RIGHT: DISCONNECTION (KA))
ERROR CODE [DXHDKB] (GOVERNOR SOLNOID RIGHT: SHORT CIRCUIT (KB))
ERROR CODE [DXHEKA] (GOVERNOR SOLNOID LEFT: DISCONNECTION (KA))
ERROR CODE [DXHEKB] (GOVERNOR SOLNOID LEFT: SHORT CIRCUIT (KB))
ERROR CODE [DXHFKA] (PRE-STROKE SOLENOID RIGHT: DISCONNECTION (KA))
ERROR CODE [DXHFKB] (PRE-STROKE SOLENOID RIGHT: SHORT CIRCUIT (KB))
ERROR CODE [DXHGKA] (PRE-STROKE SOLENOID LEFT: DISCONNECTION (KA))
ERROR CODE [DXHGKB] (PRE-STROKE SOLENOID LEFT: SHORT CIRCUIT (KB))
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
E-1 THE ENGINE DOES NOT START
E-2 THE PREHEATER DOES NOT OPERATE
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT
E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH
E-7 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH
E-8 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH
E-9 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES
E-10 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES
E-11 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON
E-12 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON
E-13 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON
E-14 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY
E-15 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL
E-16 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY
E-17 INDICATION OF THE FUEL GAUGE IS ABNORMAL
E-18 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL
E-19 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL
E-20 THE SWITCH MODULE CANNOT BE OPERATED
E-21 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT
E-22 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP
E-23 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED
E-24 THE ALARM BUZZER CANNOT BE CANCELLED
E-25 THE OPERATOR MODE CANNOT BE OPERATED
E-26 THE SERVICE MODE CANNOT BE OPERATED
E-27 THE BACK-UP ALARM DOES NOT SOUND
E-28 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON
E-29 THE AIR CONDITIONER DOES NOT OPERATE
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
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 STEERING IS NOT POSSIBLE
H-7 STEERING IS POSSIBLY ONLY ON ONE SIDE
H-8 STEERING OVERRUN OCCURS
H-9 BRAKE DOES NOT WORK
H-10 TORQUE CONVERTER DOES NOT LOCK-UP
H-11 OVERHEAT OF POWER TRAIN OIL TEMPERATURE
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE
H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER
H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO 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

30 DISASSEMBLY AND ASSEMBLY
POWER TRAIN UNIT ASSEMBLY
REMOVAL AND INSTALLATION
PTO, TORQUE CONVERTER ASSEMBLY
REMOVAL AND INSTALLATION
TORQFLOW TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
STEERING CASE ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION CONTROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION
STEERING CONTROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION
FLOOR FRAME ASSEMBLY
REMOVAL AND INSTALLATION
DASHBOARD ASSEMBLY
REMOVAL AND INSTALLATION
CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION
AIR CONDITIONER UNIT ASSEMBLY
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
ENGINE MOUNT
DAMPER, UNIVERSAL JOINT
TORQUE CONVERTER
TORQUE CONVERTER VALVE
TORQFLOW TRANSMISSION
POWER TRAIN, HYDRAULIC, LUBRICATION PUMP
TRANSFER, BEVEL PINION
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
PARKING BRAKE VALVE
FINAL DRIVE
MAIN FRAME
TRACK FRAME
RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
EQUALIZER BAR
PIVOT SHAFT
HYDRAULIC PUMP
WORK EQUIPMENT CONTROL PUMP
MAIN CONTROL VALVE
PPC VALVE
WORK EQUIPMENT CYLINDER
CYLINDER STAY
BLADE
RIPPER EQUIPMENT

90 OTHERS
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
SINGLE TILT SPECIFICATION
DUAL TILT SPECIFICATION
SUPER DOZER SPECIFICATION
ELECTRICAL CIRCUIT DIAGRAM
SINGLE TILT AND DUAL TILT SPECIFICATIONS
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/4)
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/4)
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/4)
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (4/4)
SUPER DOZER SPECIFICATION
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/3)
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/3)
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (3/3)
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB

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