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KOMATSU D475A-8R BULLDOZER SHOP MANUAL SEN06892-04 – PDF DOWNLOAD
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KOMATSU D475A-8R BULLDOZER SHOP MANUAL SEN06892-04 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D475A-8R BULLDOZER SHOP MANUAL SEN06892-04 – PDF DOWNLOAD
Language : English
Pages : 4844
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D475A-8R BULLDOZER SHOP MANUAL SEN06892-04 – PDF DOWNLOAD
Cover............................................................................................................................... 1 00 Index and Foreword.............................................................................................................. 3 Index.......................................................................................................................... 4 Abbreviation List.............................................................................................................. 24 Foreword, Safety, Basic Information............................................................................................ 27 How to Read the Shop Manual................................................................................................ 27 Safety Notice for Operation................................................................................................ 29 Precautions to Prevent Fire................................................................................................ 37 Procedures If Fire Occurs.................................................................................................. 39 Precautions When You Discard Waste Materials............................................................................... 40 Precautions When You Handle Hydraulic Equipment............................................................................ 41 Precautions When You Disconnect and Connect Pipings........................................................................ 44 Precautions When You Handle Electrical Equipment........................................................................... 50 Precautions When You Handle Fuel System Equipment.......................................................................... 52 Precautions When You Handle Intake System Equipment........................................................................ 53 Practical Use of KOMTRAX................................................................................................... 54 Disconnect and Connect Push-Pull Type Coupler.............................................................................. 55 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................ 55 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................ 56 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................ 57 Precautions for Disconnection and Connection of Connectors................................................................. 59 Disconnect and Connect Deutsch Connector................................................................................... 63 How to Disconnect and Connect Slide Lock Type Connector.................................................................... 64 Disconnect and Connect Connector with Lock to Pull......................................................................... 66 Disconnect and Connect Connector with Lock to Push......................................................................... 67 Disconnect and Connect Connector with Housing to Rotate.................................................................... 69 How to Read the Codes for Electric Cable................................................................................... 70 Explanation of Terms for Maintenance Standard.............................................................................. 74 Standard Tightening Torque Table........................................................................................... 77 Conversion Table........................................................................................................... 84 01 Specification................................................................................................................... 89 Table of Contents.............................................................................................................. 90 Specifications................................................................................................................. 91 Specification Drawing...................................................................................................... 91 Specification Drawing: D475A-8R........................................................................................ 91 Specifications............................................................................................................. 93 Specifications: D475A-8R............................................................................................... 93 Weight Table............................................................................................................... 103 Weight Table: D475A-8R................................................................................................. 103 Fuel, Coolant, Lubricant................................................................................................... 106 How to Use Fuel, Coolant and Lubricants by Ambient Temperature......................................................... 106 10 Structure and Function.......................................................................................................... 109 Table of Contents.............................................................................................................. 110 Boot-up System................................................................................................................. 114 Layout Drawing of Boot-up System........................................................................................... 114 System Operating Lamp System............................................................................................... 115 System Diagram of System Operating Lamp System......................................................................... 115 Function of Operation Lamp System...................................................................................... 115 Operation of System Operating Lamp..................................................................................... 115 Battery Isolator........................................................................................................... 116 Layout Drawing of Battery Isolator..................................................................................... 116 Function of Battery Isolator........................................................................................... 116 Operation of Battery Isolator Switch................................................................................... 116 Engine System.................................................................................................................. 118 Layout Drawing of Engine System............................................................................................ 118 Engine Control System...................................................................................................... 120 Layout Drawing of Engine Control System................................................................................ 120 System Diagram of Engine Control....................................................................................... 121 Function of Engine Control System...................................................................................... 121 Operation of Engine Control System..................................................................................... 122 Automatic Idle Stop System................................................................................................. 123 System Diagram of Automatic Idle Stop System........................................................................... 123 Function of Automatic Idle Stop System................................................................................. 123 Operation of Automatic Idle Stop System................................................................................ 123 Component Parts of Engine System........................................................................................... 126 Damper................................................................................................................. 126 Turbocharger........................................................................................................... 127 Muffler................................................................................................................ 130 Cooling System................................................................................................................. 131 Layout Drawing of Cooling System........................................................................................... 131 Specifications of Cooling System........................................................................................... 133 Component Parts of Cooling System.......................................................................................... 134 Cooling Fan Pump....................................................................................................... 134 Servo Valve (Cooling Fan Pump)......................................................................................... 146 Cooling Fan Motor...................................................................................................... 148 Hydraulic Oil Cooler Bypass Valve...................................................................................... 153 Control System................................................................................................................. 155 Layout Drawing of Control System........................................................................................... 155 Machine Monitor System..................................................................................................... 156 System Diagram of Machine Monitor System............................................................................... 156 Function of Machine Monitor System..................................................................................... 156 KOMTRAX Plus System........................................................................................................ 158 System Diagram of KOMTRAX Plus System.................................................................................. 158 Function of KOMTRAX Plus System........................................................................................ 158 Component Parts of Control System.......................................................................................... 160 Machine Monitor........................................................................................................ 160 KOMTRAX Terminal....................................................................................................... 176 KOMTRAX Plus Controller................................................................................................ 178 Wireless LAN Unit...................................................................................................... 183 Power Train Controller................................................................................................. 184 Work Equipment Controller.............................................................................................. 188 Engine Controller...................................................................................................... 192 Option Controller...................................................................................................... 203 Fuel Feed Pump......................................................................................................... 208 Fuel Feed Pump Switch.................................................................................................. 209 Hydraulic System............................................................................................................... 210 Layout Drawing of Hydraulic System......................................................................................... 210 CLSS....................................................................................................................... 211 System Diagram of CLSS................................................................................................. 211 Function of CLSS....................................................................................................... 212 Component Parts of Hydraulic System........................................................................................ 214 Hydraulic Tank......................................................................................................... 214 Duplex Pump (Work Equipment)........................................................................................... 216 LS Valve............................................................................................................... 220 CO Valve............................................................................................................... 226 LS-EPC Valve........................................................................................................... 228 Control Valve.......................................................................................................... 231 Power Train System............................................................................................................. 267 Layout Drawing of Power Train System....................................................................................... 267 Operation of Power Train System........................................................................................ 269 Transmission, Steering, and Brake Control System........................................................................... 270 Layout Drawing of Transmission, Steering, and Brake System............................................................. 270 Function of Transmission, Steering, and Brake System................................................................... 271 Layout of Transmission, Steering, and Brake System Parts (Machine with FCCS)........................................... 271 Function of Transmission, Steering, and Brake System (Machine with FCCS)............................................... 273 Palm Command Control System................................................................................................ 274 Palm Command Control System Diagram.................................................................................... 274 Gear Shift Control of Palm Command Control System...................................................................... 275 Function of Gear Shift Mode................................................................................................ 278 Centralized Pressure Pickup Port........................................................................................... 281 Layout Drawing of Centralized Pressure Pickup Port..................................................................... 281 Component Parts of Power Train System...................................................................................... 283 Universal Joint........................................................................................................ 283 Power Train Mount...................................................................................................... 284 Torque Converter and PTO............................................................................................... 285 Torque Converter Control Valve......................................................................................... 292 ECMV (Lockup Clutch Valve)............................................................................................. 293 ECMV (Stator Clutch Valve)............................................................................................. 296 Transmission........................................................................................................... 300 Transmission Control Valve............................................................................................. 313 ECMV (Directional Clutch, Gear Speed Clutch)........................................................................... 314 Main Relief Valve and Torque Converter Relief Valve.................................................................... 319 Transmission Lubrication Relief Valve.................................................................................. 322 Transfer and Bevel Pinion.............................................................................................. 323 Bevel Gear Shaft, Steering Clutch, and Steering Brake.................................................................. 324 Final Drive............................................................................................................ 330 Duplex Pump (Scavenging)............................................................................................... 334 Electric Steering Electric Lever....................................................................................... 335 Triplex Pump (Lubrication, Power Train, Torque Converter).............................................................. 339 Work Equipment System.......................................................................................................... 341 Layout Drawing of Work Equipment System.................................................................................... 341 Function of Work Equipment System.......................................................................................... 346 Component Parts of Work Equipment System................................................................................... 347 Solenoid Valve (Work Equipment Lock)................................................................................... 347 Pilot Circuit Accumulator.............................................................................................. 348 Quick Drop Valve....................................................................................................... 349 Piston Valve........................................................................................................... 350 Electric Blade Control Lever........................................................................................... 351 Ripper Electric Lever.................................................................................................. 354 Pin Puller Switch...................................................................................................... 357 ICT System..................................................................................................................... 358 Layout Drawing of ICT System............................................................................................... 358 System Diagram of ICT Control System....................................................................................... 359 Blade Control System....................................................................................................... 361 Function of Blade Control System....................................................................................... 361 Leveling Mode System Diagram........................................................................................... 363 Function of Leveling Mode.............................................................................................. 364 Operation of Leveling Mode............................................................................................. 364 Dozing Mode System Diagram............................................................................................. 365 Function of Dozing Mode................................................................................................ 365 Operation of Dozing Mode............................................................................................... 365 Smooth Start System........................................................................................................ 367 Smooth Start System Diagram............................................................................................ 367 Function of Smooth Start System........................................................................................ 367 Operation of Smooth Start System....................................................................................... 367 Slip Control System........................................................................................................ 369 Slip Control System Diagram............................................................................................ 369 Function of Slip Control System........................................................................................ 369 Operation of Slip Control System....................................................................................... 369 Assist Control System...................................................................................................... 371 Assist Control System Diagram.......................................................................................... 371 Function of Assist Control System...................................................................................... 371 Operation of Assist Control System..................................................................................... 372 Straight Travel Correction System.......................................................................................... 373 Straight Travel Correction System Diagram.............................................................................. 373 Function of Straight Travel Correction System.......................................................................... 374 Operation of Straight Travel Correction System......................................................................... 374 Smooth Carry System........................................................................................................ 375 Smooth Carry System Diagram............................................................................................ 375 Function of Smooth Carry System........................................................................................ 376 Operation of Smooth Carry System....................................................................................... 376 Component Parts of ICT System.............................................................................................. 377 Navigation Controller.................................................................................................. 377 Control Box............................................................................................................ 381 AUX BOX................................................................................................................ 383 IMU Sensor............................................................................................................. 385 Stroke and Reset Sensor for Blade Lift Cylinder........................................................................ 388 Lifting System................................................................................................................. 391 Power Ladder System........................................................................................................ 391 Layout Drawing of Power Ladder System.................................................................................. 391 Power Ladder System Diagram............................................................................................ 392 Function of Power Ladder System........................................................................................ 392 Component Parts of Lifting System.......................................................................................... 394 Switch Box............................................................................................................. 394 Power Ladder Limit Switch Part......................................................................................... 395 Power Ladder Control Valve............................................................................................. 396 Power Ladder Pump...................................................................................................... 398 Undercarriage and Frame........................................................................................................ 400 Main Frame................................................................................................................. 400 Structure of Main Frame................................................................................................ 400 Suspension................................................................................................................. 402 Structure of Suspension................................................................................................ 402 Function of Suspension................................................................................................. 403 Track Frame and Idler Cushion.............................................................................................. 404 Structure of Track Frame and Idler Cushion............................................................................. 404 Specifications of Track Frame and Idler Cushion........................................................................ 405 Function of Track Frame and Idler Cushion.............................................................................. 405 Work Equipment................................................................................................................. 406 Structure of Front Work Equipment.......................................................................................... 406 Structure of Cylinder Stay................................................................................................. 408 Structure of Variable Giant Ripper......................................................................................... 409 Structure of Variable Multi-Shank Ripper................................................................................... 410 CAB Related Parts.............................................................................................................. 411 ROPS....................................................................................................................... 411 Structure of ROPS...................................................................................................... 411 Function of ROPS....................................................................................................... 411 CAB........................................................................................................................ 412 Structure of CAB....................................................................................................... 412 CAB Mount.................................................................................................................. 413 Structure of CAB Mount................................................................................................. 413 Function of CAB Mount.................................................................................................. 413 20 Standard Value Table............................................................................................................ 415 Table of Contents.............................................................................................................. 416 Standard Value Table for Engine................................................................................................ 417 Standard Value Table for Engine: D475A-8R.................................................................................. 417 Standard Value Table for Machine............................................................................................... 422 Standard Value Table for Machine: D475A-8R................................................................................. 422 Machine Posture and Procedures to Measure Performance...................................................................... 448 30 Testing and Adjusting........................................................................................................... 451 Table of Contents.............................................................................................................. 452 Precautions Before Work........................................................................................................ 456 Related Information on Testing and Adjusting................................................................................... 457 Tools for Testing and Adjusting............................................................................................ 457 Sketch of Tools for Testing and Adjusting.................................................................................. 467 Engine and Cooling System...................................................................................................... 470 Examine Engine Speed....................................................................................................... 470 How to Examine Engine High Idle Speed.................................................................................. 470 How to Examine Engine Low Idle Speed................................................................................... 470 How to Examine Engine Speed When Decelerator Pedal is Pushed........................................................... 471 How to Examine Engine Speed at Torque Converter Stall.................................................................. 472 How to Examine Engine Speed at Full Stall (Torque Converter Stall + Work Equipment Relief)............................. 473 Examine Boost Pressure..................................................................................................... 475 How to Examine Boost Pressure on Machine Monitor....................................................................... 475 How to Examine Boost Pressure by Testing Tool.......................................................................... 477 Examine Exhaust Gas Temperature............................................................................................ 482 How to Examine Exhaust Gas Temperature................................................................................. 482 Examine Exhaust Gas Color.................................................................................................. 484 How to Examine Exhaust Gas Color with the Handy Smoke Checker.......................................................... 484 How to Examine Exhaust Gas Color with Smoke Meter...................................................................... 485 Examine and Adjust Valve Clearance......................................................................................... 487 How to Examine Valve Clearance......................................................................................... 487 How to Adjust Valve Clearance.......................................................................................... 488 Examine Compression Pressure............................................................................................... 490 How to Examine Compression Pressure.................................................................................... 490 Examine Blowby Pressure.................................................................................................... 494 How to Examine Blowby Pressure......................................................................................... 494 Examine Engine Oil Pressure................................................................................................ 500 How to Examine Engine Oil Pressure on Machine Monitor.................................................................. 500 How to Examine Engine Oil Pressure by Testing Tool..................................................................... 500 Examine Fuel Pressure...................................................................................................... 503 How to Examine Fuel Pressure........................................................................................... 503 Examine Fuel Return Rate and Leakage....................................................................................... 505 How to Examine Fuel Return Rate and Leakage............................................................................ 506 Bleed Air from Fuel System................................................................................................. 516 How to Bleed Air from Fuel System...................................................................................... 516 Examine Fuel Circuit for Leakage........................................................................................... 518 How to Examine Fuel System for Leakage................................................................................. 518 Examine Low Pressure Circuit Devices....................................................................................... 519 How to Examine Low Pressure Circuit Devices............................................................................ 519 Handle Cylinder Cut-out Mode Operation..................................................................................... 524 Handle No-Injection Cranking Operation..................................................................................... 525 Test Muffler for Looseness and Damage...................................................................................... 526 How to Test Muffler for Looseness and Damage........................................................................... 526 Examine Installation of Cylinder Head Cover and Manifolds.................................................................. 527 How to Examine Installed Condition of Cylinder Head covers and Manifolds............................................... 527 Examine Engine Piping for Damage and Looseness............................................................................. 528 How to Examine Engine Piping for Damage and Looseness.................................................................. 528 Write Injector Compensation Value to Engine Controller..................................................................... 529 Write Injector Compensation Value...................................................................................... 529 Write Correction for Ash in Soot Accumulation to Engine Controller......................................................... 536 How to Write Correction for Ash in Soot Accumulation to Engine Controller.............................................. 536 Examine Alternator, Air Conditioner Compressor Belt........................................................................ 537 How to Examine Alternator, Air Conditioner Compressor Belt............................................................. 537 Adjust Decelerator Pedal................................................................................................... 538 How to Adjust Decelerator Pedal........................................................................................ 538 Power Train.................................................................................................................... 541 Examine Power Train Oil Pressure........................................................................................... 541 How to Examine Power Train Oil Pressure................................................................................ 542 Adjust Transmission Output Shaft Speed Sensor.............................................................................. 567 How to Adjust Transmission Output Shaft Speed Sensor................................................................... 567 Examine Brake Performance Simply........................................................................................... 569 How to Examine Brake Performance Simply................................................................................ 569 Examine and Adjust Brake Pedal............................................................................................. 570 How to Examine Brake Pedal............................................................................................. 570 How to Adjust Brake Pedal.............................................................................................. 570 Release Parking Brake and Move Machine..................................................................................... 574 Release Parking Brake and Move Machine (Hydraulic Type)................................................................ 574 Release Parking Brake and Move Machine (Electric Type)................................................................. 575 Undercarriage and Frame........................................................................................................ 578 Examine and Adjust Track Tension........................................................................................... 578 How to Examine Track Tension........................................................................................... 578 How to Adjust Track Tension............................................................................................ 578 Hydraulic System............................................................................................................... 580 Release Remained Pressure in Hydraulic Circuit............................................................................. 580 How to Release Remained Pressure in Hydraulic System................................................................... 580 Examine and Adjust Work Equipment Oil Pressure............................................................................. 581 How to Examine Work Equipment Oil Pressure............................................................................. 581 Examine EPC Valve Outlet Pressure.......................................................................................... 588 How to Examine EPC Valve Outlet Pressure............................................................................... 588 Examine and Adjust Oil Pressure in Pump LS Control Circuit................................................................. 591 How to Examine LS Differential Pressure by Testing Tool................................................................ 591 How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure).................................................. 594 Adjust LS Valve........................................................................................................ 595 Examine Oil Pressure of Control Circuit.................................................................................... 596 How to Examine Oil Pressure in Control Circuit......................................................................... 596 Examine Work Equipment Lock Solenoid Valve Outlet Pressure................................................................. 598 How to Examine Work Equipment Lock Solenoid Valve Outlet Pressure...................................................... 598 Examine Ripper Pin Puller Solenoid Valve Outlet Pressure................................................................... 600 How to Examine Ripper Pin Puller Solenoid Valve Outlet Pressure........................................................ 600 Bleed Air from Work Equipment Pump......................................................................................... 602 How to Bleed Air from Work Equipment Pump.............................................................................. 602 Examine Cooling Fan Speed.................................................................................................. 603 How to Examine Cooling Fan Speed....................................................................................... 603 Examine Cooling Fan Circuit Oil Pressure................................................................................... 604 How to Examine Cooling Fan Circuit Oil Pressure........................................................................ 604 Bleed Air in Cooling Fan Pump.............................................................................................. 606 How to Bleed Air in Cooling Fan Pump................................................................................... 606 Examine Parts Which Cause Hydraulic Drift of Work Equipment................................................................ 607 How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder................................................ 607 How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder............................................ 607 How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder........................................... 608 Examine Oil Leakage from Work Equipment Cylinder........................................................................... 609 How to Examine Internal Oil Leakage of Work Equipment Cylinder......................................................... 609 Bleed Air from Work Equipment Cylinders.................................................................................... 611 Bleed Air from Work Equipment Cylinder................................................................................. 611 Operation When Work Equipment is Disabled.................................................................................. 612 Operate When Work Equipment is Disabled................................................................................ 612 Work Equipment................................................................................................................. 614 Examine and Adjust Play of Blade Electric Lever............................................................................ 614 How to Examine Play of Blade Electric Lever............................................................................ 616 Adjust Play of Blade Electric Lever.................................................................................... 616 Replace Universal Joint................................................................................................ 617 Power Ladder................................................................................................................... 624 Bleed Air from Power Ladder Cylinder....................................................................................... 624 Bleed Air in Power Ladder Cylinder..................................................................................... 624 Examine and Adjust Power Ladder Limit Switch............................................................................... 629 How to Examine and Adjust Power Ladder Limit Switch.................................................................... 629 Adjust Power Ladder Limit Switch....................................................................................... 629 CAB Related Parts.............................................................................................................. 637 Examine and Adjust Operator Cab............................................................................................ 637 Examine Operator Cab................................................................................................... 637 Adjust Operator Cab.................................................................................................... 640 Adjust Play of Operator's Seat............................................................................................. 643 How to Adjust Play of Operator's Seat.................................................................................. 643 Examine the Seating Switch................................................................................................. 644 How to Examine the Seating Switch...................................................................................... 644 Examine Work Equipment Lock Switch......................................................................................... 645 How to Examine Work Equipment Lock Switch.............................................................................. 645 Examine Parking Brake Switch............................................................................................... 646 How to Examine Parking Brake Switch.................................................................................... 646 Electrical System.............................................................................................................. 647 Set and Operate Machine Monitor............................................................................................ 647 Operator Mode.......................................................................................................... 651 Function to Show Technician Identification Status Screen............................................................... 651 Function to Show Operator Identification Input Screen.................................................................. 651 Examine Function by LCD (Liquid Crystal Display)....................................................................... 652 Examine Function of Service Meter...................................................................................... 652 Set Usage Limitation and Change Maintenance Password................................................................... 652 Service Mode........................................................................................................... 655 How to Operate Service Mode............................................................................................ 655 How to See Pre-defined Monitoring Information.......................................................................... 656 How to Examine Monitoring Information.................................................................................. 662 Abnormality Record Menu................................................................................................ 675 How to See Maintenance Record.......................................................................................... 678 Maintenance Mode Setting............................................................................................... 680 Set Phone Number Entry................................................................................................. 684 Default Setting Menu................................................................................................... 685 Testing Menu........................................................................................................... 696 Adjustment Menu........................................................................................................ 700 No-Injection Cranking Operation........................................................................................ 787 KOMTRAX Settings Menu.................................................................................................. 789 Show Service Message................................................................................................... 791 How to Handle Snap Shot................................................................................................ 791 How to Start Up KOMTRAX Terminal........................................................................................... 794 How to Stop Use of KOMTRAX Terminal........................................................................................ 798 Default Setting of KOMTRAX Plus Controller................................................................................. 800 Default Setting of KOMTRAX Plus Controller............................................................................. 800 Default Setting of Wireless LAN Modem...................................................................................... 803 Default Setting of Wireless LAN Modem.................................................................................. 803 How to Examine Wireless LAN Modem Communication........................................................................ 804 Download Data from KOMTRAX Plus Controller................................................................................. 806 How to Download Data from KOMTRAX Plus Controller...................................................................... 806 Download Data from Service Connector................................................................................... 806 How to Download Data from Wireless LAN (Wireless LAN Spec)............................................................. 807 Adjust After Replacement of KOMTRAX Plus Controller........................................................................ 809 How to Adjust After Replacement of KOMTRAX Plus Controller............................................................. 809 Adjust After Replacement of Wireless LAN Modem............................................................................. 812 How to Adjust After Replacement of Wireless LAN Modem.................................................................. 812 Adjust Rearview Camera Angle............................................................................................... 815 How to Adjust Rearview Camera Angle.................................................................................... 815 Set Region of Bluetooth(R) Compatible Radio................................................................................ 816 Set Region of Bluetooth(R) Compatible Radio............................................................................ 816 Handle Voltage Circuit of Engine Controller................................................................................ 818 Handle Battery Isolator and Starting Motor Isolator........................................................................ 819 Examine Diodes............................................................................................................. 821 Examine Diodes by Digital Tester....................................................................................... 821 How to Examine Diodes by Analog Tester................................................................................. 821 Pm Clinic...................................................................................................................... 822 Pm Clinic Service.......................................................................................................... 822 Pm Clinic Check Sheet: D475A-8R........................................................................................ 824 Pm Clinic Check Sheet for Undercarriage: D475A-8R...................................................................... 853 Perform Quick Pm........................................................................................................... 857 How to Perform Quick Pm................................................................................................ 857 40 Troubleshooting................................................................................................................. 861 Table of Contents.............................................................................................................. 862 Precautions Before Work........................................................................................................ 874 Related Information to Troubleshooting......................................................................................... 875 Precautions for Troubleshooting............................................................................................ 875 Sequence of Events in Troubleshooting...................................................................................... 876 Troubleshooting Points for Aftertreatment System........................................................................... 878 Troubleshooting for Radio Control System................................................................................... 884 Checks Before Troubleshooting (Specifications of Radio Control)........................................................ 884 Examine Operating State of Radio Control Receiver...................................................................... 885 Examine Operating State of Radio Control Transmitter................................................................... 886 Checks Before Troubleshooting.............................................................................................. 887 Inspection Procedure Before Troubleshooting................................................................................ 889 Walk-Around Check...................................................................................................... 889 Test in Accordance with Testing Procedure.................................................................................. 891 How to Drain Water and Sediment from Fuel Tank......................................................................... 891 How to Examine Water Separator, Drain Water and Sediment............................................................... 891 Examine Fuel Main Filter............................................................................................... 892 How to Examine Oil Level in Hydraulic Tank, Add Oil.................................................................... 893 How to Examine Coolant Level, Add Coolant.............................................................................. 896 How to Examine Oil Level in Engine Oil Pan, Add Oil.................................................................... 897 Examine Oil Level in Power Train Case, Add Oil......................................................................... 898 Examine Dust Indicator................................................................................................. 900 How to Examine Brake Operation......................................................................................... 901 How to Examine Electric Wiring......................................................................................... 901 How to Examine Fuel Level, Add Fuel.................................................................................... 901 How to Examine Operation of Lamps...................................................................................... 902 How to Examine Machine Monitor......................................................................................... 902 How to Remove Sediment in Engine Room.................................................................................. 903 How to Examine Operation State of Horn................................................................................. 903 How to Examine Operation State of Backup Alarm......................................................................... 904 How to Examine Electric Equipment...................................................................................... 904 Connect Adapter for Troubleshooting Controller............................................................................. 909 Connect Adapter for Troubleshooting Machine Monitor.................................................................... 909 Connect Adapter for Troubleshooting Work Equipment Controller.......................................................... 910 Connect Adapter for Troubleshooting Power Train Controller............................................................. 910 Connect Adapter to Troubleshoot KOMTRAX Terminal....................................................................... 911 Connect Adapter to Troubleshoot KOMTRAX Plus Controller................................................................ 912 Connect Adapter for Troubleshooting of Option Controller............................................................... 913 Procedure for Troubleshooting.............................................................................................. 916 Symptom and Troubleshooting Numbers........................................................................................ 917 Information Shown in Troubleshooting....................................................................................... 921 Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness................................................... 924 Connector and Wiring Harness Identification Table.......................................................................... 927 Connector Layout...........................................................................................................1112 Connector Contact Connection Table.........................................................................................1121 T-Branch Box and T-Branch Adapter Table....................................................................................1164 Fuse Location Table........................................................................................................1170 Failure Code Table.........................................................................................................1174 Troubleshooting by Failure Code (Display of Code)..............................................................................1200 Failure Code [1500L0]......................................................................................................1200 Failure Code [15SAL1]......................................................................................................1202 Failure Code [15SALH]......................................................................................................1205 Failure Code [15SBL1]......................................................................................................1208 Failure Code [15SBLH]......................................................................................................1211 Failure Code [15SEL1]......................................................................................................1214 Failure Code [15SELH]......................................................................................................1217 Failure Code [15SFL1]......................................................................................................1220 Failure Code [15SFLH]......................................................................................................1223 Failure Code [15SGL1]......................................................................................................1226 Failure Code [15SGLH]......................................................................................................1229 Failure Code [15SJL1]......................................................................................................1232 Failure Code [15SJLH]......................................................................................................1235 Failure Code [1800MW]......................................................................................................1238 Failure Code [2201L1]......................................................................................................1239 Failure Code [2201LH]......................................................................................................1242 Failure Code [2202L1]......................................................................................................1245 Failure Code [2202LH]......................................................................................................1248 Failure Code [2301L1]......................................................................................................1251 Failure Code [2301LH]......................................................................................................1254 Failure Code [2302L1]......................................................................................................1257 Failure Code [2302LH]......................................................................................................1260 Failure Code [851PKA]......................................................................................................1263 Failure Code [851PKX]......................................................................................................1265 Failure Code [851QKA]......................................................................................................1267 Failure Code [851QKX]......................................................................................................1269 Failure Code [851RKA]......................................................................................................1271 Failure Code [851RKX]......................................................................................................1273 Failure Code [851SKA]......................................................................................................1275 Failure Code [851SKX]......................................................................................................1277 Failure Code [851TKA]......................................................................................................1279 Failure Code [851TKX]......................................................................................................1281 Failure Code [851UKA]......................................................................................................1283 Failure Code [851UKX]......................................................................................................1285 Failure Code [851VKA]......................................................................................................1287 Failure Code [851VKX]......................................................................................................1288 Failure Code [851XKA]......................................................................................................1289 Failure Code [851XKX]......................................................................................................1290 Failure Code [852RKR]......................................................................................................1291 Failure Code [8590KA]......................................................................................................1293 Failure Code [8590KY]......................................................................................................1298 Failure Code [879AKA]......................................................................................................1302 Failure Code [879AKB]......................................................................................................1303 Failure Code [879BKA]......................................................................................................1305 Failure Code [879BKB]......................................................................................................1308 Failure Code [879CKA]......................................................................................................1311 Failure Code [879CKB]......................................................................................................1312 Failure Code [879DKZ]......................................................................................................1313 Failure Code [879EMC]......................................................................................................1316 Failure Code [879FMC]......................................................................................................1317 Failure Code [879GKX]......................................................................................................1318 Failure Code [989L00]......................................................................................................1321 Failure Code [989M00]......................................................................................................1322 Failure Code [989N00]......................................................................................................1323 Failure Code [A900FR]......................................................................................................1324 Failure Code [A900N6]......................................................................................................1325 Failure Code [A900NY]......................................................................................................1327 Failure Code [AA10NX]......................................................................................................1329 Failure Code [AB00KE]......................................................................................................1332 Failure Code [B@BAZG]......................................................................................................1336 Failure Code [B@BAZK]......................................................................................................1339 Failure Code [B@BCNS]......................................................................................................1342 Failure Code [B@BCZK]......................................................................................................1345 Failure Code [B@CENS]......................................................................................................1348 Failure Code [B@HANS]......................................................................................................1351 Failure Code [B@HAZK]......................................................................................................1354 Failure Code [CA115].......................................................................................................1356 Failure Code [CA122].......................................................................................................1361 Failure Code [CA123].......................................................................................................1364 Failure Code [CA131].......................................................................................................1368 Failure Code [CA132].......................................................................................................1371 Failure Code [CA135].......................................................................................................1374 Failure Code [CA141].......................................................................................................1377 Failure Code [CA144].......................................................................................................1380 Failure Code [CA145].......................................................................................................1383 Failure Code [CA153].......................................................................................................1386 Failure Code [CA154].......................................................................................................1390 Failure Code [CA212].......................................................................................................1394 Failure Code [CA213].......................................................................................................1397 Failure Code [CA221].......................................................................................................1400 Failure Code [CA222].......................................................................................................1403 Failure Code [CA234].......................................................................................................1407 Failure Code [CA238].......................................................................................................1409 Failure Code [CA239].......................................................................................................1412 Failure Code [CA271].......................................................................................................1415 Failure Code [CA272].......................................................................................................1418 Failure Code [CA273].......................................................................................................1420 Failure Code [CA274].......................................................................................................1423 Failure Code [CA322].......................................................................................................1425 Failure Code [CA323].......................................................................................................1428 Failure Code [CA324].......................................................................................................1431 Failure Code [CA325].......................................................................................................1434 Failure Code [CA331].......................................................................................................1437 Failure Code [CA332].......................................................................................................1440 Failure Code [CA343].......................................................................................................1443 Failure Code [CA351].......................................................................................................1450 Failure Code [CA352].......................................................................................................1457 Failure Code [CA386].......................................................................................................1461 Failure Code [CA428].......................................................................................................1465 Failure Code [CA429].......................................................................................................1468 Failure Code [CA441].......................................................................................................1471 Failure Code [CA442].......................................................................................................1475 Failure Code [CA449].......................................................................................................1479 Failure Code [CA451].......................................................................................................1482 Failure Code [CA452].......................................................................................................1485 Failure Code [CA515].......................................................................................................1488 Failure Code [CA516].......................................................................................................1490 Failure Code [CA553].......................................................................................................1493 Failure Code [CA559].......................................................................................................1496 Failure Code [CA689].......................................................................................................1502 Failure Code [CA691].......................................................................................................1507 Failure Code [CA692].......................................................................................................1510 Failure Code [CA697].......................................................................................................1513 Failure Code [CA698].......................................................................................................1515 Failure Code [CA731].......................................................................................................1517 Failure Code [CA778].......................................................................................................1526 Failure Code [CA1117]......................................................................................................1531 Failure Code [CA1135]......................................................................................................1535 Failure Code [CA1257]......................................................................................................1545 Failure Code [CA1843]......................................................................................................1547 Failure Code [CA1844]......................................................................................................1550 Failure Code [CA1942]......................................................................................................1553 Failure Code [CA2185]......................................................................................................1555 Failure Code [CA2186]......................................................................................................1557 Failure Code [CA2249]......................................................................................................1560 Failure Code [CA2265]......................................................................................................1567 Failure Code [CA2266]......................................................................................................1570 Failure Code [CA2555]......................................................................................................1572 Failure Code [CA2556]......................................................................................................1575 Failure Code [CA2765]......................................................................................................1578 Failure Code [CA4952]......................................................................................................1580 Failure Code [CB115].......................................................................................................1583 Failure Code [CB122].......................................................................................................1588 Failure Code [CB123].......................................................................................................1591 Failure Code [CB153].......................................................................................................1595 Failure Code [CB154].......................................................................................................1599 Failure Code [CB238].......................................................................................................1603 Failure Code [CB239].......................................................................................................1606 Failure Code [CB271].......................................................................................................1609 Failure Code [CB272].......................................................................................................1612 Failure Code [CB273].......................................................................................................1614 Failure Code [CB274].......................................................................................................1617 Failure Code [CB343].......................................................................................................1619 Failure Code [CB351].......................................................................................................1625 Failure Code [CB352].......................................................................................................1632 Failure Code [CB386].......................................................................................................1635 Failure Code [CB428].......................................................................................................1638 Failure Code [CB429].......................................................................................................1641 Failure Code [CB441].......................................................................................................1644 Failure Code [CB442].......................................................................................................1648 Failure Code [CB449].......................................................................................................1652 Failure Code [CB451].......................................................................................................1655 Failure Code [CB452].......................................................................................................1658 Failure Code [CB515].......................................................................................................1661 Failure Code [CB516].......................................................................................................1663 Failure Code [CB553].......................................................................................................1666 Failure Code [CB559].......................................................................................................1669 Failure Code [CB689].......................................................................................................1675 Failure Code [CB691].......................................................................................................1680 Failure Code [CB692].......................................................................................................1683 Failure Code [CB697].......................................................................................................1686 Failure Code [CB698].......................................................................................................1688 Failure Code [CB731].......................................................................................................1690 Failure Code [CB778].......................................................................................................1699 Failure Code [CB1117]......................................................................................................1704 Failure Code [CB1257]......................................................................................................1708 Failure Code [CB1548]......................................................................................................1710 Failure Code [CB1549]......................................................................................................1713 Failure Code [CB1551]......................................................................................................1716 Failure Code [CB1552]......................................................................................................1719 Failure Code [CB1553]......................................................................................................1722 Failure Code [CB1622]......................................................................................................1725 Failure Code [CB2249]......................................................................................................1728 Failure Code [CB2265]......................................................................................................1734 Failure Code [CB2266]......................................................................................................1737 Failure Code [CB2765]......................................................................................................1739 Failure Code [CB4952]......................................................................................................1741 Failure Code [D130KA]......................................................................................................1744 Failure Code [D130KB]......................................................................................................1747 Failure Code [D141KA]......................................................................................................1750 Failure Code [D141KB]......................................................................................................1753 Failure Code [D141KY]......................................................................................................1756 Failure Code [D162KA]......................................................................................................1759 Failure Code [D162KB]......................................................................................................1762 Failure Code [D162KY]......................................................................................................1765 Failure Code [D16CKA]......................................................................................................1768 Failure Code [D16CKB]......................................................................................................1771 Failure Code [D16CKY]......................................................................................................1774 Failure Code [D182KZ]......................................................................................................1777 Failure Code [D19CKA]......................................................................................................1780 Failure Code [D19CKB]......................................................................................................1783 Failure Code [D19CKY]......................................................................................................1786 Failure Code [D19EKA]......................................................................................................1789 Failure Code [D19EKB]......................................................................................................1792 Failure Code [D19EKY]......................................................................................................1795 Failure Code [D19FKA]......................................................................................................1798 Failure Code [D19FKB]......................................................................................................1801 Failure Code [D19FKY]......................................................................................................1804 Failure Code [D19GKA]......................................................................................................1807 Failure Code [D19GKB]......................................................................................................1810 Failure Code [D19GKY]......................................................................................................1813 Failure Code [D19JKZ]......................................................................................................1816 Failure Code [D1D5KA]......................................................................................................1819 Failure Code [D1D5KB]......................................................................................................1822 Failure Code [D1D5KY]......................................................................................................1825 Failure Code [D1EFKA]......................................................................................................1828 Failure Code [D1EFKB]......................................................................................................1831 Failure Code [D1EWKA]......................................................................................................1834 Failure Code [D1EWKB]......................................................................................................1837 Failure Code [D1EWKY]......................................................................................................1840 Failure Code [D862KA]......................................................................................................1843 Failure Code [DAF0MB]......................................................................................................1846 Failure Code [DAF0MC]......................................................................................................1847 Failure Code [DAF8KB]......................................................................................................1848 Failure Code [DAF9KQ]......................................................................................................1850 Failure Code [DAFGMC]......................................................................................................1851 Failure Code [DAFLKA]......................................................................................................1852 Failure Code [DAFLKB]......................................................................................................1856 Failure Code [DAFQKR]......................................................................................................1859 Failure Code [DAZ9KQ]......................................................................................................1871 Failure Code [DAZQKR]......................................................................................................1873 Failure Code [DB2QKR]......................................................................................................1884 Failure Code [DB2RKR]......................................................................................................1899 Failure Code [DB90KT]......................................................................................................1914 Failure Code [DB90MC]......................................................................................................1915 Failure Code [DB91KK]......................................................................................................1916 Failure Code [DB92KK]......................................................................................................1921 Failure Code [DB95KK]......................................................................................................1925 Failure Code [DB97KK]......................................................................................................1928 Failure Code [DB99KQ]......................................................................................................1931 Failure Code [DB9LKA]......................................................................................................1933 Failure Code [DB9LKB]......................................................................................................1937 Failure Code [DB9QKR]......................................................................................................1940 Failure Code [DB9RKR]......................................................................................................1952 Failure Code [DBE0KT]......................................................................................................1963 Failure Code [DBE0MC]......................................................................................................1964 Failure Code [DBE1KK]......................................................................................................1965 Failure Code [DBE2KK]......................................................................................................1970 Failure Code [DBE5KK]......................................................................................................1974 Failure Code [DBE6KK]......................................................................................................1977 Failure Code [DBE7KK]......................................................................................................1980 Failure Code [DBE9KQ]......................................................................................................1984 Failure Code [DBELKA]......................................................................................................1985 Failure Code [DBELKB]......................................................................................................1989 Failure Code [DBEQKR]......................................................................................................1992 Failure Code [DBERKR]......................................................................................................2004 Failure Code [DBU0KR]......................................................................................................2015 Failure Code [DBUSKR]......................................................................................................2016 Failure Code [DBUTKA]......................................................................................................2017 Failure Code [DBUTKN]......................................................................................................2018 Failure Code [DBV0MC]......................................................................................................2019 Failure Code [DBV1KK]......................................................................................................2020 Failure Code [DBV5KB]......................................................................................................2023 Failure Code [DBV6KB]......................................................................................................2026 Failure Code [DBVLKA]......................................................................................................2030 Failure Code [DBVLKB]......................................................................................................2033 Failure Code [DBVQKR]......................................................................................................2036 Failure Code [DBVRKR]......................................................................................................2048 Failure Code [DBVVKR]......................................................................................................2059 Failure Code [DBVWKR]......................................................................................................2060 Failure Code [DD12KA]......................................................................................................2062 Failure Code [DD12KB]......................................................................................................2065 Failure Code [DD13KA]......................................................................................................2068 Failure Code [DD13KB]......................................................................................................2071 Failure Code [DD14KA]......................................................................................................2074 Failure Code [DD14KB]......................................................................................................2078 Failure Code [DDDDKA]......................................................................................................2082 Failure Code [DDDDKB]......................................................................................................2087 Failure Code [DDDDKX]......................................................................................................2090 Failure Code [DDDHKB]......................................................................................................2092 Failure Code [DDDKKA]......................................................................................................2096 Failure Code [DDDKKB]......................................................................................................2100 Failure Code [DDDLKA]......................................................................................................2103 Failure Code [DDDLKB]......................................................................................................2107 Failure Code [DDE2KA]......................................................................................................2110 Failure Code [DDK4KA]......................................................................................................2112 Failure Code [DDK4KB]......................................................................................................2116 Failure Code [DDKAKA]......................................................................................................2119 Failure Code [DDKAKB]......................................................................................................2123 Failure Code [DDKBKA]......................................................................................................2127 Failure Code [DDKBKB]......................................................................................................2130 Failure Code [DDKCL4]......................................................................................................2133 Failure Code [DDKEL4]......................................................................................................2136 Failure Code [DDKHKA]......................................................................................................2139 Failure Code [DDKHKB]......................................................................................................2141 Failure Code [DDKQKA]......................................................................................................2143 Failure Code [DDKQKB]......................................................................................................2145 Failure Code [DDKRKA]......................................................................................................2147 Failure Code [DDKRKB]......................................................................................................2149 Failure Code [DDKSKA]......................................................................................................2151 Failure Code [DDKSKB]......................................................................................................2153 Failure Code [DDN7L4]......................................................................................................2155 Failure Code [DDN8L4]......................................................................................................2159 Failure Code [DDNLKA]......................................................................................................2162 Failure Code [DDNLKB]......................................................................................................2166 Failure Code [DDT5KQ]......................................................................................................2169 Failure Code [DDTSL1]......................................................................................................2170 Failure Code [DDTSLH]......................................................................................................2173 Failure Code [DFA4KX]......................................................................................................2176 Failure Code [DFA4KZ]......................................................................................................2178 Failure Code [DFA4L8]......................................................................................................2180 Failure Code [DFA5KA]......................................................................................................2183 Failure Code [DFA5KY]......................................................................................................2186 Failure Code [DFA6KA]......................................................................................................2189 Failure Code [DFA6KY]......................................................................................................2192 Failure Code [DFA7KX]......................................................................................................2195 Failure Code [DFA7KZ]......................................................................................................2197 Failure Code [DFA7L8]......................................................................................................2199 Failure Code [DFA8KA]......................................................................................................2202 Failure Code [DFA8KY]......................................................................................................2205 Failure Code [DFA9KA]......................................................................................................2208 Failure Code [DFA9KY]......................................................................................................2211 Failure Code [DFAAKX]......................................................................................................2214 Failure Code [DFAAKZ]......................................................................................................2216 Failure Code [DFAAL8]......................................................................................................2218 Failure Code [DFABKA]......................................................................................................2221 Failure Code [DFABKY]......................................................................................................2224 Failure Code [DFACKA]......................................................................................................2227 Failure Code [DFACKY]......................................................................................................2230 Failure Code [DGS1KA]......................................................................................................2233 Failure Code [DGS1KX]......................................................................................................2236 Failure Code [DGT1KA]......................................................................................................2239 Failure Code [DGT1KX]......................................................................................................2242 Failure Code [DGTUKY]......................................................................................................2245 Failure Code [DGTUKZ]......................................................................................................2247 Failure Code [DGTVKY]......................................................................................................2250 Failure Code [DGTVKZ]......................................................................................................2252 Failure Code [DGTWKY]......................................................................................................2255 Failure Code [DGTWKZ]......................................................................................................2257 Failure Code [DGTXKY]......................................................................................................2260 Failure Code [DGTXKZ]......................................................................................................2262 Failure Code [DH22KA]......................................................................................................2265 Failure Code [DH22KY]......................................................................................................2268 Failure Code [DH23KA]......................................................................................................2270 Failure Code [DH23KY]......................................................................................................2273 Failure Code [DHA4KA]......................................................................................................2275 Failure Code [DHT2L6]......................................................................................................2278 Failure Code [DHT3KX]......................................................................................................2280 Failure Code [DHT5KA]......................................................................................................2282 Failure Code [DHT5KY]......................................................................................................2285 Failure Code [DHT7KA]......................................................................................................2287 Failure Code [DHT7KY]......................................................................................................2290 Failure Code [DHZ1KX]......................................................................................................2292 Failure Code [DK01KA]......................................................................................................2295 Failure Code [DK01KY]......................................................................................................2298 Failure Code [DK03KA]......................................................................................................2300 Failure Code [DK03KY]......................................................................................................2303 Failure Code [DK10KA]......................................................................................................2305 Failure Code [DK10KB]......................................................................................................2308 Failure Code [DK30KA]......................................................................................................2311 Failure Code [DK30KX]......................................................................................................2314 Failure Code [DK30KY]......................................................................................................2316 Failure Code [DK30KZ]......................................................................................................2319 Failure Code [DK30L8]......................................................................................................2321 Failure Code [DK31KA]......................................................................................................2324 Failure Code [DK31KY]......................................................................................................2327 Failure Code [DK40KA]......................................................................................................2330 Failure Code [DK40KY]......................................................................................................2333 Failure Code [DK55KX]......................................................................................................2336 Failure Code [DK55KZ]......................................................................................................2338 Failure Code [DK55L8]......................................................................................................2340 Failure Code [DK56KA]......................................................................................................2342 Failure Code [DK56KY]......................................................................................................2345 Failure Code [DK57KA]......................................................................................................2348 Failure Code [DK57KY]......................................................................................................2351 Failure Code [DK60KA]......................................................................................................2354 Failure Code [DK60KY]......................................................................................................2357 Failure Code [DK80KR]......................................................................................................2359 Failure Code [DK80KT]......................................................................................................2362 Failure Code [DKH1KA]......................................................................................................2363 Failure Code [DKH1KY]......................................................................................................2366 Failure Code [DKR2KA]......................................................................................................2369 Failure Code [DKR2KB]......................................................................................................2371 Failure Code [DKSGL8]......................................................................................................2374 Failure Code [DKSHKA]......................................................................................................2376 Failure Code [DKSHKB]......................................................................................................2379 Failure Code [DKSJKA]......................................................................................................2382 Failure Code [DKSJKB]......................................................................................................2385 Failure Code [DKSKKA]......................................................................................................2388 Failure Code [DKSKKB]......................................................................................................2391 Failure Code [DKSKMB]......................................................................................................2394 Failure Code [DKSLL8]......................................................................................................2396 Failure Code [DKSMKA]......................................................................................................2398 Failure Code [DKSMKB]......................................................................................................2401 Failure Code [DKSNKA]......................................................................................................2404 Failure Code [DKSNKB]......................................................................................................2407 Failure Code [DKSPKA]......................................................................................................2410 Failure Code [DKSPKB]......................................................................................................2413 Failure Code [DKSPMB]......................................................................................................2416 Failure Code [DKW0KX]......................................................................................................2418 Failure Code [DKW0KZ]......................................................................................................2422 Failure Code [DKW0L8]......................................................................................................2426 Failure Code [DKW1KA]......................................................................................................2430 Failure Code [DKW1KY]......................................................................................................2433 Failure Code [DKW2KA]......................................................................................................2436 Failure Code [DKW2KY]......................................................................................................2439 Failure Code [DKW3KX]......................................................................................................2441 Failure Code [DKW3KZ]......................................................................................................2445 Failure Code [DKW3L8]......................................................................................................2449 Failure Code [DKW4KA]......................................................................................................2453 Failure Code [DKW4KY]......................................................................................................2456 Failure Code [DKW5KA]......................................................................................................2459 Failure Code [DKW5KY]......................................................................................................2462 Failure Code [DLM3KA]......................................................................................................2465 Failure Code [DLM3MB]......................................................................................................2468 Failure Code [DLT3KA]......................................................................................................2470 Failure Code [DLT3KB]......................................................................................................2473 Failure Code [DNDAMC]......................................................................................................2476 Failure Code [DNDBKA]......................................................................................................2479 Failure Code [DNDBKB]......................................................................................................2483 Failure Code [DNDCKA]......................................................................................................2486 Failure Code [DNDCKB]......................................................................................................2490 Failure Code [DNDDKA]......................................................................................................2493 Failure Code [DNDDKB]......................................................................................................2497 Failure Code [DNDEKA]......................................................................................................2500 Failure Code [DNDEKB]......................................................................................................2504 Failure Code [DR21KX]......................................................................................................2507 Failure Code [DR31KX]......................................................................................................2508 Failure Code [DV20KB]......................................................................................................2509 Failure Code [DW4BKA]......................................................................................................2512 Failure Code [DW4BKB]......................................................................................................2516 Failure Code [DW7BKA]......................................................................................................2520 Failure Code [DW7BKB]......................................................................................................2523 Failure Code [DWJ0KA]......................................................................................................2526 Failure Code [DWJ0KB]......................................................................................................2529 Failure Code [DWJ0KY]......................................................................................................2532 Failure Code [DWN3KA]......................................................................................................2534 Failure Code [DWN3KB]......................................................................................................2536 Failure Code [DWN3KY]......................................................................................................2539 Failure Code [DWN5KA]......................................................................................................2541 Failure Code [DWN5KB]......................................................................................................2543 Failure Code [DWN5KY]......................................................................................................2546 Failure Code [DWNCKA]......................................................................................................2548 Failure Code [DWNCKB]......................................................................................................2550 Failure Code [DWNCKY]......................................................................................................2553 Failure Code [DWNVKA]......................................................................................................2555 Failure Code [DWNVKB]......................................................................................................2558 Failure Code [DWNWKA]......................................................................................................2561 Failure Code [DWNWKB]......................................................................................................2564 Failure Code [DWNXKA]......................................................................................................2567 Failure Code [DWNXKB]......................................................................................................2570 Failure Code [DWNYKA]......................................................................................................2573 Failure Code [DWNYKB]......................................................................................................2576 Failure Code [DXE0KA]......................................................................................................2579 Failure Code [DXE0KB]......................................................................................................2582 Failure Code [DXE0KY]......................................................................................................2585 Failure Code [DXH1KA]......................................................................................................2587 Failure Code [DXH1KB]......................................................................................................2590 Failure Code [DXH1KY]......................................................................................................2593 Failure Code [DXH4KA]......................................................................................................2596 Failure Code [DXH4KB]......................................................................................................2599 Failure Code [DXH4KY]......................................................................................................2602 Failure Code [DXH5KA]......................................................................................................2604 Failure Code [DXH5KB]......................................................................................................2607 Failure Code [DXH5KY]......................................................................................................2610 Failure Code [DXH6KA]......................................................................................................2612 Failure Code [DXH6KB]......................................................................................................2615 Failure Code [DXH6KY]......................................................................................................2618 Failure Code [DXH7KA]......................................................................................................2620 Failure Code [DXH7KB]......................................................................................................2623 Failure Code [DXH7KY]......................................................................................................2626 Failure Code [DXH8KA]......................................................................................................2628 Failure Code [DXH8KB]......................................................................................................2631 Failure Code [DXH8KY]......................................................................................................2634 Failure Code [DXH9KA]......................................................................................................2636 Failure Code [DXH9KB]......................................................................................................2639 Failure Code [DXH9KY]......................................................................................................2642 Failure Code [DXHAKA]......................................................................................................2644 Failure Code [DXHAKB]......................................................................................................2647 Failure Code [DXHAKY]......................................................................................................2650 Failure Code [DXHBKA]......................................................................................................2652 Failure Code [DXHBKB]......................................................................................................2655 Failure Code [DXHBKY]......................................................................................................2658 Failure Code [DXHCKA]......................................................................................................2660 Failure Code [DXHCKB]......................................................................................................2663 Failure Code [DXHCKY]......................................................................................................2666 Failure Code [DXHRKA]......................................................................................................2668 Failure Code [DXHRKB]......................................................................................................2670 Failure Code [DXHRKY]......................................................................................................2673 Failure Code [DXHSKA]......................................................................................................2675 Failure Code [DXHSKB]......................................................................................................2677 Failure Code [DXHSKY]......................................................................................................2680 Failure Code [DXHTKA]......................................................................................................2682 Failure Code [DXHTKB]......................................................................................................2684 Failure Code [DXHTKY]......................................................................................................2687 Failure Code [DXHUKA]......................................................................................................2689 Failure Code [DXHUKB]......................................................................................................2691 Failure Code [DXHUKY]......................................................................................................2694 Failure Code [DXHWKA]......................................................................................................2696 Failure Code [DXHWKB]......................................................................................................2698 Failure Code [DXHWKY]......................................................................................................2701 Failure Code [DXHXKA]......................................................................................................2703 Failure Code [DXHXKB]......................................................................................................2705 Failure Code [DXHXKY]......................................................................................................2708 Failure Code [DXHYKA]......................................................................................................2710 Failure Code [DXHYKB]......................................................................................................2712 Failure Code [DXHYKY]......................................................................................................2715 Failure Code [DXHZKA]......................................................................................................2717 Failure Code [DXHZKB]......................................................................................................2719 Failure Code [DXHZKY]......................................................................................................2722 Failure Code [DXJ4KA]......................................................................................................2724 Failure Code [DXJ4KB]......................................................................................................2727 Failure Code [DXJ8KA]......................................................................................................2730 Failure Code [DXJ8KB]......................................................................................................2732 Failure Code [DXJ8KY]......................................................................................................2735 Failure Code [DXJ9KA]......................................................................................................2737 Failure Code [DXJ9KB]......................................................................................................2739 Failure Code [DXJ9KY]......................................................................................................2742 Failure Code [DXJBKA]......................................................................................................2744 Failure Code [DXJBKB]......................................................................................................2747 Failure Code [DXJBKY]......................................................................................................2750 Failure Code [DY2HKA]......................................................................................................2752 Failure Code [F7A0KT]......................................................................................................2755 Failure Code [F7A1KK]......................................................................................................2756 Failure Code [F7A8KB]......................................................................................................2759 Failure Code [F7ALKA]......................................................................................................2760 Failure Code [F7ALKB]......................................................................................................2764 Failure Code [F7AQKR]......................................................................................................2767 Failure Code [F7ARKR]......................................................................................................2779 Failure Code [F7ASKA]......................................................................................................2790 Failure Code [F7BSKR]......................................................................................................2794 Failure Code [F7BTKR]......................................................................................................2796 Failure Code [F7C0KR]......................................................................................................2797 Failure Code [F7CRKT]......................................................................................................2801 Failure Code [F7FQKR]......................................................................................................2802 Failure Code [F9A0KT]......................................................................................................2809 Failure Code [F9A0MC]......................................................................................................2810 Failure Code [F9A1KK]......................................................................................................2811 Failure Code [F9A2KK]......................................................................................................2815 Failure Code [F9AQKR]......................................................................................................2819 Failure Code [F9ARKR]......................................................................................................2831 Failure Code [F9ATKA]......................................................................................................2842 Failure Code [F9ATKB]......................................................................................................2846 Failure Code [F9AUMC]......................................................................................................2849 Troubleshooting of Electrical System (E-Mode)..................................................................................2853 Engine Does Not Start (Engine Does Not Crank)..............................................................................2853 Engine Does Not Start in Radio Control Mode (Engine Does Not Crank)........................................................2864 Engine Stops During Operation (Specifications of Radio Control)............................................................2869 Manual Preheating System Does Not Operate..................................................................................2876 Automatic Preheating System Does Not Operate...............................................................................2881 While Preheating is in Operation, Preheating Monitor Does Not Come On......................................................2884 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing...............................................2886 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow....2894 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation...............................................2897 Charge Level Monitor Comes On in Red While Engine is in Operation..........................................................2899 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation............................................2902 Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation...................................................2903 Power Train Oil Temperature Monitor Comes On in Red While Engine Runs......................................................2904 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation.............................................2905 Engine Coolant Temperature Gauge Does Not Show Correct Temperature.........................................................2906 Fuel Gauge Does Not Show Normally..........................................................................................2908 Power Train Oil Temperature Gauge Does Not Show Correct Temperature........................................................2912 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature..........................................................2915 Operation Mode Does Not Change.............................................................................................2917 Gear Shift Mode Does Not Change............................................................................................2918 Movement of Machine Does Not Agree to Instructions in Radio Control Transmitter Operation..................................2919 Radio Control/On-board Can Not be Changed..................................................................................2923 All Radio Control Can Not be Operated......................................................................................2928 When You Operate Customize Switch Does Not Show Customize Screen...........................................................2934 When You Change Setting on Customize Screen, Setting of Machine is Not Changed.............................................2935 Some Areas of Machine Monitor Screen are Not Shown.........................................................................2937 Alarm Buzzer Does Not Operate or Does Not Stop Operation...................................................................2938 Service Meter is Not Shown While Starting Switch is in OFF Position........................................................2939 Service Mode Cannot be Selected............................................................................................2940 Horn Does Not Sound........................................................................................................2941 Horn Does Not Stop.........................................................................................................2945 Horn Does Not Operate or Does Not Stop (Specifications of Radio Control)...................................................2947 Backup Alarm Does Not Sound................................................................................................2951 Backup Alarm Does Not Stop Operation.......................................................................................2954 Headlamp Does Not Come On..................................................................................................2956 Rear Lamp and Ripper Point Lamp Do Not Come On.............................................................................2964 Working Lamp Does Not Come On or Go Out (Radio Control Specification)......................................................2971 Red Revolving Lamp Does Not Come On or Go Out (Radio Control Specification)................................................2976 Blue Revolving Lamp Does Not Come On or Go Out (Radio Control Specification)...............................................2981 Green Revolving Lamp Does Not Come On or Go Out (Radio Control Specification)..............................................2986 No Wiper Operates..........................................................................................................2991 Front Wiper Does Not Operate...............................................................................................2999 Rear Wiper Does Not Operate................................................................................................3006 Left Door Wiper Does Not Operate...........................................................................................3013 Right Door Wiper Does Not Operate..........................................................................................3020 Fuel Feed Pump Does Not Operate or Stop Automatically......................................................................3027 Fan Does Not Rotate in Reverse.............................................................................................3037 Gear Cannot be Shifted.....................................................................................................3038 Front Washer Does Not Operate..............................................................................................3039 Rear Washer Does Not Operate...............................................................................................3042 Left Door Washer Does Not Operate..........................................................................................3045 Right Door Washer Does Not Operate.........................................................................................3048 Ripper Pin Puller Does Not Work............................................................................................3051 KOMTRAX Plus System Does Not Operate Normally..............................................................................3055 Data Download with Wireless LAN Does Not Operate...........................................................................3058 Operator Not Present Monitor Does Not Show Correctly.......................................................................3059 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)..................................................................3062 Information Shown in Troubleshooting Table (H-Mode)........................................................................3062 Machine Lacks Power (Drawbar Pull is Not Sufficient).......................................................................3063 Machine Does Not Travel (at 2nd or 3rd Gear Speed).........................................................................3078 Machine Does Not Move Off at All Gear Speeds...............................................................................3089 Machine Travels Only in One Direction, Forward or in Reverse...............................................................3105 Large Time Lag is in Gear Shifting or Directional Change...................................................................3109 Brake Does Not Work........................................................................................................3114 Power Train Oil Overheats..................................................................................................3122 Torque Converter Lockup Clutch Does Not Engage.............................................................................3126 Machine Cannot be Steered (Machine Does Not Turn Left or Right)............................................................3131 Machine Can Turn (Steering) Only in One Direction..........................................................................3139 Machine Falls Over (Steering)..............................................................................................3147 All Work Equipment Operate Slowly..........................................................................................3148 All Work Equipment Do Not Operate..........................................................................................3153 Blade Lift Speed or Power is Low...........................................................................................3158 Blade Tilt/Blade Pitch Speed is Low or Power is Low........................................................................3165 Ripper Lift Speed or Power is Low..........................................................................................3172 Ripper Tilt Speed is Low or Power is Low...................................................................................3179 Hydraulic Drift of Blade Lift is Large.....................................................................................3185 Hydraulic Drift of Tilted Blade is Large...................................................................................3186 Hydraulic Drift of Lifted Ripper is Large..................................................................................3187 Ripper Pin Puller Cylinder Does Not Operate................................................................................3188 Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve....................................3190 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)................................................................3192 Seismic Isolation Operator Seat Shakes Abnormally or Receives Shock........................................................3198 Troubleshooting of Engine (S-Mode).............................................................................................3199 Information Shown in Troubleshooting Table (S-Mode)........................................................................3199 Engine Does Not Crank When Starting Switch is Turned to Start Position.....................................................3200 Engine Cranks but Does Not Start...........................................................................................3202 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)....................................3207 Engine Startability is Unsatisfactory......................................................................................3214 Engine Does Not Pick Up Smoothly...........................................................................................3220 Engine Stops During Operation..............................................................................................3227 Engine Does Not Rotate Smoothly............................................................................................3234 Engine Lacks Output (or Lacks Power).......................................................................................3240 Exhaust Smoke is Black.....................................................................................................3246 Engine Oil Consumption is Excessive........................................................................................3251 Engine Oil Becomes Dirty Quickly...........................................................................................3255 Fuel Consumption is Excessive..............................................................................................3258 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)......................................................3262 Engine Oil Pressure Drops..................................................................................................3264 Fuel Mixes Into Engine Oil.................................................................................................3268 Water Mixes Into Engine Oil (Milky)........................................................................................3270 Coolant Temperature Increases Too High (Overheat)..........................................................................3272 Unusual Noise is Heard.....................................................................................................3276 Vibration is Excessive.....................................................................................................3279 Air Cannot be Bled from Fuel Circuit.......................................................................................3281 50 Disassembly and Assembly........................................................................................................3285 Table of Contents..............................................................................................................3286 Precautions Before Work........................................................................................................3292 Related Information on Disassembly and Assembly................................................................................3293 How to Read This Manual....................................................................................................3293 Coating Materials List.....................................................................................................3295 Special Tool List..........................................................................................................3300 Sketches of Special Tools..................................................................................................3339 Prepare........................................................................................................................3344 Drain and Add Coolant......................................................................................................3344 How to Drain Coolant...................................................................................................3345 How to Add Coolant.....................................................................................................3346 Drain and Add Hydraulic Oil................................................................................................3348 How to Drain Hydraulic Oil.............................................................................................3349 How to Add Hydraulic Oil...............................................................................................3349 Drain and Add Fuel.........................................................................................................3350 How to Drain Fuel......................................................................................................3351 How to Add Fuel........................................................................................................3351 Collect and Refill Refrigerant.............................................................................................3352 How to Collect Refrigerant.............................................................................................3352 How to Refill Refrigerant..............................................................................................3353 Engine and Cooling System......................................................................................................3354 Remove and Install Supply Pump Assembly (Right Bank).......................................................................3354 How to Remove Supply Pump Assembly (Right Bank)........................................................................3355 How to Install Supply Pump Assembly (Right Bank).......................................................................3366 Remove and Install Supply Pump Assembly (Left Bank)........................................................................3385 How to Remove Supply Pump Assembly (Left Bank).........................................................................3386 How to Install Supply Pump Assembly (Left Bank)........................................................................3395 Remove and Install Injector Assembly (Right Bank)..........................................................................3408 How to Remove Injector Assembly (Right Bank)...........................................................................3409 How to Install Injector Assembly (Right Bank)..........................................................................3422 Remove and Install Injector Assembly (Left Bank)...........................................................................3437 How to Remove Injector Assembly (Left Bank)............................................................................3438 How to Install Injector Assembly (Left Bank)...........................................................................3450 Remove and Install Cylinder Head Assembly (Right Bank).....................................................................3464 How to Remove Cylinder Head Assembly (Right Bank)......................................................................3466 How to Install Cylinder Head Assembly (Right Bank).....................................................................3494 Remove and Install Cylinder Head Assembly (Left Bank)......................................................................3534 How to Remove Cylinder Head Assembly (Left Bank).......................................................................3536 How to Install Cylinder Head Assembly (Left Bank)......................................................................3565 Remove and Install Starter Assembly........................................................................................3609 How to Remove Starting Motor Assembly..................................................................................3610 How to Install Starting Motor Assembly.................................................................................3612 Remove and Install Alternator Belt.........................................................................................3616 How to Remove Alternator Belt..........................................................................................3616 How to Install Alternator Belt.........................................................................................3618 Remove and Install Alternator Assembly.....................................................................................3620 How to Remove Alternator Assembly......................................................................................3621 How to Install Alternator Assembly.....................................................................................3627 Remove and Install Radiator Guard Assembly.................................................................................3635 How to Remove Radiator Guard Assembly..................................................................................3637 How to Install Radiator Guard Assembly.................................................................................3648 Remove and Install Radiator Assembly.......................................................................................3660 How to Remove Radiator Assembly........................................................................................3661 How to Install Radiator Assembly.......................................................................................3665 Remove and Install Radiator Tube...........................................................................................3670 Remove Radiator Tube...................................................................................................3670 Install Radiator Tube..................................................................................................3672 Remove and Install Hydraulic Oil Cooler Assembly...........................................................................3675 How to Remove Hydraulic Oil Cooler Assembly............................................................................3676 How to Install Hydraulic Oil Cooler Assembly...........................................................................3679 Remove and Install Aftercooler Assembly....................................................................................3682 How to Remove Aftercooler Assembly.....................................................................................3683 How to Install Aftercooler Assembly....................................................................................3687 How to Swing Radiator Fan Drive Assembly...................................................................................3693 Remove and Install Cooling Fan Drive Assembly..............................................................................3705 Remove Cooling Fan Drive Assembly......................................................................................3706 Install Cooling Fan Drive Assembly.....................................................................................3712 Remove and Install Cooling Fan Motor Assembly..............................................................................3719 How to Remove Cooling Fan Motor Assembly...............................................................................3720 How to Install Cooling Fan Motor Assembly..............................................................................3722 Remove and Install Engine Front Oil Seal...................................................................................3724 How to Remove Engine Front Oil Seal....................................................................................3725 How to Install Engine Front Oil Seal...................................................................................3726 Remove and Install Engine Rear Oil Seal....................................................................................3729 How to Remove Engine Rear Oil Seal.....................................................................................3730 How to Install Engine Rear Oil Seal....................................................................................3731 Remove and Install Engine Assembly.........................................................................................3734 How to Remove Engine Assembly..........................................................................................3736 How to Install Engine Assembly.........................................................................................3753 Remove and Install Engine Hood Assembly....................................................................................3772 How to Remove Engine Hood Assembly.....................................................................................3773 How to Install Engine Hood Assembly....................................................................................3781 Remove and Install Fuel Tank Assembly......................................................................................3789 How to Remove Fuel Tank Assembly.......................................................................................3790 How to Install Fuel Tank Assembly......................................................................................3799 Remove and Install Muffler Assembly........................................................................................3808 How to Remove Muffler Assembly.........................................................................................3808 How to Install Muffler Assembly........................................................................................3811 Remove and Install Turbocharger Assembly (Right Bank)......................................................................3815 How to Remove Turbocharger Assembly (Right Bank).......................................................................3815 How to Install Turbocharger Assembly (Right Bank)......................................................................3821 Remove and Install Turbocharger Assembly (Left Bank).......................................................................3830 How to Remove Turbocharger Assembly (Left Bank)........................................................................3830 How to Install Turbocharger Assembly (Left Bank).......................................................................3836 Remove and Install Air Cleaner Assembly....................................................................................3846 How to Remove Air Cleaner Assembly.....................................................................................3846 How to Install Air Cleaner Assembly....................................................................................3850 Remove and Install Air Conditioner Compressor Assembly.....................................................................3855 How to Remove Air Conditioner Compressor Assembly......................................................................3856 How to Install Air Conditioner Compressor Assembly.....................................................................3861 Remove and Install Air Conditioner Condenser Assembly......................................................................3866 How to Remove Air Conditioner Condenser Assembly.......................................................................3867 How to Install Air Conditioner Condenser Assembly......................................................................3871 Power Train....................................................................................................................3876 Remove and Install Damper Assembly.........................................................................................3876 How to Remove Damper Assembly..........................................................................................3877 How to Install Damper Assembly.........................................................................................3884 Disassemble and Assemble Damper Assembly...................................................................................3891 Disassemble Damper Assembly............................................................................................3891 How to Assemble Damper Assembly........................................................................................3894 Remove and Install Power Train Unit Assembly...............................................................................3897 Remove Power Train Unit Assembly.......................................................................................3899 How to Install Power Train Unit Assembly...............................................................................3916 Disconnect and Connect Power Train Unit Assembly...........................................................................3934 How to Disconnect Power Train Unit Assembly............................................................................3935 How to Connect Power Train Unit Assembly...............................................................................3948 Disassemble and Assemble PTO Assembly......................................................................................3963 How to Disassemble PTO Assembly........................................................................................3964 How to Assemble PTO Assembly...........................................................................................3967 Disassemble and Assemble Torque Converter Assembly.........................................................................3972 How to Disassemble Torque Converter Assembly...........................................................................3973 How to Assemble Torque Converter Assembly..............................................................................3977 Disassemble and Assemble Transmission Assembly.............................................................................3984 How to Disassemble Transmission Assembly...............................................................................3985 How to Assemble Transmission Assembly..................................................................................3994 Disassemble and Assemble Steering Case Assembly............................................................................4007 Disassemble Steering Case Assembly.....................................................................................4009 Assemble Steering Case Assembly........................................................................................4017 Remove and Install Final Drive Assembly....................................................................................4030 Remove Final Drive Assembly............................................................................................4030 How to Install Final Drive Assembly....................................................................................4033 Disassemble and Assemble Final Drive Assembly..............................................................................4037 How to Disassemble Final Drive Assembly................................................................................4039 How to Assemble Final Drive Assembly...................................................................................4051 Undercarriage and Frame........................................................................................................4069 Remove and Install Track Frame Assembly....................................................................................4069 Remove Track Frame Assembly............................................................................................4071 How to Install Track Frame Assembly....................................................................................4076 Remove and Install Recoil Spring Assembly..................................................................................4082 Remove Recoil Spring Assembly..........................................................................................4083 Install Recoil Spring Assembly.........................................................................................4092 Disassemble and Assemble Recoil Spring Assembly............................................................................4097 Disassemble Recoil Spring Assembly.....................................................................................4097 How to Assemble Recoil Spring Assembly.................................................................................4098 Remove and Install Track Roller Assembly...................................................................................4099 Remove Track Roller Assembly...........................................................................................4099 Install Track Roller Assembly..........................................................................................4101 Disassemble and Assemble Track Roller Assembly.............................................................................4103 How to Disassemble Track Roller Assembly...............................................................................4103 How to Assemble Track Roller Assembly..................................................................................4105 Remove and Install No. 1 Bogie Assembly....................................................................................4108 Remove No.1 Bogie Assembly.............................................................................................4109 Install No. 1 Bogie Assembly...........................................................................................4112 Remove and Install Bogie Assembly..........................................................................................4115 Remove Bogie Assembly..................................................................................................4117 Install Bogie Assembly.................................................................................................4120 Disassemble and Assemble Bogie Assembly....................................................................................4122 Disassemble Bogie Assembly.............................................................................................4123 How to Assemble Bogie Assembly.........................................................................................4124 Remove and Install Idler Assembly..........................................................................................4127 How to Remove Idler Assembly...........................................................................................4127 How to Install Idler Assembly..........................................................................................4129 Disassemble and Assemble Idler Assembly....................................................................................4131 How to Disassemble Idler Assembly......................................................................................4132 How to Assemble Idler Assembly.........................................................................................4133 Remove and Install Carrier Roller Assembly.................................................................................4136 How to Remove Carrier Roller Assembly..................................................................................4136 How to Install Carrier Roller Assembly.................................................................................4137 Disassemble and Assemble Carrier Roller Assembly...........................................................................4138 How to Disassemble Carrier Roller Assembly.............................................................................4138 How to Assemble Carrier Roller Assembly................................................................................4139 Remove and Install Pivot Shaft Assembly....................................................................................4142 How to Remove Pivot Shaft Assembly.....................................................................................4142 How to Install Pivot Shaft Assembly....................................................................................4143 Separate and Connect Track Assembly........................................................................................4146 Separate Track Assembly................................................................................................4147 How to Install Track Assembly..........................................................................................4151 Disassemble and Assemble Track Assembly Generally..........................................................................4155 How to Disassemble Full Track Shoe Assembly............................................................................4157 How to Assemble Full Track Shoe Assembly...............................................................................4160 Disassemble and Assemble One Track Link Assembly in Field..................................................................4174 Disassemble One Track Link Assembly in Field...........................................................................4176 Assemble One Track Link Assembly in Field..............................................................................4178 Disassemble and Assemble Master Link.......................................................................................4181 Disassemble Master Link................................................................................................4183 Assemble Master Link...................................................................................................4185 Remove and Install Equalizer Bar Assembly..................................................................................4188 How to Remove Equalizer Bar Assembly...................................................................................4190 How to Install Equalizer Bar Assembly..................................................................................4196 Disassemble and Assemble Equalizer Bar Bushing.............................................................................4202 Disassemble Equalizer Bar Bushing......................................................................................4202 How to Assemble Equalizer Bar Bushing..................................................................................4203 Remove and Install Segment Teeth...........................................................................................4205 Remove Segment Teeth...................................................................................................4205 Install Segment Teeth..................................................................................................4206 Remove and Install Power Ladder Assembly...................................................................................4207 Remove Power Ladder Assembly...........................................................................................4207 Install Power Ladder Assembly..........................................................................................4210 Open and Close Underguard Assembly.........................................................................................4213 How to Open Underguard Assembly........................................................................................4213 How to Close Underguard Assembly.......................................................................................4221 Remove and Install Under Guard Assembly....................................................................................4229 How to Remove Underguard Assembly......................................................................................4229 How to Install Underguard Assembly.....................................................................................4237 Hydraulic System...............................................................................................................4243 Remove and Install Hydraulic Tank Assembly.................................................................................4243 How to Remove Hydraulic Tank Assembly..................................................................................4244 How to Install Hydraulic Tank Assembly.................................................................................4249 Remove and Install Work Equipment Pump Assembly............................................................................4254 Remove Work Equipment Pump Assembly....................................................................................4254 Install Work Equipment Pump Assembly...................................................................................4255 Remove and Install Power Train Pump and Steering Lubrication Pump Assembly.................................................4257 Remove Power Train Pump and Steering Lubrication Pump Assembly.........................................................4258 How to Install Power Train Pump and Steering Lubrication Pump Assembly.................................................4267 Remove and Install Control Valve Assembly..................................................................................4277 How to Remove Control Valve Assembly...................................................................................4278 How to Install Control Valve Assembly..................................................................................4287 Remove and Install Cooling Fan Pump Assembly...............................................................................4297 Remove Cooling Fan Pump Assembly.......................................................................................4298 How to Install Cooling Fan Pump Assembly...............................................................................4302 Remove and Install Scavenging Pump Assembly................................................................................4306 Remove Scavenging Pump Assembly........................................................................................4307 How to Install Scavenging Pump Assembly................................................................................4308 Work Equipment.................................................................................................................4310 Remove and Install Blade Assembly..........................................................................................4310 How to Remove Blade Assembly...........................................................................................4311 How to Install Blade Assembly..........................................................................................4313 Disassemble and Assemble Blade Assembly (U dozer and Semi-U dozer spec)....................................................4316 Disassemble Blade Assembly (U dozer and Semi-U dozer spec).............................................................4316 Assemble Blade Assembly (U dozer and Semi-U dozer spec)................................................................4321 Disassemble and Assemble Blade Assembly (Super dozer spec).................................................................4327 Disassemble Blade Assembly (Super dozer spec)..........................................................................4327 Assemble Blade Assembly (Super dozer spec).............................................................................4332 Disassemble and Assemble Giant Ripper Assembly.............................................................................4338 Disassemble Giant Ripper Assembly......................................................................................4339 Assemble Giant Ripper Assembly.........................................................................................4350 Remove and Install Blade Lift Cylinder Assembly............................................................................4362 Remove Blade Lift Cylinder Assembly....................................................................................4363 Install Blade Lift Cylinder Assembly...................................................................................4368 Disassemble and Assemble Blade Lift Cylinder Assembly......................................................................4373 Disassemble Blade Lift Cylinder Assembly...............................................................................4374 Assemble Blade Lift Cylinder Assembly..................................................................................4377 Disassemble and Assemble Blade Tilt Cylinder Assembly (U dozer and Semi-U dozer spec)......................................4382 Disassemble Blade Tilt Cylinder Assembly (U dozer and Semi-U dozer spec)...............................................4382 Assemble Blade Tilt Cylinder Assembly (U dozer and Semi-U dozer spec)..................................................4384 Disassemble and Assemble Blade Tilt Cylinder Assembly (Super dozer spec)...................................................4388 Disassemble Blade Tilt Cylinder Assembly (Super dozer spec)............................................................4389 Assemble Blade Tilt Cylinder Assembly (Super dozer spec)...............................................................4391 Disassemble and Assemble Ripper Lift Cylinder Assembly.....................................................................4397 Disassemble Ripper Lift Cylinder Assembly..............................................................................4398 Assemble Ripper Lift Cylinder Assembly.................................................................................4400 Disassemble and Assemble Ripper Tilt Cylinder Assembly.....................................................................4405 Disassemble Ripper Tilt Cylinder Assembly..............................................................................4406 Assemble Ripper Tilt Cylinder Assembly.................................................................................4408 Disassemble and Assemble Ripper Pin Puller Cylinder Assembly...............................................................4413 Disassemble Ripper Pin Puller Cylinder Assembly........................................................................4413 Assemble Ripper Pin Puller Cylinder Assembly...........................................................................4414 CAB Related Parts..............................................................................................................4417 Remove and Install ROPS Guard..............................................................................................4417 Remove ROPS Guard......................................................................................................4417 How to Install ROPS Guard..............................................................................................4418 Remove and Install Operator Cab Assembly...................................................................................4419 How to Remove Operator Cab Assembly....................................................................................4420 How to Install Operator Cab Assembly...................................................................................4427 Remove and Install Operator Cab Glass (Adhered Glass)......................................................................4434 How to Remove Operator Cab Glass (Adhered Glass).......................................................................4435 How to Install Operator Cab Glass (Adhered Glass)......................................................................4435 Remove and Install Air Conditioner Unit Assembly...........................................................................4440 How to Remove Air Conditioner Unit Assembly............................................................................4441 How to Install Air Conditioner Unit Assembly...........................................................................4451 Remove and Install Operator's Seat Assembly................................................................................4462 Remove Operator's Seat Assembly........................................................................................4462 Install Operator's Seat Assembly.......................................................................................4464 How to Remove and Install Seat Belt........................................................................................4466 How to Remove Seat Belt................................................................................................4466 How to Install Seatbelt................................................................................................4467 Electrical System..............................................................................................................4469 Remove and Install Engine Controller Assembly (Right Bank).................................................................4469 How to Remove Engine Controller Assembly (Right Bank)..................................................................4470 How to Install Engine Controller Assembly (Right Bank).................................................................4471 Remove and Install Engine Controller Assembly (Left Bank)..................................................................4473 How to Remove Engine Controller Assembly (Left Bank)...................................................................4474 How to Install Engine Controller Assembly (Left Bank)..................................................................4475 Remove and Install Power Train Controller Assembly.........................................................................4477 Remove Power Train Controller Assembly.................................................................................4477 Install Power Train Controller Assembly................................................................................4480 Remove and Install Work Equipment Controller Assembly......................................................................4483 How to Remove Work Equipment Controller Assembly.......................................................................4483 How to Install Work Equipment Controller Assembly......................................................................4486 Remove and Install Machine Monitor Assembly................................................................................4489 How to Remove Machine Monitor Assembly.................................................................................4489 How to Install Machine Monitor Assembly................................................................................4491 Remove and Install Mass Air Flow and Temperature Sensor....................................................................4493 How to Remove Mass Air Flow and Temperature Sensor.....................................................................4494 How to Install Mass Air Flow and Temperature Sensor....................................................................4495 Remove and Install KOMTRAX Terminal Assembly...............................................................................4496 How to Remove KOMTRAX Terminal Assembly................................................................................4496 How to Install KOMTRAX Terminal Assembly...............................................................................4498 Remove And Install KOMTRAX Plus Controller Assembly........................................................................4500 How to Remove KOMTRAX Plus Controller Assembly.........................................................................4500 How to Install KOMTRAX Plus Controller Assembly........................................................................4502 Remove and Install Option Controller Assembly..............................................................................4505 How to Remove Option Controller Assembly...............................................................................4505 How to Install Option Controller Assembly..............................................................................4508 Remove and Install Wireless LAN Unit Assembly..............................................................................4512 How to Remove Wireless LAN Unit Assembly...............................................................................4512 How to Install Wireless LAN Unit Assembly..............................................................................4514 60 Maintenance Standard............................................................................................................4517 Table of Contents..............................................................................................................4518 Explanation of Terms for Maintenance Standard..................................................................................4520 Engine and Cooling System......................................................................................................4522 Maintenance Standard for Engine Mount......................................................................................4522 Maintenance Standard for Damper............................................................................................4524 Maintenance Standard for Cooling System....................................................................................4526 Maintenance Standard for Cooling Fan Pump..................................................................................4528 Maintenance Standard for Servo Valve (Cooling Fan Pump)....................................................................4534 Maintenance Standard for Cooling Fan Motor.................................................................................4536 Power Train....................................................................................................................4539 Maintenance Standard for Universal Joint...................................................................................4539 Maintenance Standard for Power Train Mount.................................................................................4540 Maintenance Standard for Torque Converter and PTO..........................................................................4542 Maintenance Standard for Torque Converter Control Valve....................................................................4546 Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve...............................................4547 Maintenance Standard for ECMV (Lockup Clutch)..............................................................................4549 Maintenance Standard for ECMV (Stator Clutch)..............................................................................4550 Maintenance Standard for Transmission......................................................................................4551 Maintenance Standard for Triplex Pump (Lubrication, Power Train, Torque Converter).........................................4555 Maintenance Standard for Transmission Control Valve........................................................................4557 Maintenance Standard for ECMV (Directional Operation Clutch, Gear Speed Clutch)............................................4558 Maintenance Standard for Priority Valve....................................................................................4559 Maintenance Standard for Transmission Lubrication Relief Valve.............................................................4560 Maintenance Standard for Transfer, Bevel Gear Shaft, and Steering..........................................................4561 Maintenance Standard for Solenoid Valve (Brake)............................................................................4567 Maintenance Standard for Sudden Stop Prevention Valve......................................................................4568 Maintenance Standard for Final Drive.......................................................................................4569 Maintenance Standard for Sprocket..........................................................................................4574 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing.........................................................4575 Undercarriage and Frame........................................................................................................4576 Maintenance Standard for Main Frame........................................................................................4576 Maintenance Standard for Suspension........................................................................................4578 Maintenance Standard for Track Frame and Idler Cushion.....................................................................4581 Maintenance Standard for Idler.............................................................................................4585 Maintenance Standard for Track Roller Bogie................................................................................4587 Maintenance Standard for Track Roller......................................................................................4588 Maintenance Standard for Carrier Roller....................................................................................4591 Maintenance Standard for Track Shoes.......................................................................................4592 Maintenance Standard for Single Shoes and Heavy Duty Shoes.................................................................4594 Hydraulic System...............................................................................................................4595 Maintenance Standard for Hydraulic Tank....................................................................................4595 Maintenance Standard for Duplex Pump (Work Equipment)......................................................................4596 Maintenance Standard for Scavenging Pump...................................................................................4600 Maintenance Standard for Control Valve.....................................................................................4601 Maintenance Standard for Self-Pressure Reducing Valve......................................................................4609 Maintenance Standard for Quick Drop Valve..................................................................................4612 Work Equipment.................................................................................................................4613 Maintenance Standard for Cylinder Stay.....................................................................................4613 Maintenance Standard for Front Work Equipment..............................................................................4614 Maintenance Standard for Cutting Edge and End Bit..........................................................................4621 Maintenance Standard for Variable Multi-Shank Ripper.......................................................................4622 Maintenance Standard for Variable Giant Ripper.............................................................................4625 Maintenance Standard for Blade Lift Cylinder...............................................................................4628 Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder......................................................4629 Maintenance Standard for Blade Tilt Cylinder...............................................................................4630 Maintenance Standard for Ripper Lift Cylinder..............................................................................4632 Maintenance Standard for Ripper Tilt Cylinder..............................................................................4633 Maintenance Standard for Pin Puller Cylinder...............................................................................4634 CAB Related Parts..............................................................................................................4635 Maintenance Standard for CAB Mount.........................................................................................4635 Maintenance Standard for ROPS Mount........................................................................................4636 80 Appendix........................................................................................................................4637 Table of Contents..............................................................................................................4638 Precautions Before Work........................................................................................................4640 Air Conditioner System.........................................................................................................4641 Precautions for Refrigerant................................................................................................4641 Air Conditioner Component..................................................................................................4642 Specifications of Air Conditioner..........................................................................................4644 Structure and Function of Refrigeration Cycle..............................................................................4645 Outline of Refrigeration Cycle.............................................................................................4646 Component Parts of Air Conditioner System......................................................................................4648 Air Conditioner Unit.......................................................................................................4648 Configuration Diagram of Air Conditioner Unit..........................................................................4648 Function of Air Conditioner Unit.......................................................................................4650 Component Parts of Air Conditioner Unit....................................................................................4652 Function of Evaporator as Air Conditioner Unit Component...............................................................4653 Function of Heater Core as Air Conditioner Unit Component..............................................................4653 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component............................................4653 Function of Servo Motor as Air Conditioner Unit Component..............................................................4653 Structure of Expansion Valve as Air Conditioner Unit Component.........................................................4654 Function of Expansion Valve as Air Conditioner Unit Component..........................................................4654 Operate Expansion Valve as Air Conditioner Unit Component..............................................................4654 Function of Triple Pressure Switch.....................................................................................4655 Air Conditioner Controller.................................................................................................4656 Structure of Air Conditioner Controller................................................................................4656 Compressor.................................................................................................................4657 Structure of Compressor................................................................................................4657 Specifications of Compressor...........................................................................................4657 Function of Compressor.................................................................................................4657 Condenser..................................................................................................................4658 Structure of Condenser.................................................................................................4658 Specifications of Condenser............................................................................................4658 Function of Condenser..................................................................................................4658 Receiver Drier.............................................................................................................4659 Structure of Receiver Dryer............................................................................................4659 Specifications of Receiver Dryer.......................................................................................4659 Function of Receiver Dryer.............................................................................................4659 Air Conditioner Related Sensors............................................................................................4660 Structure of Sunlight Sensor...........................................................................................4660 Function of Sunlight Sensor............................................................................................4660 Structure of Outside Temperature Sensor................................................................................4660 Function of Outside Air Temperature Sensor.............................................................................4660 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner....................................................4662 Circuit Diagram and Configuration of Connector Pins of Air Conditioner.........................................................4664 System Diagram of Air Conditioner..............................................................................................4666 Input and Output Signals of Air Conditioner Controller.....................................................................4667 Function of Air Conditioner Controller.................................................................................4668 Locations of Air Conditioner Parts and Layout of Connectors....................................................................4669 Examine Air Leakage (Duct).....................................................................................................4677 How to Examine Air Leakage (Duct)..........................................................................................4677 Examine Air Conditioner with Self-Diagnosis Function...........................................................................4680 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor........................................4681 Examine Vent (Mode) Changeover.................................................................................................4682 How to Examine Vent (Mode) Changeover......................................................................................4682 Examine Fresh/Recirc Air Changeover............................................................................................4683 How to Examine Fresh/Recirc Air Changeover.................................................................................4683 Examine Sunlight Sensor........................................................................................................4684 How to Examine Sunlight Sensor.............................................................................................4684 Examine Refrigerant (Triple) Pressure Switch...................................................................................4685 How to Examine Refrigerant (Triple) Pressure Switch........................................................................4685 Examine Relay..................................................................................................................4686 How to Examine Relay.......................................................................................................4686 Air Conditioner Troubleshooting Chart 1........................................................................................4687 Air Conditioner Troubleshooting Chart 2........................................................................................4688 Information Shown in Troubleshooting Table.....................................................................................4691 Failure Code [879AKA]..........................................................................................................4692 Failure Code [879AKB]..........................................................................................................4693 Failure Code [879BKA]..........................................................................................................4695 Failure Code [879BKB]..........................................................................................................4698 Failure Code [879CKA]..........................................................................................................4701 Failure Code [879CKB]..........................................................................................................4702 Failure Code [879DKZ]..........................................................................................................4703 Failure Code [879EMC]..........................................................................................................4706 Failure Code [879FMC]..........................................................................................................4707 Failure Code [879GKX]..........................................................................................................4708 Air Conditioner Does Not Operate...............................................................................................4711 Defective Cooling..............................................................................................................4714 Heater Does Not Operate........................................................................................................4723 Cool Air Does Not Come Out.....................................................................................................4727 No Air Comes Out or Air Flow is Abnormal.......................................................................................4733 Fresh/Recirc Air Changeover Does Not Work......................................................................................4737 Troubleshooting by Gauge Pressure..............................................................................................4741 Connect Service Tool...........................................................................................................4744 How to Connect Service Tool................................................................................................4744 Precautions for Disconnection and Connection of Air Conditioner Piping.........................................................4746 Handle Compressor Oil..........................................................................................................4748 90 Circuit Diagrams................................................................................................................4751 Table of Contents..............................................................................................................4752 How to Read the Codes for Electric Cable.......................................................................................4753 Hydraulic Circuit Diagram......................................................................................................4757 Symbols Used in Hydraulic Circuit Diagram..................................................................................4757 Hydraulic Circuit Diagram..................................................................................................4761 Power Train Hydraulic Circuit Diagram......................................................................................4763 Electrical Circuit Diagram.....................................................................................................4765 Symbols Used in Electric Circuit Diagram...................................................................................4765 Electrical Circuit Diagram (1/12)..........................................................................................4769 Electrical Circuit Diagram (2/12)..........................................................................................4771 Electrical Circuit Diagram (3/12)..........................................................................................4773 Electrical Circuit Diagram (4/12)..........................................................................................4775 Electrical Circuit Diagram (5/12)..........................................................................................4777 Electrical Circuit Diagram (6/12)..........................................................................................4779 Electrical Circuit Diagram (7/12)..........................................................................................4781 Electrical Circuit Diagram (8/12)..........................................................................................4783 Electrical Circuit Diagram (9/12)..........................................................................................4785 Electrical Circuit Diagram (10/12).........................................................................................4787 Electrical Circuit Diagram (11/12).........................................................................................4789 Electrical Circuit Diagram (12/12).........................................................................................4791 Electrical Circuit Diagram of Inside of CAB (1/15).........................................................................4793 Electrical Circuit Diagram of Inside of CAB (2/15).........................................................................4795 Electrical Circuit Diagram of Inside of CAB (3/15).........................................................................4797 Electrical Circuit Diagram of Inside of CAB (4/15).........................................................................4799 Electrical Circuit Diagram of Inside of CAB (5/15).........................................................................4801 Electrical Circuit Diagram of Inside of CAB (6/15).........................................................................4803 Electrical Circuit Diagram of Inside of CAB (7/15).........................................................................4805 Electrical Circuit Diagram of Inside of CAB (8/15).........................................................................4807 Electrical Circuit Diagram of Inside of CAB (9/15).........................................................................4809 Electrical Circuit Diagram of Inside of CAB (10/15)........................................................................4811 Electrical Circuit Diagram of Inside of CAB (11/15)........................................................................4813 Electrical Circuit Diagram of Inside of CAB (12/15)........................................................................4815 Electrical Circuit Diagram of Inside of CAB (13/15)........................................................................4817 Electrical Circuit Diagram of Inside of CAB (14/15)........................................................................4819 Electrical Circuit Diagram of Inside of CAB (15/15)........................................................................4821 Index...............................................................................................................................4823
DESCRIPTION:
KOMATSU D475A-8R BULLDOZER SHOP MANUAL SEN06892-04 – PDF DOWNLOAD
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 02/01/2025
