Komatsu D475A-5E0 & D475ASD-5E0 Bulldozer (30001 and up) Shop Manual – SEN00203-18

This complete service repair workshop manual PDF download for the Komatsu D475A-5E0 & D475ASD-5E0 Bulldozer (SN: 30001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Komatsu D475A – SN: 30001 and up
Komatsu D475ASD – SN: 30001 and up

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN00203-18
Total Pages : 1617

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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

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TABLE OF CONTENTS :

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

01 Specification
Specification and technical data
Specification drawings
Specifications
Weight table
Fuel, coolant and lubricants

10 Structure, function and maintenance standard
Engine and cooling system
Engine and cooling system
Radiator and oil cooler
Engine mount
Cooling fan pump
Cooling fan motor
Power train, Part 1
Power train
Power train hydraulic equipment arrangement diagram
Damper and universal joint
Power train system
General view of power train unit
Torque converter, PTO
Torque converter valve
Torque converter lockup control system
Scavenging pump
Transmission control
Transmission
Power train, Part 2
Transmission control valve
Transmission clutch ECMV
Priority valve
Lubricating oil relief valve
Torque converter, power train, lubricating oil pump
Steering, brake control
Final drive
Sprocket
Steering unit
Steering control valve
Steering clutch ECMV, Steering brake ECMV
Parking brake valve
Sudden stop prevention valve
Undercarriage and frame
Track frame
Recoil spring
Idler
Track roller
Carrier roller
Track roller bogie
Track shoe
Main frame
Suspension
Hydraulic system, Part 1
Hydraulic system, Part 1
Work equipment hydraulic equipment arrangement diagram
PPC control piping diagram
Work equipment control
Work equipment pump
PPC valve
PCCS lever
Hydraulic system, Part 2
Control valve
CLSS
Unload valve
Introduction of LS pressure
LS bypass plug
Pressure compensation valve
Blade lift valve
Merge-divider valve
Self pressure reducing valve
Pilot solenoid valve
Hydraulic system, Part 3
Hydraulic tank, hydraulic filter
Accumulator
Work equipment cylinder
Piston valve
Quick drop valve
Blade control knob (Dual tilt specification)
Blade control knob (Superdozer specification)
Pitch and dual solenoid valve
Pin puller hydraulic circuit diagram
Pin puller solenoid valve
Work equipment
Work equipment
Cylinder stay
Blade
Ripper equipment
Cab and its attachments
Cab and its attachments
Cab mount
Cab
Air conditioner
Electrical system
Engine control system
CRI engine control system
Monitor system
Machine monitor
Mode selection system
Electrical equipment
Palm command control system (PCCS)
Sensors
Vehicle health monitoring system (VHMS)
ORBCOMM terminal

20 Standard value table
Standard service value table
Standard value table for engine
Standard value table for chassis

30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Measuring exhaust temperature
Measuring exhaust gas color
Adjusting valve clearance
Testing compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Handling of reduced cylinder mode operation
Handling of no injection cranking operation
Testing fuel return and leak amount
Bleeding air from fuel circuit
Bleeding air from fuel circuit (Low-grade fuel specification)
Testing fuel circuit for leakage
Testing and adjusting alternator belt tension
Testing and adjusting belt tension for air conditioner compressor
Adjusting fuel control dial and decelerator pedal
Testing and adjusting, Part 2
Measuring power train oil pressure
Adjusting transmission speed sensor
Simple method to test brake performance
Adjusting brake pedal and parking brake lever
Adjusting PCCS lever console position
Emergency escape method when power train has trouble
Inspecting wear of sprocket
Testing and adjusting track shoe tension
Testing and adjusting work equipment oil pressure
Testing and adjusting control circuit basic pressure
Measuring PPC valve output pressure and solenoid valve output pressure
Adjusting play of PPC valve
Measuring outlet pressure of ripper pin puller solenoid valve
Checking parts which caused hydraulic drift of blade and ripper
Measuring internal leakage of work equipment cylinder
Releasing residual pressure from work equipment cylinder
Bleeding air from work equipment cylinder
Adjusting ripper lever position
Adjusting work equipment lock lever
Measuring fan motor speed
Measuring fan circuit oil pressure
Bleeding air from fan pump
Measurement procedure for blade tilt control angle (Dual tiltdozer specification)
Measurement procedure for blade tilt control angle (Superdozer specification)
Testing and adjusting operator’s cab
Adjusting blade
Testing and adjusting operator’s seat isolator
Testing and adjusting, Part 3
Special functions of monitor panel (EMMS)
Testing and adjusting, Part 4
Adjustment method when controller has been replaced
Preparation work for troubleshooting for electrical equipment system
Inspection procedure of diode
Handling of optional devices
Initialization procedures for VHMS controller
Precautions for replacing VHMS controller
Pm Clinic service

40 Troubleshooting
Failure code table and fuse locations
Failure code table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures of troubleshooting
Contents of troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code, Part 1
Failure code [1380MW] Lockup clutch: Clutch slip
Failure code [1500L0] Transmission clutch: Dual engagement
Failure code [15E0MW] Transmission clutch: Clutch slip
Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON
Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF
Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON
Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF
Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON
Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF
Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON
Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF
Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON
Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF
Failure code [1800MW] Power train clutch: Slip
Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON
Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF
Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON
Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF
Failure code [2300NR] Brake thermal load: Abnormal heating
Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON
Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF
Failure code [2301NR] Right steering brake thermal load: Abnormal heating
Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON
Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF
Failure code [2302NR] Left steering brake thermal load: Abnormal heating
Failure code [6001ZK] Failure code for design
Failure code [A000NS] Engine: Overheat
Failure code [AA10NX] Air cleaner: Clogging
Failure code [AB00MA] Battery charge abnormality: Malfunction
Failure code [B@BAZG] Engine oil: Oil pressure too low
Failure code [B@BAZK] Engine oil: Oil level reduction
Failure code [B@BCNS] Engine coolant: Overheat
Failure code [B@BCZK] Engine coolant: Level too low
Failure code [B@BEBF] Fuel: Water in fuel
Failure code [B@BFZK] Fuel level: Reduction
Failure code [B@CENS] Power train oil: Overheat
Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure
Failure code [B@CHZK] Power train oil: Oil level reduction
Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction
Failure code [B@HANS] Hydraulic oil: Overheat
Failure code [B@HAZK] Hydraulic oil: Level reduction
Troubleshooting by failure code, Part 2
Failure code [CA111] Engine controller (Left bank): Internal abnormality
Failure code [CB111] Engine controller (Right bank): Internal abnormality
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal
Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected
Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank): High voltage detection
Failure code [CA132] Decelerator pedal sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected
Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected
Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected
Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected
Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected
Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected
Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection
Troubleshooting by failure code, Part 3
Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA323] Injector #5 (L/B #5) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA324] Injector #3 (L/B #3) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA325] Injector #6 (L/B #6) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA331] Injector #2 (L/B #2) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA332] Injector #4 (L/B #4) system disconnection or short circuit (At left bank): Disconnection, short circuit
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence
Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection
Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected
Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected
Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error
Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected (Low-grade fuel specification)
Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal
Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection
Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase
Troubleshooting by failure code, Part 4
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data
Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error
Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level (Only left bank): High voltage detection
Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only): Excessively low voltage detected
Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected
Failure code [D110KA] Battery relay: Disconnection
Failure code [D110KB] Battery relay: Short circuit
Failure code [D130KA] Neutral safety relay: Disconnection
Failure code [D130KB] Neutral safety relay: Short circuit
Failure code [D161KA] Back-up alarm relay: Disconnection
Failure code [D161KB] Back-up alarm relay: Short circuit
Failure code [D182KZ] Preheater relay: Disconnection or short circuit
Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection
Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit
Failure code [D5ZRKA] Snap shot switch: Disconnection
Failure code [D5ZRKB] Snap shot switch: Short circuit
Failure code [DAFRKR] Monitor panel CAN communication: Communication error
Failure code [dAFRKR] Monitor panel CAN communication: Communication error
Failure code [daFRKR] Monitor panel CAN communication: Communication error
Failure code [DAQ0KT] Transmission controller: Abnormality in controller
Failure code [DAQ1KK] Transmission controller main power supply: Power supply voltage reduction (Input)
Failure code [DAQ2KK] Transmission controller load power supply: Power supply voltage reduction (Input)
Failure code [DAQ5KK] Transmission controller potentiometer power supply: Source voltage reduction (input)
Failure code [DAQ6KK] Transmission controller sensor power supply: Source voltage reduction (input)
Failure code [DAQ7KK] Transmission controller sensor power supply: Power supply voltage reduction (Input)
Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency
Failure code [DAQRKR] Transmission controller sensor CAN communication: Communication error (Objective component system abnormality)
Failure code [DAQSKR] Transmission controller S-NET communication: Defective communication (Abnormality in objective component system)
Troubleshooting by failure code, Part 5
Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error
Failure code [dB2RKR] Engine controller (Left bank) CAN communication: Communication error
Failure code [db2RKR] Engine controller (Right bank) CAN communication: Communication error
Failure code [DB30KT] Steering controller: Abnormality in controller
Failure code [DB31KK] Steering controller main power supply: Power supply voltage reduction (Input)
Failure code [DB32KK] Steering controller load power supply: Power supply voltage reduction (Input)
Failure code [DB35KK] Steering controller potentiometer power supply: Power supply voltage reduction (Input)
Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input)
Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input)
Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency
Failure code [dB3RKR] Steering controller CAN communication: Communication error
Failure code [DB3SKR] Steering controller S-NET communication: Defective communication (Abnormality in objective component system)
Failure code [DBB0KK] (or LED of VHMS controller indicates “n9” → “01”) VHMS controller: Lowering of source voltage
Failure code [DBB0KQ] (or LED of VHMS controller indicates “nF” → “11”) Check of VHMS controller model: Disagreement of model selection
Failure code [DBB3KK] (or LED of VHMS controller indicates “n9” → “05”) VHMS controller: Lowering of direct source voltage
Failure code [DBB5KP] (or LED of VHMS controller indicates “n9” → “04”) VHMS sensor power supply (5 V): Lowering of output voltage
Failure code [DBB6KP] (or LED of VHMS controller indicates “n9” → “02”) VHMS sensor power supply (24 V): Lowering of output voltage
Failure code [DBB7KP] (or LED of VHMS controller indicates “n9” → “03”) VHMS sensor power supply (12 V): Lowering of output voltage
Failure code [DBBQKR] (or VHMS_LED display “n8” → “02”) VHMS KOM-NET: Communication error
Failure code [dbBRKR] VHMS controller CAN communication: Communication error
Failure code [DD12KA] Shift up switch: Disconnection
Failure code [DD12KB] Shift up switch: Short circuit
Failure code [DD13KA] Shift down switch: Disconnection
Failure code [DD13KB] Shift down switch: Short circuit
Failure code [DD14KA] Parking brake lever switch: Disconnection
Failure code [DD14KB] Parking brake lever switch: Short circuit
Failure code [DDB9L4] Reverse switch: Signal disagreement
Failure code [DDK3L4] Forward switch: Signal disagreement
Failure code [DDK5KA] Gearshift switch: Disconnection
Failure code [DDK5KB] Gearshift switch: Short circuit
Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time
Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time
Failure code [DDN7KA] Blade pitch switch: Disconnection
Failure code [DDN7KB] Blade pitch switch: Short circuit
Failure code [DDN9KA] Blade tilt switch: Disconnection
Failure code [DDN9KB] Blade tilt switch: Short circuit
Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time
Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time
Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time
Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time
Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time
Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time
Troubleshooting by failure code, Part 6
Failure code [DDQ2KA] Parking brake lever switch: Disconnection
Failure code [DDQ2KB] Parking brake lever switch: Short circuit
Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals
Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals
Failure code [DDT5KA] Neutral switch: Disconnection
Failure code [DDT5KB] Neutral switch: Short circuit
Failure code [DDT5KQ] Lever specification selection: Model selection signal disagreement
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection
Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range
Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front): Disconnection (or LED of VHMS controller indicates “n3″ →”12”)
Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear): Disconnection (or LED of VHMS controller indicates “n3″ →”22”)
Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front): Short circuit (or LED of VHMS controller indicates “n3” → “11”)

Failure code [dGT5KB] (or LED of VHMS controller indicates “n3″ →”21”) Left bank exhaust temperature sensor system (Rear): Short circuit1
Failure code [DGT6KA] (or LED of VHMS controller indicates “n3″ →”24”) Right bank exhaust temperature sensor system (Front): Disconnection
Failure code [dGT6KA] (or LED of VHMS controller indicates “n3″ →”26”) Right bank exhaust temperature sensor system (Rear): Disconnection
Failure code [DGT6KB] (or LED of VHMS controller indicates “n3″ →”23”) Right bank exhaust temperature sensor system (Front): Short circuit
Failure code [dGT6KB] (or LED of VHMS controller indicates “n3″ →”25”) Right bank exhaust temperature sensor system (Rear): Short circuit
Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection
Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit
Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection
Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit
Failure code [DHE5KB] (or LED of VHMS controller indicates “n3″ →”32”) Blow-by pressure sensor system: Disconnection
Failure code [DHE5KY] (or LED of VHMS controller indicates “n3″ →”31”) Blow-by pressure sensor system: Hot short
Failure code [DHT3KX] (or LED of VHMS controller indicates “n6″ →”14”) Transmission oil pressure sensor: Out of input signal range
Failure code [DK01KA] Left yoke angle sensor: Disconnection
Failure code [DK01KB] Left yoke angle sensor: Short circuit
Failure code [DK03KA] Right yoke angle sensor: Disconnection
Failure code [DK03KB] Right yoke angle sensor: Short circuit
Failure code [DK10KA] Fuel dial: Disconnection
Failure code [DK10KB] Fuel dial: Short circuit
Failure code [DK30KA] Steering potentiometer (1): Disconnection
Failure code [DK30KB] Steering potentiometer (1): Short circuit
Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range
Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit
Failure code [DK30L8] Steering potentiometer (1): See table
Failure code [DK31KA] Steering potentiometer (2): Disconnection
Failure code [DK31KB] Steering potentiometer (2): Short circuit
Troubleshooting by failure code (Display of code), Part 7
Failure code [DK40KA] Brake potentiometer: Disconnection
Failure code [DK40KB] Brake potentiometer: Short circuit
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit
Failure code [DK55L8] Forward-reverse potentiometer: See table
Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection
Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection
Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit
Failure code [DK60KA] Acceleration sensor: Disconnection
Failure code [DK60KB] Acceleration sensor: Short circuit
Failure code [DKH1KA] Pitch angle sensor: disconnection
Failure code [DKH1KB] Pitch angle sensor: Short circuit
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range
Failure code [DLF1KA] Torque converter output speed sensor: Disconnection
Failure code [DLT3KA] Transmission output speed sensor: Disconnection
Failure code [dLT3KA] Transmission output speed sensor: Disconnection
Failure code [DLT3KB] Transmission output speed sensor: Short circuit
Failure code [DV00KB] Caution buzzer: Short circuit
Failure code [DW55KA] Blade pitch back solenoid: Disconnection
Failure code [DW55KB] Blade pitch back solenoid: Short circuit
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit
Failure code [DW56KY] Blade pitch dump solenoid: Hot short
Failure code [DW57KA] Left tilt limit solenoid: Disconnection
Failure code [DW57KB] Left tilt limit solenoid: Short circuit
Failure code [DW57KY] Left tilt limit solenoid: Hot short
Failure code [DW58KA] Right tilt limit solenoid: Disconnection
Failure code [DW58KB] Right tilt limit solenoid: Short circuit
Failure code [DW58KY] Right tilt limit solenoid: Hot short
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit
Failure code [DW59KY] Dual tilt selector solenoid: Hot short
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification): Disconnection
Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification): Short circuit
Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification): Hot short
Failure code [DW7BKA] Fan reverse solenoid: Disconnection
Failure code [DW7BKB] Fan reverse solenoid: Short circuit
Failure code [DW7BKY] Fan reverse solenoid: Hot short
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short
Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit
Failure code [DWN5KY] Fan pump solenoid 1: Hot short
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit
Failure code [DWNCKY] Fan pump solenoid 2: Hot short
Troubleshooting by failure code (Display of code), Part 8
Failure code [DXE0KA] LS set solenoid: Disconnection
Failure code [DXE0KB] LS set solenoid: Short circuit
Failure code [DXE0KY] LS set solenoid: Hot short
Failure code [DXH1KA] Lock-up solenoid: Disconnection
Failure code [DXH1KB] Lock-up solenoid: Short circuit
Failure code [DXH1KY] Lockup solenoid: Hot short
Failure code [DXH4KA] 1st clutch ECMV: Disconnection
Failure code [DXH4KB] 1st clutch ECMV: Short circuit
Failure code [DXH4KY] 1st clutch ECMV: Hot short
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
Failure code [DXH5KY] 2nd clutch ECMV: Hot short
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit
Failure code [DXH6KY] 3rd clutch ECMV: Hot short
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit
Failure code [DXH7KY] Reverse clutch ECMV: Hot short
Failure code [DXH8KA] Forward clutch ECMV: Disconnection
Failure code [DXH8KB] Forward clutch ECMV: Short circuit
Failure code [DXH8KY] Forward clutch ECMV: Hot short
Failure code [DXH9KA] Right steering clutch ECMV: Disconnection
Failure code [DXH9KB] Right steering clutch ECMV: Short circuit
Failure code [DXH9KY] Right steering clutch ECMV: Hot short
Failure code [DXHAKA] Left steering clutch ECMV: Disconnection
Failure code [DXHAKB] Left steering clutch ECMV: Short circuit
Failure code [DXHAKY] Left steering clutch ECMV: Hot short
Failure code [DXHBKA] Right brake ECMV: Disconnection
Failure code [DXHBKB] Right brake ECMV: Short circuit
Failure code [DXHBKY] Right brake ECMV: Hot short
Failure code [DXHCKA] Left brake ECMV: Disconnection
Failure code [DXHCKB] Left brake ECMV: Short circuit
Failure code [DXHCKY] Left brake ECMV: Hot short
Failure code [F@BBZL] (or VHMS_LED display “n3” → “38”) Engine blow-by pressure sensor: Abnormally high pressure occurrence
Failure code [F@BYNS] (or VHMS_LED display “n3” → “61”) Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise
Failure code [f@BYNS] (or VHMS_LED display “n3” → “71”) Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise
Failure code [F@BZNS] (or VHMS_LED display “n3” → “38”) Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise
Failure code [f@BZNS] (or VHMS_LED display “n3” → “39”) Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise
Failure code [F@BYNR] (or VHMS_LED display “n3” → “62”) Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise
Failure code [f@BYNR] (or VHMS_LED display “n3” → “72”) Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise
Failure code [F@BZNR] (or VHMS_LED display “n3” → “82”) Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise
Failure code [f@BZNR] (or VHMS_LED display “n3” → “92”) Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise
Troubleshooting of electrical system (E-mode)
Contents of troubleshooting table
E-1 The engine does not start
E-2 The preheater does not operate
E-3 The ripper pin puller cylinder does not operate
E-4 The monitor panel does not come on at all when the starting switch is turned on
E-5 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out
E-6 When the starting switch is turned on, the basic check items flash
E-7 While the engine is operating, any caution item flashes
E-8 An emergency caution item flashes while the engine is running
E-9 While the preheater is operating, the preheating pilot lamp does not come on
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on
E-12 The engine coolant temperature gauge does not indicate normally
E-13 Indication of the power train (torque converter) temperature gauge is abnormal
E-14 The hydraulic oil temperature gauge does not indicate normally
E-15 Indication of the fuel gauge is abnormal
E-16 Indications of gear speed and engine speed are abnormal
E-17 Indication of the shift mode service meter is abnormal
E-18 The switch module cannot be operated
E-19 The warning lamp does not flash or does not go out
E-20 The alarm buzzer does not sound or does not stop
E-21 Auto shift down is not possible or is not released
E-22 The automatic pitch back system does not operate (only superdozer specification)
E-23 The alarm buzzer cannot be cancelled
E-24 The operator mode cannot be operated
E-25 The service mode cannot be operated
E-26 The back-up alarm does not sound
E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on
E-28 Troubleshooting for air conditioner system
E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
E-30 Fan does not reverse
E-31 Gear cannot be shifted
E-32 Electric priming pump does not operate or does not stop automatically
Troubleshooting of hydraulic and mechanical system (H-mode)
Information in troubleshooting table
H-1 No force (no drawbar pull)
H-2 No travel (at 2nd or 3rd speed)
H-3 No travel at all gear speeds
H-4 Machine travels only in one direction forward or in reverse
H-5 Large time lag at gear speed shifting or forward-reverse shifting
H-6 Steering is not possible
H-7 Steering is possible only on one side
H-8 Steering overrun occurs
H-9 Brake does not work
H-10 Torque converter is not lock-up
H-11 Power train oil is overheated
H-12 All work equipment speeds are slow
H-13 Work equipment does not move
H-14 Blade lift speed is slow or lacks power
H-15 Blade tilt speed is slow or lacks power
H-16 Ripper lift speed is slow or lacks power
H-17 Ripper tilt speed is slow or lacks power
H-18 Excessive hydraulic drift of blade lift
H-19 Excessive hydraulic drift of blade tilt
H-20 Excessive hydraulic drift of ripper lift
H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine)
H-22 Blade pitch does not work (dual tilt attachment machine)
H-23 Abnormal sound comes out from around work equipment pump
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive

50 Disassembly and assembly
General information on disassembly andassembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system (SAA12V140E-3)
Engine and cooling system (SAA12V140E-3)
Removal and installation of engine assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of radiator guard assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Removal and installation of fan drive assembly
Removal and installation of fan motor assembly
Engine (SAA12V140E-3)
Removal and installation of fuel supply pump assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Power train, Part 1
Removal and installation of damper assembly
Disassembly and assembly of damper assembly
Removal and installation of powe rtrain unit assembly
Removal and installation of PTO, torque converter assembly
Disconnection and connection of PTO, torque converter assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of PTO assembly
Removal and installation of TORQFLOW transmission assembly
Disassembly and assembly of TORQFLOW transmission assembly
Power train, Part 2
Disassembly and assembly of steering case assembly
Disassembly and assembly of steering clutch, brake assembly
Disassembly and assembly of transfer gear housing assembly
Removal and installation of power train pump assembly
Removal and installation of scavenging pump assembly
Removal and installation of torque converter oil cooler
Removal and installation of torque converter valve assembly
Disassembly and assembly of torque converter valve assembly
Removal and installation of transmission control valve assembly
Disassembly and assembly of transmission control valve assembly (ECMV assembly)
Removal and installation of steering control valve assembly
Disassembly and assembly of steering control valve assembly
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame, Part 1
Removal and installation of track frame assembly
Disassembly and assembly of idler assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of bogie assembly
Disassembly and assembly of bogie assembly
Removal and installation of No.1 bogie assembly
Removal and installation of operator’s seat isolator
Disassembly and assembly of operator’s seat isolator
Undercarriage and frame, Part 2
Expansion and installation of track shoe assembly
Overall disassembly and overall assembly of track shoe
Press-fitting jig dimension table for link press
Field disassembly and assembly of one link
Disassembly and assembly of master link
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar
Disassembly and assembly of equalizer bar bushing
Hydraulic system
Removal and installation of hydraulic pump assembly
Removal and installation of hydraulic valve assembly
Disassembly and assembly of control valve
Disassembly and assembly of merge divider valve and self pressure reducing valve assembly
Removal and installation of PPC relief valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of ripper pin puller cylinder assembly
Work equipment
Work equipment
Removal and installation of blade assembly
Disassembly and assembly of giant ripper assembly
Cab and its attachments
Cab and its attachments
Removal and installation of ROPS guard
Removal and installation of operator’s cab assembly
Removal and installation of floor frame assembly
Electrical system
Removal and installation of controller assembly
Removal and installation of engine controller assembly (left)
Removal and installation of air conditioner condenser assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner unit

90 Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Hydraulic circuit diagram (1/3)
Hydraulic circuit diagram (2/3)
Hydraulic circuit diagram (3/3)
Electrical diagrams and drawings
Electrical circuit diagram (1/13)
Electrical circuit diagram (2/13)
Electrical circuit diagram (3/13)
Electrical circuit diagram (4/13)
Electrical circuit diagram (5/13)
Electrical circuit diagram (6/13)
Electrical circuit diagram (7/13)
Electrical circuit diagram (8/13)
Electrical circuit diagram (9/13)
Electrical circuit diagram (10/13)
Electrical circuit diagram (11/13)
Electrical circuit diagram (12/13)
Electrical circuit diagram (13/13)
Electrical circuit diagram of inside cab
Connector arrangement diagram

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