Komatsu D575A-3 Super Dozer (10101 and up) Shop Manual – SEBM022003

This Complete Service Repair Workshop Manual PDF Download for the Komatsu D575A-3 Super Dozer (10101 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.

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 Komatsu D575A-3 Super Dozer (10101 and up) 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

APPLICABLE MODELS :

Komatsu D575A-3 Super Dozer
Serial Numbers : 10101 and up

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM022003
Total Pages : 866

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

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

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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COVER
CONTENTS
SAFETY
SAFETY NOTICE
FOREWORD
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULLTYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
UNITS
01 GENERAL
SPECIFICATION DRAWING
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
RADIATOR, OIL COOLER
ENGINE CONTROL
POWER TRAIN SYSTEM
POWER TRAIN SKELTON
POWER TRAIN HYDRAULIC PIPING
DAMPER
TORQUE CONVERTER, PTO
TORQUE CONVERTER VALVE
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM
TORQUE CONVERTER FILTER
TRANSMISSION CONTROL
TRANSMISSION
TRANSMISSION CONTROL VALVE
LUBRICATION RELIEF VALVE
STEERING CLUTCH, BRAKE CONTROL
STEERING CONTROL VALVE
STEERING CLUTCH, STEERING BRAKE
FINAL DRIVE
TRACK FRAME
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
RECOIL SPRING
TRACK ROLLER BOGIE
SUSPENSION
HYDRAULIC PIPING DIAGRAM FOR WORK EQUIPMENT
CENTRALIZED OIL PRESSURE DETECTION PIPING DIAGRAM
HYDRAULIC TANK
PITCH, TILT SELECTOR SOLENOID VALVE ASSEMBLY
PPC VALVE
SAFETY LOCK VALVE, PPC ACCUMULATOR
PPC RELIEF VALVE
MAIN CONTROL VALVE
PITCH SELECTOR SOLENOID VALVE
PITCH PRIORITY SOLENOID VALVE
PITCH ASSIST SOLENOID VALVE
BLADE CONTROL KNOB
PISTON VALVE
QUICK DROP VALVE
WORK EQUIPMENT CYLINDER
CYLINDER STAY, YOKE
WORK EQUIPMENT
COUNTERWEIGHT
AIR CONDITIONER
ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE THROTTLE CONTROLLER
MONITOR SYSTEM
SENSOR
MODE SELECTION SYSTEM
BLADE CONTROL SYSTEM
ACTUAL ELECTRICAL WIRING DIAGRAM
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARENCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY-PRESSURE
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING BELT TENTENSION FOR AIR CONDITIONER COMPRESSOR
ADJUSTING ENGINE SPEED SENSOR
MEASURING COOLING FAN SPEED
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
MEASURING TORQUE CONVERTER STALL SPEED
MEASURING TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL ) SPEED
MEASURING POWER TRAIN OIL PRESSURE
PROCEDURE FOR RELEASING STEERING BRAKE
SIMPLE PROCEURE FOR TESTING BRAKE PERFORMANCE
ADJUSTING BRAKE PEDAL LINKAGE
ADJUSTING CLEARENCE OF IDLER
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE (MAIN RELIEF AND PPC CIRCUIT)
MEASURING PPC VALVE OUTPUT PRESSURE
ADJUSTING PPC VALVE
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE
MEASURING LEAKAGE INSIDE CYLINDER
RELEASING AIR REMAINING IN HYDRAULIC CIRCUIT ON PPC VALUE
BLEEDING AIR FROM HYDRAULIC CYLINDER
ADJUSTING WORK EQUIPMENT SAFETY LEVER
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CONNECTOR ARRANGEMENT DIAGRAM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF NETWORK SYSTEM (N MODE)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM
SERVICE CODES OF NETWORK SYSTEM
N-1 (E0101) ABNORMALITY IN NETWORK SYSTEM (ENGINE CONTROLLER SYSTEM) IS DISPLAYED
N-2 (E0104) ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL SYSTEM) IS DISPLAYED
N-3 (E0105) ABNORMALITY IN NETWORK SYSTEM (STEERING CONTROLLER SYSTEM) IS DISPLAYED
N-4 (E0101), (E0104), AND (E0105) ARE DISPLAYED AT SAME TIME (ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED)
N-5 (E0152) ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED
N-6 (E0164) ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED
N-7 (E0436) ABNORMALITY IN NETWORK SYSTEM IS DISPLAYED
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
E-1 (E0401) ABNORMALITY IN ENGINE CONTROLLER POWER SOURCE VOLTAGE IS DISPLAYED
E-2 (E0402) ABNORMALITY IN ENGINE CONTROLLER IS DISPLAYED
E-3 (E0403) MISTAKEN CONNECTION IN ENGINE CONTROLLER IS DISPLAYED
E-4 (E0405) ABNORMALITY IN FUEL CONTROL DIAL SYSTEM IS DISPLAYED
E-5 (E0406) ABNORMALITY IN DECELERATION POTENTIOMETER IS DISPLAYED
E-6 (E0407) ABNORMALITY IN SHOE SLIP CONTROL COMMAND VALUE IS DISPLAYED
E-7 (E0409) ABNORMALITY IN ENGINE SPEED SENSOR “A” SYSTEM IS DISPLAYED
E-8 (E0410) ABNORMALITY IN ENGINE SPEED SENSOR “B” SYSTEM IS DISPLAYED
E-9 (E0411) ABNORMALITY IN RIGHT RACK SENSOR SYSTEM IS DISPLAYED
E-10 (E0412) ABNORMALITY IN LEFT RACK SENSOR SYSTEM IS DISPLAYED
E-11 (E0413) ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM IS DISPLAYED
E-12 (E0421) SHORT CIRCUIT IN RIGHT GOVERNOR SOLENOID SYSTEM IS DISPLAYED
E-13 (E0422) DISCONNECTION IN RIGHT GOVERNOR SOLENOID SYSTEM IS DISPLAYED
E-14 (E0423) SHORT CIRCUIT IN LEFT GOVERNOR SOLENOID SYSTEM IS DISPLAYED
E-15 (E0424) DISCONNECTION IN LEFT GOVERNOR SOLENOID SYSTEM IS DISPLAYED
E-16 (E0425) SHORT CIRCUIT IN RIGHT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED
E-17 (E0426) DISCONNECTION IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED
E-18 (E0427) SHORT CIRCUIT IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED
E-19 (E0428) DISCONNECTION IN LEFT GOVERNOR CUT RELAY SYSTEM IS DISPLAYED
E-20 (E0433) SHORT CIRCUIT IN LEFT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED
E-21 (E0434) DISCONNECTION IN LEFT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED
E-22 (E0435) ABNORMALITY IN ENGINE WATER TEMPERATURE SENSOR SYSTEM IS DISPLAYED
E-23 (E0437) ABNORMALITY IN RIGHT GOVERNOR SERVO IS DISPLAYED
E-24 (E0438) ABNORMALITY IN LEFT GOVERNOR SERVO IS DISPLAYED
E-25 (E0440) DISCONNECTION SOLENOID POWER SOURCE “1” SYSTEM IS DISPLAYED
E-26 (E0441) DISCONNECTION IN POWER SUPPLY SYSTEM “2” OF SOLENOID IS DISPLAYED
E-27 (E0442) ABNORMALITY IN ENGINE CONTROLLER BACKUP POWER SOURCE SYSTEM IS DISPLAYED
E-28 (E0443) ABNORMALITY IN ENGINE CONTROLLER SWITCH POWER SOURCE SYSTEM IS DISPLAYED
E-29 (E0455) ENGINE OVERHEATING IS DISPLAYED
E-30 (E0456) SHORT CIRCUIT IN RIGHT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED
E-31 (E0457) DISCONNECTION IN RIGHT PRE-STROKE SOLENOID SYSTEM IS DISPLAYED
E-32 ENGINE DOES NOT REVOLVE WHEN STARTING SWITCH IS TURNED TO “ON” POSITION
E-33 ENGINE DOES NOT STOP WHEN STARTING SWITCH IS TURNED TO “OFF” POSITION
TROUBLESHOOTING OF STEERING CONTROLLER SYSTEM (ST MODE)
SERVICE CODE AND ABNORMAL SYSTEM
ST-1 (E0111) ABNORMALITY IN STEERING CONTROLLER POWER SOURCE VOLTAGE IS DISPLAYED
ST-2 (E0143) ABNORMALITY IN STEERING CONTROLLER 5V POWER SOURCE IS DISPLAYED
ST-3 (E0145) ABNORMALITY IN STEERING CONTROLLER SENSOR POWER SOURCE IS DISPLAYED
ST-4 (E0151) ABNORMALITY IN SPECIFICATION SELECTION IS DISPLAYED
ST-5 (E0161) ABNORMALITY IN STEERING CONTROLLER E2PROM IS DISPLAYED
ST-6 (E0660) DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM
ST-7 (E0661) SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM
ST-8 (E0721) ABNORMALITY IN PITCH ANGLE SENSOR SYSTEM IS DISPLAYED
ST-9 (E0730, E0731, E0732) ABNORMALITY IN TRAVEL LOWER SWING SYSTEM
ST-10 (E0733) ABNORMALITY IN SWING POTENTIOMETER “1” SYSTEM IS DISPLAYED
ST-11 (E0734) ABNORMALITY IN SWING POTENTIOMETER “2” SYSTEM IS DISPLAYED
ST-12 (E0735) LAG OF SWING SIGNAL
ST-13 (E0736) ABNORMALITY IN BRAKE POTENTIOMETER SYSTEM IS DISPLAYED
ST-14 (E0750) DISCONNECTION IN RIGHT STEERING CLUTCH ECMV SYSTEM
ST-15 (E0751) SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV SYSTEM
ST-16 (E0752) DISCONNECTION IN LEFT STEERING CLUTCH ECMV SYSTEM
ST-17 (E0753) SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV SYSTEM
ST-18 (E0754) DISCONNECTION IN RIGHT STEERING BRAKE ECMV SYSTEM
ST-19 (E0755) SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV SYSTEM
ST-20 (E0756) DISCONNECTION IN LEFT STEERING BRAKE ECMV SYSTEM
ST-21 (E0757) SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV SYSTEM
ST-22 (E0760) ABNORMALITY IN RIGHT STEERING CLUTCH OIL PRESSURE SYSTEM
ST-23 (E0761) SHORT CIRCUIT IN RIGHT STEERING CLUTCH OIL PRESSURE SYSTEM
ST-24 (E0762) ABNORMALITY IN LEFT STEERING CLUTCH OIL PRESSURE SYSTEM
ST-25 (E0763) SHORT CIRCUIT IN LEFT STEERING CLUTCH OIL PRESSURE SYSTEM
ST-26 (E0764) ABNORMALITY IN RIGHT STEERING BRAKE OIL PRESSURE SYSTEM
ST-27 (E0765) SHORT CIRCUIT IN RIGHT STEERING BRAKE OIL PRESSURE SYSTEM
ST-28 (E0766) ABNORMALITY IN LEFT STEERING BRAKE OIL PRESSURE SYSTEM
ST-29 (E0767) SHORT CIRCUIT IN LEFT STEERING BRAKE OIL PRESSURE SYSTEM
ST-30 (E0779) DISCONNECTION IN EMERGENCY STOP PREVENTION SOLENOID SYSTEM
ST-31 (E0780) SHORT CIRCUIT IN EMERGENCY STOP PREVENTION SOLENOID SYSTEM
ST-32 (E0781) ABNORMALITY IN TRAVEL LOCK SWITCH SYSTEM
A. WHEN ONLY E0781 IS DISPLAYED
B. WHEN BOTH E0781 AND E0238 ARE DISPLAYED
ST-33 (E0782) DISAGREEMENT IN TRAVEL LOCK
ST-34 (E0930) ABNORMALITY IN ENGINE SPEED SENSOR “B” SYSTEM IS DISPLAYED
ST-35 (E0933) ABNORMALITY IN BEVEL SPEED SENSOR “A” SYSTEM IS DISPLAYED
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)
SERVICE CODE AND ABNORMAL SYSTEM
T-1 (E0112) ABNORMALITY IN TRANSMISSION CONTROLLER POWER SOURCE VOLTAGE IS DISPLAYED
T-2 (E0142) ABNORMALITY IN TRANSMISSION CONTROLLER 5V POWER SOURCE IS DISPLAYED
T-3 (E0146) ABNORMALITY IN TRANSMISSION CONTROLLER SENSOR POWER SOURCE IS DISPLAYED
T-4 (E0160) ABNORMALITY IN TRANSMISSION CONTROLLER E2PROM IS DISPLAYED
T-5 (E0178), (E0179) DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM IS DISPLAYED
T-6 (E0212) SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM IS DISPLAYED
T-7 (E0213) DISCONNECTION IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM IS DISPLAYED
T-8 (E0221) ABNORMALITY IN PITCH ANGLE SENSOR SYSTEM IS DISPLAYED
T-9 (E0222) DISCONNECTION IN BEVEL SPEED SENSOR SYSTEM IS DISPLAYED
T-10 (E0225) SLIP OF POWER TRAIN CLUTCH
T-11 (E0230), (E0231), (E0232) ABNORMALITY IN TRAVEL LEVER DIRECTIONAL SYSTEM IS DISPLAYED
T-12 (E0233) ABNORMALITY IN JOYSTICK (DIRECTIONAL SHIFT LEVER) POTENTIOMETER “1” SYSTEM IS DISPLAYED
T-13 (E0234) ABNORMALITY IN JOYSTICK (DIRECTIONAL SHIFT LEVER) POTENTIOMETER “2” SYSTEM IS DISPLAYED
T-14 (E0235) LAG OF FORWARD-REVERSE SIGNAL
T-15 (E0236) ABNORMALITY IN SHIFT-UP SWITCH SYSTEM IS DISPLAYED
T-16 (E0237) ABNORMALITY IN SHIFT-DOWN SWITCH SYSTEM
T-17 (E0238) ABNORMALITY IN TRAVEL LOCK SWITCH SYSTEM
A. WHEN ONLY E0238 IS DISPLAYED
B. WHEN BOTH E0238 AND E0781 ARE DISPLAYED
T-18 (E0239) DISAGREEMENT IN TRAVEL LOCK
T-19 (E0250) DISCONNECTION IN FORWARD CLUTCH ECMV SYSTEM
T-20 (E0251) SHORT CIRCUIT IN FORWARD CLUTCH ECMV SYSTEM
T-21 (E0252) DISCONNECTION IN REVERSE CLUTCH ECMV SYSTEM
T-22 (E0253) SHORT CIRCUIT IN REVERSE CLUTCH ECMV SYSTEM
T-23 (E0254) DISCONNECTION IN 1ST CLUTCH ECMV SYSTEM
T-24 (E0255) SHORT CIRCUIT IN 1ST CLUTCH ECMV SYSTEM
T-25 (E0256) DISCONNECTION IN 2ND CLUTCH ECMV SYSTEM
T-26 (E0257) SHORT CIRCUIT IN 2ND CLUTCH ECMV SYSTEM
T-27 (E0258) DISCONNECTION IN 3RD CLUTCH ECMV SYSTEM
T-28 (E0259) SHORT CIRCUIT IN 3RD CLUTCH ECMV SYSTEM
T-29 (E0260) ABNORMALITY IN FORWARD CLUTCH OIL PRESSURE SYSTEM
T-30 (E0261) SHORT CIRCUIT IN FORWARD CLUTCH OIL PRESSURE SYSTEM
T-31 (E0262) ABNORMALITY IN REVERSE CLUTCH OIL PRESSURE SYSTEM
T-32 (E0263) SHORT CIRCUIT IN REVERSE CLUTCH OIL PRESSURE SYSTEM
T-33 (E0264) ABNORMALITY IN 1ST CLUTCH OIL PRESSURE SYSTEM
T-34 (E0265) SHORT CIRCUIT IN 1ST CLUTCH OIL PRESSURE SYSTEM
T-35 (E0266) ABNORMALITY IN 2ND CLUTCH OIL PRESSURE SYSTEM
T-36 (E0267) SHORT CIRCUIT IN 2ND CLUTCH OIL PRESSURE SYSTEM
T-37 (E0268) ABNORMALITY IN 3RD CLUTCH OIL PRESSURE SYSTEM
T-38 (E0269) SHORT CIRCUIT IN 3RD CLUTCH OIL PRESSURE SYSTEM
T-39 (E0270) DOUBLE FAILURE IN TRANSMISSION CLUTCH (CLUTCH IS NOT ENGAGED)
T-40 (E0271) DOUBLE FAILURE IN TRANSMISSION CLUTCH (CLUTCH IS NOT DISENGAGED)
T-41 (E0273) ABNORMALITY IN NEUTRAL SIGNAL SYSTEM IS DISPLAYED
T-42 (E0301) ABNORMALITY IN LEFT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED
T-43 (E0302) ABNORMALITY IN LEFT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED
T-44 (E0303) ABNORMALITY IN RIGHT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED
T-45 (E0304) ABNORMALITY IN RIGHT BLADE TILT ANGLE SENSOR SYSTEM IS DISPLAYED
T-46 (E0305) SHORT CIRCUIT IN BLADE RAISE OIL PRESSURE SWITCH SYSTEM IS DISPLAYED
T-47 (E0311) ABNORMALITY IN PITCH-DUMP SWITCH SYSTEM
T-48 (E0312) ABNORMALITY IN PITCH-BACK SWITCH SYSTEM
T-49 (E0313) DISCONNECTION IN PITCH BACK SOLENOID SYSTEM IS DISPLAYED
T-50 (E0314) SHORT CIRCUIT IN PITCH BACK SOLENOID SYSTEM IS DISPLAYED
T-51 (E0315) DISCONNECTION IN PITCH DUMP SOLENOID SYSTEM IS DISPLAYED
T-52 (E0316) SHORT CIRCUIT IN PITCH DUMP SOLENOID SYSTEM IS DISPLAYED
T-53 (E0317) DISCONNECTION IN LIFT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED
T-54 (E0318) SHORT CIRCUIT IN LEFT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED
T-55 (E0319) DISCONNECTION IN RIGHT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED
T-56 (E0320) SHORT CIRCUIT IN RIGHT TILT LIMIT SOLENOID SYSTEM IS DISPLAYED
T-57 (E0341) DISCONNECTION IN BLADE LIFT “1” PUMP CUT SOLENOID SYSTEM IS DISPLAYED
T-58 (E0342) SHORT CIRCUIT IN BLADE LIFT “1” PUMP CUT SOLENOID SYSTEM IS DISPLAYED
T-59 (E0343) DISCONNECTION IN PITCH DUMP ASSIST RELAY SYSTEM IS DISPLAYED
T-60 (E0344) SHORT CIRCUIT IN PITCH DUMP ASSIST RELAY SYSTEM IS DISPLAYED
T-61 (E0345) DISCONNECTION IN PITCH SOLENOID SYSTEM IS DISPLAYED
T-62 (E0346) SHORT CIRCUIT IN PITCH SOLENOID SYSTEM IS DISPLAYED
T-63 (E0347) DISCONNECTION IN PITCH PRIORITY SOLENOID SYSTEM IS DISPLAYED
T-64 (E0348) SHORT CIRCUIT IN PITCH PRIORITY SOLENOID SYSTEM IS DISPLAYED
T-65 (E0364) DISCONNECTION IN WORK EQUIPMENT OIL PRESSURE SENSOR 1 (200 PUMP) SYSTEM IS DISPLAYED
T-66 (E0365) SHORT CIRCUIT IN WORK EQUIPMENT OIL PRESSURE SENSOR 1 (200 PUMP) SYSTEM IS DISPLAYED
T-67 (E0366) DISCONNECTION IN WORK EQUIPMENT OIL PRESSURE SENSOR 2 (200 PUMP) SYSTEM IS DISPLAYED
T-68 (E0367) SHORT CIRCUIT IN WORK EQUIPMENT OIL PRESSURE SENSOR 2 (200 PUMP) SYSTEM IS DISPLAYED
T-69 (E0372) SHORT CIRCUIT IN BLADE RAISE (FULL) OIL PRESSURE SWITCH SYSTEM IS DISPLAYED
T-70 (E0486) ABNORMALITY IN SPECIFICATION SELECTION IS DISPLAYED
T-71 (E0610), (E0611) DISCONNECTION IN BACKUP ALARM RELAY SYSTEM IS DISPLAYED
T-72 (E0931) ABNORMALITY IN ENGINE SPEED SENSOR “B” SYSTEM IS DISPLAYED
T-73 (E0932) ABNORMALITY IN BEVEL SPEED SENSOR A SYSTEM IS DISPLAYED
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)
TABLE OF FAILURE MODES AND CAUSES (ELECTRIC, HYDRAULIC, MECHANICAL SYSTEM)
H-1 BRAKES DO NOT WORK
H-2 MACHINE DOES NOT TURN (MACHINE CAN TRAVEL ONLY IN A STRAIGHT LINE)
H-3 THERE IS TRAVEL DEVIATION
H-4 MACHINE TURNS ONLY IN ONE DIRECTION (LEVER OPERATED)
H-5 TIME LAG IS EXCESSIVE
H-6 MACHINE TRAVELS ONLY IN ONE DIRECTION (FORWARD OR IN REVERSE)
H-7 MACHINE DOES NOT MOVE (2ND, 3RD)
H-8 MACHINE DOES NOT MOVE IN ANY SPEED RANGE
H-9 TORQUE CONVERTER OVERHEATS
H-10 ABNORMAL NOISE FROM AROUND HYDRAULIC PUMP
H-11 BLADE RAISE SPEED SLOW OR WORK EQUIPMENT LACKS POWER
H-12 BLADE PITCH SPEED SLOW OR BLADE PITCH LACKS POWER
H-13 EXCESSIVE HYDRAULIC DRIFT OF BLADE
H-14 EXCESSIVE HYDRAULIC DRIFT OF BLADE PITCH
TROUBLESHOOTING OF MONITOR PANEL AND ELECTRICAL SYSTEM (M MODE)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
M-1 (E0120) SHORT CIRCUIT IN CAUTION LAMP OUTPUT SYSTEM IS DISPLAYED
M-2 (E0121) SHORT CIRCUIT IN CAUTION BUZZER SYSTEM IS DISPLAYED
M-3 (E0211) ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER OIL TEMPERATURE) IS DISPLAYED
M-4 (E0329) ABNORMALITY IN HYDRAULIC OIL TEMPERATURE IS DISPLAYED
M-5 (E0430) ABNORMALITY IN ENGINE OIL PRESSURE IS DISPLAYED
M-6 (E0431) ABNORMALITY IN RADIATOR WATER LEVEL IS DISPLAYED
M-7 (E0432) ABNORMALITY IN ENGINE WATER TEMPERATURE IS DISPLAYED
M-8 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL GIVES NO DISPLAY
A. CAUTION MODULE (GUAGE/LAMP UNIT) GIVES NO DISPLAY
B. TACHOMETER MODULE (TACHOMETER/SERVICE METER UNIT) GIVES NO DISPLAY
M-9 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT
A. CAUTION MODULE (GAUGE/LAMP UNIT) DISPLAYS ALL STAY LIGHTED UP AND DO NOT GO OUT
B. TACHOMETER MODULE (TACHOMETER/SERVICE METER UNIT) DISPLAYS ALL STAY LIGHTED UP AND DO NOT GO OUT
M-10 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK BEFORE STARTING ITEMS FLASH
A. (RADIATOR WATER LEVEL) FLASHES
B. (ENGINE OIL LEVEL) FLASHES
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH (BUT BATTERY CHARGE, ENGINE OIL PRESSURE CAUTION
A. ENGINE OIL PRESSURE SENSOR SYSTEM
B. ALTERNATOR SYSTEM
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH (BUT THERE IS NO ABNORMALITY IN CHECKS BEFORE ST
A. (BATTERY CHARGE) FLASHES
B. (ENGINE OIL PRESSURE) FLASHES
C. (RADIATOR WATER LEVEL) FLASHES
D. (ENGINE WATER TEMPERATURE) FLASHES
E. (POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE) FLASHES
F. (HYDRAULIC OIL TEMPERATURE) FLASHES
G. (AIR CLEANER CLOGGING) FLASHES
M-13 ABNORMALITY IN CAUTION BUZZER
A. CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND, OR BUZZER DOES NOT SOUND FOR 1 SECOND AFTER STARTING SWITCH IS TURNED ON
B. NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS
M-14 ABNORMALITY IN CAUTION LAMP
A. CAUTION ITEM FLASHES BUT CAUTION LAMP DOES NOT FLASH, OR CAUTION LAMP DOES NOT LIGHT UP FOR 2 SECONDS AFTER STARTING SWITC
B. NO ABNORMALITY IS DISPLAYED ON MONITOR BUT CAUTION LAMP LIGHTS UP
M-15 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE
A. ENGINE WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE
B. ENGINE WATER TEMPERATURE GAUGE GIVES NO DISPLAY (GAUGE DOES NOT EVEN DISPLAY ONE LEVEL)
M-16 ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE GAUGE
A. POWER TRAIN OIL TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE
B. POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE GAUGE GIVES NO DISPLAY (GAUGE DOES NOT EVEN DISPLAY ONE LEVEL)
M-17 ABNORMALITY IN FUEL LEVEL GAUGE
A. FUEL LEVEL GAUGE ALWAYS DISPLAY FULL
B. FUEL LEVEL GAUGE GIVES NO DISPLAY (GAUGE DOES NOT EVEN DISPLAY ONE LEVEL)
M-18 SPEED RANGE DISPLAY SHOWS “–“, ENGINE SPEED IS NOT DISPLAYED
M-19 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING
M-20 ABNORMALITY IN SERVICE MODE
A. DOES NOT SWITCH TO SERVICE MODE EVEN WHEN SERVICE SWITCH IS OPERATED
B. STAYS IN SERVICE MODE
M-21 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (FRONT LAMP, WORKING LAMP ARE NORMAL)
A. TACHOMETER MODULE LAMP DOES NOT LIGHT UP
B. CAUTION MODULE LAMP DOES NOT LIGHT UP
C. SWITCH MODULE LAMP DOES NOT LIGHT UP
M-22 L.H. FRONT LAMP DO NOT LIGHT UP
A. ANY ONE OF FRONT LAMPS AND WORKING LAMPS DOES NOT LIGHT UP
M-23 R.H. FRONT LAMP DO NOT LIGHT UP
A. ANY ONE OF FRONT LAMPS AND WORKING LAMPS DOES NOT LIGHT UP
M-24 L.H. WORKING LAMPS DO NOT LIGHT UP
A. ANY ONE OF FRONT LAMPS AND WORKING LAMPS DOES NOT LIGHT UP
M-25 R.H. WORKING LAMPS DO NOT LIGHT UP
A. ANY ONE OF FRONT LAMPS AND WORKING LAMPS DOES NOT LIGHT UP
TROUBLESHOOTING OF ENGINE (S MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 Starting performance is poor (Starting always takes time)
S-2 Engine does not start
(1) Engine does not turn
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
S-3 Engine does not pick-up smoothly (Follow-up is poor)
S-4 Engine stops during operations (with electronical governor)
S-5 Engine does not rotate smoothly (Hunting) (with electronical governor)
S-6 Engine lacks output (no power) (with electronical governor)
S-7 Exhaust gas is black (incomplete combustion) (with electronical governor)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive (with electronical governor)
S-11 Oil is in cooling water, or water spurts back, or water level goes down
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)
S-13 Oil level rises
S-14 Water temperature becomes too high (Overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
S-17 Abnormality in governor servo system is displayed in troubleshooting for engine controller
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECATIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
ENGINE OIL COOLER
REMOVAL
INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
AFTER-COOLER CORE
REMOVAL AND INSTALLATION
NOZZLER HOLDER
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
HYDRAULIC COOLER
REMOVAL AND INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
FAN DRIVE SUPPORT
REMOVAL
INSTALLATION
FAN DRIVE PULLEY (FAN END)
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
FAN DRIVE PULLEY (ENGINE END)
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
DAMPER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
POWER TRAIN
REMOVAL
INSTALLATION
PTO, TORQUE CONVERTER
REMOVAL
INSTALLATION
DISCONNECTON
CONNECTION
PTO
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
TORQFLOW TRANSMISSION
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING CASE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING CLUTCH
DISASSEMBLY
ASSEMBLY
STEERING BRAKE
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
POWER TRAIN PUMP
REMOVAL AND INSTALLATION
TRANSMISSION LUBRICATION PUMP
REMOVAL AND INSTALLATION
SCAVENGING PUMP
REMOVAL AND INSTALLATION
FINAL DRIVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK FRAME
REMOVAL
INSTALLATION
RECOIL SPRING, TUBE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
IDLER YOKE CYLINDER
DISASSEMBLY
ASSEMBLY
IDLER
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BOGIE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK SHOE
CHECKING BEFORE REMOVAL
REMOVAL
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)
INSTALLATION
DISASSEMBLY
ASSEMBLY
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
FIELD DISASSEMBLY OF ONE LINK
DISASSEMBLY
ASSEMBLY
MASTER LINK
DISASSEMBLY
ASSEMBLY
ADJUSTING TRACK SHOE TENSION
PIVOT SHAFT
REMOVAL AND INSTALLATION
EQUALIZER BAR
REMOVAL
INSTALLATION
REPLACING EQUALIZER BAR BUSHING
SEGMENT TEETH
REMOVAL AND INSTALLATION
WORK EQIPMENT PUMP
REMOVAL AND INSTALLATION
WORK EQUIPMENT ASSIST, CONTROL PUMP
REMOVAL AND INSTALLATION
BLADE VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
MAIN RELIEF VALVE
DISASSEMBLY AND ASSEMBLY
BLADE LIFT CYLINDER
REMOVAL AND INSTALLATION
BLADE PITCH CYLINDER
REMOVAL AND INSTALLATION
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
BLADE PPC VALUE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BLADE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
POTENTIOMETER
REMOVAL
INSTALLATION
OPERATOR’S COMPARTMENT FRAME
REMOVAL
INSTALLATION
CAB
REMOVAL
INSTALLATION
ROPS
REMOVAL
INSTALLATION
COUNTERWEIGHT FRAME
REMOVAL AND INSTALLATION
BLADE CYLINDER SUPPORT
REMOVAL
INSTALLATION
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT
ELECTRICAL CIRCUIT DIAGRAM (1/7)
ELECTRICAL CIRCUIT DIAGRAM (2/7)
ELECTRICAL CIRCUIT DIAGRAM (3/7)
ELECTRICAL CIRCUIT DIAGRAM (4/7)
ELECTRICAL CIRCUIT DIAGRAM (5/7)
ELECTRICAL CIRCUIT DIAGRAM (6/7)
ELECTRICAL CIRCUIT DIAGRAM (7/7)

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