Seb D 033703

SEBM033703
MACHINE MODEL SERIAL No.

D475A-5 20001 and up
This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
D475A-5 mount the SDA12V140E-1 engine.

For details of the engine, see the 12V140-1 Series Engine Shop Manual.
2004
All Rights Reserved
Printed in Japan 07-04 (01) 00-1
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GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD............................................ 10-1
20 TESTING AND ADJUSTING ........................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
90 OTHERS ................................................................................................................................ 90-1
00-2 D475A-5
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LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
q 00-1 (3) q 00-22 10-8 10-39 10-69
00-2 (2) 10-10 10-40 10-70
q 00-2-1 (3) 10-11 10-41 10-71
q 00-2-2 (3) 01-1 10-12 10-42 10-72
q 00-2-3 (3) 01-2 10-13 10-43 10-73
q 00-2-4 (3) 01-3 10-14 10-44 10-74
q 00-2-5 (3) 01-4 10-15 10-45 10-76
q 00-2-6 (3) 01-5 10-16 10-46 10-77
q 00-2-7 (3) 01-6 10-17 10-47 10-78
q 00-3 01-7 10-18 10-48 10-79
q 00-4 01-8 10-19 10-49 10-80
q 00-5 01-9 10-20 10-50 10-81
q 00-6 01-10 10-21 10-51 10-82
q 00-7 01-11 10-22 10-52 10-83
q 00-8 01-12 10-24 10-53 10-84
q 00-9 01-13 10-25 10-54 10-85
q 00-10 01-14 10-26 10-55 10-86
q 00-11 01-15 10-27 q 10-56 (3) 10-87
q 00-12 01-16 10-28 10-57 10-88
q 00-13 01-17 10-29 10-58 10-89
q 00-14 10-30 10-60 10-90
q 00-15 10-31 10-61 10-92
q 00-16 10-1 10-32 10-62 10-93
q 00-17 10-2 10-33 10-63 10-94
q 00-18 10-4 10-34 10-64 10-95
q 00-19 10-5 10-35 10-65 10-96
q 00-20 10-6 10-36 10-66 10-97
q 00-21 10-7 10-38 10-68 10-98
D475A-5 00-2-1
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10-99 10-142 10-182 10-224 10-268
10-100 10-143 10-183 10-225 10-269
10-101 10-144 10-184 10-226 10-270
10-102 10-145 10-185 10-228 10-271
10-103 10-146 q 10-186 (3) 10-229 10-272
10-104 10-148 q 10-187 (3) 10-230 10-273
10-105 10-149 10-188 10-231 10-274
10-106 10-150 10-189 10-232 10-275
10-108 10-151 q 10-190 (3) 10-233 10-276
10-109 10-152 q 10-191 (3) 10-234 10-277
10-111 10-153 10-192 10-235 10-278
10-112 10-154 10-193 10-236 10-279
10-113 10-155 10-194 10-238 10-280
10-114 10-156 10-195 10-239 10-281
10-115 10-157 10-196 10-240 10-282
10-116 10-158 10-197 10-242
10-117 10-159 10-198 10-243
10-118 10-160 (2) 10-199 10-244 20-1 (1)
10-120 10-161 (2) 10-200 10-245 20-2 (1)
10-121 10-162 10-201 10-246 20-3 (1)
10-122 10-163 (2) 10-202 10-248 (2) 20-4 (1)
10-123 10-163-1 (2) 10-204 10-249 20-5 (1)
10-124 10-163-2 (2) 10-205 10-250 20-6 (1)
10-125 10-164 (2) 10-206 10-251 20-7 (1)
10-126 10-165 (2) 10-207 10-252 20-8 (1)
10-127 10-166 10-208 10-253 20-9 (1)
10-128 10-167 10-209 10-254 20-10 (1)
10-129 10-168 10-210 10-255 20-11 (1)
10-130 10-169 10-211 10-256 20-12 (1)
10-131 10-170 10-212 10-257 20-13 (1)
10-132 10-171 10-213 10-258 20-14 (1)
10-133 10-172 10-214 10-259
10-134 10-173 10-215 10-260 20-101 (1)
10-135 10-174 10-216 10-261 20-102 (1)
10-136 10-175 10-217 10-262 20-103 (1)
10-137 10-176 10-218 10-263 20-104 (1)
10-138 10-177 10-219 10-264 20-105 (1)
10-139 10-178 10-220 10-265 20-106 (1)
10-140 10-180 10-221 10-266 20-107 (1)
10-141 10-181 10-222 10-267 20-108 (1)
00-2-2 D475A-5
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20-109 (1) 20-149 (1) 20-190 (1) 20-230 (1) 20-305 (1)
20-110 (1) 20-150 (1) 20-191 (1) 20-231 (1) 20-306 (1)
20-111 (1) 20-151 (1) 20-192 (1) 20-232 (1) 20-307 (1)
20-112 (1) 20-152 (1) 20-193 (1) 20-233 (1) 20-308 (1)
20-113 (1) 20-154 (1) 20-194 (1) 20-234 (1) 20-309 (1)
20-114 (1) 20-155 (1) 20-195 (1) 20-235 (1) 20-310 (1)
20-115 (1) 20-156 (1) 20-196 (1) 20-236 (1) 20-311 (1)
20-116 (1) 20-157 (1) 20-197 (1) 20-237 (1) 20-312 (1)
20-117 (1) 20-158 (1) 20-198 (1) 20-238 (1) 20-313 (1)
20-118 (1) 20-159 (1) 20-199 (1) 20-239 (1) 20-314 (1)
20-119 (1) 20-160 (1) 20-200 (1) 20-240 (1) 20-315 (1)
20-120 (1) 20-161 (1) 20-201 (1) 20-241 (1) 20-316 (1)
20-121 (1) 20-162 (1) 20-202 (1) 20-242 (1) 20-317 (1)
20-122 (1) 20-163 (1) 20-203 (1) 20-243 (1) 20-318 (1)
20-123 (1) 20-164 (1) 20-204 (1) 20-244 (1) 20-319 (1)
20-124 (1) 20-165 (1) 20-205 (1) 20-245 (1) 20-320 (1)
20-125 (1) 20-166 (1) 20-206 (1) 20-246 (1) 20-321 (1)
20-126 (1) 20-167 (1) 20-207 (1) 20-247 (1) 20-322 (1)
20-127 (1) 20-168 (1) 20-208 (1) 20-248 (1) 20-323 (1)
20-128 (1) 20-169 (1) 20-209 (1) 20-249 (1) 20-324 (1)
20-129 (1) 20-170 (1) 20-210 (1) 20-250 (1) 20-325 (1)
20-130 (1) 20-171 (1) 20-211 (1) 20-251 (1) 20-326 (1)
20-131 (1) 20-172 (1) 20-212 (1) 20-252 (1) 20-328 (1)
20-132 (1) 20-173 (1) 20-213 (1) 20-253 (1) 20-329 (1)
20-133 (1) 20-174 (1) 20-214 (1) 20-254 (1) 20-330 (1)
20-134 (1) 20-175 (1) 20-215 (1) 20-255 (1) 20-331 (1)
20-135 (1) 20-176 (1) 20-216 (1) 20-256 (1) 20-332 (1)
20-136 (1) 20-177 (1) 20-217 (1) 20-257 (1) 20-333 (1)
20-137 (1) 20-178 (1) 20-218 (1) 20-258 (1) 20-334 (1)
20-138 (1) 20-179 (1) 20-219 (1) 20-259 (1) 20-335 (1)
20-139 (1) 20-180 (1) 20-220 (1) 20-260 (1) 20-336 (1)
20-140 (1) 20-181 (1) 20-221 (1) 20-261 (1) 20-337 (1)
20-141 (1) 20-182 (2) 20-222 (1) 20-262 (1) 20-338 (1)
20-142 (1) 20-183 (2) 20-223 (1) 20-263 (1) 20-340 (1)
20-143 (1) 20-184 (2) 20-224 (1) 20-264 (1) 20-341 (1)
20-144 (1) 20-185 (2) 20-225 (1) 20-342 (1)
20-145 (1) 20-186 (1) 20-226 (1) 20-301 (1) 20-343 (1)
20-146 (1) 20-187 (2) 20-227 (1) 20-302 (1) 20-344 (1)
20-147 (1) 20-188 (1) 20-228 (1) 20-303 (1) 20-346 (1)
20-148 (1) 20-189 (1) 20-229 (1) 20-304 (1) 20-347 (1)
D475A-5 00-2-3
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20-348 (1) 20-412 (1) 20-452 (2) 20-494 (1) 20-535 (1)
20-350 (1) 20-413 (1) 20-453 (1) 20-495 (1) 20-536 (1)
20-351 (1) 20-414 (1) 20-454 (2) 20-496 (1) 20-537 (1)
20-352 (1) 20-415 (1) 20-455 (1) 20-497 (1) 20-538 (1)
20-354 (1) 20-416 (1) 20-456 (2) 20-498 (1) 20-539 (1)
20-355 (1) 20-417 (1) 20-457 (1) 20-499 (1) 20-540 (1)
20-356 (1) 20-418 (1) 20-458 (1) 20-500 (2) 20-541 (1)
20-357 (1) 20-419 (1) 20-459 (1) 20-501 (2) 20-542 (1)
20-358 (1) 20-420 (1) 20-460 (2) 20-502 (1) 20-543 (1)
20-359 (1) 20-421 (1) 20-461 (1) 20-503 (1) 20-544 (1)
20-360 (1) 20-422 (1) 20-462 (1) 20-504 (1) 20-545 (1)
20-361 (1) 20-423 (1) 20-463 (1) 20-505 (1) 20-546 (1)
20-362 (1) 20-424 (1) 20-464 (2) 20-506 (1) 20-548 (1)
20-363 (1) 20-425 (1) 20-465 (1) 20-507 (1) 20-549 (1)
20-364 (1) 20-426 (1) 20-466 (1) 20-508 (1) 20-550 (1)
20-365 (1) 20-427 (1) 20-468 (1) 20-510 (1) 20-551 (1)
20-366 (1) 20-428 (1) 20-469 (1) 20-511 (1) 20-552 (1)
20-367 (1) 20-429 (1) 20-470 (1) 20-512 (1) 20-554 (1)
20-368 (1) 20-430 (1) 20-471 (1) 20-513 (1) 20-555 (1)
20-369 (1) 20-431 (1) 20-472 (1) 20-514 (1) 20-556 (1)
20-370 (1) 20-432 (1) 20-473 (1) 20-515 (1) 20-557 (1)
20-371 (1) 20-433 (1) 20-474 (1) 20-516 (1) 20-558 (1)
20-372 (1) 20-434 (1) 20-476 (1) 20-517 (1) 20-559 (1)
20-373 (1) 20-435 (1) 20-477 (1) 20-518 (1) 20-560 (1)
20-374 (1) 20-436 (1) 20-478 (1) 20-519 (1) 20-561 (1)
20-375 (1) 20-437 (1) 20-479 (1) 20-520 (1) 20-562 (1)
20-376 (1) 20-438 (1) 20-480 (1) 20-521 (1) 20-563 (1)
20-377 (1) 20-439 (1) 20-481 (1) 20-522 (1) 20-564 (1)
20-440 (1) 20-482 (1) 20-523 (1) 20-565 (1)
20-401 (1) 20-441 (1) 20-483 (1) 20-524 (1) 20-566 (1)
20-402 (1) 20-442 (1) 20-484 (1) 20-525 (1) 20-567 (1)
20-403 (1) 20-443 (1) 20-485 (1) 20-526 (1) 20-568 (1)
20-404 (1) 20-444 (1) 20-486 (1) 20-527 (1) 20-569 (1)
20-405 (1) 20-445 (1) 20-487 (1) 20-528 (1) 20-570 (1)
20-406 (1) 20-446 (1) 20-488 (1) 20-529 (1) 20-572 (1)
20-407 (1) 20-447 (1) 20-489 (1) 20-530 (1) 20-573 (1)
20-408 (1) 20-448 (1) 20-490 (1) 20-531 (1) 20-574 (1)
20-409 (1) 20-449 (1) 20-491 (1) 20-532 (1) 20-575 (1)
20-410 (1) 20-450 (2) 20-492 (1) 20-533 (1) 20-576 (1)
20-411 (1) 20-451 (1) 20-493 (1) 20-534 (1) 20-577 (1)
00-2-4 D475A-5
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20-578 (2) 20-618 (1) 20-658 (1) 20-724 (1) 20-805 (1)
20-579 (1) 20-619 (1) 20-659 (1) 20-725 (1) 20-806 (1)
20-580 (1) 20-620 (1) 20-660 (1) 20-726 (1) 20-807 (1)
20-581 (1) 20-621 (1) 20-661 (1) 20-727 (1) 20-808 (1)
20-582 (1) 20-622 (1) 20-662 (1) 20-728 (1) 20-809 (1)
20-583 (1) 20-623 (1) 20-663 (1) 20-729 (1) 20-810 (1)
20-584 (1) 20-624 (1) 20-664 (1) 20-730 (1) 20-811 (1)
20-585 (1) 20-625 (1) 20-665 (2) 20-731 (1) 20-812 (1)
20-586 (1) 20-626 (1) 20-666 (2) 20-732 (1) 20-813 (1)
20-587 (1) 20-627 (1) 20-667 (2) 20-733 (1) 20-814 (1)
20-588 (1) 20-628 (1) 20-668 (2) 20-734 (1) 20-815 (1)
20-589 (1) 20-629 (1) 20-669 (1) 20-735 (1) 20-816 (1)
20-590 (1) 20-630 (1) 20-670 (1) 20-736 (1)
20-591 (1) 20-631 (1) 20-671 (1) 20-737 (1) 20-901 (1)
20-592 (1) 20-632 (1) 20-672 (1) 20-738 (1) 20-902 (1)
20-593 (1) 20-633 (1) 20-673 (1) 20-739 (1) 20-903 (1)
20-594 (1) 20-634 (1) 20-740 (1) 20-904 (1)
20-595 (1) 20-635 (1) 20-701 (1) 20-741 (1) 20-905 (1)
20-596 (1) 20-636 (1) 20-702 (1) 20-742 (1) 20-906 (1)
20-597 (1) 20-637 (1) 20-703 (1) 20-743 (1) 20-907 (1)
20-598 (1) 20-638 (1) 20-704 (1) 20-744 (1) 20-908 (1)
20-599 (1) 20-639 (1) 20-705 (1) 20-745 (1) 20-909 (1)
20-600 (2) 20-640 (1) 20-706 (1) 20-746 (1) 20-910 (1)
20-601 (1) 20-641 (1) 20-707 (1) 20-747 (1) 20-911 (1)
20-602 (1) 20-642 (1) 20-708 (1) 20-748 (1) 20-912 (1)
20-603 (1) 20-643 (1) 20-709 (1) 20-749 (1) 20-913 (1)
20-604 (1) 20-644 (1) 20-710 (1) 20-750 (1) 20-914 (1)
20-605 (1) 20-645 (1) 20-711 (1) 20-751 (1) 20-915 (1)
20-606 (1) 20-646 (1) 20-712 (1) 20-752 (1) 20-916 (1)
20-607 (1) 20-647 (1) 20-713 (1) 20-753 (1) 20-917 (1)
20-608 (1) 20-648 (1) 20-714 (1) 20-754 (1) 20-918 (1)
20-609 (1) 20-649 (1) 20-715 (1) 20-755 (1) 20-919 (1)
20-610 (2) 20-650 (1) 20-716 (1) 20-756 (1) 20-920 (1)
20-611 (1) 20-651 (1) 20-717 (1) 20-757 (1) 20-921 (1)
20-612 (1) 20-652 (1) 20-718 (1) 20-758 (1) 20-922 (1)
20-613 (1) 20-653 (1) 20-719 (1) 20-923 (1)
20-614 (1) 20-654 (1) 20-720 (1) 20-801 (1)
20-615 (1) 20-655 (1) 20-721 (1) 20-802 (1)
20-616 (1) 20-656 (1) 20-722 (1) 20-803 (1) 30-1 (2)
20-617 (1) 20-657 (1) 20-723 (1) 20-804 (1) 30-2 (2)
D475A-5 00-2-5
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30-3 (2) 30-43 (2) 30-83 (2) 30-124 (2) 30-164 (2)
30-4 (2) 30-44 (2) 30-84 (2) 30-125 (2) 30-165 (2)
30-5 (2) 30-45 (2) 30-85 (2) 30-126 (2) 30-166 (2)
30-6 (2) 30-46 (2) 30-86 (2) 30-127 (2) 30-167 (2)
30-7 (2) 30-47 (2) 30-87 (2) 30-128 (2) 30-168 (2)
30-8 (2) 30-48 (2) 30-89 (2) 30-129 (2) 30-169 (2)
30-9 (2) 30-49 (2) 30-90 (2) 30-130 (2) 30-170 (2)
30-10 (2) 30-50 (2) 30-91 (2) 30-131 (2) 30-171 (2)
30-11 (2) 30-51 (2) 30-92 (2) 30-132 (2) 30-172 (2)
30-12 (2) 30-52 (2) 30-93 (2) 30-133 (2) 30-173 (2)
30-13 (2) 30-53 (2) 30-94 (2) 30-134 (2) 30-174 (2)
30-14 (2) 30-54 (2) 30-95 (2) 30-135 (2) 30-175 (2)
30-15 (2) 30-55 (2) 30-96 (2) 30-136 (2) 30-176 (2)
30-16 (2) 30-56 (2) 30-97 (2) q 30-137 (3) 30-177 (2)
30-17 (2) 30-57 (2) 30-98 (2) 30-138 (2) 30-178 (2)
30-18 (2) 30-58 (2) 30-99 (2) 30-139 (2) 30-179 (2)
30-19 (2) 30-59 (2) 30-100 (2) 30-140 (2) 30-180 (2)
30-20 (2) 30-60 (2) 30-101 (2) 30-141 (2) 30-181 (2)
30-21 (2) 30-61 (2) 30-102 (2) 30-142 (2) 30-182 (2)
30-22 (2) 30-62 (2) 30-103 (2) 30-143 (2) 30-183 (2)
30-23 (2) 30-63 (2) 30-104 (2) 30-144 (2) 30-184 (2)
30-24 (2) 30-64 (2) 30-105 (2) 30-145 (2) 30-185 (2)
30-25 (2) 30-65 (2) 30-106 (2) 30-146 (2) 30-186 (2)
30-26 (2) 30-66 (2) 30-107 (2) 30-147 (2) 30-187 (2)
30-27 (2) 30-67 (2) 30-108 (2) 30-148 (2) 30-188 (2)
30-28 (2) 30-68 (2) 30-109 (2) 30-149 (2) 30-189 (2)
30-29 (2) 30-69 (2) 30-110 (2) 30-150 (2) 30-190 (2)
30-30 (2) 30-70 (2) 30-111 (2) 30-151 (2) 30-191 (2)
30-31 (2) 30-71 (2) 30-112 (2) 30-152 (2) 30-192 (2)
30-32 (2) 30-72 (2) 30-113 (2) 30-153 (2) 30-193 (2)
30-33 (2) 30-73 (2) 30-114 (2) 30-154 (2) 30-194 (2)
30-34 (2) 30-74 (2) 30-115 (2) 30-155 (2) 30-195 (2)
30-35 (2) 30-75 (2) 30-116 (2) 30-156 (2) 30-196 (2)
30-36 (2) 30-76 (2) 30-117 (2) 30-157 (2) 30-197 (2)
30-37 (2) 30-77 (2) 30-118 (2) 30-158 (2) 30-198 (2)
30-38 (2) 30-78 (2) 30-119 (2) 30-159 (2) 30-199 (2)
30-39 (2) 30-79 (2) 30-120 (2) 30-160 (2) 30-200 (2)
30-40 (2) 30-80 (2) 30-121 (2) 30-161 (2) 30-201 (2)
30-41 (2) 30-81 (2) 30-122 (2) 30-162 (2) 30-202 (2)
30-42 (2) 30-82 (2) 30-123 (2) 30-163 (2) 30-203 (2)
00-2-6 D475A-5
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30-204 (2)
30-205 (2)
30-206 (2)
30-207 (2)
30-208 (2)
30-209 (2)
30-210 (2)
30-211 (2)
30-212 (2)
30-213 (2)
30-214 (2)
30-215 (2)
30-216 (2)
30-217 (2)
30-218 (2)
30-219 (2)
90-1
90-3
90-5
90-7
q 90-9 (3)
90-11
90-13
90-15
90-17
90-19
90-21
90-23
90-25
90-27
D475A-5 00-2-7
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive () terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop 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 judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120 hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150.
The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
The adapter can be pushed in about 3.5
mm.
Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
Quick hardening type adhesive
Three bond Polyethylene Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly for adhesion of metals,
rubbers, plastics and woods.
Quick hardening type adhesive
Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container Used mainly for adhesion of rubbers,
plastics and metals.
Resistance to heat, chemicals
Loctite 79A-129-9110 50 cc Polyethylene Used at joint portions subject to high
648-50 container temperatures.
Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
Features: Silicon based, resistance
to heat, cold
Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1g Tube Used as sealant for flywheel hous-
ing, intake manifold, oil an, thermo-
stat housing, etc.
Three bond Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum Used for heavy load portion

SYG2-400M 400 g 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
"S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 14.7 1.2 1.5

8 13 27 34 2.8 3.5
10 17 59 74 6 7.5
12 19 98 123 10 12.5
14 22 153 190 15.5 19.5
16 24 235 285 23.5 29.5

18 27 320 400 33 41
20 30 455 565 46.5 58
22 32 610 765 62.5 78
24 36 785 980 80 100
27 41 1150 1440 118 147

30 46 1520 1910 155 195
33 50 1960 2450 200 250
36 55 2450 3040 250 310
39 60 2890 3630 295 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0

8 13 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 27 74.5 90.2 7.6 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 4.9 2.5 0.5

18 24 49 19.6 52
22 27 78.5 19.6 82
24 32 137.3 29.4 14 3
30 36 176.5 29.4 18 3
33 41 196.1 49 20 5
36 46 245.2 49 25 5
42 55 294.2 49 30 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 74 6 7.5
12 17 98 123 10 12.5
16 22 235 285 23.5 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 63 {3.5 6.5} 44 {4.5}

03, 04 20 Varies depending 84 132 {8.5 13.5} 103 {10.5}
05, 06 24 on type of 128 186 {13.0 19.0} 157 {16.0}
10, 12 33 connector. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1010 {76.0 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}

10 10 17 9.8 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 {9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 124.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR BW RW YR GW LW
2
Color White & Red White & Black Red & White Rellow & Red Green & White Blue & White
Code WB BY RB YB GR LR
3
Color White & Black Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG RG YL GB LB
5
Color White & Green Red & Green Yellow & Blue Green & Black Blue & Black
Code RL YW GL n
6
Color Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
GENERAL SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
DIMENSIONS
Semi-U tiltdozer Full-U tiltdozer Superdozer +

Symbol Item Unit
+ giant ripper + giant ripper counterweight
A Overall length mm 11,565 12,065 10,525
B Overall height mm 4,590 4,590 4,590
C Overall width mm 5,265 6,205 6,465
01-2 D475A-5
GENERAL SPECIFICATIONS
SPECIFICATIONS
Semi-U tiltdozer and full-U tiltdozer specifications
Machine model D475A-5
Serial Number 20001 and up
Machine weight
Tractor 77,310
Weight
Above + Semi-U tiltdozer kg 93,810

Above + Variable giant ripper 101,110
Above + ROPS cab + Air conditioner 102,500
Min. turning radius m 4.6
Gradeability deg. 30
Stability (Forward, reverse, left, right) deg. 35
1st 0 3.5
Forward
2nd km/h 0 6.3

speeds
3rd 0 10.9
Gear
Performance
1st 0 4.7
Reverse
2nd km/h 0 8.4

3rd 0 14.3
Tractor 122.6 {1.25}
Semi-U dozer 148.1 {1.51}
pressure
Ground
Semi-U dozer + Variable giant ripper kPa {kg/cm }

2
159.8 {1.63}
Above + ROPS cab + Air conditioner 122.6 {1.65}
+ Perforated side cover
Tractor 6,680
Overall
Semi-U dozer 8,705

length
mm
Semi-U dozer + Variable giant ripper 11,565
Full-U dozer + Variable giant ripper 12,065
Tractor 3,610
Overall
width
Semi-U dozer mm 5,265

Dimensions
Full-U dozer 6,205

Up to ROPS top 4,590
Overall
height
Up to exhaust pipe end mm 4,240

Up to exhaust duct top 3,805
Track gauge 2,770
Length of track on ground 4,365
mm
Track shoe width 710
Minimum ground clearance 655
D475A-5 01-3
Model name Komatsu SDA12V140E-1

Type 4-cycle, water-cooled, V-type, direct-injection
engine with turbocharger and aftercooler
Number of cylinderBore x Stroke mm 12140 x 165
Total displacement l {cc} 30.48 {30,480}
Rated output kW/rpm {HP/rpm} 641/2,000 {860/2,000}
Performance
Max. torque Nm/rpm {kgm/rpm} 3,825/1,400 {390/1,400}

Engine
High idling speed under no load rpm 2,150

Low idling speed under no load rpm 660
Min. fuel consumption ratio g/kWh {g/HPh} 240 {153}
(at rated operation)
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 100 A
Battery 12V, 170 Ah x 4
Type of radiator core D-type
3-element, 1-stage, 1-phase type

Torque converter
(With lock-up clutch)
Planetary gear, multiple disc clutch,
Transmission hydraulic, pump-forced lubrication,
3 forward/reverse gear speeds type
Bevel gear shaft Spiral bevel gear, splash lubrication type

Power train
Wet, multiple disc clutch, spring-actuated,

Steering clutch hydraulic (hand-operated) type
interlocked with brake
Steering brake hydraulic (foot/hand-operated) type
1-stage spur gear and 1-stage planetary gear,
Final drive
splash lubrication type
Type of suspension Hard, equalizing beam type

Undercarriage
Carrier roller 2 pieces on each side
Track roller 7 pieces on each side
Assembly type single grouser shoe,

Track shoe 40 pieces on each side,
Pitch: 317.5 mm, Width: 710 mm
Power train + Lubricating oil pump (Tandem) Gear type (BAL 160 + 160 + 112)
Scavenging pump (Tandem) Gear (BAR 63 + 320)
01-4 D475A-5
Max. pressure MPa {kg/cm2} 27.5 {280}

Work equipment
Type Variable swash plate type:

pump
2 pcs. (HPV 125 + 125)

l/min
Capacity 542
(at engine speed of 2,000 rpm)
Variable swash plate type: 2 pcs. (LPV 90 + 30)

Fan pump MPa {kg/cm2} Max. discharge pressure: 17.5 {178}
l/min/rpm Theoretical discharge pressure: 178/1,934
Fixed swash plate type (LMF 180)
Fan motor
Work equipment hydraulic system
MPa {kg/cm2} Max. using pressure: 17.5 {178}

Type
Work equipment
For blade lift

6-spool type: 1 pc.
valve
For blade tilt

Hydraulic
For ripper lift
For ripper tilt
Type Reciprocating piston
Bore of cylinder 180

blade lift cylinder
Dimensions of
Outside diameter of piston rod 110

Stroke of piston mm 1,925
Hydraulic
Max. distance between pins 3,155

cylinders
Min. distance between pins 1,230

blade tilt cylinder
Dimensions of

Stroke of piston mm 293
D475A-5 01-5

(Both of right and left)
Dimensions of blade

dual tilt cylinder

Stroke of piston 293
mm

Hydraulic cylinders

ripper lift cylinder
Dimensions of

ripper tilt cylinder
Dimensions of

Hydraulic tank Box type (External control valve type)
01-6 D475A-5
Hydraulic semi-U tiltdozer

Type
Hydraulic full-U tiltdozer
Blade supporting method Brace type (Right tilt cylinder)
Max. lift above ground mm 1,620
Performance
Max. drop below ground mm 1,010

Max. tilting distance mm 770
Semi-U dozer
Changing range of blade deg. 6

cutting edge angle
Capacity of blade m3 38.1 <SAE 27.2>
Dimensions
Width of blade mm 5,265

Height of blade mm 2,690
Angle of blade cutting edge deg. 52

Performance
Max. drop below ground mm 1,010

Max. tilting distance mm 905
Changing range of blade deg. 6
Full-U dozer
cutting edge angle

Dimensions

Angle of blade cutting edge deg. 52
Work equipment
Semi-U dozer
Performance
Max. tilting distance mm 1,145

+ Pitch
Max. pitch angle deg. 6

Max. pitch back angle deg. 6
Performance
Full-U dozer
Max. tilting distance mm 1,350

+ Pitch
Max. pitch angle deg. 6

Performance
Max. digging depth mm 1,180

Max. lift mm 1,140
Multi-ripper
Digging angle (Standard) deg. 45 (Adjustable steplessly to 32.5 54)

Dimensions
Length of beam mm 3,085
Number of shanks pcs. 3

Performance
Max. digging depth mm 1,800

Max. lift mm 1,140
Giant ripper
Digging angle (Standard) deg. 45 (Adjustable steplessly to 34 56)

Dimensions
Length of beam mm 1,477
Number of shanks pcs. 1
D475A-5 01-7
Superdozer specification
Machine weight
Weight
Tractor 78,510
kg
Superdozer + ROPS cab + Air conditioner 108,000
+ Counterweight
Min. turning radius m 4.6
Gradeability deg. 30
Stability (Forward, reverse, left, right) deg. 35
1st 0 3.5
Forward
2nd km/h 0 6.3

Performance
Gear speeds
3rd 0 10.9
1st 0 4.7
Reverse
2nd km/h 0 8.4

3rd 0 14.3
Tractor 97.09 {0.99}
pressure
Ground
Superdozer + ROPS cab + kPa {kg/cm }

2
133.37 {1.36}
Air conditioner + Counterweight
Overall
Tractor 6,680
length
mm
Superdozer + Counterweight 10,525
Overall
Tractor 3,610
width
mm
Superdozer 6,465
Dimensions
Up to ROPS top 4,590

Overall
height
Up to exhaust pipe end mm 4,240

Up to exhaust duct top 3,805
Track gauge 2,770
Length of track on ground 4,365
mm
Track shoe width 810
Minimum ground clearance 655
01-8 D475A-5
Model name Komatsu SDA12V140E-1

Type 4-stroke, water-cooled, V-type, direct-injection
engine with turbocharger and aftercooler
Number of cylinderBore x Stroke mm 12140 x 165
Total displacement l {cc} 30.48 {30,480}
Rated output kW/rpm {HP/rpm} 632/2,000 {848/2,000}
Max. torque Nm/rpm {kgm/rpm} 3,825/1,400 {390/1,400}
Performance
Engine
High idling speed under no load rpm 2,150

Low idling speed under no load rpm 660
Min. fuel consumption ratio g/kWh {g/HPh} 240 {148}
(at rated operation)
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 100 A
Battery 12 V, 220 Ah x 4
Type of radiator core D-type
3-element, 1-stage, 1-phase type
Torque converter
(With lock-up clutch)
Planetary gear, multiple disc clutch,
Transmission hydraulic, pump-forced lubrication,
3 forward/reverse gear speeds type
Bevel gear shaft Spiral bevel gear, splash lubrication type
Power train

Steering clutch hydraulic (hand-operated) type
Steering brake hydraulic (foot/hand-operated) type
1-stage spur gear and 1-stage planetary gear,
Final drive
splash lubrication type
Type of suspension Hard, equalizing beam type
Carrier roller 2 pieces on each side
Undercarriage
Track roller 7 pieces on each side

Assembly type single grouser shoe,
Track shoe 40 pieces on each side,
Pitch: 317.5 mm, Width: 810 mm
Power train + Lubrication pump (Tandem) Gear type (BAL 160 + 160 + 112)
Scavenging pump (Tandem) Gear (BAR 63 + 320)
D475A-5 01-9
Max. pressure MPa {kg/cm2} 27.5 {280}

Work equipment
Type Variable swash plate type:

2 pcs. (HPV 125 + 125)
pump
Capacity l/min 542

(at engine speed of 2,000 rpm)
Variable swash plate type: 2 pcs. (LPV 90 + 30)

Fan pump MPa {kg/cm2} Max. discharge pressure: 17.5 {178}
l/min/rpm Theoretical discharge pressure: 178/1,934
Fixed swash plate type (LMF 180)

Fan motor
MPa {kg/cm } 2
Max. using pressure: 17.5 {178}
Type
Work equipment
For blade lift

6-spool type: 1 pc.
valve
For blade tilt

Hydraulic
For ripper lift
For ripper tilt
Type Reciprocating piston

blade lift cylinder
Dimensions of

Stroke of piston mm 1,925
Hydraulic
cylinders

blade pitch cylinder

Dimensions of

Hydraulic tank Box type (External control valve type)
01-10 D475A-5
Type Hydraulic superdozer (Pitchdozer)

Blade supporting method Cylinder type

Performance
Max. drop below ground mm 860

Work equipment
Max. tilting distance mm 900 (at cutting edge angle of 52 deg.)

Max. pitch dump angle deg. 15
Superdozer

Dimensions

Angle of blade cutting edge deg. 42 67
D475A-5 01-11
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This weight table is a reference for handling and transportation of components.
Semi-U tiltdozer and full-U tiltdozer specifications Unit: kg
Engine and damper assembly 4,250

Engine assembly 4,035
Damper assembly 215
Main radiator assembly 485
Sub radiator assembly 144
Oil cooler assembly 129
Fuel tank assembly [When full] 863 [2,335]
Power train unit (Including work equipment pump and fan pump) 5,350
Torque converter and PTO assembly 830
Transmission assembly 1,335
Transmission valve assembly 40
Steering clutch and brake assembly 2,290
Steering valve assembly 75
Work equipment pump 180
Fan pump 72
Power train and lubricating oil pump 64
Scavenging pump 25
Power train filter assembly (3 pcs.) 100
Final drive assembly (Each side) 3,575
Main frame assembly 9,120
Track group assembly (Each side) 11,180
Track frame 2,996
Idler assembly (Each side) 708
Track roller assembly (1 single flange) 222
Track roller assembly (1 double flange) 237
Carrier roller assembly (1 pc.) 106
Track shoe assembly (710 mm) 13,200
Pivot shaft assembly (each side) 370
Equalizer bar 598
Hydraulic tank assembly 290
Main control valve 195
Blade lift cylinder assembly (Each side) 509
Blade tilt cylinder assembly 504
Tiltdozer assembly 16,500 (18,500)
Blade 8,550 (9,760)
Straight frame (Left) 1,770 (1,770)
Straight frame (Right) 1,770 (1,770)
Tilt cylinder assembly 504 (504)
Variable giant ripper assembly 7,300
Shank assembly 1,040
Ripper lift cylinder assembly 389
Ripper tilt cylinder assembly 394
a Values in ( ) are for full-U blade.
01-12 D475A-5
Unit: kg
Radiator guard assembly 4,640

Radiator guard 2,530
Fan motor 65
Radiator mask (Including grille) (Each side) 100
Engine underguard (Front) 267
Engine underguard (Rear) 324
Power train underguard (Front) 340
Power train underguard (Rear) 448
Hood 197
Fender (Left) 474
Fender (Right) 570
ROPS mount assembly (Left) 527
ROPS mount assembly (Right) 520
ROPS assembly 934
Floor frame assembly 600
Cab assembly 455
Operator's seat assembly 64
D475A-5 01-13
Superdozer specification Unit: kg
Engine and damper assembly 4,250

Engine assembly 4,035
Damper assembly 215
Main radiator assembly 485
Sub radiator assembly 144
Oil cooler assembly 129
Fuel tank assembly [When full] 863 [2,335]
Power train unit (Including work equipment pump and fan pump) 5,350
Torque converter and PTO assembly 830
Transmission assembly 1,335
Transmission valve assembly 40
Steering clutch and brake assembly 2,290
Steering valve assembly 75
Work equipment pump 180
Fan pump 72
Power train and lubricating oil pump 64
Scavenging pump 25
Power train filter assembly (3 pcs.) 100
Final drive assembly (Each side) 3,575
Main frame assembly 9,120
Track group assembly (Each side) 11,180
Track frame 2,996
Idler assembly (Each side) 708
Track roller assembly (1 single flange) 222
Track roller assembly (1 double flange) 237
Carrier roller assembly (1 pc.) 106
Track shoe assembly (810 mm) 14,100
Pivot shaft assembly (each side) 370
Equalizer bar 598
Hydraulic tank assembly 290
Main control valve 195
Blade pitch cylinder assembly (Each side) 508
Superdozer assembly 21,200
Blade 11,950
Straight frame (Left) 1,770
Straight frame (Right) 1,770
Pitch cylinder assembly (Each side) 508
Counterweight 6,400
Radiator guard assembly 4,640
Radiator guard 2,530
Fan motor 65
01-14 D475A-5
Unit: kg
Radiator mask (Including grille) (Each side) 100

Engine underguard (Front) 267
Engine underguard (Rear) 324
Power train underguard (Front) 340
Power train underguard (Rear) 448
Hood 197
Fender (Left) 474
Fender (Right) 570
ROPS mount assembly (Left) 527
ROPS mount assembly (Right) 520
ROPS assembly 934
Floor frame assembly 600
Cab assembly 455
Operator's seat assembly 64
D475A-5 01-15
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
01-16 D475A-5
GENERAL FUEL, COOLANT AND LUBRICANTS
NOTE: (2) When starting the engine in an atmospheric

(1) When fuel sulphur content is less than 0.5 %, temperature of lower than 0C, be sure to use
change oil in the oil pan every periodic mainte- e n g i n e o i l of S A E 10 W, S A E 1 0 W - 3 0 a n d
nance hours described in this manual. Change SAE15W-40, even though an atmospheric tem-
oil according to the following table if fuel sulphur perature goes up to 10C more or less in the day
content is above 0.5 %. time.
(3) Use API classification CD as engine oil and if
Change interval of oil in API classification CC, reduce the engine oil
Fuel sulphur content
engine oil pan
change interval to half.
0.5 to 1.0 % 1/2 of regular interval (4) There is no problem if single grade oil is mixed
with multigrade oil (SAE10W-30, 15W-40), but
Above 1.0 % 1/4 of regular interval
be sure to add single grade oil that matches the
temperature in the table on the left.
ASTM: American Society of Testing and Material (5) We recommend Komatsu genuine oil which has
SAE: Society of Automotive Engineers been specifically formulated and approved for
API: American Petroleum Institute use in engine and hydraulic work equipment
applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
D475A-5 01-17
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
RADIATOR AND OIL COOLER............... 10- 4 COOLING FAN MOTOR ..........................10-160
ENGINE MOUNT..................................... 10- 5 PPC VALVE .............................................10-166
POWER TRAIN ....................................... 10- 6 ELECTRIC LEVER (STEERING) .............10-176
POWER TRAIN HYDRAULIC CONTROL VALVE ...................................10-180
EQUIPMENT ARRANGEMENT MAIN RELIEF VALVE...............................10-194
DIAGRAM .......................................... 10- 8 CLSS ........................................................10-195
DAMPER AND UNIVERSAL JOINT ........ 10- 10 UNLOAD VALVE ......................................10-198
POWER TRAIN UNIT .............................. 10- 12 INTRODUCTION OF LS PRESSURE
TORQUE CONVERTER AND PTO ......... 10- 14 (LS SHUTTLE VALVE)........................10-199
TORQUE CONVERTER VALVE ............. 10- 24 LS BYPASS PLUG ...................................10-200
TORQUE CONVERTER LOCK-UP PRESSURE COMPENSATION VALVE....10-201
CONTROL SYSTEM .......................... 10- 34 BLADE LIFT VALVE .................................10-204
SCAVENGING PUMP ............................. 10- 35 MERGE-DIVIDER VALVE ........................10-212
TRANSMISSION CONTROL................... 10- 36 SELF-REDUCING PRESSURE VALVE ...10-214
TRANSMISSION ..................................... 10- 38 PILOT SOLENOID VALVE .......................10-218
TRANSMISSION ECMV .......................... 10- 50 HYDRAULIC TANK ..................................10-220
TRANSMISSION CLUTCH ECMV .......... 10- 52 ACCUMULATOR......................................10-222
PRIORITY VALVE ................................... 10- 56 WORK EQUIPMENT CYLINDER.............10-224
LUBRICATING OIL RELIEF VALVE ....... 10- 57 PISTON VALVE ........................................10-226
POWER TRAIN, LUBRICATION PUMP .. 10- 58 QUICK DROP VALVE ..............................10-228
STEERING, BRAKE CONTROL ............. 10- 60 BLADE CONTROL KNOB........................10-230
FINAL DRIVE .......................................... 10- 63 PITCH AND DUAL SOLENOID VALVE....10-232
POWER TRAIN ....................................... 10- 68 PIN-PULLER HYDRAULIC CIRCUIT
STEERING ECMV ................................... 10- 80 DRAWING...........................................10-233
STEERING CLUTCH ECMV, PIN-PULLER SOLENOID VALVE ............10-234
STEERING BRAKE ECMV ................ 10- 82 CYLINDER STAY .....................................10-236
PARKING BRAKE VALVE ....................... 10- 88 BLADE......................................................10-238
SUDDEN STOP PREVENTION VALVE.. 10- 90 RIPPER EQUIPMENT..............................10-242
SPROCKET ............................................. 10- 92 CAB MOUNT............................................10-244
TRACK FRAME ....................................... 10- 94 CAB ..........................................................10-245
RECOIL SPRING .................................... 10- 96 AIR CONDITIONER .................................10-248
IDLER ...................................................... 10- 98 ENGINE CONTROL .................................10-250
TRACK ROLLER ..................................... 10-100 ENGINE CONTROL SYSTEM .................10-251
CARRIER ROLLER ................................. 10-102 DECELERATION POTENTIOMETER......10-252
TRACK ROLLER BOGIE......................... 10-103 ENGINE CONTROL SYSTEM WITH
TRACK SHOE ......................................... 10-104 ELECTRONIC ENGINE THROTTLE
MAIN FRAME .......................................... 10-108 CONTROLLER ...................................10-253
SUSPENSION ......................................... 10- 111 FUEL INJECTION PUMP WITH
WORK EQUIPMENT HYDRAULIC ELECTRONIC GOVERNOR...............10-254
EQUIPMENT ARRANGEMENT MONITOR SYSTEM.................................10-255
DIAGRAM .......................................... 10- 114 MONITOR PANEL....................................10-257
PPC CONTROL PIPING DIAGRAM........ 10- 118 SENSORS................................................10-261
WORK EQUIPMENT CONTROL ............ 10-120
WORK EQUIPMENT PUMP.................... 10-122
COOLING FAN PUMP ............................ 10-139
D475A-5 10-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MODE SELECTION SYSTEM................. 10-265

ELECTRICAL EQUIPMENT .................... 10-271
STEERING ELECTRONIC CONTROL
SYSTEM............................................. 10-274
VHMS CONTROLLER............................. 10-276
SENSORS ............................................... 10-279
COMMUNICATION (ORB: ORBCOMM)
CONTROLLER/ANTENNA................. 10-282
10-2 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RADIATOR AND OIL COOLER
RADIATOR AND OIL COOLER
1. Main radiator Outline

2. Sub radiator The radiator consists of two systems: The main ra-
3. Turbocharger diator and sub radiator.
4. Aftercooler The main radiator system carries out cooling for the
5. Engine engine and power train oil cooler; the sub radiator
6. Power train oil cooler system carries out cooling for the aftercooler.
7. Water pump (for main radiator) There are water pumps for each system.
8. Water pump (for sub radiator)
10-4 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between bracket size Shaft Hole clearance limit
1
and cushion
0.030 +0.006 0.018
78 0.1
0.060 0.048 0.066
Replace
Clearance between bracket 0.043 +0.072 0.043
2 200 0.1
and bushing 0.083 +0.072 0.155
Standard size Repair limit
3 Free height of rubber mount
118 116
D475A-5 10-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
Outline
The power generated by engine (1) has its tor- bevel pinion and bevel gear of the bevel gear
sional vibration dampened by damper (2), and shaft, and it is then divided at right angles to the
then passes through universal joint (3), and is left and right and transmitted to the respective
transmitted to torque converter (7). steering clutches (9). The power transmitted
The power from the engine is transmitted from the bevel gear shaft to the final drive is
through oil by torque converter (7) to the input used to steer the machine by engaging or disen-
shaft (turbine shaft) of transmission (8) in accor- gaging steering clutch (9).
dance with the change in the load. The steering lever is operated to disengage the
There is a lock-up clutch assembled to the steering clutch on the side to which the machine
torque converter, and when the rotating speed is to be steered in order to change the direction
beyond the torque converter becomes higher, of travel. The size of the turning radius is con-
the lock-up clutch is engaged. When this hap- trolled by steering brake (10) installed to the out-
pens, the drive case and turbine form one unit, side of the steering clutch.
so the power from the engine is transmitted Steering brake (10) uses the same disc system
directly to the transmission input shaft. that is used for the steering clutch.
Transmission (8) uses a combination of a plane- The power output from the steering clutch
tary gear system and hydraulic equipment to enters final drive (11), where it is reduced, and
reduce the speed and shift the gears (forward: 3 rotates sprocket (12).
gears, reverse: 3 gears). It connects two sets of Final drive is a double reduction type consisting
clutches selected with the gear shift lever of a single stage spur gear and single stage
according to the change in the load, and trans- planetary gear system.
mits the power from the transmission to transfer It rotates the sprocket to drive track shoe (13)
(14) from output shaft. and move the machine.
The power entering transfer (14) has its speed
reduced. Its speed is further reduced by the
10-6 D475A-5
1. Engine (SDA12V140E-1) 6. Fan pump (LPV90+30) 13. Track shoe

2. Damper 7. Torque converter 14. Transfer
3. Universal joint 8. Transmission 15. Transfer drive gear
4. Power train, lubrication pump 9. Steering clutch 16. Bevel pinion
(BAL160+160+112) 10. Steering brake 17. Bevel gear
5. Work equipment pump 11. Final drive 18. PTO
(HPV125+125) 12. Sproket 19. Scavenging pump
D475A-5 10-7
POWER TRAIN HYDRAULIC EQUIP-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MENT ARRANGEMENT DIAGRAM
POWER TRAIN HYDRAULIC EQUIPMENT ARRANGEMENT

DIAGRAM
1. Torque converter oil filter A. Transmission main relief pressure pick-up port (TM)
2. Transmission lubricating oil filter B. Transmission R clutch pressure pick-up port (REV)
3. Transmission oil filter C. Transmission F clutch pressure pick-up port (FWD)
4. Torque converter valve D. Torque converter inlet pressure pick-up port (IN)
5. Transmission control valve E. Lock-up clutch pressure pick-up port (LU)
6. Steering control valve F. Left clutch pressure pick-up port (LC)
7. Power train oil strainer G. Left brake pressure pick-up port (LB)
8. Oil tank H. Right brake pressure pick-up port (RB)
9. Power train, lubrication pump J. Right clutch pressure pick-up port (RC)
(BAL160+160+112) K. Stator clutch pressure pick-up port (SC)
10. Scavenging pump L. Torque converter outlet pressure pick-up port (OUT)
11. Power train oil cooler M. Transmission 1st clutch pressure pick-up port (1ST)
N. Transmission 2nd clutch pressure pick-up port (2ND)
P. Transmission 3rd clutch pressure pick-up port (3RD)
10-8 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DAMPER AND UNIVERSAL JOINT
DAMPER AND UNIVERSAL JOINT
1. Output shaft Outline

2. Flywheel The damper damps the tensional vibration
3. Outer body caused by fluctuation of the engine torque and
4. Flange the impact torque caused by sudden accelera-
5. Oil level gauge tion and heavy digging work to protect the torque
6. Breather converter, transmission, and other power train
7. Cover components.
8. Coupling Since this damper employs rubber coupling (10),
9. Universal joint vibrations are damped by the compressive
10. Rubber coupling damping effect of the rubber and less component
11. Drain plug parts are used.
Operation
The power from the engine is transmitted
through flywheel (2) to outer body (3). The ten-
sional vibration of the engine is absorbed in rub-
ber coupling (10) and the power is transmitted to
output shaft (1), and then transmitted through
universal joint (9) to the torque converter and
transmission.
10-10 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DAMPER AND UNIVERSAL JOINT
Unit: mm

Clearance between flywheel size Shaft Hole clearance limit
12
housing and cover
0.024 +0.080 0.024
647.7 0.2
0.104 +0.080 0.184
Clearance between flywheel 0.022 +0.070 0.022
13 571.5 0.2 Replace
housing and damper 0.092 +0.070 0.162
Outer diameter of oil seal Standard size Repair limit

14
contact face on coupling 120 119.9
Outer diameter of bearing
15 55 54.9
contact face on output shaft
D475A-5 10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN UNIT
POWER TRAIN UNIT

General view of power train
10-12 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN UNIT
A : Main relief pressure pick-up port (TM) 1. Oil filler

B : R clutch pressure pick-up port (REV) 2. Centralized pressure pick-up port
C : F clutch pressure pick-up port (FWD) 3. Oil level gauge
D : Torque converter inlet pressure pick-up port (IN) 4. Torque converter and PTO
E : Lock-up clutch pressure pick-up port (LU) 5. Torque converter valve
F : Left steering clutch pressure pick-up port (LC) 6. Transmission ECMV
G : Left steering brake pressure pick-up port (LB) 7. Transmission
H : Right steering brake pressure pick-up port (RB) 8. Steering ECMV
J : Right steering clutch pressure pick-up port (RC) 9. Steering unit
K : Stator clutch pressure pick-up port (SC) 10. Torque converter filter
L : Torque converter outlet pressure pick-up port 11. Transmission lubrication filter
(OUT) 12. Power train filter
M: 1st clutch pressure pick-up port (1ST) 13. Torque converter, power train, and lubricating
N : 2nd clutch pressure pick-up port (2ND) oil pump
P : 3rd clutch pressure pick-up port (3RD) 14. Power train oil strainer
R : Transmission lubricating pressure pick-up port 15. Scavenging pump
Outline
The power train unit consists of the main compo-
nents of torque converter and PTO (4), transmis-
sion (7), and steering unit (9). Accordingly, after
the power train unit is removed, it can be divided
into torque converter and PTO (4), transmission
(7), and steering unit (9).
Steering unit (9) consists of the transfer, bevel
gear shaft, steering clutch, and steering brake.
D475A-5 10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER AND PTO
TORQUE CONVERTER AND PTO

a PTO: Abbreviation for Power Take Off
10-14 D475A-5
D475A-5 10-15
A : To transmission ECMV 1. Cooling fan pump mounting port

B : To transmission lubrication circuit 2. Work equipment pump mounting port
C : To transmission oil pan 3. Power train, torque converter, and lubricating oil
D : From steering case pump mounting port
E : From power train pump 4. Scavenging pump mounting port
F : From lubricating oil pump 5. Torque converter valve
G : To transmission oil pan 6. Coupling
H : To scavenging pump 7. Retainer
J : To scavenging pump 8. Input shaft (Number of teeth: 59)
K : To power train filter 9. Front housing
L : To transmission lubricating oil filter 10. PTO idler gear (Number of teeth: 74)
M : From power train filter 11. PTO idler gear shaft
N : From transmission lubricating oil filter 12. Lock-up clutch housing
P : Torque converter outlet oil temperature 13. Drive case
pick-up port 14. Turbine
R : Torque converter outlet oil pressure 15. Rear housing
pick-up port (OUT) 16. Stator
S : To power train oil cooler 17. Pump
18. Stator shaft
19. Guide
20. Retainer
21. Pump shaft
22. Transmission input shaft
23. Stator clutch hub gear
24. Stator clutch housing
25. Return spring
26. Stator clutch plate
27. Stator clutch disc
28. Stator clutch piston
29. Turbine boss
30. Lock-up clutch plate
31. Lock-up clutch disc
32. Lock-up clutch piston
33. Scavenging pump drive gear (Number of teeth: 65)
34. Sleeve
35. Bearing race
36. Power train, torque converter, lubricating oil pump,
and fan pump drive gear (Number of teeth: 61)
37. Drive gear boss
38. Cover
39. Cover
40. Work equipment pump drive gear
(Number of teeth: 61)
41. Cover
42. Strainer
10-16 D475A-5
Outline Structure
The torque converter is a 3-element, 1-stage, Pump (17) is combined with coupling (6), input
and 1-phase type, which is combined with the shaft (8), lock-up clutch housing (12), and drive
transmission into 1 unit. case (13) into 1 unit and rotated by the engine
The torque converter is equipped with a lock-up power.
device of wet multiple disc type and a stator Turbine (14) is combined with turbine boss (29)
clutch of wet double disc type to reduce fuel con- and transmission input shaft (22) into 1 unit and
sumption, increase operability, and reduce rotated by the oil from pump (17).
horsepower consumption by the engine. Stator (16) is combined with stator shaft (18) and
For higher efficiency of continuous light dozing stator clutch hub gear (23) into 1 unit and fixed to
and leveling work, the torque converter is locked rear housing (15) through the stator clutch unit.
up and the engine power is transmitted directly to The lock-up clutch unit consists of clutch plate
the input shaft of the transmission. (30) meshed with drive case (13), clutch disc (31)
When the torque converter is locked up (pump meshed with turbine boss (29), and clutch piston
and turbine is combined into one unit), oil is still (32) which slides inside clutch housing (12) com-
supplied to the torque converter. Accordingly, oil bined with drive case (13) into 1 unit.
flowing from the pump through the turbine to the The stator clutch unit consists of clutch disc (27)
stator is obstructed by the stator blades and does meshed with clutch hub gear (23) coupled with
not flow any direction. As a result, this oil resists stator shaft (18) by the spline, clutch plate (26)
revolution of the pump and turbine (it is agitated). supported by the pins on clutch housing (24) and
To reduce the rotating resistance of the pump rear housing (15), and clutch piston (28) which
and turbine, the stator clutch is disengaged when slides inside the rear housing (15).
the torque converter is locked up so that the sta- The PTO unit consists of input shaft (8), PTO
tor can rotate freely. idler gear (10), and pump drive gears (33), (36),
As the stator rotates together with the pump and and (40).
turbine, the oil returns from the turbine to the
pump smoothly against less resistance.
The torque converter is locked up when both of

the following conditions are satisfied.
Torque converter output shaft speed:
Min. 1,360 rpm
Set transmission pressure:
Min. 1.91 MPa {19.5 kg/cm2}
The torque converter is unlocked when either of

the following conditions is satisfied.
Torque converter output shaft speed:
Max. 1,330 rpm
Set transmission pressure:
Max. 1.47 MPa {15.0 kg/cm2}
D475A-5 10-17
10-18 D475A-5
Unit: mm
Standard size Tolerance Repair limit

Outside diameter of oil seal
1 0.063
contact face of input coupling 125 124.8
0.063
Repair by
Inside diameter of seal ring +0.035
2 115 115.1 hard chro-
contact face of input shaft +0.035
mium plating
Inside diameter of seal ring +0.046 or replace
3 190 190.5
contact face of pump shaft +0.046
4 120 120.5
contact face of stator shaft +0.035
Backlash between input shaft
5 0.198 0.484
and PTO idler gear
Backlash between PTO idler
gear and power train/torque
6 0.198 0.484
converter/ lubricating oil pump
and fan pump drive gear
Backlash between PTO idler
7 gear and work equipment 0.198 0.484
pump drive gear
Backlash between input shaft
8 and scavenging pump drive 0.198 0.484
gear
Wear of seal 0.01

Width 4 3.6
9 ring of input 0.03
shaft Thickness 4.5 0.12 4.05
Thickness of lock-up clutch
5.4 0.1 4.9
disc
Replace
Thickness of lock-up clutch
10 5.0 0.1 4.5
plate
Overall thickness of lock-up
26.2 0.22 24.6
clutch assembly
Thickness of stator clutch disc 5.4 0.1 4.9
Thickness of stator clutch

11 5.0 0.05 4.5
plate
Overall thickness of stator
15.8 0.15 14.7
clutch assembly
Tolerance
Standard size
Fitting toler- Shaft Hole
ance of PTO Outside 0.018 0.008
12 140
idler gear bear- diameter 0.018 0.033
ing
Inside 0.019 0.015
80
diameter 0.019 0.015
D475A-5 10-19
Tolerance
Standard size
Shaft Hole
Fitting toler-
ance of power Outside
+0.012
train/torque diameter
0.028
converter/lubri- (Cover side) 0.018
13 140
cating oil pump 0.018
Outside
and fan pump +0.015
diameter
drive gear 0.010
(Case side)
bearing
Inside +0.030 0.015
65
diameter +0.011 0.015
Outside
0.025 +0.012
diameter 160
0.025 0.028
(Cover side)
Outside
Fitting toler- 0.018 +0.015
diameter 140
ance of work 0.018 0.010
(Case side)
14 equipment Replace
pump drive Inside
gear bearing diameter 75
(Cover side) +0.030 0.015
Inside +0.011 0.015
diameter 65
(Case side)
Fitting toler- Outside 0.013 +0.009
72
ance of scav- diameter 0.013 0.021
15 enging pump
drive gear Inside +0.025 0.010
35
bearing diameter +0.009 0.010

Installed Installed Installed
Free length Free length
16 Stator clutch return spring length load load
125.4 N 106.9 N
54.1 37.0 50.9
{12.8 kg} {10.9 kg}
10-20 D475A-5
Power train route
When lock-up clutch is OFF and stator clutch is

ON
If lock-up clutch (3) is OFF, drive case (5) and
turbine (7) are disconnected from each other.
If stator clutch (9) is ON at this time, rear hous-
ing (10) and stator shaft (11) are connected to
each other to fix stator (8).
Accordingly, the lock-up torque converter works
as an ordinary torque converter.
The engine power is transmitted through the
damper and universal joint to coupling (1).
The power transmitted to coupling (1) rotates in-
put shaft (2), clutch housing (4), drive case (5),
and pump (6) as 1 unit.
The power transmitted to the pump rotates tur-
bine (7) through oil and is transmitted to trans-
mission input shaft (12) coupled with turbine (7)
by the spline.
When lock-up clutch is ON and stator clutch is

OFF
If lock-up clutch (3) is ON, drive case (5) and tur-
bine (7) are connected to each other. If stator
clutch (9) is OFF at this time, rear housing (10)
and stator shaft (11) are disconnected from each
other and stator (5) is dragged and rotated by
pump (6) and turbine (7).
Accordingly, the torque converter works as a
lock-up torque converter.
The engine power is transmitted through the
damper and universal joint to coupling (1).
The power transmitted to the pump rotates tur-
bine (7) through oil and is transmitted to trans-
mission input shaft (12) coupled with turbine (7)
by the spline.
The power transmitted to case (5) rotates turbine
(7) directly since lock-up clutch (3) is fixed, and
then transmitted to transmission input shaft (12)
coupled with turbine (7) by the spline.
D475A-5 10-21
Flow of oil
The oil flows through the main relief valve and its
pressure is reduced to below the set pressure by
the torque converter relief valve. Then, it flows
through inlet port A and oil passages of rear
housing (1), pump shaft (2), and guide (3) to
pump (4).
The oil is given a centrifugal force by pump (4)
and flows in turbine (5) to transmit its energy to
turbine (5).
The oil from turbine (5) is sent to stator (6) and
flows in pump (4) again. A part of it, however, is
sent through outlet port B to the power train oil
cooler.
10-22 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
PTF : From power train filter

TCF : From torque converter filter
TC : To torque converter
SC : To stator clutch
LC : To lock-up clutch
drT : Drain (Torque converter relief)
dr : Drain
P3 : Lock-up clutch oil pressure pick-up port (LU)
P8 : Main relief oil pressure pick-up port (TM)
PSC : Stator clutch oil pressure pick-up port (SC)
PPL : Pilot oil pressure pick-up port
10-24 D475A-5
1. Valve body 18. Plug

2. Torque converter relief valve 19. Valve body
3. Cover 20. Lock-up selector valve
4. Main relief valve 21. Piston
5. Piston 22. Cover
6. Piston
7. Stator clutch modulating valve Lock-up solenoid valve
8. Piston 23. Cap
9. Piston 24. Coil
10. Cover 25. Valve
11. Piston 26. Ball
12. Piston 27. Valve
13. Lock-up clutch modulating valve 28. Base
14. Shaft 29. Shaft
15. Stopper 30. Case
16. Load piston 31. Plunger
17. Cover
D475A-5 10-25
10-26 D475A-5
Unit: mm

Clearance between main size Shaft Hole clearance limit
1
relief valve and valve body
0.035 +0.016 0.035
40 0.081
0.045 +0.016 0.061
Clearance between torque
0.035 +0.016 0.035
2 converter relief valve and valve 40 0.081
0.045 +0.016 0.061
body
Clearance between stator
0.035 +0.013 0.035
3 clutch modulating valve and 25 0.078
0.045 +0.013 0.058
valve body
Clearance between lock-up
0.035 +0.013 0.035
4 clutch modulating valve and 25 0.078
0.045 +0.013 0.058
valve body
Clearance between lock-up 0.035 +0.013 0.035
5 25 0.078
selector valve and valve body 0.045 +0.013 0.058
Replace
Free Installed Installed Free Installed
6 Main relief valve spring length length load length load
1,455 N 1,383 N
120.3 101.5 116.7
{148.5 kg} {141.1 kg}
Torque converter relief valve 550.4 N 524 N
7 116.92 90.8 113.41
spring {56.16 kg} {53.4 kg}
Stator clutch modulating valve 151.9 N 144 N
8 103.5 95.2 100.4
spring {15.5 kg} {14.7 kg}
Lock-up clutch modulating 158.6 N 151 N
9 141.4 88.7 137.16
valve spring (Outside) {16.18 kg} {15.4 kg}
Lock-up clutch modulating
10 80.5 80.5 78.09
valve spring (Inside)
55.9 N 53.0 N
11 Lock-up selector valve spring 66 54.0 64.0
{5.7 kg} {5.42 kg}
D475A-5 10-27
Outline
The torque converter valve is installed to the top
of the rear housing of the torque converter and
consists of valves of the following 6 types.
Main relief valve

The main relief valve regulates the pressure in
the lock-up clutches and stator clutches of the
transmission, steering clutch, steering brake,
and torque converter to the set pressure.
Set pressure: 2.6 3.0 MPa {27.0 30.4 kg/cm2}
Torque converter relief valve

The torque converter relief valve regulates the
torque converter inlet circuit pressure below the
set pressure to protect the torque converter from
abnormally high pressure.
Set pressure: 0.88 MPa {9.0 kg/cm2}
Lock-up solenoid valve

The lock-up solenoid valve receives electric sig-
nals from the controller and changes the pilot
pressure for the lock-up selector valve to control
the lock-up selector valve.
Lock-up selector valve

The lock-up selector valve turns the lock-up
clutch and stator clutch ON and OFF.
Stator clutch modulating valve

The stator clutch modulating valve regulates the
clutch pressure below the set pressure to protect
the stator clutch circuit from abnormally high
pressure and heightens the clutch pressure
gradually to the set pressure.
Set pressure: 2.7 MPa {27 kg/cm2}
Lock-up clutch modulating valve

The lock-up clutch modulating valve regulates
the clutch pressure below the set pressure to
protect the lock-up clutch circuit from abnormally
high pressure and heightens the clutch pressure
gradually to the set pressure.
10-28 D475A-5
Operation of main relief valve

The oil from the hydraulic pump flows through
the filter, port A of the torque converter valve,
and orifice a of spool (1) to chamber B.
When the circuit is filled with the oil from the
pump, the oil pressure starts rising.
As the oil pressure in the circuit rises, the oil in

chamber B pushes piston (2), the reaction force
of which compresses valve spring (3) and moves
spool (1) to the left to open ports A and C.
Then, the oil from the pump is relieved through
ports A and C into the torque converter.
Operation of torque converter relief valve

The oil relieved through the main relief valve
flows through port C into the torque converter. It
also flows through orifice b of spool (4) into
chamber D.
When the torque converter is filled with oil, the
oil pressure starts rising.
As the oil pressure in the torque converter rises,
the oil in chamber D pushes piston (5), the reac-
tion force of which compresses valve spring (6)
and moves spool (4) to the right to open ports C
and E.
Then, the oil in port C is relieved through port E
and drained into the oil tank.
D475A-5 10-29
When traveling in torque converter range
While the machine is in the "torque converter The oil from the pump flows through port D into
range", the lock-up solenoid valve is de-ener- port E and applies back pressure to stator clutch
gized and plunger (1) is pushed back upward by piston (7) and turns "ON" the stator clutch when
the oil pressure from the pump. the circuit oil pressure rises.
Since the seats of valve (2) and ball (3) are At the same time, the oil which has been apply-
opened, the drain circuit of port B is opened and ing back pressure to lock-up clutch piston (8) is
the oil in ports A and C are drained. drained through port F into H and the lock-up
Since lock-up selector valve (5) is pushed back clutch is turned "OFF".
to the right by spring (6), the passages between The oil from the pump flows in ports A and D.
ports D and F and between ports E and G are The oil in port A is drained since the lock-up so-
closed and the passages between ports D and E lenoid valve is de-energized, but the oil pressure
and between ports F and H are opened in port D is secured by orifice a and regulated by
modulating valve (9).
10-30 D475A-5
When traveling in direct range
While the machine is in "direct range", the lock- The oil from the pump flows through port D into
up solenoid valve is energized and plunger (1) port F and applies back pressure to lock-up
moves down. clutch piston (8) and turns "ON" the lock-up
Since seats of valve (2) and ball (3) are closed, clutch when the circuit oil pressure rises.
the drain circuit of port B is closed and oil in port At the same time, the oil which has been apply-
A flows into port C. ing back pressure to the stator clutch piston is
Since the oil from port C pushes piston (4) to drained through port E into G and the stator
move lock-up selector valve (5) to the left, the clutch is turned "OFF".
passages between ports D and E and between The pressure of the oil flowing from the pump
ports F and H are closed and the passages be- into port D is regulated by modulating valve (10).
tween ports D and F and between ports E and G
are opened.
D475A-5 10-31
Modulating valve
Outline
The modulating valve is installed between the
lock-up selector valve and the inlet of each
clutch.
When each clutch is turned ON, the modulating
valve heightens the oil pressure applied to the
piston gradually to the specified pressure to en-
gage the clutch smoothly and reduce the impacts
given to the torque converter and transmission.
a The following is the explanation of the modulat-
ing valve for the stator clutch. The modulating
valve for the lock-up clutch operates similar to
the stator clutch. Oil flows into the clutches in
the direct range and the torque converter range
is reversed.
Operation
When traveling in torque converter range
While the machine is in the "torque converter
range", the lock-up solenoid valve is de-ener-
gized and the oils from the pump and in port B
are drained.
Lock-up selector valve (2) is pushed back to the
right by tension of spring (3), the passages be-
tween ports A and E and ports D and G are
closed, the passage between ports A and D are
opened. As a result, the circuit is connected
through modulating valve (5) to stator clutch (9).
The oil from the pump flows through port A to sta-
tor clutch (9) and the oil pressure in the circuit
starts rising.
If the circuit pressure rises, oil flowing through or-
ifice "a" of modulating valve (5) pushes piston
(6), reaction force which moves modulating valve
(5) to the left to narrow port C.
Port D is connected to port F to apply back pres-
sure to load piston (7). Load piston (7) is pushed
to the right to compress spring (8), tension of the
spring opens port C.
This operation is repeated intermittently to in-
crease the load on spring (8). During this opera-
tion, oil pressure gradually rises.
Finally, modulating valve (5) stops and port C is
closed. Then a rise in the oil pressure is com-
pleted and stator clutch (9) is turned "ON".
10-32 D475A-5
When traveling in direct range

While the machine is in the "direct range", the
lock-up solenoid valve is energized to let the oil
from the pump flow into port B.
The oil pressure in port B becomes higher than
the tension of spring (3) and pushes piston (4) to
move valve (2) to the left. As a result, the pas-
sage between ports A and D is closed and the
passage between ports D and G is opened.
If the oil pressure in port D lowers, modulating
valve (5) is pushed back to the right by tension of
spring (8) to fully open port C.
At this time, operating oil of stator clutch (9) is
drained from port D to port G and the stator
clutch is turned OFF.
The oil from the pump flows through port A to
port E and lock-up clutch (10) is turned "ON".
D475A-5 10-33
TORQUE CONVERTER LOCK-UP CON-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TROL SYSTEM
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM

System diagram
Operation
The torque converter lock-up control system con- a As for the details of the valve, refer to section
trols the lock-up operation of the torque convert- TORQUE CONVERTER VALVE.
er automatically with a sensor signal and the
controller in it according to the load on the ma-
chine. When the torque converter is locked up,
the pilot lamp on the monitor panel lights up.
The signal of the transmission outlet speed sen-
sor is input to the transmission controller.
The lock-up mode is set with the mode selection
panel.
The machine controller receives the gear speed
information from the transmission controller and
the transmission outlet speed sensor signal from
the shoe slip controller and turns ON and OFF
the lock-up system by connecting and discon-
necting the lock-up solenoid and pilot lamp to
and from the chassis ground.
10-34 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SCAVENGING PUMP
SCAVENGING PUMP
BAR (3) 63+320
A. Suction port
B. Discharge port
C. Suction port (Front side)
Specifications
Type: BAR (3) 63 + 320
Theoretical capacity
Front : 63.3 cc/rev
Rear : 319.4 cc/rev
Max. discharge pressure: 0.98 MPa {10 kg/cm2}
Max. speed: 1,997 rpm
(Oil: EO30-CD)
(Oil temperature: 30 to 120 C)
Outline
The scavenging pump is installed to the bottom
of the PTO case of the torque converter and driv-
en by the engine power.
The scavenging pump sucks the oil collecting in
the bottom of the transmission case through the
strainer and returns it to the steering case.
D475A-5 10-35
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION CONTROL
TRANSMISSION CONTROL
a PCCS: Abbreviation for Palm Command Control System
a For steering operation concerned to operation of the Palm Command Control System lever (PCCS lever),
see Steering and Brake Control.
1. Brake pedal Lever positions Outline

2. Safety lever A: Neutral The transmission is controlled with PCCS lever
3. PCCS lever B: Forward (3).
(Forward-Reverse, Gear shift) C: Reverse The PCCS lever is used to select the travel
4. Transmission neutral safety D: Free direction and shift the gear.
switch E: Lock Since the safety mechanism is employed, trans-
5. Cable mission neutral safety switch (4) does not work
6. Transmission control valve and the engine does not start unless safety lever
7. UP switch (2) is in the FREE position (D).
(Gear is shifted up each time
this switch is pressed.)
8. DOWN switch
(Gear is shifted down each time
this switch is pressed.)
10-36 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
10-38 D475A-5
A : To transmission lubrication circuit 1. Transmission input shaft

B : To priority valve 2. Transmission ECMV
C : To scavenging pump (From steering case) 3. Front case
D : From scavenging pump (To transmission oil pan) 4. Rear case
E : From power train filter
F : To lubricating oil relief valve
G : From transmission ECMV (For 1st clutch)
H : From transmission ECMV (For 2nd clutch)
J : From transmission ECMV (For F clutch)
K : From transmission ECMV (For 3rd clutch)
L : From transmission ECMV (For R clutch)
M : Air vent (From steering case)
N : To steering ECMV
P : From steering case (To scavenging pump)
dr : Drain
D475A-5 10-39
10-40 D475A-5
Outline
The transmission is a "forward 3-gear speed and
5. Front cover reverse 3-gear speed" transmission consisting of
6. R sun gear (Number of teeth: 32) planetary gear mechanisms and disc clutches.
7. R ring gear (Hub) (Number of internal teeth: 89) Among the 5 sets of a planetary gear mechanism
8. Pinion shaft and a disc clutch, 2 clutches are operated with an
9. R planetary pinion (Number of teeth: 25) ECMV and fixed hydraulically to select 1 rotation
10. R ring gear (Number of teeth 82) direction and 1 speed.
11. Pinion shaft The transmission transmits the power of the
12. F ring gear (Number of internal teeth: 89) transmission input shaft through the F and R
13. F planetary pinion (Number of teeth: 25) clutches and 3 speed clutches, changing the re-
14. F sun gear (Number of teeth: 39) volving speed to forward 1st 3rd gear speed or
15. 3rd ring gear (Number of internal teeth: 89) reverse 1st 3rd gear speed.
16. 3rd planetary pinion (Number of teeth: 25)
17. 3rd sun gear (Number of teeth: 39) Number of plates and discs used
18. 2nd ring gear (Number of internal teeth: 89)
Number of Number of
19. 2nd planetary pinion (Number of teeth: 21) Clutch name
plates discs
20. 2nd sun gear (Number of teeth: 47)
21. Pinion shaft R clutch 6 7
22. 1st clutch inner drum F clutch 6 7
23. Output shaft
24. Collar 3rd clutch 4 5
25. Drive shaft (For sensor) 2nd clutch 3 4
26. 1st clutch piston housing
1st clutch 5 6
27. 1st clutch piston
28. 2nd carrier
29. 2nd clutch piston Gear speeds and operated clutches
30. 2nd clutch piston housing
31. F, 3rd carrier Reduction
Gear speed Operated clutch
32. 3rd clutch piston ratio
33. F, 3rd clutch piston housing Forward 1st speed F x 1st 3.282
34. F clutch piston
Forward 2nd speed F x 2nd 1.789
35. R carrier
36. R clutch piston housing Forward 3rd speed F x 3rd 1.000
37. R clutch piston (*1) Neutral 1st
38. Tie rod pin
39. Washer spring Reverse 1st speed R x 1st 2.563
40. Clutch spring Reverse 2nd speed R x 2nd 1.397
41. Clutch plate
Reverse 3rd speed R x 3rd 0.781
42. Clutch disc
*1. Unused when the temperature is low or abnor-

mality is detected.
D475A-5 10-41
10-42 D475A-5
Unit: mm

1 R clutch spring (12 pcs.) length load load
140.5 N 119.6 N
100.0 90.0 94.0
{14.3 kg} {12.2 kg}
84.3 N 70.6 N
2 F clutch spring (12 pcs.) 100.0 94.0 94.0
{8.5kg} {7.2 kg}
150.5 N 128.5 N
3 3rd clutch spring (12 pcs.) 84.0 72.0 79.0
{15.4 kg} {13.1 kg}
119.1 N 102.0 N
4 2nd clutch spring (12 pcs.) 81.7 63.0 76.8
{12.2 kg} {10.4 kg}
238.7 N 203.0 N
5 1st clutch spring (12 pcs.) 103.5 76.0 97.3
{24.4 kg} {20.7 kg}
Assembly thickness of 7 discs Standard size Tolerance Repair limit

6
and 6 plates of R clutch 72.6 0.36 68.9
Assembly thickness of 7 discs
7 72.6 0.36 68.9
and 6 plates of F clutch
8 50.2 0.30 47.5
and 4 plates of 3rd clutch
9 39.0 0.26 36.9
and 3 plates of 2nd clutch
Assembly thickness of 6 discs Replace
10 61.4 0.43 58.2
and 5 plates of 1st clutch
F, R, 2nd,
0.1
Thickness of 3rd
11 5.4 4.9
clutch disc
1st 0.15
12 Thickness of clutch plate 5.8 0.1 5.2

0.01
Width 3.0 2.70
Wear of seal 0.03
13
ring
Thickness 4.0 0.12 3.85
0.01
Width 4.0 3.60
Wear of seal 0.03
14
ring
Thickness 5.0 0.15 4.85
0.01
Width 4.0 3.60
Wear of seal 0.03
15
ring
Thickness 5.0 0.15 4.85
0.01
Width 6.0 5.50
Wear of seal 0.03
16
ring
Thickness 6.8 0.15 6.65
D475A-5 10-43

0.01
Wear of seal Width 4.0 3.60
17 0.04
ring
Thickness 5.0 0.15 4.85
0.01
Width 4.0 3.60
Wear of seal 0.04 Replace
18
ring
Thickness 4.0 0.15 3.85
Backlash between sun gear

19 0.16 0.35
and planetary pinion
Backlash between planetary
20 0.18 0.38
pinion and ring gear
10-44 D475A-5
Disc clutch
Structure
The disc clutch consists of piston (2), plates (3),
discs (4), pin (5), return spring (6), etc. to secure
ring gear (1).
The internal teeth of discs (4) are meshed with
the external teeth of ring gear (1).
Plates (3) are secured to clutch housing (7) with
pin (5).
Operation
Clutch "ON" (Fixed)
The oil sent from the ECMV flows through the oil
passage in housing (7) to the back side of piston
(2) to move piston (2) to the left.
Piston (2) presses plates (3) and discs (4) to fit
them together, and discs (4) is stopped by the
friction force between them and plates (3).
Since the internal teeth of discs (4) are meshed
with the external teeth of ring gear (1), ring gear
(1) is fixed.
Clutch "OFF" (Released)

When the oil sent from the ECMV is shut off, pis-
ton (2) is returned to the right by return spring (6).
The friction force between plates (3) and discs
(4) is released and ring gear (1) is released.
D475A-5 10-45
Power train route
Forward 1st
When the transmission is set to FORWARD 1st, The rotation of F-3rd carrier (10) is transmitted
the F clutch and 1st clutch are engaged. The through 3rd planetary pinion (11) to 3rd ring gear
power transmitted from the torque converter to (12).
input shaft (1) is then transmitted to output shaft Since 3rd ring gear (12) and 2nd carrier (13) are
(20). connected by the spline and rotated as 1 unit, the
The F clutch is actuated by the hydraulic pres- rotation of 3rd ring gear (12) is transmitted
sure applied to the F clutch piston, and holds F through 2nd carrier (13) to 1st clutch piston hous-
ring gear (4). The 1st clutch is actuated by the ing (14).
hydraulic pressure applied to the 1st clutch pis- Since 1st clutch inner drum (16) is fixed by the
ton, and holds 1st clutch inner drum (16). 1st clutch, the power transmitted to 1st clutch
The power from the torque converter is transmit- piston housing (14) is transmitted through 1st
ted to input shaft (1), and then transmitted clutch inner drum (16) to output shaft (20).
through F sun gear (2) to F planetary pinion (3).
Since F ring gear (4) is held by the F clutch, the
power transmitted to F planetary pinion (3) ro-
tates F-3rd carrier (10) on the inside of F ring
gear (4).
10-46 D475A-5
Forward 2nd
When the transmission is set to FORWARD 2nd, Since F ring gear (4) is held by the F clutch, the
the F clutch and 2nd clutch are engaged. The power transmitted to F planetary pinion (3) ro-
power transmitted from the torque converter to tates F-3rd carrier (10) on the inside of F ring
input shaft (1) is then transmitted to output shaft gear (4).
(20). The rotation of F-3rd carrier (10) is transmitted
The F clutch is actuated by the hydraulic pres- through 3rd planetary pinion (11) to 3rd ring gear
sure applied to the F clutch piston, and holds F (12).
ring gear (4). The 2nd clutch is actuated by the Since 3rd ring gear (12) and 2nd carrier (13) are
hydraulic pressure applied to the 2nd clutch pis- connected by the spline and rotated as 1 unit, the
ton, and holds 2nd ring gear (17). rotation of 2nd carrier (13) is transmitted to the
The power from the torque converter is transmit- 2nd planetary pinion.
ted to input shaft (1), and then transmitted Since 2nd ring gear (17) is fixed by the 2nd
through F sun gear (2) to F planetary pinion (3). clutch, the power transmitted to 2nd planetary
pinion (13) is transmitted through 2nd sun gear
(18) to output shaft (20).
D475A-5 10-47
Forward 3rd
When the transmission is set to FORWARD 3rd,

the F clutch and 3rd clutch are engaged. The
power transmitted from the torque converter to
input shaft (1) is then transmitted to output shaft
(20).
The F clutch is actuated by the hydraulic pres-
sure applied to the F clutch piston, and holds F
ring gear (4). The 3rd clutch is actuated by the
hydraulic pressure applied to the 3rd clutch pis-
ton, and holds 3rd ring gear (12).
The power from the torque converter is transmit-
ted to input shaft (1), and then transmitted
through F sun gear (2) to F planetary pinion (3).
Since F ring gear (4) is held by the F clutch, the
power transmitted to F planetary pinion (3) ro-
tates F-3rd carrier (10) on the inside of F ring
gear (4).
Since 3rd ring gear (14) is fixed by the 3rd clutch,
the power transmitted to F-3rd carrier (10) is
transmitted through 3rd planetary pinion (12) to
output shaft (20).
10-48 D475A-5
Reverse 1st
When the transmission is set to REVERSE 1st, The rotation of F-3rd carrier (10) is transmitted
the R clutch and 1st clutch are engaged. The through 3rd planetary pinion (11) to 3rd ring gear
power transmitted from the torque converter to (12).
input shaft (1) is then transmitted to output shaft Since 3rd ring gear (12) and 2nd carrier (13) are
(20). connected by the spline and rotated as 1 unit, the
The R clutch is actuated by the hydraulic pres- rotation of 3rd ring gear (12) is transmitted
sure applied to the R clutch piston, and holds ring through 2nd carrier (13) to the 1st clutch piston
gear (7). The 1st clutch is actuated by the hy- housing (14).
draulic pressure applied to the 1st clutch piston, Since 1st clutch inner drum (16) is fixed by the
and holds 1st clutch inner drum (16). 1st clutch, the power transmitted to 1st clutch
The power from the torque converter is transmit- piston housing (14) is transmitted through 1st
ted to input shaft (1), and then transmitted clutch inner drum (16) to output shaft (20).
through R sun gear (5) to R planetary pinion (6).
Since ring gear (7) is meshed with carrier (8) and
held by the R clutch, R planetary pinion (6) ro-
tates R ring gear (9). R ring gear (9) rotates F-
3rd carrier (10) in the opposite direction to input
shaft (1).
D475A-5 10-49
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION ECMV
TRANSMISSION ECMV
a ECMV: Abbreviation for Electronic Control Modulation Valve
10-50 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION ECMV
ECMV operation table

PF : F clutch oil pressure pick-up port (FWD)
PR : R clutch oil pressure pick-up port (REV) ECMV
F R 1st 2nd 3rd
P1 : 1st clutch oil pressure pick-up port (1ST)
Gear speed
P2 : 2nd clutch oil pressure pick-up port (2ND)
P3 : 3rd clutch oil pressure pick-up port (3RD) F1 Q Q
PV : To priority valve F2 Q Q
LV : To lubricating oil relief valve
LD : Drain (From lubricating oil relief valve) F3 Q Q
CF : To F clutch R1 Q Q
CR : To R clutch
R2 Q Q
C1 : To 1st clutch
C2 : To 2nd clutch R3 Q Q
C3 : To 3rd clutch (*1) N
dr : Drain
1. Filter *1. Unused when the temperature is low or abnor-

2. Priority valve mality is detected.
3. Lubricating oil relief valve
4. 1st clutch ECMV
5. 2nd clutch ECMV
6. 3rd clutch ECMV
7. F clutch ECMV
8. R clutch ECMV
9. Valve seat
D475A-5 10-51
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION CLUTCH ECMV
TRANSMISSION CLUTCH ECMV
A : To clutch
P : From pump
T : Drain
Dr : Drain
P1 : Clutch oil pressure pick-up port
P2 : Pilot oil pressure pick-up port
1. Connector for fill switch

2. Connector for proportional solenoid
3. Oil pressure pick-up valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
10-52 D475A-5
Outline of ECMV
The ECMV consists of the following two units, a
pressure control valve and fill switch.
Pressure control valve
Converts a current sent from the transmission
controller to the proportional solenoid valve, to
an oil pressure.
Fill switch
Detects that the clutch is filled with oil. It has the
functions below.
1. It outputs a signal (fill signal) to the control-
ler as soon as the clutch is filled with oil to
report the completion of filling.
2. It outputs a signal (fill signal) to the control-
ler while an oil pressure is applied to the
clutch to report the presence/absence of oil
pressure.
A region : Before gear shift (When draining)
B region : During filling
C region : Voltage regulation
D region : During filling (During trigger)
E region : Filling starts
F region : Filling finishes
a The logic is designed so the controller will not
recognize completion of filling, even if the fill
switch is turned ON during the triggering (range
D).
ECMV and proportional solenoid Characteristics of proportional solenoid current - pro-

One proportional solenoid is attached to one pulsion force
ECMV.
After receiving the command current from the
controller, it produces thrust in the figure at the
right. By making the proportional solenoid-pro-
duced thrust act on the pressure control valve
spool, it produces an oil pressure shown in the
figure at the right. By controlling the amount of
command current, the thrust is changed to oper-
ate the pressure control valve, controlling the oil
flow and oil pressure.
ECMV and fill switch Characteristics of proportional solenoid propulsion -

One fill switch is attached to one ECMV. oil pressure
When the clutch completes filling, the pressure
of the clutch turns ON the fill switch. By this
signal, the oil pressure starts build-up.
D475A-5 10-53
Operation of ECMV
ECMV is controlled with the command current
sent from the controller to the proportional sole-
noid and the fill switch output signal.
The relationship between the proportional sole-
noid command current of ECMV, clutch input
pressure, and fill switch output signal is shown
below.
Range A: Before shifting gear (when draining)

Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Range E: Start of filling
Range F: Finish of filling
a The logic is designed so the controller will

not recognize completion of filling, even if the
fill switch is turned "ON" during the triggering
(range D).
1. Before shifting gear (when draining)

(Range A in chart)
While any current is not flowing in proportional
solenoid (1), pressure control valve (3) drains
the oil from clutch port A through drain port Dr.
At this time, since any oil pressure is not applied
to oil pressure sensor valve (4), fill switch (6) is
turned "OFF".
10-54 D475A-5
2. When filling starts (Range B in chart)

If a current is given to proportional solenoid (1)
while there is not oil in the clutch, a hydraulic
force balanced with the solenoid force is applied
to chamber B and it pushes pressure control
valve (3) to the left. As a result, pump port P
and clutch port A open, then the oil starts flow-
ing into the clutch. When the clutch is filled with
oil, fill switch (6) is turned ON.
3. Pressure adjustment (Range C in chart)

If a current flows in proportional solenoid (1), the
solenoid generates a propulsion force in propor-
tion to the current. This propulsion force of the
solenoid is balanced with the sum of the propul-
sion force generated by the oil pressure in clutch
port and the reaction force of pressure control
valve spring (2), then the pressure is settled.
D475A-5 10-55
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
Outline
The priority valve is installed in the circuit be-
tween the pump and clutch ECMV. When the
gear speed is changed, even if the oil pressure in
the transmission circuit lowers sharply, the prior-
ity valve disconnects the transmission circuit and
pilot circuit and keeps the oil pressure on the up-
stream side (steering side) of the priority valve to
the set pressure so that the gear speed will be
changed smoothly.
Operation from start to finish of gear shifting

The oil from the pump flows through port A and
orifice a to chamber C.
If the oil flow from the pump increases and the oil
pressure rises, the oil in chamber C pushes pis-
ton (1). Then, the reaction force of piston (1)
compresses spring (2) and moves valve (3) to
the left.
If valve (3) moves, ports A and B open and the
oil from the pump flows through port B to the
ECMV. The oil pressure at this time is the set
pressure of the priority valve.
Then, the pressure of the oil flowing from port B
to the ECMV rises to the set pressure of the
clutch.
Operation just after finish of gear shifting

If the gearshift lever is operated, oil pressure
above port B is lowered sharply to near "0" by the
ECMV.
The oil pressure in port A is also lowered, but
valve (3) is pushed back by the tension of spring
(2).
Accordingly, the oil pressure in port A (pilot pres-
sure) is kept above the set pressure.
10-56 D475A-5
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LUBRICATING OIL RELIEF VALVE
LUBRICATING OIL RELIEF VALVE
1. Lubricating oil pressure pick-up port Outline

2. Spool The lubricating oil relief valve is installed to the
3. Valve body transmission ECMV. It keeps the lubricating oil cir-
cuit pressure below the set pressure.
Set pressure: 0.26 MPa {2.7 kg/cm2}
D475A-5 10-57
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN, LUBRICATION PUMP
POWER TRAIN, LUBRICATION PUMP

(BAL160 + 160 + 112)
Unit: mm
Clearance Type Standard clearance Clearance limit

between gear
1 BAL160 0.04 0.10 0.13
case and side
plate, gear BAL112 0.04 0.10 0.13
Clearance
between plain BAL160
bearing inner
2 0.060 0.145 0.20
diameter and Replace
gear shaft outer BAL112
diameter
Type Standard size Tolerance Repair limit

Pin insertion
3 BAL160 0.5
depth 14
BAL112 0.5
4 Rotating torque of spline shaft 5.88 Nm {0.6 kgm}

Delivery Standard Delivery
Type Speed (rpm) pressure delivery limit
(MPa {kg/cm2}) (l/min.) (l/min.)
Delivery
2.94
EO10 CD BAL160 2,000 288 266
{30}
45 55 C
2.94
BAL112 2,000 205 188
{30}
10-58 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL

a PCCS: Abbreviation for Palm Command Control System
a Regarding the transmission related description of operation of the PCCS lever, refer to "Transmission con-
trol".
10-60 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING, BRAKE CONTROL
1. Brake pedal Positions of lever and pedal

2. Safety lever A : Neutral
3. PCCS lever (Steering) B : Forward straight-travel
4. Limit switch C : Reverse straight-travel
5. Steering ECMV D : Left clutch OFF
6. Brake valve E : Left clutch OFF
7. Parking brake lever (From safety lever) Left brake ON
8. Cable F : Right clutch OFF
9. Rod (From brake pedal) G : Right clutch OFF
10. Potentiometer Right brake ON
11. Steering controller H : Brake RELEASE
12. Transmission controller J : Brake ON
13. Engine controller K : Free
L : Lock
Outline
PCCS lever (3) sends an electric signal to steer-
ing controller (11). After receiving it, steering
controller (11) sends a proportional current to
steering ECMV (5) to operate the steering clutch
and brake.
The brake pedal (1) sends an electric signal to
steering controller (11) via potentiometer (10).
After receiving it, steering controller (11) sends a
proportional current to steering ECMV (5) to op-
erate the brake. In this case, the right and left
brakes operate at the same time to activate brak-
ing. Rod (9) operates the brake via brake valve
(6) for redundant use. (Only at the time of com-
plete braking)
If you slightly tilt PCCS lever (3) towards the left,
the left steering clutch is partially disengaged,
causing the machine to make a slow left turn.
If you completely tilt PCCS lever (3) towards the
left, the left steering clutch is turned "OFF" and
the left steering brake is turned "ON", causing
the machine to make a sudden left turn.
Safety lever (2) is connected to parking brake le-
ver (7) and it also serves as a parking brake.
D475A-5 10-61
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
Outline
The final drive is a single stage spur gear, single
stage planetary gear reduction type. The lubrica-
tion is of splash type using the rotation of the
gears.
The final drive can be removed and installed as
a single unit.
Floating seal (1) is installed to the rotating sliding
portion of the sprocket to prevent the entry of dirt
or sand and to prevent leakage of lubricating oil.
D475A-5 10-63
1. Floating seal 8. Floating seal guard 15. No. 1 pinion

2. Sun gear 9. Cover 16. Final drive case
3. Carrier 10. Planetary pinion 17. Bearing cage
4. Hub 11. Ring gear 18. Shaft
5. Cover 12. Cover 19. Wear guard
6. Sprocket hub 13. No. 1 gear
7. Sprocket teeth 14. No. 1 gear hub
10-64 D475A-5
Unit: mm
Backlash between No.1 Standard clearance Clearance limit

20
pinion and No.1 gear 0.26 0.96 0.96
Backlash between sun gear
21 0.25 0.70 0.70
and planet pinion
Backlash between planet
22 0.26 0.83 0.83
pinion and ring gear
Outside diameter of No.1 Standard size Repair limit

23
pinion oil seal contact surface 120.0 119.9
Thickness of thrust collar of
24 24.8 24.75
inner body roller bearing
Replace
Thickness of thrust coller of
25 14.0 13.95
No.1 gear boss roller bearing
26 Height of button 20 18.5

Clearance between planetary size clearance limit
Shaft Hole
27 pinion shaft and carrier
(small end) 0.035 0.024 0.024
110 0.030
0.054 0.059 0.030
Clearance between planetary
0.035 0.067 0.072
28 pinion shaft and carrier 135 0.013
0.054 0.107 0.013
(large end)
Standard shim thickness for
29 2
No.1 pinion bearing cage
Dimension of end face of final
30 drive cover and end face of 7.3 8.3 Adjust
bearing
Clearance of floating seal
31 3.1 4.7
guard
Standard size Repair limit Rebuild or
32 Wear of wear guard
47.5 17 replace
D475A-5 10-65
PATH OF POWER TRANSMISSION
The power from the bevel gear shaft and steering The rotation direction of carrier (3) is the same
clutch is transmitted to No. 1 pinion (15). It then as sun gear (2).
passes through No. 1 gear (13), which is meshed The rotating force transmitted to sprocket hub
with the No. 1 pinion, and is transmitted to sun (6) is transmitted to sprocket teeth (7).
gear (2) to rotate it.
The rotation of sun gear (2) is transmitted to
planet pinion (10), but ring gear (11), which is
meshed with the planet pinion, is fixed to cover
(9), so the planet pinion rotates on its own axis
and moves around the sun gear along the ring
gear.
Then, the rotating force of sun gear (2) forms
the rotating force of carrier (3), which supports
the planet pinion, and is transmitted to sprocket
hub (6).
10-66 D475A-5
POWER TRAIN
Steering unit
A : To steering ECMV
B : Air vent (To transmission case)
C : To scavenging pump
D : To pin puller solenoid valve
E : From pin puller solenoid valve
F : From power train oil cooler
G : Mounting port of torque converter output speed sensor
PLC : Left steering clutch oil pressure pick-up port (LC)
PLB : Left steering brake oil pressure pick-up port (LB)
PRC : Right steering clutch oil pressure pick-up port (RC)
PRB : Right steering brake oil pressure pick-up port (RB)
10-68 D475A-5
D475A-5 10-69
1. Transmission 22. Stopper

2. Steering ECMV 23. Brake plate
3. Steering unit 24. Brake disc
4. Breather 25. Brake hub
5. Drain plug 26. Brake cage
6. Output shaft 27. Brake piston
7. Sleeve 28. Brake spring
8. Pin 29. Case
9. Clutch piston 30. Input shaft
10. Pin 31. Drive shaft
11. Clutch plate 32. Drive gear (Number of teeth: 27)
12. Clutch disc 33. Transmission output speed sensor
13. Stopper 34. Case
14. Clutch hub 35. Cage
15. Clutch cage 36. Torque converter output speed sensor
16. Flange 37. Cage
17. Bevel gear (Number of teeth: 37) 38. Drum
18. Cage 39. Cover
19. Steering shaft 40. Cage
20. Clutch spring 41. Driven gear (Number of teeth: 30)
21. Housing 42. Bevel pinion (Number of teeth: 22)
10-70 D475A-5
Outline
Transfer Steering brakes

The transfer reduces the rotation speed of the The steering brakes are connected to the steer-
output power of the transmission and transmits it ing clutches on both sides respectively. They
to the bevel pinion. control the power transmitted from the steering
The transfer consists of input shaft (30) meshed clutches to the final drives to change the turning
with the transmission output shaft, drive gear direction of the machine and brake the machine.
(32), driven gear (41), and bevel pinion (42). The steering brakes are wet-type, multiple disc
clutch-type, spring force brakes. They are driven
Bevel gear shaft hydraulically together with the clutches by the
The bevel gear shaft device changes the power steering ECMV operated with the PCCS lever.
transmitted to the bevel pinion by a right angle to The steering brakes are forced lubricated with oil
the lateral directions and reduces the output supplied by the power train lubricating oil pump.
speed by using a bevel pinion and a bevel gear. Lubricating oil flows through paths in the steering
The bevel gear shaft device has a spiral bevel case, cage, hub, discs, and plates.
pinion and spiral bevel gear and is forced lubri- While the engine is stopped, even if the brake
cated with pressurized oil. pedal is not pressed, the back pressure of the
The bevel gear shaft device consists of bevel brake piston lowers and the brake is "applied".
gear (17) meshed with the bevel pinion, steering After the engine is started again, however, as the
shaft (19), and bearing to support the steering hydraulic pressure in the circuit rises, the brake
shaft. is "released". Accordingly, the parking brake
must be locked.
Steering clutch Each steering brake consists of hub (25) con-
The steering clutch is connected to the bevel nected to housing (21), discs (24) engaged with
gear shaft through the spline. It transmits and the hub, plates secured by piston and pin (8), pis-
cuts out the power of the bevel gear shaft for the ton (27) to press the discs and plates against
final drive to change the turning direction of the each other, cage (26) to support these parts,
machine. case (29), bearing, and output shaft (6) connect-
The steering clutch is wet-type multiple-disc hy- ed with the hub by the spline.
draulic clutch. It is driven hydraulically together Piston (27) and case (29) are fixed to the steer-
with the brake by the steering ECMV operated ing case.
with the PCCS lever.
The steering clutch is forced lubricated with oil
supplied by the power train lubricating oil pump.
Lubricating oil flows through paths in the steering
case, cage, hub, discs, and plates.
The steering clutch consists of hub (14) connect-
ed to the bevel gear shaft by spline, disc (12) en-
gaged with the hub, plate (11), the periphery of
which is connected to the housing by spline,
housing (21), piston (9) to press the discs and
plates against each other, and cage (15) and
bearing to support these parts. Housing (21) is
connected to hub (25) and it transmits the power
from the bevel gear shaft through hub (25) to out-
put shaft (6).
D475A-5 10-71
10-72 D475A-5
Unit: mm

Replace
Thickness 4.2 0.1 3.8
1 Brake plate
Repair or
Strain Max. 0.3 0.4
replace
Thickness 5.4 0.1 4.3 Replace
2 Brake disc Repair or
Strain Max. 0.3 0.4
replace
Thickness of assembly of 8
3 82.2 0.41 72.6
brake plates and 9 discs Replace
Thickness 4.2 0.1 3.8
4 Clutch plate Repair or
Strain Max. 0.3 0.4
replace
Thickness 5.4 0.1 4.5 Replace
5 Clutch disc Repair or
Strain Max. 0.4 0.5
replace
Thickness of assembly of 8
6 76.8 0.40 69.3
clutch plates and 9 discs
7 190 190.5
contact face of sleeve +0.046
Inside diameter Big end +0.089

350 350.1
of seal ring con- +0.089
8
tact face of +0.052
brake piston Small end 300 300.1
+0.052
Inside diameter Big end +0.089

350 350.1
of seal ring con- +0.089
9
tact face of +0.052
clutch piston Small end 300 300.1
+0.052
Installed Installed Installed Replace
10 Brake spring length load load
46.97 kN 44.62 kN
19.7 12.9 19.1
{4,790 kg} {4,550 kg}
55.7 kN 52.96 kN
11 Clutch spring 20.4 12.9 20.0
{5,680 kg} {5,400 kg}
Standard Tolerance Standard Repair

Clearance between bevel gear size Shaft Hole clearance clearance
12
and reamer bolt
+0.023 +0.033 0.023
20 Max. 0.031
+0.002 +0.033 0.031
Backlash between brake hub Standard clearance Clearance limit

13
and disc 0.4 0.7 1.0
Backlash between clutch hub
14 0.4 0.7 1.0
and disc
Backlash between bevel Adjust or
15 0.30 0.40 0.75
pinion and bevel gear replace
D475A-5 10-73
Standard rotating torque: 9.8 11.8 Nm {1.0 1.2 kgm}

Preload on bevel gear shaft
16 (When bevel pinion and gear are not meshed: Adjust
tapered roller bearing
51 61.8 Nm {5.2 6.3 kgm} at bevel gear end)
17 2.0 Adjust shim
bearing cage
10-74 D475A-5
Unit: mm
Backlash between transfer Standard clearance Clearance limit Adjust or

18
gears 0.26 0.67 0.75 replace
Thickness of collar between Standard size Tolerance Repair limit

19 Replace
transfer gear and bearing 19.3 0.1 18.9
20 2.0 Adjust shim
bearing cage
10-76 D475A-5
Operation of steering clutch
When steering clutch is turned "ON"

When the PCCS lever is in the "neutral" position,
the oil on the back side of clutch piston (1) is
drained by the steering ECMV.
Under this condition, clutch piston (1) is pushed
back to the right by the tension of clutch spring
(2) to press discs (3) and plates (4) against stop-
per (5).
Accordingly, the power from steering shaft (6) is
transmitted through clutch hub (7) and pressed
discs and plates to housing (8).
Since housing (8) is connected to brake hub (9)
and output shaft (10), the power is transmitted
through output shaft (10) to the final drive.
When steering clutch is turned "OFF"

If the PCCS lever is operated to the right or left,
oil pressure is applied to the back side of clutch
piston (1) by the steering ECMV.
As the oil pressure rises, clutch piston (1) com-
presses clutch spring (2) and moves to the right
to eliminate the pressure on discs (3) and plates
(4).
The power from steering shaft (6) is not transmit-
ted over housing (8), that is, it is not transmitted
to the final drive.
If the PCCS lever is released, the oil on the back
side of clutch piston (1) is drained by the steering
ECMV, thus the steering clutch is turned "ON".
If the left steering clutch is turned "OFF", the
power is transmitted only to the right steering
clutch, and consequently the machine turns to
the left.
D475A-5 10-77
Operation of steering brake
When steering brake is "released"

When the PCCS lever is in the "neutral" position
and the brake pedal is released, the steering
ECMV sets only the brake pressure to the maxi-
mum. Accordingly, the steering clutch is turned
"ON" and oil pressure is applied to the back side
of brake piston (1).
As the oil pressure rises, brake piston (1) com-
presses brake spring (2) and moves to the right
to eliminate the pressure on discs (3) and plates
(4).
The power transmitted from steering shaft (6)
through the steering clutch to brake hub (7) is fur-
ther transmitted output shaft (8) to the final drive.
When steering brake is "applied"

(When PCCS lever is "operated")
If the PCCS lever is operated to the right or left,
the steering ECMV turns the steering clutch
"OFF" and the oil on the back side of brake piston
(1) starts draining.
At this time, brake piston (1) is pushed back to
the right by the tension of brake spring (2), then
discs (3) and plates (4) are pressed against stop-
per (5).
Stopper (5) and brake piston (1) are connected
and fixed to the steering case.
Brake hub (7) and output shaft (8), which contin-
ue inertia revolution even after the steering
clutch is turned "OFF", stops as the discs and
plates are fixed to each other.
Since the braking force can be adjusted by con-
trolling the oil pressure the back side of brake
piston (1) with the PCCS lever, the turning radius
and turning speed can be controlled.
10-78 D475A-5
When steering brake is "applied"

(When PCCS lever is in "neutral" position and
brake pedal is "pressed")
If the brake pedal is pressed while the PCCS le-
ver is in the "neutral" position, the steering ECMV
starts draining the oil on the back side of brake
piston (1). Then, the steering clutch is turned ON
and the steering brake operates to stop revolu-
tion of output shaft (8).
The braking force can be adjusted by controlling
the oil pressure applied to the back side of brake
piston (1) with the brake pedal.
D475A-5 10-79
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING ECMV
STEERING ECMV
a ECMV: Abbreviation for Electronic Control Modulation valve
10-80 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING ECMV
P : From power train pump Outline

L : From power train oil cooler The steering ECMV unit consists of 4 ECMV's in-
PS : To pin puller solenoid valve stalled on the valve seat to control the steering
LC : To left steering clutch clutch and steering brake.
LL : To left steering lubrication circuit The steering ECMV unit is between the power train
LB : To left steering brake pump and the pistons of the steering clutch and
LBL : To left bevel gear shaft bearing lubrication steering brake. It consists of 2 sets of a steering
circuit clutch ECMV (right and left) and 2 sets of a steering
RC : To right steering clutch brake ECMV (right and left).
RL : To right steering lubrication circuit The steering ECMV unit sends the oil from the pow-
RB : To right steering brake er train pump to the steering clutch and steering
RBL : To right bevel gear shaft bearing lubrication brake to control each disc clutch.
circuit If the PCCS lever is leaned to the right or left, the
BPL : To bevel pinion bearing lubrication circuit steering clutch is disengaged. If the PCCS lever is
DPS : From pin puller solenoid valve leaned further, the steering brake operates.
DLC : Drain (Left steering clutch) The controller sends commands to each ECMV ac-
DLP : Drain (Left steering clutch pilot) cording to the right or left stroke of the PCCS lever
DLB : Drain (Left steering brake) to adjust the turning radius of the machine.
DRC : Drain (Right steering clutch) If the brake pedal is pressed, the controller sends
DRP : Drain (Right steering clutch pilot) commands to the steering brake ECMV according to
DRB : Drain (Right steering brake) the pedal stroke to apply the right and left brakes,
DB : Drain (Sudden stop prevention valve) thus the machine stops.
DBP : Drain (Sudden stop prevention valve pilot) The controller connected electrically to the PCCS le-
DPB : Drain (Parking brake) ver and brake pedal operates the steering clutch
and steering brake by controlling each ECMV.
1. Filter The sudden stop prevention valve is installed to pre-
2. Right steering clutch ECMV vent the machine from stopping suddenly when the
3. Left steering clutch ECMV electric system has abnormality.
4. Sudden stop prevention valve When the parking brake lever is set in the "LOCK"
5. Right steering brake ECMV position, the parking brake valve port is changed to
6. Left steering brake ECMV drain the oil between the steering brake ECMV and
7. Parking brake valve brake piston on each side to operate the brake. The
8. Valve seat parking brake valve is connected to the brake pedal
by linkage.
D475A-5 10-81
STEERING CLUTCH ECMV, STEERING
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE ECMV
STEERING CLUTCH ECMV, STEERING BRAKE ECMV
A : To clutch or brake Outline

P : From pump Each ECMV keeps the steering clutch oil pressure
T : Drain and steering brake oil pressure to the set pressure
Dr : Drain and changes the circuit of the piston chambers of
P1 : Clutch or brake pressure pick-up port the steering clutch and steering brake.
P2 : Pilot pressure pick-up port
1. Fill switch connector

2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
10-82 D475A-5
Outline of ECMV
The ECMV (Electronic Control Modulating valve)
consists of a pressure control valve and a fill
switch.
Pressure control valve
This valve allows a proportional solenoid to
receive a current sent from a steering controller
and converts it to oil pressure.
Fill switch
This component detects that a clutch or a brake
is filled with oil and has the following functions.
1) When the clutch or brake is filled with the oil,
the fill switch outputs a signal (fill signal) to
the controller to notify finish of filling.
2) While oil pressure is applied to the clutch,
the signal (fill signal) is output to the control-
ler and transmits the presence of oil pres-
sure.
ECMV and Proportional Solenoid

One proportional solenoid is mounted for each
ECMV. A thrust is generated according to the
command current of the controller.
The thrust generated by the proportional sole-
noid is actuated on a pressure control valve
spool and generates oil pressure. Accordingly,
by controlling an amount of the command cur-
rent, the thrust changes and the pressure con-
trol valve is actuated, then a flow of oil and the
oil pressure is controlled.
ECMV and fill switch

Each ECMV has 1 fill switch. If the clutch is filled
with oil, the fill switch is turned ON by the pres-
sure of the clutch. The oil pressure is built up ac-
cording to this signal.
Operation of ECMV
The ECMV is controlled using the command cur-
rent from the controller to the proportional sole-
noid and a fill switch output signal.
D475A-5 10-83
When PCCS lever is in "neutral", brake pedal is "released", and parking brake lever is in
"FREE" position: Straight travel
(When both clutches are turned "ON", both brakes are "released", and parking brake is "released")
When the PCCS lever is in "neutral" and the The oil in port Pb of the brake ECMV flows in port
brake pedal is "released", proportional solenoid E and pushes valve (7) to the left to open ports
(1) of the clutch ECMV is de-energized and the Pb and B and close ports B and Dr. At this time,
sealing part of ball (2) is opened. the oil flows in the back pressure port of the
The oil from the power train pump flows through brake piston. As the oil pressure rises, the brake
port Pc of the clutch ECMV to orifice a, then it is piston is pushed to the left to compress the brake
drained through sealing part of ball (2). spring and "release" the brake.
Valve (3) is moved to the right by the tension of When the parking brake lever is in the "FREE"
spring (4) to close ports Pc and C and open ports position, the parking brake valve is closed and
C and Dr. At this time, the oil from the back pres- the oil in the brake circuit is not drained.
sure port of the clutch piston is drained through
port C and the clutch is turned "ON" by the ten-
sion of the clutch spring.
The oil pressure in the brake circuit, etc. is se-
cured by orifice a.
Proportional solenoid (5) of the brake ECMV is
energized to push ball (6) to the left and close the
sealing part.
10-84 D475A-5
When PCCS lever is "operated to left halfway", brake pedal is "released", and parking brake is
in "FREE" position: Gradual turn to left
(When left clutch is turned "OFF", left brake is "half released", right clutch is turned "ON", right brake is
"released", and parking brake is "released")
When the PCCS lever is operated to the left half- command current to proportional solenoid (5) ac-
way and the brake pedal is "released", propor- cording to the stroke of the PCCS lever.
tional solenoid (1) of the left clutch ECMV is Proportional solenoid (5) generates a propulsion
energized and the sealing part of ball (2) is force in proportion to the command current. This
closed. propulsion force is balanced with the sum of the
The oil from the power train pump flows through propulsion force generated by the oil pressure in
port Pc of the clutch ECMV and orifice a to port the back pressure port of the brake piston and
F to push valve (3) to the left to connect port Pc the tension of spring (8), then the brake oil pres-
to C and disconnect port C from Dr. At this time, sure is settled, or the braking force is adjusted.
the oil flows in the back pressure port of the Accordingly, if the stroke of the PCCS lever is
clutch piston. As the oil pressure rises, the clutch short, the oil pressure after port B is set high and
piston is pushed to the left to compress the clutch the brake is "released half". If the stroke of the
spring and turn the clutch "OFF". PCCS lever is long, the oil pressure after port B
Proportional solenoid (5) of the brake ECMV is is set low and the brake is "applied".
energized to push ball (6) to the left and close the When the parking brake lever is in the "FREE"
sealing part. position, the parking brake valve is closed and
The oil in port Pb of the brake ECMV flows in port the oil in the brake circuit is not drained.
E and pushes valve (7) to the left. As for the oil
pressure after port B, the controller outputs a
D475A-5 10-85
When PCCS lever is "operated to left fully", brake pedal is "released", and parking brake is in
"FREE" position: Sharp turn to left
(When left clutch is turned "OFF", left brake is "applied", right clutch is turned "ON", right brake is
"released", and parking brake is "released")
When the PCCS lever is completely operated to

the left, proportional solenoid (5) of the left brake
ECMV is de-energized and the sealing part of
ball (6) is opened.
Since the oil in port E is drained through the seal-
ing part, valve (7) is moved to the right by the ten-
sion of spring (8) to disconnect port Pb from port
B and connect port B and Dr. At this time, the oil
from the back pressure port of the brake piston is
drained through port B and the brake is "applied"
by the tension of the brake spring.
The oil from the power train pump flows through
port Pb of brake ECMV and orifice b, then it is
drained through the sealing part of ball (6).
The oil pressure in the clutch circuit, etc. is se-
cured by orifice b.
When the parking brake lever is in the "FREE"
position, the parking brake valve is closed and
the oil in the brake circuit is not drained.
10-86 D475A-5
When PCCS lever is in "neutral", brake pedal is "pressed", and parking brake lever is in
"FREE" position: Stop
(When both clutches are turned "ON", both brakes are "applied", and parking brake is "released")
When the brake pedal is completely pressed, If the brake pedal is pressed, the parking brake
proportional solenoid (5) of the brake ECMV is valve connected by the linkage operates to open
de-energized and the sealing part of ball (6) is the brake circuit and drain the oil.
opened.
The controller outputs a command current to pro-
portional solenoid (5) according to the stroke of
the brake pedal.
Proportional solenoid (5) generates a propulsion
force in proportion to the command current. This
propulsion force is balanced with the sum of the
propulsion force generated by the oil pressure in
the back pressure port of the brake piston and
the tension of spring (8), then the brake oil pres-
sure is settled, or the braking force is adjusted.
Since the PCCS lever is in the "neutral" position,
proportional solenoids (1) of both clutch ECMV's
are de-energized and both clutches are turned
"ON".
D475A-5 10-87
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE VALVE
PARKING BRAKE VALVE
Unit: mm

Clearance between spool and size Shaft Hole clearance limit
1 Replace
valve body
0.020 +0.011 0.020
14 0.05
0.030 +0.011 0.041
Standard size Tolerance Repair limit Hard chrome
Outside diameter of dust seal plating
2 0.020
contact face of spool 14 13.9 correction or
0.030 replace
3 Return spring length load load Replace
38.2 N 36.3 N
65 47.7 63
{3.9 kg} {3.7 kg}
10-88 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE VALVE
When PCCS lever is in "neutral", brake pedal is "released", and parking brake lever is in
"LOCK" position: Parking
(When both clutches are turned "ON", both brakes are "applied", and parking brake is "applied")
If the parking brake lever is set in the "lock" posi-

tion, spool (1) moves to the left to connect ports
A, B, and C.
The oil which has been flowing in the back pres-
sure port of the brake piston is drained through
ports A, B, and C.
The oil pressure in the back pressure port of the
brake piston continue lowering, then the brake is
kept "fixed" completely.
When the engine is started again, ports A, B, and
C are still connected, the brake is kept "fixed".
If the parking brake lever is set in the "free" posi-
tion, spool (1) moves to the right to disconnect
ports A, B, and C from each other. Then, the oil
pressure from the brake ECMV is applied to the
back pressure port of the brake piston and the
brake is "released".
D475A-5 10-89
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUDDEN STOP PREVENTION VALVE
SUDDEN STOP PREVENTION VALVE
Outline
The sudden brake prevention valve is installed to
prevent the machine from stopping suddenly
when the electric system has a trouble.
Sudden brake prevention valve (1) is installed in
the brake ECMV drain circuit. If brake ECMV
proportional solenoid (2) is de-energized, the oil
pressure in port D lowers suddenly and the brake
is applied. The sudden stop prevention valve
prevents this phenomenon.
If the electric system has any trouble, solenoid
valve (3) of sudden brake prevention valve (1) is
de-energized. Then, the oil in port D is drained
through orifice a so that the brake will be applied
gradually.
10-90 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm

1 Wear of tooth tip Replace or
486 470 overlaying
welding
2 Thickness of tooth root 32.5 26.5
10-92 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET
Full-scale drawing of sprocket tooth profile
a The above drawing is reduced to 35%. Enlarge it to 287% to return it to the full scale and make its copy on
an OHP sheet.
D475A-5 10-93
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
1. Idler 7. Track roller bogie

2. Recoil spring assembly 8. Track roller
3. Carrier roller 9. Cap
4. Track frame 10. Idler yoke
5. Sprocket 11. Cylinder
6. Sprocket guard 12. Guide
Track roller, bogie

(Semi U, full U, superdozer specification)
Track roller flange type arrangement
1st 2nd 3rd 4th 5th 6th 7th
S D D D D D S
10-94 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME
Outline
The track roller uses an K-shape bogie mount to
increase the ground contact area between the
track shoe and ground surface on rough surfac-
es, thereby increasing the drawbar pull.
The K-shape bogie is fitted with rubber pads to
absorb the shock from the ground surface.
Unit: mm
Item Repair limit
Deformation of track frame Curvature 7 (for length of 3,000) Repair or

4
outer cylinder Twisting 3 (for level length of 3,000) Replace
Dents (cylinder portion) 12

Clearance between inner size clearance limit
Shaft Hole
13 cylinder and adjustment Replace
cylinder protrusion 0.15 +0.3
70 0.15 0.65 2.0
0.35 +0.3
Clearance between idler bogie Standard clearance Clearance limit

14 Adjust
and guide 0 0.5 3.0
15 Press-fitting force for cartridge 275 510 kN {28 52 ton}
D475A-5 10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RECOIL SPRING
RECOIL SPRING
1. Yoke Outline
2. Nut Recoil spring (11) damps sudden shocks applied to
3. Retainer the idler.
4. Rod The recoil spring is also used to adjust the track
5. Spring cylinder shoe tension by supplying or discharging grease
6. Retainer through lubricator (9) and moving rod (4) forward or
7. Holder in reverse.
8. Piston
9. Lubricator (for supplying and discharging grease)
10. Grease chamber cylinder
10-96 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RECOIL SPRING
Unit: mm

Installation Installation Installation
11 Recoil spring length load load
725.7 kN 683.1 kN
1,713 1,425 1,696
{74,000 kg} {69,700 kg}
Standard Tolerance Standard Clearance Replace

Clearance between inner size clearance limit
Shaft Hole
12 cylinder and outer cylinder of
outer cylinder bushing 0.068 +0.323 0.128
445 0.8
0.165 +0.600 0.488
Clearance between adjust- Shaft: 164 0.3 +0.063 1.000
13
ment cylinder and bushing Hole: 165 0.3 +0.063 1.363
Press-fitting force for outer
14 cylinder bushing 51.0 99 kN {5.2 10.1 ton}
(outer cylinder side)
Press-fitting force for outer
15 cylinder bushing 129.4 389.1 kN {13.2 39.7 ton} Adjust
(inner cylinder side)
Clearance between recoil
16 spring mount nut and lock 0 1.0
plate
D475A-5 10-97
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
IDLER
10-98 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
Unit: mm
Outside diameter of protruding Standard size Repair limit

1
part 1,043
Outside diameter of tread sur-
2 990 959 Rebuild or
face
replace
3 Depth of tread 26.5 42
4 Thickness of tread 36 20.5
5 Overall width 347
6 Width of tread 96 105

Replace
Clearance between shaft and size Shaft Hole clearance limit
7 bushing
bushing
0.350 +0.168 0.353
180
0.413 +0.003 0.581
Standard size Repair limit Rebuild or
8 Width of shaft flange
335.0 replace
Standard Tolerance Standard Interference

Interference between ring and size Shaft Hole interference limit
9
shaft
+0.046 0.15 0.15
115 Replace ring
+0.046 0.20 0.246
10 End play
0.52 0.98
D475A-5 10-99
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
10-100 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
Unit: mm
Outside diameter of flange Standard size Repair limit

1
(outside) 344
Outside diameter of flange
2 332
(inside)
(Single
Outside 300 230
flange)
3 diameter of
tread (Double
300 246
flange)
(Single
71.5 36.5
Thickness flange)
4 Rebuild or
of tread (Double replace
71.5 44.5
flange)
5 Overall width 423
6 Width of tread (single flange) 99.5
7 Width of tread (double flange) 99.5
Width of flange
8 34.5 19.5
(Outside of double flange)
Width of flange
9 27.5 12.5
(Inside of double flange)
10 Width of shaft flange 379

Clearance between shaft and size Shaft Hole clearance limit Replace
11
bushing bushing
0.350 +0.170 0.350
147
0.413 +0.170 0.583

Interference between shaft size Shaft Hole interference limit
12 Replace
and ring
+0.046 0.15 0.150
84
+0.046 0.20 0.246
Adjust or
13 End play 0.44 0.91
replace
D475A-5 10-101
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
275
Outside diameter of carrier
2 240 215 Rebuild or
roller tread
replace
3 Width of carrier roller tread 96
4 Thickness of tread 49.5 37
5 Width of flange 25 14

Interference between shaft size Shaft Hole interference limit
6
and ring
+0.046 0.15 0.150
95
+0.046 0.20 0.246
Replace
Clearance between shaft and 0.2 +0.35
7 90 0 0.55
support 0.2 +0.35
Standard size Clearance limit
8 Play in axial direction of roller
0 0.22 0.3
10-102 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
1. Guide 6. Small bogie

2. Cap 7. Track roller assembly
3. Track roller assembly (double) 8. Cover
4. Large bogie 9. Cartridge pin
5. Rubber mount
Outline
The track rollers are installed to small bogie (6).
The track rollers and track shoes are always in
contact.
The vibration of the machine from the ground
surface is absorbed by rubber mount (5).
D475A-5 10-103
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
a Portion P shows the link on the side where the bushing is pressed fitted.
10-104 D475A-5
Unit: mm
Standard size Repair limit Turn or

1 Link pitch
317.8 320.8 replace
2 Height of grouser 105 35 Weld lug,

rebuild, or
3 Overall height of shoe 133 63 replace
Turning
Standard size
4 Outside diameter of bushing Load Heavy load Turn or
116 107.5 110 replace
5 Thickness of bushing 22.5 14 16.5

6 Height of link
109 181 (*1) Rebuild or
replace
Thickness of link
7 53.5 35.5 (*2)
(bushing press-fitting portion)
Clearance One side 1.6

8
between links Both sides 3.2
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference Adjust or
9 replace
and link
+0.652 +0.087
113 0.465 0.652
+0.552 +0.087
Interference between regular +0.496 +0.124
10 70 0.312 0.446
pin and link +0.436 +0.050
a. Regular Tightening torque (Nm {kgm}) Tightening angle (deg)

link 785 78 {80 8} 180 10
11 Shoe bolt Retighten
b. Master
980 98 {100 10} 180 10
link
*1: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit is
183 mm.
*2: If wear has reduced the outside diameter of the double flange track roller to less than 250 mm, the limit is
37.5 mm.
D475A-5 10-105
SHINGLE SHOE
Unit: mm

1 Height
105 35 Repair by
build-up
2 Thickness 28
welding or
3 Length of base 52 replace
4 Length at tip 36
10-106 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MAIN FRAME
MAIN FRAME
10-108 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MAIN FRAME
Unit: mm

size Shaft Hole clearance limit
Interference between steering
1
case and bushing (Std.inter-
0.108 +0.052 ference)
315 Min. 0
+0.056 +0.052 0.004
0.108
Clearance between steering 0.018 +0.057 0.018
2 390 0.2
frame and final drive cage 0.075 +0.057 0.132
Clearance between bracket 0.030 +0.006 0.018
3 78 0.1
and cushion 0.060 0.048 0.066
Clearance between ripper arm 0.043 +0.210 0.093
4 140 1.5
mounting pin and bushing 0.106 +0.050 0.316
Clearance between ripper Replace
0.036 +0.301 0.154
5 cylinder mounting pin and 110 1.5
0.090 +0.118 0.371
bushing
Clearance between radiator
Hole 100.2 0.036 +0.164 0.298
6 guard mounting pin and 1.5
Shaft 100 0.090 +0.062 0.454
bushing
Clearance between radiator
Hole 115.2 0.043 +0.140 0.274
7 guard mounting pin and 1.5
Shaft 115 0.106 +0.031 0.446
bushing
Clearance between equalizer 0.043 +0.208 0.174
8 140 1.5
bar shaft and bushing 0.083 +0.131 0.291
Protrusion of rubber at end Standard size Repair limit

9
face of seal 1 0.5
Free height of front mount
10 118 116
rubber
Free height of rear mount
11 58 56
rubber
Press-fitting force for ripper
12 126.5 253 kN {12.9 25.8 ton}
arm mounting bushing
Press-fitting force for ripper
13 111.8 267.7 kN {11.4 27.3 ton}
cylinder mounting bushing
Adjust
Press-fitting force for radiator
14 62.8 142.2 kN {6.4 14.5 ton}
guard mounting bushing
Press-fitting force for radiator
15 53.9 106.9 kN {5.5 10.9 ton}
guard mounting bushing
Press-fitting force for equalizer
16 65.7 153 kN {6.7 15.6 ton}
bar shaft mounting bushing
D475A-5 10-109
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION
SUSPENSION
D475A-5 10-111
1. Equalizer bar Outline

2. Pivot shaft assembly The front part of the track frame moves up and
3. Cover down around pivot shaft (6) at its rear end.
4. Thrust plate Equalizer bar (1) rocks around center pin (11)
5. Thrust plate and is connected to the right and left track
6. Pivot shaft frames by side pins (10).
7. Seal cage
8. Cover
9. Seal cage
10. Side pin
11. Center pin
10-112 D475A-5
Unit: mm
Press-fitting force for side pin

12 47.0 96.0 kN {4.8 9.8 ton}
bushing
Press-fitting force for side pin
13 121.5 294 kN {12.4 30 ton}
bushing
Press-fitting force for center
14 68.6 232.2 kN {7 23.8 ton}
pin bushing

Clearance between center pin size Shaft Hole clearance limit
15
and bushing
0.043 +0.225 0.186
140 1.0
0.083 +0.143 0.308
Clearance between side pin 0.048 +0.015 0.033
16 115 1.0
and bushing 0.078 0.015 0.093
Clearance between pivot shaft 0.190 +0.138 0.216 Replace
17 260 1.0
and bushing 0.271 +0.026 0.409 bushing
Clearance between pivot shaft 0.145 +0.114 0.204
18 220 1.0
and bushing 0.208 +0.038 0.340

Interference between side pin size Shaft Hole interference limit
19
boss and bushing
+0.051 0.033 0.064
200
+0.031 0.079 0.130
Interference between thrust +0.216 0.234 0.320
20 270
washer and seal +0.086 0.286 0.502
Interference between thrust +0.096 0.075 0.125
21 194 Replace
washer and seal +0.050 0.147 0.243
Interference between pivot +0.108 0.122 0.178
22 263
shaft and seal +0.056 0.203 0.311
D475A-5 10-113
WORK EQUIPMENT HYDRAULIC EQUIP-
WORK EQUIPMENT HYDRAULIC EQUIPMENT ARRANGEMENT

DIAGRAM
SEMI U-DOZER (SINGLE TILT)
1. Blade tilt cylinder

2. R.H. blade lift cylinder
3. Main control valve
4. Accumulator
5. Dual tilt solenoid valve
6. Hydraulic tank
7. Fan pump
8. Work equipment pump
9. L.H. blade lift cylinder
10. Fan motor
11. Oil cooler
10-114 D475A-5
SUPERDOZER (FULL U-DOZER + DUAL TILT)
1. Blade tilt cylinder 7. Fan pump

2. R.H. blade lift cylinder 8. Work equipment pump
3. Main control valve 9. L.H. blade lift cylinder
4. Accumulator 10. Blade pitch cylinder
5. Dual tilt solenoid valve 11. Fan motor
6. Hydraulic tank 12. Oil cooler
D475A-5 10-115
MULTI-SHANK RIPPER

2. Divider block
3. Ripper tilt cylinder (right)
4. Ripper lift cylinder (right)
5. Ripper lift cylinder (left)
6. Ripper tift cylinder (left)
10-116 D475A-5
GIANT RIPPER
The diagram shows a machine equipped with a pin puller cylinder
1. Main control valve 6. Ripper lift cylinder (left)

2. Divider block 7. Ripper tilt cylinder (left)
3. Ripper tilt cylinder (right) 8. Pin puller solenoid valve
4. Ripper lift cylinder (right) 9. Brake valve
5. Pin puller cylinder
D475A-5 10-117
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM

BLADE AND RIPPER CONTROL
1. Blade control PPC valve

3. Accumulator
4. Ripper control PPC valve
5. PPC lock valve
6. Work equipment safety lever
7. Work equipment pump
10-118 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL

The diagram shows a machine equipped with pitch dozer and pin puller cylinder.
10-120 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
1. Work equipment safety lever

2. Blade control lever
3. Pitch button
4. Tilt switch
5. Ripper control lever
6. Pin puller switch
7. PPC lock valve
Lever and switch positions

A : Blade HOLD
B : Blade LOWER
C : Blade FLOAT
D : Blade RAISE
E : Blade LEFT TILT/PITCH
F : Blade RIGHT TILT/PITCH
G : Ripper HOLD
H : Ripper RAISE
J : Ripper LOWER
K : Ripper TILT IN
L : Ripper TILT BACK
M : FREE
N : LOCK
P : Single tilt
Q : Dual tilt
R : Pitch OFF
S : Pitch ON
T : Pin puller switch PUSH IN
U : Pin puller switch PUSH OUT
Outline
The work equipment control employs a PPC
method which uses a PPC valve to move each
control valve spool.
Work equipment safety lever (1) is interconnect-
ed with PPC lock valve (7), and at the LOCK po-
sition (N), the oil in the PPC circuit is stopped.
D475A-5 10-121
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PUMP
WORK EQUIPMENT PUMP

Type: HPV125 + 125 (140 cm3/rev specification)
Outline
This pump consists of two variable-capacity
swash plate-type piston pumps, CO valve, LS
valve, and EPC valve.
10-122 D475A-5
A. PBF : Front pump pressure input port 1. Front main pump

B. PAF : Front pump discharge port 2. Rear main pump
C. PLSC : LS set selector pressure pick-up port 3. LS valve
D. PBR : Rear pump pressure input port 4. CO valve
E. PENR : Control pressure pick-up port 5. LS-EPC valve
F. PAR : Rear pump discharge port 6. Front shaft
G. PENF : Control pressure pick-up port 7. Cradle
H. PD1F : Case drain port 8. Front case
J. PEPB : EPC basic pressure pick-up port 9. Rocker cam
K. PRC : Rear pump discharge pressure pick-up port 10. Shoe
L. PLSR : Load pressure input port 11. Piston
M. PLSRC : Load pressure pick-up port 12. Cylinder block
N. PLSFC : Load pressure pick-up port 13. Valve plate
P. PLSF : Load pressure input port 14. End cap
Q. PEPC : EPC basic pressure port 15. Rear shaft
R. PFC : Front pump discharge pressure pick-up port 16. Rear case
S. PD2F : Drain plug 17. Servo piston
T. ISIG : LS set selector current
U. PS : Pump suction port
V. PD2R : Air breather mounting port
D475A-5 10-123
Function Structure
The rotation and torque transmitted to the pump Cylinder block (7) is supported to shaft (1) by a
shaft are converted into hydraulic pressure, and spline, and shaft (1) is supported by the front and
pressurized oil is discharged according to the rear bearings.
load. The tip of piston (6) is a concave ball, and shoe
It is possible to change the discharge amount by (5) is caulked to it to form one unit. Piston (6) and
changing the swash plate angle. shoe (5) form a spherical bearing.
Shoe (5) is always pressed against flat surface A
of rocker cam (4) while sliding in a circular move-
ment.
Rocker cam (4) brings high pressure oil at cylin-
der surface B with cradle (2), which is secured
to the case, and forms a static pressure bearing
when it slides.
Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
The cylinder block (7) seals the pressure oil to
valve plate (8) and carries out relative rotation.
This surface is designed so that the oil pressure
balance is maintained at a suitable level. The oil
inside each cylinder chamber of cylinder block
(7) is sucked in and discharged through valve
plate (8).
10-124 D475A-5
Operation
1. Operation of pump
Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle is called the swash plate
angle.)
Center line X of rocker cam (4) maintains

swash plate angle in relation to the axial
direction of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this amount F E per each piston.
In other words, when cylinder block (7) ro-
tates and the volume of chamber E becomes
smaller, the oil is discharged during that
stroke. On the other hand, the volume of
chamber F becomes larger, and as the vol-
ume becomes bigger, the oil is sucked in.
If center line X of rocker cam (4) is in line with

the axial direction of cylinder block (7)
(swash plate angle = 0), the difference be-
tween volumes E and F inside cylinder block
(7) becomes 0, so the pump does not carry
out any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
D475A-5 10-125
2. Control of discharge amount

If the swash plate angle becomes larger,
the difference between volumes E and F be-
comes larger and discharge amount Q in-
creases.
Swash plate angle is changed by servo

piston (12).
Servo piston (12) moves in a reciprocal
movement according to the signal pressure
from the CO - LS valve. This straight line
movement is transmitted through rod (13) to
rocker cam (4), and rocker cam (4), which is
supported by the cylindrical surface to cradle
(2), slides in a rotating movement.
With servo piston (12), the area receiving the
pressure is different on the left and the right,
so main pump discharge pressure (self pres-
sure) PP is always brought to the chamber
receiving the pressure at the small diameter
piston end.
Output pressure PEN of the LS valve is
brought to the chamber receiving the pres-
sure at the large diameter end. The relation-
ship in the size of pressure PP at the small
diameter piston end and pressure PEN at
the large diameter end, and the ratio be-
tween the area receiving the pressure of the
small diameter piston and the large diameter
piston controls the movement of servo piston
(12).
10-126 D475A-5
3. LS valve
1. Sleeve A. PLS : LS pressure input port

2. Piston B. PP : Pump port
3. Spool C. PLP : LS control pressure output port
4. Spring D. PPL : CO control pressure input port
5. Seat E. PDP : Drain port
6. Sleeve F. PSIG : LS mode selection pilot port
7. Plug G. PA : Pump port
8. Locknut
4. CO valve
1. Plug A. PPL : CO control pressure output port

2. Servo piston assembly B. PA : Pump port
3. Ball C. PDP : Drain port
4. Spool
5. Spring
6. Retainer
7. Cover
8. Spring
D475A-5 10-127
Function
(1) LS valve
The LS (Load Sensing) valve detects the load
and controls the discharge amount.
This valve controls main pump discharge amount
Q according to differential pressure PLS be-
tween main pump pressure PP and control valve
outlet port pressure PLS (= PP PLS) [called the
LS differential pressure].
Main pump pressure PP, pressure PLS [called
the LS pressure] from the control valve output,
and pressure PSIG from the proportional sole-
noid valve [called the LS selector pressure] enter
this valve.
The relationship between differential pressure
PLS between main pump pressure PP and LS
pressure (= PP PLS) and discharge amount Q
changes according to LS selector current ISIG of
the LS-EPC valve as shown in the figure on the
right.
As ISIG changes from 0 to 0.9 A, the set force of
the spring changes. As a result, the median of
the standard changing point of the pump dis-
charge amount changes from 2.5 to 0.98 MPa
{from 25 to 10 kg/cm2}.
(2) CO valve
When the pump pressure in the hydraulic circuit
becomes maximum, the CO (Cut-OFF) valve
minimizes the pump swash plate angle to limit
the pressure and protect the circuit.
Since the pump swash plate angle is minimized,
the pump absorption torque is reduced and the
fuel consumption is reduced.
10-128 D475A-5
Operation
(1) LS valve
1) When control valve is at neutral position
The LS valve is a three-way selector valve, At this point, spool (6) is pushed to the left,
with pressure PLS (LS pressure) from the in- and port C and port D are connected. Pump
let port of the control valve brought to spring pressure PP enters the large diameter end of
chamber B, and main pump discharge pres- the piston from port K and the same pump
sure PP brought to port H of sleeve (8). The pressure PP also enters port J at the small
size of this LS pressure PLS + force Z of diameter end of the piston, so the swash
spring (4) and the main pump pressure (self plate is moved to the minimum angle by the
pressure) PP determines the position of difference in the area of the piston (12).
spool (6). However, the size of the output
pressure PSIG (the LS selection pressure) of
the EPC valve for the LS valve entering port
G also changes the position of spool (6).
(The set pressure of the spring changes).
Before the engine is started, servo piston
(11) is pushed to the right. (See the diagram
on the right)
When the engine is started and the control
lever is at the neutral position, LS pressure
PLS is 0 MPa {0 kg/cm2}. (It is interconnect-
ed with the drain circuit through the control
valve spool.)
D475A-5 10-129
2) Operation in direction of maximum pump discharge amount
When the difference between main pump If the output pressure of the EPC valve for
pressure PP and LS pressure PLS, or LS dif- the LS valve is applied to port G at this time,
ferential pressure PLS, becomes smaller it pushes piston (7) to the left.
(for example, when the area of opening of If piston (7) is pushed to the left, the set force
the control valve becomes larger and LS of spring (4) is reduced and LS differential
pressure PLS increases), the combined pressure PLS (the difference between oil
force of LS pressure PLS and force of spring pressures PLS and PP) changes when ports
(4) pushes spool (6) to the right. D and E of spool (6) are connected.
As spool (6) moves, ports D and E are con-
nected to each other and to the CO valve.
At this time, the CO valve is connected to the
drain port and the pressure in circuit D K
becomes drain pressure PT. (Operation of
the CO valve will be explained later.)
Accordingly, the pressure on the large diam-
eter end of servo piston (12) becomes drain
pressure PT. Since pump pressure PP is
constantly applied to port J on the small di-
ameter end, servo piston (12) is pushed to
the left and the swash plate is moved in the
direction for increasing the discharge
amount.
10-130 D475A-5
3) Operation in direction of minimum pump discharge amount
The following explains the case where servo

piston (12) moves to the left (where the dis-
charge amount becomes smaller). When LS
differential pressure PLS increases (for ex-
ample, when the area of opening of the con-
trol valve becomes smaller and LS pressure
PLS lowers), pump pressure PP pushes
spool (6) to the left.
As spool (6) moves, main pump pressure PP
flows from port C to port D, and then it enters
the large diameter end of the piston through
port K.
Main pump pressure PP also enters port J
on the small diameter end of servo piston
(12), but servo piston (12) is pushed to the
right because of the difference in area be-
tween its large diameter end and small diam-
eter end. As a result, the swash plate angle
is reduced.
D475A-5 10-131
4) When servo piston is balanced
Let us take the area receiving the pressure at The position where spool (6) is balanced and
the large diameter end of the piston as A1, stopped is the standard center. The force of
the area receiving the pressure at the small spring (4) is so adjusted that the standard
diameter end as A0, and the pressure flow- center will be decided when PP PLS = 2.5
ing into the large diameter end of the piston MPa {25 kg/cm2}.
as PEN. When the input current to the LS-EPC valve
When main pump pressure PP of the LS changes from 0 to 0.9A and PSIG (the output
valve is balanced with the combined force of pressure of the LS-EPC valve varying from 0
LS pressure PLS and the force of spring (4) to 2.9 MPa {0 to 30 kg/cm2}) is applied to port
and their relationship is A0 x PP = A1 x PEN, G, however, the balancing and stopping po-
servo piston (12) stops in the current posi- sition changes in proportion to the PSIG
tion. pressure in the range from PP PLS = 2.5 to
Then, swash plate is kept at an intermediate 0.98 MPa {25 to 10 kg/cm2}.
position. (It stops at a position where the
opening between ports D and E of spool (6)
and that between ports C and D are approx-
imately the same.)
At this time, the relationship between the are-
as receiving the pressure at both ends of ser-
vo piston (12) is A0 : A1 = 1 : 2. Accordingly,
the relationship between the pressures ap-
plied to both ends of the piston when the pis-
ton is balanced becomes PP : PEN = 2 : 1.
10-132 D475A-5
The operation of the LS valve is shown in the following table.
Solenoid drive table

Superdozer
Single specification Dual specification
specification
Raise
Lift
Lower
Left tilt q q q
Left tilt limit q
Single tilt
Right tilt q q q
Right tilt limit q
Blade
Left tilt q
Left tilt limit q
Dual tilt
Right tilt q
Right tilt limit q
Rear pitch q
Pitch
Forward pitch q
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
D475A-5 10-133
(2) CO valve
1) When actuator load is small and pump pressure PP is low
Spool (3) is a little to the left position. At this

time, port C is connected to port D through
the internal passage of spool (3).
Port C of the CO valve is connected to port E
of the LS valve.
Pump pressure PP is applied to port B and
small diameter side of servo piston (9). The
pressure in port E of the LS valve is drain
pressure PT.
If ports E and G of the LS valve are connect-
ed at this time, the pressure on the large di-
ameter side of the piston becomes drain
pressure PT and servo piston (9) moves to
the left.
As a result, the pump swash plate angle is in-
creased to increase the pump discharge
amount.
10-134 D475A-5
2) When actuator load is large and pump discharge pressure reaches maximum
When the load is large and pump discharge

pressure PP is high, the force to push spool
(3) to the right is increased and spool (3) is
set in the position shown in the above figure.
Port C of the CO valve is connected to port E
of the LS valve.
Pump pressure PP is applied to port B and
small diameter side of servo piston (9).
Then, the pressure applied through port C to
the LS valve is main pump pressure PP from
port B.
If ports E and G of the LS valve are connect-
ed at this time, main pump pressure PP is
applied to the large diameter side of servo
piston (9).
Main pump pressure PP is applied to the
small diameter side of the piston, too. Servo
piston (9) is pushed to the right, however, be-
cause of the difference in area between the
large diameter side and small diameter side
of the piston.
D475A-5 10-135
5. LS-EPC valve
1. Coil A. PSIG : To LS valve

2. Body B. PT : To tank
3. Spring C. PEPC : From self-reducing pressure valve
4. Spool
5. Rod
6. Plunger
7. Connector
10-136 D475A-5
Function
The EPC valve consists of the solenoid portion
and the hydraulic valve portion.
When it receives signal current i from the pump
controller, it generates the EPC output pressure
in proportion to the size of the signal, and outputs
it to the LS valve.
Operation
(1) When signal current is 0 (coil de-energized)
When there is no signal current flowing from the
controller to coil (1), coil (1) is de-energized.
For this reason, spool (4) is pushed to the right in
the direction of the arrow by spring (3).
As a result, port C (PEPC) closes and the pres-
surized oil from the main pump does not flow to
the LS valve.
At the same time, the pressurized oil from the LS
valve passes from port A (PSIG) through port B
(PT) and is drained to the tank.
D475A-5 10-137
(2) When signal current is small

(Coil is energized)
If a small signal current flows in coil (1), coil (1) is
"energized" and a thrust to the right is generated
in plunger (6).
Rod (5) pushes spool (2) to the right and the oil
from port C (PEPC) flows in port A (PSIG).
The pressure in port A (PSIG) rises. If the total
of the force applied to spool (2) and the load of
spring (3) exceeds the thrust of plunger (6), spool
(2) is pushed to the left. Then, port C (PEPC)
and port A (PSIG) are disconnected and port A
(PSIG) and port (PT) are connected simultane-
ously.
As a result, spool (2) moves up and down until
the thrust of plunger (6) is balanced with the total
of the pressure in port A (PSIG) and the load of
spring (3).
Accordingly, the pressure in the circuit between
the EPC valve and LS valve is controlled in pro-
portion to the signal current.
(3) When signal current is maximum

(Coil is energized)
If the signal current flows in coil (1), coil (1) is "en-
ergized".
Since the signal current is at the maximum, the
thrust in plunger (6) becomes maximum.
Accordingly, rod (5) presses spool (2) to the
right.
As a result, the maximum oil flows from port C
(PEPC) to port A (PSIG) and the pressure in the
circuit between the EPC valve and LS valve be-
comes highest.
At this time, port C (PT) is closed and the oil does
not flow in the tank.
10-138 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING FAN PUMP
COOLING FAN PUMP

Type: LPV90 + 30
SC : Suction port 1. LPV90 Hydraulic pump

DC : Discharge port 2. LPV30 Hydraulic pump
D475A-5 10-139
1. LPV90 Hydraulic pump
SC : Suction port
DC : Discharge port
10-140 D475A-5
IM : Control current input connector 1. Shaft

PA : Pump discharge port 2. Cradle
PS : Pump suction port 3. Case
PD1 : Drain port 4. Rocker cam
PD2 : Drain port (Plug) 5. Shoe
PDA : Breather 6. Piston
PEN : Control pressure pick-up port (Plug) 7. Cylinder block
PEPC : EPC basic pressure input port 8. Valve plate
9. Spring
10. Servo piston
D475A-5 10-141
Function Structure
The rotation and torque of the engine are trans- Cylinder block (7) is supported on shaft (1)
mitted to the shaft of this pump. Then, this pump through spline a. Shaft (1) is supported on the
converts the rotation and torque into hydraulic front and rear bearings.
energy and discharges hydraulic oil according to The end of piston (6) has a spherical hollow
the load. which is combined with shoe (5). Piston (6) and
The discharge of this pump can be changed by shoe (5) form a spherical bearing.
changing the swash plate angle in it. Shoe (5) is kept pressed against the plane of
rocker cam (4) and slid circularly. Rocker cam
(4) receives high-pressure oil and forms a static
pressure bearing and slides on cylindrical sur-
face B of cradle (2).
Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
Cylinder block (7) rotates relatively against valve
plate (8), sealing the hydraulic oil. The hydraulic
balance on the valve plate is maintained proper-
ly.
The oil in each cylinder of cylinder block (7) can
be sucked and discharged through valve plate
(8).
10-142 D475A-5
Operation
(1) Operation of pump
Cylinder block (7) rotates together with shaft (1).
Shoe (5) slides on plane A. At this time, rocker
cam (4) moves along cylindrical surface B. As a
result, angle between center line X of rocker
cam (4) and the axis of cylinder block (7) chang-
es. Angle is called the swash plate angle.
If angle is made between center line X of rock-

er cam (4) and the axis of cylinder block (7),
plane A works as a cam for shoe (5).
Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between vol-
umes E and F in cylinder block (7). As a result,
each piston (6) sucks and discharges oil by F
E.
In other words, if cylinder block (7) rotates and
the volume of chamber E is decreased, the oil is
discharged from chamber E. On the other hand,
the volume of chamber F is increased and the oil
is sucked in chamber F. (In the figure, chamber
F is at the end of the suction stroke and chamber
E is at the end of the discharge stroke.)
If center line X of rocker cam (4) is equal to the

axial of cylinder block (7) (the swash plate angle
is 0), there is not a difference between volumes
E and F in cylinder block (7) and the oil is not
sucked or discharged. (The swash plate angle is
not set to 0 actually, however.)
In short, swash plate angle is in proportion to

the pump discharge.
D475A-5 10-143
(2) Control of discharge

If swash plate angle is increased, the differ-
ence between volumes E and F is increased, or
discharge Q is increased. Swash plate angle
is changed with servo piston (1).
Servo piston (1) reciprocates straight according
to the signal pressure of the PC valve. This
straight motion is transmitted to rocker cam (4).
Then, rocker cam (4) supported on the cylindrical
surface of cradle (2) slides in the rotating direc-
tion.
The pressure receiving area of the top of servo
piston (1) is different from that of the bottom.
Main pump discharge pressure (self-pressure)
PA is kept led in the pressure chamber on the
small-diameter piston side (upper side).
PC valve output pressure PEN is led in the pres-
sure chamber on the large-diameter piston side
(lower side).
The movement of servo piston (1) is controlled
according to the difference between pressure PA
on the small-diameter piston side and pressure
PEN on the large-diameter piston side and the
ratio of the pressure receiving area of the small-
diameter piston to that of the large-diameter pis-
ton.
10-144 D475A-5
(3) PC valve, EPC valve, and servo piston
IM : Control current input connector

PA : Pump discharge port
PEPC : EPC basic pressure input port
Servo piston PC valve EPC valve

1. Servo piston 4. Piston 10. EPC valve
2. Lever 5. Seat
3. Spring 6. Spring
7. Spool
8. Sleeve
9. Plug
D475A-5 10-145
Function
The PC valve works so the relationship between
the current input to the EPC valve and pump
swash plate angle will be as shown in the figure
on the right.
10-146 D475A-5
1) When EPC output pressure is high (When EPC current "i" is large)
10-148 D475A-5
Operation
The relationship between the EPC valve input
current and EPC valve output pressure F is as
shown in the figure on the right.
If the EPC discharge pressure rises, spool (7) is
pushed to the left because of the difference in
sectional areas between parts S1 and S2 of the
spool (S1 > S2).
Port f is connected to port g and pump discharge
pressure PA flows through port g to port f. Port
f is disconnected from the drain circuit.
Pump discharge pressure PA from port f of the
PC valve enters chamber X on the large diame-
ter side of servo piston (1).
Pump pressure PA is also constantly applied to
chamber Y on the small diameter side of servo
piston (1). Since a larger force is applied to the
large diameter side because of the difference in
area between both ends of servo piston (1), how-
ever, servo piston (1) moves toward the mini-
mum swash plate angle side (upper side).
If servo piston (1) moves up, piston (4) is moved

to the right through lever (2). Accordingly, spring
(6) is compressed and spool (7) moves to the
right.
If spool (7) moves to the right and port f is discon-
nected from port g, servo piston (1) stops moving
up.
At this time, servo piston (1) stops at a place
higher (nearer to the minimum swash plate an-
gle) than when the EPC discharge pressure is
low.
D475A-5 10-149
2) When EPC output pressure is low (When EPC current "i" is small)
10-150 D475A-5
Operation
If EPC current "i" reduces and the EPC output
pressure lowers, spool (7) is pushed to the right
by the force of spring (6).
Accordingly, port g is disconnected from port f
and port f is connected to the drain circuit.
At this time, the oil in chamber X on the large di-
ameter side of servo piston (1) flows through port
f of the PC valve to the drain circuit.
As a result, servo piston (1) is moved toward the
maximum swash plate angle side (lower side) by
the pressure of chamber Y on the small diameter
side.
D475A-5 10-151
2. LPV30 Hydraulic pump
P1 : Pump discharge port

PS : Pump suction port
TO : Drain port
PDA2 : Breather
PEPC : EPC valve basic pressure input port
PAEPC : EPC output pressure pick-up port
10-152 D475A-5
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball
D475A-5 10-153
Function
The rotation and torque of the engine are trans-
mitted to the shaft of this pump. Then, this pump
converts the rotation and torque into hydraulic
energy and discharges hydraulic oil according to
the load.
The discharge of this pump can be changed by
changing the swash plate angle in it.
Structure
Cylinder block (7) is supported on shaft (1)
through spline a. Shaft (1) is supported on the
front and rear bearings.
The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6) and
shoe (5) form a spherical bearing.
Shoe (5) is kept pressed against plane A of rock-
et cam (4) and slid circularly. Rocker cam (4)
slides around ball (11).
Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
Cylinder block (7) rotates relatively against valve
plate (8), sealing the hydraulic oil. The hydraulic
balance on the valve plate is maintained proper-
ly.
The oil in each cylinder of cylinder block (7) can
be sucked and discharged through valve plate
(8).
10-154 D475A-5
Operation
(1) Operation of pump
Cylinder block (7) rotates together with shaft (1).
Shoe (5) slides on plane A. At this time, rocker
cam (4) tilts around ball (11). As a result, angle
between center line X of rocker cam (4) and
the axis of cylinder block (7) changes. Angle
is called the swash plate angle.
If angle is made between center line X of rock-
er cam (4) and the axis of cylinder block (7),
plane A works as a cam for shoe (5).
Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between vol-
umes E and F in cylinder block (7). As a result,
each piston (6) sucks and discharges oil by F
E.
In other words, if cylinder block (7) rotates and
the volume of chamber E is decreased, the oil is
discharged from chamber E. On the other hand,
the volume of chamber F is increased and the oil
is sucked in chamber F. (In the figure, chamber
F is at the end of the suction stroke and chamber
E is at the end of the discharge stroke.)
If center line X of rocker cam (4) is equal to the

axial of cylinder block (7) (the swash plate angle
is 0), there is not a difference between volumes
E and F in cylinder block (7) and the oil is not
sucked or discharged. (The swash plate angle is
not set to 0 actually, however.)
In short, swash plate angle is in proportion to
the pump discharge.
D475A-5 10-155
(2) Control of discharge

If swash plate angle is increased, the differ-
ence between volumes E and F is increased, or
discharge Q is increased. Swash plate angle
is changed with servo piston (10).
Servo piston (10) reciprocates straight according
to the signal pressure of the servo valve. This
straight motion is transmitted to rocker cam (4).
Then, rocker cam (4) supported on ball (11)
rocks around ball (11).
10-156 D475A-5
(3) Servo valve
P : EPC valve basic pressure input port

T : Drain port
PE : Control piston pressure output port
PH : Pump discharge pressure input port
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
D475A-5 10-157
A: Drain side D: EPC output pressure side

B: Pump discharge pressure input side P: EPC basic pressure input side
C: EPC output pressure receiving pressure
Function
The servo valve works so the relationship be-
tween the current input to the EPC valve and
pump swash plate angle will be as shown in the
figure on the right.
10-158 D475A-5
The relationship between the EPC valve input

current and EPC valve output pressure F is as
shown in the figure on the right.
Operation
The output oil of the EPC valve flows in the pis-
ton chamber to push piston (6). Piston (6) push-
es spool (5) until it is balanced with the spring.
Then, the land of the servo piston pressure pas-
sage is connected to the pump discharge pas-
sage by the cut of spool (5) and the discharge
pressure is led to the servo piston.
The servo piston is raised by the rocker cam.
The position feedback is applied and the lever
moves to compress the spring.
If spool (5) is pushed back, the pump discharge
circuit and the servo piston circuit are shut off.
The pressure in the servo piston chamber lowers
and the rocker cam returns toward the maximum
swash plate angle.
These processes are repeated until the swash
plate is fixed to a position where the EPC output
pressure is balanced with the spring force.
Accordingly, as the EPC output pressure is
heightened, the swash plate angle is decreased.
As the EPC output pressure is lowered, the
swash plate angle is increased.
D475A-5 10-159
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR
COOLING FAN MOTOR

Type: LMF180
P : From fan pump

T : From cooler to tank
TC : To tank
Specifications
Type : LMF180
Capacity : 180 cc/rev
Rated speed : 982 rpm
Rated flow : 178 l/min
Check valve cracking pressure:
0.07 MPa {0.7 kg/cm2}
10-160 D475A-5
(2)
1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Center spring
10. Safety-suction valve
D475A-5 10-161
(2)
1. Hydraulic motor
Function
This hydraulic motor is a swash plate-type axial
piston motor, which converts the pressure of the
hydraulic oil sent from the hydraulic pump into
revolution.
Principle of operation
The oil sent from the hydraulic port flows through
valve plate (7) into cylinder block (5). This oil can
flow on only one side of the Y Y line connecting
the top dead center and bottom dead center of
the stroke of piston (4).
The oil sent to one side of cylinder block (5)
presses pistons (4) (4 or 5 pieces) and generates
force F1 (F1 kg = P kg/cm2 x x/4D2 cm2).
This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of degrees
to the output shaft (1), the force is divided into
components F2 and F3.
Radial component F3 generates torque against
the Y Y line connecting the top dead center and
bottom dead center (T = F3 x ri).
The resultant of this torque [T = (F3 x ri)] ro-
tates the cylinder block (5) through the piston.
Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output shaft
revolves to transmit the torque.
10-162 D475A-5
1. Piston
2. Main valve
3. Piston spring
4. Valve seat
5. Poppet
6. Poppet spring
7. Suction valve
8. Suction valve spring
9. Adjustment screw
Function
When the pressure in port P of the motor rises at
the starting time of the engine, this valve protects
the fan system circuit. (Safety valve)
When the fan pump stops, the hydraulic oil does
not flow into the motor. Since the motor contin-
ues revolution because of the force of inertia,
however, the pressure on the outlet side of the
motor rises.
When the oil stops flowing in from inlet port P, the

safety-suction valve sucks in the oil on the outlet
side and supplies it to the port MA where there is
not sufficient oil to prevent cavitation. (Suction
valve)
D475A-5 10-163
(2)
Operation
(1) Operation as safety valve
Port A is connected to port P of the motor and
port B is connected through port MB to port T.
The hydraulic oil in port A flows through the hole
of piston (1) to port C. Since d2 < d3, main valve
(2) is seated on the left side.
The order of the diameters (areas) of the sec-
tions is d5 > d4 > d1 > d3 > d2.
If abnormal pressure generated in port A reach-

es the set pressure of spring (6), poppet (5)
opens and the hydraulic oil in port C is drained
through port D and periphery a of suction valve
(7).
If poppet (5) opens, the pressure in port C lowers

and piston (1) moves to the right. Piston (1)
comes in contact with the tip of poppet (5) and
the hydraulic oil is drained through throttle b and
port D.
Since the pressure in port C is lower than that in

port A, main valve (2) moves to the right and the
hydraulic oil flows through port A to port B, thus
generation of abnormal pressure is prevented.
Even if abnormal pressure is generated, suction
valve (7) having a large section diameter does
not operate since d1 < d4.
10-163-1 D475A-5
(2)
(2) Operation as suction valve

If negative pressure is generated in port P of the
motor, the pressure in ports A and C becomes
negative since those ports are connected.
A right force caused by the hydraulic pressure
equivalent to the area difference between d4 and
d1 is applied to suction valve (7).
If the differential pressure between ports B and A
increases above the set pressure, it moves suc-
tion valve (7) to the right. Accordingly, hydraulic
oil flows from port B to port A to prevent genera-
tion of negative pressure in port A.
D475A-5 10-163-2
(2)
3. Operation for forward and reverse revolution
(1) Forward revolution (Counterclockwise revolution)
If ON-OFF solenoid (1) for selector valve is de-

energized, the hydraulic oil in port MA is sent to
chamber E and spool (5) moves to the left.
The hydraulic oil in port MB is returned to the
tank through passage a on the periphery of spool
(5).
If ON-OFF solenoid (1) for selector valve is de-
energized, the hydraulic oil from the pump is
blocked by ON-OFF selector valve (2) and port C
is connected to the tank circuit.
Accordingly, selector spool (3) is pushed by
spring (4) to the right to open motor port MA and
then the hydraulic oil flows in the motor to revolve
the motor forward (counterclockwise).
10-164 D475A-5
(2)
(2) Reverse revolution (Clockwise revolution)
If ON-OFF solenoid (1) for selector valve is ener-

gized, the hydraulic oil in port MB is sent to
chamber F and spool (5) moves to the right.
The hydraulic oil in port MA is returned from
chamber E to the tank through passage a on the
periphery of spool (5).
If ON-OFF solenoid (1) for selector valve is ener-
gized, ON-OFF selector valve (2) changes to let
the hydraulic oil from the pump flow through port
C into spool chamber D.
The hydraulic oil in chamber D pushes selector
spool (3) to the left against spring (4). As a re-
sult, motor port MB opens and the hydraulic oil
flows in the motor to revolve the motor in reverse
(clockwise).
D475A-5 10-165
(2)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC VALVE
PPC VALVE
1. Blade PPC valve
P : From self-reducing pressure valve P2 : To blade lift valve PPC port

T : To hydraulic tank P3 : To blade tilt valve PPC port
P1 : To blade lift valve PPC port P4 : To blade tilt valve PPC port
10-166 D475A-5
1. Disc
2. Plate
3. Body
D475A-5 10-167
Operation
(1) When in neutral
1) For lifting blade
Ports A and B of the blade lift valve of the
control valve and ports P1 and P2 of the
PPC valve are connected through fine con-
trol hole f of spool (1) to drain chamber D.
2) For tilting blade

Ports C and D of the blade tilt valve of the
control valve and ports P3 and P4 of the
PPC valve are connected through fine con-
trol hole f of spool (1) to drain chamber D.
10-168 D475A-5
(2) When in fine control (Neutral o Fine control)

If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
Accordingly, fine control hole f is disconnected
from drain chamber D and connected to pump
pressure chamber PP almost simultaneously,
and then the pilot oil flows from port P1 through
fine control hole f to port B.
If the pressure in port P1 rises, spool (1) is
pushed back and fine control hole f is discon-
nected from pump pressure chamber PP and
connected to drain chamber D almost simultane-
ously to release the pressure in port P1.
As a result, spool (1) moves up and down to bal-
ance the force of metering spring (2) with the
pressure in port P1.
The positional relationship between spool (1)
and body (10) (where fine control hole f is be-
tween drain chamber D and pump pressure
chamber PP) does not change until retainer (9)
comes in contact with spool (1).
Since metering spring (2) is compressed in pro-
portion to the stroke of the control lever, the pres-
sure in port P1 rises in proportion to the stroke of
the control lever.
Accordingly, the control valve spool moves to a
position at which the pressure in port B (equal to
the pressure in port P1) is balanced with the
force of the control valve spool return spring.
D475A-5 10-169
(3) When in fine control

(When control lever is returned)
If lever (5) begins to return, the force of centering
spring (3) and the pressure in port P1 push up
spool (1).
As a result, fine control hole f is connected to
drain chamber D and the oil in port P1 is re-
leased.
If the pressure in port P1 lowers too much, spool
(1) is pushed down by metering spring (2) and
fine control hole f is disconnected from drain
chamber D and connected to pump pressure
chamber PP almost simultaneously. Then, the
pump pressure is applied until the pressure in
port P1 is restored to the level corresponding to
the position of the lever.
When the control valve spool returns, the oil in
drain chamber D flows in through fine control
hole f of the valve which is not in operation and
then flows through port P2 into port A.
(4) When lever is operated to stroke end

If disc (5) pushes down piston (4) and retainer (9)
pushes down spool (1), fine control hole f is dis-
connected from drain chamber D and connected
to pump pressure chamber PP.
Accordingly, the pilot oil flows through fine con-
trol hole f and port P1 into port B and pushes the
control valve spool.
The oil returning from port A flows through port
P2 and fine control f into drain chamber D.
10-170 D475A-5
(5) When blade is "floated"

If piston (4) on the "lower" side of port P1 is
pushed down by disc (5), ball (11) touches pro-
jection a of the piston in the middle of the stroke
(The detent starts to operate).
If piston (4) is pushed in further, ball (11) pushes
up collar (12) supported on detent spring (13)
and escapes out to go over projection a of the
piston.
At this time, piston (4') on the opposite side is
pushed up by spring (14).
As a result, the oil in chamber F flows through b
and c to chamber E and piston (4') follows disc
(5). Since passage d is connected to port P1, al-
most the same pressure is applied to passage d
and port P1.
Chamber E is normally connected to drain cham-
ber D. If ball (11) goes over projection a of the
piston, passage d and chamber E are connected
and the oil starts flowing.
At this time, the control valve moves to the "float"
position and the blade is floated.
Since piston (4') is pushed up by the pressure in
chamber E, the "float" state is kept even if the le-
ver is released.
(6) When "float" state of blade is reset

Disc (5) is pushed down with a force larger than
the oil pressure in chamber E to return from the
"float" position.
As a result, chamber E is disconnected from pas-
sage d and connected to the drain chamber. Ac-
cordingly, the oil pressure in chamber E is lost
and the "float" state is reset.
D475A-5 10-171
2. Ripper PPC valve
P : From self-reducing pressure valve 1. Spool

T : To tank 2. Metering spring
P1 : To ripper tilt valve PPC port 3. Centering spring
P2 : To ripper tilt valve PPC port 4. Piston
P3 : To ripper lift valve PPC port 5. Disc
P4 : To ripper lift valve PPC port 6. Nut (For connecting lever)
7. Joint
8. Plate
9. Retainer
10. Body
11. Filter
10-172 D475A-5
Unit: mm

Free length
Centering spring x Outside Free length
12 length load load
(For ports P3 and P4) diameter
If spring is
55.9 N 44.7 N damaged or
50.4 x 15.5 34.0
{5.7 kg} {4.56 kg} deformed,
replace it
Centering spring 71.4 N 56.9 N
13 50.1 x 15.5 34.0
(For ports P1 and P2) {7.28 kg} {5.8 kg}
16.7 N 13.3 N
14 Metering spring 26.5 x 8.20 24.9
{1.70 kg} {1.36 kg}
D475A-5 10-173
Operation
(1) When in neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected through
fine control hole f of spool (1) to drain chamber
D.
(2) When in fine control (Neutral o Fine control)

If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
Accordingly, fine control hole f is disconnected
from drain chamber D and connected to pump
pressure chamber PP almost simultaneously,
and then the pilot oil flows from port P1 through
fine control hole f to port A.
If the pressure in port P1 rises, spool (1) is
pushed back and fine control hole f is discon-
nected from pump pressure chamber PP and
connected to drain chamber D almost simultane-
ously to release the pressure in port P1.
As a result, spool (1) moves up and down to bal-
ance the force of metering spring (2) with the
pressure in port P1. The positional relationship
between spool (1) and body (10) (where fine con-
trol hole f is between drain chamber D and pump
pressure chamber PP) does not change until re-
tainer (9) comes in contact with spool (1).
Since metering spring (2) is compressed in pro-
portion to the stroke of the control lever, the pres-
sure in port P1 rises in proportion to the stroke of
the control lever.
Accordingly, the control valve spool moves to a
position at which the pressure in chamber A
(equal to the pressure in port P1) is balanced
with the force of the control valve spool return
spring.
10-174 D475A-5
(3) When in fine control

(When control lever is returned)
If lever (5) begins to return, the force of centering
spring (3) and the pressure in port P1 push up
spool (1).
As a result, fine control hole f is connected to
drain chamber D and the oil in port P1 is re-
leased.
If the pressure in port P1 lowers too much, spool
(1) is pushed down by metering spring (2) and
fine control hole f is disconnected from drain
chamber D and connected to pump pressure
chamber PP almost simultaneously. Then, the
pump pressure is applied until the pressure in
port P1 is restored to the level corresponding to
the position of the lever.
When the control valve spool returns, the oil in
drain chamber D flows in through fine control
hole f of the valve which is not in operation and
then flows through port P2 into chamber B.
(4) When lever is operated to stroke end

If disc (5) pushes down piston (4) and retainer (9)
pushes down spool (1), fine control hole f is dis-
connected from drain chamber D and connected
to pump pressure chamber PP.
Accordingly, the pilot oil flows through fine con-
trol hole f and port P1 into chamber A and push-
es the control valve spool.
The oil returning from chamber B flows through
port P2 and fine control f into drain chamber D.
D475A-5 10-175
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRIC LEVER (STEERING)
ELECTRIC LEVER (STEERING)

a Do not disassemble the electric lever. If it is disassembled, the output voltage characteristics and operating
effort characteristics will need to be adjusted.
1. Bellows 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
10-176 D475A-5
Function
1. Operating effort characteristics
(1) Operation for forward and reverse travel
The control lever is held at 3 positions of For-
ward, Neutral, and Reverse.
(2) Operation for steering

Free return.
D475A-5 10-177
2. Output voltage characteristics

The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
The operating angle (stroke) of the control lever
is sensed with potentiometers and signal voltag-
es are output to the transmission and steering
controller.
A potentiometer is installed in each of longitudi-
nal direction and lateral direction. Each potenti-
ometer outputs 2 signal voltages which are
opposite to each other as shown in the figure at
right.
10-178 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Outline
This control valve consists of a 6-spool valve and

a merge-divider valve.
Since the 6-spool valve and the merge-divider
valve are assembled into 1 unit by connecting
bolts and each passage is connected inside, the
whole unit is compact and easy to maintain.
T : To tank
A1 : To ripper lift cylinder head
A2 : To blade tilt right cylinder head
A3 : To blade lift cylinder head
A4 : To blade lift cylinder head
A5 : To blade tilt left cylinder head
A6 : To ripper tilt cylinder head
B1 : To ripper lift cylinder bottom
B2 : To blade tilt right cylinder bottom
B3 : To blade lift cylinder bottom
B4 : To blade lift cylinder bottom
B5 : To blade tilt left cylinder bottom
B6 : To ripper tilt cylinder bottom
P1 : From ripper lift PPC valve
P2 : From ripper lift PPC valve
P3 : From blade tilt PPC valve
P7 : From blade lift PPC valve
P8 : From blade lift PPC valve
P11 : From ripper tilt PPC valve
P12 : From ripper tilt PPC valve
PR : To solenoid valve, PPC valve, and EPC valve
PS : From merge-divider solenoid valve
SA : Pressure sensor mounting port
SB : Pressure sensor mounting port
TS : To tank
PP1 : From rear main pump
PP2 : From front main pump
PST : From port PR
PLS1 : To rear pump control
PLS2 : To front pump control
PPS1 : To rear pump control
PPS2 : To front pump control
1. 6-spool valve
2. Cover 1
3. Cover 2
4. Merge-divider valve
10-180 D475A-5
6-SPOOL VALVE
(1/8)
D475A-5 10-181
(2/8)
10-182 D475A-5
(3/8)
1. Unload valve 8. Pressure compensation valve

2. Pressure compensation valve (on ripper lift bottom side)
(on ripper tilt head side) 9. Pressure compensation valve
3. Pressure compensation valve (on blade right tilt bottom side)
(on blade left tilt head side) 10. Pressure compensation valve
4. Pressure compensation valve (on blade lift bottom side)
(on blade lift head side) 11. Pressure compensation valve
5. Pressure compensation valve (on blade lift bottom side)
(on blade lift head side) 12. Pressure compensation valve
6. Pressure compensation valve (on blade left tilt bottom side)
(on blade right tilt head side) 13. Pressure compensation valve
7. Pressure compensation valve (on ripper tilt bottom side)
(on ripper lift head side) 14. Main relief valve
D475A-5 10-183
(4/8)
10-184 D475A-5
1. Spool (Ripper tilt)

2. Spool (Blade left tilt)
3. Spool (Blade lift)
4. Spool (Blade lift)
5. Spool (Blade right tilt)
6. Spool (Ripper lift)
7. Unload valve
8. Main relief valve
Unit: mm

Free length
x Outside Free length
9 Spool return spring length load load
diameter
393 N 315 N
54.5 x 34.8 51.2
{40.1 kg} {32.1 kg}
If spring is
377 N 301 N damaged or
10 Spool return spring 54 x 34.8 50.5
{38.4 kg} {30.7 kg} deformed,
replace it.
390 N 312 N
11 Spool return spring 69.9 x 34.8 65
{39.8 kg} {31.8 kg}
406 N 325 N
12 Spool return spring 74.4 x 24.2 65.5
{41.4 kg} {33.1 kg}
274 N 219 N
{27.9 kg} {22.3 kg}
D475A-5 10-185
(5/8)
10-186 D475A-5
(3)
1. Safety-suction valve (Blade left tilt head)

2. Safety-suction valve (Blade lift head)
Plug (Superdozer Spec.)
3. Safety-suction valve (Blade lift head)
4. Safety-suction valve (Blade right tilt head)
5. Suction valve (Ripper lift head)
6. Safety-suction valve (Ripper lift bottom)
7. Safety-suction valve (Blade right tilt bottom)
8. Safety valve (Blade lift bottom)
9. Safety valve (Blade lift bottom)
10. Safety-suction valve (Blade left tilt bottom)
11. LS shuttle valve (Arm and right travel)
12. LS shuttle valve (Boom, left travel, and bucket)
13. LS check valve
14. Pressure release plug
Unit: mm

Free length If spring is
x Outside Free length damaged or
15 Check valve spring length load load
diameter deformed,
replace it.
1.5 N 1.2 N
11.5 x 4.6 8.5
{0.15 kg} {0.12 kg}
D475A-5 10-187
(3)
(6/8)
10-188 D475A-5
1. Unload valve
Ripper tilt valve

3. Spool
4. Pressure compensation valve (Head)
5. LS shuttle valve
6. Pressure compensation valve (Bottom)
Blade left tilt valve

8. Spool
9. Pressure compensation valve (Head)
10. LS shuttle valve
11. Pressure compensation valve (Bottom)
Unit: mm

Free length If spring is
x Outside Free length damaged or
13 Piston return spring length load load
diameter deformed,
replace it.
29.4 N 23.5 N
36.9 x 11.1 28
{3 kg} {2.4 kg}
D475A-5 10-189
(7/8)
10-190 D475A-5
(3)
Blade lift valve

2. Spool
3. Pressure compensation valve (Right)
4. Pressure compensation valve (Left)
5. Suction valve
Blade lift valve

7. Spool
8. Pressure compensation valve (Raise)
9. LS shuttle valve
10. Pressure compensation valve (Lower)
11. Suction valve
12. Check valve for regeneration circuit
Blade right tilt valve

13. Suction valve
14. Spool
15. Pressure compensation valve (Reverse)
17. Pressure compensation valve (Forward)
18. Suction valve
Ripper lift valve

19. Suction valve
20. Spool
21. Pressure compensation valve (Curl)
23. Pressure compensation valve (Dump)
Unit: mm

Free length
x Outside Free length If spring is
25 Regeneration valve spring length load load
diameter damaged or
6.2 N 4.9 N deformed,
31.5 x 10.3 19.5 replace it.
{0.6 kg} {0.5 kg}
29.4 N 23.5 N
26 Piston return spring 36.9 x 11.1 28
{3 kg} {2.4 kg}
D475A-5 10-191
(3)
(8/8)
10-192 D475A-5
1. Unload valve
3. Merge-divider valve (For Main)
4. Return spring
5. Merge-divider valve (For LS)
6. Return spring
7. Valve (Sequence valve)
8. Spring (Sequence valve)
9. LS bypass plug
10. Screw
11. Poppet
12. Spring (Pilot pressure reducing valve)
13. Spring (Main pressure reducing valve)
14. Valve (Pressure reducing valve)
15. Spring (Safety valve)
16. Ball
Unit: mm

Free
length x Installed Installed Free Installed
17 Check valve spring Outside length load length load
diameter
1.5 N 1.2 N If spring is
11.5 x 4.6 8.5 damaged or
{0.15 kg} {0.12 kg}
deformed,
156.8 N 125.5 N replace it.
{16.0 kg} {12.8 kg}
177.5 N 142.0 N
{18.1 kg} {14.5 kg}
199.8 N 160.0 N
20 Sequence valve spring 70.9 x 18 59
{20.4 kg} {16.3 kg}
D475A-5 10-193
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MAIN RELIEF VALVE
MAIN RELIEF VALVE
1. Spring
2. Poppet
Function
The main relief valve sets the maximum pump
pressure of the main valve.
Operation
The set pressure of the relief valve depends on
the installed load of spring (1).
10-194 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- The CLSS consists of a main pump (2 pumps),
tem, and has the following features. control valve, and actuators for the work equip-
ment.
Fine control not influenced by load The work equipment pump body consists of the
Control enabling digging even with fine control pump itself, the CO valve and LS valve.
Ease of compound operation ensured by flow di-
vider function using area of opening of spool dur-
ing compound operations
Energy saving using variable pump control
D475A-5 10-195
Basic principle
1) Control of pump swash plate
The pump swash plate angle (pump discharge
amount) is controlled so that LS differential pres-
sure PLS (the difference between pump pres-
sure PP and control valve outlet port LS pressure
PLS) (load pressure of actuator) is constant.
(LS pressure PLS = Pump discharge pressure
PP LS pressure PLS)
If LS differential pressure PLS becomes lower

than the set pressure of the LS valve (when the
actuator load pressure is high), the pump swash
plate moves towards the maximum position; if it
becomes higher than the set pressure of the LS
valve (when the actuator load pressure is low),
the pump swash plate moves towards the mini-
mum position.
10-196 D475A-5
2) Pressure compensation
A pressure compensation valve is installed to the
outlet port side of the control valve to balance the
load.
When two actuators are operated together, this
valve acts to make pressure difference P be-
tween the upstream (inlet port) and downstream
(outlet port) of the spool of each valve the same
regardless of the size of the load (pressure).
In this way, the flow of oil from the pump is
divided (compensated) in proportion to the area
of opening S1 and S2 of each valve.
D475A-5 10-197
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD UNLOAD VALVE
UNLOAD VALVE
Function
When the pump flow is merged and the control
valve group on one side is actuated (with the re-
maining control valve group at neutral), the sub-
unload valve drains the pump flow to the group
that is at neutral.
Operation
The pressure in pump passages A is received at
the end portion of valve (1). The control valve is
at neutral, so the pressure in LS circuit B is 0
MPa {0 kg/cm2}.
The pressurized oil in pump passage A is
stopped by valve (1) and cannot escape, so the
pressure rises. When this pressure becomes
larger than the force of spring (2), valve (1)
moves to the left, ports C and D are interconnect-
ed, and the pump pressure flows to tank pass-
sage E. In addition, the pressurized oil in LS
circuit B passes from orifice f through port D and
is drained to tank passage E. Therefore, in this
operation, LS pressure C tank pressure.
In this unload operation, pump discharge pres-
sure LS circuit pressure is greater than the
pump LS control pressure, so a signal is sent to
set the pump swash plate to the minimum angle.
10-198 D475A-5
INTRODUCTION OF LS PRESSURE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD (LS SHUTTLE VALVE)
INTRODUCTION OF LS PRESSURE (LS SHUTTLE VALVE)
1. Main pump 4. Check valve

2. Main spool 5. LS shuttle valve
3. Pressure compensation valve
Function Operation
LS pressure PLS is the actuator load pressure at When main spool (2) is operated, pump dis-
the output side of the control valve. charge pressure PP starts to flow to actuator cir-
The upstream pressure (= spool meter-in down- cuit A.
stream pressure) of pressure compensation First, this pump discharge pressure PP passes
valve (3) is taken inside main spool (2) and goes through introduction hole a of main spool (2), and
to LS shuttle valve (5). is taken to LS circuit PLS.
When this happens, it connects actuator circuit A When actuator circuit pressure A rises to the
and LS circcuit PLS through check valve (4), and necessary pressure, pump pressure PP rises
sets so that LS pressure PLS C actuator load and check valve (4) inside main spool (2) opens.
pressure. The high pressure of LS circuit PLS then flows to
Introduction hole a inside main spool (2) has a actuator circuit A.
small diameter, so it also acts as a throttle. In this way, LS pressure PLS becomes almost
the same as actuator circuit pressure A.
D475A-5 10-199
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LS BYPASS PLUG
LS BYPASS PLUG
1. Main pump Function

2. Main spool The residual pressure in LS circuit PLS is re-
3. Pressure compensation valve leased from orifices b and c.
4. LS shuttle valve This reduces the speed of the rise in the LS pres-
5. LS bypass plug sure, and prevents any sudden change in the oil
pressure. Furthermore, a pressure loss is gener-
ated by the circuit resistance between LS shuttle
valve (4) and throttle a of main spool (2) accord-
ing to the bypass flow from LS bypass plug (5).
As a result, the effective LS differential pressure
drops, and the dynamic stability of the actuator is
increased.
10-200 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRESSURE COMPENSATION VALVE
PRESSURE COMPENSATION VALVE

1. When the load pressure is higher than other actuators
1. Main pump
2. Valve
3. shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function Operation
When the maximum load pressure is generated If pump pressure PP and LS pressure PLS are
during compound operations and during inde- lower than actuator circuit B, shuttle valve (3) in-
pendent operations, and the load pressure is side the pressure compensation valve moves to
higher than other actuators, the pressure com- the left in the direction of the arrow to intercon-
pensation valve acts as a load check valve to nect spring chamber C.
prevent reverse flow in the circuit. When this happens, piston (4) is pushed to the
right by spring (5), so pump outlet circuit A clos-
es. This prevents the oil from flowing back from
actuator circuit B to pump outlet circuit A.
D475A-5 10-201
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRESSURE COMPENSATION VALVE
2. When the load pressure is lower than other actuators
Function Operation
During compound operations, if the load pres- During compound operations, if the load pres-
sure is lower than the other actuators and the sure for the other actuators rises, the oil flow in
flow of oil starts to increase, the pressure com- actuator circuit B tries to increase.
pensation valve carries out compensation. In this When this happens, LS pressure PLS for the oth-
case, it tries to make the load pressure for the er actuator also increases, so this LS pressure
other actuators greater and reduce the flow of oil. PLS pushes shuttle valve (3) of the pressure
compensation valve to the right in the direction of
the arrow, passes through the passage inside
piston (4), and flows to spring chamber C.
As a results, piston (4), and valve (2) are pushed
to the right in the direction of the arrow, and the
outlet side of pump circuit PP is closed, so outlet
port pressure A (spool meter-in downstream
pressure) becomes the same as the outlet port
pressure of the other actuators.
Pump pressure PP (spool meter-in upstream
pressure) is the same between all actuators, so
pump pressure PP and outlet port pressure A be-
come the same between all spools that are being
operated. Therefore, the pump flow is divided in
proportion to the area of the opening of each
valve.
10-202 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE LIFT VALVE
BLADE LIFT VALVE

Function
The blade lift valve supplies hydraulic oil to the
blade lift cylinder according to the 4 operations of
NEUTRAL, RAISE, LOWER, and FLOAT of the
blade lift PPC valve lever.
1. When blade lift lever is in NEUTRAL
10-204 D475A-5
Operation
When the blade lift lever is in NEUTRAL, spool
(3) is held in the neutral position by springs (1)
and (6) through retainers (2) and (4).
At this time, the oil does not flow in either of the
head and bottom of the blade lift cylinder.
D475A-5 10-205
2. When blade lift lever is set in RAISE position
10-206 D475A-5
Operation
If the blade lift lever is set in the RAISE position,
the pilot pressure is applied through the blade
PPC valve to chamber E and spool (3) moves to
the left.
The oil from the main pump flows through notch
(11) of spool (3) and cylinder port A to the cylin-
der head.
The oil returning from the cylinder bottom flows
through cylinder port B and notch (9) of spool (3)
to drain port D.
D475A-5 10-207
3. When blade lift lever is set in LOWER position
10-208 D475A-5
Operation
If the blade lift lever is set in the LOWER position,
the pilot pressure is applied through the blade
PPC valve to chamber F and spool (3) moves to
the right.
If the blade lift lever is set to the LOWER stroke
end, retainer (4) moves to retainer (5) and the
load of spring (7) is added to the load of spring
(6) and spool (3) stops moving.
At this time, the oil from the main pump flows
through notch (10) of spool (3) and cylinder port
B to the cylinder bottom.
The oil returning from the cylinder head flows
through cylinder port A and notch (12) of spool
(3) to drain port C.
D475A-5 10-209
4. When blade lift lever is set in FLOAT position
10-210 D475A-5
Operation
If the blade lift lever is moved from the LOWER
position to the FLOAT position, the pilot pressure
is applied through the blade PPC valve to cham-
ber F and spool (3) moves further to the right.
At this time, retainer (5) moves against the total
load of springs (6) and (7) until its right end
touches plug (8).
Since cylinder ports A and B are connected to
drain ports C and D respectively, both head and
bottom of the blade lift cylinder are connected to
the drain port and the blade is "floated".
D475A-5 10-211
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MERGE-DIVIDER VALVE
MERGE-DIVIDER VALVE
1. Main spool 3. LS spool

2. Spring 4. Spring
Function Operation
The merger-divider valve merges or divides oils 1. When oils from pumps are merged
PP1 and PP2 discharged from 2 pumps (It dis- (When pilot pressure PS is turned OFF)
tributes those oils to each control valve group). Since pilot pressure PS is turned OFF, main
This valve also merges and divides the LS circuit spool (1) is pressed to the left by spring (2)
pressures. and ports E and F are connected.
Accordingly, oils PP1 and PP2 discharged
from the 2 pumps are merged in ports E and
F and sent to the control valves which need
them.
Similarly, LS spool (3) is pressed to the left
by spring (4) and the connection of the LS
circuit changes as follows.
Connection of circuit:
A is connected to D.
B is connected to C.
As a result, the LS pressure transmitted from
each control valve spool to LS circuit ports A,
D, B, and C is transmitted to all the pressure
compensation valves and other hydraulic
equipment.
10-212 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MERGE-DIVIDER VALVE
2. When oils from pumps are divided

(When pilot pressure PS is turned ON)
When pilot pressure PS is turned ON, main
spool (1) is pressed to the right by the PS
pressure and ports E and F are disconnect-
ed.
Accordingly, oils discharged from the 2
pumps are sent to the set control valves re-
spectively.
Pressure PP1: Blade right tilt valve
Pressure PP2: Blade left tilt valve
Similarly, LS spool (3) is pressed to the right
by the PS pressure and the connection of the
LS circuit changes as follows.
Connection of circuit:
B is connected D.
The other ports are disconnected.
As a result, the pressures in LS circuit ports
A, B, C, and D are transmitted to the set con-
trol valves respectively.
D475A-5 10-213
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SELF-REDUCING PRESSURE VALVE
SELF-REDUCING PRESSURE VALVE
Function Operation
The self-reducing pressure valve lowers the dis- 1. When engine is stopped
charge pressure of the main pump and supplies Poppet (11) is pressed by spring (12) against
it as the control pressure for the solenoid valves, the seat and the passage between port PR
PPC valves, etc. and TS is closed.
Valve (14) is pressed to the left by spring
(13) and the passage between port P2 and
PR is open.
Valve (7) is pressed to the left by spring (8)
and the passage between ports P2 and A2 is
closed.
10-214 D475A-5
2. When in neutral and when load pressure P2 is low

(When load pressure A2 is lower than self-reducing pressure valve output pressure PR)
Operation
Valve (7) is pressed by spring (8) and PR pres- Accordingly, differential pressure is generated
sure (which is 0 MPa {0 kg/cm2} while the engine over orifice "a" in spool (14), and spool (14)
is stopped) to close the passage between ports moves in the direction to close the passage be-
P2 and A2. If hydraulic oil flows in through port tween ports P2 and PR. The P2 pressure is low-
P2, however, (d area x pressure P2) = force of ered and controlled to a constant pressure (set
spring (8) + (d area x PR pressure), and they pressure) by the opening ratio of the passage at
are balanced. Then, the passage between ports this time and supplied as the PR pressure.
P2 and A2 is so adjusted that the P2 pressure
will be kept at a certain value higher than the PR
pressure.
If the PR pressure rises higher than the set level,
poppet (11) opens and the hydraulic oil flows
from port PR through orifice "a" in spool (14) and
opening of poppet (11) into seal drain port TS.
D475A-5 10-215
3. When load pressure P2 is high
Operation
If load pressure A2 is heightened and the pump
discharge amount is increased because of dig-
ging operation, etc., the P2 pressure rises and
(d area x P2 pressure) > force of spring (8) +
(d area x PR pressure), then valve (7) moves to
the right stroke end.
As a result, the opening ratio of the passage be-
tween ports P2 and A2 is increased and the pas-
sage resistance is reduced. Consequently, the
loss of the engine horsepower is reduced.
If the PR pressure rises higher than the set level,
poppet (11) opens and the hydraulic oil flows
from port PR through orifice "a" in spool (14) and
opening of poppet (11) into seal drain port TS.
Accordingly, differential pressure is generated
over orifice "a" in spool (14) and spool (14)
moves in the direction to close the passage be-
tween ports P2 and PR. The P2 pressure is low-
ered and controlled to a constant pressure (set
pressure) by the opening ratio of the passage at
this time and supplied as the PR pressure.
10-216 D475A-5
4. When abnormally high pressure is generated
Operation
If the PR pressure of the self-reducing pressure
valve is raised abnormally, ball (16) separates
from the seat against the force of spring (15). As
a result, the hydraulic oil flows from output port
PR to TS and the PR pressure lowers. Accord-
ingly, the devices receiving the oil pressure (PPC
valves, solenoid valves, etc.) are protected from
abnormally high pressure.
D475A-5 10-217
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT SOLENOID VALVE
PILOT SOLENOID VALVE
PPB : Rear pitch solenoid

PPD : Forward pitch solenoid
TLL : Left tilt limit solenoid
TLR : Right tilt limit solenoid
PTH : Pitch changeover solenoid
DUL : Dual changeover solenoid
PPV : Pitch priority solenoid
MFD : Merge-divider solenoid
10-218 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT SOLENOID VALVE
The operation of the pilot solenoid valve is shown in the following table.
Solenoid drive table (Dual tilt specification)

PPB PPD TLL TLR PTH DUL PPV MFD
Raise
Lift
Lower
Left tilt
Single tilt
Right tilt
Left tilt q q
Blade
Left tilt limit q q q
Dual tilt
Right tilt q q
Right tilt limit q q q
Rear pitch q q
Pitch
Forward pitch q q
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
Solenoid drive table (Superdozer specification)

PPB PPD TLL TLR PTH DUL PPV MFD
Raise
Lift
Lower
Left tilt
Left tilt limit q

Blade Single tilt
Right tilt
Right tilt limit q

Rear pitch q q q q
Pitch
Forward pitch q q q q
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
D475A-5 10-219
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Pressure valve 7. Hydraulic filter element

2. Cover 8. Spring
3. Sight gauge 9. Suction valve
4. Cover 10. Strainer
5. Hydraulic tank 11. Drain plug
6. Oil filler cap 12. Drain valve
10-220 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
Specified value Specified value

Tank capacity (l) 310 Cracking pressure 150 30
(kPa {kg/cm2}) {1.53 0.3}
Hydraulic High (l) 210
Level inside Hydraulic Mesh size ( m) 30/8
tank Center (l) 170
tank filter
Filtering area (cm2) 17,600
Low (l) 140
Filtering oil flow (l/min) 703
Cracking pressure 38.2 6.9
(kPa {kg/cm2}) {0.39 0.07} Mesh size ( m) 105
Breather Strainer
2
cap Vacuum valve actuating Filtering area (cm ) 3,600
0 0.49
pressure
{0 0.005 }
(kPa {kg/cm2})
D475A-5 10-221
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
For PPC valve
1. Glass plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas: Nitrogen
Gas volume:300 cc
Max. actuation pressure:3.1 MPa {32 kg/cm2}
Min. actuation pressure:1.2 MPa {12 kg/cm2}
Function
The accumulator is installed between the pres-
sure reducing valve and the PPC valve. Even if
the engine is stopped with the work equipment
still raised, the pressure of the nitrogen gas com-
pressed inside the accumulator sends the pilot
pressure to the main control valve to actuate it
and enable the work equipment to move down
under its own weight.
Operation
After the engine is stopped, when the PPC valve
is at neutral, chamber A inside the bladder is
compressed by the oil pressure in chamber B.
When the PPC valve is operated, the oil pressure
in chamber B goes below 2.9 MPa {30 kg/cm2},
and the pressure of the nitrogen gas in chamber
A expands the bladder, so the oil in chamber B
acts as the pilot pressure and actuates the main
control valve.
10-222 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

BLADE LIFT CYLINDER
BLADE TILT CYLINDER, SUPERDOZER PITCH CYLINDER
RIPPER LIFT CYLINDER, RIPPER TILT CYLINDER
PIN PULLER CYLINDER
10-224 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
Unit: mm

size Shaft Hole clearance limit
0.036 +0.261 0.083

Blade lift 110 0.65
0.090 +0.047 0.351
0.043 +0.263 0.090
Clearance Blade tilt 140 0.67
0.106 +0.047 0.369
1 between piston
rod and bushing 0.036 +0.263 0.084
Ripper lift 120 0.65
0.090 +0.048 0.353
0.043 +0.263 0.090
Ripper tilt 140 0.67
0.106 +0.047 0.369
0.065 +0.133 0.072
Pin puller 30 0.55
0.117 +0.007 0.250
+0.5
Blade lift 65 1.0
+0.2
0.300 +0.100 0.200
Blade tilt 90 1.0
Clearance 0.200 +0.013 0.400
between piston
+0.207
2 rod support Ripper lift 110 1.0 Replace
+0.120
shaft and bush-
ing +0.207
Ripper tilt 110 1.0
+0.120
Ball 0.100
Pin puller
29 0.200
Clearance
between cylin-
0.145
3 der support Blade lift 145
0.245
shaft bushing
and yoke
+0.457
Blade tilt 90 1.0
Clearance +0.370
between cylin-
+0.207
4 der bottom sup- Ripper lift 110 1.0
+0.120
port shaft and
bushing +0.195
Ripper tilt 110 1.0
+0.122
Clearancebetween cylinder
13 26 +0.1
bottom support shaft and boss
D475A-5 10-225
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PISTON VALVE
PISTON VALVE
For blade lift cylinder
Outline
The piston valve is installed to the piston of the
blade lift cylinder. When the piston moves to the
stroke end, the piston valve relieves the oil sent
from the work equipment pump to lower the oil
pressure applied to the piston.
The piston valve also relieves the oil before the
piston reaches the bottom or head of the cylin-
der to reduce the impact made at the stroke end
and lower the surge pressure generated by the
impact.
Operation
1. When piston valve is "closed"
The oil from the work equipment pump acts on
piston (2) and piston valve (3). Then, piston
valve (3) is pushed to the right to seal the
tapered part of piston valve seat (4). As a result,
the oil pressure in the cylinder rises to move pis-
ton (2) to the right.
2. When piston valve is "open"

The end of valve (6) touches the cylinder bottom
before piston rod (1) reaches the stroke end,
and then valve (6) and piston valve (3) do not
move any more and only piston (2) continues
moving.
At this time, the oil on the cylinder head side
which has been stopped by piston valve (3) is
relieved through piston valve seats (4) and (5),
thus the oil pressure in the cylinder does not rise
any more.
10-226 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD QUICK DROP VALVE
QUICK DROP VALVE

For blade lift cylinder
Outline
The quick drop valve is installed to each of the right
and left blade lift cylinders. It increases the lowering
speed of the blade and prevents a vacuum on the
cylinder bottom side during the lowering stroke and
shortens the time lag in starting digging. The blade
lowering speed is almost determined by the pump
discharge amount. It can be heightened, however,
by the quick drop valve.
1. Valve body 3. Check valve

2. Spool 4. Spring
Operation
1. Start of lowering blade
If the blade control lever is set in the LOWER
position, the oil from the control valve flows
through port A to the cylinder bottom side and
pushes the piston.
The oil on the cylinder head side is pushed out
by the piston into port B, and then flows through
port C and control valve to the hydraulic tank.
2. While lowering blade

The oil pushed out of the cylinder head side
flows through port B to port C.
At this time, a pressure difference is made
between before and after orifice "a".
If the pressure difference becomes larger than
the tension of spring (4), it compresses the
spring and moves spool (2) and check valve (3)
to the right.
Then, ports B and A are connected and a part of
the oil which has been flowing from the head
side to port C flows in port A on the bottom side
and merges with the oil from the control valve
and flows into the bottom side.
Accordingly, the blade lowering speed is
increased by the quantity of the oil flowing into
the cylinder bottom side and a vacuum on the
bottom side is prevented.
10-228 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD QUICK DROP VALVE
Unit: mm

Clearance between spool size Shaft Hole clearance limit
1
and valve body
0.011 +0.010 0.011
38.0 0.03
0.016 +0.016 0.026
Standard size Repair limit Replace
Free Installed Installed Free Installed

2 Valve spring length length load length load
136.3 N 122.6 N
75.2 55.9 67.7
{13.9 kg} {12.5 kg}
D475A-5 10-229
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE CONTROL KNOB
BLADE CONTROL KNOB

Dual tilt specification
1. Switch (dual-single selector switch) If switch (2) is pressed and the lever is operated,
2. Switch (pitch) the blade is pitched. If the lever is tilted to the left,
3. Cover the blade is pitched back. If the former is tilted to
4. Connector (male) the right, the latter is pitched forward.
5. Connector (female) If switch (1) is set to the DUAL position and the
lever is operated, blade carries out dual tilt oper-
Outline ation. If the lever is tilted to the left, the blade car-
If the blade control knob is tilted forward, back- ries out left dual tilt operation. If the lever is tilted
ward, to the right, or to the left, the blade is to the right, the blade carries out right dual tilt op-
raised, lowered, tilted to the right, or tilted to the eration.
left. If switch (1) is set to the DUAL position and If switch (1) is set in either DUAL or SINGLE po-
the lever is tilted to the right or left, dual tilt oper- sition and the lever is tilted to the right or left
ation is carried out. If the lever is tilted to the right while switch (2) is pressed and held, the blade is
or left while (2) is pressed and held, pitching op- pitched.
eration is carried out.
10-230 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE CONTROL KNOB
Superdozer specification
1. Forward pitch switch Outline

2. Rear pitch switch The blade is raised and lowered by leaning the
3. Cover blade control knob forward and backward.
4. Connector (male) If switch (1) is pressed, the blade is pitched for-
5. Connector (female) ward. If switch (2) is pressed, the blade is
pitched back.
D475A-5 10-231
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PITCH AND DUAL SOLENOID VALVE
PITCH AND DUAL SOLENOID VALVE
1. Connector Outline
2. Solenoid (a) The pitch and dual solenoid valve is installed be-
3. Valve tween the PPC valve and main control valve and
4. Solenoid (b) used to select the PPC pilot pressure.
5. Manual push pin Operation of the pitch switch of the blade control
lever (or the rear pitch switch or forward pitch
A: Port A switch of the superdozer specification), pilot
B: Port B pressure can be applied so the right and left pitch
P: Port P cylinders will move similarly and the tilt operation
T: Port T can be changed to the pitch operation.
If the dual tilt specification is installed and the
toggle switch of the blade control lever is set in
the "dual" position, the pilot pressure is applied to
both right and left tilt cylinder spools to change
the single tilt operation to the dual tilt operation.
The pitch and dual tilt solenoid valve is operated
by the controller.
10-232 D475A-5
PIN-PULLER HYDRAULIC CIRCUIT
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRAWING
PIN-PULLER HYDRAULIC CIRCUIT DRAWING
1. Power train oil tank 8. Pin-puller cylinder

2. Oil strainer 9. Steering case
3. Power train pump 10. Scavenging pump
4. Oil filter
5. Main relief valve A: To transmission lubrication circuit
(Set pressure: 2.45 MPa {25 kg/cm2}) B: To torque converter circuit
6. Steering control valve C: To transmission valve circuit and torque converter
7. Pin-puller solenoid valve lock-up circuit
D475A-5 10-233
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PIN-PULLER SOLENOID VALVE
PIN-PULLER SOLENOID VALVE
1. Plug
2. Spring
3. Spring retainer
4. Valve body
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
A. To pin-puller cylinder head

B. From power train pump
C. To pin-puller cylinder bottom
D. To steering case
10-234 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PIN-PULLER SOLENOID VALVE
Operation
1. Pin-puller switch at PUSH IN position
When the pin-puller switch is turned to the
PUSH IN position, no current flows to solenoid
(9) and it is deactivated.
When this happens, spool (5) opens ports A and
B and ports C and D, and the oil from the power
train pump flows from port A to port B and
enters the bottom of pin-puller cylinder (10).
The oil entering the bottom end of the cylinder
increases the hydraulic pressure in the circuit
and extends the cylinder. Shank mounting pin
(11) is pushed into shank (13).
2. Pin-puller switch at PULL OUT position

When the pin-puller switch is turned to the PULL
OUT position, current flows to solenoid (9) and it
is excited.
When this happens, the solenoid pushes out
push pin (8), and spool (5) moves to the left in
the direction of the arrow.
Ports A and B and ports C and D close, and
ports A and C and ports B and D open.The oil
from the power train pump flows from port A to
port C and enters the head of pin-puller cylinder
(10).
The oil entering the head end of the cylinder
increases the hydraulic pressure in the circuit
and retracts the cylinder. Shank mounting pin
(11) is pulled out of shank (13).
D475A-5 10-235
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CYLINDER STAY
CYLINDER STAY
Unit: mm

Clearance between cylinder size Shaft Hole clearance limit
1
yoke and bushing
0.050 +0.167 0.145
210 0.5
0.122 +0.005 0.289
Replace
Clearance between cylinder 0.043 +0.192 0.172
2 160 0.5
yoke and bushing 0.106 +0.129 0.298
Clearance between lift cylinder 0.145 +0.040 0.145
3 145 0.5
supporting shaft and bushing 0.245 +0.016 0.285
10-236 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BLADE
BLADE
FULL U-DOZER, SEMI U-DOZER, SUPERDOZER
10-238 D475A-5
Unit: mm

Clearance between brace pin size Shaft Hole clearance limit
1
and brace
0.2 +0.3
90 0.3 0.6 2
0.3 +0.1
Clearance between brace pin 0.2 +0.3 Replace
2 90 0.3 0.6 2
and bracket 0.3 +0.1
Clearance between brace pin 0.3 +0.1
3 90 0.3 0.5 1
and bracket 0.4 +0.6
Clearance between brace pin 0.3 +0.1
4 90 0.3 0.5 1
and bushing 0.4 +0.6
Clearance between center
0.2 +0.3 Adjust shim
5 brace and cap spherical sur- 200 0.2 0.6 1
0.3 +0.6 or replace
face
Clearance between joint and 0.2 +1.5
6 240 1.2 1.9 3
bracket 0.4 +1.0
Clearance between frame pin 0.3 +0.3
7 120 0.3 0.8 3
and joint 0.5 +0.6
Clearance between frame pin 0.3 +0.207 0.420
8 120 2
and bracket 0.5 +0.120 0.707
Clearance between straight +0.206 0.014 0.152
9 185
frame joint bushings +0.166 0.060 0.266
Clearance between trunnion 0.5 +1.0
10 250 0.5 2.0 8
and cap spherical surface 1.0 +0.6
Clearance between joint and 0.2 +0.3
11 240 0.3 0.7 3 Replace
bracket 0.4 +0.1
Clearance between blade pin 0.3 +0.3
12 120 0.3 0.8 3
and joint 0.5 +0.6
Clearance between blade pin 0.3 +0.208 0.418
13 120 2
and bracket 0.5 +0.118 0.708
Clearance between center link 0.043 +0.225 0.149
14 145 2
pin and blade bracket 0.108 +0.106 0.333
Clearance between center link 0.043 +0.225 0.149
15 145 2
pin and center link 0.108 +0.106 0.333
Clearance between center link 0.2 +0.3
16 550 0.2 1.1 2
and blade bracket 0.8 +0.6
Clearance between center
0.2 +0.3 Adjust shim
17 brace spherical surface and 200 0.2 0.6 1
0.3 +0.6 or replace
cap
Clearance between lift cylinder 0.3 +0.5
18 65 0.5 1.0 2
head pin and cylinder 0.5 +0.2
Clearance between lift cylinder 0.3 +0.3
19 65 0.3 0.8 2
head pin and cross joint 0.5 +0.6
Replace
Clearance between bracket 0.3 +0.3
20 65 0.3 0.8 2
and lateral pin 0.5 +0.6
Clearance between cross joint 0.3 +0.5
21 65 0.5 1.0 2
and lateral pin 0.5 +0.2
D475A-5 10-239
CUTTING EDGE, END BIT
Unit: mm

1 Height of end bit outside
510 383
Replace
2 Width of end bit 720 635
3 Height of end bit inside 393 330
Replace or
4 Height of cutting edge 405 351 (240 after turned)
turn
10-240 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RIPPER EQUIPMENT
RIPPER EQUIPMENT
VARIABLE GIANT RIPPER
10-242 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RIPPER EQUIPMENT
Unit: mm

Clearance between bushing size clearance limit
Shaft Hole
1 and bracket and arm mount
pin 0.043 +0.193 0.093
140 1.5
0.106 +0.050 0.299
Clearance between bushing 0.043 +0.500 0.343
2 140 1.5
and beam and arm mount pin 0.106 +0.300 0.606
Clearance between cylinder 0.036 +0.289 0.159 Replace
3 110 1.5
mount pin and bushing 0.090 +0.123 0.379
Outside diameter of shank Standard size Tolerance Repair limit

4
mount pin 100 0.3
5 Wear of point
460 300
6 Wear of protector 224 184
D475A-5 10-243
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CAB MOUNT
CAB MOUNT
1. Support Outline
2. Damper mount (front) Viscous mounts are installed at two places at the
3. Damper mount (rear) front and two places at the rear to secure the
floor frame and cab.
An oil-filled damper mount is used to absorb the
vibration.
10-244 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CAB
CAB
CAB ASSEMBLY
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D475A-5 10-245
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CAB
ROPS GUARD
1. ROPS guard
10-246 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
10-248 D475A-5
(2)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
1. Condenser 10. Hot water return piping

2. Air conditioner compressor 11. Valve (hot water inlet)
3. Refrigerant piping 12. Air conditioner unit
4. Window defroster 13. Additional blower motor
5. Side defroster
6. Vent A. Fresh air
7. Hot water pick-up piping B. Recirculated air
8. Valve (hot water outlet) C. Hot air/cold air
9. Receiver tank
D475A-5 10-249
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Battery relay (Right) Outline

2. Steering controller Engine control is carried out in the following two
3. Battery (Right) systems.
4. Transmission controller 1. When the fuel control dial and decelerator
5. Engine controller pedal are operated, it controls the fuel injec-
6. Decelerator pedal tion pump with an electric signal.
7. Starting switch 2. When mode selection system is actuated.
8. Decelerator pedal potentiometer The throttle signal and fuel control dial sig-
9. Fuel control dial nal enter the machine controller, are pro-
10. Battery (left) cessed together with other data, and are
11. Battery relay (left) sent to the electronic engine throttle control-
12. Starting motor ler as the throttle command.
13. Fuel injection pump (left) The electronic engine throttle controller con-
(Electronic governor type) trols the fuel injection pump according to the
command.
A fuel injection pump with electronic governor is
employed. (For details, see ENGINE CONTROL
SYSTEM WITH ELECTRONIC ENGINE
THROTTLE CONTROLLER.)
10-250 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
Outline
The engine controller receives the manual sig-
nals of the 1st throttle, 2nd throttle and the 3rd
throttle signals which is the control signals from
the machine body, then selects the lower engine
speed and controls the fuel injection pump.
The 3rd throttle control signals contain the fol-
lowing.
1) High idling speed control
2) SSC (Shoe Slip Control)
3) Automatic deceleration (F3, R3, R2)
The steering controller selects the lowest engine

speed from information 1) and 2) and transmits it
as the 3rd throttle to the engine controller.
Information of the engine controller is commonly
used by all the controllers throughout the net-
work, for optimum control of the engine and ma-
chine body.
The automatic deceleration function sets the en-
gine speed to 1,000 rpm temporarily when the
travel direction is changed from F3, R3, or R2 (to
protect the transmission clutch).
D475A-5 10-251
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DECELERATION POTENTIOMETER
DECELERATION POTENTIOMETER
1. Connector Outline
2. Lever The deceleration potentiometer is installed to the
3. Body front lower part of the operators cab and con-
4. Potentiometer nected to the decelerator pedal by linkage.
5. Coupling
6. Shaft If the decelerator pedal is pressed, the throttle
7. Stopper potentiometer shaft rotates by the linkage and
the potentiometer resistance changes.
Constant voltage is applied between pins A and
C of the potentiometer and an electric signal is
sent through pin B to the engine controller
according to the position of the decelerator
pedal.
10-252 D475A-5
ENGINE CONTROL SYSTEM WITH ELEC-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRONIC ENGINE THROTTLE CONTROLLER
ENGINE CONTROL SYSTEM WITH ELECTRONIC ENGINE

THROTTLE CONTROLLER
SYSTEM DRAWING
Outline
A fuel injection pump with electronic governor is
used.
The engine controller receives the signals from
the sensor and switches, and transmits the con-
trol signal to the governor solenoid and pre-
stroke solenoid (proportional solenoid).
D475A-5 10-253
FUEL INJECTION PUMP WITH
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC GOVERNOR
FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR

STRUCTURAL DIAGRAM
1. Delivery valve Function

2. Plunger barrel After the governor actuation pressure is adjusted
3. Plunger by the hydraulic control valve in accordance with
4. Hydraulic piston the command from the engine controller, it acts
5. Hydraulic control valve (quantity adjustment) on the piston at the rear of the rack and moves
6. Hydraulic control valve the control rack to adjust the fuel injection
(injection timing adjustment) amount.
7. Gear pump The fuel injection timing is adjusted by changing
(as seen from rear, left: oil, right: fuel) the length of the injection pump plunger. The
8. Center bearing plunger is formed of two parts, and by sending
9. Cam shaft electronically controlled hydraulic pressure be-
10. Roller tween these two parts, the length is changed to
11. Tappet adjust the pre-stroke.
12. Pump housing The governor solenoid and pre-stroke solenoid
13. Tappet guide are proportional solenoids, they convert input
14. Spring nut current from the controller into propulsion. This
propulsion controls the spool of the hydraulic
control valves (two valves: one for the governor
and the other for the injection timing adjustment),
and converts the input current into hydraulic
power.
10-254 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
The monitor system monitors the machine condi- The monitor panel has the functions of displaying
tion with sensors installed to various parts of the data and selecting the SSC mode (with SSC).
machine, and quickly processes and displays ob- The CPU (Central Processing Unit) in it pro-
tained information on the monitor panel, to notify cesses, displays, and outputs the information.
the operator of machine condition. The display unit is LCD (Liquid Crystal Display)
The function of the monitor system is as follows. and the switches are seat switches.
1) Function which turns on the alarm when the
machine has a trouble on the monitor.
2) Function which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel level,
hydraulic oil level, etc.) on the gauge.
3) Function of displaying error codes.
4) Function of monitoring the current and volt-
age of the sensors and solenoids.
In the monitor panel, there are various mode se-

lector switches of the SSC (Shoe Slip Control),
which are used to operate the machine control
system (with SSC).
D475A-5 10-255
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
Processing in monitor panel (Common to all specifications)

Display of monitor panel
1. Contents and conditions of processing 2. Method 3. Flow of signals
1) Display of travel direction and gear speed. Transmission controller - Steering control-
F1, R3, etc. are notified by CAN according to informa- ler - Monitor panel
tion of transmission controller.
2) Display of engine speed in gauge number. CAN Engine speed sensor - Steering controller
The number of pulses the engine rotation is converted - Monitor panel
into a gauge number and notified to the monitor panel
by CAN.
3) Display of troubleshooting CAN Engine sensor/solenoid - Steering con-

When the machine has a trouble, the corresponding troller or transmission controller - Monitor
failure code is notified to the monitor panel by CAN. panel
Which one should be turned on, the buzzer or the cau-
tion lamp, is notified, too.
i) In normal state
User code
ii) In trouble history display mode
The service code (6-digit code) and the following Sensors and solenoids - Engine controller
items are displayed - Steering controller - Monitor panel
1. Time after first occurrence
2. Time after latest occurrence
3. Number of past occurrence
The monitor panel displays code on the hour meter sec-
tion.
Display of monitoring conditon

1) The communication conditions of each sensor, each CAN Each sensor - Steering controller or
solenoid, and CAN are displayed. transmission controller - Monitor panel
The item Nos. and device conditions are notified to the
monitor panel by CAN.
The monitor panel displays the items and each value Sensors - Engine controller - Steering
on its multi-information section. controller - Monitor panel
2) Each items is selected by using the cursor switches, Monitor panel - Controller - Monitor panel
selector switches, buzzer cancel switch, and shift UP/
DOWN switches.
Other items
1) Function selection mode (Displayed each time cancel CAN Steeging controller - Monitor panel
switch is turned to left)
i) Replacement periods of oil filter and oil are dis-
played.
ii) Engine speed, oil pressure in work equipment cir-
cuit, etc. are displayed.
iii) Failure codes related to electronic control are dis-
played.
iv) Brightness of display, etc. are adjusted.
2) Mode to change replacement periods of maintenance
mode
3) Mode to display failure codes related to the machine
such as overheating, abnormal coolant temperature, etc.
4) Mode to display service meter and information related
to load on machine
10-256 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR PANEL
MONITOR PANEL
Monitor portion
1. Engine coolant temperature gauge 14. Engine preheating pilot lamp

2. Power train oil temperature gauge 15. Maintenance caution lamp
3. Hydraulic oil temperature gauge 16. Warming lamp
4. Fuel gauge 17. Filter, oil change interval lamp
5. Radiator coolant level check lamp 18. Display panel A (Speed range, Engine speed)
6. Hydraulic oil level check lamp 19. Display panel B (Multi-information)
7. Engine oil level check lamp 20. Dual/single tilt selector display lamp
8. Charge level monitor 21. Lock-up mode switch
9. Engine oil pressure caution lamp 22. Economy mode selector switch
10. Engine coolant temperature caution lamp 23. Reverse slow mode selector switch
11. Power train oil temperature caution lamp 24. Shoe slip selection mode switch (with SSC)
12. Hydraulic oil temperature caution lamp 25. Rock selection mode selector switch (with SSC)
13. Air cleaner clogging caution lamp 26. Engine preheating pilot lamp
Outline 2. Start-up inspection

The monitor potion consists of a monitor that is- 1) After all lighting of Section 1 is terminated, if
sues an alarm when an error occurred in a vehi- there is an error in a start-up inspection
cle, a gauge that always displays the state of the item, the item flashes.
vehicle, and the service meter. 2) If the engine is started, the check items
The monitor portion installs a microcomputer before starting go off. (If the engine running
and processes and displays signals from each is judged by the signal (CAN) from the
sensor. engine controller.)
Besides, the items displayed on the monitor por- 3. Cautions
tion and gauge portion are listed in the table on Caution items are checked until the engine
the next page. stops after the engine starts.
If an error occurs, the error is displayed by flash-
Operation ing and the alarm lamp synchronously flashes.
1. When the power turns on (When the starting Further, if an emergency item flashes, the alarm
switch is ON) buzzer also sounds synchronously.
1) All items of the gauge and monitor portions a Flashing of the monitor and alarm lamp is
come on for three seconds. repeated. They come on and off for about 0.8
2) The alarm lamp comes on for two seconds. second.
a The flashing period of the monitor slightly
changes when atmospheric temperature is low
(below about 10C), but this case is not abnor-
mal.
D475A-5 10-257
Monitor panel display

Display
Symbol Display item Display range Display method
category
Displays when engine is
stopped and starting
switch is ON
Radiator coolant level Below low level
Display when normal: OFF
Display when abnormal:
Flashes
Check
When sensor is abnormal or when

Engine oil level
wiring harness is disconnected
ON
Hydraulic oil level Below low level
Displays when starting

Battery charge When charge is defective
switch is ON and engine is
Caution 1
SAP00522
running
When clogged: Flashes
Air clever clogging
Less than 6.37 kPa {650 mmH2O} CAUTION lamp flashes
Engine oil pressure Below 49.0kPa {0.5kg/cm2}
Radiator coolant level Below low level
When at highest level (108C or

Engine coolant tempera-
above) on engine coolant tempera-
ture
ture gauge
Displays when starting
switch is ON and engine is
running
Caution 2
When at highest level (130C or

Torque converter oil tem- Display when normal: OFF
above) on engine coolant tempera-
perature Display when abnormal:
ture gauge
Flashes
CAUTION lamp flashes
Alarm buzzer sounds
Hydraulic oil temperature 1053C or above
Hydraulic oil level Below low level
When replacement time of filter or oil

Maintenance
has been passed
10-258 D475A-5
Lights according to
required time
determined by engine con-
troller based.
Preheating When preheating It also lights at the time of
manual preheat by setting
starting switch at preheat
Pilot
position (turning it counter-

clockwise).
Display lights at the time

of operation.
Dual tilt At the time of operation
It goes off at the time of
non-operation.
Engine coolant tempera-

ture
Torque converter oil One place lights up to

temperature show applicable level
Gauges
Hydraulic oil temperature
All lamps light up below

Fuel level
applicable level
Multi information
Service meter Actuated when the engine

From 0 to 99999
(Hours meter) is rotating
D475A-5 10-259
Switch portion
1. Switch functions
a) ON-OFF switching in lock-up mode
b) Economy mode setting OFF, mode 1, mode 2
c) ON-OFF switching in reverse slow mode
d) ON-OFF switching in SSC mode
e) SSC mode level setting Mode 1 to 5
a), b), and c) are mounted for all specifications and d) and e) are mounted for the SSC specifications.
SSC specifications
Without SSC specifications
2. Initial Setup at key ON Economy Mode Function

The function the operator desires according to In a field, such as a rock-bed place where many
the situation of an operating place is selected shoe slips are generated, the following power is out-
and all functions shall be set to the OFF state. put in each mode so that the frequency of decelera-
tor operation can decrease.
Economy mode 1 o Set to about 90% of the full
power.
Economy mode 2 o Set to about 70% of the full
power.
REVERSE slow mode o Set to about 80% of the
full travel speed at reverse time.
10-260 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS
SENSORS
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine coolant temperature Resistance
Torque converter oil temperature Resistance
Hydraulic oil temperature Resistance
Radiator coolant level Contact ON OFF
Fuel level Resistance
Engine oil level Contact ON OFF
All cleaner clogging Contact ON OFF
Engine oil pressure sensor
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
D475A-5 10-261
Engine coolant temperature sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
Radiator coolant level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
10-262 D475A-5
Fuel level sensor
1. Connector Function
2. Float The fuel sensor is installed to the side face of the
3. Arm fuel tank. The float moves up and down accord-
4. Body ing to the fuel level. This movement of the float is
5. Spring transmitted by the arm and actuates a variable
6. Contact resistance. This sends a signal to the monitor
7. Spacer panel to indicate the remaining fuel level. When
the display on the monitor panel reaches a cer-
tain level, a warning lamp flashes.
D475A-5 10-263
Engine oil level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
Air cleaner clogging sensor
1. Boss 4. Wire
2. Switch 5. Connector
3. Conduit
10-264 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MODE SELECTION SYSTEM
MODE SELECTION SYSTEM

(SSC (Shoe Slip Control) System)
System diagram
Outline
The mode selection system automatically carries The lock-up control mode is the same as the con-
out engine control to match the operating mode ventional lock-up function. It cannot be selected
selected by the operator, and acts to reduce fuel in combination with the above modes.
consumption, extend the life of the track shoes,
and reduce the frequency of operation of the de-
celeration.
The engine control modes consist of the econo-
my mode control used when dozing, the SSC
(shoe slip control) used when ripping, and the re-
verse slow mode control, which can be used for
either operation.
D475A-5 10-265
Function of mode selection system

The system consists of the mode selection panel
(containing a microcomputer) to select working
condition, steering controller (containing a micro-
computer) to control the engine, engine control-
ler to receive the commands from the steering
controller and controls the fuel injection pump,
transmission controller to turn on and off the
lock-up system of the torque converter according
to the signals from the transmission output speed
sensor, and various sensors.
The function of each controller is explained
below.
Functions of steering controller and transmis-

sion controller
1. The steering controller calculates travel speed of
the ground from signals of the acceleration sen-
sor and inputs the transmission output speed
sensor signal to calculate the shoe speed, then
obtains the shoe slip rate.
2. If the engine speed sensor signal and transmis-
sion output speed sensor signal are input, the
steering controller calculates the traction force.
3. The steering controller calculates the optimum
engine speed from the results of 1 and 2 above,
mode set signal of the monitor panel, and speed
information from the transmission controller,
then sends it as the SSC command to the
engine controller.
4. The transmission controller sends lock-up signal
to the lock-up solenoid valve, judging from input
gear speed information from the transmission
controller.
a See "OPERATION OF TORQUE CON-
VERTER LOCK-UP CONTROL SYSTEM".
Function of engine controller

The engine controller controls the fuel injection
pump according to the lowest engine speed
(highest voltage) in the 3 signals of the manual
command input from the deceleration potentiom-
eter, manual signal of the throttle dial, and the
SSC command signal.
10-266 D475A-5
Operation of mode selection system

Work can be performed under the optimum conditions by simply or simultaneously selecting five modes in
accordance with the contents of work.
a When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the
engine output control is performed in accordance with the command having the smallest value among the
control command, throttle command, and decelerator command.
D475A-5 10-267
SENSORS
Transmission output shaft speed sensor
1. Magnet
2. Terminal
3. Case
4. Boots
5. Connector
10-268 D475A-5
Torque converter speed sensor
1. Connector
2. Flange
3. Sensor
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
The acceleration sensor is installed under the

front of the operators cab.
With the acceleration sensor, the position of the
ball inside the sensor changes according to the
acceleration.
Inside the sensor, there is a coil that detects the
position of the ball. This is amplified by the amp
and is sent as a voltage change to the SSC con-
troller.
The input and output characteristics of the sen-
sor are shown in the diagram on the right.
D475A-5 10-269
Pitch angle sensor
1. Body
2. Tube
3. Wire
4. Connector
The sensor is filled with electrolyte. If sensor

leans, the electrolyte surface slants. If electrolyte
surface slants, the contact area of two electrodes
installed in the sensor with electrolyte changes.
As a result, electrostatic capacity between the
two electrode changes. The change of electro-
static capacity is output as a change of voltage.
The input and output characteristics of the sen-
sor are shown in the figure at right.
10-270 D475A-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRICAL EQUIPMENT
ELECTRICAL EQUIPMENT
Relay box
D475A-5 10-271
Operation of lamp system
Lamp system circuit diagram
10-272 D475A-5
Preheating (Electrical intake air heater) control
Preheating circuit
D475A-5 10-273
STEERING ELECTRONIC CON-
STEERING ELECTRONIC CONTROL SYSTEM
1. Monitor panel (Multi information) 6. Steering control valve

2. Auto shift down switch 7. Transmission output shaft speed sensor
3. Engine controller 8. Transmission control valve
4. Transmission controller 9. Engine speed sensor
5. Steering controller
10-274 D475A-5
STEERING ELECTRONIC CON-
Shift Mode Function

1. Function
If you shift the lever to the forward or reverse,
the gear speed selected from the shift mode is
turned on.
2. Type of Modes
1) F1-R1 (Manual mode)
2) F1-R2 (Shift mode 1)
3) F2-R2 (Shift mode 2)
3. Selecting method
Shift the PCCS lever to "N".
Select the shift mode using UP or DOWN switch.
Up switch ON Up switch ON
Manual mode Shift mode 1 Shift mode 2
Down switch ON Down switch ON
4. Display
The selected shift mode is displayed on the
monitor panel.
Auto-shift-down function
1. Function
If the load is increased while the machine is trav-
eling or working at the 2nd or 3rd gear speed,
the gear speed is shifted down automatically.
1) The drawbar pull (load on the machine) is
calculated from the engine speed, travel
speed, and throttle information from the
steering controller, and the gear speed is
shifted down automatically according to the
load and travel speed.
2) Once the gear speed is automatically shifted
down, it is not automatically shifted up to the
former position. (Gear speed can be shifted
up with the manual switch.)
3) This function is applicable to both forward
and reverse travels.
2. How to use
Turn the auto-shift-down switch (1) ON.
D475A-5 10-275
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VHMS CONTROLLER
VHMS CONTROLLER
10-276 D475A-5
Input and output signals

CN1 [CN 1] CN2 [CN2 A, B]
Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
CN1-1 NC Input CN2-A1 Rack sensor (Right) Input
CN1-2 Sensor power supply (24V) Output CN2-A2 NC Input
CN1-3 Sensor power supply (12V) Output CN2-A3 F engine oil temperature Input
CN1-4 Sensor power supply (5V) Output CN2-A4 NC Input
CN1-5 Sensor power supply (5V) Output CN2-A5 Exhaust temperature (Right) Input
Power supply (Constant power supply) CN2-A6 NC Input
CN1-6 Input
(24V)
CN2-A7 Exhaust temperature (Left) Input
Power supply (Constant power supply)
CN1-7 Input CN2-A8 NC Input
(24V)
CN2-A9 NC Input
CN1-8 BR power supply (24V) Input
CN2-A10 Atmospheric temperature sensor Input
CN1-9 BR power supply (24V) Input
CN2-A11 NC Input
CN1-10 NC Input
CN2-A12 Sensor GND Input
CN1-11 GND Input
CN2-A13 Sensor GND Input
CN1-12 GND Input
CN2-A14 NC Input
CN1-13 NC
CN2-A15 Transmission, main Input
CN1-14 NC Input
CN2-A16 Oil pressure sensor Input
CN1-15 NC
CN2-A17 WAKE UP (Low)
CN1-16 NC
CN2-A18 Blow-by pressure Input
CN1-17 Start signal Input
CN2-B1 NC
CN1-18 NC
CN2-B2 NC Input
CN1-19 GND Input
CN2-B3 NC
CN1-20 GND Input
CN2-B4 NC Input
CN2-B5 NC Input
CN2-B6 NC
CN2-B7 NC Input
CN2-B8 NC
CN2-B9 GND Input
CN2-B10 NC Input
CN2-B11 NC Input
CN2-B12 CONNECTOR (GND) Input
D475A-5 10-277
CN3 [CN 3 A, B] CN4 [CN 4 A, B]

Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
CN3-A1 CAB OUT D/L Sw Input CN4-A1 NC
CN3-A2 NC Input CN4-A2 NC
CN3-A3 NC Input Input/
CN4-A3 NC
Output
CN3-A4 NC Output
Input/
Model selection CN4-A4 CAN (1) H (KOM-NET/c)
CN3-A5 Input Output
(See ORB connection)
CN4-A5 NC Input
CN3-A6 NC Input
Input/
CN3-A7 Engine speed Input CN4-A6 NC
Output
Input/
CN3-A8 S-NET (+) CN4-A7 NC
Output
CN4-A8 NC
CN3-A9 CONNECTOR SEL2 (OPEN) Input
CN4-A9 GND Input
CN3-A10 NC Input
CN4-A10 RS232C RX0 (PC Tool) Input
CN3-A11 NC Input
CN4-A11 RS232C TX0 (PC Tool) Output
CN3-A12 NC Input
Input/
CN3-A13 NC Input CN4-A12 CAN (1) L (KOM-NET/c)
Output
CN3-A14 NC Input
CN4-A13 CAN (1) SH (KOM-NET/c) Input
CN3-A15 NC Input
Input/
CN4-A14 NC
CN3-A16 NC Input Output
CN3-A17 GND Input CN4-B1 NC
Input/ CN4-B2 NC
CN3-A18 S-NET (+)
Output
CN4-B3 RS232C SH Input
CN3-B1 NC Input
CN4-B4 RS232C TX1 (Orbcom) Output
CN3-B2 NC
CN4-B5 NC
CN3-B3 NC
CN4-B6 NC
CN3-B4 NC
CN4-B7 NC
CN3-B5 NC
CN4-B8 NC
CN3-B6 Snap shot Sw data clear
CN4-B9 GND Input
CN3-B7 NC
CN4-B10 RS232C RX1 (Orbcom) Input
CN3-B8 NC
CN3-B9 NC
CN3-B10 NC
CN3-B11 NC
CN3-B12 NC Input
10-278 D475A-5
SENSORS
Engine oil temperature sensor
Specifications
1. Type of sensor: Thermistor
2. Measurement range: 40 130C
80 130C (Assured
accuracy: 2C)
3. Max. power consumption: 0.5 mW
4. Pressure resistance: 4.9 MPa {50 kg/cm2}
5. Using temperature: 30C to +140C
6. Performance table
Temper- Resis- Temper- Resis- Temper- Resis-
ature tance ature tance ature tance
(C) (kz) (C) (kz) (C) (kz)
30 35.27 80 6.571 110 2.887
40 24.28 85 5.682 115 2.544
50 17.05 90 4.931 120 2.248
60 12.20 95 4.293 125 1.992
70 8.884 100 3.750 130 1.769
a: Heat sensing part of sensor Outside diameter

of mounting part: R1/4
Function
The engine oil temperature sensor is installed to the
engine oil filter. It inputs the change of the tempera-
ture as the change of the thermistor resistance to
the VHMS controller.
D475A-5 10-279
Exhaust temperature sensor/amplifier

Specifications
1. Rated voltage: DC 24 V
2. Sensed temperature range:100 1,000C
300 800C (Assured
accuracy: 10C)
3. Output voltage characteristics
( A m bi en t te mp er a -
ture: 20C) --- Refer-
ence values
Sensed
50 100 400 700 800
temperature (C)
Output voltage
1.191 1.397 2.626 3.899 4.316
(V)
4. Operating temperature range: 40 to +110C

5. Current consumption: Max. 30 mA
a. Heat sensing part of sensor Outside diameter

of mounting part: R1/8
b. Amplifier
c. Connector (Power supply side)
d. Connector (Sensor side)
Function
The exhaust temperature sensor/amplifier is a ther-
mocouple-type temperature sensor, which is
installed to the turbocharger inlet. It outputs the
exhaust temperature data to the VHMS controller.
Atmospheric temperature sensor

Specifications
1. Power consumption: Max. 0.5 mW

2. Pressure resistance: 0.98 MPa
{10 kg/cm2}
3. Sensed temperature range (ambient):
30 to +120C
4. Storage temperature range: 50 to +140C
5. Performance table
Sensed
temperature 20 10 0 10 20 50
(C)
Resistance
30.32 18.58 11.74 7.623 5.077 1.712
(kz)
a. Heat sensing part of sensor Outside diameter

of mounting part: 16 x 1.5
Function
The atmospheric temperature sensor inputs the
change of the atmospheric temperature as the
change of the thermistor resistance to the VHMS
controller.
10-280 D475A-5
Engine blow-by pressure sensor
1. Sensor Specifications and function

2. Connector Pressure range: 0 20 kPa
3. Atmospheric pressure intake tube {0 2,040 mmH2O}
Allowable pressure: 20 to 100 kPa
A. GND (Black) {2,040 to 10,200 mmH2O}
B. Power supply (Red) Source voltage: 5 0.25 V
C. Output (White) Output characteristics:See graph.
The blow-by pressure sensor is a fine relative
pressure sensor which measures the difference
between the pressure in the crankcase and the
atmospheric pressure.
The pressure in the crankcase is applied to the
tip side of the sensor and the atmospheric pres-
sure is applied to the wiring harness side.
Transmission main oil pressure sensor
1. Sensor
2. Connector
D475A-5 10-281
COMMUNICATION (ORB: ORB-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COMM) CONTROLLER/ANTENNA
COMMUNICATION (ORB: ORBCOMM) CONTROLLER/ANTENNA

Controller
Specifications
1. Source voltage: DC 12 V DC 30 V
2. Size: W306 x D152 x H52 (mm)
Connectors
CN1A (ORB-A): AMP070-14
CN1B (ORB-B): AMP070-10
CN2: Communication antenna cable connector
Antenna
Specifications
1. Type: Helical whip antenna (1)
2. Impedance: 50 z
3. Input terminal: N-P type
4. Length: 165 20 mm
a. Communication antenna mounting part
Function
The communication controller transmits the data col-
lected and stored by the VHMS controller to the
computer center via the communication satellite.
10-282 D475A-5
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE ................................................................................................ 20- 2

STANDARD VALUE TABLE FOR CHASSIS.............................................................................................. 20- 3
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING ................................................................................................................................ 20-301
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
D475A-5 20-1
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Engine SDA12V140-1
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idling 2,100 2,200 2,100 2,200
Speed Low idling rpm 600 700 600 700
Rated speed 2,000 2,000
Intake air pressure
At rated output kPa {mmHg} Min. 120 {900} Min. 107 {800}
(Boost pressure)
Whole speed range
Exhaust temperature C Max. 650 Max. 750
(Outside air temperature: 20 C)
At sudden acceleration Max. 4.0 Max. 7.0
Exhaust gas color Bosch index
At high idling Max. 1.0 Max. 2.5
Valve clearance Intake valve 0.43
mm
(At normal temperature) Exhaust valve 0.80
Compression pressure
Oil temperature: 40 60 C MPa {kg/cm2} Min. 2.4 {24.6} Min. 2.84 {29}
(Engine oil: SAE15W-40
(Engine speed) (rpm) (200 250) (200 250)
or SAE30)
Blow-by pressure Coolant temperature:
(Engine oil: SAE15W-40 Within operating range kPa {mmH2O} Max. 1.47 {150} Max. 2.94 {300}
or SAE30) At rated output
Coolant temperature:
Within operating range
At high idling
Oil pressure
SAE30 or SAE15W-40 oil 0.39 0.54 {4.0 5.5} Min. 0.25 {2.5}
(oil temperature: 80 C or MPa {kg/cm2}
SAE10W oil 0.29 0.44 {3.0 4.5} Min. 0.20 {2.0}
more)
At low idling
SAE30 or SAE15W-40 oil Min. 0.12 {1.2} Min. 0.10 {1.0}
SAE10W oil Min. 0.10 {1.0} Min. 0.08 {0.8}
Oil temperature Whole speed range (In oil pan) C 80 110 Max. 120
Fuel injection timing Before top dead center 91
Deflection under finger pressure
Tension of alternator belt mm 18 22
of 58.8 N {6 kg}
Tension of air conditioner Deflection under finger pressure
mm 18 22
compressor belt of 58.8 N {6 kg}
20-2 D475A-5
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Category
Standard value
Service limit
Measurement item Measurement conditions Unit for new
value
machine
Deceleration low idling Engine coolant temperature: Within operat-
ing range 900 50 900 50
speed
Power train oil temperature: Within operat-
Deceleration high idling ing range
Hydraulic oil temperature: Within operating 2,000 50 2,000 50
speed
Engine speed
range
Torque converter stall Deceleration low idling: Press decelerator
pedal rpm 1,680 50 Min. 1,590
speed
Deceleration high idling: Set forward-
reverse lever in neutral + Set work equip-
Torque converter stall + ment control lever in neutral
Torque converter stall: Stall at F3
Work equipment relief Torque converter stall + Work equipment 1,530 50 Min. 1,420
speed 1 relief speed 1: Stall at F3 + Raise ripper or
relieve pitch back circuit
Decelerator pedal Stop engine mm 44 4 44 4

Press pedal to center
Forward,
Neutral Forward 30 10 30 10
reverse
Neutral Reverse 30 10 30 10
PCCS Stop engine mm 40 10 40 10
lever Set lever to center Neutral Left
Control lever and pedal stroke
Steering (Play: Max. 3) (Play: Max. 3)

40 10 40 10
Neutral Right
(Play: Max. 3) (Play: Max. 3)
Full stroke 78 8 78 8
Run engine at low idling
Brake pedal Press pedal to center Stroke to oil pres- mm
58 10 58 10
sure of 0
Run engine at low idling Neutral
72 10 72 10
Hydraulic oil tempera- Raise/Float
Blade control lever ture: mm
Within operating range Neutral
56 4 56 4
Set lever to center Left/Right tilt
Run engine at low idling Neutral
85 10 85 10
Hydraulic oil tempera- Raise/Lower
Ripper control lever ture: mm
Within operating range Neutral
85 10 85 10
Set lever to center Tilt in/out
49 9.8 49 9.8
Control lever and pedal operating effort
Decelerator pedal Stop engine N{kg}

Press pedal to center {5.0 1.0} {5.0 1.0}
Neutral 56.9 6.9 56.9 6.9
Forward, Forward, Reverse {5.8 0.7} {5.8 0.7}
reverse Forward, Reverse 51 6.9 51 6.9
Neutral {5.2 0.7} {5.2 0.7}
PCCS Stop engine
N{kg}
lever Set lever to center 25.5 4.9 25.5 4.9
Neutral Left
{2.6 0.5} {2.6 0.5}
Steering
28.4 4.9 28.4 4.9
Neutral Right
{2.9 0.5} {2.9 0.5}
D475A-5 20-3
(1)

Control lever and pedal operating effort Category
Standard value Service limit

Measurement item Measurement conditions Unit
for new machine value
Run engine at low idling 490.3 49.0 490.3 49.0

Brake pedal Press pedal to center N{kg}
{50.0 5.0} {50.0 5.0}
28.4 5.9 28.4 5.9
Neutral Raise
Run engine at low idling {2.9 0.6} {2.9 0.6}
Hydraulic oil tempera- 82.4 9.8 82.4 9.8
Blade control lever ture: Neutral Float N{kg}
Within operating range {8.4 1.0} {8.4 1.0}
Set lever to center Neutral 27.4 4.9 27.4 4.9
Left/Right tilt {2.8 0.5} {2.8 0.5}
Run engine at low idling Neutral 21.6 4.9 21.6 4.9
Hydraulic oil tempera- Raise/Lower {2.2 0.5} {2.2 0.5}
Ripper control lever ture: N{kg}
Within operating range Neutral 20.6 4.9 20.6 4.9
Set lever to center Tilt in/out {2.1 0.5} {2.1 0.5}
Engine at low
Max. speed 400 30 Max. 350
idling
Hydraulic oil tempera- rpm
ture: Within operating Engine at high
Fan
Min. speed 980 50 Max. 880

range idling
Fan 100% mode
Engine at high MPa 15.2 2.5 15.2 2.5
Circuit oil pressure
idling {kg/cm2} {155 25} {155 25}
0.78 0.98 0.78 0.98
High idling
Torque converter inlet pres- {8 10} {8 10}
sure 0.03 0.20 0.03 0.20
Low idling
{0.3 2} {0.3 2}
0.39 0.64 0.39 0.64
High idling
Torque converter outlet {4 6.5} {4 6.5}
pressure 0.03 0.15 0.03 0.15
Low idling
{0.3 0.15} {0.3 0.15}
Torque converter lock-up 1.27 1.47 1.27 1.47
High idling
clutch pressure {13.0 15.0} {13.0 15.0}
2.55 2.74 Min. 2.55
Power train oil pressure
High idling
Torque converter stator {26.0 28.0} {Min. 26.0}
clutch pressure 2.55 2.74 Min. 2.45
Power train oil tempera- Low idling MPa {26.0 28.0} {Min. 25.0}
ture: Within operating
range {kg/cm2} 2.65 2.98 2.55 3.04
High idling
Transmission main relief {27.0 30.4} {26.0 31.0}
pressure 2.35 2.89 2.25 3.04
Low idling
{24.0 29.5} {23.0 31.0}
Transmission F clutch pres- 2.35 2.74 2.25 2.74
Low idling
sure {24.0 28.0} {23.0 28.0}
Transmission R clutch 2.35 2.74 2.25 2.74
Low idling
pressure {24.0 28.0} {23.0 28.0}
Transmission 1st clutch 1.96 2.35 1.86 2.35
Low idling
pressure {20.0 24.0} {19.0 24.0}
Transmission 2nd clutch 2.35 2.74 2.25 2.74
Low idling
pressure {24.0 28.0} {23.0 28.0}
Transmission 3rd clutch 2.35 2.74 2.25 2.74
Low idling
pressure {24.0 28.0} {23.0 28.0}
20-4 D475A-5
(1)

Category
Standard value Service limit

Measurement item Measurement conditions Unit
for new machine value
Transmission lubricating 0.1 0.2 0.1 0.2

High idling
pressure {1.0 2.0} {1.0 2.0}
2.65 2.98 Min. 2.45
High idling
{27.0 30.4} Min. {25}
Steering left clutch pressure
2.35 2.89 2.25 2.89
Low idling
{24.0 29.5} {23.0 29.5}
2.65 2.98 Min. 2.45
High idling
{27.0 30.4} {Min. 25}
Steering left brake pressure
2.35 2.89 2.25 2.89
Power train oil pressure
Low idling
{24.0 29.5} {23.0 29.5}
Steering left brake pressure 0.93 1.23 0.93 1.23
(In sudden braking) Power train oil temper- High idling MPa {9.5 12.5} {9.5 12.5}
ature: Within operating
range {kg/cm2} 2.65 2.98 Min. 2.45
High idling
Steering right clutch pres- {27.0 30.4} {Min. 25}
sure 2.35 2.89 2.25 2.89
Low idling
{24.0 29.5} {23.0 29.5}
2.65 2.98 Min. 2.45
High idling
Steering right brake pres- {27.0 30.4} {Min. 25}
sure 2.35 2.89 2.25 2.89
Low idling
{24.0 29.5} {23.0 29.5}
Steering right brake pres- 0.93 1.23 0.93 1.23
High idling
sure (In sudden braking) {9.5 12.5} {9.5 12.5}
2.65 3.03 Min. 2.55
Ripper pin puller pressure Low idling
{27.0 30.9} {Min. 26}
Forward 1st 3.4 0.3 3.4 0.3
When lockup switch
Forward 2nd 6.2 0.3 6.2 0.3

Stop machine on flat
Forward 3rd 11.2 0.6 11.2 0.6
is OFF
and level place

Run engine at high
idling Reverse 1st 4.4 0.3 4.4 0.3
Engine coolant tem- Reverse 2nd 8.0 0.4 8.0 0.4
perature: Within
Power train
operating range Reverse 3rd 14.0 0.7 14.0 0.7

Travel speed Economy mode: km/h
OFF Forward 1st 3.5 0.3 3.5 0.3
When lockup switch
Reverse slow mode:

OFF Forward 2nd 6.3 0.3 6.3 0.3
Run-up distance: Forward 3rd 10.9 0.6 10.9 0.6
is ON
10 30 m
Measuring distance: Reverse 1st 4.7 0.3 4.7 0.3
20 m
Reverse 2nd 8.4 0.4 8.4 0.4
Reverse 3rd 14.3 0.7 14.3 0.7
D475A-5 20-5
(1)

Standard Standard
value for Service value for Service
Item
Pump new limit value new limit value
machine machine
Category
merge
Measurement
/divide Unit
Measurement
Engine speed
Specification
conditions
Work (Refer-
Relieving ence) Work equipment pump Work equipment pump
equip-
method outlet pressure (F) outlet pressure (R)
ment
26.5 1.4 26.5 1.4 26.5 1.4 26.5 1.4

High
Raise {270 14} {270 14} {270 14} {270 14}
Merge
relief 22.1 1.4 22.1 1.4 22.1 1.4 22.1 1.4
Low
{225 14} {225 14} {225 14} {225 14}
Blade
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Lower {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Left High
{280 14} {280 14} {280 14} {280 14}
steering Merge
tilt 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
Blade {280 14} {280 14} {280 14} {280 14}
single tilt 24.5 1.4 24.5 1.4 24.5 1.4 24.5 1.4
Right High
{250 14} {250 14} {250 14} {250 14}
steering Merge
tilt 23.0 1.4 23.0 1.4 23.0 1.4 23.0 1.4
Low
{235 14} {235 14} {235 14} {235 14}
Work equipment oil pressure
24.0 1.4 24.0 1.4 27.4 1.4 27.4 1.4

High
Left dual {245 14} {245 14} {280 14} {280 14}
Divide Hydraulic oil
Relief pressure
tilt 21.1 1.4 21.1 1.4 27.4 1.4 27.4 1.4

temperature: Low
Dual tilt
45 55 C MPa {215 14} {215 14} {280 14} {280 14}

Relieve only {kg/cm2} 27.4 1.4 27.4 1.4 24.0 1.4 24.0 1.4
circuit to be High
Right dual measured {280 14} {280 14} {245 14} {245 14}
Divide
tilt 27.4 1.4 27.4 1.4 21.1 1.4 21.1 1.4
Low
Blade {280 14} {280 14} {215 14} {215 14}
dual tilt 24.5 1.4 24.5 1.4 24.5 1.4 24.5 1.4
High
Pitch {250 14} {250 14} {250 14} {250 14}
Divide
dump 21.1 1.4 21.1 1.4 21.1 1.4 21.1 1.4
Low
{215 14} {215 14} {215 14} {215 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Pitch {280 14} {280 14} {280 14} {280 14}
Divide
back 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Raise {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
Ripper
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Lower {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
20-6 D475A-5
(1)

Standard Standard
Item
machine machine
Category
merge
Measurement
/divide Unit
Measurement
Engine speed
Specification
conditions
Work (Refer-
equip-
ment
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

High
{280 14} {280 14} {280 14} {280 14}
Tilt in Merge
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
Dual tilt
Ripper
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
{280 14} {280 14} {280 14} {280 14}
Tilt back Merge
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
26.5 1.4 26.5 1.4 26.5 1.4 26.5 1.4
High
Raise {270 14} {270 14} {270 14} {270 14}
Merge
relief 22.1 1.4 22.1 1.4 22.1 1.4 22.1 1.4
Low
{225 14} {225 14} {225 14} {225 14}
Blade
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Lower {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
24.5 1.4 24.5 1.4 24.5 1.4 24.5 1.4

Left High
{250 14} {250 14} {250 14} {250 14}
steering Merge Hydraulic oil
Relief pressure
tilt temperature: Low 23.0 1.4 23.0 1.4 23.0 1.4 23.0 1.4
Blade 45 55 C MPa {235 14} {235 14} {235 14} {235 14}
single tilt Relieve only {kg/cm2}
circuit to be High 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Right measured {280 14} {280 14} {280 14} {280 14}
steering Merge
tilt 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
Single tilt
{280 14} {280 14} {280 14} {280 14}

27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Raise {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Lower {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
Ripper
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
{280 14} {280 14} {280 14} {280 14}
Tilt in Merge
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
{280 14} {280 14} {280 14} {280 14}
Tilt back Merge
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
D475A-5 20-7
(1)

Standard Standard
Item
machine machine
Category
merge
Measurement
/divide Unit
Measurement
Engine speed
Specification
conditions
Work (Refer-
equip-
ment
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

High
Raise {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
Blade
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Lower {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Left steer- {280 14} {280 14} {280 14} {280 14}
Merge
ing tilt 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
Blade {280 14} {280 14} {280 14} {280 14}
single tilt 24.5 1.4 24.5 1.4 24.5 1.4 24.5 1.4
Right High
{250 14} {250 14} {250 14} {250 14}
steering Merge
tilt 23.0 1.4 23.0 1.4 23.0 1.4 23.0 1.4
Low
{235 14} {235 14} {235 14} {235 14}
25.0 1.4 25.0 1.4 25.0 1.4 25.0 1.4

High
Pitch {255 14} {255 14} {255 14} {255 14}
Divide Hydraulic oil
Relief pressure
dump 21.1 1.4 21.1 1.4 21.1 1.4 21.1 1.4

temperature: Low
{215 14} {215 14} {215 14} {215 14}
Super
Blade 45 55 C MPa
dual tilt Relieve only {kg/cm2} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
circuit to be High
Pitch measured {280 14} {280 14} {280 14} {280 14}
Divide
back 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Raise {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
Lower {280 14} {280 14} {280 14} {280 14}
Merge
relief 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
Ripper
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
{280 14} {280 14} {280 14} {280 14}
Tilt in Merge
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
High
{280 14} {280 14} {280 14} {280 14}
Tilt back Merge
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4
Low
{280 14} {280 14} {280 14} {280 14}
20-8 D475A-5
(1)

Item
Measurement
Category
Specification
Work Standard value for

Relieving Measurement conditions Unit Service limit value
equip- new machine
method
ment
2.45 0.2 2.45 0.2

Raise relief
{25 2} {25 2}
Blade
Lower 2.45 0.2 2.45 0.2
relief {25 2} {25 2}
Left 1.76 0.2 1.76 0.2
Blade steering tilt {18 2} {18 2}
single tilt Right 1.76 0.2 1.76 0.2
steering tilt {18 2} {18 2}
Left dual 1.76 0.2 1.76 0.2
tilt {18 2} {18 2}
Right dual 1.76 0.2 1.76 0.2
Dual tilt
Blade tilt {18 2} {18 2}

dual tilt 1.76 0.2 1.76 0.2
Pitch dump
{18 2} {18 2}
1.76 0.2 1.76 0.2
Pitch back
{18 2} {18 2}
2.45 0.2 2.45 0.2

Raise relief
LS differential pressure
{25 2} {25 2}
Lower 2.45 0.2 2.45 0.2
relief Hydraulic oil temperature: MPa {25 2} {25 2}
Ripper Within operating range
Run engine at high idling {kg/cm2} 2.45 0.2 2.45 0.2
Tilt in
{25 2} {25 2}
2.45 0.2 2.45 0.2
Tilt back
{25 2} {25 2}
2.45 0.2 2.45 0.2
Raise relief
{25 2} {25 2}
Blade
Lower 2.45 0.2 2.45 0.2
relief {25 2} {25 2}
Left steer- 1.76 0.2 1.76 0.2
Blade ing tilt {18 2} {18 2}
Single tilt

2.45 0.2 2.45 0.2
Raise relief
{25 2} {25 2}
Lower 2.45 0.2 2.45 0.2
relief {25 2} {25 2}
Ripper
2.45 0.2 2.45 0.2
Tilt in
{25 2} {25 2}
2.45 0.2 2.45 0.2
Tilt back
{25 2} {25 2}
D475A-5 20-9
(1)

Item
Measurement
Category
Specification
Work Standard value for

Relieving Measurement conditions Unit Service limit value
equip- new machine
method
ment
2.45 0.2 2.45 0.2

Raise relief
{25 2} {25 2}
Blade
Lower 2.45 0.2 2.45 0.2
relief {25 2} {25 2}
Left 1.76 0.2 1.76 0.2
Blade steering tilt {18 2} {18 2}
LS differential pressure

1.76 0.2 1.76 0.2
Pitch dump
Hydraulic oil temperature: {18 2} {18 2}
Super
Blade
dual tilt 1.76 0.2 1.76 0.2
Pitch back Run engine at high idling
{18 2} {18 2}
2.45 0.2 2.45 0.2
Raise relief
{25 2} {25 2}
Lower MPa 2.45 0.2 2.45 0.2
relief {kg/cm2} {25 2} {25 2}
Ripper
2.45 0.2 2.45 0.2
Tilt in
{25 2} {25 2}
2.45 0.2 2.45 0.2
Tilt back
{25 2} {25 2}
Hydraulic oil temperature:
45 55 C 2.94 4.9 2.94 4.9
Unload pressure
Set all work equipment control {30 50} {30 50}
levers in neutral
Work equipment control oil Within operating range 3.92 4.51 Min. 3.72
Set all work equipment control
pressure levers in neutral {40 46} {Min. 38}
Engine at high idling
Within operating range 3.92 4.51 Min. 3.72
PPC valve output pressure Set lever at stroke end {40 46} {Min. 38}
Engine at high idling
Work equipment
Blade tilt cylinder 5 20

Leak- Hydraulic oil temperature:
age Blade pitch cylinder Within operating range 5 20
Run engine at high idling cc/min
from Ripper lift cylinder Measure leakage for 1 minute 5 20
cylinder while relieving cylinder
Ripper tilt cylinder 5 20
20-10 D475A-5
(1)

Category
Standard value
Service limit
value
machine
Measuring posture
Low
14 3.5 Max. 20.0
idling
Raise
Blade lift High
5.0 0.5 Max. 6.0
(Single tiltdozer idling
specification) sec
(Dual tiltdozer Low
specification) 1.8 0.3 Max. 2.5
idling
Within operating range Lower
Apply no load on blade. High
Between blade on ground and rais- 1.8 0.3 Max. 2.5
idling
ing stroke end
Measuring posture
Low
15.8 3.5 Max. 22.0
idling
Raise
High
5.3 0.5 Max. 7.0
Blade lift idling
(Superdozer sec
specification) Low
1.7 0.3 Max. 3.0
idling
Work equipment

Blade speed
Between blade on ground and rais- 1.7 0.3 Max. 2.2

idling
ing stroke end
Measuring posture
Low
4.8 1.5 Max. 6.5
idling
Left tilt
High
4.1 0.5 Max. 6.0
Blade tilt idling
(Single tiltdozer sec
specification) Low
4.1 1.5 Max. 6.0
idling
Within operating range Right tilt
Between left tilt end and right tilt 3.8 0.5 Max. 6.0
idling
end
Measuring posture
Low
5.5 1.5 Max. 8.0
idling
Left tilt
High
3.1 0.5 Max. 5.0
Blade tilt idling
(Dual tiltdozer sec
specification) Low
5.5 1.5 Max. 8.0
idling
idling
end
D475A-5 20-11
(1)

Category
Standard value
Service limit
value
machine
Measuring posture
Low
4.1 0.5 Max. 6.0
idling
Left tilt
High
3.8 0.5 Max. 6.0
Blade tilt idling
(Superdozer sec
specification) Low
4.8 0.5 Max. 6.5
idling
idling
end
Measuring posture Low

9.6 1.5 13.0
idling
Pitch
dump
High
Blade speed
4.4 0.5 6.0

Blade pitch idling
(Dual tiltdozer sec
specification) Low
6.6 1.5 Max. 10.0
Hydraulic oil temperature: idling
Within operating range Pitch
Apply no load on blade. back
Work equipment
Between pitch back end and pitch High

4.1 0.5 Max. 6.0
dump end idling

23.0 3.0 Max. 30
idling
Pitch
dump
High
7.8 1.0 Max. 10
Blade pitch idling
(Superdozer sec
specification) Low
16.0 2.0 Max. 23.0
Hydraulic oil temperature: Within idling
operating range Pitch
Apply no load on blade. back
Between pitch back end and pitch High
7.2 1.0 Max. 9.5
dump end idling

7.7 1.0 Max. 12.0
idling
Raise
High
Ripper speed
2.5 0.5 Max. 4.0

idling
Ripper lift sec
Low
2.5 0.5 Max. 5.0
Select lowest shank hole.
Between ripper on ground and rais- High
2.5 0.5 Max. 4.0
ing stroke end idling
20-12 D475A-5
(1)

Category
Standard value
Service limit
value
machine

15.6 1.5 Max. 22.0
idling
Tilt in
High
Ripper speed
5.2 0.5 Max. 7.0

idling
Ripper tilt sec
Low
9.1 1.5 Max. 14.0
Within operating range Tilt out
Select lowest shank hole.
Between ripper on ground and rais- High
3.3 0.5 Max. 4.5
ing stroke end idling
Blade Hydraulic oil temperature: Within operating Low

(Single tiltdozer range idling
specification) Lower blade from max. rising position and
(Dual tiltdozer measure time after blade comes in contact High
with ground until idler is lifted. Max. 2.5 3.2
specification) idling
sec
Hydraulic oil temperature: Within operating Low
Time lag
Blade
range idling
(Superdozer Lower blade from max. rising position and
specification) measure time after blade comes in contact High
with ground until idler is lifted. Max. 2.7 3.5
idling
Hydraulic oil temperature: Within operating
Work equipment
range High
Ripper Lower ripper from max. rising position and sec Max. 1.0 1.5
measure time after ripper comes in contact idling
with ground until idler is lifted.
Measuring posture
Hydraulic drift of mm/

Max. 150/15 Max. 300/15
lifted blade min
Hydraulic oil temperature: Within operating range

Stop engine.
Raise blade to max. rising position and then measure
Hydraulic drift
reduction of blade bottom height (h) in 15 minutes.

Measuring posture
Hydraulic drift of
mm/
machine tilted by Max. 50/5 Max. 100/5
min
blade
Stop engine.
Tilt blade to maximum to push up shoe on either side
and then measure reduction of shoe height (h) in 5
minutes.
D475A-5 20-13
(1)

Category
Standard value
Service limit
value
machine
Measuring posture
Hydraulic drift of
mm/
machine lifted by Max. 50/5 Max. 100/5
min
blade
Stop engine.
Push up front part of machine with blade and then
measure reduction of idler center height (h) in 5 min-
utes.
Measuring posture
Work equipment
Hydraulic drift
Hydraulic drift of mm/

Max. 80/15 Max. 160/15
lifted ripper min

Stop engine.
Raise ripper to max. rising position and then measure
reduction of shank bottom height (h) in 15 minutes.
Measuring posture
Hydraulic drift of
mm/
machine lifted by Max. 30/5 Max. 60/5
min
ripper
Stop engine.
Push up rear part of machine with ripper and then
measure reduction of final drive center height (h) in 5
minutes.
20-14 D475A-5
(1)
TESTING, ADJUSTING, AND TROUBLESHOOTING DEVICES TABLE................................................... 20-103

MEASURING ENGINE SPEED .................................................................................................................. 20-105
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................................................................ 20-108
MEASURING EXHAUST TEMPERATURE ................................................................................................ 20-109
MEASURING EXHAUST GAS COLOR ...................................................................................................... 20- 111
ADJUSTING VALVE CLEARANCE ............................................................................................................ 20- 112
MEASURING COMPRESSION PRESSURE.............................................................................................. 20-113
MEASURING BLOW-BY PRESSURE ........................................................................................................ 20- 114
MEASURING ENGINE OIL PRESSURE .................................................................................................... 20- 115
TESTING AND ADJUSTING FUEL INJECTION TIMING ........................................................................... 20- 116
TESTING AND ADJUSTING ALTERNATOR BELT TENSION ................................................................... 20- 118
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR ....................... 20- 119
ADJUSTING ENGINE SPEED SENSOR ................................................................................................... 20- 119
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL......................................................... 20-120
MEASURING POWER TRAIN OIL PRESSURE ........................................................................................ 20-122
ADJUSTING TRANSMISSION SPEED SENSOR ...................................................................................... 20-130
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE...................................................................... 20-131
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER .................................................................. 20-132
ADJUSTING PCCS LEVER CONSOLE POSITION ................................................................................... 20-135
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE ............................................ 20-136
ADJUSTING CLEARANCE OF IDLER ....................................................................................................... 20-138
INSPECTING WEAR OF SPROCKET ....................................................................................................... 20-138
TESTING AND ADJUSTING TRACK SHOE TENSION ............................................................................. 20-139
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE......................................................... 20-140
TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE .................................................... 20-149
MEASURING PPC VALVE OUTPUT PRESSURE AND SOLENOID VALVE OUTPUT PRESSURE ....... 20-150
ADJUSTING PLAY OF PPC VALVE .......................................................................................................... 20-157
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE................................ 20-158
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER .................................. 20-159
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER .............................................. 20-160
RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDER ...................................... 20-161
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER.......................................................................... 20-161
ADJUSTING BLADE LEVER TILTING STROKE ....................................................................................... 20-162
ADJUSTING RIPPER LEVER POSITION .................................................................................................. 20-163
ADJUSTING SAFETY LOCK LEVER ......................................................................................................... 20-164
MEASURING FAN MOTOR SPEED .......................................................................................................... 20-165
MEASURING FAN CIRCUIT OIL PRESSURE ........................................................................................... 20-166
BLEEDING AIR FROM FAN PUMP............................................................................................................ 20-167
MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE
(DUAL TILTDOZER SPECIFICATION) ................................................................................................ 20-168
MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE
(SUPERDOZER SPECIFICATION) ..................................................................................................... 20-170
TESTING AND ADJUSTING OPERATOR'S CAB ...................................................................................... 20-172
ADJUSTING BLADE ................................................................................................................................... 20-176
D475A-5 20-101
(1)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) ............................................................................ 20-178

ADJUSTMENT METHOD OF REPLACED CONTROLLER ....................................................................... 20-233
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM .......... 20-235
HANDLING OF OPTIONAL DEVICES........................................................................................................ 20-238
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER.................................................................. 20-239
PROCEDURES FOR EXECUTING QUICK PM ......................................................................................... 20-244
PRECAUTIONS FOR REPLACING VHMS CONTROLLER....................................................................... 20-254
PM CLINIC SERVICE ................................................................................................................................. 20-255
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safe-
ty pins and blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt, or other rotating parts.
20-102 D475A-5
(1)
TESTING AND ADJUSTING TESTING, ADJUSTING, AND TROUBLESHOOTING DEVICES TABLE
TESTING, ADJUSTING, AND TROUBLESHOOTING DEVICES

TABLE
Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
Measuring intake air
A 799-201-2202 Boost gauge kit 1 101 200 kPa {760 1,500 mmHg}
pressure (boost pressure)
Measuring exhaust tem-
B 799-101-1502 Digital thermometer 1 99.9 1,299 C
perature
1 799-201-9000 Handy smoke meter 1 Pollution level: 0 70% (With standard
Measuring exhaust gas
C Commercially color)
color 2 Smoke meter 1
available (Pollution level x 1/10 C Bosch index)
Commercially Air intake side: 0.43 mm,
Adjusting valve clearance D Feeler gauge 1
available Exhaust side: 0.80 mm
0 6.9 MPa {0 70 kg/cm2}
795-502-1590 Compression gauge 1
Measuring compression Kit No.: 795-502-1205
E
pressure 795-502-1510 Adapter 1
795-502-1520 Plate 1
Measuring blow-by pres-
F 799-201-1504 Blow-by checker 1
sure
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
R
pressure
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
3 799-101-5210 Nipple For PT 1/4
1 {25, 60, 400, 600 kg/cm2}
Measuring power train oil 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8MPa {600 kg/cm2}
N
pressure 2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98MPa {10 kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
3
07002-11023 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8MPa {600 kg/cm2}
02781-00313 Union 1
2 07002-11823 O-ring 1
Testing and adjusting
work equipment oil pres- G 02896-11009 O-ring 1
sure 799-401-3200 Adapter (03) 1
3
02896-11009 O-ring 1
4 02789-00315 Adapter (03) 1
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
5
07002-11023 O-ring 1
19M-06-32820 Switch assembly 1
Method of escaping when 1 7824-66-6430 Resistor 1
H
power train has fault 195-06-71220 Wiring harness 1
2 790-190-1600 Pump assembly 1
Testing and adjusting Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
control circuit basic pres- J 1 {25, 60, 400, 600 kg/cm2}
sure 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
D475A-5 20-103
(1)
TESTING AND ADJUSTING TESTING, ADJUSTING, AND TROUBLESHOOTING DEVICES TABLE
Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
Pressure gauge: 2.5, 5.9, 39.2, 58.8MPa
1 {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Measuring PPC valve
K Oil pressure pickup
output pressure 2 799-401-3100 1 Size: 02
adapter
Oil pressure pickup
3 799-401-3200 1 Size: 03
adapter
Measuring ripper pin 1 {25, 60, 400, 600 kg/cm2}
puller solenoid valve out- P 790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8MPa {600 kg/cm2}
put pressure
Oil pressure pickup
2 799-401-3200 1 Size: 03
adapter
Measuring internal leak-
Commercially
age of work equipment L Measuring cylinder 1
available
cylinder
Measuring fan motor Digital display L: 60 2,000 rpm
M 799-203-8001 Multitachometer 1
speed H: 60 19,999 rpm
Measuring fan circuit oil 799-101-5002 Hydraulic tester 1
Q 1 {25, 60, 400, 600 kg/cm2}
pressure
790-261-1203 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
799-608-3101 Service kit 1
1 799-608-3211 Diskette 1
Initializing VHMS control- 799-608-3220 Wiring harness 1

W
ler Notebook type personal
Commercially computer
2 1
available (OS: Windows 98/2000/
NT/Me/XP)
Measurement procedure
S 799-402-3800 Angle gauge 1
for blade tilt control angle
Measuring coolant/oil
a Same as B described above
temperature
Measuring operating/ 79A-264-0021 Push-pull scale 1 0 294 N {0 30 kg}

pressing effort 79A-264-0091 Push-pull scale 1 0 490 N {0 50 kg}
Measuring stroke and Commercially
Scale 1
hydraulic drift available
Commercially
Measuring working speed Stopwatch 1
available
Measuring voltage/resis- Commercially
Multimeter 1
tance available
799-601-7400 T-adapter assembly
799-601-7360 Adapter For relay (5-pin)
Checking sensor/wiring
799-601-9000 T-adapter assembly For heavy duty wire connector
harness
For heavy duty wire connector (For 24 and
799-601-9300 T-adapter assembly
40-pin)
20-104 D475A-5
(1)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

a Measure the engine speed under the following 3. Measuring high idling speed
condition. 1) Start the engine and set the fuel control dial
Engine coolant temperature: in the high idling position.
Within operating range 2) Set the PCCS lever and work equipment
Torque converter oil temperature: control lever in neutral and measure the
Within operating range engine speed.
Power train oil temperature: a The high idling speed measured in the Mon-
Within operating range itoring mode or in the Pm Clinic auxiliary
mode is the auto-deceleration speed.
1. Preparation work a When measuring the high idling speed of the
Turn starting switch ON and set the monitor engine, use the Adjustment mode.
panel to the Monitoring Mode to prepare for Adjustment code:
measurement of the engine speed. 0007 (Engine decelerator cut mode)
a For the operating method, see SPECIAL
FUNCTIONS OF MONITOR PANEL
(EMMS).
Monitoring code: 01002 (Engine speed)
Unit: rpm
4. Measuring decelerator pedal speed

1) Start the engine and set the fuel control dial
in the high idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and press the decel-
2. Measuring low idling speed erator pedal and measure the engine speed.
1) Start the engine and set the fuel control dial
in the low idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the
engine speed.
D475A-5 20-105
(1)
5. Measuring torque converter stall speed 6. Measuring torque converter stall + work
1) Start the engine and set the fuel control dial equipment relief speed (Full stall speed)
in the low idling position. 1) Start the engine and set the fuel control dial
2) Press the brake pedal securely and set the in the low idling position.
parking brake lever in the FREE position 2) Keep pressing the brake pedal securely and
and set the PCCS lever in the FORWARD set the parking brake lever in the FREE
3rd gear speed position. position and set the PCCS lever in the FOR-
a Before going to the next step, check that WARD 3rd gear speed position.
the upper display unit of the monitor pan- a Before going to the next step, check that
el is set in the normal display state and it the upper display unit of the monitor pan-
displays [F3]. el is set in the normal display state and it
a Keep the steering in neutral. displays [F3].
3) Press the decelerator pedal and set the fuel a Set the PCCS lever in the steering neu-
control dial in the high idling position. tral position.
4) Return the decelerator pedal slowly to stall 3) Press the decelerator pedal and set the fuel
the torque converter with the engine at high control dial in the high idling position.
idling. 4) Return the decelerator pedal slowly to stall
k Keep pressing the brake pedal securely the torque converter with the engine at high
and keep your right foot on the deceler- idling.
ator pedal for safety until the work is fin- k Keep pressing the brake pedal securely
ished. and keep your right foot on the deceler-
5) Just after the power train oil temperature ator pedal for safety until the work is fin-
gauge reaches position "a" of the green ished.
range, return the direction of the PCCS 5) Operate the lever to move the ripper lift cyl-
lever into neutral. inder to the raising stroke end or to the pitch
back stroke end.
6) Just after the torque converter oil tempera-
ture gauge reaches position "a" of the green
range, return the direction of the PCCS
lever into neutral.
6) Repeat above steps 2) - 5) 3 times.

7) Perform steps 2) - 4) again and measure the
engine speed when the power train oil tem-
perature gauge reaches position "a" of the
green range.
a Immediately after finishing measure- 7) Repeat above steps 2) - 5) 3 times.
ment, return the direction of the PCCS 8) Perform steps 2) - 4) again and relieve the
lever into neutral and lower the power ripper circuit in the raising direction or in the
train oil temperature with the engine at pitch back direction and measure the engine
high idling. speed when the power train oil temperature
gauge reaches position "a" of the green
range.
a Immediately after finishing measure-
ment, return the direction of the PCCS
lever into neutral and lower the power
train oil temperature with the engine at
high idling.
20-106 D475A-5
(1)
a The engine speed can be measured in

the "PM Clinic Auxiliary Mode" of the
monitor panel. (Measure the high idling
speed of the engine in the "Adjustment
mode".)
D475A-5 20-107
(1)
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

a Measuring instruments for intake air pressure 3. Install nipple [1] of boost gauge kit A and connect
(boost pressure) gauge [2].
Symbol Part No. Name

A 799-201-2202 Boost gauge kit
k When installing and removing the measuring in-

strument, take care not to touch a hot part.
a Measure the intake air pressure (boost pressure)
under the following condition.
Engine coolant temperature:
Torque converter oil temperature:
4. Run the engine at medium or higher speed and
1. Open the engine right and left side covers. drain the oil from the hose.
a Insert the joint of the gauge and hose half-
2. Remove intake air pressure pickup plugs (1) and way and open the self-seal on the hose side
(2) (PT 1/8). repeatedly, and the oil is drained.
a If nipple [1] is installed to the intake air pres- a If Pm kit (A) is available, the air bleeding cou-
sure (boost pressure) pickup part, connect pling (790-261-1130) in it may be used.
gauge [2] to nipple [1]. a If any oil is left in the hose, the gauge does
Plug (1): For right bank not move. Accordingly, be sure to drain the
Plug (2): For left bank oil.
5. Run the engine at high idling and stall the torque

converter and measure the intake air pressure
(boost pressure) at this time.
a For the procedure for stalling the torque con-
verter, see MEASURING ENGINE SPEED.
a Normally, the intake air pressure (boost
pressure) should be measured while the en-
gine is operated at the rated output. In the
field, however, an approximate value can be
obtained by stalling the torque converter.
6. After finishing measurement, remove the meas-

uring instrument and return the removed parts.
20-108 D475A-5
(1)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE

a Measuring instrument for exhaust temperature

B 799-101-1502 Digital thermometer
a Measure the exhaust temperature under the fol-

lowing condition.
Engine coolant temperature:
3. Install sensor [1] of digital thermometer B and
1. If the machine is equipped with the VHMS, check
connect them to meter [2].
the exhaust temperature with the monitor panel
a Clamp the wiring harness of the digital ther-
since the machine is equipped with exhaust tem-
mometer so that it will not touch a hot part
perature sensors for the VHMS.
during measurement.
Monitoring code (Right bank): 42601
Monitoring code (Left bank): 42600
Unit: C
FUNCTIONS OF MONITOR PANEL.
2. If the machine is not equipped with the VHMS,

measure the exhaust temperature according to
the following procedure.
k Remove and install the measuring instru-
ments after the exhaust manifold is cooled
down.
a Measure the exhaust temperatures of the
right and left banks separately.
1) Open the right and left inspection covers of
the engine and remove the turbocharger 4. Procedure for measuring maximum exhaust
heat insulation cover. temperature for troubleshooting.
2) Remove exhaust temperature measuring Operate the machine and measure the maxi-
plug (1) or (2). mum exhaust temperature.
Plug (1): For right bank a Use the PEAK mode of the digital thermom-
Plug (2): For left bank eter.
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it by
the following calculation.
Corrected value [C] = Measured value
+ 2 x (20 Outside air temperature)
D475A-5 20-109
(1)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
k Just after the torque converter oil tempera-

ture gauge reads the red range, return the
direction of the PCCS lever into neutral and
lower the torque converter oil temperature.
5. Procedure for measuring exhaust temperature

periodically for preventive maintenance
a If the torque converter is stalled, the torque
converter oil temperature is overheated be-
fore the exhaust temperature is stabilized.
Measure according to the following proce-
dure.
1) Completely stall the torque converter to
raise the exhaust temperature to about
650C according to the following procedure
(Condition a in the figure).
i) Start the engine and set the fuel control
dial to the low idling position.
ii) Press the brake pedal and set the
PCCS lever in the FORWARD 3rd gear
speed position.
iii) Press the decelerator pedal and set the
fuel control dial to the high idling posi-
tion. 6. After finishing measurement, remove the meas-
iv) Return the decelerator pedal slowly to uring instrument and return the removed parts.
stall the torque converter and relieve the
ripper in raising direction or pitch back
with the engine at high idling.
k Press the brake pedal and keep your
right foot on the decelerator pedal for
safety until the work is finished.
2) Stop relieving the ripper or pitch back, and
lower the exhaust temperature by only stall-
ing the torque converter (Condition b in the
figure).
a If the temperature does not lower but ris-
es, set the temperature in step 1).
3) After the temperature lowers and is stabi-
lized, measure it (Condition c in the figure).
20-110 D475A-5
(1)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

a Measuring instrument for exhaust gas color

1 799-201-9000 Handy smoke checker
C
2 Purchased Smoke meter
k When installing and removing the measuring in-

strument, take care not to touch a hot part.
a If an air source and a electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2.
a Measure the exhaust gas color under the follow-
ing condition. 2) Connect the probe hose, receptacle of the
Engine coolant temperature: accelerator switch, and air hose to smoke
Within operating range meter C2.
a Limit the supplied air pressure to
1. Measuring with handy smoke checker C1 1.5MPa {15kg/cm2}.
1) Stock a sheet of filter paper to C1. 3) Connect the power cable to a receptacle of
2) Insert the exhaust gas intake pipe in the AC power supply.
exhaust pipe. a Before connecting the cable, check that
3) Start the engine. the power switch of the smoke meter is
4) Accelerate the engine suddenly or run it at turned off.
high idling and operate the handle of smoke 4) Before connecting the cable, check that the
checker C1 so that the filter paper will power switch of the smoke meter is turned
absorb the exhaust gas. off.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter
C2.
5) Remove the filter paper and compare it with

the attached scale.
6) After finishing measurement, remove the
m ea su ri ng i ns tr um ent an d re tur n the
removed parts. 6) Start the engine.
7) Accelerate the engine suddenly or run it at
2. Measuring with smoke meter C2 high idling and press the accelerator pedal
1) Insert probe of smoke meter C2 in the of smoke meter C2 and collect the exhaust
outlet of the exhaust pipe and fix it to the gas into the filter paper.
exhaust pipe with a clip. 8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
me as ur in g in str u men t a nd r etu r n t he
removed parts.
D475A-5 20-111
(1)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

a Adjusting instrument for valve clearance

D Purchased Feeler gauge
1. Remove the cylinder head cover.

a See DISASSEMBLY AND ASSEMBLY, Re-
moval of cylinder head assembly.
2. Rotate the crankshaft forward to bring the

stamped R1.6 TOP line (1) to pointer (2) and set
the R1 cylinder to the compression top dead
center.
a When the R1 cylinder is at the compression
top dead center, the rocker arms on both in-
take side and exhaust side can be moved by
the valve clearance with the hand. If the
rocker arms cannot be moved, the cylinder is
not at the compression top dead center. In
this case, rotate the crankshaft one more
turn and match the stamped line to the point-
er.
a Rotate the crankshaft with the hexagon shaft
of the alternator drive pulley.
4. Rotate the crankshaft by 120 to bring each

stamped TOP line (1) to pointer (2) and adjust
the valve clearance each cylinder according to
the firing order.
a Firing order: R1 L1 R5 L5 R3 L3
R6 L6 R2 L2 R4 L4
3. Insert feeler gauge D between rocker arm (3)

and crosshead (4) and turn adjustment screw (5)
so that you can move the feeler gauge lightly,
3 Locknut: 58.8 5.9 Nm {6.0 0.6 kgm}

and then tighten locknut (6).
a After tightening the locknut, check the valve

clearance again.
5. After finishing adjustment, return the removed

parts.
20-112 D475A-5
(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pressure 5. Disconnect governor solenoid connector E15 (1)
of the right fuel injection pump and governor so-
Symbol Part No. Name lenoid connector E11 (2) of the left fuel injection
795-502-1205 Compression gauge pump.
E 795-502-1510 Adapter
795-502-1520 Plate 6. Turn the starting switch ON, set the monitor pan-
el to the "Monitoring Mode", and prepare for
k When measuring the compression pressure, be measurement of the engine speed.
extremely careful not to touch the exhaust man- a For the operating method, see SPECIAL
ifold or any other hot parts or get caught in the FUNCTIONS OF MONITOR PANEL
fan belt or any other rotating parts. (EMMS).
Monitoring code: 01002 (Engine speed)
1. Adjust the valve clearance.
a For details, see ADJUSTING VALVE
CLEARANCE.
2. Warm up the engine so that the engine oil tem-

perature is 40 60C.
3. Remove nozzle holder assembly (1) from the cyl-

inder which is to be measured.
a For details, see DISASSEMBLY AND AS-
SEMBLY, REMOVAL OF NOZZLE HOLD-
ER ASSEMBLY.
4. Fit adapter [1] of compression gauge E, then

connect compression gauge E.
7. Crank the engine with the starting motor and

measure the compression pressure.
a Measure the compression pressure at the
point where the pressure gauge indicator re-
mains steady.
a When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.
D475A-5 20-113
(1)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

a Measuring instrument for blow-by pressure

F 799-201-1504 Blow-by kit
a Measure the blow-by pressure under the follow-

ing condition.
Engine coolant temperature: Within operat-
ing range
Torque converter oil temperature: Within op-
erating range
range
3) Run the engine at high idling and measure
the value on the gauge when the torque
the blow-by pressure with the monitor panel
converter is stalled.
since the machine is equipped with crankcase
a For details of the procedure for torque
pressure sensors for the VHMS.
co nve rt er s ta ll, see ME AS URING
Monitoring code: 42800 (Blow-by pressure)
TORQUE CONVERTER STALL
Unit: kPa
SPEED.
a The blow-by should be measured with
the engine running at rated output. How-
(EMMS).
ever, when measuring in the field, a sim-
ilar value can be obtained at torque
converter stall.
measure the blow-by pressure according to the
a If it is impossible to check at rated output
following procedure.
or stall speed, measure at high idling.
1) Install nozzle [1] of blow-by checker F to
In this case, the blow-by value will be
blow-by hose (1) of the left bank and block
about 80% of the value at rated output.
the hose connecting part.
a Blow-by varies greatly according to the
a Connect a short hose and bind the out-
condition of the engine. Therefore, if the
let.
blow-by value is considered abnormal,
2) Install nozzle [1] and hose [2] of blow-by
check for problems connected with de-
checker F to blow-by hose (2) of the right
fective blow-by, such as excessive oil
bank and connect blow-by checker F.
consumption, defective exhaust gas
color, and prematurely dirty or deterio-
rated oil.

mea su r ing i ns tr um ent an d re tur n th e
removed parts.
20-114 D475A-5
(1)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

a Measuring instruments for engine oil pressure 2) Install nipple R3 (PT 1/4) and connect it to
hydraulic tester R2.
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
R Hydraulic tester
2 799-401-2320
(0.98 MPa {10 kg/cm2})
3 799-101-5210 Nipple (PT 1/4)
a Measure the engine oil pressure under the fol-

lowing condition.
Engine coolant temperature: Within operat-
ing range

the engine oil pressure with the monitor panel
since the machine is equipped with engine oil 3) Run the engine at low idling and high idling
pressure sensors for the VHMS. and measure the engine oil pressure at
Monitoring code: 37200 (Engine oil pres- each speed.
sure)
Unit: MPa
(EMMS).

measure the engine oil pressure according to the
1) Open the engine right side cover and
remove engine oil pressure pickup plug (1)
(PT 1/4).

measuring instruments and return the
removed parts.
D475A-5 20-115
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

a Test and adjust the fuel injection timings on the Adjusting
right and left banks simultaneously. a When the "delivery valve method" is applied, the
copper gasket and O-ring must be replaced. Ac-
Testing cordingly, prepare new copper gasket and O-ring
1. Remove the fuel injection pump cover. in advance.
a Apply the "delivery valve method" only when
2. Rotate the crankshaft to bring stamped 9 line (1) stamped match marks "a" and "b" are not made,
of the damper to pointer (2). since dust may enter the fuel injection pump. If
the stamped match marks are made, apply the
"match mark method".
a If the fuel injection timing is not correct, adjust it
according to the following procedure.
[Match mark method]

1. Loosen the 2 sets of mounting bolts and nuts (5)
from the oblong holes of the coupling to set the
coupling free.
a At this time, check that stamped line (3) of

the coupling of the fuel injection pump is near
stamped line (4) of the body. If stamped line
(3) of the coupling is not seen, rotate the
crankshaft 1 more turn.
a Rotate the crankshaft with the hexagon shaft
of the alternator drive pulley.
3. Check that stamped line (3) of the fuel injection

pump coupling is matched to the stamped line (4) 2. Rotate the coupling to match stamped line (3) of
of the body. the coupling to stamped line (4) of the body.
3. Tighten lock bolt (6) and the 2 sets of mounting
3 Lock bolt: 157 196 Nm {16 20 kgm}

bolts and nuts (5).
Mounting bolt and nut:

98.0 122.6 Nm {8.5 9.5 kgm}
20-116 D475A-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
[Delivery valve method]

1. Disconnect fuel injection pipe (7) of the right No.
1 cylinder.
a Before disconnecting the pipe, wipe off the
fuel from the fuel injection pump top, etc. and
prevent dust from entering the fuel injection
pump.
2. Remove delivery valve holder (8).
3. Take spring (9) and delivery valve (10) out of de-

livery valve holder (8), and then assemble deliv-
ery valve holder (8) again.
a Use the removed O-ring and copper gasket
6. Rotate the crankshaft in reverse by 35 40 from
again at this time (After adjusting, replace
the TOP position of the right No. 1 cylinder.
them with new ones).
7. While operating the priming pump, rotate the
crankshaft forward slowly and check the position
at which fuel stops flowing out of the delivery
valve holder.
8. When the fuel stops flowing out, check that the

stamped fuel injection timing line of the damper
is matched to the pointer.
a If the timing line is after the pointer:
The injection timing is lagged.
a If the timing line is before the pointer:
The injection timing is advanced.
If the injection timing is incorrect as result of test-

4. Set the fuel control lever in the maximum speed ing, adjust it according to the following proce-
position. dure.
1) Rotate the crankshaft in reverse by 35 40
5. Remove rack stopper bolt (11) and tighten rack from the TOP position of the right No. 1 cyl-
push bolt [1] to move the rack. inder.
a After rack push bolt [1] reaches rack piston 2) Rotate the crankshaft slowly to match
(12), tighten it 8 more turns. stamped injection timing line (1) of the
a Part No. of rack push bolt: 01016-30850 damper to pointer (2) accurately.
3) Loosen bolt (5) of the oblong hole of the
injection pump mounting flange. While
operating the priming pump, rotate the
flange on the pump side little by little and
stop when the fuel stops flowing out of deliv-
ery valve holder (13).
4) Tighten the bolt of the oblong hole of the
injection pump mounting flange.
a Check again that the injection timing is
correct.
5) Stamp line (3) on the coupling side, match-
ing it to stamped line (4) on the fuel injection
pump side.
D475A-5 20-117
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

ALTERNATOR BELT TENSION
Testing
Measure deflection a of the belt when it is
pushed with a finger force of approx. 58.8 N {ap-
prox. 6 kg} at a point midway between the alter-
nator pulley and the drive pulley.
Deflection a of belt: 20 2 mm
a After adjusting, assemble spring (14) and

delivery valve (15) again without fail.
a Be sure to replace copper gasket (16) and O-
ring of the delivery valve with new ones. If
the existing ones are used again, fuel may
leak.
a Take care not to mistake the mounting posi-
tion of copper gasket (16) (under the seat). Adjusting
a Replace rack push bolt [1] and rack stopper a If the belt tension is not correct, adjust as follows.
bolt (11). (If they are not replaced, the en-
1. Loosen the mounting bolt and nut, mounting bolt
3 Tightening order of delivery valve holder
gine may overrun.)
(1), and locknut (2).
Unit: Nm {kgm}
2. Turn adjustment nut (3) and move alternator (4)
1st time 137.3 156.9 {14 16}
to adjust the tension of the belt.
2nd time Return to 0
3rd time 137.3 156.9 {14 16} 3. Tighten locknut (2), mounting bolt (1) and the
4th time Return to 0 mounting bolt and nut.
5th time 137.3 156.9 {14 16}
20-118 D475A-5
(1)
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER
TESTING AND ADJUSTING COMPRESSOR, ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED

BELT TENSION FOR AIR CON- SENSOR
DITIONER COMPRESSOR
Testing a Adjust both left bank speed sensor (1) and right
Measure deflection a of the belt when it is bank speed sensor (2) in the same way.
pushed with a finger force of approx. 58.8 N {ap- a The engine speed sensor is installed to the fly-
prox. 6 kg} at a point midway between the com- wheel housing.
pressor pulley and the engine drive pulley.
Deflection a of belt: 20 2 mm
1. Screw in sensor body (3) so the tip contacts ring

gear (4).
Adjusting a Be careful not to damage the sensor tip or let
2 Sensor thread:
a If the belt tension is not correct, adjust as follows. iron particles stick to it.
1. Loosen 3 mounting bolts and nuts (1) and lock- Gasket sealant (LG-6)
nut (2).
2. After sensor body (3) contacts ring gear (4), turn
2. Turn the adjustment nut and move air conditioner it back 1/2 1 turn to adjust clearance a.
compressor (3) together with the bracket to ad- Clearance a: 0.75 1.5 mm
just the tension of the belt.
3 Locknut:
3. Tighten locknut (5).
3. Tighten locknut (2) and 3 mounting bolts and
nuts (1). 49.0 68.6 Nm {5.0 7.0 kgm}
a When fixing the wiring in position, be careful that

no excessive force is brought to bear on the sen-
sor wiring.
D475A-5 20-119
(1)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
1. Outline of fuel control system

The speed signals from the fuel control dial
and the decelerator pedal potentiometers
are each input to the engine controller.
The engine controller gives priority to the
lower speed of the two input signals and
sends a command to the fuel injection pump.
Adjustment of the engine speed is all carried
out by the decelerator pedal linkage.
2. Preparatory work
1) Turn the starting switch on and set the mon-
itor panel to monitoring code [01002].
a For details, see MEASURING ENGINE
SPEED.
2) Start the engine, set the fuel control dial to
the FULL position, and check that the
engine speed is at least 1000 rpm.
a If the engine speed is below 1000 rpm,
adjust by extending installation dimen-
sion a of rod (1) to make the engine
speed more than 1000 rpm.
20-120 D475A-5
(1)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
3. Adjusting decelerator pedal speed

Set the fuel control dial at the high idling posi-
tion, depress decelerator pedal (2) until it con-
tacts the stopper, and check that the decelerator
pedal speed is normal.
Decelerator pedal speed: 900 25 rpm
a If the engine speed is not correct, adjust in-
stallation dimension a of rod (1).
Installation dimension a: 122 mm
4. Adjusting high idling speed

Set the fuel control dial to the high idling position
and check that the high idling speed is correct.
High idling speed: 2000 50 rpm
a If engine speed is too high:
To remove the play in the decelerator pedal,
set the engine speed to less than 1900 rpm
with stopper bolt (3), then adjust it to the
high idling speed.
a If engine speed is too low:
Adjust the high idling speed with stopper
bolt (3).
D475A-5 20-121
(1)
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE

a Measuring instruments for power train oil pres-
sure

1
Hydraulic tester
N 2 799-401-2320
(0.98 MPa {10 kg/cm2})
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
k Stop the machine on level ground and lower the

work equipment to the ground, then set the park-
ing brake lever and safety lock lever in the lock
position.
a Measure the power train oil pressure under the
following condition.
a Centralized pressure pickup ports (1) (14) are
installed inside the inspection cover on the right
outside of the operators cab and transmission
lubricating oil pressure pickup port (15) is in-
stalled to the top of the power train filter.
a Table of locations of centralized pressure pickup
points for measuring oil pressure and gauges to
use 1. Measuring torque converter inlet pressure
(IN)
Stam Gauge 1) Connect oil pressure gauge [1] of hydraulic
No. Measured oil pressure
p (MPa {kg/cm2})
tester N1 to oil pressure pick-up nipple (1).
1 IN T/C inlet pressure 2.5 {25} a Use an oil pressure gauge of 2.5 MPa
2 OUT T/C outlet pressure 0.98 {10} {25 kg/cm2}.
3 SC T/C stator clutch pressure 5.9 {60}
4 LU T/C lockup clutch pressure 2.5 {25}
5 TM T/M main relief pressure 5.9 {60}
6 FWD T/M F clutch pressure 5.9 {60}
7 REV T/M R clutch pressure 5.9 {60}
8 1ST T/M 1st clutch pressure 5.9 {60}
9 2ND T/M 2nd clutch pressure 5.9 {60}
10 3RD T/M 3rd clutch pressure 5.9 {60}
11 LB S/T left brake pressure 5.9 {60}
12 RB S/T right brake pressure 5.9 {60}
13 LC Left clutch pressure 5.9 {60}
14 RC Right clutch pressure 5.9 {60}
15 T/M lubricating pressure 0.98 {10} 2) Start the engine and set the PCCS lever in
the full neutral position.
3) Measure the oil pressure while the engine is
running at low idling and high idling.
20-122 D475A-5
(1)

removed parts.
3. Measuring torque converter stator clutch
pressure (SC)
1) Connect oil pressure gauge [1] of hydraulic
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.

removed parts.
2. Measuring torque converter outlet pressure

(OUT)
1) Connect hydraulic tester N2 to oil pressure
pick-up nipple (2).
{10 kg/cm2}.
2) Run the engine and set the PCCS lever in
2) Start the engine and set the PCCS lever in

removed parts.
D475A-5 20-123
(1)
4. Measuring torque converter lock-up clutch 5. Measuring transmission main relief pressure
pressure (LU) (TM)
1) Connect oil pressure gauge [1] of hydraulic a If the machine is equipped with the VHMS,
tester N1 to oil pressure pick-up nipple (4). check the transmission main relief pressure
a Use an oil pressure gauge of 2.5 MPa with the monitor panel since the machine is
{25 kg/cm2}. equipped with a transmission main relief
pressure sensor for the VHMS.
Monitoring code: 43000
(Transmission main relief pressure)
Unit: MPa
(EMMS).
a If the machine is not equipped with the
VHMS, measure the transmission main relief
pressure according to the following proce-
dure.
1) Connect oil pressure gauge [1] of hydraulic
2) Start the engine and set the monitor panel in
{60 kg/cm2}.
the "Adjustment mode" and disengage both
steering clutches.
a For the operating method, see "Special
functions of monitor panel (EMMS)".
a Adjustment code: 5535 (Disengagement
of both steering clutches)
a The transmission speed is displayed on
the service meter display section (Unit: 1
rpm).
3) Turn on the lock-up mode switch.
4) Set the PCCS lever in the FORWARD and
1st gear speed position and make the trans-
mission run idle.
5) Raise the engine speed gradually and
measure the oil pressure when the lock-up 2) Run the engine and set the PCCS lever in
pilot lamp lights up. the full neutral position.

m eas ur i ng in st ru me nt and r et ur n the
removed parts. 4) After finishing measurement, remove the
removed parts.
20-124 D475A-5
(1)
6. Measuring transmission F clutch pressure 7. Measuring transmission R clutch pressure

(FWD) (R)
1) Connect oil pressure gauge [1] of hydraulic 1) Connect oil pressure gauge [1] of hydraulic
tester N1 to oil pressure pickup nipple (6). tester N1 to oil pressure pickup nipple (7).
a Use an oil pressure gauge of 5.9 MPa a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine, set the monitor panel in the 2) Run the engine, set the monitor panel in the
"adjustment mode", and disengage both "adjustment mode", and disengage both
steering clutches. steering clutches.
a For the operating method, see SPECIAL a For the operating method, see SPECIAL
FUNCTIONS OF MONITOR PANEL FUNCTIONS OF MONITOR PANEL
(EMMS). (EMMS).
a Adjustment code: 5535 (Both steering a Adjustment code: 5535 (Both steering
clutches disengagement) clutches disengagement)
a The service meter display unit displays a The service meter display unit displays
the transmission speed (in rpm). the transmission speed (in rpm).
3) Set the parking brake lever in the FREE 3) Set the parking brake lever in the FREE
position. position.
4) Press the brake pedal, set the PCCS lever 4) Press the brake pedal, set the PCCS lever
in the FORWARD 3rd gear speed position, in the REVERSE 3rd gear speed position,
and run the transmission idle. and run the transmission idle.
5) Measure the oil pressure while the engine is 5) Measure the oil pressure while the engine is
running at low idling. running at low idling.
6) After finishing measurement, remove the 6) After finishing measurement, remove the
m ea su ri ng i ns tr um ent an d re tur n the me as ur in g in str u men t a nd r etu r n t he
removed parts. removed parts.
D475A-5 20-125
(1)
8. Measuring transmission 1st clutch pressure 9. Measuring transmission 2nd clutch pressure
(1ST) (2ND)
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine, set the monitor panel in the 2) Run the engine, set the monitor panel in the
"adjustment mode", and disengage both "adjustment mode", and disengage both
steering clutches. steering clutches.
a For the operating method, see SPECIAL a For the operating method, see SPECIAL
FUNCTIONS OF MONITOR PANEL FUNCTIONS OF MONITOR PANEL
(EMMS). (EMMS).
a Adjustment code: 5535 (Both steering a Adjustment code: 5535 (Both steering
clutches disengagement) clutches disengagement)
a The service meter display unit displays a The service meter display unit displays
the transmission speed (in rpm). the transmission speed (in rpm).
3) Set the parking brake lever in the FREE 3) Set the parking brake lever in the FREE
position. position.
4) Press the brake pedal, set the PCCS lever 4) Press the brake pedal, set the PCCS lever
in the FORWARD 1st gear speed position, in the FORWARD 2nd gear speed position,
and run the transmission idle. and run the transmission idle.
5) Measure the oil pressure while the engine is 5) Measure the oil pressure while the engine is
running at low idling. running at low idling.
k Do not raise the engine speed to high k Do not raise the engine speed to high
idling during measurement. idling during measurement.
m eas ur i ng in st ru me nt and r et ur n the mea su r ing i ns tr um ent an d re tur n th e
20-126 D475A-5
(1)
10. Measuring transmission 3rd clutch pressure 11. Measuring steering left brake pressure (LB)
(3RD) 1) Connect oil pressure gauge [1] of hydraulic
1) Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure pickup nipple (11).
tester N1 to oil pressure pickup nipple (10). a Use an oil pressure gauge of 5.9 MPa
a Use an oil pressure gauge of 5.9 MPa {60 kg/cm2}.
{60 kg/cm2}.
2) Run the engine and set the parking brake

2) Run the engine, set the monitor panel in the lever in the FREE position.
"adjustment mode", and disengage both 3) Measure the oil pressure while the engine is
steering clutches. running at low idling and high idling.
a For the operating method, see SPECIAL a Check that the oil pressure becomes 0
FUNCTIONS OF MONITOR PANEL when the PCCS lever is set to the steer-
(EMMS). ing left stroke end.
a Adjustment code: 5535 (Both steering a Check that the oil pressure becomes 0
clutches disengagement) when the brake pedal is pressed or
a The service meter display unit displays when the parking brake lever is set in the
the transmission speed (in rpm). LOCK position.
3) Set the parking brake lever in the FREE
position.
4) Press the brake pedal, set the PCCS lever
in the FORWARD 3rd gear speed position,
and run the transmission idle.
running at low idling.
k Do not raise the engine speed to high
idling during measurement.

removed parts.

removed parts.
D475A-5 20-127
(1)
12. Measuring steering right brake pressure (RB) 13. Measuring steering left clutch pressure (LC)
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the parking brake 2) Run the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) Measure the oil pressure while the engine is 3) Set the PCCS lever to the steering left
running at low idling and high idling. stroke end.
a Check that the oil pressure becomes 0 a Set the direction of the PCCS lever in
when the PCCS lever is set to the steer- neutral.
ing right stroke end. 4) Measure the oil pressure while the engine is
a Check that the oil pressure becomes 0 running at low idling and high idling.
when the brake pedal is pressed or a Check that the oil pressure becomes 0
when the parking brake lever is set in the when the steering of the PCCS lever is
LOCK position. returned to the neutral position.
m eas ur i ng in st ru me nt and r et ur n the mea su r ing i ns tr um ent an d re tur n th e
20-128 D475A-5
(1)
14. Measuring steering right clutch pressure 15. Measuring transmission lubricating oil pres-
(RC) sure
1) Connect oil pressure gauge [1] of hydraulic 1) Connect hydraulic tester N2 to oil pressure
tester N1 to oil pressure pickup nipple (14). pickup nipple (15).
{60 kg/cm2}. {10 kg/cm2}.
2) Run the engine and set the parking brake

lever in the FREE position.
3) Set the PCCS lever to the steering right
stroke end.
a Set the direction of the PCCS lever in
neutral.
a Check that the oil pressure becomes 0
when the steering of the PCCS lever is
returned to the neutral position.
2) Run the engine at high idling and measure

the oil pressure.

removed parts.

removed parts.
D475A-5 20-129
(1)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR

a The torque converter output speed sensor for the 7. Install flange (2) and the sensor together to the
2 Flange and mounting bolt:

VHMS is not adjustable. steering case.
3 Mounting bolt:
1. Remove the fuel tank undercover, and then re- Gasket sealant (LG-6)
move transmission output speed sensor (1) and
the flange together. 59 74 Nm {6 7.5 kgm}
a Before adjusting transmission speed sensor
(1), remove it temporarily and check that its
tip is free from a steel chip and a flaw.
a Before installing the transmission speed
sensor, separate sensor (1), flange (2), and
nut (3).
8. After finishing adjustment, set the monitor panel

in the "Monitoring display mode" and check that
the transmission speed is displayed normally.
(EMMS).
2. Install flange (2) to the steering case temporarily. a Monitoring code: 31400 (Transmission speed)
3. Looking at bevel gear (4) through the hole of

flange (2), check that the tooth tip is at the center
of the hole.
a If the tooth tip is not at the center, run the en-
gine and move the machine forward or in re-
verse a little to set the tooth tip to the center.
4. Tighten sensor (1) until its tip touches the tooth
2 Threads of sensor:
tip of gear (4).
Gasket sealant (LG-6)
5. Return sensor (1) from the above position by the

specified angle.
a Returning angle of sensor: 1/2 1 turn
a Adjust clearance b between the sensor tip
and gear tooth tip to 0.75 1.50 mm.
6. Remove sensor (1) and flange (2) together and

secure them with nut (3).
a Take care that the adjustment angle of the
3 Nut: 49.0 68.6 Nm {5 7 kgm}

sensor will not change.
20-130 D475A-5
(1)
TESTING AND ADJUSTING SIMPLE METHOD OF TESTING BRAKE PERFORMANCE
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE

a Carry out the simple test of brake performance
under the following condition.
1. Set the blade and ripper in the travel position on

a level place.
2. Run the engine and set the parking brake lever

in the FREE position.
3. Run the engine at low idling and press the brake

pedal and set the PCCS lever in the FORWARD
and 2nd gear speed position.
k If this test is performed in the 1st gear posi-
tion, the brake will be overloaded. Be sure
to perform this test in the 2nd gear speed.
a Set the steering unit in neutral.
4. Press the decelerator pedal and set the fuel con-

trol dial in the high idling position.
5. Slowly return the decelerator pedal and make

sure the machine does not move when the en-
gine speed reaches the high idling level.
k Since the torque converter will be stalled,
press the brake pedal and keep your right
foot on the decelerator pedal for safety, until
this procedure is finished.
D475A-5 20-131
(1)
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER

Brake pedal side
20-132 D475A-5
(1)
Parking brake lever side
Adjusting brake pedal side

1. Adjusting brake pedal stroke 3. Checking brake pedal stroke
Adjust stroke a of brake pedal (1) by adjusting 1) Press brake pedal (1) and check that its
installed dimension b of stopper bolt (2). stroke is as set in step 1 above.
a Adjust the brake pedal stroke with the brake 2) Press brake pedal (1) and check that it is
rod separated from the pedal. stopped by stopper (7).
Pedal stroke a: 78 mm 3) Press brake pedal (1) and check that spool
Installed dimension b of stopper bolt: 36.5 mm stroke g of brake valve (5) is in the normal
range.
2. Adjusting installed length of brake rod Spool stroke g: 20 24 mm
1) Connect small rod (3), brake rod (4), and
turnbuckle (6). 4. Checking brake oil pressure
Screwing distance c, d, e, and f: 23 mm 1) Start the engine and set the monitor panel in
2) Adjust the installed length of brake rod (4) the adjustment mode.
with turnbuckle (6) so that the spool of brake a For the operating method in the adjust-
valve (5) will be at the OFF position. ment mode, see SPECIAL FUNCTIONS
a The threads on the brake pedal side of OF MONITOR PANEL (EMMS).
3 Locknut:
the turnbuckle locknut are inverted. a Adjustment code: 9996
(Mechanical brake release mode)
34.3 58.8 Nm {3.5 6.0 kgm} 2) With the parking brake lever in the FREE
position, press the brake pedal and check
that the brake oil pressures on both sides
become 0.
a For the measuring points of the brake oil
pressure, see MEASURING POWER
TRAIN OIL PRESSURE.
D475A-5 20-133
(1)
5. Initializing brake potentiometer Adjusting parking brake lever side

Turn the starting switch ON, set the monitor 6. Assembly and installation of lever assembly
panel to the "Adjustment Mode", and initialize 1) Assemble lever assembly (7) and adjust the
the brake potentiometer. operation of limit switch (8).
a For the operating method in the adjustment a Assemble the lever assembly with the
mode, see SPECIAL FUNCTIONS OF parking cable disconnected from the le-
MONITOR PANEL (EMMS). ver.
a Adjustment code: 0005 When lever is at upper position: OFF, at
(Initialization of brake potentiometer) lower position: ON
Operating stroke of limit switch: 3 mm
2) Install lever assembly (7).
7. Adjusting installed length of parking cable

1) Connect parking cable (9) to the lever side,
and then adjust installed dimensions h and
j.
Installed dimension h of cable: 22.5 mm
Installed dimension j of cable: 14.5 mm
2) Connect parking cable (9) to the valve side.
Installed dimension m of cable: 15 mm
Installed dimension k of cable: 20.5 mm
3) Operate parking lever (10) between the
FREE position and LOCK position and
adjust the position of rod end (11) so that
spool stroke n of brake valve (4) will be nor-
mal.
Spool stroke n: 23.0 mm
8. Checking brake oil pressure

Run the engine and set the parking brake lever
in the FREE position and LOCK position and
check that the brake oil pressure will be as fol-
lows.
a For the measuring point of the brake oil pres-
sure, see MEASURING POWER TRAIN OIL
PRESSURE.
LOCK position: 0, FREE position: Specified
pressure
9. Checking limit switch

1) Turn the starting switch ON, set the monitor
panel to the "Monitoring Display Mode".
a For the operating method in the monitor-
ing display mode, see SPECIAL FUNC-
TIONS OF MONITOR PANEL (EMMS).
Monitoring code: 40910 (Steering con-
troller input signal 1)
position and LOCK position and check that
the limit switch signals are input normally.
20-134 D475A-5
(1)
TESTING AND ADJUSTING ADJUSTING PCCS LEVER CONSOLE POSITION
ADJUSTING PCCS LEVER CONSOLE POSITION
1. Set operators seat (1) in the forward (dozing) po-

sition.
2. Under this condition, check that console (2) is in

parallel with operators seat (1).
a If the console is not parallel with the opera-
tors seat, adjust dimension a of rod (3).
Standard dimensions a: 179 mm
a The locknut on the rear side of the turnbuckle
is a left-handed (reversing) screw.
D475A-5 20-135
(1)
TESTING AND ADJUSTING EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS

TROUBLE
a Devices used for emergency escape a Since the female side of connector PL2
is kept disconnected, mask it with a vinyl
Symbol Part No. Part name sheet, etc.
19M-06-32820 Switch assembly a Put switch assembly in the cab
1 7824-66-6430 Register through the cab window.
H
195-06-71220 Wiring harness
2 790-190-1600 Pump assembly
1. Escape with switch box (Use H1)

a If the machine cannot be moved because of
a trouble in the electric system of the power
train control unit (travel direction, gear
speed, steering), escape according to the
a The engine must be startable for the follow-
ing procedure. If the engine cannot be start-
ed, see EMERGENCY ESCAPE WITH
BRAKE RELEASING DEVICE.
1) Connect switch assembly and register
3) Disconnect neutral safety relay (NSF) in the
to wiring harness of emergency escape
fuse room and connect pins and of
device H1.
k Since register
the connector on the wiring harness side.
controls the drive volt-
a Perform this operation only when the en-
age of the solenoid, connect it to the wir-
gine does not start electrically because
ing harness before connecting to the
of a trouble in the transmission control-
machine.
k Set the all gear speed switches of switch
ler.
k If the engine is started by this method,
assembly in the OFF position and the
the neutral safety function does not
direction switch in the P position to pre-
work. Accordingly, before starting the
vent the machine from starting suddenly.
engine, set the parking brake lever in the
LOCK position and set the PCCS lever
in the full neutral position.
k Start the engine by this method only in
an emergency. If the engine does not
start in another case, be sure to carry out
troubleshooting and repair the trouble.
2) Open the left fender inspection cover and

connect wiring harness to connectors
PL1 (1) and PL2 (2).
Connector PL1 (1):
Connect to male side and female side.
Connector PL2 (2):
Connect to male side.
20-136 D475A-5
(1)
TESTING AND ADJUSTING EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
4) Start the engine and set the parking brake

lever in the FREE position.
5) Operate switch assembly and move the
machine to a safe place.
a The gear speed switch is so made that
the switch on the lower gear speed will
be operated first.
3) Remove the fuel tank undercover and dis-

connect supply hose (3) of the pin puller
solenoid valve.
4) Connect end hose of pump assembly H2 to
the supply hose.
a Block the solenoid valve side with plug .
2. Escape with brake releasing device (Use H2)

a If the engine cannot be started and the park-
ing brake cannot be released, escape ac-
cording to the following procedure.
1) Assemble pump assembly H2.
5) Turn the starting switch ON and set the

parking brake lever in the FREE position.
6) Operate the volume pump to raise the brake
releasing oil pressure to the initial pressure.
Initial pressure:
Approx. 2.74 MPa {28 kg/cm2}
a Since an accumulator is installed in the
2) Install volume pump of pump assembly circuit, the handle must be operated 30
H2 to the outside of the operators cab. 50 times to raise the oil pressure.
a If the oil pressure does not rise above a
Volume Discharge certain level, the relief valve may be set
Capacity Delivery *
pump of pressure * to low pressure. In this case, adjust the
pump H2 Max. 15 l 24 ml/stroke 5 MPa {51 kg/m2} set pressure of the relief valve.
7) Tow the machine to a safe place.
*: Reference values for #160 oil and oil temper- a The brake releasing oil pressure lowers
ature of 20C gradually because of internal leakage
and the brake is applied again about 1
minutes after. Accordingly, work quickly.
a If the brake releasing pressure lowers to
about 1.5 MPa {16 kg/cm2}, the brake is
applied. In this case, operate the volume
pump again to raise the brake releasing
pressure to the initial pressure.
D475A-5 20-137
(1)
ADJUSTING CLEARANCE OF IDLER
TESTING AND ADJUSTING INSPECTING WEAR OF SPROCKET
ADJUSTING CLEARANCE OF INSPECTING WEAR OF

IDLER SPROCKET
The idler moves forward and backward under exter- a Use the "Full-scale dimensions drawing of
nal pressure. When this happens, side guide (1) and sprocket profile" in "Sprocket" in STRUCTURE,
guide plate (2) become worn. As they become worn, FUNCTION, AND MAINTENANCE STANDARD
there is side play in the idler, or the idler turns at an as a gauge for measuring wear of the sprocket.
angle, causing the track to come off or resulting in a Make a copy of the "Full-scale dimensions draw-
uneven wear, so adjust as follows. ing of sprocket profile" on a transparent paper or
sheet and apply it directly to the sprocket to see
Adjustment if the sprocket can be used.
1. Drive the machine for 1 2 m on flat ground,
then measure clearance a (4 places: left, right,
inside, outside) between the track frame and side
guide (1).
2. If clearance a is more than 3 mm, remove bolt

(3), then take out shim (4), and adjust so that the
clearance on one side is less than 0.5 mm.
a There are two types of shim (thickness: 0.5
mm and 1.0 mm).
20-138 D475A-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION
Testing 3. If tension is too low:

1. Drive the machine forward and stop on a hori- Pump in grease through grease fitting (4).
zontal surface. a If the track tension is poor, move the ma-
a Stop the machine without using the brake. chine backwards or forwards slowly.
2. Pull steel rod (1) between the idler and carrier

roller, and measure clearance a from the bottom
of the rod to the track shoe grouser.
Standard clearance a: 20 30 mm
a After complection of the adjustment, repeat the

above procedure to check the tension again.
Adjusting
a If the track shoe tension is not normal, adjust as
follows.
1. Remove cover (2).
2. If tension is too high:

Loosen plug (3) and release some of the
grease.
k There is danger that the plug may fly out un-
der the high internal pressure of the grease,
so never loosen the plug more than 1 turn.
D475A-5 20-139
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE

a Testing and adjusting instruments for work 3) Install union G2, adapter G3, cap G4, and
equipment oil pressure nipple G5, and connect them oil pressure
gauge [1] of hydraulic tester G1.
Symbol Part No. Name a Use an oil pressure gauge of 5.9 MPa
799-101-5002 Hydraulic tester {60 kg/cm2}.
1
02781-00313 Union
2 07002-11823 O-ring
02896-11009 O-ring
G
799-401-3200 Adapter (03)
3
02896-11009 O-ring
4 02789-00315 Cap (03)
799-101-5220 Nipple (10 x 1.25 mm)
5
07002-11023 O-ring
Measuring
k Stop the machine on a level place, lower the
work equipment to the ground, and set the park-
ing brake lever and safety lock lever in the LOCK
position.
a Measure the work equipment oil pressure under
the following condition.
range
1. Measuring unload pressure

1) Remove the main valve cover above the
right fender.
2) Remove work equipment oil pressure sen-
sors (1) and (2) from the work equipment
control valve.
(1): Front pump oil pressure sensor 4) Run the engine at high idling and set the
(2): Rear pump oil pressure sensor blade lever and ripper lever in neutral, and
measure the oil pressure.

removed parts.
20-140 D475A-5
(1)
2. Measuring main relief pressure (Single tilt

specification)
a Measure the main relief pressure at the
same point with the unload pressure.
a Use an oil pressure gauge of 39.2 MPa {400
kg/cm2}.
a Since the oils from the 2 pumps are merged
in the work equipment circuit of the single tilt
specification, the oil pressure of the divided
oil cannot be measured.
1) Start the engine and set the safety lock lever
2) Run the engine at high idling, raise or tilt the
ripper to relieve the cylinder at a stroke end,
and measure the oil pressure.
removed parts.
3. Measuring main relief pressure (Dual tilt

specification and superdozer specification)
a Measure the main relief pressure at the
a The unload pressure, main relief pressure, blade kg/cm2}.
tilt relief pressure, blade pitch relief pressure, a The oil pressure of the divided oil can be
and blade raise relief pressure can also be measured by measuring while pitching back
measured in the "PM Clinic Auxiliary Mode" of the ripper.
the operator mode of the monitor panel. 1) Start the engine and set the safety lock lever
a The pressures of both the front and rear pumps in the FREE position.
can be measured simultaneously in the "Dual 2) Run the engine at high idling, raise or pitch
Display Monitoring Mode" of the service mode. back the ripper to relieve the cylinder at a
stroke end, and measure the oil pressure.
D475A-5 20-141
(1)

removed parts.
a The unload pressure, main relief pressure, blade

tilt relief pressure, blade pitch relief pressure,
and blade raise relief pressure can also be
measured in the "PM Clinic Auxiliary Mode" of
the operator mode of the monitor panel.
a The pressures of both the front and rear pumps
can be measured simultaneously in the "Dual
Display Monitoring Mode" of the service mode.

removed parts.

4. Measuring blade tilt relief pressure (Single tilt

specification)
a Measure the blade tilt relief pressure at the
kg/cm2}.
2) Run the engine at high idling, tilt the blade to
the left to relieve the cylinder at a stroke
end, and measure the oil pressure.
20-142 D475A-5
(1)
5. Measuring blade pitch relief pressure (Dual

tilt specification and superdozer specifica-
tion)
a Measure the blade pitch dump relief pres-
sure at the same point with the unload pres-
sure.
kg/cm2}.
2) Run the engine at high idling, pitch dump
the blade to relieve the cylinder at a stroke
end, and measure the oil pressure.
3) After finishing measurement, remove the 6. Measuring blade raise relief pressure
m ea su ri ng i ns tr um ent an d re tur n the a Measure the blade raise relief pressure at
removed parts. the same point with the unload pressure.
a The unload pressure, main relief pressure, blade kg/cm2}.
tilt relief pressure, blade pitch relief pressure, 1) Block the return side hose of the blade lift
and blade raise relief pressure can also be cylinder.
measured in the "PM Clinic Auxiliary Mode" of 2) Start the engine and set the safety lock lever
the operator mode of the monitor panel. in the FREE position.
a The pressures of both the front and rear pumps 3) Run the engine at high idling, raise the
can be measured simultaneously in the "Dual blade to relieve the cylinder at a stroke end,
Display Monitoring Mode" of the service mode. and measure the oil pressure.
D475A-5 20-143
(1)
4) After finishing measurement, remove the 7. Measuring LS differential pressure

m eas ur i ng in st ru me nt and r et ur n the a Measure the pump discharge pressure and
removed parts. LS pressure (actuator load pressure) at the
a When measuring the oil pressure of the same time and calculate the difference be-
single tilt specification and dual tilt spec- tween them.
ification, relieve the oil through the blade 1) Remove work equipment oil pressure sen-
raise relief valve. When measuring the sors (1) and (2) from the work equipment
oil pressure of the superdozer specifica- control valve.
tion, relieve the oil through the main re-
lief valve.

2) Remove oil pressure pickup plugs (3) and

(4) from the work equipment pump.
(1): Front pump discharge oil pressure
sensor
(2): Rear pump discharge oil pressure
sensor
(3): Front pump LS pressure plug
(4): Rear pump LS pressure plug
3) Install union G2, adapter G3, cap G4, nipple

G5 and oil pressure gauge or differential
pressure gauge G6 of hydraulic tester G1 to
the work equipment control valve.
(Pump discharge pressure)
4) Install nipple G5 to the work equipment
pump side and connect it to oil pressure
gauge [1] or differential pressure gauge G6
of hydraulic tester G1.
(LS pressure: Low pressure side)
20-144 D475A-5
(1)
a When using differential pressure gauge: 5) Operate the blade lever and ripper lever and
Connect the pump discharge pressure side measure the pump discharge pressure and
to the high pressure side and connect the LS pressure (actuator load pressure) at the
LS pressure side to the low pressure side. same time while each cylinder is moving.
Since the differential pressure gauge needs a Calculation of LS differential pressure:
a 12 V power source, connect it to a battery. LS differential pressure = Pump discharge
a When using oil pressure gauge: pressure LS pressure
Use the oil pressure gauge of 39.2 MPa 6) After finishing measurement, remove the
{400 kg/cm2}. measuring instruments and return the
Since the differential pressure is about 3.9 removed parts.
MPa {40 kg/cm2} at maximum, measure it by
installing the same gauge to the pickup 8. Measuring LS valve output pressure (servo
plugs alternately. piston inlet pressure)
1) Open the inspection cover of the cross bar
front undercover.
2) Remove oil pressure pickup plugs (5) and
(6) from the work equipment pump.
(5): For front pump LS valve output
pressure
(6): For rear pump LS valve output pres-
sure
3) Install nipple G5 and connect it to oil pres-

sure gauge [1] of hydraulic tester G1.
a Use the oil pressure gauge of 39.2 MPa
{400 kg/cm2}.

D475A-5 20-145
(1)
5) Run the engine at high idling, perform the Adjusting

operations shown in the following table, and a The unload valve cannot be adjusted.
measure the LS valve output pressure.
1. Adjusting main relief pressure
LS valve output a If the work equipment relief pressure is ab-
Specification Operation pressure normal, adjust main relief valve (7) or (8) ac-
(MPa {kg/cm2}) cording to the following procedure.
Common to all a When the main relief pressure of the dual tilt
Raise blade 0 {0}
specifications specification and superdozer specification is
Raise ripper or measured, if it is abnormal in either or both of
Dual tilt and
pitch back to the front pump circuit and rear pump circuit,
superdozer 27.4 + 2.74
1.4
relieve
+ 14
adjust the main relief valve(s) of the abnor-
{280 28} mal circuit(s).
Raise ripper or tilt
Single tilt
to right to relieve a The main relief pressure of the divided oil of
the single tilt specification cannot be meas-
ured. Accordingly, measure the main relief
pressure on either side or both sides.
(7): Main relief valve for front pump circuit
(8): Main relief valve for rear pump circuit

removed parts.
1) Loosen locknut (9) and turn adjustment

screw (10) to adjust the pressure.
a If the adjustment screw is
turned to the right, the pressure ris-
es.
turned to the left, the pressure low-
ers.
a Quantity of adjustment per turn of adjust-
3 Locknut:
ment screw: 12.6 MPa {128 kg/cm2}
29.4 39.2 Nm {3 4 kgm}
20-146 D475A-5
(1)
2) After finishing adjustment, check again that

the oil pressure is normal according to the
procedure for measurement described
above.
2. Adjusting blade pitch/tilt relief pressure

(For only single tilt specification and dual tilt
specification)
a If the blade left tilt relief pressure (single tilt
specification) or the blade pitch dump relief
pressure (dual tilt specification and super-
dozer specification) is abnormal, adjust
blade tilt relief valve (15) or (16) according to
3. Adjusting blade lift relief pressure
a When the blade tilt relief pressure of the dual
(For only single tilt specification and dual tilt
tilt specification and superdozer specification
specification)
is measured, if it is abnormal in either or both
a If the blade lift relief pressure is abnormal,
of the front pump circuit and rear pump cir-
adjust blade lift relief valve (19) or (20) ac-
cuit, adjust the blade tilt relief valve(s) of the
abnormal circuit(s).
a The blade lift relief pressure of the divided oil
a The blade tilt relief pressure of the divided oil
cannot be measured. Accordingly, measure
of the single tilt specification cannot be
the blade lift relief pressure on either side or
measured. Accordingly, measure the blade
both sides.
tilt relief pressure on either side or both
(19): Blade lift relief valve for front pump
sides.
circuit
(15): Blade tilt relief valve for front pump
(20): Blade lift relief valve for rear pump
circuit
circuit
(16): Blade tilt relief valve for rear pump
circuit
Loosen locknut (21) of the blade tilt relief

valve and turn adjustment cap (22) to adjust
Loosen locknut (18) of the blade tilt relief
the pressure.
valve and turn adjustment cap (17) to adjust
a If the adjustment cap is
the pressure.
turned to the right, the pressure rises.
a If the adjustment cap is
turned to the left, the pressure lowers.
turned to the right, the pressure rises.
turned to the left, the pressure lowers.
3 Locknut: 39 49 Nm {4 5 kgm}
ment cap: 25.3 MPa {258 kg/cm2}
3 Cap: 39 49 Nm {4 5 kgm}
3 Locknut: 39 49 Nm {4 5 kgm}
ment cap: 25.3 MPa {258 kg/cm2}
3 Cap: 39 49 Nm {4 5 kgm}
D475A-5 20-147
(1)
4. Adjusting LS differential pressure 2) After finishing adjustment, check again that

a If the LS differential pressure is abnormal, the oil pressure is normal according to the
adjust LS valves (11) and (12) according to procedure for measurement described
the following procedure. above.
(11): LS valve for front pump circuit
(12): LS valve for rear pump circuit
1) Loosen locknut (13) and turn adjustment

screw (14) to adjust the differential pres-
sure.
a If the adjustment screw is
turned to the right, the LS differential
pressure rises.
turned to the left, the LS differential
pressure lowers.
3 Locknut: 49 68.6 Nm {5 7 kgm}

ment screw: 1.3 MPa {13.3 kg/cm2}
20-148 D475A-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT BASIC PRESSURE

a Measuring instruments for control circuit basic 3. Run the engine at high idling, set the blade lever
pressure and ripper lever in neutral, and measure the oil
pressure.
Symbol Part No. Part name
J 1
a The control circuit basic pressure is the pressure

reduced by the self-reducing pressure valve of
the control valve. It is used commonly for the
work equipment PPC, fan pump control, and
work equipment pump control.
Measuring
position. 4. After finishing measurement, remove the meas-
a Measure the control circuit basic pressure under uring instrument and return the removed parts.
the following condition.
Hydraulic oil temperature: Within operating Adjusting
range a The self-reducing pressure valve cannot be ad-
justed.
1. Remove the right ROPS front cover.
2. Connect oil pressure gauge [1] of hydraulic tester

J1 to oil pressure pickup nipple (1).
a Use the oil pressure gauge of 5.9 MPa {60
kg/cm2}.
D475A-5 20-149
(1)
MEASURING PPC VALVE OUTPUT PRESSURE AND
TESTING AND ADJUSTING SOLENOID VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE AND SOLENOID

VALVE OUTPUT PRESSURE
a Measuring instruments for PPC valve output a The PPC valve output pressure of the
pressure and solenoid valve output pressure following circuits is the basic pressure of
the solenoid valve (Dual tilt specification
Symbol Part No. Part name and superdozer specification).
799-101-5002 Hydraulic tester Blade right tilt/left tilt:
1
790-261-1203 Digital hydraulic tester Pitch/Tilt solenoid valve basic pressure
K
2 799-401-3100 Pressure pickup adapter (02)
3 799-401-3200 Pressure pickup adapter (03)

position.
a Before measuring the PPC valve output pres-
sure and pitch/tilt control valve pressure, check
that the control circuit basic pressure is normal.
a Measure the PPC valve output pressure and
pitch/tilt control valve pressure under the follow-
ing condition.
range 2. Measuring solenoid valve output pressure
(Dual tilt specification and superdozer speci-
1. Measuring PPC valve output pressure (sole- fication)
noid valve basic pressure) a Measure the following solenoid valve output
a Measure the pressure of the following cir- pressures on the solenoid valve block (3)
cuits at the PPC valve. side. (It is difficult to measure on the work
Blade lift raise circuit equipment control valve side.)
Blade tilt circuit before pitch/tilt solenoid Blade left tilt circuit (Left tilt/pitch back
valve circuit) (4) after solenoid valve
Ripper raise circuit and ripper tilt back Blade right tilt circuit (Right dual tilt/pitch
circuit back circuit) (5) after solenoid valve
1) Remove pressure switch (1) of the circuit to
be measured from the blade and ripper PPC
valve.
2) Install nipple [1] of hydraulic tester K1 and
connect oil pressure gauge [2].
4) Run the engine at high idling, operate the
control lever of the circuit to be measured,
and measure the oil pressure.
a Measure the oil pressure with the lever
at a stroke end.
a The blade-lower circuit, ripper-lower cir-
cuit, and tilt-in circuit may be measured
on the work equipment control side.
a When measuring the blade-lower circuit,
operate the lever until the blade floats.
20-150 D475A-5
(1)
1) Disconnect the piping of the circuit to be a Measure the following solenoid valve output
measured and install oil pressure pickup pressures on the work equipment control
adapter K2 or K3. side.
2) Install nipple [1] of hydraulic tester K1 and Blade left tilt circuit (Left tilt/pitch dump
connect oil pressure gauge [2]. circuit) (6) after solenoid valve
Blade lower circuit (7) after solenoid
valve
Blade right tilt circuit (Left tilt/pitch dump
circuit) (8) after solenoid valve

control lever or knob switch of the circuit to
be measured, and measure the oil pressure. 1) Disconnect the piping of the circuit to be
a Measure the oil pressure with the lever measured and install oil pressure pickup
at a stroke end. adapter K2 or K3.
a When measuring the output pressure of 2) Install nipple [1] of hydraulic tester K1 and
the pitch dump solenoid valve or pitch connect oil pressure gauge [2].
back solenoid valve of the superdozer
specification, set the blade lever in neu-
tral and operate the knob switch.
a Measure the output pressure of the tilt
limit solenoid valve while checking the
tilting direction of the blade lever.
a When the blade is set at the tilt limit an-
gle, the output pressure from the PPC
valve is stopped.
D475A-5 20-151
(1)

control lever or knob switch of the circuit to
be measured, and measure the oil pressure.
a Measure the oil pressure with the lever
at a stroke end.
a When measuring the output pressure of
the pitch dump solenoid valve or pitch
back solenoid valve of the superdozer
specification, set the blade lever in neu-
tral and operate the knob switch.
a Measure the output pressure of the tilt
limit solenoid valve while checking the
tilting direction of the blade lever.
a When the blade is set at the tilt limit an-
gle, the output pressure from the PPC
valve is stopped.
20-152 D475A-5
(1)
Dual tilt specification and superdozer specification
20-154 D475A-5
(1)
D475A-5 20-155
(1)
Single tilt specification
20-156 D475A-5
(1)
TESTING AND ADJUSTING ADJUSTING PLAY OF PPC VALVE
ADJUSTING PLAY OF PPC VALVE
a If the end play of the blade lever and ripper lever

is excessive, adjust it with their PPC valves ac-
a This figure shows the PPC valve for the ripper.
Standard play a:
0.5 3.0mm at 200mm from revolution cen-
ter of lever (in both longitudinal and lateral
directions)
1. Remove boot (1).
2. Loosen locknut (2) and turn disc (3) to adjust the

play.
a Do not move the piston at this time.
3 Locknut: 98 127 Nm {10 13 kgm}

3. Fix disc (3) and tighten locknut (2).
4. Install boot (1).
D475A-5 20-157
(1)
MEASURING OUTLET PRESSURE OF RIPPER PIN
TESTING AND ADJUSTING PULLER SOLENOID VALVE
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER

SOLENOID VALVE
a Measuring instruments for outlet pressure of rip- 4. Run the engine at high idling and operate the rip-
per pin puller solenoid valve per pin puller switch and measure the oil pres-
sure.
1
P
Oil pressure pickup adapter
2 799-401-3200
(Size 03)

position.
a Measure the outlet pressure of the ripper pin pull-
er solenoid valve under the following condition.
Power train oil temperature:
1. Disconnect pin puller cylinder hose (1) or (2). uring instrument and return the removed parts.
2. Install oil pressure pickup adapter P2 and con-

nect the disconnected hose again.
3. Install nipple [1] of hydraulic tester P1 and con-

nect oil pressure gauge [2].
a Use an oil pressure gauge of 5.9 MPa {60 kg/
cm2}.
20-158 D475A-5
(1)
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF
TESTING AND ADJUSTING BLADE AND RIPPER
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE

AND RIPPER
a If the blade or ripper drifts hydraulically, check to
see if the cause is on the cylinder packing side or
control valve side according to the following pro-
cedure.
1. Set the cylinders to be tested in the following po-

sitions and stop the engine.
1) Blade lift cylinder
Brace the blade to raise the front side of the
machine body.
a Since the blade lift cylinder is equipped
with a piston valve, do not extend it to
the stroke end.
2. Extend the cylinder to be tested with the corre-

sponding lever and check its movement.
If the lowering speed is increased, the cylin-
der packing is defective.
If the lowering speed does not change, the
control valve is defective.
a If the pressure in the accumulator is lost, run
the engine for about 10 seconds to heighten
the pressure in the accumulator.
[Reference]
Reason why the lowering speed is
increased when the cylinder packing is the
2) Blade tilt cylinder cause of the hydraulic drift:
Extract the tilt cylinder to the stroke end and 1) If the machine is set in the above position
brace the blade to push up the right side of (where the holding pressure is applied to the
the machine body. bottom side), the oil leaks from the bottom
side to the head side. Since the volume on
the head side is less than that on the bottom
side by the volume of the rod, the pressure
in the head side is increased by the oil flow-
ing in from the bottom side.
2) As the pressure in the head side is
increased, it is balanced at a certain level
(which depends on the leakage), then the
lowering speed is lowered.
3) If the circuit on the head side is opened to
the drain circuit by the above operation of
the lever (the bottom side is closed by the
check valve at this time), the oil on the head
side flows in the drain circuit. As a result, the
3) Ripper lift cylinder pressure is unbalanced and the lowering
Brace the ripper to push up the rear side of speed is increased.
the machine body.
D475A-5 20-159
(1)
TESTING AND ADJUSTING MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT

CYLINDER
a Measuring instruments for internal leakage of 3. Run the engine at high idling and apply the relief
work equipment cylinder pressure to the cylinder bottom side.
Blade tilt cylinder:
Symbol Part No. Name Operate to extend the cylinder to be
L Purchased Measuring cylinder measured.
Ripper lift cylinder:
a Measure the internal leakage of work equipment Operate to lower ripper.
cylinder under the following condition. Ripper Tilt cylinder:
Hydraulic oil temperature: 45 55C Operate to tilt ripper forward.
a Since the blade lift cylinder is equipped with a
piston valve, its internal leakage cannot be 4. After 30 seconds, measure leakage for 1 minute.
measured.
5. After finishing measurement, return the removed
1. Extend the cylinder to be measured to the stroke parts.
end and set the machine in the measuring posi-
tion.
1) Blade tilt cylinder
Extend the cylinder to be measured to the
stroke end.
2) Ripper lift cylinder
Pull out the shank pin and lower the ripper
to the end.
3) Ripper tilt cylinder
Tilt the ripper forward to the end.
2. Disconnect hose on the cylinder head side and

block the hose side with a plug.
a Remove the hose cover of the blade tilt cyl-
inder.
k Take care not to disconnect the hose on the
bottom side.
20-160 D475A-5
(1)
RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLIN-
TESTING AND ADJUSTING DER, BLEEDING AIR FROM WORK EQUIPMENT CYLINDER
RELEASING RESIDUAL BLEEDING AIR FROM WORK

PRESSURE FROM WORK EQUIPMENT CYLINDER
EQUIPMENT CYLINDER
a When disconnecting the piping between the con- a If the work equipment cylinder is removed and in-
trol valve and work equipment cylinder, release stalled or its piping is disconnected and connect-
the residual pressure from the circuit according ed, bleed air from its circuit according to the
to the following procedure. following procedure.
1. Loosen the hydraulic tank oil filler cap to gradu- 1. Run the engine at low idling for about 5 minutes.
ally release the residual pressure from the tank.
2. Running the engine at low idling, extend and re-
2. Set the safety lock lever in the FREE position tract the cylinder to be bled 4 5 times.
and operate the work equipment control lever to a Move the piston rod to about 100mm before
each direction. the stroke end and never relieve the oil.
a If the work equipment control lever is operat-
ed 2 3 times, the residual pressure in the 3. Running the engine at high idling and carry out
accumulator is released. the operation in 2.
3. Run the engine at low idling for about 5 seconds, 4. Running the engine at low idling, move the cylin-
then stop it. der to the stroke end to relieve the oil.
4. Repeat steps 2 3 above 2 3 times.
D475A-5 20-161
(1)
TESTING AND ADJUSTING ADJUSTING BLADE LEVER TILTING STROKE
ADJUSTING BLADE LEVER TILTING STROKE

a Adjust the blade lever according to the following
procedure, so the strokes on the right and left
sides are the same.
1. Remove bellows (1) of the blade lever.
2. Loosen 4 mounting bolts (3) of stroke limit plate

(2).
3. Adjust stroke limit plate (2) so the strokes in both

blade lever tilting directions are the same, then
tighten the mounting bolts.
a Right and left strokes a from center of blade
lever: 56 4 mm
4. Install bellows (1).
20-162 D475A-5
(1)
TESTING AND ADJUSTING ADJUSTING RIPPER LEVER POSITION
ADJUSTING RIPPER LEVER POSITION
a Adjust the ripper lever to the best position ac-

a The ripper lever can be adjusted forward and in
reverse within the range of 40mm from the cent-
er of the lever shaft.
1. Adjusting within range of backward 40mm

from neutral position
1) Loosen lock bolt (1).
2) Set lever (2) to the best position.
3) Tighten lock bolt (1) to secure lever (2).
2. Adjusting within range of forward 40mm from

neutral position
1) Remove lock bolt (1).
2) Remove lever (2) and reverse it.
3) Install lever (2) to lever (5) and set it to the
best position.
4) Tighten lock bolt (1) to secure lever (2).
5) Loosen nut (3).
6) Reverse knob (4).
7) Tighten nut (3) to secure knob (4).
D475A-5 20-163
(1)
TESTING AND ADJUSTING ADJUSTING SAFETY LOCK LEVER
ADJUSTING SAFETY LOCK LEVER
1. Adjust dimension a between pins of rod (1).

Dimension a between pins: 441.8 mm
2. Connect rod (1) to safety lock lever (2) and PPC

lock valve (3).
a Install connecting pin (4) on the safety lock
lever side with the cotter pin on the outside of
the machine.
20-164 D475A-5
(1)
TESTING AND ADJUSTING MEASURING FAN MOTOR SPEED
MEASURING FAN MOTOR SPEED

a Measuring instruments for fan motor speed 4. Insert probe [2] of multitachometer M through the
radiator mask and set it out of the fan net with
Symbol Part No. Name stand [3].
M 799-208-8001 Multitachometer a The probe tip cannot be inserted in an open-
ing of the fan net, but it can measure the fan
1. Open the radiator mask and remove the mount- motor speed. Remove all obstacles be-
ing bolts of fan net (1) under the fan motor. tween the lighting part of the probe and the
a Fan net (1) cannot be removed since the fan reflecting tape.
motor piping is installed.
5. Start the engine and set the monitor panel in the

2. Make clearance a by shifting fan net (1) and stick adjustment mode.
reflecting tape [1] to the fan through clearance a. a For the operating method in the adjustment
a Stick the reflecting tape near the outside of mode, see SPECIAL FUNCTIONS OF
the fan (where the distance between the fan MONITOR PANEL (EMMS).
net and fan is short). a Adjustment code: 1005 (Fan 100% speed
mode)
6. Run the engine at low idling and high idling and

measure the fan motor speed.
3. Install fan net (1) and close the radiator mask.

k Be sure to close the radiator mask before
starting measurement. Do not start the en-
gine with the radiator mask open.
uring instrument and return the removed parts.
D475A-5 20-165
(1)
TESTING AND ADJUSTING MEASURING FAN CIRCUIT OIL PRESSURE
MEASURING FAN CIRCUIT OIL PRESSURE

a Measuring instruments for fan circuit oil pressure 4. Run the engine at high idling and measure the
fan circuit oil pressure.
1 799-101-5002 Hydraulic tester
Q
2 790-261-1203 Digital hydraulic tester

position.
a Measure the fan circuit oil pressure under the fol-
lowing condition.
Hydraulic oil pressure: Within operating range
1. Open the radiator mask.
2. Connect oil pressure gauge [1] of hydraulic tester 5. After finishing measurement, remove the meas-
Q1 to the oil pressure pickup nipple installed to uring instrument and return the removed parts.
the underside of fan motor (1).
a Use the oil pressure gauge of 39.2 MPa {400
kg/cm2}.
3. Start the engine and set the monitor panel in the

adjustment mode.
a For the operating method in the adjustment
mode, see SPECIAL FUNCTIONS OF
MONITOR PANEL (EMMS).
a Adjustment code: 1005 (Fan 100% speed
mode)
20-166 D475A-5
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM FAN PUMP
BLEEDING AIR FROM FAN PUMP

a If the fan pump is removed and installed or its
piping is disconnected and connected, bleed air
from the pump case according to the following
procedure.
a Before bleeding air, check that the hydraulic oil
level is proper.
1. Remove the floor inspection cover.
2. Loosen air bleeders (1) and (2), and leave it for

15 minutes.
3. After 15 minutes, run the engine at low idling.
4. After oil flows out of air bleeder, tighten air bleed-

ers (1) and (2).
D475A-5 20-167
(1)
TESTING AND ADJUSTING MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL ANGLE
MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL

ANGLE (DUAL TILTDOZER SPECIFICATION)
a Measuring instrument for blade tilt control angle 3. Hold the buzzer cancel switch in the select posi-
tion [U] for 2.5 seconds to display the mainte-
Symbol Part No. Name nance mode.
S 799-402-3800 Angle gauge
4. Set the information switch in the [>] position to
a When the blade and blade cylinder potentiome- select the adjustment mode.
ter are removed and installed or when the ma-
chine controller is replaced, adjust the blade tilt
limit angle according to the following procedure.
a If this adjustment is not performed, the blade
may not tilt sufficiently or may tilt too much and
interfere with the track shoe. Be sure to perform
this adjustment.
a Perform this adjustment on a flat place.
1. Adjust installed length a of rod (1) and connect it

to potentiometer lever (2) and yoke (3).
Installed length: 425 mm
5. Set the buzzer cancel switch in the select posi-

tion [U] to select the adjustment selection
screen.
6. Operate information switches [<] and [>] to select

the tilt limit setting screen.
2. Run the engine at low idling, set the toggle switch

of the blade lever to the dual tilt position, and set
the blade in the following standard posture.
1) Set the blade horizontally (Set it to 0).
2) Pitch back the blade to the maximum.
3) Raise the blade at 100 mm above the
ground.

tion [U] to select the tilt limit adjustment mode.
8. Press the pitch switch of the blade lever, and the

buzzer sounds and the work equipment position
in the standard posture is saved.
20-168 D475A-5
(1)
9. Raise the blade tip to about 1 m above the

ground.

tion [U] again to select the tilt limit adjustment
mode.
10. Operate the blade lever to tilt the blade to the left
and set the left tilting angle to 12. 15. Operate the blade lever to tilt the blade to the
a Since the tilt limiting function does not work right and set the right tilting angle to 12.
at this time, operate the lever slowly and take a Since the tilt limiting function does not work
care not to increase the tilting angle too at this time, operate the lever slowly and take
much. care not to increase the tilting angle too
a Adjust the tilting angle accurately with angle much.
gauge S. a Adjust the tilting angle accurately with angle
gauge S.
11. Set the toggle switch of the blade lever in the sin-
16. Set the toggle switch of the blade lever in the sig-
gle tilt position and then set it in the dual tilt posi-
nal tilt position and then set it in the dual tilt posi-
tion again to save the left tilt limit value in the
tion again to save the right tilt limit value in the
system.
system.
a When saving is finished, the buzzer sounds.
a When saving is finished, the buzzer sounds.
12. Set the buzzer cancel switch in the cancel posi-
tion [t] once to cancel the tilt limit adjustment
tion [t] to cancel the tilt limit adjustment mode.
mode temporarily.
18. Lower the work equipment to the ground and
13. Set the blade in the maximum pitch dump pos-
stop the engine.
ture (Keep the work equipment horizontally).
19. Start the engine again, tilt the blade to the right
and left, and check that the blade does not inter-
fere with the track shoe at any height.
D475A-5 20-169
(1)
MEASUREMENT PROCEDURE FOR BLADE TILT CONTROL

ANGLE (SUPERDOZER SPECIFICATION)
a Measuring instrument for blade tilt control angle 3. Hold the buzzer cancel switch in the select posi-
tion [U] for 2.5 seconds to display the mainte-
Symbol Part No. Name nance mode.
S 799-402-3800 Angle gauge
4. Set the information switch in the [>] position to
a When the blade and blade cylinder potentiome- select the adjustment mode.
ter are removed and installed or when the ma-
chine controller is replaced, adjust the blade tilt
limit angle according to the following procedure.
a If this adjustment is not performed, the blade
may not tilt sufficiently or may tilt too much and
interfere with the track shoe. Be sure to perform
this adjustment.
a Perform this adjustment on a flat place.
1. Adjust installed length a of rod (1) and connect it

to potentiometer lever (2) and yoke (3).
Installed length: 415 mm

tion [U] to select the adjustment selection
screen.
6. Operate information switches [<] and [>] to select

the tilt limit setting screen.
2. Run the engine at low idling and set the blade in

the following standard posture.
1) Set the blade horizontally (Set it to 0).
2) Pitch back the blade to the maximum.
3) Raise the blade at 100 mm above the
ground.

tion [U] to select the tilt limit adjustment mode.
8. Press the pitch back button (lower button) of the

work equipment lever, and the buzzer sounds
and the work equipment position in the standard
posture is saved.

tion [t] once to cancel the tilt limit adjustment
mode temporarily.
20-170 D475A-5
(1)
10. Operate the blade according to the following pro- 14. Tilt the work equipment to the right by 7.
cedure so that it can be tilted.
1) Raise the blade tip to 200 300 mm above
the ground.
2) Set the blade angle to 52.
a Adjust the blade angle accurately with
angle gauge S.
15. Press the pitch dump button (upper button), and

the buzzer sounds and the right limit position is
saved.
a Since the tilt limiting function does not work
at this time, operate the lever slowly and take
care not to increase the tilting angle too
11. Set the buzzer cancel switch in the select posi- much.
tion [U] again to select the tilt limit adjustment a Adjust the tilting angle accurately with angle
mode. gauge S.
12. Raise the work equipment tip to about 1 m above 16. Set the buzzer cancel switch in the cancel posi-
the ground and tilt it to the left by 7. tion [t] to cancel the tilt limit adjustment mode.
17. Lower the work equipment to the ground and

stop the engine.
18. Start the engine again, tilt the blade to the right
and left, and check that the blade stops automat-
ically in the following range at any height.
Automatic tilt stopping angle: 7 1
13. Press the pitch dump button (upper button), and

the buzzer sounds and the left limit position is
saved.
a Since the tilt limiting function does not work
at this time, operate the lever slowly and take
care not to increase the tilting angle too
much.
a Adjust the tilting angle accurately with angle
gauge S.
D475A-5 20-171
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING OPERATOR'S CAB
TESTING AND ADJUSTING OPERATOR'S CAB

Check after installing cab assembly v) Seal the mounting holes of lock lever (1)
1. Measuring pressure in cab with tape (2).
Criterion:
Measured value X 98.1 Pa {10 mmH2O}
Engine speed: High idling
Blower speed: High (Hi)
Fresh/Recirculation switch: Fresh air position
Fan: Adjustment code:1005 (Fan 100% mode)
a If the measured value is lower than the
standard value, check the following.
(1) Plug of control box
(2) Air filters (recirculated air filter and fresh
air filter) of air conditioner for clogging
1) A simple method of measuring the internal
pressure is as follows.
i) Prepare a transparent vinyl hose.
Outside diameter: 10 mm, vi) Set the water level in the vinyl hose out
Length: 3,000 mm of the cab to that in the cab.
ii) Secure the end of hose [1] to the top of vii) Run the engine at high idling and meas-
the back of operator's seat with a tape. ure water level difference c.
iii) Pour water in the hose up to about half. (Value c: Pa {mmH2O})
iv) Remove slide glass lever lock (1) and a [a] side: Inside of cab (Pressurized)
insert the other end of vinyl hose [1]. [b] side: Out of cab
(Atmospheric pressure)
a Secure the end of hose [1] to the op-

erator's seat seat with tape. 2. Check of sealing performance
1) Close the all openings of the cab.
2) Splash water around the hatched part of the
cab at the rate of about 19 l/min for 10 min-
utes.
At this time, it is not necessary to splash
pressurized water.
3) Splash water horizontally from a hose over
sealing surface (3).
4) Check around the dashboard carefully.
a If water leaks, caulk the leaking part and
check again.
20-172 D475A-5
(1)
ii) Check the relationship between the

door latch and striker (on both sides).
Close door (5) and check the engag-
ing condition of latch (6) and striker
(7).
Normal: Deviation a is 0.5 mm or
less.
a Check deviation a of latch center y
and striker center x from each other
from the direction of A.
3. Testing door lock

Close the door and check the relationship
between the operator's cab and door. If there is
any fault, repair it.
1) Check of condition
i) Check the installed height of damper
rubbers (4). (Check 4 pieces on each
side.)
Stick adhesive tape [1] to the con-
tact face of damper rubber (4), open
and close the door 2 3 times.
Then, check the contact face of ad-
hesive tape [1] against the opera-
tor's cab.
Normal: When the door is closed,
the damper rubbers
come in contact lightly.
Abnormal: When the door is closed,
the damper rubbers do
not come in contact or
come in contact so
strongly that the adhe-
sive tapes are removed.
D475A-5 20-173
(1)
2) Adjusting 4. Testing open lock

i) Adjusting height of damper rubbers Lock the door open and check the relationship
Increase or decrease the number of between the operator's cab and door. If there is
shim (8) to properly adjust the height any fault, repair it.
of damper rubber (4). 1) Check of condition
i) Check the relationship between open
lock latch (6) and striker (7) from the
direction of B.
ii) Adjusting height of latch and striker

(1) Temporarily tighten the mounting
bolt of striker (7), open and close the
door 2 - 3 times to align latch (6) and a Open the door and check the engaging
striker (7) to each other. condition of the latch and striker.
(2) Check the engaging condition of Check that the claw of latch (6) does not
latch (6) and striker (7). ride over the bent part of striker (7).
(3) Securely tighten the mounting bolt of Check that the body of latch (6) does not
striker (7). interfere with striker (7).
(4) Open and close the door and check
that it is loc ked and un lock ed
smoothly. If the door is not locked
and unlocked smoothly (If the knob
is heavy), perform the adjustment
procedure from the first.
a Operating effort of door unlock lever:
68.6 19.6 N {7 2 kg}
iii) Apply grease (G2-LI) to latch (6).
a If latch (6) is not sufficiently greased,
the knob becomes heavy.
20-174 D475A-5
(1)
ii) Check the installed height of the stopper

rubbers.
(Check both sides, 4 pieces on each.)
Lock the door open and shake it in the
forward and reverse directions to see if it
has any play.
Check that the operating effort of the un-
lock lever is not heavy.
2) Adjusting
i) Adjusting latch and striker
Loosen the adjustment nut of striker (7)
and adjust striker (7) so that it will not in-
terfere with or ride over latch (6), then
tighten the nut.
If interference cannot be eliminated by
adjusting striker (7), loosen the mount-
ing bolt of latch (6) and adjust latch (6).
Push the door. If it moves until clear-
ance b between striker (7) and latch (6)
is reduced to "0", loosen mounting nut
(10) of stopper rubber (9) and extend
stopper rubber (9) in the pushing direc-
tion to adjust.
ii) Adjusting installed height of stopper rub-

ber
(1) Loosen locknut (10) of stopper rub-
ber (9).
(2) If there is any play, adjust stopper
rubber (9) until dimension c is as fol-
lows.
a If the door is not locked easily or the
unlock lever is heavy, return stopper
rubber (9) in the range that the door
does not have any play.
Dimension c of stopper rubber
above cab: 35 0.5 mm
Dimension c of stopper rubber
under cab: 32 0.5 mm
Operating effort of door unlock
lever: 68.6 19.6 Nm {7 2 kgm}
(3) After adjusting, tighten locknut (10).
D475A-5 20-175
(1)
TESTING AND ADJUSTING ADJUSTING BLADE
ADJUSTING BLADE
a If the blade is removed and installed or disas- 2) Adjust the shim of trunnion (3).
sembled and reassemble, adjust it according to
the following procedure. Adjusted
Adjusted
Standard clear-
Standard
clear- shim thick-
point ance
1. Adjusting shims for assembly ance ness
1) Adjust the shim of center (1). 3 c
1.56 0.65 mm
12 mm
(Total thickness)
Adjusted
Adjusted Standard clear- Standard shim
clear-
point ance thickness
ance
1 a See note. 4.5 mm
Note: Adjust the shim so that the play of the

ball in the axial direction will be less than
1 mm and the ball can rotate smoothly.
20-176 D475A-5
(1)
TESTING AND ADJUSTING ADJUSTING BLADE
2. Adjusting blade tilt distance

1) Adjust dimension d of brace (4) with the
handle.
Dimension d of brace: 1,844.5 mm
2) Measure right and left tilt distances e1 and
e2.
Blade U Semi-U
Right tilt distance Approx. 900 Approx. 750
(e1) mm mm
Left tilt distance Approx. 900 Approx. 750
(e2) mm mm
3) If both tilt distances are not the same, adjust

dimension d of brace (4) according to the
e1 > e2: Increase dimension d finely.
e1 < e2: Decrease dimension d finely.
D475A-5 20-177
(1)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Display section of special Operation section 1 of special Operation section 2 of special

functions functions (Basic operation) functions (Changeover operation)
1. Gear speed display section 3. Service switch 4. Buzzer cancel switch

2. Multi-information section 5. Information switch
6. Shift-up switch
7. Shift-down switch
a EMMS: Equipment Management Monitoring System
20-178 D475A-5
(1)
Normal function and special functions of monitor panel (EMMS)

The monitor panel (EMMS) has the normal function and special functions and displays information of various
types at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed according to the operation of the switches.
1. Normal function: Operation mode
With this function, the operator can display and change the items displayed normally.
2. Special function 1: Service mode
With this function, a serviceman can display and change the displayed items with special switches for test-
ing, adjusting, and troubleshooting.
Flow of modes and functions

Operator mode
Normal display (Default) 1 Maintenance mode Maintenance item: 12 items

[>] [<]
2 Pm clinic auxiliary mode Auxiliary menu: 4 items
Travel direction/Gear speed [U] [>] [<]
+ ( )
Shift mode/Service meter 3 Error code display mode
[>] [<]
[T] 4 Adjustment mode Adjustment menu: 6 items
[>] [<]
(Automatic) 1 Maintenance mode
Action code display function
[ON] & [U]( ) [T]

Service mode
Maintenance interval change

5 Maintenance item: 12 items
mode
[>] [<]
Electric system error code
6
display mode
[>] [<]
Mechanical system error code
7
display mode
[>] [<]
8 Adjustment mode Adjustment menu: 29 items
[>] [<]
9 Load memory display mode Display menu: 9 items
[>] [<]
10 Real-time monitoring mode
[>] [<]
11 Dual display monitoring mode
[>] [<] [ON]: Service switch
Snap shot mode [U]: Buzzer cancel switch (Left)
12
(Special mode for VHMS) [T]: Buzzer cancel switch (Right)
[>] [<] [ > ]: Information switch (Right)
Maintenance interval change [ < ]: Information switch (Left)
5 ( ): Min. 2.5 sec
mode
D475A-5 20-179
(1)
Operation and display in operator mode (Outline)

a In this section, only the outline of the operation
mode is described. For the details of the contents
and operation method of each function and
mode, see Operation Manual.
Normal display mode (Default)

The monitor panel displays the following information
normally.
Gear speed display section (1):
Left side: Travel direction (PNFR)
Right side: Gear speed (123)
Graphics: Engine speed
Multi-information section (2):
a Information is displayed in 2 lines of 16 charac-
ters each.
Left side:
Gear shift mode (F1-R1F1-R2F2-R2)
Right side:
Service meter (Unit: 0.1h)
a To change the normal display mode to the oper-
ator mode, hold buzzer cancel switch (4) in the
[U] position for 2.5 seconds.
1. Maintenance mode
(1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replace-
ment of oils and filters is displayed on the multi-
information section (2) and reset after the
replacement.
a Gear speed display section (1) keeps dis-
playing normally.
Order Display Item

1 01:ENG OIL Engine oil
2 02:ENG FLT Engine oil filter
3 03:BYPS FLT Bypass filter ( )
4 04:FUEL FLT Fuel filter
5 05:CORR FLT Corrosion resistor
6 06:P/L OIL Power train oil
7 07:P/L FLT Power train oil filter
8 08:HYD OIL Hydraulic oil
9 09:HYD FLT Hydraulic oil filter
10 10:CHG FLT HSS charge filter ( )
11 11:DAMP OIL Damper oil
12 12:F/D OIL Final drive oil
: Displayed on D475A-5 but not set.
20-180 D475A-5
(1)
2. Pm clinic auxiliary mode

(2-PM CLINIC MODE)
In this mode, the condition of the machine is dis-
played on multi-information section (2) as an
auxiliary function of the periodic diagnoses such
as the Pm clinic, even if any measuring instru-
ment is not connected.
playing normally.
Order Display Item

1 01-ENG. SPEED Engine speed
Work equipment oil
2 02-H. PUMP PRES F
pressure 1
Work equipment oil
3 03-H. PUMP PRES R
pressure 2
4 04-BATTERY VOLT Battery voltage
3. Error code display mode

(3-FAULT CODE DISPLAY MODE)
In this mode, the contents of each fault in the
machine are displayed by a 6-character error
code on the multi-information section (2).
When the user or the operator needs to be noti-
fied of the error code of each fault, this mode is
applied.
playing normally.
a When a serviceman needs to check the error
codes for troubleshooting, the Electric sys-
tem error code display mode and the Me-
chanical system error code display mode
should be used for more detailed informa-
tion.
a Method of checking error code:
Turn buzzer cancel switch (4) to the [U]
position on the screen shown at right, and
the all error codes detected currently are
displayed at the interval of about 2 seconds.
(To finish displaying, turn the buzzer cancel
switch to the [ T ] position.)
D475A-5 20-181
(1)
Failure codes list
Cau- Cau-
Failure Con- Action
Failure Trouble tion tion
code troller code
lamp buzzer
1500L0 Double failure of transmission * See separate list (LO) TM CALL E03 q q
15SAL1 Forward clutch oil pressure * See separate list (L1) TM CALL E03 q q
15SALH Forward clutch oil pressure * See separate list (LH) TM CALL E03 q q
15SBL1 Reverse clutch oil pressure * See separate list (L1) TM CALL E03 q q
15SBLH Reverse clutch oil pressure * See separate list (LH) TM CALL E03 q q
15SEL1 1st clutch oil pressure * See separate list (L1) TM CALL E03 q q
15SELH 1st clutch oil pressure * See separate list (LH) TM CALL E03 q q
15SFL1 2nd clutch oil pressure * See separate list (L1) TM CALL E03 q q
15SFLH 2nd clutch oil pressure * See separate list (LH) TM CALL E03 q q
15SGL1 3rd clutch oil pressure * See separate list (L1) TM CALL E03 q q
15SGLH 3rd clutch oil pressure * See separate list (LH) TM CALL E03 q q
1800MW Power train clutch slip Slip (MV) TM E02 q q
2201L1 Right clutch oil pressure * See separate list (L1) ST CALL E04 q q
2201LH Right clutch oil pressure * See separate list (LH) ST CALL E04 q q
2202L1 Left clutch oil pressure * See separate list (L1) ST CALL E04 q q
2202LH Left clutch oil pressure * See separate list (LH) ST CALL E04 q q
2300NR Brake thermal load Abnormal heating (NR) ST
2301L1 Right brake oil pressure * See separate list (L1) ST CALL E04 q q
2301LH Right brake oil pressure * See separate list (LH) ST CALL E04 q q
2301NR Right steering brake thermal load Abnormal heating (NR) ST
2302L1 Left brake oil pressure * See separate list (L1) ST CALL E04 q q
2302LH Left brake oil pressure * See separate list (LH) ST CALL E04 q q
2302NR Left steering brake thermal load Abnormal heating (NR) ST
A000N1 Engine speed sensor abnormality Over run (N1) VHMS
A70XLK Governor servo system right abnormality * See separate list (LK) ENG CALL E04 q q
A70YLK Governor servo system left abnormality * See separate list (LK) ENG CALL E04 q q
AA1ANX Air cleaner clogging Clogging (NX) Machine
AB00MA Battery charge abnormality Malfunction (MA) Machine
B@BAZG Engine oil pressure lowering Lowering of oil pressure (ZC) Machine
B@BAZK Engine oil level lowering Lowering of level (ZK) Machine
B@BCNS Coolant overheating Overheating (NS) Machine
B@BCZK Coolant water level lowering Lowering of level (ZK) Machine
B@CENS Power train overheating Overheating (NS) Machine
B@HANS Hydraulic oil overheating Overheating (NS) Machine
B@HAZK Hydraulic oil level lowering Lowering of level (ZK) Machine
D110KA BR relay holding Disconnection (KA) ST
D110KB BR relay holding Short circuit (KB) ST
D130KA N safety relay Disconnection (KA) TM E02 q q
D130KB N safety relay Short circuit (KB) TM E02 q q
D161KA Backup alarm relay Disconnection (KA) TM E01
D161KB Backup alarm relay Short circuit (KB) TM E01
D182KZ Preheating relay Lowering of level (ZK) ST E01
D1D0KA Governor cut relay right disconnection Disconnection (KA) ENG E01
D1D0KB Governor cut relay right short circuit Short circuit (KB) ENG E01
D1D1KA Governor cut relay left disconnection Disconnection (KA) ENG E01
20-182 D475A-5
(2)
Cau- Cau-
Failure Con- Action
code troller code
lamp buzzer
D1D1KB Governor cut relay left short circuit Short circuit (KB) ENG E01
D5ZFKA N-signal 1 Disconnection (KA) TM E01
D5ZFKB N-signal 1 Short circuit (KB) TM E01
D5ZFL4 N-signal abnormality * See separate list (L4) ENG E01
D5ZGKA N-signal 2 Disconnection (KA) TM E01
D5ZGKB N-signal 2 Short circuit (KB) TM E01
D5ZKKX Chassis throttle signal abnormality Out of input signal range (KX) ENG CALL E03 q q
D5ZRKA Snap shot signal disconnection Disconnection (KA) ST
D5ZRKB Snap shot signal short circuit Short circuit (KB) ST
Defective communication (Objec-
DAFRKR RTCDB abnormality MON CALL E03 q q
tive component abnormality) (KR)
Lowering of source voltage (input)
DAQ0KK Source voltage abnormality TM CALL E04 q q
(KK)
DAQ0KT Saved value abnormality Internal defect of controller (KT) TM E01
DAQ5KK Potentiometer power supply abnormality TM CALL E03 q q
(KK)
DAQ6KK Sensor power supply abnormality TM E01
(KK)
Disagreement of model selection
DAQ9KQ Model selection 1, 2, 3 TM CALL E04 q q
signals (KQ)
DAQRKR RTCDB abnormality TM CALL E03 q q
DAQSKR Network abnormality TM E01
DB30KK Source voltage abnormality ST CALL E04 q q
(KK)
DB30KT Saved value abnormality Internal defect of controller (KT) ST E01
DB35KK Potentiometer power supply abnormality ST CALL E03 q q
(KK)
DB36KK Sensor power supply abnormality ST CALL E03 q q
(KK)
DB39KQ Model selection 1, 2, 3 ST CALL E04 q q
signals (KQ)
DB3RKR RTCDB abnormality ST CALL E03 q q
DB3SKR Network abnormality ST E01
DB40KK Source voltage abnormality ENG CALL E04 q q
(KK)
DB41KK Switch power supply abnormality ENG CALL E03 q q
(KK)
DB42KK Solenoid power supply 1 abnormality ENG CALL E04 q q
(KK)
DB43KK Backup power supply abnormality ENG CALL E03 q q
(KK)
DB44KK Solenoid power supply 2 abnormality ENG CALL E04 q q
(KK)
DB45KP Rack sensor power supply abnormality Lowering of output voltage (KP) ENG CALL E03 q q
DB49KM Connector wrong connection Mistake in operation or setting (KM) ENG CALL E04 q q
DB49KQ Model selection abnormality ENG E02 q q
signals (KQ)
D475A-5 20-183
(2)
Cau- Cau-
Failure Con- Action
code troller code
lamp buzzer
VHMS supply constant voltage abnor- Lowering of power source voltage
DBB0KK VHMS
mality (KK)
DBB0KQ VHMS contoroller abnormality VHMS
signals (KQ)
VHMS contoroller battery direct power Lowering of battery direct source
DBB3KK VHMS
source voltage (KK)
DBB5KP 5V power source for sensor abnormality Lowering of output voltage (KP) VHMS
DBBQKR VHMS KOM-NET network abnormality Defective communication (KR) VHMS
DD12KA Shift-up SW Disconnection (KA) TM E02 q q
DD12KB Shift-up SW Short circuit (KB) TM E02 q q
DD13KA Shift-down SW Disconnection (KA) TM E02 q q
DD13KB Shift-down SW Short circuit (KB) TM E02 q q
DD14KA Travel lock SW Disconnection (KA) TM CALL E03 q q
DD14KB Travel lock SW Short circuit (KB) TM CALL E03 q q
DDB9KA Reverse SW Disconnection (KA) TM CALL E03 q q
DDB9KB Reverse SW Short circuit (KB) TM CALL E03 q q
DDK3KA Forward SW Disconnection (KA) TM CALL E03 q q
DDK3KB Forward SW Short circuit (KB) TM CALL E03 q q
DDK5KA Shift SW Disconnection (KA) TM E02 q q
DDK5KB Shift SW Short circuit (KB) TM E02 q q
DDN2LD PPC tilt right oil pressure SW * See separate list (LD) TM E02 q q
DDN3LD PPC tilt left oil pressure SW * See separate list (LD) TM E02 q q
DDN7KA Pitch SW Disconnection (KA) TM E02 q q
DDN7KB Pitch SW Short circuit (KB) TM E02 q q
DDN9KA Dual tilt SW Disconnection (KA) TM E01
DDN9KB Dual tilt SW Short circuit (KB) TM E01
DDNALD PPC lift raise full oil pressure SW * See separate list (LD) TM
DDNBLD PPC ripper raise oil pressure SW * See separate list (LD) TM
DDNCLD PPC ripper lower oil pressure SW * See separate list (LD) TM
DDNDLD PPC ripper tilt oil pressure SW * See separate list (LD) TM
DDNELD PPC ripper tilt back oil pressure SW * See separate list (LD) TM
DDNFLD PPC lift lower full oil pressure SW * See separate list (LD) TM
DDQ2KA Travel lock SW Disconnection (KA) ST CALL E03 q q
DDQ2KB Travel lock SW Short circuit (KB) ST CALL E03 q q
DDQ2L4 Travel lock inconsistency 1, 2 * See separate list (L4) ST CALL E03 q q
DDT5KA Neutral SW Disconnection (KA) TM CALL E04 q q
DDT5KB Neutral SW Short circuit (KB) TM CALL E04 q q
DDT5KQ Lever specification selection error TM CALL E04 q q
signals (KQ)
DGE1KB Engine oil temperature sensor Short circuit (KB) VHMS
DGE1KY Engine oil temperature sensor Disconnection (KY) VHMS
DGE2KX Water temperature sensor abnormality Out of input signal range (KX) ENG E02
Water temperature sensor abnormality
DGE3KA Disconnection (KA) ST E01
(Low temperature side)
DGE5KB Atmospheric temperature sensor Short circuit (KB) VHMS
20-184 D475A-5
(2)
Cau- Cau-
Failure Con- Action
code troller code
lamp buzzer
DGS1KX Hydraulic oil temperature sensor Out of input signal range (KX) TM
DGT5KA Left bank exhaust temperature sensor Disconnection (KA) VHMS
DGT5KB Left bank exhaust temperature sensor Short circuit (KB) VHMS
DGT6KA Right bank exhaust temperature sensor Disconnection (KA) VHMS
DGT6KB Right bank exhaust temperature sensor Short circuit (KB) VHMS
DH22KA Hydraulic oil pressure 1 (F) sensor Disconnection (KA) TM
DH22KB Hydraulic oil pressure 1 (F) sensor Short circuit (KB) TM
DH23KA Hydraulic oil pressure 2 (R) sensor Disconnection (KA) TM
DH23KB Hydraulic oil pressure 2 (R) sensor Short circuit (KB) TM
DHE4KA Engine oil pressure sensor Disconnection (KA) ST E02 q q
DHE4KB Engine oil pressure sensor Short circuit (KB) ST E02 q q
DHE5KB Blow-by pressure sensor Disconnection (KB) VHMS
Short circuit with power supply line
DHE5KY Blow-by pressure sensor VHMS
(KY)
DHT3KX Transmission oil pressure sensor Out of input signal range (KX) VHMS
DK01KA Left yoke angle sensor Disconnection (KA) TM E02 q q
DK01KB Left yoke angle sensor Short circuit (KB) TM E02 q q
DK03KA Right yoke angle sensor Disconnection (KA) TM E02 q q
DK03KB Right yoke angle sensor Short circuit (KB) TM E02 q q
DK10KX Fuel control dial abnormality Out of input signal range (KX) ENG CALL E03 q q
DK12KX Deceleration potentiometer abnormality Out of input signal range (KX) ENG CALL E03 q q
DK30KA Swing potentiometer 1 disconnection Disconnection (KA) ST CALL E03 q q
DK30KB Swing potentiometer 1 short circuit Short circuit (KB) ST CALL E03 q q
DK30KX Swing system 2 system Out of input signal range (KX) ST CALL E04 q q
DK30KZ Steering potentiometer abnormality Disconnection or short circuit (KZ) ST CALL E04 q q
DK30L8 Swing potentiometer shifting * See separate list (L8) ST CALL E03 q q
DK31KA Swing potentiometer 2 disconnection Disconnection (KA) ST CALL E03 q q
DK31KB Swing potentiometer 2 short circuit Short circuit (KB) ST CALL E03 q q
DK40KA Brake potentiometer Disconnection (KA) ST CALL E03 q q
DK40KB Brake potentiometer Short circuit (KB) ST CALL E03 q q
DK55KX Forward-Reverse system 2 system Out of input signal range (KX) TM CALL E04 q q
Forward-Reverse potentiometer abnor-
DK55KZ Disconnection or short circuit (KZ) TM CALL E04 q q
mality
Forward-Reverse potentiometer shifting
DK55L8 and OK& potentiometer shifting when * See separate list (L8) TM CALL E03 q q
key is turned ON
Forward-Reverse potentiometer 1 dis-
DK56KA Disconnection (KA) TM CALL E03 q q
connection
Forward-Reverse potentiometer 1 short
DK56KB Short circuit (KB) TM CALL E03 q q
circuit
Forward-Reverse potentiometer 2 dis-
DK57KA Disconnection (KA) TM CALL E03 q q
connection
Forward-Reverse potentiometer 2 short
DK57KB Short circuit (KB) TM CALL E03 q q
circuit
DK60KA Acceleration sensor Disconnection (KA) ST E01
DK60KB Acceleration sensor Short circuit (KB) ST E01
DKF0KX Fuel injection pump rack sensor Out of input signal range (KX) VHMS
DKF1KX Rack sensor right abnormality Out of input signal range (KX) ENG CALL E03 q q
D475A-5 20-185
(2)
Cau- Cau-
Failure Con- Action
code troller code
lamp buzzer
DKF2KX Rack sensor left abnormality Out of input signal range (KX) ENG CALL E03 q q
DKH1KA Pitch angle sensor Disconnection (KA) ST CALL E03 q q
DKH1KB Pitch angle sensor Short circuit (KB) ST CALL E03 q q
DLE1KA Engine speed sensor Disconnection (KA) ST E01
DLE4LC Engine speed sensor A abnormality * See separate list (LC) ENG CALL E03 q q
DLE5LC Engine speed sensor B abnormality * See separate list (LC) ENG CALL E03 q q
DLF1KA Transmission speed sensor Disconnection (KA) TM E01
DLT3KA Transmission output shaft speed sensor Disconnection (KA) TM E01
DV00KB Caution buzzer Short circuit (KB) MON E01 q
DW55KA Pitch back solenoid Disconnection (KA) TM CALL E03 q q
DW55KB Pitch back solenoid Short circuit (KB) TM CALL E03 q q
DW56KA Pitch dump solenoid Disconnection (KA) TM CALL E03 q q
DW56KB Pitch dump solenoid Short circuit (KB) TM CALL E03 q q
DW57KA Left tilt limit solenoid Disconnection (KA) TM E02 q q
DW57KB Left tilt limit solenoid Short circuit (KB) TM E02 q q
DW58KA Right tilt limit solenoid Disconnection (KA) TM E02 q q
DW58KB Right tilt limit solenoid Short circuit (KB) TM E02 q q
DW59KA Dual tilt selection solenoid Disconnection (KA) TM E01
DW59KB Dual tilt selection solenoid Short circuit (KB) TM E01
DW5AKA Pitch selection solenoid Disconnection (KA) TM E02 q q
DW5AKB Pitch selection solenoid Short circuit (KB) TM E02 q q
DW5DKA Pitch selection solenoid Disconnection (KA) TM CALL E03 q q
DW5DKB Pitch selection solenoid Short circuit (KB) TM CALL E03 q q
DW7BKA Fan reverse solenoid Disconnection (KA) TM E01
DW7BKB Fan reverse solenoid Short circuit (KB) TM E01
DWJ0KA Pump merge-divider solenoid Disconnection (KA) ST CALL E03 q q
DWJ0KB Pump merge-divider solenoid Short circuit (KB) ST CALL E03 q q
DWN3KA Sudden stop prevention solenoid Disconnection (KA) ST CALL E04 q q
DWN3KB Sudden stop prevention solenoid Short circuit (KB) ST CALL E04 q q
DWN5KA Fan control solenoid 1 Disconnection (KA) TM E01
DWN5KB Fan control solenoid 1 Short circuit (KB) TM E01
DWNCKA Fan control solenoid 2 Disconnection (KA) TM E01
DWNCKB Fan control solenoid 2 Short circuit (KB) TM E01
DXE0KA LS set selector solenoid (LSV) Disconnection (KA) TM E02 q q
DXE0KB LS set selector solenoid (LSV) Short circuit (KB) TM E02 q q
DXH1KA Lockup solenoid Disconnection (KA) TM E01
DXH1KB Lockup solenoid Short circuit (KB) TM E01
DXH4KA 1st clutch ECMV Disconnection (KA) TM CALL E03 q q
DXH4KB 1st clutch ECMV Short circuit (KB) TM CALL E03 q q
DXH5KA 2nd clutch ECMV Disconnection (KA) TM CALL E03 q q
DXH5KB 2nd clutch ECMV Short circuit (KB) TM CALL E03 q q
DXH6KA 3rd clutch ECMV Disconnection (KA) TM CALL E03 q q
DXH6KB 3rd clutch ECMV Short circuit (KB) TM CALL E03 q q
DXH7KA Reverse clutch ECMV Disconnection (KA) TM CALL E03 q q
DXH7KB Reverse clutch ECMV Short circuit (KB) TM CALL E03 q q
DXH8KA Forward clutch ECMV Disconnection (KA) TM CALL E03 q q
20-186 D475A-5
(1)
Cau- Cau-
Failure Con- Action
code troller code
lamp buzzer
DXH8KB Forward clutch ECMV Short circuit (KB) TM CALL E03 q q
DXH9KA Right clutch ECMV Disconnection (KA) ST CALL E03 q q
DXH9KB Right clutch ECMV Short circuit (KB) ST CALL E03 q q
DXHAKA Left clutch ECMV Disconnection (KA) ST CALL E03 q q
DXHAKB Left clutch ECMV Short circuit (KB) ST CALL E03 q q
DXHBKA Right brake ECMV Disconnection (KA) ST CALL E04 q q
DXHBKB Right brake ECMV Short circuit (KB) ST CALL E04 q q
DXHCKA Left brake ECMV Disconnection (KA) ST CALL E04 q q
DXHCKB Left brake ECMV Short circuit (KB) ST CALL E04 q q
DXHDKA Governor solenoid right disconnection Disconnection (KA) ENG CALL E04 q q
DXHDKB Governor solenoid right short circuit Short circuit (KB) ENG CALL E04 q q
DXHEKA Governor solenoid left disconnection Disconnection (KA) ENG CALL E04 q q
DXHEKB Governor solenoid left short circuit Short circuit (KB) ENG CALL E04 q q
DXHFKA Pre-stroke solenoid right disconnection Disconnection (KA) ENG CALL E03 q q
DXHFKB Pre-stroke solenoid right short circuit Short circuit (KB) ENG CALL E03 q q
DXHGKA Pre-stroke solenoid left disconnection Disconnection (KA) ENG CALL E03 q q
DXHGKB Pre-stroke solenoid left short circuit Short circuit (KB) ENG CALL E03 q q
F@BBZL Blow-by pressure sensor abnormality Over pressure (ZL) VHMS
Left bank exhaust temperature sensor
F@BYNR Abnormal heating (NR) VHMS
(2) abnormality
Left bank exhaust temperature sensor
F@BYNS Overheating (NS) VHMS
(1) abnormality
Right bank exhaust temperature sensor
F@BZNR Abnormal heating (NR) VHMS
(2) abnormality
Right bank exhaust temperature sensor
F@BZNS Overheating (NS) VHMS
(1) abnormality
D475A-5 20-187
(2)
Separate list: Phenomenon codes list
Phenome- Phenome-
Detail of phenomenon Detail of phenomenon
non code non code
Run and stop of engine do not agree with sig-
KA Disconnection L6
nals
KB Short circuit L8 Analog signals do not agree
KK Lowing of source voltage (input) LC Revolving speed signals do not agree
KP Lowering of output voltage LD Switch is pressed for long time
While command signal current is ON, fill signal
KQ Disagreement of model selection signals LH
is OFF
Defective communication (Objective compo- Feedback signal does not agree with output sig-
KR LK
nent abnormality) nal
KT Internal defect of controller MA Malfunction
KX Out of input signal range MB Lowering of function
KZ Disconnection or short circuit MW Slip
L0 Double engagement NR Abnormal heating
L1 While command current is OFF, fill signal is ON NS Overheating
L2 Fuel pressure is too high NX Clogging
L3 Uncontrollability ZG Lowering of oil pressure
L4 ON and OFF signals do not agree ZK Lowering of level
a "Controller" in the table indicates classification of the controller in charge of system check, monitor panel, and
code.
MON: Failure code of electric system checked by monitor panel
ENG: Failure code of electric system checked by engine controller
T/M: Failure code of electric system checked by transmission controller
S/T: Failure code of electric system checked by steering controller
Machine:Failure code of mechanical system
4. Adjustment mode (4-USER ADJUST MODE)

In this mode, the display condition of the monitor
panel can be adjusted and the fan speed (for
cleaning the radiator) can be changed on the
multi-information section (2).
playing normally.
Order Display Item

Adjustment of LCD
1 01:LCD BRIGHTNES
brightness
Adjustment of dis-
2 02:DSP BRIGHTNES
play brightness
Adjustment of dis-
3 03:DSP CONTRAST
play contrast
Tilt limit adjustment
4 04:TILT LIMIT
mode
Fan 100% speed
5 05:FAN 100% SPEED mode (For cleaning
radiator)
Pre-lubrication reset
6 06:SKIP PRE_LUB mode against pre-
lubrication trouble
20-188 D475A-5
(1)
Action code display function

If a fault notifies the operator, occurs during work, an
action code and a phone number are displayed on
the multi-information section (2).
a Gear speed display section (1) keeps displaying
normally.
a The phone No. is displayed for only important ac-
tion codes. The display shown at right is an ex-
ample. (The form of the displayed phone No.
depends on the form of the input No.)
a If an important action code is displayed, the cau-
tion lamp flashes and the caution buzzer sounds.
<Reference>
An action code is displayed only when a serious
fault occurs.
Even if an action code is not displayed, a fault may
have occurred. If you feel any abnormality, be sure
to check for a error code in the Electric system error
code display mode and Mechanical system error
code display mode of the service mode.
Action codes table
Action
Indication method of fault Contents of fault Remedy
code
Torque converter is not locked up. Automatic function stops or normal

E01 Only action code is dis- Blade dual tilt mechanism does not function stops partially but machine
played. work. can work.
Call your Komatsu distributor for repair.
Stop engine and start it again, and you
Action code is displayed. Gear is not shifted up or down. can operate machine without limiting
E02 Caution lamp flashes. Blade tilt is not limited. function. You must take care, however.
Caution buzzer sounds. Blade pitch mechanism does not work. Call your Komatsu distributor for repair.
Engine coolant temperature is defec-
tive.
Action code is displayed. Usable gear speeds are limited.
CALL E03 Caution lamp flashes. Engine speed does not rise fully. Move machine to safe place.
Caution buzzer sounds. Gear shifting shocks become large. Call your Komatsu distributor for repair.
Steering performance lowers.
Brake shocks become large.
Action code is displayed. Engine cannot be controlled.
CALL E04 Caution lamp flashes. Machine cannot travel. Stop machine immediately.
Caution buzzer sounds. Machine stops. Call your Komatsu distributor for repair.
D475A-5 20-189
(1)
Operation and display in service mode

Method of changing to service mode
a When using the service mode, change the
screen by the following special operation.
1) Special operation of switches

Set the monitor panel in the service mode by
operating service switch (3) and buzzer cancel
switch (4).
a Keeping the service switch in the ON posi-
tion, hold the buzzer cancel switch in the [U]
position for 2.5 seconds.
a If the monitor panel is set in the service
mode, [1C] is displayed on the gear speed
display section (1).
a Each time the monitor panel is set in the
service mode, the Maintenance interval
change mode is displayed first.
2) Selecting and executing mode to be used

Select the mode to be used with information
switch (5) and execute it with buzzer cancel
switch (4).
[ > ]: Next mode No.
[ < ]: Previous mode No.
[U]: Execute mode.
a For the details of operation in each mode,
see the following pages.
Gear
3) Finishing mode and function Order speed Display and item
The current mode and function can be finished display
by either of the following method, regardless of 5-EXCHG, INTVAL. SET MODE
the current mode and hierarchy. 1 1C
Maintenance interval change mode
(1) When continuing the operation in another
mode or function or in the operator mode: 6-ELEC. FAULT CODE MODE
2 EE
Return to the mode screen or function Electric system fault code display mode
screen to be used next by operating buzzer 7-MACHINE FAULT CODE MODE
cancel switch (4). 3 bE Mechanical system fault code display
[T]: Screen returns. mode
(2) When finishing the all operation: 8-SERVICE ADJUST MODE
Turn off the starting switch. 4 Cb
Adjustment mode
9-LOAD MEMORY DISPLEY MODE
5 Ld
Load memory display mode
10-REAL TIME MONITORING MODE
6 5R
Real time monitoring mode
11-DUAL DISPLAY MONITORING MODE
7 dR
Dual display monitoring mode
12-SNAP SHOT MODE
8 55
Snap shot mode *
* VHMS specification only
20-190 D475A-5
(1)
5. Maintenance interval change mode

(5-EXCHG. INTVAL. SET MODE)
In this mode, you can check and set the mainte-
nance interval times of various filters and oils
which are the bases of the maintenance display
function in the operator mode.
1) Selecting and executing mode

i) Select Maintenance interval change
mode on the mode selection screen.
a If the mode is selected, code (1C) is
displayed on gear speed display
section (1) and the title is displayed
on multi-information section (2).
ii) Display the maintenance item selection
screen by operating buzzer cancel
switch (4).
[U]: Execute mode.
2) Selecting and displaying mintenance item

i) Operate information switch (5) on the
maintenance item selection screen to
select a maintenance item.
[ > ]: Next code
[ < ]: Previous code
ii) Display the maintenance item selection
switch (4).
[U]: Execute item.
3) Contents of information section

The following items are displayed on the
information section.
(1) Code
(2) Maintenance item
(3) Replacement interval time (Set time)
a The items shown at right are examples.
a If the replacement interval does not need
to be changed, finish the operation on
this screen.
a If the replacement interval needs to be
changed, go to step 4).
D475A-5 20-191
(1)
4) Changing replacement interval time

i) Change the set time by operating infor-
mation switch (5), shift-up switch (6),
and shift-down switch (7).
[ > ]: Move cursor to right.
[ < ]: Move cursor to left.
[UP]: Increase number.
[DOWN]: Decrease number.
a If you do not use the maintenance

function, set the all times to 0.
ii) If the input time is correct, enter the

change of setting by operating buzzer
cancel switch (4).
[U]: Enter change.
a If the change is finished normally,
the information display screen ap-
pears after the screen shown at
right.
a If the change is not finished normal-

ly, the information display screen
before the change appears after the
screen shown at right. In this case,
execute the above operation again.
20-192 D475A-5
(1)
Maintenance items list
Replacement interval
Order Display Item 1st time 2nd time and after
(Must not be changed) (May be changed)
1 01:ENG OIL Engine oil 0500 h 0500 h
2 02:ENG FLT Engine oil filter 0500 h 0500 h
3 03:FUEL FLT Fuel filter 0500 h 0500 h
4 04:HYD FLT Hydraulic oil filter 0250 h 2000 h
5 06:CORR RES Corrosion resistor 1000 h 1000 h
6 18:BYPS FLT Bypass filter * 0h 0h
7 07:DAMP OIL Damper oil 2000 h 2000 h
8 08:F/D OIL Final drive oil 0250 h 000 h
9 10:HYD OIL Hydraulic oil 0250 h 2000 h
10 19:POWL OIL Power train oil 0250 h 1000 h
11 20:POWL FLT Power train oil filter 0250 h 0500 h
12 12:HSS FLT Charge filter * 0h 0h
* Displayed on D475A-5 but not set.
a The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that the
first maintenance has been finished in the maintenance mode of the operator mode, then change the 2nd
and after interval times.
D475A-5 20-193
(1)
6. Electric system error code display mode

(6-ELEC. ERROR CODE MODE)
In this mode, you can check the past electric
system error codes.

i) Select Electric system error code display
mode on the mode selection screen.
a If the mode is selected, code (EE) is
ii) Display the error code display screen by
operating buzzer cancel switch (4).
[U]: Execute mode.
2) Display in the case where no codes are

recorded
If no error codes have been output up to
now, the information section displays as
shown at right.
3) Display in the case where 1 or more codes

are recorded
If any error code has been output up to now,
the information section displays as shown at
right.
(1) Record No. (Up to 20)
(2) Error code (Code being output currently
is flashing)
(3) Number of past occurrences
(4) Time measured by service meter after
first occurrence
last occurrence
a For the details of displayed error codes,
see the ERROR CODES TABLE in the
operator mode.
20-194 D475A-5
(1)
a Flashing and lighting of error code

Flashing: Code is being output currently.
Lighting: Code is not being output cur-
rently.
a Condition for detecting and keeping er-
ror code
If a error code of any item other than
communication is output, it keeps flash-
ing until the starting switch is turned off.
After the starting switch is turn on or the
engine is started again, the error code
keeps lighting until the same fault is
detected.
A error code of communication starts
lighting when the fault is solved, even if
the starting switch is turned off.
4) Operation to take when multiple codes are

recorded.
When multiple codes are recorded, they can
be displayed one by one by operating infor-
mation switch (5).
[ > ]: Next code
a The error codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting error code

While a error code to be deleted, operate
shift-up switch (6) or shift-down switch (7).
[UP] or [DOWN]: Delete error code.
a A error code which is being output cur-
rently (which is flashing) cannot be delet-
ed.
D475A-5 20-195
(1)
7. Mechanical system error code display mode

(7-MACHINE ERROR CODE MODE)
In this mode, you can check the past mechani-
cal system error codes.

i) Select Mechanical system error code
display mode on the mode selection
screen.
a If the mode is selected, code (bE) is
ii) Display the error code display screen by
operating buzzer cancel switch (4).
[U]: Execute mode.
2) Display in the case where no codes are

recorded
If no error codes have been output up to
now, the information section displays as
shown at right.
3) Display in the case where 1 or more codes

are recorded
If any error code has been output up to now,
the information section displays as shown at
right.
(1) Record No. (Up to 20)
(2) Error code (Code being output currently
is flashing)
(3) Number of past occurrences
first occurrence
last occurrence
a For the details of displayed error codes,
see the ERROR CODES TABLE in the
operator mode.
20-196 D475A-5
(1)
a Flashing and lighting of error code

Flashing: Code is being output currently.
Lighting: Code is not being output cur-
rently.
a Condition for detecting and keeping er-
ror code
If a error code of any item other than
communication is output, it keeps flash-
ing until the starting switch is turned off.
After the starting switch is turn on or the
engine is started again, the error code
keeps lighting until the same fault is
detected.
A error code of communication starts
lighting when the fault is solved, even if
the starting switch is turned off.
4) Operation to take when multiple codes are

recorded.
When multiple codes are recorded, they can
be displayed one by one by operating infor-
mation switch (5).
[ > ]: Next code
a The error codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting error code

The mechanical system error codes cannot
be deleted.
D475A-5 20-197
(1)
8. Adjustment mode
(8-SERVICE ADJUST MODE)
In this mode, you can adjust the control system
and various devices of the machine.

i) Select Adjustment mode on the mode
selection screen.
a If the mode is selected, code (Cb) is
ii) Display the adjustment code input
switch (4).
[U]: Execute mode.
2) Selecting adjustment items

On the adjustment code input screen, input
the 4-digit code of the item to be adjusted by
operating information switch (5), shift-up
switch (6), and shift-down switch (7).
a If the 4-digit code is input, the informa-
tion of that code is displayed automati-
cally.
3) Contents of display on adjustment screen

(1) Code
(2) Adjustment item
(3) Related information
a For the detailed information and adjust-
ment procedure, see ADJUSTMENT
MODE TABLE AND ADJUSTMENT
PROCEDURE.
20-198 D475A-5
(1)
a If an incorrect code is input, the adjust-

ment code input screen appears again
after the screen shown at right. In this
case, execute the above operation
again.
4) When operating machine in adjustment

mode
If the parking brake lever is set in the FREE
position, gear speed display section (1) dis-
plays normally and the machine can be
operated normally.
a To select another screen, return the
parking brake lever to the LOCK position
and perform the necessary procedure.
5) Automatic selection of adjustment item

(Limited function)
After one of some adjustment items is select-
ed, if the information switch is operated, the
next adjustment item is selected automatical-
ly, even if the code of the next adjustment
item is not input.
[ > ]: Code is increased
[ < ]: Code is decreased
a This function is applied to only the items
having numbers in the Automatic selec-
tion column of the Adjustment mode ta-
ble. Those items are selected in the
order of their numbers.
a Note that this operation is not effective
while the parking brake lever is in the
RESET position.
a You may return to the screen for input-
ting codes and enter a code without us-
ing this function.
D475A-5 20-199
(1)
Adjustment modes list and adjustment procedure
Disassembly Sending
No. Code Adjustable item Related information
and assembly in order
(1) 0001 INP TEL NO. Phone No. input mode Numerals and symbols
(2) 0002 S/T S. CODE Steering controller specification set Code q 1
(3) 0003 T/M S. CODE Transmission controller specification set Code q 2
(4) 0004 BODY TYPE Machine specification set Code q 3
(5) 0005 BRAKE BASE Brake potentiometer zero point adjustment Voltage q 4
(6) 0007 ENG. FULL CH Engine deceleration cut mode Revolving speed 5
(7) 0009 PITCH SENS. Pitch angle sensor initialization Voltage 6
(Date of adjustment in
(8) 0010 FAN 70%MODE Fan speed 70% speed mode 7
factory)
(9) 0523 SMR SET Service meter adjustment Time
(Date of adjustment in
(10) 1005 FAN 100%MODE Fan speed 100% mode 8
factory)
(11) 1012 S/T N-SET Steering lever neutral set Voltage
(12) 1013 S/T M. L-SET Steering lever left set Voltage
(13) 1014 S/T M. R-SET Steering lever right set Voltage
(14) 1015 BRKLH. OFST Left brake oil pressure offset (set) Oil pressure
(15) 1016 BRKRH. OFST Right brake oil pressure offset (set) Oil pressure
(17) 1031 BR AUTO-SET Brake automatic adjustment mode Oil pressure
1111 VB MODE SEL Mode for setting in factory Mode name
(16) 1112 PRE LUB SEL Optional pre-lubrication set Mode name
(18) 2223 R SLOW CUT Reverse slow stop set DEACTIVE or ACTIVE
(19) 5535 CLUTCH OPEN Clutch disengagement mode Revolving speed
(20) 5536 CL AUTO-SET Clutch automatic adjustment mode Oil pressure
(21) 5537 CLT LH. OFST Left clutch oil pressure offset (set) Oil pressure
(22) 5538 CLT RH. OFST Right clutch oil pressure offset (set) Oil pressure
(23) 9801 ENG. LEVEL OPT: Engine oil level display mode DEACTIVE or ACTIVE
(24) 9993 HYD. LEVEL OPT: Hydraulic oil level display mode DEACTIVE or ACTIVE
(25) 9995 LOCK BRAKE Electric brake constantly ON mode Voltage
(26) 9996 MECHA BRAKE Electric brake release mode Voltage
(27) 9997 HI IDLE SET High idling limit mode Revolving speed
(28) 9998 SFT INHIBIT 3rd speed cut set Permit
k After assembling the machine or replacing each controller, be sure to adjust the items marked with q in the
Disassembly and assembly column of the above table. (For the adjustment procedure, see ADJUSTMENT
PROCEDURE AFTER REPLACEMENT OF CONTROLLER.)
20-200 D475A-5
(1)
(1) 0001: Phone number input mode

This code inputs or changes a phone number to
be displayed simultaneously when the user code
is displayed.
The lower part displays a phone number and
symbols.
Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ?
Instructions for use:
By operating the information switch (5), shift up
switch (6), and shift down switch (7), input a
phone number and symbols.
[ > ]: Moves the cursor rightward.
[ < ]: Moves the cursor leftward.
[UP]: Advance the numeric character or
character (in the order of available charac-
ters).
[DOMN]: Reverse the numeric character or
character (in the reverse order of available
characters).
a Sixteen digits of numeric characters are pro-
vided. To avoid confusion, input symbols
other than numeric characters at digits you
will not use.
a 0 (zero) is input at all places of the lower part
before shipment from our factory. (No phone
number is displayed under this condition.)
a The setting is enabled even after ending this
code.
(2) 0002: Steering controller specification set

This code is used to initialize the specification
codes recognized by the steering controller and
the set values of the memory in the controller.
The specification code is displayed on the lower
line.
Adjustment method
1) Set buzzer cancel switch (4) in the [U] posi-
tion and check that the caution buzzer
sounds.
2) Check that the displayed specification code
has changed from [6*6] to [666].
a If specification code [666] is not displayed,
the controller wiring harness or the controller
unit may be defective.
a Even if this code is turned off, the setting is
effective.
D475A-5 20-201
(1)
(3) 0003: Transmission controller specification set

This code is used to initialize the specifica-
tion codes recognized by the transmission
controller and the set values of the memory
in the controller.
The specification code is displayed on the
lower line.
Adjustment method (HSS specification):
sounds.
2) Check that the displayed specification code
has changed from [5*5] to [555].
a If specification code [555] is not dis-
played, the controller wiring harness or
the controller unit may be defective.
a Even if this code is turned off, the setting
is effective.
(4) 0004: Machine specification set

This code is used to have the machine specifica-
tion recognized by the controllers which com-
pose the system.
The machine specification code is displayed on
the lower line.
Adjustment method:
a Since this code is reset when Transmission
controller specification set is executed, ad-
just it after that.
1) Select the code of the machine specification
by setting information switch (5) in the [ > ]
position.
a Be sure to select SSC power setting 1
as the SSC type.
No. Type of work equipment Specification
tion and check that the caution buzzer 800 Single tilt
sounds. 801 Single tilt SSC specification
k If the machine specification is different from 802 Single tilt SSCL specification
the setting in the controller, the machine
810 Dual tilt
may move abnormally or an error may be
made. Accordingly, be sure to match the 811 Dual tilt SSC specification
setting to the machine specification. 812 Dual tilt SSCL specification
a Even if this code is turned off, the setting is 820 Superdozer
effective.
20-202 D475A-5
(1)
(5) 0005: Brake potentiometer zero-point adjustment

This code is used to adjust the zero point of the
brake pedal potentiometer.
The deviation from the standard value is indicat-
ed by voltage on the lower line (Indication range:
0 5000).
Adjustment method:
1) Check that the brake pedal is in neutral (it is
not pressed).
tion and check that the alarm buz zer
sounds.
a This adjustment is performed to have the
zero point of the potentiometer recognized
by the controller. It is not performed to adjust
the effect of the brake.
a Even if this adjustment is performed, the in-
dication on the lower line does not change.
effective.
(6) 0007: Engine deceleration-cut mode

This code is used to stop the auto-deceleration
function of the engine and check the high idling
speed of the engine singly.
The engine speed is displayed on the lower line
(Display range: 0 3000).
Using method:
While this code is displayed, its function is turned
on and the auto-deceleration function is turned
off.
a If this code is turned off, its function is turned
off.
(7) 0009: Pitch angle sensor initial set

This code is used to adjust the zero point and in-
stallation error of the pitch angle sensor.
The deviation from the standard neutral position
is displayed by voltage on the lower line (Display
range: 0 5000).
Adjustment method:
Set buzzer cancel switch (4) in the [U] position
and check that the caution buzzer sounds.
effective.
D475A-5 20-203
(1)
(8) 0010: Fan 70% speed mode

This code forcedly sets the rpm of cooling fan at
70%.
The lower part displays data for factory adjust-
ment.
The function is enabled with this code displayed
to control the rpm of cooling fan to approximately
70%.
a Ending this code disables the function.
(9) 0523: Service meter adjustment

This code is used to match the value of a new
service meter to the value of the machine.
k Since this code can only put the service meter
forward and cannot put it back, operate careful-
ly.
The service meter reading is displayed on the
lower line (Display range: 00000 99999).
Using method:
a If you input a wrong value, do not enter the
setting but cancel this code, then execute
the setting again.
1) Set the service meter reading by operating
information switch (5) and shift-up switch
(6).
a The actual service meter displays by the
unit of 0.1h, but this code displays by the
unit of 1h.
sounds.
a Even if the adjustment mode is turned off,
the setting is effective.
(10)1005: Fan 100% speed mode

This code forcedly sets the rpm of cooling fan at
approximately 100%.
The lower part displays data for factory adjust-
ment.
The function is enabled with this code displayed
to control the rpm of cooling fan to approxi-
mately 100%.
a Ending this code disables the function.
20-204 D475A-5
(1)
(11)1012: Steering lever neutral set

This code is used to adjust the steering neutral
position of the PCCS lever.
The deviation of the steering potentiometer from
the standard neutral position is displayed by volt-
age on the lower line (Display range: 0 5000).
Adjustment method:
Set buzzer cancel switch (4) in the [U] position
effective.
(12)1013: Steering lever left set

This code is used to adjust the maximum left
steering position of the PCCS lever.
the standard maximum left position is displayed
by voltage on the lower line (Display range: 0
5000).
Adjustment method:
1) Set the PCCS lever to the left steering
stroke end.
sounds.
effective.
(13)1014: Steering lever right set

This code is used to adjust the maximum right
steering position of the PCCS lever.
the standard maximum right position is displayed
by voltage on the lower line (Display range: 0
5000).
Adjustment method:
1) Set the PCCS lever to the right steering
stroke end.
sounds.
effective.
D475A-5 20-205
(1)
(14)1015: Left brake oil pressure offset

This code is used to adjust the left brake oil pres-
sure manually.
The offset oil pressure (Unit: 0.01 MPa) is dis-
played on the lower line (If it has been adjusted,
its value is displayed. It can be adjusted further
within the allowable range).
Adjustment method:
a The allowable adjustment range is 0.3
MPa {3 kg/cm2} (Displayed value: 300)
1) Operate the shift switch to set the offset oil
pressure.
Shiftup switch (6): Increase oil pressure
Shiftdown switch (7): Decrease oil pres-
sure
a The offset pressure is increased or de-
creased by 0.05 MPa {0.5 kg/cm2} (Dis-
played value: 50).
sounds.
effective.
(15)1016: Right brake oil pressure offset

This code is used to adjust the right brake oil
pressure manually.
Adjustment method:
pressure.
sure
played value: 50).
2) Hold the buzzer cancel switch for 1 second
effective.
20-206 D475A-5
(1)
(16)1112: Pre-lubrication set (if equipped)

This code is used to set the machine equipped
with the pre-lubrication system.
Installation or non-installation of the pre-lubrica-
tion system is displayed on the lower line by let-
ters.
Adjustment method:
Operate information switch (5) to change the
setting.
[ < ] [ > ]: Change display
[Pre-Lub ON]: Machine is equipped with pre-
lubrication system
[Pre-Lub OFF]: Machine is not equipped with
pre-lubrication system
a If setting of installation and non-installation
of the pre-lubrication system is wrong, an er-
ror may be detected.
effective.
(17)1031: Brake automatic adjustment

This code is used to automatically adjust the
change of the performance caused by dispersion
and wear of the brake parts to keep the brake
control performance.
The brake command oil pressure (Unit: 0.01
MPa) is displayed on the lower line.
k Since the machine moves forward by 1 2 m
during this adjustment, perform the adjustment
on a flat place where the safety around the ma-
chine can be secured.
Adjustment method 1 (Preparation work)
a Perform the adjustment while the torque
converter oil temperature is in the operating
range.
1) Start the engine and select this code.
position.
3) Turn the auto shiftdown switch OFF.
4) Run the engine at low idling.
5) Press and hold the brake pedal and deceler-
ator pedal.
6) Set the PCCS lever in the FORWARD 2nd
gear speed position.
a Keep the PCCS lever in the steering
neutral position.
7) Release the decelerator pedal and brake
pedal gradually and check that the machine
does not move.
k If the machine moves, there is abnormal-
ity. In this case, stop the adjustment im-
mediately.
a After checking that the machine does not
move, go to adjustment method 2 below.
D475A-5 20-207
(1)
Adjustment method 2 (Adjustment of left brake)

stroke end.
2) Check that the displayed command oil pres-
sure changes automatically.
3) Check that the caution buzzer sounds after
the machine moves forward by 1 2 m and
stops.
4) Return the PCCS lever to the steering neu-
tral position.
a After adjusting the left brake, go to ad-
justment method 3 below.
a The corrected oil pressure of the left
brake can be checked by adjustment
code [1015].
Adjustment method 3 (Adjustment of right brake)
stroke end.
3) Check that the caution buzzer sounds after
the machine moves forward by 1 2 m and
stops.
tral position.
a The corrected oil pressure of the right
brake can be checked by adjustment
code [1016].
effective.
(18)2223: Reverse slow stop set

This code is used to turn off the reverse slow
function forcibly, regardless of the operation of
the switches on the monitor panel.
The state of the reverse slow function is dis-
played on the lower line by letters.
Adjustment method:
setting.
[DEACTIVE]: Turn reverse slow function
OFF
[ACTIVE]: Turn reverse slow function ON
a Once the reverse slow function is turned
OFF, the reverse speed is not lowered, even
if the reverse slow mode switch on the mon-
itor panel is turned ON.
effective.
20-208 D475A-5
(1)
(19)5535: Both steering clutches disengagement

This code is used to engage the transmission
clutch without driving the machine for testing, ad-
justing, troubleshooting, Pm Clinic, etc.
The transmission speed (Unit: rpm) is displayed
on the lower line.
Using method:
While this code is displayed, the function is
effective and steering clutches on both sides are
disengaged. Accordingly, the machine does not
travel even if the PCCS lever is operated.
a If this code is turned off, the function be-
comes ineffective.
(20)5536: Steering clutch automatic adjustment

This code is used to automatically adjust the
change of the performance caused by dispersion
and wear of the steering clutch parts to keep the
steering control performance.
The clutch command oil pressure (Unit: 0.01 kg/
cm2) is displayed on the lower line.
Adjustment method 1 (Preparation work)
a Perform the adjustment while the torque
converter oil temperature is in the operating
range.
1) Start the engine and select this code.
position.
3) Turn the auto shiftdown switch OFF.
4) Run the engine at low idling.
5) Press and hold the brake pedal and deceler-
ator pedal.
6) Set the PCCS lever in the FORWARD 3rd
gear speed position.
a Keep the PCCS lever in the steering
neutral position.
7) Release the decelerator pedal and brake
pedal gradually and check that the machine
does not move.
k If the machine moves, there is abnormal-
ity. In this case, stop the adjustment im-
mediately.
a After checking that the machine does not
move, go to adjustment method 2 below.
Adjustment method 2 (Adjustment of left clutch)
stroke end.
3) Check that the engine speed rises and the
caution buzzer sounds.
tral position.
a After adjusting the left clutch, go to ad-
justment method 3 below.
a The corrected oil pressure of the left
clutch can be checked by adjustment
code [5537].
D475A-5 20-209
(1)
Adjustment method 3 (Adjustment of right clutch)

stroke end.
3) Check that the engine speed rises and the
tral position.
a The corrected oil pressure of the right
clutch can be checked by adjustment
code [5538].
effective.
(21)5537: Left steering clutch oil pressure offset

This code is used to adjust the left clutch oil pres-
sure manually.
Adjustment method:
pressure.
sure
played value: 50).
sounds.
effective.
20-210 D475A-5
(1)
(22)5538: Right steering clutch oil pressure offset

This code is used to adjust the right clutch oil
pressure manually.
Adjustment method:
pressure.
sure
played value: 50).
sounds.
effective.
(23)9801: Engine oil level set (if equipped)

This code is used to set the machine equipped
with the engine oil level switch.
Installation or non-installation of the engine oil
level switch is displayed on the lower line by let-
ters.
Adjustment method:
setting.
[ACTIVE]: Machine is equipped with engine
oil level switch
[DEACTIVE]: Machine is not equipped with
engine oil level switch
a To use this function, the engine oil level switch
must be installed.
a If [ACTIVE] is selected while the engine oil level
switch is not installed, the caution buzzer
sounds. Take care.
D475A-5 20-211
(1)
(24)9993: Hydraulic oil level set (if equipped)

This code is used to set the hydraulic oil level
caution.
The setting of the hydraulic oil level caution is
displayed on the lower line by letters.
Adjustment method:
setting.
[ACTIVE]: Turn hydraulic oil level caution
function ON
[DEACTIVE]: Turn hydraulic oil level caution
function OFF
a To use this function, the hydraulic oil level switch
must be installed.
a If [ACTIVE] is selected while the hydraulic oil lev-
el switch is not installed, the caution buzzer
sounds. Take care.
a Even if this code is turned off, the setting is effec-
tive.
(25)9995: Electric brake constantly ON mode

This code is used to see if the sudden stop pre-
vent valve operates normally.
The voltage of the brake potentiometer is dis-
played on the lower line.
Using method:
effective and the electric brake is constantly
turned on.
comes ineffective.
(26)9996: Electric brake release mode

This code is used to check the operation of the
mechanical brake.
The voltage of the brake potentiometer is dis-
played on the lower line.
Using method:
effective and the electric brake is constantly
turned off.
comes ineffective.
20-212 D475A-5
(1)
(27)9997: High idling limit mode

This code is used to limit the high idling speed.
The engine speed (set value) is displayed on the
lower line.
Possible limiting range: High idling speed 400
rpm
Using method:
1) Set information switch (5) in the [ > ] or [ < ]
position to select the limit speed.
sounds.
a Once the high idling speed is limited, the en-
gine speed does not reach the original high
idling speed, even if the fuel control dial is
operated.
effective.
(28)9998: Gear speed limit mode

This code is used to prevent the gear from shift-
ing up to the 3rd gear speed.
Available gear speeds are displayed on the lower
line by bits (in the order of the 3rd, 2nd, and 1st
from the left).
Using method:
Operate information switch (5) and buzzer can-
cel switch (4) to limit or reset the maximum gear
speed.
[ > ]: Move cursor to right
[ < ]: Move cursor to left
[U] Change setting
Display of lower line [o]: Gear speed is effec-
tive
Display of lower line [ ]: Gear speed is inef-
fective
a Once a gear speed is limited, the gear does
not shift up to that gear speed, even if the
shiftup switch is operated.
effective.
D475A-5 20-213
(1)
9. Load memory display mode

(9-LOAD MEMORY DISPLAY MODE)
In this mode, you can check the load on the
machine, forward odometer, and reverse odom-
eter.

i) Select Load memory display mode on
the mode selection screen.
a If the mode is selected, code (Ld) is
ii) Display the adjustment code input
switch (4).
[U]: Execute mode.
2) Changing information screen No. Display Item

Change the information screen by operating
1000 rpm service
information switch (5). 1 01-1000 rpm SMR
data
[ > ]: Next screen.
[ < ]: Previous screen. Forward travel
2 02-FOWARD ODO M
distance
Reverse travel
3 03-REVERSE ODO M
distance
4 04-F1 ODO Meter F1 travel distance
7 07-R1 ODO Meter R1 travel distance
3) Display of 1,000rpm service meter (01)

This code is used to display the service
meter which integrates the operation hours
only while the engine speed is higher than
1,000rpm.
a The data cannot be reset.
20-214 D475A-5
(1)
4) Display of forward odometer (02)

On this screen, the integrated forward travel
distance is displayed.
5) Display of reverse odometer (03)

On this screen, the integrated reverse travel
distance is displayed.
6) Display of F1 odometer (04)

On this screen, the integrated F1 (Forward
1st gear) travel distance is displayed.

2nd gear) travel distance is displayed.
D475A-5 20-215
(1)

3rd gear) travel distance is displayed.
9) Display of R1 odometer (07)

On this screen, the integrated R1 (Reverse
1st gear) travel distance is displayed.

2nd gear) travel distance is displayed.

3rd gear) travel distance is displayed.
20-216 D475A-5
(1)
12) Moving machine with saved load displayed

position, gear speed display unit (1) is set in
the normal display mode again and the
machine can operate normally.
parking brake lever to the LOCK position
temporarily, and then start the operation.
D475A-5 20-217
(1)
10. Real-time monitoring mode

(10-REAL TIME MONITORING MODE)
In this mode, the speeds, oil pressures, oil tem-
peratures, currents, voltages, etc. can be moni-
tor ed by using the signals from sensors,
switches, and solenoids installed various parts
of the machine.
a This mode is used to monitor 1 item. When
monitoring 2 items simultaneously, use the
Dual display monitoring mode.

i) Select Real-time monitoring mode on
the mode selection screen.
a If the mode is selected, code (5R) is
ii) Display the monitoring code input
switch (4).
[U]: Execute mode.
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit code of the item to be monitored by
operating information switch (5), shift-up
ii) After inputting the code, display the

monitoring screen by operating buzzer
cancel switch (4).
[ ]: Enter input code.
a If the input code is normal, the mon-
itoring screen shown at right ap-
pears.
20-218 D475A-5
(1)
a If the input code is abnormal, the

code input screen appears again af-
ter the screen shown at right.
3) Contents of display on monitoring screen

(Right figure shows examples)
(1) Code
(2) Monitoring item
(3) Information
(4) Unit (Not displayed for some items)
a For the details, see the MONITORING
MODE TABLE.
4) Function of holding monitoring information

If an information item such as the engine
speed is not stabilized and cannot be read
easily in the monitoring mode, it can be held
and released by operating buzzer cancel
switch (4).
[U]: Hold and release.
a While the monitored item is held, the let-
ter H is displayed at the left end of the
lower line.
5) When operating machine in monitoring mode

position, gear speed display section dis-
operated normally.
parking brake lever to the FREE position
D475A-5 20-219
(1)
6) Automatic selection of monitoring item (Lim-

ited function)
After one of some monitoring items is
selected, if the information switch is oper-
ated, the next monitoring item is selected
automatically, even if the code of the next
monitoring item is not input.
[ > ]: Code is increased
[ < ]: Code is decreased
a This function is applied to only the items
having numbers in the Automatic selec-
tion column of the Monitoring mode ta-
ble. Those items are selected in the
order of their numbers.
a Note that this operation is not effective
while the parking brake lever is in the
RESET position.
a You may return to the screen for input-
ting codes and enter a code without us-
ing this function.
20-220 D475A-5
(1)
Monitoring mode table
Sending
No. Code Monitoring item Unit Display range Remarks
in order
1 01002 ENG.SPEED1 Engine speed A rpm 0 3000 1
2 01004 ENG.SPEED2 Engine speed B rpm 0 3000
3 03200 BATTERY Battery voltage mV 0 30000 29
Engine coolant temperature
4 04102 WATER HIGH C 0 150 19
(High temperature side)
5 04200 FUEL SENS Fuel level sensor voltage mV 0 5000 21
6 04401 HYD. TEMP. Hydraulic oil temperature C 0 150
7 16700 ENG.W. TEMP Engine coolant temperature mV 0 150
Monitor panel (Tachometer module) program
8 20200 MON. PROGRM Letter
No.
9 20201 T/M. PROGRM Transmission controller program No. Letter
10 20202 S/T. PROGRM Steering controller program No. Letter
11 20208 ENG-PROGRM Engine controller program No. Letter
2-digit hexadeci-
12 20300 VHMS VHMS LED display
mal number
13 30100 T/C TEMP. Torque converter oil temperature C 0 150 20
14 31200 T/M IN Torque converter speed rpm 0 5000
15 31400 T/M OUT Transmission speed rpm 0 5000 22
(See detailed
16 31520 T/M-FILL Transmission fill switch input state bit bit
information)
(See detailed
17 31521 S/T FILL Steering fill switch input state bit bit
information)
18 31602 1st CLUTCH 1st clutch ECMV output current mA 0 1000
19 31603 2nd CLUTCH 2nd clutch ECMV output current mA 0 1000
20 31604 3rd CLUTCH 3rd clutch ECMV output current mA 0 1000
23 31606 Rev CLUTCH Reverse clutch ECMV output current mA 0 1000
24 31608 Frd CLUTCH Forward clutch ECMV output current mA 0 1000
25 31612 1 CLUTCH F 1st clutch ECMV output FB current mA 0 1000 16
26 31613 2 CLUTCH F 2nd clutch ECMV output FB current mA 0 1000 17
27 31614 3 CLUTCH F 3rd clutch ECMV output FB current mA 0 1000 18
28 31616 R CLUTCH F Reverse clutch ECMV output FB current mA 0 1000 15
29 31618 BRAKE R.H. Right brake ECMV output FB current mA 0 1000 11
30 31619 BRAKE L.H. Left brake ECMV output FB current mA 0 1000 10
31 31620 BRAKE R.H. Right brake ECMV output FB current mA 0 1000
32 31621 BRAKE L.H. Left brake ECMV output FB current mA 0 1000
33 31622 F CLUTCH F Forward clutch ECMV output FB current mA 0 1000 14
Cooling fan pump solenoid output command
34 31623 FAN PUMP. O mA 0 1000
current
35 31624 FAN PUMP. F Cooling fan pump solenoid output FB current mA 0 1000
36 31625 PITCH SOL. Blade pitch solenoid drive current mA 0 1000
40 31627 L/U SOL Torque converter lockup solenoid drive current mA 0 1000 24
41 31628 E. BRAKE SL Sudden stop prevent solenoid drive current mA 0 1000 23
Cooling fan pump 2 solenoid output command
37 31633 FAN PMP2. O mA 0 1000
current
38 31634 FAN PMP2. F Cooling fan pump 2 solenoid output FB current mA 0 1000
39 31703 FUEL DIAL Accelerator voltage mV 0 5000
42 32900 BODY ANGLE Machine pitch angle -30 30 28
D475A-5 20-221
(1)
Sending
in order
43 37200 ENGOIL PRS Engine oil pressure MPa 0 10
44 37301 FUEL RATE Fuel injection rate mm /st
3
-30 600
45 37501 ATM TEMP Atmospheric temperature C -200 200
46 40001 VEHICLE SP Travel speed (Theoretical value) km/h 0 100 26
(See detailed
47 40905 T/M-SW1 Transmission controller input signal 1 bit bit
information)
(See detailed
48 40906 T/M-SW2 Transmission controller input signal 2 bit bit
information)
(See detailed
49 40907 T/M OP SIG Blade lever knob switch input signal bit bit
information)
(See detailed
50 40908 T/M SW2 Blade lever knob switch input signal bit bit
information)
(See detailed
51 40909 T/M SOL. 2 Transmission controller output signal bit bit
information)
(See detailed
52 40910 S/T-SW1 Steering controller input signal 1 bit bit
information)
(See detailed
information)
(See detailed
information)
(See detailed
55 40914 S/T SOL. 1 Steering controller output signal bit bit
information)
56 42600 EXH TEMP L Exhaust temperature left C 0 2000
57 42601 EXH TEMP R Exhaust temperature right C 0 2000
58 42700 ENGOIL TMP Engine oil temperature C 0 150
59 42800 BLOWBY PRS Blow-by pressure kPa 0 10
60 43000 T/M PRESS Transmission main relief pressure MPa 0 10
61 50001 DECEL PEDL Decelerator potentiometer voltage mV 0 5000
62 50002 DECEL PEDL Decelerator command speed rpm 0 3000 3
63 50200 T/M LEVR 1 Forward-Reverse potentiometer 1 voltage mV 0 5000 5
64 50201 T/M LEVR 2 Forward-Reverse potentiometer 2 voltage mV 0 5000 6
65 50300 S/T LEVR 1 Steering potentiometer 1 voltage mV 0 5000 7
66 50301 S/T LEVR 2 Steering potentiometer 2 voltage mV 0 5000 8
67 50400 BRAKE PEDL Brake potentiometer voltage mV 0 5000 9
68 50900 N-SAFTY Neutral safety relay drive voltage mV 0 30000 25
69 51000 FINL.THRTL Regulation command speed rpm 0 3000
70 51100 FUEL DIAL Fuel control dial command speed rpm 0 3000 2
71 51200 RACK S. RH Right rack sensor voltage mV 0 5000
72 51300 RACK S. LH Left rack sensor voltage mV 0 5000
73 51400 GOV. SOL RH Right governor solenoid current mA 0 1000
74 51500 GOV. SOL LH Left governor solenoid current mA 0 1000
75 51600 PRE. SOL RH Right pre-stroke solenoid current mA 0 1000
76 51700 PRE. SOL LH Left pre-stroke solenoid current mA 0 1000
oo____
If neutral sig-
nal is output
77 51800 NEUTRAL S. Transmission neutral signal bit information bit bit
from machine
controller, left 2
lamps light up.
20-222 D475A-5
(1)
Sending
in order
oo____
Check of selec-
tion of specifi-
78 51900 ENG MODE Selection of specification bit bit cation for
D475A-5.
Left 2 lamps
light up.
79 60000 TRACTION Drawbar pull (Theoretical value) W 0 2 27
80 60100 BODY ANGLE Machine pitch angle sensor voltage mV 0 5000
81 60200 ACCELERATN Acceleration sensor voltage mV 0 5000
82 60300 SSC ORDER SSC command speed rpm 0 5000 4
83 60301 CNTR. THRTL SSC voltage mV 0 5000
85 60500 ENG.CON. PW Engine controller drive voltage mV 0 30000
86 60600 BR HOLD Battery relay drive voltage mV 0 30000
87 60700 S/T MODE Steering condition code Letter
88 60800 FILL MODE Fill condition setting variable Letter
89 60909 MOD. MODE Modulation condition setting variable Letter
90 70000 CHG.P. MODE Gear shifting point condition setting variable Letter
(See detailed
91 70100 SLIP FLAG SSC slip flag bit bit
information)
92 70200 T/M OUT Transmission speed sensor voltage mV 0 30000
(See detailed
94 70300 B. KNOB SW Blade lever knob switch input signal bit bit
information)
(See detailed
95 70305 T/M RIPER2 Ripper lever knob switch input signal bit bit
information)
Transmission controller backup alarm relay
100 70400 BACK ALARM mV 0 3000
voltage
96 70600 DUAL SOL. Dual solenoid drive current mA 0 1000
101 70700 HYD. PUMP 1 Work equipment main relief 1 oil pressure MPa 0 500
97 70701 HYD. PUMP 1 Work equipment oil pressure sensor 1 voltage mV 0 5000
98 70702 HYD. PUMP 2 Work equipment main relief 2 oil pressure MPa 0 500
99 70703 HYD. PUMP 2 Work equipment oil pressure sensor 2 voltage mV 0 5000
(See detailed
102 90000 T/M SOL. 3 Tilt/Pitch solenoid output 3 bit information bit bit
information)
(See detailed
103 90001 T/M SOL. 4 Dual/Pitch solenoid output 4 bit information bit bit
information)
104 90002 BL YOKE L Left yoke angle sensor voltage mV 0 5000
105 90003 BL YOKE R Right yoke angle sensor voltage mV 0 5000
106 90600 S/T CLT LH Left clutch ECMV output FB current mA 0 1000 12
107 90601 S/T CLT RH Right clutch ECMV output FB current mA 0 1000 13
108 90602 S/T CLT LH Left clutch ECMV output current mA 0 1000
109 90603 S/T CLT RH Right clutch ECMV output current mA 0 1000
110 92100 F1 SMR F1 travel integrated time h 0 4294967295
113 92200 R1 SMR R1 travel integrated time h 0 4294967295
116 99901 TRIG T F Trigger time F msec 0 4294967295
D475A-5 20-223
(1)
Sending
in order
117 99902 TRIG T R Trigger time R msec 0 4294967295
118 99903 TRIG T 1 Trigger time 1 msec 0 4294967295
121 99906 TM SFT Transmission shift Letter
122 99907 LU Lockup Letter
123 99908 TM IN TRQ Transmission input torque Nm 0 1000
129 99909 DOZING h Dozing time h 0 4294967295
130 99910 RIPPING h Ripping time h 0 4294967295
131 99913 TC IN TRQ Torque converter input torque Nm 0 1000
132 99914 H. P 1 TRQ Work equipment pump 1 input torque Nm 0 1000
135 99917 BR L PRESS Left brake oil pressure MPa 0 500
136 99918 BR R PRESS Right brake oil pressure MPa 0 500
137 99919 CL L PRESS Left clutch oil pressure MPa 0 500
138 99920 CL R PRESS Right clutch oil pressure MPa 0 500
20-224 D475A-5
(1)
Detailed information on bit display codes
Examples of display of bit information

a The display position of the bit information in the
Real-time monitoring mode (Display of only 1
item) is different from that in the Dual display
monitoring mode (Simultaneous display of 2
items).
a The bit information is displayed by [ ] for OFF
and [o] for ON in the places .
a The state of each item shown below is the condi-
tion for turning on the bit.
31520: Input state of transmission fill switch

: Forward clutch fill switch: ON
: Reverse clutch fill switch: ON
: 1st clutch fill switch: ON
: 2nd clutch fill switch: ON
: 3rd clutch fill switch: ON
: (Unused)
: (Unused)
: (Unused)
31521: Input state of steering fill switch

: Left brake fill switch: ON
: Left clutch fill switch: ON
: (Unused)
: (Unused)
: Right clutch fill switch: ON
: Right brake fill switch: ON
: (Unused)
: (Unused)
40906: Transmission controller input signal 2

: Automatic gear shift-down switch: ON
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: Automatic pitch back switch: ON
D475A-5 20-225
(1)
40907: Blade lever knob switch input signal

: ACC signal switch: ON
: Monitoring signal switch: ON
: R signal: ON
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: (Unused)
40908: Blade lever oil pressure switch input signal

: Blade lift raise oil pressure switch: ON
: Blade lift lower oil pressure switch: ON
: (Unused)
: (Unused)
: Blade left tilt oil pressure switch: ON
: Blade right tilt oil pressure switch: ON
: (Unused)
: (Unused)
40909: Transmission controller input signal 1

: N signal 1: ON
: N signal 2: ON
: (Unused)
: Backup alarm relay: ON
: Neutral safety relay: ON
: Lockup: ON
: (Unused)
: (Unused)
40910: Steering controller input signal 1

: (Unused)
: (Unused)
: (Unused)
: (Unused)
: Parking brake lever switch: FREE
: Parking brake lever switch: LOCK
: (Unused)
: (Unused)
20-226 D475A-5
(1)

: Buzzer cancel switch: U position
: Buzzer cancel switch: T position
: Information switch: < position
: Information switch: > position
: Service switch: ON
: (Unused)
: (Unused)
: (Unused)

: ACC signal: ON
: Pre-lubrication oil pressure switch: ON
: Engine low idling signal: ON
: Monitoring signal: ON
: N signal 1: ON
: N signal 2: ON
: (Unused)
: (Unused)
40914: Steering controller output signal

: Pre-heater relay drive: ON
: Snap shot switch: ON
: Fan reverse solenoid: ON
: Merge-divider valve selector solenoid: ON
: Battery relay drive: ON
: Sudden stop prevent solenoid: ON
: LS solenoid: ON
: Pre-lubrication motor relay: ON

: Electrical intake air heater signal: ON
: C signal: ON
: (Unused)
: Night lighting signal: ON
: Hydraulic oil level switch signal: ON
: (Unused)
: (Unused)
: (Unused)
D475A-5 20-227
(1)
70100: SSC slip flag

: Shoe slip ratio: Min. 25%
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: (Unused)
70300: Blade lever knob switch input signal

: Blade lever tilt switch: DUAL
: Blade lever tilt switch: SINGLE
: Blade lever pitch switch: OFF
: Blade lever pitch switch: ON
: (Unused)
: (Unused)
: (Unused)
: (Unused)
70305: Ripper lever oil pressure switch input signal

: (Unused)
: Ripper lift raise oil pressure switch:
ON (Operated)
: Ripper lift lower oil pressure switch:
ON (Operated)
: Ripper tilt in oil pressure switch: ON (Operated)
: Ripper tilt out oil pressure switch: ON (Operated)
: (Unused)
: (Unused)
: (Unused)
90000: Tilt/Pitch solenoid output 3 bit output signal

(Superdozer specification)
: Left tilt limit solenoid: ON
: Right tilt limit solenoid: ON
: Pitch solenoid: ON
: (Unused)
: Pitch dump solenoid: ON
: (Unused)
: (Unused)
: (Unused)
20-228 D475A-5
(1)
90000: Dual/Pitch dump solenoid output 4 bit output

signal (Other than superdozer specification)
: Left tilt limit solenoid: ON
: Right tilt limit solenoid: ON
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: (Unused)
90001: Transmission controller output signal

: Dual tilt solenoid: ON
: Pitch solenoid: ON
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: (Unused)
: (Unused)
D475A-5 20-229
(1)
11. Dual display monitoring mode

(11-DUAL DISPLAY MONITORING MODE)
In this mode, 2 monitored items can be dis-
played simultaneously.
a Note that only codes and monitoring infor-
mation are displayed in this mode since the
usable display columns are limited. (Item
names and units cannot be displayed.)

i) Select Dual display monitoring mode
on the mode selection screen.
a If the mode is selected, code (dR) is
ii) Display the monitoring code input
switch (4).
[U]: Execute mode.
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit codes of the items to be monitored
to the upper and lower lines by operat-
ing information switch (5), shift-up
ii) After inputting the codes, display the

monitoring screen by operating buzzer
cancel switch (4).
[U]: Enter input code.
a If the input codes are normal, the
monitoring screen shown at right ap-
pears.
20-230 D475A-5
(1)
a If the input codes are abnormal, the

code input screen appears again af-
ter the screen shown at right.
3) Contents of display on monitoring screen

(Right figure shows examples)
(1) Code 1
(2) Information 1
(3) Code 2
(4) Information 2
a For the details, see the Monitoring
mode table.
4) When operating machine in monitoring

mode
position, gear speed display section (1) dis-
operated normally.
parking brake lever to the FREE position
D475A-5 20-231
(1)
12. Snap shot mode (12-SNAPSHOT MODE)

The VHMS specification has the manual snap
shot function and automatic snap shot function.
While the manual snap shot function is turned
ON, various data in 7 minutes 30 seconds for
the Pm clinic, testing, and adjusting can be
saved in the VHMS controller.
1) Select "Snap shot mode" on the mode
selection screen.
a If the mode is selected, code (55) is dis-
played on gear speed display unit (1) and the
title is displayed on multi-information unit (2).
For details of the operating method in the
snap shot mode, see EXECUTION
METHOD OF QUICK PM.
(1) Manual snap shot function
To collect data periodically for the Pm
clinic, the machine must be operated as
specified by the Quick Pm. When data
is required and collected for testing, ad-
justing, etc., the operations of the ma-
chine are not limited.
To use the data saved with the manual
snap shot function, a personal computer
must be connected. For the procedure
for connecting the personal computer,
see "Initialization procedure for VHMS
controller". (The personal computer
may be connected either before or after
the snap shot operation.)
(1) Automatic snap shot function
While the automatic snap shot function
is turned ON, if an item which the VHMS
controller monitors constantly becomes
abnormal (if the corresponding failure
code is displayed), the snap shot data of
that item in 7 minutes 30 seconds are
saved in the VHMS controller automati-
cally.
Since the VHMS controller automatically
performs the automatic snap shot func-
tion according to the monitoring item da-
ta, the operator does not need to operate
the monitor.
How to collect snap shot data
If the value of a monitoring item data
becomes abnormal, that data is
recorded and saved for 7 minutes 30
seconds from 5 minutes 30 seconds
ago.
a The data is recorded at 10 second inter-
vals for the first 5 minutes, and at 1 sec-
ond intervals for 2 minutes 30 seconds
after the first 5 minutes.
20-232 D475A-5
(1)
TESTING AND ADJUSTING ADJUSTMENT METHOD OF REPLACED CONTROLLER
ADJUSTMENT METHOD OF REPLACED CONTROLLER

a After the machine is assembled or transmission
controller or steering controller is replaced, ad-
just the system according to the following proce-
dure.
k If the system is not adjusted, the machine may
not operate normally and may move suddenly.
Accordingly, be sure to adjust it.
a Precautions for replacing a controller:
If a controller is replaced, the memory of the oil
and filter maintenance mode is reset. According-
ly, take a record of the next replacement periods
of the oils and filters.
a Precautions for replacing a controller:
When replacing a controller, stop the machine in
4. Turning power on again
a safe place and turn the starting switch off.
Turn the starting switch off and on, then reset
the monitor panel in the Adjustment Mode of
1. Setting system in service mode
the service mode.
Turn the starting switch on and set the monitor
panel in the Adjustment mode of the service
5. Adjusting machine specification
mode.
Select Machine specification set (0004) and
adjust the machine specification.
2. Adjusting steering controller
Select Steering controller specification set
(0002) and adjust the steering controller.
a Execute this code only when the transmis-
sion controller is also replaced.
6. Adjusting brake potentiometer

Select Brake potentiometer initial set (0005) and
adjust the brake potentiometer.
3. Adjusting transmission controller

Select Transmission controller specification set
(0003) and adjust the transmission controller.
a Execute this code only when the steering
controller is also replaced.
D475A-5 20-233
(1)
TESTING AND ADJUSTING ADJUSTMENT METHOD OF REPLACED CONTROLLER
7. Turning power on again

Turn the starting switch off and on.
8. Checking error codes

1) Set the monitor panel in the Electric system
error code display mode of the service
mode.
2) See if any error code is currently being out-
put. If any error code is not being output,
delete all the error codes.
a If any error code is being output, remove its
cause by troubleshooting and execute steps
7 and 8 again.
a Precautions after replacing controller:

If any controller is replaced, the service meter in
the oil and filter maintenance mode is reset to 0.
As a result, the replacement period displayed on
the monitor panel may be different from the
actual operating hours. To solve this problem,
determine the first replacement periods of the
oils and filters after the replacement of the con-
troller according to the replacement periods
recorded before the replacement of the control-
ler.
20-234 D475A-5
(1)
PREPARATION WORK FOR TROUBLESHOOTING FOR
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT SYSTEM

ELECTRICAL EQUIPMENT SYSTEM
a When performing troubleshooting for an electri- 2. Engine controller
cal circuit related to the monitor panel, engine 1) Remove dashboard cover (3).
controller, transmission controller, steering con-
troller, or VHMS terminal, expose the related
connectors according to the following procedure.
1. Monitor panel
1) Remove cover (1).
2) Remove the 2 mounting bolts and pull out
monitor panel (2) toward the operators
seat.
2) Insert or connect T-adapters in or to con-

nectors of engine controller (4) (LE1, LE2,
LE31, LE32, LE4, LE51, and LE52).
a If it is difficult to remove and install the
connectors, remove the controller for the
ease of work.
3) Insert or connect T-adapters in or to con-

nectors S01, S02, S03, and S04 of monitor
panel (2).
D475A-5 20-235
(1)
3. Transmission controller 4. Steering controller

1) Remove cover (5). 1) Remove dashboard undercover (3).
2) Referring to 2 above, remove the engine 2) Insert or connect T-adapters in or to con-

controller. nectors STCN1, STCN2, and STCN3 of
3) Insert or connect T-adapters in or to con- transmission controller (7).
nectors TMCN1, TMCN2, and TMCN3 of a If the connectors cannot be disconnect-
transmission controller (6). ed and connected easily, remove the
a If the connectors cannot be disconnect- controller from the floor frame.
ed and connected easily, remove the a Since the connectors are secured with
controller from the floor frame. screws, loosen those screws before dis-
a Since the connectors are secured with connecting.
screws, loosen those screws before dis- a When connecting the connectors again,
connecting. tighten their screws to the specified
3 Screw: 2.82 Nm {0.288 kgm}

a When connecting the connectors again, torque.
tighten their screws to the specified
3 Screw: 2.82 Nm {0.288 kgm}

torque.
20-236 D475A-5
(1)
5. VHMS controller 6. ORBCOMM terminal

1) Open the floor left side cover and remove 1) Open the floor left side cover and remove
cover (8). cover (8).
2) Insert or connect T-adapters in or to con- 2) Referring to 5 above, remove VHMS con-

nectors V1, V2A, V2B, V3A, and V3B of troller (9).
VHMS controller (9). 3) Insert or connect T-adapters in or to con-
a If it is difficult to remove and install the nectors CM29 and CM30 of ORBCOMM ter-
connectors, remove the controller for the minal (10).
ease of work. a If it is difficult to remove and install the
connectors, remove the terminal for the
ease of work.
D475A-5 20-237
(1)
TESTING AND ADJUSTING HANDLING OF OPTIONAL DEVICES
HANDLING OF OPTIONAL DEVICES

a D475A-5 has connectors to install optional devic-
es in its fuse box. When installing any optional
device, receive the necessary signals and power
through those connectors without modifying the
wiring harness.
1. Connecting the ACC signal of starting switch

If the ACC signal (ON signal) of the starting
switch is necessary for a optional device such
as the turbocharger timer, connect it through the
following connector pin.
Pin (B) of CN-ESD (3-pole heavy duty wire
connector)
a A 20A fuse is installed on the upstream side
of this connector pin.
2. Inputting engine low-idling command

If it is required to keep the engine speed at low
idling for an optional device such as the engine
protector, connect the following connector pin to
the chassis ground.
Pin (C) of CN-ESD (3-pole heavy duty wire
connector)
a While this connector pin is connected to the
chassis ground, the engine speed is kept at
low idling, regardless of the fuel control dial
position.
3. Connecting C signal of starting switch

If the C signal (starting signal) of the starting
switch is necessary for a optional device such
as the pre-lubricator, connect it through the fol-
lowing connector pin.
CN-PRS (2-pole heavy duty wire connector)
a Remove the connector installed when the
machine is shipped, and connector pin (1) to
the starting signal to be final output by the
pre-lubricator and connector pin (2) to the in-
put signal from the starting switch.
4. Connecting external power source

If an external power source is necessary, con-
nect it through the following connectors.
AUX1 (Plug connector)
AUX2 (Plug connector)
a A 20A fuse is installed on the upstream side
of each of these connectors.
a AUX1 is used for the machine with air sus-
pension seat (if equipped).
20-238 D475A-5
(1)
TESTING AND ADJUSTING INITIALIZATION PROCEDURES FOR VHMS CONTROLLER
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

a Initialization tools for VHMS controller a The VHMS controller and ORBCOMM termi-
nal are in the VHMS controller box under the
Symbol Part No. Part name
left side cover of the floor.
799-608-3101 Service kit
1 799-608-3211 Diskette
W 799-608-3220 Wiring harness

Notebook type personal com-
Commercially
2 puter (OS: Windows98/2000/
available
NT/Me/XP)
a Before starting operation after completion of lo-

cal assembly or before resuming operation after
storage for a long period, initialize the VHMS
controller according to the following procedure.
a Machine data collected with the VHMS controller
are stored and managed in WebCARE data-
base. To process the data smoothly on the We-
2. Connection of personal computer
bCARE, it is necessary to set the VHMS
1) Make sure the starting switch is turned to
controller consistently. If it is not set correctly,
the OFF position.
k Be sure to connect and disconnect the
data will not be taken into the WebCARE and
data in the VHMS controller may not be utilized.
personal computer while the starting
Be sure to perform the initialization.
switch is turned to the OFF position.
a For method of installation for the VHMS Initializa-
2) Connect the personal computer W2 and the
tion Program to a personal computer, refer to the
download connectors DL1 and VDW with
Operation and Maintenance Manual contained in
wiring harness [1] of service kit W1.
the W1 service kit package.
a The download connectors are installed
a The initialization procedures cover both "ORB-
to the following places.
COMM Specification" and "ORBCOMMLESS
VDW: Inside of cab (Left rear lower
Specification". In case of "ORBCOMMLESS"
part)
Specification", omit the procedures necessary
DL1: Rear side of chassis (Hull
for "ORBCOMM Specification" only.
frame)
a During the initialization work, make necessary
a Connect the personal computer to the
confirmations for each work according to the
RS232C terminal.
"VHMS Initialization Work Checklist".
1. Check of machine information, engine infor-

mation, and controller information
a This step applied to works on the whole ma-
chine.
Check and record the machine information,
engine information, VHMS controller informa-
tion, and ORBCOMM terminal information.
Information to be checked
No. Information Remarks
1 Machine model
2 Machine serial No. 5 digits
3 Engine serial No. 6 digits
4 Transmission serial No. 6 digits
5 VHMS controller serial No. 5 digits
ORBCOMM terminal serial No.
6 11 digits
[For only ORBCOMM specification]
D475A-5 20-239
(1)
4. Startup of VHMS initialization tool

1) Switch on the personal computer and start
the OS.
2) Click the icon of [VHMS Initialization Tool]
on the personal computer screen to start the
VHMS initialization tool.
3) Input the 10-digit service ID in [Service ID].

a Service ID: 7826113000
4) Select [Data clear and Set up] in the [Select
Function] column.
5) Press the [OK] button to shift to the setup
screen.
3. Performance check of VHMS controller

1) Set the starting switch to the ON position.
2) Select "Service mode" and "Real-time moni-
toring mode" in order on the monitor panel.
3) Input ID = 20300.
4) If the central part of the lower line of the
multi-information display unit counts up, the
VHMS controller is normal.
20-240 D475A-5
(1)
5. Performance check of ORBCOMM terminal

Decimal point
[For only ORBCOMM specification] Indication
at right bottom
1) Judge the operation of the ORBCOMM con-
troller by the state of the dot at the right bot- Power is not applied to ORBCOMM
OFF
controller.
tom of the LED digit of the VHMS controller.
2) The dot at the right bottom of the LED digit ON Satellite is not captured.
of the VHMS controller can be checked in ORBCOMM controller does not
the multi-information display unit of the mon- Quick flashing have transmission data.Satellite is
itor by the following method. captured.
i) Set the starting switch to the ON posi-
ORBCOMM controller has transmis-
tion. Slow flashing
sion data.Satellite is captured.
ii) For monitor panel specification: Refer-
ring to 10 "Real-time monitoring mode"
6. Initialization of VHMS controller
or 11 "Dual display monitoring mode"
[Machine information]
above, input ID = 20300.
1) Open the [Machine information] tab.
a The [Machine information] tab is dis-
played first in the [Data clear and Set up]
menu.
2) Check all the data.
3) At least 3 minutes after starting the VHMS,

check the decimal point at the right bottom
of the LED of the VHMS controller or the
decimal point at the right bottom of the cen-
tral part of the lower line of the multi-infor-
mation display unit.
3) When information in the [Date/Time] box is

not correct, change it according to the fol-
lowing procedures:
i) Click on [Edit] (1) located in the right
lower part of the [Date/Time] box to dis-
play the correction screen.
ii) Correct the information, then click [OK].
D475A-5 20-241
(1)
4) When information in the [Machine informa- [For ORBCOMM specification only]

tion] box is not correct, change it according a Set the ORBCOMM terminal after the date of
to the following procedures: opening the terminal.
i) Click on [Edit] (2) located in the right 1) Open the VHMS Setting Tool according to
lower part of the [Machine information] the procedure for "Start of VHMS initializa-
box to display the correction screen. tion tool".
ii) Correct the information, then click [OK]. 2) Open the [Communication Setting] tab.
5) After checking and changing all the data in

[Machine information], click on the [Apply]
(3) to apply the settings.
a Click [Apply] (3), the screen for checking
the settings will appear. Recheck the
settings and click [OK] when all the set- 3) To change setting in [SHORT FAULT
tings are correct. HISTRY], follow the procedure below:
a In case of the ORBCOMM Specification, i) Select [SHORT FAULT HISTRY] on the
execute [Communication Setting] and screen and click [Edit] (5) located in the
settle it. left lower part of the [File Transfer Set-
ting] block to display the setting screen.
ii) Change the settings, then click [OK].
a At initialization, select [Occurrence] at
[Timing] screen, and set the function to
[ON].
6) After checking/changing the data of

4) To change setting in [SHORT TREND
[Machine Information], click [Exit] (4) to fin-
ANALYSIS], follow the procedures below:
ish [VHMS Initialization Tool].
i) Select [SHORT TREND ANALYSIS] on
the screen and click [Edit] (5) located in
the left lower part of the [File Transfer
Setting] block to display the setting
screen.
ii) Change the settings, then click [OK].
20-242 D475A-5
(1)
a At initialization, select [20h] at [SMR]

screen, and set the function to [ON].
5) To change the setting of [Satellite Setting],

follow the procedure below: (Important)
[Exit]
i) Click [Edit] (6) in the [Satellite Setting]
7) After checking/changing the data of [Com-
block to display the setting screen.
munication Setting], click [Exit] (8) to finish
ii) Bring GCC Code to the applicable area,
[VHMS Initialization Tool].
then click [OK].
GCC Code and Application Area

Code Applicable Area
1 U.S.A.
120 Italy
121 Malaysia
122 Korea
123 Brazil
130 Japan
6) After checking and changing all data in the

[Communication Setting], click [Apply] (7) to
apply the settings.
a Click [Apply] (3), the screen for checking
the settings will appear. Recheck the
settings and click [OK] when all the set-
tings are correct.
D475A-5 20-243
(1)
TESTING AND ADJUSTING PROCEDURES FOR EXECUTING QUICK PM
PROCEDURES FOR EXECUTING QUICK PM

a The Quick Pm means the Pm Clinic executed
with the snap shot function of the monitor panel.
k Stop the machine on a flat place.
1. Start the engine.
2. Set the monitor panel to display the service

menu.
a For the operating method, see "Special func-
tions of monitor panel".
3. Mode selection and excution

1) Select "Snap shot mode" on the mode
selection screen.
a If the mode is selected, code (55) is dis-
played in gear speed display unit (1) and the
title is displayed in multi-information unit (2).
2) Set the buzzer cancel switch in the [U]
position.
3) "READY" is displayed as shown in the figure

and the system is ready to start.
4) If the buzzer cancel switch is set in the [U]

position, the snap shot function starts.
a After the snap shot function is started, the
elapsed time is displayed.
a On the lower line, 1 " " is added every 30
seconds. While multiple " " are displayed,
the one at the right end flashes.
a To interrupt the snap shot function, set the
buzzer cancel switch in the [t] position.
20-244 D475A-5
(1)
5) After starting the snap shot function, operate

the machine according to Table 1.
a Check that the engine coolant and torque
converter oil temperatures are in operating
range.
a After 10 " " are displayed (After 5 minutes),
"#" is added up to 5.
" ": The data sampling interval is 10
seconds.
"#": The data sampling interval is 1 sec-
ond.
Operation of machine
Time (sec)
Finish
Start
Fuel
No.
State of machine Steeri Decelera- Brake Parking

Transmission Work equipment control
ng tor pedal pedal brake
dial
1 0:00 0:30 30 N LH N LOW HI Released Released
Low idling
2 0:30 1:00 30 N RH N LOW HI Released Released
3 1:00 2:00 60 High idling N N N HI HI Released Released
4 2:00 3:00 60 Deceleration slow N N N HI LOW Released Released
High-pressure Right tilt (or
5 3:00 3:30 30 N N HI HI Released Released
relief & high idling pitch back in
High-pressure case of dual tilt
6 3:30 4:00 30 N N model) LOW HI Released Released
relief & low idling
Port relief &
7 4:00 4:30 30 N N Left tilt (or pitch HI HI Released Released
high idling
dump in case of
Port relief & dual tilt model)
8 4:30 5:00 30 N N LOW HI Released Released
low idling
NoF1oF2oF3o
Torque converter
9 5:00 5:30 30 NoR1oR2oR3 N N LOW HI ON Released
stall & low idling
oN
Torque converter NoF3 (Shift to F3, LOWo
10 5:30 6:00 30 stall (F3) & high then run engine at N N HI Shift to F3, ON Released
idling (Note 1) full throttle) then HI
11 6:00 6:30 30 High idling N N N HI HI Released Released
Torque converter NoF3 (Shift to F3, Left tilt (or pitch LOWo
12 6:30 7:00 30 stall + High-pres- then run engine at N dump in case of HI Shift to F3, ON Released
sure relief high idling) dual tilt model) then HI
High idlingo HIo
13 7:00 7:30 30 N N N HI Released ON
Low idling (Note 2) LOW
(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.
(Note 2): Keep running the engine at low idling until the oil temperature is lowered to the normal level.
a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine speed
to high idling.
a After stalling the torque converter, watch the power train oil temperature gauge and take care not to overheat
the power train oil.
(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature
gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the
engine at high idling to lower the oil temperature.)
D475A-5 20-245
(1)
6) The screen shown below appears 7 minutes 8) Open the data of the Quick Pm and trans-
30 seconds after the snap shot is started, late them into a graph.
and then the initial screen appears 5 sec- a Set the time to the X-axis and set the follow-
onds after. (End of snap shot) ing items to the Y-axis.
Engine Speed
Fuel Inject
Blowby Press
Exhaust Temp RB (Exhaust tempera-
ture of right bank: 1, 2, 3, 4, 5, 6)
Exhaust Temp LB (Exhaust temperature
of left bank: 1, 2, 3, 4, 5, 6)
Engine Oil Press
Engine Oil Temp
Eng Coolant Temp
Ambient Temp
Demand Eng Speed
(Engine speed demanded by controller)
T/C Oil Temp
Important (Torque converter oil temperature)
The data of the Quick Pm is recorded on once. T/M Main Press
If the Quick Pm is executed again, the current (Transmission main relief pressure)
data are overwritten. Accordingly, be sure to T/M Output Speed
save the data in the personal computer after (Transmission output speed)
executing the Quick Pm. Shift Position
(Transmission, travel, gear speed)
7) Using the analysis tool, read the data of the S/T Clutch Pos.
Quick Pm. (Steering clutch position)
a For the usage of the analysis tool, see the S/T Brake Pos. (Steering brake position)
operation manual. Hydr Oil Temp
(Hydraulic oil temperature)
Pump 1 Press
(Work equipment pump 1 oil pressure)
Pump 2 Press
(Work equipment pump 2 oil pressure)
Body Pitch Angle (Pitch angle)
20-246 D475A-5
(1)
9) Check "Click position graphic value display".
D475A-5 20-247
(1)
10) Click a point in the graph, and the value of

each measurement item at that point on the
X-axis is displayed under the graph.
(Example of displayed graph: This is differ-
ent from the actual graph.)
20-248 D475A-5
(1)
11) Enter the above value in the Pm Clinic Inspection Sheet.

a The relationship between the data necessary for the Pm Clinic and the measurement conditions is as
follows.
Measurement items
Transmission main relief pressure
Steering right clutch fill switch
Steering right brake fill switch

Steering left clutch fill switch
Steering left brake fill switch
Work equipment pump (FR)

Front clutch fill switch
Rear clutch fill switch

Exhaust temperature
State of machine
2nd clutch fill switch
3rd clutch fill switch

Engine oil pressure
1st clutch fill switch

Blow-by pressure
Engine speed
Engine at low idling Q Q Q Q Q Q Q
Engine at high idling Q Q Q
Deceleration slow Q
High-pressure relief & engine at full throttle Q Q
High-pressure relief & engine at slow Q
Port relief & engine at full throttle Q Q
Port relief & engine at slow Q
Torque converter stall & engine at slow Q Q Q Q Q Q Q Q
Torque converter stall (F3) & engine at full throttle Q Q Q
Engine at full throttle
Torque converter stall & high-pressure relief Q
Engine at high idling o Engine at low idling Q Q
D475A-5 20-249
(1)
4. Downloading of Set Data 5. Check of Downloaded Data

1) Turn the starting switch to the ON position. a This step applies to works in the cab (on the
2) Click the icon of [VHMS Technical Analysis personal computer).
Tool] on the personal computer to start the 1) Check the set data with [View] function.
VHMS analysis tool. a For the operation procedures, refer to
the Operation and Maintenance Manual
for VHMS Technological Analysis Tool.
a Make sure that the [MFA0] code at the
time of snapshot is displayed in [Fault
History].
a Make sure that the SNAPSHOT data
has been recorded.
a Input [User Name] and [Password].

a For the operation procedures, refer to
the Operation and Maintenance Manual
2) After having checked the set data, terminate

[VHMS Technical Analysis Tool].
6. Disconnection of Personal Computer

1) Make sure the starting switch is turned to
the OFF position.
k Be sure to turn off the starting switch be-
fore connecting or disconnecting the
personal computer.
3) Use the [Download] function to download 2) Terminate the OS of the personal computer
the data recorded in the VHMS controller to and switch off the personal computer.
the personal computer. 3) Disconnect the wiring harness [1] of the
a For the operation procedures, refer to service kit W1 from the download connec-
the Operation and Maintenance Manual tors VDW and DL1.
a Make sure that the downloading has
completed before proceeding to the next
step.
20-250 D475A-5
(1)
7. Communication to Komatsu
After having completed Steps 1 to 15 success-
fully, please send the check sheet and the
VHMS data to VHMS/WebCARE Support Cen-
ter of Komatsu, Tokyo.
a Since Komatsu has to arrange the setting for
satellite communication on the receiving
side, please be sure to inform Komatsu of
the completion of the setting.
a Fax the check sheet to Komatsu.
a Send the VHMS data by Notes (LAN) or E-
mail (WAN).
Contact VHMS/WebCARE Support

Center by
Telephone: 81-3-5561-2765
FAX: 81-3-5561-4766
E-mail: webcare@komatsu.co.jp
D475A-5 20-251
(1)
20-252 D475A-5
(1)
D475A-5 20-253
(1)
TESTING AND ADJUSTING PRECAUTIONS FOR REPLACING VHMS CONTROLLER
PRECAUTIONS FOR REPLACING VHMS CONTROLLER

a Tools for replacing VHMS controller 2) Open the [Communication Setting] tab and
check and record all the information.
Symbol Part No. Name (For only ORBCOMM specification)
799-608-3101 Service kit
1 799-608-3211 Diskette
799-608-3220 Wiring harness
W Notebook type per-
Commercially sonal computer
2
available (OS: Windows98/2000/
NT/Me/XP)
a When the VHMS controller needs to be replaced,

set it before removing it and the installed new
VHMS controller according to the following pro-
cedure.
a Machine data collected with the VHMS controller
are stored and managed in WebCARE data-
base. To process the data smoothly on the We-
bCARE, it is necessary to set the VHMS
controller consistently. If it is not set correctly, 3) After checking and recording all the data,
data will not be taken into the WebCARE and press the [Exit] button at the right lower part
data in the VHMS controller may not be utilized. of the screen to finish the "VHMS Initializa-
Accordingly, be sure to carry out the initialization. tion Tool".
a During the initialization work, make necessary
confirmations for each work according to the [Work after replacing VHMS controller]
"VHMS Initialization Work Check Sheet". a After replacing the VHMS controller, carry out in-
itialization according to the "Initialization Proce-
[Work before replacing VHMS controller] dure for VHMS Controller".
1. Downloading of remaining a Change the data to the information recorded be-
Use the [Download] function to download the fore the VHMS controller was replaced. (Input
data currently recorded in the VHMS controller the date and time when the VHMS controller was
to the personal computer. replaced.)
a For the operation procedures, refer to the a After completing the setting after the replace-
"initialization procedure for VHMS control- ment, send the check sheet to VHMS/WebCARE
ler". Support Center of Komatsu, Tokyo.
a Send the check sheet to Komatsu by fax.
2. Checking and recording set information a Send the data downloaded before and after re-
1) Open the [Machine information] tab and placing the VHMS controller by Notes (LAN) or
check and record all the information. E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)
FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
20-254 D475A-5
(1)
pm clinic service
D475A-5 20-255
(1)
Pm-clinic measuring points for D475A-5 (1/3)
Reference items of measurement procedure (Pages)

1. Engine speed: Measuring engine speed (20-105 20-107 page)
2. Blow-by pressure: Measuring blow-by pressure (20-114 page)
3. Engine oil pressure: Measuring engine oil pressure (20-115 page)
4. Boost pressure: Measuring intake air pressure (boost pressure) (20-108 page)
5. Exhaust temperature: Measuring exhaust temperature (20-109 20-110 page)
20-256 D475A-5
(1)

6. Items related to torque converter: Measuring power train oil pressure (20-122 20-124 page)
7. Items related to transmission: Measuring power train oil pressure (20-124 20-127 page)
8. Items related to steering: Measuring power train oil pressure (20-127 20-129 page)
D475A-5 20-257
(1)

9. Items related to work equipment: Testing and adjusting work equipment oil pressure. (20-140 20-148
page)
10. Items related to work equipment: Testing and adjusting work equipment oil pressure, Testing and adjust-
ing control circuit basic pressure (20-140 20-148 page and 20-149 page)
11. Items related to fan: Measuring fan motor speed, Measuring fan circuit oil pressure (20-166 page)
20-258 D475A-5
(1)
D475A-5 20-259
(1)
20-260 D475A-5
(1)
D475A-5 20-261
(1)
20-262 D475A-5
(1)
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
(Program form No.: SELA195001)
D475A-5 20-263
(1)
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
(Program form No.: SELA195001)
20-264 D475A-5
(1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-302

SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-303
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-304
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-312
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING......................................................... 20-313
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF
EACH SYSTEM.................................................................................................................................... 20-316
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-354
T-BRANCH BOX AND T-BRANCH TABLE................................................................................................. 20-376
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE

"MECHANICAL SYSTEM" ARE INDICATED ....................................................................................... 20-401
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-701
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) ......................................... 20-801
TROUBLESHOOTING OF ENGINE BODY (S MODE) .............................................................................. 20-901
D475A-5 20-301
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. Use the results of the investigation and in-
spection in Items 2 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-302 D475A-5
(1)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
D475A-5 20-303
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-304 D475A-5
(1)
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins will
be short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.
D475A-5 20-305
(1)
2) Removing, installing, and drying connectors

and wiring harnesses
Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
a If the connector is twisted up and down
or to the left or right, the housing may
break.
3) Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
a If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-306 D475A-5
(1)
Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
a If there is any damage or breakage, re-
place the connector.
2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3) Correct any protrusion of the boot and any

misalignment of the wiring harness.
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
Normal locking state (Horizontal): a, b, d
Incomplete locking state (Diagonal): c
D475A-5 20-307
(1)
Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows:
1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
a After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-308 D475A-5
(1)
3) Handling control box

1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand)
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in that circuit.
D475A-5 20-309
(1)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger or dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt, or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-310 D475A-5
(1)
5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic tank;
also drain the oil from the filter and from the
drain plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
D475A-5 20-311
(1)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
Value
1. Check fuel level Add fuel
2. Check for impurities in fuel Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level Add oil

Checks before starting
4. Check oil level in damper case Add oil

5. Check power train oil level Add oil
6. Check engine oil level (engine oil pan level) Add oil
7. Check coolant level Add water
8. Check dust indicator for clogging Clean or replace
9. Check travel of brake pedal Adjust
equipment
10. Check for looseness, corrosion of battery terminal, wiring Tighten or replace
Electrical
11. Check for looseness, corrosion of alternator terminal, wiring Tighten or replace
12. Check for looseness, corrosion of starting motor terminal, wiring Tighten or replace
mechanical
equipment
Hydraulic,
13. Check for abnormal noise, smell Repair

14. Check for oil leakage Repair
15. Carry out air bleeding Bleed air
16. Check battery voltage (engine stopped) 20 30 V Replace

17. Check battery electrolyte level Add or replace
Other check items
18. Check for discolored, burnt, exposed wiring Replace

19. Check for missing wiring clamps, hanging wire Repair
Electrical equipment
20. Check for water leaking on wiring (pay particularly careful attention Disconnect con-
to water leaking on connectors or terminals) nector and dry
21. Check for blown, corroded fuses Replace
22. Check alternator voltage (engine running at 1/2 throttle or above) After running Replace
for several
minutes:
27.5 29.5 V
23. Check operating sound of battery relay (starting switch ON, OFF) Replace
20-312 D475A-5
(1)
TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING

Classification of Troubleshooting
Mode Explanation
Error code Troubleshooting when a error code is displayed
E Mode Troubleshooting of the electrical system
H Mode Troubleshooting of the hydraulic and mechanical systems
S Mode Troubleshooting of the engine body
Troubleshooting Procedures
When any phenomenon supposed to be a failure appeared on the machine, select a Troubleshooting No.
according to the procedures below and proceed to the text of the relevant troubleshooting:
1. Troubleshooting Procedures when any action code is displayed on the monitor panel:
When an action code is displayed on the monitor panel, display a error code in the error code display mode
(electrical system, mechanical system) on the monitor display (EMMS).
Execute a troubleshooting of the relevant [Error Code] in accordance with the displayed error code.
a Since a error code flashes when a problem was detected, the failure has not always been corrected even
if it lights when the starting switch is set to ON. (For some codes, problems can be detected only when
the starting switch is set to ON.)
a When a error code has been recorded, be sure to reproduce the code and check if the problem of the
code has still remained or has already been corrected. (For the reproducing method, refer to the trouble-
shooting of the error code.)
2. Troubleshooting Procedures when error codes have been recorded:

When no action code is displayed on the monitor panel, check a error code in the error code display mode
(electrical system, mechanical system) on the monitor panel (EMMS).
When error codes have been recorded, execute a troubleshooting of the relevant [Error Code] in accor-
dance with the error code.
a Since a error code flashes when a problem was detected, the failure has not always been corrected even
if it lights when the starting switch is set to ON. (For some codes, problems can be detected only when
the starting switch is set to ON.)
a When a error code has been recorded, be sure to reproduce the code and check if the problem of the
code has still remained or has already been corrected. (For the reproducing method, refer to the trouble-
shooting of the error code.)
3. Troubleshooting Procedures when no action code is displayed and error codes have not been
recorded:
When error codes have not been recorded in the monitor panel (EMMS), a failure that the machine cannot
diagnose by itself is supposed to have occurred in the electrical system or the hydraulic/mechanical system.
In this case, check again a phenomenon supposed to be a failure and select the relevant phenomenon out
of the table of Phenomena supposed to be Failures and Troubleshooting No. Then, execute the trouble-
shooting in the [E Mode] or [H Mode] related to the phenomenon.
D475A-5 20-313
(1)
Phenomena considered to be failures and troubleshooting Nos.
Troubleshooting
No. Phenomenon considered to be failure Error
E mode H mode S mode
code
Phenomena related to action code or error code
1 Action codes are displayed on the monitor panel Check the error code
2 Error codes are displayed in the error code display mode q
Phenomena related to engine
3 The engine does not start easily (It always takes time to start) S-1
4 The engine does not crank E-1 S-2a)
The engine
5 The engine cranks but exhaust smoke does not come out S-2b)
does not start
6 Exhaust smoke comes out but the engine does not start S-2c)
7 The engine speed does not rise sharply (Follow-up performance is low) S-3
8 The engine stops during operation S-4
9 Engine rotation is abnormal (The engine hunts) S-5
10 Output is insufficient or power is low S-6
11 Exhaust gas color is bad (Incomplete combustion) S-7
12 Oil is consumed much or exhaust gas color is bad S-8
13 Oil becomes dirty quickly S-9
14 Fuel is consumed much S-10
15 Coolant contains oil (or it blows back or reduces) S-11
16 The engine oil pressure caution lamp lights up (Oil pressure lowers) S-12
17 Oil level rises S-13
18 Water temperature rises too high (Overheating) S-14
19 Abnormal sound comes out S-15
20 Vibration is excessive S-16
21 The preheater does not operate E-2
Phenomena related to power train
22 Power is low (Drawbar pull is low) H-1 S-6
23 The machine does not travel (in the 2nd or 3rd gear speed) H-2
24 The machine does not travel start in any gear speed H-3
25 The machine can travel in only forward or reverse direction H-4
26 Time lag is large in shifting the gear speed or changing the travel direction H-5
27 The machine cannot be steered H-6
28 The machine can be steered in only 1 direction H-7
29 The machine overruns when steered H-8
30 The brake does not operate H-9
31 The torque converter is not locked up H-10
32 The torque converter oil is overheated H-11
Phenomena related to work equipment
33 Speed of the whole work equipment is low H-12
34 Any part of the equipment does not move H-13
35 Blade lifting speed or power is low H-14
36 Blade tilting speed or power is low H-15
37 Ripper lifting speed or power is low H-16
38 Ripper tilting speed or power is low H-17
20-314 D475A-5
(1)
Troubleshooting
No. Phenomenon considered to be failure Error
E mode H mode S mode
code
39 Hydraulic drift of blade lifting is large H-18
40 Hydraulic drift of blade tilting is large H-19
41 Hydraulic drift of ripper lifting is large H-20
42 The ripper pin puller cylinder does not operate (if the giant ripper is installed) E-3 H-21
43 The blade does not pitch (if the dual tilt system installed) H-22
44 Abnormal sound comes out from around hydraulic pump H-23
Phenomena related to monitor panel (Operator mode: Ordinary screen)
When the starting switch is turned ON, no items are displayed on monitor
45 E-4
panel
When the starting switch is turned ON, all items are kept displayed on moni-
46 E-5
tor panel
47 When the starting switch is turned ON, the basic check items flash E-6
48 Caution items flash while the engine is running E-7
49 Emergency warning items flash while the engine is started E-8
50 When the preheater is operated, the preheater pilot lamp does not light up E-9
When the dual tilt is selected, the dual/single tilt selector lamp does not light
51 E-10
up (if the dual tilt system is equipped)
When the torque converter is locked up, the torque converter lockup pilot
52 E-11
lamp does not light up
53 Display of the engine coolant temperature gauge is abnormal E-12
54 Display of the power train oil temperature gauge is abnormal E-13
55 Display of the hydraulic oil temperature gauge is abnormal E-14
56 Display of the fuel level gauge is abnormal E-15
57 Display of the gear speed and engine speed is abnormal E-16
58 Display of the shift mode and service meter is abnormal E-17
59 The switch module cannot be operated E-18
60 The caution lamp does not flash or go off E-19
61 The caution buzzer does not sound or go off E-20
62 The auto shift-down system does not operate or reset E-21
63 The auto pitch-back system does not operate or reset E-22
64 The caution buzzer cannot be canceled E-23
65 The operator mode does not operate E-24
Phenomena related to monitor panel (Service mode: Special function screen)
66 The service mode does not operate E-25
Other phenomena
67 The backup alarm does not sound E-26
The night lamp of the panel, headlamp, working lamp, and rear lamp do not
68 E-27
light up
69 The air conditioner does not operate E-28
70 The ORBCOMM terminal does not operate normally E-29
D475A-5 20-315
(1)
CONNECTOR ARRANGEMENT DRAWING AND ELEC-
TROUBLESHOOTING TRIC CIRCUIT DIAGRAM OF EACH SYSTEM
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC

CIRCUIT DIAGRAM OF EACH SYSTEM
Connectors list
Address
Connec- No. of
Type Name of device Stereo- M E T S V
tor No. pins
gram circuit circuit circuit circuit circuit
00A Terminal 1 Ground D-8 R-1
001 Terminal 1 Ground I-2 S-1
002 Terminal 1 Ground M-3
003 Terminal 1 Ground U-2 K-1 D-1 M-1
12S1 YAZAKI 2 Accessory socket U-8
12S2 YAZAKI 2 Accessory socket U-8
12V DT 3 Intermediate connector (Cab wiring harness) W-4
Intermediate connector
19 DT 4 J-2
(Windshield washer wiring harness)
20 DTHD#8 1 Cab power supply W-3
DTHD
21 1 Cab constant power supply W-3
#12
101 DT (Gr) 12 M-3 I-6 K-3 H-6
(Bulkhead wiring harness)
102 DT 6 M-3 F-3
(Bulkhead wiring harness)
103 DT 2 Intermediate connector (Starting motor) (A) AQ-2 S-9 G-8 M-8
104 DT 2 Intermediate connector (Starting motor) (B) AR-2 S-8 G-8 N-8
111 HD30 23 AV-6 I-7 I-8 O-6 L-4
(Engine wiring harness)
Intermediate connector (Atmospheric tempera-
122 DT 4 M-5 I-6
ture sensor wiring harness)
134 Terminal 1 Left electrical intake air heater AU-3 T-7 R-3
135 Terminal 1 Right electrical intake air heater AS-7 T-8
137 Terminal 1 Right electrical intake air heater AR-7 T-7 R-4
201 DT 6 D-1 G-2
(Yoke angle sensor wiring harness)
202 DT (B) 12 C-1 R-4 Q-5
(Radiator guard wiring harness)
203 DT 2 Right headlamp B-7 S-5
204 DT 2 Left headlamp C-7 S-4
205 Terminal 1 Horn D-1
206 Terminal 1 Horn B-7
206 DT 2 Right headlamp B-7 S-4
207 DT 2 Left headlamp C-8 S-4
209 DT (B) 12 C-7 R-4
(Small hood wiring harness)
217 DT 2 Caution buzzer Y-7 B-9
218 KES1 4 Rear lamp switch AD-6 H-9
219 KES1 4 Headlamp and working lamp switch AD-6 H-9
221 DT 2 Left working lamp G-1 T-2
223 DT 2 Left working lamp K-6 T-3
20-316 D475A-5
(1)
Address
Connec- No. of
tor No. pins
226 DT 2 Ripper lamp (if equipped) L-9 T-2
241 DT (Gr) 12 F-9 I-5 H-7 F-5 K-6
(Left fender wiring harness)
242 DT 2 Right working lamp D-8 T-4
243 DT 2 Right working lamp G-9 T-3
244 DT 2 Pin puller solenoid H-9
244 DT 2 Backup alarm K-5 P-9
250 Terminal 1 Starting switch terminal B AD-9 A-8 L-5 O-1 J-9 J-1
255 Terminal 1 Starting switch terminal R1 AD-8
256 Terminal 1 Starting switch terminal R2 AD-8 J-9
260 Terminal 1 Starting switch terminal BR AC-8 A-8 L-5 O-1 J-9
262 X 2 Intermediate connector (Horn switch) P-9
263 X 2 Intermediate connector (Pin puller switch) R-9
Intermediate connector (Horn switch, pin puller
264 DT 4 N-9
switch wiring harness)
265 Terminal 1 Horn switch Q-9
266 Terminal 1 Horn switch Q-9
270 Terminal 1 Starting switch terminal ACC AC-9 A-8 L-5 J-9 J-1
280 Terminal 1 Starting switch terminal C AD-9 A-8 L-5 O-1 J-9
301 DT 6 AS-8 S-6 I-9 N-7 Q-2
351 DT-T 2 Air conditioner clutch AQ-5
360 DT 6 Windshield washer tank motor J-3
369 DT 6 Windshield washer tank motor K-3
402 DT 2 Engine coolant temperature sensor AQ-3 S-6 I-9
404 DT 2 Engine oil level switch AQ-4 S-6
405 DT 2 Radiator coolant level sensor (Main) B-2 S-5
414 Terminal 1 Left electrical intake air heater AQ-3 T-7 R-3
422 DT 2 Fuel level gauge K-5 T-3
Intermediate connector (Right working lamp,
431 DT 4 H-9 S-3 P-8
backup alarm wiring harness)
453 DT 2 Torque converter oil level sensor AN-2 E-1
599 DT 6 Floor right switch wiring harness W-4 I-5 J-7 P-6 L-3
653 DT 2 Lockup solenoid AL-5 G-8
One-pin Intermediate connector
800 1 AG-4
connector (Spare power supply 1)
One-pin Intermediate connector
801 1 AH-4
connector (Spare power supply 2)
One-pin
810 1 Spare power supply 1 W-5
connector
One-pin
811 1 Spare power supply 2 W-5
connector
995 HD30 31 AV-6 F-5 N-8 Q-8
AC1 DT (B) 12 T-8
(Air conditioner wiring harness)
D475A-5 20-317
(1)
Address
Connec- No. of
tor No. pins
AC2 HD30 31 W-6
(Air conditioner wiring harness)
ACT DT 3 Air conditioner fresh air sensor D-8
ACU S (Gr) 12 Air conditioner unit W-6
ADH KES1 4 Additional heater switch AD-6
AF1 DT 2 Air filter switch AS-8 S-6
AFL DT 6 Intermediate connector AS-8 S-6
ANB Terminal 1 Alternator terminal B AQ-5 T-6 M-9
ANR Terminal 1 Alternator terminal R AQ-6 S-6 J-9 M-9
AP1 AMP040 16 Air conditioner control panel R-2
AP2 AMP040 20 Air conditioner control panel R-2
AP3 SWP 12 Air conditioner unit W-7
AP4 SWP 16 Air conditioner unit V-7
AP5 SWP 8 Air conditioner unit W-6
ASD KES1 4 Auto shift-down switch AC-8 Q-2
ATMD DT 3 Atmospheric temperature sensor (*1) D-8 K-6
BB1 R 5 Headlamp relay AF-2 L-9
BB2 R 5 Headlamp 2 relay AF-1 L-9
BB3 R 5 Rear lamp relay AF-2 O-9
BB4 R 5 Ripper lamp relay (if equipped) AG-1 O-9
BKA R 2 Backup alarm relay AF-2 R-8
BLD DT 2 Blade lower oil pressure switch N-8 K-8
BLMT YAZAKI 2 Additional blower U-8
BLSW KES1 4 Additional blower motor switch AD-6
BLU DT 2 Blade raise oil pressure switch N-8 K-8
BR Terminal 1 Battery relay terminal BR E-9 R-7
BRK DT 3 Brake potentiometer R-2 E-9
BSW HD30 14 S-1 C-9
(BULGA specification only)
BUZ KES1 3 Buzzer cancel switch AD-7 L-4 K-8
CA1 DT 3 CAN terminal resistance (*1) U-1 A-2 I-1 M-5 L-9
CA2 DT 3 CAN terminal resistance AA-8 A-2 Q-1 K-8 O-9
CAN DT (Gr) 12 AD-5 I-3 K-4 Q-1 K-5 P-1
CB1 Terminal 1 Steering controller power supply AF-4 P-7 Q-7
CB2 Terminal 1 Monitor panel power supply AF-4
CB3 Terminal 1 Transmission controller power supply AF-4 J-9 Q-7
CB4 Terminal 1 Air conditioner power supply AF-3
CB5 Terminal 1 Headlamp power supply AF-3 P-8
CB6 Terminal 1 Starting switch B signal power supply AF-3 P-8 J-8 Q-7 Q-7
CB7 Terminal 1 Rear lamp power supply AF-3 P-7
CM29 AMP070 10 ORBCOMM terminal (*1) AE-8 E-2
CM30 AMP070 14 ORBCOMM terminal (*1) AE-7 E-3
One-pin
CN-1 1 Lamp outlet connector (Cab) I-9
connector
CN-2 Terminal 1 Rear right speaker (Cab) I-9
20-318 D475A-5
(1)
Address
Connec- No. of
tor No. pins
CN-3 Terminal 1 Rear right speaker (Cab) I-9
CN-4 4 Rear wiper motor (Cab) H-9
CN-5 Terminal 1 Rear right speaker (Cab) H-9
CN-6 Terminal 1 Rear right speaker (Cab) H-9
CN-9 6 Front wiper motor (Cab) F-9
CN-10 9 Radio (Cab) J-9
CN-11 KES1 6 Left wiper switch (Cab) I-1
CN-12 KES1 6 Front wiper switch (Cab) I-2
CN-13 KES1 6 Right wiper switch (Cab) J-2
CN-14 KES1 6 Rear wiper switch (Cab) J-2
CN-15 M 2 Lamp switch (Cab) J-2
CN-17 YAZAKI 4 Right door wiper motor (Cab) F-9
CN-18 YAZAKI 4 Left door wiper motor (Cab) K-4
CN-22 Terminal 1 Cigarette lighter (Cab) K-9
One-pin
CN-25 1 Rotary lamp outlet connector (Cab) J-9
connector
CN-26 M 2 Rotary lamp switch (Cab) J-2
CN-81 2 Room lamp (Cab) G-9
CONV DT 6 Converter U-8
CSL DT 3 Left yoke angle sensor E-1 H-1
CSR DT 3 Right yoke angle sensor B-2 H-1
CUR KES1 3 Cursor switch AD-7 K-8
DIAL M 3 Fuel control dial T-9 E-9
DL1 BENDIX 6 Download connector (*1) L-3 J-5
DLT DT 2 Download lamp (*1) K-2 K-5
DPNL DT 2 Diode AL-8
DRT DT 2 Radiator coolant level switch (Dual) B-2 S-5
DUL DT 2 Dual selector solenoid valve O-8 J-8
E9 DT-T 6 Rack sensor (Left bank) AV-4 H-5
E10 DT-T 3 Pre-stroke solenoid (Left bank) AV-3 H-4
E11 DT-T 2 Governor solenoid (Left bank) AU-3 H-4
E12 DT-T 2 Engine speed sensor (Left bank) AV-4 H-4 N-8 R-8
E13 DT-T 6 Rack sensor (Right bank) AQ-9 H-6
E14 DT-T 3 Pre-stroke solenoid (Right bank) AR-9 H-5
E15 DT-T 2 Governor solenoid (Right bank) AR-9 H-5
E16 DT-T 2 Engine speed sensor (Right bank) AQ-8 H-5
ENBP DT 3 Blow-by pressure (*1) AQ-2 J-8
ENGP DT 3 Engine oil pressure sensor AQ-7 Q-2
ENGT DT 2 Engine oil temperature sensor (*1) AQ-6 J-9
ESD DT 3 ACC, engine L1 signal (if equipped) AH-1
Amplifier for exhaust temperature sensor
EX1L DT 3 AI-8 F-9
(Left) (*1)
EX1R DT 3 AG-5 E-9
(Right) (*1)
D475A-5 20-319
(1)
Address
Connec- No. of
tor No. pins
EX2L DT 2 AF-6 E-9
(Left) (*1)
EX2R DT 2 AI-8 E-9
(Right) (*1)
EXHL DT 2 Exhaust temperature sensor (Left) (*1) AV-5 J-8
EXHR DT 2 Exhaust temperature sensor (Right) (*1) AR-7 J-8
F1T8 DT 2 Transmission 1st ECMV AM-6 E-9
F2T6 DT 2 Transmission 2nd ECMV AM-6 F-9
F3T4 DT 2 Transmission 3rd ECMV AN-6 F-9
F32 Terminal 1 Battery relay terminal B H-2
F96 Terminal 1 Battery relay terminal M G-1
FA1 DT 2 Fan pulley solenoid AN-3 G-8
FA2 DT 2 Fan pulley solenoid AN-3 G-8
FAN KES1 4 Fan reverse mode switch AD-7 L-8
FAR2 DT 2 Fan reverse solenoid C-1 Q-5
FCD DT 3 Decelerator potentiometer Q-2 D-9
FD5 DT (Gr) 12 Fuse wiring harness W-4 S-2 Q-7 Q-6
FFT2 DT 2 Transmission F clutch ECMV AN-6 D-9
FL82 DT 2 Left brake ECMV AP-6 H-8
FLC6 DT 2 Left clutch ECMV AO-6 G-8
FR84 DT 2 Right brake ECMV AP-6 I-8
FRC8 DT 2 Right clutch ECMV AO-7 H-8
FRT2 DT 2 Transmission R clutch ECMV AM-5 E-9
FS12 5 Fuse box AG-4 P-8 H-4
FS22 5 Fuse box AH-4
FS42 5 Fuse box AH-4 P-8 J-8 Q-7 Q-7 H-4
FSB HD30 31 S-1 I-8 K-7 P-6 L-4 H-3
(Floor left wiring harness)
FTU KES1 4 Auto pitch back switch AC-8 Q-3
GA Junction wiring harness (Shield) P-1
GB Junction wiring harness (Shield) M-1
GCL R 5 L.H. governor cut relay AC-2 C-9
GCR R 5 R.H. governor cut relay AC-2 B-9
One-pin
H01 1 Additional heater switch (if equipped) U-2
connector
One-pin
H02 1 Additional heater switch (if equipped) V-2
connector
HLS DT 2 Hydraulic oil level switch (if equipped) G-9 O-8
HP1 DT 3 Work equipment pump oil pressure (F) E-9 K-5
HP2 DT 3 Work equipment pump oil pressure (R) E-9 K-5
HR1 DT 6 Intermediate connector (Hood wiring harness) M-4 G-3
HR2 DT (Gr) 12 Intermediate connector (Hood wiring harness) M4 Q-4 P-5
J1 Junction wiring harness AI-1
J2 Junction wiring harness W-3 J-9 J-9 R-9
J3 Junction wiring harness T-1 J-9
20-320 D475A-5
(1)
Address
Connec- No. of
tor No. pins
J4 Junction wiring harness (ACC signal) T-1 J-9 J-9 H-1
J5 Junction wiring harness (Rear lamp) AI-1 K-9
J6 Junction wiring harness T-1 J-9
J7 Junction wiring harness (GND) AI-1 K-9 R-8
J8 Junction wiring harness AH-4 K-9 R-6
J9 Junction wiring harness (Working lamp) W-3 I-9
J10 Junction wiring harness (Air conditioner) AH-4 R-8
JC1 Junction wiring harness (CANOH) (*1) W-3 C-1 J-3 N-6 L-9
JC2 Junction wiring harness (CANOL) (*1) W-3 D-1 J-3 N-6 L-9
JC3 Junction wiring harness (CAN H) Y-6 D-1 R-5 H-1 N-1
JC4 Junction wiring harness (CAN L) Y-6 E-1 R-5 H-1 O-1
JC5 Junction wiring harness (CAN shield) Y-6 E-1 R-5 H-1 O-1
JC6 Junction wiring harness (CAN shield) (*1) X-3 D-1 J-3 N-6 K-9
JCA Junction wiring harness (CAN H) Z-8 B-1 R-3 I-8 N-9
JCB Junction wiring harness (CAN L) Z-8 C-1 R-3 I-8 O-9
JCC Junction wiring harness (CAN shield) Z-8 C-1 R-3 I-7 O-9
JCZ Junction wiring harness (C signal) Y-6
JE1 Junction wiring harness (Power supply) AC-1 A-9
Junction wiring harness
JE2 AB-1 C-1
(Sensor power supply +5 V)
JE3 Junction wiring harness (Analog GND) AB-1 K-1 D-1
JE4 Junction wiring harness (GND) AB-1 K-1 D-1 N-1
JE5 Junction wiring harness (Engine speed ) M-1 E-1 O-1 P-9
JE6 Junction wiring harness (Engine speed +) AC-1 E-1 N-1 Q-9
JEA M-1 C-1
JEC Junction wiring harness (Engine speed ) AC-1 E-1 N-1 Q-9
JED Junction wiring harness (Power supply) AB-1 A-9
JEE Junction wiring harness (GND) AC-2 D-9
JEF Junction wiring harness (Engine speed +) M-1 F-1 O-1 P-9
JEG AC-2 J-1 B-1
(Constant power supply +24 V)
JEH Junction wiring harness (GND) AB-1 C-1
JF1 DT 6 Junction connector (Headlamp) C-2 R-5
JF2 DT 6 Junction connector (Horn) C-2
JF3 Junction wiring harness (Left rear lamp) L-9 R-1
JF4 Junction wiring harness (Right head lamp) C-2
JM1 Junction wiring harness (Panel power supply) AA-8 C-9
JM2 Y-7 C-9 H-1 M-5 L-1 J-1
(Constant power supply)
JM3 Junction wiring harness (C signal) Y-6 D-9 H-1
JM4 Junction wiring harness (R signal) Y-6 D-9 N-1
JM5 Junction wiring harness (Lamp signal) R-1 E-9
JM6 M-1 E-9 I-1
(Water temperature sensor)
D475A-5 20-321
(1)
Address
Connec- No. of
tor No. pins
JM7 Junction wiring harness (BR signal) Y-4 F-9 J-1 M-1 G-1
JM8 Junction wiring harness (ACC signal) Q-1 H-1
JMA Y-8 C-9 H-1 M-6 L-1 K-1
(Constant power supply)
JMB Junction wiring harness (C signal) Y-6 D-9 J-1 N-1 K-1 I-1
JMC Junction wiring harness (R signal) N-1 D-9 I-1 M-5
JMD Junction wiring harness (Lighting signal) AA-8 E-9
JME M-1 E-9 I-1
(Water temperature sensor GND)
JMF Q-1 F-9 G-1
(Electrical intake air heater)
JMH Junction wiring harness (GND) Y-8 J-1 I-1
JMJ Junction wiring harness (GND) Z-8 R-2
JMK Junction wiring harness (GND) AA-8 B-9
JML Junction wiring harness (GND) Y-6 H-1 R-1 K-1
JMM Junction wiring harness (GND) AA-1 B-1
JMN Junction wiring harness (ACC signal) AD-3 B-1
JMR Junction wiring harness (ACC signal) Y-8 G-1 K-1 I-1 I-1
JN1 Junction wiring harness (S-NET +) Y-5 G-1 G-1 M-6 J-1 M-1
JN2 Junction wiring harness (S-NET ) Y-5 G-1 G-1 M-6 J-1 M-1
JNA Junction wiring harness (S-NET +) AC-2 L-1 D-9 I-1 P-1 R-6
JNB Junction wiring harness (S-NET ) AC-1 L-1 D-9 J-1 P-1 R-6
JS1 Junction wiring harness (GND) AA-1 E-1
JS2 AA-1 F-1
(Controller power supply)
JS3 Junction wiring harness (Travel lock switch) M-2 L-1 D-1
JS4 Junction wiring harness (Solenoid GND) M-2 D-1
JS5 Junction wiring harness (Solenoid GND) M-2 C-1
JS6 Junction wiring harness (Analog GND) M-2 C-1
JS7 M-2 C-1
JS8 Junction wiring harness (Buzzer cancel switch) Y-5
JS9 Junction wiring harness (Analog GND) N-1 C-1
JSA Junction wiring harness (Service switch) AC-2 K-1 C-1 M-1
D-1
JSB Junction wiring harness (Travel lock switch) M-2 H-1 L-1
J-1
JSC Junction wiring harness (Solenoid GND) M-2 L-1 D-1
JSE Junction wiring harness (GND) AA-1 E-1
JSF U-1 B-1
JT1 Junction wiring harness (GND) AD-4 E-1
JT2 AD-4 E-1
JT3 Junction wiring harness (Solenoid GND) P-1 E-1
JT4 Junction wiring harness (Solenoid GND) P-1 D-1
JT5 Junction wiring harness (Signal GND) U-1 B-1
20-322 D475A-5
(1)
Address
Connec- No. of
tor No. pins
JT6 Junction wiring harness (Signal) P-1 A-1
JT7 Junction wiring harness (Analog GND) P-1 F-1
JT8 Junction wiring harness (Backup alarm) Q-1 C-1
JT9 Junction wiring harness (Signal GND) Q-9 L-6
JT10 Junction wiring harness (Signal GND) Q-9 K-6
JT11 Junction wiring harness (Solenoid GND) P-8 H-8
JT12 Junction wiring harness (Solenoid GND) P-8 H-8 D-9
JTA P-1 B-1
JTB M-7 D-1
JTC Junction wiring harness (Analog GND) M-2 F-1
JTD Junction wiring harness (Solenoid GND) P-1 D-1
JTE Junction wiring harness (GND) AD-3 E-1
JTF Q-1 C-1
JTG Junction wiring harness (Signal GND) Q-9 L-6
JTH U-1
JTJ Junction wiring harness (Signal GND) Y-3 A-1
JTK Junction wiring harness (Solenoid GND) P-8 H-7
JTL M-4 B-1
JV1 AG-5 C-9
(Constant power supply +24 V) (*1)
JV2 L-1 K-6
(Download connector) (*1)
JV2 AG-5 C-9
(Sensor power supply +24 V) (*1)
JV3 Junction wiring harness (Analog GND) (*1) AH-5 C-9
JV4 Junction wiring harness (Analog GND) (*1) AH-5 C-9
JV5 Junction wiring harness (*1) AH-6 D-1
JV7 Junction wiring harness (*1) AI-6 D-1
JV9 Junction wiring harness AH-5 C-9
JV13 Junction wiring harness AI-7 A-3 Q-9 E-1
JV14 Junction wiring harness (*1) AI-7
KEY DT 6 Starting switch AC-8 A-8 K-4 O-1 J-8 J-2
LBR Terminal 1 Battery relay terminal BR H-1 R-7 H-8 O-8 P-3
One-pin Engine coolant temperature sensor for low
LCT 1 AQ-3 Q-3
connector temperature
LE1 MIC 17 Engine controller AD-2 O-1 A-9
D475A-5 20-323
(1)
Address
Connec- No. of
tor No. pins
LE2 MIC 21 Engine controller Z-1 A-8 Q-7
LE4 AMP040 12 Engine controller AD-3 O-1 A-4 J-1 M-8 Q-7
LE31 AMP040 20 Engine controller AD-2 O-1 A-6 M-8
LE32 AMP040 16 Engine controller AD-2 O-1 A-4
LE51 AMP040 20 Engine controller AD-3 P-1 A-3 J-1 M-8
LE52 AMP040 16 Engine controller AD-3 A-1
LSV DT 2 LS selector solenoid AK-5 G-8
E-8, O-8, P-3,
M Terminal 1 Battery relay terminal M R-8 H-9 J-3
G-1 O-9 P-4
MFD DT 2 Merge-divider solenoid valve O-7 I-8 E-9
NSF R 5 Neutral safety relay AF-2 P-9 K-9 R-8
NSW DT 3 Travel lock switch AI-4 P-9 Q-5
OZH1 Terminal 1 Ground T-1 H-1 K-1 H-5
OZH3 Terminal 1 Ground T-1 H-1
P03 DT 6 Work equipment knob switch N-9 L-7
PL1 HD30 23 AP-4 E-7
(Power train wiring harness)
Intermediate connector (Emergency escape
PL1F HD30 23 AM-8
system) (if equipped)
PL1M HD30 23 AM-8
Intermediate connector AM-8,
PL2 HD30 31 E-2 G-8 G-7 R-3
(Power train wiring harness) AP-4
PL3 HD30 14 AP-4 G-8 G-7 H-7
(Power train wiring harness)
PLR R 5 Pre-lubrication relay AD-5 L-8
PNL HD30 31 AK-9
POP Terminal 1 Engine oil pressure switch for pre-lubrication AS-2 P-2
PPB DT 2 Pitch back solenoid valve O-8 I-8
PPD DT 2 Pitch back solenoid valve O-8 I-8
PPV DT 2 Pitch priority solenoid valve P-8 J-8 E-9
PRE DT 2 Pre-lubrication AI-2 K-9 J-9 R-9
PRS DT 2 Pre-lubrication AI-3
PT1 DT 3 Pitch angle sensor O-1 E-9
PTH DT 2 Pitch selector solenoid valve O-8 J-8
PWR1 DTHD#4 1 Intermediate connector (Fuse) W-5 Q-8
PWR2 DTHD#4 1 Intermediate connector (Fuse) W-5 Q-8 I-9 Q-7 P-6 H-4
RHR R 5 Preheater relay AG-1 P-9 R-7
RPD DT 2 Ripper lower oil pressure switch M-9 K-8
RPNL X 2 Resistor AM-8
RPU DT 2 Ripper raise oil pressure switch N-9 J-8
RT8 DT 2 Ripper tilt back oil pressure switch N-8 K-8
RT1 DT 2 Ripper tilt in oil pressure switch M-9 J-8
S01 AMP040 12 Monitor panel AB-8 A-7 K-6 Q-4 I-9 M-8
S02 M 2 Monitor panel AA-8 A-6
20-324 D475A-5
(1)
Address
Connec- No. of
tor No. pins
S03 AMP070 20 Monitor panel AB-8 A-6 K-5
S04 AMP070 12 Monitor panel AB-8 A-5 Q-4 I-9 N-8
S1T7 DT 2 Transmission 1st ECMV AM-6 E-9
S2T5 DT 2 Transmission 2nd ECMV AM-6 F-9
S3T3 DT 2 Transmission 3rd ECMV AN-6 F-9
S21 DT 3 SCC initializing jumper AB-8 B-9
S24 Service switch AD-4 J-1 B-2 M-2 K-6
S24-1 Terminal 1 Download switch (*1) L-1
S28 X 4 Engine controller memory writing AB-1 C-9
SDR DT 2 Turbocharger timer AI-3 K-9
SDS DT 2 Hydraulic oil temperature sensor AN-2 H-8
SFT1 DT 2 Transmission F clutch ECMV AN-6 D-9
SFTD 3 PCCS lever shift-down S-9 H-1
SFTU 3 PCCS lever shift-up S-9 G-1
SL81 DT 2 Left brake ECMV AP-6 H-8
SLC5 DT 2 Left clutch ECMV AO-7 G-8
SLS YAZAKI 2 Daylight sensor AA-8
SR1 Terminal 1 Starting motor (A) terminal C AT-2 T-9
SR2 Terminal 1 Starting motor (A) terminal R AT-2
SR3 Terminal 1 Starting motor terminal B AR-2
SR4 Terminal 1 Starting motor (B) terminal C AU-2 T-8
SR5 Terminal 1 Starting motor (B) terminal R AU-2
SR6 Terminal 1 Starting motor terminal B AT-2
SR83 DT 2 Right brake ECMV AO-6 H-8
SRC7 DT 2 Right clutch ECMV AO-7 G-8
SRT1 DT 2 Transmission R clutch ECMV AM-5 E-9
E-8,
SSA DT 4 Acceleration sensor (SSC machine) O-1
F-8
STB DT 2 Sudden stop prevent solenoid AP-6
STCN1 DRC-26 24 Steering controller Y-2 P-1 L-1 A-9
STCN2 DRC-26 40 Steering controller Z-2 P-1 K-1 A-7 P-2
STCN3 DRC-26 40 Steering controller AA-1 K-1 A-5
STF X 4 Steering controller writing connector Y-4 F-1
SX8 Terminal 1 Ground J-3
TC1 DT 2 Torque converter outlet speed sensor (*1) AP-5 H-8 R-2
Y-5,
TEG DT (Gr) 12 Intermediate connector (Engine controller) I-4 F-3 K-3 K-7 O-5
AD-3
TL1 HD30 23 S-1 E-8 F-3 A-2
(PCCS lever wiring harness)
TL2 DT 8 PCCS lever potentiometer T-8 G-1 A-1
TL3 DT 6 T-9 G-2
(PCCS lever wiring harness)
D475A-5 20-325
(1)
Address
Connec- No. of
tor No. pins
TLL DT 2 Left tilt limit solenoid valve N-7 I-8
TLR DT 2 Right tilt limit solenoid valve N-7 I-8
TLS DT 2 Blade tilt left oil pressure switch N-8 L-8
TM1 DT 2 Transmission outlet speed sensor AP-5 H-8
TMCN1 DRC-26 24 Transmission controller AD-5 Q-1 A-8 N-8
TMCN2 DRC-26 40 Transmission controller AD-5 Q-1 E-9 A-6 O-8 Q-2
TMCN3 DRC-26 40 Transmission controller AD-4 A-4
TMF X 4 Transmission writing connector Y-3 B-9
TMMD DT 3 Transmission main oil pressure (*1) AK-5 I-7
TRS DT 2 Blade tilt right oil pressure switch M-8 K-8
TS1 DT (G) 12 Y-4 I-3 K-3 K-2 E-6 O-4
(Monitor panel wiring harness)
TS1F DT (G) 12 Y-4
(Steering controller wiring harness)
TS2 DT (Br) 12 Y-4 I-3 K-3 K-2 E-6 O-3
(Monitor panel wiring harness)
TS2F DT (Br) 12 Y-4
(Steering controller wiring harness)
TTMF DT (B) 12 Y-5 I-4 F-7 F-4 O-4
(Transmission controller wiring harness)
USB DT 1 Intermediate connector (Fuse) W-4 Q-8 I-8 Q-7 P-6 H-4
V1 AMP070 20 VHMS controller (*1) AE-6 B-8
V2A AMP070 18 VHMS controller (*1) AF-9 K-8 B-7
V2B AMP070 12 VHMS controller (*1) AG-9 B-5
V3A AMP070 18 VHMS controller (*1) AH-5 A-4 L-8 P-8 B-5
V3B AMP070 12 VHMS controller (*1) AG-5 P-8 B-3
V4A AMP070 14 VHMS controller (*1) AI-7 A-3 I-1 P-8 B-3
V4B AMP070 10 VHMS controller (*1) AI-6 B-1
V12 DT (B) 12 AI-6 G-4
(VHMS wiring harness) (*1)
V25 DT 3 U-8 I-4
(Download connector wiring harness)
VDA HD30 14 L-3 I-5
(Download wiring harness)
VDB DT (Gr) 8 W-4 H-5
(Fender wiring harness) (*1)
VDW BENDIX 5 Download connector V-8 J-4
VEG HD30 14 AV-6 H-8
(Engine wiring harness) (*1)
VF1 HD30 14 AE-6 G-8
(Floor wiring harness) (*1)
VF2 HD30 23 AF-5 C-3 G-6 I-3 O-6 G-7
(Floor wiring harness) (*1)
X7 Junction wiring harness (Shield) AB-1
X8 Junction wiring harness (Shield) AB-1
(*1): VHMS specification only
20-326 D475A-5
(1)
Connector Location Stereogram
20-328 D475A-5
(1)
D475A-5 20-329
(1)
20-330 D475A-5
(1)
D475A-5 20-331
(1)
20-332 D475A-5
(1)
D475A-5 20-333
(1)
20-334 D475A-5
(1)
D475A-5 20-335
(1)
Circuit diagram of monitor panel system (M circuit)
20-336 D475A-5
(1)
a This circuit diagram is made by excerpting the monitor panel system, engine preheating/starting/charging
system, light system, and communication network system from the general electric circuit diagram.
D475A-5 20-337
(1)
20-338 D475A-5
(1)
Circuit diagram of engine controller system (E circuit)
20-340 D475A-5
(1)
a This circuit diagram is made by excerpting the engine controller system from the general electric circuit dia-
gram.
D475A-5 20-341
(1)
Circuit diagram of transmission controller system (T-circuit)
20-342 D475A-5
(1)
a This circuit diagram is made by excerpting the transmission controller system from the general electric circuit
diagram.
D475A-5 20-343
(1)
20-344 D475A-5
(1)
Circuit diagram of steering controller system (S-circuit)
20-346 D475A-5
(1)
a This circuit diagram is made by excerpting the steering controller system from the general electric circuit di-
agram.
D475A-5 20-347
(1)
20-348 D475A-5
(1)
Circuit diagram of VHMS controller system (V-circuit)
20-350 D475A-5
(1)
a This circuit diagram is made by excerpting the VHMS controller system from the general electric circuit dia-
gram.
D475A-5 20-351
(1)
20-352 D475A-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
Electric wire size: 0.85 Electric wire size: 0.85

Grommet: Black Grommet: Black
Qty: 20 Qty : 20

Grommet: Red Grommet: Red
Qty: 20 Qty: 20
20-354 D475A-5
(1)
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
D475A-5 20-355
(1)
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:

Grommet: Black Grommet: Black
Qty: 20 Qty: 20
Terminal part No.: Terminal part No.:

Grommet: Red Grommet: Red
Qty: 20 Qty: 20
20-356 D475A-5
(1)
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
D475A-5 20-357
(1)
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-358 D475A-5
(1)
S type connector
No.of
pins T-adapter
Part No.
10

(Blue)
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
D475A-5 20-359
(1)
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Qty: 5) Body part No.: 79A-222-2630 (Qty: 5)
11 Body part No.: 79A-222-2680 (Qty: 5) Body part No.: 79A-222-2670 (Qty: 5)
5 799-601-2710
Body part No.: 79A-222-2620 (Qty: 5) Body part No.: 79A-222-2610 (Qty: 5)
9 799-601-2950
13 799-601-2720
20-360 D475A-5
(1)
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740

(Qty: 50) (Qty: 50)
D475A-5 20-361
(1)
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
Housing part No.: 79A-222-3430 (Qty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
20-362 D475A-5
(1)
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
Part No.: 08195-10210
12 799-601-7520
Part No.: 08195-12210
14 799-601-7530
Part No.: 08195-14210
18 799-601-7540
Part No.: 08195-18210
20 799-601-7550
Part No.: 08195-20210
D475A-5 20-363
(1)
L type connector
No.of
pins T-adapter Part
No.
Connector for PA
No.of
pins T-adapter Part
No.
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
20-364 D475A-5
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
Part No.:08027-10310 Part No.:08027-10360
08027-10420 (Black) 08027-10470 (Black)
08027-10620 (Black) 08027-10670 (Black)
D475A-5 20-365
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
6 799-601-7370
20-366 D475A-5
(1)
F type connector
No.of
pins T-adapter
Part No.
D475A-5 20-367
(1)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-368 D475A-5
(1)

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
D475A-5 20-369
(1)

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-370 D475A-5
(1)

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
D475A-5 20-371
(1)

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-372 D475A-5
(1)
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
D475A-5 20-373
(1)
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
20-374 D475A-5
(1)
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
D475A-5 20-375
(1)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins

part name
799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P
20-376 D475A-5
(1)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins

part name
799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD24 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DEUTSCH 40P
799-601-9360 DEUTSCH 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 3P
press.
799-601-9430 PVC socket 2P
D475A-5 20-377
(1)
TROUBLESHOOTING WHEN SERVICE CODE
"ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE INDICATED
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-407

ERROR CODE [1500L0] (TRANSMISSION CLUTCH: SEE THE LIST. (L0)) ............................................ 20-409
ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST. (L1))..................................................... 20-410
ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST. (LH)) ................................................... 20- 411
ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST. (L1))...................................................... 20-412
ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST. (LH))..................................................... 20-413
ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST. (L1)) ................................................................ 20-414
ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST. (LH)) ............................................................... 20-415
ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST. (L1)) ................................................................ 20-416
ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST. (LH))............................................................... 20-417
ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST. (L1)) ............................................................... 20-418
ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST. (LH)) .............................................................. 20-419
ERROR CODE [1800MW] (POWER TRAIN CLUTCH: SLIP (MW)) .......................................................... 20-420
ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST. (L1))............................................................. 20-421
ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST. (LH)) ........................................................... 20-422
ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST. (L1)) ............................................................... 20-423
ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST. (LH)).............................................................. 20-424
ERROR CODE [2300NR] (BRAKE THERMAL LOAD: ABNORMAL HEATING (NR)) ............................... 20-425
ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST. (L1)) ............................................................... 20-426
ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST. (LH)).............................................................. 20-427
ERROR CODE [2301NR] (RIGHT STEERING BRAKE THERMAL LOAD:
ABNORMAL HEATING (NR))............................................................................................................... 20-428
ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST. (L1)) ................................................................. 20-429
ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST. (LH)) ................................................................ 20-430
ERROR CODE [2302NR] (LEFT STEERING BRAKE THERMAL LOAD: ABNORMAL HEATING (NR)) .. 20-431
ERROR CODE [A000N1] (or VHMS_LED IS DISPLAYED "n2" o"01") ENGINE OVERRUN ................... 20-431
ERROR CODE [A70XLK] (GOVERNOR SERVO SYSTEM RIGHT: * REFER TO TABLE (LK))................ 20-432
ERROR CODE [A70YLK] (GOVERNOR SERVO SYSTEM LEFT: * REFER TO TABLE (LK)) .................. 20-433
ERROR CODE [AA1ANX] (AIR CLEANER: CLOGGING (NX)) ................................................................. 20-434
ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA))........................................................... 20-434
ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)) ..................................... 20-435
ERROR CODE [B@BAZK] (ENGINE OIL: OIL LEVEL REDUCTION (ZK)) ............................................... 20-435
ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS)) ................................................... 20-436
ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK))...................................... 20-436
ERROR CODE [B@CENS] (POWER TRAIN OIL: OVERHEAT (NS)) ....................................................... 20-437
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))............................................................ 20-437
ERROR CODE [B@HAZK] (HYDRAULIC OIL: LEVEL REDUCTION (ZK)) .............................................. 20-438
ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA)) ................................................... 20-439
ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB)) ..................................................... 20-440
ERROR CODE [D130KA] (NEUTRAL SAFETY RELAY: DISCONNECTION (KA)) ................................... 20-441
ERROR CODE [D130KB] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB)) ..................................... 20-443
ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA))...................................... 20-444
ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB)) ........................................ 20-446
D475A-5 20-401
(1)
TROUBLESHOOTING
ERROR CODE [D182KZ] (PREHEATER RELAY: LOWERING OF LEVEL (KZ)) ...................................... 20-448
ERROR CODE [D1D0KA] (GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION (KA)) .................. 20-450
ERROR CODE [D1D0KB] (GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT (KB)) .................... 20-452
ERROR CODE [D1D1KA] (GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION (KA)) .................... 20-454
ERROR CODE [D1D1KB] (GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT (KB)) ...................... 20-456
ERROR CODE [D5ZFKA] (NEUTRAL SIGNAL 1: DISCONNECTION (KA)) ............................................. 20-458
ERROR CODE [D5ZFKB] (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB)) ............................................... 20-459
ERROR CODE [D5ZFL4] (ENGINE CONTROLLER NEUTRAL SIGNAL:
ON AND OFF SIGNALS DO NOT AGREE (L4)).................................................................................. 20-460
ERROR CODE [D5ZGKA] (NEUTRAL SIGNAL 2: DISCONNECTION (KA))............................................. 20-462
ERROR CODE [D5ZGKB] (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB))............................................... 20-463
ERROR CODE [D5ZKKX] (CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL RANGE (KX)) ...... 20-464
ERROR CODE [D5ZRKA] (SNAP SHOT SWITCH: DISCONNECTION (KA)) ........................................... 20-465
ERROR CODE [D5ZRKB] (SNAP SHOT SWITCH: SHORT CIRCUIT (KB)) ............................................. 20-466
ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION:
DEFECTIVE COMMUNICATION (KR)) ................................................................................................ 20-468
ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER:
SOURCE VOLTAGE REDUCTION (INPUT) (KK))............................................................................... 20-470
ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER:
ABNORMALITY IN CONTROLLER (KT)) ............................................................................................ 20-471
ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY:
ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY:
ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION:
TYPE SELECT SIGNAL INCONSISTENCY (KQ))............................................................................... 20-474
ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION:
DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR)) . 20-476
ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET COMMUNICATION:
ERROR CODE [DB30KK] (STEERING CONTROLLER:
ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) .......... 20-481
ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY:
ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY:
ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION:
TYPE SELECT SIGNAL INCONSISTENCY (KQ))............................................................................... 20-485
ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION:
ERROR CODE [DB3SKR] (STEERING CONTROLLER S-NET COMMUNICATION:
ERROR CODE [DB40KK] (ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK))........... 20-490
ERROR CODE [DB41KK] (SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)) ...... 20-490
ERROR CODE [DB42KK] (SOLENOID POWER SUPPLY 1:
LOWERING OF SOURCE VOLTAGE (KK))......................................................................................... 20-492
ERROR CODE [DB43KK] (BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLTAGE (KK)) ...... 20-494
ERROR CODE [DB44KK] (SOLENOID POWER SUPPLY 2:
LOWERING OF SOURCE VOLTAGE (KK))......................................................................................... 20-496
ERROR CODE [DB45KP] (RACK SENSOR POWER SUPPLY:
LOWERING OF OUTPUT VOLTAGE (KP)) ......................................................................................... 20-498
ERROR CODE [DB49KM] (WRONG CONNECTION OF CONNECTOR:
MISTAKE IN OPERATION OR SETTING (KM))................................................................................... 20-500
ERROR CODE [DB49KQ] (ENGINE CONTROLLER SPECIFICATION:
DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)) ............................................................. 20-501
ERROR CODE [DBB0KK] (OR LED OF VHMS CONTROLLER INDICATES "n9" o "01")
(VHMS CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK)).................................................. 20-502
20-402 D475A-5
(1)
TROUBLESHOOTING
ERROR CODE [DBB0KQ] (OR LED OF VHMS CONTROLLER INDICATES "nF" o "11") (CHECK OF
VHMS CONTROLLER MODEL: DISAGREEMENT OF MODEL SELECTION SIGNALS (KQ)) ......... 20-504
(VHMS CONTROLLER: LOWERING OF BATTERY DIRECT SOURCE VOLTAGE (KK)).................. 20-505
ERROR CODE [DBB5KP] (OR LED OF VHMS CONTROLLER INDICATES "n9" o "04")
(SENSOR POWER SUPPLY (5 V): LOWERING OF OUTPUT VOLTAGE (KP)) ................................ 20-506
(SENSOR POWER SUPPLY (24 V): LOWERING OF OUTPUT VOLTAGE (KP)) .............................. 20-507
(SENSOR POWER SUPPLY (12 V): LOWERING OF OUTPUT VOLTAGE (KP)) .............................. 20-508
ERROR CODE [DBBQKR] (OR LED OF VHMS CONTROLLER INDICATES "n8" o "02")
(VHMS KOM-NET: DEFECTIVE COMMUNICATION (KR)) ................................................................. 20-510
ERROR CODE [DD12KA] (SHIFT UP SWITCH: DISCONNECTION (KA)) ............................................... 20-512
ERROR CODE [DD12KB] (SHIFT UP SWITCH: SHORT CIRCUIT (KB)) ................................................. 20-514
ERROR CODE [DD13KA] (SHIFT DOWN SWITCH: DISCONNECTION (KA)) ......................................... 20-516
ERROR CODE [DD13KB] (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB)) ........................................... 20-518
ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)) ................................... 20-520
ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) ..................................... 20-522
ERROR CODE [DDN2LD] (BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM:
REFER TO TABLE (LD)) ...................................................................................................................... 20-524
ERROR CODE [DDN3LD] (BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM:
REFER TO TABLE (LD)) ...................................................................................................................... 20-525
ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA))........................................ 20-526
ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB)).......................................... 20-528
ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA)) ........................................... 20-530
ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB)) ............................................. 20-532
ERROR CODE [DDNALD] (BLADE LIFT RAISE FULL OIL PRESSURE SWITCH:
REFER TO TABLE (LD)) ...................................................................................................................... 20-534
ERROR CODE [DDNBLD] (RIPPER LIFT RAISE OIL PRESSURE SWITCH: REFER TO TABLE (LD)) .. 20-535
ERROR CODE [DDNCLD] (RIPPER LIFT LOWER OIL PRESSURE SWITCH:
REFER TO TABLE (LD)) ...................................................................................................................... 20-536
ERROR CODE [DDNDLD] (RIPPER TILT IN OIL PRESSURE SWITCH: REFER TO TABLE (LD)) ......... 20-537
ERROR CODE [DDNELD] (RIPPER TILT BACK OIL PRESSURE SWITCH: REFER TO TABLE (LD)) ... 20-538
ERROR CODE [DDNFLD] (BLADE LIFT LOWER FULL OIL PRESSURE SWITCH:
REFER TO TABLE (LD)) ...................................................................................................................... 20-539
ERROR CODE [DDQ2KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)) .................................. 20-540
ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB)) ....................... 20-542
ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4)) ................................. 20-544
ERROR CODE [DGE1KB] (OR LED OF VHMS CONTROLLER INDICATES "n2" o "42")
(ENGINE OIL TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB))
(30 MINUTES AFTER ENGINE IS STARTED (ABOVE 500 RPM))..................................................... 20-545
ERROR CODE [DGE1KY] (OR LED OF VHMS CONTROLLER INDICATES "n2" o "41")
(ENGINE OIL TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KY)) .................................. 20-546
ERROR CODE [DGE2KX] (COOLANT TEMPERATURE SENSOR:
OUT OF INPUT SIGNAL RANGE (KX))............................................................................................... 20-548
ERROR CODE [DGE3KA] (ENGINE COOLANT TEMPERATURE SENSOR GAUGE)
(FOR LOW TEMPERATURE): DISCONNECTION (KA))..................................................................... 20-550
(ATMOSPHEREIC TEMPERATURE SENSOR SYSTEM:
DISCONNECTION OR SHORT CIRCUIT (KY OR KB)) ...................................................................... 20-551
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR:
INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))......................................................................... 20-552
ERROR CODE [DGT5KA] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "22")
(LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KA)) ................. 20-554
ERROR CODE [DGT5KB] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "21")
(LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB)) ................... 20-556
(RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KA))............... 20-558
D475A-5 20-403
(1)
TROUBLESHOOTING
(RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB)) ................. 20-560
ERROR CODE [DH22KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (F):
DISCONNECTION (KA)) ...................................................................................................................... 20-562
ERROR CODE [DH22KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (F):
SHORT CIRCUIT (KB)) ........................................................................................................................ 20-563
ERROR CODE [DH23KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (R):
ERROR CODE [DH23KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (R):
SHORT CIRCUIT (KB)) ........................................................................................................................ 20-565
ERROR CODE [DHE4KA] (ENGINE OIL PRESSURE SENSOR: DISCONNECTION (KA)) ..................... 20-566
ERROR CODE [DHE4KB] (ENGINE OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) ....................... 20-567
ERROR CODE [DHE5KB] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "32")
(ENGINE BLOW-BY PRESSURE SENSOR SYSTEM: DISCONNECTION (KB))............................... 20-568
ERROR CODE [DHE5KY] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "31")
(ENGINE BLOW-BY PRESSURE SENSOR SYSTEM:
SHORT CIRCUIT WITH POWER SUPPLY LINE (KY)) ....................................................................... 20-569
ERROR CODE [DHT3KX] (OR LED OF VHMS CONTROLLER INDICATES "n6" o "14")
(TRANSMISSION OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX)) .................... 20-570
ERROR CODE [DK01KA] (LEFT YOKE ANGLE SENSOR: DISCONNECTION (KA)) .............................. 20-572
ERROR CODE [DK01KB] (LEFT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB)) ................................ 20-574
ERROR CODE [DK03KA] (RIGHT YOKE ANGLE SENSOR: DISCONNECTION (KA))............................ 20-575
ERROR CODE [DK03KB] (RIGHT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB)).............................. 20-577
ERROR CODE [DK10KX] (FUEL DIAL: OUT OF INPUT SIGNAL RANGE (KX)) ...................................... 20-578
ERROR CODE [DK12KX] (DECELERATOR POTENTIOMETER:
OUT OF INPUT SIGNAL RANGE (KX))............................................................................................... 20-580
ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA)) .......................... 20-582
ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)) ............................ 20-583
ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1:
INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) .......................................................................... 20-584
ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1:
DISCONNECTION OR SHORT CIRCUIT (KZ))................................................................................... 20-584
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8)) ...................................... 20-585
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA)) .......................... 20-586
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB)) ............................ 20-587
ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA)) ................................... 20-588
ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB)) ..................................... 20-590
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER:
INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) .......................................................................... 20-591
ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER:
DISCONNECTION OR SHORT CIRCUIT (KZ))................................................................................... 20-591
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8)) ....................... 20-592
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA))........ 20-593
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB)).......... 20-594
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA))........ 20-595
ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB)).......... 20-596
ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA)) ................................... 20-597
ERROR CODE [DK60KB] (ACCELERATION SENSOR: SHORT CIRCUIT (KB)) ..................................... 20-598
ERROR CODE [DKF0KX] (OR LED OF VHMS CONTROLLER INDICATES "n2" o "62")
(INJECTION PUMP RACK SENSOR: OUT OF INPUT SIGNAL RANGE (KX)) .................................. 20-599
ERROR CODE [DKF1KX] (RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE (KX)) .................. 20-600
ERROR CODE [DKF2KX] (RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE (KX)) .................... 20-602
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA)) ...................................... 20-604
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB))......................................... 20-605
ERROR CODE [DLE1KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA)) .................................... 20-606
ERROR CODE [DLE4LC] (ENGINE SPEED SENSOR A: * REFER TO TABLE (LC))............................... 20-608
ERROR CODE [DLE5LC] (ENGINE SPEED SENSOR B: * REFER TO TABLE (LC))............................... 20-610
ERROR CODE [DLF1KA] (TORQUE CONVERTER OUTPUT SPEED SENSOR:
20-404 D475A-5
(1)
TROUBLESHOOTING
ERROR CODE [DLT3KA] (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION (KA)) ....... 20-613
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB)).................................................. 20-614
ERROR CODE [DW55KA] (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA)) ........................ 20-615
ERROR CODE [DW55KB] (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB)) .......................... 20-616
ERROR CODE [DW56KA] (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA)) ....................... 20-617
ERROR CODE [DW56KB] (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB)) ......................... 20-618
ERROR CODE [DW57KA] (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA)) ............................... 20-619
ERROR CODE [DW57KB] (LEFT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB)) ................................. 20-620
ERROR CODE [DW58KA] (RIGHT TILT LIMIT SOLENOID: DISCONNECTION (KA)) ............................. 20-621
ERROR CODE [DW58KB] (RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB)) ............................... 20-622
ERROR CODE [DW59KA] (BLADE DUAL SELECTOR SOLENOID: DISCONNECTION (KA))................ 20-623
ERROR CODE [DW59KB] (BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT (KB)) .................. 20-624
ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA)) .............. 20-625
ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB)) ................ 20-626
ERROR CODE [DW5DKA] (BLADE PITCH DUMP SOLENOID (SUPERDOZER SPECIFICATION):
DISCONNECTION (KA))...................................................................................................................... 20-627
ERROR CODE [DW5DKB] (BLADE PITCH DUMP SOLENOID (SUPERDOZER SPECIFICATION):
SHORT CIRCUIT (KB)) ........................................................................................................................ 20-628
ERROR CODE [DW7BKA] (FAN REVERSE SOLENOID: DISCONNECTION (KA)) ................................. 20-629
ERROR CODE [DW7BKB] (FAN REVERSE SOLENOID: SHORT CIRCUIT (KB)) ................................... 20-630
ERROR CODE [DWJ0KA] (PUMP MERGE-DIVIDER SOLENOID: DISCONNECTION (KA)) .................. 20-631
ERROR CODE [DWJ0KB] (PUMP MERGE-DIVIDER SOLENOID: SHORT CIRCUIT (KB)) .................... 20-632
ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA))........ 20-633
ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT (KB)).......... 20-634
ERROR CODE [DWN5KA] (FAN PUMP SOLENOID 1: DISCONNECTION (KA))..................................... 20-635
ERROR CODE [DWN5KB] (FAN PUMP SOLENOID 1: SHORT CIRCUIT (KB))....................................... 20-636
ERROR CODE [DWNCKA] (FAN PUMP SOLENOID 2: DISCONNECTION (KA)) .................................... 20-637
ERROR CODE [DWNCKB] (FAN PUMP SOLENOID 2: SHORT CIRCUIT (KB)) ...................................... 20-638
ERROR CODE [DXE0KA] (LS SET SOLENOID: DISCONNECTION (KA))............................................... 20-639
ERROR CODE [DXE0KB] (LS SET SOLENOID: SHORT CIRCUIT (KB))................................................. 20-640
ERROR CODE [DXH1KA] (LOCK-UP SOLENOID: DISCONNECTION (KA)) ........................................... 20-641
ERROR CODE [DXH1KB] (LOCK-UP SOLENOID: SHORT CIRCUIT (KB)) ............................................. 20-642
ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA)) ............................................. 20-643
ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)) ............................................... 20-644
ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA)) ............................................ 20-645
ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))............................................... 20-646
ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA)) ............................................ 20-647
ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))............................................... 20-648
ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA)) .................................. 20-649
ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))..................................... 20-650
ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA)) ................................. 20-651
ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB)) ................................... 20-652
ERROR CODE [DXH9KA] (RIGHT STEERING CLUTCH ECMV: DISCONNECTION (KA)) ..................... 20-653
ERROR CODE [DXH9KB] (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) ....................... 20-654
ERROR CODE [DXHAKA] (LEFT STEERING CLUTCH ECMV: DISCONNECTION (KA)) ....................... 20-655
ERROR CODE [DXHAKB] (LEFT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB)) ......................... 20-656
ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA)) .......................................... 20-657
ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB))............................................. 20-658
ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA))............................................. 20-659
ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))............................................... 20-660
ERROR CODE [DXHDKA] (GOVERNOR SOLENOID RIGHT: DISCONNECTION (KA)) .......................... 20-661
ERROR CODE [DXHDKB] (GOVERNOR SOLENOID RIGHT: SHORT CIRCUIT (KB)) ............................ 20-662
ERROR CODE [DXHEKA] (GOVERNOR SOLENOID LEFT: DISCONNECTION (KA))............................. 20-663
ERROR CODE [DXHEKB] (GOVERNOR SOLENOID LEFT: SHORT CIRCUIT (KB)).............................. 20-664
ERROR CODE [DXHFKA] (PRE-STROKE SOLENOID RIGHT: DISCONNECTION (KA))........................ 20-665
ERROR CODE [DXHFKB] (PRE-STROKE SOLENOID RIGHT: SHORT CIRCUIT (KB)).......................... 20-666
ERROR CODE [DXHGKA] (PRE-STROKE SOLENOID LEFT: DISCONNECTION (KA)) ......................... 20-667
ERROR CODE [DXHGKB] (PRE-STROKE SOLENOID LEFT: SHORT CIRCUIT (KB)) ........................... 20-668
D475A-5 20-405
(1)
TROUBLESHOOTING
ERROR CODE [F@BBZL] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "38")
(ENGINE BLOW-BY PRESSURE: OVERPRESSURE (ZL)) ............................................................... 20-669
ERROR CODE [F@BYNR] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "62")
(LEFT BANK EXHAUST TEMPERATURE (2): ABNORMAL HEATING (NR))..................................... 20-670
ERROR CODE [F@BYNS] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "61")
(LEFT BANK EXHAUST TEMPERATURE (1): OVERHEATING (NS)) ................................................ 20-671
ERROR CODE [F@BZNR] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "72")
(RIGHT BANK EXHAUST TEMPERATURE (2): ABNORMAL HEATING (NR)) .................................. 20-672
ERROR CODE [F@BZNS] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "71")
(RIGHT BANK EXHAUST TEMPERATURE (1): OVERHEATING (NS)).............................................. 20-673
20-406 D475A-5
(1)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
a The troubleshooting list and related circuit diagram summarize the following information. Understand their
contents well to advance troubleshooting.
Action code Error code

Trouble Trouble that appeared on machine
Panel display Panel display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of
Action to be taken to protect the system and equipment when the monitor panel or controller detects a
monitor panel or
trouble
controller
Problem that
Problem that appears as an abnormality in the main unit by the action taken by the monitor panel or con-
appears on
troller (above)
machine
Related
Information related to a detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
Standard value in normal state required to judge the assumed
cause (good or not)
1 Remarks required to judge whether the cause is good
<Phenomenon of defective harness>

Disconnection in wiring
The connector connection is defective or the wiring harness is dis-
connected.
2 Grounding fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
Defective hot short
A harness not connected to the power (24V) circuit comes into con-
Possible causes tact with the power (24V) circuit.
Cause by which a trouble
and standard Defective short
is assumed to be detected
value in normal 3 A harness of an independent circuit abnormally comes into contact
(The order number indi-
state with one of another circuit.
cates a serial number, not
a priority sequence.)
<Notes on troubleshooting>
1) Method of indicating connector numbers and handling T-junction
For troubleshooting, insert or connect the T-junction adapter as
shown below unless especially specified.
4 When male or female is not indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in both
the male and female.
When male or female is indicated for a connector number, dis-
connect the connector, and insert the T-junction adapter in only ei-
ther the male or female.
2) Pin number description sequence and tester lead handling
5 For troubleshooting, connect the plus (+) and minus () leads as
Connect the plus (+) lead to a pin or harness indicated in the front.
Connect the minus () lead to a pin or harness indicated in the rear.
D475A-5 20-407
(1)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Related circuit diagram
This is the excerpted circuit diagram related to trouble

Connector No.: Indicates (Model-No. of pins) (Color).
Arrow ( ): Roughly indicates mounting place on machine.
TROUBLE CODE TABLE

a Regarding trouble code provided with instruction Refer to table, check it against table below.
Trouble Trouble
Detail of trouble Detail of trouble
code code
AL Air leakage L4 ON and OFF signals do not agree
KA Disconnection L6 Run and stop of engine do not agree with signals
KB Short circuit L8 Analog signals do not agree
KK Lowing of source voltage (input) LC Revolving speed signals do not agree
KM Mistake in operation or setting LD Switch is pressed for long time
KP Lowering of output voltage LH Command current is ON and fill signal is OFF
KQ Disagreement of model selection signals Feedback signal does not agree with output
LK
Defective communication signal
KR
(Objective component abnormality) NR Abnormal heating
KT Internal defect of controller NX Clogging
KX Out of input signal range MA Malfunction
KY Short circuit with power source line MB Lowering of function
KZ Disconnection or short circuit MW Slip
L0 Double engagement NS Overheating
L1 Command current is OFF and fill signal is ON ZG Lowering of oil pressure
L2 Fuel pressure is too high ZK Lowering of level
L3 Uncontrollability ZL Overpressure
20-408 D475A-5
(1)
TROUBLESHOOTING 1500L0
ERROR CODE [1500L0] (TRANSMISSION CLUTCH: SEE THE LIST. (L0))
Action code Error code Transmission clutch: See the list. (L0)
Trouble
CALL E03 1500L0 (Transmission controller system)
Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Connection error)
1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Disconnection error)
2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
Contents of
3) [DXH6KA] and [DXH6KB]
trouble
4) [15SFL1] and [15SGL1]
5) [15SFLH] and [15SGLH]
6) [15SAL1], [15SBL1], and [15SEL1]
7) [15SALH] and [15SBLH]
8) [15SALH] and [15SELH]
9) [15SBLH] and [15SELH]
Action of Flashes caution lamp and turns on caution buzzer.
controller Limits operation of engine and transmission.
Problem that The auto shift down function does not start.
appears on Once machine is stopped, engine speed is limited to medium (half).
machine Once machine is stopped, running is limited to F1 and R1.
Related
Method of reproducing error code: Engine start + Run
information

Possible causes Confirm the error codes displayed at the same time, then carry out troubleshooting for the codes.
and standard [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
value in normal [15SGLH]
state [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB], [DXH8KA],
[DXH8KB]
D475A-5 20-409
(1)
TROUBLESHOOTING 15SAL1
ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST. (L1))
Action code Error code Forward clutch: See the list. (L1)
Trouble
CALL E03 15SAL1 (Transmission controller system)
Contents of
The fill switch signal is not set off at output stop of the transmission forward clutch solenoid circuit.
trouble
Flashes caution lamp and turns on caution buzzer.
Action of
Decides that engine speed is neutral (N) at reverse operation.
controller
Limits operation of engine and transmission.
Problem that
Once machine is stopped, engine speed is limited to medium (half).
appears on
Once machine is stopped, running is limited to F1.
machine
The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
(Code 31520: Transmission fill switch input state)
information
Method of reproducing error code: Engine start + Neutral running

aPrepare with starting switch OFF, then start the engine for trouble-
shooting.
Defective forward clutch fill
1 FFT2 (male) PCCS lever Resistance
switch (Internal short)
Between (1) N Min. 1 Mz
chassis ground F (Forward) Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting with-
Defective harness ground- out turning starting switch ON.
Possible causes
2 ing (Contact with ground cir-
and standard Wiring harness between TMCN1 (female) (5)
cuit) Resistance Min. 1 Mz
value in normal FFT2 (female) (1) with chassis ground
state aPrepare with starting switch OFF, then start the engine for trouble-
shooting.
Defective transmission con-
3 TMCN1 PCCS lever Voltage
troller
Between (5) N 20 30 V
chassis ground F (Forward) Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pres-
4 system is assumed to be abnormal. Carry out the related troubleshoot-
sure system
ing (H mode).
Circuit diagram related to transmission forward clutch ECMV
20-410 D475A-5
(1)
TROUBLESHOOTING 15SALH
ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST. (LH))
Action code Error code Forward clutch: See the list. (LH)
Trouble
CALL E03 15SALH (Transmission controller system)
Contents of
The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit.
trouble
Action of
Decides that engine speed is neutral (N) at forward operation.
controller
Problem that
appears on
Once machine is stopped, running is limited to R1.
machine
The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
information
Method of reproducing error code: Engine start + Forward running

shooting.
Defective forward clutch fill
1 FFT2 (male) PCCS lever Resistance
chassis ground F (Forward) Max. 1 z
Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting with-
Possible causes ness (Disconnection in wir- out turning starting switch ON.
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) (5)
value in normal connector) Resistance Max. 1 z
FFT2 (female) (1)
shooting.
troller
chassis ground F (Forward) Max. 1 V
sure system
ing (H mode).
D475A-5 20-411
(1)
TROUBLESHOOTING 15SBL1
ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST. (L1))
Action code Error code Reverse clutch: See the list. (L1)
Trouble
CALL E03 15SBL1 (Transmission controller system)
Contents of
The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.
trouble
Action of
Decides that engine speed is neutral (N) at forward operation.
controller
Problem that
appears on
Once machine is stopped, running is limited to R1.
machine
The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective reverse clutch fill
1 FRT2 (male) PCCS lever Resistance
chassis ground R (Reverse) Max. 1 z
Possible causes
value in normal FFT2 (female) (1) with chassis ground
shooting.
troller
chassis ground R (Reverse) Max. 1 V
sure system
ing (H mode).
Circuit diagram related to transmission reverse clutch ECMV
20-412 D475A-5
(1)
TROUBLESHOOTING 15SBLH
ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST. (LH))
Action code Error code Reverse clutch: See the list. (LH)
Trouble
CALL E03 15SBLH (Transmission controller system)
Contents of
The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit.
trouble
Action of
Decides that engine speed is neutral (N) at reverse operation.
controller
Problem that
appears on
Once machine is stopped, running is limited to F1.
machine
The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective reverse clutch fill
1 FRT2 (male) PCCS lever Resistance
chassis ground R (Reverse) Max. 1 z
2
FRT2 (female) (1)
shooting.
troller
chassis ground R (Reverse) Max. 1 V
sure system
ing (H mode).
D475A-5 20-413
(1)
TROUBLESHOOTING 15SEL1
ERROR CODE [15SEL1] (1ST CLUTCH: SEE THE LIST. (L1))
Action code Error code 1st clutch: See the list. (L1)
Trouble
CALL E03 15SEL1 (Transmission controller system)
Contents of
The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit.
trouble
Problem that
appears on
Once machine is stopped, running is limited to F1 and R1.
machine
The input state (ON/OFF) from the level 1 clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 1st clutch fill F1T8 (male) PCCS lever Resistance
1
Between (1) Other than F1/R1 Min. 1 Mz
chassis ground F1R1 Max. 1 z
Defective harness ground-
Possible causes out turning starting switch ON.
value in normal F1T8 (female) (1) with chassis ground
shooting.
Defective transmission con- TMCN1 PCCS lever Voltage
3
troller
Between (23) Other than F1/R1 5 11 V
chassis ground F1R1 Max. 1 V
sure system
ing (H mode).
Circuit diagram related to transmission level 1 clutch ECMV
20-414 D475A-5
(1)
TROUBLESHOOTING 15SELH
ERROR CODE [15SELH] (1ST CLUTCH: SEE THE LIST. (LH))
Action code Error code Level 1 clutch: See the list. (LH)
Trouble
CALL E03 15SELH (Transmission controller system)
Contents of
The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit.
trouble
Problem that The auto shift down function does not start.
The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Related
information
Method of reproducing error code: Engine start + F1 or R1 running

shooting.
Defective 1st clutch fill F1T8 (male) PCCS lever Resistance
1
2
F1T8 (female) (1)
shooting.
3
troller
sure system
ing (H mode).
Circuit diagram related to transmission 1st clutch ECMV
D475A-5 20-415
(1)
TROUBLESHOOTING 15SFL1
ERROR CODE [15SFL1] (2ND CLUTCH: SEE THE LIST. (L1))
Action code Error code 2nd clutch: See the list. (L1)
Trouble
CALL E03 15SFL1 (Transmission controller system)
Contents of
The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit.
trouble
Problem that The auto shift down function does not operate.
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance
1
shooting.
3
troller
sure system
ing (H mode).
Circuit diagram related to transmission 2nd clutch ECMV
20-416 D475A-5
(1)
TROUBLESHOOTING 15SFLH
ERROR CODE [15SFLH] (2ND CLUTCH: SEE THE LIST. (LH))
Action code Error code 2nd clutch: See the list. (LH)
Trouble
CALL E03 15SFLH (Transmission controller system)
Contents of
The fill switch signal is not set on at output to the transmission level 2 clutch solenoid circuit.
trouble
Problem that
appears on
machine
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance
1
2
F2T6 (female) (1)
shooting.
3
troller
sure system
ing (H mode).
D475A-5 20-417
(1)
TROUBLESHOOTING 15SGL1
ERROR CODE [15SGL1] (3RD CLUTCH: SEE THE LIST. (L1))
Action code Error code 3rd clutch: See the list. (L1)
Trouble
CALL E03 15SGL1 (Transmission controller system)
Contents of
The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit.
trouble
Problem that The auto shift down function does not operate.
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 3rd clutch fill F3T4 (male) PCCS lever Resistance
1
shooting.
3
troller
sure system
ing (H mode).
Circuit diagram related to transmission 3rd clutch ECMV
20-418 D475A-5
(1)
TROUBLESHOOTING 15SGLH
ERROR CODE [15SGLH] (3RD CLUTCH: SEE THE LIST. (LH))
Action code Error code 3rd clutch: See the list. (LH)
Trouble
CALL E03 15SGLH (Transmission controller system)
Contents of
The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit.
trouble
Problem that
appears on
machine
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 3rd clutch fill F3T4 (male) PCCS lever Resistance
1
2
F3T4 (female) (1)
shooting.
3
troller
sure system
ing (H mode).
D475A-5 20-419
(1)
TROUBLESHOOTING 1800MW
ERROR CODE [1800MW] (POWER TRAIN CLUTCH: SLIP (MW))
Action code Error code Power train clutch slip

Trouble
E02 1800MW (Transmission controller system)
Contents of At lock-up of the torque converter, the number of transmission rotations obtained from the number of
trouble engine rotations is different from the actual number of rotations by 200rpm or more.
Action of
controller
Problem that
appears on The auto shift down function does not operate.
machine
The number of engine rotations and the number of transmission rotations can be checked in monitoring
mode.
Related
(Code 01000: Number of engine rotations A, code 01004: Number of engine rotations B, code 31400:
information
Number of transmission rotations)
Method of reproducing error code: Engine start + Lock-up switch ON + Actual running

Power train clutch slip
aClutch slip was detected; check the cause and machine damage
1 (When the system is nor-
state, then repair the machine.
mal)
Possible causes
Defective engine rotation Check whether error codes [DLE4LC] and [DLE5LC] are displayed. If
and standard 2
sensor they are displayed, carry out the troubleshooting.
value in normal
state Defective transmission rota-Check whether error code [DLF1KA] is displayed. If it is displayed, carry
3
tion sensor system out the troubleshooting.
Internally trouble; troubleshooting is impossible.
4 (If no visible abnormality is detected on the machine, the controller may
troller
be used continuously.)
20-420 D475A-5
(1)
ERROR CODE [2201L1] (RIGHT CLUTCH: SEE THE LIST. (L1))
Action code Error code Right clutch: See the list. (L1)
Trouble
CALL E04 2201L1 (Steering controller system)
Contents of
The fill switch signal is not set off at output stop of the right steering clutch solenoid circuit.
trouble
controller Limits operation of engine, transmission, and brake.
Problem that
appears on
Once machine is stopped, it never runs.
machine
The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring mode.
Related
(Code 31521: Steering fill switch input state)
information
Method of reproducing error code: Engine start

aPrepare with starting switch OFF. Engine start for troubleshooting.
Defective right steering FRB (male) PCCS lever Resistance
1 clutch fill switch
(Internal short) Between (1) N (Neutral) Min. 1 Mz
chassis ground Right steering Max. 1 z
Possible causes 2 ing (Contact with ground cir-
Wiring harness between STCN3 (female) (39)
and standard cuit) Resistance Min. 1 Mz
FRC8 (female) (1) with chassis ground
value in normal
state aPrepare with starting switch OFF. Engine start + Pivot turn switch ON
+ Forward for troubleshooting.
3 Defective steering controller STCN3 PCCS lever Voltage
Between (39) N (Neutral) 5 11 V
chassis ground Right steering Max. 1 V
sure system
ing (H mode).
Circuit diagram related to right steering clutch ECMV
D475A-5 20-421
(1)
TROUBLESHOOTING 2201LH
ERROR CODE [2201LH] (RIGHT CLUTCH: SEE THE LIST. (LH))
Action code Error code Right clutch: See the list. (LH)
Trouble
CALL E04 2201LH (Steering controller system)
Contents of
The fill switch signal is not set off at output to the right steering clutch solenoid circuit.
trouble
Problem that
appears on
machine
The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring mode.
Related (Code 31521: Steering fill switch input state)
information Method of reproducing error code: Engine start + Parking lever release + PCCS lever operate
(right steering)

Defective right steering FRC8 (male) PCCS lever Resistance
1 clutch fill switch
Between (1) N (Neutral) Min. 1 Mz
(Internal short)
2
and standard ing or defective contact in Wiring harness between STCN2 (female) (39)
FRC8 (female) (1)
state aPrepare with starting switch OFF. Engine start for troubleshooting.
STCN2 PCCS lever Voltage
3 Defective steering controller
chassis ground Right steering Max. 1 V
sure system
ing (H mode).
20-422 D475A-5
(1)
ERROR CODE [2202L1] (LEFT CLUTCH: SEE THE LIST. (L1))
Action code Error code Left clutch: See the list. (L1)
Trouble
Contents of
The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit.
trouble
Problem that
appears on
machine
The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring mode.
Related
information

Defective left steering clutch FLC6 (male) PCCS lever Resistance
1 fill switch
chassis ground Left steering Max. 1 z
Possible causes
and standard Wiring harness between STCN3 (female) (29)
value in normal FLC6 (female) (1) with chassis ground
chassis ground Left steering Max. 1 V
sure system
ing (H mode).
Circuit diagram related to left clutch ECMV
D475A-5 20-423
(1)
ERROR CODE [2202LH] (LEFT CLUTCH: SEE THE LIST. (LH))
Action code Error code Left clutch: See the list. (LH)
Trouble
Contents of
The fill switch signal is not set off at output to the left steering clutch solenoid circuit.
trouble
Problem that
appears on
machine
The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring mode.
Related
information
Method of reproducing error code: Engine start + Parking lever release + PCCS lever

Defective left steering clutch FLC6 (male) PCCS lever Resistance
1 fill switch
2
Resistance Max. 1 z
value in normal connector) FLC6 (female) (1)
chassis ground Left steering Max. 1 V
sure system
ing (H mode).
Circuit diagram related to left clutch ECMV
20-424 D475A-5
(1)
TROUBLESHOOTING 2300NR
ERROR CODE [2300NR] (BRAKE THERMAL LOAD: ABNORMAL HEATING (NR))
Action code Error code Brake thermal load: abnormal heating (NR)
Trouble
2300NR (Steering controller system)
Contents of The steering controller multiplied the continuous operating times of the pitch angle sensor, travel speed
trouble sensor, and brake potentiometer, and then judged that the brake was heating abnormally.
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Possible causes
and standard 1 Improper braking during downslope travel (Machine traveled down with brake pedal pressed)
value in normal
state 2 Defective steering controller When the operation in cause 1 is not performed
D475A-5 20-425
(1)
ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST. (L1))
Action code Error code Right brake: See the list. (L1)
Trouble
Contents of
The fill switch signal is not set off at output stop of the right steering brake solenoid circuit.
trouble
Problem that The loose brake functions during running.
machine Once machine is stopped, it never runs.
The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring mode.
Related
information
Method of reproducing error code: Engine start + Parking lever release

aPrepare with starting switch OFF. Engine start + Pivot turn switch ON
Defective right steering + Forward for troubleshooting.
1 brake fill switch FRB4 (male) PCCS lever Resistance
value in normal FRB4 (female) (1) with chassis ground
state aPrepare with starting switch OFF. Engine start + Forward for trouble-
shooting.
Between (25) N (Neutral) Max. 1 V
chassis ground Right steering 5 11 V
sure system
ing (H mode).
Circuit diagram related to right steering brake ECMV
20-426 D475A-5
(1)
ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST. (LH))
Action code Error code Right brake: See the list. (LH)
Trouble
Contents of
The fill switch signal is not set off at output to the right steering brake solenoid circuit.
trouble
The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring mode.
Related
information

Defective right steering + Forward for troubleshooting.
1 clutch fill switch FRB4 (male) PCCS lever Resistance
Disconnection in wiring aPrepare with starting switch OFF, then carry out troubleshooting with-
Possible causes harness (Disconnection in out turning starting switch ON.
2
and standard wiring or defective contact Wiring harness between STCN2 (female) (25)
value in normal in connector) Resistance Max. 1 Mz
FRB4 (female) (1)
shooting.
chassis ground Right steering 5 11 V
sure system
ing (H mode).
D475A-5 20-427
(1)
TROUBLESHOOTING 2301NR
ERROR CODE [2301NR] (RIGHT STEERING BRAKE THERMAL LOAD: ABNORMAL

HEATING (NR))
Action code Error code Right steering brake thermal load: Abnormal heating (NR)
Trouble
Contents of The steering controller multiplied the continuous operating times of the pitch angle sensor and right
trouble steering potentiometer, and then judged that the right steering brake was heating abnormally.
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Possible causes
Improper steering during downslope travel (Machine traveled down and was steered to right continu-
and standard 1
ously)
value in normal
20-428 D475A-5
(1)
ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST. (L1))
Action code Error code Right brake: See the list. (L1)
Trouble
Contents of
The fill switch signal is not set off at output stop of the left steering brake solenoid circuit.
trouble
The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring mode.
Related
information

Defective left steering brake + Forward for troubleshooting.
1 fill switch FRB2 (male) PCCS lever Resistance
value in normal FLB2 (female) (1) with chassis ground
shooting.
chassis ground Left steering 5 11 V
sure system
ing (H mode).
Circuit diagram related to left steering brake ECMV
D475A-5 20-429
(1)
ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST. (LH))
Action code Error code Left brake: See the list. (LH)
Trouble
Contents of
The fill switch signal is not set on at output stop of the left steering brake solenoid circuit.
trouble
The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring mode.
Related
information

Defective left steering brake + Forward for troubleshooting.
1 fill switch FLB2 (male) PCCS lever Resistance
2
FLB2 (female) (1)
state aPrepare with starting switch OFF. Engine start + Pivot turn switch ON
+ Forward for troubleshooting.
chassis ground Left steering 5 11 V
sure system
ing (H mode).
20-430 D475A-5
(1)
TROUBLESHOOTING 2302NR, A000N1
ERROR CODE [2302NR] (LEFT STEERING BRAKE THERMAL LOAD: ABNORMAL

HEATING (NR))
Action code Error code Left steering brake thermal load: Abnormal heating (NR)
Trouble
The steering controller multiplied the continuous operating times of the pitch angle sensor and travel
Contents of
speed sensor, and then judged that the brake was heating abnormally (The machine traveled down with
trouble
the foot brake pressed).
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Possible causes
Improper steering during downslope travel (Machine traveled down and was steered to left continu-
and standard 1
value in normal ously)
ERROR CODE [A000N1] (or VHMS_LED IS DISPLAYED "n2" o"01") ENGINE OVERRUN
Action code Error code Engine overrun

Trouble
A000N1 (VHMS controller system)
Contents of
While the engine was running, its speed exceeded 2,700 rpm.
trouble
Action of
None in particular.
controller
Problem that
appears on If the machine is operated as it is, the engine may be damaged.
machine
The monitor panel does not display the error code. (If the data saved in the VHMS controller are down-
Related loaded to a personal computer, however, the error code can be checked.)
information The LED of the VHMS controller indicates "n2" o "01".
If error codes "C115KZ" and "C121LC" are displayed, carry out troubleshooting for them first.

Possible causes 1 Engine overrun Check the engine, then repair it if it has any abnormality.
and standard Defective engine speed
2 Carry out troubleshooting for error codes "C115KZ" and "C121LC".
value in normal sensor
state When no fault is detected by 1 and 2 above, replace the VHMS control-
3 Defective VHMS controller
ler. If the condition becomes normal, the VHMS controller is defective.
D475A-5 20-431
(1)
TROUBLESHOOTING A70XLK
ERROR CODE [A70XLK] (GOVERNOR SERVO SYSTEM RIGHT: * REFER TO TABLE

(LK))
Action code Error code Governor servo system right: Refer to table (LK)
Trouble
CALL E04 A70XLK (Engine controller system)
Contents of Abnormality was detected in the governor solenoid system or rack sensor system of the right bank (The
trouble governor command value does not agree with the rack sensor signal).
Action of Flashes the caution lamp and turns on the caution buzzer.
controller Stops the right bank fuel injection pump injecting.
Problem that
appears on Only the left bank of the engine operates.
machine
Related
Method of reproducing error code: Start the engine.
information

Defective solenoid power The solenoid power supply R system may be defective. Carry out trou-
1
Possible causes supply R system bleshooting for error code [DB42KK].
and standard Defective right bank fuel The right bank fuel injection pump may have a defect in it. Check it
value in normal 2
injection pump directly.
state If neither of causes 1 and 2 is the cause of the trouble, the engine con-
3 Defective engine controller troller may be defective (Troubleshooting cannot be carried out since the
defect is in the engine controller).
20-432 D475A-5
(1)
TROUBLESHOOTING A70YLK
ERROR CODE [A70YLK] (GOVERNOR SERVO SYSTEM LEFT: * REFER TO TABLE

(LK))
Action code Error code Governor servo system left: Refer to table (LK)
Trouble
CALL E04 A70YLK (Engine controller system)
Contents of Abnormality was detected in the governor solenoid system or rack sensor system of the left bank
trouble (The governor command value does not agree with the rack sensor signal).
controller Stops the left bank fuel injection pump injecting.
Problem that
appears on Only the right bank of the engine operates.
machine
Related
information

Defective solenoid power The solenoid power supply L system may be defective. Carry out trou-
1
Possible causes supply L system bleshooting for error code [DB43KK].
and standard Defective left bank fuel The left bank fuel injection pump may have a defect in it. Check it
value in normal 2
injection pump directly.
D475A-5 20-433
(1)
TROUBLESHOOTING AA1ANX, AB00MA
ERROR CODE [AA1ANX] (AIR CLEANER: CLOGGING (NX))
Action code Error code Air cleaner: clogging (NX)

Trouble
AA1ANX (Mechanical system)
Contents of
While the engine was running, the air cleaner clogging lamp flashed.
trouble
Action of
controller
Problem that
appears on If the machine is operated as it is, the brake will be damaged.
machine
Related
information

It is suspected that a problem causing clogging of the air cleaner is
Possible causes Clogged air cleaner
1 occurring at present or occurred in past. Investigate the cause and
and standard (When system is normal)
damage condition, and correct it.
value in normal
state Carry out troubleshooting of the air cleaner clogging caution lamp sys-
Defective air cleaner clog-
2 tem in accordance with "During running of engine, caution item flashes"
ging caution lamp system
in E-mode.
ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA))

Trouble Alternator: Malfunction (MA) (Mechanical system)
AB00MA
Contents of
During rotation of engine, charge level caution lamp flashes.
trouble
Action of
controller
Problem that
appears on If machine is operated as it is, battery may be discharged.
machine
Related
Method of reproducing error code: Start engine.
information

Defective battery charge It is suspected that problem causing defective battery charge is occur-
Possible causes
1 (When system is in normal ring at present or occurred in past. Investigate cause and damage con-
and standard
state) dition, and correct it.
value in normal
state Carry out troubleshooting of charge level caution lamp system in accor-
Defective charge level cau-
2 dance with During running of engine, emergency caution item flashes
tion lamp system
in E mode.
20-434 D475A-5
(1)
TROUBLESHOOTING B@BAZG, B@BAZK
ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))

Trouble Engine oil: Oil pressure reduction (ZG) (Mechanical system)
B@BAZG
Contents of
During rotation of engine, engine oil pressure caution lamp flashes.
trouble
Action of
Turns on caution buzzer. (Function of monitor panel)
controller
Problem that
appears on If machine is operated as it is, engine may be damaged.
machine
Related
information

Engine oil pressure reduc- It is suspected that problem causing engine oil pressure reduction is
Possible causes
1 tion (When system is in nor- occurring at present or occurred in past. Investigate cause and damage
and standard
mal state) condition, and correct it.
value in normal
state Carry out troubleshooting of engine oil pressure caution lamp system in
Defective engine oil pres-
2 accordance with During running of engine, emergency caution item
sure caution lamp system
flashes in E mode.
ERROR CODE [B@BAZK] (ENGINE OIL: OIL LEVEL REDUCTION (ZK))

Trouble Engine oil: Oil level reduction (ZK) (Mechanical system)
B@BAZK
Contents of
During rotation of engine, engine oil level caution lamp flashes.
trouble
Action of
controller
Problem that
machine
Related
information

Engine oil level reduction It is suspected that problem causing engine oil level reduction is occur-
Possible causes
1 (When system is in normal ring at present or occurred in past. Investigate cause and damage con-
and standard
state) dition, and correct it.
value in normal
state Carry out troubleshooting of engine oil level caution lamp system in
Defective engine oil level
caution lamp system
flashes in E mode.
D475A-5 20-435
(1)
TROUBLESHOOTING B@BCNS, B@BCZK
ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))

Trouble Radiator coolant: Overheat (NS) (Mechanical system)
B@BCNS
Contents of
During rotation of engine, engine water temperature caution lamp flashes.
trouble
Action of
controller
Problem that
machine
Related
information

Engine water temperature It is suspected that problem causing engine water temperature overheat
Possible causes
1 overheat (When system is is occurring at present or occurred in past. Investigate cause and dam-
and standard
in normal state) age condition, and correct it.
value in normal
state Defective engine water tem- Carry out troubleshooting of engine water temperature caution lamp
2 perature caution lamp sys- system in accordance with During running of engine, emergency cau-
tem tion item flashes in E mode.
ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK))

Trouble Radiator coolant: Level reduction (ZK) (Mechanical system)
B@BCZK
Contents of
When turning starting switch ON, radiator coolant caution lamp flashes.
trouble
Action of
controller
Problem that
machine
Related
Method of reproducing error code: Turn starting switch ON.
information

Radiator coolant level It is suspected that problem causing radiator coolant level reduction is
Possible causes
1 reduction (When system is occurring at present or occurred in past. Investigate cause and damage
and standard
in normal state) condition, and correct it.
value in normal
state Carry out troubleshooting of radiator coolant level caution lamp system
Defective radiator coolant
2 in accordance with When turning starting switch ON, basic check item
level caution lamp system
flashes in E mode.
20-436 D475A-5
(1)
TROUBLESHOOTING B@CENS, B@HANS
ERROR CODE [B@CENS] (POWER TRAIN OIL: OVERHEAT (NS))

Trouble Power train oil: Overheat (NS) (Mechanical system)
B@CENS
Contents of
During rotation of engine, power train oil temperature caution lamp flashes.
trouble
Action of
controller
Problem that
appears on If machine is operated as it is, power train may be damaged.
machine
Related
information

Power train oil temperature It is suspected that problem causing power train oil temperature over-
Possible causes
1 overheat (When system is heat is occurring at present or occurred in past. Investigate cause and
and standard
in normal state) damage condition, and correct it.
value in normal
state Defective power train oil Carry out troubleshooting of power train oil temperature caution lamp
2 temperature overheat cau- system in accordance with During running of engine, emergency cau-
tion lamp system tion item flashes in E mode.
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))

Trouble Hydraulic oil: Overheat (NS) (Mechanical system)
B@HANS
Contents of
During rotation of engine, hydraulic oil caution lamp flashes.
trouble
Action of
controller
Problem that
appears on If machine is operated as it is, work equipment circuit units may be damaged.
machine
Related
information

Hydraulic oil temperature It is suspected that problem causing hydraulic oil temperature overheat
Possible causes
1 overheat (When system is is occurring at present or occurred in past. Investigate cause and dam-
and standard
in normal state) age condition, and correct it.
value in normal
state Defective hydraulic oil tem- Carry out troubleshooting of hydraulic oil temperature caution lamp sys-
2 perature caution lamp system in accordance with During running of engine, emergency caution
tem item flashes in E mode.
D475A-5 20-437
(1)
TROUBLESHOOTING B@HAZK
ERROR CODE [B@HAZK] (HYDRAULIC OIL: LEVEL REDUCTION (ZK))
Action code Error code Hydraulic oil: Level reduction (ZK)

Trouble
B@HAZK (Mechanical system)
Contents of
During rotation of engine, hydraulic oil caution lamp flashes.
trouble
Action of
controller
Problem that
appears on If machine is operated as it is, work equipment circuit units may be damaged.
machine
Related
information

Hydraulic oil level reduction It is suspected that problem causing hydraulic oil level reduction is
Possible causes
1 (When system is in normal occurring at present or occurred in past. Investigate cause and damage
and standard
state) condition, and correct it.
value in normal
state Carry out troubleshooting of hydraulic oil level caution lamp system in
Defective hydraulic oil level
caution lamp system
flashes in E mode.
20-438 D475A-5
(1)
TROUBLESHOOTING D110KA
ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA))
Action code Error code Battery relay: Disconnection (KA)

Trouble
D110KA (Steering controller system)
Contents of
Current does not flow when outputting it to battery relay circuit.
trouble
Action of
Stops output to battery relay circuit.
controller
Problem that
appears on Problem may occur in data writing to ROM (nonvolatile storage) of each controller.
machine
Output state (voltage) to battery relay can be checked in monitoring mode.
Related
(Code 60600: Battery relay drive voltage)
information
Method of reproducing error code: Switch starting switch from ON to OFF.

out turning starting switch ON.
Defective battery relay
1 Battery relay Continuity
(Internal disconnection)
Between terminals SW
Continue
ground terminal
Disconnection in wiring har- out turning starting switch ON.
ness (Disconnection in wir- Wiring harness between STCN3 (female) (4)
Possible causes 2 Resistance Max. 1 z
ing or defective contact in battery relay SW terminal
and standard
connector) Wiring harness between battery relay ground
value in normal Resistance Max. 1 z
terminal chassis ground
state
aPrepare with starting switch OFF, then turn starting switch ON and
Hot short circuit in wiring carry out troubleshooting.
3 harness (Contact with 24 V Short circuit of wiring harness between STCN3
circuit) (female) (4) battery relay terminal BR KEY Voltage Max. 1 V
(female) (4) with chassis ground
STCN3 (female) Continuity
Between (4) chassis ground Continue
Circuit diagram related to battery relay
D475A-5 20-439
(1)
TROUBLESHOOTING D110KB
ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB))
Action code Error code Battery relay: Short circuit (KB)

Trouble
D110KB (Steering controller system)
Contents of
Abnormal current flowed to battery relay circuit when outputting it.
trouble
Action of
Stops output to battery relay circuit.
controller
Problem that
appears on Problem may occur in data writing to ROM (nonvolatile storage) of each controller.
machine
Output state (voltage) to battery relay can be checked in monitoring mode.
Related
(Code 60600: Battery relay drive voltage)
information
Method of reproducing error code: Switch starting switch from ON to OFF.

Battery relay Continuity/resistance
1 Between terminals BR
(Internal short circuit) Continue
ground terminal
Between terminal BR
Min. 1 Mz
Possible causes chassis ground
and standard aPrepare with starting switch OFF, then carry out troubleshooting with-
value in normal Short circuit with chassis out turning starting switch ON.
state 2 ground in wiring harness Short circuit of wiring harness between STCN3
(Contact with ground circuit) (female) (4) battery relay terminal BR KEY Resistance Min. 1 Mz
carry out troubleshooting.
3 Defective steering controller STCN3 Starting switch Voltage
Between (4)
ON 20 30 V
chassis ground
Circuit diagram related to battery relay
20-440 D475A-5
(1)
ERROR CODE [D130KA] (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))
Action code Error code Neutral safety relay: Disconnection (KA)

Trouble
E02 D130KA (Transmission controller system)
Contents of
24 V is not generated when ground of neutral safety relay circuit is interrupted.
trouble
controller Stops ground output to neutral safety relay circuit.
Problem that
appears on Engine does not start.
machine
Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Related
Method of reproducing error code: Turn starting switch ON and operate parking lever (Lock position).
information
aThis error code detects abnormality in primary side (coil side) of neutral safety relay, but not in second-
ary side (contact side)

Defective circuit breaker
1 If circuit breaker is tripped, circuit probably has short circuit with ground.
(CB3)
Defective neutral safety out turning starting switch ON.
2 relay (Internal disconnec-
NSF (male) Resistance
tion)
Between (1) (2) 200 400 z
Defective disconnection in out turning starting switch ON.
wiring harness (Disconnec- Wiring harness between TMCN2 (female) (8)
3 Resistance Max. 1 z
tion in wiring or defective NSF (female) (2)
Possible causes contact in connector) Wiring harness between NSF (female) (1)
and standard Resistance Max. 1 z
CB3 (1)
value in normal
state aPrepare with starting switch OFF, then carry out troubleshooting with-
Short circuit with chassis Short circuit of wiring harness between TMCN2
4 ground in wiring harness (female) (8) NSF (female) (2) with chassis Resistance Min. 1 Mz
(Contact with ground circuit) ground
Short circuit of wiring harness between NSF
Resistance Min. 1 Mz
(female) (1) CB3 (1) with chassis ground
5 TMCN2 Parking lever Voltage
troller
Between (8) Lock position Max. 1 V
chassis ground Free position 20 30 V
D475A-5 20-441
(1)
Circuit diagram related to neutral safety relay
20-442 D475A-5
(1)
ERROR CODE [D130KB] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB))
Action code Error code Neutral safety relay: Short circuit (KB)
Trouble
E02 D130KB (Transmission controller system)
Contents of
Abnormal current flowed in neutral safety relay circuit at the time of ground output.
trouble
controller Stops ground output to neutral safety relay circuit.
Problem that
appears on Engine does not start.
machine
Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Related
Method of reproducing error code: Turn starting switch ON and operate parking lever (Free position).
information
aThis error code detects abnormality in primary side (coil side) of neutral safety relay, but not in second-

Defective neutral safety out turning starting switch ON.
1
relay (Internal short circuit) NSF (male) Resistance
Between (1) (2) 200 400 z
Possible causes
and standard
2 harness Short circuit of wiring harness between TMCN2
value in normal
(Contact with 24 V circuit) (female) (8) NSF (female) (2) with chassis Voltage Max. 1 V
state
ground
troller
Between (8) Lock position Max. 1 V
chassis ground Free position 20 30 V
Circuit diagram related to neutral safety relay
D475A-5 20-443
(1)
ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA))
Action code Error code Back-up alarm relay: Disconnection (KA)

Trouble
E01 D161KA (Transmission controller system)
Contents of
24 V is not generated when ground output of neutral safety relay circuit is interrupted.
trouble
Action of
Stops output to back-up alarm relay circuit.
controller
Problem that
appears on Back-up alarm is not turned on.
machine
Output state (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70900: Back-up alarm relay drive voltage)
Related
Method of reproducing error code: Turn starting switch ON and operate parking lever (Neutral position).
information
aThis error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in second-

1 Defective fuse FS4-1 If fuse is burnout, circuit probably has short circuit with chassis ground.
Defective back-up alarm out turning starting switch ON.
BKA (male) Resistance
tion)
Between (1) (2) 200 400 z
Defective disconnection in out turning starting switch ON.
wiring harness (Disconnec- Wiring harness between TMCN2 (female) (18)
tion in wiring or defective BKA (female) (2)
contact in connector) Wiring harness between BKA (female) (1)
Possible causes Resistance Max. 1 z
FS4-1 outlet port
and standard
value in normal aPrepare with starting switch OFF, then carry out troubleshooting with-
state out turning starting switch ON.
Short circuit of wiring harness between TMCN2
Short circuit with chassis
(female) (18) BKA (female) (2) with chassis Resistance Min. 1 Mz
4 ground in wiring harness
ground
(Contact with ground circuit)
Short circuit of wiring harness between BKA
(female) (1) FS4-1 outlet port with chassis Resistance Min. 1 Mz
ground
troller
Between (18) Neutral position 20 30 V
chassis ground Reverse position Max. 1 V
20-444 D475A-5
(1)
Circuit diagram related to back-up alarm relay
D475A-5 20-445
(1)
ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
Action code Error code Back-up alarm relay: Short circuit (KB)
Trouble
E01 D161KB (Transmission controller system)
Contents of
Abnormal current flowed in back-up alarm relay circuit at the time of ground output.
trouble
Action of
Stops output to back-up alarm relay circuit.
controller
Problem that
appears on Back-up alarm is not turned on.
machine
Output state (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
Related
Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Reverse position).
information
aThis error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in second-

Defective back-up alarm out turning starting switch ON.
1
relay (Internal short circuit) BKA (male) Resistance
Between (1) (2) 200 400 z
Possible causes
and standard
2 harness Short circuit of wiring harness between TMCN2
value in normal
(Contact with 24 V circuit) (female) (18) BKA (female) (2) with chassis Voltage Max. 1 V
state
ground
troller
Between (18) Neutral position 20 30 V
chassis ground Reverse position Max. 1 V
20-446 D475A-5
(1)
Circuit diagram related to back-up alarm relay
D475A-5 20-447
(1)
TROUBLESHOOTING D182KZ
ERROR CODE [D182KZ] (PREHEATER RELAY: LOWERING OF LEVEL (KZ))
Action code Error code Preheater relay: Lowering of level (KZ)

Trouble
E01 D182KZ (Steering controller system)
Contents of
The upstream relay of the preheater relay does not operate.
trouble
Action of
controller
Problem that
Automatic preheater system does not operate.
appears on
The preheater can be operated manually.
machine
The output state to the preheater relay can be checked in the monitoring mode.
(Code 40914: Steering controller output signal)
Related
Method of reproducing error code: Turn the starting switch ON + Set the parking brake lever in neutral.
information
aThis error code detects abnormality on the primary (coil) side of the preheater relay and cannot detect
abnormality on the secondary (contact) side.

1 Defective fuse FS4-4 If the fuse is broken, the circuit probably has a grounding fault, etc.
Defective preheater relay out turning starting switch ON.
2
(Internal disconnection) RHR (male) Resistance
Between (1) and (2) 200 400 z
Disconnection in wiring out turning starting switch ON.
harness
Wiring harness between STCN2 (female) (19)
3 (Disconnection in wiring Resistance Max. 1 z
and RHR (female) (2)
harness or defective contact
Possible causes in connector) Wiring harness between RHR (female) (1) and
Resistance Max. 1 z
and standard FS4-4 outlet side
Short circuit with chassis Between wiring harness between STCN2
4 ground in wiring harness (female) (19) and RHR (female) (2) and chassis Resistance Min. 1 Mz
(Contact with ground circuit) ground
Between wiring harness between RHR (female)
(1) and FS4-4 outlet side and chassis ground
5 Defective steering controller STCN2 Starting switch Voltage
Between (19) chassis ON 20 30 V
ground OFF Max. 1 V
20-448 D475A-5
(1)
TROUBLESHOOTING D182KZ
Circuit diagram related to preheater relay
D475A-5 20-449
(1)
TROUBLESHOOTING D1D0KA
ERROR CODE [D1D0KA] (GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION (KA))
Action code Error code Governor cutout relay right: Disconnection (KA)
Trouble
E01 D1D0KA (Engine controller system)
Contents of
The output voltage to the right governor cutout relay is below 2 V.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related If cause 3 occurs, circuit breaker CB6 is turned OFF and other systems will also have abnormalities.
information Method of reproducing error code: Turn the starting switch ON.

Defective right governor
GCR (male) Resistance
1 cutout relay
Between (1) and (2) 200 900 z
You may replace the right governor cutout relay with another one and
check by reproducing the error code.
harness Wiring harness between starting switch termi-
Possible causes 2 (Disconnection in wiring nal ACC, JMR, JM8, JE1, JED, and GCR Resistance Max. 1 z
and standard harness or defective contact (female) (1)
value in normal in connector) Wiring harness between GCR (female) (2) and
state Resistance Max. 1 z
LE1 (female) (4)
Between wiring harness between starting
(Contact with ground circuit) switch terminal ACC, JMR, JM8, JE1, JED, Resistance Min. 1 Mz
GCR (female) (1), and other related circuits and
chassis ground
4 Defective engine controller
LE1 Voltage
Between (4) and (13) 20 30 V
20-450 D475A-5
(2)
Circuit diagram related to right governor cutout relay
D475A-5 20-451
(1)
TROUBLESHOOTING D1D0KB
ERROR CODE [D1D0KB] (GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT (KB))
Action code Error code Governor cutout relay right: short circuit (KB)
Trouble
E01 D1D0KB (Engine controller system)
Contents of
The output voltage to the right governor cutout relay is 5 15 V.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
Method of reproducing error code: Turn the starting switch OFF, then ON.
information

Defective right governor
GCR (male) Resistance
1 cutout relay
Between (1) and (2) 200 900 z
(Internal short circuit)
You may replace the right governor cutout relay with another one and
Possible causes check by reproducing the error code.
value in normal Short circuit with power out turning starting switch ON.
state 2 source in wiring harness Between wiring harness between GCR
(Contact with 24-V circuit) (female) (2) and LE1 (female) (4) and chassis Voltage Max. 1 V
ground
LE1 Voltage
Between (4) and (13) Max. 1 V
20-452 D475A-5
(2)
D475A-5 20-453
(1)
ERROR CODE [D1D1KA] (GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION (KA))
Action code Error code Governor cutout relay left: Disconnection (KA)
Trouble
E01 D1D1KA (Engine controller system)
Contents of
The output voltage to the left governor cutout relay is below 2 V.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine

Defective left governor
GCL (male) Resistance
1 cutout relay
Between (1) and (2) 200 900 z
You may replace the left governor cutout relay with another one and
check by reproducing the error code.
harness Wiring harness between starting switch termi-
Possible causes 2 (Disconnection in wiring nal ACC, JMR, JM8, JE1, JED, and GCL Resistance Max. 1 z
and standard harness or defective contact (female) (1)
value in normal in connector) Wiring harness between GCL (female) (2) and
LE1 (female) (5)
Between wiring harness between starting
(Contact with ground circuit) switch terminal ACC, JMR, JM8, JE1, JED, Resistance Min. 1 Mz
GCL (female) (1), and other related circuits and
chassis ground
LE1 Voltage
Between (5) and (14) 20 30 V
20-454 D475A-5
(2)
Circuit diagram related to left governor cutout relay
D475A-5 20-455
(1)
ERROR CODE [D1D1KB] (GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT (KB))
Action code Error code Governor cutout relay left: Short circuit (KB)
Trouble
E01 D1DKB (Engine controller system)
Contents of
The output voltage to the left governor cutout relay is 5 15 V.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
Method of reproducing error code: Turn the starting switch OFF, then ON.
information

Defective left governor
GCL (male) Resistance
1 cutout relay
Between (1) and (2) 200 900 z
You may replace the left governor cutout relay with another one and
Possible causes check by reproducing the error code.
and standard
Short circuit with power out turning starting switch ON.
state 2 source in wiring harness
(Contact with 24-V circuit) Between wiring harness between GCL (female)
Voltage Max. 1 V
(2) and LE1 (female) (5) and chassis ground
LE1 Voltage
Between (5) and (14) Max. 1 V
20-456 D475A-5
(2)
D475A-5 20-457
(1)
TROUBLESHOOTING D5ZFKA
ERROR CODE [D5ZFKA] (NEUTRAL SIGNAL 1: DISCONNECTION (KA))
Action code Error code Neutral signal 1: Disconnection (KA)

Trouble
E01 D5ZFKA (Transmission controller system)
Contents of
The neutral signal 1 circuit to the engine controller is disconnected or has a grounding fault.
trouble
Action of
Stops outputting the signal to the neutral signal 1 circuit.
controller
Problem that
appears on
machine
The output state of the neutral signal 1 can be checked in the monitoring mode.
Related
(Code 40909: Transmission controller ON/OFF output)
information
Method of reproducing error code: Turn the starting switch ON.

harness (Disconnection in out turning starting switch ON.
1
wiring harness or defective Wiring harness between TMCN2 (female) (19)
contact in connector) Resistance Max. 1 z
and LE51 (female) (5)
Short circuit with chassis out turning starting switch ON.
2 ground in wiring harness Between wiring harness between TMCN2
Possible causes (Contact with ground circuit) (female) (19) and LE51 (female) (5) and chas- Resistance Min. 1 Mz
and standard sis ground
value in normal
state carry out troubleshooting.
Defective transmission
controller
Between (19) and Neutral Max. 1 V
chassis ground Forward or reverse 20 30 V
LE51 Voltage
Between (5) and chassis ground 20 30 V
Circuit diagram related to neutral signal 1
20-458 D475A-5
(1)
TROUBLESHOOTING D5ZFKB
ERROR CODE [D5ZFKB] (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB))
Action code Error code Neutral signal 1: Short circuit (KB)

Trouble
E01 D5ZFKB (Transmission controller system)
Contents of
An abnormal current flowed in the neutral signal 1 circuit to the engine controller.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Short circuit with power
1 source in wiring harness
Wiring harness between TMCN2 (female) (19)
(Contact with 24 V circuit) Resistance Max. 1 z
Possible causes aPrepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
Defective transmission TMCN2 PCCS lever Voltage
value in normal 2
controller
state Between (19) and Neutral Max. 1V
LE51 Voltage
D475A-5 20-459
(1)
TROUBLESHOOTING D5ZFL4
ERROR CODE [D5ZFL4] (ENGINE CONTROLLER NEUTRAL SIGNAL: ON AND OFF

SIGNALS DO NOT AGREE (L4))
Action code Error code Engine controller neutral signal: ON and OFF signals do not agree (L4)
Trouble
E01 D5ZFL4 (Engine controller system)
Contents of The neutral signal circuit from the transmission controller to the engine controller is disconnected or has
trouble a grounding fault.
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

harness Resistance Max. 1 z
1 (Disconnection in wiring
harness or defective contact aPrepare with starting switch OFF, then carry out troubleshooting with-
in connector)
Resistance Max. 1 z
Between wiring harness between TMCN2
(female) (9) and LE51 (female) (6) and chassis Resistance Min. 1 Mz
ground
ground in wiring harness
Possible causes (Contact with ground circuit)
and standard
value in normal
(female) (19) and LE51 (female) (5) and chas- Resistance Min. 1 Mz
state
2 sis ground
Voltage Max. 1 V
Short circuit with power (female) (9) and LE51 (female) (6)
source in wiring harness aPrepare with starting switch OFF, then turn starting switch ON and
(Contact with 24 V circuit) carry out troubleshooting.
(female) (19) and LE51 (female) (5) and chas- Voltage Max. 1 V
sis ground
3 Defective engine controller TMCN2 PCCS lever Voltage
Between (9), (19) and Neutral Max. 1V
20-460 D475A-5
(2)
TROUBLESHOOTING D5ZFL4
Circuit diagram related to engine controller neutral signal
D475A-5 20-461
(1)
TROUBLESHOOTING D5ZGKA
ERROR CODE [D5ZGKA] (NEUTRAL SIGNAL 2: DISCONNECTION (KA))
Action code Error code Neutral signal 2: Disconnection (KA)

Trouble
E01 D5ZGKA (Transmission controller system)
Contents of
The neutral signal 2 circuit to the engine controller is disconnected or has a grounding fault.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Possible causes (Contact with ground circuit) (female) (9) and LE51 (female) (6) and chassis Resistance Min. 1 Mz
and standard ground
value in normal
controller
Between (9) and Neutral Max. 1 V
LE51 Voltage
20-462 D475A-5
(1)
TROUBLESHOOTING D5ZGKB
ERROR CODE [D5ZGKB] (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB))
Action code Error code Neutral signal 2: Short circuit (KB)

Trouble
E01 D5ZGKB (Transmission controller system)
Contents of
An abnormal current flowed in the neutral signal 2 circuit to the engine controller.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

(Contact with 24-V circuit) Voltage Max. 1 V
Defective transmission TMCN2 PCCS lever Voltage
value in normal 2
controller
state Between (9) and Neutral Max. 1V
LE51 Voltage
D475A-5 20-463
(1)
TROUBLESHOOTING D5ZKKX
ERROR CODE [D5ZKKX] (CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL

RANGE (KX))
Action code Error code Chassis throttle signal: Out of input signal range (KX)
Trouble
CALL E03 D5ZKKX (Engine controller system)
Contents of
The input voltage of the shoe slip control signal is below 0.3 V or above 4.75 V.
trouble
Flashes the caution lamp and turns on the caution buzzer.
Action of
Keeps the last value in the normal range.
controller
Stops the shoe slip function after the machine stops.
Problem that
appears on The shoe slip control does not operate normally.
machine
Related
Method of reproducing error code: Turn the starting switch ON or start the engine in the SSC mode.
information

1
wiring harness or defective Wiring harness between LE31 (female) (9) and
Resistance Max. 1 z
contact in connector) STCN2 (female) (11)
2 ground in wiring harness Between wiring harness between LE31
(Contact with ground circuit) (female) (9) and STCN 2 (female) (11) and Resistance Min. 1 z
chassis ground
value in normal
3 source in wiring harness Between wiring harness between LE31
state (Contact with 24-V circuit) (female) (9) and STCN 2 (female) (11) and Voltage Max. 1 V
chassis ground
LE31 Voltage
Between (9) and chassis ground 0.3 4.75 V
STCN2 Voltage
Between (11) and chassis ground 0.3 4.75 V
Circuit diagram related to shoe slip control signal
20-464 D475A-5
(2)
TROUBLESHOOTING D5ZRKA
ERROR CODE [D5ZRKA] (SNAP SHOT SWITCH: DISCONNECTION (KA))
Action code Error code Snap shot switch: Disconnection (KA)

Trouble
D5ZRKA (Steering controller system)
Contents of
When the snap shot switch circuit is disconnected from the chassis ground, 24 V is not generated.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
Enter the snap shot mode and apply a trigger.
information

1
wiring harness or defective Wiring harness between STCN2 (female) (9)
Voltage Max. 1 V
contact in connector) and V3B (female) (6)
2 ground in wiring harness Between wiring harness between STCN2
Possible causes (Contact with ground circuit) (female) (9) and V3B (female) (6) and chassis Resistance Min. 1 Mz
and standard ground
value in normal aPrepare with starting switch OFF, then turn starting switch ON and
STCN2 Snap shot switch Voltage
Trigger Max. 1 V
Between (9) and
chassis ground Out of period just
20 30 V
after trigger
V3B Voltage
Circuit diagram related to snap shot switch
D475A-5 20-465
(1)
TROUBLESHOOTING D5ZRKB
ERROR CODE [D5ZRKB] (SNAP SHOT SWITCH: SHORT CIRCUIT (KB))
Action code Error code Snap shot switch: Short circuit (KB)
Trouble
D5ZRKB (Steering controller system)
Contents of
When the snap shot switch circuit is disconnected from the chassis ground, 24 V is not generated.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
Enter the snap shot mode and apply a trigger.
information

Short circuit with power carry out troubleshooting.
1 source in wiring harness Between wiring harness between STCN2
(Contact with 24-V circuit) (female) (9) and V3B (female) (6) and chassis Voltage Max. 1 V
ground
value in normal STCN2 Snap shot switch Voltage
state Trigger Max. 1 V
Between (9) and
chassis ground Out of period
20 30 V
just after trigger
V3B Voltage
Circuit diagram related to snap shot switch
20-466 D475A-5
(1)
TROUBLESHOOTING DAFRKR
ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE

COMMUNICATION (KR))
Action code Error code Monitor panel CAN communication: Defective communication (KR)
Trouble
CALL E03 DAFRKR (Monitor panel system)
Contents of
Monitor panel cannot recognize steering controller with CAN communication circuit.
trouble
Problem that System may not operate normally.
machine Once machine is stopped, travel is limited to F1 and R1.
Related
information

Wiring harness between S04 (female) (1), (2)
Disconnection in wiring har- STCN2 (female) (32), TMCN2 (female) (32),
Resistance Max. 1 z
ness (Disconnection in wir- CA1 (female) (A), CA2 (female) (A), V4A
1
ing or defective contact in (female) (4)
connector) Wiring harness between S04 (female) (3) (4)
STCN2 (female) (22), TMCN2 (female) (22)
Resistance Max. 1 z
CA1 (female) (B) CA2 (female) (B), V4A
(female) (12)
Short circuit of wiring harness between S04
(female) (1), (2) STCN2 (female) (32),
TMCN2 (female) (32) CA1 (female) (A), Resistance Min. 1 Mz
CA2 (female) (A), V4A (female) (4) with chas-
sis ground
Possible causes (female) (3), (4) STCN2 (female) (22),
and standard TMCN2 (female) (22), CA1 (female) (B) Resistance Min. 1 Mz
value in normal CA2 (female) (B), V4A (female) (12) with
state chassis ground
TMCN2 (female) (32) CA1 (female) (A) CA2 Voltage Max. 1 V
Hot short circuit in wiring
(female) (A), V4A (female) (4) with chassis
3 harness (Contact with 24 V
ground
circuit)
TMCN2 (female) (22) CA1 (female) (B) CA2 Voltage Max. 1 V
(female) (B), V4A (female) (12) with chassis
ground
Defective CAN terminal out turning starting switch ON.
4
resistance CA1 (male), CA2 (male) Resistance
Between (A) (B) 40 80 z
If no problem is found in causes 1 to 4, it is suspected that monitor panel
Defective monitor panel or
5 or steering controller is defective. (Troubleshooting cannot be carried
defective steering controller
out since it is internal defect.)
20-468 D475A-5
(1)
TROUBLESHOOTING DAFRKR
Circuit diagram related to CAN communication
D475A-5 20-469
(1)
TROUBLESHOOTING DAQ0KK
ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE

REDUCTION (INPUT) (KK))
Action code Error code Transmission controller power supply: Source voltage reduction (input)
Trouble
CALL E04 DAQ0KK (KK) (Transmission controller system)
Contents of
Source voltage of transmission controller is below 17 V.
trouble
Monitor panel may not display normally.
Problem that
Relays and solenoids cannot operate, not allowing system operate normally.
appears on
machine
Once machine is stopped, it cannot travel any more.
Charge level (voltage) of battery can be checked in monitoring mode.
Related
(Code 03200: Battery voltage)
information

Defective circuit breaker If circuit breaker (20 A) is tripped, circuit probably has short circuit with
1
(20 A) (CB3) chassis ground.
Defective circuit breaker If circuit breaker (105 A) is burnout, circuit probably has short circuit with
2
(105 A) chassis ground.
Disconnection in wiring har- Wiring harness between TMCN3 (female) (1),
Resistance Max. 1 z
ness (Disconnection in wir- (11) CB3 (1)
3
ing or defective contact in Wiring harness between CB3 (2) fusible link
Resistance Max. 1 z
connector) battery relay terminal C
Possible causes
(31) (32) (33) chassis ground
value in normal
Short circuit with chassis Short circuit of wiring harness between TMCN3
4 ground in wiring harness (female) (1), (11) CB3 (1) with chassis ground
(Contact with ground circuit) Short circuit of wiring harness between CB3 (2)
fusible link battery relay terminal C with Resistance Min. 1 Mz
chassis ground
5 TMCN3 Voltage
troller
Between (1), (11) (21), (31), (32),
20 30 V
(33)
20-470 D475A-5
(1)
TROUBLESHOOTING DAQ0KK, DAQ0KT
Circuit diagram related to transmission controller power supply
ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CON-

TROLLER (KT))
Action code Error code Transmission controller: abnormality in controller (KT)

Trouble
E02 DAQ0KT (Transmission controller system)
Contents of
Information of ROM (nonvolatile storage) of transmission controller is not normal.
trouble
controller Sets default internal adjustment value.
Problem that
appears on Gear shift feeling of transmission may become worse.
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard Troubleshooting cannot be carried out since it is internal defect.
value in normal Defective transmission con-
1 (It is no problem even if you use controller unless no visible problem
troller
state appears on machine.)
D475A-5 20-471
(1)
ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER

SUPPLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK))
Action code Error code Transmission controller potentiometer power supply: Source voltage
Trouble
CALL 03 DAQ5KK reduction (input) (KK) (Transmission controller system)
Contents of Voltage of 5 V power supply circuit of transmission controller sensor is below 4.5 V or above 5.5 V.
trouble Abnormal current flowed in 5 V power supply circuit of transmission controller sensor.
Action of
Stops output to 5 V power supply circuit if abnormal voltage flows
controller
machine Once machine is stopped, travel is limited to F1 an R1.
Related
information

Defective forward-reverse
TL2 (male) Resistance
1 potentiometer (Internal
Between (4) (1) 2 kz 20%
short circuit)
Sensor 1 (FR3) Between (1)
Min. 1 Mz
chassis ground
Possible causes
2 ground in wiring harness Short circuit of wiring harness between TMCN1
and standard
(Contact with ground circuit) (female) (22) TL2 (female) (4) with chassis Resistance Min. 1 Mz
value in normal
state ground
3 harness (Contact with 24 V Short circuit of wiring harness between TMCN1
circuit) (female) (22) TL1 (female) (4) with chassis Voltage Max. 1 V
ground
Defective transmission con- carry out troubleshooting.
4
troller TMCN1 Voltage
Between (22) (21) 4.5 5.5 V
Circuit diagram related to transmission controller 5 V power supply
20-472 D475A-5
(1)
ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY:

SOURCE VOLTAGE REDUCTION (INPUT) (KK))
Action code Error code Transmission controller sensor power supply: Source voltage reduction
Trouble
E01 DAQ6KK (input) (KK) (Transmission controller system)
Contents of Voltage of 24 V power supply circuit of transmission controller sensor is below 17 V or above 30 V.
trouble Abnormal current flowed in 24 V power supply circuit of transmission controller sensor.
Action of
Stops output to 24 V power supply circuit if abnormal voltage flows
controller
Problem that
appears on Oil pressure of work equipment cannot be monitored in service mode.
machine
Related
information

It is internal defect if error code lights on (reset display)
Defective work equipment HP1 or
when disconnecting right connector.
1 pump oil pressure sensor HP2
aDisconnect connector with starting switch OFF, then turn
(Internal short circuit) connector
starting switch ON and carry out troubleshooting.
Possible causes aPrepare with starting switch OFF, then carry out troubleshooting with-
and standard Short circuit with chassis out turning starting switch ON.
value in normal 2 ground in wiring harness Short circuit of wiring harness between TMCN1
state (Contact with ground circuit) (female) (16) HP1 or HP2 (female) (B) with Resistance Min. 1 Mz
chassis ground
3
(16) (21) 20 30 V
Circuit diagram related to transmission controller 24 V power supply
D475A-5 20-473
(1)
TROUBLESHOOTING DAQ9KQ
ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE

SELECT SIGNAL INCONSISTENCY (KQ))
Action code Error code Transmission controller type collation/type select signal inconsistency
Trouble
CALL E04 DAQ9KQ (KQ) (Transmission controller system)
Contents of
Internal spec. setting of transmission controller is inconsistent with spec. set signal.
trouble
Action of
Stops all outputs to transmission controller.
controller
Limits operation of engine, transmission, and brake.
Problem that Machine does not operate at all.
machine Once machine is stopped, it cannot travel any more.
Related
information

It is normal if error code lights on (reset display) after carrying out adjust-
1 ment mode.
troller adjustment
Adjustment code: 0003: Transmission controller spec.
Possible causes Disconnection in wiring har- aPrepare with starting switch OFF, carry out troubleshooting without
and standard ness (Disconnection in wir- turning starting switch ON.
2
value in normal ing or defective contact in Short circuit of wiring harness between TMCN3
Resistance Max. 1 z
state connector) (female) (10) with chassis ground
3
Between (10) chassis ground Max. 1 V
Circuit diagram related to transmission controller type select
20-474 D475A-5
(1)
TROUBLESHOOTING DAQRKR
ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION:

DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM)
(KR))
Action code Error code Transmission controller CAN communication: Defective communication
Trouble (Abnormality in objective component system) (KR)
CALL E03 DAQRKR (Transmission controller system)
Contents of Transmission controller cannot recognize monitor panel, steering controller, engine controller, or VHMS
trouble controller with CAN communication circuit.
Related
information

Wiring harness between S04 (female) (1), (2)
Disconnection in wiring har- STCN2 (female) (32), TMCN2 (female) (32)
Resistance Max. 1 z
ness (Disconnection in wir- CA1 (female) (A) CA2 (female) (A), V4A
1
connector) Wiring harness between S04 (female) (3), (4)
STCN2 (female) (22), TMCN2 (female) (22),
Resistance Max. 1 z
CA1 (female) (B), CA2 (female) (B), V4A
(female) (12)
TMCN2 (female) (32), CA1 (female) (A), Resistance Min. 1 Mz
sis ground
and standard
value in normal
TMCN2 (female) (22), CA1 (female) (B) Resistance Min. 1 Mz
state
CA2 (female) (B), V4A (female) (12) with
chassis ground
TMCN2 (female) (32), CA1 (female) (A), Voltage Max. 1 V
3 harness
sis ground
(Contact with 24 V circuit)
TMCN2 (female) (22), CA1 (female) (B), Voltage Max. 1 V
chassis ground
4
20-476 D475A-5
(1)
TROUBLESHOOTING DAQRKR

Defective monitor panel,
Possible causes
and standard defective engine controller, If no problem is found in causes 1 to 4, it is suspected that monitor panel,
value in normal defective transmission con- engine controller, transmission controller, steering controller or VHMS
5
troller, defective steering controller is defective. (Troubleshooting cannot be carried out since it is
state
controller or VHMS control- internal defect.)
ler
D475A-5 20-477
(1)
TROUBLESHOOTING DAQSKR
ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET COMMUNICATION:

DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT
SYSTEM) (KR))
Action code Error code Transmission controller S-NET communication: Defective communica-
Trouble tion (Abnormality in objective component system) (KR)
E01 DAQSKR (Transmission controller system)
Contents of
Transmission controller cannot recognize S-NET.
trouble
Action of
Takes no particular action.
controller
Problem that
appears on Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine
Related
information

ness (Disconnection in wir- out turning starting switch ON.
1
ing or defective contact in Wiring harness between TMCN2 (female) (21)
connector) Resistance Max. 1 z
S01 (female) (8)
(Contact with ground circuit) (female) (21) S01 (female) (8) with chassis Resistance Min. 1 Mz
ground
and standard Hot short circuit in wiring carry out troubleshooting.
value in normal 3 harness Short circuit of wiring harness between TMCN2
state
(Contact with 24 V circuit) (female) (21) S01 (female) (8) with chassis Voltage Max. 1 V
ground
Defective monitor panel carry out troubleshooting.
4
(Switch module) S01 Voltage
Between (8) chassis ground 69V
5
Between (21) (31) 69V
20-478 D475A-5
(1)
TROUBLESHOOTING DAQSKR
Circuit diagram related to S-NET communication
D475A-5 20-479
(1)
TROUBLESHOOTING DB30KK
ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION

(INPUT) (KK))
Action code Error code Steering controller power supply: Source voltage reduction (input) (KK)
Trouble
CALL E04 DB30KK (Steering controller system)
Contents of
Source voltage of steering controller is below 17 V.
trouble
Monitor panel may not display normally.
Problem that
Relays and solenoids cannot operate, not allowing system operate normally.
appears on
machine
Charge level (voltage) of battery can be checked in monitoring mode.
Related
(Code 03200: Battery voltage)
information

Defective circuit breaker If circuit breaker is tripped, circuit probably has short circuit with chassis
1
(20 A) (CB1) ground.
Defective circuit breaker If circuit breaker (105 A) is burnout, circuit probably has short circuit with
2
(105 A) chassis ground.
Disconnection in wiring har- Wiring harness between STCN3 (female) (1)
Resistance Max. 1 z
ness (Disconnection in wir- (11) CB1 (1)
3
ing or defective contact in Wiring harness between CB1 (2) fusible link
Resistance Max. 1 z
connector) battery relay terminal C
Possible causes Wiring harness between STCN3 (female) (21),
Resistance Max. 1 z
and standard (31), (32), (33) chassis ground
Short circuit with chassis Short circuit of wiring harness between STCN3
4 ground in wiring harness (female) (1), (11) CB1 (1) with chassis ground
(Contact with ground circuit) Short circuit of wiring harness between CB1
(2) fusible link battery relay terminal C with Resistance Min. 1 Mz
chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
STCN3 Voltage
Between (1) (21), (1) (31),
(1) (32), (1) (33), (11) (21), 20 30 V
(11) (31), (11) (32), (11) (33)
20-480 D475A-5
(1)
TROUBLESHOOTING DB30KK, DB30KT
Circuit diagram related to steering controller power supply
ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROL-

LER (KT))
Action code Error code Steering controller power supply: Abnormality in controller (KT)
Trouble
E01 DB30KT (Steering controller system)
Contents of
Information of ROM (nonvolatile storage) of steering controller is not normal.
trouble
Action of
Sets default internal adjustment value.
controller
Problem that
Steering performance may be reduced.
appears on
Brake performance may be reduced.
machine
Related
information

and standard Troubleshooting cannot be carried out since it is internal defect. (It is no
value in normal 1 Defective steering controller problem even if you use controller unless no visible problem appears on
state machine.)
D475A-5 20-481
(1)
ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWER SUP-

PLY: SOURCE VOLTAGE REDUCTION (INPUT) (KK))
Action code Error code Steering controller potentiometer power supply: Source voltage reduc-
Trouble
CALL E03 DB35KK tion (input) (KK) (Steering controller system)
Contents of Voltage of 5 V power supply circuit of steering controller sensor is below 4.5 V or above 5.5 V.
trouble Abnormal current flowed in 5 V power supply circuit of steering controller sensor.
Action of
Stops output to 5 V power supply circuit if abnormal voltage flows.
controller
Related
information

Defective brake potentiom- when disconnecting right connector. BRK
1
eter (Internal short circuit) aDisconnect connector with starting switch OFF, then turn connector
Defective acceleration sen- when disconnecting right connector. SSA
2
sor (Internal short circuit) aDisconnect connector with starting switch OFF, then turn connector
Defective steering potenti- out turning starting switch ON.
3 ometer (Internal short cir- TL1 (male) Resistance
cuit) Between (A), (M) (F), (G) 2 kz 20%
Possible causes Between (A), (M) chassis ground Min. 1 Mz
value in normal out turning starting switch ON.
state Short circuit with chassis
Short circuit of wiring harness between STCN1
(female) (22), TL1 (female) (A), (M), BRK
(Contact with ground circuit) Resistance Min. 1 Mz
(female) (C), SSA (female) (1) with chassis
ground
5 harness (Contact with 24 V Short circuit of wiring harness between STCN1
(female) (22) TL1 (female) (A), (M), BRK
circuit) Voltage Max. 1 V
(female) (C), SSA (female) (1) with chassis
ground
STCN1 Voltage
Between (22) (21) 4.5 5.5 V
20-482 D475A-5
(1)
Circuit diagram related to steering controller 5V power supply
D475A-5 20-483
(1)
ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY:

SOURCE VOLTAGE REDUCTION (INPUT) (KK))
Action code Error code Steering controller sensor power supply: Source voltage reduction
Trouble
CALL E03 DB36KK (input) (KK) (Steering controller system)
Contents of Voltage of 24 V power supply circuit of steering controller sensor is below 17 V or above 30 V.
trouble Abnormal current flowed in 24 V power supply circuit of steering controller sensor.
Action of
Stops output of 24 V power supply circuit if abnormal voltage flows.
controller
Related
information

Defective blade pitch angle
when disconnecting right connector. PT1
1 sensor (Internal short cir-
aDisconnect connector with starting switch OFF, then turn connector
cuit)
value in normal 2 ground in wiring harness Short circuit of wiring harness between STCN1
state (Contact with ground circuit) (female) (16) PT1 (female) (C) with chassis Resistance Min. 1 Mz
ground
STCN1 Voltage
Between (16) (21) 20 30 V
Circuit diagram related to steering controller 24V power supply
20-484 D475A-5
(1)
TROUBLESHOOTING DB39KQ
ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE

SELECT SIGNAL INCONSISTENCY (KQ))
Action code Error code Steering controller type collation: Type select signal inconsistency (KQ)
Trouble
CALL E04 DB39KQ (Steering controller system)
Contents of
Internal spec. setting of steering controller is inconsistent with spec. set signal.
trouble
Action of
Stops all outputs of steering controller.
controller
Problem that Machine does not operate at all.
Related
information

It is normal if error code indicates P (reset display) after carrying out
Defective steering controller
1 adjustment mode.
adjustment
Adjustment code: 0002 (Steering controller spec. set)
Possible causes Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting with-
and standard ness (Disconnection in wir- out turning starting switch ON.
2
value in normal ing or defective contact in Wiring harness between STCN3 (female) (20)
Resistance Max. 1 z
state connector) chassis ground
Prepare with starting switch OFF, turn starting switch ON and carry out
troubleshooting.
STCN3 Voltage
Between (20) chassis ground Max. 1 V
Circuit diagram related to steering controller type select
D475A-5 20-485
(1)
TROUBLESHOOTING DB3RKR
ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFEC-

TIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))
Action code Error code Steering controller CAN communication: Defective communication
CALL E03 DB3RKR
(Steering controller system)
Contents of Steering controller cannot recognize monitor panel, transmission controller, engine controller, or VHMS
trouble controller with CAN communication circuit.
Related
information

Between wiring harness between S04 (female)
Disconnection in wiring har- (1), (2) STCN2 (female) (32), TMCN2
Resistance Max. 1 z
ness (Disconnection in wir- (female) (32) CA1 (female) (A), CA2
1
ing or defective contact in (female) (A), V4A (female) (4)
connector) Wiring harness between S04 (female) (3) (4)
STCN2 (female) (22), TMCN2 (female) (22),
Resistance Max. 1 z
CA1 (female) (B), CA2 (female), V4A
(female) (12)
TMCN2 (female) (32), CA1 (female) (A), Resistance Min. 1 Mz
sis ground
and standard
value in normal
TMCN2 (female) (22), CA1 (female) (B), Resistance Min. 1 Mz
state
chassis ground
(female) (1), (2), STCN2 (female) (32),
TMCN2 (female) (32), CA1 (female) (A), Voltage Max. 1 V
sis ground
circuit)
TMCN2 (female) (22), ECN2 (female) (22), Voltage Max. 1 V
CA1 (female) (B), CA2 (female) (B), V4A
4
20-486 D475A-5
(1)
TROUBLESHOOTING DB3RKR

Defective monitor panel,
Possible causes
and standard defective engine controller, If no problem is found in causes 1 to 4, it is suspected that monitor panel,
value in normal defective transmission con- engine controller, transmission controller, steering controller, or VHMS
5
troller, defective steering controller is defective. (Troubleshooting cannot be carried out since it is
state
controller, or defective internal defect.)
VHMS controller
D475A-5 20-487
(1)
TROUBLESHOOTING DB3SKR
ERROR CODE [DB3SKR] (STEERING CONTROLLER S-NET COMMUNICATION:

DEFECTIVE COMMUNICATION (ABNORMALITY IN OBJECTIVE COMPONENT SYS-
TEM) (KR))
Action code Error code Steering controller S-NET communication: Defective communication
E01 DB3SKR (Steering controller system)
Contents of
Transmission controller cannot recognize S-NET.
trouble
Action of
Takes no particular action.
controller
Problem that
appears on Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine
Related
information

ness (Disconnection in wir- out turning starting switch ON.
1
ing or defective contact in Wiring harness between STCN2 (female) (21)
S01 (female) (8)
2 ground in wiring harness Short circuit of wiring harness between STCN2
(Contact with ground circuit) (female) (21) S01 (female) (8) with chassis Resistance Min. 1 Mz
ground
Possible causes aPrepare with starting switch OFF, turn starting switch ON and carry
and standard Hot short circuit in wiring out troubleshooting.
value in normal 3 harness (Contact with 24 V Short circuit of wiring harness between STCN2
state
circuit) (female) (21) S01 (female) (8) with chassis Voltage Max. 1 V
ground
Defective monitor panel out troubleshooting.
4
Between (8) chassis ground 69V
STCN2 Voltage
Between (21) (31) 69V
20-488 D475A-5
(1)
TROUBLESHOOTING DB3SKR
Circuit diagram related to S-NET communication
D475A-5 20-489
(1)
TROUBLESHOOTING DB40KK, DB41KK
ERROR CODE [DB40KK] (ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE

(KK))
Action code Error code Engine controller: Lowering of source voltage (KK)
Trouble
CALL E04 DB40KK (Engine controller system)
Contents of
The source voltage of the engine controller is below 17 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective switch power The switch power supply system of the controller may be defective.
1
Possible causes supply system of controller Carry out troubleshooting for error code [DB41KK].
and standard Defective backup power The backup power supply system of the controller may be defective.
value in normal 2
supply system of controller Carry out troubleshooting for error code [DB43KK].
ERROR CODE [DB41KK] (SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLT-

AGE (KK))
Action code Error code Switch power supply: Lowering of source voltage (KK)
Trouble
Contents of
The switch source voltage of the controller is 5 V or more below the backup source voltage.
trouble
controller Controls with the backup power supply.
Problem that
appears on
machine

harness (Disconnection in
1 Wiring harness between starting switch termi-
wiring harness or defective
nal ACC, JMR, JM8, JE1, and LE1 (female) (9), Resistance Max. 1 z
contact in connector)
(17)
and standard out turning starting switch ON.
value in normal Between wiring harness between starting
state
(Contact with ground circuit) switch terminal ACC, JMR, JM8, JE1, LE1 Resistance Min. 1 Mz
(female) (9), (17), and other related circuits and
chassis ground
LE1 Voltage
Between (9), (17) and (8), (16) 20 30 V
20-490 D475A-5
(1)
Circuit diagram related to controller power source (constant and switch)
D475A-5 20-491
(1)
ERROR CODE [DB42KK] (SOLENOID POWER SUPPLY 1: LOWERING OF SOURCE

VOLTAGE (KK))
Action code Error code Solenoid power supply 1: Lowering of source voltage (KK)
Trouble
Contents of While the switch source voltage of the controller is above 24 V, the voltage of solenoid power supply R
trouble is below 5 V.
Action of
controller
Problem that
machine
Related
Method of reproducing error code: Turn the starting switch OFF.
information

Defective right governor Replace the right governor cutout relay with another relay.
1 GCR
cutout relay (Internal defect) If the condition becomes normal, the relay is defective.
2
Possible causes contact in connector) Resistance Max. 1 z
GCR (female) (6)
and standard
value in normal Short circuit with chassis
state 3 ground in wiring harness
Between wiring harness between LE2 (female)
(1) and GCR (female) (6) and chassis ground
LE2 Voltage
Between (1) and (21) 20 30 V
20-492 D475A-5
(1)
D475A-5 20-493
(1)
ERROR CODE [DB43KK] (BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLT-

AGE (KK))
Action code Error code Backup power supply: Lowering of source voltage (KK)
Trouble
Contents of
The backup source voltage of the controller is 5 V or more below the switch source voltage.
trouble
controller Controls with the switch power supply.
Problem that
appears on
machine

1
wiring harness or defective Wiring harness between JMA branching point,
JEG, and LE1 (female) (7)
value in normal 2 ground in wiring harness Between wiring harness between JMA branch-
state (Contact with ground circuit) ing point, JEG, and LE1 (female) (7) and chas- Resistance Min. 1 Mz
sis ground
LE1 Voltage
Between (7) and (8), (16) 20 30 V
20-494 D475A-5
(1)
Circuit diagram related to controller power supply (constant/switch)
D475A-5 20-495
(1)
ERROR CODE [DB44KK] (SOLENOID POWER SUPPLY 2: LOWERING OF SOURCE

VOLTAGE (KK))
Action code Error code Solenoid power supply 2: Lowering of source voltage (KK)
Trouble
Contents of While the switch source voltage of the controller is above 24 V, the voltage of solenoid power supply L
trouble is below 5 V.
Action of
controller
Problem that
machine
Related
information

Defective left governor cut- Replace the left governor cutout relay with another relay. If
1 GCL
out relay (Internal defect) the condition becomes normal, the relay is defective.
2
GCL (female) (6)
and standard
value in normal Short circuit with chassis
(12) and GCL (female) (6) and chassis ground
LE2 Voltage
Between (12) and (21) 20 30 V
20-496 D475A-5
(1)
D475A-5 20-497
(1)
TROUBLESHOOTING DB45KP
ERROR CODE [DB45KP] (RACK SENSOR POWER SUPPLY: LOWERING OF OUTPUT

VOLTAGE (KP))
Action code Error code Rack sensor power supply: Lowering of output voltage (KP)
Trouble
CALL E03 DB45KP (Engine controller system)
Contents of
The source voltage of the rack sensor is below 3.4 V.
trouble
controller Lowers the engine output by 20%.
Problem that
appears on The output is lowered.
machine
Related
Method of reproducing error code: Turn the starting switch OFF.
information

Disconnect the devices Rack sensor of
Defective rack sensor of at right in order. If the Connector E13
right bank
right or left bank error code disappears
1
(Internal disconnection or when a device is dis-
short circuit) connected, that device Rack sensor of
Connector E9
has a defect in it. left bank
Wiring harness between LE2 (female) (16),
JE2, and E13 (female) (1) [Rack sensor system Resistance Max. 1 z
of right bank]
Disconnection in wiring Wiring harness between LE2 (female) (16),
harness (Disconnection in JE2, and E9 (female) (1) [Rack sensor system Resistance Max. 1 z
2
wiring harness or defective of left bank]
Possible causes contact in connector) Wiring harness between LE31 (female) (16),
and standard
value in normal of right bank]
state
Wiring harness between LE31 (female) (16),
of left bank]
(16), JE2, and E13 (female) (1) and chassis Resistance Min. 1 Mz
ground [Rack sensor system of right bank]
(16), JE2, and E9 (female) (1) and chassis Resistance Min. 1 Mz
ground [Rack sensor system of left bank]
LE2, LE31 Voltage
Between LE2 (16) and LE31 (16) 4.6 5.4 V
20-498 D475A-5
(1)
TROUBLESHOOTING DB45KP
Circuit diagram related to right bank rack sensor and left bank rack sensor
D475A-5 20-499
(1)
TROUBLESHOOTING DB49KM
ERROR CODE [DB49KM] (WRONG CONNECTION OF CONNECTOR: MISTAKE IN

OPERATION OR SETTING (KM))
Action code Error code Wrong connection of connector: Mistake in operation or setting (KM)
Trouble
CALL E04 DB49KM (Engine controller system)
Contents of
Wrong connection of connectors LE31 and LE51 of the controller is detected.
trouble
Action of
controller
Problem that
appears on The engine cannot be started.
machine
Related
Method of reproducing error code: Turn starting switch ON
information

Wrong connection of Connectors LE31 and LE51 may be connected wrongly (inversely).
1
controller connectors Check them directly.
and standard 2
wiring harness or defective Wiring harness between LE51 (female) (1),
contact in connector) JEE, JE4, and chassis ground
state
LE51 Voltage
Between (1) and chassis ground Max. 1 V
Circuit diagram related to connection of connector chuck harness
20-500 D475A-5
(2)
TROUBLESHOOTING DB49KQ
ERROR CODE [DB49KQ] (ENGINE CONTROLLER SPECIFICATION: DISAGREEMENT

OF MODEL SELECTION SIGNALS (KQ))
Action code Error code Engine controller specification: Disagreement of model selection signals
Trouble (KQ)
E02 DB49KQ (Engine controller system)
Contents of
Either of the chassis ground circuits of the engine controller is disconnected.
trouble
controller None in particular.
Problem that
appears on Information of the VHMS may not be obtained normally.
machine
Related
information

Disconnection in wiring Wiring harness between LE52 (female) (14)
Resistance Max. 1 z
harness (Disconnection in and chassis ground
Possible causes 1
wiring harness or defective aPrepare with starting switch OFF, then carry out troubleshooting with-
and standard contact in connector) out turning starting switch ON.
value in normal
state Wiring harness between LE52 (female) (15)
Resistance Max. 1 z
and chassis ground
LE52 Voltage
Between (15) and chassis ground Max. 1 V
Circuit diagram related to engine controller model selection
D475A-5 20-501
(2)
TROUBLESHOOTING DBB0KK
(VHMS CONTROLLER: LOWERING OF SOURCE VOLTAGE (KK))
Action code Error code VHMS controller: Lowering of source voltage (KK)
Trouble
DBB0KK (VHMS controller system)
Contents of
The switch source voltage is below 19.5 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The system may not operate normally.
machine
Related
loaded to a personal computer, however, the error code can be checked.)
information
The LED of the VHMS controller indicates "n9" o "01".

Disconnection in wiring Wiring harness between V1 (female) (6), (7),
Resistance Max. 1 z
harness (Disconnection in V12 (female) (7), and FS1 (fuse) (5)
1
wiring harness or defective Wiring harness between V1 (female) (8), (9),
V12 (female) (8), and FS4 (fuse) (3)
Wiring harness between V1 (female) (11), (12),
Resistance Max. 1 z
VF2 (female) (K), and chassis ground
Possible causes
and standard
value in normal Between wiring harness between V1 (female)
state (6), (7), V12 (female) (7), and FS1 (fuse) (5) Resistance Min. 1 Mz
and chassis ground
Between wiring harness between V1 (female)
(8), (9), V12 (female) (8), and FS4 (fuse) (3) Resistance Min. 1 Mz
and chassis ground
Between V1 (female) (6), (7) and V1 (female)
3 Defective VHMS controller Voltage 20 30 V
(11), (12) or chassis ground
Between V1 (female) (8), (9) and V1 (female)
Voltage 20 30 V
(11), (12) or chassis ground
20-502 D475A-5
(1)
Circuit diagram related to VHMS controller power supply
D475A-5 20-503
(1)
TROUBLESHOOTING DBB0KQ
ERROR CODE [DBB0KQ] (OR LED OF VHMS CONTROLLER INDICATES "nF" o "11")
(CHECK OF VHMS CONTROLLER MODEL: DISAGREEMENT OF MODEL SELECTION
SIGNALS (KQ))
Action code Error code VHMS controller: Disagreement of model selection signals (KQ)
Trouble
DBB0KQ (VHMS controller system)
Contents of
Wrong connection of connectors is displayed.
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information
The LED of the VHMS controller indicates "nF" o "11".

Wrong connection of VHMS
Check that the couple of connectors V2A and V3A and that of connec-
1 controller connectors
tors V2B and V3B are connected correctly. If not, correct.
(When system is normal)
Possible causes harness (Disconnection in
and standard 2 Between V1 (female) (11), (12) and chassis
wiring harness or defective Resistance Max. 1 z
value in normal ground
state Between V3A (female) (9) and chassis ground Resistance Max. 1 z
3 Defective VHMS controller Between V1 (female) (11), (12) and chassis
Voltage Max. 1 V
ground
Between V3A (female) (9) and chassis ground Voltage Max. 1 V
Circuit diagram related to model selection power supply
20-504 D475A-5
(1)
(VHMS CONTROLLER: LOWERING OF BATTERY DIRECT SOURCE VOLTAGE (KK))
Action code Error code VHMS controller: Lowering of battery direct source voltage (KK)
Trouble
DBB3KK (VHMS controller system)
Contents of
The sensor source voltage (24 V) is out of the normal range (20 30 V).
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

(6), (7) and V12 (female) (7) and chassis Resistance Min. 1 Mz
Possible causes 1 ground in wiring harness
ground
and standard (Contact with ground circuit)
value in normal
(8), (9) and V12 (female) (8) and chassis Resistance Min. 1 Mz
state
ground
V1 (female) Voltage
Between (2) and (11), (12) 20 30 V
Circuit diagram related to battery power supply
D475A-5 20-505
(1)
TROUBLESHOOTING DBB5KP
(SENSOR POWER SUPPLY (5 V): LOWERING OF OUTPUT VOLTAGE (KP))
Action code Error code Sensor power supply (5 V): Lowering of output voltage
Trouble (Disconnection or short circuit) (KP)
DBB5KP
(VHMS controller system)
Contents of
The sensor source voltage (5 V) is out of the normal range (4.5 5.5 V).
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

(Contact with ground circuit) Between wiring harness V1 (female) (4) and
Possible causes ENBP (female) (B)
and standard Disconnection in wiring aPrepare with starting switch OFF, then carry out troubleshooting with-
value in normal harness (Disconnection in out turning starting switch ON.
state 2
wiring harness or defective Between wiring harness V1 (female) (4) and
ENBP (female) (B)
3 Defective VHMS controller carry out troubleshooting.
Between V1 (female) (4) and V2A (female) (12) Voltage 4.5 5.5 V
Circuit diagram related to sensor power supply 5 V
20-506 D475A-5
(1)
DBB6KP
Contents of
The sensor source voltage (24 V) is out of the normal range (20 30 V).
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

1 Between wiring harness V1 (female) (2), EX1R
(female) (A), V1 (female) (2), EX1L (female) Resistance Max. 1 z
Possible causes (A), V1 (female) (2), and TMMD (female) (B)
state 2 ground in wiring harness Between wiring harness V1 (female) (2), EX1R
(Contact with ground circuit) (female) (A), V1 (female) (2), EX1L (female) Resistance Min. 1 Mz
(A), V1 (female) (2), and TMMD (female) (B)
3 Defective VHMS controller carry out troubleshooting.
Between V1 (2) and V2A (13) Voltage 20 30 V
D475A-5 20-507
(1)
DBB7KP
Contents of
The sensor source voltage (12 V) is out of the normal range (11.5 12.5 V).
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

1
wiring harness or defective Between wiring harness V1 (female) (3) and
DLT (female) (1)
Possible causes
value in normal 2 ground in wiring harness
state (Contact with ground circuit) Between wiring harness V1 (female) (3) and
DLT (female) (1)
V1 Voltage
Between (3) and (11), (12) 11.5 12.5 V
20-508 D475A-5
(1)
TROUBLESHOOTING DBBQKR
ERROR CODE [DBBQKR] (OR LED OF VHMS CONTROLLER INDICATES "n8" o "02")
(VHMS KOM-NET: DEFECTIVE COMMUNICATION (KR))
Action code Error code VHMS KOM-NET: Defective communication (KR)

Trouble
DBBQKR (VHMS controller system)
Contents of
Information from each controller cannot be obtained by communication (CAN).
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

Wiring harness between V4A (female) (4), S04
(female) (1), (2), TMCN3 (female) (32), and Resistance Max. 1 z
STCN2 (female) (32)
Wiring harness between V4A (female) (12),
S04 (female) (3), (4), TMCN3 (female) (22), and Resistance Max. 1 z
1 STCN2 (female) (22)
contact in connector) Wiring harness between V3A (female) (8), (18),
S01 (female) (8), CN4 (female) (6), (12),
Resistance Max. 1 z
TMCN3 (female) (21), and STCN2 (female)
(21)
Possible causes CN4 (female) (10), TMCN3 (female) (31), and Resistance Max. 1 z
and standard STCN (2) (female) (31)
Between wiring harness between V4A (female)
(4), S04 (female) (1), (2), TMCN3 (female) (32), Resistance Min. 1 Mz
and STCN2 (female) (32) and chassis ground
(12), S04 (female) (3), (4), TMCN3 (female)
Short circuit with chassis Resistance Min. 1 Mz
(22), and STCN2 (female) (22) and chassis
ground
Wiring harness between V3A (female) (8), (18),
(21) and chassis ground
CN4 (female) (10), TMCN3 (female) (31), and Resistance Min. 1 Mz
STCN (2) (female) (31) and chassis ground
20-510 D475A-5
(1)
TROUBLESHOOTING DBBQKR

(4), S04 (female) (1), (2), TMCN3 (female) (32), Voltage Max. 1 V
and STCN2 (female) (32) and chassis ground
(12), S04 (female) (3), (4), TMCN3 (female)
Short circuit with power Voltage Max. 1 V
(22), and STCN2 (female) (22) and chassis
Possible causes 3 source in wiring harness
ground
and standard (Contact with 24-V circuit)
Wiring harness between V3A (female) (8), (18),
value in normal
state Voltage Max. 1 V
CN4 (female) (10), TMCN3 (female) (31), and Voltage Max. 1 V
STCN (2) (female) (31) and chassis ground
4
resistor Resistance between terminal resistors (A) and 110
Resistance
(B) 130 z
Circuit diagram related to communication (CAN)
D475A-5 20-511
(1)
TROUBLESHOOTING DD12KA
ERROR CODE [DD12KA] (SHIFT UP SWITCH: DISCONNECTION (KA))

Trouble Shift up switch: Disconnection (KA) (Transmission controller system)
E02 DD12KA
Contents of
Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time.
trouble
controller Recognizes that switch is not pressed.
Problem that
Shift up is not possible.
appears on
Auto shift down does not function.
machine
Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
Related Input state (ON/OFF) from shift up switch can be checked in monitoring mode.
information (Code 40905: Transmission controller input signal 1)
Method of reproducing error code: Turn starting switch ON and operate shift up switch.

Shift up switch
TL3 (male)
Defective shift up switch OFF (Release) ON (Press)
1
(Internal disconnection) Resistance between
Max. 1 z Min. 1 Mz
(2) (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) (1)
Disconnection in wiring har- Wiring harness between TMCN1 (female) (6)
Resistance Max. 1 z
ness (Disconnection in wir- TL3 (male) (3)
2
Resistance Max. 1 z
connector) TL3 (male) (1)
TL3 (male) (2)
and standard
value in normal aPrepare with starting switch OFF, turn starting switch ON and carry
state out troubleshooting.
(female) (6) TL3 (male) (3) with chassis Voltage Max. 1 V
ground
circuit)
ground
Shift up switch
TMCN1,TMCN2
OFF (Release) ON (Press)
Defective transmission con- Voltage between
4
troller TMCN1 (6) TMCN1 Max. 1 V 5 11 V
(4)
Voltage between
TMCN2 (37) TMCN1 5 11 V Max. 1 V
(4)
20-512 D475A-5
(1)
Circuit diagram related to shift up switch and shift down switch
D475A-5 20-513
(1)
TROUBLESHOOTING DD12KB
ERROR CODE [DD12KB] (SHIFT UP SWITCH: SHORT CIRCUIT (KB))

Trouble Shift up switch: Short circuit (KB) (Transmission controller system)
E02 DD12KB
Contents of
Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
Shift up is not possible.
appears on
machine
Related Input state (ON/OFF) from shift up switch can be checked in monitoring mode.

Shift up switch
TL3 (male)
Defective shift up switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(2) (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) (1)
Possible causes Short circuit with chassis
(female) (6) TL3 (male) (3) with chassis Resistance Min. 1 Mz
and standard 2 ground in wiring harness
state Short circuit of wiring harness between TMCN2
(female) (37) TL3 (male) (1) with chassis Resistance Min. 1 Mz
ground
Shift up switch
TMCN1,TMCN2
3
(4)
Voltage between
(4)
20-514 D475A-5
(1)
D475A-5 20-515
(1)
ERROR CODE [DD13KA] (SHIFT DOWN SWITCH: DISCONNECTION (KA))
Action code Error code Shift down switch: Disconnection (KA)

Trouble
E02 DD13KA (Transmission controller system)
Contents of
Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
Shift down is not possible.
appears on
machine
Related Input state (ON/OFF) from shift down switch can be checked in monitoring mode.
information (Code 40905:Transmission controller input signal 1)
Method of reproducing error code: Turn starting switch ON and operate shift down switch.

Shift down switch
TL3 (male)
Defective shift down switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(5) (6)
Resistance between
Min. 1 Mz Max. 1 z
(5) (4)
Resistance Max. 1 z
ness (Disconnection in wir- TL3 (male) (6)
2
Resistance Max. 1 z
connector) TL3 (male) (4)
TL3 (male) (5)
and standard
ground
circuit)
(female) (29) TL3 (female) (4) with chassis Voltage Max. 1 V
ground
Shift down switch
TMCN1, TMCN3
4
(4)
Voltage between
(4)
20-516 D475A-5
(1)
D475A-5 20-517
(1)
ERROR CODE [DD13KB] (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))
Action code Error code Shift down switch: Short circuit (KB)
Trouble
E02 DD13KB (Transmission controller system)
Contents of
Signals of two systems of shift down switch circuit were turned ON (CLOSE) or OFF at the same time.
trouble
Problem that
Shift down is not possible.
appears on
machine
Related Input state (ON/OFF) from shift down switch can be checked in monitoring mode.

Shift down switch
TL3 (male)
Defective shift down switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(5) (6)
Resistance between
Min. 1 Mz Max. 1 z
(5) (4)
(female) (19) TL3 (female) (6) with chassis Resistance Min. 1 Mz
(female) (29) TL3 (female) (4) with chassis Resistance Min. 1 Mz
ground
Shift down switch
TMCN1, TMCN3
3
(4)
Voltage between
(4)
20-518 D475A-5
(1)
D475A-5 20-519
(1)
ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA))
Action code Error code Parking lever switch: Disconnection (KA)

Trouble
CALL E03 DD14KA (Transmission controller system)
Contents of
Signals of two systems of parking lever switch circuit were turned OFF (OPEN) at the same time.
trouble
Action of
Recognizes parking lever is in Free position.
controller
Problem that
appears on
Once machine is stopped, travel is limited to F1 and R1.
machine
aSignals of parking brake switch are commonly used by transmission controller and steering controller.
Depending on where problem occurs, related codes may be displayed at the same time.
(Related code: DDQ2KA, DDQ2L4).
Related
information
Input state (ON/OFF) from parking brake switch can be checked in monitoring mode.
(Code 40905: Transmission controller input signal 1)
Method of reproducing error code: Turn starting switch ON and operate parking lever.
When error code [DD14KA] occurred alone

ness (Disconnection in wir- Wiring harness between TMCN1 (female) (18)
ing or defective contact in branched point of circuit JS3
connector) Wiring harness between TMCN1 (female) (12)
branched point of circuit JSB
and standard
value in normal
state
Parking lever
TMCN1
Defective transmission con- Free position Lock position
2
troller Between (18)
Max. 1 V 5 11 V
chassis ground
Between (12)
5 11 V Max. 1 V
chassis ground
When error codes [DD14KA] and [DDQ2KA] occurred at the same time
Parking lever switch Parking lever
1 NSW
(Internal disconnection) Free position Lock position
Between (A) (B) Max. 1 z Min. 1 Mz
Possible causes
Between (A) (B) Min. 1 Mz Max. 1 z
and standard
Disconnection in wiring har- Wiring harness between NSW (female) (B)
Resistance Max. 1 z
ness (Disconnection in wir- merged point of circuit
2
ing or defective contact in Wiring harness between NSW (female) (C)
Resistance Max. 1 z
connector) merged point of circuit
Wiring harness between NSW (female) (A)
Resistance Max. 1 z
chassis ground
20-520 D475A-5
(1)
When error codes [DD14KA] and [DDQ2KA] occurred at the same time
Possible causes
and standard Short circuit of wiring harness between NSW
(female) (B) TMCN1 (female) (18) STCN2 Voltage Max. 1 V
value in normal 3 harness (Contact with 24 V
state (female) (5) with chassis ground
circuit)
Short circuit of wiring harness between NSW
(female) (C) TMCN1 (female) (12) STCN2 Voltage Max. 1 V
Circuit diagram related to parking brake switch
D475A-5 20-521
(1)
ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
Action code Error code Parking lever switch: Short circuit (KB)
Trouble
CALL E03 DD14KB (Transmission controller system)
Contents of
Signals of two systems of parking lever switch circuit were turned ON (CLOSE) at the same time.
trouble
Action of
controller
Problem that
appears on
machine
Depending on where problem occurs, related codes may be displayed at the same time.
(Related code: DDQ2KB, DDQ2L4).
Related
information
(Code 40905: Transmission controller input signal 1)

1 NSW
Possible causes Wiring harness between NSW (female) (B)
TMCN1 (female) (18) STCN2 (female) (5) Resistance Min. 1 Mz
with chassis ground
value in normal (Contact with ground circuit)
state Wiring harness between NSW (female) (C)
TMCN1 (female) (12) STCN2 (female) (15) Resistance Min. 1 Mz
with chassis ground
Parking lever
TMCN1
Defective transmission con- Free position Lock position
3
troller Between (18)
Max. 1 V 5 11 V
chassis ground
Between (12)
5 11 V Max. 1 V
chassis ground
20-522 D475A-5
(1)
D475A-5 20-523
(1)
TROUBLESHOOTING DDN2LD
ERROR CODE [DDN2LD] (BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM:
REFER TO TABLE (LD))
Action code Error code Blade tilt right oil pressure switch system: Refer to table (LD)
Trouble
E02 DDN2LD (Transmission controller system)
Contents of
The signal of the blade tilt right oil pressure switch circuit is kept turned ON for 180 seconds.
trouble
controller Recognizes that the oil pressure switch is turned OFF.
Problem that
appears on During right dual tilt operation, tilting is not limited.
machine
The input state (ON/OFF) from the blade tilt right oil pressure switch can be checked in the monitoring
Related
mode. (Code 40908: Blade lever oil pressure switch input state)
information
Method of reproducing error code: Turn the starting switch ON (Error is reproduced after 180 seconds).

Wrong operation of lever If the error code lamp still lights up (resetting is still urged) after the
1 (When electrical system is reproductive operation is performed, it is suspected that the lever was
normal) operated to cause an error.
aPrepare with starting switch OFF, then start engine and carry out trou-
Defective blade tilt right oil bleshooting.
2 pressure switch TRS (male) Blade lever Resistance
(Internal short circuit) Neutral Min. 1 Mz
Possible causes Between (1) and (2)
Right tilt Max. 1 z
and standard
value in normal
state
(Contact with ground circuit) (female) (6) and TRS (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
Defective transmission TMCN2, TMCN1 Blade lever Voltage
4
controller
Between TMCN2 (6) Neutral 5 11 V
and TMCN1 (10) Right tilt Max. 1 V
Circuit diagram related to blade tilt right oil pressure switch
20-524 D475A-5
(1)
TROUBLESHOOTING DDN3LD
ERROR CODE [DDN3LD] (BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM:
REFER TO TABLE (LD))
Action code Error code Blade tilt left oil pressure switch system: Refer to table (LD)
Trouble
E02 DDN3LD (Transmission controller system)
Contents of
The signal of the blade tilt left oil pressure switch circuit is kept turned ON for 180 seconds.
trouble
controller Recognizes that the oil pressure switch is turned OFF.
Problem that
appears on During left dual tilt operation, tilting is not limited.
machine
The input state (ON/OFF) from the blade tilt left oil pressure switch can be checked in the monitoring
Related
mode. (Code 40908: Blade lever oil pressure switch input state)
information

1 (When electrical system is reproductive operation is performed, it is suspected that the lever was
normal) operated to cause an error.
Defective blade tilt left oil bleshooting.
2 pressure switch (Internal TLS (male) Blade lever Resistance
short circuit) Neutral Min. 1 Mz
Left tilt Max. 1 z
and standard
value in normal
state
(Contact with ground circuit) (female) (16) and TLS (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
Defective transmission TMCN2, TMCN1 Blade lever Voltage
4
controller
and TMCN1 (10) Left tilt Max. 1 V
Circuit diagram related to blade tilt left oil pressure switch
D475A-5 20-525
(1)
TROUBLESHOOTING DDN7KA
ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA))
Action code Error code Blade pitch switch: Disconnection (KA)

Trouble
E02 DDN7KA (Transmission controller system)
Contents of
The signals of the 2 blade pitch switch circuit systems are turned OFF (opened) simultaneously.
trouble
controller Recognizes that the switch is not pressed.
Problem that
appears on The blade is not pitched (When pitching operation is performed, the blade is tilted).
machine
"NO" of the 2 switch system signals is for detection of operations and "NC" is for detection of errors.
Related The input state (ON/OFF) from the blade pitch switch can be checked in the monitoring mode.
information (Code 70300: Blade lever knob switch input signal)
Method of reproducing error code: Turn the starting switch ON + (Operate blade tilt switch).

Blade pitch switch
P03 (male)
Defective blade pitch switch OFF (Released) ON (Pressed)
1
Max. 1 z Min. 1 Mz
(1) and (5)
Resistance between
Min. 1 Mz Max. 1 z
(1) and (2)
Disconnection in wiring Wiring harness between TMCN2 (female) (15)
Resistance Max. 1 z
harness (Disconnection in and P03 (female) (5)
2
Resistance Max. 1 z
contact in connector) and P03 (female) (2)
and P03 (female) (1)
and standard
(female) (15) and P03 (female) (5) and chassis Voltage Max. 1 V
ground
(Contact with 24-V circuit)
(female) (5) and P03 (female) (2) and chassis Voltage Max. 1 V
ground
Blade pitch switch
TMCN1, TMCN2
OFF (Released) ON (Pressed)
Defective transmission Voltage between
4
controller TMCN2 (15) and Max. 1 V 5 11 V
TMCN1 (10)
Voltage between
TMCN2 (5) and 5 11 V Max. 1 V
TMCN1 (10)
20-526 D475A-5
(1)
Circuit diagram related to blade pitch switch and blade tilt switch
D475A-5 20-527
(1)
TROUBLESHOOTING DDN7KB
ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))

Trouble Blade pitch switch: Short circuit (KB) (Transmission controller system)
E02 DDN7KB
Contents of
Signals of two systems of blade pitch switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
appears on Blade pitch does not function (Operating blade pitch causes tilt operation.)
machine
Related Input state (ON/OFF) from blade pitch switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input)
Method of reproducing error code: Turn starting switch ON and operate blade tilt switch.

Blade pitch switch
P03 (male)
Defective blade pitch switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(1) (5)
Resistance between
Min. 1 Mz Max. 1 z
(1) (2)
(female) (15) P03 (female) (5) with chassis Voltage Max. 1 V
ground
Blade pitch switch
TMCN1, TMCN2
3
(10)
Voltage between
(10)
20-528 D475A-5
(1)
Circuit diagram related to blade pitch switch & blade tilt switch
D475A-5 20-529
(1)
ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA))

Trouble Blade tilt switch: Disconnection (KA) (Transmission controller system)
E01 DDN9KA
Contents of
Signals of two systems of blade tilt switch circuit were turned OFF (OPEN) at the same time.
trouble
Action of
Recognizes switch is set at SINGLE side.
controller
Problem that
appears on Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.)
machine
Related Input state (ON/OFF) from blade tilt switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input signal)
Method of reproducing error code: Turn starting switch ON (and operate blade tilt switch).

Blade tilt switch
P03 (male)
Defective blade tilt switch SINGLE DUAL
1
Max. 1 z Min. 1 Mz
(3) (6)
Resistance between
Min. 1 Mz Max. 1 z
(3) (4)
Resistance Max. 1 z
ness (Disconnection in wir- P03 (female) (6)
2
Resistance Max. 1 z
connector) P03 (female) (4)
P03 (female) (3)
and standard
ground
circuit)
ground
Blade tilt switch
TMCN1, TMCN2
SINGLE DUAL
4
(10)
Voltage between
(10)
20-530 D475A-5
(1)
D475A-5 20-531
(1)
ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB))

Trouble Blade tilt switch: Short circuit (KB) (Transmission controller system)
E01 DDN9KB
Contents of
Signals of two systems of blade tilt switch circuit were turned ON (CLOSE) at the same time.
trouble
Action of
Recognizes switch is set at SINGLE side.
controller
Problem that
appears on Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.)
machine
Related Input state (ON/OFF) from blade tilt switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input state)
Method of reproducing error code: Turn starting switch ON (and operate blade tilt switch).

Blade tilt switch
P03 (male)
Defective blade tilt switch SINGLE DUAL
1
Max. 1 z Min. 1 Mz
(3) (6)
Resistance between
Min. 1 Mz Max. 1 z
(3) (4)
ground
Blade tilt switch
TMCN1, TMCN2
SINGLE DUAL
3
(10)
Voltage between
(10)
20-532 D475A-5
(1)
D475A-5 20-533
(1)
TROUBLESHOOTING DDNALD
ERROR CODE [DDNALD] (BLADE LIFT RAISE FULL OIL PRESSURE SWITCH: REFER
TO TABLE (LD))
Action code Error code Blade lift raise full oil pressure switch: Refer to table (LD)
Trouble
DDNALD (Transmission controller system)
Contents of
The signal of the blade lift raise full oil pressure switch circuit is kept turned ON for 180 seconds.
trouble
Action of
Recognizes that the oil pressure switch is turned OFF.
controller
Problem that
appears on The data of the VHMS may become abnormal.
machine
The input state (ON/OFF) from the blade lift raise full oil pressure switch can be checked in the moni-
Related
toring mode. (Code 40908: Ripper lever oil pressure switch input signal)
information

Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after the
1 (When electrical system is resetting operation is performed, it is suspected that the lever was oper-
normal) ated to cause an error.
Defective blade lift raise full bleshooting.
2 oil pressure switch BLU (male) Blade lever Resistance
Raise Max. 1 z
and standard
value in normal
state
(Contact with ground circuit) (female) (36) and BLU (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
Defective transmission TMCN1, TMCN2 Ripper lever Voltage
4
controller
and TMCN1 (10) Tilt in Max. 1 V
Circuit diagram related to blade lift raise full oil pressure switch
20-534 D475A-5
(1)
TROUBLESHOOTING DDNBLD
ERROR CODE [DDNBLD] (RIPPER LIFT RAISE OIL PRESSURE SWITCH: REFER TO
TABLE (LD))
Action code Error code Ripper lift raise oil pressure switch: Refer to table (LD)
Trouble
DDNBLD (Transmission controller system)
Contents of
The signal of the ripper lift raise oil pressure switch circuit is kept turned ON for 60 seconds.
trouble
Action of
controller
Problem that
appears on The shoe slip control (SSC) function does not operate normally.
machine
The input state (ON/OFF) from the ripper lift raise oil pressure switch can be checked in the monitoring
Related
mode. (Code 70305: Steering controller input signal 3)
information

Defective ripper lift raise oil bleshooting.
2 pressure switch RPU (male) Ripper lever Resistance
Raise Max. 1 z
and standard
value in normal
state
(Contact with ground circuit) (female) (3) and RPU (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
4
controller
and TMCN1 (10) Raise Max. 1 V
Circuit diagram related to ripper lift raise oil pressure switch
D475A-5 20-535
(1)
TROUBLESHOOTING DDNCLD
ERROR CODE [DDNCLD] (RIPPER LIFT LOWER OIL PRESSURE SWITCH: REFER TO
TABLE (LD))
Action code Error code Ripper lift lower oil pressure switch: Refer to table (LD)
Trouble
DDNCLD (Transmission controller system)
Contents of
The signal of the ripper lift lower oil pressure switch circuit is kept turned ON for 60 seconds.
trouble
Action of
controller
Problem that
machine
The input state (ON/OFF) from the ripper lift lower oil pressure switch can be checked in the monitoring
Related
mode. (Code 70305: Steering controller input signal 3)
information

Defective ripper lift lower oil bleshooting.
2 pressure switch RPD (male) Ripper lever Resistance
Lower Max. 1 z
and standard
value in normal
state
(Contact with ground circuit) (female) (3) and RPD (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
4
controller
and TMCN1 (10) Lower Max. 1 V
Circuit diagram related to ripper lift lower oil pressure switch
20-536 D475A-5
(1)
TROUBLESHOOTING DDNDLD
ERROR CODE [DDNDLD] (RIPPER TILT IN OIL PRESSURE SWITCH: REFER TO TABLE
(LD))
Action code Error code Ripper tilt in oil pressure switch: Refer to table (LD)
Trouble
DDNDLD (Transmission controller system)
Contents of
The signal of the ripper tilt in oil pressure switch circuit is kept turned ON for 60 seconds.
trouble
Action of
controller
Problem that
machine
The input state (ON/OFF) from the ripper tilt in oil pressure switch can be checked in the monitoring
Related
mode. (Code 70305: Ripper lever oil pressure switch input signal)
information

Defective ripper tilt in oil bleshooting.
2 pressure switch (Internal RT1 (male) Ripper lever Resistance
short circuit) Neutral Min. 1 Mz
Tilt in Max. 1 z
and standard
value in normal
state
(Contact with ground circuit) (female) (2) and RT1 (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
4
controller
and TMCN1 (10) Tilt in Max. 1 V
Circuit diagram related to ripper tilt in oil pressure switch
D475A-5 20-537
(1)
TROUBLESHOOTING DDNELD
ERROR CODE [DDNELD] (RIPPER TILT BACK OIL PRESSURE SWITCH: REFER TO
TABLE (LD))
Action code Error code Ripper tilt back oil pressure switch: Refer to table (LD)
Trouble
DDNELD (Transmission controller system)
Contents of
The signal of the ripper tilt back oil pressure switch circuit is kept turned ON for 60 seconds.
trouble
Action of
controller
Problem that
The shoe slip control (SSC) function does not operate normally.
appears on
The tilt back speed of the ripper lowers.
machine
The input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked in the monitoring
Related
mode. (Code 70305: Ripper lever oil pressure switch input signal)
information

Defective ripper tilt back oil bleshooting.
2 pressure switch RT8 (male) Ripper lever Resistance
Tilt back Max. 1 z
and standard
value in normal
state
(Contact with ground circuit) (female) (38) and RT8 (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
4
controller
and TMCN1 (10) Tilt back Max. 1 V
Circuit diagram related to ripper tilt back oil pressure switch
20-538 D475A-5
(1)
TROUBLESHOOTING DDNFLD
ERROR CODE [DDNFLD] (BLADE LIFT LOWER FULL OIL PRESSURE SWITCH: REFER
TO TABLE (LD))
Action code Error code Blade lift lower full pressure switch: Refer to table (LD)
Trouble
DDNFLD (Transmission controller system)
Contents of
The signal of the blade lift lower full oil pressure switch circuit is kept turned ON for 60 seconds.
trouble
Action of
controller
Problem that
appears on The lift lower speed of the blade lowers.
machine
The input state (ON/OFF) from the blade lift lower full oil pressure switch can be checked in the moni-
Related
toring mode. (Code 40908: Ripper lever oil pressure switch input signal)
information

Defective blade lift lower full bleshooting.
2 oil pressure switch BLD (male) Blade lever Resistance
Lower full Max. 1 z
and standard
value in normal
state
(Contact with ground circuit) (female) (26) and BLD (female) (1) and chassis Resistance Min. 1 Mz
ground
bleshooting.
4
controller
TMCN2 (26) Neutral 5 11 V
TMCN1 (10) Tilt in Max. 1 V
Circuit diagram related to blade lift lower full oil pressure switch
D475A-5 20-539
(1)
TROUBLESHOOTING DDQ2KA
ERROR CODE [DDQ2KA] (PARKING LEVER SWITCH: DISCONNECTION (KA))
Action code Error code Parking lever switch: Disconnection (KA)

Trouble
CALL E03 DDQ2KA (Transmission controller system)
Contents of
Signals of two systems of parking lever switch circuit were turned OFF (OPEN) at the same time.
trouble
Action of
controller
Problem that
appears on
machine
Depending on where problem occurs, related codes may be displayed at the same time. (Related code:
DD14KA, DDQ2L4).
Related
information
(Code 40907: Blade lever knob switch input signal)
When error code [DDQ2KA] occurred alone

ing or defective contact in branched point of circuit JS3
connector) Wiring harness between STCN2 (female) (15)
branched point of circuit JSB
and standard
value in normal
state
Parking lever
STCN2
Free position Lock position
Between (5)
Max. 1 V 5 11 V
chassis ground
Between (15)
5 11 V Max. 1 V
chassis ground
When error codes [DDQ2KA] and [DD14KA] occurred at the same time
1 NSW
Possible causes
and standard
Disconnection in wiring har- Wiring harness between NSW (female) (B)
Resistance Max. 1 z
ness (Disconnection in wir- merged point of circuit JS3
2
ing or defective contact in Wiring harness between NSW (female) (C)
Resistance Max. 1 z
connector) merged point of circuit JSB
Wiring harness between NSW (female) (A)
Resistance Max. 1 z
chassis ground
20-540 D475A-5
(1)
TROUBLESHOOTING DDQ2KA
When error codes [DDQ2KA] and [DD14KA] occurred at the same time
Possible causes
and standard Short circuit of wiring harness between NSW
(female) (B) TMCN1 (female) (18) STCN2 Voltage Max. 1 V
value in normal 3 harness (Contact with 24 V
state (female) (5) with chassis ground
circuit)
(female) (C) TMCN1 (female) (12) STCN2 Voltage Max. 1 V
D475A-5 20-541
(1)
TROUBLESHOOTING DDQ2KB
ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB))
Action code Error code Parking brake lever switch: Short circuit (KB)
Trouble
CALL E03 DDQ2KB (Steering controller system)
Contents of
Signals of both parking brake lever switch circuit systems are turned ON (closed) simultaneously.
trouble
Action of
Recognizes that parking brake lever is at FREE position.
controller
Problem that
appears on
machine
aSince parking brake switch signal is used by both transmission controller and steering controller, related
codes may be displayed simultaneously, depending on troubled part. (Related codes: DD14KB,
DDQ2L4)
Related
NO and NC signals of both switch systems are for detecting operation and error respectively.
information
Inputting from parking brake switch (ONOFF) can be checked in monitoring mode.
(Code 40907: Blade control lever knob switch input signal)
Method of reproducing error code: Turn starting switch ON and operate parking brake lever.
When error codes [DDQ2KA] and [DD14KA] are displayed simultaneously

Defective parking brake Parking brake lever
1 lever switch (Internal short NSW
At FREE At LOCK
circuit)
and standard (female) (B) TMCN1 (female) (18) STCN2 Resistance Min. 1 Mz
value in normal (Contact with ground circuit)
state Short circuit of wiring harness between NSW
(female) (C) TMCN1 (female) (12) STCN2 Resistance Min. 1 Mz
Parking brake lever
STCN2
At FREE At LOCK
Between (5)
Max. 1 V 5 11 V
chassis ground
Between (15)
5 11 V Max. 1 V
chassis ground
20-542 D475A-5
(1)
TROUBLESHOOTING DDQ2KB
D475A-5 20-543
(1)
TROUBLESHOOTING DDQ2L4
ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4))
Action code Error code Parking brake lever switch: See table (L4)
Trouble
CALL E03 DDQ2L4 (Steering controller system)
Contents of Switch input signal of steering controller disagrees with communication signal from transmission con-
trouble troller.
Problem that
appears on
machine
aSince parking brake switch signal is used by both transmission controller and steering controller and
information is exchanged by CAN communication, related codes may be displayed simultaneously, de-
pending on troubled part. (Related codes: DAFRKR, DB2RKR, DB3RKR, DAQRKR, DD14KA,
Related
DD14KB, DDQ2KA, DDQ2KB)
information
Inputting from parking brake switch (ONOFF) can be checked in monitoring mode.
(Code 40907: Parking brake lever switch input signal)
Method of reproducing error code: Turn starting switch ON and operate parking brake lever.

See if error codes [DAFRKR], [DBBQKR], [DB3RKR], and [DAQRKR]
Possible causes Defective CAN communica-
1 are displayed. If they are displayed, carry out troubleshooting for them
and standard tion signal system
first.
value in normal
Defective parking brake See if error codes [DD14KA], [DD14KB], [DDQ2KA], and [DDQ2KB] are
state 2
lever switch signal system displayed. If they are displayed, carry out troubleshooting for them first.
3 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
20-544 D475A-5
(1)
TROUBLESHOOTING DGE1KB
(ENGINE OIL TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB)) (30 MINUTES
AFTER ENGINE IS STARTED (ABOVE 500 RPM))
Action code Error code Engine oil temperature sensor system: Short circuit (KB)
Trouble (30 minutes after engine is started (above 500 rpm))
DGE1KB (VHMS controller system)
Contents of
The signal voltage of the engine oil temperature sensor is above 4.9 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The engine oil temperature cannot be monitored with the monitoring function.
machine
Related
information

ENGT (male) Engine oil temperature Resistance
Before
Defective engine oil engine is 25C Approx. 35 50 kz
1
temperature sensor started
Between (1) and (2) After
engine is
100C Approx. 3.3 4.3 kz
warmed
Possible causes
up
and standard
Short circuit in wiring Resistance between wiring har-
2 Wiring harness
ness between V2A (female) (3) and
harness between V2A (female)
ENGT (female) (2) and wiring har- Min. 1 Mz
(3), (12) and ENGT
ness between V2A (female) (12)
(female) (2), (1)
and ENGT (female) (1)
3 ground in wiring harness Wiring harness Resistance between V2A (female)
(Contact with ground circuit) between V2A (female) (3), ENGT (female) (1) and chassis Min. 1 Mz
and ENGT (female) ground
Circuit diagram related to engine oil temperature sensor
D475A-5 20-545
(1)
TROUBLESHOOTING DGE1KY
ERROR CODE [DGE1KY] (OR LED OF VHMS CONTROLLER INDICATES "n2" o "41")
(ENGINE OIL TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KY))
Action code Error code Engine oil temperature sensor system: Disconnection (KY)
Trouble
DGE1KY (VHMS controller system)
Contents of
The signal voltage of the engine oil temperature sensor is below 0.3 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The engine oil temperature cannot be monitored with the monitoring function.
machine
Related
information

ENGT (male) Engine oil temperature Resistance
Before
Defective engine oil engine is 25C Approx. 35 50 kz
1
temperature sensor started
Possible causes
and standard
engine is
value in normal 100C Approx. 3.3 4.3 kz
warmed
state
up
harness (Disconnection in Wiring harness between V2A (female) (3) and
wiring harness or defective ENGT (female) (1)
contact) Wiring harness between V2A (female) (12) and
Resistance Max. 1 z
ENGT (female) (2)
Circuit diagram related to engine oil temperature sensor
20-546 D475A-5
(1)
TROUBLESHOOTING DGE2KX
ERROR CODE [DGE2KX] (COOLANT TEMPERATURE SENSOR: OUT OF INPUT SIG-

NAL RANGE (KX))
Action code Error code Engine coolant temperature: Out of input signal range (KX)
Trouble
E02 DGE2KX (Engine controller system)
Contents of The input voltage from the engine coolant temperature sensor (high temperature) is below 0.3 V or
trouble above 4.7 V.
Action of
Assumes the engine coolant temperature to be 90C for control.
controller
Problem that
appears on
machine
The signals of the engine coolant temperature sensor (high temperature) are used by the monitor panel,
Related too. Depending on the cause of the trouble, the engine coolant temperature gauge may not indicate
information normally.
Method of reproducing error code: Turn the starting switch ON or start the engine.

Defective engine coolant out turning starting switch ON.
temperature sensor 402 (male) Resistance
1 (high temperature)
(Internal disconnection or Between (1) and (2) 3.8 k 80 kz
short circuit) Between (1), (2) and
Min. 1 Mz
chassis ground
harness (Disconnection in Wiring harness between LE32 (female) (5),
wiring harness or defective JM6, and 402 (female) (1)
contact in connector) Wiring harness between LE31 (female) (16),
Resistance Max. 1 z
JE3, and 402 (female) (2)
value in normal 3 ground in wiring harness Between wiring harness between LE32
state (Contact with ground circuit) (female) (5), JM6, 402 (female) (1), or S04 Resistance Min. 1 Mz
(female) (11) and chassis ground
(Contact with 24-V circuit) (female) (5), JM6, 402 (female) (1), or S04 Voltage Max. 1 V
LE31 (female), LE32 (female) Resistance
Between LE32 (5) and LE31 (16) 3.8 k 80 kz
If none of causes 1 5 is the cause of the trouble, the monitor panel may
6 Defective monitor panel be defective (Troubleshooting cannot be carried out since the defect is
in the monitor panel).
20-548 D475A-5
(1)
TROUBLESHOOTING DGE2KX
Circuit diagram related to engine coolant temperature sensor (high temperature)
D475A-5 20-549
(1)
TROUBLESHOOTING DGE3KA
ERROR CODE [DGE3KA] (ENGINE COOLANT TEMPERATURE SENSOR GAUGE) (FOR

LOW TEMPERATURE): DISCONNECTION (KA))
Action code Error code Engine coolant temperature sensor (for low temperature): Disconnec-
Trouble tion (KA)
DGE3KA
(Steering controller system)
Contents of
The signal voltage of the engine coolant temperature sensor is above 4.7 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The automatic preheater does not operate.
machine
The state (temperature) of the engine coolant temperature can be checked in the monitoring mode.
Related
(Code 04104: Engine coolant temperature (on low temperature side))
information

Defective engine low cool- out turning starting switch ON.
ant temperature sensor
1 LCT (male) Resistance
(Internal discoloration or
short circuit) Between LCT (1) and
0.2 k 20 kz
chassis ground
2
wiring harness or defective Wiring harness between STCN1 (female) (20)
and LCT (female) (1)
and standard
Between wiring harness between STCN1
(female) (20) and LCT (female) (1)
Between STCN1 (female) (20) and chassis 0.2 k
Resistance
4 Defective steering controller ground 20 kz
(female) (20) and LCT (female) (1) and chassis Resistance Min. 1 Mz
ground
Circuit diagram related to engine low coolant temperature sensor
20-550 D475A-5
(1)
TROUBLESHOOTING DGE5KB
(ATMOSPHEREIC TEMPERATURE SENSOR SYSTEM: DISCONNECTION OR SHORT
CIRCUIT (KY OR KB))
Action code Error code Trouble in atmospheric temperature sensor system: (KA or KB)
Trouble
DGE5KB (VHMS controller system)
Contents of
The input signal voltage of the atmospheric temperature sensor is above 4.9 V or below 0.3 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The atmospheric temperature cannot be monitored with the monitoring function.
machine
Related
information

Atmospheric
Defective atmospheric ATMO (male) Resistance
1 temperature
temperature sensor
0C Approx. 10 15 kz
Between (1) and (2) 20C Approx. 3 5 kz
50C Approx. 1 2 kz
Possible causes harness (Disconnection in Wiring harness between V2A (female) (11) and
and standard wiring harness or defective ATMO (female) (1)
value in normal contact) Wiring harness between V2A (female) (12) and
ATMO (female) (2)
Short circuit in wiring Wiring harness between V2A (female) (11) and
3 Resistance Min. 1 Mz
harness ATMO (female) (2)
Wiring harness between V2A (female) (12) and
ATMO (female) (1)
(11) and ATMO (female) (1)
Circuit diagram related to fuel temperature sensor
D475A-5 20-551
(1)
TROUBLESHOOTING DGS1KX
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL

IS OUT OF NORMAL RANGE (KX))
Action code Error code Hydraulic oil temperature sensor: Input signal is out of normal range
Trouble
DGS1KX (KX) (Transmission controller system)
Contents of
Hydraulic oil temperature sensor signal is out of normal range.
trouble
Action of
Does not take any particular action.
controller
Problem that
appears on Hydraulic oil temperature gauge of monitor panel may not display normally.
machine
Hydraulic oil temperature (temperature) can be checked in monitoring mode.
Related
(Code 04401: Hydraulic oil temperature)
information
Method of reproducing error code: Turn starting switch ON or start engine.

Defective hydraulic oil tem- out turning starting switch ON.
perature sensor (Internal
1 SDS (male) Resistance
disconnection or short cir-
Between (1) (2) 3.5 k 90 kz
cuit)
Between (1) chassis ground Min. 1 Mz
ing or defective contact in SDS (female) (1)
Resistance Max. 1 z
SDS (female) (2)
Possible causes
value in normal
state 3 ground in wiring harness Short circuit of wiring harness between TMCN2
(Contact with ground circuit) (female) (14) SDS (female) (1) with chassis Resistance Min. 1 Mz
ground
Short circuit with power out troubleshooting.
4 source in wiring harness Short circuit of wiring harness between TMCN1
(Contact with 24 V circuit) (female) (14) SDS (female) (1) with chassis Voltage Max. 1 V
ground
Defective transmission con- TMCN1 (female) Resistance
5
troller
Between (14) (21) 1 k 50 kz
Circuit diagram related to hydraulic oil temperature sensor
20-552 D475A-5
(1)
TROUBLESHOOTING DGT5KA
(LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KA))
Action code Error code Left bank exhaust temperature sensor system: Disconnection (KA)
Trouble
DGT5KA (VHMS controller system)
Contents of
The signal voltage of the left bank exhaust temperature sensor is below 0.3 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The left bank exhaust temperature cannot be monitored with the monitoring function.
machine
Related
information

Abnormal rise of left bank
1 exhaust temperature Check the engine, then repair it if it has any abnormality.
When the left bank exhaust temperature sensor
Defective left bank exhaust Exhaust temperature
2 is replaced, the condition does not become nor-
temperature sensor sensor is normal
mal.
When the left bank exhaust temperature sensor Exhaust temperature
is replaced, the condition becomes normal. sensor is defective
bleshooting.
Between (A) and (C) Voltage 20 30 V
Before
Approx.
Possible causes Defective left bank exhaust engine is 20C Voltage
3 temperature sensor 0.9 1.2 V
and standard EX1L started
value in normal amplifier V1, V2A Between After
state line (B) and (C) engine is
Approx.
started 500C Voltage
2.6 3.5 V
(with no
load)
Wiring harness between V1 (female) (2) and
Resistance Max. 1 z
EX1L (female) (A)
Disconnection in wiring Wiring harness between V2A (female) (7) and
Resistance Max. 1 z
harness (Disconnection in EX1L (female) (B)
4
wiring harness or defective Wiring harness between V2A (female) (13) and
contact) Resistance Max. 1 z
EX1L (female) (C)
Wiring harness between EX2L (female) (1) and
Resistance Max. 1 z
EXHL (female) (1)
Wiring harness between EX2L (female) (2) and
Resistance Max. 1 z
EXHL (female) (2)
20-554 D475A-5
(1)

bleshooting.
bleshooting.
Possible causes
and standard V2A Exhaust temperature Voltage
value in normal 5 Defective VHMS controller Before
state engine is 20C Approx. 0.9 1.2 V
started
engine is
started 500C Approx. 2.6 3.5 V
(with no
load)
Circuit diagram related to left bank exhaust temperature sensor
D475A-5 20-555
(1)
TROUBLESHOOTING DGT5KB
(LEFT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB))
Action code Error code Left bank exhaust temperature sensor system: Short circuit (KB)
Trouble
DGT5KB (VHMS controller system)
Contents of
The signal voltage of the left bank exhaust temperature sensor is above 4.9 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The left bank exhaust temperature cannot be monitored with the monitoring function.
machine
Related
information

When the left bank exhaust temperature sensor
Defective left bank exhaust Exhaust temperature
1 is replaced, the condition does not become nor-
temperature sensor sensor is normal
mal.
When the left bank exhaust temperature sensor Exhaust temperature
is replaced, the condition becomes normal. sensor is defective
bleshooting.
Before
Approx.
Defective left bank exhaust engine is 20C Voltage
2 temperature sensor 0.9 1.2 V
EX1L started
amplifier V1, V2A Between After
Possible causes line (B) and (C) engine is
and standard Approx.
value in normal 2.6 3.5 V
(with no
state
load)
(2) and EX1L (female) (A) and chassis ground
3 ground in wiring harness Resistance Min. 1 Mz
(7) and EX1L (female) (B) and chassis ground
Between wiring harness between EX2L (male)
(1) and EXHL (female) (1) and chassis ground
Between wiring harness between EX2L (male)
(2) and EXHL (male) (2) and chassis ground
(Contact with 24-V circuit) Resistance Min. 1 Mz
(2) and EX1L (female) (B), (C)
20-556 D475A-5
(1)

bleshooting.
bleshooting.
Possible causes
started
engine is
(with no
load)
D475A-5 20-557
(1)
(RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: DISCONNECTION (KA))
Action code Error code Right bank exhaust temperature sensor system: Disconnection (KA)
Trouble
DGT6KA (VHMS controller system)
Contents of
The signal voltage of the right bank exhaust temperature sensor is below 0.3 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The right bank exhaust temperature cannot be monitored with the monitoring function.
machine
Related
information

Abnormal rise of right bank
When the right bank exhaust temperature sen-
Defective right bank Exhaust temperature
2 sor is replaced, the condition does not become
exhaust temperature sensor sensor is normal
normal.
When the right bank exhaust temperature sen- Exhaust temperature
sor is replaced, the condition becomes normal. sensor is defective
bleshooting.
Before
Approx.
Possible causes Defective right bank engine is 20C Voltage
3 exhaust temperature sensor EX1R 0.9 1.2 V
and standard started
value in normal amplifier V1, V2A Between After
state line (B) and (C) engine is
Approx.
2.6 3.5 V
(with no
load)
Wiring harness between V1 (female) (2) and
Resistance Max. 1 z
EX1R (female) (A)
Disconnection in wiring Wiring harness between V2A (female) (5) and
Resistance Max. 1 z
harness (Disconnection in EX1R (female) (B)
4
wiring harness or defective Wiring harness between V2A (female) (13) and
contact) Resistance Max. 1 z
EX1R (female) (C)
Wiring harness between EX2R (female) (1) and
Resistance Max. 1 z
EXHR (female) (1)
Wiring harness between EX2R (female) (2) and
Resistance Max. 1 z
EXHR (female) (2)
20-558 D475A-5
(1)

bleshooting.
bleshooting.
Possible causes
started
engine is
(with no
load)
Circuit diagram related to right bank exhaust temperature sensor
D475A-5 20-559
(1)
(RIGHT BANK EXHAUST TEMPERATURE SENSOR SYSTEM: SHORT CIRCUIT (KB))
Action code Error code Right bank exhaust temperature sensor system: Short circuit (KB)
Trouble
DGT6KB (VHMS controller system)
Contents of
The signal voltage of the right bank exhaust temperature sensor is above 4.9 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The right bank exhaust temperature cannot be monitored with the monitoring function.
machine
Related
information

When the right bank exhaust temperature sen-
Defective right bank Exhaust temperature
1 sor is replaced, the condition does not become
exhaust temperature sensor sensor is normal
normal.
When the right bank exhaust temperature sen- Exhaust temperature
sor is replaced, the condition becomes normal. sensor is defective
bleshooting.
Before
Approx.
Defective right bank engine is 20C Voltage
2 exhaust temperature sensor EX1R 0.9 1.2 V
started
amplifier V1, V2A Between After
Possible causes line (B) and (C) engine is
and standard Approx.
value in normal 2.6 3.5 V
(with no
state
load)
(2) and EX1R (female) (A) and chassis ground
3 ground in wiring harness Resistance Min. 1 Mz
(5) and EX1R (female) (B) and chassis ground
Between wiring harness between EX2R (male)
(1) and EXHR (female) (1) and chassis ground
Between wiring harness between EX2R (male)
(2) and EXHR (male) (2) and chassis ground
(2) and EX1R (female) (B), (C)
20-560 D475A-5
(1)

bleshooting.
Between V1 (2) and chassis ground Voltage 20 30 V
bleshooting.
Possible causes
started
engine is
(with no
load)
D475A-5 20-561
(1)
TROUBLESHOOTING DH22KA
ERROR CODE [DH22KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (F):
DISCONNECTION (KA))
Action code Error code Work equipment pump oil pressure sensor (F): Disconnection (KA)
Trouble
DH22KA (Transmission controller system)
Contents of
Signal voltage of work equipment pump oil pressure sensor (F) circuit is below 0.5 V.
trouble
Action of
controller
Problem that
appears on Work equipment pump (F) oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment pump oil pressure sensor (F) can be checked in monitoring mode.
Related
(Code 70701: Voltage of work equipment pump oil sensor (F))
information

Defective 24 V power See if error code [DAQ6KK] is displayed. If it is displayed, carry out trou-
1
source system bleshooting for it first.
Defective work equipment out troubleshooting.
2 pump oil pressure sensor
HP1 Voltage
(F) (Internal trouble)
Between (C) (A) 0.5 6.0 V
Possible causes ness (Disconnection in wir- Wiring harness between TMCN1 (female) (16)
and standard ing or defective contact in HP1 (female) (B)
value in normal connector) Wiring harness between TMCN1 (female) (9)
HP1 (female) (C)
(Contact with ground circuit) (female) (9) HP1 (female) (C) with chassis Resistance Min. 1 Mz
ground
Defective transmission con- out troubleshooting.
5
troller TMCN1 (female) Voltage
Between (9) (21) 0.5 6.0 V
Circuit diagram related to work equipment pump oil pressure sensor (F)
20-562 D475A-5
(1)
TROUBLESHOOTING DH22KB
ERROR CODE [DH22KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (F):
SHORT CIRCUIT (KB))
Action code Error code Work equipment pump oil pressure sensor (F): Short circuit (KB)
Trouble
DH22KB (Transmission controller system)
Contents of
Signal voltage of work equipment pump oil pressure sensor (F) circuit is above 6.0 V
trouble
Action of
controller
Problem that
appears on Work equipment pump (F) oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment pump oil pressure sensor (F) can be checked in monitoring mode.
Related
(Code 70701: Voltage of work equipment pump oil pressure sensor (F))
information

1
HP1 Voltage
(F) (Internal trouble)
Possible causes Between (C) (A) 0.5 6.0 V
and standard aPrepare with starting switch OFF, turn starting switch ON and carry
value in normal Short circuit with power out troubleshooting.
state 3 source in wiring harness Short circuit of wiring harness between TMCN1
(Contact with 24 V circuit) (female) (9) HP1 (female) (C) with chassis Voltage Max. 1 V
ground
4
Between (9) (21) 0.5 6.0 V
Circuit diagram related to work equipment pump oil pressure sensor (F)
D475A-5 20-563
(1)
TROUBLESHOOTING DH23KA
ERROR CODE [DH23KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (R):
DISCONNECTION (KA))
Action code Error code Work equipment pump oil pressure sensor (R): Disconnection (KA)
Trouble
DH23KA (Transmission controller system)
Contents of
Signal voltage of work equipment pump oil pressure sensor (R) circuit is below 0.5 V.
trouble
Action of
controller
Problem that
appears on Work equipment pump (R) oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment pump oil pressure sensor (R) can be checked in monitoring mode.
Related
(Code 70703: Voltage of work equipment pump oil sensor (R))
information

1
HP2 Voltage
(R) (Internal trouble)
Between (C) (A) 0.5 6.0 V
Possible causes ness (Disconnection in wir- Wiring harness between TMCN1 (female) (16)
and standard ing or defective contact in HP2 (female) (B)
value in normal connector) Wiring harness between TMCN1 (female) (3)
HP2 (female) (C)
(Contact with ground circuit) (female) (3) HP2 (female) (C) with chassis Resistance Min. 1 Mz
ground
5
Between (3) (21) 0.5 6.0 V
Circuit diagram related to work equipment pump oil pressure sensor (R)
20-564 D475A-5
(1)
TROUBLESHOOTING DH23KB
ERROR CODE [DH23KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR (R):
SHORT CIRCUIT (KB))
Action code Error code Work equipment pump oil pressure sensor (R): Short circuit (KB)
Trouble
DH23KB (Transmission controller system)
Contents of
Signal voltage of work equipment pump oil pressure sensor (R) circuit is above 6.0 V
trouble
Action of
controller
Problem that
appears on Work equipment pump (R) oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment pump oil pressure sensor (R) can be checked in monitoring mode.
Related
(Code 70701: Voltage of work equipment pump oil pressure sensor (R))
information

1
HP2 Voltage
(R) (Internal trouble)
Possible causes Between (C) (A) 0.5 6.0 V
and standard aPrepare with starting switch OFF, turn starting switch ON and carry
value in normal Short circuit with power out troubleshooting.
state 3 source in wiring harness Short circuit of wiring harness between TMCN1
(Contact with 24 V circuit) (female) (3) HP2 (female) (C) with chassis Voltage Max. 1 V
ground
4
Between (3) (21) 0.5 6.0 V
Circuit diagram related to work equipment pump oil pressure sensor (R)
D475A-5 20-565
(1)
TROUBLESHOOTING DHE4KA
ERROR CODE [DHE4KA] (ENGINE OIL PRESSURE SENSOR: DISCONNECTION (KA))
Action code Error code Engine oil pressure sensor: Disconnection (KA)
Trouble
E02 DHE4KA (Steering controller system)
Contents of
The signal voltage of the engine oil pressure sensor circuit is below 0.3 V.
trouble
Action of
controller
Problem that
appears on The engine oil pressure cannot be monitored.
machine
The input state (voltage) from the engine oil pressure sensor can be checked in the monitoring mode.
Related
(Code 37200: Engine oil pressure sensor voltage)
information

Defective sensor 5-V power
1 If error code [DB35KK] is displayed, carry out troubleshooting for it first.
supply system
Defective engine oil carry out troubleshooting.
2 pressure sensor
HNGP Voltage
(Internal defect)
Between (C) and (A) 0.3 6.0 V
Possible causes
harness (Disconnection in Wiring harness between STCN1 (female) (22)
and standard 3 Resistance Max. 1 z
wiring harness or defective and HNGP (female) (B)
value in normal
contact in connector) Wiring harness between STCN1 (female) (7)
and HNGP (female) (C)
(Contact with ground circuit) Between wiring harness between STCN1 Resistance Min. 1 Mz
(female) (7) and HNGP (female) (C)
STCN1 (female) Voltage
Between (7) and (21) 0.3 6.0 V
Circuit diagram related to engine oil pressure sensor
20-566 D475A-5
(1)
TROUBLESHOOTING DHE4KB
ERROR CODE [DHE4KB] (ENGINE OIL PRESSURE SENSOR: SHORT CIRCUIT (KB))
Action code Error code Engine oil pressure sensor: Short circuit (KB)
Trouble
E02 DHE4KB (Steering controller system)
Contents of
The signal voltage of the work engine oil pressure sensor circuit is above 6.0 V.
trouble
Action of
controller
Problem that
appears on The engine oil pressure cannot be monitored.
machine
The input state (voltage) from the engine oil pressure sensor can be checked in the monitoring mode.
Related
(Code 37200: Engine oil pressure sensor voltage)
information

supply system
2 pressure sensor
ENGP Voltage
Possible causes (Internal defect)
and standard
state 3 source in wiring harness
(Contact with 24-V circuit) Between wiring harness between STCN1 Voltage Max. 1 V
(female) (7) and ENGP (female) (C)
Between (7) and (21) 0.3 6.0 V
D475A-5 20-567
(1)
TROUBLESHOOTING DHE5KB
ERROR CODE [DHE5KB] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "32")
(ENGINE BLOW-BY PRESSURE SENSOR SYSTEM: DISCONNECTION (KB))
Action code Error code Engine blow-by pressure sensor system: Disconnection (KB)
Trouble
DHE5KB (VHMS controller system)
Contents of
The signal voltage of the blow-by pressure sensor is below 0.1 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The blow-by pressure cannot be monitored with the monitoring function.
machine
Related
information

Defective engine blow-by
1 ENBP Voltage
pressure sensor
Between (B) and (A) 4.5 5.5 V
Possible causes
and standard
value in normal harness (Disconnection in Wiring harness between V1 (female) (4) and
state wiring harness or defective ENBP (female) (B)
contact) Wiring harness between 2A (female) (18) and
Resistance Max. 1 z
ENBP (female) (C)
3 Defective VHMS controller Between V1 (female) (4) and V2A (female) (12) Voltage 4.5 5.5 V
Between V2A (female) (18) and V2A (female)
Voltage 0.3 0.7 V
(12)
Circuit diagram related to engine blow-by pressure sensor
20-568 D475A-5
(1)
TROUBLESHOOTING DHE5KY
ERROR CODE [DHE5KY] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "31")
(ENGINE BLOW-BY PRESSURE SENSOR SYSTEM: SHORT CIRCUIT WITH POWER
SUPPLY LINE (KY))
Action code Error code Engine blow-by pressure sensor system: Short circuit with power source
Trouble (KY)
DHE5KY (VHMS controller system)
Contents of
The signal voltage of the blow-by pressure sensor is above 4.7 V.
trouble
Action of
None in particular.
controller
Problem that
appears on The blow-by pressure cannot be monitored with the monitoring function.
machine
Related
information

Defective engine blow-by ENBP Voltage
1
pressure sensor
Between (B) and (A) 4.5 5.5 V
Possible causes
and standard Short circuit with power out turning starting switch ON.
value in normal 2 source in wiring harness
state Wiring harness between V2 (female) (18) and
(Contact with 24-V circuit) Voltage Max. 1 V
ENBP (female) (C)
3 Defective VHMS controller Between V1 (female) (4) and V2A (female) (12) Voltage 4.5 5.5 V
Voltage 0.3 0.7 V
(12)
Circuit diagram related to engine blow-by pressure sensor
D475A-5 20-569
(1)
TROUBLESHOOTING DHT3KX
ERROR CODE [DHT3KX] (OR LED OF VHMS CONTROLLER INDICATES "n6" o "14")
(TRANSMISSION OIL PRESSURE SENSOR: OUT OF INPUT SIGNAL RANGE (KX))
Action code Error code Transmission oil pressure sensor: Out of input signal range (KX)
Trouble
DHT3KX (VHMS controller system)
Contents of
The transmission oil pressure signal cannot be obtained.
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

harness (Disconnection in Wiring harness between V1 (female) (2) and
wiring harness or defective TMMD (female) (A)
contact) Wiring harness between V2A (female) (15) and
Resistance Max. 1 z
TMMD (female) (C)
Short circuit with chassis Between wiring harness between V1 (female)
Possible causes Resistance Min. 1 Mz
2 ground in wiring harness (2) and TMMD (female) (A) and chassis ground
and standard (Contact with ground circuit) Between wiring harness between V2A (female)
value in normal
(15) and TMMD (female) (C) and chassis Resistance Min. 1 Mz
state
ground
Short circuit with power out turning starting switch ON.
Wiring harness between V1A (female) (2) and
TMMD (female) (A), (C)
4 Defective VHMS controller V1A (female) and V2A (female) (13) Voltage
Below 20 30 V
(13)
Circuit diagram related to transmission oil pressure sensor
20-570 D475A-5
(1)
TROUBLESHOOTING DK01KA
ERROR CODE [DK01KA] (LEFT YOKE ANGLE SENSOR: DISCONNECTION (KA))
Action code Error code Left yoke angle sensor: Disconnection (KA)
Trouble
E02 DK01KA (Transmission controller system)
Contents of
The signal voltage of the left yoke angle sensor circuit is below 0.5 V.
trouble
Action of
controller
Problem that
appears on The tilt limiting system does not function.
machine
The input state (voltage) from the left yoke angle sensor can be checked in the monitoring mode.
Related
(Code 90002: Left yoke angle sensor voltage)
information

1 If error code [DAQ5KK] is displayed, carry out troubleshooting for it first.
supply system
Defective left yoke angle out turning starting switch ON.
sensor CSL (male) Resistance
2
(Internal disconnection or Between (A) and (C) 4.0 6.0 kz
short circuit) Between (A) and (B) 0.25 7.0 kz
Between (B) and (C) 0.25 7.0 kz
Possible causes Disconnection in wiring out turning starting switch ON.
and standard harness (Disconnection in Wiring harness between TMCN1 (female) (22)
value in normal 3 Resistance Max. 1 z
wiring harness or defective and CSL (female) (A)
state contact in connector) Wiring harness between TMCN1 (female) (7)
Resistance Max. 1 z
and CSL (female) (B)
(Contact with ground circuit) (female) (7) and CSL (female) (B) and chassis Resistance Min. 1 Mz
ground
Defective transmission carry out troubleshooting.
5
controller TMCN1 Voltage
Between (7) and (21) 0.5 4.5 V
20-572 D475A-5
(1)
Circuit diagram related to left yoke angle sensor
D475A-5 20-573
(1)
TROUBLESHOOTING DK01KB
ERROR CODE [DK01KB] (LEFT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB))
Action code Error code Left yoke angle sensor: Short circuit (KB)
Trouble
E02 DK01KB (Transmission controller system)
Contents of
The signal voltage of the left yoke angle sensor circuit is below 0.5 V or above 4.5 V.
trouble
Action of
controller
Problem that
machine
The input state (voltage) from the left yoke angle sensor can be checked in the monitoring mode.
Related
(Code 90002: Left yoke angle sensor voltage)
information

supply system
Defective left yoke angle out turning starting switch ON.
sensor CSL (male) Resistance
2
Possible causes short circuit) Between (A) and (B) 0.25 7.0 kz
and standard Between (B) and (C) 0.25 7.0 kz
state Short circuit with power carry out troubleshooting.
3 source in wiring harness Between wiring harness between TMCN1
(Contact with 24-V circuit) (female) (7) and CSL (female) (B) and chassis Voltage Max. 1 V
ground
4
Between (7) and (21) 0.5 4.5 V
Circuit diagram related to left yoke angle sensor
20-574 D475A-5
(1)
ERROR CODE [DK03KA] (RIGHT YOKE ANGLE SENSOR: DISCONNECTION (KA))
Action code Error code Right yoke angle sensor: Disconnection (KA)
Trouble
E02 DK03KA (Transmission controller system)
Contents of
The signal voltage of the right yoke angle sensor circuit is below 0.5 V.
trouble
Action of
controller
Problem that
machine
The input state (voltage) from the right yoke angle sensor can be checked in the monitoring mode.
Related
(Code 90003: Right yoke angle sensor voltage)
information

supply system
Defective right yoke angle out turning starting switch ON.
sensor CSR (male) Resistance
2
Between (B) and (C) 0.25 7.0 kz
and standard harness (Disconnection in Wiring harness between TMCN1 (female) (22)
wiring harness or defective and CSR (female) (A)
state contact in connector) Wiring harness between TMCN1 (female) (3)
Resistance Max. 1 z
and CSR (female) (B)
(Contact with ground circuit) (female) (13) and CSR (female) (B) and chassis Resistance Min. 1 Mz
ground
5
Between (13) and (21) 0.5 4.5 V
D475A-5 20-575
(1)
Circuit diagram related to right yoke angle sensor
20-576 D475A-5
(1)
ERROR CODE [DK03KB] (RIGHT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB))
Action code Error code Right yoke angle sensor: Short circuit (KB)
Trouble
E02 DK03KB (Transmission controller system)
Contents of
The signal voltage of the right yoke angle sensor circuit is below 0.5 V or above 4.5 V.
trouble
Action of
controller
Problem that
machine
The input state (voltage) from the right yoke angle sensor can be checked in the monitoring mode.
Related
(Code 90003: Right yoke angle sensor voltage)
information

supply system
Defective right yoke angle out turning starting switch ON.
sensor CSR (male) Resistance
2
Possible causes short circuit) Between (A) and (B) 0.25 7.0 kz
and standard Between (B) and (C) 0.25 7.0 kz
(Contact with 24-V circuit) (female) (3) and CSR (female) (B) and chassis Voltage Max. 1 V
ground
4
Between (13) and (21) 0.5 4.5 V
Circuit diagram related to right yoke angle sensor
D475A-5 20-577
(1)
TROUBLESHOOTING DK10KX
ERROR CODE [DK10KX] (FUEL DIAL: OUT OF INPUT SIGNAL RANGE (KX))
Action code Error code Fuel dial: Out of input signal range (KX)
Trouble
CALL E03 DK10KX (Engine controller system)
Contents of
The input voltage from the fuel dial is below 0.3 V or above 4.75 V.
trouble
Action of
controller
Fixes the engine speed at 1,300 rpm after the machine is stopped (and set in neutral).
Problem that
appears on The engine speed cannot be controlled.
machine
Related
information

Defective fuel dial DIAL (male) Resistance
1 (Internal disconnection or
Between (1) and (3) 4.0 6.0 kz
short circuit)
Between (1) and (2) 0.25 7.0 kz
Between (3) and (2) 0.25 7.0 kz
harness (Disconnection in JEA, and DIAL (female) (1)
2
contact in connector) Resistance Min. 1 Mz
JE3, and DIAL (female) (3)
Wiring harness between LE32 (female) (1) and
DIAL (female) (2)
Possible causes Between wiring harness between LE31
and standard Short circuit with chassis
(female) (6), JEA, and DIAL (female) (1) and Resistance Min. 1 Mz
chassis ground
state (Contact with ground circuit)
Between wiring harness between LE32
(female) (1) and DIAL (female) (2) and chassis Resistance Min. 1 Mz
ground
(female) (6), JEA, and DIAL (female) (1) and Voltage Max. 1 V
chassis ground
(female) (1) and DIAL (female) (2) and chassis Voltage Max. 1 V
ground
LE31, LE32 Voltage
5 Defective engine controller Between LE31 (6)
Power supply 4.6 5.4 V
and (16)
Between LE32 (1)
Signal 0.3 4.75 V
and LE31 (16)
20-578 D475A-5
(2)
Circuit diagram related to fuel dial
D475A-5 20-579
(1)
ERROR CODE [DK12KX] (DECELERATOR POTENTIOMETER: OUT OF INPUT SIGNAL

RANGE (KX))
Action code Error code Decelerator potentiometer: Out of input signal range (KX)
Trouble
CALL E03 DK12KX (Engine controller system)
Contents of
The input voltage from the decelerator potentiometer is below 0.3 V or above 4.75 V.
trouble
Action of
controller
Fixes the engine speed at 1,300 rpm after the machine is stopped (and set in neutral).
Problem that
appears on The engine speed cannot be controlled.
machine
Related
information

Defective decelerator out turning starting switch ON.
potentiometer FCD (male) Resistance
1
Between (C) and (B) 0.25 7.0 kz
harness (Disconnection in JEA, and FCD (female) (A)
2
contact in connector) Resistance Min. 1 Mz
JE3, and FCD (female) (C)
Wiring harness between LE32 (female) (11)
and FCD (female) (B)
Possible causes Between wiring harness between LE31
(female) (6), JEA, and FCD (female) (A) and Resistance Min. 1 Mz
chassis ground
state (Contact with ground circuit)
(female) (11) and FCD (female) (B) and chassis Resistance Min. 1 Mz
ground
(female) (6), JEA, and FCD (female) (A) and Voltage Min. 1 V
chassis ground
(female) (11) and FCD (female) (B) and chassis Voltage Min. 1 V
ground
LE31, LE32 Voltage
5 Defective engine controller Between LE31 (6)
and (16)
Between LE32 (6)
Signal 0.3 4.75 V
and LE31 (16)
20-580 D475A-5
(1)
Circuit diagram related to decelerator potentiometer
D475A-5 20-581
(1)
ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA))
Action code Error code Steering potentiometer 1: Disconnection (KA)

Trouble
CALL E03 DK30KA (Steering controller system)
Contents of
Signal voltage of steering potentiometer 1 system (L) is below 0.5 V.
trouble
Action of
Continues controlling with signal of steering potentiometer 2 system (R).
controller
Problem that
appears on
machine
Input (Voltage) from steering potentiometer 1 (L) can be checked in monitoring mode.
Related
(Code 50300: Voltage of steering potentiometer 1)
information
Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).

Defective 5 V sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out trou-
1
Defective steering potenti- TL2 (male) Resistance
2 ometer 1 (Internal discon-
Between (5) (8) 2.56 3.84 kz
nection or short circuit)
Between (7) (5)
Between (7) (8)
Possible causes Disconnection in wiring har- out turning starting switch ON.
and standard ness (Disconnection in wir- Wiring harness between STCN1 (female) (22)
ing or defective contact in TL2 (female) (5)
state connector) Wiring harness between STCN1 (female) (2)
Resistance Max. 1 z
TL2 (female) (7)
ground
STCN1 Voltage
Between (2) (21) 0.5 4.5 V
Circuit diagram related to steering potentiometer
20-582 D475A-5
(1)
ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))
Action code Error code Steering potentiometer 1: Short circuit (KB)

Trouble
CALL E03 DK30KB (Steering controller system)
Contents of
Signal voltage of steering potentiometer 1 system (L) is above 4.5 V.
trouble
Action of
Continues controlling with signal of steering potentiometer 2 system (R).
controller
Problem that
appears on
machine
Input (Voltage) from steering potentiometer 1 (L) can be checked in monitoring mode.
Related
information

1
Defective steering potenti- TL2 (male) Resistance
Between (5) (8) 2.56 3.84 kz
Possible causes Between (7) (5)
and standard Between (7) (8)
3 source in wiring harness Short circuit of wiring harness between STCN1
(Contact with 24 V circuit) (female) (2) TL2 (female) (7) with chassis Voltage Max. 1 V
ground
STCN1 Voltage
Between (2) (21) 0.5 4.5 V
D475A-5 20-583
(1)
TROUBLESHOOTING DK30KX, DK30KZ
ERROR CODE [DK30KX] (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF

NORMAL RANGE (KX))
Action code Error code Steering potentiometer 1: Input signal is out of normal range (KX)
Trouble
CALL E04 DK30KX (Steering controller system)
Contents of Either of error codes [DK30KA] and [DK30KB] of steering potentiometer systems 1 and 2 and error
trouble codes [DK31KA] and [DK31KB] are displayed simultaneously.
Problem that
appears on
machine
Input (Voltage) from steering potentiometers can be checked in monitoring mode.
Related (Code 50300: Voltage of steering potentiometer 1)
information (Code 50301: Voltage of steering potentiometer 2)

and standard
value in normal Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
state
ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR

SHORT CIRCUIT (KZ))
Action code Error code Steering potentiometer 1: Disconnection or short circuit (KZ))
Trouble
CALL E04 DK30KZ (Steering controller system)
When starting switch is turned ON, either of steering potentiometer systems 1 and 2 is abnormal, then
Contents of
either of error codes [DK30KA] and [DK30KB] and error codes [DK31KA] and [DK31KB] are displayed
trouble
simultaneously.
Problem that
appears on
machine

and standard
state
20-584 D475A-5
(1)
TROUBLESHOOTING DK30L8
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8))
Action code Error code Steering potentiometer 1: See table (L8)

Trouble
CALL E03 DK30L8 (Steering controller system)
Contents of Total signal voltage of each of steering potentiometer 1 system (ST1) and 2 system (ST2) is below
trouble 4.41 V or above 5.59 V.
Action of
Continues controlling with signal of normal one of steering potentiometer 1 system (ST1) and 2 (ST2).
controller
Problem that
appears on
machine

and standard
state
D475A-5 20-585
(1)
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA))
Action code Error code Steering potentiometer 2: Disconnection (KA)

Trouble
Contents of
Signal voltage of steering potentiometer 2 system (R) is below 0.5 V.
trouble
Action of
Continues controlling with signal of steering potentiometer 1 system (L).
controller
Problem that
appears on
machine
Input (Voltage) from steering potentiometer 2 (R) can be checked in monitoring mode.
Related
information

Defective sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out trou-
1
Defective steering potenti- out turning starting switch ON.
2 ometer 2 (Internal discon- TL2 (male) Resistance
nection or short circuit) Between (5) (8) 1.8 2.2 kz
Between (6) (5)
Possible causes
value in normal
TL2 (female) (6)
ground
STCN1 Voltage
Between (19) (21) 0.5 4.5 V
20-586 D475A-5
(1)
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB))
Action code Error code Steering potentiometer 2: Short circuit (KB)

Trouble
Contents of
Signal voltage of steering potentiometer 2 system (R) is above 4.5 V.
trouble
Action of
Continues controlling with signal of steering potentiometer 1 system (L).
controller
Problem that
appears on
machine
Input (Voltage) from steering potentiometer 2 (R) can be checked in monitoring mode.
Related
information

Defective sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out trou-
1
Defective steering potenti- TL2 (male) Voltage
Between (5) (8) 1.8 2.2 kz
Possible causes Between (6) (5)
(Contact with 24 V circuit) (female) (19) TL2 (female) (6) with chassis Resistance Max. 1 V
ground
STCN1 Voltage
Between (19) (21) 0.5 4.5 V
D475A-5 20-587
(1)
ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION (KA))
Action code Error code Brake potentiometer: Disconnection (KA)

Trouble
Contents of
Signal voltage of brake potentiometer circuit is below 0.5 V.
trouble
Action of
Does not control with signal of brake potentiometer (Brake can be operated with pedal).
controller
Problem that Brake control performance of brake pedal lowers.
Input (Voltage) from brake potentiometer can be checked in monitoring mode.
Related
(Code 50400: Voltage of brake potentiometer)
information
Method of reproducing error code: Turn starting switch ON and operate brake pedal.

1
Defective brake potentiom- BRK (male) Resistance
2 eter (Internal disconnection
Between (A) (C) 4.0 6.0 kz
or short circuit)
Between (A) (B) 0.25 7.0 kz
Between (B) (C) 0.25 7.0 kz
ing or defective contact in BRK (female) (C)
state connector) Wiring harness between STCN1 (female) (3)
Resistance Max. 1 z
BRK (female) (B)
(Contact with ground circuit) (female) (3) BRK (female) (B) with chassis Resistance Min. 1 Mz
ground
STCN1 Voltage
Between (3) (21) 0.5 4.5 V
20-588 D475A-5
(1)
Circuit diagram related to brake potentiometer
D475A-5 20-589
(1)
ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))
Action code Error code Brake potentiometer: Short circuit (KB)

Trouble
Contents of
Signal voltage of brake potentiometer circuit is below 0.5 V or above 4.5 V.
trouble
Action of
Does not control with signal of brake potentiometer (Brake can be operated with pedal).
controller
Problem that Brake control performance of brake pedal lowers.
Input (Voltage) from brake potentiometer can be checked in monitoring mode.
Related
(Code 50400: Voltage of brake potentiometer)
information
Method of reproducing error code: Turn starting switch ON and operate brake pedal.

1
Defective brake potentiom- BRK (male) Resistance
2 eter (Internal disconnection
(A) (C) 4.0 6.0 kz
or short circuit)
Possible causes (A) (B) 0.25 7.0 kz
and standard (B) (C) 0.25 7.0 kz
(Contact with 24 V circuit) (female) (3) BRK (female) (B) with chassis Voltage Max. 1 V
ground
STCN1 Voltage
Between (3) (21) 0.5 4.5 V
Circuit diagram related to brake potentiometer
20-590 D475A-5
(1)
TROUBLESHOOTING DK55KX, DK55KZ
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS

OUT OF NORMAL RANGE (KX))
Action code Error code Forward-reverse potentiometer: Input signal is out of normal range (KX)
Trouble
CALL E04 DK55KX (Transmission controller system)
Contents of Either of error codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and 2 and
trouble either of error codes [DK57KA] and [DK57KB] are displayed simultaneously.
Problem that
appears on
machine
Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
Related
information
Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
verse travel).

and standard
state
ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION

OR SHORT CIRCUIT (KZ))
Action code Error code Forward-reverse potentiometer: Disconnection or short circuit (KZ))
Trouble
CALL E04 DK55KZ (Transmission controller system)
When starting switch is turned ON, either of forward-reverse potentiometer systems 1 and 2 is abnor-
Contents of
mal, then either of error codes [DK56KA] and [DK56KB] and either of error codes [DK57KA] and
trouble
[DK57KB] are displayed simultaneously.
Problem that
appears on
machine
Related Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse
information travel).

and standard
state
D475A-5 20-591
(1)
TROUBLESHOOTING DK55L8
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))
Action code Error code Forward-reverse potentiometer: See table (L8)

Trouble
CALL E03 DK55L8 (Transmission controller system)
Contents of Total signal voltage of each of forward-reverse potentiometer 1 system (FR3) and 2 system (FR4) is be-
trouble low 4.41 V or above 5.59 V.
Action of Continues controlling with signal of normal one of forward-reverse potentiometer 1 system (FR3) and 2
controller (FR4).
Problem that
appears on
machine
Related
information
Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse
travel).

and standard
state
20-592 D475A-5
(1)
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNEC-

TION (KA))
Action code Error code Forward-reverse potentiometer 1: Disconnection (KA)

Trouble
CALL E03 DK56KA (Transmission controller system)
Contents of
Signal voltage of forward-reverse potentiometer 1 system (R) is below 0.5 V.
trouble
Action of
Continues controlling with signal of forward-reverse potentiometer 2 system (F).
controller
Problem that
appears on
machine
Input (Voltage) from forward-reverse potentiometer 1 (R) can be checked in monitoring mode. (Code
Related 50200: Voltage of forward-reverse potentiometer 1)
information Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse
travel).

Defective 5 V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out trou-
1
Defective forward-reverse out turning starting switch ON.
potentiometer 1 (Internal TL2 (male) Resistance
2
disconnection or short cir- Between (4) (1) 1.8 2.2 kz
cuit) Between (3) (4)
Between (3) (1)
and standard ness (Disconnection in wir- Wiring harness between TMCN1 (female) (22)
state connector) Wiring harness between TMCN1 (female) (2)
Resistance Max. 1 z
TL2 (female) (3)
ground
5
Between (2) (21) 0.5 4.5 V
Circuit diagram related to forward-reverse potentiometer
D475A-5 20-593
(1)
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT

(KB))
Action code Error code Forward-reverse potentiometer 1: Short circuit (KB)

Trouble
CALL E03 DK56KB (Transmission controller system)
Contents of
Signal voltage of forward-reverse potentiometer 1 system (R) is above 4.5 V.
trouble
Action of
Continues controlling with signal of forward-reverse potentiometer 2 system (L).
controller
Problem that
appears on
machine
Input (Voltage) from forward-reverse potentiometer 1 (R) can be checked in monitoring mode. (Code
Related 50200: Voltage of forward-reverse potentiometer 1)
travel).

Defective 5 V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out trou-
1
2
Possible causes cuit) Between (3) (4)
(Contact with 24 V circuit) (female) (2) TL2 (female) (3) with chassis Resistance Max. 1 V
ground
4
Between (2) (21) 0.5 4.5 V
20-594 D475A-5
(1)
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNEC-

TION (KA))
Action code Error code Forward-reverse potentiometer 2: Disconnection (KA)

Trouble
CALL E03 DK57KA (Transmission controller system)
Contents of
Signal voltage of forward-reverse potentiometer 2 system (F) is below 0.5 V.
trouble
Action of
Continues controlling with signal of forward-reverse potentiometer 1 system (R).
controller
Problem that
appears on
machine
Input (Voltage) from forward-reverse potentiometer 2 (F) can be checked in monitoring mode.
Related (Code 50201: Voltage of forward-reverse potentiometer 2)
travel).

Defective 5 V sensor power aSee if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
source system troubleshooting for it first.
2
cuit) Between (2) (4)
Between (2) (1)
and standard ness (Disconnection in wir- Wiring harness between TMCN1 (female) (22)
state connector) Wiring harness between TMCN1 (female) (19)
Resistance Max. 1 z
TL2 (female) (2)
(Contact with ground circuit) (female) (19) TL2(female) (2) with chassis Resistance Min. 1 Mz
ground
5
Between (19) (21) 0.5 4.5 V
D475A-5 20-595
(1)
ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT

(KB))
Action code Error code Forward-reverse potentiometer 2: Short circuit (KB)

Trouble
CALL E03 DK57KB (Transmission controller system)
Contents of
Signal voltage of forward-reverse potentiometer 2 system (F) is above 4.5 V.
trouble
Action of
Continues controlling with signal of forward-reverse potentiometer 1 system (R).
controller
Problem that
appears on
machine
Input (Voltage) from forward-reverse potentiometer 2 (F) can be checked in monitoring mode.
Related (Code 50201: Voltage of forward-reverse potentiometer 2)
travel).

Disconnection in wiring har-
ness (Disconnection in wir- See if error code [DAQ5KK] is displayed. If it is displayed, carry out trou-
1
ing or defective contact in bleshooting for it first.
connector)
2
Possible causes disconnection or short cir- Between (4) (1) 1.8 2.2 kz
and standard cuit) Between (2) (4)
value in normal Between (2) (1)
state aPrepare with starting switch OFF, then turn starting switch ON and
(Contact with 24 V circuit) (female) (19) TL2 (female) (2) with chassis Voltage Max. 1 V
ground
4
Between (19) (21) 0.5 4.5 V
20-596 D475A-5
(1)
ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA))
Action code Error code Acceleration sensor: Disconnection (KA)

Trouble
E01 DK60KA (Steering controller system)
Contents of
Signal voltage of acceleration sensor is below 0.5 V.
trouble
Action of
Turns shoe slip control (SSC) function OFF.
controller
Problem that
appears on Even if shoe slips, engine speed does not change.
machine
Input (Voltage) from acceleration sensor can be checked in monitoring mode.
Related
(Code 60200: Voltage of acceleration sensor)
information

Defective 24 V power See if error code [DB36KK] is displayed. If it is displayed, carry out trou-
1
Defective acceleration sen- carry out troubleshooting.
2
sor (Internal trouble) SSA Voltage
Between (2) (3) 0.75 4.25 V
Possible causes ness (Disconnection in wir- Wiring harness between STCN1 (female) (22)
and standard ing or defective contact in SSA (female) (1)
value in normal connector) Wiring harness between STCN1 (female) (1)
SSA (female) (2)
(Contact with ground circuit) (female) (1) SS3 (female) (2) with chassis Resistance Min. 1 Mz
ground
STCN1 Voltage
Between (1) (21) 0.75 4.25 V
Circuit diagram related to acceleration sensor
D475A-5 20-597
(1)
ERROR CODE [DK60KB] (ACCELERATION SENSOR: SHORT CIRCUIT (KB))
Action code Error code Acceleration sensor: Short circuit (KB)

Trouble
E01 DK60KB (Steering controller system)
Contents of
Signal voltage of acceleration sensor is above 4.7 V.
trouble
Action of
Turns shoe slip control (SSC) function OFF.
controller
Problem that
appears on Even if shoe slips, engine speed does not change.
machine
Input (Voltage) from acceleration sensor can be checked in monitoring mode.
Related
(Code 60200: Voltage of acceleration sensor)
information

1
Defective acceleration sen- carry out troubleshooting.
2
sor (Internal trouble) SSA Voltage
Possible causes Between (2) (3) 0.75 4.25 V
and standard aPrepare with starting switch OFF, then turn starting switch ON and
value in normal Short circuit with power carry out troubleshooting.
state 3 source in wiring harness Short circuit of wiring harness between STCN1
(Contact with 24 V circuit) (female) (1) SSA (female) (2) with chassis Voltage Max. 1 V
ground
STCN1 Voltage
Between (1) (21) 0.75 4.25 V
Circuit diagram related to acceleration sensor
20-598 D475A-5
(1)
TROUBLESHOOTING DKF0KX
ERROR CODE [DKF0KX] (OR LED OF VHMS CONTROLLER INDICATES "n2" o "62")
(INJECTION PUMP RACK SENSOR: OUT OF INPUT SIGNAL RANGE (KX))
Action code Error code Injection pump rack sensor: Out of input signal range (KX)
Trouble
DKF0KX (VHMS controller system)
Contents of
Signals (Racks) from the engine controller cannot be obtained.
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

harness (Disconnection in Wiring harness between V2A (female) (1) and
wiring harness or defective CN2 (female) (6)
contact) Wiring harness between CN-V2A (female) (13)
Resistance Max. 1 z
Possible causes and chassis ground
(Contact with ground circuit) Between wiring harness between V2A (female) Resistance Min. 1 Mz
(1) and CN2 (female) (6) and chassis ground
Defective VHMS controller carry out troubleshooting.
3 (When engine controller is V2A (female) Voltage
normal) Between (1) and (12) and
0.45 0.55 V
between (1) and (13)
Circuit diagram related to injection pump rack sensor
D475A-5 20-599
(1)
ERROR CODE [DKF1KX] (RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE
(KX))
Action code Error code Rack sensor right: Out of input signal range (KX)
Trouble
CALL E03 DKF1KX (Engine controller system)
Contents of
The input voltage from the right bank rack sensor is below 0.1 V or above 4.4 V.
trouble
controller Stops injection from the right bank fuel pump.
Problem that
machine
Related
information

Defective sensor power
1 If error code [DB45KP] is displayed, carry out troubleshooting for it first.
supply system
aPrepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
E13 Voltage
Between (1) and (2) Power supply 4.6 5.4 V
Defective right bank rack Between (3) and (2) Signal (+) 0.1 4.4 V
2
sensor (Internal defect) Between (4) and (2) Signal () 0.1 4.4 V
The voltage of the rack sensor is measured with the wiring harness con-
nected. Accordingly, if the voltage is abnormal, check the wiring har-
ness and controller, too, for another cause of the trouble, and then
judge.
harness (Disconnection in Wiring harness between LE31 (female) (7) and
wiring harness or defective E13 (female) (3)
Possible causes contact in connector) Wiring harness between LE31 (female) (17)
and E13 (female) (4)
value in normal
state
(female) (7) and E13 (female) (3) and chassis Resistance Min. 1 Mz
ground
ground
(16), JE2, and E13 (female) (1) and chassis Voltage Max. 1 V
Short circuit with power ground
(Contact with 24-V circuit) (female) (7) and E13 (female) (3) and chassis Voltage Max. 1 V
ground
(female) (17) and E13 (female) (4) and chassis Voltage Max. 1 V
ground
20-600 D475A-5
(2)

Possible causes LE2, LE31 Voltage
and standard Between LE2 (16)
value in normal 6 Defective engine controller and LE31 (16)
state Between LE31 (7)
Signal (+) 0.1 4.4 V
and LE31 (16)
Between LE31 (17)
Signal () 0.1 4.4 V
and LE31 (16)
Circuit diagram related to right bank rack sensor
D475A-5 20-601
(1)
ERROR CODE [DKF2KX] (RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE (KX))
Action code Error code Rack sensor left: Out of input signal range (KX)
Trouble
CALL E03 DKF2KX (Engine controller system)
Contents of
The input voltage from the left bank rack sensor is below 0.1 V or above 4.4 V.
trouble
controller Stops injection from the left bank fuel pump.
Problem that
machine
Related
information

Defective sensor power
1 If error code [DB45KP] is displayed, carry out troubleshooting for it first.
supply system
aPrepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
E9 Voltage
Between (1) and (2) Power supply 4.6 5.4 V
Defective left bank rack Between (3) and (2) Signal (+) 0.1 4.4 V
2
sensor (Internal defect) Between (4) and (2) Signal () 0.1 4.4 V
The voltage of the rack sensor is measured with the wiring harness con-
nected. Accordingly, if the voltage is abnormal, check the wiring har-
ness and controller, too, for another cause of the trouble, and then
judge.
Possible causes contact in connector) Wiring harness between LE31 (female) (18)
and E9 (female) (4)
value in normal
state
ground
ground
(16), LE2, and E9 (female) (1) and chassis Voltage Min. 1 V
Short circuit with power ground
(Contact with 24-V circuit) (female) (8) and E9 (female) (3) and chassis Voltage Min. 1 V
ground
(female) (18) and E9 (female) (4) and chassis Voltage Min. 1 V
ground
20-602 D475A-5
(1)

Possible causes LE2, LE31 Voltage
and standard Between LE2 (16)
value in normal 6 Defective engine controller and LE31 (16)
state Between LE31 (8)
Signal (+) 0.1 4.4 V
and LE31 (16)
Between LE31 (18)
Signal () 0.1 4.4 V
and LE31 (16)
Circuit diagram related to left bank rack sensor
D475A-5 20-603
(1)
TROUBLESHOOTING DKH1KA
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA))
Action code Error code Pitch angle sensor: Disconnection (KA)

Trouble
CALL E03 DKH1KA (Steering controller system)
Contents of
Signal voltage of pitch angle sensor is below 0.15 V.
trouble
Action of
Cannot recognize pitch angle.
controller
Problem that Shocks are made when gear is shifted on slope and when machine is steered on level place.
Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
Related
(Code 60100: Voltage of pitch angle sensor)
information

1
Defective pitch angle sen- carry out troubleshooting.
2
sor (Internal trouble) PT1 Voltage
Between (B) (A) 0.15 4.85 V
Possible causes ness (Disconnection in wir- Wiring harness between STCN1 (female) (16)
and standard ing or defective contact in PT1 (female) (C)
value in normal connector) Wiring harness between STCN1 (female) (13)
PT1 (female) (B)
(Contact with ground circuit) (female) (13) PT1 (female) (B) with chassis Resistance Min. 1 Mz
ground
STCN1 Voltage
Between (13) (21) 0.15 4.85 V
Circuit diagram related to pitch angle sensor
20-604 D475A-5
(1)
TROUBLESHOOTING DKH1KB
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB))
Action code Error code Pitch angle sensor: Short circuit (KB)
Trouble
CALL E03 DKH1KB (Steering controller system)
Contents of
Signal voltage of pitch angle sensor is above 4.85 V.
trouble
Action of
Cannot recognize pitch angle.
controller
Problem that Shocks are made when gear is shifted on slope and when machine is steered on level place.
Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
Related
(Code 60100: Voltage of pitch angle sensor)
information

1
Defective pitch angle sen- carry out troubleshooting.
2
sor (Internal trouble) PT1 Voltage
Possible causes Between (B) (A) 0.15 4.85 V
value in normal Short circuit with power carry out troubleshooting.
state 3 source in wiring harness Short circuit of wiring harness between STCN1
(Contact with 24 V circuit) (female) (13) PT1 (female) (B) with chassis Voltage Max. 1 V
ground
STCN1 Voltage
Between (13) (21) 0.15 4.85 V
Circuit diagram related to pitch angle sensor
D475A-5 20-605
(1)
TROUBLESHOOTING DLE1KA
ERROR CODE [DLE1KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))
Action code Error code Engine speed sensor: Disconnection (KA)

Trouble
CALL E03 DLE1KA (Steering controller system)
Contents of
Signals of the engine speed sensor are not input.
trouble
Action of
Recognizes the engine speed to be 0 rpm after the machine is stopped.
controller
Problem that
appears on Gear shifting shocks of the transmission become large.
machine
Related
information

Defective engine speed out turning starting switch ON.
sensor E12 (male) Resistance
1
(Internal disconnection or
short circuit) Between (1) and (2) 500 1,000 z
Between (1) and chassis ground Min. 1 Mz
wiring harness or defective and E12 (female) (1)
and E12 (female) (2)
and standard
ground
ground
4 Defective steering controller STCN2 (female) Resistance
Between (40) and (29) 500 1,000 z
20-606 D475A-5
(1)
TROUBLESHOOTING DLE1KA
Circuit diagram related to engine speed sensor
D475A-5 20-607
(1)
TROUBLESHOOTING DLE4LC
ERROR CODE [DLE4LC] (ENGINE SPEED SENSOR A: * REFER TO TABLE (LC))
Action code Error code Engine speed sensor A: Refer to table (LC)
Trouble
CALL E03 DLE4LC (Engine controller system)
Contents of
After the engine is started, the input value from engine speed sensor A is below 300 rpm.
trouble
controller Controls with the signals from engine speed sensor B.
Problem that
appears on
machine
Related
information

1 sensor A (Internal discon- E16 (male) Resistance
nection or short circuit) Between (1) and (2) 500 1,000 z
Defective adjustment of
2 Refer to TESTING AND ADJUSTING, Adjusting engine speed sensor.
engine speed sensor A
Possible causes harness (Disconnection in Wiring harness between LE31 (female) (2) and
and standard wiring harness or defective E16 (female) (1)
value in normal contact in connector) Wiring harness between LE31 (female) (14),
JEC, and E16 (female) (2)
4 ground in wiring harness Between wiring harness between LE31
(Contact with ground circuit) (female) (2) and E16 (female) (1) and chassis Resistance Min. 1 Mz
ground
5 Defective engine controller LE31 (female) Resistance
Between (2) and (14) 500 1,000 z
20-608 D475A-5
(1)
Circuit diagram related to engine speed sensor A
D475A-5 20-609
(1)
ERROR CODE [DLE5LC] (ENGINE SPEED SENSOR B: * REFER TO TABLE (LC))
Action code Error code Engine speed sensor B: Refer to table (LC)
Trouble
CALL E03 DLE5LC (Engine controller system)
Contents of
After the engine is started, the input value from engine speed sensor B is below 300 rpm.
trouble
controller Controls with the signals from engine speed sensor A.
Problem that
appears on
machine
The signals of engine speed sensor B are used by the steering controller, too. Depending on the cause
Related
of the trouble, error code [DLE1KA] may be displayed at the same time.
information

sensor B
1 E12 (male) Resistance
short circuit) Between (1) and (2) 500 1,000 z
Defective adjustment of
2 Refer to TESTING AND ADJUSTING, Adjusting engine speed sensor.
engine speed sensor B
Possible causes
harness (Disconnection in Wiring harness between LE31 (female) (3),
and standard 3 Resistance Max. 1 z
wiring harness or defective JE6, JEF, and E12 (female) (1)
value in normal
contact in connector) Wiring harness between LE31 (female) (14),
JEC, JE5, and E12 (female) (2)
(Contact with ground circuit) Between wiring harness between LE31
(female) (3), JE6, JEF, and E12 (female) (1)
5 Defective engine controller LE31 (female) Resistance
Between (3) and (14) 500 1,000 z
20-610 D475A-5
(2)
Circuit diagram related to engine speed sensor B
D475A-5 20-611
(1)
TROUBLESHOOTING DLF1KA
ERROR CODE [DLF1KA] (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCON-

NECTION (KA))
Action code Error code Torque converter output speed sensor: Disconnection (KA)
Trouble
CALL E03 DLF1KA (Transmission controller system)
Contents of
Signals from the torque converter output speed sensor are not input.
trouble
Action of
None in particular.
controller
Problem that
appears on The torque converter speed cannot be monitored.
machine
The input state (rpm) from the torque converter output speed sensor can be checked in the monitoring
Related
mode. (Code 31200: Torque converter speed)
information
Method of reproducing error code: Start the engine + Drive the machine actually.

Defective torque converter out turning starting switch ON.
output speed sensor
1 TC1 (male) Resistance
Between (1) and (2) 500 1,000 z
short circuit)
harness (Disconnection in Wiring harness between TMCN2 (female) (20)
Possible causes wiring harness or defective and TC1 (female) (1)
and standard contact in connector) Wiring harness between TMCN2 (female) (39)
and TC1 (female) (2)
(Contact with ground circuit) (female) (20) and TC1 (female) (1) and chassis Resistance Min. 1 Mz
ground
Defective transmission TMCN2 (female) Resistance
4
controller
Between (20) and (39) 500 1,000 z
Circuit diagram related to torque converter output speed sensor
20-612 D475A-5
(1)
TROUBLESHOOTING DLT3KA
ERROR CODE [DLT3KA] (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNEC-

TION (KA))
Action code Error code Transmission output speed sensor: Disconnection (KA)
Trouble
E01 DLT3KA (Transmission controller system)
Contents of
Signal is not input from transmission output speed sensor.
trouble
Action of
Assumes that transmission output speed is 0 rpm.
controller
Problem that
Transmission speed cannot be monitored.
appears on
Traction force cannot be calculated.
machine
Input (rpm) from transmission output speed sensor can be checked in monitoring mode.
Related
(Code 31400: Transmission speed
information
Method of reproducing error code: Start engine and travel machine actually.

Defective transmission out- carry out troubleshooting.
put speed sensor (Internal
1 TM1 (male) Resistance
disconnection or short cir-
Between (1) (2) 500 1,000 z
cuit)
Between (1), (2) chassis ground Min. 1 Mz
Possible causes ing or defective contact in TM1 (female) (1)
and standard connector) Wiring harness between TMCN2 (female) (39)
TM1 (female) (2)
(Contact with ground circuit) (female) (30) TM1 (female) (1) with chassis Resistance Min. 1 Mz
ground
4
troller
Between (30) (39) 500 1,000 z
Circuit diagram related to transmission output speed sensor
D475A-5 20-613
(1)
TROUBLESHOOTING DV00KB
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB))
Action code Error code Caution buzzer: Short circuit (KB)

Trouble
E01 DV00KB (Monitor panel system)
Contents of
Abnormal current flowed when caution buzzer circuit output ground signal.
trouble
Action of Flashes caution lamp.
controller Stops caution buzzer circuit from outputting ground signal.
Problem that
appears on Caution buzzer does not sound.
machine
Related Method of reproducing error code: Turn starting switch ON (When it is turned ON, buzzer sounds for 1
information second).

Defective caution buzzer out turning starting switch ON.
1
(Internal short circuit) 217 (male) Resistance
Between (1) (2) 200 z
Possible causes Short circuit with power carry out troubleshooting.
and standard 2 source in wiring harness Short circuit of wiring harness between 217
value in normal (Contact with 24 V circuit) (female) (1) S03 (female) (18) with chassis Voltage Max. 1 V
state ground
S03 Caution buzzer Voltage
3 Defective monitor panel
When turned OFF 20 30 V
Between (18)
When turned ON
chassis ground Max. 3 V
(sounding)
Circuit diagram related to caution buzzer
20-614 D475A-5
(1)
TROUBLESHOOTING DW55KA
ERROR CODE [DW55KA] (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA))
Action code Error code Blade pitch back solenoid: Disconnection (KA)
Trouble
E01 DW55KA (Transmission controller system)
Contents of
When the signal is output to the blade pitch back solenoid circuit, no current flows.
trouble
Action of
Stops outputting the signal to the blade pitch back solenoid circuit.
controller
Problem that
appears on The blade is not pitched back.
machine
The output state (ON/OFF) to the blade pitch back solenoid can be checked in the monitoring mode.
Related
(Code 90001: Transmission ON/OFF output 3, 4)
information
Method of reproducing error code: Turn the starting switch ON. + Pitch back blade.

Defective blade pitch back out turning starting switch ON.
1 solenoid
PPB (male) Resistance
Between (1) and (2) 20 60 z
Possible causes wiring harness or defective and PPB (female) (1)
and PPB (female) (2)
(Contact with 24-V circuit) (female) (26) and PPB (female) (1) and chassis Voltage Max. 1 V
ground
Defective transmission out turning starting switch ON.
4
controller TMCN3 (female) Resistance
Between (26) and (23) 20 60 z
Circuit diagram related to blade pitch back solenoid
D475A-5 20-615
(1)
TROUBLESHOOTING DW55KB
ERROR CODE [DW55KB] (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Blade pitch back solenoid: Short circuit (KB)
Trouble
E01 DW55KB (Transmission controller system)
Contents of
When the signal is output to the blade pitch back solenoid circuit, an abnormal current flows.
trouble
Action of
Stops outputting the signal to the blade pitch back solenoid circuit.
controller
Problem that
machine
The output state (ON/OFF) to the blade pitch back solenoid can be checked in the monitoring mode.
Related
(Code 90001: Transmission controller ON/OFF output 4)
information
Method of reproducing error code: Turn the starting switch ON. + Pitch the blade back.

Defective blade pitch back out turning starting switch ON.
1 solenoid PPB (male) Resistance
(Internal short circuit) Between (1) and (2) 20 60 z
value in normal 2 ground in wiring harness Between wiring harness between TMCN3
state (Contact with ground circuit) (female) (26) and PPB (female) (1) and chassis Resistance Min. 1 Mz
ground
3 TMCN3 (female) Resistance
troller
Between (26) and (23) 20 60 z
Circuit diagram related to blade pitch back solenoid
20-616 D475A-5
(1)
ERROR CODE [DW56KA] (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA))
Action code Error code Blade pitch dump solenoid: Disconnection (KA)
Trouble
Contents of
When the signal is output to the blade pitch dump solenoid circuit, no current flows.
trouble
Action of
Stops outputting the signal to the blade pitch dump solenoid circuit.
controller
Problem that
appears on The blade is not pitched forward.
machine
The output state (ON/OFF) to the blade pitch dump solenoid can be checked in the monitoring mode.
Related
information
Method of reproducing error code: Turn the starting switch ON. + Pitch the blade forward.

Defective blade pitch dump out turning starting switch ON.
1 solenoid
PPD (male) Resistance
Possible causes wiring harness or defective and PPD (female) (1)
and PPD (female) (2)
(Contact with 24-V circuit) (female) (16) and PPD (female) (1) and chassis Voltage Max. 1 V
ground
4
Between (16) and (23) 20 60 z
Circuit diagram related to blade pitch dump solenoid
D475A-5 20-617
(1)
ERROR CODE [DW56KB] (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Blade pitch dump solenoid: Short circuit (KB)
Trouble
Contents of
When the signal is output to the blade pitch dump solenoid circuit, an abnormal current flows.
trouble
Action of
controller
Problem that
machine
Related
information

1 solenoid PPD (male) Resistance
state (Contact with ground circuit) (female) (16) and PPD (female) (1) and chassis Resistance Min. 1 Mz
ground
controller
Between (16) and (23) 20 60 z
Circuit diagram related to blade pitch dump solenoid
20-618 D475A-5
(1)
ERROR CODE [DW57KA] (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA))
Action code Error code Left tilt limit solenoid: Disconnection (KA)
Trouble
Contents of
When the signal is output to the left tilt limit solenoid circuit, no current flows.
trouble
controller Stops outputting the signal to the left tilt limit solenoid circuit.
Problem that
The blade is not pitched forward.
appears on
The left tilt limit function does not operate.
machine
The output state (ON/OFF) to the left tilt limit solenoid can be checked in the monitoring mode.
Related
information
Method of reproducing error code: Turn the starting switch ON. + Execute the dual tilt mode.

Defective left tilt limit out turning starting switch ON.
1 solenoid
TLL (male) Resistance
Possible causes wiring harness or defective and TLL (female) (1)
and TLL (female) (2)
(Contact with 24-V circuit) (female) (27) and TLL (female) (1) and chassis Voltage Max. 1 V
ground
4
Between (27) (23) 20 60 z
Circuit diagram related to left tilt limit solenoid
D475A-5 20-619
(1)
ERROR CODE [DW57KB] (LEFT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Left tilt limit solenoid: Short circuit (KB)
Trouble
Contents of
When the signal is output to the left tilt limit solenoid circuit, an abnormal current flows.
trouble
controller Stops outputting the signal to the left tilt limit solenoid circuit.
Problem that
The blade is not pitched forward.
appears on
The left tilt limit function does not operate.
machine
The output state (ON/OFF) to the left tilt limit solenoid can be checked in the monitoring mode.
Related
information

Defective left tilt limit out turning starting switch ON.
1 solenoid TLL (male) Resistance
state (Contact with ground circuit) (female) (27) and TLL (female) (1) and chassis Resistance Min. 1 Mz
ground
controller
Between (27) and (23) 20 60 z
Circuit diagram related to left tilt limit solenoid
20-620 D475A-5
(1)
ERROR CODE [DW58KA] (RIGHT TILT LIMIT SOLENOID: DISCONNECTION (KA))
Action code Error code Right tilt limit solenoid: Disconnection (KA)
Trouble
Contents of
When the signal is output to the right tilt limit solenoid circuit, no current flows.
trouble
controller Stops outputting the signal to the right tilt limit solenoid circuit.
Problem that
The blade is not pitched back.
appears on
The right tilt limit function does not operate.
machine
The output state (ON/OFF) to the right tilt limit solenoid can be checked in the monitoring mode.
Related
information

Defective right tilt limit out turning starting switch ON.
1 solenoid
TLR (male) Resistance
Possible causes wiring harness or defective and TLR (female) (1)
and TLR (female) (2)
(Contact with 24-V circuit) (female) (37) and TLR (female) (1) and chassis Voltage Max. 1 V
ground
4
Between (37) and (23) 20 60 z
Circuit diagram related to right tilt limit solenoid
D475A-5 20-621
(1)
ERROR CODE [DW58KB] (RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Right tilt limit solenoid: Short circuit (KB)
Trouble
Contents of
When the signal is output to the right tilt limit solenoid circuit, an abnormal current flows.
trouble
controller Stops outputting the signal to the right tilt limit solenoid circuit.
Problem that
machine
The output state (ON/OFF) to the right tilt limit solenoid can be checked in the monitoring mode.
Related
information

Defective right tilt limit out turning starting switch ON.
1 solenoid TLR (male) Resistance
state (Contact with ground circuit) (female) (37) and TLR (female) (1) and chassis Resistance Min. 1 Mz
ground
controller
Between (37) and (23) 20 60 z
Circuit diagram related to right tilt limit solenoid
20-622 D475A-5
(1)
ERROR CODE [DW59KA] (BLADE DUAL SELECTOR SOLENOID: DISCONNECTION

(KA))
Action code Error code Blade dual selector solenoid: Disconnection (KA)
Trouble
Contents of
When signal is output to blade dual selector solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to blade dual selector solenoid circuit.
controller
Problem that
appears on Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works).
machine
Output (Current) to blade dual selector solenoid can be checked in monitoring mode.]
Related
(Code 70600: Blade dual solenoid drive current)
information
Method of reproducing error code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selec- out turning starting switch ON.
1 tor solenoid (Internal short
PPA (male) Resistance
circuit)
Between (1) (2) 10 40 z
Possible causes ing or defective contact in DUL (female) (1)
Resistance Max. 1 z
value in normal DUL (female) (2)
(Contact with 24 V circuit) (female) (6) DUL (female) (1) with chassis Voltage Max. 1 V
ground
Defective transmission con- out turning starting switch ON.
4
troller TMCN3 (female) Resistance
Between (6) (3) 10 40 z
Circuit diagram related to blade dual selector solenoid
D475A-5 20-623
(1)
ERROR CODE [DW59KB] (BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT

(KB))
Action code Error code Blade dual selector solenoid: Short circuit (KB)
Trouble
Contents of
When signal is output to blade dual selector solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to blade dual selector solenoid circuit.
controller
Problem that
appears on Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works).
machine
Output (Current) to blade dual selector solenoid can be checked in monitoring mode.
Related
(Code 70600: Blade dual solenoid drive current)
information
Method of reproducing error code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selec- out turning starting switch ON.
1 tor solenoid (Internal short DUL (male) Resistance
circuit) Between (1) (2) 10 40 z
value in normal 2 ground in wiring harness Short circuit of wiring harness between TMCN3
state (Contact with ground circuit) (female) (6) DUL (female) (1) with chassis Resistance Min. 1 Mz
ground
3
troller
Between (6) (3) 10 40 z
Circuit diagram related to blade dual selector solenoid
20-624 D475A-5
(1)
TROUBLESHOOTING DW5AKA
ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION

(KA))
Action code Error code Blade pitch selector solenoid: Disconnection (KA)
Trouble
E02 DW5AKA (Transmission controller system)
Contents of
When the signal is output to the blade pitch selector solenoid circuit, no current flows.
trouble
controller Stops outputting the signal to the blade pitch selector solenoid circuit.
Problem that
appears on The blade is not pitched back. (When the pitch back operation is performed, the blade may be tilted.)
machine
The output state (ON/OFF) to the blade pitch selector solenoid can be checked in the monitoring mode.
Related
information

Defective blade pitch out turning starting switch ON.
1 selector solenoid
PTH (male) Resistance
Possible causes wiring harness or defective and PTH (female) (1)
Resistance Max. 1 z
value in normal and PTH (female) (2)
(Contact with 24-V circuit) (female) (28) and PTH (female) (1) and chassis Voltage Max. 1 V
ground
4
Between (28) and (3) 10 40 z
Circuit diagram related to blade pitch selector solenoid
D475A-5 20-625
(1)
TROUBLESHOOTING DW5AKB
ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT

(KB))
Action code Error code Blade pitch selector solenoid: Short circuit (KB)
Trouble
E02 DW5AKB (Transmission controller system)
Contents of
When the signal is output to the blade pitch selector solenoid circuit, an abnormal current flows.
trouble
controller Stops outputting the signal to the blade pitch selector solenoid circuit.
Problem that
appears on The blade is not pitched back. (When the pitch back operation is performed, the blade may be tilted.)
machine
The output state (ON/OFF) to the blade pitch selector solenoid can be checked in the monitoring mode.
Related
information

Defective blade pitch out turning starting switch ON.
1 selector solenoid PTH (male) Resistance
state (Contact with ground circuit) (female) (28) and PTH (female) (1) and chassis Resistance Min. 1 Mz
ground
3
controller
Between (28) and (3) 10 40 z
Circuit diagram related to blade pitch selector solenoid
20-626 D475A-5
(1)
TROUBLESHOOTING DW5DKA
ERROR CODE [DW5DKA] (BLADE PITCH DUMP SOLENOID (SUPERDOZER SPECIFI-

CATION): DISCONNECTION (KA))
Action code Error code Blade pitch dump solenoid (Superdozer specification): Disconnection
Trouble (KA)
E01 DW5DKA
(Transmission controller system)
Contents of
When the signal is output to the blade pitch dump solenoid circuit, no current flows.
trouble
Action of
controller
Problem that
machine
Related
information

1 solenoid
PPD (male) Resistance
Possible causes wiring harness or defective and PPD (female) (1)
Resistance Max. 1 z
value in normal and PPD (female) (2)
(Contact with 24-V circuit) (female) (16) and PPD (female) (1) and chassis Voltage Max. 1 V
ground
4
Between (16) and (23) 20 60 z
Circuit diagram related to blade pitch dump solenoid (Superdozer)
D475A-5 20-627
(1)
TROUBLESHOOTING DW5DKB
ERROR CODE [DW5DKB] (BLADE PITCH DUMP SOLENOID (SUPERDOZER SPECIFI-

CATION): SHORT CIRCUIT (KB))
Action code Error code Blade pitch dump solenoid (Superdozer specification): Short circuit (KB)
Trouble
E02 DW5DKB (Transmission controller system)
Contents of
When the signal is output to the blade pitch dump solenoid circuit, an abnormal current flows.
trouble
Action of
Stops outputting the signal to the blade pitch dump solenoid.
controller
Problem that
machine
Related
information

1 solenoid PPD (male) Resistance
state (Contact with ground circuit) (female) (16) and PPD (female) (1) and chassis Resistance Min. 1 Mz
ground
3
controller
Between (16) and (3) 20 60 z
Circuit diagram related to blade pitch dump solenoid (Superdozer specification)
20-628 D475A-5
(1)
TROUBLESHOOTING DW7BKA
ERROR CODE [DW7BKA] (FAN REVERSE SOLENOID: DISCONNECTION (KA))
Action code Error code Fan reverse solenoid: Disconnection (KA)

Trouble
DW7BKA (Transmission controller system)
Contents of
When the signal is output to the fan reverse solenoid circuit, no current flows.
trouble
Action of
Stops outputting the signal to the fan reverse solenoid circuit.
controller
Problem that
appears on The fan reverse function cannot be used.
machine
The output state (ON/OFF) to the fan reverse solenoid can be checked in the monitoring mode.
Related
(Code 40914: Steering controller ON/OFF output)
information
Method of reproducing error code: Turn the starting switch ON. + Reverse the fan rotation direction.

Defective fan reverse out turning starting switch ON.
1 solenoid
FAR2 (male) Resistance
Possible causes wiring harness or defective and FAR2 (female) (1)
and standard contact in connector) Wiring harness between STCN3 (female) (3)
and FAR2 (female) (2)
(Contact with 24-V circuit) (female) (17) and FAR2 (female) (1) and chas- Voltage Max. 1 V
sis ground
4
controller STCN3 (female) Resistance
Between (17) and (3) 34 44 z
Circuit diagram related to fan reverse solenoid
D475A-5 20-629
(1)
TROUBLESHOOTING DW7BKB
ERROR CODE [DW7BKB] (FAN REVERSE SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Fan reverse solenoid: Short circuit (KB)
Trouble
E01 DW7BKB (Transmission controller system)
Contents of
When the signal is output to the fan reverse solenoid circuit, an abnormal current flows.
trouble
Action of
Stops outputting the signal to the fan reverse solenoid.
controller
Problem that
appears on The fan reverse function cannot be used.
machine
The output state (ON/OFF) to the fan reverse solenoid can be checked in the monitoring mode.
Related
information
Method of reproducing error code: Turn the starting switch ON. + Reverse the fan rotation direction.

Defective fan reverse out turning starting switch ON.
1 solenoid FAR2 (male) Resistance
Possible causes (Contact with ground circuit) (female) (17) and FAR2 (female) (2) and chas- Resistance Min. 1 Mz
and standard sis ground
state Short circuit in wiring out turning starting switch ON.
harness Between wiring harness between STCN3
3
(Short circuit between (female) (17) and FAR2 (female) (1) and wiring
wiring harnesses) harness between STCN3 (female) (3) and
FAR2 (female) (2)
Defective transmission STCN3 (female) Resistance
4
controller
Between (17) and (3) 34 44 z
Circuit diagram related to fan reverse solenoid
20-630 D475A-5
(1)
TROUBLESHOOTING DWJ0KA
ERROR CODE [DWJ0KA] (PUMP MERGE-DIVIDER SOLENOID: DISCONNECTION (KA))
Action code Error code Pump merge-divider solenoid: Disconnection (KA)

Trouble
CALL E03 DWJ0KA (Steering controller system)
Contents of
When the signal is output to the pump merge-divider solenoid circuit, no current flows.
trouble
controller Stops outputting the signal to the pump merge-divider solenoid circuit.
Problem that Once machine is stopped, engine speed is limited to medium (half).
appears on Once machine is stopped, travel is limited to F1 and R1.
machine Blade tilt/pitch work may not be performed normally.
The output state (ON/OFF) to the pump merge-divider solenoid can be checked in the monitoring mode.
Related
information

Defective pump out turning starting switch ON.
1 merge-divider solenoid
MFD (male) Resistance
Possible causes wiring harness or defective and MFD (female) (1)
and MFD (female) (2)
(Contact with 24-V circuit) (female) (27) and MFD (female) (1) and chassis Voltage Max. 1 V
ground
STCN3 (female) Resistance
Between (27) and (3) 20 60 z
Circuit diagram related to pump merge-divider solenoid
D475A-5 20-631
(1)
TROUBLESHOOTING DWJ0KB
ERROR CODE [DWJ0KB] (PUMP MERGE-DIVIDER SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Pump merge-divider solenoid: Short circuit (KB)
Trouble
CALL E03 DWJ0KB (Steering controller system)
Contents of
When the signal is output to the pump merge-divider solenoid circuit, an abnormal current flows.
trouble
controller Stops outputting the signal to the pump merge-divider solenoid.
Problem that Once machine is stopped, engine speed is limited to medium (half).
appears on Once machine is stopped, travel is limited to F1 and R1.
machine Blade tilt/pitch work may not be performed normally.
The output state (ON/OFF) to the pump merge-divider solenoid can be checked in the monitoring mode.
Related
information

Defective pump out turning starting switch ON.
1 merge-divider solenoid MFD (male) Resistance
value in normal 2 ground in wiring harness Between wiring harness between STCN3
state (Contact with ground circuit) (female) (27) and MFD (female) (1) and chassis Resistance Min. 1 Mz
ground
Between (27) and (3) 20 60 z
Circuit diagram related to pump merge-divider solenoid
20-632 D475A-5
(1)
TROUBLESHOOTING DWN3KA
ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNEC-

TION (KA))
Action code Error code Sudden stop prevention solenoid: Disconnection (KA)
Trouble
CALL E04 DWN3KA (Steering controller system)
Contents of
When signal is output to sudden stop prevention solenoid circuit, any current does not flow.
trouble
Problem that Brake is applied lightly during travel.
Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode.
Related
(Code 31628: Sudden stop prevention solenoid drive current)
information

Defective sudden stop pre- out turning starting switch ON.
1 vention solenoid (Internal
STB (male) Resistance
disconnection)
Between (1) (2) 5 25 z
ing or defective contact in STB (female) (1)
Possible causes
STB (female) (2)
value in normal
(Contact with 24 V circuit) (female) (25) STB (female) (1) with chassis Voltage Max. 1 V
ground
4 Defective steering controller STCN2, STCN3 Resistance
Between STCN2 (25)
5 25 z
STCN3 (13)
Circuit diagram related to sudden stop prevention solenoid
D475A-5 20-633
(1)
TROUBLESHOOTING DWN3KB
ERROR CODE [DWN3KB] (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT

(KB))
Action code Error code Sudden stop prevention solenoid: Short circuit (KB)
Trouble
CALL E04 DWN3KB (Steering controller system)
Contents of
When signal was output to sudden stop prevention solenoid circuit, abnormal current flowed.
trouble
Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode.
Related
(Code 31628: Sudden stop prevention solenoid drive current)
information

Defective sudden stop pre- out turning starting switch ON.
1 vention solenoid (Internal STB (male) Resistance
short circuit) Between (1) (2) 5 25 z
(Contact with ground circuit) (female) (25) STB (female) (1) with chassis Resistance Min. 1 Mz
Possible causes ground
value in normal out turning starting switch ON.
state Short circuit in wiring har-
Short circuit in wiring harness between STCN2
3 ness (with another wiring
(female) (25) STB (female) (1) with wiring har-
harness) Resistance Min. 1 Mz
ness between STCN3 (female) (13) STB
(female) (2)
STCN2, STCN3 Resistance
4 Defective steering controller Between STCN2 (25)
5 25 z
STCN3 (13)
Between STCN2 (25)
Min. 1 Mz
chassis ground
Circuit diagram related to sudden stop prevention solenoid
20-634 D475A-5
(1)
TROUBLESHOOTING DWN5KA
ERROR CODE [DWN5KA] (FAN PUMP SOLENOID 1: DISCONNECTION (KA))
Action code Error code Fan pump solenoid 1: Disconnection (KA)

Trouble
E01 DWN5KA (Transmission controller system)
Contents of
When signal is output to fan pump solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to fan pump solenoid circuit.
controller
Problem that
appears on Output of the fan pump (LPV90) becomes maximum.
machine
Output (Current) to fan pump solenoid can be checked in monitoring mode.
Related
(Code 31623, 31624: Cooling fan solenoid output current)
information
Method of reproducing service code: Turn starting switch ON.

Defective fan pump sole- out turning starting switch ON.
1 noid (Internal disconnec-
FA1 (male) Resistance
tion)
Between (1) (2) 15 25 z
Possible causes ing or defective contact in FA1 (female) (1)
FA1 (female) (2)
(Contact with 24 V circuit) (female) (17) FA1 (female) (1) with chassis Voltage Max. 1 V
ground
4
Between (17) (13) 15 25 z
Circuit diagram related to fan pump solenoid
D475A-5 20-635
(1)
TROUBLESHOOTING DWN5KB
ERROR CODE [DWN5KB] (FAN PUMP SOLENOID 1: SHORT CIRCUIT (KB))
Action code Error code Fan pump solenoid 1: Short circuit (KB)
Trouble
E01 DWN5KB (Transmission controller system)
Contents of
When signal was output to fan pump solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to fan pump solenoid circuit.
controller
Problem that
machine
Output (Current) to fan pump solenoid can be checked in monitoring mode.
Related
information
Method of reproducing service code: Turn starting switch ON.

Defective fan pump sole- FA1 (male) Resistance
1
noid (Internal short circuit)
Between (1) (2) 15 25 z
Possible causes (Contact with ground circuit) (female) (17) FA1 (female) (1) with chassis Resistance Min. 1 Mz
and standard ground
Short circuit in wiring har-
3 ness (with another wiring Short circuit in wiring harness between TMCN3
(female) (17) FA1 (female) (1) with wiring har-
ness between TMCN3 (female) (13) FA1
(female) (2)
Defective transmission con- TMCN3 Resistance
4
troller
Between (17) (13) 15 25 z
20-636 D475A-5
(1)
TROUBLESHOOTING DWNCKA
ERROR CODE [DWNCKA] (FAN PUMP SOLENOID 2: DISCONNECTION (KA))
Action code Error code Fan pump solenoid 2: Disconnection (KA)

Trouble
E01 DWNCKA (Transmission controller system)
Contents of
When the signal is output to the fan pump solenoid circuit, no current flows.
trouble
Action of
Stops outputting the signal to the fan pump solenoid circuit.
controller
Problem that
machine
The output state (current) to the fan pump solenoid can be checked in the monitoring mode.
Related
information

Defective fan pump out turning starting switch ON.
1 solenoid 2
FA2 (male) Resistance
Possible causes wiring harness or defective and FA2 (female) (1)
and FA2 (female) (2)
(Contact with 24-V circuit) (female) (7) and FA2 (female) (1) and chassis Voltage Max. 1 V
ground
4
Between (17) and (13) 15 25 z
D475A-5 20-637
(1)
TROUBLESHOOTING DWNCKB
ERROR CODE [DWNCKB] (FAN PUMP SOLENOID 2: SHORT CIRCUIT (KB))
Action code Error code Fan pump solenoid 2: Short circuit (KB)
Trouble
E01 DWNCKB (Transmission controller system)
Contents of
When the signal is output to the fan pump solenoid circuit, an abnormal current flows.
trouble
Action of
Stops outputting the signal to the fan pump solenoid.
controller
Problem that
machine
The output state (ON/OFF) to the fan pump solenoid can be checked in the monitoring mode.
Related
information

Defective fan pump out turning starting switch ON.
1 solenoid 2 FA2 (male) Resistance
Possible causes (Contact with ground circuit) (female) (7) and FA2 (female) (1) and chassis Resistance Min. 1 Mz
and standard ground
harness Between wiring harness between TMCN3
3
(Short circuit between (female) (7) and FA2 (female) (1) and wiring
wiring harnesses) harness between TMCN3 (female) (13) and
FA2 (female) (2)
Defective transmission TMCN3 Resistance
4
controller
Between (7) and (13) 15 25 z
20-638 D475A-5
(1)
TROUBLESHOOTING DXE0KA
ERROR CODE [DXE0KA] (LS SET SOLENOID: DISCONNECTION (KA))
Action code Error code LS set solenoid: Disconnection (KA)

Trouble
E02 DXE0KA (Steering controller system)
Contents of
When the signal is output to the LS set solenoid circuit, no current flows.
trouble
Action of Stops outputting the signal to the LS set solenoid circuit.
controller Flashes the caution lamp and turns on the caution buzzer.
Problem that
appears on Pitching and tilting speed of the work equipment may become too high.
machine
The output state (ON/OFF) to the LS set solenoid can be checked in the monitoring mode.
Related
information

Defective LS set solenoid out turning starting switch ON.
1
(Internal short circuit) LSV (male) Resistance
Possible causes wiring harness or defective and LSV (female) (1)
and LSV (female) (2)
(Contact with 24-V circuit) (female) (37) and LSV (female) (1) and chassis Voltage Max. 1 V
ground
Between (37) and (3) 15 25 z
Circuit diagram related to LS set solenoid
D475A-5 20-639
(1)
TROUBLESHOOTING DXE0KB
ERROR CODE [DXE0KB] (LS SET SOLENOID: SHORT CIRCUIT (KB))
Action code Error code LS set solenoid: Short circuit (KB)

Trouble
E02 DXE0KB (Steering controller system)
Contents of
When the signal is output to the LS set solenoid circuit, an abnormal current flows.
trouble
Action of Stops outputting the signal to the LS set solenoid circuit.
controller Flashes the caution lamp and turns on the caution buzzer.
Problem that
appears on Pitching and tilting speed of the work equipment may become too high.
machine
The output state (ON/OFF) to the LS set solenoid can be checked in the monitoring mode.
Related
information

Defective LS set solenoid LSV (male) Resistance
1
Possible causes (Contact with ground circuit) (female) (37) and LSV (female) (1) and chassis Resistance Min. 1 Mz
and standard ground
harness Between wiring harness between STCN3
3
(Short circuit between (female) (37) and LSV (female) (1) and wiring
wiring harnesses) harness between STCN3 (female) (3) and LSV
(female) (2)
4 Defective steering controller STCN3 Resistance
Between (37) and (3) 15 25 z
Circuit diagram related to LS set solenoid
20-640 D475A-5
(1)
TROUBLESHOOTING DXH1KA
ERROR CODE [DXH1KA] (LOCK-UP SOLENOID: DISCONNECTION (KA))
Action code Error code Lock-up solenoid: Disconnection (KA)

Trouble
E01 DXH1KA (Transmission controller system)
Contents of
When signal is output to torque converter lock-up solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to torque converter lock-up solenoid circuit.
controller
Problem that
appears on Torque converter is not locked-up.
machine
Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode.
Related
(Code 31627: Torque converter lock-up solenoid drive current)
information
Method of reproducing service code: Start engine and turn lock-up switch ON and drive machine.

1 lock-up solenoid (Internal
653 (male) Resistance
short circuit)
Between (1) (2) 30 80 z
Possible causes ing or defective contact in 653 (female) (1)
653 (female) (2)
(Contact with 24 V circuit) (female) (38) 653 (female) (1) with chassis Voltage Max. 1 V
ground
4
Between (38) (23) 30 80 z
Circuit diagram related to torque converter lock-up solenoid
D475A-5 20-641
(1)
TROUBLESHOOTING DXH1KB
ERROR CODE [DXH1KB] (LOCK-UP SOLENOID: SHORT CIRCUIT (KB))

Trouble Lock-up solenoid: Short circuit (KB)(Transmission controller system)
E01 DXH1KB
Contents of
When signal was output to torque converter lock-up solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to torque converter lock-up solenoid circuit.
controller
Problem that
appears on Torque converter is not locked-up.
machine
Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode.
Related
(Code 31627: Torque converter lock-up solenoid drive current)
information
Method of reproducing service code: Start engine and turn lock-up switch ON and drive machine.

1 lock-up solenoid (Internal 653 (male) Resistance
Possible causes (Contact with ground circuit) (female) (38) 653 (female) (1) with chassis Resistance Min. 1 Mz
and standard ground
3 ness (with another wiring Short circuit in wiring harness between TMCN3
(female) (38) 653 (female) (1) with wiring har-
ness between TMCN3 (female) (23) 653
(female) (2)
Defective transmission con- TMCN3 Resistance
4
troller
Between (38) (23) 30 80 z
Circuit diagram related to torque converter lock-up solenoid
20-642 D475A-5
(1)
ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code 1st clutch ECMV: Disconnection (KA)

Trouble
CALL E03 DXH4KA (Transmission controller system)
Contents of
When signal is output to 1st clutch solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to transmission 1st clutch solenoid circuit.
controller
Problem that Automatic shift-down function does not work.
Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
Related
(Code 31602, 31612: Output current of 1st clutch ECMV)
information
Method of reproducing service code: Start engine and drive machine in F1 or R1.

Defective 1st clutch sole- out turning starting switch ON.
1
noid (Internal short circuit) S1T7 (male) Resistance
Between (1) (2) 5 15 z
Possible causes ing or defective contact in S1T7 (female) (1)
Resistance Max. 1 z
value in normal S1T7 (female) (2)
(Contact with 24 V circuit) (female) (15) S1T7 (female) (1) with chassis Voltage Max. 1 V
ground
4
Between (15) (3) 5 15 z
D475A-5 20-643
(1)
ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code 1st clutch ECMV: Short circuit (KB)
Trouble
CALL E03 DXH4KB (Transmission controller system)
Contents of
When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to transmission 1st clutch solenoid circuit.
controller
Problem that Automatic shift-down function does not work.
Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
Related
(Code 31602, 31612: Output current of 1st clutch ECMV)
information

Defective 1st clutch sole-
1 S1T7 (male) Resistance
Between (1) (2) 5 15 z
Possible causes (Contact with ground circuit) (female) (15) S1T7 (female) (1) with chassis Resistance Min. 1 Mz
and standard ground
Short circuit in wiring harness between TMCN3
(female) (15) S1T7 (female) (1) with wiring
harness between TMCN3 (female) (3) S1T7
(female) (2)
4 TMCN3 Resistance
troller
Between (15) (3) 5 15 z
20-644 D475A-5
(1)
ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code 2nd clutch ECMV: Disconnection (KA)

Trouble
Contents of
When signal is output to 2nd clutch solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to transmission 2nd clutch solenoid circuit.
controller
Problem that
appears on
machine
Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
Related
(Code 31603, 31613: Output current of 2nd clutch ECMV)
information

Defective 2nd clutch sole- out turning starting switch ON.
1
Between (1) (2) 5 15 z
Resistance Max. 1 z
ground
4
Between (30) (13) 5 15 z
D475A-5 20-645
(1)
ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code 2nd clutch ECMV: Short circuit (KB)
Trouble
Contents of
When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to transmission 2nd clutch solenoid circuit.
controller
Problem that
appears on
machine
Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
Related
(Code 31603, 31613: Output current of 2nd clutch ECMV)
information

Defective 2nd clutch sole-
Between (1) (2) 5 15 z
and standard ground
(female) (30) S2T5 (female) (1) with wiring
harness between TMCN3 (female) (13) S2T5
(female) (2)
4 TMCN3 Resistance
troller
Between (30) (13) 5 15 z
20-646 D475A-5
(1)
ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code 3rd clutch ECMV: Disconnection (KA)

Trouble
Contents of
When signal is output to 3rd clutch solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to transmission 3rd clutch solenoid circuit.
controller
Problem that
appears on
machine
Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
Related
(Code 31604, 31614: Output current of 3rd clutch ECMV)
information

Defective 3rd clutch sole- out turning starting switch ON.
1
Between (1) (2) 5 15 z
Resistance Max. 1 z
ground
4
Between (5) (3) 5 15 z
D475A-5 20-647
(1)
ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code 3rd clutch ECMV: Short circuit (KB)
Trouble
Contents of
When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to transmission 3rd clutch solenoid circuit.
controller
Problem that
appears on
machine
Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
Related
(Code 31604, 31614: Output current of 3rd clutch ECMV)
information

Defective 3rd clutch sole-
Between (1) (2) 5 15 z
and standard ground
(female) (5) S3T3 (female) (1) with wiring har-
ness between TMCN3 (female) (3) S3T3
(female) (2)
4 TMCN3 Resistance
troller
Between (5) (3) 5 15 z
20-648 D475A-5
(1)
ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code Reverse clutch ECMV: Disconnection (KA)

Trouble
Contents of
When signal is output to reverse clutch solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to transmission reverse clutch solenoid circuit.
controller
Problem that
appears on
Once machine is stopped, travel is limited to F1.
machine
Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information
Method of reproducing service code: Start engine and drive machine in reverse.

Defective reverse clutch out turning starting switch ON.
1 solenoid (Internal short cir-
SRT1 (male) Resistance
cuit)
Between (1) (2) 5 15 z
Possible causes ing or defective contact in SRT1 (female) (1)
Resistance Max. 1 z
value in normal SRT1 (female) (2)
(Contact with 24 V circuit) (female) (25) SRT1 (female) (1) with chassis Voltage Max. 1 V
ground
4
Between (25) (13) 5 15 z
D475A-5 20-649
(1)
ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Reverse clutch ECMV: Short circuit (KB)
Trouble
Contents of
When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to transmission reverse clutch solenoid circuit.
controller
Problem that
appears on
Once machine is stopped, travel is limited to F1.
machine
Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information
Method of reproducing service code: Start engine and drive machine in reverse.

Defective reverse clutch out turning starting switch ON.
1 solenoid (Internal short cir- SRT1 (male) Resistance
cuit) Between (1) (2) 5 15 z
Possible causes (Contact with ground circuit) (female) (25) SRT1 (female) (1) with chassis Resistance Min. 1 Mz
and standard ground
(female) (25) SRT1 (female) (1) with wiring
harness between TMCN3 (female) (13) SRT1
(female) (2)
4 TMCN3 Resistance
troller
Between (25) (13) 5 15 z
20-650 D475A-5
(1)
ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code Forward clutch ECMV: Disconnection (KA)

Trouble
Contents of
When signal is output to forward clutch solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to transmission forward clutch solenoid circuit.
controller
Problem that
appears on
Once machine is stopped, travel is limited to R1.
machine
Output (Current) to forward clutch solenoid can be checked in monitoring mode.
Related
(Code 31608, 31622: Output current of forward clutch ECMV)
information
Method of reproducing service code: Start engine and drive machine forward.

Defective forward clutch out turning starting switch ON.
SFT1 (male) Resistance
cuit)
Between (1) (2) 5 15 z
Possible causes ing or defective contact in SFT1 (female) (1)
Resistance Max. 1 z
value in normal SFT1 (female) (2)
(Contact with 24 V circuit) (female) (35) SFT1 (female) (1) with chassis Voltage Max. 1 V
ground
4
Between (35) (13) 5 15 z
D475A-5 20-651
(1)
ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Forward clutch ECMV: Short circuit (KB)
Trouble
Contents of
When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to transmission forward clutch solenoid circuit.
controller
Problem that
appears on
Once machine is stopped, travel is limited to R1.
machine
Output (Current) to forward clutch solenoid can be checked in monitoring mode.
Related
(Code 31608, 31622: Output current of forward clutch ECMV)
information
Method of reproducing service code: Start engine and drive machine forward.

Defective forward clutch out turning starting switch ON.
1 solenoid (Internal short cir- SFT1 (male) Resistance
Possible causes (Contact with ground circuit) (female) (35) SFT1 (female) (1) with chassis Resistance Min. 1 Mz
and standard ground
(female) (35) SFT1 (female) (1) with wiring
harness between TMCN3 (female) (13) SFT1
(female) (2)
4 TMCN3 Resistance
troller
Between (35) (13) 5 15 z
20-652 D475A-5
(1)
ERROR CODE [DXH9KA] (RIGHT STEERING CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code Right steering clutch ECMV: Disconnection (KA)
Trouble
CALL03 DXH9KA (Steering controller system)
Contents of trou-
When signal is output to right steering clutch solenoid circuit, current does not flow.
ble
Action of
Stops outputting to right steering clutch solenoid circuit.
controller
Problem that Machine cannot be steered to right.
Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
Related (Code 90601, 90603: Right steering clutch ECMV (E-POCV) output current)
information Method of reproducing error code:
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).

Defective right steering out turning starting switch ON.
1 clutch solenoid
SRC7 (male) Resistance
Between (1) (2) 5 15 z
Possible causes wiring or defective contact SRC7 (female) (1)
and standard in connector) Wiring harness between STCN3 (female) (23)
SRC7 (female) (2)
(Contact with 24 V circuit) (female) (35) SRC7 (female) (1) with chassis Voltage Max. 1 V
ground
Between (35) (23) 5 15 z
D475A-5 20-653
(1)
ERROR CODE [DXH9KB] (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Right steering clutch ECMV: SHORT CIRCUIT (KB)
Trouble
CALL03 DXH9KB (Steering controller system)
Contents of
When signal was output to right steering clutch solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to right steering clutch solenoid circuit.
controller
Problem that Machine cannot be steered to right.
Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
Related (Code 90601, 90603: Right steering clutch ECMV (E-POCV) output current)
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).

1 clutch solenoid SRC7 (male) Resistance
(Internal short circuit) Between (1) (2) 5 15 z
Possible causes (Contact with ground circuit) (female) (35) SRC7 (female) (1) with chassis Resistance Min. 1 Mz
and standard ground
Short circuit in wiring
3 harness (with another wiring
harness) (female) (35) SRC7 (female) (1) with wiring
harness between STCN3 (female) (23) SRC7
(female) (2)
Between (35) (23) 5 15 z
20-654 D475A-5
(1)
TROUBLESHOOTING DXHAKA
ERROR CODE [DXHAKA] (LEFT STEERING CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code Left steering clutch ECMV: Disconnection (KA)
Trouble
CALL03 DXHAKA (Steering controller system)
Contents of
When signal is output to left steering clutch solenoid circuit, current does not flow.
trouble
Action of
Stops outputting to left steering clutch solenoid circuit.
controller
Problem that Machine cannot be steered to left.
Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
Related (Code 90600, 90602: Left steering clutch ECMV (E-POCV) output current)
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).

Defective left steering clutch out turning starting switch ON.
1 solenoid
SLC5 (male) Resistance
Between (1) (2) 5 15 z
Possible causes wiring or defective contact SLC5 (female) (1)
and standard in connector) Wiring harness between STCN3 (female) (23)
SLC5 (female) (2)
(Contact with 24 V circuit) (female) (25) SLC5 (female) (1) with chassis Voltage Max. 1 V
ground
Between (25) (23) 5 15 z
Circuit diagram related to left steering clutch ECMV
D475A-5 20-655
(1)
TROUBLESHOOTING DXHAKB
ERROR CODE [DXHAKB] (LEFT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Left steering clutch ECMV: Short circuit (KB)
Trouble
CALL03 DXHAKB (Steering controller system)
Contents of
When signal was output to left steering clutch solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to left steering clutch solenoid circuit.
controller
Problem that Machine cannot be steered to left.
Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
Related (Code 90601, 90603: Left steering clutch ECMV (E-POCV) output current)
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).

Defective left steering clutch out turning starting switch ON.
1 solenoid SLC5 (male) Resistance
(Internal short circuit) Between (1) (2) 5 15 z
Possible causes (Contact with ground circuit) (female) (25) SLC5 (female) (1) with chassis Resistance Min. 1 Mz
and standard ground
Short circuit in wiring
3 harness (with another wiring
harness) (female) (25) SLC5 (female) (1) with wiring
harness between STCN3 (female) (23) SLC5
(female) (2)
Between (25) (23) 5 15 z
Circuit diagram related to left steering clutch ECMV
20-656 D475A-5
(1)
TROUBLESHOOTING DXHBKA
ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA))
Action code Error code Right brake ECMV: Disconnection (KA)

Trouble
CALL E04 DXHBKA (Steering controller system)
Contents of
When signal is output to right steering brake solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to right steering brake solenoid circuit.
controller
Limits operation of engine, transmission and brake.
Output (Current) to right steering brake solenoid can be checked in monitoring mode.
Related
(Code 31620, 31618: Output current of right steering brake ECMV)
information
Method of reproducing service code: Turn starting switch ON and release parking brake lever.

1 brake solenoid (Internal
SRB3 (male) Resistance
short circuit)
Between (1) (2) 5 15 z
Possible causes ing or defective contact in SRB3 (female) (1)
and standard connector) Wiring harness between STCN3 (female) (13)
Resistance Max. 1 z
value in normal SRB3 (female) (2)
(Contact with 24V circuit) (female) (15) SRB3 (female) (1) with chassis Voltage Max. 1 V
ground
Between (15) (13) 5 15 z
D475A-5 20-657
(1)
TROUBLESHOOTING DXHBKB
ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB))
Action code Error code Right brake ECMV: Short circuit (KB)
Trouble
CALL E04 DXHBKB (Steering controller system)
Contents of
When signal was output to right steering brake solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to right steering brake solenoid circuit.
controller
Output (Current) to right steering brake solenoid can be checked in monitoring mode.
Related
(Code 31620, 31618: Output current of right steering brake ECMV)
information
Method of reproducing service code: Start engine and release parking brake lever.

1 brake solenoid (Internal SRB3 (male) Resistance
Possible causes (Contact with ground circuit) (female) (15) SRB3 (female) (1) with chassis Resistance Min. 1 Mz
and standard ground
(female) (15) SRB3 (female) (1) with wiring
harness between STCN3 (female) (13) SRB3
(female) (2)
Between (15) (13) 5 15 z
20-658 D475A-5
(1)
TROUBLESHOOTING DXHCKA
ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA))
Action code Error code Left brake ECMV: Disconnection (KA)

Trouble
CALL E04 DXHCKA (Steering controller system)
Contents of
When signal is output to left steering brake solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to left steering brake solenoid circuit.
controller
Limits operation of engine, transmission and brake.
Output (Current) to left steering brake solenoid can be checked in monitoring mode.
Related
(Code 31621, 31619: Output current of left steering brake ECMV)
information
Method of reproducing service code: Turn starting switch ON and release parking brake lever.

Defective left steering brake out turning starting switch ON.
SLB1 (male) Resistance
cuit)
Between (1) (2) 5 15 z
Possible causes ing or defective contact in SLB1 (female) (1)
and standard connector) Wiring harness between STCN3 (female) (13)
Resistance Max. 1 z
value in normal SLB1 (female) (2)
(Contact with 24V circuit) (female) (5) SLB1 (female) (1) with chassis Voltage Max. 1 V
ground
Between (5) (13) 5 15 z
D475A-5 20-659
(1)
TROUBLESHOOTING DXHCKB
ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))
Action code Error code Left brake ECMV: Short circuit (KB)
Trouble
CALL E04 DXHCKB (Steering controller system)
Contents of
When signal was output to left steering brake solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to left steering brake solenoid circuit.
controller
Output (Current) to left steering brake solenoid can be checked in monitoring mode.
Related
(Code 31621, 31619: Output current of left steering brake ECMV)
information
Method of reproducing error code: Start engine and release parking brake lever.

Defective left steering brake out turning starting switch ON.
1 solenoid (Internal short cir- SLB (male) Resistance
Possible causes (Contact with ground circuit) (female) (5) SLB (female) (1) with chassis Resistance Min. 1 Mz
and standard ground
(female) (5) SLB (female) (1) with wiring har-
ness between STCN3 (female) (13) SLB
(female) (2)
Between (5) (13) 5 15 z
20-660 D475A-5
(1)
TROUBLESHOOTING DXHDKA
ERROR CODE [DXHDKA] (GOVERNOR SOLENOID RIGHT: DISCONNECTION (KA))
Action code Error code Governor solenoid right: Disconnection (KA)

Trouble
CALL E04 DXHDKA (Engine controller system)
Contents of
The output current to the right bank governor solenoid is below 0.1 A.
trouble
Action of
controller
Problem that
machine
Related
information

Defective right bank E15 (male) Resistance
1 governor solenoid
(Internal disconnection) Between (1) and (2) 10 21 z
Between (1), (2) and
Min. 1 Mz
chassis ground
and standard contact in connector) Wiring harness between LE2 (female) (17) and
state E15 (female) (2)
(17) and E15 (female) (2) and chassis ground
LE2 (female) Resistance
Between (7) and (17) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to right bank governor solenoid
D475A-5 20-661
(1)
TROUBLESHOOTING DXHDKB
ERROR CODE [DXHDKB] (GOVERNOR SOLENOID RIGHT: SHORT CIRCUIT (KB))
Action code Error code Governor solenoid right: Short circuit (KB)
Trouble
CALL E04 DXHDKB (Engine controller system)
Contents of
The output current to the right bank governor solenoid is above 2.1 A.
trouble
Action of
controller
Problem that
machine
Related
information

Defective right bank E15 (male) Resistance
1 governor solenoid
Min. 1 Mz
chassis ground
Possible causes (Contact with ground circuit) Resistance Min. 1 Mz
and standard
value in normal
3 source in wiring harness Voltage Max. 1 V
Voltage Max. 1 V
Between (7) and (17) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to right bank governor solenoid
20-662 D475A-5
(1)
TROUBLESHOOTING DXHEKA
ERROR CODE [DXHEKA] (GOVERNOR SOLENOID LEFT: DISCONNECTION (KA))
Action code Error code Governor solenoid left: Disconnection (KA)

Trouble
CALL E04 DXHEKA (Engine controller system)
Contents of
The output current to the left bank governor solenoid is below 0.1 A.
trouble
Action of
controller
Problem that
machine
Related
information

Defective left bank governor E11 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
and standard contact in connector) Wiring harness between LE2 (female) (18) and
state E11 (female) (2)
Between (8) and (18) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to left bank governor solenoid
D475A-5 20-663
(1)
TROUBLESHOOTING DXHEKB
ERROR CODE [DXHEKB] (GOVERNOR SOLENOID LEFT: SHORT CIRCUIT (KB))
Action code Error code Governor solenoid left: Short circuit (KB)
Trouble
CALL E04 DXHEKB (Engine controller system)
Contents of
The output current to the left bank governor solenoid is above 2.1 A.
trouble
Action of
controller
Problem that
machine
Related
information

Defective left bank governor E11 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal carry out troubleshooting.
state Between wiring harness between LE2 (female)
(8) and E11 (female) (1) and short circuit or
short circuit with chassis ground in wiring
between
Voltage Max. 1 V
Between (8) and (18) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to left bank governor solenoid
20-664 D475A-5
(1)
TROUBLESHOOTING DXHFKA
ERROR CODE [DXHFKA] (PRE-STROKE SOLENOID RIGHT: DISCONNECTION (KA))
Action code Error code Pre-stroke solenoid right: Disconnection (KA)

Trouble
CALL E03 DXHFKA (Engine controller system)
Contents of
The output current deviation to the right bank pre-stroke solenoid is above 0.2 A.
trouble
controller Reduces the engine output by 20%.
Problem that
appears on The output is reduced.
machine
Related
information

Defective right bank
E14 (male) Resistance
1 pre-stroke solenoid
Between (A) and (B) 10 21 z
Between (A), (B) and
Min. 1 Mz
chassis ground
wiring harness or defective E14 (female) (A)
and standard
contact in connector) Wiring harness between LE2 (female) (19) and
E14 (female) (B)
state
(Contact with ground circuit) Between wiring harness between LE2 (female)
(9) and E14 (female) (A) and chassis ground
Between (9) and (19) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to right bank pre-stroke solenoid
D475A-5 20-665
(2)
TROUBLESHOOTING DXHFKB
ERROR CODE [DXHFKB] (PRE-STROKE SOLENOID RIGHT: SHORT CIRCUIT (KB))
Action code Error code Pre-stroke solenoid right: Short circuit (KB)
Trouble
CALL E03 DXHFKB (Engine controller system)
Contents of
The output current to the right bank pre-stroke solenoid is above 4 A.
trouble
Problem that
machine
Related
information

Defective right bank
Min. 1 Mz
chassis ground
Possible causes Resistance Min. 1 Mz
and standard
state Short circuit with power
Voltage Max. 1 V
(19) and E14 (female) (B) and chassis ground
Between (9) and (19) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to right bank pre-stroke solenoid
20-666 D475A-5
(2)
TROUBLESHOOTING DXHGKA
ERROR CODE [DXHGKA] (PRE-STROKE SOLENOID LEFT: DISCONNECTION (KA))
Action code Error code Pre-stroke solenoid left: Disconnection (KA)

Trouble
CALL E03 DXHGKA (Engine controller system)
Contents of
The output current deviation to the left bank pre-stroke solenoid is above 0.2 A.
trouble
Problem that
machine
Related
information

Defective left bank
Min. 1 Mz
chassis ground
wiring harness or defective E10 (female) (A)
and standard
contact in connector) Wiring harness between LE2 (female) (20) and
E10 (female) (B)
state
Between (10) and (20) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to left bank pre-stroke solenoid
D475A-5 20-667
(2)
TROUBLESHOOTING DXHGKB
ERROR CODE [DXHGKB] (PRE-STROKE SOLENOID LEFT: SHORT CIRCUIT (KB))
Action code Error code Pre-stroke solenoid left: Short circuit (KB)
Trouble
CALL E03 DXHGKB (Engine controller system)
Contents of
The output current to the left bank pre-stroke solenoid is above 4 A.
trouble
Problem that
machine
Related
information

Defective left bank
Min. 1 Mz
chassis ground
Possible causes
value in normal
state Between wiring harness between LE2 (female)
(10) and E10 (female) (A) and short circuit or
short circuit with chassis ground in wiring
between
Voltage Max. 1 V
(20) and E10 (female) (B) and chassis ground
Between (10) and (20) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to left bank pre-stroke solenoid
20-668 D475A-5
(2)
TROUBLESHOOTING F@BBZL
ERROR CODE [F@BBZL] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "38")
(ENGINE BLOW-BY PRESSURE: OVERPRESSURE (ZL))
Action code Error code Engine blow-by pressure: Overpressure (ZL)

Trouble
CALL E04 F@BBZL (VHMS controller system)
Contents of
The blow-by pressure is above 8.83 kPa {900 mmH O}.
trouble 2
Action of
None in particular.
controller
Problem that
machine
If error code "DHE5KB" or "DHE5KY" is displayed, carry out troubleshooting for it first.

Check the engine, then repair it if it has any abnormality.
Abnormal rise of blow-by
Possible causes 1 If the breather hose outlet is clogged with dirt and sand, bent, or broken,
pressure
and standard repair it.
value in normal Defective blow-by pressure
state 2 Check the sensor, then repair it if it has any abnormality.
sensor
If neither of causes 1 and 2 is the cause of the trouble, the VHMS con-
troller is defective.
D475A-5 20-669
(1)
TROUBLESHOOTING F@BYNR
ERROR CODE [F@BYNR] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "62")
(LEFT BANK EXHAUST TEMPERATURE (2): ABNORMAL HEATING (NR))
Action code Error code Left bank exhaust temperature (2): Abnormal heating (NR)
Trouble
CALL E04 F@BYNR (VHMS controller system)
The signal circuit of the left bank exhaust temperature sensor detected exhaust temperature above ex-
Contents of haust temperature limit line (2) for more than 10 seconds. (Exhaust temperature limit line 2: Straight
trouble line between 750C at speed above rated output speed and 800C at speed below maximum torque
speed)
Action of
None in particular.
controller
Problem that
machine
If error code "DGT5KA" or "DGT5KB" is displayed, carry out troubleshooting for it first.

Possible causes aPrepare with starting switch OFF, then start engine and carry out trou-
and standard bleshooting.
value in normal
state
2 Defective VHMS controller Before engine is approx.
Between started 20C Voltage
0.9 1.2 V
V2A (7)
and (13) After engine is started approx.
500C Voltage
(with no load) 2.6 3.5 V
20-670 D475A-5
(1)
TROUBLESHOOTING F@BYNS
ERROR CODE [F@BYNS] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "61")
(LEFT BANK EXHAUST TEMPERATURE (1): OVERHEATING (NS))
Action code Error code Left bank exhaust temperature (1): Overheating (NS)
Trouble
F@BYNS (VHMS controller system)
The signal circuit of the left bank exhaust temperature sensor detected exhaust temperature above ex-
Contents of
haust temperature limit line (1) for more than 1 second. (Exhaust temperature limit line 1: Straight line
trouble
between 700C at speed above rated output speed and 750C at speed below maximum torque speed)
Action of
None in particular.
controller
Problem that
machine

and standard bleshooting.
value in normal
state
0.9 1.2 V
V2A (7)
and (13) After engine is started approx.
500C Voltage
D475A-5 20-671
(1)
TROUBLESHOOTING F@BZNR
ERROR CODE [F@BZNR] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "72")
(RIGHT BANK EXHAUST TEMPERATURE (2): ABNORMAL HEATING (NR))
Action code Error code Right bank exhaust temperature (2): Abnormal heating (NR)
Trouble
F@BZNR (VHMS controller system)
The signal circuit of the right bank exhaust temperature sensor detected exhaust temperature above
Contents of exhaust temperature limit line (2) for more than 10 seconds. (Exhaust temperature limit line 2: Straight
speed)
Action of
None in particular.
controller
Problem that
machine

Abnormal rise of exhaust
temperature of No. 4, 5, 6
1 Check the engine, then repair it if it has any abnormality.
(rear side)
Possible causes (When system is normal)
and standard aPrepare with starting switch OFF, then start engine and carry out trou-
value in normal bleshooting.
state Between V1 (2) and V2A (13) Voltage 20 30 V
Between 20C Voltage
started 0.9 1.2 V
V2A (5)
After engine is started approx.
and (13) 500C Voltage
20-672 D475A-5
(1)
TROUBLESHOOTING F@BZNS
ERROR CODE [F@BZNS] (OR LED OF VHMS CONTROLLER INDICATES "n3" o "71")
(RIGHT BANK EXHAUST TEMPERATURE (1): OVERHEATING (NS))
Action code Error code Right bank exhaust temperature (1): Overheating (NS)
Trouble
F@BZNS (VHMS controller system)
The signal circuit of the right bank exhaust temperature sensor detected exhaust temperature above
Contents of exhaust temperature limit line (1) for more than 1 second. (Exhaust temperature limit line 1: Straight
speed)
Action of
None in particular.
controller
Problem that
machine

Abnormal rise of right bank
and standard
bleshooting.
value in normal
state
0.9 1.2 V
V2A (5)
After engine is started approx.
and (13) 500C Voltage
D475A-5 20-673
(1)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST................................................................... 20-702

E-1 THE ENGINE DOES NOT START. .................................................................................................... 20-703
E-2 THE PREHEATER DOES NOT OPERATE. (MANUAL PREHEATING FUNCTION) ........................ 20-706
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE. ..................................................... 20-708
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS
TURNED ON. .................................................................................................................................... 20-709
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY
REMAINS LIGHTED AND DOES NOT GO OUT............................................................................... 20-710
E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH................ 20- 711
E-7 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES......................................... 20-712
E-8 AN EMERGENCY CAUTION ITEM FLASHES WHILE THE ENGINE IS RUNNING. ....................... 20-715
E-9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT
COME ON.......................................................................................................................................... 20-719
E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP
DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE)........................................................... 20-721
E-11 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER
LOCK-UP DISPLAY LAMP DOES NOT COME ON. ......................................................................... 20-721
E-12 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY. ................... 20-722
E-13 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL. ......................... 20-723
E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.................... 20-724
E-15 INDICATION OF THE FUEL GAUGE IS ABNORMAL. ..................................................................... 20-725
E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL. .................................. 20-726
E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL. ........................................ 20-726
E-18 THE SWITCH MODULE CANNOT BE OPERATED.......................................................................... 20-727
E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT. ............................................ 20-728
E-20 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP................................................. 20-729
E-21 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED.................................................. 20-730
E-22 THE AUTOMATIC PITCH BACK SYSTEM DOES NOT OPERATE
(ONLY SUPERDOZER SPECIFICATION)......................................................................................... 20-731
E-23 THE ALARM BUZZER CANNOT BE CANCELLED. ......................................................................... 20-732
E-24 THE OPERATOR MODE CANNOT BE OPERATED......................................................................... 20-733
E-25 THE SERVICE MODE CANNOT BE OPERATED............................................................................. 20-734
E-26 THE BACK-UP ALARM DOES NOT SOUND.................................................................................... 20-736
E-27 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP
ON THE PANEL DO NOT COME ON................................................................................................ 20-737
E-28 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM ............................................................. 20-742
E-29 ORBCOMM TERMINAL DOES NOT OPERATE NORMALLY (DATA ARE NOT TRANSMITTED). . 20-757
D475A-5 20-701
(1)
TROUBLESHOOTING INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST

a Troubleshooting lists and related circuit diagrams contain the following information all together. Understand
the contents carefully and troubleshoot the machine.
Trouble Problem that appears on the machine.

Related
Information related to problems occurred or troubleshooting
information
<Described contents>
Standard value in normal state required to judge the assumed cause
(good or not)
1 Remarks required to judge whether the cause is good
<Phenomenon of defective harness>

The connector connection is defective or the wiring harness is discon-
nected.
Grounding fault
A harness not connected to the ground (earth) circuit comes into con-
tact with the ground (earth) circuit.
2 Defective hot short
A harness not connected to the power (24 V) circuit comes into con-
tact with the power (24 V) circuit.
Possible causes Cause by which a trouble is
Defective short
and standard assumed to be detected
A harness of an independent circuit abnormally comes into contact
value in normal (The order number indi-
with one of another circuit.
state cates a serial number, not a
priority sequence.)
<Notes on troubleshooting>
1) Method of indicating connector numbers and handling T-junction
3 For troubleshooting, insert or connect the T-junction adapter as
When male or female is not indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in both
the male and female.
When male or female is indicated for a connector number, dis-
connect the connector, and insert the T-junction adapter in only ei-
ther the male or female.
2) Pin number description sequence and tester lead handling
4 For troubleshooting, connect the plus (+) and minus () leads as
Connect the plus (+) lead to a pin or harness indicated in the front.
Connect the minus () lead to a pin or harness indicated in the rear.
Related circuit diagram
This is the excerpted circuit diagram related to trouble

Connector No.: Indicates (Model-No. of pins) (Color).
Arrow ( ): Roughly indicates mounting place on machine.
20-702 D475A-5
(1)
TROUBLESHOOTING E-1
E-1 THE ENGINE DOES NOT START.
Trouble (1) The engine does not start.

The engine start circuit has the neutral safety function, and the engine does not start unless the parking
lever is set to the lock position.
Related
If the monitor panel does not come on or the battery relay does not cause operating sound when the
information
starting switch is set to ON, the main electric power supply system is supposed to be out of order. So,
inspect the main electric power supply system.

Battery voltage Battery specific gravity
1 Insufficient battery capacity
Min. 24 V Min. 1.26
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective starting switch
2 KEY (male) Switch position Resistance
(internal disconnection)
OFF Min. 1 Mz
Between (5) and (3)
START Max. 1 z
aPrepare with the starting switch OFF, then start the engine and carry
Defective neutral safety out troubleshooting.
3 relay (internal disconnec- If the engine starts in accordance with the engine starting arrangement
tion) after the neutral safety relay (NSF) is replaced with another one while
the starting switch is set to OFF, the relay is defective.
aPrepare with the starting switch OFF, then turn the starting switch ON
Defective alternator (inter- and carry out troubleshooting.
4
nal short-circuit) Alternator Voltage
Between Terminal R and ground Max. 1 V
Possible causes Starting motor Voltage
and standard Electric power supply : between
20 30 V
value in normal Terminal B and ground
state Detective starting motor Charge : between Terminal R
5 Max. 1 V
(internal defect) and ground
Starting : between Terminal C
20 30 V
and ground
When the voltages of electric power supply, for charging and starting are
normal but the starting motor does not rotate, the starting motor is defec-
tive.
Disconnection in wiring har- without turning the starting switch ON.
ness (disconnection in wir- Wiring harness between KEY (female) (3) and
ing or defective contact in NFS (female) (3)
connector) Wiring harness between NSF (female) (5) and
Resistance Max. 1 z
starting motor C terminal
and carry out troubleshooting.
Hot short circuit of wiring harness between
Hot short circuit of wiring
alternator R terminal and starting motor R termi-
nal or TMCN1 (female) (15) or S04 (female) (9)
with ground (Note : While a hot short circuit
occurs, the battery charge level lamp comes on
when the starting switch is turned ON.)
D475A-5 20-703
(1)
TROUBLESHOOTING E-1
Trouble (1) is not detected but the engine does not start (When the machine is equipped with pre-lubri-
Trouble (2)
cator).
"PE" is displayed on the gear speed display unit and "E" on the right side flashes.
After the engine is started, if "Po" is displayed on the gear speed display unit and "0" on the right side
Related
flashes, the engine oil pressure is not heightened. (In this case, the pre-lubrication motor and the en-
information
gine oil pressure switch for pre-lubrication may be defective. Accordingly, carry out the following trou-
bleshooting.)

Defective engine oil aPrepare with starting switch OFF, then keep starting switch OFF or
pressure switch for start engine and carry out troubleshooting.
1 pre-lubrication STCN2 Starting switch Resistance
(Internal disconnection or Between (3) and OFF Max. 1 z
short circuit) chassis ground Start engine Min. 1 Mz
aWhen the relay is replaced with another one with the starting switch
Defective pre-lubrication OFF, the engine starts or "PE" is displayed on the gear speed display
2
relay (PLR) unit and "E" on the right side flashes after the starting switch is turned
ON.
Defective pre-lubrication
3 Pre-lubrication motor Voltage
motor
Between signal terminal
20 30 V
and chassis ground
and standard Between negative pressure switch terminal
Disconnection in wiring POP and STCN2 (female) (3)
state harness (Disconnection in Between junction wiring harness (JMR) and
wiring harness or defective pre-lubrication relay (PLR) (female) (1)
contact in connector) Between pre-lubrication relay (PLR) (female)
Resistance Max. 1 z
(2) and STCN2 (female) (18)
Between pre-lubrication motor signal terminal
Resistance Max. 1 z
and STCN1 (female) (15)
Between wiring harness between junction wir-
ing harness (JMR) and pre-lubrication relay Resistance Min. 1 Mz
Short circuit with chassis (PLR) (female) (1) and chassis ground
5 ground in wiring harness Between wiring harness between pre-lubrica-
(Contact with ground circuit) tion relay (PLR) (female) (2) and STCN2 Resistance Min. 1 Mz
Between wiring harness between pre-lubrica-
tion motor signal terminal and STCN1 (female) Resistance Min. 1 Mz
20-704 D475A-5
(1)
TROUBLESHOOTING E-1
Engine start/charge-related circuit diagram
D475A-5 20-705
(1)
TROUBLESHOOTING E-2
E-2 THE PREHEATER DOES NOT OPERATE. (MANUAL PREHEATING FUNCTION)
Trouble The preheater does not operate. (Manual preheating function)

aThis troubleshooting describes the procedures to be followed when the manual preheating function can-
not heat the electrical intake air heater mounting section. (When the preheating lamp only does not
come on, carry out the troubleshooting of The preheating lamp does not come on.)
Related For preheating, both the Automatic Preheating Function and the Manual Preheating Function are
information available. When either function is performed, the preheating lamp comes on.
If the monitor panel does not come on or the battery relay does not cause operating sound hen the
starting switch is turned ON, the main electric power supply system supposed to be out of order. So,
inspect the main electric power supply system.

1 KEY (male) Switch position Resistance
OFF Min. 1 Mz
Between (5) and (2)
HEAT Max. 1 z
aPrepare with the starting switch OFF, then set the starting switch to
HEAT and carry out troubleshooting.
Heater relay Voltage
Electric power supply : between
Defective heater relay 20 30 V
2 Terminal 134 and 135 ground
(internal defect)
Signal : between Terminal 136 and
20 30 V
137 ground
When the both voltages of electric power supply and signal are normal
Possible causes and no operating sound is caused, the heater relay is defective.
and standard aPrepare with the starting switch OFF, then carry out troubleshooting
value in normal Defective electrical intake without turning the starting switch ON.
state 3
air heater (internal defect) Electrical intake air heater Continuity
Between terminals Continue
Wiring harness between FS4-4 output RHR
Resistance Max. 1 z
(female) (3)
Wiring harness between RHR (female) (5) and
Disconnection in wiring har-
KEY (female) (2) or heater relay 136, 137 termi- Resistance Max. 1 z
ness (Disconnection in wir-
4 nal
ing or defective contact in
connector) Wiring harness between battery relay M termi-
nal and starting motor, or heater relay 134, 135 Resistance Max. 1 z
terminal
Wiring harness between electrical intake air
heater terminal of heater relay and electrical Resistance Max. 1 z
intake air heater
20-706 D475A-5
(1)
TROUBLESHOOTING E-2
Engine preheat-related circuit diagram
D475A-5 20-707
(1)
TROUBLESHOOTING E-3
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE.
Trouble The ripper pin puller cylinder does not operate.

Related
information

When the fuse is blown, a ground fault may have possibly occurred to
1 Defective fuse (FS4-1)
the circuit.
Defective pin puller switch without turning the starting switch ON.
2 (Internal disconnection or 263 (male) Switch Resistance
short circuit) Pull Max. 1 z
Between (1) and (2)
Press Min. 1 Mz
Defective pin puller solenoid without turning the starting switch ON.
3 (Internal disconnection or 224 (male) Resistance
short circuit) Between (1) and (2) 10 80 z
Between (1) and ground Min. 1 Mz
Possible causes aPrepare with the starting switch OFF, then carry out troubleshooting
and standard without turning the starting switch ON.
value in normal Disconnection of wiring har- Wiring harness between FS4-1 outlet and 263
Resistance Max. 1 z
state ness (Disconnection in wir- (female) (1)
4
ing or defective contact in Wiring harness between 263 (female) (2) and
Resistance Max. 1 z
connector) 224 (female) (1)
Wiring harness between 224 (female) (2) and
Resistance Max. 1 z
ground
Ground fault of wiring har-
Between wiring harness related to FS4-1 (outlet
5 ness (Contact with ground Resistance Min. 1 Mz
side) and ground
circuit)
Between wiring harness (between 263 (female)
(2) and 224 (female) (1)) and ground
Between wiring harness (between 263 (female)
Circuit diagram related to ripper pin puller solenoid
20-708 D475A-5
(1)
TROUBLESHOOTING E-4
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING
SWITCH IS TURNED ON.
Trouble The monitor panel does not come on at all when the starting switch is turned ON.
Related When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge
information section and the lamp section come on for 2 sec.

Defective circuit breaker When the circuit breaker is cut off, the circuit may have possibly been
1
(CB2) short-circuited with ground.
Disconnection of wiring har- without turning the starting switch ON.
ness (Disconnection in wir- Wiring harness between S03 (female) (1) (2)
ing or defective contact in and CB2 outlet
Possible causes connector) Wiring harness between S03 (female) (3) (4)
and ground
value in normal
state Ground fault of wiring har-
3 ness (Contact with ground
Between wiring harness related to CB2 (outlet
circuit) Resistance Min. 1 Mz
side) and ground
Defective monitor panel and carry out troubleshooting.
4
(Gauge/lamp module) S03 Voltage
Between (1) (2) and (3) (4) 20 30 V
Circuit diagram related to monitor panel electric power supply
D475A-5 20-709
(1)
TROUBLESHOOTING E-5
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COM-
PLETELY REMAINS LIGHTED AND DOES NOT GO OUT.
When the starting switch is turned ON, the monitor panel completely remains lighted and does not go
Trouble
out.
Related When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge
information section and the lamp section come on for 2 sec. and go out.

and standard
Defective monitor panel
value in normal 1 This internal defect cannot be diagnosed.
(Gauge/lamp module)
state
20-710 D475A-5
(1)
TROUBLESHOOTING E-6
E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS
FLASH.
Trouble The radiator water level caution lamp flashes.

Related
When any basic check items are detected to be abnormal before the engine starts, they will flash.
information

A drop of radiator water level (main radiator or dual radiator) was
Drop of radiator water level
1 detected, inspect the radiator water levels. (The lamp flashes when the
(when the system is normal)
level is below the specified level.)
The main radiator water without turning the starting switch ON.
2 level sensor is defective. 405 (male) Radiator water level Resistance
(Internal disconnection) Normal level Max. 1 z
Between (1) and (2)
Lower level Min. 1 Mz
The dual radiator water without turning the starting switch ON.
3 level sensor is defective. DRT (male) Radiator water level Resistance
Possible causes (Internal disconnection) Normal level Max. 1 z
and standard Between (1) and (2)
Lower level Min. 1 Mz
value in normal
state aPrepare with the starting switch OFF, then carry out troubleshooting
Disconnection of wiring har- Wiring harness between S03 (female) (11) and
Resistance Max. 1 z
ness (Disconnection in wir- DRT (female) (1)
4
ing or defective contact in Wiring harness between DRT (female) (2) and
Resistance Max. 1 z
Resistance Max. 1 z
ground
5 S03 Radiator water level Voltage
(Gauge/lamp module)
Between (11) and Normal level Max. 1 V
ground Lower level 20 20 V
Circuit diagram related to monitor panel electric power supply
D475A-5 20-711
(1)
TROUBLESHOOTING E-7
E-7 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES.
Trouble (1) The battery charge level caution lamp flashes.

Related
When any abnormality is detected during engine operation, the relevant caution item will flash.
information

Defective alternator (insuffi-
1 Alternator Engine speed Voltage
cient power generation)
Between Terminal R Min. medium speed
20 30 V
and ground (half)
Disconnection of wiring har- aPrepare with the starting switch OFF, then carry out troubleshooting
ness (Disconnection in wir- without turning the starting switch ON.
2
ing or defective contact in Wiring harness between S04 (female) (9) and
connector) alternator R terminal
and standard
value in normal aPrepare with the starting switch OFF, then carry out troubleshooting
state without turning the starting switch ON.
(9), alternator terminal R, starting motor termi-
nal C, CAN (male) (5), and TMCN2 (female)
4 S04 Voltage
(Gauge/lamp module)
Between (9) and Min. medium speed
20 30 V
ground (half)
20-712 D475A-5
(1)
TROUBLESHOOTING E-7
Engine start/charge-related circuit diagram
D475A-5 20-713
(1)
TROUBLESHOOTING E-7
Trouble (2) The air cleaner clogging caution lamp flashes.

Related
If abnormality is detected while the engine is running, the caution item lamp flashes.
information

1 Clogged air cleaner Clean or replace the air cleaner.
2
wiring harness or defective Wiring harness between S03 (female) (13) and
Resistance Max. 1 z
contact in connector) AF1 (female) (1)
Possible causes
state (Contact with ground circuit) Resistance Min. 1 Mz
(13) and AF1 (female) (1) and chassis ground
4 S03 Air cleaner Voltage
(gauge, lamp module)
Between (13) and When normal Max. 1 V
chassis ground When clogged 20 30 V
Circuit diagram related to air cleaner
20-714 D475A-5
(1)
TROUBLESHOOTING E-8
E-8 AN EMERGENCY CAUTION ITEM FLASHES WHILE THE ENGINE IS RUNNING.
Trouble (1) The engine oil pressure caution lamp flashes.

If abnormality is detected while the engine is running, the emergency calculation item flashes and the
Related
information
The engine oil pressure sensor signal is received from the steering controller by communication.

supply system
2 pressure sensor
ENGP Voltage
(Internal defect)
wiring harness or defective and ENGP (female) (B)
Resistance Max. 1 z
and ENGP (female) (C)
Possible causes
and standard
value in normal
state 4 ground in wiring harness Between wiring harness between STCN1
(Contact with ground circuit) (female) (7) and ENGP (female) (C) and chas- Resistance Min. 1 Mz
sis ground
(Contact with 24-V circuit) (female) (7) and ENGP (female) (C) and chas- Voltage Max. 1 V
sis ground
Between (7) and (22) 0.3 6.0 V
Defective monitor panel Troubleshooting cannot be carried out since the defect is in the monitor
7
(Gauge, lamp module) panel.
D475A-5 20-715
(1)
TROUBLESHOOTING E-8
Trouble (2) The hydraulic oil level caution lamp flashes.

If abnormality is detected while the engine is running, the emergency calculation item flashes and the
Related
information
The hydraulic oil level switch signal is received from the steering controller by communication.

Low hydraulic oil level
1 Low hydraulic oil level is detected. Check the hydraulic oil level.
Defective hydraulic oil level HLS Hydraulic oil level Resistance
2
switch (Internal short circuit)
Specified level Min. 1 Mz
Between (1) and (2)
Insufficient level Max. 1 z
Possible causes
and standard
value in normal harness (Disconnection in Wiring harness between STCN3 (female) (9)
state wiring harness or defective and HLS (female) (1)
contact in connector) Wiring harness between HLS (female) (2) and
Resistance Max. 1 z
STCN1 (female) (4)
(Contact with ground circuit) (female) (9) and HLS (female) (1) and chassis Resistance Min. 1 Mz
ground
Defective monitor panel Troubleshooting cannot be carried out since the defect is in the monitor
5
(Gauge, lamp module) panel.
Circuit diagram related to hydraulic oil level switch
20-716 D475A-5
(1)
TROUBLESHOOTING E-8
Trouble (3) The engine water temperature caution lamp flashes.

When any abnormality is detected during engine operation, the relevant emergency warning item will
Related sound the alarm buzzer.
information The engine water temperature caution lamp flashes or goes out as it links with indication on the engine
water temperature gauge.

As overheated engine water was detected, check the engine water tem-
Overheated engine water
perature. (When the water temperature is over 102C, the lamp flashes.
1 temperature (when the sys-
When the water temperature is over 108C, the lamp flashes and the
tem is normal)
buzzer sounds.)
Check the indication on the engine water temperature gauge. If the indi-
cation is abnormal, carry out the troubleshooting of Indication on the
engine water temperature gauge is abnormal.
aWater temperatures are guides for selecting
indications.
Possible causes
and standard
The engine water tempera-
value in normal
ture sensor system is defec- Water temperature
state 2
tive. (Engine controller gauge
system)
White range/
Water temperature Red range
Green range
lamp
Goes out. Flashes.
Defective monitor panel When Causes 1 and 2 are not applicable, the monitor panel is supposed
3
(Gauge/lamp module) to be defective. (This is an internal defect, which cannot be troubleshot.)
Trouble (4) The power train oil temperature caution lamp flashes.
information The power train oil temperature caution lamp flashes or goes out as it links with indication on the power
train oil temperature gauge.

Overheated oil temperature As an overheated power train oil temperature was detected, check the
1 of power train (when the power train oil temperature. (When the oil temperature is over 130C,
system is normal) the lamp flashes.)
Check the indication on the power train oil temperature gauge. If the
indication is abnormal, carry out the troubleshooting of Indication on the
power train oil temperature gauge is abnormal.
aOil temperatures are guides for selecting in-
dications.
Possible causes
and standard
The power train oil tempera-
value in normal
2 ture sensor system is defec- Oil temperature gauge
state
tive. (Monitor panel system)
White range/
Red range
Oil temperature lamp Green range
Goes out. Flashes.
3
D475A-5 20-717
(1)
TROUBLESHOOTING E-8
Trouble (5) The hydraulic oil temperature caution lamp flashes.

information The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the hydraulic
oil temperature gauge.

Overheated hydraulic oil As an overheated hydraulic oil temperature was detected, check the
1 temperature (when the sys- hydraulic oil temperature. (When the oil temperature is over 130C, the
tem is normal) lamp flashes.)
Check the indication on the engine water temperature gauge. If the indi-
cation is abnormal, carry out the troubleshooting of Indication on the
hydraulic oil temperature gauge is abnormal.
aOil temperatures are guides for selecting in-
dications.
Possible causes
and standard
The hydraulic oil tempera-
value in normal
2 ture sensor system is defec- Oil temperature gauge
state
tive. (Monitor panel system)
White range/
Red range
Oil temperature lamp Green range
Goes out. Flashes.
3
20-718 D475A-5
(1)
TROUBLESHOOTING E-9
E-9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES
NOT COME ON.
Trouble While the preheater is operating, the preheating pilot lamp does not come on.
aThis troubleshooting describes the procedures to be followed when the preheating lamp doe not come
on. (When the preheater mounting section is not heated, carry out the troubleshooting of The preheater
Related
does not work.)
information
For preheating, both the Automatic Preheating Function and the Manual Preheating Function are
available. Even when either function is performed, the preheating lamp comes on.

1
Resistance Max. 1 z
connector) heater relay 414 terminal
and standard without turning the starting switch ON.
value in normal Between wiring harness between S03 (female)
state (9) and heater relay 414 terminal and ground
3 S03 Starting switch Voltage
(Gauge/lamp module)
Between (9) and ON Max. 1 V
ground HEAT 20 30 V
D475A-5 20-719
(1)
TROUBLESHOOTING E-9
Engine preheat-related circuit diagram
20-720 D475A-5
(1)
TROUBLESHOOTING E-10, E-11
E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR
LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE)
At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tilt-mounted
Trouble
machine)
Before troubleshooting the blade, make sure that the dual tilt can operate. (When the blade does not
Related
operate normally, the electrical system on the machine side or the hydraulic/mechanical system is sup-
information
posed to be out of order. So, troubleshoot the relevant system.)

and standard
value in normal 1 This is an internal defect, which cannot be troubleshot.
(Gauge/lamp module)
state
E-11 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CON-

VERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON.
Trouble At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on.
Before troubleshooting the torque converter, make sure that the lock-up is operating. (When the lock-
Related
up does not operate normally, the electrical system on the machine side or the hydraulic/mechanical
information
system is supposed to be out of order. So, troubleshoot the relevant system.)

and standard
(Gauge/lamp module)
state
D475A-5 20-721
(1)
TROUBLESHOOTING E-12
E-12 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.
Trouble The engine water temperature gauge does not indicate normally.
Signals of the engine water high temperature sensor are received from the engine controller through
Related communication.
information When any abnormality occurred in the engine hot water temperature sensor system, the failure code
[DGE2KX] is displayed sometimes.

The engine water high tem- without turning the starting switch ON.
perature sensor is defec-
1 402 (male) Resistance
tive. (Internal disconnection
Between (1) and (2) 3.5 k 90 kz
or short circuit)
Between (1) (2) and ground Min. 1 Mz
ness (Disconnection in wir- Wiring harness between LE32 (female) (5) and
ing or defective contact in 402 (female) (1)
connector) Wiring harness between LE31 (female) (16) Resistance Max. 1 z
and 402 (female) (2) Resistance Max. 1 z
and standard Ground fault of wiring har-
value in normal 3 ness (Contact with ground
Between wiring harness (between LE32
state circuit) Resistance Min. 1 Mz
(female) (5) and 402 (female) (1)) and ground
Between wiring harness (between LE32
LE31, LE32 Resistance
Between LE32 (5) LE31 (16) 3.5 k 90 kz
Between LE32 (5) LE31 (16)
Min. 1 Mz
and ground
6 This is an internal defect, which cannot be troubleshot.
(Gauge/lamp module)
Circuit diagram related to engine water high temperature sensor
20-722 D475A-5
(1)
E-13 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL.
Trouble Indication of the power train temperature gauge is abnormal.

Related
information

The power train oil tempera- Torque converter oil
453 (male) Resistance
ture sensor is defective. temperature
1
(Internal disconnection or About 3.8 k
Between (1) and (2)
short circuit) about 80 kz
10 100C
Between (1) and
Min. 1 Mz
ground
ness (Disconnection in wir- Wiring harness between S04 (female) (12) and
Possible causes connector) Wiring harness between 453 (female) (1) and Resistance Max. 1 z
and standard
ground Resistance Max. 1 z
value in normal
state aPrepare with the starting switch OFF, then carry out troubleshooting
Between wiring harness (between S04 (female)
Defective monitor panel Torque converter oil
5 S04 (female) Resistance
(Gauge/lamp module) temperature
Between (12) and About 3.8 k
10 100C
ground about 80 kz
Circuit diagram related to power train oil temperature sensor
D475A-5 20-723
(1)
E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.
Trouble The hydraulic oil temperature gauge does not indicate normally.
Signals of the hydraulic oil temperature sensor are received from the transmission controller through
Related communication.
information When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
[DGS1KX] is displayed sometimes.

The hydraulic oil tempera- without turning the starting switch ON.
ture sensor is defective.
1 SDS (male) Resistance
Between (1) and (2) 3.5 k 90 kz
short circuit)
ing or defective contact in and SDS (female) (1)
Resistance Max. 1 z
and SDS (female) (2)
Possible causes
and standard Ground fault of wiring har-
value in normal 3 ness (Contact with ground
state Between wiring harness (between TMCN1
(female) (14) and SDS (female) (1)) and ground
Between wiring harness (between TMCN1
(female) (14) and SDS (female) (1)) and ground
troller
Between (14) and (21) 3.5 k 90 kz
(Gauge/lamp module)
Circuit diagram related to hydraulic oil temperature sensor
20-724 D475A-5
(1)
E-15 INDICATION OF THE FUEL GAUGE IS ABNORMAL.
Trouble Indication of the fuel gauge is abnormal.

Related
information

Defective fuel level sensor. without turning the starting switch ON.
1 (Internal disconnection or 422 (male) Remained fuel level Resistance
short circuit) Between (1) and (2) Full About 4 z
(ground) Empty About 85 z
ness (Disconnection in wir- Wiring harness between S04 (female) (10) and
connector) Wiring harness between 422 (female) (2) and
ground
and standard
value in normal Ground fault of wiring har-
state 3 ness (Contact with ground
5 S04 (female) Remained fuel level Resistance
(Gauge/lamp module)
Between (10) and Full About 4 z
ground Empty About 85 z
Circuit diagram related to fuel level sensor
D475A-5 20-725
(1)
TROUBLESHOOTING E-16, E-17
E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL.
Trouble Indications of gear speed and engine speed are abnormal.

Related Signals of gear speed and engine speed are received from the transmission controller and the engine
information controller through communication.

and standard
(Gauge/lamp module)
state
E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL.
Trouble (1) During engine operation, the service meter does not advance.
Related The service meter measures time according to engine drive signals (alternator voltage and engine oil
information pressure).

When the battery charge level caution lamp flashes during engine oper-
1 Defective alternator system ation, carry out the troubleshooting of While the engine is operating,
Possible causes
caution items flash.
and standard
The engine oil pressure When the engine oil pressure caution lamp flashes during engine oper-
value in normal
2 sensor system is defective. ation, carry out the troubleshooting of While the engine is operating,
state
(Engine controller system) emergency warning items flash.
(Gauge/lamp module)
Trouble (2) Shift mode and service meter are not displayed at all.
Related
information

and standard
(Gauge/lamp module)
state
20-726 D475A-5
(1)
E-18 THE SWITCH MODULE CANNOT BE OPERATED.
Trouble (1) Though the switch is used, lamps do not change.

Related
information

and standard
(Switch module)
state
Trouble (2) Though the switch is used, the system setting does not change.
Related
Switch module signals are transmitted to each controller through communication.
information

ness (Disconnection in wir- Wiring harness between S01 (female) (8)
Possible causes 1
ing or defective contact in STCN2 (female) (21), TMCN2 (female) (21),
connector) LE4 (female) (6), (12), V3A (female) (8),
value in normal
(18)
state
Defective monitor panel out the troubleshooting.
2
Between (8) and ground 69V
Circuit diagram related to S-NET Communication
D475A-5 20-727
(1)
E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT.
Trouble The warning lamp does not flash or does not go out.
Related
information

and standard
(Gauge/lamp module)
state
20-728 D475A-5
(1)
E-20 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP.
Trouble The alarm buzzer does not sound or does not stop.
Related When a short circuit occurs in the alarm buzzer system, the failure code is displayed but no other failure
information codes are displayed.

Defective circuit breaker When the circuit breaker is cut off, a ground fault may have possibly
1
(CB2) occurred in the circuit.
Defective alarm buzzer without turning the starting switch ON.
2 (Internal disconnection or 217 (male) Resistance
short circuit) Between (1) and (2) 200 z
Possible causes ness (Disconnection in wir- Wiring harness between S03 (female) (18) and
and standard ing or defective contact in 217 (female) (1)
value in normal connector) Wiring harness between 217 (female) (2) and
CB2 outlet
side) and ground
Defective monitor panel S03 Alarm buzzer Voltage
5
(Gauge/lamp module) At stop 20 30 V
Between (18) and
At operation (sound-
ground Max. 3 V
ing)
Circuit diagram related to alarm buzzer
D475A-5 20-729
(1)
E-21 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED.
Trouble Auto shift down is not possible or is not released.

Related
Defective auto shift down switch (Internal disconnection or short circuit)
information

Defective auto shift down without turning the starting switch ON.
1 switch (Internal disconnec- ASD (male) Auto shift down switch Resistance
tion or short circuit) OFF (0) Min. 1 Mz
Between (2) and (3)
ON (1) Max. 1 z
ing or defective contact in and ADS (female) (3)
Possible causes connector) Wiring harness between ADS (female) (2) and
Resistance Max. 1 z
and standard ground
value in normal aPrepare with the starting switch OFF, then carry out troubleshooting
state Ground fault of wiring har-
Between wiring harness (between TMCN3
(female) (39) and ASD (female) (3)) and ground
4 TMCN3 Auto shift down switch Voltage
troller
Between (39) and OFF (0) 20 30 V
ground ON (1) Max. 3 V
When Causes 1 to 4 are not applicable, the transmission control system
5 is supposed to be out of order. (Since the system is defective, the control
trol system
system cannot be troubleshot.)
Circuit diagram related to auto shift down switch
20-730 D475A-5
(1)
E-22 THE AUTOMATIC PITCH BACK SYSTEM DOES NOT OPERATE (ONLY SUPER-
DOZER SPECIFICATION).
Trouble The machine cannot start or stop a pivot turn.

Related
information

Defective pivot turn switch out turning starting switch ON.
1 (Internal disconnection or FTU (male) Pivot turn switch Resistance
short circuit) OFF (0) Min. 1 Mz
Between (2) and (3)
ON (1) Max. 1 z
wiring harness or defective and FTU (female) (3)
contact in connector) Wiring harness between FTU (female) (2) and
TMCN1 (female) (4)
and standard
(female) (9) and FTU (female) (3)
Defective transmission Automatic pitch
4 TMCN1, TMCN3 Voltage
controller back switch
Between TMCN3 (9) OFF (0) 20 30 V
and TMCN1 (4) ON (1) Max. 3 V
If none of causes 1 4 is the cause of the trouble, the transmission con-
5 trol system may be defective (Troubleshooting cannot be carried out
control system
since the defect is in the system).
Circuit diagram related to automatic pitch back switch
D475A-5 20-731
(1)
E-23 THE ALARM BUZZER CANNOT BE CANCELLED.
Trouble The alarm buzzer cannot be cancelled.

Related
information

BUZ (male) Buzzer cancel switch Resistance
Defective buzzer cancel
1 switch (Internal disconnec- OFF (0) Min. 1 Mz
Between (1) and (2)
tion or short circuit) Max. 1 z
OFF (0) Min. 1 Mz
Between (1) and (3)
Max. 1 z
Disconnection of wiring har- Wiring harness between STCN2 (36) and BUZ
Resistance Max. 1 z
ness (Disconnection in (female) (2)
2
wiring or defective contact Wiring harness between STCN2 (26) and BUZ
in connector) (female) (3)
and standard
Wiring harness between BUZ (female) (1) and
STCN1 (female) (10)
state
Between wiring harness (between STCN2 (36)
and BUZ (female) (2)) and ground
circuit)
and BUZ (female) (3)) and ground
and carry out the troubleshooting.
STCN2 Buzzer cancel switch Voltage
4 Defective steering controller Between STCN2 (36) OFF (0) 20 30 V
STCN1 (10) Max. 1 V
Between STCN2 (26) OFF (0) 20 30 V
STCN1 (10) Max. 1 V
Circuit diagram related to buzzer cancel switch
20-732 D475A-5
(1)
E-24 THE OPERATOR MODE CANNOT BE OPERATED.
Trouble The operator mode cannot be operated.

Related
information

Defective buzzer cancel Since the buzzer cancel switch system is supposed to be out of order,
1
switch system carry out the troubleshooting of The alarm buzzer cannot be cancelled.
Defective information switch CUR (male) Information switch Resistance
2 (Internal short circuit or dis- OFF (0) Min. 1 Mz
Between (1) and (2)
connection) Max. 1 z
OFF (0) Min. 1 Mz
Between (1) and (3)
Max. 1 z
Disconnection of wiring har- Wiring harness between STCN2 (16) and CUR
Resistance Max. 1 z
ness (Disconnection in wir- (female) (2)
Possible causes 3
ing or defective contact in Wiring harness between STCN2 (6) and CUR
and standard
connector) (female) (3)
value in normal
state Wiring harness between CUR (female) (1) and
Resistance Max. 1 z
STCN1 (female) (10)
and CUR (female) (2)) and ground
circuit)
and CUR (female) (3)) and ground
STCN2 Buzzer cancel switch Voltage
5 Defective steering controller Between STCN2 (16) OFF (0) 20 30 V
STCN1 (10) Max. 1 V
Between STCN2 (6) OFF (0) 20 30 V
STCN1 (10) Max. 1 V
Circuit diagram related to information switch
D475A-5 20-733
(1)
E-25 THE SERVICE MODE CANNOT BE OPERATED.
Trouble The service mode cannot be operated.

Related
information

Defective buzzer cancel Since the buzzer cancel switch system is supposed to be out of order,
1
switch system carry out the troubleshooting of The alarm buzzer cannot be cancelled.
Defective information switch Since the information switch system is supposed to be out of order, carry
2
system out the troubleshooting of The operator mode cannot be cancelled.
3
Defective service switch without turning the starting switch ON.
4 (Internal short circuit or dis- S24 Service switch Resistance
connection) Between (1) and (2), OFF Min. 1 Mz
Between (4) and (5) ON Max. 1 z
Disconnection of wiring har- Wiring harness between CB6 outlet and S24 (1) Resistance Max. 1 z
Possible causes ness (Disconnection in wir- Wiring harness between S24 (6) and ground Resistance Max. 1 z
5
and standard ing or defective contact in Wiring harness between S03 (female) (16) and
value in normal S24 (2)
state Wiring harness between STCN1 (female) (6)
Resistance Max. 1 z
and S24 (4)
side) and ground
7 S03 Service switch Voltage
(Gauge/lamp module)
Between (16) and OFF Max. 1 V
ground ON 20 30 V
8 Defective steering controller STCN1 Service switch Voltage
Between (6) and OFF 20 30 V
ground ON Max. 1 V
20-734 D475A-5
(1)
Circuit diagram related to service switch
D475A-5 20-735
(1)
E-26 THE BACK-UP ALARM DOES NOT SOUND.
Trouble The back-up alarm does not sound.

Related When a failure occurs on the primary side (coil side) of the back-up alarm relay, a relevant failure code
information is displayed, but in case of failure on the secondary side (contact side), no failure code is displayed.

When the fuse is blown, a ground fault may have probably occurred in
the circuit.
Defective back-up relay When the relay is replaced with another relay while the starting switch is
2
(internal disconnection) set to OFF and the alarm sounds after the starting switch is turned on
and the machine is operated in reverse, the back-up alarm relay (BKA)
is defective.
Possible causes
Disconnection of wiring har- Wiring harness between FS4-1 outlet and BKA
ness (Disconnection in wir- (female) (3)
value in normal 3
ing or defective contact in Wiring harness between BKA (female) (5) and
Resistance Max. 1 z
ground
Between wiring harness related to FS4-1 (outlet
side) and ground
circuit)
Between wiring harness (between BKA
Defective back-up alarm When Causes 1 to 4 are not applicable, the back-up alarm is supposed
5
(internal defect) to be defective.
Circuit diagram related to back-up alarm
20-736 D475A-5
(1)
E-27 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR
LAMP ON THE PANEL DO NOT COME ON.
Trouble (1) None of the night light, the headlamp and the working lamp on the panel comes on.
Related
information

Headlamp and working without turning the starting switch ON.
1 lamp switch (international 219 (male) Switch Resistance
disconnection) OFF Min. 1 Mz
Between (2) and (3)
ON Max. 1 z
Possible causes
value in normal without turning the starting switch ON.
state Wiring harness between 219 (female) (2) and
Resistance Max. 1 z
Ground fault of wiring har- CB5
2 ness (Contact with ground Wiring harness between 219 (female) (3), BB1
circuit) (female) (1), and BB2 (female) (1) or BB3 Resistance Max. 1 z
(female) (1)
Wiring harness between BB1 (female) (1), BB2
Resistance Max. 1 z
(female) (2) or BB3 (female) (1) and ground
Trouble (2) Only the night light on the panel does not comes on. (whole or part)
Related
information

Defective night lamp
1 The night lamp is supposed to be defective. Check if the bulb is blown.
(blown)
Wiring harness between S01 (female) (10) and
Resistance Max. 1 z
circuit branching point
Disconnection of wiring har- Wiring harness between S01 (female) (2) and
Resistance Max. 1 z
ness (Disconnection in wir- ground
2
Resistance Max. 1 z
connector) circuit branching point
Possible causes
Wiring harness between S03 (female) (8) and
circuit branching point
value in normal
state Wiring harness between S03 (female) (3), (4)
Resistance Max. 1 z
and ground
Defective monitor panel Between S01 (10)
3
(Switch module) and (2)
Light switch ON 20 30 V
Between S02 (1)
and ground
Defective monitor panel and carry out troubleshooting.
4
(Gauge/lamp module) Between S03
Light switch ON 20 30 V
(8) and (3), (4)
D475A-5 20-737
(1)
Trouble (3) Only the headlamp does not comes on. (Both right and left)
Related
information

1
Possible causes
and standard 2
ing or defective contact in Wiring harness between CB5 outlet and BB1
connector) (female) (3), BB2 (female) (3)
state
side) and ground
Trouble (4) Only the left headlamp does not comes on.
Related
information

Defective left headlamp
1 The headlamp is supposed to be defective. Check if the bulb is blown.
(blown)
Defective headlamp relay 1 When the relay is replace with another relay while the starting switch is
2
(Internal disconnection) set to OFF and the headlamp comes on after the starting switch is
turned ON and the light switch is turned ON, the headlamp relay (BB1)
is defective.
and standard Disconnection of wiring har- without turning the starting switch ON.
value in normal ness (Disconnection in wir- Wiring harness between CB5 outlet and BB1
state ing or defective contact in (female) (3)
connector) Wiring harness between BB1 (female) (5) and
Resistance Max. 1 z
204 (female) (1) or 207 (female) (1)
Ground fault of wiring har- Between wiring harness related to CB5 (outlet
4 ness (Contact with ground side) and ground
circuit) Between wiring harness (between BB1
(female) (5) and 204 (female) (1) or 207 Resistance Min. 1 Mz
(female) (1)) and ground
20-738 D475A-5
(1)
Trouble (5) Only the right headlamp does not comes on.
Related
information

Defective right headlamp
1 The headlamp is supposed to be defective. Check if the bulb is blown.
(blown)
Defective headlamp relay 2 When the relay is replace with another relay while the starting switch is
2
(Internal disconnection) set to OFF and the headlamp comes on after the starting switch is
turned ON and the light switch is turned ON, the headlamp relay (BB2)
is defective.
and standard Disconnection of wiring har- without turning the starting switch ON.
value in normal ness (Disconnection in wir- Wiring harness between CB5 outlet and BB2
state ing or defective contact in (female) (3)
Resistance Max. 1 z
203 (female) (1) or 206 (female) (1)
Ground fault of wiring har- Between wiring harness related to CB5 (outlet
Trouble (6) Only the working lamp does not comes on. (Both right and left, or one side only)
Related
information

Defective working lamp The working lamp is supposed to be defective. Check if the bulb is
1
(blown) blown.
When the fuse is blown, a ground fault may have probably occurred in
the circuit.
Defective working lamp
When the relay is replace with another relay while the starting switch is
set to OFF and the headlamp comes on after the starting switch is
tion)
turned ON and the light switch is turned ON, the working lamp relay
Possible causes (BB3) is defective.
value in normal Disconnection of wiring har- without turning the starting switch ON.
state ness (Disconnection in wir- Wiring harness between FS2-4 outlet and BB3
Resistance Max. 1 z
221 (female) (1) or 242 (female) (1)
Ground fault of wiring har- Between wiring harness related to FS2-4 (outlet
D475A-5 20-739
(1)
Trouble (7) Only the rear lamp does not comes on. (Both right and left, or one side only)
Related
information

The working lamp is supposed to be defective. Check if the bulb is
1 Defective rear lamp (blown)
blown.
Defective circuit breaker If the circuit breaker is turned OFF, the circuit probably has a grounding
2
(CB7) fault, etc.
Possible causes Defective rear lamp switch and carry out troubleshooting.
and standard 3 (international disconnec- 218 (male) Switch Resistance
value in normal tion) OFF Min. 1 Mz
state Between (2) and (3)
ON Max. 1 z
ness (Disconnection in wir- Wiring harness between 218 (female) (2) and
ing or defective contact in circuit branching point J3.
connector) Wiring harness between 218 (female) (3) and
Resistance Max. 1 z
223 (female) (1) or 243 (female) (1)
20-740 D475A-5
(1)
Circuit diagram related to night light, headlamp, working lamp and rear lamp on panel
D475A-5 20-741
(1)
E-28 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM
Troubleshooting procedure for air conditioner system

a The control panel of the air conditioner constantly monitors the sensors and other devices in the system.
When it detects any abnormality, "Self-diagnosis notice" is displayed by operating switches specially.
a If you feel any abnormality in the air conditioner system, check the "Self-diagnosis notice" first according to
the procedure for "Troubleshooting by self-diagnosis notice", and then;
If the "Self-diagnosis notice" is displayed, continue the "Troubleshooting by self-diagnosis notice".
If the "Self-diagnosis notice" is not displayed, carry out the "Troubleshooting by failure phenomenon".
Troubleshooting by self-diagnosis notice

a Check the "Self-diagnosis notice" on the control
panel according to the following procedure.
How to display "Self-diagnosis notice"

1) Turn the starting switch ON.
2) Press OFF switch (1) and check that any-
thing is not displayed on display monitor (2).
3) Hold the UP switch ( ) and DOWN switch
( ) of temperature setting switch (3) simul-
taneously for 3 seconds or more.
4) Check the "Self-diagnosis notice" displayed
on display monitor (2).
How to select "Self-diagnosis notice" Self-diagnosis

If multiple "Self-diagnosis notices" are recorded, Failure mode
notice
press the UP switch ( ) or DOWN switch ( ) of E-- No failures
temperature setting switch (3) to select another E11 Disconnection in recirculated air sensor
notice. E12 Short circuit in recirculated air sensor
E13 Disconnection in fresh air sensor
How to delete "Self-diagnosis notice" E14 Short circuit in fresh air sensor
When reproducing the "Self-diagnosis notices"
Disconnection in water temperature sen-
or after removing the cause of a failure, press E15
sor
the switches on both sides of recirc/fresh air E16 Short circuit in water temperature sensor
selector switch (4) simultaneously for 3 seconds
E18 Short circuit in daylight sensor
or more, and all the "Self-diagnosis notices" are
E21 Disconnection in air blow sensor
deleted.
E22 Short circuit in air blow sensor
E43 Abnormality in air outlet damper
Finishing display of "Self-diagnosis notice"
E44 Abnormality in air mix damper
To finish display of the "Self-diagnosis notice",
press OFF switch (1) or turn the starting switch Abnormality in recirculated and fresh air
E45
damper
OFF.
E51 Abnormal refrigerant pressure
20-742 D475A-5
(1)
Self-diagnosis
notice Trouble Disconnection in recirculated air sensor
E11
Contents of
Disconnection in the recirculated air sensor system is detected.
trouble
Fixes the recirculated air temperature for control.
Action of control When the following condition is satisfied, the operation returns to normalcy.
panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information

Defective recirculated air out turning starting switch ON.
1 sensor
THI (male) Resistance
Between (1) and (2) 300 z 430 kz
and standard Disconnection of wiring out turning starting switch ON.
value in normal harness (Disconnection or Wiring harness between AP1 (female) (13) and
state 2 Resistance Max. 1 z
defective contact with THI (female) (2)
connector) Wiring harness between AP2 (female) (20) and
Resistance Max. 1 z
THI (female) (1)
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner
Defective air conditioner
3 system may be defective. Refer to CHASSIS COMPONENT, Shop
system
Manual, "Air conditioner".
Self-diagnosis
notice Trouble Short circuit in recirculated air sensor
E12
Contents of
Disconnection in the recirculated air sensor system is detected.
trouble
Fixes the recirculated air temperature for control.
Related
information

Defective recirculated air out turning starting switch ON.
1 sensor
THI (male) Resistance
defective contact with THI (female) (2)
Resistance Max. 1 z
THI (female) (1)
system
D475A-5 20-743
(1)
Self-diagnosis
notice Trouble Disconnection in fresh air sensor
E13
Contents of
Disconnection in the fresh air sensor system is detected.
trouble
Assumes that the fresh air sensor is not installed for control.
Related
information

Defective fresh air sensor out turning starting switch ON.
1
(Internal disconnection) ACT (male) Resistance
value in normal harness (Disconnection or Wiring harness between AP1 (female) (10), air
defective contact with conditioner unit, and ACT (female) (2)
connector) Wiring harness between AP2 (female) (20), air
Resistance Max. 1 z
conditioner unit, and ACT (female) (1)
system
Self-diagnosis
notice Trouble Short circuit in fresh air sensor
E14
Contents of
Short circuit in the fresh air sensor system is detected.
trouble
Assumes that the fresh air sensor is not installed for control.
Related
information

Defective fresh air sensor out turning starting switch ON.
1
(Internal disconnection) ACT (male) Resistance
value in normal harness (Disconnection or Wiring harness between AP1 (female) (10), air
defective contact with conditioner unit, and ACT (female) (2)
connector) Wiring harness between AP2 (female) (11), air
Resistance Max. 1 z
conditioner unit, and ACT (female) (1)
system
20-744 D475A-5
(1)
Self-diagnosis
notice Trouble Disconnection in water temperature sensor
E15
Contents of
Disconnection in the water temperature sensor system is detected.
trouble
Ignores the warm-up control and fixes the engine water temperature at 60C for control.
Related
information

Defective water out turning starting switch ON.
1 temperature sensor
THW (male) Resistance
defective contact with THW (female) (2)
Resistance Max. 1 z
THW (female) (1)
system
Self-diagnosis
notice Trouble Short circuit in water temperature sensor
E16
Contents of
Short circuit in the water temperature sensor system is detected.
trouble
Ignores the warm-up control and fixes the engine water temperature at 60C for control.
Related
information

Defective water out turning starting switch ON.
1 temperature sensor
THW (male) Resistance
defective contact with THW (female) (2)
Resistance Max. 1 z
THW (female) (1)
system
D475A-5 20-745
(1)
Self-diagnosis
notice Trouble Short circuit in daylight sensor
E18
Contents of
Short circuit in the daylight sensor system is detected.
trouble
Assumes that the daylight sensor is not installed for control.
Related
information

Defective daylight sensor
1 The daylight sensor may be defective. Check it directly.
Possible causes Disconnection of wiring out turning starting switch ON.
and standard harness (Disconnection or Wiring harness between AP1 (female) (9), air
value in normal defective contact with conditioner, and SLS (female) (2)
state connector) Wiring harness between AP1 (female) (6), air
Resistance Max. 1 z
conditioner, and SLS (female) (1)
system
20-746 D475A-5
(1)
Self-diagnosis
notice Trouble Disconnection in air blow sensor
E21
Contents of
Disconnection in the air blow sensor (frost sensor) system is detected.
trouble
Fixes the evaporator temperature at 10C for control.
Related
information

Defective air blow sensor out turning starting switch ON.
1 (frost sensor)
THF (male) Resistance
defective contact with THF (female) (2)
Resistance Max. 1 z
THF (female) (1)
system
Self-diagnosis
notice Trouble Short circuit in air blow sensor
E22
Contents of
Short circuit in the air blow sensor (frost sensor) system is detected.
trouble
Fixes the evaporator temperature at 10C for control.
Related
information

Defective air blow sensor out turning starting switch ON.
1 (frost sensor)
THF (male) Resistance
defective contact with THF (female) (2)
Resistance Max. 1 z
THF (female) (1)
system
D475A-5 20-747
(1)
Self-diagnosis
notice Trouble Abnormality in air outlet damper
E43
Contents of
Abnormality in air outlet servomotor system or front air outlet servomotor system is detected.
trouble
Stops the air outlet servomotor and front air outlet servomotor.
Related aDo not connect the power cables to the motor terminals directly to drive the motor. Doing so can dam-
information age the motor output shaft and break the motor coils.

Defective air outlet
1 The air outlet servomotor may be defective. Check it directly.
servomotor (Internal defect)
Defective front air outlet
2 The front air outlet servomotor may be defective. Check it directly.
servomotor (Internal defect)
Wiring harness between MV1 (female) (1) and
Resistance Max. 1 z
AP2 (female) (20)
Disconnection in wiring Wiring harness between MV1 (female) (3) and
Resistance Max. 1 z
harness (Disconnection in AP1 (female) (6)
3
wiring harness or defective Wiring harness between MV1 (female) (5) and
Resistance Max. 1 z
contact in connector) AP1 (female) (16)
Resistance Max. 1 z
Possible causes AP2 (female) (2)
and standard Wiring harness between MV1 (female) (7) and
Resistance Max. 1 z
value in normal AP2 (female) (3)
Resistance Max. 1 z
AP1 (female) (6)
Disconnection in wiring Wiring harness between MV2 (female) (3) and
Resistance Max. 1 z
4
wiring harness or defective Wiring harness between MV2 (female) (5) and
Resistance Max. 1 z
Resistance Max. 1 z
AP2 (female) (1)
Resistance Max. 1 z
AP2 (female) (11)
If none of causes 1 4 is the cause of the trouble, the air conditioner
system
20-748 D475A-5
(1)
Self-diagnosis
notice Trouble Abnormality in air mix damper
E44
Contents of
Abnormality in air mix servomotor system is detected.
trouble
Stops the air mix servomotor.

Defective air mix servomo-
1 The air mix servomotor may be defective. Check it directly.
tor (Internal defect)
Wiring harness between MAM (female) (1) and
Resistance Max. 1 z
AP2 (female) (20)
Possible causes Disconnection in wiring Wiring harness between MAM (female) (3) and
Resistance Max. 1 z
and standard harness (Disconnection in AP1 (female) (6)
2
value in normal wiring harness or defective Wiring harness between MAM (female) (5) and
Resistance Max. 1 z
AP2 (female) (7)
Resistance Max. 1 z
AP2 (female) (6)
system
D475A-5 20-749
(1)
Self-diagnosis
notice Trouble Abnormality in recirculated and fresh air damper
E45
Contents of
Abnormality in recirculated and fresh air servomotor system is detected.
trouble
Stops the recirculated and fresh air servomotor.

Defective recirculated and
The recirculated and fresh air servomotor may be defective. Check it
1 fresh air servomotor
directly.
(Internal defect)
Wiring harness between MRF (female) (1) and
Resistance Max. 1 z
AP2 (female) (20)
Possible causes
Disconnection in wiring Wiring harness between MRF (female) (3) and
value in normal 2
wiring harness or defective Wiring harness between MRF (female) (5) and
Resistance Max. 1 z
AP2 (female) (4)
Resistance Max. 1 z
AP2 (female) (5)
system
20-750 D475A-5
(1)
Self-diagnosis
notice Trouble Abnormality in refrigerant pressure
E51
Contents of
Abnormality in refrigerant pressure circuit is detected.
trouble
Turns the compressor clutch OFF.
Related
information

Defective high-low pressure
1 The high-low pressure switch may be defective. Check it directly.
switch (Internal defect)
and standard harness (Disconnection in Wiring harness between AP1 (female) (5) and
value in normal wiring harness or defective SPHL (female) (2)
state contact in connector) Wiring harness between SPHL (female) (1) and
Resistance Max. 1 z
chassis ground
system
D475A-5 20-751
(1)
Circuit diagram related to air conditioner
20-752 D475A-5
(1)
Troubleshooting by failure phenomenon
Trouble The air conditioner does not operate. (1) The air conditioner does not operate at all.
Related
information
Standard value in normal state/Remarks on troubleshooting

Defective circuit breaker If the circuit breaker is turned OFF, the circuit probably has a grounding
1
CB4 fault, etc. (Refer to cause 3.)
Wiring harness between circuit breaker CB4
Resistance Max. 1 z
Disconnection in wiring outlet and ACU (female) (4), (5)
harness (Disconnection in Wiring harness between AP3 (male) (6) and
wiring harness or defective AP1 (female) (3)
contact in connector) Wiring harness between AP2 (female) (19) and
Resistance Max. 1 z
AP5 (male) (7)
Wiring harness between ACU (female) (8) and
Resistance Max. 1 z
chassis ground
and standard Short circuit with chassis Between wiring harness between circuit
value in normal 3 ground in wiring harness breaker CB4 outlet and ACU (female) (4), (5) Resistance Min. 1 Mz
state (Contact with ground circuit) and chassis ground
Between wiring harness between AP3 (male)
(6) and AP1 (female) (3) and chassis ground
Defective air conditioner ACU Voltage
4
unit Between (4) and (8) 20 30 V
If the above voltage is normal and the air conditioner does not operate,
the air conditioner is defective.
AP1, AP2 Voltage
5 Defective control panel
Between AP1 (3) and AP2 (19) 20 30 V
If the above voltage is normal and the control panel does not operate,
the control panel is defective.
D475A-5 20-753
(1)
Trouble The air conditioner does not operate. (2) Air does not come out (Air flow is insufficient).
Related
information

If the fuse (in the unit) is broken, the circuit probably has a grounding
1 Defective fuse (in unit)
fault, etc. Check the related circuits.
Defective blower main relay out turning starting switch ON.
2
(on coil side) RLBM (male) Resistance
Between (1) and (3) 300 440 z
Defective blower main relay
3 RLBM Fan switch Voltage
(on contact side)
Between (4) and
ON (Operated) 20 30 V
chassis ground
Defective blower linear
4 Fan switch If air flow can be changed with fan
controller (Internal defect)
Operate in range of Low, switch, blower linear controller is
Medium, and High normal.
Defective blower motor MB (female) Fan switch Voltage
5
(Internal defect) Between (1) and (2) ON (Operated) 20 30 V
Possible causes If the above voltage is normal and the blower motor does not rotate, the
and standard blower motor is defective.
Resistance Max. 1 z
outlet, AP3 (female) (6), and RLBM (female) (1)
Resistance Max. 1 z
outlet and RLBM (female) (3)
Wiring harness between AP2 (female) (8) and
Resistance Max. 1 z
RLBM (female) (2)
Disconnection in wiring Wiring harness between AP2 (female) (19) and
Resistance Max. 1 z
harness (Disconnection in chassis ground
6
wiring harness or defective Wiring harness between BLC (female) (3) and
Resistance Max. 1 z
contact in connector) RLBM (female) (4)
Wiring harness between MB (female) (1) and
Resistance Max. 1 z
RLBM (female) (4)
Wiring harness between MB (female) (2) and
Resistance Max. 1 z
BLC (female) (4)
Wiring harness between BLC (female) (1) and
Resistance Max. 1 z
chassis ground
Wiring harness between AP1 (female) (1) and
Resistance Max. 1 z
BLC (female) (2)
system
20-754 D475A-5
(1)
Trouble The air conditioner does not operate. (3) Air is not cooled (Cooling capacity is low).
Related
information

If the fuse (in the unit) is broken, the circuit probably has a grounding
1 Defective fuse (in unit)
fault, etc. Check the related circuits.
Defective compressor out turning starting switch ON.
2
clutch relay (on coil side) RLCC (male) Resistance
Between (1) and (3) 140 340 z
carry out troubleshooting (Setting of temperature: Highest cooling po-
Defective compressor sition).
3 clutch relay
RLCC Fan switch Voltage
(on contact side)
Between (3) and
ON (Operated) 20 30 V
chassis ground
Defective compressor
4 The compressor clutch may be defective. Check it directly.
Possible causes clutch (Internal defect)
and standard Defective compressor
value in normal 5 The compressor may be defective. Check it directly.
(Internal defect)
Resistance Max. 1 z
outlet, AP1 (female) (3), and RLCC (female) (1)
Disconnection in wiring Wiring harness between circuit breaker CB4
Resistance Max. 1 z
harness (Disconnection in outlet and RLCC (female) (4)
6
wiring harness or defective Wiring harness between AP2 (female) (9) and
Resistance Max. 1 z
contact in connector) RLCC (female) (2)
Wiring harness between AP2 (19) and chassis
Resistance Max. 1 z
ground
Wiring harness between RLCC (female) (3) and
Resistance Max. 1 z
351 (female) (1)
system
D475A-5 20-755
(1)
Circuit diagram related to air conditioner
20-756 D475A-5
(1)
E-29 ORBCOMM TERMINAL DOES NOT OPERATE NORMALLY (DATA ARE NOT
TRANSMITTED).
Trouble The ORBCOMM terminal does not operate normally (Data are not transmitted).
Related
Even if the ORBCOMM terminal is abnormal, it does not cause a trouble in the machine.
information

At least 3 minutes after starting the VHMS, check the decimal point at
the right bottom of the LED of the VHMS controller or the decimal point
at the right bottom of the central part of the lower line of the multi-infor-
mation display unit.
* To check the decimal point on the multi-information display unit, turn
the starting switch ON and select the "Real-time monitoring mode" or
Terminal power supply is "Dual display monitoring mode" and input the ID = 20300.
1 abnormal or satellite is not Lamp is Power is not applied to ORBCOMM terminal.
captured OFF
Lamp is ORBCOMM terminal is normal, but it does not capture sat-
ON ellite.
Quick ORBCOMM terminal is normal and capturing satellite, but
Possible causes flashing there is no data to be sent.
and standard Slow ORBCOMM terminal is normal and capturing satellite and
value in normal flashing transmitting data.
harness (Disconnection in Between CM30 (female) (7), (8) and V12 (male)
wiring harness or defective (7)
contact in connector) Between CM30 (female) (10) and chassis
Resistance Max. 1 z
ground
Defective ORBCOMM
terminal
(When LED is turned OFF)
3 * Constant power supply is
used. When disconnecting
Between CM-30 (female) (7), (8) and CM-30
connector and carrying out Voltage 20 30 V
(female) (10)
troubleshooting, take care.
Decimal point position of VHMS controller
D475A-5 20-757
(1)
Decimal point position of multi-function monitor
Related electric circuit diagram
20-758 D475A-5
(1)
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM (H MODE)
INFORMATION IN TROUBLESHOOTING TABLE ..................................................................................... 20-802

H-1 NO FORCE (NO DRAWBAR PULL).................................................................................................. 20-803
H-2 NO TRAVEL (AT 2ND OR 3RD SPEED) ........................................................................................... 20-804
H-3 NO TRAVEL AT ALL GEAR SPEEDS ............................................................................................... 20-805
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE ............................ 20-806
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING ............... 20-807
H-6 STEERING IS NOT POSSIBLE......................................................................................................... 20-808
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE .............................................................................. 20-808
H-8 STEERING OVERRUN OCCURS ..................................................................................................... 20-809
H-9 BRAKE DOES NOT WORK............................................................................................................... 20-809
H-10 TORQUE CONVERTER IS NOT LOCK-UP ...................................................................................... 20-810
H-11 TORQUE CONVERTER OIL IS OVERHEATED ............................................................................... 20-810
H-12 ALL WORK EQUIPMENT SPEEDS ARE SLOW .............................................................................. 20- 811
H-13 WORK EQUIPMENT DOES NOT MOVE .......................................................................................... 20-812
H-14 BLADE LIFT SPEED IS SLOW OR LACKS POWER........................................................................ 20-812
H-15 BLADE TILT SPEED IS SLOW OR LACKS POWER ........................................................................ 20-813
H-16 RIPPER LIFT SPEED IS SLOW OR LACKS POWER ...................................................................... 20-813
H-17 RIPPER TILT SPEED IS SLOW OR LACKS POWER ...................................................................... 20-814
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT .......................................................................... 20-814
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT .......................................................................... 20-815
H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT ........................................................................ 20-815
H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK
(GIANT RIPPER ATTACHMENT MACHINE) .................................................................................... 20-816
H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE).................................... 20-816
H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP........................ 20-816
D475A-5 20-801
(1)
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Trouble Trouble in machine
Related
Information related to detected trouble or troubleshooting
information
Possible causes 2
Possible causes of trouble
and standard <Contents of description>
value in normal (Given numbers are refer-
Standard value in normal state to judge possible causes
state ence numbers, which do not
Remarks on judgment
indicate priority)
3
20-802 D475A-5
(1)
TROUBLESHOOTING H-1
H-1 NO FORCE (NO DRAWBAR PULL)

Trouble No force (No drawbar pull)
Related
Before troubleshooting, check that the power train oil level is normal.
information

1 Defective power train pump The power train pump is supposed to be defective. Check it directly.
aSet the starting switch to OFF for preparation and idle the engine at a
high speed for troubleshooting (after checking that the transmission
main relief pressure is normal).
Internal defect of torque
2 Torque converter Torque converter
converter PCCS lever
inlet pressure outlet pressure
0.8 1.0 MPa 39.2 63.7 MPa
Full neutral
{8.0 10.0 kg/cm2} {4.0 6.5 kg/cm2}
Incorrect pressure set to high speed for troubleshooting.
3 transmission main relief
PCCS lever Transmission main relief pressure
valve
Full neutral 2.55 3.04 MPa {26.0 31.0 kg/cm2}
aSet the starting switch to OFF for preparation and troubleshoot while
Defective operation of
keeping it to OFF.
Check it directly that the spring free length (120.3 mm) is normal and
valve
that the spool moves smoothly.
low speed for troubleshooting (after checking that the transmission
Transmission clutch Clutch pressure
Defective operation of FWD 2.4 2.84 MPa {24.5 29.0 kg/cm2}
5
transmission valve (ECMV)
REV 2.4 2.84 MPa {24.5 29.0 kg/cm2}
1ST 1.96 2.45 MPa {20.0 25.0 kg/cm2}
Possible causes
2ND 2.4 2.84 MPa {24.5 29.0 kg/cm2}
and standard
value in normal 3RD 2.4 2.84 MPa {24.5 29.0 kg/cm2}
state aSet the starting switch to OFF for preparation and idle the engine at a
high speed for troubleshooting.
Internal defect of transmis- Measuring conditions Engine speed
6
sion F3 stall Min. 1,570 rpm
F3 stall + Work equipment relief
Min. 1,450 rpm
(pitch back)
aMove the machine to a flat ground and start the engine for trouble-
shooting.
Defective operation (drag-
7 Idle the engine at a low speed and operate F2. Unless the machine
ging) of brake
moves, the brake is being dragged. (Execute the troubleshooting of
Brake does not work.)
PCCS lever Left stroke end Right stroke end
Min. 2.45 MPa 0 MPa
Left clutch pressure
{Min. 25 kg/cm2} {0 kg/cm2}
0 MPa Min. 2.45 MPa
8 Defective steering clutch Right clutch pressure
{0 kg/cm2} {Min. 25 kg/cm2}
0 MPa Min. 2.45 MPa
Left brake pressure
Min. 2.45 MPa 0 MPa
Right brake pressure
When the oil pressure is abnormal, execute the troubleshooting of
Steering is not possible.
D475A-5 20-803
(1)
TROUBLESHOOTING H-2
H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)

Trouble No travel (at 2nd or 3rd speed)
Related Before troubleshooting, check that the power train oil level is normal.
information Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

Internal defect of torque Torque converter Torque converter
1 PCCS lever
converter inlet pressure outlet pressure
0.8 1.0 MPa 39.2 63.7 MPa
Full neutral
{8.0 10.0 kg/cm2} {4.0 6.5 kg/cm2}
low speed for troubleshooting.
Defective operation of Transmission clutch Clutch pressure
2
2ND 2.4 2.84 MPa {24.5 29.0 kg/cm 2}
3RD 2.4 2.84 MPa {24.5 29.0 kg/cm 2}
Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supposed to
3
sion clutch be defective. Check it directly.
4 Defective operation (dragging) is supposed, check linkage valves.
Possible causes ging) of parking brake
and standard aMove the machine to a flat ground and start the engine for trouble-
value in normal shooting.
state Defective operation (drag-
ging) of brake
Min. 2.45 MPa 0 MPa
0 MPa Min. 2.45 MPa
Defective steering clutch, Right clutch pressure
6 {0 kg/cm2} {Min. 25 kg/cm2}
brake
0 MPa Min. 2.45 MPa
Left brake pressure
Min. 2.45 MPa 0 MPa
Right brake pressure 2
{Min. 25 kg/cm } {0 kg/cm2}
When the oil pressure is abnormal, execute the troubleshooting of
Steering is not possible.
20-804 D475A-5
(1)
TROUBLESHOOTING H-3
H-3 NO TRAVEL AT ALL GEAR SPEEDS

Trouble No travel at all gear speeds
Related
information

Incorrect pressure set to high speed for troubleshooting.
PCCS lever Transmission main relief pressure
valve
Full neutral 2.55 3.04 MPa {26.0 31.0 kg/cm2}
Defective operation of keeping it to OFF.
valve Check it directly that the spring free length (120.3 mm) is normal and
Transmission clutch Clutch pressure
Defective operation of FWD 2.4 2.84 MPa {24.5 29.0 kg/cm2}
4
REV 2.4 2.84 MPa {24.5 29.0 kg/cm2}
1ST 1.96 2.45 MPa {20.0 25.0 kg/cm2}
2ND 2.4 2.84 MPa {24.5 29.0 kg/cm2}
3RD 2.4 2.84 MPa {24.5 29.0 kg/cm2}
Possible causes
Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supposed to
and standard 5
sion clutch be defective. Check it directly.
value in normal
state aMove the machine to a flat ground and idle the engine at a high speed
for troubleshooting (after checking that the transmission main relief
pressure is normal).
6 Defective operation of brake Brake pedal Brake oil pressure (right and left)
Release Min. 2.45 MPa {Min. 25 kg/cm2}
Step on 0 MPa {0 kg/cm2}
Min. 2.45 MPa 0 MPa
Defective seal of steering {Min. 25 kg/cm2} {0 kg/cm2}
7
clutch 0 MPa Min. 2.45 MPa
Right clutch pressure
0 MPa Min. 2.45 MPa
Left brake pressure
Min. 2.45 MPa 0 MPa
Internal defect of steering The inside of the steering clutch is supposed to be defective, check it
8
clutch directly.
D475A-5 20-805
(1)
TROUBLESHOOTING H-4
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE

Trouble Machine travels only in one direction Forward or in Reverse.
Related
information

Incorrect pressure set to PCCS lever Transmission main relief pressure
valve Full neutral 2.55 3.04 MPa {26.0 31.0 kg/cm2}
When the oil pressure is abnormal, clean the valve and then check the
oil pressure again.
Defective operation of keeping it to OFF.
valve Check it directly that the spring free length (120.3 mm) is normal and
Possible causes low speed for troubleshooting (after checking that the transmission
and standard main relief pressure is normal).
value in normal Transmission clutch Clutch pressure
state Defective operation of FWD 2.4 2.84 MPa {24.5 29.0 kg/cm 2}
4
REV 2.4 2.84 MPa {24.5 29.0 kg/cm 2}
1ST 1.96 2.45 MPa {20.0 25.0 kg/cm2}
2ND 2.4 2.84 MPa {24.5 29.0 kg/cm 2}
3RD 2.4 2.84 MPa {24.5 29.0 kg/cm 2}
Defective seal of transmis- When the cause 4 is not applicable, the clutch seal is supposed to be
5
sion clutch defective. Check it directly.
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective, check
6
sion clutch it directly.
shooting.
ging) of brake
20-806 D475A-5
(1)
TROUBLESHOOTING H-5
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFT-

ING
Trouble Large time lag at gear speed shifting or forward-reverse shifting
Related
information

Defective operation of PCCS lever Transmission main relief pressure
valve Full neutral 2.55 3.04 MPa {26.0 31.0 kg/cm2}
When the oil pressure is abnormal, clean the valve and then check the
oil pressure again.
Possible causes Transmission clutch Clutch pressure
and standard Defective operation of FWD 2.4 2.84 MPa {24.5 29.0 kg/cm2}
3
value in normal transmission valve (ECMV)
REV 2.4 2.84 MPa {24.5 29.0 kg/cm2}
state 1ST 1.96 2.45 MPa {20.0 25.0 kg/cm2}
2ND 2.4 2.84 MPa {24.5 29.0 kg/cm2}
3RD 2.4 2.84 MPa {24.5 29.0 kg/cm2}
Defective seal of transmis- When the cause 3 is not applicable, the clutch seal is supposed to be
4
sion clutch defective. Check it directly.
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective, check
5
sion clutch it directly.
shooting.
ging) of brake
D475A-5 20-807
(1)
TROUBLESHOOTING H-6, H-7
H-6 STEERING IS NOT POSSIBLE

Trouble Steering is not possible.

aStart the engine for preparation and idle it at a low speed for trouble-
shooting.
1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for F3
travel (or R3 travel). If the track shoe stops, the brake is defective. (Exe-
cute the troubleshooting of Brake does not work.)
Possible causes Min. 2.45 MPa 0 MPa
and standard Left clutch pressure
Defective operation of {Min. 25 kg/cm2} {0 kg/cm2}
value in normal
2 steering clutch valve 0 MPa Min. 2.45 MPa
state Right clutch pressure
(ECMV) {0 kg/cm2} {Min. 25 kg/cm2}
0 MPa Min. 2.45 MPa
Left brake pressure
Min. 2.45 MPa 0 MPa
Defective seal of steering When the cause 2 is not applicable, the clutch seal is supposed to be
3
clutch defective. Check it directly.
4
clutch directly.
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE

Trouble Steering is possible only on one side.

Min. 2.45 MPa 0 MPa
Defective operation of {Min. 25 kg/cm2} {0 kg/cm2}
Possible causes 1 steering clutch valve 0 MPa Min. 2.45 MPa
and standard (ECMV) {0 kg/cm2} {Min. 25 kg/cm2}
value in normal 0 MPa Min. 2.45 MPa
state Left brake pressure
Min. 2.45 MPa 0 MPa
Defective seal of steering When the cause 1 is not applicable, the clutch seal is supposed to be
2
clutch defective. Check it directly.
3
clutch directly.
20-808 D475A-5
(1)
H-8 STEERING OVERRUN OCCURS

Trouble Steering overrun occurs.

aStart the engine for preparation and idle it at a low speed for trouble-
shooting.
Possible causes
1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for F3
and standard
value in normal travel (or R3 travel). If the track shoe stops, the brake is defective. (Exe-
cute the troubleshooting of Brake does not work.)
state
When the track shoe does not stop in the troubleshooting of the cause
Defective operation of
2 1, the steering clutch is defective. (Execute the troubleshooting of
steering clutch
Steering is not possible.)
H-9 BRAKE DOES NOT WORK

Trouble Brake does not work.

aStart the engine for troubleshooting.
1 Degradation of brake Step on the brake pedal, shift the gear to F2 and idle the engine at a high
speed. When the machine moves, the brake performance is degraded.
Defective operation of brake The brake pedal and the brake valve are supposed not to work normally.
2
pedal Check them directly.
Possible causes PCCS lever Left stroke end Right stroke end
and standard Min. 2.45 MPa 0 MPa
value in normal Defective operation of {Min. 25 kg/cm2} {0 kg/cm2}
state 3 steering brake valve 0 MPa Min. 2.45 MPa
(ECMV) {0 kg/cm2} {Min. 25 kg/cm2}
0 MPa Min. 2.45 MPa
Left brake pressure
Min. 2.45 MPa 0 MPa
When the brake seal is not normal in the troubleshooting of the cause 3,
4 Defective brake seal
the brake seal is supposed to be defective. Check it directly.
5 Internal defect of brake The inside of the brake is supposed to be defective. Check it directly.
D475A-5 20-809
(1)
H-10 TORQUE CONVERTER IS NOT LOCK-UP

Trouble The torque converter is not lock-up.

Defective operation of high speed for troubleshooting.
2 torque converter lock-up Torque converter Clutch pressure
valve Min. 1.27 1.47 MPa
At lock-up time
{Min. 13.0 15.0 kg/cm2}
Possible causes
Defective seal of lock-up When the troubleshooting of the case 2 is not normal, the lock-up clutch
and standard 3
clutch seal is supposed to be defective. Check it directly.
value in normal
state Internal defect of lock-up The inside of the lock-up clutch is supposed to be defective. Check it
4
clutch directly.
Internal defect of torque Measuring conditions Engine speed
5
converter F3 stall 1,570 rpm
F3 stall + Work equipment relief
1,450 rpm
(pitch back)
H-11 TORQUE CONVERTER OIL IS OVERHEATED

Trouble The torque converter oil is overheated.
Before troubleshooting, check that the indication of the torque converter oil temperature gauge agrees
Related with actual temperature of the torque converter oil. (When the indication does not agree with actual tem-
information perature, execute the troubleshooting of The indication of torque converter oil temperature gauge is
abnormal.)
Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

Engine output is supposed to have increased abnormally. Troubleshoot
1 Rise of engine output
referring to the shop manual for engine.
Defective power train pump The power train pump is supposed to be defective, or air is supposed to
2
or air entry in suction circuit have entered from the suction circuit. Check them directly.
Internal defect of torque Torque converter Torque converter
Possible causes 3 PCCS lever
converter inlet pressure outlet pressure
and standard
0.8 1.0 MPa 39.2 63.7 MPa
value in normal Full neutral
state {8.0 10.0 kg/cm2} {4.0 6.5 kg/cm2}
Defective operation (slide) The inside of the transmission clutch is supposed to be defective (the
4
of transmission clutch clutch slides). Check it directly.
aStart the engine for troubleshooting.
Defective operation (drag- Idle the engine at a low speed and operate F2. Unless the machine
5
ging) of brake moves, the brake is being dragged. (Execute the troubleshooting of
Defective operation (slide) The inside of the steering clutch is supposed to be defective (the clutch
6
of steering clutch slides). Check it directly.
20-810 D475A-5
(1)
TROUBLESHOOTING H-12
H-12 ALL WORK EQUIPMENT SPEEDS ARE SLOW

Trouble All work equipment speeds are slow.
Related
Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information

Defective PTO (pump drive The PTO pump drive unit of the work equipment is assumed to be defec-
1
unit of work equipment) tive; directly check it.
Defective work equipment The pump of the work equipment is assumed to be defective; directly
2
pump check it.
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Defective unload valve
3 Work equipment lever Unload pressure
function
3.9 1.0 MPa
Full neutral
Possible causes {40 10 kg/cm2}
and standard aPrepare with starting switch OFF, then drive the engine in high idling
value in normal Defective set pressure or mode for troubleshooting.
state 4 defective function of main Work equipment lever Main relief pressure
relief valve Stroke end 27.44 1.38 MPa
(Except blade cylinder) {280 14 kg/cm2}
Defective function of self- mode for troubleshooting.
5 pressure reducing valve Work equipment lever Original pressure of control circuit
(PPC original pressure) Min. 3.72 MPa
Full neutral
{Min. 38 kg/cm2}
Internally defective PPC When the troubleshooting in cause 5 is abnormal, the PPC valve is
6
valve assumed to be defective internally; directly check it.
D475A-5 20-811
(1)
H-13 WORK EQUIPMENT DOES NOT MOVE

Trouble Work equipment does not move.
Related
information

Defective PTO (Pump drive The PTO pump drive unit of the work equipment is assumed to be defec-
1
unit of work equipment) tive; directly check it.
Defective work equipment
2 The work equipment pump is assumed to be defective; directly check it.
pump
Defective unload valve
3 Work equipment lever Unload pressure
function
Possible causes 3.9 1.0 MPa
Full neutral
and standard {40 10 kg/cm2}
value in normal aPrepare with starting switch OFF, then drive the engine in high idling
state Defective set pressure or mode for troubleshooting.
4 defective function of main Work equipment lever Main relief pressure
relief valve 27.44 1.38 MPa
Stroke end
{280 14 kg/cm2}
Defective function of self- mode for troubleshooting.
5 pressure reducing valve Work equipment lever Original pressure of control circuit
(PPC original pressure) Min. 3.72 MPa
Full neutral
{Min. 38 kg/cm2}
H-14 BLADE LIFT SPEED IS SLOW OR LACKS POWER

Trouble Blade lift speed is slow or lacks power.
Related Confirm whether the blade is remodeled.
information When the hydraulic drift rate of the blade lift is also high, carry out troubleshooting High Hydraulic Drift
Rate of Blade Lift.

Defective PPC valve func-
Possible causes 1 Blade lever PPC valve output pressure
tion
and standard Min. 3.72 MPa
Lift stroke end
value in normal {Min. 38 kg/cm2}
state Defective function of blade The spool function of the blade lift operation valve is assumed to be
2
lift operation valve (Spool) defective; directly check it.
The blade lift cylinder is assumed to be aired; carry out the air bleed and
3 Aired blade lift cylinder
observe how the phenomenon changes.
20-812 D475A-5
(1)
H-15 BLADE TILT SPEED IS SLOW OR LACKS POWER

Trouble Blade tilt speed is slow or lacks power.
information When the hydraulic drift rate of the blade tilt is also high, carry out troubleshooting High Hydraulic Drift
Rate of Blade Tilt.

Possible causes 1 Blade lever PPC valve output pressure
tion
value in normal Lift stroke end
{Min. 38 kg/cm2}
state Defective function of blade The spool function of the blade tilt operation valve is assumed to be
2
tilt operation valve (Spool) defective; directly check it.
The blade tilt cylinder is assumed to be aired; carry out the air bleed and
3 Aired blade tilt cylinder
H-16 RIPPER LIFT SPEED IS SLOW OR LACKS POWER

Trouble Ripper lift speed is slow or lacks power.
Related Confirm whether the ripper is remodeled.
information When the hydraulic drift rate of the ripper lift is also high, carry out troubleshooting High Hydraulic Drift
Rate of Ripper Lift.

Possible causes 1 Ripper lever PPC valve output pressure
tion
value in normal Lift stroke end
{Min. 38 kg/cm2}
state Defective function of ripper The spool function of the ripper lift operation valve is assumed to be
2
lift operation valve (Spool) defective; directly check it.
The ripper lift cylinder is assumed to be aired; carry out the air bleed and
3 Aired ripper lift cylinder
D475A-5 20-813
(1)
H-17 RIPPER TILT SPEED IS SLOW OR LACKS POWER

Trouble Ripper tile speed is slow or lacks power.
Related Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information Confirm whether the ripper is remodeled.

1 Ripper lever PPC valve output pressure
tion
3.82 4.12 MPa
Tilt stroke end
Possible causes {39 42 kg/cm2}
and standard Defective function of ripper The spool function of the ripper tilt operation valve is assumed to be
value in normal 2
tilt operation valve (Spool) defective; directly check it.
state
The suction valve of the ripper tilt operation valve is assumed to be
Defective function of ripper
defective; directly check it.
3 tilt operation valve (Suction
aReplace the suction valve in the head with one at the bottom, and ob-
valve)
serve how the phenomenon changes.
The ripper tilt cylinder is assumed to be aired; carry out the air bleed and
4 Aired ripper tilt cylinder
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT

Trouble Excessive hydraulic drift of blade lift.
information Confirm that no oil leaks the circuits in the work equipment before troubleshooting.

Prepare with starting the engine, then stop the engine for troubleshoot-
ing.
Follow the procedure below for troubleshooting. If the hydraulic drift
speed becomes high, the spool seal of the blade lift operation valve is
Possible causes
Defective seal of blade lift assumed to be defective.
and standard 1
operation valve (Spool) 1) Prop up the machine using the blade lift, and lift the front of the
value in normal
machine.
state
2) Stop the engine, and release the safety lock lever.
3) Set the blade lever to the lift lowering side, and confirm how the phe-
nomenon changes.
Defective seal of blade lift The seal of the blade lift cylinder is assumed to be defective; directly
2
cylinder check it.
20-814 D475A-5
(1)
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT

Trouble Excessive hydraulic drift of blade tilt.

aPrepare with starting the engine, then stop the engine for trouble-
shooting.
speed becomes high, the spool seal of the blade tilt operation valve is
Defective seal of blade tilt assumed to be defective.
Possible causes 1
operation valve (Spool) 1) Prop up the machine using the blade tilt, and lift the right of the
and standard machine.
value in normal
state 3) Set the blade lever to the right tilt side, and confirm how the phenom-
enon changes.
Defective seal of blade tilt mode for troubleshooting.
2
cylinder Blade tilt cylinder Cylinder leak quantity
Right tilt stroke end 20 cc/min
H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT

Trouble Excessive hydraulic drift of ripper lift.
Related Confirm whether the ripper is remodeled.

aPrepare with starting the engine, then stop the engine for trouble-
shooting.
speed becomes high, the spool seal of the ripper lift operation valve (Hi)
Defective seal of ripper lift is assumed to be defective.
Possible causes 1
operation valve (Spool) 1) Prop up the machine using the blade tilt, and lift the rear of the
and standard machine.
value in normal
state 3) Set the blade lever to the lift lowering side, and confirm how the phe-
nomenon changes.
Defective seal of ripper lift mode for troubleshooting.
2
cylinder Ripper lift cylinder Cylinder leak quantity
Lowering stroke end 20 cc/min
D475A-5 20-815
(1)
TROUBLESHOOTING H-21, H-22, H-23
H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACH-
MENT MACHINE)
Trouble The ripper pin puller cylinder does not work.
Related
Confirm that the main relief pressure for transmission is normal before troubleshooting.
information

Possible causes Pin puller working
Defective function of pin
and standard 1 Pin puller switch Measurement position
puller solenoid pressure
value in normal
Push-in Cylinder bottom side Min. 2.55 MPa
state
Pull-in Cylinder head side {Min. 26 kg/cm2}
Internally defective pin The pin puller cylinder is assumed to be defective internally; directly
2
puller cylinder check it.
H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE)
Trouble The blade pitch does not work.
Related
information

Defective function of blade
The spool of the blade pitch operation valve is assumed to be defective;
1 pitch selection solenoid
Possible causes directly check it.
valve
and standard
value in normal Defective function of blade
The function of the blade pitch cylinder is assumed to be defective;
2 pitch operation valve
state directly check it.
(Spool)
Defective function of blade The function of the blade pitch selection solenoid valve is assumed to
3
pitch cylinder be defective; directly check it.
H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP
Trouble Abnormal noise from around work equipment pump.
Related
information

1 Inappropriate oil The oil used is assumed to be inappropriate; directly check it.
Possible causes Clogged hydraulic oil tank The strainer of the hydraulic oil tank is assumed to be clogged; directly
2
and standard strainer check it.
value in normal Air is assumed to be inhaled in the suction circuit of the work machine
state 3 Air inhaled in suction circuit
pump; directly check the pipes.
Internally defective work The work equipment pump is assumed to be defective internally; directly
4
equipment pump check it.
20-816 D475A-5
(1)
TROUBLESHOOTING OF ENGINE BODY (S MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-902

METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-903
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) ................................. 20-906
S-2 ENGINE DOES NOT START ............................................................................................................. 20-907
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) ............................................ 20-910
S-4 ENGINE STOPS DURING OPERATIONS ........................................................................................ 20- 911
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).................................................................. 20-912
S-6 ENGINE LACKS OUTPUT(NO POWER) .......................................................................................... 20-913
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) ............................................................ 20-914
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) ............................................. 20-915
S-9 OIL BECOMES CONTAMINATED QUICKLY .................................................................................... 20-916
S-10 FUEL CONSUMPTION IS EXCESSIVE ............................................................................................ 20-917
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..... 20-918
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE).................................................... 20-919
S-13 OIL LEVEL RISES ............................................................................................................................. 20-920
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) ............................................... 20-921
S-15 ABNORMAL NOISE IS MADE........................................................................................................... 20-922
S-16 VIBRATION IS EXCESSIVE .............................................................................................................. 20-923
D475A-5 20-901
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the
parking brake is securely applied.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
burns. Always wait for the water temperature to go down before removing the radiator cap.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing a plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the ma-
If components are disassembled immediately chine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be disassem- 4) Other maintenance items can be checked
bled. externally, so check any item that is consid-
It will become impossible to find the cause of ered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out troubleshoot- judge whether to handle it as a real failure or as
ing, it is necessary to carry out thorough prior in- a problem with the method of operation, etc.
vestigation and to carry out troubleshooting in a When operating the machine to re-enact the
accordance with the fixed procedure. troubleshooting symptoms, do not carry out
any investigation or measurement that may
2. Points to ask user or operator make the problem worse.
1) Have any other problems occurred apart
from the problem that has been reported? 5. Troubleshooting
2) Was there anything strange about the ma- Use the results of the investigation and inspec-
chine before the failure occurred? tion in Items 2 4 to narrow down the causes of
3) Did the failure occur suddenly, or were there failure, then use the troubleshooting matrix or
problems with the machine condition before flowchart to locate the position of the failure ex-
this? actly.
4) Under what conditions did the failure occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before the as follows.
failure? When were these repairs carried 1) Start from the simple points.
out? 2) Start from the most likely points.
6) Has the same kind of failure occurred be- 3) Investigate other related parts or information.
fore?
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root cause.
20-902 D475A-5
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in (B) are
items that can be obtained from the user,
depending on the users level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under (C) in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the
user and the results of (C) that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with , and of these, causes that have a high prob-
ability are marked with .
Check each of the [Questions] and [Check items]
in turn, and marked the or in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
D475A-5 20-903
(1)
Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is black

Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel Causes
Leakage of air between turbocharger and cylinder head
Defective injection pump (rack, plunger seized)

Defective variable prestroke spool, solenoid
Defective contact of valve, valve seat
Seized turbocharger, interference
Clogged, seized injection nozzle

Worn piston ring, cylinder liner
Clogged air cleaner element
Improper valve clearance

Crushed, clogged muffler
Improper injection timing
Confirm recent rapair history
Degree of use Operated for long period
Suddenly became black
Questions
Color of exhaust gas Gradually became black

Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel is being used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Check items
Match marks on fuel injection pump are out of alignment

Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and cylinder head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Troubleshooting
Stop fuel injection to one cylinder at a time. If there is no change in engine

speed, that cylinder is not working
When check is made using delivery method, injection timing is found to be incorrect
When valve clearance is checked directly it is found to be outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy, or does not return
Check sliding of spool, solenoid at variable prestroke end
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Clean
Remedy
20-904 D475A-5
(1)
Five causes
Step 1
Clarify the relationship between the three symptoms in

the [Questions] and [Check items] section and the five
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of and marks where the horizontal
limes for the three symptoms and the vertical columns for
the causes intersect.
(1) Clogged air cleaner element:
(2) Defective contact of valve, valve seat:
(3) Leakage of air between turbocharger
and head:
(4) Worn piston ring, cylinder liner:
(5) Defective timing rail pressure sensor:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Worn piston ring, cylinder liner].
Follow this column down to the troubleshooting area and
carry out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
D475A-5 20-905
(1)
TROUBLESHOOTING S-1
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)

General causes why starting performance is poor Legend
Defective electrical system : Possible cause (judging from Questions and check items)
Insufficient supply of fuel : Most probable causes (judging from Questions and Check items)
Insufficient intake of air : Possible causes due to length of use (used for a long period)
Improper selection of fuel : Items to confirm the cause.
(At ambient temperature of -10C [-14F] or below, use ASTM
D975 No. 1, and -10C [14F] or above, use ASTM D975 No. 2 Causes
diesel fuel.)
Defective operation of governor oil pump relief valve

a Battery charging rate
Defective injection pump (rack, plunger stuck)

Defective heater, electrical intake air heater
Charging rate
Clogged fuel filter, priming pump strainer
Defective injection pump overflow valve

Ambient 100% 90% 80% 75% 70%
Leakage, clogging, air in fuel system

temperature
Catching of rack dust cover and link

Clogged fuel tank air breather hole
20C [68F] 1.28 1.26 1.24 1.23 1.22
Defective or deteriorated battery

0C [32F] 1.29 1.27 1.25 1.24 1.23

10C [14F] 1.30 1.28 1.26 1.25 1.24
Defective injection nozzle

Worn piston ring, cylinder
Defective injection timing
Stiff rack link bearing

The specific gravity should be for the charging rate of 70% or more in the
Defective alternator
Defective regulator
above table.
In cold weather the specific gravity must be for the charging rate of at
least 75% in the above table.
Confirm recent repair history

Gradually became worse
Ease of starting
Starts when warm
Questions
Takes time to start again after warming up

Indicator lamp does not light up
Replacement of filters has not been carried out according to operation manual
Non-specified fuel has been used
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
Engine does not pick up smoothly, and combustion is irregular

Check items

Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump sleeve nut is loosened
2) Little fuel comes out even when air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When priming pump strainer is inspected directly, it is found to be clogged
Heater mount does not become warm
Yes
Troubleshooting
Voltage is 26 - 30 V between alternator termal B and

terminal E with engine at low idling
No
Either specific gravity of electrolyte or voltage of battery is low
Stop fuel injecton to one cylinder at a time. If there is no change in engine

When check is made using dilivery method, injection timing is found to be incorrect
When control rack is pushed, it does not return (when rack stopper bolt at rear of
pump is removed and rack piston is pushed with a screwdriver, rack does not move)
When fuel cap is inspected directly, it is found to be clogged

When overflow valve is inspected, it is found to be stiff, or always stays open
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Remedy
20-906 D475A-5
(1)
TROUBLESHOOTING S-2
S-2 ENGINE DOES NOT START

1) Engine does not turn
General causes why engine does not turn
Internal parts of engine seized
+ If internal parts of the engine are seized,
carry out troubleshooting for "Engine
stops during operations".
Failure in power train
Defective electrical system
Causes
Defective adjustment of engine stop motor wire

Defective safety relay or safety switch
Defective battery terminal connection

Defective wiring of staring circuit
Defective engine stop motor

Defective starting motor

Legend Broken ring gear
: Possible cause (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.

Questions

Condition of horn when starting Horn does not sound
switch is turned ON Horn sound level is low
Rotating speed is slow
When starting switch is turned to Makes grating noise
START, pinion moves out, but Soon disengages again
Makes rattling noise and does not turn
Check items
When starting switch is turned to START, pinion does not move out
When starting switch is turned to ON, there is no clicking sound
Carry out troubleshooting for defective wiring of starting circuit
Battery terminal is loose

When starting switch is turned to ON, linkage does not move
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 5), turn the starting switch OFF, connect the
cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are connected, engine

starts
Troubleshooting
2) Even when terminal B and terminal C of starting motor are connected,

engine does not start
3) When terinal B and terminal C of safety relay are connected, engine starts
4) When terminal of safety switch and terminal B of starting motor are
connected, engine starts
5) There is no 24V voltage between battery relay terminal B and terminal E
When ring gear is inspected directly, tooth surface is found to be chipped
Does not move even when engine stop motor linkage is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
D475A-5 20-907
(1)
TROUBLESHOOTING S-2
2) Engine turns but no exhaust gas comes out (Fuel is not being injected)
(including cases with V-type engine where there is fuel injection for the bank on only one side)
General causes why engine turns but no

exhaust gas comes out
Supply of fuel impossible
Supply of fuel is extremely small
Improper selection of fuel (particularly in win-
ter)
Legend
Standards for use of fuel
Causes
Defective operation of governor oil pump relief valve *

Defective injection pump (seized plunger, rack)
Defective fuel cut solenoid (valve stuck)

Seized, broken feed pump (gear, shaft)
Seized governor oil pump gear, shaft *

Broken injection pump drive shaft, key
Clogged governor oil supply pipe *

Clogged priming pump strainer
Clogged governor oil strainer *

Governor spool valve stuck *
Clogged, leaking fuel piping
Clogged fuel filter, strainer
Improper fuel used

Lack of fuel
*: "Abnormality in servo system" is displayed by troubleshooting function.

Exhaust gas sddenly (when starting again) stopped coming out
Questions
Fuel tank is found to be empty
There is leakage from fuel piping
When fuel filter is drained, fuel does not come out
When egine is cranked wth starting motor,
1) Injection pump coupling does not turn
Check items
2) No fuel comes out even when fuel filter air bleed plug is loosened
3) No fuel comes out even when injection pump air bleed plug is loosened
4) No fuel spurts out even when injection pipe sleeve nut is loosened
Rust and water are found when fuel is drained
Inspect injection pump directly

Control rack does not move
Inspect feed pump directly
Troubleshooting
Inspect fuel cut solenoid directly
Inspect governor oil pump directly
Inspect governor spool valve directly
When governor oil supply pipe is inspected directly, it is found to be clogged
When governor oil strainer is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
Add
20-908 D475A-5
(1)
TROUBLESHOOTING S-2
3) Exhaust gas comes out but engine does not start (Fuel is being injected)
General causes why exhaust gas comes out but

engine does not start
Lack of rotating force due to defective electri-
cal system
Insufficient supply of fuel
Insufficient intake of air Causes
Improper selection of fuel
Defective, broken valve system (valve, rocker lever, etc.)
Defective electric heater, intake heater (ribbon type)

Defective injection pump (rack, plunger stuck)
Clogged injection nozzle, defective spray

Leakage, clogging, air in fuel system

Clogged feed pump strainer
Improper fuel used

Legend

Suddenly failed to start
When engine is cranked, abnormal noise is heard from around cylinder head
Questions

Rust is found when fuel is drained
Indicator lamp does not light up
Starting motor cranks engine slowly
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pipe sleeve nut is loosened
Check items
2) Little fuel comes out even when fuel filter air bleed plug and injection
pump air bleed plug are loosened

temperature of some cylinder is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

Troubleshooting
When feed pump strainer is inspected directly, it is found to be clogged

When air element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or pump is heavy
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Clean
Clean
Clean
Remedy
D475A-5 20-909
(1)
TROUBLESHOOTING S-3
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
General causes why engine does not pick up

smoothly
Insufficient supply of fuel Causes
Improper fuel used
Defective injection pump boost compensator


Defective adjustment of governor link
Seized injection pump plunger


Legend

Questions

Engine pick-up suddenly became poor
Color of exhaust gas
Black
Engine pick-up is different between left and right banks
Check items
High idling speed under no load is normal, but speed suddenly drops when
load is applied
There is hunting from engine (rotation is irregular)

Troubleshooting

When valve clearance is checked directly, it is found to be outside standard value
When feed pump is operated, operation is too light or too heavy
Link connecting left and right injection pumps is stiff
Boost compensator does not work
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-910 D475A-5
(1)
TROUBLESHOOTING S-4
S-4 ENGINE STOPS DURING OPERATIONS

(Including cases with V-type engine where there is fuel injection for the bank on
only one side)
General causes why engine stops during opera-

tions
Internal parts of engine seized
Insufficient supply of fuel Causes
Overheating
+ If there is overheating and the engine
Defective operation of governor oil pump relief valve *

stops, carry out troubleshooting for over-
Defective injection pump (rack, plunger stuck) *

heating.
Broken, valve system (valve, rocker lever, etc.)

Failure in power train
+ If the engine stops because of a failure in
Seized governor oil pump gear, shaft *

Broken, seized piston, connecting rod
the power train, carry out troubleshooting
Clogged governor oil supply pipe *

Broken, seized crankshaft bearing
Broken, pump auxiliary equipment

Broken fuel pump drive shaft, key
for the chassis.
Clogged priming pump strainer
Clogged governor oil strainer *

Failure in chassis power train
Broken, seized gear, shaft

Broken, seized gear train
Legend
Lack of fuel

Abnormal noise was heard and engine stopped suddenly
Condition when
Engine overheated and stopped
Questions
engine stopped
Engine stopped slowly
There was hunting and engine stopped
Fuel gauge lamp lights up
When feed pump is operated, there is no response or it is heavy
Engine turns, but stops when transmission control lever is operated
Does not turn at all
Check items
Try to turn by hand Turns in opposite direction

using barring tool Moves amount of backlash
Shaft does not turn
Carry out troubleshooting for chassis

Metal particles are found when oil is drained
Remove oil pan and inspect directly

Remove head cover and inspect directly
When gear train is inspected, it does not turn
Turns when pump auxiliary equipment is removed
Troubleshooting
Inspect feed pump directly
Control rack does not move
Inspect governor oil pump directly
When governor oil suply pipe is inspected directly, it is found to be clogged
When governor oil strainer is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
Add
*: "Abnormality in servo system" is displayed by troubleshooting function.
D475A-5 20-911
(1)
TROUBLESHOOTING S-5
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
General causes why engine does not rotate

smoothly
Air in fuel system
Defective governor mechanism
Causes
Clogged, air in circuit between feed pump and injection nozzle

Clogged, air in circuit between fuel tank and feed pump
Defective operation of governor (Defective adjustment)
Clogged governor oil pump inlet port filter, pipe

Defective sliding of governor (solenoid spool)
Clogged governor oil pump screen filter

Defective operation of control rack

Low speed is too low
Legend
Lack of fuel


Occurs at certain speed range
Questions
Occurs at low idling

Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Replacement of filter has not been carried out according to operation manual
Rust is found when fuel is drained
When feed pump is operated,
Check items
1) No response, light, return is quick

2) No response, light, return is normal
Engine speed sometimes rises too high
Engine is sometimes difficult to stop
Governor lever (solenoid plunger) is stiff

Spool valve is stiff
Troubleshooting

When governor oil pump screen filter is inspected, it is found to be clogged
When governor oil pump inlet filter, oil supply pipe are inspected, they are
found to be clogged
Replace
Repair
Repair
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
20-912 D475A-5
(1)
TROUBLESHOOTING S-6
S-6 ENGINE LACKS OUTPUT(NO POWER)

(With V-type engine, for cases where there is injection for only one bank, go to
troubleshooting S-2-2) or S-4.)
General causes why engine lacks output

Insufficient intake of air Causes
Insufficient supply of fuel
Improper fuel used
(if non-specified fuel is used, output drops)

Lack of output due to overheating

+ If there is overheating and insufficiet out-

put, carry out troubleshooting for over-

heating.
Seized injection pump plunger



Legend

Questions
Suddenly
Power was lost
Gradually
Black
Color or exhaust gas
High idling speed under no load is normal, but speed suddenly drops when
Check items
load is applied

There is huntling from engine (rotation is irregular)
High idling speed of engine is low

Troubleshooting
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Clean
Clean
Clean
Clean
Remedy
D475A-5 20-913
(1)
TROUBLESHOOTING S-7
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)
General causes why exhaust gas is black

Excessive injection of fuel
Causes



Crushed, clogged muffler
Improper injection timing
Legend

Suddenly became black
Questions
Color of exhaust gas Gradually became black

Suddenly
Power was lost
Gradually
Check items

Exhaust noise is abnormal
Muffler is crushed

When air cleaner is inspected directly, it is found to be clogged
Troubleshooting

When check is made using delivery method, injection timing is found to be incorrect
When valve clearance is checked directly it is found to be outside standard value
When muffler is removed, exhaust gas color returns to normal
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Clean
Remedy
20-914 D475A-5
(1)
TROUBLESHOOTING S-8
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)
a Do not run the engine at idling for more than

20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is exces-

sive
Abnormal combustion of oil
External leakage of oil
Wear of lubrication system
a Judge the oil consumption by comparing it
with the fuel consumtion during the same pe-
riod.
More than 0.5%: Check the engine
More than 1.0%: There is some abnormality
Causes
Turbocharger
Leakage from oil pan, cylinder head, etc.
Worn valve (stem, guide), broken seal

Worn, broken rear seal, seal surface
Dust sucked in from intake system.
Clogged breather or breather hose
Leakage from oil filter, oil cooler
Leakage from oil drain plug
Worn seal at turbine end

Worn seal at blower end
Leakage from oil piping
Broken piston ring
Legend
: Possible cause (judging from Questions and check items) Broken oil cooler
Excessive oil

Questions

Oil consumption suddenly increased
Engine oil becomes contaminated quickly
Exhaust gas is blue under light load
Abnormally excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

Inside of turbocharger intake pipe is dirty with oil
Oil level in clutch or TORORLOW transmission damper chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be clogged with dirty oil
Troubleshooting
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Check rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty with oil
Oil is above H level on oil level gauge
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
D475A-5 20-915
(1)
TROUBLESHOOTING S-9
S-9 OIL BECOMES CONTAMINATED QUICKLY
General causes why oil becomes contaminated

quickly
Intake of exhaust gas due to internal wear
Clogging of lubrication passage
Improper combustion
Improper oil used
Operation under excessive load
Causes
Defective seal at turbocharger turbine end

Clogged turbocharger drain tube
Clogged breather, breather tube
Worn valve, valve guide
Defective safety valve

Exhaust gas is black
Legend
Clogged oil cooler
Clogged oil filter

Excessive oil


Questions

Color of exhaust gas
Black
Abnormally excessive
Amount of blow-by gas
Check items
None
Carry out troubleshooting for "Exhaust is black".
Oil filter caution lamp stays on even when oil pressure rises
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly

When breather element is inspected directly, it is found to be clogged with
dirty oil, or hose is broken
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to be catching or broken
Oil is above H level on oil level gauge
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
Remedy
20-916 D475A-5
(1)
TROUBLESHOOTING S-10
S-10 FUEL CONSUMPTION IS EXCESSIVE
General causes why fuel consumption is exces-

sive
Leakage of fuel
Excessive injection of fuel
Causes
Defective injection pump (excessive injection)

External leakage from fuel piping, fuel filter
Leakage of fuel inside head cover
Defective injection pump plunger
Defective injection nozzle spray
Improper fuel injection timing
Legend

Questions
More than for other machies of same model

Condition of fuel consumption Gradually increased
Suddenly increased
Black
Exhaust gas color
White
There is irregular combustion
Check items
Match mark on injection pump is misaligned

There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling speed is high
Injection pump test shows that injectin amount is excessive

Troubleshooting

When check is made using delivery method, injection timing is found to be
incorrect
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust
Remedy
D475A-5 20-917
(1)
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL

GOES DOWN
General causes why oil is in cooling water

Internal leakage in lubrication system
Internal leakage in cooling system
Causes
Broken cylinder liner O-ring, holes caused by pitting
Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Broken oil cooler for power train
Internal cracks in cylinder block

Broken oil cooler core, O-ring
Broken water pump seal
Legend

Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Check items
Engine oil level has risen, oil is cloudy white

Excessive air bubbles inside radiator, spurts back
Hydraulic oil, torque converter, transmission oil is cloudy white
When hydraulic oil, torque converter, transmission oil is drained, water is found
Troubleshooting

Pressure-tightness test of cylinder head shows there is leakage
Remove cylinder head and check directly
Remove oil pan and check directly
Check water seal and oil seal of water pump
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-918 D475A-5
(1)
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
General causes why oil pressure lamp lights up

Leakage, clogging, wear of lubricating system
Defective oil pressure control
Improper oil used (improper viscosity)
Deterioration of oil due to overheating
a Standard for use of oil
Causes
Clogged, broken oil pipe inside oil pan
Leaking, crushed hydraulic piping

Clogged strainer inside oil pan
Defective oil pressure sensor

Broken suction pipe brazing
Defective oil level sensor

Defective regulator valve
Insufficient oil in oil pan
Worn bearing journal
Defective relief valve

Defective oil pump
Clogged oil cooler

Legend
Clogged oil filter
Water, fuel in oil

Confirm recent history

Questions

Caution lamp lights up
Lights up at low idling
Lights up at low, high idling
Condition when oil pressure
lamp lights up Lights up on slopes
Sometimes lights up
There is clogging, leakage from hydraulic piping (external)
Oil level sensor lamp lights up
Check items
When oil level in oil pan is checked, it is found to be low

Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
Back of head cover is black with carbon from oil
When oil filter is inspected directly, it is found to be clogged

Carry out troubleshooting for
Troubleshooting

"Oil level rises"
Oil pump roration is heavy, there is play

There is catching of relief valve or regulator valve, spring or valve guide is broken
When oil level sensor is replaced, oil pressure sensor lamp goes out
When oil pressure is measured, it is found to be within standard value
When oil cooler is inspected, it is found to be clogged
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
D475A-5 20-919
(1)
S-13 OIL LEVEL RISES
a If there is oil in the cooling water, carry out

troubleshooting for "Oil is in cooling water".
General causes why oil level rises

Water in oil (cloudy white)
Fuel in oil (diluted, and smells of diesel fuel)
Entry of oil from other componenet
Causes
Broken cylinder liner O-ring, holes made by pitting

Clogged water pump breather hole, defective seal
Defective part inside injection pump (flange type)

Defective seal of pump or auxiliary equipment
Leakage of fuel from nozzle holder

Worn, damaged rear seal surface
Defective nozzle holder sleeve
Broken oil cooler core, O-ring
Cracks inside cylinder block

Legend Defective thermostat seat

Questions

There is oil in radiator cooling water
Exhaust gas is white
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is run at idling, an abnormal number
of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud

Check items
When water pump breather hole is clean, water comes out

Oil level goes down in clutch, TORQFLOW transmission, or damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel is added more frequently

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Remove water pump and check directly

Check rear seal directly
When pump auxiliary equipment is removed, seal is found to be broken
Remove injection pump and check directly
There is improper contact of thermostat seat valve
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
20-920 D475A-5
(1)
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
General causes why water temperature becomes

too high
Lack of cooling water (deformation, damage
of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
Rise in oil temperature of power train
+ Carry out troubleshooting for chassis.
Causes
Damaged cylinder liner O-ring, holes made by pitting

Rise in torque converter oil temperature
Defective thermostat (does not open)
Defective water temperature gauge

Fan belt slipping, worn fan pulley
Clogged, crushed radiator fin
Clogged, broken oil cooler

Defective pressure valve
Insufficient cooling water
Clogged radiator core
Broken water pump
Legend

Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Rises quickly
Water temperature gauge
Does not go down from red range
Radiator water level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
There is play when fan pulley is rotated
Check items
Radiator shroud, inside of underguard are clogged with dirt or mud

When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
Belt tension is found to be slack
Power train oil temperature enters red range before engine water temperature
Temperature difference between top and bottom radiator tanks is excessive

Carry out troubleshooting for chassis
Temperature difference between top and bottom radiator tanks is slight

When water filler port is inspected, the core is found to be clogged
Troubleshooting
When a function test is carried out on the thermostat, it does not open even at
the cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set pressure is found to
be low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
Add
D475A-5 20-921
(1)
S-15 ABNORMAL NOISE IS MADE
a Judge if the noise is an internal noise or an

external noise.
General causes why abnormal noise is made

Abnormality due to defective parts
Abnormal combustion noise
Air sucked in from intake system
Causes

Defect inside muffler (dividing board out of position)
Broken valve system (valve, rocker lever, etc.)

Improper adjustment of valve clearance

Deformed fan, interference of fan belt

Improper gear train backlash
Seized crankshaft, bearing

Missing, seized bushing
Legend

Questions
Gradually occurred
Condition of abnormal noise
Suddenly occurred
Color or exhaust gas
Black
Metal particles are found in oil filter
Check items

Abnormal noise is loud when accelerating engine
Vibrating noise is heard from around muffler

Remove gear cover and check directly
Troubleshooting

When control rack is pushed, it is found to be heavy or does not return
Injection pump test shows that injection amount is incorrect
Fan is deformed, or belt is loose
Remove cylinder head cover and check directly
When muffler is removed, abnormal noise disappears
Metal particles are found in oil pan, oil filter
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Adjust
Adjust
Remedy
20-922 D475A-5
(1)
S-16 VIBRATION IS EXCESSIVE
a If there is abnormal noise together with the vi-

bration, carry out troubleshooting for "Abnor-
mal noise is made".
General causes why vibration is excessive

Defective parts (abnormal wear, breakage)
Improper alignment
Abnormal combustion
Causes
Misalignment between engine and power train

Loose engine mounting bolts, broken cushion
Valve system (valve, rocker lever, etc.) stuck

Broken part inside output shaft (damper)
Worn connecting rod, main bearing
Improper gear train backlash

Worn balancer, cam bushing
Defective vibration damper

Worn support pilot
Legend

Questions

Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Check items
Oil pressure is low at low idling

Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust gas is black

Remove side cover and check directly
Check directly for worn support pilot, play
Troubleshooting
Check directly for loose engine mouting bolts, broken cushion

Check inside of output shaft (damper) directly
When radial runout, face runout are measured, they are found to be outside
standard value
Remove front cover and check directly
Injection pump test shows that injection amount is incorrect
Dent in vibration damper
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Remedy
D475A-5 20-923
(1)
30 DISASSEMBLY AND
ASSEMBLY
METHOD OF USING MANUAL ......................... 30-3 DISASSEMBLY AND ASSEMBLY OF
PRECAUTIONS WHEN CARRYING OUT TORQUE CONVERTER ASSEMBLY ........ 30-47
OPERATION................................................. 30-5 DISASSEMBLY AND ASSEMBLY OF
SPECIAL TOOL LIST......................................... 30-7 PTO ASSEMBLY........................................ 30-55
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF
ENGINE OIL COOLER ASSEMBLY .......... 30-14 TORQFLOW TRANSMISSION
REMOVAL AND INSTALLATION OF ASSEMBLY ................................................ 30-60
FUEL INJECTION PUMP ASSEMBLY DISASSEMBLY AND ASSEMBLY OF
(BOTH LEFT AND RIGHT)......................... 30-14 TORQFLOW TRANSMISSION
AFTERCOOLER CORE ASSEMBLY ......... 30-16 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF STEERING CASE ASSEMBLY.................. 30-75
NOZZLE HOLDER ASSEMBLY ................. 30-18 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF STEERING CLUTCH,
ENGINE FRONT SEAL .............................. 30-19 BRAKE ASSEMBLY................................... 30-82
REMOVAL AND INSTALLATION OF DISASSEMBLY AND ASSEMBLY OF
ENGINE REAR SEAL................................. 30-20 TRANSFER GEAR HOUSING
CYLINDER HEAD ASSEMBLY .................. 30-22 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF POWER TRAIN PUMP ASSEMBLY .......... 30-92
FUEL TANK ASSEMBLY............................ 30-26 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY............ 30-92
MAIN RADIATOR ASSEMBLY................... 30-27 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF TORQUE CONVERTER OIL COOLER ..... 30-93
SUB RADIATOR ASSEMBLY .................... 30-28 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF TORQUE CONVERTER VALVE
RADIATOR GUARD ASSEMBLY............... 30-30 ASSEMBLY ................................................ 30-94
FAN DRIVE ASSEMBLY ............................ 30-32 TORQUE CONVERTER VALVE
FAN MOTOR PUMP................................... 30-33 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF TRANSMISSION CONTROL VALVE
ENGINE ASSEMBLY ................................. 30-34 ASSEMBLY ................................................ 30-99
DAMPER ASSEMBLY ................................ 30-37 TRANSMISSION CONTROL VALVE
DISASSEMBLY AND ASSEMBLY OF ASSEMBLY (ECMV ASSEMBLY) ............ 30-100
DAMPER ASSEMBLY ................................ 30-38 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF STEERING CONTROL VALVE
POWER TRAIN UNIT ASSEMBLY ............ 30-40 ASSEMBLY .............................................. 30-103
REMOVAL AND INSTALLATION OF PTO, DISASSEMBLY AND ASSEMBLY OF
TORQUE CONVERTER ASSEMBLY ........ 30-43 STEERING CONTROL VALVE
DISCONNECTION AND CONNECTION OF ASSEMBLY .............................................. 30-104
PTO, TORQUE CONVERTER
ASSEMBLY ................................................ 30-45
D475A-5 30-1
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF

FINAL DRIVE ASSEMBLY .......................30-106 HYDRAULIC PUMP ASSEMBLY ............. 30-184
DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF
FINAL DRIVE ASSEMBLY .......................30-107 HYDRAULIC VALVE ASSEMBLY ............ 30-185
TRACK FRAME ASSEMBLY.................... 30-119 CONTROL VALVE.................................... 30-186
DISASSEMBLY AND ASSEMBLY OF DISASSEMBLY AND ASSEMBLY OF
IDLER ASSEMBLY...................................30-121 MERGE-DIVIDER VALVE AND
REMOVAL AND INSTALLATION OF SELF-REDUCING PRESSURE
RECOIL SPRING ASSEMBLY .................30-123 VALVE ASSEMBLY ................................. 30-190
DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF
RECOIL SPRING ASSEMBLY .................30-127 PPC RELIEF VALVE ASSEMBLY ............ 30-192
TRACK ROLLER ASSEMBLY ..................30-129 HYDRAULIC CYLINDER ASSEMBLY ..... 30-193
DISASSEMBLY AND ASSEMBLY OF DISASSEMBLY AND ASSEMBLY OF
TRACK ROLLER ASSEMBLY ..................30-132 RIPPER PIN-PULLER CYLINDER
REMOVAL AND INSTALLATION OF ASSEMBLY .............................................. 30-197
CARRIER ROLLER ASSEMBLY ..............30-134 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF BLADE ASSEMBLY.................................. 30-200
CARRIER ROLLER ASSEMBLY ..............30-134 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF GIANT RIPPER ASSEMBLY .................... 30-202
BOGIE ASSEMBLY ..................................30-137 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF ROPS GUARD ......................................... 30-205
BOGIE ASSEMBLY ..................................30-142 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF OPERATORS CAB ASSEMBLY .............. 30-206
NO. 1 BOGIE ASSEMBLY ........................30-144 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY ................... 30-207
TRACK SHOE ASSEMBLY ......................30-151 REMOVAL AND INSTALLATION OF
OVERALL DISASSEMBLY AND OVERALL CONTROLLER ASSEMBLY..................... 30-210
ASSEMBLY OF TRACK SHOE ................30-154 REMOVAL AND INSTALLATION OF
PRESS-FITTING JIG DIMENSION TABLE AIR CONDITIONER CONDENSER
FOR LINK PRESS ....................................30-167 ASSEMBLY .............................................. 30-211
FIELD DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF
OF ONE LINK ...........................................30-168 AIR CONDITIONER COMPRESSOR
DISASSEMBLY AND ASSEMBLY OF ASSEMBLY .............................................. 30-212
MASTER LINK..........................................30-172 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ........................ 30-214
PIVOT SHAFT ASSEMBLY ......................30-176 REMOVAL AND INSTALLATION OF
REMOVAL AND INSTALLATION OF HOOD ASSEMBLY................................... 30-216
EQUALIZER BAR .....................................30-178 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF FAN DRIVE ASSEMBLY.......................... 30-217
EQUALIZER BAR BUSHING....................30-181 REMOVAL AND INSTALLATION OF
FAN MOTOR ASSEMBLY ....................... 30-218
30-2 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

REMOVAL AND INSTALLATION OF ASSEMBLIES
SPECIAL TOOLS INSTALLATION OF PARTS

Special tools that are deemed necessary for Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
List of the special tools contains the following Instructions and precautions for installing parts
kind of information. are shown with [*1] mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
t: Special tools which cannot be substi- are intended for.
tuted, should always be used. Marks shown in the INSTALLATION Section
q: Special tools which are very useful if stand for the following.
k
available, can be substituted with com-
mercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly a This mark gives guidance or precau-
developed for this model.
2 This mark stands for a specific coating
tions when doing the procedure.
R: Tools with upgraded part numbers,
remodeled from already available tools
3 This mark indicates the specified
agent to be used.
for other models.
Blank: Tools already available for other mod-
5
torque.
els, used without any modification. This mark indicates an amount of oil or
3) Circle mark (Q) in sketch column: water to be added.
A circle mark means that a sketch of the
special tool is presented in the section of
Sketches for Special Tools. SKETCHES OF SPECIAL TOOLS
a Part No. of special tools starting with 79*T means Various special tools are illustrated for the con-
that they are locally made parts and as such not venience of local manufacture.
interchangeable with those made by Komatsu in
Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS
The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
Various symbols used in the REMOVAL Section
are explained and listed below.
k This mark indicates safety-related pre-

doing the work.
a This mark gives guidance or precautions
when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be

drained.
D475A-5 30-3
(2)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS ASSEMBLY

Special tools which are deemed necessary for Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
tion. well as the amount of oil or water to be added.
List of the special tools contains the following Various symbols used in the ASSEMBLY Sec-
kind of information. tion are explained and listed below.
k
1) Necessity
t: Special tools which cannot be substi- This mark indicates safety-related pre-
tuted, should always be used. cautions which must be followed when
q: Special tools which are very useful if doing the work.
available, can be substituted with com- a This mark gives guidance or precau-
2 This mark stands for a specific coating

mercially available tools. tions when doing the procedure.
2) Distinction of new and existing special tools
3 This mark indicates the specified
agent to be used.
N: Tools with new part numbers, newly
developed for this model.
5
torque.
R: Tools with upgraded part numbers,
This mark indicates an amount of oil or
remodeled from already available tools
water to be added.
for other models.
Blank: Tools already available for other mod-
els, used without any modification.
SKETCHES OF SPECIAL TOOLS
3) Circle mark (Q) in sketch column: 1) Various special tools are illustrated for the
A circle mark means that a sketch of the convenience of local manufacture.
special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T--- xxx
--- xxxx.
DISASSEMBLY
The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or
water to be drained.
Various symbols used in the DISASSEMBLY
Section are explained and listed below.
k This mark indicates safety-related pre-

doing the work.
a This mark gives guidance or precautions
when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be

drained.
30-4 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal number Plug (nut end) Nut (elbow end)

02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
D475A-5 30-5
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79OT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a New/remodel:N: Tools with new part numbers, newly developed for this model
R: Tools with upgraded part numbers, remodeled from items already available for
other models.
Blank:Tools already available for other models, used without any modification
a Tools marked in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
Necessity
remodel
Sketch
New/
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
Press fitting of front seal,

1 795-602-2200 Installer kit t 1
sleeve
Press fitting of rear seal,
2 795-602-2300 Installer kit t 1
sleeve
3 790-331-1110 Wrench t 1 Installation of cylinder head
790-431-1120 Adapter t 1
791-520-4140 Screw t 1
Disassembly and
A
assembly of engine 791-181-1020 Sleeve t 1
791-765-1150 Plate t 1
Pulling out pin or radiator
4 791-112-1180 Nut t 1 guard
790-101-2540 Washer t 1
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Disassembly and 790-413-1010 Bracket t 1
Disassembly, assembly of
assembly of torque C
790-501-5000 Repair stand t 1 torque converter
converter
790-413-1010 Bracket t 1
Disassembly and Disassembly, assembly of
assembly of trans- D 790-501-5000 Repair stand t 1 transmission
mission Checking actuation of piston
799-301-1600 Oil leak tester t 1
791-622-1110 Bracket t 1
Removal, installation of clutch,
1 01016-51690 Bolt t 1
brake assembly
01011-81600 Bolt t 1
Disassembly and
E 791T-822-1810 Push tool t 1 N Q
assembly of steering
2 Press fitting of bearing
791T-822-1820 Push tool t 1 N Q
Removal, installation of bear-
3 791-822-1830 Wrench t 1 N
ing round nut
790-337-1032 Lifting tool t 1
Removal, installation of final
1 791-827-1910 Plate t 1
drive assembly
01011-83015 Bolt t 3
790-431-1081 Guide t 1
Disassembly and
assembly of final J 790-431-1031 Block t 1
drive
790-101-2350 Leg t 2
2 Pulling out sprocket bearing
790-101-2430 Adapter t 2
790-101-2360 Plate t 4
02215-11622 Nut t 2
D475A-5 30-7
(2)
Necessity
remodel
Sketch
New/
Q'ty
Puller
790-101-2102 t 1
2 (294 kN {30 ton}) Pulling out sprocket bearing
790-101-1102 Pump t 1
790-431-1101 Installer assembly t 1
Puller Press fitting of sprocket bear-
3 790-101-2102 t 1
(294 kN {30 ton}) ing
790-101-1102 Pump t 1
4 791-585-1510 Installer t 1 Installation of floating seal
790-431-1220 Remover assembly t 1
Disassembly and Puller

5 790-101-2102 t 1 Pulling out center hub
assembly of final J (294 kN {30 ton})
drive assembly 790-101-1102 Pump t 1
Puller
6 790-101-2102 t 1 Press fitting of center hub
(294 kN {30 ton})
790-101-1102 Pump t 1
790-431-1230 Remover & installer t 1
Puller Pulling out, press fitting of car-
7 790-101-2102 t 1
(294 kN {30 ton}) rier pin
790-101-1102 Pump t 1
8 790-431-1240 Guide t 1 Assembly of No. 1 pinion
791-830-1760 Plate t 1 N
791-830-1320 Rod t 2
790-101-2510 Block t 1
790-101-2570 Plate t 2
1 01580-01613 Nut t 2 Press fitting of idler bushing
01643-31645 Washer t 2
Assembly of Idler
Puller
790-101-2102 t 2
(294 kN {30 ton})
790-101-1102 Pump t 1
L 2 791-560-1520 Installer t 1 Installation of floating seal
3 791-830-1480 Push tool t 1 N Press fitting of seal guide
4 791-601-1000 Oil pump t 1 Filling with oil
Disassembly and Press fitting of floating seal col-
6 790-830-1770 Push tool t 1 N
assembly of carrier lar
roller
Removal, installation of round
7 791-630-1270 Wrench t 1
nut
Assembly of track 8 791-830-1740 Plate t 1 N Press fitting of bushing

roller 9 791-515-1520 Installer t 1 Installation of floating seal
30-8 D475A-5
(2)
Necessity
remodel
Sketch
New/
Q'ty
10 791-830-1730 Push tool t 1 N Press fitting of seal ring

Assembly of track 790-401-1700 Lifting tool t 1

roller 790-401-1761 Adapter t 1 Removal, installation of track
12
790-401-1540 Shackle t 2 roller assembly
790-401-1770 T-bolt t 2
791T-830-1780 Plate t 3 N Q
Disassembly and
assembly of bogie 13 01011-62700 Bolt t 6 Fixture of bogie
and track roller
01673-32780 Washer t 6
1 791-830-1620 Plate t 1 N
2 791-830-1630 Spacer t 1 N
3 791-830-1640 Screw t 3 N
4 01580-12722 Nut t 3
14 Pulling out ring and shaft
5 01630-32780 Washer t 3
Puller
6 790-101-4000 t 1
(490 kN {50 ton})
7 790-101-1102 Pump t 1
1 791-830-1650 Plate t 1 N
2 791-830-1660 Spacer t 1 N
3 796-670-1120 Plate t 1
L 4 790-434-1070 Screw t 1 N
15 5 01580-13629 Nut t 2 Pulling out ring
6 01643-33690 Washer t 1
Puller
7 790-101-4000 t 1
(490 kN {50 ton})
Disassembly and
assembly of bogie 8 790-101-1102 Pump t 1
1 791-830-1620 Plate t 1 N
2 791-830-1640 Screw t 3 N
3 01580-12722 Nut t 3
16 4 01643-32780 Washer t 3
Press fitting of pin assembly
Puller
5 790-101-4000 t 1
(490 kN {50 ton})
6 790-101-1102 Pump t 1
17 791T-830-1670 Guide t 2 N Q
791-630-1860 Bracket t 1
791-630-1870 Bracket t 1
Removal of No. 1 bogie
20 791T-830-1510 Spacer t 2 Q
assembly
19M-09-12850 Bolt t 2
01643-33380 Washer t 2
D475A-5 30-9
(2)
Necessity
remodel
Sketch
New/
Q'ty
791T-830-1700 Lifting tool t 1 N

791T-830-1710 Bar 1 N Q
791T-830-1720 Plate 1 N Q
Disassembly and Removal of No. 1 bogie track
L 21 07283-31079 Grip 1
assembly of bogie roller
01582-01210 Nut 2
01643-31232 Washer 2
04530-11628 Eye bolt 1
Puller Pulling out idler cushion guide
1 790-101-2102 t 1
(294 kN {30 ton}) pin
790-101-1102 Pump t 1
791-685-8502 Compressor t 1
791-635-3160 Extension t 1
Disassembly and
assembly of recoil M 790-201-2790 Spacer t 1 Disassembly, assembly of
2
spring recoil spring
Cylinder
790-101-1300 t 1
(980 kN {100 ton})
790-101-1102 Pump t 1
791-730-1120 Bolt t 6
Removal of recoil cylinder
3 01580-13326 Nut t 6
assembly
01643-33380 Washer t 6
792-900-1610 Adapter t 1
792-900-1530 Screw t 1
791-775-1110 Sleeve t 1
791T-850-1150 Plate t 1 N Q
1 01582-53024 Nut t 1 Pulling out center pin
01643-33080 Washer t 1
Puller
790-101-2102 t 1
(294 kN {30 ton})
Disassembly and
assembly of N 790-101-1102 Pump t 1
equalizer bar
791T-850-1160 Bracket t 1 N Q
791T-850-1170 Bracket t 1 N Q
790-438-1110 Screw t 1
790-101-2540 Washer t 2
2 Pulling out side pin bushing
791-112-1180 Nut t 2
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
30-10 D475A-5
(2)
Necessity
remodel
Sketch
New/
Q'ty
791T-850-1180 Sleeve t 1 N Q
791T-850-1190 Plate t 1 N Q
791-730-1130 Bolt t 2
Disassembly and 791-101-3310 Plate t 1
assembly of pivot P Press fitting of seal
shaft 01643-32060 Washer t 2
01580-02016 Nut t 2
790-105-2300 Jack assembly t 1
790-101-1102 Pump t 1
1 791-646-7531 Plug remover t 1 Knocking out small plug
2 791-660-7460 Pin brush t 1 Cleaning of pin
3 791-646-7900 Push tool t 1 Knocking in large plug
4 791-932-1110 Push tool t 1 Knocking in all plugs
790-701-3000 Seal checker
Filling with oil and checking air
5 and t 1
tightness
791-601-1000 Oil pump
6 791-632-1010 Installer t 1 Replacing of link seal
1 791-832-1610 Plate t 1
2 791-832-1270 Bracket t 1
3 01010-81495 Bolt t 1
4 791-832-1250 Bracket t 1
5 01010-62050 Bolt t 2
6 791-832-1220 Plate t 1
7 791-832-1230 Shaft t 2
8 791-832-1210 Frame t 1
Disassembly and
9 791-832-1240 Nut t 2
assembly of track R
shoe 10 04530-11628 Eye bolt t 2
11 791-832-1310 Adapter t 1
12 791-832-1280 Adapter t 1
Pulling out and press fitting of
8 13 791-832-1320 Guide t 1
pin and bush
14 01320-41030 Screw t 5
15 791-832-1640 Pusher t 1
16 791-832-1340 Extension t 2
17 791-832-1650 Adapter t 1
18 791-832-1480 Adapter t 1 N
19 791-832-1670 Guide t 1
20 791-832-1330 Guide t 1
21 791-832-1660 Adapter t 1
22 791-832-1630 Guide t 1
23 791-832-1470 Guide t 1 N
24 791-832-1410 Extension t 1
25 791-832-1350 Pusher t 1
D475A-5 30-11
(2)
Necessity
remodel
Sketch
New/
Q'ty
26 791-832-1620 Guide t 1
27 04530-11018 Eye bolt t 1
Cylinder
28 790-101-4500 t 1
(1960 kN {200 ton}) Pulling out and press fitting of
8
29 790-101-1102 Pump t 1 pin and bush
Puller
30 790-101-4200 t 1
(294 kN {30 ton})
31 790-685-9230 Spacer t 1 N
1 791-685-5600 Push tool assembly t 1 N
2 791-685-5640 Adapter 1 N
3 791-685-5660 Ring 1 N
4 791-685-5670 Plate 1 N
5 791-685-5680 Ring 1 N
Press fitting ring
9 6 791-685-5690 Push tool 1 N
(For large plug)
7 791-685-5710 Adapter 1 N
8 791-685-5720 Spring 1 N
Disassembly and 9 791-685-5730 Bar 1 N
assembly of track R 10 01252-30655 Bolt 1
shoe
11 01580-01210 Nut 1
10 790-685-5740 Push tool t 1 N Press fitting ring
1 791-832-1490 Push tool t 1 N
11 Press fitting ring
2 791-832-1510 Push tool t 1 N
1 791-685-5700 Push tool assembly t 1 N
2 791-685-5650 Adapter 1 N
3 791-685-5660 Ring 1 N
4 791-685-5670 Plate 1 N
5 791-685-5680 Ring 1 N
Press fitting ring
12 6 791-685-5690 Push tool 1 N
(For small plug)
7 791-685-5710 Adapter 1 N
8 791-685-5720 Spring 1 N
9 791-685-5730 Bar 1 N
10 01252-30655 Bolt 1
11 01580-01210 Nut 1
13 791-685-5750 Push tool t 1 N Press fitting ring
30-12 D475A-5
(2)
Necessity
remodel
Sketch
New/
Q'ty
Disassembly, assembly of cyl-

1 790-502-1003 Cylinder repair stand q 1
inder
790-201-1702 Push tool kit t 1 Press fitting of coil bushing
Blade tilt
(standard specification)
790-201-1881 Push tool 1 Blade pitch
(superdozer specification)
Ripper tilt
2
790-201-1871 Push tool 1 Ripper lift
790-201-1721 Push tool 1 Ripper puller
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1500 Push tool kit t 1 Press fitting of dust seal
790-201-1670 Plate 1 Blade lift
790-201-1680 Plate 1 Ripper lift
Blade tilt
3 790-201-1690 Plate 1 Blade pitch
Disassembly, assem- Ripper tilt
bly of hydraulic cylin- U
der 790-201-1530 Plate 1 Pin puller
790-101-5021 Grip 1
01010-50816 Bolt 1
Installation of all cylinder piston
4 790-720-1000 Expander t 1
rings
796-720-1690 Ring t 1 Blade lift (standard specifica-
07281-01919 Clamp t 1 tion)
796-720-1690 Ring t 1 Blade lift (superdozer specifi-

07281-02169 Clamp t 1 cation)
Ripper tilt, lift

5 796-720-1710 Ring t 1 Blade tilt
07281-02709 Clamp t 1 Blade pitch
796-720-1630 Ring t 1
Pin puller
07281-00709 Clamp t 1
Removal and installation of pin
6 790-102-2303 Wrench t 1
puller cylinder head
799-703-1200 Service tool kit t 1 Charging with freon gas
799-703-1100 Vacuum pump t 1 (100 V specification)
Air conditioner
X 799-703-1110 Vacuum pump t 1 (220 V specification)
related
799-703-1120 Vacuum pump t 1 (240 V specification)
799-703-1400 Gas leak detector t 1
D475A-5 30-13
(2)
ENGINE OIL COOLER
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL AND REMOVAL AND

INSTALLATION OF ENGINE INSTALLATION OF FUEL
OIL COOLER ASSEMBLY INJECTION PUMP ASSEMBLY
(BOTH LEFT AND RIGHT)
REMOVAL
1. Remove fuel injection pump assembly (right). REMOVAL
For details, see REMOVAL OF FUEL INJEC- 1. Open engine side cover (1) and remove left and
TION PUMP ASSEMBLY (RIGHT). right side covers (2) and (3).
2. Drain coolant. 2. Close fuel supply valve.
3. Remove front oil cooler assembly (1).
4. Remove manifold (2).
5. Remove manifold (3).
6. Remove oil cooler assembly (rear) (4).
Left side of engine

3. Remove mounting bolts (5) of fuel strainer (4),
and move fuel strainer assembly to side.
4. Disconnect fuel hose (6).
INSTALLATION
Carry out installation in the reverse order to
removal.
Refilling with coolant

Add coolant to the specified level, and run the
engine to circulate the coolant through the sys-
tem. Then check the coolant level again.
5. Disconnect hose (7) for field pump.
6. Remove coupling cover (8).
30-14 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
Left and right of engine
12. Disconnect tubes (17) and (18).
13. Disconnect oil inlet tube (19).
Right side of engine

7. Disconnect oil filter tube (9) and remove oil filter
assembly (10).
8. Remove lubrication tube (11) and oil level gauge

(12).
14. Disconnect fuel injection tubes (20).
15. Disconnect tube (21).
16. Remove coupling bolts (22).
17. Remove injection pump mounting bolts (23).
18. Remove injection pump (24).

a Be careful not be lose the coupling key, and
store it in a safe place.
4 Fuel injection pump assembly: 45 kg
9. Disconnect field pump hose (13) and clamp

(14).
10. Disconnect heater hose clamp (15).
11. Remove coupling cover (16) and cover (17).
INSTALLATION
3 Coupling lock bolt:

removal.
157 196 Nm {16 20 kgm}
Adjust the injection timing.

Adjusting fuel injection timing.
D475A-5 30-15
(2)
DISASSEMBLY AND ASSEMBLY AFTERCOOLER CORE
REMOVAL AND Left bank

11. Disconnect electrical intake air heater wiring (8).
INSTALLATION OF AFTER-
COOLER CORE ASSEMBLY 12. Remove intake connector (9).
REMOVAL 13. Remove air cleaner connector (10).

1. Drain coolant.
2. Remove hood assembly.

For details, see REMOVAL OF HOOD ASSEM-
BLY.
3. Remove engine side cover of both side.
Right bank
4. Remove air cleaner assembly (1).
Remove the air cleaner bracket also.
5. Disconnect electrical intake air heater wiring (2).
6. Remove intake connector (3). 14. Disconnect corrosion resistor tube (11) and
remove corrosion resistor assembly (12) with
7. Disconnect hose clamp (4). bracket.
8. Disconnect hose clamp (5). 15. Remove muffler assembly (13) and bracket (14).
9. Remove oil cooler tube (6). 16. Disconnect all wiring clamps.
10. Remove engine oil filter assembly (7). 17. Disconnect water separator hose (15) and
remove water separator assembly (16).
18. Disconnect fuel filter tube (17) and remove fuel

filter with bracket.
19. Disconnect corrosion filter (19).
30-16 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY AFTERCOOLER CORE
20. Removal of aftercooler core assembly (for left 2) Remove connectors (14) and (15), and
bank) cover (16).
1) Remove aftercooler tubes (6), (7), and (8). 3) Remove aftercooler core assembly (17).
2) Remove connectors (9) and (10), and cover

(11). INSTALLATION
3) Remove aftercooler core assembly (12). Carry out installation in the reverse order to
removal.

21. Removal of aftercooler core assembly (for right

bank)
1) Remove aftercooler tube (13).
D475A-5 30-17
(2)
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL AND
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
REMOVAL
BLY.
2. Remove engine side cover (1).
7. Remove nozzle holder assembly (7). [*4]

a Using the removed holder and mounting
bolts, screw into the head of the nozzle hold-
er, and pull out the nozzle holder.
a Check that there is a gasket fitted to the tip of
the nozzle holder.
a Mark each nozzle holder with the cylinder
number, be careful not to damage the tip,
and keep in a safe place.
3. Remove cylinder head cover (2).
4. Disconnect fuel tube (3). [*1]
INSTALLATION
removal.
3 Sleeve nut:
[*1]
5. Loosen locknut (4), and remove connection (5).
[*2] 23.5 0.98 Nm {2.4 0.1 kgm}
6. Remove holder (6). [*3]

3 Connection:
[*2]
3 Locknut:
34.3 39.2 Nm {3.5 4.0 kgm}
29.4 34.3 Nm {3.0 3.5 kgm}
3 Holder mounting bolt:

[*3]
66.2 7.4 Nm {6.75 0.75 kgm}
[*4]
Align with the connection mount hole of the noz-
zle holder, then insert the nozzle holder.
30-18 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL AND INSTALLATION

INSTALLATION OF ENGINE removal.
FRONT SEAL
[*1]
SPECIAL TOOLS a Align the dowel pin when installing the crankshaft
pulley.
New/remodel
a Tighten the mounting bolts in the order shown in
Necessity
Symbol
Sketch
3 Crankshaft pulley mounting bolt:
the diagram below.
Q'ty
Part No. Part Name
1st step: 73.5 19.6 Nm {7.5 2 kgm}

2nd step:245 19.6 Nm {25 2 kgm}
A 1 795-602-2200 Installer kit t 1
3rd step: 744.8 19.6 Nm {76 2 kgm}
REMOVAL
1. Remove radiator guard assembly.
For details, see REMOVAL OF RADIATOR
GUARD ASSEMBLY.
2. Remove crankshaft pulley (1). [*1]
[*2]
a Do as follows according to the wear of the crank-
shaft seal contact surface.
1) When crankshaft is a new part or when
there is no wear of oil seal contact surface.
i) Press fit by tool A1
ii) After press fitting, check mounting
3. Remove front seal (2). [*2] dimension a.
Front seal mounting dimension a:
17.5 mm
iii) Install dust seal (3).
Dust seal mounting dimension b:
approx. 7 mm
D475A-5 30-19
(2)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

1. Using guide bolt, and install flywheel (2).
INSTALLATION OF ENGINE
REAR SEAL
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
A 2 795-602-2300 Installer kit t 1
REMOVAL
1. Remove damper assembly.
F or details, s ee RE MOVAL OF DAMPER
ASSEMBLY. 2. Secure flywheel (2) and housing with plate [3].
2. Sling with eyebolts [1] (M16, P=2), remove

mounting bolts (1), screw in forcing screws [2]
(M12, P=1.75), then remove flywheel (2).
4 Flywheel: 140 kg
a Tighten the mounting bolts in the order shown in
3 Flywheel mounting bolt:

the diagram below.
1st step: 98 19.6 Nm {10 2 kgm}

2nd step: 294 19.6 Nm {30 2 kgm}
3rd step: 539 19.6 Nm {55 2 kgm}
3. Remove rear seal (3). [*1]
30-20 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
3. After installing flywheel, use dial gauge [4] to

measure radial and face runout of flywheel.
Face runout: Max. 0.30 mm
Radial runout: Max. 0.30 mm
[*1]
a Do as follows according to the wear of the crank-
shaft seal contact surface.
1) When crankshaft is a new part or when
there is no wear of oil seal contact surface.
i) Press fit by tool A2.
ii) After press fitting, check mounting
dimension a.
Front seal mounting dimension a:
18.5 mm
D475A-5 30-21
(2)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL AND 13. Remove oil cooler tube (11).
INSTALLATION OF 14. Remove engine oil filter assembly (12).

CYLINDER HEAD ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
A 3 790-331-1110 Wrench t 1
REMOVAL
1. Drain coolant.

Left bank
15. Disconnect electrical intake air heater wiring
BLY.
(13).
3. Remove left and right engine side covers.
16. Remove intake connector (14).
4. Remove air cleaner assembly (1).
17. Remove air cleaner connector (15).
5. Remove left and right heat covers (2).
18. Remove oil supply tube (16) and drain tube (17).
Remove air cleaner bracket also.
19. Disconnect clamp and connector of wiring (18).
Right bank
6. Disconnect electrical intake air heater (3).
7. Remove intake connector (4).
8. Remove oil supply tube (5) and drain tube (6).
9. Remove dust indicator (7).
10. Disconnect intake hose (8).
11. Disconnect hose clamp (9).
12. Disconnect clamp and connector of wiring (10).
20. Disconnect corrosion resistor tube (19) and

remove corrosion resistor assembly (20) with
bracket.
21. Remove muffler assembly (21) and bracket (22).
22. Disconnect water separator hose (23) and

remove water separator assembly (24).
23. Disconnect fuel filter tube (25) and remove fuel

filter (26) with bracket.
24. Disconnect corrosion filter (27).
30-22 D475A-5
(2)
25. Remove turbocharger assembly (28). [*1] 28. Removal of exhaust manifold assembly (for right
bank)
26. Remove exhaust manifold assembly (29). [*2] 1) Remove aftercooler tube (36).
2) Remove electrical intake air heater wiring
harness (37).
3) Sling intake manifold and aftercooler
assembly (38), and remove mounting bolts.
a To prevent the electrical intake air heater
from falling, install a guide bar in the bot-
tom intake manifold mounting bolt hole.
4) Remove intake manifold and aftercooler
assembly (38). [*3]
4 Intake manifold, aftercooler assem-
bly: 50 kg
5) Remove electrical intake air heater (39).
27. Removal of intake manifold assembly (for left

bank)
1) Remove aftercooler tubes (30), (31) and
(32).
2) Remove electrical intake air heater wiring
harness (33).
3) Sling intake manifold and aftercooler
assembly (34), and remove mounting bolts.
a To prevent the electrical intake air heater
from falling, install a guide bar in the bot-
tom intake manifold mounting bolt hole.
4) Remove intake manifold and aftercooler
assembly (34). [*3]
4
29. Remove fuel injection tube (40) and spill tube
Intake manifold, aftercooler assem- (41). [*4]
bly: 50 kg
5) Remove electrical intake air heater (35). 30. Remove air vent tube (42).
D475A-5 30-23
(2)
31. Remove head cover (43). [*5] INSTALLATION

removal.
3 Turbocharger mounting bolt:

[*1]
2 Bolt thread, seat surface:

49 4.9 Nm {5.0 0.5 kgm}
Anti-friction compound (LM-P)
3 Exhaust manifold mounting bolt:

[*2]

49 4.9 Nm {5.0 0.5 kgm}

a Tighten the mounting bolts in the order
32. Remove rocker arm (44). [*6] shown in the diagram.
a To prevent pressure on the push rod when
installing the rocker arm, loosen the locknut
and turn the adjustment screw back 2 3
turns.
33. Remove push rod (45) and crosshead (46). [*7]
3 Intake manifold mounting bolt:

[*3]
66.15 7.35 Nm {6.75 0.75 kgm}

a Tighten the mounting bolts in the order
shown in the diagram.
34. Remove nozzle holder assembly.

Fo r de tai l s , s e e R E M O VA L O F N O Z ZL E
HOLDER ASSEMBLY.
35. Remove rocker housing (47). [*8]
36. Remove cylinder head (48). [*9]
3 Sleeve nut:
[*4]
23.5 0.98 Nm {2.4 0.1 kgm}
3 Head cover mounting bolt:

[*5]
4.9 0.98 Nm {0.5 0.1 kgm}
30-24 D475A-5
(2)
[*6] a Tighten bolt [7] to 66.15 7.35 Nm {6.75

a Check that the ball of the adjustment screw is fit- 0.75 kgm}
3 Rocker arm mounting bolt:

ted properly into the socket of the push rod. a After tightening, make one punch mark on
the bolt head to indicate the number of times
98 4.9 Nm {10 0.5 kgm} it has been tightened.
a If any bolt already has five punch marks, do
[*7] not reuse it. Replace it with a new bolt.
a Check that the push rod is inserted securely in
the cam follower.
a Adjust the crosshead as follows.
1) Loosen the locknut and turn back the adjust-
ment screw.
2) Press down lightly with a finger on the top of
the crosshead and screw in the adjustment
screw.
3) When the adjustment screw contacts the
valve stem, tighten it a further 20.
4) Tighten the locknut to hold the adjustment
3 Locknut:
screw in position.
58.8 5.9 Nm {6.0 0.6 kgm}
[*8]
a Adjust the valve clearance.
Adjusting valve clearance.

[*9]
3 Tighten the mounting bolts by hand for

at least the first 2 3 turns, then tighten

as follows.
1st step:
137.2 156.8 Nm {14 16 kgm}
2nd step:
210.7 220.5 Nm {21.5 22.5 kgm}
3rd step:
Using wrench A3, tighten 90 +30+0
When not using wrench A3, tighten as fol-

lows.
Order Procedure
1st step 137.2 156.8 Nm {14 16 kgm}
2nd step 210.7 220.5 Nm {21.5 22.5 kgm}
Make marks with paint on bolt and
3rd step +30
head, then tighten bolt a further 90 +0
D475A-5 30-25
(2)
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL AND 6. Remove fuel tank mounting bolt (9).
INSTALLATION OF FUEL
TANK ASSEMBLY
REMOVAL
1. Disconnect hose (1).
a Before disconnecting the hose, close the fuel
valve.
2. Remove bracket (2).
7. Lift off fuel tank assembly (10).

4 Fuel tank assembly (when full):2,335kg
3. Remove joint (3) and hose clamp (4).
4. Disconnect fuel return hoses (5) and (6), and

remove hose clamp (7).
5. Disconnect fuel gauge wiring connector (8).
INSTALLATION
removal.
30-26 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY MAIN RADIATOR
REMOVAL AND 8. Disconnect head lamp connector (8).
INSTALLATION OF MAIN
RADIATOR ASSEMBLY
REMOVAL
1. Drain coolant.
2. Lift off radiator top cover (1).

4 Radiator top cover assembly: 85 kg
9. Disconnect wiring harness clamp (9) at the top

of radiator and radiator coolant level sensor con-
nector (10).
10. Sling radiator assembly (11), then remove top

mount bolts (12) (left and right: 2 each).
3. Disconnect radiator inlet hose (2) (left and right)

and aeration hose (3) (left and right).
4. Disconnect sub tank hose (4).
5. Disconnect power line cooler aeration hose (5).
11. Remove bottom cover (13).
a Remove the fan motor assembly.

For details, see REMOVAL OF FAN MO-
TOR ASSEMBLY.
6. Remove isolator bolt (6) (left and right: 2 each).
7. Remove wind breaker plate (7) (top and bottom,

left and right).
D475A-5 30-27
(2)
DISASSEMBLY AND ASSEMBLY SUB RADIATOR
12. Remove tube (14). REMOVAL AND

13. Remove bottom mount bolts (15) (left and right). INSTALLATION OF SUB
RADIATOR ASSEMBLY
14. Lift off radiator assembly (11).
a Be careful not to damage the core when lift- REMOVAL
ing the radiator off. 1. Drain coolant.
4 Radiator assembly: 550 kg
3. Remove hood (2) and side cover.

BLY.
INSTALLATION
removal.

Add coolant to the specified level, and run the 4. Disconnect wiring harness clamps (3) and (4) at
engine to circulate the coolant through the sys- the top of radiator.
5. Disconnect harness connector (5) and coolant
level sensor connector (6).
6. Disconnect radiator inlet hose (7), aeration hose

(8) and sub tank hose (9).
7. Disconnect power train aeration hose (10).
8. Remove radiator top mount bolts (11) (left and

right: 2 each).
9. Disconnect sub radiator hose (12).
10. Remove hose clamp (13).
30-28 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY SUB RADIATOR
11. Remove clamp and disconnect wiring harness 13. Disconnect radiator bottom tube (16).
(14).
14. Remove radiator bottom mount bolt (17).
INSTALLATION
removal.

12. Remove bottom cover bolt (15) and open bot-

tom cover.
D475A-5 30-29
(2)
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD
REMOVAL AND INSTALLA- 3. Sling blade lift cylinder assembly (4), then fit cyl-
inder holder tool and secure to radiator guard.
TION OF RADIATOR GUARD
ASSEMBLY 4. Drain coolant.
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-431-1120 Adapter t 1
791-520-4140 Screw t 1
791-181-1020 Sleeve t 1
791-765-1150 Plate t 1
A 4 791-112-1180 Nut t 1
790-101-2540 Washer t 1 5. Disconnect radiator inlet and outlet hoses, aera-
Puller tion hose, and wiring harness clip.
790-101-2102 t 1 For details, see REMOVAL AND INSTALLA-
(294 kN {30 ton})
TION OF MAIN RADIATOR ASSEMBLY.
790-101-1102 Pump t 1
6. Disconnect hydraulic cooler hose (5).
REMOVAL Disconnect fan motor hose (6).
1. Remove lock plate (1) of the lift cylinder rod pin, k Release the remaining pressure from the
then remove pin (2). [*1] hydraulic circuit.
a Start the engine and retract the piston rod For details, see TESTING AND ADJUST-
fully, then tie the piston rod with wire to pre- ING, Releasing remaining pressure from
vent it from coming out. hydraulic circuit.
a Tie the piston rod on the opposite side in the a Fit a cover to prevent dirt from entering the
same way. piping.

For details, see REMOVAL AND INSTALLA-
TION OF HOOD ASSEMBLY.
Remove engine side covers (left and right).
30-30 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD
7. Disconnect work equipment tubes (7) and (8). INSTALLATION

removal.
[*1]
a Standard shim thickness: 4 mm

8. Sling radiator guard assembly and remove lock

bolt, then using tool A4, push rear pin (11) to
inside of radiator guard and remove.
9. Remove lock plate, then using tool A4, pull front

pin (12) to outside of radiator guard and remove.
10. Lift off radiator guard assembly (13).

a Be extremely careful not to damage the wir-
ing and piping when removing.
4 Radiator guard assembly: 4,700 kg
D475A-5 30-31
(2)
DISASSEMBLY AND ASSEMBLY FAN DRIVE
REMOVAL AND 5. Disconnect fan motor hoses (5), (6) and (7).
INSTALLATION OF FAN 6. Sling fan drive assembly (9), and remove

DRIVE ASSEMBLY bracket mounting bolt (8).
REMOVAL 7. Sling fan drive assembly (9) and remove fan

1. Drain oil from hydraulic tank. motor assembly.
6 Hydraulic tank: 340 l 4 Fan motor assembly: 70 kg
2. Remove 8 mounting bolts (2) of radiater guard

mask (1).
INSTALLATION
3. Remove net (3). removal.
4. Remove fan blades (4). Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified level,
and run the engine to circulate the oil through
the system. Then check the oil level again.
30-32 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY FAN MOTOR PUMP
REMOVAL AND 6. Disconnect pump outlet hoses (5) and (6).
INSTALLATION OF 7. Disconnect wiring clamp (7).

FAN MOTOR PUMP
8. Disconnect EPC hose (8).
REMOVAL
k Lower the work equipment to the ground and
stop the engine. Release the remaining pres-
sure in the hydraulic piping.
Releasing remaining pressure from hydraulic
circuit.
Then loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
k Disconnect the cable from the negative () ter-
minal of the battery.
1. Drain oil from hydraulic tank.

6 Hydraulic tank: 340 l
9. Disconnect wiring connector (9).
2. Remove floor frame assembly.
For detail, see REMOVAL OF FLOOR FRAME 10. Remove pump inlet tube (10).
ASSEMBLY.
11. Remove pump inlet connector (11).
3. Remove hydraulic oil pump inlet tube (1).
12. Sling fan motor pump assembly (12) and
4. Disconnect fan pump drain hoses (2) and (3). remove.
4 fan motor pump assembly: 75 kg
5. Disconnect EPC hose (4).
INSTALLATION
Carryout installation in the reverse order to
removal
D475A-5 30-33
(2)
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL AND
INSTALLATION OF ENGINE
ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
799-703-1200 Service tool kit t 1

799-703-1100 Vacuum pump t 1
6. Disconnect radiator inlet hose (4) and aeration
X 799-703-1110 Vacuum pump t 1 hose (5).
799-703-1120 Vacuum pump t 1
799-703-1400 Gas leak detector t 1 7. Disconnect sub radiator inlet hose (6).
REMOVAL
1. Drain coolant.
2. Remove radiator upper cover (1).

4 Radiator upper cover assembly: 85 kg
3. Remove hood assembly (2).

BLY.
8. Disconnect air conditioner hose (7).
a Loosen the sleeve nut slightly and release
the air conditioner gas (R134a) completely
before disconnecting the hose.
a Fit covers to prevent dirt or moisture from en-
tering the hose.
a Disconnect all the clamps for hose (7).
4. Remove engine side covers (3) (left and right).
5. Open underguards (1st and 2nd from front of

machine).
30-34 D475A-5
(2)
9. Disconnect radiator outlet tube (8).
10. Disconnect torque converter oil cooler tubes (9)

and (10).
11. Disconnect heater hose (11).
12. Disconnect sub radiator outlet hose (12).
19. Disconnect heater hose (23) at the valve por-

tion.
20. Disconnect air conditioner hose (24) and hose

clamp together.
21. Disconnect fuel hose (25) and hose clamp.
13. Disconnect hose (13) between fuel strainer and

water separator.
14. Disconnect water separator and hose (14)

between fuel pump on the right side.
15. Disconnect fuel supply hose (15), drain hose

(16), starting motor wire clamp (17) and hose
clamp (18).
22. Disconnect air conditioner hose (26) and heater

hose (27).
23. Remove rubber shield (28) at damper.
16. Disconnect wiring connector (995.111.VEG)

(19).
17. Disconnect air conditioner gas receiver hose

(20).
18. Disconnect starting motor wirings (21) and (22),

and remove clamp.
D475A-5 30-35
(2)
24. Sling universal joint (29), then remove mounting INSTALLATION

bolts and remove. [*2] Carry out installation in the reverse order to
4
removal.
Universal joint: 65 kg
[*1]
a Install the hoses without twisting or interfer-
ence.
a When installing the air conditioner circuit
hoses, be extremely careful not to let any
dirt, dust, or moisture get inside the hoses.
a Check that there is an O-ring at the piping
connection for the air conditioner hose, then
tighten the hose.
Coat the O-ring thoroughly with compressor
oil (Showa Shell Suniso 4G or 5G).
25. Remove front mount bolts (30) and rear mount

bolots (31).
3 Tightening torque of air conditioner gas

piping:
Tightening torque
Thread size
(Nm {kgm})
26. Remove engine assembly (32). [*3] 16 x 1.5 13.23 1.47 {1.35 0.15}
4 Engine assembly: 4,250 kg 22 x 1.5 22.05 2.45 {2.25 0.25}
a When removing the engine, check that all 24 x 1.5 31.85 2.45 {3.25 0.25}
the wiring and piping has been disconnect-
M6 bolt (receiver portion) 5.39 1.47 {0.55 0.15}
ed.
Operate the lever block so that there is no M6 bolt
9.8 1.96 {1.0 0.2}
interference with other parts, set with the (compressor portion)
front slightly raised, and lift off.
3 Universal joint mounting bolt:

[*2]
156.8 196 Nm {16 20 kgm}
3 Engine mount mounting bolt:

[*3]
1,715 1,911 Nm {175 195 kgm}

Charging with air conditioner gas

Using tool X, charge the air conditioner circuit
with air conditioner gas (R134a).
30-36 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY DAMPER
k
REMOVAL AND Install guide bolts (12mm, P=1.75, l=100) in
2 mounting bolt holes in the top of the
INSTALLATION OF DAMPER damper cover so that the damper cover
ASSEMBLY does not come out suddenly.
4 Damper cover: 50 kg
REMOVAL
BLY.
2. Open underguard (3rd from front of machine).
3. Remove drain plug (1) and drain damper oil.

6 Damper case: Approx. 2.2 l
4. Remove dipstick and dipstick guide (2).
9. Sling damper assembly (8), then using guide

bolt [2] (16mm, P=2.0) and nut [3], loosen nut
slowly so that damper assembly does not come
out suddenly, then remove.
4 Damper assembly: 85 kg
5. Sling universal joint (3), then remove mounting

bolts, and lift off. [*1]
4 Universal joint: 65 kg
INSTALLATION
removal.

[*1]
156.8 196 Nm {16 20 kgm}
2 Holder mounting bolt thread:

6. Remove holder (4) and coupling (5). [*2] [*2]

7. Remove retainer (6). Thread tightener (LT-2)
8. Sling damper cover (7), then use forcing screw 490 607.6 Nm {50 62 kgm}
[1] (12mm, P=1.75) to remove damper cover.
Refilling with oil (damper case)
D475A-5 30-37
(2)
DISASSEMBLY AND
ASSEMBLY OF DAMPER
ASSEMBLY
DISASSEMBLY
1. Remove bolt (1), then remove flange (2).
2. Remove seal (3).
3. Remove shaft (4).
4. Remove rubber (5).

2. Install seal (8) to flange (6), and seal (3) to
5. Remove flange (6) from body (7).
flange (2).
a Install the seal with the lip facing the inside
6. Remove seal (8).
as shown in the diagram.
7. Remove bearing (9).
3. Align the bolt holes with body (7), then install
2 Flange mating surface:

flange (6).
Disassembly of damper cover assembly
8. Remove bearing (10) and seal (11) from cover
(12).
a Check that there are no dents, rust, oil or
grease, or water on the mating surface, then
9. Remove oil seal (13) from retainer (14).
coat both the flange and body surfaces with
gasket sealant.
a Coat with a thickness of about 0.1 0.2 mm,
leave to dry for 2 3 minutes, then tighten.
ASSEMBLY
2 Flywheel pilot portion: Grease (G2-U)

1. Using push tool, press fit bearing (9).
a Fill 50% (approx. 55 g) of clearance a.
30-38 D475A-5
(2)
4. Set shaft (4) to flange and body assembly in a Coat the inside surface of the retainer thinly
position. with gasket sealant and wipe off any sealant
2 Lip of oil seal: Grease (G2-LI)

that is forced out.
5. Assemble rubber (5).
a When assembling the rubber, coat the whole
surface of the rubber, the outside circumfer-
ence of the shaft, and the inside circumfer-
ence of the body with grease (G2-LI).
a After assembling the rubber, fill approx. 50%
(approx. 400 g) of the space (b portion: 16
places) between the shaft and body with
grease (G2-LI).
9. Using push tool [2], press fit bearing (10) to

cover (12).
2 Flange mating surface:

6. Install flange (2).

a Check that there are no dents, rust, oil or
grease, or water on the mating surface, then
coat both the flange and body surfaces with
gasket sealant.
a Coat with a thickness of about 0.1 0.2 mm,
leave to dry for 2 3 minutes, then tighten. 10. Using push tool [1], press fit oil seal (11) to cover
2 Oil seal press-fitting surface:

(12).
7. Tighten bolt (1).
a Coat the inside surface of the cover thinly
with gasket sealant and wipe off any sealant

that is forced out.
Assembly of damper cover assembly

8. Using push tool [1], press fit oil seal (13) to

retainer (14).
D475A-5 30-39
(2)
DISASSEMBLY AND ASSEMBLY POWER TRAIN UNIT
REMOVAL AND 8. Remove hydraulic pump inlet tube coupling (5)

and hydraulic tank side coupling (6), and
INSTALLATION OF POWER remove tube (7).
TRAIN UNIT ASSEMBLY
9. Disconnect fan motor hose (8).
REMOVAL
1. Drain oil from hydraulic tank and power train 10. Disconnect hoses (9) and (10).
case.
6 Hydraulic tank: Approx. 120 l
6 Power train case: Approx. 150 l
2. Remove floor frame assembly.

For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
3. Remove fuel tank assembly.

For details, see REMOVAL OF FUEL TANK
ASSEMBLY.
4. Remove brake rod (1).

11. Disconnect steering hose (11).
5. Disconnect brake safety lever cable (2).
12. Disconnect hoses (12) and (13).
6. Disconnect lubrication hose (3).

13. Remove hydraulic pump inlet tube (14).
7. Disconnect fan motor pump tube coupling (4).
14. Disconnect hydraulic pump PPC hoses (15) and
(16).
30-40 D475A-5
(2)
15. Disconnect hydraulic pump outlet hoses (17) 19. Remove universal joint (23). [*1]
4
and (18).
Universal joint: 65 kg
16. Disconnect hydraulic PPC hoses (19) and (20).
20. Remove front mount bolt (24). [*2]

17. Disconnect wiring connector (21) (PL1, PL2,
PL3). 21. Remove rear mount bolt (25), then remove
mount cap (26). [*3]
4 Mount cap: 30 kg
18. Disconnect hose (22), then disconnect clamp (1

place) on top of steering case.
22. Remove housing clip (27), and move flange (28)
towards final drive end. [*4]
23. Using forcing screws [1], remove cover (29).
D475A-5 30-41
(2)
24. Remove shaft (30). INSTALLATION

a Pull out the shaft with forcing screws [2]. Carry out installation in the reverse order to
a If the shaft will not come out, set jack [3] on removal.
the ground and push the shoe grouser up,

then move the sprocket to the front or rear to [*1]
a position where the shaft will come out, and
remove the shaft. 156.8 196 Nm {16 20 kgm}
3 Front mount bolt:

[*2]
1,519 1,911 Nm {155 195 kgm}
3 Rear mount bolt:

[*3]
823.2 1,029 Nm {84 105 kgm}
[*4]
a Check that the housing clip is fitted securely
3 Housing clip:
in the flange.
4.9 8.8 Nm {0.5 0.9 kgm}

25. Lift off power train unit assembly (31). [*5]
4
[*5]
Power train unit assembly: 5,500 kg a When installing the power train unit assem-
bly, pay attention to the mating surface of the
coupling, and be careful not to damage the
seal of the rear mount coupling.
Refilling with oil

5 Power train case: Approx. 210 l
5 Hydraulic tank: Approx. 140 l
30-42 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY PTO, TORQUE CONVERTER
REMOVAL AND 6. Sling filter assembly (6), then remove.
INSTALLATION OF PTO, 4 Transmission filter assembly: 40 kg

TORQUE CONVERTER 4 Torque converter, transmission lubrica-
ASSEMBLY tion filter assembly: Approx. 80 kg
REMOVAL
1. Remove power train unit assembly.
For details, see REMOVAL OF POWER TRAIN
UNIT ASSEMBLY.
2. Raise power train unit assembly (1) and set on

block.
a Set blocks under the front of the oil pan,
transmission rear case, and steering case.
7. Remove power train pump (7) and strainer

assembly (8).
k Sling the power train pump, then remove to-
gether with the strainer.
4 Power train pump, strainer assembly:
100 kg
8. Lift off mount bracket (9). [*2]

4 Mount bracket: 70 kg
3. Remove brake rod (2). [*1]
9. Remove tube (10) and scavenging pump (11).
k Sling the scavenging pump, then remove
the mounting bolts.
4 Scavenging pump: 24 kg
4. Disconnect central pressure detection hose (3),

then remove together with central pressure
detection bracket (4).
a Before removing the pressure detection hos-
es, mark them with tags to prevent any mis-
take in the mounting position when installing.
5. Remove oil filler tube (5).
D475A-5 30-43
(2)
10. Remove hose (12). 14. Remove PTO and torque converter assembly
(19). [*3]
11. Remove gauge guide (13). k Sling the PTO and torque converter assem-
bly, then remove the mounting bolts.
a Using a lever block, lift off the PTO and
torque converter assembly horizontally.
4 PTO, torque converter assembly:
830 kg
12. Removal of fan pump

1) Remove tube (14).
2) Remove wire (15).
3) Remove connector (16).
4) Lift off pump assembly (17).
4 Fan pump assembly: 75 kg
INSTALLATION
removal.
[*1]
k Bend the cotter pin securely.
2 PTO boss rotating portion:

[*2]
Grease (G2-LI)
[*3]
a Using a lever block, raise the PTO and
torque converter assembly horizontally, align
13. Remove oil pan (18). it with the spline of the shaft at the steering
a Remove the block under the oil pan, sling the case end, then install.
oil pan, then remove the mounting bolts and
disconnect the oil pan.
4 Oil pan: 120 kg
30-44 D475A-5
(2)
DISCONNECTION AND 5. Remove oil seal (6). [*2]
CONNECTION OF PTO, 6. Remove spacer (7).

TORQUE CONVERTER a Remove snap ring (8), then remove the
ASSEMBLY spacer.
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-413-1010 Bracket t 1
C
790-501-5000 Repair stand t 1
DISCONNECTION
1. Set PTO and torque converter assembly (1) to
tool C.
7. Remove PTO assembly (9) and torque con-
verter assembly (10).
a Using eyebolts [1], raise the PTO assembly,
then disconnect it from the torque converter
assembly.
4 PTO, torque converter assembly:
830 kg
2. Remove coupling assembly (2).
3. Remove cap (3).

a Remove snap ring (4), then remove the cap.
4. Remove retainer assembly (5). [*1]

a Using forcing screws, remove the cover, re-
tainer assembly, and shims.
a Check the number and thickness of the
shims, and keep in a safe place.
D475A-5 30-45
(2)
CONNECTION 3) Measure shim thickness.

Carry out connection in the reverse order to dis- a (0 to 0.05 mm)
connection. a Shim thickness: 0.15 mm, 0.20 mm, 0.50
mm
[*1] 4) Assemble the selected thickness of shim,
Adjust the clearance of the taper roller bearing and tighten the retainer assembly to the
3 Retainer mounting bolt:

as follows. specified torque.
1) Assemble the oil seal to the retainer assem-
bly, then install the cover, and tighten to 9.8 58.8 73.5 Nm {6 7.5 kgm}
Nm {1 kgm}. a Assemble the shim as shown in the diagram
2) Using a clearance gauge, measure clear- below so that it does not come at position b
ance a between the retainer and the hous- of the retainer removal tap.
ing.
a Measure clearance a at four points (A,
B, C, D) around the circumference, and
take the average as clearance a.
2 Outer circumference of oil seal:

[*2]
30-46 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY AND 2) Using eyebolts [1], remove lockup clutch

and drive case assembly (4).
ASSEMBLY OF TORQUE a Disassemble the lockup clutch and drive
CONVERTER ASSEMBLY case assembly as follows.
i) Remove seal ring (5), and using forcing
SPECIAL TOOLS screws [2], remove input shaft (6).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-413-1010 Bracket t 1
C
790-501-5000 Repair stand t 1
DISASSEMBLY
Set the torque converter assembly to tool C.
ii) Remove snap ring (7), then remove

plate (8).
iii) Set clutch housing side at bottom, and
using forcing screws [3], remove turbine
(9).
1. Torque converter valve assembly

Remove torque converter valve assembly (1).
2. Draining oil
Remove 2 drain plugs (2), and drain oil from
pump case.
a After draining the oil, tighten the plugs.
3. Lockup clutch, drive case assembly

1) Leaving 2 mounting bolts (3) in position,
remove mounting bolts, then place input
shaft side on top and remove remaining
mounting bolts.
D475A-5 30-47
(2)
iv) Set clutch housing at top, then using ix) Remove 3 discs (16) and 2 plates (17)
eyebolts [4], remove housing and piston from drive case (18).
assembly (10). a After removing the discs and plates,
a When the assembly is removed, the keep them in a flat place to prevent
piston will fall out, so support it by them from becoming distorted.
hand when removing.
v) Remove piston (11) from housing (12).
4. Stator assembly
1) Remove snap ring (19), then remove stator
vi) Remove seal ring (13) from piston. assembly (20).
vii) Remove seal ring (14) from housing. 2) Disassemble stator assembly as follows.
i) Remove snap ring (21), then remove
race (22) from stator (23).
viii) Using push tool [5], remove bearing (15)

from housing.
ii) Remove snap ring (24) from stator (23).
30-48 D475A-5
(2)
5. Pump assembly 9. Pin

1) Remove snap ring (25). Remove pin (37).
2) Remove pump assembly (26).
3) Disassemble pump assembly as follows.
i) Remove retainer (27).
ii) Remove bearing and guide assembly
(28) from pump (29).
10. Inner gear

Remove snap ring (38), then remove inner gear
(39).
11. Piston
iii) Remove bearing outer race (30) from 1) Remove piston (40) from case (41).
guide (31).

Set stator clutch housing at top and remove sta-
tor clutch housing (32).
2) Remove seal ring (42) from piston.

3) Remove seal ring (43) from case.
7. Spring
Remove spring (33).
8. Springs, discs, plate

Remove springs (34), 2 discs (35), and 1 plate
(36).
a After removing the discs and plates, keep
them in a flat place to prevent them from be-
coming distorted.
D475A-5 30-49
(2)
12. Stator shaft assembly ASSEMBLY

1) Tap stator shaft assembly (44) with a plastic a Wash all parts in clean flushing oil (in particular,
hammer, and remove from case (45). oil holes, etc.), then dry them, and check for dirt
2) Disassemble stator shaft assembly as fol- or damage. Coat the sliding surfaces of all parts
lows. with engine oil before installing.
i) Using push tool [6], remove shaft Set case (41) to tool C.
assembly (46) from stator shaft assem-
bly.
1. Stator shaft assembly

1) Assemble plate (56) to stator shaft (52), and
ii) Remove snap ring (47), then remove using push tool, press fit bearing (55).
bearing inner race (48), bushing (49), a Put drops (approx. 6 cc) of engine oil
and seal ring (50) from shaft. (SAE10W-CD or SAE30-CD) on the
iii) Remove seal ring (51) from stator shaft bearing and rotate about 10 times.
(52). 2) Install plate (54), and secure with snap ring
iv) Remove snap ring (53), then remove (53).
plate (54). 3) Install seal ring (51) to stator shaft (52).
a After installing the seal ring, coat it with
grease (G2-LI) to fix it to the shaft se-
curely.
v) Using push tool [7], remove bearing

(55), then remove plate (56).
4) Install seal ring (50) to shaft.

a After installing the seal ring, coat it with
grease (G2-LI) to fix it to the shaft se-
curely.
5) Using push tool [9], press fit bushing (49) to
shaft.
a Be careful not to deform the bushing
when press fitting.
6) Using push tool [10], press fit inner race (48)
to shaft.
7) Install snap ring (47), and secure inner race.
30-50 D475A-5
(2)
2. Piston
2 Outer circumference of seal ring:

1) Install seal ring (43) to case.
Grease (G2-LI)
a Be careful to assemble the seal ring fac-
ing in the direction shown in the diagram
below.
2 Outer circumference of seal ring:

2) Install seal ring (42) to piston.
Grease (G2-LI)
a Be careful to assemble the seal ring fac-
ing in the direction shown in the diagram
below.
8) Tap stator shaft (52) with a plastic hammer

2 Contact surface of seal ring:
3) Install piston (40) to case (41).
and press fit bearing portion to case.
9) Set shaft (46) to stator shaft, then using
Grease (G2-LI)
push tool, press fit bearing portion.
10) Turn over case and tighten mounting bolts
3. Inner gear
of shaft from case end.
Install inner gear (39) and secure with snap ring
(38).
2 Mounting bolt:
3 Mounting bolt:
Thread tightener (LT-2)
4. Pin
Install pin (37).
58.8 73.5 Nm {6 7.5 kgm}
5. Plate, discs, springs
Install 1 plate (36), 2 discs (35), and springs
(34).
D475A-5 30-51
(2)
6. Spring 2) Install pump assembly (26).

Install spring (33). a When installing the pump, be careful not
to damage the seal ring assembled to
the shaft.
3) Install snap ring (25).

Install stator clutch housing (32).
a Check that the springs are fitted securely in
2 Mounting bolt: Thread tightener (LT-2)

the holes in the housing and piston. 9. Stator assembly
3 Mounting bolt:
1) Assemble stator assembly as follows.
i) Install snap ring (24) to stator (23).
98 122.5 Nm {10 12.5 kgm}
8. Pump assembly
1) Assemble pump assembly as follows.
i) Using push tool, press fit bearing outer
race (30) to guide (31).
a Put drops (approx. 6 cc) of engine oil
(SAE10W-CD or SAE30-CD) on the
bearing and rotate about 10 times.
ii)Assemble race (22) to stator (23), and

secure with snap ring (21).
2) Install stator assembly (20) to stator shaft,
and secure with snap ring (19).
ii) Set bearing and guide assembly (28) to

pump (29), then tap with a plastic ham-
mer and press fit bearing portion.
2 Mounting bolt:
iii) Install retainer (27).
3 Mounting bolt:
58.8 74.5 Nm {6 7.5 kgm}
30-52 D475A-5
(2)
2 Contact surface of seal ring:

10. Lock-up clutch, drive case assembly v) Install piston (11) to housing (12).
1) Assemble lock-up clutch and drive case
assembly as follows. Grease (G2-LI)
i) Set turbine (9) to block [11], and set a When installing, be careful not to
drive case (18) to turbine. damage the seal ring.
vi) Using eyebolts [4], install housing and
piston assembly (10).
a Support the piston assembly by
hand to prevent it from falling out
2 Mounting bolt:
when installing.
3 Mounting bolt:
98 122.5 Nm {10 12.5 kgm}
ii) Install 3 discs (16) and 2 plates (17).
vii) Using push tool, press fit bearing (15).

viii) Install plate (8), and secure with snap
ring (7).
2 Mounting bolt:
ix) Install input shaft (6).
2 Outer circumference of seal
iii) Install seal ring (14) to housing.
3 Mounting bolt:
ring: Grease (G2-LI) Thread tightener (LT-2)
2 Outer circumference of seal

iv) Install seal ring (13) to piston.
156.8 196 Nm {16 20 kgm}
ring: Grease (G2-LI) x) Install 2 seal rings (5).
D475A-5 30-53
(2)
2) Using eyebolt [1], install lock-up clutch and

drive case assembly (4).
a Align the positions of the turbine oil
groove ( mark) and drain plug (2) when
installing.
3) Tighten mounting bolts (3).
3 Mounting bolt:
a Check that drain plug (2) is tightened.
3 Drain plug:
49 58.8 Nm {5 6 kgm}
9.8 12.7 Nm {1 1.3 kgm}
11. Torque converter valve assembly

Install torque converter valve assembly (1).
a Tighten the mounting bolts uniformly in turn
3 Mounting bolt:
and be careful not to tighten them unevenly.
43.1 53.9 Nm {4.4 5.5 kgm}
30-54 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY PTO
DISASSEMBLY AND 3) Using puller [2], remove bearings (5) and (6)
from gear (7).
ASSEMBLY OF PTO
ASSEMBLY
DISASSEMBLY
1. PTO lubrication tube
Sling PTO assembly and remove lubrication
tube (1).
a Remove the 3 lubrication tubes on the oppo-
site side also, set the torque converter end at
the bottom, then lower.
3. Power train PPC pump gear assembly

1) Using forcing screw [1], pull out cover
assembly (8) and lift off.
2) Using puller [2], remove bearing (9).
3) Remove gear (10).
2. Hydraulic pump gear assembly

1) Using forcing screws [1], pull out cover
assembly (2) and lift off.
2) Using puller [2], remove gear assembly (3)
from cover (4).
4) Using push tool [3], remove boss (11) and

bearing (12) from cover.
5) Using forcing screw [4], remove bearing (12)
from boss (11).
4. Scavenging drive gear

Remove snap ring (13) from bottom of PTO
case, then remove gear (14).
D475A-5 30-55
(2)
5. Shaft assembly 7. PTO case

1) Remove plate (15) of idler gear. 1) Remove race assembly (24) together with
bearing outer race (25).
2) Turn over PTO case, then using forcing

screw [1], remove shaft assembly (16). 2) Remove bearing inner races (26) and (27)
a The bearing outer race and key assem- from race (28).
bly will come out from the bottom of the
PTO case, so place a wooden block in
position and be careful not to damage
the assembly.
3) Remove plug (17), then using forcing screw,
push out bearing (18).
a After removing the bearing, assemble
the plug again in the correct position.
3) Remove bearing outer race (29).

4) Remove sleeve (30).
6. Idler gear assembly

1) Remove idler gear assembly (19) and bear-
ing (20) from bottom of PTO case.
2) Remove outer race (21).
30-56 D475A-5
(2)
8. Bearing
1) Remove snap ring (22).
2) Remove bearing (23).
3) Using push tool, press fit bearing inner

races (27) and (26) to race (28).
ASSEMBLY
a Clean all parts, and check for dirt or damage.
a Check that the snap ring is fitted securely in the
groove.
1. Bearing
1) Using push tool, press fit bearing (23) to
case.
2) Install snap ring (22).
2 Internal surface of race:
4) Install race assembly (24).

5) Using push tool, press fit bearing outer race
(25).
2. PTO case
1) Install sleeve (30) to case.
a Install the sleeve with the chamfered in-
side circumference facing down.
a Expand-fit the sleeve.
2) Using push tool, press fit bearing outer race
(29).
D475A-5 30-57
(2)
2 Mounting bolt:
3. Idler gear 2) Install plate (15).
1) Using push tool [5], press fit bearing outer
3 Mounting bolt:
race (21) to gear (19). Thread tightener (LT-2)
2) Position idler gear to PTO case.
98 123 Nm {10 12.5 kgm}
6. Scavenging drive gear
2 Spline portion: Grease (G2-LI)

1) Install gear (14).
4. Shaft assembly
1) Using push tool [6], press fit bearing inner
race (18) to shaft.
2) Fit O-ring, align shaft assembly (16) with
idler gear, then insert.
2) Install snap ring (13) from bottom of PTO
case.
7. Power train, PPC pump gear assembly

1) Using push tool [7], press fit bearing (12) to
boss (11).
5. Bearing
1) Turn over PTO case, and press fit bearing
spacer (31) and bearing inner race (20) to
shaft, then tighten mounting bolts of shaft
assembly.
(SAE10W-CD or SAE30-CD) on the 2) Using push tool [8], press fit boss (11) and
bearing, then rotate approx. 10 turns. bearing (12) to cover.
2 Boss spline portion:Grease (G2-LI)

a Expand fit the bearing.
30-58 D475A-5
(2)
2 Gear spline portion:Grease (G2-LI)

3) Install gear (10). 2) Using push tool [8], press fit gear assembly
2 Gear mounting bolt:

(3) to cover (4).
a Expand fit the bearing.
3 Gear mounting bolt:

Thread tightener (LT-2) a Set the end where the bearing end face
and gear end face are level so that it fac-
2 Gear spline portion:Grease (G2-LI)

98 122.6 Nm {10 12.5 kgm} es the cover.
3) Fit O-ring, then raise cover assembly (2)

and install to case.
a If the cover assembly is stiff and does
not enter the case, use a plastic hammer
and tap evenly on the side face to install.
4) Using push tool [7], press fit bearing (9) to

gear (10).
5) Raise cover assembly (8) and install.
a If the cover assembly is stiff and does
not enter the case, use a plastic hammer
and tap evenly on the side face to install.
9. Lubrication tube
Sling PTO assembly, then install lubrication tube
(1).
a Install 3 lubrication tubes also on the oppo-
3 Mounting bolt:
site side.
19.6 29.4 Nm {2 3 kgm}
8. Hydraulic pump gear assembly

1) Using push tool [7], press fit bearings (5)
and (6) to gear (7).
D475A-5 30-59
(2)
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
REMOVAL AND
INSTALLATION OF
TORQFLOW TRANSMISSION
ASSEMBLY
REMOVAL
Remove PTO and torque converter assembly.
For details, see REMOVAL OF PTO, TORQUE
CONVERTER ASSEMBLY.
1. Remove TORQFLOW transmission assembly

(1). [*1]
k Sling the transmission assembly, then re-
move the mounting bolts.
a Using a lever block, raise the transmission
horizontally, then remove from the steering.
4 TORQFLOW transmission assembly:
1,330 kg
INSTALLATION
removal.
[*1]
a Using a lever block, sling transmission as-
sembly (1) horizontally, align with spline of
shaft at steering case end, then install.
30-60 D475A-5
(2)
DISASSEMBLY AND 3. Transmission case

1) Turn over transmission assembly, and
ASSEMBLY OF TORQFLOW remove plate (10).
TRANSMISSION ASSEMBLY 2) Using eyebolts, remove transmission case
(11).
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
790-413-1010 Bracket t 1
D 790-501-5000 Repair stand t 1
799-301-1600 Oil leak tester t 1
DISASSEMBLY
Set the transmission assembly on the block.
1. Control valve assembly 4. Housing

1) Remove cover (1). 1) Remove 17 tie bolts (12).
2) Remove control valve assembly (2) together 2) Using eyebolts, remove housing (13).
with seat. 3) Remove seal ring (14) from housing.
2. Sleeve 5. Spring
1) Remove plug (8). Remove spring (15).
2) Using eyebolts [1], pull out sleeve (9).
6. Discs, plates, springs
Remove discs (16), plates (17), and springs (18)
in turn.
a Keep the discs and plates in a flat place to
prevent them from becoming deformed.
D475A-5 30-61
(2)
7. No. 1 ring gear 11. Sleeve, guide pin

Remove ring gear (19). 1) Remove sleeve (27).
2) Remove guide pin (28).
8. No. 1 housing, piston

1) Using eyebolts, remove No. 1 housing and 12. Shaft, No. 1, 2, 3 carrier assembly
piston assembly (20). Using eyebolts, remove No. 1, 2, and 3 carrier
2) Remove piston (22) from housing (21). assembly (29).
4 Shaft, No. 1, 2, 3 carrier assembly:
200 kg
1) Disassemble the shaft and carrier assembly
as follows.
i) Remove snap ring (130), then remove
sun gear (30).
9. Spring
Remove spring (23).

in turn.
ii) Using eyebolts, remove shaft and No. 1
carrier assembly (31) from No. 2 and 3
carrier assembly (32).
30-62 D475A-5
(2)
2) Disassemble the shaft and No. 1 carrier 3) Disassemble the No. 2, No.3 carrier assem-
assembly as follows. bly as follows.
i) Raise the assembly, then using forcing i) Remove sun gear (48).
screw [2] , rem ove shaft and cage ii) Using eyebolts, remove plate and gear
assembly (33). assembly (49).
ii) Using plastic hammer, remove cage
assembly (34), spacer (35), and bearing
(36).
iii) Remove seal ring (37) from cage
assembly.
iv) Remove seal ring (38) from cage.
v) Remove seal ring (40) from shaft (39).
iii) Remove ring (50), and disassemble

plate (51) and gear (52).
iv) Remove plate (54) from No. 2, 3 carrier
assembly (53).
v) Remove seal ring (55) from plate.
vi) Remove shaft (42), ball (43), thrust

washer (44), gear (45), and bearing (46)
from No. 1 carrier assembly (41).
vii) Remove seal rings (47) and (131).
vi) Remove shaft (56), ball (57), thrust

washer (58), gear (59), and bearing
(60).
D475A-5 30-63
(2)
vii) Using push tool, remove collar and 15. No. 3 piston
bearing assembly (61) from carrier. Remove No. 3 piston (71).
viii) Using push tool, remove bearing (62).
16. Spring
Remove spring (72).

in turn.
ix) Using puller and push tool, remove

bearing (63) and spacer (64) from collar
(65).
x) Remove seal ring (66).
18. Seat
Remove seat (76).
19. No. 3 housing

Using eyebolts, remove No. 3 housing (77).
4 No. 3 housing: 55 kg
20. No. 4 piston

Remove No. 4 piston (78).
13. No. 2 ring gear

Remove ring gear (67).

1) Using eyebolts, remove No. 2 housing and
piston assembly (68).
4 No. 2 housing, piston: 80 kg
2) Remove piston (70) from housing (69).
21. Spring
Remove spring (79).

in turn.
30-64 D475A-5
(2)
23. Guide pin 26. No. 3 ring gear

Remove guide pin (83). 1) Remove ring gear (91).
2) Remove ring (92) from ring gear.
24. Sun gear
Remove snap ring (132), then remove sun gear
(84).
27. Plate, ring gear

1) Using forcing screws, remove plate and ring
gear assembly (93).
25. Plate, bearing 2) Remove ring gear (94).
1) Using eyebolts, remove plate and bearing
assembly (85). 28. No. 4 carrier, No. 5 clutch assembly
2) Using push tool [3], remove bearing (87) Using eyebolts, remove No. 4 carrier and No. 5
from plate (86). clutch assembly (95).
3) Using puller [4] and push tool [3], remove
bearing (88).
4) Using push tool, remove bearing (90) from
collar (89).
1) Disassemble the No. 4 carrier and No. 5

clutch assembly as follows.
i) Remove 2 mounting bolts, then install
guide bolts.
ii) Remove remaining mounting bolts, then
l oosen guide bolts [5] sl ow ly, and
remove No. 4 carrier assembly (96)
from No. 5 clutch assembly (97).
4 No. 4 carrier assembly, No. 5
clutch assembly: 160 kg
D475A-5 30-65
(2)
29. Shaft
Remove shaft (115).
iii) Remove shaft (98), ball (99), thrust

washer (100), gear (101), and bearing
(102).
30. Shaft assembly
Set case so that shaft is at bottom, then using
eyebolts, remove shaft assembly (117) from
case (116).
4 Shaft assembly: 80 kg
1) Disassemble the shaft assembly as follows.
i) Remove snap ring, then using eyebolts,
sling shaft assembly, knock out bearing
portion, and remove shaft assembly
(118).
iv) Remove spring (103) and pin (104).

v) Remove discs (105), plates (106), and
springs (107).
a Keep the discs and plates in a flat
place to prevent them from becom-
ing deformed.
vi) Remove guide pin (108).
vii) Remove inner gear (109).
viii) Remove seal ring (110) from inner gear.
ii) Remove cage (119).

iii) Using stand [6], remove bearing (120).
ix) Remove piston (112) from No. 5 hous-

ing (111).
x) Remove spacer (113) and seal ring
(114) from No. 5 housing.
30-66 D475A-5
(2)
iv) Remove snap ring (134), then remove ASSEMBLY

bearing (121) from cage (133). a Wash all parts in clean flushing oil (in particular,
v) Remove seal ring (122). oil holes, etc.), then dry them, and check for dirt
vi) Remove cover (123). or damage. Coat the sliding surfaces of all parts
with engine oil before installing.
a Set the seal ring with the side taking the pressure
facing the housing, then coat with grease (G2-LI)
and install uniformly so that it is positioned cor-
rectly.
a Align the notches of the oil groove when install-
ing the discs.
vii) Remove bearing (124).

viii) Remove seal ring (126).
1. Shaft assembly
1) Assemble the shaft assembly as follows.
i) Install seal ring (126).
ii) Using push tool, install baring (124).
ix) Remove snap ring (135), then remove

boss and bearing (127).
x) Remove snap ring (136), then using
push tool, remove bearing (129) from
boss (128).
D475A-5 30-67
(2)
iii) Install cover (123). 2. No. 4 carrier, No. 5 clutch assembly

iv) Install seal ring (122). 1) Assemble the No. 4 carrier and No. 5 clutch
v) Install bearing (121) to cage (133) and assembly as follows.
secure with snap ring (134). i) Using push tool, install spacer (113) to
No. 5 housing (111).
ii) Install seal ring (114).
iii) Install piston assembly (112) to No. 5
housing (111).
vi) Using push tool, press fit bearing (120).

vii) Fit seal ring and install cage (119).
iv) Install seal ring (110) to inner gear.

v) Install inner gear (109).
vi) Install guide pin (108).
vii) Install springs (107), plates (106), and
discs (105) in turn.
viii) Install pin (104) and spring (103).
a Free length of spring: 103.5 mm
viii) Using eyebolts, sling shaft assembly

(118), then press fit bearing, and secure
with snap ring.
2) Set the case so that the side for installing
the steering assembly is at the top, then
using eyebolts, install shaft assembly (117)
in the case (116).
30-68 D475A-5
(2)
ix) Assemble bearing (102) in gear (101), 2) Install ring gear (94).
and fit thrust washers (100) to both
sides, then set in position in carrier.
x) Assemble ball (99) to shaft (98), and
push shaft into carrier.
4. No. 3 ring gear

1) Install ring gear (92).
2) Install No. 3 ring gear (91).
xi) Set No. 4 carrier assembly (96) to No. 5

clutch assembly (97), and using 2 guide
bolts [5], compress spring, then tighten
mounting bolts.
a Check that the spring is fitted se-
curely in the hole of the housing,
2 Mounting bolt:
then tighten the mounting bolts.
3 Mounting bolt:
157 196 Nm {16 20 kgm}
5. Plate, bearing
1) Using push tool, press fit bearing (90) in col-
lar (89).
2) Using push tool, press fit bearing (88).
2) Using eyebolts, install No. 4 carrier and No.

5 clutch assembly (95).
3. Plate, ring gear

1) Using eyebolts, align with dowel pin, then
install plate (93).
a To ensure that the plate is fitted facing in 3) Using push tool, press fit bearing (87) in
the correct direction, check the bolt hole, plate (86).
then knock in the dowel pin portion with a Set the large protrusion of the bearing
a plastic hammer until there is no clear- assembly on top as shown in the dia-
ance at the mating surface. gram below, and install to the plate.
D475A-5 30-69
(2)
4) Using eyebolts, install plate and bearing 10. No. 4 piston

assembly (85). Fit seal ring and install No. 4 piston (78).
11. No. 3 housing

Using eyebolts, fit seal ring and install No. 3
housing (77).
12. Seat
Install seat (76).

Install springs (75), plates (74), and discs (73) in
turn.
14. Spring
Install spring (72).
6. Sun gear a Free length of spring: 84 mm
Install sun gear (84), and secure with snap ring
(132). 15. No. 3 piston
Fit seal ring and install No. 3 piston (71).
7. Guide pin
Install guide pin (83).

turn.
9. Spring
a Free length of spring: 81.7 mm

1) Fit seal ring, and install piston (70) to hous-
ing (69).
2) Using eyebolts, install No. 2 housing and
piston (68).
a Check that the spring is fitted securely in
the hole of the housing.
30-70 D475A-5
(2)
17. No. 2 ring gear v) Assemble bearing (60) in gear (59),

Install ring gear (67). then fit thrust washers (58) to both
sides, and set in carrier.
vi) Assemble ball (57) to shaft (56), and
push shaft into carrier.
18. Shaft, No. 1, 2, 3 carrier assembly

1) Assemble the No. 2, No. 3 carrier as follows.
i) Install seal ring (66) to carrier.
ii) Using push tool, press fit spacer (64) vii) Install seal ring (55) to plate.
and bearing (63) in collar (65). viii) Install plate (54) to No. 2, 3 carrier
assembly (53).
ix) Set plate (51) to gear (52), and install
ring (50).
iii) Using push tool, press fit bearing (62).

iv) Using push tool, press fit collar and
bearing (61) in carrier.
x) Using eyebolts, install plate and gear
assembly (49).
xi) Install sun gear (48), and secure with
snap ring.
D475A-5 30-71
(2)
2) Assemble the shaft and No. 1 carrier viii) Set spacer (35) to bearing and cage
assembly as follows. assembly (34), and press fit shaft (39).
i) Install seal rings (47), (131) to carrier.
ii) Assemble bearing (46) in gear (45),
then fit thrust washers (44) to both
sides, and set in carrier.
iii) Assemble ball (43) to shaft (42), and
push shaft into carrier case (41).
ix) Using eyebolts, install shaft and cage

assembly (33).
3) Assemble the shaft and carrier assembly as
follows.
i) Using eyebolts, install shaft and No. 1
carrier assembly (31) to No. 2, 3 carrier
iv) Install seal ring (40) to shaft (39). assembly (32).
v) Install seal ring (38) to cage. a Align the sun gear with the tooth
face of the planetary gear, and tap
with a plastic hammer to install.
vi) Using push tool, press fit bearing (37) in

cage.
vii) Press fit bearing (36) in shaft. ii) Set carrier assembly on its side, then
install sun gear (30), and secure with
snap ring (130).
Using eyebolts, install shaft and No. 1,
2, 3 carrier assembly (29) to housing.
30-72 D475A-5
(2)
19. Sleeve, guide pin 25. Spring

1) Install guide pin (28). Install spring (15).
2) Install sleeve (27). a Free length of spring: 112 mm

turn.
21. Spring
a Free length of spring: 112 mm
26. Housing
1) Install seal ring (14) to housing.
2) Using eyebolts, set housing (13) in position.
3 Tie bolts:
3) Tighten 17 tie bolts (12) in turn.
353 392 Nm { 36 40 kgm}

1) Fit seal ring and install piston (22) to hous-
ing (21).
2) Using eyebolts, install No. 1 housing and
piston (20).
a Check that the spring is fitted securely in
the hole of the housing.
27. Checking piston stroke

Using tool D, check each piston stroke.
a Air pressure: 0.5 0.6 MPa {5 6 kg/cm2}
Unit: mm
Piston Standard stroke
No. 1 (R) 7.4
No. 2 (F) 8.4
No. 3 (3) 4.8
23. No. 1 ring gear
Install ring gear (19). No. 4 (2) 5.0
No. 5 (1) 7.1
24. Discs, plates, springs.
turn.
D475A-5 30-73
(2)
2) Using push tool, install bearing (129) to

boss (128), and secure with snap ring (136).
3) Install boss and bearing assembly (127) to
output shaft, and secure with snap ring
(135).
a Install the bearing slowly and be careful
that shaft (115) is mated with the lock
portion of boss (128).
28. Transmission case

1) Using eyebolts, install transmission case
(11).
2) Install plate (10).
30. Sleeve
1) 1nstall sleeve (9).
2) Install plug (8).
29. Rotation detection shaft

1) Set case so that valve mounting surface is
at top, then insert rotation detection shaft
(115) from output end.
a Check that the tip of the shaft is mated
with the lock portion of its mating boss.
31. Control valve assembly

1) Install control valve assembly (2) together
with seat.
2) Install cover (1).
30-74 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY STEERING CASE
DISASSEMBLY AND
ASSEMBLY OF STEERING
CASE ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791-622-1110 Bracket t 1
1 01016-51690 Bolt t 1
5. Pipes
E 01011-81600 Bolt t 1
1) Remove left and right pipes (6).
791T-822-1810 Push tool t 1 N Q 2) Remove pipe (7).
2
791T-822-1820 Push tool t 1 N Q
DISASSEMBLY
1. Steering valve
1) Remove cover (1).
2) Remove tube (2).
3) Remove brake rod bracket (20).
4) Remove steering valve assembly (21) with
seat.
2. Clutch, brake assembly

Using tool E1, sling clutch and brake assembly,
then remove mounting bolts, and remove clutch
and brake assembly (3).
a Remove the clutch and brake assembly on 6. Input shaft
the opposite side in the same way. When 1) Remove cage assembly (8).
pulling out the clutch and brake assembly, 2) Remove snap ring, and pull out input shaft
be careful not to damage the discs and (9) from case.
plates.
7. Transfer, gear housing assembly

3. Shafts Fit guide bolt and screw in forcing screws [1],
Remove left and right shafts (4). then remove housing assembly (10).
4. Lubrication tube
Remove lubrication tube (5).
D475A-5 30-75
(2)
8. Cage 10. Cage

1) Turn over so that right cage is at top, then 1) Turn over steering case, and remove bear-
remove bearing cage (11). ing cage (18).
a Check the number and thickness of the a Check the number and thickness of the
shims, and keep in a safe place. shims, and keep in a safe place.
2) Remove outer race (19) from bearing cage.
2) Using eyebolts [2], remove cage (12).
9. Bevel gear, shaft assembly ASSEMBLY

Using eyebolts, remove bevel gear and shaft a Wash all parts, then dry them, and check for dirt
assembly (13). or damage. Coat the sliding surfaces of all parts
with engine oil before installing.
1. Cage
1) Using push tool, press fit outer race (19)
2) Assemble shim, and install bearing cage
(18).
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
1) Disassemble the bevel gear and shaft

assembly as follows.
i) Pull out reamer bolt, and remove bevel
gear (14) from shaft (15).
ii) Using puller [3], remove bearings (16)
and (17) from shaft.
30-76 D475A-5
(2)
2. Bevel gear, shaft assembly

1) Assemble bevel gear and shaft as follows.
i) Using tool E2, press fit bearings (17)
and (16).
ii) Set bevel gear (14) to shaft (15), and
3 Reamer bolt:
tighten reamer bolt.
490 607.6 Nm {50 62 kgm}
5. Transfer, gear housing assembly

Fit guide bolt [5] to steering case, and install
3 Mounting bolt:
housing assembly (10).
245 308.7 Nm {25 31.5 kgm}
iii) Using eyebolts, install bevel gear and

shaft assembly (13).
3. Cage
3 Mounting bolt:
1) Using eyebolts [2], install cage (12).
245 308.7 Nm {25 31.5 kgm}
6. Adjusting tooth contact, backlash

1) Adjusting backlash
Put the probe of dial gauge [6] in contact
with the tip of the bevel gear teeth at right
angles. Hold the bevel pinion in position,
and read the measurement when the bevel
gear is moved forward and backward.
a Standard value for backlash:
0.3 0.4 mm
a Measure at a minimum of three points on
diagonally opposite sides.
2) Assemble shim, and install bearing cage
(11).
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
4. Adjusting preload
Rotate bevel gear 2 3 turns, and fit push-pull
scale [4] to tip of teeth, then measure rotating
torque of bevel gear shaft.
a Standard value of rotating torque:
9.8 11.8 Nm {1.0 1.2 kgm}
D475A-5 30-77
(2)
Adjusting 2) Adjusting tooth contact

If the result of the inspection shows that the Testing
correct backlash is not being obtained, i) Coat the tooth face of the bevel pinion
adjust as follows. lightly with red lead (minium). Rotate
i) If backlash is too small: the bevel gear in both the forward and
Adjust the shim thickness at the bevel reverse directions, and inspect the pat-
pinion end to move the bevel pinion in tern left on the teeth.
direction A, or adjust the shim thickness ii) The standard tooth contact should be as
at the bearing cage of the bevel gear follows:
shaft to move the bevel gear in direction (from small end of pinion)
B. a) Width of tooth contact: 30 75%
b) Center of tooth contact: 20 40%
c) Position of tooth contact: 20 40%
a It must be within the standard value
when preload is given to the taper roller
bearing which is supporting the bevel
gear, and only the bevel pinion is
meshed, with no load.
a The tooth contact should be in the center
of the tooth height and there should be
no strong contact at the root of the teeth.
The contact should be in about the
same position when the gear is rotated
in forward or reverse.
ii)
If backlash is too large:
Adjust the shim thickness at the bevel
pinion end to move the bevel pinion in
direction A (the opposite direction from
A above), or adjust the shim thickness
at the bearing cage of the bevel gear
shaft to move the bevel gear in direc-
tion B (the opposite direction from B
above).
a When adjusting the shim thickness at
the bearing cage of the bevel gear shaft,
do not change the preload of the bear-
ing. Adjust by moving shims between
the bearing cage and the bevel pinion.
Always keep the same total thickness of
shims.
30-78 D475A-5
(2)
Adjustment
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) If bevel pinion is too far from center line
of bevel gear.
Contact is at the small end of the con-
vex tooth face of the bevel gear and at
the big end of the concave tooth face.
[Correct the tooth contact as follows.]
Adjust the thickness of the shims at the
bevel pinion to move the bevel pinion in
direction A.
Or adjust the thickness of the shims at
7. Input shaft
the bearing cage of the bevel gear shaft
1) Assemble input shaft (9) in case, and
to move the bevel gear in direction B,
secure with snap ring.
then check the tooth contact pattern and
2) Install cage assembly (8).
backlash again.
ii) If bevel pinion is too close to center line
of bevel gear.
Contact is at the big end of the convex
tooth face of the bevel gear and the
small end of the concave tooth face.
[Correct the tooth contact as follows.]
Adjust the thickness of the shims at the
bevel pinion to move the bevel pinion in
direction A (the opposite direction from
A above).
Or adjust the thickness of the shims at
the bearing cage of the bevel gear shaft
to move the bevel gear in direction B
(the opposite direction from B above),
then check the tooth contact pattern and 8. Pipes
backlash again. 1) Install pipe (7).
a When adjusting the movement in or out 2) Install left and right pipes (6).
of the bevel gear, do not change the a Coat the O-rings thinly with grease (G2-LI),
preload of the bearing. Adjust by moving and be careful not to damage them when in-
shims between the bearing cage and the stalling.
bevel pinion. Always keep the same to-
tal thickness of shims.
D475A-5 30-79
(2)
9. Lubrication tube 12. Steering valve

Install lubrication tube (5). 1) Install steering valve assembly (21) together
with seat.
10. Clutch, brake assembly 2) Install brake rod bracket (20).
Using tool E1, install clutch and brake assembly 3) Install tube (2).
3 Mounting bolt:
(3). 4) Install cover (1).
279 30 Nm {28.5 3 kgm}
11. Shafts
Install left and right shafts (4).
a If it is difficult to insert the shafts with the bev-
el locked, release the steering brake before
inserting.
1) Remove plugs (20), then remove bolts (21),
and tighten them in plug holes to compress
clutch spring and release brake.
30-80 D475A-5
(2)
E2 Push tool
D475A-5 30-81
(2)
DISASSEMBLY AND ASSEMBLY STEERING CLUTCH, BRAKE
DISASSEMBLY AND 3. Clutch, brake assembly

Turn over clutch and brake assemblies, and
ASSEMBLY OF STEERING using eyebolts [3], disconnect clutch assembly
CLUTCH, BRAKE ASSEMBLY (6) and brake assembly (7).
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
E 3 791-822-1830 Wrench t 1 N
DISASSEMBLY
Disconnection of clutch, brake assembly

1. Collar
Remove plate (1), then remove collar (2).
Disassembly of clutch assembly
2. Sleeve 1. Stopper
1) Remove plate (3). Remove stopper (8).

Remove discs (9), springs (10), and plates (11)
in turn.
2) Using forcing screws [1], remove sleeve

(4).
3) Using puller [2], pull out bearing (5) from
sleeve.
3. Torque pin
Remove torque pin (12).
4. Clutch hub
Using eyebolts, remove clutch hub (13).
5. Plate
1) Using forcing screws [4], remove flange
(14).
30-82 D475A-5
(2)
3) Remove outer race (25) from clutch cage.
9. Belleville springs
Remove Belleville springs (26).
2) Remove outer race (15) from flange.
6. Bearing cage
1) Remove bearing cage assembly (16).
10. Brake hub

1) Using eyebolts [5], remove brake hub (27).
2) Remove bearing (28) from brake hub.
2) Remove plate (18) and nut (19), then

remove bearings (20) and (21) from cage
(17).
7. Spacer Disassembly of brake assembly

Remove spacer (22). 1. Stopper
Remove stopper (29).
8. Clutch cage, piston
1) Using eyebolts, remove clutch cage (23). 2. Discs, plates, springs
2) Remove piston (24). Remove discs (30), springs (31), and plates (32)
in turn.
D475A-5 30-83
(2)
3. Brake cage ASSEMBLY

1) Using eyebolts [6], remove brake cage (33).
2) Remove outer race (34) and seal ring (35) Assembly of brake assembly
from brake cage. 1. Belleville springs
Install Belleville springs (39).
a Fit the Belleville springs back to back when
installing.
4. Torque pin
Remove torque pin (36).
5. Piston 2. Piston
Remove piston (37) and seal ring (38). Fit seal ring (38) and install piston (37).
3. Torque pin
Install torque pin (36).
Remove Belleville springs (39).
30-84 D475A-5
(2)
4. Brake cage Assembly of clutch assembly

1) Using push tool, install outer race (34) to 1. Brake hub
brake cage. 1) Using push tool, press fit bearing (28) in
2) Install seal ring (35). brake hub.
3 Mounting bolt:
3) Using eyebolts [6], install brake cage (33). 2) Using eyebolts [5], install brake hub (27) to
clutch housing.
245 308.7 Nm {25 31.5 kgm}
5. Discs, plates, springs Install Belleville springs (26).
Install plates (32), springs (31), and discs (30) in a Fit the Belleville springs back to back when
turn. installing.
a Check the mating surfaces of the discs and
plates for dirt or damage, and coat them thin- 3. Clutch cage, piston
ly with engine oil before assembling. 1) Install outer race (25) to clutch cage.
6. Stopper
3 Mounting bolt:
Install stopper (29).
245 308.7 Nm {35 31.5 kgm}
2) Install piston (24).

3) Using eyebolts, fit seal ring and install clutch
cage (23) to housing.
D475A-5 30-85
(2)
4. Spacer 8. Torque pin

Install spacer (22). Install torque pin (12).
5. Bearing cage
1) Using push tool, press fit bearings (21) and
(20) to cage (17), then tighten nut (19), and
install plate (18).
a Hold the cage with press, and using a
3 Nut:
hook wrench (tool E3), tighten the nut.
490 607.6 Nm {50 62 kgm}

Install plates (11), springs (10), and discs (9) in
turn.
a Check the mating surfaces of the discs and
plates for dirt or damage, and coat them thin-
ly with engine oil before assembling.
10. Stopper
3 Mounting bolt:
Install stopper (8).
2) Install bearing cage (16).
245 308.7 Nm {25 31.5 kgm}
6. Plate
1) Using push tool, press fit outer race (15) to
flange.
3 Mounting bolt:
2) Install flange (14).
245 308.7 Nm {25 31.5 kgm}
7. Clutch hub
Set guide bolts to housing, and using eyebolts,
install clutch hub (13).
30-86 D475A-5
(2)
Connection of clutch, brake assembly

1. Clutch, brake assembly
Using eyebolts [3], install brake assembly (7) to
clutch assembly (6).
2. Sleeve
1) Using push tool [7], press fit bearing (5) in
sleeve.
2) Set sleeve (4) to clutch and brake assem-

blies.
3 Mounting bolt:
112 9.8 Nm {11.5 1.0 kgm}
3. Collar
Fit collar (2) and install plate (1).
D475A-5 30-87
(2)
DISASSEMBLY AND ASSEMBLY TRANSFER GEAR HOUSING
DISASSEMBLY AND 4. Pinion housing

1) Remove lubrication tube (7).
ASSEMBLY OF TRANSFER 2) Using eyebolts [2], remove pinion housing
GEAR HOUSING ASSEMBLY assembly (8).
DISASSEMBLY slims, and keep in a safe place.
a Set the transfer gear housing assembly on a
block.
1. Lubrication tube
Remove lubrication tube (1) together with block.
2. Bearing cage
1) Remove bearing cage (2).
2) Using push tool, remove bearing (3).
3) Remove snap ring, and using push tool,
remove bearing (4)
5. Pinion assembly
1) Using forcing screws, remove cover (9).
2) Remove holder (10).
3) Push pinion shaft with press, then pull out
pinion gear (11).
4) Remove holder, and using puller [3], remove
inner race (12) from pinion gear (11).
3. Transfer gear
1) Remove transfer gear (5).
2) Using puller [1], remove inner races (6) on
both sides.
5) Remove cage, bearing assembly (13).

6) Remove collar (14) from transfer gear (15).
D475A-5 30-89
(2)
7) Using push tool [4], remove outer race (16), 4) Using push tool [5], press fit inner race (12)

bearings (17) and (18), collar (19), and outer in pinion gear (11), and install holder.
race (20).
245 308.7 Nm {25 31.5 kgm}
5) Install transfer gear (15) and collar (14) to
pinion gear.
ASSEMBLY
1. Pinion assembly
1) Using push tool, press fit outer race (20) in 6) Using push tool [6], press fit cage, bearing
bearing cage. assembly (13).

2) Assemble collar (19), bearing inner races 7) Install holder (10).
(17) and (18).
3) Using push tool, press fit bearing outer race 245 308.7 Nm {25 31.5 kgm}
(16).
30-90 D475A-5
(2)
8) Install cover (9) as follows. 3. Transfer gear

Tighten cover mounting bolts temporari- 1) Using push tool [7], press fit inner races (6)
ly in the order shown in diagram below. on both sides.
(Approx. 49 Nm {5 kgm}) 2) Set transfer gear (5) in case.
Check clearance A between cover and
cage, and check that it is as follows.
Clearance A: 0.53 0.47 mm
a Check that the variation around the
whole circumference is less than 0.05
mm. Check also that the bearing is com-
pletely press fitted and is not at an angle.
After checking the above, tighten the
mounting bolts of cover (9) in the order
3 Mounting bolt:
shown in the diagram below.
58.8 73.5 Nm {6 7.5 kgm}
4. Bearing cage
1) Using push tool, press fit bearing (4), and
secure with snap ring.
2) Using push tool, press fit bearing (3).
3 Mounting bolt:
3) Install bearing cage assembly (2) to case.
245 308.7 Nm {25 31.5 kgm}
5. Lubrication tube
Install lubrication tube (1) together with block.
2. Pinion housing
1) Assemble shim, and using eyebolts [2],
install pinion housing assembly (8).
2) Install lubrication tube (7).
D475A-5 30-91
(2)
POWER TRAIN PUMP
DISASSEMBLY AND ASSEMBLY SCAVENGING PUMP
REMOVAL AND REMOVAL AND

INSTALLATION OF POWER INSTALLATION OF
TRAIN PUMP ASSEMBLY SCAVENGING PUMP
ASSEMBLY
REMOVAL
1. Remove oil strainer inspection cover at front left REMOVAL
of operators platform. 1. Open undercover. (3rd from front of machine).
2. Open undercover. (3rd from front of machine). 2. Disconnect inlet tube (1).
a Oil will leak out from inside the piping, so pre-
3. Remove oil strainer (1). pare a container to catch the oil.
a Disconnect coupling (2) and remove strainer
mounting bolts. 3. Disconnect outlet tube (2).
4. Disconnect hose (3). 4. Remove scavenging pump assembly (3).
5. Lift off power train pump assembly (4). 4 Scavenging pump assembly: 25 kg
4 Power train pump assembly: 64 kg
INSTALLATION
INSTALLATION removal.
removal. Refilling with oil (power train case)
30-92 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER OIL COOLER
REMOVAL AND 7. Sling torque converter oil cooler assembly (8),

then lower assembly to remove.
INSTALLATION OF TORQUE
4
CONVERTER OIL COOLER Torque converter oil cooler assembly:
170 kg
REMOVAL
1. Remove engine undercover.
2. Drain coolant.
3. Open engine left side cover (1) and remove side

cover (2).
INSTALLATION
removal.

4. Remove water tubes (3) and (4). engine to circulate the coolant through the sys-
5. Remove oil inlet tube (5) and outlet tube (6).
6. Disconnect aeration hose (7).
D475A-5 30-93
(2)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER VALVE
REMOVAL AND 7. Remove hose clamp (6).
INSTALLATION OF 8. Remove torque converter valve assembly (7).

TORQUE CONVERTER VALVE
4 Torque converter valve assembly:
[*2]
ASSEMBLY
33 kg
REMOVAL
1. Remove operators cab assembly.
For details, see REMOVAL OF OPERATORS
CAB ASSEMBLY.
2. Remove operators seat and floor frame cover.

a Use turnbuckle (1) when disconnecting the
brake rod. Check the mounting dimensions
of the rod before disconnecting. [*1]
INSTALLATION
removal.
[*1]
a Adjust the brake pedal linkage.
For details, see TESTING AND ADJUST-
3 Turnbuckle locknut:
ING, Adjusting brake pedal linkage.
3. Disconnect connector of solenoid valve (2).
34.3 58.8 Nm {3.5 6 kgm}
3 Torque converter valve assembly

[*2]
5. Disconnect central pressure detection hose (4).
a Before removing the pressure detection hos- mounting bolt:
es, mark them with tags to prevent any mis- 43.1 53.9 Nm {4.4 5.5 kgm}
6. Disconnect hose (5).
30-94 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER

VALVE ASSEMBLY
Disassembly of lock-up valve Assembly of lock-up valve

1. Remove solenoid valve (14), then remove ball 1. Assemble spool (6).
(16), valve (15) and plug (19).
2. Assemble piston (10) to cover (7), then fit O-
2. Remove plug (3), then remove spring (5). riing and install cover.
3. Remove cover (7), then remove piston (10). 3. Assemble spring (5), then fit O-ring and install
plug (3).
4. Pull out spool (6).
4. Fit O-ring (17) to plug (19), then assemble.
5. Assemble valve (15), then fit O-ring (18) to sole-

noid valve (14) and install.
D475A-5 30-95
(2)
30-96 D475A-5
(2)
D I S AS S EM B LY OF T O R QU E C O NV E RT E R
RELIEF VALVE, MAIN RELIEF VALVE, STATOR
CLUTCH MODULATING VALVE, AND LOCK-UP
CLUTCH MODULATING VALVE
1. Disassembly of torque converter relief valve

1) Remove cover (10), then remove spring (9).
2) Remove cover (2), then remove valve (5),
spring (6), and valve (7).
3) Pull out spool (8).
2. Disassembly of main relief valve

1) Remove cover (14), then remove spring
(18).
3. Disassembly of stator clutch modulating

valve
1) Remove cover (27), then remove piston (34)
and spring (35).
2) Remove ring (30) from body.
4) Pull out spool (37), then remove shim (36)
from spool.
4. Disassembly of lock-up clutch modulating

valve
1) Remove cover (45), then remove piston
(52), springs (53) and (55).
2) Remove ring (47) from body.
5) Remove shaft (56) and shim (54) from spool
(57).
D475A-5 30-97
(2)
ASSEMBLY OF LOCK-UP MODULATING VALVE,

STATOR CLUTCH MODULATING VALVE, MAIN
RELIEF VALVE AND TORQUE CONVERTER
RELIEF VALVE

Coat the sliding surfaces of all parts with engine
oil before installing.
a When assembling valves (32) and (34), (12) and
(14), (23) and (21), and (7) and (5), assemble as
shown in the diagram so that the end with the
hole in the center of the valve is on the inside of
the spool.
1. Assembly of lock-up clutch modulating valve

1) Set shim to shaft (56) and assemble to
spool (57).
a Standard shim thickness: 2.0 mm
2) Assemble spool (57).
3) Assemble valve (58), spring (59), and valve
(60) to spool, then fit O-ring and install cover
(61).
4) Assemble ring (47) to body.
5) Assemble springs (53) and (55).
6) Assemble piston (52) to cover (45), then fit
O-ring and install cover.
2. Assembly of stator clutch modulating valve

(40) to spool (37), then fit O-ring and install
cover (41).
3) Set shim (36) to spool (37) and assemble
ring (30) to body.
a Standard shim thickness: 0.5 mm
4) Assemble spring (35).
5) Assemble piston (34) to cover (27), then fit
O-ring and install cover.
3. Assembly of main relief valve

(21) to spool, then fit O-ring and install cover
(24).
3) Assemble spring (18), then fit O-ring and
install cover (14).
4. Assembly of torque converter relief valve

2) Assemble valve (7), spring (6), and valve (5)
to spool, then fit O-ring and install cover (2).
3) Assemble spring (9), then fit O-ring and
install cover (10).
30-98 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL AND 5. Disconnect wiring harness connector (4). (8

places)
INSTALLATION OF
TRANSMISSION CONTROL 6. Disconnect central pressure detection hose (5).
VALVE ASSEMBLY (4 places)
a Before removing the pressure detection hos-
REMOVAL es, mark them with tags to prevent any mis-
CAB ASSEMBLY. 7. Remove transmission control valve assembly
(6). (4 places)
2. Remove operators seat and floor frame cover.
a Use turnbuckle (1) when disconnecting the
brake rod. Check the mounting dimensions
of the rod before disconnecting. [*1]
INSTALLATION
removal.
[*1]
4. Remove valve cover (3). a Adjust the brake pedal linkage.
3 Turnbuckle locknut:
34.3 58.8 Nm {3.5 6 kgm}
D475A-5 30-99
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROL

VALVE ASSEMBLY (ECMV ASSEMBLY)
Disassembly of ECMV assembly 2. Pressure control valve

Before removing the ECMV assembly from the 1) Remove solenoid (2) from valve body (1).
transmission assembly, clean around it so that a Mask the solenoid to prevent dirt from
dirt will not enter it and transmission assembly. entering it.
Keep the removed parts so that they will not be 2) Remove valve (3) and ball (4).
damaged. a Keep the ball so that it will not be lost.
3) Remove spool (7).
1. Flow control valve a When removing the spool, check that it
1) Remove bracket (20) and switch assembly moves smoothly.
(12) from valve body (1). 4) Remove spring (8) and shims (9) and (10)
2) Remove spring (13), shim (14), and spring from spool (7).
seat (15). a Check the quantity of shims (9) and (10).
3) Remove sleeve (18), spring (17), and pin
(16).
30-100 D475A-5
(2)
Assembly of ECMV assembly 3. Testing ECMV oil pressure

a If the pressure control valve was disassembled Check the ECMV oil pressure. For details, see
or any part of it was replaced, be sure to check TESTING AND ADJUSTING, Testing ECMV oil
the oil pressure. pressure.
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine 4. Adjusting ECMV oil pressure
oil before installing. As a result of testing, if the oil pressure is out of
the standard range, adjust it with shims (9) and
1. Pressure control valve (10).
1) Install shims (9) and (10) and spring (8) to
spool (7), and then install the spool to body Quantity of adjustment
0.06 MPa
per shim (0.5 mm thick)
(1). {Approx. 0.65 kg/cm2}
714-23-15580
Standard number of shims: 3
Standard shim thickness: 1.5 mm Quantity of adjustment
0.025 MPa
(Thickness of 1 shim: 0.2 mm, 0.5 mm) per shim (0.2 mm thick)
{Approx. 0.26 kg/cm2}
a Check that the spool moves smoothly. 714-28-15590
2) Put ball (4) in valve (3), fit O-ring (5), and
install them. a If the shim is increased, the oil pressure is
3) Fit O-ring (6) to the solenoid and install them heightened. If the former is decreased, the
to body (1). latter is lowered.
a When reusing all of valve body (1), a Install the shim securely and do not drop it in
spring (8), spool (7), solenoid (2), and the valve.
valve (3), install the standard number of a After adjusting the shim, test the oil pressure
the shims. again.
a When replacing solenoid valve (2),
check that spring (8) is installed secure-
ly.
2. Flow control valve

1) Install sleeve (18), spring (17), and pin (16)
to body (1).
2) Install shim (14) and spring (13) to spring
seat (15), fit O-ring (21) to body (1), and
install switch assembly (12) and bracket
(20) with bolts (19).
D475A-5 30-101
(2)
Disassembly of priority valve Assembly of priority valve

Remove the priority valve assembly from the 1. Install valve (6), spring (7), and sleeve (5) to
transmission assembly. valve body (1).
a Before removing the priority valve assembly,
clean around it so that dirt will not enter the 2. Fit the O-ring to plug (10) and install them to
3 Plug: 58.8 78.4 Nm {6 8 kgm}

transmission assembly. body (1).
Keep the removed parts so that they will not be
damaged.
3. Install spool (2).
1. Remove plug (8) from valve body (1). a Check that the spool moves smoothly.
2. Remove shim (4) and spring (3). 4. Install spring (7) and shim (4). Fit O-ring (9) to
3 Plug: 58.8 78.4 Nm {6 8 kgm}

a Check the quantity of shim (4). plug (8) and install them to body (1).
3. Remove spool (2).

a When removing the spool, check that it Quantity of adjustment
52 kPa {0.53 kg/cm2}
moves smoothly.
4. Remove plug (10) from valve body (1). a If the shim is increased, the oil pressure is
heightened. If the former is decreased, the
5. Remove sleeve (5), spring (7), and valve (6). latter is lowered.
a After adjusting the shim, test the oil pressure
again.
30-102 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY STEERING CONTROL VALVE

INSTALLATION OF removal.
STEERING CONTROL VALVE
ASSEMBLY
REMOVAL
1. Remove fuel tank assembly.
For details, see REMOVAL OF FUEL TANK
ASSEMBLY.
2. Disconnect 3 wiring clamps (1).
3. Remove valve cover (2).
4. Disconnect harness connector (3).
5. Remove steering control valve assembly (4).
D475A-5 30-103
(2)
DISASSEMBLY AND ASSEMBLY OF STEERING CONTROL

VALVE ASSEMBLY
Disassembly of ECMV assembly 2. Pressure control valve

Before removing the ECMV assembly from the 1) Remove solenoid (2) from valve body (1).
steering assembly, clean around it so that dirt a Mask the solenoid to prevent dirt from
will not enter it and steering assembly. entering it.
Keep the removed parts so that they will not be 2) Remove valve (3) and ball (4).
damaged. a Keep the ball so that it will not be lost.
1. Flow control valve a When removing the spool, check that it
1) Remove bracket (25), switch assembly (17), moves smoothly.
and cover (28) from valve body (1). 4) Remove spring (13) and shims (14) and (15)
2) Remove springs (18) and (19) and spring from spool (7). Then, remove ring (12),
seat (20). sleeve (10), spring (9), and poppet (8).
3) Remove sleeve (23), spring (22), and pin a Check the quantity of shims (14) and
(21). (15).
30-104 D475A-5
(2)
Assembly of ECMV assembly 2. Flow control valve

a If the pressure control valve was disassembled 1) Install sleeve (23), spring (22), and pin (21)
or any part of it was replaced, be sure to check to body (1).
the oil pressure. 2) Install springs (19) and (18) to spring seat
a Clean the all parts and check them for dirt or (20) and put them in cover (28). Fit O-rings
damage. Coat their sliding surfaces with engine (26) and (27) and install switch assembly
oil before installing. (17) and bracket (25) with bolts (24).
1. Pressure control valve 3. Testing ECMV oil pressure

1) Install poppet (8), spring (9), O-ring (11), Check the ECMV oil pressure. For details, see
sleeve (10), and ring (12) to spool (7). TESTING AND ADJUSTING, Testing ECMV oil
2) Install shims (14) and (15) and spring (13) to pressure.
spool (7), and then install the spool to body
(1). 4. Adjusting ECMV oil pressure
Standard number of shims: 3 As a result of testing, if the oil pressure is out of
Standard shim thickness: 1.5 mm the standard range, adjust it with shims (14) and
(Thickness of 1 shim: 0.2 mm, 0.5 mm) (15).
a Check that the spool moves smoothly.
3) Fit the O-ring to valve (3), install the ball, fit Quantity of adjustment
0.06 MPa
the O-ring to the solenoid, and install them {Approx. 0.65 kg/cm2}
714-23-15580
to body (1).
a When reusing all of valve body (1), Quantity of adjustment
0.025 MPa
spring (13), spool (7), solenoid (2), valve per shim (0.2 mm thick)
{Approx. 0.26 kg/cm2}
(3), sleeve (10), and spring (9), install 714-23-15590
the standard number of the shims.
a When replacing solenoid valve (2), a If the shim is increased, the oil pressure is
check that spring (13) is installed se- heightened. If the former is decreased, the
curely. latter is lowered.
a Install the shim securely and do not drop it in
the valve.
a After adjusting the shim, test the oil pressure
again.
D475A-5 30-105
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL AND
INSTALLATION OF FINAL
DRIVE ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

J 1 791-827-1910 Plate t 1
5. Remove 3 bolts of final drive and install tool J1.
01011-83015 Bolt t 3
6. Sling final drive assembly (5), then remove
REMOVAL mounting bolts, and lift off. [*2]
4
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE Final drive assembly: 3,600 kg
ASSEMBLY.
2. Raise chassis with jack or ripper and set stand

[1] under frame.
3. Remove covers (1) and (2).
INSTALLATION
removal.
[*1]
4. Remove cover (3), then using forcing screw, pull a If the shaft will not go in, set a jack on the
out drive shaft (4). [*1] ground and push the shoe grouser up, then
a If the shaft will not come out, set a jack on the move the sprocket to the front or rear to a po-
ground and push the shoe grouser up, then sition where the shaft will go in, and install
move the sprocket to the front or rear to a po- the shaft.
sition where the shaft will come out, and re-
2 Final drive assembly mounting bolt:

move the shaft. [*2]
a Pull the shaft out to a position where it con-
3 Final drive assembly mounting bolt:

tacts the sprocket. Thread tightener (LT-2)
1,960 2,450 Nm (200 250 kgm)
Refilling with oil (final drive case)

Add oil through the oil filler to the specified level.
5 Final drive case: 71 l (GO140)
30-106 D475A-5
(2)
DISASSEMBLY AND DISASSEMBLY

1. Draining oil
ASSEMBLY OF FINAL DRIVE Remove drain plug and drain oil from final drive
ASSEMBLY case.
SPECIAL TOOLS 6 Final drive case: Approx. 71 l
2. Sprocket
New/remodel
Necessity
Symbol
1) Set final drive assembly to block (height:
Sketch
Q'ty
Part No. Part Name approx. 50 mm).
2) Remove sprocket (1).
790-431-1081 Guide t 1
790-431-1031 Block t 1
790-101-2350 Leg t 2
790-101-2430 Adapter t 2
2 790-101-2360 Plate t 4
02215-11622 Nut t 2
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Puller
3 790-101-2102 t 1 3. Cover
(294 kN {30 ton})
Using eyebolts [1], remove cover (2).
790-101-1102 Pump t 1
J 4 791-585-1510 Installer t 1
Puller
5 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Puller
6 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
790-431-1230 Remover & installer t 1
Puller
7 790-101-2102 t 1 4. Hub
(294 kN {30 ton})
1) Remove plate (3).
790-101-1102 Pump t 1
2) Using eyebolts [2], lift off hub (4).
8 790-431-1240 Guide t 1
D475A-5 30-107
(2)
5. Sprocket hub assembly 4) Remove bearing inner race (8) from

1) Remove holder (5). sprocket hub assembly.
5) Turn over sprocket hub assembly, then

remove floating seal cover (9) and bearing
2) Using tool J2, disconnect sprocket hub outer races (10) and (11).
assembly (6) and bearing (7) portion. 6) Remove floating seal (12) from floating seal
3) Using eyebolts [3], remove sprocket hub cover.
assembly (6). a Keep the floating seal in a safe place to
protect it from damage.
6. Wear guard
Lift off wear guard (13).
7. Cover assembly
1) Using eyebolts, lift off cover assembly (14).
30-108 D475A-5
(2)
2) Disassemble cover assembly as follows. 2) Disassemble carrier assembly as follows.

i) Remove floating seal cover (15). i) Set carrier assembly on block (height:
ii) Remove floating seal (16) from floating approx. 100mm).
seal cover. ii) Remove holder (21).
a Keep the floating seal in a safe place iii) Using tool J7, remove planetary gear
to protect it from damage. shaft (22).
iii) Remove spacer (17) and bearing inner iv) Remove planet gear (23), bearing inner
race (18). races (24A) and (24B), and spacer
(24C).
iv) Remove plate, then remove ring gear

(19). v) Remove bearing outer race (24D).
8. Carrier assembly
1) Using eyebolts [5], remove carrier assembly
(20).
D475A-5 30-109
(2)
9. Sun gear 2) Using tool J5, pull out hub assembly (29)
1) Remove plate (25). and bearing inner race (30) from shaft
2) Remove holder (26). assembly (31).
3) Pull out sun gear shaft assembly (27).
3) Disassemble hub assembly (29) as follows.

4) Remove holder (51) from sun gear shaft i) Remove gear (32) from hub (33).
assembly, and pull out sun gear (52) ii) Remove bearing outer races (34A) and
(34B).
10. Hub, shaft assembly

1) Remove plate (28). 4) Using eyebolts [6], pull out shaft assembly
(31) from case.
5) Disassemble shaft assembly as follows.
i) Remove collar (36).
ii) Remove bearing inner race (37) and
collar (38).
30-110 D475A-5
(2)
11. Cage assembly 13. Outer race, oil seals

1) Using eyebolts [7], remove cage assembly 1) Using puller [10], remove bearing outer race
(39). (48).
2) Remove shims (40). 2) Remove oil seals (49) and (50) from cover.
ASSEMBLY
3) Disassemble cage assembly as follows. a Clean all parts, and check for dirt or damage.
i) Using puller [8], remove bearing outer Coat the sliding surfaces of all parts with engine
race (41). oil before installing.
ii) Remove oil seals (42) and (43).
1. Hub, shaft assembly
1) Assemble shaft assembly as follows.
i) Install collar (38).
ii) Using push tool [17], press fit bearing
inner race (37).
iii) Install collar (36).
12. Gear assembly

1) Remove gear assembly (44).
2) Using puller [9], remove bearing inner races
(45) and (46) from gear (47).
2) Using eyebolts [6], install shaft assembly

(31) to case.
3) Assemble hub assembly as follows.
i) Using push tool, press fit bearing outer
races (34A) and (34B) to hub (33).
D475A-5 30-111
(2)
2. Carrier assembly
1) Assemble carrier assembly as follows.
a The planetary gear bearing forms a set,
so align the distinguishing marks on the
inner race, outer race, and spacer when
assembling.
2 Mounting bolt:
ii)Set gear (32) to hub (33).
3 Mounting bolt:
823 1,029 Nm {84 105 kgm}

4) Set shaft assembly (31) and hub assembly
(29) in position, then using tool J6, press fit
bearing (30) portion. i) Install ring and spacer to planet gear,
then using push tool [18], press fit top
and bottom bearing outer races (24D).
2 Mounting bolt:
ii) Assemble spacer (24C) and bearing

3 Mounting bolt:
inner races (24B) and (24A) to planet
490 608 Nm{50 62 kgm} gear (23), then set to carrier.
a Set so that the protruding part at the
end face of the planet gear faces the
outside of the machine.
30-112 D475A-5
(2)
iii) Using tool J7, press fit planetary gear

shaft (22).
a Align the shaft with the position of
the bearing and spacer hole, and
press fit gradually.
2 Mounting bolt:
iv) Install holder (21).
3 Mounting bolt:
490 608 Nm {50 62 kgm}

a After tightening the bolts, check that
the gear rotates smoothly.
5. Cover assembly
1) Assemble cover assembly as follows.
i) Using push tools [11] and [12], install oil
seals (50) and (49).
a Install the bottom oil seal with the part re-
ceiving the pressure at the bottom; in-
s tall the top oil seal wit h t he part

receiving the pressure at the top.

a Coat the inside surface of the case thinly
with gasket sealant and wipe off any
3. Sun gear sealant that is forced out.
1) Press fit sun gear (52) to sun gear shaft,

and install holder (51).

2) Assemble sun gear shaft assembly (27) to
carrier (53), then install holder (26) and

spacer (25).

outer race (48) to cover.
4. Carrier, sun gear assembly

Using eyebolts [5], install carrier and sun gear
assembly (20).
D475A-5 30-113
(2)
iii) Fit ring gear (19) and install plate. a Install so that the cut-out portion of
a Fit so that the notched part of the the floating seal cover is facing the
end face of the gear faces the inside bottom as shown in the diagram be-
of the machine. low.
iv) Install spacer (54), then using tool J3,
press fit bearing inner race (18).
v) Install spacer (17).
2) Using eyebolts, raise cover assembly (14)
2 Case mating surface:

and install.
vi) Using tool J4, press fit floating seal (16) Gasket sealant (Three Bond 1216)
to floating seal cover. a Check that there are no dents, rust, oil,
a Remove all oil and grease from the grease, or water on the mating surface
O-ring and O-ring contact surface, of the case and cover.
and dry before installing. a Coat the whole circumference of the
a After installing the floating seal, mating surface of the case (one side)
check that the angle of the seal is with gasket sealant without any break.
less than 1 mm. a Install the cover assembly within 20 min-
3 Mounting bolt:
utes after coating with gasket sealant.
1,715 1,911 Nm {175 195 kgm}
6. Wear guard
1) Raise wear guard (13) and install.
3 Mounting bolt:
2) Install wer guard plate (13a).
823 1,029 Nm {84 105 kgm}
vii) Install floating seal cover (15).

a Fit a cork plug in the forcing tap.
30-114 D475A-5
(2)
7. Sprocket hub assembly 5) Using eyebolts [3], sling sprocket hub

1) Using tool J4, install floating seal (12) to assembly (6) and set to cover.
floating seal cover. a Check that there is no dirt on the sliding
a Remove all oil and grease from the O- surface of the floating seal, then coat
ring and O-ring contact surface, and dry thinly with engine oil.
before installing.
a After installing the floating seal, check
that the angle of the seal is less than 1
mm.
6) Using tool J3, press fit bearing (7) portion.

a Rotate the sprocket hub assembly when
press fitting.
2) Using push tool, press fit bearing outer

races (11) and (10).
3) Install floating seal cover (9).
7) Install holder (5).

a Tighten 6 mounting bolts temporarily at
equal distances around the circumfer-
ence, then adjust with shims so that
4) Set bearing (8) to sprocket hub assembly. clearance X between cover (14) and
holder (5) is within the standard value.
3 Mounting bolt (temporary tight-

Clearance X: 0.1 0.3 mm
ening):
2 Mounting bolt:
Approx. 74 Nm {7.5 kgm}
3 Mounting bolt:
490 608 Nm {50 62 kgm}
D475A-5 30-115
(2)
10. Sprocket
3 Mounting bolt:
Install sprocket (1).
2,500 2,794 Nm {255 285 kgm}
8. Hub
1) Using eyebolts [2], raise hub (4) and install.
2 Mounting bolt:
3 Mounting bolt:
11. Gear assembly
245 309 Nm {25 31.5 kgm} 1) Using push tool [14], press fit bearing inner
races (46) and (45) to gear.
2) Set tool J8 to cover (14), and install gear
assembly (44).
a Leave tool J8 in position until the cage is
installed.
9. Cover
Using eyebolts [1], install cover (2).
12. Cage assembly

1) Assemble cage assembly as follows.
i) Using push tools [11] and [12], install oil
seals (43) and (42).
a Install the bottom oil seal with the
part receiving the pressure at the
bottom; install the top oil seal with
the part receiving the pressure at the

top.

a Coat the inside surface of the case
thinly with gasket sealant and wipe
off any sealant that is forced out.
30-116 D475A-5
(2)
3) Tighten mounting bolts C, D, E, and F of

cage A uniformly to a tightening torque of 69
Nm {7 kgm}, then loosen bolts.
4) Tighten mounting bolts C and D of cage A
uniformly to a tightening torque of 20 Nm {2
kgm}.
5) In this condition, use feeler gauge [16] to
measure clearances a and b between cage
A and cage B.
6) Determine thickness c of shims to insert
according to Table 1 on next page.
7) Assemble shim set on the previous stage,
then tighten mounting bolts of cage A uni-
3 Mounting bolts:
formly.
outer race (41).
319 608 Nm {32.5 62 kgm}
2) Using eyebolt [7], set cage assembly (39) to

case, and remove tool J8.
13. Refilling with oil

Tighten drain plug and add engine oil through
the oil filler to the specified level.
5 Final drive case:
Approx. 71 l (GO140)
D475A-5 30-117
(2)
Table 1
a + b (mm) Number of shim to use Total shim

More than Less than t = 0.15 t = 0.5 t = 1.0 thickness c (mm)
3.05 3.15 9 1 1.85
3.15 3.25 6 1 1.90
3.25 3.35 3 1 1 1.95
3.35 3.45 2 2.00
3.45 3.55 7 1 2.05
3.55 3.65 4 1 1 2.10
3.65 3.75 1 2 2.15
3.75 3.85 8 1 2.20
3.85 3.95 5 1 1 2.25
3.95 4.05 2 2 2.30
4.05 4.15 9 1 2.35
4.15 4.25 6 1 1 2.40
4.25 4.35 3 2 2.45
4.35 4.45 1 2 2.50
4.45 4.55 7 1 1 2.55
4.55 4.65 4 2 2.60
4.65 4.75 1 1 2 2.65
4.75 4.85 8 1 1 2.70
4.85 4.95 5 2 2.75
4.95 5.05 2 1 2 2.80
5.05 5.15 9 1 1 2.85
5.15 5.25 6 2 2.90
5.25 5.35 3 1 2 2.95
5.35 5.45 3 3.00
5.45 5.55 7 2 3.05
5.55 5.65 4 1 2 3.10
5.65 5.75 1 3 3.15
5.75 5.85 8 2 3.20
5.85 5.95 5 1 2 3.25
5.95 6.05 2 3 3.30
6.05 6.15 9 3 3.35
6.15 6.25 6 1 2 3.40
6.25 6.35 3 3 3.45
6.35 6.45 1 3 3.50
6.45 6.55 7 1 2 3.55
6.55 6.65 4 3 3.60
6.65 6.75 1 1 3 3.65
6.75 6.85 8 1 2 3.70
6.85 6.95 5 3 3.75
6.95 7.05 2 1 3 3.80
7.05 7.15 9 1 2 3.85
7.15 7.25 6 3 3.90
7.25 7.35 3 1 3 3.95
30-118 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY TRACK FRAME
REMOVAL AND 7. Using eyebolts [3], pull out pin (3). [*1]
a It is difficult to remove the pin if the centers of
INSTALLATION OF TRACK the equalizer bar hole and track frame hole
FRAME ASSEMBLY are not aligned, so adjust the height of the
track frame before removing.
REMOVAL
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Raise chassis with jack or ripper, then set sup-

port [1] under frame to keep rear of chassis off
ground.
3. Set hydraulic jack [2] to center of equalizer bar,

and raise front of chassis.
4. Sling track frame assembly.
8. Remove mounting bolts, and disconnect cover

(4) from track frame.

a With the right track frame, disconnect 4
blade tilt cylinder hoses from the cover.
10. Remove seal (6) together with washer (7). [*2]
11. Remove washer (8), then remove spacer (9).
D475A-5 30-119
(2)
DISASSEMBLY AND ASSEMBLY TRACK FRAME
12. Lift off track frame assembly (10). [*3] INSTALLATION

a Oil will flow out from the pivot case, so catch Carry out installation in the reverse order to
it in an oil container. removal.
6 Pivot case: 26 l
4 2 Inside surface of bushing:
[*1]
Track frame assembly: 11,180 kg
Grease (G2-LI)
a Before installing the pin, adjust the height of
the track frame and align the center of the
equalizer bar hole and track frame hole.
a Set the pin with the grease hole facing the
[*2]
a After removing the grease from the press-fit-
ting surface of the seal, coat with gasket
sealant (LG-6).
a Be careful not to install with the seal dis-
placed in the direction of twisting.
[*3]
a Be careful not to install the track frame with
seal (11) displaced in the direction of twist-
ing.
Refilling with oil (pivot case)

Add oil through oil filler to the specified level.
5 Pivot case: 26 l (SAE30)
30-120 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY AND 6. Using puller [4], remove seal guide (6) and
retainer (7) and plate (8).
ASSEMBLY OF IDLER
ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791-830-1760 Plate t 1 N
791-830-1320 Rod t 2
790-101-2510 Block t 1
790-101-2570 Plate t 2
1 01580-01613 7. Remove seal guides (2) and (6) from retainers
Nut t 2
(3) and (7).
01643-31645 Washer t 2
L
Puller
790-101-2102 t 2
(294 kN {30 ton})
790-101-1102 Pump t 1
2 791-560-1520 Installer t 1
3 791-830-1480 Push tool t 1 N
4 791-601-1000 Oil pump t 1
DISASSEMBLY
1. Remove oil filler plug and drain oil.
6 Idler: 2.0 2.2 l (GO140)
2. Set idler assembly (1) on block [1]. 8. Remove floating seal (9) from seal guides (2)
and (6).
3. Remove mounting bolts, then using forcing a Keep the floating seal in a safe place to pro-
screws [2], remove seal guide (2) together with tect it from damage.
retainer (3) and plate (4).
9. Remove floating seal (10) from seal guides (3)
and (7).
a Keep the floating seal in a safe place to pro-
tect it from damage.
4. Turn over idler assembly.
5. Remove mounting bolts, then using eyebolts [3],

remove shaft (5) together with retainer.
D475A-5 30-121
(2)
DISASSEMBLY AND ASSEMBLY IDLER
10. Remove bushings (11) from idler (12).
4. Using eyebolts [3], set idler (12) to shaft (5).

a Set block (height: approx. 200 mm) under
the idler.
ASSEMBLY
a Clean all parts, and check for dirt or damage. 5. Turn over idler assembly.
1. Set bushing (11) and tool L1 to idler (12), and a Tie with wire to prevent the shaft from falling
press fit bushing (11). out.
a First, center the bushing with a plastic ham-
mer, then press fit with a puller. 6. Fit O-ring and install retainer (7) and plate (8) to
a Press fit so that press-fitting dimension a idler.
from the end face of the idler to the top sur-
face of the bushing is the dimension given
below.
Press-fitting dimension a: 17 0.5 mm
7. Using tool L2, install floating seal (9) to seal

guides (2) and (6).
2. Using tool L2, install floating seal (10) to retain-

ers (3) and (7).
3. Fit O-ring and install retainer (3) and plate (4) to

idler.
a Check that the plate can be turned smoothly
with the hand.
8. Set seal guide (2) to shaft, then using tools L1

and L3, press fit seal guide (2).
a Seal guide press-fitting force:
83.3 137.2 kN {8.5 14 ton}
30-122 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
REMOVAL AND
INSTALLATION OF RECOIL
SPRING ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

Puller
a Press fit the seal guide so that press-fitting M 1 790-101-2102 t 1
(294 kN {30 ton})
dimension a from the end face of the shaft to
790-101-1102 Pump t 1
the top surface of the seal guide is the di-
mension given below.
Press-fitting dimension a: REMOVAL
124.5 0.2 mm 1. Remove track shoe assembly.
a Turn over the idler assembly and repeat the For details, see REMOVAL OF TRACK SHOE
same procedure to press fit the seal guide ASSEMBLY.
(6) on the opposite side. k To prevent danger, never stand in front of
the idler yoke assembly.
2. Drain oil from recoil cylinder chamber using oil

pump.
6 Recoil cylinder chamber: Approx. 75 l
3. Using eyebolt [1], remove cover (1).

4 Cover: 70 kg
9. Using tool L4, fill with oil to specified level, then

tighten oil filler plug.
5
3 Oil filler plug:
Idler: 1.4 1.5 l (GO140)
156.8 254.8 Nm {16 26 kgm}
D475A-5 30-123
(2)
5. Lift off trunnion (3).

4 Trunnion: 140 kg
9. Disconnect recoil cylinder assembly (7) from

idler yoke assembly (8) as follows. [*3]
1) Put idler yoke assembly (8) in contact with
ground, then raise recoil cylinder assembly
(7).
6. Remove covers (4). a When doing this, check that there is no
a Remove both the inside and outside covers. damage to the weld of recoil cylinder as-
sembly (7).
a Wrap cloth around the chrome plated
bushing to protect it.
7. Using tool M1, remove pins (5). [*1]

a Remove both the inside and outside pins.
2) Loosen idler yoke mounting bolts (9) gradu-

ally in turn on diagonally opposite sides. [*4]
8. Lift off idler and recoil spring assembly (6). [*2]

a Using a lever block, keep the assembly hori-
zontal, and be careful not to damage the oil
seal at the track frame end.
4 Idler, recoil spring assembly: 3,500 kg
30-124 D475A-5
(2)
k To prevent danger, never stand in front k When disconnecting the idler yoke assem-
of the idler yoke assembly or behind the bly and recoil cylinder assembly, do not
recoil cylinder assembly. stand in front of the idler yoke assembly or
k The recoil spring inside the recoil cylin- behind the recoil cylinder assembly until
der is applying a pushing force of ap- safety has been confirmed and the recoil
prox. 788 kN {approx. 81 tons} on the spring assembly has been removed.
idler yoke, so be careful not to loosen i) Prepare the following parts.
the mounting bolts suddenly. Loosen Bolt [1] (x 6): 791-730-1120
the mounting bolts gradually until clear- Nut [2] (x 6): 01580-13326
ance a between the flange of the recoil Washer [3] (x 6):
cylinder and idler yoke is 8 12 mm. 01643-33380 (use again)
ii) Remove 6 bolts marked , then install
bolts [1], nuts [2], and washers [3].
a Check that dimension L is less than
450 mm.
a Screw in bolts [1] until they contact
the bottom of the yoke (Y) thread.
iii) Remove remaining 12 bolts (those not
marked ).
iv) Hold bolts [1] with a wrench to prevent
them from turning, and loosen 2 nuts [2]
simultaneously on diagonally opposite
sides.
a Be careful not to let the load bear on
only one bolt.
3) When the bolts are loosened, the torque will v) When recoil spring is fully extended and
suddenly drop. Check that the installed load torque has completely dropped in loos-
of the recoil spring is not applying any push- ening direction of nut [2], remove bolt
ing forc e on t he mounting bolts, then [1].
remove all bolts. a When clearance b is approx. 280
a If the torque increases (the installed load mm, the spring is fully extended.
of the recoil spring is applied) during the
loosening operation, stop the loosening
operation and disassemble as follows.
k If the torque does not drop during Steps 2)

and 3) described above, and the torque
when the bolts are loosened remains large,
there is probably damage to recoil spring
set bolt (10), or nut (11) at the tip of the shaft
has fallen off, so there is danger that the
idler yoke assembly may fly off to the front.
For this reason, disassemble as follows.
D475A-5 30-125
(2)
12. Disassemble piston assembly (15) as follows.

1) Remove wear ring (16) from piston.
2) Remove snap ring (17), then remove pack-
ing (18).
10. Remove ring (12).
13. Remove recoil spring assembly (19).

4 Recoil spring assembly: 780 kg
11. Pump in grease through lubricator (13), and

remove cylinder (14) and piston assembly (15).
[*5]
14. Remove holder (20) from recoil spring assem-

bly.
30-126 D475A-5
(2)
INSTALLATION DISASSEMBLY AND

removal. ASSEMBLY OF RECOIL
SPRING ASSEMBLY
[*1]
a Before installing the pin, align the center of SPECIAL TOOLS
the hole in the track frame and the dowel pin
New/Remodel
at the recoil cylinder end with a bar.
Necessity
Symbol
Sketch
Qty
Part No. Part Name
[*2]
a Using a lever block, keep horizontal and be
careful not to damage the oil seal at the track
791-685-8502 Compressor t 1
frame end when installing.
a Adjust the clearance. 791-635-3160 Extension t 1
For details, see TESTING AND ADJUST- 790-201-2790 Spacer t 1
M 2
ING, Adjusting clearance of idler. Cylinder (980 kN
790-101-1300 t 1
{100 ton})
[*3] 790-101-1102 Pump t 1
a If the recoil spring set bolt is broken or the
nut at the tip of the shaft has fallen off, see DISASSEMBLY
ASSEMBLY OF RECOIL SPRING ASSEM- 1. Remove recoil spring assembly (1) with tool M2.
k The spring is under high installed load, so
BLY when assembling.
be careful to set it correctly.
2 Idler yoke assembly mounting bolt:
[*4] a Installed load of spring:
Approx. 788 kN {approx. 81 ton}
3 Idler yoke assembly mounting bolt:
2,205 2,695 Nm {225 275 kgm}
[*5]
a To prevent air from accumulating inside the
cylinder, fill with grease as follows.
i) Fill the inside of the cylinder with
approx. 2.0 l of grease.
ii) Set with the cylinder drain hole facing
up, then loosen the lubricator.
iii) Push the piston until it contacts the
stopper. This will push out the air and
any extra grease.
2. Apply hydraulic pressure slowly to compress

spring, then remove lock plate (2) and remove
nut (3).
3. Release hydraulic pressure gradually and

relieve tension of spring.
D475A-5 30-127
(2)
4. Remove rear pilot (5), spacer (6), bolt (7), and 3. Fit nut (3), then install lock plate (2).
front pilot (8) from spring (4). a When securing the recoil spring mounting
nut, make a clearance b of 0 1 mm be-
tween lock plate (2) and nut (3), then bring
lock plate (2) and bolt (7) into tight contact,
2 Lock plate mounting bolt:

and secure in position.
ASSEMBLY
1. Assemble front pilot (8), bolt (7), spacer (6), and
rear pilot (5) to spring (4), then set in tool M2.
k The spring is under high installed load, so
be careful to set all parts correctly.
4. Gradually release hydraulic pressure to com-
2. Apply hydraulic pressure slowly to compress pletely release tension of spring, then remove
spring, and set so that installed length of spring recoil spring assembly (1) from tool M2.
is specified value.
a Installed length a of spring: 1,461 mm
a Installed load of spring:
Approx. 788 kN {approx. 81 ton}
30-128 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL AND 4. Place steel plate [1] on the track shoe and oper-
ate the blade and ripper to lower the machine
INSTALLATION OF TRACK body until the track roller assembly comes in
ROLLER ASSEMBLY contact with the steel plate.
a Operate the blade and ripper slowly, running
SPECIAL TOOLS the engine at the low idling speed.
New/Remodel
Necessity
Symbol
Sketch
Qty
Part No. Part Name

790-401-1761 Adapter t 1
12
790-401-1540 Shackle t 2
L 790-401-1770 T-bolt t 2
791T-830-1780 Plate t 3 N Q
13 01011-62700 Bolt t 6
01673-32780 Washer t 6
5. Remove the mounting bolts and place track

REMOVAL roller assembly (2) on steel plate [1]. [*2]
1. Loosen the track shoe. For details, see
EXPANDING TRACK SHOE ASSEMBLY. 6. Operate the blade and ripper to lift the machine
body until track roller assembly (2) separates
2. Install tool L13 and secure bogie assembly (1). from the bogie.
[*1]
7. Pull track roller assembly (2) out of the machine

3. Operate the blade and ripper to lift the machine body from the top of the steel plate with a bar,
body until track roller assembly (2) separates etc. [*3]
4
from the track shoe.
Track roller assembly: 240 kg
D475A-5 30-129
(2)
INSTALLATION a Install the track roller assembly with the oil

Carry out installation in the reverse order to filler plug out.
removal.
a After installing the track roller assembly, set
2 Track roller assembly mounting bolt:

[*1] the position of dowel pin (4).
After removing tool L13, replace the mounting
3 Cover mounting bolt: 3 Track roller assembly mounting bolt:

bolts of cover (3) with the regular parts. Adhesive (LT-2)
883 1,470 Nm {90 150 kgm} 2,205 2,695 Nm {222 275 kgm}
[*2] [*3]
Install S to the first and last track rollers and When using the assembling tool
install D to the other track rollers. Set tool L12 under the track roller assembly
S: Single flange (2) and lift up and set track roller assembly
D: Double flange (2) to the track frame.
30-130 D475A-5
(2)
SKETCH OF SPECIAL TOOLS
L13 Plate
D475A-5 30-131
(2)
DISASSEMBLY AND 6. Using press, remove seal guide (6) together with
retainer (7) and plate (8) from shaft.
ASSEMBLY OF TRACK
ROLLER ASSEMBLY 7. Remove seal guides (2) and (6) from retainers
(3) and (7).
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Qty
Part No. Part Name
8 791-830-1740 Plate t 1 N
9 791-515-1520 Installer t 1
L
10 791-830-1730 Push tool t 1 N
11 791-601-1000 Oil pump t 1
DISASSEMBLY
1. Remove oil filler plug and drain oil.
6
8. Remove floating seal (9) from seal guides (2)
Track roller: 1.4 1.5 l and (6).
a Keep the floating seal in a safe place to pro-
2. Set track roller assembly (1) on block [1]. tect it from damage.
3. Remove mounting bolts, then using forcing 9. Remove floating seal (10) from retainers (3) and
screws [2], remove seal guide (2) together with (7).
retainer (3) and plate (4). a Keep the floating seal in a safe place to pro-
tect it from damage.
4. Turn over track roller assembly.
5. Remove mounting bolts, then using eyebolts [3],

remove shaft (5) together with retainer.
10. Remove bushing (11) from roller (12).
30-132 D475A-5
(2)
ASSEMBLY
1. Set roller (12) to press, then using tool L8, press
fit bushing (11).
a First, center the bushing with a plastic ham-
mer, then press fit with a press.
a Press fit so that press-fitting dimension a
from the end face of the roller to the top sur-
face of the bushing is the dimension given
below.
2. Set shaft (5) to roller.

a Press fit the seal guide so that press-fitting
dimension b from the end face of the shaft to
the top surface of the seal guide is the di-
mension given below.
Press-fitting dimension b: 86 0.2 mm
a Turn over the track roller assembly and
press fit seal guide (6) on the opposite side
according to the above procedure.
3. Using tool L9, install floating seal (10) to retain-

ers (3) and (7).
4. Fit O-ring and install retainers (3), (7) and plate

(8) to roller.
a Check that the plate can be turned smoothly
with the hand.
7. Using tool L11, fill with oil to specified level, then

tighten oil filler plug.
5
3 Oil filler plug:
Track roller: 1.4 1.5 l (GO140)
156.8 254.8 Nm {16 26 kgm}
5. Using tool L9, install floating seal (9) to seal

guides (2) and (6).
6. Using tool L10, press fit seal guide (2) to shaft.

a Seal guide press-fitting force:
49 83 kN {5 8.5 ton}
D475A-5 30-133
(2)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL AND DISASSEMBLY AND

INSTALLATION OF CARRIER ASSEMBLY OF CARRIER
ROLLER ASSEMBLY ROLLER ASSEMBLY
REMOVAL SPECIAL TOOLS
New/Remodel
EXPANDING TRACK SHOE ASSEMBLY.
Necessity
Symbol
Sketch
Qty
Part No. Part Name
2. Lift up the track shoe with hydraulic jack [1].
3. Lift off carrier roller assembly (1). [*1]

4
4 791-601-1000 Oil pump t 1
Carrier roller assembly: 105 kg 5 791-515-1520 Installer t 1
L
6 790-830-1770 Push tool t 1 N
7 791-631-1270 Wrench t 1
DISASSEMBLY
1. Remove the oil filler plug and drain the oil.
a Drain the oil, turning the shaft.
6 Carrier roller: Approx. 13 l
2. Set carrier roller assembly (1) to block [1].
3. Remove the mounting bolts and cover (2).
4. Remove ring (3).
INSTALLATION
removal.
[*1]
a Make a clearance a of 5 mm between the
2 Carrier roller assembly mounting bolt:

carrier roller and support as shown below.
3 Carrier roller assembly mounting bolt:

Adhesive (LT-2)
744.8 83.3 Nm {76 8.5 kgm}
30-134 D475A-5
(2)
POWER TRAIN PUMP
5. Using tool L7, remove nut (4).
6. Remove the fitted part of the seal guide with

puller [2] and remove bearing (5) and roller (6)
as one unit by using eyebolts.
ASSEMBLY
a Clean the all parts and check them for dirt.
1. Press fit bearing inner race (9) with push tool [5].
7. Remove bearing outer race (7) from the roller. 2. Press fit bearing outer race (7) with push tool
[6].
8. Remove seal guide (8) and bearing inner race
(9) as one unit with puller [3].
3. Set roller (6) and bearing inner race (5) to the

shaft.
9. Remove floating seal (10) from seal guide (8).
4. Press fit bearing inner race (5) to the shaft with
push tool [7].
a Press fit the bearing inner race, turning the
roller, until the roller becomes a little hard to
turn.
10. Remove seal guide (11) with push tool [4].
11. Remove floating seal (12) from seal guide (11).
D475A-5 30-135
(2)
3 Nut: 98 Nm {10 kgm}

5. Tighten nut (4) with tool L7. 10. Install floating seal (12) to seal guide (11) with
tool L5.
a After the nut is tightened, if its hole is not
matched to the hole of the shaft, match its
hole by loosening the nut.
6. Install ring (3).
11. Press fit seal guide (11) with tool L6.

a Press fit the seal guide so that dimension a
between the shaft end and seal guide top will
be 181.25 0.2 mm.
7. Fit the O-ring to cover (2) and install them.
12. Supply specified quantity of oil by using tool L4

and tighten the oil filler plug.
5
8. Install floating seal (10) to seal guide (8) with
3 Oil filler plug:
Carrier roller: 1.25 1.35 l (GO140)
tool L5.
9. Fit the O-ring to seal guide (8) and install them, 157 255 Nm {16 26 kgm}
matching them to the dowel pin.
30-136 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY BOGIE
REMOVAL AND REMOVAL

INSTALLATION OF BOGIE EXPANDING TRACK SHOE ASSEMBLY.
ASSEMBLY
2. Install tool L13 and secure the bogie assembly.
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Qty
Part No. Part Name
791T-830-1780 Plate t 3 N Q
13 01011-62700 Bolt t 6
01673-32780 Washer t 6
1 791-830-1620 Plate t 1 N
2 791-830-1630 Spacer t 1 N
3 791-830-1640 Screw t 3 N
4 01580-12722 Nut t 3
14 3. Operate the blade and ripper to lift the machine
5 01630-32780 Washer t 3
body until the track roller assembly separates
Pullar from the track link.
6 790-101-4000 t 1
k Set a block between the track roller and
(490 kN {50 ton})
7 790-101-1102 Pump t 1 track link so that the machine body will not
1 791-830-1650 Plate t 1 N lower.
2 791-830-1660 Spacer t 1 N
3 796-670-1120 Plate t 1 4. Set block [1] out of the track shoe, matching it to
4 790-434-1070 Screw t 1 N
the height of the track link.
L
15 5 01580-13629 Nut t 2
5. Set steel plate [2] on the track shoe and block
6 01643-33690 Washer t 1 [1].
Pullar
7 790-101-4000 t 1
(490 kN {50 ton}) 6. Operate the blade and ripper to lower the
8 790-101-1102 Pump t 1 machine body until the track roller of bogie
1 791-830-1620 Plate t 1 N assembly (1) comes in contact with steel plate
2 791-830-1640 Screw t 3 N [2].
a Operate the blade and ripper slowly, running
3 01580-12722 Nut t 3
the engine at the low idling speed.
16 4 01643-32780 Washer t 3
Pullar
5 790-101-4000 t 1
(490 kN {50 ton})
6 790-101-1102 Pump t 1
17 791T-830-1670 Guide t 2 N Q
18 791-530-1510 Installer t 1
19 791-601-1000 Oil pump t 1
D475A-5 30-137
(3)
7. Remove cover (2). 4) Set tool L15.

5) Pull out spacer (6) and rings (7) and (8).
a Pulling out force:
225.5 460.9 kN {23 47 tons}
8. Pulling out shaft and ring

1) Set tool L14.
2) Push out shaft (3) and ring (4) to the oppo-
site side simultaneously. 6) Remove spacer (6).
a Pushing out force: 7) Remove spacer (9) and floating seals (10)
225.5 460.9 kN {13 47 tons} between rings (7) and (8).
a Store the floating seals so that they will
not be damaged.
8) Pull out the shaft and rings on the opposite
side according to above steps 1) 7).
3) Remove floating seals (5) from the end

faces of rings (4) and (7).
not be damaged.
9. Remove tool L13.
10. Place bogie assembly (1) on steel plate [2].
11. Operate the blade and ripper to raise the

machine body until the bogie assembly can be
pulled out.
k Set a block between the track roller and
track link so that the machine body will not
lower.
30-138 D475A-5
(2)
12. Sling bogie assembly (1) and pull it out, sliding it 2) Press fit shaft (3) to ring (8).
on steel plate [2]. 3) Install spacer (9).
4
4) Press fit ring (7) to shaft (3).
Bogie assembly: 1,200 kg
5) Install spacer (6).
2 Apply lubricant (LM-P) to parts a

(about 10 mm) of rings (8) and (4).
INSTALLATION
1. Assembly of pin assembly
1) Using tool L18, install floating seals (5) to 2. Apply lever block [3] between the guard of bogie
rings (4) and (7) and install floating seals assembly (1) and the bogie assembly on the
(10) to the opposite side of ring (7) and ring opposite side. Slide bogie assembly (1) on the
(8). steel plate to set it to the mounting position.
a When installing the floating seals, com-
pletely degrease the O-rings and O-ring
contacting surfaces.
a Check that each floating seal is not in-
clined more than 1 mm.
3. Match the pin hole of the track frame to that of

the bogie and set guide tool L17.
D475A-5 30-139
(2)
4. Press fitting of pin assembly 5. Refilling with oil

1) Set tool L16 and cover (2). Supply the specified quantity of oil by using tool
L19.
a Oil supplying pressure: 0.49 MPa {5 kg/cm2}
5 Pin assembly: 180 200 cc (GO-140)
2) Press fit pin assembly (11).

a Direct arrow a on the end face of the pin
assembly up (when the pin assembly is
installed to the machine).
6. Press fit the pin assembly on the opposite side
a Push in the pin assembly with cover (2).
of the bogie according to above steps 3 and 4.
a Push in the pin assembly to machined
2 Apply lubricant (LM-P) all over the

face b of the bogie.
7. Tighten the mounting bolts of pin assembly
3 Cover mounting bolt:

cover (2) (2 places on inside and outside).
side of the pin assembly.
a Total press fitting force of pin assembly:
883 1,470 Nm {90 150 kgm}
294.2 490.5 kN {30 50 tons}
8. Adjust the tension of the track shoe. For detail,

see TESTING AND ADJUSTING, Testing and
adjusting track shoe tension.
30-140 D475A-5
(2)
L13 Plate
L17 Guide
D475A-5 30-141
(2)
DISASSEMBLY AND 3. Disassemble the pin assembly according to

REMOVAL OF BOGIE ASSEMBLY (Step 8).
ASSEMBLY OF BOGIE
ASSEMBLY 4. Disconnection of bogie
Disconnect inner bogie (4) and outer bogie (5).
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Qty
Part No. Part Name
1 791-830-1620 Plate t 1 N
2 791-830-1640 Screw t 3 N
3 01580-12722 Nut t 3
16 4 01643-32780 Washer t 3
L
Pullar
5 790-101-4000 t 1
(490 kN {50 ton})
6 790-101-1102 Pump t 1
19 791-601-1000 Oil pump t 1
ASSEMBLY
DISASSEMBLY
Assemble the pin assembly according t o
1. Track roller assembly
INSTALLATION OF BOGIE ASSEMBLY (Steps
Turn over bogie assembly (1) and lift off 2 track
3 5).
roller assemblies (2).
2. Set inner bogie (4) to outer bogie (5).
3. Press fitting of pin assembly

1) Set tool L16 and cover (3).
30-142 D475A-5
(2)
2) Press fit the pin assembly. 5. Press fit the pin assembly on the opposite side
a Direct arrow a on the end face of the pin of the bogie according to above steps 3 and 4.
assembly up (when the pin assembly is a After press fitting the pin assembly, rock the
installed to the machine). small bogie so that it can be moved with light
a Push in the pin assembly with cover (3). force.
a Push in the pin assembly to the ma-
chined face b of the bogie and secure 6. Tighten the mounting bolts of pin assembly
3 Cover mounting bolt:

the level difference of 5 mm between the cover (3) (2 places on inside and outside).
2 Apply lubricant (LM-P) all over

bogie and pin assembly.
883 1,470 Nm {90 150 kgm}
the side of the pin assembly.
a Total press fitting force of pin assembly: 7. Track roller assembly
294.2 490.5 kN {30 50 tons} Sling and install 2 track roller assemblies (2) to
2 Track roller mounting bolt:

bogie assembly (1).
3 Track roller mounting bolt:

Adhesive (LT-2)
2,205 2,695 Nm {225 275 kgm}
4. Refilling with oil

Supply the specified quantity of oil by using tool
L19.
5 Pin assembly: 180 200 cc (GO140)
D475A-5 30-143
(2)
DISASSEMBLY AND ASSEMBLY NO. 1 BOGIE
REMOVAL AND REMOVAL

1. Loosen track shoe tension.
INSTALLATION OF NO. 1 For details, see REMOVAL OF TRACK SHOE
BOGIE ASSEMBLY ASSEMBLY.
SPECIAL TOOLS 2. Operate blade and ripper, and raise chassis to a

position where track roller of No. 2 bogie assem-
New/Remodel
bly is separated from track link.
k Set a block between the track roller and the
Necessity
Symbol
Sketch
Qty
Part No. Part Name
track link to prevent the chassis from com-
ing down.
1 791-830-1620 Plate t 1 N
3. Fit eyebolts to holes of pad mounting bolt (M12 x
2 791-830-1630 Spacer t 1 N 2) portion at rear of No. 1 bogie assembly, and
3 791-830-1640 Screw t 3 N raise No. 1 bogie assembly (1).
4 01580-12722 Nut t 3
14
5 01630-32780 Washer t 3
Puller
6 790-101-4000 t 1
(490 kN {50 ton})
7 790-101-1102 Pump t 1
1 791-830-1650 Plate t 1 N
2 791-830-1660 Spacer t 1 N
3 796-670-1120 Plate t 1
4 790-434-1070 Screw t 1 N
15 5 01580-13629 Nut t 2
6 01643-33960 Washer t 1
Puller
7 790-101-4000 t 1
(490 kN {50 ton})
4. Put steel plate between track shoe and roller,
8 790-101-1102 Pump t 1
then loosen roller cap bolts (2) approx. 20 mm.
1 791-830-1620 Plate t 1 N (Both inside and outside)
2 791-830-1640 Screw t 3 N
L 3 01580-12722 Nut t 3 5. Tap end face of shaft (3) with hammer and
16 4 01643-32780 Washer t 3 remove track roller assembly (4).
Puller There is a dowel pin on the near side of the
5 790-101-4000 t 1 track roller assembly, so be careful not to
(490 kN {50 ton})
6 790-101-1102 Pump t 1
break it.
(Dowel pin insertion tolerance: 5 6 mm)
17 791T-830-1670 Guide t 2 N Q
18 791-530-1510 Installer t 1 6. Remove roller cap bolt (2), then put track roller
19 791-601-1000 Oil pump t 1 assembly (4) on steel plate, and pull out.
4
791-630-1860 Bracket t 1
Track roller assembly: 240 kg
791-630-1870 Bracket t 1
20 791T-830-1510 Spacer t 2 Q
19M-09-12850 Bolt t 2
01643-33380 Washer t 2
791T-830-1700 Lifting tool t 1 N
791T-830-1710 Bar 1 N Q
791T-830-1720 Plate 1 N Q
21 07283-31079 Grip 1
01582-01210 Nut 2
01643-31232 Washer 2
04530-11628 Eye bolt 1
30-144 D475A-5
(2)
7. Raise No. 1 bogie (5) with tool L20 and hold in 3) Remove floating seals (9) from the end
position. faces of rings (8) and (12).
8. Remove cover (6). not be damaged.
9. Pulling out shaft and ring 4) Set tool L15.

1) Set tool L14.
2) Push out shaft (7) and ring (8) to the oppo-
site side simultaneously.
a Pushing out force:
225.5 460.9 kN {13 47 tons}
a When the ring is pushed out, it interferes
with the idler. Accordingly, supply
grease to the track tension adjustment
parts in advance and move the idler
cushion assembly to the front side of the
machine body.
5) Pull out spacer (11) and rings (12) and (13).

a Pulling out force:
225.5 460.9 kN {23 47 tons}
6) Remove spacer (11).
7) Remove spacer (14) and floating seals (10)
between rings (12) and (13).
not be damaged.
D475A-5 30-145
(2)
10. Lower bogie (5) on the steel plate and pull it out. 2) Press fit shaft (7) to ring (13).
4
Bogie assembly: 180 kg
2 Apply lubricant (LM-P) to parts a

(about 10 mm) of rings (13) and

(8).
INSTALLATION
1) Using tool L18, install floating seals (9) to
rings (8) and (12) and install floating seals
(10) to the opposite side of ring (12) and ring 2. Slide bogie (5) on steel plate [1] to the center.
(13).
a When installing the floating seals, com- 3. Set bogie (5) to the mounting position with tool
pletely degrease the O-rings and O-ring L20.
contacting surfaces.
a Check that each floating seal is not in-
clined more than 1 mm.
4. Match the pin hole of the track frame to that of

the bogie and insert guide tool L17.
30-146 D475A-5
(2)
5. Press fitting of pin assembly 6. Refilling with oil

1) Set tool L16 and cover (6). Supply the specified quantity of oil by using tool
L19.
5 Pin assembly: 180 200 cc
2) Press fit the pin assembly (11).

a Direct arrow a on the end face of the pin
assembly up in the mounting state on
the machine body.
7. Press fit the pin assembly on the opposite side
a Push in the pin assembly with cover (6).
of the bogie according to above steps 5 and 6.
a Push in the pin assembly to machined
face b of the bogie and secure the level
8. Install covers (6) (2 places on inside and out-
difference of 5 mm between the bogie
side).
2 Apply lubricant (LM-P) all over
and pin assembly.
9. Install eyebolts instead of the pad mounting
the side of the pin assembly.
bolts (M12 x 2 pieces) of bogie (5) and lift and
a Total press fitting force of pin assembly:
hold the bogie.
294.2 490.5 kN {30 50 tons}
D475A-5 30-147
(2)
10. Insert tool L21 in the shaft of track roller assem-

bly (4), then lift and balance the track roller
assembly and set it on the track shoe.
4 Track roller assembly: 220 kg
11. Lower the machine body slowly. When the clear-

ance between bogie (5) and shaft (3) becomes
about 20 mm, install cap (15) and secure it with
bolts (2) temporarily.
2 Cap mounting bolt: Adhesive (LT-2)

12. Matching the dowel pin holes, tighten bolts (2).
3 Cap mounting bolt:

2,205 2,695 Nm {225 275 kgm}
13. Adjust the tension of the track shoe. For detail,

see TESTING AND ADJUSTING, Testing and
adjusting track shoe tension.
30-148 D475A-5
(2)
L17 Guide
L20 Spacer
D475A-5 30-149
(2)
L21 Bar
L-21 Plate
30-150 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL AND
INSTALLATION OF TRACK
SHOE ASSEMBLY
REMOVAL
Checking before removal of track shoe assem-

bly
k In some cases, it may be extremely dangerous
to remove the track shoe assembly. To prevent
danger, carry out the following checks before re-
moving the track shoe assembly.
k Never loosen the lubricator more than one turn.
2. Relieve track shoe tension. [*1]
k Never loosen lubricator (1) more than one
Loosen lubricator (1) at the adjustment cylinder,
release the grease, then move the machine
turn.
backwards and forwards a short distance, and
a If the track is not relieved by loosening the lu-
check that the track tension is relieved.
bricator, move the machine backwards and
a If the shoe tension is relieved, go to REMOVAL
forwards.
OF TRACK SHOE ASSEMBLY (NORMAL).
3. Remove track shoe (2). [*2]

If the above procedure does not relieve the track
a Loosen each of the 4 bolts by 1 2 turns.
tension and the track shoe assembly remains
Check that the 4 bolts can be turned lightly,
tense, there may be an abnormality inside the
then pull them out. Do not pull out only 1 bolt
track frame (the recoil spring case is broken, the
without loosening the other three.
recoil spring set bolt is broken, or the nut at the
a If a bolt is turned forcibly while it cannot be
end of shaft has fallen off).
turned lightly, the threads of it and master
a If the shoe tension is not relieved, go to REMOV-
link (3) may be damaged.
AL OF TRACK SHOE ASSEMBLY (WHEN
THERE IS ABNORMALITY INSIDE TRACK
FRAME).
Removal of track shoe assembly (Normal)

a If CHECKING BEFORE REMOVAL OF TRACK
SHOE ASSEMBLY shows that there is no abnor-
mality, do as follows.
1. Set master link in position.

a Bring the master link above the idler (just be-
hind the center).
a Set blocks [1] and [2] at the front end of the
idler and between the carrier rollers so that
the mating faces of the master link will not
open until the master bolt is removed.
D475A-5 30-151
(2)
4. Raise tip of master link, move machine towards 3. Drive slowly forward to put track shoe at idler
rear slowly, and lay out track shoe assembly (4). end in contact with large block [3] or a wall (if
a Length of track: Approx. 12.5 m another large bulldozer of the same capacity as
k To prevent danger, never stand in front of the machine being repaired is available, put in
the idler yoke assembly. contact with the blade). Stop machine when
recoil spring bends and slack is formed in track
shoe assembly, then apply brake.
When doing this, set so that master link is
between idler and front carrier roller.
For safety reasons, fit a lever block between
carrier roller support and link.
4. Remove shoe (2), then disconnect master link

(3).
5. Move machine towards rear slowly and lay out

track shoe assembly.
Removal of track shoe assembly (when there is

abnormality inside track frame)
a When CHECKING BEFORE REMOVAL OF
TRACK SHOE ASSEMBLY shows any abnor-
mality, do as follows.
k If there is any abnormality inside the track frame,
there is danger that the track shoe assembly
may spring back when it is removed or that the
idler may spring out when the track shoe assem-
bly is removed. This may lead to serious injury,
so remove the track shoe assembly as follows.
1. Remove work equipment assembly.

For details, see REMOVAL OF WORK EQUIP-
MENT ASSEMBLY.
2. Loosen lubricator (1), then move machine back-

wards and forwards to remove grease.
k Never loosen lubricator (1) more than one
turn.
a Check that all the grease has been removed.
30-152 D475A-5
(2)
INSTALLATION
removal.
[*1]
a For details of the track shoe tension, see
TESTING AND ADJUSTING, Testing and
adjusting of track shoe tension.
a Tighten all of the 4 bolts with the fingers until
the master link contacting faces are fitted to
each other.
a If a bolt is tightened forcibly before the mas-
ter link contacting faces are fitted to each
other, the threads of that bolt and the master
link may be damaged.
[*2]
a Tighten the master link shoe mounting bolts
2 Shoe mounting bolt:

in the order shown in the diagram below.
Seizure prevention compound

( M a r u z en M o l y m a x N o . 2 o r
3 Shoe mounting bolt:

equivalent)
1st step:
980 98 Nm {100 10 kgm}
2nd step:
Tighten a further 180 10
D475A-5 30-153
(2)
OVERALL DISASSEMBLY OVERALL DISASSEMBLY

a When disassembling the track shoe, see shop
AND OVERALL ASSEMBLY manual GUIDANCE FOR REUSABLE PARTS
OF TRACK SHOE LUBRICATED TRACKS (III) (Form No.:
SEBG4092).
SPECIAL TOOLS
1. Removal of shoe
New/remodel
Sling the shoe assembly and set it on a floor
Necessity
Sketch
with the shoe up. Remove the shoe with a shoe
Q'ty
Symbol Part No. Part Name
bolt impact wrench.
a If a shoe bolt is still hard (If its torque is not
1 791-646-7531 Plug remover t 1 lowered to 0) after it is unscrewed by 1 turn,
loosen the other bolts, and it can be removed
2 791-660-7460 Pin brush t 1
easily.
3 791-646-7900 Push tool t 1 a If a bolt is unscrewed forcibly while its torque
4 791-932-1110 Push tool t 1 is not 0, it will stick to the link and will need to
be repaired.
790-701-3000 Seal checker
5 and t 1 a When moving the shoe assembly, take care
791-601-1000 Oil pump not to damage the master link.
a If it is obliged to cut a shoe nut with gas, keep
6 791-632-1010 Installer t 1
the temperature of the sealing parts below
1 791-685-5600
Push tool
t 1 N
80C and prevent the spatters from entering
assembly the clearance of the link so that the sealing
2 791-685-5640 Adapter 1 N parts will not be deteriorated by the heat.
3 791-685-5660 Ring 1 N
4 791-685-5670 Plate 1 N
5 791-685-5680 Ring 1 N
9
6 791-685-5690 Push tool 1 N
7 791-685-5710 Adapter 1 N
8 791-685-5720 Spring 1 N
R
9 791-685-5730 Bar 1 N
10 01252-30655 Bolt 1
11 01580-01210 Nut 1
Push tool
1 791-685-5700 t 1 N
assembly
2 791-685-5650 Adapter 1 N
3 791-685-5660 Ring 1 N
4 791-685-5670 Plate 1 N
5 791-685-5680 Ring 1 N
12
6 791-685-5690 Push tool 1 N
7 791-685-5710 Adapter 1 N
8 791-685-5720 Spring 1 N
9 791-685-5730 Bar 1 N
10 01252-30655 Bolt 1
11 01580-01210 Nut 1
13 791-685-5750 Push tool t 1 N
30-154 D475A-5
(2)
2. Disassembly of link
1) Set the link assembly on the link press and
hit it with a hammer so that the bushing will
be fitted to the jaw.
a If the link tread, outside of the bushing,
etc. are worn, adjust the height of the jaw
or guide plate to align the disassembly
jig with the pin and bushing so that the
link hole will not be damaged during dis-
assembly.
a If the above parts are not aligned per-
fectly, the link hole may be damaged and
the pin and bushing may be broken dur-
ing disassembly.
3) Return the left cylinder and operate the right
a Drive the small plug of the pin inward
cylinder to pull out the right link, pin, and
with tool R1 after disassembly to avoid
bushing simultaneously.
making the workshop dirty.
4) Return the right cylinder and take out the

links, pins, bushings, and spacers on both
sides, then send the next link assembly to
the jaw.
a If the end faces of the bushings and
sealing surfaces are damaged, oil will
leak. Accordingly, handle them with
care.
a Take care not to scratch your hands with
the sharp edges of a cut wedge link.
2) Operate the left cylinder to pull out the fitted

parts of the left link, pin, and bushing simul-
taneously.
a Check the pulling out force of the pin and
bushing to see if the necessary fitting
force of the pin and bushing is obtained
when they are turned over and assem-
bled.
a When the wedge link is cut, it bangs.
This phenomenon is normal.
D475A-5 30-155
(2)
3. Inspection a Precautions for storage

Inspect the following items to see if the parts can 1) Store the seal without removing it from the
be reused for an oil lubricated track or a grease link to prevent rusting of the counterbore of
lubricated tr ack, then generall y ex ami ne the link, taking care not to damage the seal
whether the link assembly should be recycled as lip.
an oil lubricated track or as an grease lubricated 2) Apply rust-preventive oil to the pin and
track. bushing fitting parts and shoe and master
a For judgment of recycling of the parts, see link mating faces of the link.
shop manual GUIDANCE FOR REUSA- 3) Apply rust-preventive oil all over the pin,
BLE PARTS LUBRICATED TRACKS (III) bushing, and spacer. In particular, take care
(Form No.: SEBG4092). not to damage the end faces of the bushing.
1) Check the parts visually for damage, then
apply a dye penetrant test or a magnetic
flaw test to the parts which seem to be dam-
aged. Discard a cracked part since it cannot
be reused.
2) Measure the outside diameters of the fitting
parts of the pin and bushing and those of the
pin and bushing fitting parts of the link with a
micrometer and a cylinder gauge to see if
the allowable interference is obtained.
When reusing the parts for an oil lubricated
track, the pin and link must have the stand-
ard interference.
a If the allowable interference is not ob-
tained, replace the parts with new ones.
a For the criteria, see "Maintenance stand- OVERAll ASSEMBLY
ard". a When assembling the track shoe, see shop man-
ual GUIDANCE FOR REUSABLE PARTS
LUBRICATED TRACKS (III) (Form No.:
SEBG4092).
When recycling for oil lubricated track

1. Preparation work
1) Cleaning of seal assembly
Take the seal assembly out of the link and
divide it into the seal ring and load ring, then
clean them.
a Since the seal ring and load ring are de-
teriorated easily by cleaning liquid
(trichloroethylene, etc.), clean them
quickly. After cleaning them, wipe off the
cleaning liquid.
30-156 D475A-5
(2)
2) When reusing the pin, chamfer the corners iv) Drive the bar with a hammer.
of its end smoothly with a grinder. Remove a Driving distance a from pin end:
the projections of the fitting parts with the 10 1 mm
grinder. a If the edge of the pin hole is worn
a If the corners of the pin end are worn and and sharpened, chamfer it with a
sharpened, they may scuff the fitting small grinder (wheel tip angle: 45
parts to cause oil leakage. 60) so that the plug will not be dam-
aged.
a Coat the plug with GO90 and drive it
with the smaller end ahead.
3) Clean the link, pin, bushing, and spacer, if

they are dirty. Remove the projections of the
link and bushing with the grinder.
a Since the parts are rusted easily, clean 5) Installation of seal assembly
them just before assembling them. Clean the counterbore of the link carefully
a Do not repair the end faces of the bush- and push in the seal to the bottom with tool
ing with a grinder, etc. since that can R6.
cause oil leakage. a If any oil sticks to the counterbore of the
4) If the large plug has been driven out, drive it link and seal assembly, the seal turns
with tool R3. and its sealing performance is lowered.
Clean the pin hole with tool R2 in advance. Accordingly, do not apply any oil. Take
care that oil will not stick to the seal
when the seal is inserted in the counter-
bore.
i) Insert the plug in the hole of the guide

through the plug inserting hole.
ii) Push the bar with the hand and insert
the plug until it stops.
iii) Push the plug with the bar to press the
guide against the pin.
D475A-5 30-157
(2)
6) Adjust the dimensions of the fitting jig of the

link press to keep the projection distance of
the pin and bushing constant and keep the
fitting dimensions of the seal within the limits
when those parts are assembled.
a For the standard dimensions, see
"Press-fitting jig dimension table for link
press".
a If the pin end (Part P) and link sides
(Parts Q and R) are worn, count in the
quantity of the wear when adjusting the
dimensions of the fitting jig so that the
pin and bushing will be projected by the
same distance on both sides.
2) Press fit both bushing-side master links to
the bushings with the shoe fitting faces up.
a At this time, use the pin-side master links
as supports.
a Fitting force of bushing:
245 382 kN {25 39 tons}
7) Adjust the relief pressure of the link press so

that the pressing force will not exceed the
specified value.
a If the pressing force is too large, the
spacer is pressed against the bushing
with an excessive force. As a result, the
3) Measure the distance between the shoe bolt
spacer may be broken or it and bushing
holes of both links with a shoe bolt hole
end may be worn abnormally.
pitch gauge. Press fit the master link until
a Press cutting force of pin and bushing:
t h e s pe c i f i ed s h oe b o l t h o l e p i t c h i s
1,274 kN {130 tons}
obtained.
Press cutting force C
a Remove the all chips made when the
1.8 x Average press fitting force
bushing is press fitted by blowing air
(Set the press cutting force by adjusting
against them.
the relief pressure of the link press.)
4) Turn over the master links and check that
they are press fitted in parallel.
6. Assembly of link
1) Apply oil (GO90) between the pin and bush-
ing with a clean brush, then set them on this
side of the link press jaw.
a When reusing (turning) the bushing, set
its worn side to the shoe fitting face of
the link (which is directed up on the link
press).
30-158 D475A-5
(2)
5) Measure the projections of the bushing on 8) Set the right link and install the spacer to the
both sides with a depth gauge. pin.
a Adjust the fitting jig of the link press so a Check that the sealing surface and bush
that the bushing will be projected by the ends are free from dirt and apply oil
same distance on both sides. (GO90) to them with a clean cloth or
brush.
a Clean the spacer with a clean cloth be-
fore installing it.
6) Send out the master link and set the next

pin and bushing.
a When reusing the pin, install it with its
side hole on the link tread side similarly 9) Set the right jig on the receiving side and the
to a new one. If it is not installed in this left jig on the pushing side and press fit the
direction, its strength may lower. Ac- pin and bushing simultaneously.
cordingly, make a mark of the side hole a If the jigs shake while the pin and bush-
on the end face of the pin. ing are press fitted, the seal may come
off t he link. Accordingly, press fit
smoothly. If the seal comes off the link,
stop press fitting and install the seal to
the link correctly, then start press fitting
again.
a Press fitting force of pin and bushing:
578 833 kN {59 85 tons}
7) Apply gasket sealant (198-32-19890) to the

pin fitting hole of the link to prevent oil from
oozing through the scuffs of the pin fitting
parts.
D475A-5 30-159
(2)
10) Using the spacer for fine adjustment, press 13) Press fit until the link, spacer, and bushing
fit the pin until it is fitted to the lower part of are fitted to each other.
the pin end receiving jig. a Actually, you cannot see from outside if
a Adjust the depth of the receiving jig so the above parts are fitted. Accordingly,
that the pin will be projected by the same control the hydraulic pressure of the link
distance on both sides. press. Set the relief pressure to a proper
level and heighten the hydraulic pres-
sure to that level.
For setting of the relief pressure, see
PREPARATION WORK.
a Check that adjacent 2 links can turn
around each other.
11) Set the left link and install the spacer to the
pin.
a Apply oil similarly to the right link.

holes with a shoe bolt hole pitch gauge and
check that the result is within the limits.
a If the distance between the shoe bolt
holes is longer than the limit, disassem-
ble and check for abnormality, then
press fit again.
a If the distance between the shoe bolt
holes is shorter than the limit and the
shoe cannot be installed, the spacer or
bushing end may be worn more than the
12) Set the left jig on the receiving side and the allowable limit. In this case, disassemble
right jig on the pushing side and press fit the and replace the parts.
left link.
a When press fitting, take care that the
seals and spacers on both sides will not
come off.
Press fitting force of link:
578 833 kN {59 85 tons}
30-160 D475A-5
(2)
15) Install the ring to jig R12. 18) Push in the ring with jig R13.
Pushing force of ring:
392 490 kN {40 50 tons}
16) Match the jig to the pin hole and push it in

until the ring is inserted in the pin hole.
a A sound is made when the ring is insert- 19) After each link is assembled, bleed air from
ed in the pin hole. the pin with tool R5 and check the sealing
performance.
a Keep the degree of vacuum inside the
pin at 91 95 kPa {680 710 mmHg} for
5 seconds and check that the pressure
does not change.
If the pressure changes, disassemble
and check the seal. If the seal is free
from abnormality, assemble again.
17) Similarly, insert the ring in the pin groove on

the opposite side with jig R9.
20) Supply oil (GO90) with tool R5 until the oil

supply pressure rises to 196 294 kPa {2
3 kg/cm2}.
a In a cold or very cold district, supply Ko-
matsu genuine oil (150-09-19270 or
195-32-61990) having better low-tem-
perature characteristics instead of
GO90.
a If the oil pressure is heightened too
much, it has bad effects on the seal.
Take care.
D475A-5 30-161
(2)
7. Installation of shoe
1) Set the link assembly on the bed and install
the shoe with a shoe bolt impact wrench and
3 Shoe bolt (Regular link)

a torque wrench.
Initial torque:
784 78 Nm {80 8 kgm}
2 Shoe bolt:
Retightening angle: 180 10
Lubricant containing
molybdenum disulfide (LM-P)
a Supply oil so that the depth L of the hol-

low of the pin hole will be in the following
range when the link is left with the small
plug side up (when the link assembly is
placed on its side) for 30 minutes.
Dimension L: 40 70 mm
2) When installing a double track, place the

assembled double shoes on a level place in
1 line with the shoe side up. Pull pin-side
master link (1) and bushing-side master link
(2) together and set them to each other by
the mating faces. Place shoe (3) on the links
and check that shoe bolt (4) can be tight-
ened easily until the mating faces of the
links are fitted together, then connect the
21) After supplying oil, drive in the small plug to
links with the master bolts.
the specified position with tool R4.
a Apply GO90 around the small plug.
a Drive in the plug to the following depth.
Driving depth from end: 7.5 1 mm
22) Assemble the master link on the pin side at
last.
a Check that the master links on both
sides are press fitted in parallel.
2 Shoe bolt:
Lubricant containing molybde-
3 Shoe bolt (Master link)

num disulfide (LM-P)
Initial torque:
980 98 Nm {100 10 kgm}
30-162 D475A-5
(2)
a Tighten the bolts in the order of [1] [4]. 3) Drive the large plug and small plug with
tools R3 and R4.
i) Insert each plug in the hole of the guide
through the plug inserting hole.
(Apply oil to the plug.)
ii) Push the bar with the hand and insert
the plug until it stops.
iii) Push the plug with the bar to press the
guide against the pin.
iv) Drive the bar with a hammer.
a Driving distance a from pin end:
Small plug: 7.5 1 mm
Large plug: 10 1 mm
a If the plugs were not pull out of the
pin when disassembled, use them
When recycling for grease lubricated track as they are.
1. Preparation work 4) Clean the outside of the pin, surfaces of the
1) Cleaning of seal assembly spacer, and end faces and inside of the
Take the seal assembly out of the link and bushing, if they are dirty.
divide it into the seal ring and load ring, then 5) Apply grease to the outside of the pin and
clean them. surfaces of the spacer.
a Since the seal ring and load ring are de-
teriorated easily by cleaning liquid, clean
them quickly. After cleaning them, wipe
off the cleaning liquid.
6) Installation of seal assembly

Clean the counterbore of the link carefully
and push in the seal to the bottom with tool
R6.
2) When reusing the pin, chamfer the corners a If any grease sticks to the counterbore of
of its end carefully with a grinder so that it the link and seal assembly, the seal
will be press fitted smoothly. turns and its sealing performance is low-
ered. Accordingly, do not apply any
grease.
D475A-5 30-163
(2)
7) Adjust the dimensions of the fitting jig of the

link press to keep the projection distance of
the pin and bushing constant and keep the
fitting dimensions of the seal within the limits
when those parts are assembled.
a For the standard dimensions, see
"Press-fitting jig dimension table for link
press".
a If the pin end (Part P) and link sides
(Parts Q and R) are worn, count in the
quantity of the wear when adjusting the
dimensions of the fitting jig so that the
pin and bushing will be projected by the
holes of both links with a shoe bolt hole
pitch gauge. Press fit the master link until
t h e s pe c i f i ed s h oe b o l t h o l e p i t c h i s
obtained.
a Remove the all chips made when the
bushing is press fitted by blowing air
against them.
4) Turn over the master links and check that
they are press fitted in parallel.
2. Assembly of link
1) Apply lithium grease (G2-LI) between the
pin and bushing, then set them on this side
of the link press jaw.
a When reusing (turning) the bushing, set
its worn side to the shoe fitting face of
the link (which is directed up on the link
press).
5) Measure the projections of the bushing on

both sides with a depth gauge.
a Adjust the fitting jig of the link press so
that the bushing will be projected by the
2) Press fit both bushing-side master links to

the bushings with the shoe fitting faces up.
a At this time, use the pin-side master links
as supports.
a Fitting force of bushing:
245 382 kN {25 39 tons}
30-164 D475A-5
(2)
6) Send out the master link and set the next 8) Measure the distance between the shoe bolt
pin and bushing. holes with a shoe bolt hole pitch gauge. If
a When reusing the pin, install it with its the result is within the limits, stop press fit-
side hole on the link tread side similarly ting.
to a new one. If it is not installed in this
direction, its strength may lower. Ac-
cordingly, make a mark of the side hole
on the end face of the pin.
a If the outside of the pin is worn, set it with
the un-worn part on the traction side. In
this case, install it with its side hole on
the link tread side, too.
9) Install the ring to jig R12.
10) Match the jig to the pin hole and push it in

until the ring is inserted in the pin groove.
Similarly, insert the ring on the opposite side
with jig R9.
a A sound is made when the ring is insert-
ed in the pin.
7) Set both links and operate both pushing jigs
to press fit the pin and bushing simultane-
ously.
a If the jigs shake while the pin and bush-
ing are press fitted, the seal may come
off the link. Accordingly, press fit smooth-
ly. If the seal comes off the link, stop
press fitting and install the seal to the link
correctly, then start press fitting again.
a Press cutting force of pin and bushing:
1,274 kN {130 tons}
Press cutting force C
1.8 x Average press fitting force
(Set the press cutting force by adjusting
the relief pressure of the link press.)
D475A-5 30-165
(2)
11) Push in the ring with jig R13. 4. Assembly of 1/2 track
Pushing force of ring: Place the assembled 2 shoes on a level place in
392 490 kN {40 50 tons} 1 line with the shoe side up. Pull pin-side master
link (1) and bushing-side master link (2) together
and set them to each other by the mating faces.
Place shoe (3) on the links and check that shoe
bolt (4) can be tightened easily until the mating
faces of the links are fitted together, then con-
2 Shoe bolt:
nect the links with the master bolts.

Initial torque:
980 98 Nm {100 10 kgm}
a Tighten the bolts in the order of [1] [4].
12) Assemble the master link on the pin side at
last.
a Check that the master links on both
sides are press fitted in parallel.
3. Shoe (Regular link)

Set the link assembly on the bed and install the
shoe with a shoe bolt impact wrench and a
2 Shoe bolt:
torque wrench.
3 Shoe bolt (Regular link)

Initial torque:
784 78 Nm {80 8 kgm}
30-166 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY LINK PRESS
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
Jig dimension (mm)

a 4.6
b 2.0
c 59.1
D475A-5 30-167
(2)
DISASSEMBLY AND ASSEMBLY ONE LINK
FIELD DISASSEMBLY AND

ASSEMBLY OF ONE LINK
SPECIAL TOOLS
New/Remodel
New/Remodel
Necessity
Necessity
Symbol
Symbol
Sketch
Sketch
Qty
Qty
Part No. Part Name Part No. Part Name
1 791-832-1610 Plate t 1 1 791-832-1490 Push tool t 1 N

11
2 791-832-1270 Bracket t 1 2 791-832-1510 Push tool t 1 N
3 01010-81495 Bolt t 1 Push tool
1 791-685-5700 t 1 N
4 791-832-1250 Bracket t 1 assembly
5 01010-62050 Bolt t 2 2 791-685-5650 Adapter 1 N
6 791-832-1220 Plate t 1 3 791-685-5660 Ring 1 N
7 791-832-1230 Shaft t 2 4 791-685-5670 Plate 1 N
8 791-832-1210 Frame t 1 R 5 791-685-5680 Ring 1 N
12
9 791-832-1240 Nut t 2 6 791-685-5690 Push tool 1 N
10 04530-11628 Eye bolt t 2 7 791-685-5710 Adapter 1 N
11 791-832-1310 Adapter t 1 8 791-685-5720 Spring 1 N
12 791-832-1280 Adapter t 1 9 791-685-5730 Bar 1 N
13 791-832-1320 Guide t 1 10 01252-30655 Bolt 1
14 01320-41030 Screw t 5 11 01580-01210 Nut 1
8 15 791-832-1640 Pusher t 1 13 791-685-5750 Push tool t 1 N
16 791-832-1340 Extension t 2
DISASSEMBLY
17 791-832-1650 Adapter t 1
1. Install tools R8-4, R8-1, and R8-5 to link (1) with
18 791-832-1480 Adapter t 1 N 2 bolts (2).
19 791-832-1670 Guide t 1 a Use 2 track bolts as 2 bolts (2).
20 791-832-1330 Guide t 1
R 21 791-832-1660 Adapter t 1
22 791-832-1630 Guide t 1
23 791-832-1470 Guide t 1 N
24 791-832-1410 Extension t 1
25 791-832-1350 Pusher t 1
29 790-101-1102 Pump t 1
Puller (294 kN
30 790-101-4200 t 1
{30 ton})
31 790-685-9230 Spacer t 1
Push tool
1 791-685-5600 1 N
assembly
2 791-685-5640 Adapter 1 N
3 791-685-5660 Ring 1 N
4 791-685-5670 Plate 1 N
5 791-685-5680 Ring 1 N
9
6 791-685-5690 Push tool 1 N
7 791-685-5710 Adapter 1 N
8 791-685-5720 Spring 1 N
9 791-685-5730 Bar 1 N
10 01252-30655 Bolt 1
11 01580-01210 Nut 1
30-168 D475A-5
(2)
2. Install tool R8-12 to tool R8-4. 5. Pulling out of pin

a Check that the hole of R8-12 is aligned. If it 1) Set tools R8-13, R8-14, and R8-15 to R8-
is not aligned, retighten R8-5 and adjust the 11, then apply hydraulic pressure to push
position of R8-12. pin (3).
Install tool R8-10 to tool R8-8. Install a rope to 2) After the cylinder reaches the stroke end,
R8-10, then sling and install R8-10 to R8-12. connect tools R8-16 and R8-14 and repeat
Install tools R8-2 and R8-3 to tool R8-1. the work.
a Hitch and install R8-2 to the rib of R8-8 so 3) Repeat step 5.2).
that R8-8 will not lean. 4) After the cylinder reaches the stroke end
again, remove tools R8-13 and R8-14 and
add R8-25 and R8-14 to pull out pin (3).
3. Install tools R8-6, R8-10, R8-7, and R8-11 to

tool R8-28.
Install ropes to the eyebolt of R8-28 and R8-10,
then sling them so that R8-7 will be horizontal.
4. Insert R8-7 in the hole of R8-8 installed to the

track, then clamp it with R8-9.
6. Set tools R8-30 and R8-31 to the roller tread

side of the link to be disassembled, then con-
nect tool R8-29 and apply hydraulic pressure to
open the link by 5 6 mm and disconnect the
link.
D475A-5 30-169
(2)
7. Repeat steps 1 5 to remove pin (4) on the 2) Set tool R8-18 to the pin-side end of the link
opposite side. and press fit pin (8).
a Set the pin with its side hole on the link
tread side.
a Press fitting force of pin:
333 451 kN {34 46 tons}
8. Repeat step 6 to remove link (5).
2. Set link sub-assembly (9) to the link to be con-

nected.
ASSEMBLY
1. Assemble the link sub-assembly according to
1) Set tool R8-17 to the bushing-side end of
link (6) and press fit bushing (7). 3. Set link (10) on the opposite side and support it
a Press fitting force of bushing: with tool R8-19.
245 382 kN {25 39 tons}
4. Similarly to the disassembly procedure, set tools

R8-29, R8-6 R8-11, and R8-24 to the link.
30-170 D475A-5
(2)
5. Use R8-18 and R8-23 to press fit the pin. Use 8. Press fitting of pin
tools R8-21, R8-17, R8-20, and R8-14 to press 1) Set tools R8-28, R8-6 R8-12, R8-26, R8-
fit the bushing. Press fit the pin and bushing 27, R8-14, and R8-22 and apply hydraulic
alternately. pressure to press fit pin (13).
a Press fit the pin first. After the bushing is en- 2) After the cylinder reaches the stroke end,
gaged with the link, remove tool R8-19 in- remove tools R8-26, R8-27, and R8-14 and
stalled in step 3, then press fit the bushing. repeat the work with tools R8-16, R8-14,
a Press fitting force of pin: R8-25, and R8-14.
333 451 kN {34 46 tons} 3) After the cylinder reaches the stroke end
a Press fitting force of bushing: again, remove tools R8-12, R8-16, R8-25,
245 382 kN {25 39 tons} R8-14, and R8-22 and press fit the pin with
2 Pin fitting hole of link:

tools R8-18, R8-23, and R8-24.
Gasket sealant (198-32-19890)

tread side.
a Press fitting force of pin:
666 902 kN {68 92 tons}
6. Similarly to the disassembly procedure, push

open link (11) to be connected by using tools
R8-30 and R8-31.
7. Set link (12) to be connected to link (11) and

connect them with tool R8-22, then remove tools
R8-30 and R8-31.
9. Install the ring with tools R9, R11, R12, and R13.
a For the method of using the tools, see
OVERALL ASSEMBLY OF TRACK SHOE.
D475A-5 30-171
(2)
DISASSEMBLY AND ASSEMBLY MASTER LINK
DISASSEMBLY AND
ASSEMBLY OF MASTER LINK
SPECIAL TOOLS
New/Remodel
New/Remodel
Necessity
Necessity
Symbol
Symbol
Sketch
Sketch
Qty
Qty
Part No. Part Name Part No. Part Name
1 791-832-1610 Plate t 1 9 791-685-5730 Bar 1 N

2 791-832-1270 Bracket t 1 9 10 01252-30655 Bolt 1
3 01010-81495 Bolt t 1 11 01580-01210 Nut 1
4 791-832-1250 Bracket t 1 1 791-832-1490 Push tool t 1 N
11
5 01010-62050 Bolt t 2 2 791-832-1510 Push tool t 1 N
6 791-832-1220 Plate t 1 Push tool
1 791-685-5700 t 1 N
7 791-832-1230 Shaft t 2 assembly
8 791-832-1210 Frame t 1 2 791-685-5650 Adapter 1 N
9 791-832-1240 Nut t 2 3 791-685-5660 Ring 1 N
R
10 04530-11628 Eye bolt t 2 4 791-685-5670 Plate 1 N
11 791-832-1310 Adapter t 1 5 791-685-5680 Ring 1 N
12
12 791-832-1280 Adapter t 1 6 791-685-5690 Push tool 1 N
13 791-832-1320 Guide t 1 7 791-685-5710 Adapter 1 N
14 01320-41030 Screw t 5 8 791-685-5720 Spring 1 N
15 791-832-1640 Pusher t 1 9 791-685-5730 Bar 1 N
16 791-832-1340 Extension t 2 10 01252-30655 Bolt 1
8 17 791-832-1650 Adapter t 1 11 01580-01210 Nut 1
18 791-832-1480 Adapter t 1 N 13 791-685-5750 Push tool t 1 N
19 791-832-1670 Guide t 1
20 791-832-1330 Guide t 1
DISASSEMBLY
R 21 791-832-1660 Adapter t 1
a For the method of using tool R8, see FIELD DIS-
22 791-832-1630 Guide t 1
ASSEMBLY OF ONE LINK.
23 791-832-1470 Guide t 1 N
24 791-832-1410 Extension t 1 1. Removal of track shoe assembly
25 791-832-1350 Pusher t 1 Remove the track shoe assembly from the track
26 791-832-1620 Guide t 1 frame. For details, see EXPANDING TRACK
SHOE ASSEMBLY.
27 04530-11018 Eye bolt t 1
Cylinder
28 791-101-4500 t 1 2. Disassembly of shoe
(1960 kN {200 ton}
Disconnect the all master links and divide the
29 790-101-1102 Pump t 1 shoes into 4 parts.
Puller (294 kN
30 790-101-4200 t 1
{30 ton})
31 790-685-9230 Spacer t 1
Push tool
1 791-685-5600 1 N
assembly
2 791-685-5640 Adapter 1 N
3 791-685-5660 Ring 1 N
9 4 791-685-5670 Plate 1 N
5 791-685-5680 Ring 1 N
6 791-685-5690 Push tool 1 N
7 791-685-5710 Adapter 1 N
8 791-685-5720 Spring 1 N
30-172 D475A-5
(2)
3. Removal of master link Master link type

Master pin type 1) Cutting and removal of master link on bush-
1) Cutting of regular link with gas ing side with gas
Cut the parts marked with gas and Cut the parts marked with gas and
remove the parts marked . remove the parts marked . Move mas-
Necessary special tool: ter links (5) and (6) in the direction of and
Gas cutting machine to pull them out. Then, push pins (8) and
(9) out of regular link (7) in the directions of
and with a press.
Necessary special tools:
1. Gas cutting machine
2. Tool R8
2) Removal of regular link

Push pin (1) in the direction of with a
press to remove it from link (2), then pull pin
(1) and link (3) together out of bushing (4).
2) Removal of master link on pin side

Cut the parts marked with gas and
remove the parts marked . Push pin
(10) out of link (11) in the direction of with
a press. Then, pull pin (10) and link (12)
together out of bushing (13).
Necessary special tools:
1. Gas cutting machine
2. Tool R8
D475A-5 30-173
(2)
ASSEMBLY 2) Set spacer (3) and seal assembly (4) to the

a For the method of using tool R8, see FIELD DIS- counterbore of the link of the connecting
ASSEMBLY OF ONE LINK. part.
1. Assembly of bushing-side link

1) Press fit bushing-side master link (1) to
bushing (2) with a press.
a When press fitting both master links,
take care that they will be in parallel with
each other.
a Do not damage the mating surfaces of
the master links and end faces of the
bushing.
Unit: mm
L1 226 0.7
L2 276 0.7
D1 36 drill hole
D2 33 x 2.0 3) Match the pin hole and bushing hole to each
other and connect the pin and bushing with
guide pin [2].
2. Installation of bushing-side link

4) Press fit pin (5) with tool R8 and install
1) Expand the center of the link tread with tool
2 Apply gasket sealant (198-32-
bushing-side master link (1).
R8 as shown in the figure. (Expand the link
end by 10 mm.)
19890) to the pin hole of the link.
tread side.
30-174 D475A-5
(2)
5) Install ring (6) with tools R8, R9, R11, R12, 2) Pass pin (10) through bushing (9) and set
and R13. and press fit pin-side master links (11) from
6) Install the shoe to the link of the connecting both sides with tool R8.
part. 3) Install the ring with tools R8, R9, R11, R12,
7) Drive large plug (7) with tool R3 and supply and R13.
oil with tool R5, then drive small plug (8) 4) Drive large plug (13) with tool R3 and supply
with tool R4. oil with tool R5, then drive small plug (14)
a When press fitting both master links, with tool R4.
take care that they will be in parallel with
each other (Bushing side and pin side).
a Do not damage the mating surfaces of
the master links and end faces of the
bushing.
a Take care that dirt and sand will not stick
to the seal, spacer, end of bushing, and
tap-hole mating face of the master link.
4. Connection of master links

Place the assembled 2 shoes on a level place in
1 line with the shoe side up. Pull pin-side master
link (15) and bushing-side master link (16)
together and set them to each other by the mat-
ing faces. Place the shoe on the links and check
that the shoe bolt can be tightened easily until
the mating faces of the links are fitted together,
2 Shoe bolt:
3. Assembly of link on pin side then connect the links with the master bolts.
1) Set spacer (3) and seal assembly (4) to the
counterbore of the master link. Lubricant containing molybdenum

disulfide (LM-P)
Initial torque:
980 98 Nm {100 10 kgm}
D475A-5 30-175
(2)
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT
REMOVAL AND 3. Remove seal (2), then remove cover (3). [*2]
INSTALLATION OF PIVOT
SHAFT ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791T-850-1180 Sleeve t 1 N Q
791T-850-1190 Plate t 1 N Q
791-730-1130 Bolt t 2
791-101-3310 Plate t 1
P INSTALLATION
01643-32060 Washer t 2
01580-02016 Nut t 2 removal.
790-105-2300 Jack assembly t 1
2 Pivot shaft press-fitting surface:

[*1]
790-101-1102 Pump t 1

REMOVAL
1. Remove track frame assembly. [*2]
For details, see REMOVAL OF TRACK FRAME a Using tool P, press fit seal (2) to the pivot
ASSEMBLY.
2 Seal press-fitting surface:
shaft.
2. Sling pivot shaft assembly (1) and remove Gasket sealant (LG-6)
mounting bolts, then using forcing screw [1] , a Check that press-fitting dimension a of the
pull out pivot shaft assembly. [*1] seal from the end face of the shaft is the
4 Pivot shaft assembly: 390 kg specified dimension.
30-176 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT
P Sleeve
P Plate
D475A-5 30-177
(2)
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
REMOVAL AND 5. Set stand and hydraulic jack [1] (294 kN {30
ton}) under radiator guard.
INSTALLATION OF
EQUALIZER BAR
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
792-900-1610 Adapter t 1
792-900-1530 Screw t 1
791-775-1110 Sleeve t 1
791T-850-1150 Plate t 1 N Q
N 1 01582-53024 Nut 6. Remove cover (6).
t 1
01643-33080 Washer t 1 7. Remove cover (7).
Puller
790-101-2102 t 1 8. Remove main bolt (8) of side pin.
(294 kN {30t on})
790-101-1102 Pump t 1
REMOVAL
1. Remove engine underguard and power train
underguard (front).
4 Engine underguard: 330 kg
4 Power train underguard (front): 340 kg

a At the right track frame, disconnect 4 blade
tilt cylinder hoses from the cover.
a The front of the machine is raised using the
blade, so install a blind plug securely in the 9. Using eyebolt [2], remove side pin (9). [*3]
hose at the tilt cylinder end. a It is difficult to remove the pin if the centers of
the equalizer bar hole and track frame hole
3. Remove seal (2) together with washer (3). [*1] are not aligned, so use hydraulic jack [1] to
adjust the height at the equalizer bar end be-
4. Remove washer (4), then remove spacer (5). fore removing.
a Oil will flow out from the pivot case, so catch a Repeat Steps 6 to 9 to remove the side pin
it in an oil container. on the opposite side.
6 Pivot case: 26 l
30-178 D475A-5
(2)
10. Operate hydraulic jack [1] slowly and lower 15. Raise equalizer bar (13), move it past main
chassis to point where equalizer bar contacts frame and track frame, and remove.
left and right track frames. k After removing the equalizer bar, do not
lower the chassis.
4
11. Disconnect lubrication tube (10).
Equalizer bar assembly: 600 kg
12. Remove lock plate (11). [*4]
13. Using tool N1, remove center pin (12). [*5] INSTALLATION
a It is difficult to remove the pin if the centers of Carry out installation in the reverse order to
the equalizer bar hole and main frame hole removal.
are not aligned, so use hydraulic jack [1] to
adjust the height at the main frame end be- [*1]
fore removing. a After removing the grease from the press-fit-
ting surface of the seal, coat with gasket
sealant (LG-6).
a Be careful not to install with the seal dis-
placed in the direction of twisting.
3 Main mounting bolt of side pin:

[*2]
2,450 2,695 Nm {250 275 kgm}

a After tightening main mounting bolts (8) of
the side pin, tighten the mounting bolts of
covers (6) and (7).
a Take care of the tightening order of main
mounting bolts (8) of the side pin and the
mounting bolts of covers (6) and (7).
14. Operate blade and raise front of chassis, and
set hydraulic jack under radiator guard.
D475A-5 30-179
(2)
2 Inside surface of bushing:

[*3]
Grease (G2-LI)
a Before installing the pin, operate hydraulic
jack [1] to adjust the height of the main frame
and align the center of the equalizer bar hole
and track frame hole.
a Set the pin with the grease hole facing the

[*4]

Tread tightener (LT-2)
1,519 1,911 Nm {155 195 kgm}
2 Equalizer bar bushing and main frame

[*5]
bushing: Grease (G2-LI)

a Before installing the pin, operate the crane to
align the center of the main frame hole and
the equalizer bar hole.
Refilling with oil (pivot case)

5 Pivot case: 26 l (SAE30)
SKETCH OF SPECIAL TOOL
N1 Plate
30-180 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR BUSHING
DISASSEMBLY AND 3) Set tool N2 in position and remove side

bushing (4) from equalizer bar (5).
ASSEMBLY OF EQUALIZER
BAR BUSHING
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791T-850-1160 Bracket t 1 N Q
791T-850-1170 Bracket t 1 N Q
790-438-1110 Screw t 1
790-101-2540 Washer t 2
N 2
791-112-1180 Nut t 2
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
DESASSEMBLY
1. Center bushing
Remove center bushings (1).
2. Side bushing
1) Remove seals (2).
2) Remove snap ring (3).
D475A-5 30-181
(2)
ASSEMBLY 2) Install snap ring (3).

1. Side bushing a After installing the snap ring, fill front and
1) Set side bushing (4) and tool N2 in position, rear portion C of side bushing with
2 Amount of grease to fill side

then press fit side bushing (4) to equalizer grease (G2-LI).
2 Outer circumference of bushing:

bar (5).
bushing: 0.45 l
Anti-friction compound (LM-P) 3) Using press, press fit seal (2).
a Seal press-fitting force:
9.8 29.4 kN {1 3 ton}
a Press fit so that the mouthpiece of the
seal does not extend from the end face

of the equalizer bar.
a Align the direction of installation of the side

bushing as shown in the diagram below.
i) Make split surface (mating surface) a of
outer bushing horizontal.
ii) Set inner bushing and outer bushing
grease hole b at an angle.
a Side bushing press-fitting force: 2. Center bushing
2 Outer circumference of center bush-

47 96 kN {4.8 9.8 ton} Using press, press fit bushing (1).
ing: Anti-friction compound (LM-P)

a Center bushing press-fitting force:
68.6 233.2 kN {7 23.8 ton}
30-182 D475A-5
(2)
N2 Bracket
N2 Bracket
D475A-5 30-183
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
REMOVAL AND 6. Remove tube coupling (6).
INSTALLATION OF
HYDRAULIC PUMP
ASSEMBLY
REMOVAL
circuit.
k Disconnect the cable from the negative () ter- 7. Remove pump inlet tube (7).
8. Disconnect PPC hoses (8) and (9).
1. Drain oil from hydraulic tank.
6
9. Disconnect wiring clamp at the top of pump (10)
Hydraulic tank: 170 l and wiring harness connector (11).
2. Remove floor frame assembly. 10. Sling hydraulic assembly (12), then remove
For details, see REMOVAL OF FLOOR FRAME mounting bolts, and remove.
ASSEMBLY.
3. Disconnect pump outlet hoses (1) and (2).
4. Disconnect PPC hoses (3) and (4).
INSTALLATION
removal.
5. Disconnect hoses (5). Refilling with oil (hydraulic tank)
30-184 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC VALVE
REMOVAL AND 6. Disconnect 5 PPC hoses (5) from bottom side.

a PPC hoses are distinguished by color bands.
INSTALLATION OF
HYDRAULIC VALVE 7. Disconnect ripper hoses (6) and (7).
ASSEMBLY
REMOVAL
circuit.
1. Drain oil from hydraulic tank. 8. Disconnect tubes (8) and (9).
6 Hydraulic tank: 170 l 9. Disconnect hose (10).
2. Remove right cover of operator cab. 10. Disconnect wiring connectors (11) and (12), and
clamp (13).
3. Remove hose (1).
11. Sling control valve assembly (14), and then
4. Disconnect 5 PPC hoses (2) from upper side. remove.
4 Main control valve assembly: 195 kg
5. Disconnect blade lift hoses (3) and blade tilt

hoses (4).
INSTALLATION
removal.
Refilling with oil (hydraulic tank)

Bleeding air in the hydraulic piping

For detail, see TESTING AND ADJUSTING, Air
bleeding from hydraulic cylinder.
D475A-5 30-185
(2)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE
30-186 D475A-5
(2)
D475A-5 30-187
(2)
DISASSEMBLY ASSEMBLY
1. Ripper lift valve Coat the sliding surface of each part with engine
1) Remove case (1), spring (12), and retainer oil before installing.
(9).
2) Remove lower case (1), spring (12), and 1. Ripper tilt valve
retainer (9). 1) Install spool (2) to the valve body.
3) Remove spool (2). 2) Install lower retainer (9) and spring (12). Fit
a Do not disassemble spool assembly (2). the O-ring to case (1) and install them.
3) Install retainer (9) and spring (12). Fit the O-
3 Case mounting bolt:

2. Blade right tilt valve ring to case (1) and install them.
1) Remove case (1), spring (15), and retainer
(9). 27.5 34.3 Nm {2.8 3.5 kgm}
2) Remove lower case (1), spring (15), and
retainer (9). 2. Blade left tilt valve
3) Remove spool (3). 1) Install spool (3) to the valve body.
a Do not disassemble spool assembly (3). 2) Install lower retainer (9) and spring (15). Fit
the O-ring to case (1) and install them.
3. Blade lift valve 3) Install retainer (9) and spring (15). Fit the O-

1) Remove case (3), loosen bolt (8), and ring to case (1) and install them.
remove retainer (7) and spring (6).
2) Remove plate (2), spring (13), and retainer 27.5 34.3 Nm {2.8 3.5 kgm}
(10).
3) Remove lower case (1), plate (2), spring 3. Blade lift valve
(14), and retainer (11). 1) Install spool (4) to the valve body.
4) Remove spool (4). 2) Install lower retainer (11), spring (14), and
a Do not disassemble spool assembly (4). plate (2). Fit the O-ring to case (1) and
install them.
4. Blade lift valve 3) Install retainer (10), spring (13), and plate
1) Remove case (3), loosen bolt (8), and (2).
remove retainer (7) and spring (6). 4) Install spring (6) and retainer (7) to case (3)
2) Remove plate (2), spring (13), and retainer and secure them with bolt (8). Fit the O-ring

(10). to case (3) and install them.
3) Remove lower case (1), plate (2), spring

(14), and retainer (11). 11.8 14.6 Nm {1.2 1.5 kgm}
a Do not disassemble spool assembly (4). 27.5 34.3 Nm {2.8 3.5 kgm}
5. Blade left tilt valve 4. Blade lift valve

1) Remove case (1), spring (15), and retainer 1) Install spool (4) to the valve body.
(9). 2) Install lower retainer (11), spring (14), and
2) Remove lower case (1), spring (15), and plate (2). Fit the O-ring to case (1) and
retainer (9). install them.
3) Remove spool (3). 3) Install retainer (10), spring (13), and plate
a Do not disassemble spool assembly (3). (2).
4) Install spring (6) and retainer (7) to case (3)
6. Ripper tilt valve and secure them with bolt (8). Fit the O-ring

1) Remove case (1), spring (12), and retainer to case (3) and install them.
(9).

2) Remove lower case (1), spring (12), and 11.8 14.6 Nm {1.2 1.5 kgm}
retainer (9).
3) Remove spool (2). 27.5 34.3 Nm {2.8 3.5 kgm}
a Do not disassemble spool assembly (2).
30-188 D475A-5
(2)
5. Blade right tilt valve

1) Install spool (3) to the valve body.
2) Install lower retainer (9) and spring (15). Fit

ring to case (1) and install them.
27.5 34.3 Nm {2.8 3.5 kgm}
6. Ripper lift valve

1) Install spool (2) to the valve body.
2) Install lower retainer (9) and spring (12). Fit

ring to case (1) and install them.
27.5 34.3 Nm {2.8 3.5 kgm}
D475A-5 30-189
(2)
DISASSEMBLY AND ASSEMBLY MERGE-DIVIDER VALVE AND SELF-REDUCING PRESSURE VALVE
DISASSEMBLY AND ASSEMBLY OF MERGE-DIVIDER VALVE

AND SELF-REDUCING PRESSURE VALVE ASSEMBLY
30-190 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY MERGE-DIVIDER VALVE AND SELF-REDUCING PRESSURE VALVE
DISASSEMBLY ASSEMBLY
1. Remove case (7) from valve body (1). Loosen Coat the sliding surface of each part with engine
bolt (6) and remove retainer (8), spring (5), oil before installing.
retainer (4), plug (3), and spool (2).
1. Fit the O-ring and install ball (37), spring (36),
3 Seat: 9.8 12.7 Nm {1.1 1.3 kgm}

2. Remove plug (14), spring (12), and spool (11). and seat (35) to block (30).
3. Remove plug (18), spring (17), and spool (16).

2. Fit the O-ring and install valve assembly (42) to
3 Valve assembly:
4. Remove plug (33), spring (32), and spool (31) block (30).
from block (30).
24.5 34.3 Nm {2.3 3.5 kgm}
5. Remove valve assembly (42) from block (30).
3. Install spool (31) and spring (32). Fit the O-ring
3 Plug assembly:
6. Remove seat (35), spring (36), and ball (37) and install plug (33).
from block (30).
a After disassembling, if any of body (1) and 19.6 24.5 Nm {2 2.5 kgm}
spools (2), (11), and (16) is defective, re-
place the whole merge-divider valve assem- 4. Install spool (16) and spring (17). Fit the O-ring
3 Plug assembly:
bly. to plug (18) and install them to valve body (1).
147.1 186.3 Nm {15 19 kgm}
5. Install spring (12) to spool (11). Fit the O-ring to
3 Plug assembly:
plug (14) and install them.
147.1 186.3 Nm {15 19 kgm}
6. Install retainer (4), spring (5), retainer (8), and

plug (3) to spool (2) and install them to body (1).
3 Mounting bolt of case (7):

Fit the O-ring and install case (7).
27.5 34.3 Nm {2.8 3.5 kgm}
D475A-5 30-191
(2)
DISASSEMBLY AND ASSEMBLY PPC RELIEF VALVE
REMOVAL AND
INSTALLATION OF PPC
RELIEF VALVE ASSEMBLY
REMOVAL
circuit.
1. Remove operators cab right cover.
2. Remove hoses (1), (2), and (3).
3. Disconnect connector (4).
4. Remove PPC relief valve assembly (5).
INSTALLATION
removal.
30-192 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY AND
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Cylinder repair
1 790-502-1003 q 1
stand
790-201-1702 Push tool kit t 1 2) Disassemble quick drop valve assembly as
follows.
790-201-1881 Push tool 1
i) Remove elbow (2).
790-201-1871 Push tool 1 ii) Remove spring (3), washer (4), and
2
790-201-1721 Push tool 1 valves (5) and (6), and pull out collar
(7).
790-101-5021 Grid 1
01010-50816 Bolt 1
790-201-1500 Push tool kit t 1
790-201-1670 Plate 1
790-201-1680 Plate 1
3 790-201-1690 Plate 1
U 790-201-1530 Plate 1
790-101-5021 Grip 1
01010-50816 Bolt 1
4 790-720-1000 Expander t 1
796-720-1690 Ring t 1
07281-01919 Clamp t 1 3. Piston rod assembly
796-720-1690 Ring t 1 1) Set cylinder assembly (8) to tool U1.
2) Remove head assembly (9).
07281-02169 Clamp t 1
5 3) Pull out piston rod assembly (10).
796-720-1710 Ring t 1 a Put an oil container under the cylinder to
07281-02709 Clamp t 1 catch the oil.
796-720-1630 Ring t 1
07281-00709 Clamp t 1
6 790-102-2303 Wrench t 1
DISASSEMBLY
1. Cylinder tube
Remove cylinder tube.
2. Quick drop valve assembly

a Blade lift cylinder only.
1) Remove quick drop valve assembly (1).
D475A-5 30-193
(2)
4. Piston assembly 5. Head assembly

1) Set piston rod assembly (10) to tool U1. 1) Remove head assembly (19) from piston
rod.
2) Remove spacer (11).

3) Remove piston assembly (12). 2) Disassemble head assembly as follows.
4) Remove backup rings (13) and (14), and O- i) Remove O-ring (20) and backup ring
ring (15). (21).
5) Remove retainer (16).
ii) Remove snap ring (22), then remove

6) Disassemble piston assembly as follows. seal (23).
i) Remove wear ring (17). iii) Remove packing (24), then remove
ii) Remove piston ring (18). bushing (25).
30-194 D475A-5
(2)
ASSEMBLY 2) Install head assembly (19) to piston rod.

a Coat the sliding surfaces of all parts with engine
oil before installing. Be careful not to damage the
packings, dust seals, and O-rings when install-
ing.
1. Head assembly
1) Assemble head assembly as follows.
i) Using tool U2, press fit bushing (25) to
head.
ii) Install packing (24).
iii) Using tool U3, press fit seal (23).
iv) Install snap ring (22).
2. Piston assembly
1) Assemble piston assembly as follows.
i) Using tool U4, expand piston ring (18).
a Set the piston ring on the expander
and turn the handle 8 10 times to
expand the ring.
ii) Remove piston ring (18) from tool U4,
then install to piston.
iii) Set tool U5 in position and compress
piston ring (18).
iv) Install wear ring (17) to piston.
v) Install backup ring (21) and O-ring (20).
D475A-5 30-195
(2)
2) Install retainer (16). 3 Mounting bolt:

3) Install O-ring (15) and backup rings (14) and Blade lift:
(13). 490 49 Nm {50 5 kgm}
a Coat the O-ring and backup ring portion Blade tilt, ripper lift, ripper tilt:
with grease, and secure the backup ring 1,320 140 Nm {135 15 kgm}
to prevent it from opening.
4) Install piston assembly (12).
5) Assemble spacer (11) and tighten mounting
2 Mounting bolt:
bolts.
3 Mounting bolt:
Blade lift:
98 123 Nm {10 12.5 kgm}
Blade lift, ripper lift, ripper tilt:
157 196 Nm {16 20 kgm}
4. Quick drop valve assembly

a Blade lift cylinder only.
1) Assemble quick drop valve assembly as fol-
lows.
i) Assemble collar (7), and install valves
(6) and (5), washer (4), and spring (3).
ii) Install elbow (2).
3. Piston rod assembly

1) Set cylinder (8) to tool U1.
2) Install quick drop valve assembly (1).
2) Assemble piston rod (10) to cylinder (8).

a Coat the seal portion of the piston with
grease.
a Push in the piston rod fully.
3) Push head assembly to cylinder and tighten
mounting bolts.
a Coat the backup ring with grease.
5. Cylinder tube
Install cylinder tube.
30-196 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY RIPPER PIN-PULLER CYLINDER
DISASSEMBLY AND
ASSEMBLY OF RIPPER
PIN-PULLER CYLINDER
ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Cylinder repair
1 790-502-1003 q 1 2. Cylinder head assembly
stand
1) Remove cylinder head assembly (2) from
piston rod (3).
790-201-1881 Push tool 1
790-201-1871 Push tool 1
2
790-201-1721 Push tool 1
790-101-5021 Grid 1
01010-50816 Bolt 1
790-201-1670 Plate 1
790-201-1680 Plate 1
3 790-201-1690 Plate 1
U 790-201-1530 Plate 1
790-101-5021 Grip 1
01010-50816 Bolt 1 2) Remove O-ring (5) and backup ring (6).
3) Remove O-ring (7).
4 790-720-1000 Expander t 1 4) Remove snap ring (8), then remove dust
796-720-1690 Ring t 1 seal (9).
07281-01919 Clamp t 1 5) Remove rod packing (10), then remove
bushing (11).
796-720-1690 Ring t 1
07281-02169 Clamp t 1
5
796-720-1710 Ring t 1
07281-02709 Clamp t 1
796-720-1630 Ring t 1
07281-00709 Clamp t 1
6 790-102-2303 Wrench t 1
DISASSEMBLY
1. Cylinder assembly
1) Set pin-puller cylinder assembly (1) to tool
U1.
2) Using tool U6, loosen cylinder head assem-
bly (2).
3) Remove piston rod (3) together with cylinder
head assembly (2).
a Put an oil container under the cylinder to
catch the oil.
D475A-5 30-197
(2)
3. Piston rod assembly 2. Cylinder head assembly

Remove piston ring (12) from piston rod (3). 1) Using tool U2, press fit bushing (11) to cylin-
der head (4).
ASSEMBLY 2) Using tool U3, press fit dust seal (9) to cylin-
a Coat the sliding surfaces of all parts with engine der head (4).
oil before installing. Be careful not to damage the
packings, dust seals, and O-rings when install-
ing.
1. Piston rod assembly

1) Using tool U4, expand piston ring (12).
a Set the piston ring on the expander and
turn the handle 8 10 time to expand the
ring.
2) Remove piston ring (12) from tool, then
install to piston rod (3).
3) Using tool U5, compress piston ring (12).
3) Install snap ring (8) and rod packing (10).

4) Install O-ring (7).
5) Install backup ring (6) and O-ring (4).
30-198 D475A-5
(2)
6) Install cylinder head assembly (2) to piston

rod (3).
3. Cylinder assembly
1) Set cylinder to tool U1 and support with
block [1].
2) Install piston rod (3) together with cylinder
head assembly (2).
a Coat the seal portion of the piston with
grease.
a Coat the backup ring with grease.
a Push in the piston fully.
3) Using tool U6, tighten cylinder head assem-
3 Cylinder head assembly:

bly (2).
441 44.1 Nm {45 4.5 kgm}
D475A-5 30-199
(2)
DISASSEMBLY AND ASSEMBLY BLADE
k
REMOVAL AND Release the remaining pressure from the hy-
draulic circuit.
INSTALLATION OF BLADE For details, see TESTING AND ADJUSTING,
ASSEMBLY Releasing remaining pressure from hydraulic
circuit.
k Lower the work equipment to the ground in a Then loosen the oil filler cap slowly to release
horizontal place, and set blocks [1] securely un- the pressure inside the hydraulic tank.
der the left and right straight frames.
3. Remove left and right covers (4).
4. Disconnect hoses (5).

a Mark the hoses before disconnecting.
a Fit blind plugs to prevent dirt or dust from en-
tering the piping.
5. Remove left and right trunnion caps (6).
1. Remove lock plate (1) of lift cylinder rod pin and

extract pin (2). [*1]
2. Sling lift cylinder assembly (3), then start engine

and retract piston rod fully, fit cylinder lock tool
and secure to radiator guard.
a Tie the piston rod with wire to prevent it from
coming out.
Repeat the same procedure to disconnect 6. Remove blade assembly (7).
the cylinder from the blade on the opposite a Start the engine, drive the machine slowly in
side. reverse, and disconnect the blade assembly
from the trunnions.
30-200 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY BLADE
INSTALLATION
removal.
[*1]
a Adjust with block [1] so that height b and width c
of the left and right straight frames are the dimen-
sions given below.
Height b of trunnion portion:
Approx. 981 mm
Brace width c: Approx. 3,840 mm
Refilling with oil (hydraulic tank)

Run the engine to circulate the oil through the
system. Then check the oil level again.
D475A-5 30-201
(2)
DISASSEMBLY AND ASSEMBLY GIANT RIPPER
DISASSEMBLY AND 7. Disconnect 4 lift cylinder hoses (4), 4 tilt cylinder

hoses (5), and 2 pin-puller cylinder hoses (6).
ASSEMBLY OF GIANT RIPPER
ASSEMBLY
DISASSEMBLY
1. Mount machine on block [1] and lower blade to
ground.
k Lock the brake securely.
2. Sling shank, then operate pin-puller switch and

pull out shank pin.
3. Raise ripper fully, and lower shank (1) to

remove.
4 Shank: 1,050 kg
8. Sling tilt cylinder assembly (7), then remove pin
4. Set stand [2] under arm and beam. (8) and lift off tilt cylinder assembly (7).
4 Tilt cylinder assembly: 410 kg
5. Sling lift cylinder assembly and remove pin (2).

a Start the engine, retract the piston rod fully, 9. Sling lift cylinder assembly (9), then remove pin
and lower on top of the arm. (10) and lift off lift cylinder assembly (9).
4
6. Sling lift cylinder assembly and remove pin (3).
a Start the engine, retract the piston rod fully, Lift cylinder assembly: 400 kg
and lower on top of the lift cylinder.
k Release the remaining pressure from the
hydraulic circuit.
ING, Releasing remaining pressure from
hydraulic circuit.
30-202 D475A-5
(2)
10. Sling beam (11), then remove left and right pins 2. Sling beam (11) and set in mounting position,
(12) and lift off beam (11). then fit left and right pins (12) and secure with
4
lock plate.
4 Arm: 2,450 kg
Beam: 2,450 kg
a Set a stand under the beam.
11. Sling arm (13), then remove left and right pins
(14) and lift off arm (13).
4
3. Sling lift cylinder assembly (9) and set in mount-
Arm: 1,800 kg
ing position, then fit pin (10) and secure with
lock plate.
4 Lift cylinder assembly: 400 kg
ASSEMBLY
1. Sling arm (13) and set in mounting position, then
fit left and right pins (14) and secure with lock 4. Sling tilt cylinder assembly (7) and set in mount-
plate. ing position, then fit pin (8) and secure with lock
4 Arm: 1,800 kg
plate.
a Set a stand under the arm. 4 Tilt cylinder assembly: 410 kg
D475A-5 30-203
(2)
5. Connect 2 pin-puller cylinder hoses (6), 4 tilt cyl- 8. Mount machine on block [1] and lower blade to
inder hoses (5), and 4 lift cylinder hoses (4). ground.
k Lock the brake securely.
9. Operate ripper and raise slightly to remove

stand [2].
10. Raise ripper fully, pass wire through shank

holder, then raise shank (1) slowly, align with pin
hole, and operate pin-puller switch to insert
shank pin.
11. Raise blade and lower machine from block [1].
6. Sling tilt cylinder assembly, start engine, extend

piston rod and align with pin hole, then install pin
(3) and secure with lock plate.
7. Sling lift cylinder assembly, start engine, extend

piston rod and align with pin hole, then install pin
(2) and secure with lock plate.
12. Bleed air from cylinder.

Bleed air from hydraulic cylinder.
30-204 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY ROPS GUARD
REMOVAL AND
INSTALLATION OF ROPS
GUARD
REMOVAL
1. Sling ROPS guard (1) and remove 16 mounting
bolts (2). [*1]
2. Lift off ROPS guard (1).

4 ROPS guard: 918 kg
INSTALLATION
removal.
3 ROPS guard mounting bolt:

[*1]
1,960 2,450 Nm {200 250 kgm}
D475A-5 30-205
(2)
DISASSEMBLY AND ASSEMBLY OPERATORS CAB
REMOVAL AND 6. Remove front covers (8), (9) and (10).
INSTALLATION OF 7. Remove 3 mounting bolts (11), 6 bolts (12) and

OPERATORS CAB 15 bolts (13).
ASSEMBLY
REMOVAL
1. Remove ROPS gurd.

For details, see REMOVAL OF ROPS GUARD.
2. Remove left cover (1) of operators cab.
3. Disconnect wiring connectors (12V, 21 and 20)

(2).
4. Disconnect 4 washer hoses (3) and 19 washer 8. Sling operators cab assembly (14), then
wires (4). remove.
4
Washer hose
Operators assembly: 500 kg
Red : Right door Black : Rear window
Blue: Left door : Front window
INSTALLATION
5. Remove garnishes (5), (6) and (7).
removal.
30-206 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL AND 4. Remove sidecover (5).
INSTALLATION OF FLOOR
FRAME ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

799-703-1100 Vacuum pump t 1
X 799-703-1110 Vacuum pump t 1
799-703-1120 Vacuum pump t 1 5. Disconnect brake pedal linkage (6).
a Check the mounting dimensions of brake rod
before disconnection.
REMOVAL
CAB ASSEMBLY.
2. Remove covers (1), (2) and (3).
6. Disconnect wiring harness connectors (7) (VF1-

CA1-VF2), (8) (PL1-PL2-PL3), (9) (FD5-BWR1-
PWR2-USB-12V-20-21), and (10) (TCI-V12-
BSW), and then disconnect the wiring clamp.
Disconnect washer hose (11) and the clamp.
3. Lift off operator's seat (4).

a Remove the seat together with the under-
cover.
4 Operators seat: 64 kg
7. Remove wiring connector (12) (CN2-SSA-PT1)

and the clamp.
D475A-5 30-207
(2)
8. Disconnect wiring connector (13) (995-111-VFD) 16. Remove floor frame bracket bolt (23) on right
and remove the connector bracket. side.
17. Disconnect ground wiring (24).
18. Remove floor frame bracket bolt (25) on left

side.
9. Disconnect blade PPC hose (14A), hose (14B)

and ripper PPC hose (15).
10. Disconnect wiring connector and clamp (16).
19. Remove 8 floor frame rear mounting bolts (26).
11. Remove brake rod (17).
12. Disconnect parking brake cable (18). 20. Lift off floor frame assembly (27).
4 Floor frame assembly: 500 kg
13. Disconnect air conditioner hose (19).
a Use a chain block to adjust the balance in all di-
rections (front, rear, left, and right), and lift off
14. Disconnect heater hose (20).
slowly.
15. Disconnect wiring connector (21) and clamp

(22).
30-208 D475A-5
(2)
INSTALLATION [*2] [*3]

Carry out installation in the reverse order to a The connecting positions of the PPC hoses
removal. are indicated by the band colors on their
quick couplers. When connecting them, con-
[*1] firm them by the band colors.
ence. [*4]
a Install the air conditioner circuit hoses care- a Adjust the directional, speed control, and
fully to prevent dirt, dust, or water from get- parking brake linkage. For details, see
ting inside the hoses. TESTING AND ADJUSTING, Adjusting
a Check that there are O-rings at the piping brake pedal and parking brake lever.
connection of the air conditioner hoses be-
fore installing.
Coat the O-rings thoroughly with compressor
oil (Shell Suniso 4G or 5G).
3 Tighten the air conditioner gas piping to

the following tightening torques.
Thread size Tightening torque (Nm {kgm})
16 x 1.5 13.23 1.47 {1.35 0.15}
22 x 1.5 22.05 2.45 {2.25 0.25}
24 x 1.5 31.85 2.45 {3.25 0.25}
M6 bolt
5.39 1.47 {0.55 0.15}
(receiver portion)
[*5]
M6 bolt
9.8 1.96 {1.0 0.2} a Adjust the brake pedal linkage.
(compressor portion)
3 Brake pedal linkage turnbuckle:

34.3 58.8 Nm {3.5 6 kgm}


D475A-5 30-209
(2)
DISASSEMBLY AND ASSEMBLY CONTROLLER
REMOVAL AND 5. Disconnect wiring connectors of engine control-

ler (6).
INSTALLATION OF (CN-LE1, CN-LE32, CN-LE31, CN-LE4, CN-
CONTROLLER ASSEMBLY LE2, CN-LE52, CN-LE51)
REMOVAL 6. Remove engine controller (6).

minal of the battery. 7. Remove engine controlller mounting bracket (7).
1. Remove cover (1). 8. Disconnect wiring connectors of transmission

controller (8).
(CN-TMCN1, CN-TMCN2, CN-TMCN3)
9. Remove transmission controller (8).
10. Disconnect wiring connectors of steering con-

t rol ler (9) . (CN -STC N1, C N-S TCN2, CN-
STCN3)
11. Remove steering controller (9).
2. Remove services switch (2) and connector

bracket (3).
3. Remove 2 clips for wiring harness (5).
4. Remove 3 brackets (4).
INSTALLATION
removal.
30-210 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL AND a Loosen the sleeve nut slightly and release

INSTALLATION OF AIR before disconnecting the hoses.
CONDITIONER CONDENSER a Fit blind plugs to prevent dirt or moisture
ASSEMBLY from entering the hoses.
a Be careful not to damage or drop the O-
rings.
SPECIAL TOOLS
3. Remove air conditioner condenser assembly (5)
New/remodel
Necessity
from right side of chassis.
Symbol
Sketch
Q'ty
Part No. Part Name

799-703-1100 Vacuum pump t 1
799-703-1120 Vacuum pump t 1
REMOVAL
1. Open engine right side cover (1) and remove
side cover (2) and (3).
INSTALLATION
removal.
[*1]
a Install the air conditioner circuit hoses care-
fully to prevent dirt, dust, or water from get-
ting inside the hoses.
a Check that there are O-rings at the piping
fore installing.
3 Air conditioner hose sleeve nut:

2. Disconnect hoses (4). [*1] oil (Shell Suniso 4G or 5G).
Outside:
22.05 2.45 Nm {2.25 0.25 kgm}
Inside:
13.25 1.47 Nm {1.35 0.15 kgm}

D475A-5 30-211
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL AND 2. Disconnect air conditioner compressor clutch

connector (CN-351) (4).
INSTALLATION OF AIR
CONDITIONER 3. Disconnect 2 compressor hoses (5). [*1]
COMPRESSOR ASSEMBLY a Loosen the sleeve nut slightly and release
before disconnecting the hoses.
SPECIAL TOOLS
a Fit blind plugs to prevent dirt or moisture
from entering the hoses.
New/remodel
Necessity
a Be careful not to damage or drop the O-
Symbol
Sketch
Q'ty
Part No. Part Name rings.

799-703-1100 Vacuum pump t 1
799-703-1120 Vacuum pump t 1
REMOVAL
minal of the battery
1. Open engine right side cover (1) and remove

side covers (2) and (3). 4. Loosen 4 mount bolts (6).
5. Loosen locknut, and remove adjustment bolt (7),

then remove belt from pulley. [*2]
6. Remove 4 mount bolts (6), then remove air con-

ditioner compressor assembly (8).
30-212 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION
removal.
[*1]
fore installing.
3 Air conditioner hose mounting bolt:

10 2 Nm {1.0 0.2 kgm}
[*2]
a Adjust the belt tension.
ING, Testing and adjusting tension of air
conditioner compressor belt.

D475A-5 30-213
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL AND 6. Disconnect air hose (7).
INSTALLATION OF AIR CON-

DITIONER UNIT
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

799-703-1100 Vacuum pump t 1
799-703-1120 Vacuum pump t 1 7. Remove fresh air filter bracket (8).
8. Disconnect 2 air conditioner hoses (9).
REMOVAL 9. Disconnect heater hose (10).

1. Remove operator's seat (1).
10. Disconnect wire and wiring connector (11).
11. Remove air conditioner unit (12).

a Before disconnecting each hose, loosen the
sleeve nut a little to discharge all the air con-
ditioner refrigerant (R134a).
a Plug the hoses to prevent dirt and water from
entering them.
2. Remove fresh air filter (2).
4. Remove duct (4).
5. Remove garnishes (5) and (6).
30-214 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
INSTALLATION
removal.
[*1]
ence.
fore installing.
3 Tighten the air conditioner gas pip-

ing to t he following tight ening

torques.
Thread size Tightening torque (Nm {kgm})

16 x 1.5 13.231.47 {1.350.15}
22 x 1.5 22.052.45 {2.250.25}
24 x 1.5 31.852.45 {3.250.25}
M6 bolt (receiver
5.391.47 {0.550.15}
portion)
M6 bolt (com-
9.81.96 {1.00.2}
pressor portion)


D475A-5 30-215
(2)
DISASSEMBLY AND ASSEMBLY HOOD
REMOVAL AND 5. Disconnect radiator sub tank hose (6), and

remove hose clamp (7).
INSTALLATION OF HOOD
ASSEMBLY 6. Remove radiator sub tank assembly (8).


7. Disconnect wiring connector (9) (201-202) from

the left front part of the hood.
8. Disconnect wiring connector (10) (HR1-HR2-

112) from the right rear part of the hood.
2. Disconnect precleaner tubs (2) and (3).
9. Lift of hood (11).

4 Hood assembly: 350 kg
3. Remove air cleaner hood (4). Open the side cover and raise.
4. Remove exhaust pipe (5).
INSTALLATION
removal.
30-216 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY FAN DRIVE
REMOVAL AND 6. Disconnect fan motor hoses (8), (9), and (10).
a Plug the hoses to prevent dirt from entering
INSTALLATION OF FAN them.
DRIVE ASSEMBLY
REMOVAL
1. Drain the hydraulic oil.
2. Remove the mounting bolts and open the fan

guard.
3. Remove fan nets (1) and (2) (left and right).
4. Remove sound absorbing blades (3) (left and

right) and (4).
7. Sling fan drive assembly (11) temporarily and
remove the mounting bolts.
8. Lift off fan drive assembly (11).

4 Fan drive assembly: 250 kg
5. Remove shrouds (5), (6), and (7).
INSTALLATION
removal.
Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
D475A-5 30-217
(2)
DISASSEMBLY AND ASSEMBLY FAN MOTOR
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY
REMOVAL
1. Remove the fan drive assembly. For details, see 3. Remove nut (2). [*2]
REMOVAL OF FAN DRIVE ASSEMBLY.
4. Remove fan (3). [*3]
2. Remove the mounting bolt and lock plate (1). [*1]
5. Remove the 4 mounting bolts and fan motor
assembly (4).
4 Fan motor assembly: 60 kg
30-218 D475A-5
(2)
DISASSEMBLY AND ASSEMBLY FAN MOTOR
INSTALLATION
removal.
[*1]
Be sure to adjust the hole of lock plate (1) by
turning nut (2) in the tightening direction.
3 Mounting nut (2):

[*2]
1,080 1,275 Nm {110 130 kgm}

a After tightening the nut, check dimension d
shown below.
MIN: 2.0 mm
MAX: 4.0 mm
[*3]
a When fitting the fan motor and fan, clean and
degrease them thoroughly.
D475A-5 30-219
(2)
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...................................................................................... 90- 3

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/3) ..................................................................... 90- 5
ELECTRICAL CIRCUIT DIAGRAM (1/8) ...................................................................................................... 90-11
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE CAB ................................................................................... 90-27
D475A-5 90-1
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
D475A-5 90-3
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/3)
D475A-5 90-5
D475A-5 90-7
D475A-5 90-9
(3)
ELECTRICAL CIRCUIT DIAGRAM (1/8)
D475A-5 90-11
D475A-5 90-13
D475A-5 90-15
D475A-5 90-17
D475A-5 90-19
D475A-5 90-21
D475A-5 90-23
D475A-5 90-25
OTHERS ELECTRICAL CIRCUIT DIAGRAM OF INSIDE CAB
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE CAB
D475A-5 90-27

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SEBM033703

MACHINE MODEL SERIAL No.

D475A-5 mount the SDA12V140E-1 engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ........................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

90 OTHERS ................................................................................................................................ 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

If a part cannot be smoothly removed from the

The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

Used to prevent rubber gaskets, rub-

Holtz Used as heat-resisting sealant for re-

Used as lubricant for sliding portion

SYG2-400CA Used for normal temperature, light

Molybdenum Used for heavy load portion

SUNSTAR Used as primer for cab side

"S" is used for high-tempera-

SUNSTAR Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 14.7 1.2 1.5

16 24 235 285 23.5 29.5

27 41 1150 1440 118 147

6 10 5.9 9.8 0.6 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 4.9 2.5 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS