Shop Manual D475a-5

SEN00203-02
BULLDOZER
D475A-5E0
D475ASD-5E0
D475A- 30001
SERIAL NUMBERS and up
D475ASD-30001
SEN00205-02
BULLDOZER 1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model Serial number

D475A-5E0 30001 and up
D475ASD-5E0 30001 and up
00 Index and foreword 1

Index
Composition of shop manual................................................................................................................ 2

Table of contents .................................................................................................................................. 4
D475A, D475ASD-5E0 1
SEN00205-02 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00203-02
00 Index and foreword SEN00204-02

Index SEN00205-02 q
Foreword and general information SEN00206-01 q
01 Specification SEN00207-00
Specification and technical data SEN00208-00
10 Structure, function and maintenance standard SEN00209-00

Engine and cooling system SEN00210-00
Power train, Part 1 SEN00211-00
Undercarriage and frame SEN00213-00
Hydraulic system, Part 1 SEN00214-00
Work equipment SEN00217-00
Cab and its attachments SEN00218-00
Electrical system SEN00219-00
20 Standard value table SEN00220-00

Standard service value table SEN01816-00
30 Testing and adjusting SEN00221-00

Testing and adjusting, Part 1 SEN01817-00
40 Troubleshooting SEN00222-00
Failure code table and fuse locations SEN01821-00
General information on troubleshooting SEN01822-00
Troubleshooting by failure code (Display of code), Part 1 SEN01823-00
2 D475A, D475ASD-5E0

Troubleshooting of electrical system (E-mode) SEN01831-00
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01832-00
Troubleshooting of engine (S-mode) SEN01833-00
50 Disassembly and assembly SEN00223-00

General information on disassembly and assembly SEN02013-00 Q
Engine and cooling system (SAA12V140E-3) SEN02014-00 Q
Engine (SAA12V140E-3) SEN02338-00 Q
Power train, Part 1 SEN02015-00 Q
Power train, Part 2 SEN02016-00 Q
Undercarriage and frame, Part 1 SEN02017-00 Q
Undercarriage and frame, Part 2 SEN02018-00 Q
Hydraulic system SEN02019-00 Q
Work equipment SEN02020-00 Q
Cab and its attachments SEN02021-00 Q
Electrical system SEN02339-00 Q
90 Diagrams and drawings SEN00224-01

Hydraulic diagrams and drawings SEN00225-00
Electrical diagrams and drawings SEN00226-01
D475A, D475ASD-5E0 3
Table of contents 1
00 Index and foreword
Index SEN00205-02
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN00206-01

Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling electric equipment and hydraulic component ........................................................... 11
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table .............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN00208-00
Specification and technical data .................................................................................................. 2
Specification drawings ............................................................................................................. 2
Specifications........................................................................................................................... 3
Weight table ............................................................................................................................. 12
Fuel, coolant and lubricants..................................................................................................... 16
10 Structure, function and maintenance standard

Engine and cooling system SEN00210-00
Engine and cooling system ......................................................................................................... 2
Radiator and oil cooler............................................................................................................. 2
Engine mount........................................................................................................................... 3
Cooling fan pump..................................................................................................................... 4
Cooling fan motor .................................................................................................................... 26
Power train, Part 1....................................................................................................................... 2
Power train............................................................................................................................... 2
Power train hydraulic equipment arrangement diagram .......................................................... 4
Damper and universal joint ...................................................................................................... 6
Power train system .................................................................................................................. 8
General view of power train unit .............................................................................................. 8
Torque converter, PTO............................................................................................................. 10
Torque converter valve ............................................................................................................ 18
Torque converter lockup control system .................................................................................. 28
Scavenging pump .................................................................................................................... 29
Transmission control................................................................................................................ 31
Transmission............................................................................................................................ 32
Power train, Part 2....................................................................................................................... 2
Transmission control valve ...................................................................................................... 2
Transmission clutch ECMV...................................................................................................... 4
Priority valve ............................................................................................................................ 8
Lubricating oil relief valve ........................................................................................................ 10
Torque converter, power train, lubricating oil pump ................................................................. 11
Steering, brake control............................................................................................................. 12
Final drive ................................................................................................................................ 14
4 D475A, D475ASD-5E0
Sprocket................................................................................................................................... 18
Steering unit............................................................................................................................. 21
Steering control valve .............................................................................................................. 32
Steering clutch ECMV, Steering brake ECMV ......................................................................... 34
Parking brake valve ................................................................................................................. 40
Sudden stop prevention valve ................................................................................................. 42
Undercarriage and frame SEN00213-00
Undercarriage and frame ............................................................................................................ 2
Track frame.............................................................................................................................. 2
Recoil spring............................................................................................................................ 4
Idler.......................................................................................................................................... 6
Track roller............................................................................................................................... 8
Carrier roller............................................................................................................................. 12
Track roller bogie ..................................................................................................................... 13
Track shoe ............................................................................................................................... 14
Main frame............................................................................................................................... 18
Suspension.............................................................................................................................. 20
Hydraulic system, Part 1 ............................................................................................................. 2
Work equipment hydraulic equipment arrangement diagram .................................................. 2
PPC control piping diagram..................................................................................................... 6
Work equipment control........................................................................................................... 8
Work equipment pump ............................................................................................................ 10
PPC valve................................................................................................................................ 27
PCCS lever.............................................................................................................................. 38
Control valve............................................................................................................................ 2
CLSS ....................................................................................................................................... 17
Unload valve............................................................................................................................ 20
Introduction of LS pressure ..................................................................................................... 21
LS bypass plug ........................................................................................................................ 22
Pressure compensation valve ................................................................................................. 23
Blade lift valve ......................................................................................................................... 26
Merge-divider valve ................................................................................................................. 34
Self pressure reducing valve ................................................................................................... 36
Pilot solenoid valve.................................................................................................................. 40
Hydraulic tank, hydraulic filter.................................................................................................. 2
Accumulator............................................................................................................................. 4
Work equipment cylinder ......................................................................................................... 6
Piston valve ............................................................................................................................. 8
Quick drop valve...................................................................................................................... 10
Blade control knob (Dual tilt specification)............................................................................... 12
Blade control knob (Superdozer specification) ........................................................................ 13
Pitch and dual solenoid valve .................................................................................................. 14
Pin puller hydraulic circuit diagram .......................................................................................... 15
Pin puller solenoid valve.......................................................................................................... 16
Work equipment .......................................................................................................................... 2
Cylinder stay ............................................................................................................................ 2
Blade ....................................................................................................................................... 4
Ripper equipment .................................................................................................................... 8
D475A, D475ASD-5E0 5

Cab and its attachments.............................................................................................................. 2
Cab mount ............................................................................................................................... 2
Cab .......................................................................................................................................... 3
Air conditioner.......................................................................................................................... 6
Electrical system ......................................................................................................................... 2
Engine control.......................................................................................................................... 2
Engine control system ............................................................................................................. 3
Deceleration potentiometer...................................................................................................... 4
CRI engine control system....................................................................................................... 6
Monitor system ........................................................................................................................ 8
Monitor panel ........................................................................................................................... 11
Sensors.................................................................................................................................... 15
Mode selection system ............................................................................................................ 18
Electrical equipment ................................................................................................................ 24
Steering electronic control system ........................................................................................... 27
VHMS controller....................................................................................................................... 29
Communication (ORB: ORBCOMM) controller/antenna.......................................................... 35
20 Standard value table

Standard service value table SEN01816-00
Standard service value table ....................................................................................................... 2
Standard value table for engine ............................................................................................... 2
Standard value table for chassis .............................................................................................. 3
30 Testing and adjusting

Testing and adjusting, Part 1 ....................................................................................................... 3
Tools for testing, adjusting, and troubleshooting...................................................................... 3
Measuring engine speed ......................................................................................................... 6
Measuring intake air pressure (boost pressure) ...................................................................... 9
Measuring exhaust temperature .............................................................................................. 11
Measuring exhaust gas color................................................................................................... 13
Adjusting valve clearance ........................................................................................................ 15
Testing compression pressure ................................................................................................. 17
Measuring blow-by pressure.................................................................................................... 19
Measuring engine oil pressure................................................................................................. 21
Handling of fuel system devices .............................................................................................. 22
Releasing residual pressure from fuel system......................................................................... 22
Testing fuel pressure................................................................................................................ 23
Handling of reduced cylinder mode operation ......................................................................... 24
Handling of no injection cranking operation............................................................................. 24
Testing fuel return and leak amount......................................................................................... 25
Bleeding air from fuel circuit .................................................................................................... 28
Testing fuel circuit for leakage ................................................................................................. 30
Testing and adjusting alternator belt tension ........................................................................... 31
Testing and adjusting belt tension for air conditioner compressor ........................................... 32
Adjusting fuel control dial and decelerator pedal ..................................................................... 33
Testing and adjusting, Part 2 ....................................................................................................... 3
Measuring power train oil pressure.......................................................................................... 3
Adjusting transmission speed sensor ...................................................................................... 12
Simple method to test brake performance............................................................................... 13
Adjusting brake pedal and parking brake lever........................................................................ 14
Adjusting PCCS lever console position ................................................................................... 17
6 D475A, D475ASD-5E0
Emergency escape method when power train has trouble...................................................... 18

Inspecting wear of sprocket..................................................................................................... 20
Testing and adjusting track shoe tension................................................................................. 21
Testing and adjusting work equipment oil pressure................................................................. 22
Testing and adjusting control circuit basic pressure ................................................................ 33
Measuring PPC valve output pressure and solenoid valve output pressure ........................... 34
Adjusting play of PPC valve .................................................................................................... 40
Measuring outlet pressure of ripper pin puller solenoid valve ................................................. 41
Checking parts which caused hydraulic drift of blade and ripper............................................. 42
Measuring internal leakage of work equipment cylinder.......................................................... 43
Releasing residual pressure from work equipment cylinder .................................................... 44
Bleeding air from work equipment cylinder.............................................................................. 44
Adjusting ripper lever position ................................................................................................. 45
Adjusting work equipment lock lever ....................................................................................... 46
Measuring fan circuit oil pressure............................................................................................ 48
Bleeding air from fan pump ..................................................................................................... 49
Measurement procedure for blade tilt control angle (Dual tiltdozer specification) ................... 50
Measurement procedure for blade tilt control angle (Superdozer specification) ..................... 53
Testing and adjusting operator's cab ....................................................................................... 55
Adjusting blade ........................................................................................................................ 59
Testing and adjusting, Part 3....................................................................................................... 2
Special functions of monitor panel (EMMS)............................................................................. 2
Testing and adjusting, Part 4....................................................................................................... 2
Adjustment method when controller has been replaced.......................................................... 2
Preparation work for troubleshooting for electrical equipment system .................................... 4
Inspection procedure of diode ................................................................................................. 8
Handling of optional devices.................................................................................................... 9
Initialization procedures for VHMS controller .......................................................................... 10
Precautions for replacing VHMS controller.............................................................................. 31
Pm Clinic service ..................................................................................................................... 36
40 Troubleshooting
Failure code table and fuse locations SEN01821-00
Failure code table and fuse locations.......................................................................................... 2
Failure code table .................................................................................................................... 2
Fuse locations ......................................................................................................................... 12
General information on troubleshooting SEN01822-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting ................................................................................... 3
Checks before troubleshooting................................................................................................ 4
Classification and procedures of troubleshooting.................................................................... 5
Contents of troubleshooting table ............................................................................................ 8
Wiring table for connector pin numbers ................................................................................... 10
T-adapter box and T-adapter table .......................................................................................... 39
Troubleshooting by failure code (Display of code), Part 1........................................................... 3
Failure code [1500L0] Transmission clutch: Dual engagement............................................... 3
Failure code [15SAL1] Forward clutch oil pressure:
Command current OFF and fill signal ON............................................................................ 4
Failure code [15SALH] Forward clutch oil pressure:
Command current ON and fill signal OFF............................................................................ 5
Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON ................. 6
D475A, D475ASD-5E0 7
Failure code [15SBLH] Reverse clutch oil pressure:

Command current ON and fill signal OFF ............................................................................ 7
Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON ...... 8
Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF...... 9
Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON ..... 10
Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF..... 11
Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON ..... 12
Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF..... 13
Failure code [1800MW] Power train clutch: Slip ...................................................................... 14
Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON ... 15
Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF... 16
Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON ...... 17
Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF ..... 18
Failure code [2300NR] Brake thermal load: Abnormal heating ............................................... 19
Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON.... 20
Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF ... 21
Failure code [2301NR] Right steering brake thermal load: Abnormal heating......................... 22
Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON ...... 23
Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF...... 24
Failure code [2302NR] Left steering brake thermal load: Abnormal heating ........................... 25
Failure code [AA10NX] Air cleaner: Clogging.......................................................................... 26
Failure code [AB00MA] Battery charge abnormality: Malfunction ........................................... 27
Failure code [B@BAZG] Engine oil: Oil pressure too low........................................................ 28
Failure code [B@BAZK] Engine oil: Oil level reduction ........................................................... 29
Failure code [B@BCNS] Radiator coolant: Overheat .............................................................. 30
Failure code [B@BCZK] Radiator coolant: Level too low ........................................................ 31
Failure code [B@CENS] Power train oil: Overheat ................................................................. 32
Failure code [B@CHZG] Power train oil: Low oil pressure...................................................... 33
Failure code [B@HANS] Hydraulic oil: Overheat..................................................................... 34
Failure code [B@HAZK] Hydraulic oil: Level reduction ........................................................... 35
Failure code [CA111] Engine controller (Left bank): Internal abnormality................................ 4
Failure code [CB111] Engine controller (Right bank): Internal abnormality ............................. 6
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank):
Abnormal speed sensor signal............................................................................................. 8
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank):
Abnormal speed sensor signal............................................................................................. 9
Failure code [CA122] Charge pressure sensor too high (At left bank only):
Excessively high voltage detected ....................................................................................... 10
Failure code [CA123] Charge pressure sensor too low (At left bank only):
Excessively low voltage detected......................................................................................... 12
Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank):
High voltage detection.......................................................................................................... 13
Failure code [CA132] Decelerator pedal sensor too low (At left bank only):
Failure code [CA135] Oil pressure sensor too high (At left bank only):
Failure code [CA141] Oil pressure sensor too low (At left bank only):
Failure code [CA144] Coolant temperature sensor too high:
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Failure code [CA154] Charge temperature sensor too low (At left bank only):
8 D475A, D475ASD-5E0
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank):
Low voltage detection .......................................................................................................... 28
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank):
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank):
High voltage detection ......................................................................................................... 30
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank):
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Excessively low voltage detected ........................................................................................ 34
Failure code [CA227] Sensor power source (2) too high (At left bank):
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank):
High voltage detection ......................................................................................................... 38
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed ........... 40
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Failure code [CA263] Fuel temperature sensor too high (At left bank):
Failure code [CB263] Fuel temperature sensor too high (At right bank):
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit .......................................... 50
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ....................................... 51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection................................... 52
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection ................................ 53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit .......................................... 54
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ....................................... 55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection................................... 56
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection ................................ 57
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit
(At left bank): Disconnection, short circuit............................................................................ 4
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch ....................... 16
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch..................... 17
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit.............. 18
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality ....... 20
D475A, D475ASD-5E0 9
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank):
Failure code [CA441] Power supply voltage abnormally low level (Left bank):
Failure code [CB441] Power supply voltage abnormally low level (Right bank):
Failure code [CA442] Power supply voltage abnormally high level (Left bank):
Failure code [CB442] Power supply voltage abnormally high level (Right bank):
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank):
Abnormally high pressure occurrence.................................................................................. 30
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank):
Abnormally high pressure occurrence.................................................................................. 30
Failure code [CA451] Common rail pressure sensor too high (At left bank):
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank):
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank):
Abnormally low voltage detection......................................................................................... 36
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank):
Abnormally low voltage detection......................................................................................... 36
Failure code [CA553] Common rail pressure too high (1) (At left bank):
Excessively high pressure detected..................................................................................... 37
Failure code [CB553] Common rail pressure too high (1) (At right bank):
Excessively high pressure detected..................................................................................... 38
Failure code [CA554] In-range error in common rail pressure sensor (At left bank):
In-range error ....................................................................................................................... 39
Failure code [CB554] In-range error in common rail pressure sensor (At right bank):
In-range error ....................................................................................................................... 39
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank):
Loss of pressure feed detected............................................................................................ 40
Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank):
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal ..... 48
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal ... 50
Failure code [CA691] Intake air temperature sensor abnormally high level
(Only left bank): High voltage detection ............................................................................... 52
Failure code [CA692] Intake air temperature sensor abnormally low level
(Only left bank): Low voltage detection ................................................................................ 54
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank):
Abnormal phase ................................................................................................................... 55
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank):
Abnormal phase ................................................................................................................... 55
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data........... 3
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data......... 3
Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank):
Abnormal Bkup signal .......................................................................................................... 4
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank):
Bkup signal error .................................................................................................................. 6
Failure code [CA781] Inter-multicontroller communication error (Left bank):
Communication error............................................................................................................ 8
10 D475A, D475ASD-5E0
Failure code [CB781] Inter-multicontroller communication error (Right bank):

Communication error ........................................................................................................... 10
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank):
Distinction error.................................................................................................................... 11
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank):
Distinction error.................................................................................................................... 12
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit
(Right bank): Disconnection/Short circuit............................................................................. 14
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error ................... 26
Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level
(Only left bank): High voltage detection ............................................................................... 28
Failure code [CA2186] Decelerator pedal sensor power source too low
(At left bank only): Excessively low voltage detected........................................................... 30
Failure code [D110KA] Battery relay: Disconnection ............................................................... 32
Failure code [D110KB] Battery relay: Short circuit .................................................................. 34
Failure code [D130KA] Neutral safety relay: Disconnection.................................................... 36
Failure code [D130KB] Neutral safety relay: Short circuit ....................................................... 38
Failure code [D161KA] Back-up alarm relay: Disconnection ................................................... 40
Failure code [D161KB] Back-up alarm relay: Short circuit ...................................................... 42
Failure code [D182KZ] Preheater relay: Disconnection or short circuit ................................... 44
Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection ................. 46
Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit ..................... 48
Failure code [D5ZRKA] Snap shot switch: Disconnection....................................................... 50
Failure code [D5ZRKB] Snap shot switch: Short circuit .......................................................... 51
Failure code [DAFRKR] Monitor panel CAN communication: Communication error ............... 52
Failure code [dAFRKR] Monitor panel CAN communication: Communication error................ 54
Failure code [daFRKR] Monitor panel CAN communication: Communication error ................ 56
Failure code [DAQ0KT] Transmission controller: Abnormality in controller............................. 58
Failure code [DAQ1KK] Transmission controller main power supply:
Power supply voltage reduction (Input)................................................................................ 60
Failure code [DAQ2KK] Transmission controller load power supply:
Failure code [DAQ5KK] Transmission controller potentiometer power supply:
Source voltage reduction (input) .......................................................................................... 64
Failure code [DAQ6KK] Transmission controller sensor power supply:
Failure code [DAQ9KQ] Transmission controller type collation:
Type select signal inconsistency.......................................................................................... 67
Failure code [DAQRKR] Transmission controller sensor CAN communication:
Communication error (Objective component system abnormality) ...................................... 68
Failure code [DAQSKR] Transmission controller S-NET communication:
Defective communication (Abnormality in objective component system) ............................ 70
D475A, D475ASD-5E0 11

Failure code [DB2RKR] Engine controller (Left bank) CAN communication:
Communication error............................................................................................................ 4
Failure code [DB30KT] Steering controller: Abnormality in controller...................................... 6
Failure code [DB31KK] Steering controller main power supply:
Failure code [DB32KK] Steering controller load power supply:
Failure code [DB35KK] Steering controller potentiometer power supply:
Failure code [DB36KK] Steering controller sensor power supply:
Failure code [DB39KQ] Steering controller type selection:
Type select signal inconsistency .......................................................................................... 16
Failure code [dB3RKR] Steering controller CAN communication: Communication error......... 18
Failure code [DB3SKR] Steering controller S-NET communication:
Defective communication (Abnormality in objective component system) ............................ 20
Failure code [DBB0KK] (or LED of VHMS controller indicates "n9" o "01")
VHMS controller: Lowering of source voltage ...................................................................... 22
Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o "11")
Check of VHMS controller model: Disagreement of model selection................................... 23
VHMS controller: Lowering of direct source voltage ............................................................ 24
Failure code [DBB5KP] (or LED of VHMS controller indicates "n9" o "04")
VHMS sensor power supply (5 V): Lowering of output voltage............................................ 25
VHMS sensor power supply (24 V): Lowering of output voltage.......................................... 26
VHMS sensor power supply (12 V): Lowering of output voltage.......................................... 28
Failure code [DBBQKR] (or VHMS_LED display "n8" o "02")
VHMS KOM-NET: Communication error .............................................................................. 30
Failure code [dbBRKR] VHMS controller CAN communication: Communication error ........... 32
Failure code [DD12KA] Shift up switch: Disconnection ........................................................... 34
Failure code [DD12KB] Shift up switch: Short circuit............................................................... 36
Failure code [DD13KA] Shift down switch: Disconnection....................................................... 38
Failure code [DD13KB] Shift down switch: Short circuit .......................................................... 40
Failure code [DD14KA] Parking brake lever switch: Disconnection ........................................ 42
Failure code [DD14KB] Parking brake lever switch: Short circuit ............................................ 44
Failure code [DDB9L4] Reverse switch: Signal disagreement ................................................ 46
Failure code [DDK3L4] Forward switch: Signal disagreement ................................................ 48
Failure code [DDK5KA] Gearshift switch: Disconnection ........................................................ 50
Failure code [DDK5KB] Gearshift switch: Short circuit ............................................................ 52
Failure code [DDN2LD] (Blade tilt right oil pressure switch system:
Switch is ON for long time.................................................................................................... 54
Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time .. 55
Failure code [DDN7KA] Blade pitch switch: Disconnection ..................................................... 56
Failure code [DDN7KB] Blade pitch switch: Short circuit......................................................... 58
Failure code [DDN9KA] Blade tilt switch: Disconnection ......................................................... 60
Failure code [DDN9KB] Blade tilt switch: Short circuit............................................................. 62
Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time ... 64
Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time ........ 65
Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time ....... 66
Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time ............. 67
Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time ....... 68
Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time ... 69
12 D475A, D475ASD-5E0

Failure code [DDQ2KA] Parking brake lever switch: Disconnection ....................................... 4
Failure code [DDQ2KB] Parking brake lever switch: Short circuit ........................................... 6
Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals ........................ 8
Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals ......................... 9
Failure code [DDT5KA] Neutral switch: Disconnection ........................................................... 10
Failure code [DDT5KB] Neutral switch: Short circuit ............................................................... 12
Failure code [DDT5KQ] Lever specification selection:
Model selection signal disagreement................................................................................... 14
Failure code [DGS1KX] Hydraulic oil temperature sensor:
Input signal is out of normal range....................................................................................... 15
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection ........................... 16
Failure code [DGT1KX] Power train oil temperature sensor:
Input signal is out of normal range....................................................................................... 18
Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front):
Disconnection (or LED of VHMS controller indicates "n3" o "12") ...................................... 20
Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear):
Disconnection (or LED of VHMS controller indicates "n3" o "22") ...................................... 22
Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front):
Short circuit (or LED of VHMS controller indicates "n3" o "11") .......................................... 24
Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" o "21")
Left bank exhaust temperature sensor system (Rear): Short circuit .................................... 26
Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o "24")
Right bank exhaust temperature sensor system (Front): Disconnection ............................. 28
Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o "26")
Right bank exhaust temperature sensor system (Rear): Disconnection.............................. 30
Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o "23")
Right bank exhaust temperature sensor system (Front): Short circuit................................. 32
Right bank exhaust temperature sensor system (Rear): Short circuit ................................. 34
Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection ......... 36
Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit............. 37
Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection......... 38
Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit ............ 39
Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o "32")
Blow-by pressure sensor system: Disconnection ................................................................ 40
Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o "31")
Blow-by pressure sensor system: Hot short ........................................................................ 41
Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o "14")
Transmission oil pressure sensor: Out of input signal range ............................................... 42
Failure code [DK01KA] Left yoke angle sensor: Disconnection .............................................. 43
Failure code [DK01KB] Left yoke angle sensor: Short circuit .................................................. 44
Failure code [DK03KA] Right yoke angle sensor: Disconnection ............................................ 45
Failure code [DK03KB] Right yoke angle sensor: Short circuit ............................................... 46
Failure code [DK10KA] Fuel dial: Disconnection ..................................................................... 47
Failure code [DK10KB] Fuel dial: Short circuit ........................................................................ 48
Failure code [DK30KA] Steering potentiometer (1): Disconnection......................................... 49
Failure code [DK30KB] Steering potentiometer (1): Short circuit ............................................ 50
Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range ......... 51
Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit ................. 52
Failure code [DK30L8] Steering potentiometer (1): See table ................................................. 53
Failure code [DK31KA] Steering potentiometer (2): Disconnection......................................... 54
Failure code [DK31KB] Steering potentiometer (2): Short circuit ............................................ 55
Failure code [DK40KA] Brake potentiometer: Disconnection .................................................. 3
Failure code [DK40KB] Brake potentiometer: Short circuit...................................................... 4
D475A, D475ASD-5E0 13
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range ... 5
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit.......... 6
Failure code [DK55L8] Forward-reverse potentiometer: See table ......................................... 7
Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection............................ 8
Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit .............................. 10
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection............................ 12
Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit .............................. 14
Failure code [DK60KA] Acceleration sensor: Disconnection ................................................... 16
Failure code [DK60KB] Acceleration sensor: Short circuit....................................................... 18
Failure code [DKH1KA] Pitch angle sensor: disconnection ..................................................... 19
Failure code [DKH1KB] Pitch angle sensor: Short circuit ........................................................ 20
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range.................................... 21
Failure code [DLF1KA] Torque converter output speed sensor: Disconnection ...................... 22
Failure code [DLT3KA] Transmission output speed sensor: Disconnection ............................ 23
Failure code [dLT3KA] Transmission output speed sensor: Disconnection............................. 24
Failure code [DLT3KB] Transmission output speed sensor: Short circuit................................ 26
Failure code [DV00KB] Caution buzzer: Short circuit .............................................................. 27
Failure code [DW55KA] Blade pitch back solenoid: Disconnection......................................... 28
Failure code [DW55KB] Blade pitch back solenoid: Short circuit ............................................ 29
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection ....................................... 30
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit ........................................... 31
Failure code [DW56KY] Blade pitch dump solenoid: Hot short ............................................... 32
Failure code [DW57KA] Left tilt limit solenoid: Disconnection ................................................. 33
Failure code [DW57KB] Left tilt limit solenoid: Short circuit ..................................................... 34
Failure code [DW57KY] Left tilt limit solenoid: Hot short ......................................................... 35
Failure code [DW58KA] Right tilt limit solenoid: Disconnection............................................... 36
Failure code [DW58KB] Right tilt limit solenoid: Short circuit .................................................. 37
Failure code [DW58KY] Right tilt limit solenoid: Hot short....................................................... 38
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection.......................................... 39
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit ............................................. 40
Failure code [DW59KY] Dual tilt selector solenoid: Hot short.................................................. 41
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection ................................... 42
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit ....................................... 43
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short ........................................... 44
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification):
Disconnection....................................................................................................................... 45
Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification):
Short circuit .......................................................................................................................... 46
Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification):
Hot short............................................................................................................................... 47
Failure code [DW7BKA] Fan reverse solenoid: Disconnection................................................ 48
Failure code [DW7BKB] Fan reverse solenoid: Short circuit ................................................... 49
Failure code [DW7BKY] Fan reverse solenoid: Hot short........................................................ 50
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection ................................... 51
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit....................................... 52
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short ........................................... 53
Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection............................. 54
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit ................................ 55
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short..................................... 56
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection ............................................... 57
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ................................................... 58
Failure code [DWN5KY] Fan pump solenoid 1: Hot short ....................................................... 59
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection............................................... 60
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit .................................................. 61
Failure code [DWNCKY] Fan pump solenoid 2: Hot short....................................................... 62
Failure code [DXE0KA] LS set solenoid: Disconnection.......................................................... 3
14 D475A, D475ASD-5E0
Failure code [DXE0KB] LS set solenoid: Short circuit ............................................................. 4

Failure code [DXE0KY] LS set solenoid: Hot short ................................................................. 5
Failure code [DXH1KA] Lock-up solenoid: Disconnection....................................................... 6
Failure code [DXH1KB] Lock-up solenoid: Short circuit .......................................................... 7
Failure code [DXH1KY] Lockup solenoid: Hot short................................................................ 8
Failure code [DXH4KA] 1st clutch ECMV: Disconnection ....................................................... 9
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ........................................................... 10
Failure code [DXH4KY] 1st clutch ECMV: Hot short ............................................................... 11
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ...................................................... 12
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit.......................................................... 13
Failure code [DXH5KY] 2nd clutch ECMV: Hot short .............................................................. 14
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ....................................................... 15
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit........................................................... 16
Failure code [DXH6KY] 3rd clutch ECMV: Hot short ............................................................... 17
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection............................................... 18
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit .................................................. 19
Failure code [DXH7KY] Reverse clutch ECMV: Hot short....................................................... 20
Failure code [DXH8KA] Forward clutch ECMV: Disconnection ............................................... 21
Failure code [DXH8KB] Forward clutch ECMV: Short circuit................................................... 22
Failure code [DXH8KY] Forward clutch ECMV: Hot short ....................................................... 23
Failure code [DXH9KA] Right steering clutch ECMV: Disconnection ...................................... 24
Failure code [DXH9KB] Right steering clutch ECMV: Short circuit.......................................... 25
Failure code [DXH9KY] Right steering clutch ECMV: Hot short .............................................. 26
Failure code [DXHAKA] Left steering clutch ECMV: Disconnection ........................................ 27
Failure code [DXHAKB] Left steering clutch ECMV: Short circuit............................................ 28
Failure code [DXHAKY] Left steering clutch ECMV: Hot short ................................................ 29
Failure code [DXHBKA] Right brake ECMV: Disconnection.................................................... 30
Failure code [DXHBKB] Right brake ECMV: Short circuit ....................................................... 31
Failure code [DXHBKY] Right brake ECMV: Hot short............................................................ 32
Failure code [DXHCKA] Left brake ECMV: Disconnection ...................................................... 33
Failure code [DXHCKB] Left brake ECMV: Short circuit.......................................................... 34
Failure code [DXHCKY] Left brake ECMV: Hot short .............................................................. 35
Failure code [F@BBZL] (or VHMS_LED display "n3" o "38")
Engine blow-by pressure sensor: Abnormally high pressure occurrence ............................ 36
Failure code [F@BYNS] (or VHMS_LED display "n3" o "61")
Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise ................. 38
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71")
Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise .................. 40
Failure code [F@BZNS] (or VHMS_LED display "n3" o "38")
Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise ............... 42
Failure code [f@BZNS] (or VHMS_LED display "n3" o "39")
Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise ................ 44
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62")
Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise ................. 46
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72")
Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise .................. 48
Failure code [F@BZNR] (or VHMS_LED display "n3" o "82")
Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise ............... 50
Failure code [f@BZNR] (or VHMS_LED display "n3" o "92")
Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise ................ 52
Troubleshooting of electrical system (E-mode) SEN01831-00
Troubleshooting of electrical system (E-mode) ........................................................................... 2
Contents of troubleshooting table ............................................................................................ 2
E-1 The engine does not start. ................................................................................................ 3
E-2 The preheater does not operate. ...................................................................................... 7
D475A, D475ASD-5E0 15
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01832-00

Troubleshooting of hydraulic and mechanical system (H-mode)................................................. 3
Information in troubleshooting table......................................................................................... 3
H-1 No force (no drawbar pull) ................................................................................................ 4
H-2 No travel (at 2nd or 3rd speed) ......................................................................................... 6
H-3 No travel at all gear speeds .............................................................................................. 7
H-4 Machine travels only in one direction forward or in reverse.............................................. 8
H-5 Large time lag at gear speed shifting or forward-reverse shifting ..................................... 9
H-6 Steering is not possible ..................................................................................................... 10
H-7 Steering is possible only on one side................................................................................ 11
H-8 Steering overrun occurs .................................................................................................... 12
H-9 Brake does not work ......................................................................................................... 13
H-10 Torque converter is not lock-up....................................................................................... 14
H-11 Power train oil is overheated ........................................................................................... 15
H-12 All work equipment speeds are slow............................................................................... 16
H-13 Work equipment does not move ..................................................................................... 17
H-14 Blade lift speed is slow or lacks power ........................................................................... 18
H-15 Blade tilt speed is slow or lacks power ........................................................................... 19
H-16 Ripper lift speed is slow or lacks power .......................................................................... 20
H-17 Ripper tilt speed is slow or lacks power .......................................................................... 21
H-18 Excessive hydraulic drift of blade lift ............................................................................... 22
H-19 Excessive hydraulic drift of blade tilt ............................................................................... 23
H-20 Excessive hydraulic drift of ripper lift............................................................................... 24
H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine) .................. 24
H-22 Blade pitch does not work (dual tilt attachment machine)............................................... 25
H-23 Abnormal sound comes out from around work equipment pump ................................... 25
Troubleshooting of engine (S-mode) SEN01833-00
Troubleshooting of engine (S-mode) ........................................................................................... 3
Method of using troubleshooting chart..................................................................................... 3
S-1 Starting performance is poor ............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operations......................................................................................... 11
S-5 Engine does not rotate smoothly....................................................................................... 12
S-6 Engine lacks output (or lacks power) ................................................................................ 13
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 15
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 16
S-9 Oil becomes contaminated quickly.................................................................................... 17
S-10 Fuel consumption is excessive ....................................................................................... 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 19
S-12 Oil pressure drops........................................................................................................... 20
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 21
S-14 Coolant temperature becomes too high (overheating).................................................... 22
S-15 Abnormal noise is made.................................................................................................. 23
S-16 Vibration is excessive...................................................................................................... 24
50 Disassembly and assembly

General information on disassembly and assembly SEN02013-00
General information on disassembly and assembly.................................................................... 2
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tool list ......................................................................................................................... 7
Sketches of special tools ......................................................................................................... 14
Engine and cooling system (SAA12V140E-3) SEN02014-00
Engine and cooling system (SAA12V140E-3)............................................................................. 2
Removal and installation of engine assembly.......................................................................... 2
Removal and installation of radiator assembly ........................................................................ 6
16 D475A, D475ASD-5E0
Removal and installation of aftercooler assembly ................................................................... 8

Removal and installation of radiator guard assembly .............................................................. 10
Removal and installation of fuel tank assembly....................................................................... 12
Removal and installation of engine hood assembly ................................................................ 13
Removal and installation of fan drive assembly ...................................................................... 15
Removal and installation of fan motor assembly ..................................................................... 16
Engine (SAA12V140E-3) SEN02338-00
Engine (SAA12V140E-3) ............................................................................................................ 2
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of cylinder head assembly ........................................................... 8
Removal and installation of fuel injector assembly .............................................................. 19
Removal and installation of engine front seal ...................................................................... 25
Removal and installation of engine rear seal ....................................................................... 26
Power train, Part 1 ...................................................................................................................... 2
Removal and installation of damper assembly ........................................................................ 2
Disassembly and assembly of damper assembly.................................................................... 4
Removal and installation of power train unit assembly............................................................ 7
Removal and installation of PTO, torque converter assembly................................................. 10
Disconnection and connection of PTO, torque converter assembly ........................................ 12
Disassembly and assembly of torque converter assembly...................................................... 14
Disassembly and assembly of PTO assembly......................................................................... 23
Removal and installation of TORQFLOW transmission assembly .......................................... 29
Disassembly and assembly of TORQFLOW transmission assembly ...................................... 30
Power train, Part 2 ...................................................................................................................... 2
Disassembly and assembly of steering case assembly .......................................................... 2
Disassembly and assembly of steering clutch, brake assembly.............................................. 14
Disassembly and assembly of transfer gear housing assembly.............................................. 20
Removal and installation of power train pump assembly ........................................................ 24
Removal and installation of scavenging pump assembly ........................................................ 24
Removal and installation of torque converter oil cooler ........................................................... 25
Removal and installation of torque converter valve assembly................................................. 26
Disassembly and assembly of torque converter valve assembly ............................................ 27
Removal and installation of transmission control valve assembly ........................................... 31
Disassembly and assembly of transmission control valve assembly (ECMV assembly) ........ 32
Removal and installation of steering control valve assembly .................................................. 35
Disassembly and assembly of steering control valve assembly .............................................. 36
Removal and installation of final drive assembly ..................................................................... 38
Disassembly and assembly of final drive assembly ................................................................ 40
Undercarriage and frame, Part 1 SEN02017-00
Undercarriage and frame, Part 1................................................................................................. 2
Removal and installation of track frame assembly .................................................................. 2
Disassembly and assembly of idler assembly ......................................................................... 4
Removal and installation of recoil spring assembly ................................................................. 7
Disassembly and assembly of recoil spring assembly ............................................................ 11
Removal and installation of track roller assembly ................................................................... 13
Disassembly and assembly of track roller assembly ............................................................... 15
Removal and installation of carrier roller assembly ................................................................. 17
Disassembly and assembly of carrier roller assembly............................................................. 18
Removal and installation of bogie assembly ........................................................................... 21
Disassembly and assembly of bogie assembly ....................................................................... 25
Removal and installation of No.1 bogie assembly ................................................................... 27
Undercarriage and frame, Part 2 SEN02018-00
Undercarriage and frame, Part 2................................................................................................. 2
Expansion and installation of track shoe assembly ................................................................. 2
D475A, D475ASD-5E0 17
Overall disassembly and overall assembly of track shoe ........................................................ 5

Press-fitting jig dimension table for link press.......................................................................... 21
Field disassembly and assembly of one link............................................................................ 22
Disassembly and assembly of master link............................................................................... 27
Removal and installation of pivot shaft assembly .................................................................... 31
Removal and installation of equalizer bar................................................................................ 32
Disassembly and assembly of equalizer bar bushing.............................................................. 35
Hydraulic system SEN02019-00
Hydraulic system ......................................................................................................................... 2
Removal and installation of hydraulic pump assembly ............................................................ 2
Removal and installation of hydraulic valve assembly............................................................. 4
Disassembly and assembly of control valve ............................................................................ 5
Disassembly and assembly of merge divider valve and self pressure reducing valve assembly 9
Removal and installation of PPC relief valve assembly ........................................................... 11
Disassembly and assembly of hydraulic cylinder assembly .................................................... 12
Disassembly and assembly of ripper pin puller cylinder assembly.......................................... 17
Work equipment .......................................................................................................................... 2
Removal and installation of blade assembly............................................................................ 2
Disassembly and assembly of giant ripper assembly .............................................................. 4
Cab and its attachments.............................................................................................................. 2
Removal and installation of ROPS guard ................................................................................ 2
Removal and installation of operator’s cab assembly.............................................................. 3
Removal and installation of floor frame assembly ................................................................... 4
Electrical system ......................................................................................................................... 2
Removal and installation of controller assembly...................................................................... 2
Removal and installation of engine controller assembly (left).................................................. 3
Removal and installation of air conditioner condenser assembly ............................................ 4
Removal and installation of air conditioner compressor assembly .......................................... 5
Removal and installation of air conditioner unit ....................................................................... 7
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN00225-00
Hydraulic diagrams and drawings ............................................................................................... 3
Power train hydraulic circuit diagram....................................................................................... 3
Hydraulic circuit diagram (1/3) ................................................................................................. 5
Electrical diagrams and drawings SEN00226-01
Electrical diagrams and drawings................................................................................................ 3
Electrical circuit diagram (1/13) ............................................................................................... 3
Electrical circuit diagram (10/13) ............................................................................................. 21
Electrical circuit diagram (11/13).............................................................................................. 23
Electrical circuit diagram of inside cab..................................................................................... 29
18 D475A, D475ASD-5E0
Connector arrangement diagram............................................................................................. 31
D475A, D475ASD-5E0 19
SEN00205-02
D475A, D475ASD-5E0 Bulldozer

Form No. SEN00205-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (01)
20
SEN00206-01
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
D475A, D475ASD-5E0 1
Safety notice 1 (Rev. 2006/09)

Important safety notice
Proper service and repair are 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 dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
Wearing protective goggles
wear loose work clothes, or clothes with 7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc. Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 D475A, D475ASD-5E0
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When larly careful to check that they are
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electric wiring.
Damaged wiring may cause electric fires.
D475A, D475ASD-5E0 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 D475A, D475ASD-5E0
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
D475A, D475ASD-5E0 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant
gas (R134a).
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or adding
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 D475A, D475ASD-5E0
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
D475A, D475ASD-5E0 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 D475A, D475ASD-5E0
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
D475A, D475ASD-5E0 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 D475A, D475ASD-5E0
Handling electric equipment and hydraulic component 1

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).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors 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,
during 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
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
D475A, D475ASD-5E0 11
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 sol-
dering 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 struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. 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-cir-
cuited 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 connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 D475A, D475ASD-5E0
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
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 connec-

tors
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 disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
D475A, D475ASD-5E0 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
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 connector, 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 break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 D475A, D475ASD-5E0
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
D475A, D475ASD-5E0 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, 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
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove 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 related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 D475A, D475ASD-5E0
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting 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 con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
D475A, D475ASD-5E0 17
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 circuit. When adding hydraulic oil, or when disassembling 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 check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked 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
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect 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

refilling 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.
18 D475A, D475ASD-5E0
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. (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 secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
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 ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D475A, D475ASD-5E0 19
Connectors newly used for Tier 3 engines

1. Slide lock type 2. Pull lock type (PACKARD-2)
(FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engine
q 107 – 170, 12V140 engines q Various temperature sensors
q Various pressure sensors and NE Example)
speed sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure in intake manifold: Fuel temperature sensor: TFUEL
PIM (125, 170, 12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL Coolant temperature sensor: TWTR,
(125, 170, 12V140 engines) etc.
Oil pressure switch Disconnect the connector by pulling lock
(107, 114 engines) (B) (on the wiring harness side) of connec-
Ne speed sensor of flywheel housing: tor (2) outward.
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part (A) does not float. In this
case, float part (A) with a small screw-
driver while pressing lock (L2), and
then pull out connector (1) toward
you.
20 D475A, D475ASD-5E0
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
D475A, D475ASD-5E0 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 D475A, D475ASD-5E0
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
D475A, D475ASD-5E0 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 D475A, D475ASD-5E0
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
D475A, D475ASD-5E0 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
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.
Nominal Dimensions
Part Number
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
26 D475A, D475ASD-5E0
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q 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
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 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

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
D475A, D475ASD-5E0 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 D475A, D475ASD-5E0
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the 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.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a 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. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D475A, D475ASD-5E0 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 D475A, D475ASD-5E0
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
D475A, D475ASD-5E0 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

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 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

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
a Fig. A a Fig. B
32 D475A, D475ASD-5E0
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

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

Nominal 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 connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

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

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 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} 127.4 {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}
D475A, D475ASD-5E0 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
No. of across Thread diame-
Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(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 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
34 D475A, D475ASD-5E0
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
D475A, D475ASD-5E0 35
Conversion table 1
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), and then draw a hori-
zontal 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 2 lines cross as (C). This point (C) gives the value when converting from
millimeters 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 it 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 (B)

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
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
36 D475A, D475ASD-5E0
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
Liters to U.S. Gallons

1 l = 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
D475A, D475ASD-5E0 37
Liters to U.K. Gallons

1 l = 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 7.699 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
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
38 D475A, D475ASD-5E0
kg/cm2 to lb/in2
1 kg/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 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D475A, D475ASD-5E0 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°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 81 177.8
–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 60 140.0 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
40 D475A, D475ASD-5E0
D475A, D475ASD-5E0 41
SEN00206-01

© 2007 KOMATSU
All Rights Reserved
42
SEN00208-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 2
Specification drawings.......................................................................................................................... 2
Specifications ....................................................................................................................................... 3
Weight table ....................................................................................................................................... 12
Fuel, coolant and lubricants ............................................................................................................... 16
D475A, D475ASD-5E0 1
SEN00208-00 01 Specification
Specification and technical data 1

Specification drawings 1
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 (including ROPS) mm 4,646 4,646 4,646
C Overall width mm 5,265 6,205 6,465
2 D475A, D475ASD-5E0
Specifications 1
Semi-U tiltdozer and full-U tiltdozer specifications
Machine model D475A-5E0
Serial Number 30001 and up
Machine weight
• Tractor 83,510
Weight
• Above + Semi-U tiltdozer kg 100,010

• Above + Variable giant ripper 107,370
• Above + ROPS cab + Air conditioner 108,310
Min. turning radius m 4.6
Gradeability deg. 30
Stability (Front, Rear, 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 127.5 {1.30}
Semi-U dozer 152.7 {1.56}
pressure
Ground
Semi-U dozer + Variable giant ripper kPa {kg/cm }

2
163.9 {1.67}
Above + ROPS cab + Air conditioner 165.3 {1.69}
+ 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 3,620
Overall
width
Semi-U dozer mm 5,265

Dimensions
Full-U dozer 6,205

Up to ROPS top 4,646
Overall
height
Up to exhaust pipe end mm 4,546

Up to exhaust duct top 3,861
Track gauge 2,770
Length of track on ground 4,524
mm
Track shoe width 710
Minimum ground clearance 711
D475A, D475ASD-5E0 3
Model name Komatsu SAA12V140E-3

Type 4-cycle, water-cooled, V-type, direct-injection
engine with turbocharger and aftercooler
Number of cylinder–Bore x Stroke mm 12–140 x 165
Total displacement l {cc} 30.48 {30,480}
Rated output kW/rpm {HP/rpm} 664/2,000 {890/2,000}
Performance
Max. torque Nm/rpm {kgm/rpm} 3,825/1,400 {390/1,400}

Engine
High idle rpm 2,150

Low idle rpm 600
Min. fuel consumption ratio g/kWh {g/HPh} 215 {160}
(at rated output)
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 100 A
Battery 12V, 220 Ah x 4
Type of radiator core D-type
3-element, 1-stage, 1-phase type

Torque converter
(With lockup 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
Final drive
gear, splash lubrication type
Type of suspension Hard, equalizing beam type

Undercarriage
Carrier roller 2 pieces on each side
Track roller 8 pieces on each side
Assembly type single grouser shoe,

Track shoe 41 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)
4 D475A, D475ASD-5E0
Max. pressure MPa {kg/cm2} 27.5 {280}

Work equipment
Type Variable swash plate type:

pump
2 pcs. (HPV 125 + 125)

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

Cooling fan pump MPa {kg/cm } 2
Max. discharge pressure: 17.5 {178}
l/min/rpm Theoretical discharge pressure: 178/1,934
Fixed swash plate type (LMF 180)
Cooling fan motor
Work equipment hydraulic system
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 Double acting 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, D475ASD-5E0 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)
6 D475A, D475ASD-5E0
Hydraulic semi-U tiltdozer

Type
Hydraulic full-U tiltdozer
Blade supporting method Brace type (Right tilt cylinder)
Max. lift above ground mm 1,676
Performance
Max. drop below ground mm 954

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. 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 1,124

Max. lift mm 1,196
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 1,744

Max. lift mm 1,196
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, D475ASD-5E0 7
Superdozer specification
Machine model D475ASD-5E0
Machine weight
Weight
• Tractor 84,430
kg
• Superdozer + ROPS cab + Air conditioner 113,120
+ Counterweight
Min. turning radius m 4.6
Gradeability deg. 30
Stability (Front, Rear, 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 113.0 {1.15}
pressure
Ground
Superdozer + ROPS cab + kPa {kg/cm }

2
151.4 {1.54}
Air conditioner + Counterweight
Overall
Tractor 6,680
length
mm
Superdozer + Counterweight 10,525
Overall
Tractor 3,620
width
mm
Superdozer 6,465
Dimensions
Up to ROPS top 4,646

Overall
height
Up to exhaust pipe end mm 4,546

Up to exhaust duct top 3,861
Track gauge 2,770
Length of track on ground 4,524
mm
Track shoe width 810
Minimum ground clearance 711
8 D475A, D475ASD-5E0
Model name Komatsu SAA12V140E-3

Type 4-stroke, water-cooled, V-type, direct-injection
engine with turbocharger and aftercooler
Number of cylinder–Bore x Stroke mm 12–140 x 165
Total displacement l {cc} 30.48 {30,480}
Rated output kW/rpm {HP/rpm} 677/2,000 {908/2,000}
Max. torque Nm/rpm {kgm/rpm} 3,825/1,400 {390/1,400}
Performance
Engine
High idle rpm 2,150

Low idle rpm 600
Min. fuel consumption ratio g/kWh {g/HPh} 215 {160}
(at rated output)
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 lockup 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 8 pieces on each side

Assembly type single grouser shoe,
Track shoe 41 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, D475ASD-5E0 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)

Cooling fan pump MPa {kg/cm } 2
Max. discharge pressure: 17.5 {178}
l/min/rpm Theoretical discharge pressure: 178/1,934
Fixed swash plate type (LMF 180)

Cooling fan motor
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 Double acting 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)
10 D475A, D475ASD-5E0
Type Hydraulic superdozer (Pitchdozer)

Blade supporting method Cylinder type

Performance

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

Max. pitch dump angle deg. 15
Superdozer

Dimensions

Angle of blade cutting edge deg. 42 – 67
D475A, D475ASD-5E0 11
Weight table 1
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 4,115

• Engine assembly 3,900
• Damper assembly 215
Main radiator assembly 485
Aftercooler assembly 30
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
• Cooling 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) 13,190
• Track frame 2,976
• Idler assembly (Each side) 708
• Track roller assembly (1 single flange) 248
• Track roller assembly (1 double flange) 237
• Carrier roller assembly (1 pc.) 106
Track shoe assembly (710 mm) 13,530
Pivot shaft assembly (each side) 370
Equalizer bar 733
Hydraulic tank assembly 290
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.
12 D475A, D475ASD-5E0
Unit: kg
Radiator guard assembly 4,550

• Radiator guard 2,530
• Blade lift cylinder assembly (Each side) 509
• Cooling 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, D475ASD-5E0 13
Superdozer specification
Unit: kg
Engine and damper assembly 4,115

• Engine assembly 3,900
• Damper assembly 215
Main radiator assembly 485
Aftercooler assembly 30
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
• Cooling 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) 13,190
• Track frame 2,976
• Idler assembly (Each side) 708
• Track roller assembly (1 single flange) 248
• Track roller assembly (1 double flange) 237
• Carrier roller assembly (1 pc.) 106
Track shoe assembly (810 mm) 14,450
Pivot shaft assembly (each side) 370
Equalizer bar 733
Hydraulic tank assembly 290
Control valve 195
Blade lift cylinder assembly (Each side) 509
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
• Blade lift cylinder assembly (Each side) 509
• Cooling fan motor 65
14 D475A, D475ASD-5E0
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, D475ASD-5E0 15
Fuel, coolant and lubricants 1

a For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
16 D475A, D475ASD-5E0
Unit: l
D475A, D475ASD-5E0
Refilling points
Specified capacity Refill capacity
Engine oil pan 126 121
Damper case 2.2 2.2
Power train case 410 210
Final drive case (each) 75 75
Hydraulic system
420 170
(with blade, without ripper)
Cooling system
210 —
(including reservoir tank)
Fuel tank 1670 —
D475A, D475ASD-5E0 17
SEN00208-00

© 2006 KOMATSU
All Rights Reserved
18
SEN00210-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Radiator and oil cooler ......................................................................................................................... 2
Engine mount ....................................................................................................................................... 3
Cooling fan pump ................................................................................................................................. 4
Cooling fan motor............................................................................................................................... 26
D475A, D475ASD-5E0 1
SEN00210-00 10 Structure, function and maintenance standard
Engine and cooling system 1

Radiator and oil cooler 1
1. Main radiator
2. Sub radiator
3. Turbocharger
4. Engine
5. Power train oil cooler
6. Water pump
2 D475A, D475ASD-5E0
Engine mount 1
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, D475ASD-5E0 3
Cooling fan pump 1

Type: LPV90 + 30
DC: Discharge port

SC: Suction port
1. LPV90 Hydraulic pump

4 D475A, D475ASD-5E0
DC: Discharge port

SC: Suction port
6 D475A, D475ASD-5E0
IM: Control current input connector 1. Shaft

PA: Pump discharge port 2. Cradle
PD1: Drain port 3. Case
PD2: Drain port (Plug) 4. Rocker cam
PDA: Breather 5. Shoe
PEN: Control pressure pick-up port (Plug) 6. Piston
PEPC: EPC basic pressure input port 7. Cylinder block
PS: Pump suction port 8. Valve plate
9. Spring
10. Servo piston
D475A, D475ASD-5E0 7
Function Structure
q The rotation and torque of the engine are q Cylinder block (7) is supported on shaft (1)
transmitted to the shaft of this pump. Then, through spline (C). Shaft (1) is supported on
this pump converts the rotation and torque into the front and rear bearings.
hydraulic energy and discharges hydraulic oil q The end of piston (6) has a spherical hollow
according to the load. which is combined with shoe (5). Piston (6)
q The discharge of this pump can be changed by and shoe (5) form a spherical bearing.
changing the swash plate angle in it. q Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly. Rocker cam
(4) receives high-pressure oil and forms a
static pressure bearing and slides on cylindri-
cal surface B of cradle (2).
q Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
q Cylinder block (7) rotates relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic balance on the valve plate is main-
tained properly.
q The oil in each cylinder of cylinder block (7)
can be sucked and discharged through valve
plate (8).
8 D475A, D475ASD-5E0
Operation q If center line (X) of rocker cam (4) is equal to

the axial of cylinder block (7) (the swash plate
1) Operation of pump
angle is 0), there is not a difference between
q Cylinder block (7) rotates together with shaft
volumes (E) and (F) in cylinder block (7) and
(1). Shoe (5) slides on plane (A). At this time,
the oil is not sucked or discharged. (The
rocker cam (4) moves along cylindrical surface
(B). As a result, angle (a) between center line swash plate angle is not set to 0 actually, how-
(X) of rocker cam (4) and the axis of cylinder ever.)
block (7) changes. Angle (a) is called the
swash plate angle.
q In short, swash plate angle (a) is in proportion

to the pump discharge.
q If angle (a) is made between center line (X) of
rocker cam (4) and the axis of cylinder block
(7), plane (A) works as a cam for shoe (5).
q Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
result, each piston (6) sucks and discharges oil
by (F) – (E).
q 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.]
D475A, D475ASD-5E0 9
2) Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (1).
q Servo piston (1) reciprocates straight accord-
ing 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 direction.
q 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).
q PC valve output pressure (PEN) is led in the
pressure chamber on the large-diameter piston
side (lower side).
q 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 piston.
10 D475A, D475ASD-5E0
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, D475ASD-5E0 11
Function
q The PC valve works so the relationship
between the current input to the EPC valve
and pump swash plate angle (a) will be as
shown in the figure below.
12 D475A, D475ASD-5E0
(1) When EPC output pressure is high [When EPC current (i) is large]
14 D475A, D475ASD-5E0
Operation
q The relationship between the EPC valve input
current (i) and EPC valve output pressure (F)
is as shown in the figure below.
q 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).
q Port (f) is connected to port (g) and pump dis-
charge pressure (PA) flows through port (g) to
port (f). Port (f) is disconnected from the drain
circuit.
q Pump discharge pressure (PA) from port (f) of
the PC valve enters chamber (X) on the large
diameter side of servo piston (1).
q 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 dif-
ference in area between both ends of servo
piston (1), however, servo piston (1) moves
toward the minimum swash plate angle side
(upper side).
q If servo piston (1) moves up, piston (4) is

moved to the right through lever (2). Accord-
ingly, spring (6) is compressed and spool (7)
moves to the right.
q If spool (7) moves to the right and port (f) is
disconnected from port (g), servo piston (1)
stops moving up.
q At this time, servo piston (1) stops at a place
higher (nearer to the minimum swash plate
angle) than when the EPC discharge pressure
is low.
D475A, D475ASD-5E0 15
(2) When EPC output pressure is low [When EPC current (i) is small]
16 D475A, D475ASD-5E0
Operation
q If EPC current (i) reduces and the EPC output
pressure lowers, spool (7) is pushed to the
right by the force of spring (6).
q Accordingly, port (g) is disconnected from port
(f) and port (f) is connected to the drain circuit.
q At this time, the oil in chamber (X) on the large
diameter side of servo piston (1) flows through
port (f) of the PC valve to the drain circuit.
q 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, D475ASD-5E0 17
P1: Pump discharge port

PAEPC: EPC output pressure pickup port
PDA2: Breather
PEPC: EPC valve basic pressure input port
PS: Pump suction port
TO: Drain port
18 D475A, D475ASD-5E0
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, D475ASD-5E0 19
Function
q The rotation and torque of the engine are
transmitted 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.
q The discharge of this pump can be changed by
changing the swash plate angle in it.
Structure
q Cylinder block (7) is supported on shaft (1)
through spline (B). Shaft (1) is supported on
the front and rear bearings.
q The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6)
and shoe (5) form a spherical bearing.
q Shoe (5) is kept pressed against plane (A) of
rocket cam (4) and slid circularly. Rocker cam
(4) slides around ball (11).
q Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
q Cylinder block (7) rotates relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic balance on the valve plate is main-
tained properly.
q The oil in each cylinder of cylinder block (7)
can be sucked and discharged through valve
plate (8).
20 D475A, D475ASD-5E0
Operation q If center line (X) of rocker cam (4) is equal to

1) Operation of pump the axial of cylinder block (7) (the swash plate
q Cylinder block (7) rotates together with shaft angle is 0), there is not a difference between
(1). Shoe (5) slides on plane (A). At this time, volumes (E) and (F) in cylinder block (7) and
rocker cam (4) tilts around ball (11). As a the oil is not sucked or discharged. (The
result, angle (a) between center line (X) of swash plate angle is not set to 0 actually, how-
rocker cam (4) and the axis of cylinder block ever.)
(7) changes. Angle (a) is called the swash q In short, swash plate angle (a) is in proportion
plate angle. to the pump discharge.
q If angle (a) is made between center line (X) of
rocker cam (4) and the axis of cylinder block
(7), plane (A) works as a cam for shoe (5).
q Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
result, each piston (6) sucks and discharges oil
by (F) – (E).
q 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.]
D475A, D475ASD-5E0 21
2) Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (10).
q Servo piston (10) reciprocates straight accord-
ing 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).
22 D475A, D475ASD-5E0
3) Servo valve
P: EPC valve basic pressure input port

PE: Control piston pressure output port
PH: Pump discharge pressure input port
T: Drain port
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
D475A, D475ASD-5E0 23
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
q The servo valve works so the relationship
between the current input to the EPC valve
and pump swash plate angle (a) will be as
shown in the figure below.
24 D475A, D475ASD-5E0
q The relationship between the EPC valve input

current (i) and EPC valve output pressure (F)
is as shown in the figure below.
Operation
q The output oil of the EPC valve flows in the pis-
ton chamber (C) to push piston (6). Piston (6)
pushes spool (5) until it is balanced with the
spring.
q Then, land (PE) of the servo piston pressure
passage is connected to the pump discharge
passage by the cut of spool (5) and the dis-
charge pressure is led to the servo piston.
q The servo piston is raised by the rocker cam.
The position feedback is applied and the lever
moves to compress the spring.
q If spool (5) is pushed back, the pump dis-
charge 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.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with the spring force.
q 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, D475ASD-5E0 25
Cooling fan motor 1

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}
26 D475A, D475ASD-5E0
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, D475ASD-5E0 27
1. Hydraulic motor
Function
q 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
q The oil sent from the hydraulic pump 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).
q The oil sent to one side of cylinder block (5)
presses pistons (4) (4 or 5 pieces) and gener-
ates force (F1) (F1 kg = P kg/cm2 x x/4D2 cm2).
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a)
degrees to the output shaft (1), the force is
divided into components (F2) and (F3).
q Radial component (F3) generates torque
against the (Y – Y) line connecting the top
dead center and bottom dead center (T = F3 x
ri).
q The resultant of this torque [T = s (F3 x ri)]
rotates cylinder block (5) through the piston.
q Since cylinder block (5) is coupled with the out-
put shaft by means of spline, the output shaft
revolves to transmit the torque.
28 D475A, D475ASD-5E0
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
q 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)
q When the fan pump stops, the hydraulic oil
does not flow into the motor. Since the motor
continues revolution because of the force of
inertia, however, the pressure on the outlet
side of the motor rises.
q 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 port (MA) where
there is not sufficient oil to prevent cavitation.
(Suction valve)
D475A, D475ASD-5E0 29
Operation q If poppet (5) opens, the pressure in port (C)

1) Operation as safety valve lowers and piston (1) moves to the right. Pis-
q Port (A) is connected to port (P) of the motor ton (1) comes in contact with the tip of poppet
and port (B) is connected through port (MB) to (5) and the hydraulic oil is drained through
port (T). throttle (b) and port (D).
q 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.
q The order of the diameters (areas) of the sec-
tions is (d5) > (d4) > (d1) > (d3) > (d2).
q 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.
q If abnormal pressure generated in port (A) q Even if abnormal pressure is generated, suc-
reaches the set pressure of spring (6), poppet tion valve (7) having a large section diameter
(5) opens and the hydraulic oil in port (C) is does not operate since (d1) < (d4).
drained through port (D) and periphery (a) of
suction valve (7).
30 D475A, D475ASD-5E0
2) Operation as suction valve

q If negative pressure is generated in port (P) of
the motor, the pressure in ports (A) and (C)
becomes negative since those ports are con-
nected.
A right force caused by the hydraulic pressure
equivalent to the area difference between (d4)
and (d1) is applied to suction valve (7).
q If the differential pressure between ports (B)
and (A) increases above the set pressure, it
moves suction valve (7) to the right. Accord-
ingly, hydraulic oil flows from port (B) to port
(A) to prevent generation of negative pressure
in port (A).
D475A, D475ASD-5E0 31
3. Operation for forward and reverse revolution

1) Forward revolution (Counterclockwise revolution)
q 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.
q The hydraulic oil in port (MB) is returned to the
tank through passage (a) on the periphery of
spool (5).
q 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.
q 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).
32 D475A, D475ASD-5E0
2) Reverse revolution (Clockwise revolution)
q If ON-OFF solenoid (1) for selector valve is

energized, the hydraulic oil in port (MB) is sent
to chamber (F) and spool (5) moves to the
right.
q The hydraulic oil in port (MA) is returned from
chamber (E) to the tank through passage (a)
on the periphery of spool (5).
q If ON-OFF solenoid (1) for selector valve is
energized, ON-OFF selector valve (2) changes
to let the hydraulic oil from the pump flow
through port (C) into spool chamber (D).
q The hydraulic oil in chamber (D) pushes selec-
tor spool (3) to the left against spring (4). As a
result, motor port (MB) opens and the hydrau-
lic oil flows in the motor to revolve the motor in
reverse (clockwise).
D475A, D475ASD-5E0 33
SEN00211-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Power train, Part 1
Power train, Part 1 .......................................................................................................................................... 2
Power train ........................................................................................................................................... 2
Power train hydraulic equipment arrangement diagram ...................................................................... 4
Damper and universal joint .................................................................................................................. 6
General view of power train unit........................................................................................................... 8
Torque converter, PTO ....................................................................................................................... 10
Torque converter valve....................................................................................................................... 18
Torque converter lockup control system............................................................................................. 28
Scavenging pump .............................................................................................................................. 29
Transmission control .......................................................................................................................... 31
Transmission ...................................................................................................................................... 32
D475A, D475ASD-5E0 1
Power train, Part 1 1

Power train 1
Outline
q The power generated by engine (1) has its tor- shaft, and it is then divided at right angles to
sional vibration dampened by damper (2), and the left and right and transmitted to the respec-
then passes through universal joint (3), and is tive steering clutches (9). The power transmit-
transmitted to torque converter (7). ted from the bevel gear shaft to the final drive
The power from the engine is transmitted is used to steer the machine by engaging or
through oil by torque converter (7) to the input disengaging steering clutch (9).
shaft (turbine shaft) of transmission (8) in The steering lever is operated to disengage
accordance with the change in the load. the steering clutch on the side to which the
There is a lockup clutch assembled to the machine is to be steered in order to change the
torque converter, and when the rotating speed direction of travel. The size of the turning
beyond the torque converter becomes higher, radius is controlled by steering brake (10)
the lockup clutch is engaged. When this hap- installed to the outside of the steering clutch.
pens, the drive case and turbine form one unit, Steering brake (10) uses the same disc system
so the power from the engine is transmitted that is used for the steering clutch.
directly to the transmission input shaft. The power output from the steering clutch
Transmission (8) uses a combination of a plan- enters final drive (11), where it is reduced, and
etary gear system and hydraulic equipment to rotates sprocket (12).
reduce the speed and shift the gears (forward: Final drive is a double reduction type consist-
3 gears, reverse: 3 gears). It connects two sets ing of a single stage spur gear and single stage
of clutches selected with the gear shift lever planetary gear system.
according to the change in the load, and trans- It rotates the sprocket to drive track shoe (13)
mits the power from the transmission to trans- and moves the machine.
fer (14) from output shaft.
The power entering transfer (14) has its speed
reduced. Its speed is further reduced by the
bevel pinion and bevel gear of the bevel gear
2 D475A, D475ASD-5E0
1. Engine (SAA12V140E-3) 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, D475ASD-5E0 3
Power train hydraulic equipment arrangement diagram 1
1. Torque converter oil filter A. Transmission main relief pressure pickup port (TM)
2. Transmission lubricating oil filter B. Transmission R clutch pressure pickup port (REV)
3. Transmission oil filter C. Transmission F clutch pressure pickup port (FWD)
4. Torque converter valve D. Torque converter inlet pressure pickup port (IN)
5. Transmission control valve E. Lockup clutch pressure pickup port (LU)
6. Steering control valve F. Left clutch pressure pickup port (LC)
7. Power train oil strainer G. Left brake pressure pickup port (LB)
8. Oil tank H. Right brake pressure pickup port (RB)
9. Power train, lubrication pump J. Right clutch pressure pickup port (RC)
(BAL160+160+112) K. Stator clutch pressure pickup port (SC)
10. Scavenging pump L. Torque converter outlet pressure pickup port (OUT)
11. Power train oil cooler M. Transmission 1st clutch pressure pickup port (1ST)
N. Transmission 2nd clutch pressure pickup port (2ND)
P. Transmission 3rd clutch pressure pickup port (3RD)
4 D475A, D475ASD-5E0
Damper and universal joint 1
1. Output shaft Outline

2. Flywheel q 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
6. Breather torque converter, transmission, and other
7. Cover power train components.
8. Coupling q Since this damper employs rubber coupling
9. Universal joint (10), vibrations are damped by the compres-
10. Rubber coupling sive damping effect of the rubber and less
11. Drain plug component parts are used.
Operation
q The power from the engine is transmitted
through flywheel (2) to outer body (3). The
tensional vibration of the engine is absorbed in
rubber coupling (10) and the power is transmit-
ted to output shaft (1), and then transmitted
through universal joint (9) to the torque con-
verter and transmission.
6 D475A, D475ASD-5E0
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, D475ASD-5E0 7
Power train system 1

General view of power train unit 1
8 D475A, D475ASD-5E0
A: Main relief pressure pickup port (TM) 1. Oil filler port

B: R clutch pressure pickup port (REV) 2. Centralized pressure pickup port
C: F clutch pressure pickup port (FWD) 3. Oil level gauge
D: Torque converter inlet pressure pickup port 4. Torque converter and PTO
(IN) 5. Torque converter valve
E: Lockup clutch pressure pickup port (LU) 6. Transmission control valve
F: Left steering clutch pressure pickup port (LC) 7. Transmission
G: Left steering brake pressure pickup port (LB) 8. Steering control valve
H: Right steering brake pressure pickup port (RB) 9. Steering unit
J: Right steering clutch pressure pickup port (RC) 10. Torque converter oil filter
K: Stator clutch pressure pickup port (SC) 11. Transmission lubricating oil filter
L: Torque converter outlet pressure pickup port 12. Power train oil filter
(OUT) 13. Torque converter, power train, and lubricating
M: 1st clutch pressure pickup port (1ST) oil pump
N: 2nd clutch pressure pickup port (2ND) 14. Power train oil strainer
P: 3rd clutch pressure pickup port (3RD) 15. Scavenging pump
R: Transmission lubricating pressure pickup port
Outline
q The power train unit broadly consists of torque
converter and PTO (4), transmission (7), and
steering unit (9). Therefore, after the power
train unit is removed, it can be divided into
torque converter and PTO (4), transmission
(7), and steering unit (9).
q Steering unit (9) consists of the transfer, bevel
gear shaft, steering clutch, and the steering
brake.
D475A, D475ASD-5E0 9
Torque converter, PTO 1

a PTO: Abbreviation for Power Take Off
10 D475A, D475ASD-5E0
D475A, D475ASD-5E0 11
A: To transmission control valve 1. Cooling fan pump mounting port

B: To transmission lubrication circuit 2. Hydraulic pump mounting port
C: To transmission oil pan 3. Power train, torque converter, and lubricating
D: From steering case oil 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 oil filter 9. Front housing
L: To transmission lubricating oil filter 10. PTO idler gear (number of teeth: 74)
M: From power train oil filter 11. PTO idler gear shaft
N: From transmission lubricating oil filter 12. Lockup clutch housing
P: Torque converter outlet oil temperature pickup 13. Drive case
port 14. Turbine
R: Torque converter outlet oil pressure pickup port 15. Rear housing
(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. Lockup clutch plate
31. Lockup clutch disc
32. Lockup 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 cooling fan pump drive gear (num-
ber of teeth: 61)
37. Drive gear boss
38. Cover
39. Cover
40. Hydraulic pump drive gear (number of teeth:
61)
41. Cover
42. Strainer
12 D475A, D475ASD-5E0
Outline Structure
q The torque converter is a 3-element, 1-stage, q Pump (17) is integral with coupling (6), input
and 1-phase type, which is integral with the shaft (8), lockup clutch housing (12), and drive
transmission. case (13), and rotated by the engine power.
q The torque converter is equipped with a wet q Turbine (14) is integral with turbine boss (29)
multiple disc clutch type torque converter and transmission input shaft (22), and rotated
lockup device and a wet double disc clutch by the oil from pump (17).
type stator clutch in order to reduce fuel con- q Stator (16) is integral with stator shaft (18) and
sumption, to increase the operability, and to stator clutch hub gear (23), and fixed to rear
reduce the horsepower consumption by the housing (15) through the stator clutch unit.
engine. q The lockup clutch unit consists of clutch plate
q For higher efficiency of continuous light dozing (30) meshed with drive case (13), clutch disc
and leveling operation, the torque converter is (31) meshed with turbine boss (29), and clutch
locked up and the engine power is transferred piston (32) which slides inside clutch housing
directly to the transmissions input shaft. (12) integral with drive case (13).
q When the torque converter is locked up (the q The stator clutch unit consists of clutch hub
pump and turbine is integrated into 1 unit), the gear (23) attached to stator shaft (18) with
oil is still supplied to the torque converter. spline, clutch disc (27) meshed with clutch hub
Accordingly, the oil flowing from the pump gear (23), clutch plate (26) supported by the
through the turbine to the stator is obstructed pins on clutch housing (24) and rear housing
by the stator blades and cannot flow in any (15), and clutch piston (28) which slides inside
direction. As a result, this oil resists the rotation rear housing (15).
of the pump and turbine (it is agitated). q The PTO unit consists of input shaft (8), PTO
q To reduce the rotating resistance of the pump idler gear (10), and pump drive gears (33), (36)
and turbine, the stator clutch is disengaged and (40).
simultaneously with lockup of the torque con-
verter so that the stator can rotate freely.
As the stator is dragged and turned by the
pump and turbine, the oil returns from the tur-
bine to the pump smoothly against less resis-
tance.
Conditions for the direct (lockup) range

Torque converter output shaft speed:
Min. 1,360 rpm
Set transmission pressure:
Min. 1.91 MPa {19.5 kg/cm2}
Both conditions must be satisfied.
Conditions for the torque converter (unlock)

range
Torque converter output shaft speed:
Max. 1,330 rpm
Set transmission pressure:
Max. 1.47 MPa {15.0 kg/cm2}
Either condition must be satisfied.
D475A, D475ASD-5E0 13
14 D475A, D475ASD-5E0
Unit: mm
Standard size Tolerance Repair limit
1 Outside diameter of oil seal contact
surface of input coupling 125 0 124.8
–0.063
Inside diameter of seal ring con- +0.035 Repair by hard
2 tact surface of sleeve 115 0 115.1 chrome plating
or replace
3 Inside diameter of seal ring contact 190 +0.046 190.5
surface of retainer 0
4 Inside diameter of seal ring contact 120 +0.035 120.5

surface of pump shaft 0
5 Backlash between input shaft and 0.198 – 0.484

PTO idler gear
Backlash between PTO idler gear
6 and power train, torque converter, 0.198 – 0.484
lubricating oil pump, and cooling
fan pump drive gear
7 Backlash between PTO idler gear 0.198 – 0.484

and hydraulic pump drive gear
8 Backlash between input shaft and 0.198 – 0.484

scavenging pump drive gear
Width 4 –0.01 3.6

9 Wear of input shaft –0.03
seal ring
Thickness 4.5 ±0.12 4.05
Thickness of lockup clutch disc 5.4 ±0.1 4.9
10 Thickness of lockup clutch plate 5.0 ±0.1 4.5

Overall thickness of lockup clutch 26.2 ±0.22 24.6
assembly
Thickness of stator clutch disc 5.4 ±0.1 4.9
11 Thickness of stator clutch plate 5.0 ±0.05 4.5

Overall thickness of stator clutch 15.8 ±0.15 14.7
assembly
Tolerance
Standard size
Shaft Hole
Fitting tolerance of
12 PTO idler gear bear- Outside 140 0 –0.008
ing diameter –0.018 –0.033 Replace
Inside 80 0 0
diameter –0.019 –0.015
Outside 0 +0.012
diameter 140 –0.018 –0.028
Fitting tolerance of (cover side)
power train, torque
13 converter, lubricat- Outside 0 +0.015
ing oil pump, and diameter 140 –0.018 –0.010
cooling fan pump (case side)
drive gear bearing
Inside 65 +0.030 0
diameter +0.011 –0.015
Outside 0 +0.012
diameter 160 –0.025 –0.028
(cover side)
Outside 0 +0.015
diameter 140 –0.018 –0.010
Fitting tolerance of (case side)
14 hydraulic pump
drive gear bearing Inside +0.030 0
diameter 75 +0.011 –0.015
(cover side)
Inside +0.030 0
diameter 65 +0.011 –0.015
(case side)
Outside 72 0 +0.009
Fitting tolerance of diameter –0.013 –0.021
15 scavenging pump
drive gear bearing Inside 35 +0.025 0
diameter +0.009 –0.010
16 Stator clutch return spring Free length Installed length Installed load Free length Installed load
125.4 N 106.9 N
54.1 37.0 50.9
{12.8 kg} {10.9 kg}
D475A, D475ASD-5E0 15
Power transmitting route
When lockup clutch is “disengaged” and stator When lockup clutch is “engaged” and stator
clutch is “engaged” clutch is “disengaged”
q If lockup clutch (3) is “disengaged”, drive case q If lockup clutch (3) is “engaged”, drive case (5)
(5) and turbine (7) are disconnected from each and turbine (7) are connected to each other.
other. If stator clutch (9) is “disengaged” at this time,
If stator clutch (9) is “engaged” at this time, rear housing (10) and stator shaft (11) are dis-
rear housing (10) and stator shaft (11) are con- connected from each other, and stator (8) is
nected to each other to fix stator (8). dragged and turned by pump (6) and turbine
Therefore, the torque converter works as an (7).
ordinary torque converter. Therefore, the torque converter works as a
q The power from the engine is transmitted to lockup torque converter.
coupling (1) through the damper and the uni- q The power from the engine is transmitted to
versal joint. coupling (1) through the damper and the uni-
q The power transmitted to coupling (1) rotates versal joint.
input shaft (2), clutch housing (4), drive case q The power transmitted to coupling (1) rotates
(5) and pump (6) integrally. input shaft (2), clutch housing (4), drive case
q The power transmitted to pump (6) rotates tur- (5) and pump (6) integrally.
bine (7) through the medium of oil and is trans- q The power transmitted to drive case (5) rotates
ferred to transmission input shaft (12) attached turbine (7) directly since lockup clutch (3) is
to turbine (7) with spline. fixed, and is transferred to transmission input
shaft (12) attached to turbine (7) with spline.
16 D475A, D475ASD-5E0
Oil flow
q The oil flows through the main relief valve and

its pressure is reduced to below the set pres-
sure by the torque converter relief valve. It then
flows in inlet port (A), goes through the oil pas-
sages of rear housing (1), pump shaft (2) and
guide (3), and flows into pump (4).
q The oil is given a centrifugal force by pump (4),
and then it enters turbine (5) to transmit its
energy to turbine (5).
q The oil from turbine (5) is sent to stator (6) and
flows in pump (4) again. A part of the oil, how-
ever, is sent through outlet port (B) to the
power train oil cooler.
D475A, D475ASD-5E0 17
Torque converter valve 1
PTF: From power train oil filter

TCF: From torque converter oil filter
TC : To torque converter
SC : To stator clutch
LC : To lockup clutch
drT: Drain (Torque converter relief)
dr: Drain
P3 : Lockup clutch oil pressure pickup port (LU)
P8 : Main relief oil pressure pickup port (TM)
PSC: Stator clutch oil pressure pickup port (SC)
PPL: Pilot oil pressure pickup port
18 D475A, D475ASD-5E0
1. Valve body 18. Plug

2. Torque converter relief valve 19. Valve body
3. Cover 20. Lockup selector valve
4. Main relief valve 21. Piston
5. Piston 22. Cover
6. Piston
7. Stator clutch modulating valve Lockup solenoid valve
8. Piston 23. Cap
9. Piston 24. Coil
10. Cover 25. Valve
11. Piston 26. Ball
12. Piston 27. Valve
13. Lockup clutch modulating valve 28. Base
14. Shaft 29. Shaft
15. Stopper 30. Case
16. Load piston 31. Plunger
17. Cover
D475A, D475ASD-5E0 19
20 D475A, D475ASD-5E0
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
1
valve and valve body –0.035 +0.016 0.035 –
40 0.081
–0.045 0 0.061
Clearance between torque con- –0.035 +0.016 0.035 –
2 40 0.081
verter relief valve and valve body –0.045 0 0.061
Clearance between stator clutch –0.035 +0.013 0.035 –
3 25 0.078
modulating valve and valve body –0.045 0 0.058
Clearance between lockup clutch –0.035 +0.013 0.035 –
4 25 0.078
modulating valve and valve body –0.045 0 0.058
Clearance between lockup selec- –0.035 +0.013 0.035 –
5 25 0.078
tor valve and valve body –0.045 0 0.058
Installed Installed Installed Replace
Free length Free length
6 Main relief valve spring length load load
1,455 N 1,383 N
120.3 101.5 116.7
{148.5 kg} {141.1 kg}
Torque converter relief valve 645.6 N 613 N
7 116.92 86.3 113.4
spring {65.83 kg} {62.5 kg}
Stator clutch modulating valve 151.9 N 144 N
8 103.5 95.2 100.4
spring {15.5 kg} {14.7 kg}
Lockup clutch modulating valve 158.6 N 151 N
9 141.4 88.7 137.2
spring (outside) {16.18 kg} {15.4 kg}
Lockup clutch modulating valve
10 80.5 80.5 — 78.1 —
spring (inside)
55.9 N 53.0 N
11 Lockup selector valve spring 66 54 64.0
{5.7 kg} {5.4 kg}
D475A, D475ASD-5E0 21
Outline
q The torque converter valve is installed at the
top of the rear housing of the toque converter,
and consists of the following 6 types of valves.
Main relief valve

q The main relief valve maintains each hydraulic
circuit of the lockup clutches and stator
clutches of the transmission, steering clutch,
steering brake and torque converter constantly
at the set pressure.
Set pressure:
2.6 – 3.0 MPa {27.0 – 30.4 kg/cm2}
Torque converter relief valve

q The torque converter relief valve maintains the
oil pressure in the torque converter inlet circuit
always below the set pressure in order to pro-
tect the torque converter from abnormally high
pressure.
Set pressure: 1.00 MPa {10.2 kg/cm2}
Lockup solenoid valve

q The lockup solenoid valve controls the lockup
selector valve by changing the pilot pressure
for it in response to electrical signals received
from the controller.
Lockup selector valve

q The lockup selector valve turns the lockup
clutch and stator clutch “engaged” and “disen-
gaged”.
Stator clutch modulating valve

q The stator clutch modulating valve maintains
the clutch pressure below the set pressure to
protect the stator clutch circuit from abnormally
high pressure, as well as raising the clutch
pressure gradually to the set pressure.
Set pressure: 2.7 MPa {27 kg/cm2}
Lockup clutch modulating valve

q The lockup clutch modulating valve maintains
the clutch pressure below the set pressure to
protect the lockup clutch circuit from abnor-
mally high pressure, as well as raising the
clutch pressure gradually to the set pressure.
22 D475A, D475ASD-5E0
Operation of main relief valve Operation of torque converter relief valve
q The oil from the hydraulic pump flows through q The oil from the main relief valve flows through
the filter, port (A) of the torque converter valve, port (C) to the torque converter, and at the
and orifice (a) of torque converter relief valve same time, also flows through orifice (b) of
(1) to chamber (B). torque converter relief valve (3) to chamber
(D).
q When the oil pressure on the torque converter
exceeds the set pressure, the oil in chamber
(D) pushes piston (4), the reaction force of
which moves torque converter relief valve (3)
to the right to open port (C) and port (E).
Then the oil in port (C) is drained from port (E)
to the oil tank.
q When the oil pressure in the circuit exceeds

the set pressure, the oil in chamber (B) pushes
piston (2), the reaction force of which moves
spool (1) to the left to open port (A) and port
(C).
Then the oil from the pump flows through port
(C) into the torque converter.
D475A, D475ASD-5E0 23
Operation of lockup solenoid valve and lockup selector valve
When traveling in torque converter range
q While the machine is in the “torque converter q The oil from the pump flows through port (D)
range”, the lockup solenoid valve is “de-ener- into port (E) and applies back pressure to sta-
gized” and therefore plunger (1) is pushed tor clutch piston (7). It turns “engaged” the sta-
back upward by the oil pressure from the tor clutch as the oil pressure in the circuit is
pump. raised.
q As the seats of valve (2) and ball (3) are At the same time, the oil which applied back
opened, the drain circuit of port (B) is opened pressure to lockup clutch piston (8) is drained
and the oil in port (A) and port (C) is drained. through port (F) into port (H) to turn the lockup
q Lockup selector valve (5) is pushed back to the clutch “disengaged”.
right by the tension of spring (6). As a result, q The oil from the pump flows into port (A) and
the passages between port (D) and port (F) port (D). The oil in port (A) is drained as the
and between port (E) and port (G) are closed, lockup solenoid valve is “de-energized”, while
while the passages between port (D) and port the oil pressure in port (D) is secured by orifice
(E) and between port (F) and port (H) are (a) and adjusted by modulating valve (9).
opened.
24 D475A, D475ASD-5E0
When traveling in direct range
q While the machine is in the “direct range”, the q The oil from the pump flows through port (D)
lockup solenoid valve is “energized” and there- into port (F) and applies back pressure to sta-
fore plunger (1) moves downward. tor clutch piston (8). It turns the lockup clutch
q As the seats of valve (2) and ball (3) are “engaged” as the oil pressure in the circuit is
closed, the drain circuit of port (B) is closed raised.
and the oil in port (A) flows to port (C) At the same time, the oil which had applied
q The oil from port (C) pushes piston (4) to move back pressure to stator clutch piston (7) is
lockup selector valve (5) to the left. As a drained through port (E) into port (G) to turn
result, the passages between port (D) and port the stator clutch “disengaged”.
(E) and between port (F) and port (H) are q The pressure of the oil which flows from the
closed, while the passages between port (D) pump into port (D) is adjusted by modulating
and port (F) and between port (E) and port (G) valve (10).
are opened.
D475A, D475ASD-5E0 25
Modulating valve
Outline
q The modulating valve is located between the
lockup selector valve and the inlet of each
clutch.
q When each clutch is turned “engaged”, it
raises the oil pressure applied to the piston
gradually to the set pressure to engage the
clutch smoothly and to reduce the shock given
to the torque converter and transmission.
a Though the following explanation on operation
takes the modulating valve for the stator clutch
as an example, the modulating valve for the
lockup clutch also operates in a similar way.
However, please note that the oil flow into the
clutches in the torque converter range and in
the direct range is opposite in direction.
Operation
When traveling in torque converter range
q While the machine is in the “torque converter
range”, lockup solenoid valve (1) is “de-ener-
gized” and the oil from the pump and the oil in
port (B) are drained.
q Lockup selector valve (2) is pushed back to the
right by the tension of spring (3). Then the pas-
sages between port (A) and port (E) and
between port (D) and port (G) are closed, while
the passage between port (A) and port (D) is
opened. As a result, the circuit is connected
through modulating valve (5) to stator clutch
(9).
q The oil from the pump flows through port (A)
into stator clutch (9), and the oil pressure in the
circuit starts rising.
q If the oil pressure in the circuit rises, the oil
flowing through orifice (a) of modulating valve
(5) pushes piston (6), the reaction force of
which moves modulating valve (5) to the left to
throttle part (C).
q Port (D) is connected to port (F) which applies
back pressure to load piston (7). Load piston
(7) is pushed to the right to retract spring (8),
the tension of which opens part (C).
q By repeating the above operation intermit-
tently, load on spring (8) increases and the oil
pressure rises gradually.
Ultimately, modulating valve (5) stops at the
position where it closed part (C). Rise in the oil
pressure is completed and stator clutch (9) is
completely turned “engaged”.
26 D475A, D475ASD-5E0
When traveling in direct range

q While the machine is in the “direct range”, the
lockup solenoid valve is “energized” to let the
oil from the pump flow into port (B).
q The oil pressure in port (B) becomes higher
than the tension of spring (3) and pushes pis-
ton (4) to move lockup selector valve (2) to the
left. As a result, the passage between port (A)
and port (D) is closed and the passage
between port (D) and port (G) is opened.
q By reducing the oil pressure in port (D), modu-
lating valve (5) is pushed back to the right by
the tension of spring (8), and fully opens part
(C).
At this time, the operating pressure of stator
clutch (9) is drained from port (D) to port (G),
and the stator clutch is turned “disengaged”.
q The oil from the pump flows through port (A) to
port (E), and lockup clutch (10) is turned
“engaged”.
D475A, D475ASD-5E0 27
Torque converter lockup control system 1

System diagram
Operation
q The torque converter lockup control system
controls the lockup operation of the torque
converter automatically with a sensor signal
and the controller in it according to the load on
the machine. When the torque converter is
locked up, the pilot lamp on the monitor panel
lights up.
q The signal of the transmission outlet speed
sensor is input to the transmission controller.
q The lockup mode is set with the mode selec-
tion panel.
q The machine controller receives the gear
speed information from the transmission con-
troller and the transmission outlet speed sen-
sor signal from the shoe slip controller and
turns ON and OFF the lockup system by con-
necting and disconnecting the lockup solenoid
and pilot lamp to and from the chassis ground.
a As for the details of the valve, refer to section
“Torque converter valve”.
28 D475A, D475ASD-5E0
Scavenging pump 1
Type: BAR(3)63+320
A: Suction port from torque converter Outline

B: Suction port from steering unit q The scavenging pump is installed to the PTO
C: Discharge port case and driven by the power from the engine.
q Front pump (1) sucks the oil collected in the
1. Front pump torque converter case through the filter and
2. Rear pump returns it to the power train oil pan.
q Rear pump (2) sucks the oil collected in the
steering case and returns it to the power train
oil pan.
Specifications
Type Tandem gear pump

Nominal delivery Front 63.3
amount
(cc/rev) Rear 319.4
Maximum discharge pressure

0.98 {10}
(MPa {kg/cm2})
Maximum speed (rpm) 1,997
D475A, D475ASD-5E0 29
Transmission control 1
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

2. Lock lever A: Neutral
3. PCCS lever B: Forward
(Forward-Reverse, Gear shift) C: Reverse
4. Transmission neutral switch D: Free
5. Cable E: Lock
6. Transmission control valve
7. UP switch Outline
(Gear is shifted up each time this switch is q The transmission is controlled with PCCS lever
pressed.) (3).
8. DOWN switch The PCCS lever is used to select the travel
(Gear is shifted down each time this switch is direction and shift the gear.
pressed.) q Since the safety mechanism is employed,
transmission neutral switch (4) does not work
and the engine does not start unless lock lever
(2) is in the FREE position (D).
D475A, D475ASD-5E0 31
Transmission 1
32 D475A, D475ASD-5E0
A: To transmission lubrication circuit

B: To priority valve
C: To scavenging pump (from steering case)
D: From scavenging pump (to transmission oil pan)
E: From power train oil filter
F: To lubricating oil relief valve
G: From 1st clutch ECMV
H: From 2nd clutch ECMV
J: From F clutch ECMV
K: From 3rd clutch ECMV
L: From R clutch ECMV
M: Air vent (from steering case)
N: To steering control valve
P: From steering case (to scavenging pump)
dr: Drain
1. Transmission input shaft

2. Transmission control valve
3. Front case
4. Rear case
D475A, D475ASD-5E0 33
34 D475A, D475ASD-5E0
5. Front cover Outline

6. R sun gear (number of teeth: 32) q The transmission adopted is a “forward 3-gear
7. R ring gear (hub) (number of internal teeth: 89) speed and reverse 3-gear speed” transmission
8. Pinion shaft which consists of the planetary gear mecha-
9. R planetary pinion (number of teeth: 25) nisms and the disc clutches.
10. R ring gear (number of teeth: 82) q Out of the 5 sets of planetary gear mecha-
11. Pinion shaft nisms and disc clutches, 2 clutches are fixed
12. F ring gear (number of internal teeth: 89) hydraulically by the operation of ECMV to
13. F planetary pinion (number of teeth: 25) select 1 rotation direction and 1 speed.
14. F sun gear (number of teeth: 39) q The transmission transmits the power received
15. 3rd ring gear (number of internal teeth: 89) by the transmission input shaft to the output
16. 3rd planetary pinion (number of teeth: 25) shaft while changing the gear speed (forward
17. 3rd sun gear (number of teeth: 39) 1st-3rd or reverse 1st-3rd) by any combination
18. 2nd ring gear (number of internal teeth: 89) of the F, R clutches and 3 speed clutches.
19. 2nd planetary pinion (number of teeth: 21)
20. 2nd sun gear (number of teeth: 47)
21. Pinion shaft Number of plates and discs used
22. 1st clutch inner drum
23. Output shaft Number of
24. Collar Clutch No. Number of discs
plates
25. Drive shaft (for sensor)
R clutch 6 7
26. 1st clutch piston housing
27. 1st clutch piston F clutch 6 7
28. 2nd carrier 3rd clutch 4 5
29. 2nd clutch piston 2nd clutch 3 4
30. 2nd clutch piston housing
1st clutch 5 6
31. F and 3rd carrier
32. 3rd clutch piston
33. F and 3rd clutch piston housing
Combinations of clutches at respective gear
34. F clutch piston
35. R carrier speeds and reduction ratio
36. R clutch piston housing
37. R clutch piston Gear speed Clutch used Reduction ratio
38. Tie rod pin Forward 1st
F × 1st 3.282
39. Washer spring speed
40. Clutch spring Forward 2nd
41. Clutch plate F × 2nd 1.789
speed
42. Clutch disc
Forward 3rd
F × 3rd 1.000
speed
Neutral 1st (*) —
Reverse 1st
R × 1st 2.563
speed
Reverse 2nd
R × 2nd 1.397
speed
Reverse 3rd
R × 3rd 0.781
speed
*: Filled with oil at low pressure.
(Except for low temperature and abnormal conditions.)
D475A, D475ASD-5E0 35
36 D475A, D475ASD-5E0
Unit: mm
Installed Installed Installed
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
{8.5 kg} {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}
Total assembled thickness of Standard size Tolerance Repair limit

6
7 discs and 6 plates of R clutch 72.6 ±0.36 68.9
Total assembled thickness of
7 72.6 ±0.36 68.9
7 discs and 6 plates of F clutch
8 50.2 ±0.30 47.5
5 discs and 4 plates of 3rd clutch
9 39.0 ±0.26 36.9
4 discs and 3 plates of 2nd clutch
10 61.4 ±0.43 58.2
6 discs and 5 plates of 1st clutch
F, R,
5.4 ±0.1 4.9
11 Thickness of clutch disc 2nd, 3rd Replace
1st 5.4 ±0.15 4.9
12 Thickness of clutch plate 5.8 ±0.1 5.2
–0.01
Wear of seal ring Width 3.0 2.70
13 –0.03
(1 place)
Thickness 4.0 ±0.12 3.85
–0.01
14 –0.03
(4 places)
Thickness 5.0 ±0.15 4.85
–0.01
15 –0.03
(2 places)
Thickness 5.0 ±0.15 4.85
–0.01
16 –0.03
(2 places)
Thickness 6.8 ±0.15 6.65
–0.01
17 –0.04
(1 place)
Thickness 5.0 ±0.15 4.85
–0.01
18 –0.04
(3 places)
Thickness 4.0 ±0.15 3.85
Backlash between
19 0.16 – 0.35
sun gear and planetary pinion
Backlash between
20 0.18 – 0.38
planetary pinion and ring gear
D475A, D475ASD-5E0 37
Disc clutch
Structure Operation
When clutch is “engaged” (fixed)
q The disc clutch consists of piston (2), plates q The oil from ECMV is sent with pressure to the
(3), discs (4), pin (5), return spring (6) etc. to fix rear side of piston (2) through the oil passage
ring gear (1). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
When clutch is “disengaged” (released)
q As the oil from ECMV is stopped, piston (2) is

pushed back rightward by return spring (6).
q Plate (3) and disc (4) are released from the
frictional force and ring gear (1), as the result,
is also released.
38 D475A, D475ASD-5E0
Power transmitting route

Forward 1st speed
q When the transmission is set to the forward 1st q The rotation of F and 3rd carrier (10) is trans-
s p e e d , th e F c l u t c h a n d 1 s t c l u t c h a r e mitted through 3rd planetary pinion (11) to 3rd
engaged. The power transmitted from the ring gear (12).
torque converter to input shaft (1) is then trans- q 3rd ring gear (12) and 2nd carrier (13) are
mitted to output shaft (20). meshed with each other and rotate integrally.
q The F clutch is actuated by the oil pressure Accordingly, the rotation of 3rd ring gear (12) is
applied to the F clutch piston, and fixes F ring transmitted through 2nd carrier (13) to 1st
gear (4). The 1st clutch is actuated by the oil clutch piston housing (14).
pressure applied to the 1st clutch piston, and q As 1st clutch inner drum (16) is fixed by the 1st
fixes 1st clutch inner drum (16). clutch, the power transmitted to 1st clutch pis-
q The power from the torque converter is trans- ton housing (14) is transmitted through 1st
mitted to F planetary pinion (3) through input clutch inner drum (16) to output shaft (20).
shaft (1) and F sun gear (2).
q As F ring gear (4) is fixed by the F clutch, the
power transmitted to F planetary pinion (3)
rotates F and 3rd carrier (10) located inside of
F ring gear (4).
D475A, D475ASD-5E0 39
Forward 2nd speed
q When the transmission is set to the forward q The rotation of F and 3rd carrier (10) is trans-
2nd speed, the F clutch and 2nd clutch are mitted through 3rd planetary pinion (11) to 3rd
engaged.The power transmitted from the ring gear (12).
q The F clutch is actuated by the oil pressure Accordingly, the rotation of 2nd carrier (13) is
applied to the F clutch piston, and fixes F ring transmitted to 2nd planetary pinion (15).
gear (4). The 2nd clutch is actuated by the oil q As 2nd ring gear (17) is fixed by the 2nd clutch,
pressure applied to the 2nd clutch piston, and the power transmitted to 2nd planetary pinion
fixes 2nd ring gear (17). (15) is transmitted through 2nd sun gear (18)
q The power from the torque converter is trans- to output shaft (20).
mitted to F planetary pinion (3) through input
F ring gear (4).
40 D475A, D475ASD-5E0
Forward 3rd speed
q When the transmission is set to the forward 3rd q As 3rd ring gear (12) is fixed by the 3rd clutch,
s p e ed , th e F c l u t c h an d 3 r d c l ut c h a r e the power transmitted to F and 3rd carrier (10)
engaged. The power transmitted from the is transmitted through 3rd planetary pinion (11)
torque converter to input shaft (1) is then trans- and 3rd sun gear (19) to output shaft (20).
mitted to output shaft (20).
q The F clutch is actuated by the oil pressure
applied to the F clutch piston, and fixes F ring
gear (4). The 3rd clutch is actuated by the oil
pressure applied to the 3rd clutch piston, and
fixes 3rd ring gear (12).
q The power from the torque converter is trans-
mitted to F planetary pinion (3) through input
F ring gear (4).
D475A, D475ASD-5E0 41
Reverse 1st speed
q When the transmission is set to the reverse 1st q The rotation of F and 3rd carrier (10) is trans-
s p e ed , th e R c l ut c h a nd 1 s t c l ut c h a r e mitted through 3rd planetary pinion (11) to 3rd
engaged. The power transmitted from the ring gear (12).
q The R clutch is actuated by the oil pressure Accordingly, the rotation of 3rd ring gear (12) is
applied to the R clutch piston, and fixes ring transmitted through 2nd carrier (13) to 1st
gear (7). The 1st clutch is actuated by the oil clutch piston housing (14).
pressure applied to the 1st clutch piston, and q As 1st clutch inner drum (16) is fixed by the 1st
fixes 1st clutch inner drum (16). clutch, the power transmitted to 1st clutch pis-
q The power from the torque converter is trans- ton housing (14) is transmitted through 1st
mitted to R planetary pinion (6) through input clutch inner drum (16) to output shaft (20).
shaft (1) and R sun gear (5).
q Ring gear (7) and R carrier (8) are meshed
with each other and fixed by the R clutch.
Accordingly, the rotation of R planetary pinion
(6) rotates R ring gear (9). The rotation of R
ring gear (9), the direction of which is opposite
to that of input shaft (1), rotates F and 3rd car-
rier (10).
42 D475A, D475ASD-5E0
SEN00211-00

© 2006 KOMATSU
All Rights Reserved
44
SEN00212-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Power train, Part 2
Power train, Part 2 .......................................................................................................................................... 2
Transmission control valve................................................................................................................... 2
Transmission clutch ECMV .................................................................................................................. 4
Priority valve......................................................................................................................................... 8
Lubricating oil relief valve................................................................................................................... 10
Torque converter, power train, lubricating oil pump.............................................................................11
Steering, brake control ....................................................................................................................... 12
Final drive........................................................................................................................................... 14
Sprocket ............................................................................................................................................. 18
Steering unit ....................................................................................................................................... 21
Steering control valve......................................................................................................................... 32
Steering clutch ECMV, Steering brake ECMV .................................................................................... 34
Parking brake valve............................................................................................................................ 40
Sudden stop prevention valve............................................................................................................ 42
D475A, D475ASD-5E0 1

Transmission control valve 1
2 D475A, D475ASD-5E0
PF: F clutch oil pressure pickup port (FWD) Operation table of ECMV
PR: R clutch oil pressure pickup port (REV)
P1: 1st clutch pressure pickup port (1ST) ECMV
P2: 2nd clutch pressure pickup port (2ND) F R 1st 2nd 3rd
Gear speed
P3: 3rd clutch pressure pickup port (3RD)
Forward 1st Q Q
PV: To priority valve
LV: To lubricating oil relief valve Forward 2nd Q Q
LD: Drain (from lubricating oil relief valve) Forward 3rd Q Q
CF: To F clutch Reverse 1st Q Q
CR: To R clutch
Reverse 2nd Q Q
C1: To 1st clutch
C2: To 2nd clutch Reverse 3rd Q Q
C3: To 3rd clutch * Neutral Q
dr: Drain *: Filled with oil at low pressure.
(Except for low temperature and abnormal conditions.)
1. Filter
2. Priority valve
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, D475ASD-5E0 3
Transmission clutch ECMV 1

a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch
P: From pump *1:
T: Drain
Stamp of the
Dr: Drain Clutch used
nameplate
P1: Clutch oil pressure pickup port
F, R, 1st, 2nd, 3rd A*******
1. Fill switch connector
2. Proportional solenoid connector
3. Flow rate pickup valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
4 D475A, D475ASD-5E0
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
This valve receives the current sent from the shown below according to the command cur-
transmission controller with a proportional rent from the controller.
solenoid, and then converts it into oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller by controlling the command current to operate
to notify that filling is completed when the the pressure control valve to control the flow
clutch is filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is Current – propulsion force characteristics of
applied or not while oil pressure is applied to proportional solenoid
the clutch.
Propulsion force – Hydraulic pressure charac-

teristics of proportional solenoid
Range A: Before shifting gear (When draining)

Range B: During filling ECMV and fill switch
Range C: Pressure regulation q For each ECMV, 1 fill switch is installed.
Range D: During filling (During triggering) If the clutch is filled with oil, the fill switch is
Point E: Start of filling turned “ON” by the pressure of the clutch. The
Point F: Finish of filling oil pressure is built up according to this signal.
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
D475A, D475ASD-5E0 5
Operation of ECMV Before shifting gear (when draining) (Range A

q ECMV is controlled with the command current in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q Under the condition where any current is not

sent to proportional solenoid (1), pressure con-
trol valve (3) drains the oil from clutch port (A)
through drain port (T).
Also at this time, fill switch (5) is turned “OFF”
because oil pressure is not applied to pressure
Range A: Before shifting gear (When draining) detection valve (4).
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
6 D475A, D475ASD-5E0
During filling (Range B in chart) Pressure regulation (Range C in chart)
q If current is applied to proportional solenoid (1) q If current flows in proportional solenoid (1), the
with no oil in the clutch, the oil pressure force solenoid generates thrust in proportion to the
balanced with the solenoid force is applied to current. This thrust of the solenoid is balanced
chamber (B) and pushes pressure control with the sum of the thrust generated by the oil
valve (3) to the left. This opens pump port (P) pressure in clutch port and the tension of pres-
and clutch port (A) to feed oil in the clutch. sure control valve spring (2), and then the
When the clutch is filled with oil, pressure pressure is settled.
detection valve (4) actuates to turn “ON” fill
switch (5).
D475A, D475ASD-5E0 7
Priority valve 1
Unit: mm

Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.035 +0.013 0.035 –
22 0.078
–0.045 0 0.058
Standard size Repair limit Replace

2 Return spring length load load
84.7 kN 80.4 kN
38.8 28.5 37.6
{8.6 kg} {8.2 kg}
3. Valve body Outline

4. Spool q The priority valve is installed in the circuit
5. Piston between the pump and the clutch ECMV.
When shifting the gear, even if the oil pressure
in the transmission circuit decreases sharply,
the priority valve disconnects the transmission
circuit and pilot circuit and keeps the oil pres-
sure to the set pressure so that the decrease
of the brake oil pressure and stator clutch oil
pressure can be prevented during the gear
shifting operation.
8 D475A, D475ASD-5E0
Operation from start to finish of gear shifting Operation right after finishing of gear shifting
q The oil from the pump flows through port (A) q If the gear shift lever is operated, the oil pres-
and orifice (a) to chamber (C). sure in port (B) decreases sharply nearing 0
q If the oil flow from the pump increases and the MPa { 0 kg/cm2} as a result of the ECMV oper-
oil pressure rises, the oil in chamber (C) ation.
pushes piston (1). Then, the reaction force of q Then, the oil pressure in port (A) also
piston (1) compresses spring (2) and moves decreases, but valve (3) is pushed back to the
valve (3) to the left. right by the tension of spring (2).
q If valve (3) moves, port (A) and port (B) are q As a result, the oil pressure in port (A) (pilot
connected and the oil from the pump flows pressure) is kept to the set pressure.
through port (B) to the ECMV. The oil pressure
at this time is the set pressure of the priority
valve.
q Then, the oil pressure transmitted from port (B)
to the ECMV rises to the set pressure of the
clutch.
D475A, D475ASD-5E0 9
Lubricating oil relief valve 1
Unit: mm

1
valve body –0.035 +0.013 0.035 –
22 0.078
–0.045 0 0.058

2 Return spring length load load
91.9 N 87.3 N
68.5 37 66.5
{9.37 kg} {8.9 kg}
3. Lubricating oil pressure pickup port Outline

4. Spool q The lubricating oil relief valve is installed to the
5. Valve body transmission control valve. It keeps the lubri-
cating oil circuit below the set pressure.
Set pressure: 0.26 MPa {2.7 kg/cm2}
10 D475A, D475ASD-5E0
Torque converter, power train, lubricating oil pump 1

Type: BAL(4)160+(4)160+(4)112
Unit: mm
Type Standard clearance Clearance limit
1 Side clearance BAL(4)160
0.04 – 0.10 0.13
BAL(4)112
Clearance between plain bearing BAL(4)160

2 0.060 – 0.145 0.20 Replace
inner diameter and gear shaft BAL(4)112
Type Standard size Tolerance Repair limit
3 Depth to knock in pin BAL(4)160 0
14 —
BAL(4)112 –0.5
4 Rotating torque of spline shaft 5.9 Nm {0.6 kgm}

Discharge Standard
Delivery
Speed pressure delivery
Type amount limit
Delivery amount (rpm) (MPa{kg/ amount —
(ll/min)
— Oil: SAE10WCD cm2}) (ll/min)
Oil temperature: 45 – 55 °C
BAL(4)160 2,000 2.94 {30} 288 266
BAL(4)112 2,000 2.94 {30} 205 188
5. Lubricating oil pump Outline

6. Power train pump q The torque converter pump, power train pump
7. Torque converter pump and lubricating oil pump are installed to the
PTO case. They are driven by the power from
A: Suction port the engine to supply the oil pressure to the
B: Lubricating oil pump discharge port torque converter, transmission and steering
C: Power train pump discharge port unit.
D: Torque converter pump discharge port
D475A, D475ASD-5E0 11
Steering, brake control 1

a PCCS: Abbreviation for Palm Command Control System
a Regarding the transmission related description of operation of the PCCS lever, refer to “Transmission
control”.
12 D475A, D475ASD-5E0
1. Brake pedal Outline

2. Lock lever q PCCS lever (3) sends an electric signal to
3. PCCS lever (Steering) steering controller (11). After receiving it, steer-
4. Limit switch ing controller (11) sends a proportional current
5. Steering ECMV to steering ECMV (5) to operate the steering
6. Brake valve clutch and brake.
7. Parking brake lever (From lock lever) q The brake pedal (1) sends an electric signal to
8. Cable steering controller (11) through potentiometer
9. Rod (From brake pedal) (10). After receiving it, steering controller (11)
10. Potentiometer sends a proportional current to steering ECMV
11. Steering controller (5) to operate the brake. In this case, the right
12. Transmission controller and left brakes operate at the same time to
13. Engine controller activate braking. Rod (9) operates the brake
through brake valve (6) for redundant use.
Positions of lever and pedal (Only at the time of complete braking)
A: Neutral q If you slightly tilt PCCS lever (3) towards the
B: Forward straight-travel left, the left steering clutch is partially disen-
C: Reverse straight-travel gaged, causing the machine to make a slow
D: Left clutch OFF left turn.
E: Left clutch OFF q If you completely tilt PCCS lever (3) towards
Left brake ON the left, the left steering clutch is turned “disen-
F: Right clutch OFF gaged” and the left steering brake is turned
G: Right clutch OFF “engaged”, causing the machine to make a
Right brake ON sudden left turn.
H: Brake RELEASE q Lock lever (2) is connected to parking brake
J: Brake ON lever (7) and it also serves as a parking brake.
K: Free
L: Lock
D475A, D475ASD-5E0 13
Final drive 1
Outline
q The final drive is a single stage spur gear, sin-
gle stage planetary gear reduction type. The
lubrication is of splash type using the rotation
of the gears.
The final drive can be removed and installed
as a single unit.
q Floating seal (1) is installed to the rotating slid-
ing portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubri-
cating oil.
14 D475A, D475ASD-5E0
1. Floating seal 11. Ring gear

2. Sun gear 12. Cover
3. Carrier 13. No. 1 gear
4. Hub 14. No. 1 gear hub
5. Cover 15. No. 1 pinion
6. Sprocket hub 16. Final drive case
7. Sprocket teeth 17. Bearing cage
8. Floating seal guard 18. Shaft
9. Cover 19. Wear guard
10. Planetary pinion
D475A, D475ASD-5E0 15
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 planetary
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 sur-
face 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 plane- size clearance limit
Shaft Hole
27 tary pinion shaft and carrier
(small end) –0.035 –0.024 –0.024 –
110 0.030
–0.054 –0.059 0.030
Clearance between plane-
–0.035 –0.067 –0.072 –
28 tary 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
30 final drive cover and end face 7.3 – 8.3 Adjust
of 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
16 D475A, D475ASD-5E0
Path of power transmission
q The power from the bevel gear shaft and steer- Then, the rotating force of sun gear (2) forms
ing clutch is transmitted to No. 1 pinion (15). It the rotating force of carrier (3), which supports
then passes through No. 1 gear (13), which is the planetary pinion, and is transmitted to
meshed with the No. 1 pinion, and is transmit- sprocket hub (6).
ted to sun gear (2) to rotate it. The rotation direction of carrier (3) is the same
The rotation of sun gear (2) is transmitted to as sun gear (2).
planetary pinion (10), but ring gear (11), which The rotating force transmitted to sprocket hub
is meshed with the planetary pinion, is fixed to (6) is transmitted to sprocket teeth (7).
cover (9), so the planetary pinion rotates on its
own axis and moves around the sun gear
along the ring gear.
D475A, D475ASD-5E0 17
Sprocket 1
Unit: mm

1 Wear of tooth tip Replace or
486 470 overlaying
welding
2 Thickness of tooth root 32.5 26.5
18 D475A, D475ASD-5E0
Full-scale drawing of sprocket tooth profile
D475A, D475ASD-5E0 19
Steering unit 1
A: To steering control valve 1. Transmission

B: Air vent (To transmission case) 2. Steering control valve
C: To scavenging pump 3. Steering unit
D: To pin puller solenoid valve 4. Breather
E: From pin puller solenoid valve 5. Drain plug
F: From power train oil cooler
G: Torque converter output speed sensor mount-
ing port
PLC: L.H. steering clutch oil pressure pickup port
(LC)
PLB: L.H. steering brake oil pressure pickup port
(LB)
PRC: R.H. steering clutch oil pressure pickup port
(RC)
PRB: R.H. steering brake oil pressure pickup port
(RB)
D475A, D475ASD-5E0 21
22 D475A, D475ASD-5E0
6. Output shaft 25. Brake hub

7. Sleeve 26. Brake cage
8. Pin 27. Brake piston
9. Clutch piston 28. Brake spring
10. Pin 29. Case
11. Clutch plate 30. Input shaft
12. Clutch disc 31. Drive shaft
13. Stopper 32. Drive gear (number of teeth: 27)
14. Clutch hub 33. Transmission output speed sensor
15. Clutch cage 34. Case
16. Flange 35. Cage
17. Bevel gear (number of teeth: 37) 36. Torque converter output speed sensor
18. Cage 37. Cage
19. Steering shaft 38. Drum
20. Clutch spring 39. Cover
21. Housing 40. Cage
22. Stopper 41. Driven gear (number of teeth: 30)
23. Brake plate 42. Bevel pinion (number of teeth: 22)
24. Brake disc
D475A, D475ASD-5E0 23
Outline
Transfer Steering brake

q The transfer transmits the output power from q The steering brakes are connected to the L.H.
the transmission to the bevel pinion with and R.H. steering clutch respectively. They
reduced speed. control the power transmitted from the steering
q The transfer consists of input shaft (30) clutches to the final drive to change the turning
meshed with the transmission output shaft, direction of the machine and to brake the
drive gear (32), driven gear (41) and bevel pin- machine.
ion (42). q The steering brakes have wet-type multiple-
disc hydraulic clutches and are driven hydrauli-
Bevel gear shaft cally together with the clutches by the brake
q The bevel gear shaft changes the direction of pedal and steering control valve operated with
the power transmitted to the bevel pinion by a the PCCS lever.
right angle to the left-and-right direction by q As for the lubrication, the steering brakes
using a bevel pinion and a bevel gear, and also adopt the forced lubrication system where the
decelerates the output speed. oil from the power train lubricating pump is
q The bevel gear shaft has spiral gears for a sent through the hydraulic circuit in the steer-
bevel pinion and a bevel gear, and adopts the ing case to the cage, and eventually to the
forced lubrication by the pressurized oil for the discs and plates.
lubrication. q While the engine is stopped, even if the brake
q The bevel gear shaft consists of bevel gear pedal is not depressed, the back pressure of
(17) meshed with the bevel pinion, steering the brake piston decreases and the steering
shaft (19) and the bearing to support the steer- brakes become “applied”.
ing shaft. When restarting the engine, if the parking
brake lever is not in “locked” position, the
Steering clutch engine does not start.
q The steering brakes consist of hub (25) con-
q The steering clutch is connected to the bevel
nected to housing (21), discs (24) engaged
gear shaft through the spline. It transmits and
with the hub, plates (23) fixed to piston (27) by
cuts out the power from the bevel gear shaft to
pin (8), piston (27) to press the discs and
the final drive to change the turning direction of
plates against each other, cage (26) to support
the machine.
these parts, case (29), the bearing and output
q The steering clutch has a wet-type multiple-
shaft (6) connected to the hub by the spline.
disc hydraulic clutch and is driven hydrauli-
And piston (27) and case (29) are fixed to the
cally, together with the brake by the steering
steering case.
control valve operated with the PCCS lever.
q As for the lubrication, the steering clutch
adopts the forced lubrication system where the
oil from the power train lubricating pump is
sent through the hydraulic circuit in the steer-
ing case to the cage and hub, and eventually
to the discs and plates.
q The steering clutch consists of hub (14) con-
nected to the bevel gear shaft by the spline,
discs (12) engaged with the hub, plates (11)
whose periphery is fixed to housing (21) by pin
(10), housing (21), piston (9) to press the discs
and the plates against each other and cage
(15), and the bearing to support these parts.
And as housing (21) is connected to hub (25),
the power from the bevel gear shaft is transmit-
ted to output shaft (6) through hub (25).
24 D475A, D475ASD-5E0
26 D475A, D475ASD-5E0
Unit: mm
Standard size Tolerance Repair limit
Replace
1 Brake plate Thickness 4.2 ±0.1 3.8
Strain — Max. 0.3 0.4 Repair or replace
Thickness 5.4 ±0.1 4.3 Replace
2 Brake disc
3 82.2 ±0.41 72.6
8 brake plates and 9 discs Replace
Thickness 4.2 ±0.1 3.8
4 Clutch plate
Thickness 5.4 ±0.1 4.5 Replace
5 Clutch disc
6 76.8 ±0.40 69.3
8 clutch plates and 8 discs
Inside diameter of seal ring +0.046
7 190 190.5
contact surface of sleeve 0
Large
+0.089
diameter 350 350.1
Inside diameter 0
parts
8 of seal ring contact
surface of brake piston Small
+0.052
diameter 300 300.1
0
parts
Large
+0.089
diameter 350 350.1
Inside diameter 0
parts
9 of seal ring contact
face of clutch piston Small
+0.052
diameter 300 300.1
0
parts

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}

Clearance between bevel gear size Shaft Hole clearance limit
12
and reamer bolt
+0.023 +0.033 –0.023 –
20 Max. 0.031
+0.002 0 0.031
Backlash between brake hub and Standard clearance Clearance limit

13
disc 0.4 – 0.7 1.0
Backlash between clutch hub and
14 0.4 – 0.7 1.0
disc
Backlash between bevel pinion and
15 0.30 – 0.40 0.75 Adjust or replace
bevel gear
Standard rotating torque: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}
Preload of bevel gear shaft taper
16 (When bevel pinion and gear are not meshed: Adjust
roller bearing
51 – 61.8 Nm {5.2 – 6.3 kgm} at bevel gear end )
Standard shim thickness of bearing
17 2.0 Adjust shim
cage
D475A, D475ASD-5E0 27
Unit: mm
Standard clearance Clearance limit
18 Backlash between transfer gears Adjust or replace
0.26 – 0.67 0.75
Thickness of collar between Standard size Tolerance Repair limit

19 Replace
transfer gear and bearing 19.3 ±0.1 18.9
Standard shim thickness of
20 2.0 Adjust shim
bearing cage
28 D475A, D475ASD-5E0
Operation of steering clutch
When steering clutch is turned “engaged” When steering clutch is turned “disengaged”
q When the PCCS lever is in the “neutral” posi- q If the PCCS lever is operated to the left or
tion, the oil in the back side of clutch piston (1) right, the oil pressure is applied to the back of
is drained by the steering control valve. clutch piston (1) by the steering control valve.
q At this time, clutch piston (1) is pushed back to q As the oil pressure rises, clutch piston (1) com-
the right by the tension of clutch spring (2) to press clutch spring (2) and moves to the left to
press discs (3) and plates (4) against stopper eliminate the pressing force between discs (3)
(5). and plates (4).
q The power from steering shaft (6) is transmit- q The power from steering shaft (6) is not trans-
ted through clutch hub (7), pressed discs (3) mitted after housing (8) and accordingly is not
and plates (4) to housing (8). transmitted to the final drive.
q Since housing (8) is connected to brake hub q If the PCCS lever is released, the oil in the
(9) and output shaft (10), the power is transmit- back side of clutch piston (1) is drained by the
ted through output shaft (10 ) to the final drive. steering control valve, thus the steering clutch
is turned “engaged”.
q If the L.H. steering clutch is turned “disen-
gaged”, the power is transmitted only to the
R.H. steering clutch, and consequently the
machine turns to the left.
D475A, D475ASD-5E0 29
Operation of steering brake
When steering brake is “released” When steering brake is “applied”

(When PCCS lever is “operated”)
q When the PCCS lever is in the “neutral” posi- q If the PCCS lever is operated to the left or
tion and the brake pedal is released, the steer- right, the steering control valve turns the steer-
ing control valve only sets the brake pressure ing clutch “disengaged” and the oil in the back
to the maximum. Accordingly, the steering side of piston (1) starts to be drained.
clutch is turned “engaged” and the oil pressure q At this time, brake piston (1) is pushed back to
is applied to the back of brake piston (1). the right by the tension of brake spring (2) to
q As the oil pressure rises, brake piston (1) compress discs (3) and plates (4) against stopper
presses brake spring (2) and moves to the left (5).
to eliminate the pressing force between discs q Brake piston (1) and stopper (5) are fixed to
(3) and plates (4). the steering case by the pin.
q The power transmitted from the steering shaft q Brake hub (7) and output shaft (8), which tend
(6) through the steering clutch to brake hub (7) to rotate by the inertia force even after the
is further transmitted through output shaft (8) steering clutch is turned “disengaged”, can be
to the final drive. stopped by pressing discs (3) and plates (4) to
each other.
q The turning radius and speed can be adjusted
by the brake force controlled by the oil pres-
sure in the back side of piston (1) according to
the stroke of the PCCS lever to the left and
right.
30 D475A, D475ASD-5E0
When steering brake is “applied”

(When PCCS lever is in “neutral” and brake pedal
is “depressed”)
q If the brake pedal is depressed while the

PCCS lever is in the “neutral” position, the
steering control valve starts to drain the oil in
the back of brake piston (1). Then the steering
brake operates with the steering clutch turned
“engaged” and stops the rotation of output
shaft (8).
q The brake force can be adjusted by controlling
the oil pressure applied to the back side of
brake piston (1) according to the stroke of the
brake pedal.
D475A, D475ASD-5E0 31
Steering control valve 1
32 D475A, D475ASD-5E0
P: From power train pump Outline

L: From power train oil cooler q The steering control valve consists of 4
PS: To pin puller solenoid valve ECMV's installed on the valve seat, to control
LC: To L.H. steering clutch the steering clutch and steering brake.
LL: To L.H. steering lubrication circuit q The steering control valve is located in the cir-
LB: To L.H. steering brake cuit between the power train pump and pistons
LBL: To L.H. bevel gear shaft bearing lubrication of the steering clutch and steering brake. It
circuit consists of 2 sets of the steering clutch ECMV
RC: To R.H. steering clutch (L.H. and R.H.) and 2 sets of the steering
RL: To R.H. steering lubrication circuit brake ECMV (L.H. and R.H.).
RB: To R.H. steering brake q The steering control valve sends the oil from
RBL: To R.H. bevel gear shaft bearing lubrication the power train pump to the steering clutch and
circuit steering brake to control each disc clutch.
BPL: To bevel pinion bearing lubrication circuit q If the PCCS lever is leaned to the right or left,
DPS: From pin puller solenoid valve the steering clutch is disengaged. The steering
DLC: Drain (L.H. steering clutch) brake will operate by further leaning the PCCS
DLC: Drain (L.H. steering clutch pilot) lever.
DLB: Drain (L.H. steering brake) q The controller sends commands to each
DRC:Drain (R.H. steering clutch) ECMV according to the right or left stroke of
DRP: Drain (R.H. steering clutch pilot) the PCCS lever and adjusts the gradual or
DRB: Drain (R.H. steering brake) sharp turns.
DB: Drain (Sudden stop prevention valve) q If the brake pedal is depressed, the controller
DBP: Drain (Sudden stop prevention valve pilot) sends commands to the steering brake ECMV
DPB: Drain (Parking brake) according to the pedal stroke to apply the L.H.
and R.H. brake, thus stopping the machine.
q The controller, connected electrically to the
1. Filter PCCS lever and brake pedal operates the
2. R.H. steering clutch ECMV steering clutch and steering brake by control-
3. L.H. steering clutch ECMV ling each ECMV.
4. Sudden stop prevention valve q The sudden stop prevention valve is installed
5. R.H. steering brake ECMV to prevent the machine from stopping sud-
6. L.H. steering brake ECMV denly, when an abnormality takes place in the
7. Parking brake valve electrical system.
8. Valve seat q When the parking brake lever is set in the
“lock” position, the parking brake valve port is
changed to drain the oil between the L.H. and
R.H. steering brake ECMV and the brake pis-
ton to operate the brake. Also the parking
brake valve is connected to the brake pedal by
the linkage.
D475A, D475ASD-5E0 33
Steering clutch ECMV, Steering brake ECMV 1

a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don’t try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch or brake
P: From pump *1:
T: Drain
Clutch used Stamp of the nameplate
Dr: Drain
P1: To clutch or brake pressure pickup port Steering clutch,
R*******
Steering brake
1. Fill switch connector
2. Proportional solenoid connector Outline
3. Pressure detection valve q Each ECMV keeps the steering clutch oil pres-
4. Fill switch sure and steering brake oil pressure to the set
5. Proportional solenoid pressure and furthermore changes the circuit
6. Pressure control valve to the piston chamber of the steering clutch
7. Nameplate (*1) and steering brake.
34 D475A, D475ASD-5E0
Outline of ECMV
q The ECMV consists of 1 pressure control valve
and 1 fill switch.
q Pressure control valve
A proportional solenoid in this valve receives a
current sent from the steering controller and
this valve converts it to an oil pressure.
q Fill switch
This is a switch to detect that a clutch or brake
is filled with oil and has the following functions.
1. At the moment when the clutch or brake is
filled with oil, the fill switch outputs the sig-
nal (fill signal) to the controller to notify the
finishing of filling.
2. While the oil pressure is applied to the
clutch or brake, the fill switch outputs the
signal (fill signal) to the controller to notify
the presence of the oil pressure.
ECMV and proportional solenoid

q One proportional solenoid is mounted for
each ECMV.
The propulsion force is generated accord-
ing to the command current from the con-
troller.
The propulsion force generated by the
proportional solenoid is actuated on the
spool of the pressure control valve and
generates the oil pressure. Accordingly, by
controlling the amount of the command
current, the propulsion force changes and
the pressure control valve is actuated,
then the oil flow and oil pressure is con-
trolled.
ECMV and fill switch

q For each ECMV, 1 fill switch is installed.
If the clutch is filled with oil, the fill switch
is turned “engaged” by the pressure of the
clutch. The oil pressure is built up accord-
ing to this signal.
Operation of ECMV
q The ECMV is controlled by the command
current from the controller to the propor-
tional solenoid and the fill switch output
signal.
D475A, D475ASD-5E0 35
When PCCS lever is in “neutral” position, brake pedal is “released”, and parking brake lever is in
“free” position: Straight travel
(L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “released”, and parking brake is
“released”.)
q When the PCCS lever is in “neutral” position q Proportional solenoid (5) of the brake ECMV is
and the brake pedal is “released”, proportional energized and pushes ball (6) to the left and
solenoid (1) of the clutch ECMV is de-ener- closes the sealing part.
gized and the sealing part of ball (2) is opened. q The oil in port (Pb) of the brake ECMV flows in
q The oil from the power train pump flows port (E) and pushes valve (7) to the left to con-
through port (Pc) of the clutch ECMV to orifice nect port (Pb) with port (B) and disconnect port
(a), then it is drained through the sealing part (B) from port (Dr). At this time, the oil flows in
of ball (2). the back pressure port of the brake piston. As
q Valve (3) is moved to the right by the tension of the oil pressure rises, the brake piston is
spring (4) to disconnect port (Pc) from port (C), pushed to the left to compress the brake
and connect port (C) with port (Dr). At this spring, then the brake is “released”.
time, the oil from the back pressure port of the q When the parking brake lever is in “free” posi-
clutch piston is drained through port (C) and tion, as the parking brake valve is closed, the
the clutch is turned “engaged” by the tension of oil in the brake circuit is not drained.
the clutch spring.
q The oil pressure in the brake circuit, etc. is
secured by orifice (a).
36 D475A, D475ASD-5E0
When PCCS lever is “operated to the left halfway”, brake pedal is “released”, and parking brake lever
is in “free” position: Gradual left turn
(L.H. clutch is turned “disengaged”, L.H. brake is “semi-released”, R.H. clutch is turned “engaged”, R.H.
brake is “released”, and parking brake is “released”.)
q When the PCCS lever is “operated to left half- q Proportional solenoid (5) generates the propul-
way” and the brake pedal is “released”, propor- sion force in proportion to the command cur-
tional solenoid (1) of the L.H. clutch ECMV is rent. This propulsion force is balanced with the
energized and the sealing part of ball (2) is sum of the propulsion force generated by the
closed. oil pressure in the back pressure port of the
q The oil from the power train pump flows brake piston and the tension of spring (8), then
through port (Pc) of the clutch EMCV and ori- the brake pressure is set up to adjust the brake
fice (a) to port (F) and pushes valve (3) to the force.
left to connect port (Pc) with port (C) and dis- q Accordingly, if the stroke of the PCCS lever is
connect port (C) from port (Dr). At this time, the short, the oil pressure after port (B) is set high
oil flows in the back pressure port of the clutch and the brake is turned from “released” to
piston. As the oil pressure rises, the clutch pis- “semi-released”. If the stroke of the PCCS
ton is pushed to the left to compress the clutch lever is long, the oil pressure after port (B) is
spring, then the clutch is turned “disengaged”. set low and the brake is turned from “semi-
q Proportional solenoid (5) of the brake ECMV is released” to “applied”.
energized and pushes ball (6) to the left and q When the parking brake lever is in “free” posi-
closes the sealing part. tion, as the parking brake valve is closed, the
q The oil in port (Pb) of the brake ECMV flows in oil in the brake circuit is not drained.
port (E) and pushes valve (7) to the left. As for
the oil pressure after port (B), the controller
outputs the command current to proportional
solenoid (5) according to the stroke of the
PCCS lever.
D475A, D475ASD-5E0 37
When PCCS lever is “operated fully to the left”, brake pedal is “released”, and parking brake lever is
in “free” position: Sharp left turn
(L.H. clutch is turned “disengaged”, L.H. brake is “applied”, R.H. clutch is turned “engaged”, R.H. brake is
“released”, and parking brake is “released”.)
q When the PCCS lever is shifted from “operated q When the parking brake lever is in “free” posi-
to left halfway” to “operated to left fully”, pro- tion, as the parking brake valve is closed, the
portional solenoid (5) of the L.H. brake ECMV oil in the brake circuit is not drained.
is de-energized and the sealing part of ball (6)
is fully opened.
q Since the oil in port (E) is drained through the
sealing part, valve (7) is moved to the right by
the tension of spring (8) to disconnect port (Pb)
from (B) and connect port (B) with port (Dr). At
this time, the oil from the back pressure port of
the brake piston is drained through port (B)
and the brake is turned “applied” by the tension
of the brake spring.
q The oil from the power train pump flows
through port (Pb) of the brake ECMV and ori-
fice (b), then it is drained through sealing part
of ball (6).
q The oil pressure in the clutch circuit, etc. is
secured by orifice (b).
38 D475A, D475ASD-5E0
When PCCS lever is in “neutral”, brake pedal is “depressed”, and parking brake lever is in “free”
position: Stop
(L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “applied”, and parking brake is
“released”.)
q When the brake pedal is depressed fully, pro- q If the brake pedal is depressed, the parking
portional solenoids (5) of L.H. and R.H. brake brake valve connected by the linkage operates
ECMV are de-energized to open the sealing to open the brake circuit and drain the oil.
part of ball (6).
q The controller outputs the command current to
proportional solenoid (5) according to the
brake pedal stroke.
q Proportional solenoid (5) generates the propul-
sion force in proportion to the command cur-
rent. 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 pressure is set up to adjust the brake
force.
q Since the PCCS lever is in “neutral” position,
proportional solenoids (1) of L.H. and R.H.
clutch ECMV are de-energized and L.H. and
R.H. clutch are turned “engaged”.
D475A, D475ASD-5E0 39
Parking brake valve 1
Unit: mm

1 Replace
valve body –0.020 +0.011 0.020 –
14 0.05
–0.030 0 0.041
Standard size Tolerance Repair limit Repair by hard
Outside diameter of dust seal
2 –0.020 chrome plating
contact surface of spool 14 13.9
–0.030 or replace

3 Return spring length load load Replace
38.2 N 36.3 N
65 47.7 63
{3.9 kg} {3.7 kg}
4. Spool Outline
5. Valve body q The parking brake valve is installed to the
steering control valve, and spool (4) operates
with the parking brake lever.
q When the parking brake lever is in “lock” posi-
tion, the brake operates by draining the operat-
ing pressure of the L.H. and R.H. steering
brake.
40 D475A, D475ASD-5E0
When PCCS lever is in “neutral” position, brake pedal is “released”, and parking brake lever is in
“lock” position : Parking
(L.H. and R.H. clutches are turned “engaged”, L.H. and R.H. brakes are “applied”, and parking brake is
“applied”.)
q If the parking brake lever is turned to the “lock”

position, spool (1) is moved to the left to open
ports (A), (B) and (C).
q The oil which had flown into the brake piston
back pressure port is drained through ports
(A), (B) and (C).
q The oil pressure in the back pressure port of
the brake piston continues to decrease, then
the brake is fully “applied” and that situation is
kept.
q When the engine is started again, as ports (A),
(B) and (C) are still opened, the brake is con-
tinuously “applied”.
q If the parking brake lever is shifted to “free”
position, spool (1) moves to the right to discon-
nect ports (A), (B) and (C). Then the oil pres-
sure from the brake ECMV is applied to the
back pressure port of the brake piston and the
brake becomes “released”.
D475A, D475ASD-5E0 41
Sudden stop prevention valve 1
Outline
q The sudden stop prevention valve is installed
to prevent the machine from stopping suddenly
when an abnormality takes place in the electri-
cal system.
q Sudden stop prevention valve (1) is installed in
the drain circuit of the brake ECMV so that the
sudden oil pressure drop of port (DR) when
brake ECMV coil (2) is de-energized, and con-
sequently the sudden brake can be avoided.
q If an abnormality takes place in the electrical
system, also solenoid (3) of sudden stop pre-
vention valve (1) is de-energized. Then, the oil
of port (DR) is drained through orifice (a) so
that the brake is applied gradually.
42 D475A, D475ASD-5E0
SEN00212-00

© 2006 KOMATSU
All Rights Reserved
44
SEN00213-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Undercarriage and frame
Undercarriage and frame ................................................................................................................................ 2
Track frame .......................................................................................................................................... 2
Recoil spring ........................................................................................................................................ 4
Idler ...................................................................................................................................................... 6
Track roller ........................................................................................................................................... 8
Carrier roller ....................................................................................................................................... 12
Track roller bogie................................................................................................................................ 13
Track shoe.......................................................................................................................................... 14
Main frame ......................................................................................................................................... 18
Suspension ........................................................................................................................................ 20
D475A, D475ASD-5E0 1
Undercarriage and frame 1

Track frame 1
1. Idler Track roller, bogie

2. Recoil spring assembly (Semi U, full U, superdozer specification)
3. Carrier roller
4. Track frame Track roller flange type arrangement
5. Sprocket 1st 2nd 3rd 4th 5th 6th 7th 8th
6. Sprocket guard
S D D D D D D S
7. Track roller bogie
8. Track roller
9. Cap S: Single
10. Idler yoke D: Double
11. Cylinder
12. Guide
2 D475A, D475ASD-5E0
Outline
q The track roller uses K-shape bogie mount to
increase the ground contact area between the
track shoe and ground surface on rough sur-
faces, thereby increasing the drawbar pull.
q 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 Shaft Hole clearance limit
13 Replace
cylinder and guide
–0.15 +0.3
70 0.15 – 0.65 2.0
–0.35 +0.3
Clearance between idler Standard clearance Clearance limit

14 Adjust
bogie and guide 0 – 0.5 3.0
Press-fitting force for car-
15 294.20 – 490.33 kN {30 – 50 ton} —
tridge
D475A, D475ASD-5E0 3
Recoil spring 1
1. Yoke Outline
2. Nut q Recoil spring (10) damps sudden shocks
3. Retainer applied to the idler.
4. Rod q The recoil spring is also used to adjust the
5. Spring cylinder track shoe tension by supplying or discharging
6. Retainer grease through lubricator (8) and moving rod
7. Piston (4) forward or in reverse.
8. Lubricator
(for supplying and discharging grease)
9. Grease chamber cylinder
4 D475A, D475ASD-5E0
Unit: mm

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

Clearance between inner size clearance limit
Shaft Hole
11 cylinder and outer cylinder of
outer cylinder bushing –0.068 +0.323 0.128 –
445 0.8
–0.165 +0.600 0.488
Press-fitting force for outer
12 cylinder bushing 129.4 – 389.1 kN {13.2 – 39.7 ton}
(inner cylinder side)
Adjust
Clearance between recoil
13 spring mount nut and lock 0 – 1.0
plate
D475A, D475ASD-5E0 5
Idler 1
Unit: mm
6 D475A, D475ASD-5E0
Outside diameter of Standard size Repair limit

1
protruding part 1,043 —
Outside diameter of tread
2 990 959 Rebuild or
surface
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 size Shaft Hole clearance limit
7 bushing
and 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 size Shaft Hole interference limit
9
and shaft
+0.046 –0.15
115 0.15 – 0.246 — Replace ring
+0.046 –0.20
10 End play
0.52 – 0.98 —
D475A, D475ASD-5E0 7
Track roller 1
8 D475A, D475ASD-5E0
2nd – 7th track rollers (double flanged roller)

Unit: mm
Outside diameter of flange Standard size Repair limit

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

Clearance between shaft size Shaft Hole clearance limit Replace
10
and bushing bushing
–0.350 +0.170 0.350 –
147 —
–0.413 +0.170 0.583

Interference between shaft size Shaft Hole interference limit
11 Replace
and seal ring
+0.046 –0.15 0.150 –
84 —
+0.046 –0.20 0.246
Standard size Clearance limit Adjust or
12 End play
0.44 – 0.91 — replace
D475A, D475ASD-5E0 9
1st and 8th track rollers (single flanged roller)

Unit: mm

1 Outside diameter of flange
349 —
3 Outside diameter of tread 315 240
4 Thickness of tread 74 36.5 Rebuild or
5 Overall width — — replace
6 Width of tread — —
7 Width of flange 34.5 19.5
9 Width of shaft flange 377 —

Clearance between shaft and size Shaft Hole clearance limit Replace
10
bushing bushing
–0.350 +0.171 0.350 – 0.343 –
157
–0.413 +0.007 0.583 0.584
Tolerance Standard Interfer-
Standard
interference
Interference between shaft size Shaft Hole
11 ence limit Replace
and seal guide
0 +0.054
93.5 0 – 0.174 —
–0.12 0
Adjust or
12 End play 0.44 – 0.91 —
replace
10 D475A, D475ASD-5E0
Carrier roller 1
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
Standard Tolerance Standard Standard

Interference between shaft size Shaft Hole interference clearance
6
and ring
+0.046 –0.15 0.150 –
95 —
+0.046 –0.20 0.246
Replace
Clearance between shaft –0.2 +0.35
7 90 — 0 – 0.55
and support –0.2 +0.35
Play in axial direction of Standard size Clearance limit

8
roller 0 – 0.22 0.3
12 D475A, D475ASD-5E0
Track roller bogie 1
Outline 1. Guide
q The track rollers are installed to small bogie 2. Cap
(6). The track rollers and track shoes are 3. Track roller assembly (double)
always in contact. 4. Large bogie
q The vibration of the machine from the ground 5. Rubber mount
surface is absorbed by rubber mount (5). 6. Small bogie
7. Track roller assembly (single)
8. Cover
9. Cartridge pin
D475A, D475ASD-5E0 13
Track shoe 1
a Portion P shows the link on the side where the bushing is pressed fitted.
14 D475A, D475ASD-5E0
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, D475ASD-5E0 15
Triple grouser shoe
Unit: mm

1 Height
37 25
2 Thickness 18
3 33 Repair by
Length of base build-up
4 27 welding or
replace
5 25.5
6 Length of tip 17.5
7 23.5
16 D475A, D475ASD-5E0
Main frame 1
18 D475A, D475ASD-5E0
Unit: mm

size Shaft Hole clearance limit
Interference between steer-
1
ing 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
–0.043 +0.210 0.093 –
4 arm mounting pin and 140 1.5
–0.106 +0.050 0.316
bushing
Clearance between ripper
–0.036 +0.301 0.154 –
5 cylinder mounting pin and 110 1.5 Replace
–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
Press-fitting force for radiator
14 62.8 – 142.2 kN {6.4 – 14.5 ton}
guard mounting bushing Adjust
Press-fitting force for radiator
15 53.9 – 106.9 kN {5.5 – 10.9 ton}
guard mounting bushing
Press-fitting force for
16 equalizer bar shaft mounting 65.7 – 153 kN {6.7 – 15.6 ton}
bushing
D475A, D475ASD-5E0 19
Suspension 1
20 D475A, D475ASD-5E0
1. Equalizer bar Outline

2. Pivot shaft assembly q 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
D475A, D475ASD-5E0 21
Unit: mm
Press-fitting force for side

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

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

Interference between side size Shaft Hole interference limit
19
pin boss and bushing
+0.051 –0.033 0.064 –
200 —
+0.031 –0.079 0.130
Interference between +0.216 –0.234 0.320 – Replace
20 270 —
thrust washer and seal +0.086 –0.286 0.502
Interference between +0.096 –0.075 0.125 –
21 194 —
thrust 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
22 D475A, D475ASD-5E0
SEN00213-00

© 2006 KOMATSU
All Rights Reserved
24
SEN00214-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Hydraulic system, Part 1
Hydraulic system, Part 1 ................................................................................................................................. 2
Work equipment hydraulic equipment arrangement diagram............................................................... 2
PPC control piping diagram ................................................................................................................. 6
Work equipment control ....................................................................................................................... 8
Work equipment pump ....................................................................................................................... 10
PPC valve .......................................................................................................................................... 27
PCCS lever ........................................................................................................................................ 38
D475A, D475ASD-5E0 1
Hydraulic system, Part 1 1

Work equipment hydraulic equipment arrangement diagram 1
Semi U-dozer (single 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. Fan motor
5. Dual tilt solenoid valve 11. Oil cooler
6. Hydraulic tank
2 D475A, D475ASD-5E0
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, D475ASD-5E0 3
Multi-shank ripper
1. Main control valve

2. Divider block
3. Ripper tilt cylinder (right)
4. Ripper lift cylinder (right)
5. Ripper lift cylinder (left)
6. Ripper tift cylinder (left)
4 D475A, D475ASD-5E0
Giant ripper
q 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, D475ASD-5E0 5
PPC control piping diagram 1

Blade and ripper control
1. Blade control PPC valve

2. Main control valve
3. Accumulator
4. Ripper control PPC valve
5. PPC lock valve
6. Work equipment lock lever
7. Work equipment pump
6 D475A, D475ASD-5E0
Work equipment control 1

q The diagram shows a machine equipped with pitch dozer and pin puller cylinder.
1. Work equipment lock lever 5. Ripper control lever

2. Blade control lever 6. Pin puller switch
3. Pitch button 7. PPC lock valve
4. Tilt switch
8 D475A, D475ASD-5E0
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
q The work equipment control employs a PPC
method which uses a PPC valve to move each
control valve spool.
q Work equipment lock lever (1) is intercon-
nected with PPC lock valve (7), and at the
LOCK position (N), the oil in the PPC circuit is
stopped.
D475A, D475ASD-5E0 9
Work equipment pump 1

3
Type: HPV125 + 125 (140 cm /rev specification)
DC: Discharge Outline

SC: Suction q This pump consists of two variable-capacity
swash plate-type piston pumps, CO valve, LS
valve, and EPC valve.
10 D475A, D475ASD-5E0
A PBF : Front pump pressure input port L PLSR : Load pressure input port
B PAF : Front pump discharge port M PLSRC: Load pressure pickup port
C PLSC : LS set selector pressure pickup port N PLSFC : Load pressure pickup port
D PBR : Rear pump pressure input port P PLSF : Load pressure input port
E PENR : Control pressure pickup port Q PEPC : EPC basic pressure port
F PAR : Rear pump discharge port R PFC : Front pump discharge pressure pickup
G PENF : Control pressure pickup port port
H PD1F : Case drain port S PD2F : Drain plug
J PEPB : EPC basic pressure pickup port T ISIG : LS set selector current
K PRC : Rear pump discharge pressure pickup U PS : Pump suction port
port V PD2R : Air breather mounting port
1. Front main pump 10. Shoe

2. Rear main pump 11. Piston
3. LS valve 12. Cylinder block
4. CO valve 13. Valve plate
5. LS-EPC valve 14. End cap
6. Front shaft 15. Rear shaft
7. Cradle 16. Rear case
8. Front case 17. Servo piston
9. Rocker cam
D475A, D475ASD-5E0 11
Function Structure
q The rotation and torque transmitted to the q Cylinder block (7) is supported to shaft (1) by a
pump shaft are converted into hydraulic pres- spline, and shaft (1) is supported by the front
sure, and pressurized oil is discharged accord- and rear bearings.
ing to the load. q The tip of piston (6) is a concave ball, and shoe
q It is possible to change the discharge amount (5) is caulked to it to form one unit. Piston (6)
by changing the swash plate angle. and shoe (5) form a spherical bearing.
q Shoe (5) is always pressed against flat surface
(A) of rocker cam (4) while sliding in a circular
movement.
q Rocker cam (4) brings high pressure oil at cyl-
inder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q 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 pres-
sure balance is maintained at a suitable level.
The oil inside each cylinder chamber of cylin-
der block (7) is sucked in and discharged
through valve plate (8).
12 D475A, D475ASD-5E0
Operation q If center line (X) of rocker cam (4) is in line

with the axial direction of cylinder block (7)
1. Operation of pump
(swash plate angle = 0), the difference
q Cylinder block (7) rotates together with between volumes (E) and (F) inside cylin-
shaft (1), and shoe (5) slides on flat sur- der block (7) becomes 0, so the pump
face (A). does not carry out any suction or dis-
When this happens, rocker cam (4) moves charge of oil.
along cylindrical surface (B), so angle (a) (In actual fact, the swash plate angle
between center line (X) of rocker cam (4) never becomes 0.)
and the axial direction of cylinder block (7)
changes. (Angle (a) is called the swash
plate angle.)
q Center line (X) of rocker cam (4) maintains

swash plate angle (a) in relation to the
axial direction of cylinder block (7), and
flat surface (A) moves as a cam in relation
to shoe (5).
q 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 carried out by this amount (F)
– (E) per each piston.
q In other words, when cylinder block (7)
rotates 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 volume becomes bigger, the oil
is sucked in.
D475A, D475ASD-5E0 13
2. Control of delivery amount

q If the swash plate angle (a) becomes
larger, the difference between volumes (E)
and (F) becomes larger and delivery
amount (Q) increases.
q Swash plate angle (a) is changed by servo
piston (12).
q Servo piston (12) moves in a reciprocal
movement according to the signal pres-
sure from the CO valve and 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.
q With servo piston (12), the area receiving
the pressure is different on the left and the
right, so main pump discharge pressure
(self pressure) (PP) is always brought to
the chamber receiving the pressure at the
small diameter piston end.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pres-
sure at the large diameter end. The rela-
tionship in the size of pressure (PP) at the
small diameter piston end and pressure
(PEN) at the large diameter end, and the
ratio between the area receiving the pres-
sure of the small diameter piston and the
large diameter piston controls the move-
ment of servo piston (12).
14 D475A, D475ASD-5E0
3. LS valve
A. PLS : LS pressure input port 1. Sleeve

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

B. PA : Pump port 4. Spool
A. PDP : Drain port 5. Spring
6. Retainer
1. Plug 7. Cover
2. Servo piston assembly 8. Spring
D475A, D475ASD-5E0 15
Function 2) CO valve
1) LS valve q When the pump pressure in the hydraulic cir-
q The LS (Load Sensing) valve detects the load cuit becomes maximum, the CO (Cut-OFF)
and controls the discharge amount. valve minimizes the pump swash plate angle
q This valve controls main pump delivery amount to limit the pressure and protect the circuit.
(Q) according to differential pressure (dPLS) q Since the pump swash plate angle is mini-
between main pump pressure (PP) and con- mized, the pump absorption torque is reduced
trol valve outlet port pressure (PLS) (= PP – and the fuel consumption is reduced.
PLS) [called the LS differential pressure].
q Main pump pressure (PP), pressure (PLS)
[called the LS pressure] from the control valve
output, and pressure (PSIG) from the propor-
tional solenoid valve [called the LS selector
pressure] enter this valve.
q The relationship between differential pressure
(dPLS) between main pump pressure (PP) and
LS pressure (PLS) (= PP – PLS) and delivery
amount (Q) changes according to LS selector
current (ISIG) of the LS-EPC valve as shown in
the figure below.
q 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 delivery amount changes from 2.5 to
0.98 MPa {from 25 to 10 kg/cm2}.
16 D475A, D475ASD-5E0
Operation
1) LS valve
(1) When control valve is at neutral position
q The LS valve is a three-way selector valve, q At this point, spool (6) is pushed to the right,
with pressure (PLS) (LS pressure) from the and port (C) and port (D) are connected. Pump
inlet 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 of spring diameter end of the piston, so the swash plate
(4) and the main pump pressure (self pres- is moved to the minimum angle by the differ-
sure) (PP) determines the position of spool (6). ence in the area of piston (12).
q 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).
q Before the engine is started, servo piston (12)
is pushed to the right. (See the diagram on the
right)
q 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 interconnected
with the drain circuit through the control valve
spool.)
D475A, D475ASD-5E0 17
(2) Operation in direction of maximum pump delivery amount
q When the difference between main pump pres- q If the output pressure of the EPC valve for the
sure (PP) and LS pressure (PLS), or LS differ- LS valve is applied to port (G) at this time, it
ential pressure (dPLS), becomes smaller (for pushes piston (7) to the left.
example, when the area of opening of the con- q If piston (7) is pushed to the left, the set force
trol valve becomes larger and LS pressure of spring (4) is reduced and LS differential
(PLS) increases), the combined force of LS pressure (dPLS) [the difference between oil
pressure (PLS) and force of spring (4) pushes pressures (PLS) and (PP)] changes when
spool (6) to the right. ports (D) and (E) of spool (6) are connected.
q As spool (6) moves, ports (D) and (E) are con-
nected to each other and to the CO valve.
q 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.)
q Accordingly, the pressure on the large diame-
ter end of servo piston (12) becomes drain
pressure (PT). Since pump pressure (PP) is
constantly applied to port (J) on the small
diameter end, servo piston (12) is pushed to
the left and the swash plate is moved in the
direction for increasing the delivery amount.
18 D475A, D475ASD-5E0
(3) Operation in direction of minimum pump delivery amount
q The following explains the case where servo

piston (12) moves to the right (where the deliv-
ery amount becomes smaller). When LS dif-
ferential pressure (dPLS) increases [for
example, 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.
q 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).
q 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 between its
large diameter end and small diameter end.
As a result, the swash plate angle is reduced.
D475A, D475ASD-5E0 19
(4) When servo piston is balanced
q Let us take the area receiving the pressure at q At this time, the relationship between the areas
the large diameter end of the piston as (A1), receiving the pressure at both ends of servo
the area receiving the pressure at the small piston (12) is (A0) : (A1) = 1 : 2. Accordingly,
diameter end as (A0), and the pressure flowing the relationship between the pressures applied
into the large diameter end of the piston as to both ends of the piston when the piston is
(PEN). balanced becomes (PP) : (PEN) C 2 : 1.
q When main pump pressure (PP) of the LS q The position where spool (6) is balanced and
valve is balanced with the combined force of stopped is the standard center. The force of
LS pressure (PLS) and the force of spring (4) spring (4) is so adjusted that the standard cen-
and their relationship is (A0) × (PP) = (A1) × ter will be decided when (PP) – (PLS) = 2.5
(PEN), servo piston (12) stops in the current MPa {25 kg/cm2}.
position. q When the input current to the LS-EPC valve
q Then, swash plate is kept at an intermediate changes from 0 to 0.9A and (PSIG) (the output
position. [It stops at a position where the pressure of the LS-EPC valve varying from 0 to
opening between ports (D) and (E) of spool (6) 2.9 MPa {0 to 30 kg/cm2}) is applied to port (G),
and that between ports (C) and (D) are approx- however, the balancing and stopping position
imately the same.] changes in proportion to the (PSIG) pressure
in the range from (PP) – (PLS) = 2.5 to 0.98
MPa {25 to 10 kg/cm2}.
20 D475A, D475ASD-5E0
q 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, D475ASD-5E0 21
2) CO valve
(1) When actuator load is small and pump pressure (PP) is low
q 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).
q Port (C) of the CO valve is connected to port
(E) of the LS valve.
q 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).
q If ports (E) and (G) of the LS valve are con-
nected at this time, the pressure on the large
diameter side of the piston becomes drain
pressure (PT) and servo piston (9) moves to
the left.
q As a result, the pump swash plate angle is
increased to increase the pump delivery
amount.
22 D475A, D475ASD-5E0
(2) When actuator load is large and pump discharge pressure reaches maximum
q 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.
q Port (C) of the CO valve is connected to port
(E) of the LS valve.
q Pump pressure (PP) is applied to port (B) and
small diameter side of servo piston (9).
q Then, the pressure applied through port (C) to
the LS valve is main pump pressure (PP) from
port (B).
q If ports (E) and (G) of the LS valve are con-
nected at this time, main pump pressure (PP)
is applied to the large diameter side of servo
piston (9).
q Main pump pressure (PP) is applied to the
small diameter side of the piston, too. Servo
piston (9) is pushed to the right, however,
because of the difference in area between the
large diameter side and small diameter side of
the piston.
q As a result, the pump swash plate angle is
decreased to decrease the pump delivery
amount.
D475A, D475ASD-5E0 23
5. LS-EPC valve
A. PSIG : To LS valve 1. Coil

B. PT : To tank 2. Body
C. PEPC: From self pressure reducing valve 3. Spring
4. Spool
5. Rod
6. Plunger
7. Connector
24 D475A, D475ASD-5E0
Function Operation
q The EPC valve consists of the solenoid portion 1) When signal current is 0
and the hydraulic valve portion. (coil de-energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
pump controller, it generates the EPC output the controller to coil (1), coil (1) is de-energized.
pressure in proportion to the size of the signal, q For this reason, spool (4) is pushed to the right
and outputs it to the LS valve. in the direction of the arrow by spring (3).
q As a result, port (C) (PEPC) closes and the
pressurized oil from the main pump does not
flow to the LS valve.
q 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, D475ASD-5E0 25
2) When signal current is small (Coil is ener- 3) When signal current is maximum (Coil is
gized) energized)
q If a small signal current flows in coil (1), coil (1) q If the signal current flows in coil (1), coil (1) is
is “energized” and a thrust to the right is gener- “energized”.
ated in plunger (6). q Since the signal current is at the maximum, the
q Rod (5) pushes spool (2) to the right and the oil thrust in plunger (6) becomes maximum.
from port (C) (PEPC) flows in port (A) (PSIG). q Accordingly, rod (5) presses spool (2) to the
q The pressure in port (A) (PSIG) rises. If the right.
total of the force applied to spool (2) and the q As a result, the maximum oil flows from port
load of spring (3) exceeds the thrust of plunger (C) (PEPC) to port (A) (PSIG) and the pressure
(6), spool (2) is pushed to the left. Then, port in the circuit between the EPC valve and LS
(C) (PEPC) and port (A) (PSIG) are discon- valve becomes highest.
nected and port (A) (PSIG) and port (B) (PT) q At this time, port (C) (PT) is closed and the oil
are connected simultaneously. does not flow in the tank.
q 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).
q Accordingly, the pressure in the circuit
between the EPC valve and LS valve is con-
trolled in proportion to the signal current.
26 D475A, D475ASD-5E0
PPC valve 1
1. Blade PPC valve
P : From self pressure reducing valve P3 : To blade tilt valve (LEFT TILT) PPC port
P1 : To blade lift valve (LOWER) PPC port P4 : To blade tilt valve (RIGHT TILT) PPC port
P2 : To blade lift valve (RAISE) PPC port T : To hydraulic tank
D475A, D475ASD-5E0 27
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connecting lever)
28 D475A, D475ASD-5E0
Unit: mm

Free length
Centering spring x Outside Free length
12 length load load
(For port P1) diameter
94 N 75.2 N
34.0 x 15.5 31.9 —
{9.6 kg} {7.68 kg}
Centering spring 78.5 N 62.8 N If spring is
13 43.2 x 15.5 34.0 —
(For port P2) {8 kg} {6.4 kg} damaged or
Centering spring 107.9 N 86.3 N deformed,
14 48.57 x 15.5 32.5 — replace it
(For ports P3 and P4) {11 kg} {8.8 kg}
Metering spring 16.7 N 13.3 N
15 29.27 x 8.15 25.4 —
(For port P1) {1.70 kg} {1.36 kg}
16 26.3 x 8.15 24.1 —
(For port P2) {1.70 kg} {1.36 kg}
17 26.53 x 8.15 24.9 —
(For ports P3 and P4) {1.70 kg} {1.36 kg}
D475A, D475ASD-5E0 29
Operation
1) When in neutral
(1) For lifting blade (2) For tilting blade
q Ports (A) and (B) of the blade lift valve of the q Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P1) and (P2) of the control valve and ports (P3) and (P4) of the
PPC valve are connected through fine control PPC valve are connected through fine control
hole (f) of spool (1) to drain chamber (D). hole (f) of spool (1) to drain chamber (D).
30 D475A, D475ASD-5E0
2) When in fine control

(Neutral o Fine control)
q If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
q Accordingly, fine control hole (f) is discon-
nected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simul-
taneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (B).
q 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 simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1).
q The positional relationship between spool (1)
and body (10) [where fine control hole (f) is
between drain chamber (D) and pump pres-
sure chamber (PP)] does not change until
retainer (9) comes in contact with spool (1).
q Since metering spring (2) is compressed in
proportion to the stroke of the control lever, the
pressure in port (P1) rises in proportion to the
stroke of the control lever.
q 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, D475ASD-5E0 31
3) When in fine control 4) When lever is operated to stroke end

(When control lever is returned) q If disc (5) pushes down piston (4) and retainer
q If lever (5) begins to return, the force of center- (9) pushes down spool (1), fine control hole (f)
ing spring (3) and the pressure in port (P1) is disconnected from drain chamber (D) and
push up spool (1). connected to pump pressure chamber (PP).
q As a result, fine control hole (f) is connected to q Accordingly, the pilot oil flows through fine con-
drain chamber (D) and the oil in port (P1) is trol hole (f) and port (P1) into port (B) and
released. pushes the control valve spool.
q If the pressure in port (P1) lowers too much, q The oil returning from port (A) flows through
spool (1) is pushed down by metering spring port (P2) and fine control (f’) into drain cham-
(2) and fine control hole (f) is disconnected ber (D).
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simulta-
neously. Then, the pump pressure is applied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q 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).
32 D475A, D475ASD-5E0
5) When blade is “floated” 6) When “FLOAT” state of blade is reset

q If piston (4) on the “LOWER” side of port (P1) q Disc (5) is pushed down with a force larger
is pushed down by disc (5), ball (11) touches than the oil pressure in chamber (E) to return
projection (a) of the piston in the middle of the from the “FLOAT” position.
stroke (The detent starts to operate). q As a result, chamber (E) is disconnected from
q If piston (4) is pushed in further, ball (11) passage (d) and connected to the drain cham-
pushes up collar (12) supported on detent ber. Accordingly, the oil pressure in chamber
spring (13) and escapes out to go over projec- (E) is lost and the “FLOAT” state is reset.
tion (a) of the piston.
q At this time, piston (4') on the opposite side is
pushed up by spring (14).
q 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 con-
nected to port (P1), almost the same pressure
is applied to passage (d) and port (P1).
q Chamber (E) is normally connected to drain
chamber (D). If ball (11) goes over projection
(a) of the piston, passage (d) and chamber (E)
are connected and the oil starts flowing.
q At this time, the control valve moves to the
“FLOAT” position and the blade is floated.
q Since piston (4') is pushed up by the pressure
in chamber (E), the “FLOAT” state is kept even
if the lever is released.
D475A, D475ASD-5E0 33
2. Ripper PPC valve
P : From self pressure reducing valve 1. Spool

P1 : To ripper tilt valve PPC port 2. Metering spring
P2 : To ripper tilt valve PPC port 3. Centering spring
P3 : To ripper lift valve PPC port 4. Piston
P4 : To ripper lift valve PPC port 5. Disc
T : To tank 6. Nut (For connecting lever)
7. Joint
8. Plate
9. Retainer
10. Body
11. Filter
34 D475A, D475ASD-5E0
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, D475ASD-5E0 35
Operation q Since metering spring (2) is compressed in

proportion to the stroke of the control lever, the
1) When in neutral
pressure in port (P1) rises in proportion to the
q Ports (A) and (B) of the control valve and ports stroke of the control lever.
(P1) and (P2) of the PPC valve are connected q Accordingly, the control valve spool moves to a
through fine control hole (f) of spool (1) to drain position at which the pressure in chamber (A)
chamber (D). [equal to the pressure in port (P1)] is balanced
with the force of the control valve spool return
spring.
2) When in fine control

(Neutral o Fine control)
q If piston (4) is pushed by disc (5), retainer (9) is
pushed and spool (1) is also pushed down
through metering spring (2).
q Accordingly, fine control hole (f) is discon-
nected from drain chamber (D) and connected
to pump pressure chamber (PP) almost simul-
taneously, and then the pilot oil flows from port
(P1) through fine control hole (f) to port (A).
q 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 simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1). The positional rela-
tionship between spool (1) and body (10)
[where fine control hole (f) is between drain
chamber (D) and pump pressure chamber
(PP)] does not change until retainer (9) comes
in contact with spool (1).
36 D475A, D475ASD-5E0
3) When in fine control 4) When lever is operated to stroke end

(When control lever is returned) q If disc (5) pushes down piston (4) and retainer
q If disc (5) begins to return, the force of center- (9) pushes down spool (1), fine control hole (f)
ing spring (3) and the pressure in port (P1) is disconnected from drain chamber (D) and
push up spool (1). connected to pump pressure chamber (PP).
q As a result, fine control hole (f) is connected to q Accordingly, the pilot oil flows through fine con-
drain chamber (D) and the oil in port (P1) is trol hole (f) and port (P1) into chamber (A) and
released. pushes the control valve spool.
q If the pressure in port (P1) lowers too much, q The oil returning from chamber (B) flows
spool (1) is pushed down by metering spring through port (P2) and fine control (f’) into drain
(2) and fine control hole (f) is disconnected chamber (D).
from drain chamber (D) and connected to
pump pressure chamber (PP) almost simulta-
neously. Then, the pump pressure is applied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q 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).
D475A, D475ASD-5E0 37
PCCS lever 1
Travel and steering PCCS lever
a Do not disassemble the PCCS lever. If it is disassembled, the output voltage characteristics and operat-
ing effort characteristics will need to be adjusted.
1. Bellows 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
38 D475A, D475ASD-5E0
Function
1. Operating effort characteristics
1) Operation for forward and reverse travel 2) Operation for steering
q The control lever is held at 3 positions of For- q Free return.
ward, Neutral, and Reverse.
D475A, D475ASD-5E0 39
2. Output voltage characteristics

q The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
q The operating angle (stroke) of the control
lever is sensed with potentiometers and signal
voltages are output to the transmission and
steering controller.
q A potentiometer is installed in each of longitu-
dinal direction and lateral direction. Each
potentiometer outputs 2 signal voltages which
are opposite to each other as shown in the fig-
ure at right.
40 D475A, D475ASD-5E0
SEN00214-00

© 2006 KOMATSU
All Rights Reserved
42
SEN00215-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Control valve ........................................................................................................................................ 2
CLSS.................................................................................................................................................. 17
Unload valve ...................................................................................................................................... 20
Introduction of LS pressure ................................................................................................................ 21
LS bypass plug................................................................................................................................... 22
Pressure compensation valve ............................................................................................................ 23
Blade lift valve .................................................................................................................................... 26
Merge-divider valve............................................................................................................................ 34
Self pressure reducing valve.............................................................................................................. 36
Pilot solenoid valve ............................................................................................................................ 40
D475A, D475ASD-5E0 1

Control valve 1
Outline
q This control valve consists of a 6-spool valve
and a merge-divider valve.
q 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 main-
tain.
A1 : To ripper lift cylinder head P10 : From blade tilt PPC valve
A2 : To blade tilt right cylinder head P11 : From ripper tilt PPC valve
A3 : To blade lift cylinder head P12 : From ripper tilt PPC valve
A4 : To blade lift cylinder head PLS1 : To rear pump control
A5 : To blade tilt left cylinder head PLS2 : To front pump control
A6 : To ripper tilt cylinder head PP1 : From rear main pump
B1 : To ripper lift cylinder bottom PP2 : From front main pump
B2 : To blade tilt right cylinder bottom PPS1: To rear pump control
B3 : To blade lift cylinder bottom PPS2: To front pump control
B4 : To blade lift cylinder bottom PR : To solenoid valve, PPC valve, and EPC valve
B5 : To blade tilt left cylinder bottom PS : From merge-divider solenoid valve
B6 : To ripper tilt cylinder bottom PST : From port PR
P1 : From ripper lift PPC valve SA : Pressure sensor mounting port
P2 : From ripper lift PPC valve SB : Pressure sensor mounting port
P3 : From blade tilt PPC valve T : To tank
P4 : From blade tilt PPC valve TS : To tank
P7 : From blade lift PPC valve
P8 : From blade lift PPC valve
P9 : From blade tilt PPC valve
1. 6-spool valve
2. Cover 1
3. Cover 2
4. Merge-divider valve
2 D475A, D475ASD-5E0
6-spool valve
(1/8)
D475A, D475ASD-5E0 3
(2/8)
4 D475A, D475ASD-5E0
(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, D475ASD-5E0 5
(4/8)
6 D475A, D475ASD-5E0
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}
354 N 283 N
12 Spool return spring 72.3 x 37.0 65.5 —
{36.1 kg} {28.9 kg}
274 N 219 N
{27.9 kg} {22.3 kg}
D475A, D475ASD-5E0 7
(5/8)
8 D475A, D475ASD-5E0
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, D475ASD-5E0 9
(6/8)
10 D475A, D475ASD-5E0
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, D475ASD-5E0 11
(7/8)
12 D475A, D475ASD-5E0
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, D475ASD-5E0 13
(8/8)
14 D475A, D475ASD-5E0
1. Unload valve
3. Merge-divider valve (For main)
4. Spool return spring
5. Merge-divider valve (For LS)
6. Spool return spring
7. Valve (Sequence valve)
8. Spring (Sequence valve)
9. LS bypass plug
10. Spring (Safety valve)
11. Ball
12. Valve (Pressure reducing valve)
13. Spring (Main pressure reducing valve)
14. Spring (Pilot pressure reducing valve)
15. Poppet
16. Screw
17. Spring (Safety valve)
18. Ball
Unit: mm

Free length
x Outside Free length
19 Check valve spring length load load
diameter
1.5 N 1.2 N If spring is
11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg} damaged or
156.8 N 125.5 N deformed,
20 Spool return spring 46.6 x 21.8 33 — 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
22 Sequence valve spring 70.9 x 18 59 —
{20.4 kg} {16.3 kg}
D475A, D475ASD-5E0 15
Main relief valve
1. Spring
2. Poppet
Function
q The main relief valve sets the maximum pump
pressure of the main valve.
Operation
q The set pressure of the relief valve depends on
the installed load of spring (1).
16 D475A, D475ASD-5E0
CLSS 1
1. Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q The CLSS consists of a main pump (2 pumps),
tem, and has the following features. control valve, and actuators for the work equip-
q Fine control not influenced by load ment.
q Control enabling digging even with fine control q The work equipment pump body consists of
q Ease of compound operation ensured by flow the pump itself, CO valve and LS valve.
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
D475A, D475ASD-5E0 17
2. Basic principle
1) Control of pump swash plate
q The pump swash plate angle (pump delivery q If LS differential pressure (dPLS) becomes
amount) is controlled so that LS differential lower than the set pressure of the LS valve
pressure (dPLS) [the difference between pump (when the actuator load pressure is high), the
pressure (PP) and control valve outlet port LS pump swash plate moves towards the maxi-
pressure (PLS)] (load pressure of actuator) is mum position; if it becomes higher than the set
constant. pressure of the LS valve (when the actuator
[LS pressure (dPLS) = Pump discharge pres- load pressure is low), the pump swash plate
sure (PP) – LS pressure (PLS)] moves towards the minimum position.
18 D475A, D475ASD-5E0
2) Pressure compensation
q A pressure compensation valve is installed to
the outlet port side of the control valve to bal-
ance the load.
q When two actuators are operated together, this
valve acts to make pressure difference (dP)
between the upstream (inlet port) and down-
stream (outlet port) of the spool of each valve
the same regardless of the size of the load
(pressure).
q In this way, the flow of oil from the pump is
divided (compensated) in proportion to the
area of openings (S1) and (S2) of each valve.
D475A, D475ASD-5E0 19
Unload valve 1
Function
q When the pump flow is merged and the control
valve group on one side is actuated (with the
remaining control valve group at neutral), the
sub-unload valve drains the pump flow to the
group that is at neutral.
Operation
q 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}.
q The pressurized oil in pump passage (A) is
stopped by valve (1) and cannot escape, so
the pr essur e r ises . When this pr essur e
becomes larger than the force of spring (2),
valve (1) moves to the left, ports (C) and (D)
are interconnected, and the pump pressure
flows to tank passsage (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.
q 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.
20 D475A, D475ASD-5E0
Introduction of LS pressure 1
(LS shuttle valve)
1. Main pump 4. Check valve

2. Main spool 5. LS shuttle valve
3. Pressure compensation valve
Function Operation
q LS pressure (PLS) is the actuator load pres- q When main spool (2) is operated, pump dis-
sure at the output side of the control valve. charge pressure (PP) starts to flow to actuator
q The upstream pressure (= spool meter-in circuit (A).
downstream pressure) of pressure compensa- q First, this pump discharge pressure (PP)
tion valve (3) is taken inside main spool (2) and passes through introduction hole (a) of main
goes to LS shuttle valve (5). spool (2), and is taken to LS circuit (PLS).
q When this happens, it connects actuator circuit q When actuator circuit pressure (A) rises to the
(A) and LS circcuit (PLS) through check valve necessary pressure, pump pressure (PP) rises
(4), and sets so that LS pressure (PLS) C actu- and check valve (4) inside main spool (2)
ator load pressure. opens. The high pressure of LS circuit (PLS)
q Introduction hole (a) inside main spool (2) has then flows to actuator circuit (A).
a small diameter, so it also acts as a throttle. q In this way, LS pressure (PLS) becomes
almost the same as actuator circuit pressure
(A).
D475A, D475ASD-5E0 21
LS bypass plug 1
1. Main pump Function

2. Main spool q The residual pressure in LS circuit (PLS) is
3. Pressure compensation valve released from orifices (b) and (c).
4. LS shuttle valve q This reduces the speed of the rise in the LS
5. LS bypass plug pressure, and prevents any sudden change in
the oil pressure. Furthermore, a pressure loss
is generated by the circuit resistance between
LS shuttle valve (4) and throttle (a) of main
spool (2) according 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.
22 D475A, D475ASD-5E0
Pressure compensation valve 1

1. When the load pressure is higher than other actuators
1. Main pump Function

2. Valve q When the maximum load pressure is gener-
3. Shuttle valve ated during compound operations and during
4. Piston independent operations, and the load pressure
5. Spring is higher than other actuators, the pressure
6. LS shuttle valve compensation valve acts as a load check valve
to prevent reverse flow in the circuit.
Operation
q If pump pressure (PP) and LS pressure (PLS)
are lower than actuator circuit (B), shuttle valve
(3) inside the pressure compensation valve
moves to the left in the direction of the arrow to
interconnect spring chamber (C).
q When this happens, piston (4) is pushed to the
right by spring (5), so pump outlet circuit (A)
closes. This prevents the oil from flowing back
from actuator circuit (B) to pump outlet circuit
(A).
D475A, D475ASD-5E0 23
2. When the load pressure is lower than other actuators
Function Operation
q During compound operations, if the load pres- q 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 q When this happens, LS pressure (PLS) for the
this case, it tries to make the load pressure for other actuator also increases, so this LS pres-
the other actuators greater and reduce the flow sure (PLS) pushes shuttle valve (3) of the
of oil. pressure compensation valve to the right in the
direction of the arrow, passes through the pas-
sage inside piston (4), and flows to spring
chamber (C).
q As a results, piston (4) is pushed to the right in
the direction of the arrow, and the outlet side of
pump circuit (PP) is closed, so outlet port pres-
sure (A) (spool meter-in downstream pressure)
becomes the same as the outlet port pressure
of the other actuators.
q Pump pressure (PP) (spool meter-in upstream
pressure) is the same between all actuators,
so pump pressure (PP) and outlet port pres-
sure (A) become 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.
24 D475A, D475ASD-5E0
Blade lift valve 1

Function
q 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
26 D475A, D475ASD-5E0
Operation
q 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).
q At this time, the oil does not flow in either of the
head and bottom of the blade lift cylinder.
D475A, D475ASD-5E0 27
2. When blade lift lever is set in RAISE position
28 D475A, D475ASD-5E0
Operation
q If the blade lift lever is set in the RAISE posi-
tion, the pilot pressure is applied through the
blade PPC valve to chamber (E) and spool (3)
moves to the left.
q The oil from the main pump flows through
notch (11) of spool (3) and cylinder port (A) to
the cylinder head.
q The oil returning from the cylinder bottom flows
through cylinder port (B) and notch (9) of spool
(3) to drain port (D).
D475A, D475ASD-5E0 29
3. When blade lift lever is set in LOWER position
30 D475A, D475ASD-5E0
Operation
q If the blade lift lever is set in the LOWER posi-
tion, the pilot pressure is applied through the
blade PPC valve to chamber (F) and spool (3)
moves to the right.
q 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.
q At this time, the oil from the main pump flows
through notch (10) of spool (3) and cylinder
port (B) to the cylinder bottom.
q The oil returning from the cylinder head flows
through cylinder port (A) and notch (12) of
spool (3) to drain port (C).
D475A, D475ASD-5E0 31
4. When blade lift lever is set in FLOAT position
32 D475A, D475ASD-5E0
Operation
q If the blade lift lever is moved from the LOWER
position to the FLOAT position, the pilot pres-
sure is applied through the blade PPC valve to
chamber (F) and spool (3) moves further to the
right.
q At this time, retainer (5) moves against the
total load of springs (6) and (7) until its right
end touches plug (8).
q 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, D475ASD-5E0 33
Merge-divider valve 1
1. Main spool Operation

2. Spring 1. When oils from pumps are merged
3. LS spool (When pilot pressure (PS) is turned OFF)
4. Spring q Since pilot pressure (PS) is turned OFF, main
spool (1) is pressed to the left by spring (2) and
Function ports (E) and (F) are connected.
q The merge-divider valve merges or divides oils q Accordingly, oils (PP1) and (PP2) discharged
(PP1) and (PP2) discharged from 2 pumps (It from the 2 pumps are merged in ports (E) and
distributes those oils to each control valve (F) and sent to the control valves which need
group). them.
q This valve also merges and divides the LS cir- q Similarly, LS spool (3) is pressed to the left by
cuit pressures. 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).
q 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 pres-
sure compensation valves and other hydraulic
equipment.
34 D475A, D475ASD-5E0
2. When oils from pumps are divided

(When pilot pressure (PS) is turned ON)
q 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 discon-
nected.
q Accordingly, oils discharged from the 2 pumps
are sent to the set control valves respectively.
Pressure (PP1): Blade right tilt valve
Pressure (PP2): Blade left tilt valve
q 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 to (D).
The other ports are disconnected.
q As a result, the pressures in LS circuit ports
(A), (B), (C), and (D) are transmitted to the set
control valves respectively.
D475A, D475ASD-5E0 35
Self pressure reducing valve 1
Function q Poppet (11) is pressed by spring (12) against

q The self pressure reducing valve lowers the the seat and the passage between port (PR)
discharge pressure of the main pump and sup- and (TS) is closed.
plies it as the control pressure for the solenoid q Valve (14) is pressed to the left by spring (13)
valves, PPC valves, etc. and the passage between ports (P2) and (PR)
is open.
Operation q Valve (7) is pressed to the left by spring (8) and
1. When engine is stopped the passage between ports (P2) and (A2) is
closed.
36 D475A, D475ASD-5E0
2. When in neutral and when load pressure (P2) is low

[When load pressure (A2) is lower than self pressure reducing valve output pressure (PR)]
Operation
q Valve (7) is pressed by spring (8) and (PR) q Accordingly, differential pressure is generated
pressure (which is 0 MPa {0 kg/cm2} while the over orifice (a) in spool (14), and spool (14)
engine is stopped) to close the passage moves in the direction to close the passage
between ports (P2) and (A2). If hydraulic oil between ports (P2) and (PR). The P2 pressure
flows in through port (P2), however, (ød area x is lowered and controlled to a constant pres-
pressure P2) = force of spring (8) + (ød area x sure (set pressure) by the opening ratio of the
PR pressure), and they are balanced. Then, passage at this time and supplied as the PR
the passage between ports (P2) and (A2) is so pressure.
adjusted that the P2 pressure will be kept at a
certain value higher than the PR pressure.
q 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, D475ASD-5E0 37
3. When load pressure (P2) is high
Operation
q If load pressure (A2) is heightened and the q Accordingly, differential pressure is generated
pump delivery amount is increased because of over orifice (a) in spool (14) and spool (14)
digging operation, etc., the P2 pressure rises moves in the direction to close the passage
{(ød area × P2 pressure) > force of spring (8) + between ports (P2) and (PR). The P2 pressure
(ød area × PR pressure)}, then valve (7) is lowered and controlled to a constant pres-
moves to the right stroke end. sure (set pressure) by the opening ratio of the
q As a result, the opening ratio of the passage passage at this time and supplied as the PR
between ports (P2) and (A2) is increased and pressure.
the passage resistance is reduced. Conse-
quently, the loss of the engine horsepower is
reduced.
q 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).
38 D475A, D475ASD-5E0
4. When abnormally high pressure is generated
Operation
q If the PR pressure of the self pressure reduc-
ing valve is raised abnormally, ball (16) sepa-
rates 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. Accordingly, the devices receiving the
oil pressure (PPC valves, solenoid valves, etc.)
are protected from abnormally high pressure.
D475A, D475ASD-5E0 39
Pilot solenoid valve 1
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
40 D475A, D475ASD-5E0
q 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, D475ASD-5E0 41
SEN00215-00

© 2006 KOMATSU
All Rights Reserved
42
SEN00216-00

2SHOP
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Hydraulic tank, hydraulic filter .............................................................................................................. 2
Accumulator ......................................................................................................................................... 4
Work equipment cylinder...................................................................................................................... 6
Piston valve.......................................................................................................................................... 8
Quick drop valve ................................................................................................................................ 10
Blade control knob (Dual tilt specification) ......................................................................................... 12
Blade control knob (Superdozer specification)................................................................................... 13
Pitch and dual solenoid valve............................................................................................................. 14
Pin puller hydraulic circuit diagram .................................................................................................... 15
Pin puller solenoid valve .................................................................................................................... 16
D475A, D475ASD-5E0 1

Hydraulic tank, hydraulic filter 1
1. Pressure valve 6. Oil filler cap

2. Cover 7. Hydraulic filter element
3. Sight gauge 8. Spring
4. Cover 9. Suction valve
5. Hydraulic tank 10. Strainer
11. Drain plug
12. Drain valve
2 D475A, D475ASD-5E0
Specified value
Tank capacity (l) 310
Hydraulic High (l) 210

tank Level inside
Center (l) 170
tank
Low (l) 140
Cracking pressure 38.2 ± 6.9
(kPa {kg/cm2}) {0.39 ± 0.07}
Breather
cap Vacuum valve
0 – 0.49
actuating pressure
{0 – 0.005 }
(kPa {kg/cm2})
Specified value
Cracking pressure 150 ± 30
(kPa {kg/cm2}) {1.53 ± 0.3}
Hydraulic Mesh size (µm) 30/8
filter
Filtering area (cm )
2
17,600
Filtering oil flow (l/min) 703
Mesh size (µm) 105
Strainer 2
Filtering area (cm ) 3,600
D475A, D475ASD-5E0 3
Accumulator 1
For PPC valve Operation
q After the engine is stopped, when the PPC
valve is at neutral, chamber (A) inside the blad-
der is compressed by the oil pressure in cham-
ber (B).
q When the PPC valve is operated, the oil pres-
sure 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.
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
q 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
compressed inside the accumulator sends the
pilot pressure to the main control valve to actu-
ate it and enable the work equipment to move
down under its own weight.
4 D475A, D475ASD-5E0
Work equipment cylinder 1

q Blade lift cylinder
q Blade tilt cylinder, superdozer pitch cylinder
q Ripper lift cylinder, ripper tilt cylinder
6 D475A, D475ASD-5E0
q Pin puller 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
–0.200 +0.013 0.400
Clearance
between piston +0.207 Replace
2 Ripper lift 110 1.0
rod support shaft +0.120
and bushing
+0.207
Ripper tilt 110 1.0
+0.120
Ball –0.100
Pin puller
29 –0.200
Clearance
between cylinder –0.145
3 Blade lift 145
support shaft –0.245
bushing and yoke
+0.457
Blade tilt 90 — — 1.0
+0.370
Clearance
between cylinder +0.207
4 Ripper lift 110 1.0
bottom support +0.120
shaft and bushing
+0.195
Ripper tilt 110 1.0
+0.122
Clearance between cylinder
5 26 +0.1
bottom support shaft and boss
D475A, D475ASD-5E0 7
Piston valve 1
For blade lift cylinder
Outline 2. When piston valve is “open”

q The piston valve is installed to the piston of the The end of valve (6) touches the cylinder bot-
blade lift cylinder. When the piston moves to tom before piston rod (1) reaches the stroke
the stroke end, the piston valve relieves the oil end, and then valve (6) and piston valve (3) do
sent from the work equipment pump to lower not move any more and only piston (2) contin-
the oil pressure applied to the piston. ues moving.
The piston valve also relieves the oil before the At this time, the oil on the cylinder head side
piston reaches the bottom or head of the cylin- which has been stopped by piston valve (3) is
der to reduce the impact made at the stroke relieved through piston valve seats (4) and (5),
end and lower the surge pressure generated thus the oil pressure in the cylinder does not
by the impact. rise any more.
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 piston (2) to the right.
8 D475A, D475ASD-5E0
Quick drop valve 1

For blade lift cylinder 2. While lowering blade
The oil pushed out of the cylinder head side
Outline flows through port (B) to port (C).
The quick drop valve is installed to each of the right At this time, a pressure difference is made
and left blade lift cylinders. It increases the lowering between before and after orifice (a).
speed of the blade and prevents a vacuum on the If the pressure difference becomes larger than
cylinder bottom side during the lowering stroke and the tension of spring (4), it compresses the
shortens the time lag in starting digging. The blade spring and moves spool (2) and check valve
lowering speed is almost determined by the pump (3) to the right.
delivery amount. It can be heightened, however, by Then, ports (B) and (A) are connected and a
the quick drop valve. 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.
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.
10 D475A, D475ASD-5E0
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

2 Valve spring length load load
136.3 N 122.6 N
75.2 55.9 67.7
{13.9 kg} {12.5 kg}
D475A, D475ASD-5E0 11
Blade control knob (Dual tilt specification) 1
1. Switch (dual-single selector switch) q If switch (2) is pressed and the lever is oper-
2. Switch (pitch) ated, the blade is pitched. If the lever is tilted to
3. Cover the left, the blade is pitched back. If the former
4. Connector (male) is tilted to the right, the latter is pitched for-
5. Connector (female) ward.
q If switch (1) is set to the “DUAL” position and
Outline the lever is operated, blade carries out dual tilt
q If the blade control knob is tilted forward, back- operation. If the lever is tilted to the left, the
ward, to the right, or to the left, the blade is blade carries out left dual tilt operation. If the
raised, lowered, tilted to the right, or tilted to the lever is tilted to the right, the blade carries out
left. If switch (1) is set to the “DUAL” position right dual tilt operation.
and the lever is tilted to the right or left, dual tilt q If switch (1) is set in either “DUAL” or
operation is carried out. If the lever is tilted to “SINGLE” position and the lever is tilted to the
the right or left while switch (2) is pressed and right or left while switch (2) is pressed and
held, pitching operation is carried out. held, the blade is pitched.
12 D475A, D475ASD-5E0
Blade control knob (Superdozer specification) 1
1. Forward pitch switch Outline

2. Rear pitch switch q The blade is raised and lowered by leaning the
3. Cover blade control knob forward and backward.
4. Connector (male) q 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, D475ASD-5E0 13
Pitch and dual solenoid valve 1
1. Connector Outline
2. Solenoid (a) q The pitch and dual solenoid valve is installed
3. Valve between the PPC valve and main control valve
4. Solenoid (b) and used to select the PPC pilot pressure.
5. Manual push pin q Operation of the pitch switch of the blade con-
trol lever (or the rear pitch switch or forward
A: Port A pitch switch of the superdozer specification),
B: Port B pilot pressure can be applied so the right and
P: Port P left pitch cylinders will move similarly and the
T: Port T tilt operation can be changed to the pitch oper-
ation.
q 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.
q The pitch and dual tilt solenoid valve is oper-
ated by the controller.
14 D475A, D475ASD-5E0
Pin puller hydraulic circuit diagram 1
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
7. Pin-puller solenoid valve converter lockup circuit
D475A, D475ASD-5E0 15
Pin puller solenoid valve 1
1. Plug A. To pin puller cylinder head

2. Spring B. From power train pump
3. Spring retainer C. To pin puller cylinder bottom
4. Valve body D. To steering case
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
16 D475A, D475ASD-5E0
Operation
1. Pin puller switch at PUSH IN position 2. Pin-puller switch at PULL OUT position
When the pin-puller switch is turned to the When the pin puller switch is turned to the
PUSH IN position, no current flows to solenoid PULL OUT position, current flows to solenoid
(9) and it is deactivated. (9) and it is excited.
When this happens, spool (5) opens ports (A) When this happens, the solenoid pushes out
and (B) and ports (C) and (D), and the oil from push pin (8), and spool (5) moves to the left in
the power train pump flows from port (A) to the direction of the arrow.
port (B) and enters the bottom of pin puller cyl- Ports (A) and (B) and ports (C) and (D) close,
inder (10). and ports (A) and (C) and ports (B) and (D)
The oil entering the bottom end of the cylinder open. The oil from the power train pump flows
increases the hydraulic pressure in the circuit from port (A) to port (C) and enters the head of
and extends the cylinder. Shank mounting pin pin puller cylinder (10).
(11) is pushed into shank (12). 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 (12).
D475A, D475ASD-5E0 17
SEN00216-00

© 2006 KOMATSU
All Rights Reserved
18
SEN00217-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Cylinder stay ........................................................................................................................................ 2
Blade .................................................................................................................................................... 4
Ripper equipment................................................................................................................................. 8
D475A, D475ASD-5E0 1
Work equipment 1
Cylinder stay 1
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
2 D475A, D475ASD-5E0
Blade 1
Full U-dozer, Semi U-dozer, Superdozer
Unit: mm
4 D475A, D475ASD-5E0

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 200 0.2 – 0.6 1
–0.3 +0.6 or replace
surface
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 –0.043 +0.225 0.149 –
14 145 2
link pin and blade bracket –0.108 +0.106 0.333
Clearance between center –0.043 +0.225 0.149 –
15 145 2
link pin and center link –0.108 +0.106 0.333
Clearance between center –0.2 +0.3
16 550 0.2 – 1.1 2
link and blade bracket –0.8 +0.6
Clearance between center –0.2 +0.3 Adjust shim
17 200 0.2 – 0.6 1
brace spherical surface and cap –0.3 +0.6 or replace
Clearance between lift –0.3 +0.5
18 65 0.5 – 1.0 2
cylinder 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 –0.3 +0.5
21 65 0.5 – 1.0 2
joint and lateral pin –0.5 +0.2
D475A, D475ASD-5E0 5
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
6 D475A, D475ASD-5E0
Ripper equipment 1
Variable giant ripper
8 D475A, D475ASD-5E0
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, D475ASD-5E0 9
SEN00217-00
D475A, D475ASD-5 Bulldozer

© 2006 KOMATSU
All Rights Reserved
10
SEN00218-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Cab and its attachments
Cab and its attachments ................................................................................................................................. 2
Cab mount............................................................................................................................................ 2
Cab....................................................................................................................................................... 3
Air conditioner ...................................................................................................................................... 6
D475A, D475ASD-5E0 1
Cab and its attachments 1

Cab mount 1
1. Support Outline
2. Damper mount (front) q Mounts are installed at two places at the front
3. Damper mount (rear) and two places at the rear to secure the floor
frame and cab.
q An oil-filled damper mount is used to absorb
the vibration.
2 D475A, D475ASD-5E0
Cab 1
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D475A, D475ASD-5E0 3
ROPS guard
1. ROPS guard
4 D475A, D475ASD-5E0
Air conditioner 1
Air conditioner piping
6 D475A, D475ASD-5E0
1. Condenser
2. Air conditioner compressor
3. Refrigerant piping
4. Window defroster
5. Side defroster
6. Vent
7. Hot water pickup piping
8. Valve (hot water outlet)
9. Receiver tank
10. Hot water return piping
11. Valve (hot water inlet)
12. Air conditioner unit
13. Additional blower motor
A. Fresh air
B. Recirculated air
C. Hot air/cold air
D475A, D475ASD-5E0 7
SEN00218-00

© 2006 KOMATSU
All Rights Reserved
8
SEN00219-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Electrical system
Electrical system ............................................................................................................................................. 2
Engine control ...................................................................................................................................... 2
Engine control system.......................................................................................................................... 3
Deceleration potentiometer .................................................................................................................. 4
CRI engine control system ................................................................................................................... 6
Monitor system..................................................................................................................................... 8
Monitor panel ......................................................................................................................................11
Sensors .............................................................................................................................................. 15
Mode selection system....................................................................................................................... 18
Electrical equipment........................................................................................................................... 24
Steering electronic control system ..................................................................................................... 27
VHMS controller ................................................................................................................................. 29
Communication (ORB: ORBCOMM) controller/antenna .................................................................... 35
D475A, D475ASD-5E0 1
Electrical system 1
Engine control 1
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 throttle controller pedal are operated, it controls the fuel injection
6. Decelerator pedal 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 signal
9. Fuel control dial enter the machine controller, are processed
10. Battery (left) together with other data, and are sent to the
11. Battery relay (left) electronic engine throttle controller as the
12. Starting motor throttle command.
13. Fuel supply pump The electronic engine throttle controller con-
trols the fuel supply pump according to the
command.
This machine uses CRI system.
2 D475A, D475ASD-5E0
Engine control system 1
Outline
q The engine throttle controller receives the q The steering controller sends the most suitable
manual signals of the 1st throttle, 2nd throttle for engine speed from informations 1) and 2)
and the 3rd throttle signals which is the control and transmits it as the 3rd throttle to the engine
signals from the machine body, then selects throttle controller.
the lower engine speed and controls the fuel q Information of the engine throttle controller is
supply pump. commonly used by all the controllers through-
The 3rd throttle control signals contain the fol- out the network, for optimum control of the
lowing. engine and machine body.
1) High idle speed control q The automatic deceleration function sets the
2) SSC (Shoe Slip Control) engine speed to 1,000 rpm temporarily when
3) Automatic deceleration (F3, R3, R2) the travel direction is changed from F3, R3, or
R2 (to protect the transmission clutch).
D475A, D475ASD-5E0 3
Deceleration potentiometer 1
1. Connector Outline
2. Lever q The deceleration potentiometer is installed to
3. Body the front lower part of the operator’s cab and
4. Potentiometer connected to the decelerator pedal by linkage.
5. Coupling q If the decelerator pedal is pressed, the throttle
6. Shaft potentiometer shaft rotates by the linkage and
7. Stopper 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
throttle controller according to the position of
the decelerator pedal.
4 D475A, D475ASD-5E0
CRI engine control system 1

a CRI: Abbreviation for Common Rail Injection.
System diagram
Outline
q The signals detected by various sensors are
input to the engine throttle controller.
q The input signals are processed by the control-
ler and output to each actuator to control the
fuel injection rate and fuel injection timing.
6 D475A, D475ASD-5E0
1. Fuel tank System configuration

2. Fuel supply pump assembly q The CRI system consists of the fuel supply
2A. PCV pump (2), common rail (5), injector (8), engine
2B. High pressure pump throttle controller (9) to control them, and sen-
2C. Priming pump sors.
2D. Feed pump q The fuel supply pump generates fuel pressure
2E. Bypass valve in the common rail. The fuel pressure is con-
2F. G speed sensor trolled by the fuel discharge rate of the supply
3. Fuel filter pump.
4. Overflow valve The discharge rate is controlled by turning on
5. Common rail and off PCV (discharge control valve) (2A) of
6. Pressure limiter the fuel supply pump according to the electric
7. Flow damper signals from the engine throttle controller.
8. Injector assembly The common rail receives the pressurized fuel
8A. Orifice from the fuel supply pump and distributes it to
8B. Control chamber the cylinders.
8C. Hydraulic piston The fuel pressure is sensed by the common
8D. Injector rail fuel pressure sensor installed to the com-
8E. Nozzle mon rail and controlled by the feedback
9. Engine throttle controller method so that the actual fuel pressure will
10. NE speed sensor match to the command pressure set according
to the engine speed and the load on the
engine.
The fuel pressure in the common rail is applied
to nozzle (8E) side of the injector and control
chamber (8B) through the fuel injection pipe of
each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve). If the TWV is
turned on, the fuel circuit is so changed that
the high-pressure fuel in the control chamber
will flow through orifice (8A). The needle valve
is raised to start fuel injection by the nozzle
cracking pressure applied as the high-pressure
fuel on the nozzle side. If the TWV is turned
off, the fuel circuit is so changed that the high-
pressure fuel will be applied to the control
chamber through the orifice. As a result, the
needle valve lowers and finishes fuel injection.
Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.
D475A, D475ASD-5E0 7
Monitor system 1
q The monitor system monitors the machine con- q In the monitor panel, there are various mode
dition with sensors installed to various parts of selector switches of the SSC (Shoe Slip Con-
the machine, and quickly processes and dis- trol), which are used to operate the machine
plays obtained information on the monitor control system (with SSC).
panel, to notify the operator of machine condi- q The monitor panel has the functions of display-
tion. ing data and selecting the SSC mode (with
The function of the monitor system is as fol- SSC).
lows. q The CPU (Central Processing Unit) in it pro-
1) Function which turns on the alarm when cesses, displays, and outputs the information.
the machine has a trouble on the monitor. The display unit is LCD (Liquid Crystal Display)
2) Function which constantly displays the and the switches are seat switches.
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
voltage of the sensors and solenoids.
8 D475A, D475ASD-5E0
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 o Steering
F1, R3, etc. are notified by CAN according to CAN controller o Monitor panel
information of transmission controller. (Controller
Area Network)
2) Display of engine speed in gauge number. CAN Engine speed sensor o Steering
The number of pulses the engine rotation is controller o Monitor panel
converted into a gauge number and notified to the
monitor panel by CAN.
3) Display of failure
When the machine has a failure, the corresponding CAN Engine sensor/solenoid o Steering
failure code is notified to the monitor panel by CAN. controller or transmission controller
Which one should be turned on, the buzzer or the o Monitor panel
caution lamp, is notified, too.
i) In normal state
User code
ii) In fault history display mode Sensors and solenoids o Engine
The service code (6-digit code) and the throttle controller o Steering
following items are displayed controller o 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
section.
Display of monitoring conditon

1) The communication conditions of each sensor, CAN Each sensor o Steering controller
each solenoid, and CAN are displayed. or transmission controller o Monitor
The item Nos. and device conditions are notified to panel
the monitor panel by CAN.
The monitor panel displays the items and each Sensors o Engine throttle controller
value on its multi-information section. o Steering controller o Monitor
panel
2) Each items is selected by using the cursor
switches, selector switches, buzzer cancel switch, Monitor panel o Controller o
and shift UP/DOWN switches. Monitor panel
Other items
1) Function selection mode (Displayed each time CAN Steeging controller o Monitor panel
cancel switch is turned to left)
i) Replacement periods of oil filter and oil are
displayed.
ii) Engine speed, oil pressure in work equipment
circuit, etc. are displayed.
iii) Failure codes related to electronic control are
displayed.
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
D475A, D475ASD-5E0 9
Monitor panel 1
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. Lockup 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. Fan operation confirmation lamp
Outline 2. Start-up inspection

q The monitor potion consists of a monitor that 1) After all lighting of Section 1 is terminated,
issues an alarm when an error occurred in a if there is an error in a start-up inspection
vehicle, a gauge that always displays the state item, the item flashes.
of the 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 run-
and processes and displays signals from each ning is judged by the signal (CAN) from
sensor. the engine controller.)
Besides, the items displayed on the monitor 3. Cautions
portion and gauge portion are listed in the table Caution items are checked until the engine
on the next page. stops after the engine starts.
If an error occurs, the error is displayed by
Operation flashing and the alarm lamp synchronously
1. When the power turns on (When the start- flashes.
ing switch is ON) Further, if an emergency item flashes, the
1) All items of the gauge and monitor por- alarm buzzer also sounds synchronously.
tions come on for three seconds. a Flashing of the monitor and alarm lamp is
2) The alarm lamp comes on for two sec- repeated. They come on and off for about 0.8
onds. second.
a The flashing period of the monitor slightly
changes when atmospheric temperature is low
(below about –10°C), but this case is not
abnormal.
D475A, D475ASD-5E0 11
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
When sensor is abnormal or

Check
Engine oil level when wiring harness is

disconnected
Display when abnormal: ON
Hydraulic oil level Below low level
Battery charge When charge is defective

Displays when starting switch is
Caution 1
SAP00522 ON and engine is running

Display when abnormal: Flashes
When clogged: Less than CAUTION lamp flashes
Air clever clogging
6.37 kPa {–650 mmH2O}
Engine oil pressure Below 49.0kPa {0.5kg/cm2}
Radiator coolant level Below low level
When at highest level (108°C or

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

Torque converter oil Display when normal: OFF
above) on engine coolant
temperature Display when abnormal: Flashes
temperature gauge
CAUTION lamp flashes
Alarm buzzer sounds
Hydraulic oil
105±3°C or above
temperature
Hydraulic oil level Below low level
When replacement time of filter

Maintenance
or oil has been passed
12 D475A, D475ASD-5E0
Display
Symbol Display item Display range Display method
category
Lights according to required time
determined by engine controller
based.
Preheating When preheating It also lights at the time of manual
preheat by setting starting switch
at preheat position (turning it
Pilot
counterclockwise).
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
temperature
Torque converter oil One place lights up to show

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

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

Multi
From 0 to 99999
(Hours meter) rotating
D475A, D475ASD-5E0 13
Switch portion
1. Switch functions
1) ON-OFF switching in lockup mode
2) Economy mode setting – OFF, mode 1, mode 2
3) ON-OFF switching in reverse slow mode
4) ON-OFF switching in SSC mode
5) 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.
q SSC specifications
q 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
and all functions shall be set to the OFF state. output in each mode so that the frequency of decel-
erator operation can decrease.
q Economy mode 1 o Set to about 90% of the
full power.
q Economy mode 2 o Set to about 70% of the
full power.
q REVERSE slow mode o Set to about 80% of
the full travel speed at reverse time.
14 D475A, D475ASD-5E0
Sensors 1
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 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
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
D475A, D475ASD-5E0 15
Radiator coolant level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
Fuel level sensor
1. Connector Function
2. Float q The fuel level sensor is installed to the side
3. Arm face of the fuel tank. The float moves up and
4. Body down according to the fuel level. This move-
5. Spring ment of the float is transmitted by the arm and
6. Contact actuates a variable resistance. This sends a
7. Spacer signal to the monitor panel to indicate the
remaining fuel level. When the display on the
monitor panel reaches a certain level, a warn-
ing lamp flashes.
16 D475A, D475ASD-5E0
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
D475A, D475ASD-5E0 17
Mode selection system 1

(SSC (Shoe Slip Control) System)
System diagram
Outline
q The mode selection system automatically car- q The lockup control mode is the same as the
ries out engine control to match the operating conventional lockup function. It cannot be
mode selected by the operator, and acts to selected in combination with the above modes.
reduce fuel consumption, extend the life of the
track shoes, and reduce the frequency of oper-
ation of the deceleration.
q The engine control modes consist of the econ-
omy mode control used when dozing, the SSC
(shoe slip control) used when ripping, and the
reverse slow mode control, which can be used
for either operation.
18 D475A, D475ASD-5E0
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 controller
to receive the commands from the steering control-
ler and controls the fuel injection pump, transmis-
sion controller to turn on and off the lockup 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
sensor 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 trans-
mission 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 lockup sig-
nal to the lockup solenoid valve, judging from
input gear speed information from the trans-
mission controller.
a See "Operation of torque converter lockup
control system".
Function of engine controller

q 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 potenti-
ometer, manual signal of the throttle dial, and
the SSC command signal.
D475A, D475ASD-5E0 19
Operation of mode selection system

q Work can be performed under the optimum conditions by simply or simultaneously selecting five modes
in accordance with the contents of work.
Simultaneous
Work Mode Single selection Mode work conditions Mode operation, characteristic
switch selection
• ON/OFF switching is automatically 1. When the torque converter approaches to the
performed in accordance with the load. stall area or performs gear shift operation, lock-up
is set to OFF. When the torque converter reaches
a light load, lock-up is set to ON.
Speed number of F1, F2, F3, 2. Can be used in all number of gear ratios.
Lock-up
gear ratios R1, R2, R3 3. Simultaneous selection disabled with another

Low ON 1,360 rpm or more mode
4. Suitable for dozing work of comparatively a few
T/C speed OFF 1,330 rpm or more load fluctuations.
output side
shaft High ON 2,570 rpm or more
speed speed
side OFF 2,600 rpm or more
Dozing
1. When F1 is shifted with the economy 1. When the economy mode (1 or 2) and SSC are
mode switch 1) or 2) ON set simultaneously, the F1 shift economy control
is performed. When the ripper lever is actuated
and the switch is turned on, the slip control is
Economy
performed.
2. The engine output can be suppressed in two
stages without performing the decelerator
operation of the engine.
Mode 1): 90% (at 1.5 km/h)
Mode 2): 65% (at 1.5 km/h)
3. At neutral time, the engine speed can be
suppressed partially.
1. When R1, R2, and R3 are shifted 1. The engine speed can be suppressed without
Reverse slow
performing the decelerator operation of the

engine.
2. Target travel speed at reverse time
R1
R2 70% at full operation
R3
The following conditions are satisfied: 1. At start, to prevent rashing out, the modulating
1) When F1 is shifted. valve is actuated. At this time, the steering
2) After the ripper down, ripper tilt levers controller performs index characteristic down
are actuated and the switch is set to of about 40% and performs the engine output
ON control if a ripper down signal is input.
SSC (Shoe Slip Control)
2. The steering controller performs the engine

output control in accordance with the index
Ripping
force characteristic (refer to the rock-bed

selection shown below) selected by the operator
among the index force characteristics set in five
stages and suppresses the generation of a slip.
3. The steering controller regards the index force
immediately before the slip (exceeding the shoe
slipping ratio of 30% is generated, as the
maximum, and performs the engine output
control. At this time, the steering controller
performs index characteristic down of about 30
to 80% and performs the engine output control
if a ripper tilt or ripper up signal is input.
4. At neutral time, the engine speed is suppressed
partially.
Rock-bed
selection
Set to ON in connection with SSC 1. When the SSC is set to ON, the selection mode
3 comes on.
2. 1 ⇔ 3 ⇔ 5 is selected in accordance with the
state and load of the rock-bed.
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.
20 D475A, D475ASD-5E0
Sensors
Transmission output shaft speed sensor
1. Magnet 4. Boots
2. Terminal 5. Connector
3. Case
Torque converter speed sensor
1. Connector
2. Flange
3. Sensor
D475A, D475ASD-5E0 21
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
q The acceleration sensor is installed under the

front of the operator’s cab.
q With the acceleration sensor, the position of
the ball inside the sensor changes according to
the acceleration.
q 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 controller.
q The input and output characteristics of the sen-
sor are shown in the diagram below.
22 D475A, D475ASD-5E0
Pitch angle sensor
1. Body
2. Tube
3. Wire
4. Connector
q The sensor is filled with electrolyte. If sensor

leans, the electrolyte surface slants. If electro-
lyte surface slants, the contact area of two
electrodes installed in the sensor with electro-
lyte changes. As a result, electrostatic capacity
between the two electrode changes. The
change of electrostatic capacity is output as a
change of voltage.
q The input and output characteristics of the sen-
sor are shown in the figure at right.
D475A, D475ASD-5E0 23
Electrical equipment 1
Relay box
24 D475A, D475ASD-5E0
Operation of lamp system
Lamp system circuit diagram
D475A, D475ASD-5E0 25
Preheating (Electrical intake air heater) control
Preheating circuit
26 D475A, D475ASD-5E0
Steering electronic control system 1
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
D475A, D475ASD-5E0 27
Shift mode function Auto-shift-down function

Function Function
If you shift the lever to the forward or reverse, the If the load is increased while the machine is travel-
gear speed selected from the shift mode is turned ing or working at the 2nd or 3rd gear speed, the
on. gear speed is shifted down automatically.
q The drawbar pull (load on the machine) is cal-
Type of modes culated from the engine speed, travel speed,
q F1-R1 (Manual mode) and throttle information from the steering con-
q F1-R2 (Shift mode 1) troller, and the gear speed is shifted down
q F2-R2 (Shift mode 2) automatically according to the load and travel
speed.
Selecting method q Once the gear speed is automatically shifted
Shift the PCCS lever to “N”. down, it is not automatically shifted up to the
Select the shift mode using UP or DOWN switch. former position. (Gear speed can be shifted up
with the manual switch.)
Display q This function is applicable to both forward and
The selected shift mode is displayed on the monitor reverse travels.
panel.
How to use
Turn auto-shift-down switch (1) ON.
Manual mode
Down switch ON Up switch ON
Shift mode 1
Down switch ON Up switch ON
Shift mode 2
28 D475A, D475ASD-5E0
VHMS controller 1
D475A, D475ASD-5E0 29
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 Input
CN1-2 Sensor power supply (24V) Output CN2-A2 NC Input
CN1-3 Sensor power supply (12V) Output CN2-A3 Input
CN1-4 Sensor power supply (5V) Output CN2-A4 NC Input
CN1-5 Sensor power supply (5V) Output CN2-A5 Exhaust temperature (Right 1) Input
Power supply (Constant power supply) CN2-A6 Exhaust temperature (Left 2) Input
CN1-6 Input
(24V)
CN2-A7 Exhaust temperature (Left 1) 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 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 Exhaust temperature (Right 2) 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 Wake up HI —
CN2-B7 NC Input
CN2-B8 NC —
CN2-B9 GND Input
CN2-B10 NC Input
CN2-B11 NC Input
CN2-B12 CONNECTOR (GND) Input
30 D475A, D475ASD-5E0
CN3 [CN 3 A, B] CN4 [CN 4 A, B]

Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
CN3-A1 Input CN4-A1 NC —
CN3-A2 CAB out D/L Sw Input CN4-A2 NC —
CN3-A3 NC Input Input/
CN4-A3 RS232C GND
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 CAN (0) shield CGC Input
CN3-A6 NC Input
Input/
CN3-A7 Input CN4-A6 CAN (0) H CGC
Output
Input/
CN3-A8 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/
CN3-A16 NC Input CN4-A14 CAN (0) L CGC
Output
CN3-A17 NC Input CN4-B1 NC —
Input/ CN4-B2 NC —
CN3-A18 NC
Output
CN4-B3 RS232C GND 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
D475A, D475ASD-5E0 31
Sensors
Engine oil temperature sensor Exhaust temperature sensor/amplifier
Specifications Specifications
Type of sensor: Thermistor Rated voltage: DC 24 V
Measurement range: 40 – 130°C Sensed temperature range: 100 – 1,000°C
80 – 130°C 300 – 800°C
(Assured accuracy: ±2°C) (Assured accuracy: ±10°C)
Max. power consumption: 0.5 mW Output voltage characteristics
Pressure resistance: 4.9 MPa {50 kg/cm2} (Ambient temperature: 20°C)
– Reference values
Using temperature: –30°C to +140°C
Sensed
Performance table
temperature 50 100 400 700 800
Temper- Resis- Temper- Resis- Temper- Resis- (°C)
ature tance ature tance ature tance
Output voltage
(°C) (kz) (°C) (kz) (°C) (kz) 1.191 1.397 2.626 3.899 4.316
(V)
30 35.27 80 6.571 110 2.887
40 24.28 85 5.682 115 2.544 Operating temperature range: –40 to +110°C
Current consumption: Max. 30 mA
50 17.05 90 4.931 120 2.248
a: Heat sensing part of sensor – Outside diame-
60 12.20 95 4.293 125 1.992
ter of mounting part: R1/8
70 8.884 100 3.750 130 1.769 b: Amplifier
a: Heat sensing part of sensor – Outside diame- c: Connector (Power supply side)
ter of mounting part: R1/4 d: Connector (Sensor side)
Function Function
The exhaust temperature sensor/amplifier is a ther-
The engine oil temperature sensor is installed to
mocouple-type temperature sensor, which is
the engine oil filter. It inputs the change of the tem-
installed to the turbocharger inlet. It outputs the
perature as the change of the thermistor resistance
exhaust temperature data to the VHMS controller.
to the VHMS controller.
32 D475A, D475ASD-5E0
Atmospheric temperature sensor

Specifications
Power consumption: Max. 0.5 mW
Pressure resistance: 0.98 MPa {10 kg/cm2}
Sensed temperature range (ambient):
–30 to +120°C
Storage temperature range: –50 to +140°C
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 diame-

ter 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.
D475A, D475ASD-5E0 33
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.
q The blow-by pressure sensor is a fine relative
pressure sensor which measures the differ-
ence between the pressure in the crankcase
and the atmospheric pressure.
q The pressure in the crankcase is applied to the
tip side of the sensor and the atmospheric
pressure is applied to the wiring harness side.
Transmission main oil pressure sensor

1. Sensor
2. Connector
34 D475A, D475ASD-5E0
Communication (ORB: ORBCOMM) controller/antenna 1

Controller Antenna
Specifications Specifications
Source voltage: DC 12 V – DC 30 V Type: Helical whip antenna (1)
Size: W306 x D152 x H52 (mm) Impedance: 50 z
Connectors Input terminal:N-P type
CN1A (ORB-A): AMP070-14 Length: 165 ± 20 mm
CN1B (ORB-B): AMP070-10 a. Communication antenna mounting part
CN2: Communication antenna cable connector
Function
The communication controller transmits the data
collected and stored by the VHMS controller to the
computer center via the communication satellite.
D475A, D475ASD-5E0 35
SEN00219-00

© 2006 KOMATSU
All Rights Reserved
36
SEN01816-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard value table for engine ........................................................................................................... 2
Standard value table for chassis .......................................................................................................... 3
D475A, D475ASD-5E0 1
SEN01816-00 20 Standard value table
Standard service value table 1

Standard value table for engine 1
Machine model D475A, D475ASD-5E0

Engine SAA12V140E-3
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idle (*1) 2,150 ± 50 2,150 ± 50
Speed Low idle rpm 650 ± 50 650 ± 50
Rated speed 2,000 —
Intake air pressure
At rated output kPa {mmHg} Min. 132.30 {1000} —
(Boost pressure)
Whole speed range
Exhaust temperature °C Max. 650 Max. 700
(Outside air temperature: 20°C)
At sudden acceleration Max. 4.5 Max. 5.5
Exhaust gas color Bosch index
At high idle (*1) Max. 1.0 Max. 2.0
Valve clearance Intake valve 0.35 ± 0.02 —
mm
(At normal temperature) Exhaust valve 0.57 ± 0.02 —
Compression pressure
Oil temperature: 40 – 60 °C MPa {kg/cm2} Min. 4.1 {42} Min. 2.0 {20}
(Engine oil: SAE15W-40
(Engine speed) (rpm) (200 – 250) (200 – 250)
or SAE30)
Blow-by pressure Coolant temperature:
kPa
(Engine oil: SAE15W-40 Within operating range Max. 2.94 {300} Max. 5.88 {600}
{mmH2O}
or SAE30) At rated output
At high idle
SAE0W30EOS
SAE5W40EOS 0.29 – 0.44
Min. 0.20 {2.0}
SAE10W30DH {3.0 – 4.5}
SAE15W40DH
Oil pressure SAE30DH MPa
(oil temperature: 90 –
At low idle {kg/cm2}
110°C)
SAE0W30EOS
SAE5W40EOS
Min. 0.08 {0.8} Min. 0.07 {0.7}
SAE10W30DH
SAE15W40DH
SAF30DH
Oil temperature Whole speed range (In oil pan) ºC 80 – 110 Max. 120
Deflection under finger pres-
Tension of alternator belt mm 20 ± 2 —
sure of 58.8 N {6 kg}
Tension of air condi- Deflection under finger pres-
mm 20 ± 2 —
tioner compressor belt sure of 58.8 N {6 kg}
(*1): Refer to the item 3. of “Measuring engine speed” in Testing and adjusting, Part 1.
2 D475A, D475ASD-5E0
Standard value table for chassis 1

Category
Standard value
Service limit
Measurement item Measurement conditions Unit for new
value
machine
Deceleration low idle • Engine coolant temperature: Within operating
range 900 ± 50 900 ± 50
speed
• Power train oil temperature: Within operating
Deceleration high idle range
• Hydraulic oil temperature: Within operating 2,000 ± 50 2,000 ± 50
speed
Engine speed
range
• Deceleration low idle: Press decelerator pedal
Torque converter stall • Deceleration high idle: Set forward-reverse rpm
lever in neutral + Set work equipment control 1,690 ± 50 Min. 1,590
speed lever in neutral
• Torque converter stall: Stall at F3
Torque converter stall + • Torque converter stall + Work equipment relief
Work equipment relief speed: Stall at F3 + Raise ripper or relieve 1,615 ± 75 Min. 1,450
speed pitch back circuit
• Stop engine
Decelerator pedal mm 45 ± 15 45 ± 15
• Press pedal to center
Forward, Neutral o Forward 30 ± 5 30 ± 5

reverse Neutral o Reverse 30 ± 5 30 ± 5
PCCS • Stop engine 40 ± 5 40 ± 5
Neutral o Left mm
lever • Set lever to center (Play: Max. 3) (Play: Max. 3)
Steering
Control lever and pedal stroke
40 ± 5 40 ± 5
Neutral o Right
(Play: Max. 3) (Play: Max. 3)
Full stroke 78 ± 10 78 ± 10
• Run engine at low idle
Brake pedal Stroke to oil pres- mm
• Press pedal to center 58 ± 10 58 ± 10
sure of 0
Neutral o Float 90 ± 10 90 ± 10
• Run engine at low idle
• Hydraulic oil tempera- Neutral o
60 ± 10 60 ± 10
Blade control lever ture: Raise/Lower mm
Within operating range
• Set lever to center Neutral o
60 ± 10 60 ± 10
Left/Right tilt
• Run engine at low idle Neutral o
• Hydraulic oil tempera- 78 ± 10 78 ± 10
Raise/Lower
Ripper control lever ture: mm
Within operating range Neutral o
• Set lever to center 81 ± 10 81 ± 10
Tilt in/out
59 ± 9.8 59 ± 9.8
Control lever and pedal operating effort
• Stop engine
Decelerator pedal N{kg}
• Press pedal to center {6.0 ± 1.0} {6.0 ± 1.0}
Neutral o 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
o 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 o Left
{2.6 ± 0.5} {2.6 ± 0.5}
Steering
28.4 ± 4.9 28.4 ± 4.9
Neutral o Right
{2.9 ± 0.5} {2.9 ± 0.5}
D475A, D475ASD-5E0 3

Category
Standard value
Service limit
value
machine
• Run engine at low idle 490.3 ± 49.0 490.3 ± 49.0

Brake pedal N{kg}
• Press pedal to center {50.0 ± 5.0} {50.0 ± 5.0}
Control lever and pedal operating effort
39.2 ± 9.8 39.2 ± 9.8

Neutral o Raise
{4.0 ± 1.0} {4.0 ± 1.0}
• Run engine at low idle 39.2 ± 9.8 39.2 ± 9.8
• Hydraulic oil tempera- Neutral o Lower {4.0 ± 1.0} {4.0 ± 1.0}
Blade control lever ture: N{kg}
Within operating range 82.4 ± 13.7 82.4 ± 13.7
• Set lever to center Neutral o Float
{8.4 ± 1.4} {8.4 ± 1.4}
Neutral o 28.4 ± 9.8 28.4 ± 9.8
Left/Right tilt {2.9 ± 1.0} {2.9 ± 1.0}
• Run engine at low idle Neutral o 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 o 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
idle
• Hydraulic oil tempera- rpm
ture: Within operating Engine at high
Fan
Min. speed 980 ± 50 Max. 880

range idle
• Fan 100% mode
Engine at high MPa 15.2 ± 2.5 15.2 ± 2.5
Circuit oil pressure
idle {kg/cm2} {155 ± 25} {155 ± 25}
0.78 – 0.98 0.78 – 0.98
High idle
Torque converter inlet pres- {8 – 10} {8 – 10}
sure 0.03 – 0.20 0.03 – 0.20
Low idle
{0.3 – 2} {0.3 – 2}
0.39 – 0.64 0.39 – 0.64
High idle
Torque converter outlet {4 – 6.5} {4 – 6.5}
pressure 0.03 – 0.15 0.03 – 0.15
Low idle
{0.3 – 0.15} {0.3 – 0.15}
Torque converter lock-up 1.3 – 1.42 1.3 – 1.42
High idle
clutch pressure {11.5 – 14.5} {11.5 – 14.5}
Power train oil pressure
2.55 – 2.74 Min. 2.55

High idle
Torque converter stator {26.0 – 28.0} {Min. 26.0}
clutch pressure • Power train oil temper- MPa 2.55 – 2.74 Min. 2.45
ature: Within operating Low idle
range {kg/cm2} {26.0 – 28.0} {Min. 25.0}
2.65 – 2.98 2.55 – 3.04
High idle
Transmission main relief {27.0 – 30.4} {26.0 – 31.0}
pressure 2.35– 2.89 2.45 – 3.04
Low idle
{24.0 – 29.5} {25.0 – 31.0}
Transmission F clutch pres- 2.35 – 2.74 2.25 – 2.74
Low idle
sure {24.0 – 28.0} {23.0 – 28.0}
Transmission R clutch 2.35 – 2.74 2.25 – 2.74
Low idle
pressure {24.0 – 28.0} {23.0 – 28.0}
Transmission 1st clutch 1.96 – 2.35 1.86 – 2.35
Low idle
pressure {20.0 – 24.0} {19.0 – 24.0}
Transmission 2nd clutch 2.35 – 2.74 2.25 – 2.74
Low idle
pressure {24.0 – 28.0} {23.0 – 28.0}
4 D475A, D475ASD-5E0

Category
Standard value
Service limit
value
machine
Transmission 3rd clutch 2.35 – 2.74 2.25 – 2.74
Low idle
pressure {24.0 – 28.0} {23.0 – 28.0}
Transmission lubricating 0.15 – 0.29 0.15 – 0.29
High idle
pressure {1.5 – 3.0} {1.5 – 3.0}
2.65 – 2.98 Min. 2.45
High idle
{27.0 – 30.4} Min. {25}
Steering left clutch pressure
2.35 – 2.89 2.26 – 2.89
Low idle
{24.0 – 29.5} {23.0 – 29.5}
2.65 – 2.98 Min. 2.45

High idle
{27.0 – 30.4} {Min. 25}
Steering left brake pressure • Power train oil tem-
MPa 2.35 – 2.89 2.26 – 2.89
perature: Within Low idle
operating range {kg/cm2} {24.0 – 29.5} {23.0 – 29.5}
2.65 – 2.98 Min. 2.45
High idle
Steering right clutch pres- {27.0 – 30.4} {Min. 25}
sure 2.35 – 2.89 2.26 – 2.89
Low idle
{24.0 – 29.5} {23.0 – 29.5}
2.65 – 2.98 Min. 2.45
High idle
Steering right brake pres- {27.0 – 30.4} {Min. 25}
sure 2.35 – 2.89 2.26 – 2.89
Low idle
{24.0 – 29.5} {23.0 – 29.5}
2.65 – 3.03 Min. 2.55
Ripper pin puller pressure Low idle
{27.0 – 30.9} {Min. 26}
Forward 1st 3.3 ± 0.3 3.3 ± 0.3
When lockup switch
Forward 2nd 6.2 ± 0.3 6.2 ± 0.3

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

• Run engine at high
idle Reverse 1st 4.2 ± 0.3 4.2 ± 0.3
• Engine coolant Reverse 2nd 8.0 ± 0.4 8.0 ± 0.4
temperature: Within
Power train
operating range Reverse 3rd 14.0 ± 0.7 14.0 ± 0.7

Travel speed • Economy mode: km/h
OFF Forward 1st 3.4 ± 0.3 3.4 ± 0.3
When lockup switch
• Reverse slow
mode: OFF Forward 2nd 6.3 ± 0.3 6.3 ± 0.3
• Run-up distance: Forward 3rd 11.6 ± 0.6 11.6 ± 0.6
is ON
10 – 30 m
• Measuring dis- Reverse 1st 4.4 ± 0.3 4.4 ± 0.3
tance: 20 m
Reverse 2nd 8.4 ± 0.4 8.4 ± 0.4
Reverse 3rd 14.3 ± 0.7 14.3 ± 0.7
D475A, D475ASD-5E0 5

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
Blade Low
{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 • Hydraulic {245 ± 14} {245 ± 14} {280 ± 14} {280 ± 14}
Divide
Relief pressure
tilt oil temper- 21.1 ± 1.4 21.1 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
ature: Low
Dual tilt
45 – 55°C MPa {215 ± 14} {215 ± 14} {280 ± 14} {280 ± 14}
• Relieve {kg/cm2} 27.4 ± 1.4 27.4 ± 1.4 24.0 ± 1.4 24.0 ± 1.4
only circuit High
Right dual to be mea- {280 ± 14} {280 ± 14} {245 ± 14} {245 ± 14}
Divide
tilt sured 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}
6 D475A, D475ASD-5E0

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
• Hydraulic {250 ± 14} {250 ± 14} {250 ± 14} {250 ± 14}
steering Merge
Relief pressure
oil temper-
tilt ature: 23.0 ± 1.4 23.0 ± 1.4 23.0 ± 1.4 23.0 ± 1.4
Blade Low
45 – 55°C MPa {235 ± 14} {235 ± 14} {235 ± 14} {235 ± 14}
single • Relieve {kg/cm2}
tilt only circuit High 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
Right to be mea- {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
steering Merge sured
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, D475ASD-5E0 7

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
Blade Low
{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 • Hydraulic {255 ± 14} {255 ± 14} {255 ± 14} {255 ± 14}
Divide
Relief pressure
dump oil temper- 21.1 ± 1.4 21.1 ± 1.4 21.1 ± 1.4 21.1 ± 1.4
ature: Low
{215 ± 14} {215 ± 14} {215 ± 14} {215 ± 14}
Super
Blade 45 – 55°C MPa

dual tilt • Relieve {kg/cm2} 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4 27.4 ± 1.4
only circuit High
Pitch to be mea- {280 ± 14} {280 ± 14} {280 ± 14} {280 ± 14}
Divide
back sured 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}
8 D475A, D475ASD-5E0

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 idle {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
steering tilt {18 ± 2} {18 ± 2}

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, D475ASD-5E0 9

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
steering tilt {18 ± 2} {18 ± 2}

1.76 ± 0.2 1.76 ± 0.2
Pitch dump
• Hydraulic oil temperature: {18 ± 2} {18 ± 2}
Super
Blade
dual tilt • Run engine at high idle 1.76 ± 0.2 1.76 ± 0.2
Pitch back
{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 {30 – 50} {30 – 50}
control levers in neutral
Work equipment control oil Within operating range 3.92 – 4.51 Min. 3.72
• Set all work equipment
pressure control levers in neutral {40 – 46} {Min. 38}
• Engine at high idle
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 idle
Work equipment
Blade tilt cylinder • Hydraulic oil temperature: 5 20

Leak- Within operating range
age Blade pitch cylinder • Run engine at high idle 5 20
cc/min
from Ripper shift cylinder • Measure leakage for 1 5 20
cylinder minute while relieving cyl-
Ripper tilt cylinder inder 5 20
10 D475A, D475ASD-5E0

Category
Standard
Service limit
Measurement item Measurement conditions Unit value for new
value
machine
Measuring posture
Low
14 ± 3.5 Max. 20.0
idle
Raise
Blade lift High
5.0 ± 0.5 Max. 6.0
(Single tiltdozer idle
specification) sec
(Dual tiltdozer Low
specification) 1.8 ± 0.3 Max. 2.5
idle
Within operating range Lower
• Apply no load on blade. High
• Between blade on ground and rais- 1.8 ± 0.3 Max. 2.5
idle
ing stroke end
Measuring posture
Low
15.8 ± 3.5 Max. 22.0
idle
Raise
High
5.1 ± 0.5 Max. 7.0
Blade lift idle
(Superdozer sec
specification) Low
1.7 ± 0.3 Max. 3.0
idle
Work equipment

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

idle
ing stroke end
Measuring posture
Low
4.0 ± 1.5 Max. 6.5
idle
Left tilt
High
3.3 ± 0.5 Max. 6.0
Blade tilt idle
(Single tiltdozer sec
specification) Low
4.4 ± 1.5 Max. 6.0
idle
Within operating range Right tilt
• Between left tilt end and right tilt 3.6 ± 0.5 Max. 6.0
idle
end
Measuring posture
Low
5.5 ± 1.5 Max. 8.0
idle
Left tilt
High
3.1 ± 0.5 Max. 5.0
Blade tilt idle
(Dual tiltdozer sec
specification) Low
5.5 ± 1.5 Max. 8.0
idle
• Between left tilt end and right tilt 3.1 ± 0.5 Max. 5.0
idle
end
D475A, D475ASD-5E0 11

Category
Standard
Service limit
value
machine
Measuring posture
Low
4.0 ± 1.5 Max. 6.0
idle
Left tilt
High +0.5
3.3 Max. 6.0
Blade tilt idle -0.8
(Superdozer sec
specification) Low
4.4 ± 1.5 Max. 6.5
idle
• Apply no load on blade. High +0.5
• Between left tilt end and right tilt 3.6 Max. 6.0
idle -0.8
end
Measuring posture Low

9.6 ± 1.5 13.0
idle
Pitch
dump
High
Blade speed
4.4 ± 0.5 6.0

Blade pitch idle
(Dual tiltdozer sec
specification) Low
6.6 ± 1.6 Max. 10.0
• Hydraulic oil temperature: idle
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 idle

23.0 ± 3.0 Max. 30
idle
Pitch
dump
High
7.8 ± 1.0 Max. 10
Blade pitch idle
(Superdozer sec
specification) Low
16.0 ± 2.0 Max. 23.0
• Hydraulic oil temperature: Within idle
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 idle

7.7 ± 1.0 Max. 12.0
idle
Raise
High
Ripper speed
3.0 ± 0.5 Max. 4.0

idle
Ripper lift sec
Low
3.0 ± 0.5 Max. 5.0
• Select lowest shank hole.
• Between ripper on ground and rais- High
3.0 ± 0.5 Max. 4.0
ing stroke end idle
12 D475A, D475ASD-5E0

Category
Standard
Service limit
value
machine

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

idle
Ripper tilt sec
Low
9.1 ± 1.5 Max. 14.0
Within operating range Tilt out
• Select lowest shank hole.
• Between forward tilt end and rear High
3.3 ± 0.5 Max. 4.5
tilt end idle
Blade • Hydraulic oil temperature: Within operating Low

— —
(Single tiltdozer range idle
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) idle
sec
• Hydraulic oil temperature: Within operating Low
Time lag
Blade — —
range idle
(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
idle
• 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 idle
with ground until sprocket 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, D475ASD-5E0 13

Category
Standard
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 sprocket center height (h) in 5
minutes.
14 D475A, D475ASD-5E0
SEN01816-00

© 2006 KOMATSU
All Rights Reserved
16
SEN01817-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Testing and adjusting, Part 1........................................................................................................................... 3
Tools for testing, adjusting, and troubleshooting .................................................................................. 3
Measuring engine speed...................................................................................................................... 6
Measuring intake air pressure (boost pressure)................................................................................... 9
Measuring exhaust temperature .........................................................................................................11
Measuring exhaust gas color ............................................................................................................. 13
Adjusting valve clearance .................................................................................................................. 15
Testing compression pressure ........................................................................................................... 17
Measuring blow-by pressure .............................................................................................................. 19
Measuring engine oil pressure ........................................................................................................... 21
Handling of fuel system devices......................................................................................................... 22
Releasing residual pressure from fuel system ................................................................................... 22
Testing fuel pressure .......................................................................................................................... 23
Handling of reduced cylinder mode operation.................................................................................... 24
Handling of no injection cranking operation ....................................................................................... 24
Testing fuel return and leak amount ................................................................................................... 25
D475A, D475ASD-5E0 1
SEN01817-00 30 Testing and adjusting
Bleeding air from fuel circuit ............................................................................................................... 28

Testing fuel circuit for leakage ............................................................................................................ 30
Testing and adjusting alternator belt tension ...................................................................................... 31
Testing and adjusting belt tension for air conditioner compressor...................................................... 32
Adjusting fuel control dial and decelerator pedal................................................................................ 33
2 D475A, D475ASD-5E0
Testing and adjusting, Part 1 1

Tools for testing, adjusting, and
troubleshooting 1
Quantity
Symbol
Testing or adjusting
Part No. Part name Remarks
item
Air boost pressure 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
A
(boost pressure) 790-401-2220 Hose 1
Coolant temperature,
oil temperature and B 799-101-1502 Digital temperature gauge 1 –99.9 – 1,299°C
exhaust temperature
1 799-201-9001 Handy smoke checker 1
Exhaust gas color C Commercial Bosch index: 0 – 9
2 Smoke meter 1
item
Commercial
Valve clearance D Thickness gauge 1
item
0 – 6.9 MPa {0 – 70 kg/cm2}
1 795-502-1590 Compression gauge 1
KIT Part No.: 795-502-1205
Compression pressure E
2 795-471-1310 Adapter 1
3 6217-71-6150 Gasket 1
Blow-by pressure F 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Engine oil pressure G
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester 1
1 *As common as G1
Testing fuel pressure H 2 799-401-2320 Hydraulic tester 1 *As common as G2
3 795-471-1450 Adapter 1
4 07005-00812 Gasket 1
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
Commercial
3 Hose 1
item
Commercial
Testing fuel return and 4 Hose 1
J item
leak amount
Commercial
5 Measuring cylinder 1
item
Commercial
6 Stopwatch 1
item
7 07376-70315 Plug 1
1 *As common as G1
Power train oil pressure K 2 799-401-2320 Hydraulic tester 1 *As common as G2
799-101-5220 Nipple (10 x 1.25 mm) 1
3
07002-11023 O-ring 1
D475A, D475ASD-5E0 3
Quantity
Symbol
item
19M-06-32820 Switch assembly 1

1
Emergency escape 17M-06-41530 Wiring harness 1
method when power L 799-101-5220 Nipple (10 x 1.25 mm) 1
train has trouble 2
07002-11023 O-ring 1
3 790-190-1601 Pump assembly 1
1 *As common as G1
566-35-43561 Nipple (18 x 1.5 mm) 1
Testing and adjusting 2
07002-11823 O-ring 1
work equipment and M
HSS oil pressure 3 799-101-5160 Nipple (R1/8) 1
4 799-401-2701 Differential pressure gauge 1
799-101-5220 Nipple (10 x 1.25 mm) 1
5
07002-11023 O-ring 1
Testing control circuit 799-101-5002 Hydraulic tester 1
N 1 *As common as G1
basic pressure 790-261-1204 Digital hydraulic tester 1
1 *As common as G1
Measuring PPC valve 790-261-1204 Digital hydraulic tester 1
P
output pressure 2 799-401-3100 Adapter (size 02) 1
3 799-401-3200 Adapter (size 03) 1
Measuring ripper pin 799-101-5002 Hydraulic tester 1

1 *As common as G1
puller solenoid valve Q 790-261-1204 Digital hydraulic tester 1
output pressure 2 799-401-3200 Adapter (size 03) 1 *As common as P3
Measuring internal
Commercial
leakage of work R Measuring cylinder 1
item
equipment cylinder
Measuring fan motor
S 799-205-1100 Tachometer KIT 1
speed
Measuring fan pump 799-101-5002 Hydraulic tester 1
T 1 *As common as G1
circuit pressure 790-261-1204 Digital hydraulic tester 1
Adjusting blade tilt
U 799-402-3800 Angle gauge 1
angle control
79A-264-0021 0 – 294 N {0 – 30 kg} 1
Operating effort V
79A-264-0091 0 – 490 N {0 – 50 kg} 1
Stroke and hydraulic Commercial
W Scale 1
drift item
Commercial
Work equipment speed X Stopwatch 1
item
Commercial
Voltage and resistance Y Tester 1
item
1 799-608-3211 Diskette 1
Initializing VHMS con- 2 799-608-3220 Harness 1
Z
troller Commercial Notebook type personal OS: Windows 98/2000/Me/XP
3 1
item computer Terminal "RS232C" is with it
4 D475A, D475ASD-5E0
Quantity
Symbol
item
799-601-4100 T-adapter 1 For engine

799-601-7400 T-adapter 1 For AMP040
799-601-7500 T-adapter 1 For AMP070
799-601-9100 T-adapter 1 For HD30
Diagnosis of sensor 799-601-9200 T-adapter 1 For DT connector
—
and harness 799-601-9300 T-adapter 1 For DRC26 (24, 26 pins)
799-601-7310 Adapter 1 For SWP 12 pins
799-601-7320 Adapter 1 For SWP 16 pins
799-601-7360 Adapter 1 For relay (5 pins)
799-601-3450 Adapter 1 For VHMS 5 pins
D475A, D475ASD-5E0 5
Measuring engine speed 1 3. Measuring high idle speed

1) Start the engine and set the fuel control
a Measure the engine speed under the following dial in the high idle position.
condition. 2) Set the PCCS lever and work equipment
q Coolant temperature: control lever in neutral and measure the
Within operating range engine speed.
q Hydraulic oil temperature: a The high idle speed measured in the
Within operating range “Monitoring mode” or in the “Pm Clinic
q Power train oil temperature: auxiliary mode” is the auto-deceleration
Within operating range speed.
a When measuring the high idle speed of
1. Preparatory work the engine, use the “Adjustment mode”.
Turn the starting switch ON and set the monitor Adjustment code:
panel in the “Monitoring mode” to prepare for 0007 (Engine decelerator cut mode)
measurement of the engine speed.
a For the operating method, see “Special
functions of monitor panel (EMMS)”.
q Monitoring code:
01002 (Left bank engine speed)
01004 (Right bank engine speed)
a Usually, confirm the left bank engine
speed.
4. Measuring decelerator pedal speed

dial in the high idle position.
2) Set the PCCS lever and work equipment
control lever in neutral, and measure the
engine speed with the decelerator pedal
depressed.
2. Measuring low idle speed

dial in the low idle position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the
engine speed.
6 D475A, D475ASD-5E0
5. Measuring torque converter stall speed 7) Perform steps 2) – 4) again and measure
a Use Adjustment mode to measure. the engine speed when the power train oil
q Adjustment mode: temperature gauge reaches position (a) of
0530 (Stall speed check mode) the green range.
k This machine is equipped with the a After finishing measurement, return
cooling fan speed control function to the direction of the PCCS lever into
protect the radiator when the engine is neutral and lower the power train oil
not fully warmed up. Since that func- temperature with the engine at high
tion does not work while this mode is idle.
used, warm up the engine fully before a After finishing measurement, finish
using this mode. the Adjustment mode.
dial in the low idle position. 6. Measuring torque converter stall + work
2) With the brake pedal depressed securely equipment relief speed (full stall speed)
and the parking brake lever in the “free” a Use Adjustment mode to measure.
position, set the PCCS lever in the “for- q Adjustment mode:
ward” and 3rd gear speed position. 0530 (Stall speed check mode)
a Before going to the next step, check 1) Start the engine and set the fuel control
that the upper display unit of the mon- dial in the low idle position.
itor panel is set in the normal display 2) With the brake pedal depressed securely
state and it displays [F3]. and the parking brake lever in the “free”
a Keep the steering unit in neutral. position, set the PCCS lever in the “for-
3) Press the decelerator pedal and set the ward” and 3rd gear speed position.
fuel control dial in the high idle position. a Before going to the next step, check
4) Return the decelerator pedal slowly to stall that the upper display unit of the mon-
the torque converter with the engine at itor panel is set in the normal display
high idle. state and it displays [F3].
k Keep pressing the brake pedal a Keep the steering unit in neutral.
securely and keep your right foot 3) Press the decelerator pedal and set the
on the decelerator pedal for safety fuel control dial in the high idle position.
until the work is finished. 4) Return the decelerator pedal slowly to stall
5) Just after the power train oil temperature the torque converter with the engine at
gauge reaches position (a) of the green high idle.
range, return the direction of the PCCS k Keep pressing the brake pedal
lever into neutral. securely and keep your right foot
on the decelerator pedal for safety
until the work is finished.
5) Operate the ripper lever to raise the ripper
lift cylinder to the stroke end or pitch back
stroke end.
6) Just after the power train oil temperature
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.
D475A, D475ASD-5E0 7
7) Repeat above steps 2) – 6) 3 times.

8) Perform steps 2) – 4) and also operate rip-
per RAISE relief and pitch back relief and
measure the engine speed when the
power train oil temperature gauge reaches
position (a) of the green range.
a After finishing measurement, return
the direction of the PCCS lever into
neutral and lower the power train oil
temperature with the engine at high
idle.
a After finishing measurement, finish
the Adjustment mode.
a The engine speed can be measured
by the following operation:
q “Pm clinic auxiliary mode” of the
monitor panel
q Each time the information switch
is set to the right or left when the
monitor panel is in the normal
display state, the display in the
multi information section turns to
the display of service meter or
engine speed. (However, mea-
sure the high idle speed of the
engine in the “Adjustment
mode”).
8 D475A, D475ASD-5E0
Measuring intake air pressure 2. Remove air intake connector boost pressure
(boost pressure) 1 pickup plugs (2) and (3) (R1/8).
a If nipple [1] is installed as standard to the
a Measuring instruments for intake air pressure intake air pressure (boost pressure) mea-
(boost pressure) suring port, install gauge [2] without
installing anything to the port.
Symbol Part No. Part name
q Plug (2): For left bank
799-201-2202 Boost gauge kit q Plug (3): For right bank
A
790-401-2220 Hose
k When installing and removing the measur-

ing instrument, take care not to touch a hot
part of the engine.
a Measure the intake air pressure (boost pres-
sure) under the following condition.
q Coolant temperature:
q Hydraulic oil temperature:
q Power train oil temperature:
1. Open the left and right side covers of the

engine.
3. Install nipple [1] of boost gauge kit A and con-

nect gauge [2].
q Left bank
D475A, D475ASD-5E0 9
q Right bank
4. Run the engine at medium or higher speed and

drain the oil from the hose.
a Insert the joint of the gauge and hose half-
way and open the self-seal on the hose
side repeatedly, and the oil is drained.
a If Pm kit (A) is available, the air bleeding
coupling (790-261-1130) in it may be
used.
a If any oil is left in the hose, the gauge does
not move. Accordingly, be sure to drain
the oil.
5. Measure the intake air pressure (boost pres-

sure) while the engine is running at high idle
and the torque converter is stalling.
a For the procedure for stalling the torque
converter, see “Measuring engine speed”.
a Normally, the intake air pressure (boost
pressure) should be measured while the
engine is running at the rated output. In
the field, however, an approximate value
can be obtained by stalling the torque con-
verter.
6. After finishing measurement, remove the mea-

suring instrument and reinstall the removed
parts.
10 D475A, D475ASD-5E0
Measuring exhaust temperature 1 2) Remove exhaust temperature measuring

plugs.
q Plug (2): For left bank front
a Measuring instrument for exhaust temperature q Plug (3): For left bank rear
q Plug (4): For right bank front
Symbol Part No. Name
q Plug (5): For right bank rear
B 799-101-1502 Digital thermometer
a Measure the exhaust temperature under the

following condition.
q Engine coolant temperature:
q Hydraulic oil temperature:
1. Check the exhaust temperature with the moni-

tor panel since the machine is equipped with
exhaust temperature sensors for the VHMS.
q Monitoring code (Right bank front): 42602
q Monitoring code (Right bank rear): 42601 3. Install sensor [1] to the measuring plugs and
q Monitoring code (Left bank front): 42600 connect them to digital thermometer B.
q Monitoring code (Left bank rear): 42606 a Clamp the wiring harness of the digital
q Unit: °C thermometer so that it will not touch a hot
a For the operating method, see “Special part during measurement.
functions of monitor panel”. a Example of the right bank rear
2. If the monitor panel is not used, measure the

exhaust temperature according to the following
procedure.
k Remove and install the measuring
instruments 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 side covers (1) of
the engine.
D475A, D475ASD-5E0 11
4. Procedure for measuring maximum exhaust 2) Stop relieving the ripper or pitch back, and
temperature for troubleshooting. lower the exhaust temperature by only
Operate the machine and measure the maxi- stalling the torque converter (Condition (b)
mum exhaust temperature. in the figure).
a Use the PEAK mode of the digital ther- a If the temperature does not lower but
mometer. rises, set the temperature to high in
a The exhaust temperature largely depends step 1).
on the outside air temperature (intake air 3) After the temperature lowers and is stabi-
temperature of the engine). Accordingly, if lized, measure it (Condition (c) in the fig-
any abnormal value is obtained, correct it ure).
by the following calculation. k Just after the power train oil tempera-
q Corrected value [°C] = Measured ture gauge reads the red range, return
value + 2 x (20 – Outside air tempera- the direction of the PCCS lever into
ture) neutral and lower the power train oil
temperature.
5. Procedure for measuring exhaust temperature

periodically for preventive maintenance 6. After finishing measurement, remove the mea-
a If the torque converter is stalled, the suring instrument and return the removed
torque converter oil temperature is over- parts.
heated before the exhaust temperature is
stabilized. Measure according to the fol-
lowing procedure.
1) Completely stall the torque converter to
raise the exhaust temperature to about
650°C according to the following proce-
dure (Condition (a) in the figure).
i) Start the engine and set the fuel con-
trol dial to the low idle 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 idle
position.
iv) Return the decelerator pedal slowly to
stall the torque converter and relieve
the ripper in raising direction or pitch
back with the engine at high idle.
k Press the brake pedal and keep
your right foot on the decelerator
pedal for safety until the work is
finished.
12 D475A, D475ASD-5E0
Measuring exhaust gas color 1 2. Measuring with smoke meter C2

1) Insert probe [1] of smoke meter C2 in the
a Measuring instrument for exhaust gas color outlet of the exhaust pipe and fix it to the
exhaust pipe with a clip.
1 799-201-9001 Handy smoke checker
C Commercial
2 Smoke meter
item
k When installing and removing the measur-

ing instrument, 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, etc.,
use smoke meter C2.
a Measure the exhaust gas color under the fol-
lowing condition.
q Coolant temperature:
Within operating range 2) Connect the probe hose, receptacle of the
accelerator switch, and air hose to smoke
1. Measuring with handy smoke checker C1 meter C2.
1) Stock a sheet of filter paper to smoke a Restrict the supplied air pressure
checker C1. below 1.5 MPa {15 kg/cm2}.
2) Insert the exhaust gas intake pipe in the 3) Connect the power cable to a receptacle
exhaust pipe. of AC100V power source.
3) Start the engine. a Before connecting the cable, check
4) As increasing the engine speed rapidly or that the power switch of the smoke
running it at high idle, operate the handle meter is turned off.
of smoke checker C1 so that the filter 4) Loosen the cap nut of the suction pump
paper will absorb the exhaust gas. and fit the filter paper.
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 to make a judge-
ment.
6) After finishing measurement, remove the
measuring instrument and reinstall the 6) Start the engine.
removed parts. 7) As increasing the engine speed rapidly or
running it at high idle, press the accelera-
tor pedal of smoke meter C2 and collect
the exhaust gas with the filter paper.
D475A, D475ASD-5E0 13
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.
measuring instrument and reinstall the
removed parts.
14 D475A, D475ASD-5E0
Adjusting valve clearance 1 a At near the compression top dead center

of the RH No. 1 cylinder, the intake valve
of RH No. 6 cylinder moves.(opens).
a Adjusting tool for valve clearance
Commercially
D Thickness gauge
available
1. Remove cylinder head cover.

a For details, see “Removal and installation
of cylinder head assembly” in Disassem-
bly and assembly.
2. Rotate the crankshaft forward and match

stamped line of R1.6 TOP on vibration damper
(1) to pointer (2), by setting RH No. 1 cylinder
to the compression top dead center while
watching the movement of the intake valve of 3. Loosen locknut (6) of RH No. 1 cylinder adjust
RH No. 6 cylinder. screw (5). Insert a clearance gauge D of speci-
fied clearance between the crosshead (4) and
rocker arm (3) and adjust the adjustment
screw to the degree that the clearance gauge
can be moved lightly.
a Valve clearance
Air Intake valve: 0.35 mm, Exhaust valve:
0.57 mm
a Crank the engine using the barring tool (B)

mounted to the front right-hand side of the
flywheel housing.
D475A, D475ASD-5E0 15
4. Tighten locknut (6) to secure adjustment

screw.
3 Locknut tightening torque:
52.9 – 64.7 Nm {5.4 – 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.
5. Hereafter crank the engine similar way in the

firing order. Match the stamped line of the
damper to the pointer and adjust the valve
clearance of each cylinder.
a Firing order
R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 –
R2 – L2 – R4 – L4
6. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
14.7 – 34.3 Nm {1.5 – 3.5 kgm}
16 D475A, D475ASD-5E0
Testing compression pressure 1 4. Install adapter E2 to the mounting hole on the

injector and compression gauge E1.
a Fit the gasket to the injector end without
a Testing tools for compression pressure fail
Symbol Part No. Part name a Fix the adapter with the injector holder.
3 Holder mounting bolt:
1 795-502-1590 Compression gauge
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
E 795-471-1310 Adapter a Apply a little amount of engine oil to the
2
6261-71-6150 Gasket connecting parts of the adapter and gauge
so that air will not leak easily.
k When measuring the compression pres-
sure, take care not to burn yourself on the 5. Install rocker arm assembly (2) and adjust the
exhaust manifold, muffler, etc. or get valve clearance.
caught in a rotating part. 3 Rocker arm assembly mounting bolt:
a Measure the compression pressure after the 93 – 103 Nm {9.5 – 10.5 kgm}
engine is warmed up. a See “Adjusting valve clearance”.
(Engine oil temperature: 40 – 60°C).
1. Remove cylinder head cover of the cylinder to

be tested for compression pressure.
a For details, see “Removal and installation
of cylinder head assembly” in Disassem-
bly and assembly.
2. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
a See “Adjusting valve clearance”.
3. Disconnect fuel high-pressure tube (3) and

injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wir- 6. Disconnect engine controller connectors (1)
ing harness on the injector side and the (PW R) and (2) (PW L).
bracket on the rocker housing side and
r e mo v e t he i n j ec to r w i r i ng h a r n es s
(Loosen the 2 terminal nuts alternately)
from the injector.
a Pass injector under the fuel path projected
sideways and pull up the injector through
wire (Do not pry the injector top up).
k If these connectors are not discon-

nected, the engine may start while you
are measuring, and that is dangerous.
Accordingly, be sure to disconnect
these connectors.
k Since connectors (1) and (2) are in the
power supply circuit, cover them on
the wiring harness side with vinyl
sheets etc. to prevent electric leakage
and grounding fault.
D475A, D475ASD-5E0 17
7. Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
a Measure the engine speed at this time,
referring to “Special functions of monitor
panel (EMMS)”.
q Monitoring code: 01002
8. After finishing testing, remove the testing tools

and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
2) Tighten bolt (13) and washer (14) tempo- 4) Tighten the clamp and spacer with the
rarily. bolt.
2 Spherical part of washer: Engine oil 5) Install rocker arm assembly.
3) Tighten sleeve nut (15) of the fuel high- 3 Rocker arm assembly mounting bolt:
pressure tube temporarily. 93 – 103 Nm {9.5 – 10.5 kgm}
4) Tighten bolt (13) permanently. a Adjust the valve clearance. For details,
3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} see “Adjusting valve clearance”.
5) Tighten sleeve nut (15) permanently. 6) Install head cover.
3 Sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm} 3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
a Install the injector wiring harness accord-

ing to the following procedure
1) Install the injector wiring harness to the
rocker arm housing and fix the connector
side with the plate. Install O-ring (16).
2) Install cap (17) with clip on the injector
side of wiring harness.
Press wiring harness (18) between the
injector top and cap to the injector main
body without slack.
3) Tighten nut (19) on the injector side.
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
18 D475A, D475ASD-5E0
Measuring blow-by pressure 1
a Measuring instrument for blow-by pressure

F 799-201-1504 Blow-by checker
a Measure the blow-by pressure under the fol-

lowing condition.
q Engine coolant temperature: Within oper-
ating range
q Power train oil temperature: Within operat-
ing range
q Hydraulic oil temperature: Within operat-
ing range 3) Install nozzle [2] of blow-by checker F and
hose [3] to blow-by hose (4) of the left
1. Check the blow-by pressure with the monitor bank and connect blow-by checker F.
panel since the machine of standard specifica-
tion is equipped with crankcase pressure sen-
sors for the VHMS.
q Monitoring code: 42800 (Blow-by pres-
sure)
q Unit: kPa
a The monitor indicates the absolute value.
2. If the VHMS is not installed, measure by the

following method.
1) Remove right and left covers (2) of engine
undercover (1).
4) Run the engine at high idle and measure

the blow-by pressure when the torque
converter is stalled.
a For details of the procedure for torque
c on v er te r stal l, s e e “ Me as u ri n g
engine speed”.
a The blow-by pressure should be mea-
sured with the engine running at rated
output. However, when measuring in
the field, a similar value can be
obtained at torque converter stall.
a If it is impossible to check at rated
output or stall speed, measure at high
idle.
2) Install nozzle [1] of blow-by checker F to In this case, the blow-by value will be
blow-by hose (3) of the right bank and about 80% of the value at rated out-
block the hose joint. put.
a Connect a short hose and tie the out-
let.
a Either of the right and left blow-by
hoses may be blocked.
D475A, D475ASD-5E0 19
a Blow-by pressure varies greatly

according to the condition of the
engine. Therefore, if the blow-by
value is considered abnormal, check
for problems connected with defective
blow-by, such as excessive oil con-
sumption, defective exhaust gas
color, and prematurely dirty or deteri-
orated oil.

measuring instrument and return the
removed parts.
20 D475A, D475ASD-5E0
Measuring engine oil pressure 1
a Measuring instruments for engine oil pressure

799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
a Measure the engine oil pressure under the fol-

lowing condition.
q Engine coolant temperature: Within oper-
ating range
1. Check the engine oil pressure with the monitor 5) After finishing measurement, remove the
panel since the machine is equipped with measuring instruments and return the
engine oil pressure sensors for the VHMS. removed parts.
q Monitoring code: 37200 (Engine oil pres-
sure)
q Unit: MPa
2. If the monitor panel is not used, measure the

engine oil pressure according to the following
procedure.
1) Open the engine left upper side cover.
2) Remove oil pressure sensor (1).
3) Install nipple [1] of hydraulic tester G1 to

the sensor mounting part and connect
them to hydraulic tester G2.
4) Run the engine at low idle and high idle
and measure the engine oil pressure at
each speed.
D475A, D475ASD-5E0 21
Handling of fuel system devices 1 Releasing residual pressure from

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low pressure cir-
The common rail fuel injection system (CRI) cuit and high pressure circuit of the fuel system
consists of more precise parts than the con- while the engine is running.
ventional fuel injection pump and nozzle. If for- Low pressure circuit: Feed pump – Fuel main
eign matter enters this system, it can cause a filter – Fuel supply pump
trouble. High-pressure circuit: Fuel supply pump –
When testing and maintaining the fuel system, Common rail – Fuel injector
take care more than the past. If dust, etc. sticks a The pressure in both low pressure circuit and
to any part, wash that part thoroughly with high pressure circuit lowers to a safety level
clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use Komatsu genuine fuel filter car- a Before the fuel circuit is tested and its parts are
tridge. removed or installed, the residual pressure in
Since the common rail fuel injection system the fuel circuit must be released completely.
(CRI) consists of more precise parts than the Accordingly, observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system, or removing
employs a high-efficiency special filter to pre- or installing its parts, wait at least 30 sec-
vent foreign matter from entering it. onds after stopping the engine until the
If a filter other than the genuine one is used, residual pressure in the fuel circuit is
the fuel system may have a trouble. Accord- released. (Do not start the work just after
ingly, never use such a filter. stopping the engine since there is residual
pressure.)
22 D475A, D475ASD-5E0
Testing fuel pressure 1 4. Start the engine and inspect the fuel pressure
with the engine running at high idle or at the
a Measuring tools for fuel pressure equivalent of rated output speed (stall load).
a If the fuel pressure is in the following
range, it is normal.
1 Engine speed Fuel pressure
790-261-1204 Digital hydraulic tester
At high idle or
H 2 799-401-2320 Hydraulic tester 0.15 – 0.3 MPa
at the equivalent of rated
{1.5 – 3 kg/cm2}
3 795-471-1450 Adapter output speed
4 07005-00812 Gasket
a Measure the fuel pressure only for the low

pressure circuit between the feed pump – fuel
filter – fuel supply pump.
k Since the pressure in the high pressure cir-
cuit from the fuel supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Open the left upper side cover of the engine

and remove fuel pressure inspection plug (1)
(M8 X 1.25) of fuel filter head.
5. Since the fuel circuits of the right and left banks

after the priming pump are independent from
each other, check them separately.
6. After finishing testing, remove the testing tools

and return the removed parts.
2. Install adapter H3 and gasket H4 to the plug

hole.
3. Install nipple [1] of hydraulic tester H1, and

connect to hydraulic tester H2.
D475A, D475ASD-5E0 23
Handling of reduced cylinder Handling of no injection cranking

mode operation 1 operation 1
a Reduced cylinder mode operation means to a No injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The purpose
the number of effective cylinders. The pur- and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. engine unit has been stored for a long period,
1. This operation is used to find out a cylinder the no injection cranking is performed to lubri-
which does not output power normally (or, cate the engine parts and protect them from
combustion in it is abnormal). seizure.
2. When engine speed and output do not change a Use the no-injection cranking function for only
from the normal operation (all cylinder operat- the above purposes while the engine is
ing mode) even though the fuel injection has mounted on the machine.
been cut out for any cylinder, the cylinder is a To implement no injection cranking operation,
suspected to be defective. see “Special functions of monitor panel
The following problems can be considered: (EMMS)”.
q Leaking of cylinder head gasket
q Defective injection of injector
q Defective piston, piston ring or cylinder
liner
q Defective valve mechanism (valve sys-
tem)
q Defective electrical system
3. Since the injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, the reduced cylinder mode
operation can be obtained by easier operations
of the switches when compared with the
mechanical fuel injection system. This allows
to narrow down the causes of the incident eas-
ily.
a To implement reduced cylinder mode
operation, see “Special functions of moni-
tor panel (EMMS)”.
a Use the reduced cylinder mode for only
the purpose of troubleshooting.
24 D475A, D475ASD-5E0
Testing fuel return and leak amount 1
a Testing tools for fuel return and leak amount 1. Preparation work (example for left bank)
1) Remove tube (3) between common rail (1)
Symbol Part No. Part name and supply pump (2).
1 6151-51-8490 Spacer 2) Insert spacer J1 to supply pump (2) side
2 6206-71-1770 Joint and retighten it with the currently removed
joint bolt.
Commercially
3 Hose a Be sure to fit the gaskets to both ends
available
of the spacer.
Commercially 3) Connect the return piping to the fuel tank
4 Hose
J available
side again.
5
Commercially
Measuring cylinder a Be sure to fit the gaskets to both ends
available of the spacer.
Commercially
6 Stopwatch
available
7 07376-70315 Plug
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
D475A, D475ASD-5E0 25
4) Insert joint J2 to common rail (1) side and

retighten it with the currently removed joint
bolt.
a Be sure to fit the gaskets to both ends
of the joint.
5) Connect inspection hose J3 to the tip of
joint J2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
3. Testing return rate from injector

a During testing injector return amount,
keep the end of hose J3 connected to
pressure limiter and insert the other end to
oil pan (receiver).
1) Disconnect fuel return hose (4) and install
plug J7 to hose (4) side and fix it to the
frame.
2. Testing leakage from pressure limiter

1) Adjust routing to prevent its slacking of
inspection hose J3 and insert the hose
end to the oil pan (saucer).
2) Referencing “Measuring engine speed”,
set up the condition necessary for check-
ing the engine speed.
3) Start the engine and operate at the equiv-
alent to rated operation (torque converter
stall load).
4) After making sure that the engine speed is
stabilized, measure leakage volume per
minute by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Engine speed Leaking amount
(rpm) (cc/min)
Equivalent to rated
Max. 10
operation
26 D475A, D475ASD-5E0
2) Connect inspection hose J4 to joint (5)

side. Rated output speed Return (Spill) limit
a Bind the connecting part of the test (rpm) (cc/min)
hose with a wire, etc. to prevent it
1,600 960
from coming off.
3) Adjust routing to prevent its slacking of 1,700 1,020
inspection hose J4 and insert the hose 1,800 1,080
end to the oil pan (container). 1,900 1,140
2,000 1,200
7) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
5. Check the right bank similarly.
4) Referencing “Measuring engine speed”,

set up the condition necessary for check-
ing the engine speed.
5) Start the engine and operate at the equiv-
alent to rated operation (torque converter
stall load).
6) After making sure that the engine speed is
stabilized, measure return rate per minute
by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
D475A, D475ASD-5E0 27
Bleeding air from fuel circuit 1
a If fuel is used up or if a fuel circuit part is a Don't fill fuel directly after removing main
removed and installed, bleed air from the fuel filter (2).
circuit according to the following procedure.
1. Remove fuel pre-filter (1) and fill it with fuel.

a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the fuel pre-filter (1), and
then add fuel through part (b) (holes
around the central hole).
a After filling the fuel pre-filter (1) with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the filter but fill it with the fuel by
operating priming pump (3).
28 D475A, D475ASD-5E0
2. Install fuel pre-filter (1) to the filter head.

a Apply engine oil thinly over the packing on
the fuel pre-filter side.
a After the packing of the fuel pre-filter
touches the sealing face of the filter head,
tighten the fuel filter 1/2 – 3/4 turns.
3. Loosen air bleed plug (3) (plug on the outlet

side) of the fuel main filter and operate priming
pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and tighten the
plug after checking the fuel.
3 Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4. Loosen air bleeder (5) of the fuel supply pump

and operate priming pump (4) 90 - 100 times.
a Operate the priming pump until the fuel
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
5. Bleed the air from the RH bank according to

the above procedure.
6. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 2.
D475A, D475ASD-5E0 29
Testing fuel circuit for leakage 1 9. Inspect the fuel piping and the devices for fuel
leakage.
k Very high pressure is generated in the high- a Inspect the high-pressure circuit parts
pressure circuit of the fuel system. If fuel concentration on the areas coated with the
leaks while the engine is running, it is dan- color checker, for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
and installing its components, check for a If any fuel leakage is not detected, inspec-
fuel leakage according to the following pro- tion is completed.
cedure.
a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at a speed less than 1,000 rpm

and stop it after its rotation is stabilized.
3. Inspect the fuel piping and the devices for fuel

leakage.
a Inspect the high-pressure circuit parts
concentration on the areas coated with the
color checker, for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

leakage.
6. Run the engine at high idle.

leakage.
8. Run the engine at high idle to apply load to the

engine.
a Relieve by tilting the blade or raising the
ripper.
30 D475A, D475ASD-5E0
Testing and adjusting alternator Adjusting

belt tension 1 a If the deflection is out of the standard range,
adjust it according to the following procedure.
Testing 1. Loosen nut (B) and bolt (2) alternately.

Press the intermediate point of the belt between
alternator pulley and drive pulley with a finger and 2. Adjust belt tension using nut (A).
measure deflection (a) of the belt.
a Pressing force: Approx. 59 Nm {Approx. 6 kg} 3. Tighten bolt (2) to have adjust bolt (1) and
a Deflection (a): 20 ± 2 mm plate (3) made orthogonal to each other.
3 Bolt:
53.9 – 122.6 Nm {5.5 – 12.5 kgm}
4. Tighten nut (B) to fix plate (3).

a After adjusting, test the belt tension again.
D475A, D475ASD-5E0 31
Testing and adjusting belt tension

for air conditioner compressor 1
Testing
q Measure deflection (a) of the belt when it is
pus hed with a fing er at a point midwa y
between the compressor pulley and the engine
drive pulley.
q Pushing force: Approx. 59 N {approx. 6 kg}
q Deflection (a) of belt: 20 ± 2 mm
Adjusting
a If the belt deflection is outside the standard
value, adjust as follows.
1. Loosen 3 mounting bolts and nuts (1) and lock-

nuts (2) and (3).
2. Turn locknut (3) and move air conditioner com-

pressor (4) together with the bracket to adjust
the tension of the belt.
3. Tighten locknuts (2), (3) and 3 mounting bolts

and nuts (1).
32 D475A, D475ASD-5E0
Adjusting fuel control dial and decelerator pedal 1
1. Outline of fuel control system [1] Fuel control dial (2nd throttle signal)
q The following signals are inputted as rota- [2] Engine controller
tion command signals to the engine con- [3] Steering controller
troller. [4] Decelerator pedal (1st throttle signal)
q Decelerator pedal potentiometer signal [5] Decelerator potentiometer
q 3rd throttle signal [6] Engine (CRI system)
The engine controller controls the fuel [7] Machine control signal
control system of the engine (CRI system) (3rd throttle signal)
according to the lowest engine speed sig- [8] Rod
nal among those input signals.
q Adjust the deceleration slow speed by
adjusting the decelerator pedal linkage.
D475A, D475ASD-5E0 33
2. Preparatory work 4. Adjusting high idle speed

1) Start the engine, set the monitor panel in Set the fuel control dial to the high idle position
the “Adjustment mode”, and prepare to and check that the high idle speed is correct.
measure the engine speed. q High idle speed: 2000 ± 50 rpm
a For the operation method, see “Spe- a When engine speed is high:
cial functions of monitor panel Lower the engine speed to below 1,900
(EMMS)”. rpm temporarily with stopper bolt (3) to
q Adjustment code: 0007 eliminate the play of the decelerator pedal,
(Engine deceleration cut mode) and then adjust the engine speed to the
a The engine speed is displayed by 1 rpm. high idle speed.
a When engine speed is low:
Adjust the engine speed to the high idle
speed with stopper bolt (3).
5. Check of decelerator position (decelerator

potentiometer signal)
a Measure the decelerator position in the
monitoring mode.
q Monitoring mode: 31701
(Decelerator position)
Check that displayed position is 100% while
the decelerator pedal is released.
If the displayed position is less than 100%,
adjust it to 100% with the pedal linkage.
If this adjustment is not made perfectly, the
engine control function etc. may not operate
normally. Accordingly, be sure to check the dis-
played position.
q The decelerator position can be checked
while the engine is stopped.
6. Check of final accelerator position

a Measure the final accelerator position in
the monitoring mode.
q Monitoring mode: 31706 (Final accel-
erator position)
While the decelerator pedal is released, set the
fuel control dial to the MAX position, set the
parking brake lever in the FREE position, set
3. Adjusting decelerator pedal speed the PCCS lever in the F or R position, and
Set the fuel control dial at the high idle position, check that the displayed position is 100%.
depress decelerator pedal (2) until it contacts (Finish the check in 5 above in advance.)
the stopper, and check that the decelerator If the displayed position is less than 100%,
pedal speed is normal. check the voltage signal of the fuel circuit for
q Decelerator pedal speed: 900 ± 50 rpm error.
a If the engine speed is not correct, adjust If this adjustment is not made perfectly, the
installation dimension (a) of rod (1). engine control function etc. may not operate
q Installation dimension (a): 122 mm normally. Accordingly, be sure to check the dis-
played position.
q The accelerator position can be checked
while the engine is stopped.
34 D475A, D475ASD-5E0
SEN01817-00

© 2006 KOMATSU
All Rights Reserved
36
SEN01818-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Measuring power train oil pressure ...................................................................................................... 3
Adjusting transmission speed sensor................................................................................................. 12
Simple method to test brake performance ......................................................................................... 13
Adjusting brake pedal and parking brake lever .................................................................................. 14
Adjusting PCCS lever console position.............................................................................................. 17
Emergency escape method when power train has trouble ................................................................ 18
Inspecting wear of sprocket ............................................................................................................... 20
Testing and adjusting track shoe tension ........................................................................................... 21
Testing and adjusting work equipment oil pressure ........................................................................... 22
Testing and adjusting control circuit basic pressure........................................................................... 33
Measuring PPC valve output pressure and solenoid valve output pressure...................................... 34
Adjusting play of PPC valve ............................................................................................................... 40
Measuring outlet pressure of ripper pin puller solenoid valve ............................................................ 41
Checking parts which caused hydraulic drift of blade and ripper ....................................................... 42
Measuring internal leakage of work equipment cylinder .................................................................... 43
D475A, D475ASD-5E0 1
Releasing residual pressure from work equipment cylinder............................................................... 44

Bleeding air from work equipment cylinder ........................................................................................ 44
Adjusting ripper lever position ............................................................................................................ 45
Adjusting work equipment lock lever .................................................................................................. 46
Measuring fan motor speed................................................................................................................ 47
Measuring fan circuit oil pressure....................................................................................................... 48
Bleeding air from fan pump ................................................................................................................ 49
Measurement procedure for blade tilt control angle (Dual tiltdozer specification) .............................. 50
Measurement procedure for blade tilt control angle (Superdozer specification) ................................ 53
Testing and adjusting operator's cab .................................................................................................. 55
Adjusting blade................................................................................................................................... 59
2 D475A, D475ASD-5E0

Measuring power train oil
pressure 1
a Measuring instruments for power train oil pres-

sure

1
K 2 799-401-2320 Hydraulic tester
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 parking brake lever and work
equipment 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 operator’s cab and trans-
mission lubricating oil pressure pickup port
(15) is installed to the top of the power train fil-
ter.
a Table of locations of centralized pressure
pickup points for measuring oil pressure and
gauges to use
Gauge
No. Stamp Measured oil pressure
(MPa {kg/cm2})
1 IN T/C inlet pressure 2.5 {25}
2 OUT T/C outlet pressure 0.98 {10}
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}
D475A, D475ASD-5E0 3
1. Measuring torque converter inlet pressure 2. Measuring torque converter outlet pressure
(IN) (OUT)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect hydraulic tester K2 to oil pres-
lic tester K1 to oil pressure pick-up nipple sure pick-up nipple (2).
(1). a Use an oil pressure gauge of 0.98
a Use an oil pressure gauge of 2.5 MPa MPa {10 kg/cm2}.
{25 kg/cm2}.
2) Start the engine and set the PCCS lever in

2) Start the engine and set the PCCS lever in the full neutral position.
the full neutral position. 3) Measure the oil pressure while the engine
3) Measure the oil pressure while the engine is running at low idle and high idle.
is running at low idle and high idle.
4) After finishing measurement, remove the 4) After finishing measurement, remove the
measuring instrument and return the measuring instrument and return the
removed parts. removed parts.
4 D475A, D475ASD-5E0
3. Measuring torque converter stator clutch 4. Measuring torque converter lock-up clutch
pressure (SC) pressure (LU)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester K1 to oil pressure pick-up nipple lic tester K1 to oil pressure pick-up nipple
(3). (4).
a Use an oil pressure gauge of 5.9 MPa a Use an oil pressure gauge of 2.5 MPa
{60 kg/cm2}. {25 kg/cm2}.
2) Run the engine and set the PCCS lever in 2) Start the engine and set the monitor panel
the full neutral position. in the “Adjustment mode” and disengage
3) Measure the oil pressure while the engine both steering clutches.
is running at low idle and high idle. a For the operating method, see “Spe-
cial functions of monitor panel
(EMMS)”.
a Adjustment code: 5535 (Disengage-
ment of both steering clutches)
a The transmission speed is displayed
on the lower display section (Unit: 1
rpm).

removed parts.
3) Turn on the lock-up mode switch.

4) Set the PCCS lever in the FORWARD and
2nd gear speed position and make the
transmission run idle.
5) Raise the engine speed gradually and
measure the oil pressure when the lock-up
pilot lamp lights up.
removed parts.
D475A, D475ASD-5E0 5
5. Measuring transmission main relief pres- 6. Measuring transmission F clutch pressure

sure (TM) (FWD)
a Check the transmission main relief pres- 1) Connect oil pressure gauge [1] of hydrau-
sure with the monitor panel since the lic tester K1 to oil pressure pickup nipple
machine is equipped with a transmission (6).
main relief pressure sensor for the VHMS. a Use an oil pressure gauge of 5.9 MPa
q Monitoring code: 43000 {60 kg/cm2}.
(Transmission main relief pressure)
q Unit: MPa
a For the operating method, see “Spe-
(EMMS)”.
a If the machine is not equipped with the
VHMS, measure the transmission main
relief pressure according to the following
procedure.
1) Connect oil pressure gauge [1] of hydrau-
lic tester K1 to oil pressure pick-up nipple
(5).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
2) Run the engine, set the monitor panel in

the “Adjustment mode”, and disengage
both steering clutches.
(EMMS)”.
a Adjustment code: 5535 (Both steering
clutches disengagement)
a The lower message display displays
the transmission speed (Unit: 1 rpm).
3) Set the parking brake lever in the FREE
position.
4) Set the PCCS lever in the FORWARD 3rd
2) Run the engine and set the PCCS lever in gear speed position, and run the transmis-
the full neutral position. sion idle.
k Keep ready to press the brake
3) Measure the oil pressure while the engine
is running at low idle and high idle. pedal at any time for safety.
5) Measure the oil pressure while the engine
is running at low idle.

measuring instrument and return the 6) After finishing measurement, remove the
removed parts. measuring instrument and return the
removed parts.
6 D475A, D475ASD-5E0
7. Measuring transmission R clutch pressure 8. Measuring transmission 1st clutch pres-

(R) sure (1ST)
lic tester K1 to oil pressure pickup nipple lic tester K1 to oil pressure pickup nipple
(7). (8).
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine, set the monitor panel in 2) Run the engine, set the monitor panel in
the “Adjustment mode”, and disengage the “Adjustment mode”, and disengage
both steering clutches. both steering clutches.
a For the operating method, see “Spe- a For the operating method, see “Spe-
cial functions of monitor panel cial functions of monitor panel
(EMMS)”. (EMMS)”.
a Adjustment code: 5535 (Both steering a Adjustment code: 5535 (Both steering
clutches disengagement) clutches disengagement)
a The lower message display displays a The lower message display displays
the transmission speed (in rpm). the transmission speed (Unit: 1 rpm).
3) Set the parking brake lever in the FREE 3) Set the parking brake lever in the FREE
position. position.
4) Set the PCCS lever in the REVERSE 3rd 4) Set the PCCS lever in the FORWARD 1st
gear speed position, and run the transmis- gear speed position, and run the transmis-
sion idle. sion idle.
k Keep ready to press the brake k Keep ready to press the brake
pedal at any time for safety. pedal at any time for safety.
5) Measure the oil pressure while the engine 5) Measure the oil pressure while the engine
is running at low idle. is running at low idle.
D475A, D475ASD-5E0 7
9. Measuring transmission 2nd clutch pres- 10. Measuring transmission 3rd clutch pres-
sure (2ND) sure (3RD)
(9). (10).
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine, set the monitor panel in 2) Run the engine, set the monitor panel in
the “Adjustment mode”, and disengage the “Adjustment mode”, and disengage
both steering clutches. both steering clutches.
a For the operating method, see “Spe- a For the operating method, see “Spe-
cial functions of monitor panel cial functions of monitor panel
(EMMS)”. (EMMS)”.
a Adjustment code: 5535 (Both steering a Adjustment code: 5535 (Both steering
clutches disengagement) clutches disengagement)
a The lower message display displays a The message display displays the
the transmission speed (in rpm). 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) Set the PCCS lever in the FORWARD 2nd 4) Set the PCCS lever in the FORWARD 3rd
gear speed position, and run the transmis- gear speed position, and run the transmis-
sion idle. sion idle.
k Keep ready to press the brake k Keep ready to press the brake
pedal at any time for safety. pedal at any time for safety.
is running at low idle. is running at low idle.
8 D475A, D475ASD-5E0
11. Measuring steering left brake pressure (LB) 12. Measuring steering right brake pressure
1) Connect oil pressure gauge [1] of hydrau- (RB)
lic tester K1 to oil pressure pickup nipple 1) Connect oil pressure gauge [1] of hydrau-
(11). lic tester K1 to oil pressure pickup nipple
a Use an oil pressure gauge of 5.9 MPa (12).
{60 kg/cm2}. a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
2) Run the engine and set the parking brake

lever in the FREE position. 2) Run the engine and set the parking brake
3) Measure the oil pressure while the engine lever in the FREE position.
is running at low idle and high idle. 3) Measure the oil pressure while the engine
a Check that the oil pressure becomes is running at low idle and high idle.
0 when the PCCS lever is set to the a Check that the oil pressure becomes
steering left stroke end. 0 when the PCCS lever is set to the
a Check that the oil pressure becomes steering right stroke end.
0 when the brake pedal is pressed a Check that the oil pressure becomes
fully or when the parking brake lever 0 when the brake pedal is pressed
is set in the LOCK position. fully or when the parking brake lever
is set in the LOCK position.

measuring instrument and return the 4) After finishing measurement, remove the
removed parts. measuring instrument and return the
removed parts.
D475A, D475ASD-5E0 9
13. Measuring steering left clutch pressure 14. Measuring steering right clutch pressure
(LC) (RC)
(13). (14).
{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) Set the PCCS lever to the steering left 3) Set the PCCS lever to the steering right
stroke end. stroke end.
a Set the direction of the PCCS lever in a Set the direction of the PCCS lever in
neutral. neutral.
is running at low idle and high idle. is running at low idle and high idle.
a Check that the oil pressure becomes a Check that the oil pressure becomes
0 when the steering of the PCCS 0 when the steering of the PCCS
lever is returned to the neutral posi- lever is returned to the neutral posi-
tion. tion.
10 D475A, D475ASD-5E0
15. Measuring transmission lubricating oil

pressure
1) Connect hydraulic tester K2 to oil pres-
sure pickup nipple (15).
a Use an oil pressure gauge of 0.98
MPa {10 kg/cm2}.
2) Run the engine at high idle and measure

the oil pressure.

removed parts.
D475A, D475ASD-5E0 11
Adjusting transmission speed 6. Remove sensor (1) and flange (2) together and
sensor 1 secure them with nut (3).
a Take care that the adjustment angle of the
sensor will not change.
a The torque converter output speed sensor for 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
the VHMS is not adjustable.
7. Install flange (2) and the sensor together to the
1. Remove the fuel tank undercover, and then steering case.
remove transmission output speed sensor (1) 2 Flange and mounting bolt:
and the flange together. Gasket sealant (LG-6)
a Before adjusting transmission speed sen- 3 Mounting bolt:
sor (1), remove it temporarily and check 59 – 74 Nm {6 – 7.5 kgm}
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.
2. Install flange (2) to the steering case tempo- functions of monitor panel (EMMS)”.
rarily. 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 cen-
ter of the hole.
a If the tooth tip is not at the center, run the
engine and move the machine forward or
in reverse a little to set the tooth tip to the
center.
4. Tighten sensor (1) until its tip touches the tooth

tip of gear (4).
2 Threads of sensor:
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.
12 D475A, D475ASD-5E0
Simple method to test brake

performance 1
a Implement simple method to test brake perfor-

mance under the following condition.
1. Set the blade and ripper in the travel posture

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

in free position.
3. While the engine is running at low idle and the

brake pedal is depressed securely, set PCCS
lever in the forward and 2nd gear speed posi-
tion.
k If this test is carried out in the 1st gear
position, the brake is overloaded.
Therefore, be sure to carry it out in 2nd
gear speed.
a Set the steering unit in neutral.
4. Press the decelerator pedal and set the fuel

control dial in the high idle position.
5. Return the decelerator pedal slowly and check

that the machine does not start when the
engine speed reaches the high idle level.
k Since the torque converter is stalled,
press the brake pedal securely and
keep your right foot on the decelerator
pedal for safety until the work is fin-
ished.
D475A, D475ASD-5E0 13
Adjusting brake pedal and parking brake lever 1

Brake pedal side
14 D475A, D475ASD-5E0
Parking brake lever side
Adjusting brake pedal side

3. Checking brake pedal stroke
1. Adjusting brake pedal stroke 1) Press brake pedal (1) and check that its
Adjust stroke (a) of brake pedal (1) by adjust- stroke is as set in step 1 above.
ing installed dimension (b) of stopper bolt (2). 2) Press brake pedal (1) and check that it is
a Adjust the brake pedal stroke with the stopped by stopper (7).
brake rod separated from the pedal. 3) Press brake pedal (1) and check that
q Pedal stroke (a): 78 mm spool stroke (g) of brake valve (5) is in the
q Installed dimension (b) of stopper bolt: normal range.
36.5 mm q Spool stroke (g): 20 – 24 mm
2. Adjusting installed length of brake rod 4. Checking brake oil pressure

1) Connect small rod (3), brake rod (4), and 1) Start the engine and set the monitor panel
turnbuckle (6). in the adjustment mode.
q Screwing distance (c), (d), (e), and (f): a For the operating method in the
23 mm adjustment mode, see “Special func-
2) Adjust the installed length of brake rod (4) tions of monitor panel (EMMS)”.
with turnbuckle (6) so that the spool of a Adjustment code: 9996
brake valve (5) will be at the OFF position. (Mechanical brake release mode)
a The threads on the brake pedal side 2) With the parking brake lever in the FREE
of the turnbuckle locknut are inverted. position, press the brake pedal fully and
3 Locknut: check that the brake oil pressures on both
34.3 – 58.8 Nm {3.5 – 6.0 kgm} sides become 0.
a For the measuring points of the brake
oil pressure, see “Measuring power
train oil pressure”.
D475A, D475ASD-5E0 15
5. Initializing brake potentiometer Adjusting parking brake lever side

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

cable
1) Connect parking brake cable (9) to the
lever side, and then adjust installed
dimensions (h) and (j).
q Installed dimension (h) of cable: 22.5
mm
q Installed dimension (j) of cable: 14.5
mm
2) Connect parking brake cable (9) to the
valve side.
q Installed dimension (m) of cable: 15
mm
q Installed dimension (k) of cable: 20.5
mm
3) Operate parking brake 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
normal.
q 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
pressure, see “Measuring power train oil
pressure”.
q LOCK position: 0, FREE position: Speci-
fied pressure
9. Checking limit switch

1) Turn the starting switch ON, set the moni-
tor panel to the “Monitoring display mode”.
a For the operating method in the moni-
toring display mode, see “Special
q Monitoring code: 40910 (Steering
controller input signal 1)
2) Set the parking brake lever in the FREE
position and LOCK position and check that
the limit switch signals are input normally.
16 D475A, D475ASD-5E0
Adjusting PCCS lever console position 1
1. Set operator’s seat (1) in the forward (dozing)

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

in parallel with operator’s seat (1).
a If the console is not parallel with the oper-
ator’s seat, adjust dimension (a) of rod (4).
q Standard dimensions (a): 179 mm
a The locknut on the rear side of the turn-
buckle is a left-handed (reversing) screw.
D475A, D475ASD-5E0 17
Emergency escape method when a Since the female side of connector

power train has trouble 1 PL2 is kept disconnected, mask it
with a vinyl sheet, etc.
a Put switch assembly [1] in the cab
a Devices used for emergency escape through the cab window.
19M-06-32820 Switch assembly
1 7824-66-6430 Register
L
195-06-71220 Wiring harness
2 790-190-1601 Pump assembly
1. Emergency escape method with switch box

(Use L1)
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 following procedure.
a The engine must be startable for the fol-
3) Disconnect neutral safety relay (NSF) in
lowing procedure. If the engine cannot be
the fuse room and connect pins [3] and [5]
started, see “Emergency escape with
of the connector on the wiring harness
brake releasing device”.
side.
1) Connect switch assembly [1] and register
a Perform this operation only when the
[2] to wiring harness [3] of emergency
engine does not start electrically
escape device L1.
k Since register [2] controls the drive
because of a trouble in the neutral
safety relay or the transmission con-
voltage of the solenoid, connect it
troller.
to the wiring harness before con-
k If the engine is started by this
necting to the machine.
k Set the all gear speed switches of
method, the neutral safety function
does not work. Accordingly, before
switch assembly [1] in the OFF
starting the engine, set the parking
position and the direction switch in
brake lever in the LOCK position
the P position to prevent the
and set the PCCS lever in the full
machine from starting suddenly.
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 [3] to connectors
PL1 (1) and PL2 (2).
q Connector PL1 (1):
Connect to male side and female
side.
q Connector PL2 (2):
Connect to male side.
18 D475A, D475ASD-5E0
4) Start the engine and set the parking brake

lever in the FREE position.
5) Operate switch assembly [1] 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.
k Take care when the machine trav-
els in reverse, since the steering
direction is reversed.
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 L2
to the supply hose. (Use the nipple of face
seal type.)
a Block the solenoid valve side with
plug.
Plug: 02789-00315
2. Emergency escape method with brake

releasing device (Use L2)
a If the engine cannot be started and the
parking brake cannot be released, escape
according to the following procedure.
1) Assemble pump assembly L2.
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.
q Initial pressure:
Approx. 2.74 MPa {28 kg/cm2}
2) Install volume pump [4] of pump assembly a Since an accumulator is installed in
L2 to the outside of the operator’s cab. the circuit, the handle must be oper-
ated 30 – 50 times to raise the oil
pressure.
a If the oil pressure does not rise above
a certain level, the relief valve may be
set to low pressure. In this case,
adjust the set pressure of the relief
valve.
D475A, D475ASD-5E0 19
7) Tow the machine to a safe place. Inspecting wear of sprocket 1

a The brake releasing oil pressure low-
ers gradually because of internal
leakage and the brake is applied a Use the “Full-scale dimensions drawing of
again about 1 minutes after. Accord- sprocket profile” in “Sprocket” in “Structure,
ingly, work quickly. function, and maintenance standard” as a
a If the brake releasing pressure lowers gauge for measuring wear of the sprocket.
to about 1.57 MPa {16 kg/cm 2}, the a Make a copy of the “Full-scale dimensions
brake is applied. In this case, operate drawing of sprocket profile” on a transparent
the volume pump again to raise the paper or sheet and apply it directly to the
brake releasing pressure to the initial sprocket to see if the sprocket can be used.
pressure.
20 D475A, D475ASD-5E0
Testing and adjusting track shoe

tension 1
Testing
1. Move the machine slowly on a level place, then
stop it.
a Do not apply the brake when stopping.
2. Place straight steel bar (1) between the idler
and front carrier roller and measure clearance
(a) between the bottom of the steel bar and
shoe grouser.
q Standard clearance (a): 20 – 30 mm
Adjusting
a If the track shoe tension is abnormal, adjust it
1. Remove cover (2).

2. When the tension is too high
Loosen plug (3) to discharge the grease.
k Since the high-pressure grease may
spout out, do not loosen the plug more
than 1 turn.
3 Plug: 59 – 88 Nm {6 – 9 kgm}
3. When tension is low

Add grease through grease fitting (4).
a If the track shoe is not tensed well, move
the machine forward and in reverse slowly.
a After the adjustment is finished, check the
track tension again.
D475A, D475ASD-5E0 21
Testing and adjusting work

equipment oil pressure 1
a Testing and adjusting instruments for work

equipment oil pressure

1
566-35-43561 Nipple (18 x 1.5 mm)
2
07002-11823 O-ring
M
3 799-101-5160 Nipple (R1/8)
4 799-401-2701 Differential pressure gauge
799-101-5220 Nipple (10 x 1.25 mm) 4) Run the engine at high idle and set the
5
07002-11023 O-ring blade lever and ripper lever in neutral, and
measure the oil pressure.
Measuring
k Stop the machine on a level place, lower
the work equipment to the ground, and set
the parking brake lever and work equip-
ment lock lever in the LOCK position.
a Measure the work equipment oil pressure
under the following condition.
q Hydraulic oil temperature: Within operat-
ing 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. 5) After finishing measurement, remove the
q (1): Front pump oil pressure sensor measuring instrument and return the
q (2): Rear pump oil pressure sensor removed parts.
3) Install nipples M2, M3, and connect them

to oil pressure gauge [1] of hydraulic
tester M1.
{60 kg/cm2}.
22 D475A, D475ASD-5E0
2. Measuring main relief pressure (Single tilt

specification)
a Measure the main relief pressure at the
same point as the unload pressure.
{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 work equip-
ment lock lever in the FREE position.
2) Run the engine at high idle, raise or tilt the
ripper to relieve the cylinder at a stroke
end, and measure the oil pressure.

removed parts.
a The unload pressure, main relief pressure,
blade tilt relief pressure, blade pitch relief pres-
sure, 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.
D475A, D475ASD-5E0 23
3. Measuring main relief pressure (Dual tilt

specification and superdozer specification)
a Measure the main relief pressure at the
same point as the unload pressure.
{400 kg/cm2}.
a The oil pressure of the divided oil can be
measured by measuring while pitching
back the ripper.
2) Run the engine at high idle, raise or pitch
back the ripper to relieve the cylinder at a
stroke end, and measure the oil pressure.

removed parts.

mode.
24 D475A, D475ASD-5E0
4. Measuring blade tilt relief pressure (Single

tilt specification)
a Measure the blade tilt relief pressure at
the same point as the unload pressure.
{400 kg/cm2}.
a Since all of 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.
2) Run the engine at high idle, tilt the blade
to the left to relieve the cylinder at a stroke

removed parts.

mode.
D475A, D475ASD-5E0 25
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 as the unload pres-
sure.
{400 kg/cm2}.
a Measure the pressure of the divided oil
from the 2 pumps during pitch dump oper-
ation.
2) Run the engine at high idle, pitch dump
the blade to relieve the cylinder at a stroke

removed parts.

mode.
26 D475A, D475ASD-5E0
6. Measuring blade raise relief pressure

a Measure the blade raise relief pressure at
the same point as the unload pressure.
{400 kg/cm2}.
1) Block the return side hose of the blade lift
cylinder.
3) Run the engine at high idle, raise the

blade to relieve the cylinder at a stroke
removed parts.
a When measuring the oil pressure of
the single tilt specification and dual tilt
specification, relieve the oil through
the blade raise relief valve. When
measuring the oil pressure of the
superdozer specification, relieve the
oil through the main relief valve.

mode.
D475A, D475ASD-5E0 27
7. Measuring LS differential pressure a When using differential pressure gauge:

a Measure the pump discharge pressure Connect the pump discharge pressure
and LS pressure (actuator load pressure) side to the high pressure side (back side)
at the same time and calculate the differ- and connect the LS pressure side to the
ence between them. low pressure side (lower side).
1) Remove work equipment oil pressure sen- Since the differential pressure gauge
sors (1) and (2) from the work equipment needs a 12 V power source, connect it to
control valve. a battery.
2) Remove oil pressure pickup plugs (3) and

(4) from the work equipment pump.
q (1): Front pump discharge oil pres-
sure sensor
q (2): Rear pump discharge oil pres-
sure sensor
q (3): Front pump LS pressure plug
q (4): Rear pump LS pressure plug
3) Install nipple M2, M3 to the work equip-

ment control valve and connect it to oil
pressure gauge [1] of hydraulic tester M1
or differential pressure gauge M4.
(Pump discharge pressure)
4) Install nipple M5 to the work equipment
pump side and connect it to oil pressure
gauge [1] of hydraulic tester M1 or differ-
ential pressure gauge M4.
(LS pressure: Low pressure side)
28 D475A, D475ASD-5E0
a When using oil pressure gauge: 8. Measuring LS valve output pressure (servo
Use the oil pressure gauge of 39.2 MPa piston inlet pressure)
{400 kg/cm2}. 1) Open the inspection cover of the cross bar
Since the differential pressure is about 3.9 front undercover.
MPa {40 kg/cm2} at maximum, measure it 2) Remove oil pressure pickup plugs (5) and
by installing the same gauge to the pickup (6) from the work equipment pump.
plugs alternately. q (5):For front pump LS valve output
pressure
q (6):For rear pump LS valve output
pressure
3) Install nipple M5 and connect it to oil pres-

sure gauge [1] of hydraulic tester M1.
a Use the oil pressure gauge of 39.2
MPa {400 kg/cm2}.
5) Operate the blade lever and ripper lever

and measure the pump discharge pres-
sure and LS pressure (actuator load pres-
sure) at the same time while each cylinder
is moving.
a Calculation of LS differential pressure:
LS differential pressure = Pump discharge
pressure – LS pressure
6) After finishing measurement, remove the 4) Start the engine and set the work equip-
measuring instruments and return the ment lock lever in the FREE position.
removed parts.
D475A, D475ASD-5E0 29
5) Run the engine at high idle, perform the Adjusting

operations shown in the following table, a The unload valve cannot be adjusted.
and measure the LS valve output pres-
sure. 1. Adjusting main relief pressure
a If the work equipment relief pressure is
LS valve output abnormal, adjust main relief valve (7) or
Specification Operation pressure
(8) according to the following procedure.
(MPa {kg/cm2})
a When the main relief pressure of the dual
Common to all tilt specification and superdozer specifica-
Raise blade 0 {0}
specifications tion is measured, if it is abnormal in either
Raise ripper or or both of the front pump circuit and rear
Dual tilt and
pitch back to p um p c i rc ui t, ad jus t the m ain r el ie f
superdozer 27.4 +– 2.74
1.4
relieve valve(s) of the abnormal circuit(s).
+ 14
{280 – 28}
Raise ripper or tilt a The main relief pressure of the divided oil
Single tilt
to right to relieve of the single tilt specification cannot be
measured. Accordingly, measure the main
relief pressure on either side or both
sides.
q (7): Main relief valve for front pump
circuit
q (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
q turned to the right, the pressure
rises.
q turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment screw: 12.6 MPa {128 kg/
cm2}
3 Locknut:
29.4 – 39.2 Nm {3 – 4 kgm}
30 D475A, D475ASD-5E0
q Loosen locknut (18) of the blade tilt relief

valve and turn adjustment nut (17) to
adjust the pressure.
a If the adjustment nut is
q turned to the right, the pressure rises.
q turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjust-
ment nut: 25.3 MPa {258 kg/cm2}
3 Locknut: 39 – 49 Nm {4 – 5 kgm}
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

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

valve and turn adjustment nut (22) to
adjust the pressure.
a If the adjustment nut is
q turned to the right, the pressure rises.
q turned to the left, the pressure lowers.
D475A, D475ASD-5E0 31
a Quantity of adjustment per turn of adjust-

ment nut: 25.3 MPa {258 kg/cm2}
3 Locknut: 39 – 49 Nm {4 – 5 kgm}
2) After finishing adjustment, check again

that the oil pressure is normal according to
the procedure for measurement described
4. Adjusting LS differential pressure above.
a If the LS differential pressure is abnormal,
adjust LS valves (11) and (12) according
q (11): LS valve for front pump circuit
q (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
q turned to the right, the LS differ-
ential pressure rises.
q turned to the left, the LS differen-
tial pressure lowers.
a Quantity of adjustment per turn of
adjustment screw: 1.3 MPa {13.3 kg/
cm2}
3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}
32 D475A, D475ASD-5E0
Testing and adjusting control 3. Run the engine at high idle, set the blade lever
circuit basic pressure 1 and ripper lever in neutral, and measure the oil
pressure.
a Measuring instruments for control circuit basic

pressure

N 1
a The control circuit basic pressure is the pres-

sure reduced by the self-pressure reducing
valve of the control valve. It is used commonly
for the work equipment PPC, fan pump control,
and work equipment pump control.
Measuring
k Stop the machine on a level place, lower 4. After finishing measurement, remove the mea-
the work equipment to the ground, and set suring instrument and return the removed
the parking brake lever and work equip- parts.
a Measure the control circuit basic pressure Adjusting
under the following condition. a The self-pressure reducing valve cannot be
q Hydraulic oil temperature: Within operat- adjusted.
ing range
1. Remove the right ROPS front cover.
2. Connect oil pressure gauge [1] of hydraulic

tester N1 to oil pressure pickup nipple (1).
a Use the oil pressure gauge of 5.9 MPa {60
kg/cm2}.
D475A, D475ASD-5E0 33
Measuring PPC valve output a The PPC valve output pressure of the
pressure and solenoid valve following circuits is the basic pressure
of the solenoid valve (Dual tilt specifi-
output pressure 1 cation and superdozer specification).
q Blade right tilt/left tilt:
a Measuring instruments for PPC valve output Pitch/Tilt solenoid valve basic pres-
pressure and solenoid valve output pressure sure

1
P
2 799-401-3100 Adapter (02)
3 799-401-3200 Adapter (03)

a Before measuring the PPC valve output pres-
sure and pitch/tilt control valve pressure, check
that the control circuit basic pressure is nor-
mal. 2. Measuring solenoid valve output pressure
a Measure the PPC valve output pressure and (Dual tilt specification and superdozer
pitch/tilt control valve pressure under the fol- specification)
lowing condition. a Measure the following solenoid valve out-
q Hydraulic oil temperature: Within operat- put pressures on the solenoid valve block
ing range (3) side. (It is difficult to measure on the
work equipment control valve side.)
1. Measuring PPC valve output pressure q Blade left tilt circuit (Left tilt/pitch back
(solenoid valve basic pressure) circuit) (4) after passing through sole-
a Measure the pressure of the following cir- noid valve
cuits at the PPC valve. q Blade right tilt circuit (Right dual tilt/
q Blade lift raise circuit pitch back circuit) (5) after passing
q Blade tilt circuit before entering pitch/ through solenoid valve
tilt solenoid valve
q Ripper raise circuit and ripper tilt back
circuit
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 idle, 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
circuit, and tilt-in circuit may be mea-
sured on the work equipment control
side.
a When measuring the blade-lower cir-
cuit, operate the lever until the blade
floats.
34 D475A, D475ASD-5E0
1) Disconnect the piping of the circuit to be

measured and install oil pressure pickup a Measure the following solenoid valve out-
adapter P2 or P3. put pressures on the work equipment con-
2) Install nipple [1] of hydraulic tester P1 and trol side.
connect oil pressure gauge [2]. q Blade left tilt circuit (Left tilt/pitch
d u m p c i r c u i t ) ( 6 ) a f t e r pa s s i n g
through solenoid valve
q Blade lower circuit (7) after passing
q Blade right tilt circuit (Right tilt/pitch
d u m p c i r c u i t ) ( 8 ) a f t e r pa s s i n g

control lever or knob switch of the circuit to
be measured, and measure the oil pres-
sure.
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 neutral 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.
When the blade is set at the tilt limit
angle, the output pressure from the
PPC valve is stopped.
D475A, D475ASD-5E0 35
1) Disconnect the piping of the circuit to be

measured and install oil pressure pickup
adapter P2 or P3.
2) Install nipple [1] of hydraulic tester P1 and
connect oil pressure gauge [2].

control lever or knob switch of the circuit to
be measured, and measure the oil pres-
sure.
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 neutral 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.
When the blade is set at the tilt limit
angle, the output pressure from the
PPC valve is stopped.
36 D475A, D475ASD-5E0
Single tilt specification
D475A, D475ASD-5E0 37
Dual tilt specification and superdozer specification
38 D475A, D475ASD-5E0
D475A, D475ASD-5E0 39
Adjusting play of PPC valve 1
a If the end play of the blade lever and ripper

lever is excessive, adjust it with their PPC
valves according to the following procedure.
a This figure shows the PPC valve for the ripper.
q Standard play (a):
0.5 – 3.0mm at 200mm from revolution center
of lever (in both longitudinal and lateral direc-
tions)
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. Fix disc (3) and tighten locknut (2).

3 Locknut: 98 – 127 Nm {10 – 13 kgm}
4. Install boot (1).
40 D475A, D475ASD-5E0
Measuring outlet pressure of

ripper pin puller solenoid valve 1
a Measuring instruments for outlet pressure of

ripper pin puller solenoid valve

1
Q
Oil pressure pickup adapter
2 799-401-3200
(Size 03)

the parking brake lever and work equip- 4. Run the engine at high idle and operate the rip-
ment lock lever in the LOCK position. per pin puller switch and measure the oil pres-
a Measure the outlet pressure of the ripper pin sure.
puller solenoid valve under the following condi-
tion.
1. Disconnect pin puller cylinder hose (1) or (2).

suring instrument and return the removed
parts.
2. Install oil pressure pickup adapter Q2 and con-

nect the disconnected hose again.
3. Install nipple [1] of hydraulic tester Q1 and con-

nect oil pressure gauge [2].
a Use an oil pressure gauge of 5.9 MPa {60
kg/cm2}.
D475A, D475ASD-5E0 41
Checking parts which caused 3) Ripper lift cylinder

hydraulic drift of blade and ripper1 Tens e r ipp er to pus h u p the re ar of
machine.
a When a hydraulic drift of blade or ripper
occurred, check if the parts causing the drift is
located in cylinder packing side or in control
valve side according to the following proce-
dure.
1. Stop the engine with the cylinder at the follow-

ing positions.
1) Blade lift cylinder
Tense blade to push up the fr ont of
machine.
a Do not extend the blade lift cylinder to
the stroke end since it is equipped
with the piston valve.
2. Move the control lever of cylinder to be

checked to the direction of extending cylinder
and validate the movement of cylinder.
q If the drift speed becomes faster, a cylin-
der packing is defective.
q If the speed does not change, a control
valve is defective.
a If the pressure of the accumulator is lost,
run the engine for approx. 10 seconds to
build up the pressure.
[Reference] In case of the hydraulic drift is caused

by defective cylinder packing, the rea-
son why the drift speed becomes
2) Blade tilt cylinder faster by above mentioned operation
Retract the tilt cylinder to the stroke end is as follows:
and tense blade further to push up the 1) When work equipment is set in the above
right side of the machine. mentioned position, where the holding
pressure is applied to the bottom side, the
oil leaks from bottom side to head side.
Since the volume of head side is smaller
than that of bottom side by the volume of
the rod, the inner pressure of head side
rises by the oil leak from bottom side.
2) If the inner pressure of head side rises,
cylinder is balanced at certain pressure
(depending on the amount of leakage)
which is in proportion to the inner pres-
s u r e . T h e r e f or e , th e d r i fti n g s p e e d
becomes slower.
3) At this time, if the circuit in the head side is
opened (bottom side is closed by check
valve) to drain circuit by above mentioned
lever operation, the oil in the head side
flows into the drain circuit causing the lost
of the pressure balance. Then the drift
speed becomes faster.
42 D475A, D475ASD-5E0
Measuring internal leakage of 3. Run the engine at high idle and apply the relief
work equipment cylinder 1 pressure to the cylinder bottom side.
q Blade tilt cylinder:
Operate to extend the cylinder to
a Measuring instruments for internal leakage of be measured.
work equipment cylinder q Ripper lift cylinder:
Operate to lower ripper.
q Ripper Tilt cylinder:
L Purchased Measuring cylinder Operate to tilt ripper forward.
a Measure the internal leakage of work equip- 4. After 30 seconds, measure leakage for 1
ment cylinder under the following condition. minute.
q Hydraulic oil temperature: 45 – 55ºC
a Since the blade lift cylinder is equipped with a 5. After finishing measurement, return the
piston valve, its internal leakage cannot be removed parts.
measured.
1. Extend the cylinder to be measured to the

stroke end and set the machine in the measur-
ing position.
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
cylinder.
k Take care not to disconnect the hose
on the bottom side.
D475A, D475ASD-5E0 43
Releasing residual pressure from Bleeding air from work equipment

work equipment cylinder 1 cylinder
1
a When disconnecting the piping between the
control valve and work equipment cylinder, a If the work equipment cylinder is removed and
release the residual pressure from the circuit installed or its piping is disconnected and con-
according to the following procedure. nected, bleed air from its circuit according to
the following procedure.
1. Loosen the hydraulic tank oil filler cap gradu-
ally to release the residual pressure from the 1. Run the engine at low idle for about 5 minutes.
tank.
2. Running the engine at low idle, extend and
2. Set the work equipment lock lever in the FREE retract the cylinder to be bled 4 – 5 times.
position and operate the work equipment con- a Move the piston rod to about 100mm
trol lever to each direction. before the stroke end and never relieve
a If the work equipment control lever is the oil.
operated 2 – 3 times, the residual pres-
sure in the accumulator is released. 3. Running the engine at high idle and carry out
the operation in 2.
3. Run the engine at low idle for about 5 seconds,
then stop it. 4. Running the engine at low idle, move the cylin-
der to the stroke end to relieve the oil.
4. Repeat steps 2 – 3 above 2 – 3 times.
44 D475A, D475ASD-5E0
Adjusting ripper lever position 1
a Adjust the ripper lever to the best position

a The ripper lever can be adjusted forward and
in reverse within the range of ±40mm from the
center 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, D475ASD-5E0 45
Adjusting work equipment lock lever 1
1. Adjust dimension (a) between pins of rod (1).

q Dimension (a) between pins: 442.6 mm
2. Connect rod (1) to work equipment lock lever

(2) and PPC lock valve (3).
a Install connecting pin (4) on the lock lever
side with the cotter pin on the outside of
the machine.
46 D475A, D475ASD-5E0
Measuring fan motor speed 1 4. Insert probe [2] of tachometer kit S through the
radiator mask and set it out of the fan net with
stand [3] and connect it to multi-tachometer [4].
a Measuring instruments for fan motor speed a The probe tip cannot be inserted in an
opening of the fan net, but it can measure
the fan motor speed. Remove all obsta-
S 799-205-1100 Tachometer kit
cles between the lighting part of the probe
and the reflecting tape.
1. Open the radiator mask and remove the
mounting bolts of fan net (1) under the fan
motor.
a Fan net (1) cannot be removed since the
fan motor piping is installed.
5. Start the engine and set the monitor panel in

the adjustment mode.
a For the operating method in the adjust-
ment mode, see “Special functions of
monitor panel (EMMS)”.
2. Make clearance (a) by shifting fan net (1) and a Adjustment code: 1005 (Fan 100% speed
stick reflecting tape [1] to the fan through clear- mode)
ance (a).
a Stick the reflecting tape near the outside of 6. Run the engine at low idle and high idle and
the fan (where the distance between the measure the fan motor speed.
fan net and fan is short).

3. Install fan net (1) and close the radiator mask. suring instrument and return the removed
k Be sure to close the fan net and the parts.
radiator mask before starting measure-
ment. Do not start the engine with the
radiator mask open.
D475A, D475ASD-5E0 47
Measuring fan circuit oil

pressure 1
a Measuring instruments for fan circuit oil pres-

sure

T 1

a Measure the fan circuit oil pressure under the 5. After finishing measurement, remove the mea-
following condition. suring instrument and return the removed
q Hydraulic oil temperature: Within operat- parts.
ing range
1. Open the radiator mask.
2. Connect oil pressure gauge [1] of hydraulic

tester T1 to the oil pressure pickup nipple
installed to 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 adjust-
ment mode, see “Special functions of
monitor panel (EMMS)”.
a Adjustment code: 1005 (Fan 100% speed
mode)
4. Run the engine at high idle and measure the

fan circuit oil pressure.
48 D475A, D475ASD-5E0
Bleeding air from fan pump 1
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 follow-
ing 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 idle.
4. After oil flows out of air bleeder, tighten air

bleeders (1) and (2).
D475A, D475ASD-5E0 49
Measurement procedure for blade 2. Run the engine at low idle, set the toggle
tilt control angle switch of the blade lever to the dual tilt posi-
tion, and set the blade in the following standard
(Dual tiltdozer specification) 1 posture.
1) Set the blade horizontally (Set it to 0°).
a Measuring instrument for blade tilt control 2) Pitch back the blade to the maximum.
angle 3) Raise the blade at 100 mm above the
ground.
U 799-402-3800 Angle gauge
a When the blade and blade cylinder potentiom-

eter are removed and installed or when the
machine 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 per-
form this adjustment.
a Perform this adjustment on a level ground.
1. Adjust installed length (a) of rod (1) and con-

nect it to potentiometer lever (2) and yoke (3). 3. Hold the buzzer cancel switch in the select
q Installed length (a): 425 mm position [U] for 2.5 seconds to display the
maintenance mode.
4. Set the information switch in the [>] position to

select the adjustment mode.
5. Set the buzzer cancel switch in the select posi-

tion [U] to select the adjustment selection
screen.
50 D475A, D475ASD-5E0
6. Operate information switches [<] and [>] to 10. Operate the blade lever to tilt the blade to the
select the tilt limit setting screen. left and set the left tilting angle to 12°.
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 U.

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.
11. Set the toggle switch of the blade lever in the
9. Raise the blade tip to about 1 m above the single tilt position and then set it in the dual tilt
ground. position again to save the left tilt limit value in
the system.
a When saving is finished, the buzzer
sounds.
12. Set the buzzer cancel switch in the cancel

position [t] once to cancel the tilt limit adjust-
ment mode temporarily.
13. Set the blade in the maximum pitch dump pos-

ture (Keep the work equipment horizontal).
D475A, D475ASD-5E0 51

tion [U] again to select the tilt limit adjustment
mode.
15. Operate the blade lever to tilt the blade to the

right and set the right tilting angle to 12°.
angle too much.
angle gauge U.
16. Set the toggle switch of the blade lever in the

signal tilt position and then set it in the dual tilt
position again to save the right tilt limit value in
the system.
a When saving is finished, the buzzer
sounds.
17. Set the buzzer cancel switch in the cancel

position [t] to cancel the tilt limit adjustment
mode.
18. Lower the work equipment to the ground and

stop the engine.
19. Start the engine again, tilt the blade to the right
and left, and check that the blade does not
interfere with the track shoe at any height.
52 D475A, D475ASD-5E0
Measurement procedure for blade

tilt control angle
(Superdozer specification) 1
a Measuring instrument for blade tilt control

angle

U 799-402-3800 Angle gauge
a When the blade and blade cylinder potentiom-

eter are removed and installed or when the
machine controller is replaced, adjust the
blade tilt limit angle according to the following
procedure. 3. Hold the buzzer cancel switch in the select
a If this adjustment is not performed, the blade position [U] for 2.5 seconds to display the
may not tilt sufficiently or may tilt too much and maintenance mode.
interfere with the track shoe. Be sure to per-
form this adjustment. 4. Set the information switch in the [>] position to
a Perform this adjustment on a level ground. select the adjustment mode.
1. Adjust installed length (a) of rod (1) and con-

nect it to potentiometer lever (2) and yoke (3).
q Installed length (a): 425 mm

tion [U] to select the adjustment selection
screen.
2. Run the engine at low idle and set the blade in 6. Operate information switches [<] and [>] to
the following standard posture. select the tilt limit setting screen.
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.
D475A, D475ASD-5E0 53
7. Set the buzzer cancel switch in the select posi- 13. Press the pitch dump button (upper button),
tion [U] to select the tilt limit adjustment mode. and the buzzer sounds and the left limit posi-
tion is saved.
8. Press the pitch back button (lower button) of a Since the tilt limiting function does not
the work equipment lever, and the buzzer work at this time, operate the lever slowly
sounds and the work equipment position in the and take care not to increase the tilting
standard posture is saved. angle too much.
9. Set the buzzer cancel switch in the cancel angle gauge U.
position [t] once to cancel the tilt limit adjust-
ment mode temporarily. 14. Tilt the work equipment to the right by 7°.
10. Operate the blade according to the following

procedure 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 U.
15. Press the pitch dump button (upper button),

and the buzzer sounds and the right limit posi-
tion is saved.
angle too much.
11. Set the buzzer cancel switch in the select posi- angle gauge U.
tion [U] again to select the tilt limit adjustment
mode. 16. Set the buzzer cancel switch in the cancel
position [t] to cancel the tilt limit adjustment
12. Raise the work equipment tip to about 1 m mode.
above the ground and tilt it to the left by 7°.
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 auto-
matically in the following range at any height.
q Automatic tilt stopping angle: 7 ± 1°
54 D475A, D475ASD-5E0
Testing and adjusting operator's

cab 1
Check after installing cab assembly

1. Measuring pressure in cab
q Criterion:
Measured value X 98.1 Pa {10 mmH2O}
q Engine speed: High idle
q Blower speed: High (Hi)
q Fresh/Recirculation switch: Fresh air posi-
tion
q Fan: Adjustment code:1005 (Fan 100%
mode)
a If the measured value is lower than the
standard value, check the following. 5] Seal the mounting holes of lock lever
(1) Plug of control box (1) with tape (2).
(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.
1] Prepare a transparent vinyl hose.
q Outside diameter: 10 mm,
Length: 3,000 mm
2] Secure the end of hose [1] to the top
of the back of operator's seat with a
tape.
3] Pour coolant in the hose up to about
half.
4] Remove slide glass lever lock (1) and
insert the other end of vinyl hose [1].
6] Set the coolant level in the vinyl hose
out of the cab to that in the cab.
7] Run the engine at high idle and
measure coolant level difference (c).
(Value (c): Pa {mmH2O})
a [a] side: Inside of cab
(Pressurized)
[b] side: Out of cab
(Atmospheric pressure)
a Secure the end of hose [1] to the

operator's seat with tape.
D475A, D475ASD-5E0 55
2. Check of sealing performance 3. Testing door lock

1) Close the all openings of the cab. Close the door and check the relationship
2) Splash coolant around the hatched part of between the operator's cab and door. If there is
the cab at the rate of about 19 l/min for 10 any fault, repair it.
minutes. 1) Check of condition
q At this time, it is not necessary to 1] Check the installed height of damper
splash pressurized coolant. rubbers (4). (Check 4 pieces on each
3) Splash coolant horizontally from a hose side.)
over sealing surface (3). Stick adhesive tape [1] to the contact
4) Check around the dashboard carefully. face of damper rubber (4), open and
a If coolant leaks, caulk the leaking part close the door 2 – 3 times. Then,
and check again. check the contact face of adhesive
tape [1] against the operator'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
adhesive tapes are removed.
56 D475A, D475ASD-5E0
2] Check the relationship between the 2) Adjusting

door latch and striker (on both sides). 1] Adjusting height of damper rubbers
q Close door (5) and check the q Loosen the mounting bolt of
engaging condition of latch (6) damper rubber (4).
and striker (7). q The shim can be removed or
q Normal: Deviation (a) is 0.5 mm installed without removing the
or less. mounting bolt.
a Check deviation (a) of latch cen- q Increase or decrease the number
ter (y) and striker center (x) from of shim (8) installed at the bottom
each other from the direction of of damper rubber (4) to properly
(A). adjust the height of damper rub-
ber (4).
2] 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 striker (7) to each other.
(2) Check the engaging condition of
latch (6) and striker (7).
(3) Securely tighten the mounting
bolt of striker (7).
(4) Open and close the door and
check that it is locked and un-
locked 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}
3] Apply grease (G2-LI) to latch (6).
a If latch (6) is not sufficiently
gr ease d, the knob bec omes
heavy.
D475A, D475ASD-5E0 57
4. Testing open lock ii) Check the installed height of the stop-
Lock the door open and check the relationship per rubbers.
between the operator's cab and door. If there is (Check both sides, 4 pieces on each.)
any fault, repair it. q Lock the door open and shake it in
1) Check of condition the forward and reverse directions to
1] Check the relationship between open see if it has any play.
lock latch (9) and striker (10) from the q Check that the operating effort of the
direction of B. unlock lever is not heavy.
2) Adjusting
1] Adjusting latch and striker
q Loosen the adjustment nut of striker
(10) and adjust striker (10) so that it
will not interfere with or ride over
open latch (9), then tighten the nut.
q If interference cannot be eliminated
by adjusting striker (10), loosen the
mounting bolt of open latch (9) and
adjust open latch (9).
q Push the door. If it moves until clear-
ance (b) between striker (7) and open
latch (9) is reduced to “0”, loosen
mounting nut (12) of stopper rubber
a Open the door and check the engag- (11) and extend stopper rubber (11) in
ing condition of the open latch and the pushing direction to adjust.
striker.
q Check that the claw of open latch (9)
does not ride over the bent part of
striker (10).
q Check that the body of open latch (9)
does not interfere with striker (10).
2] Adjusting installed height of stopper

rubber
(1) Loosen locknut (12) of stopper
rubber (11).
(2) If there is any play, adjust stopper
rubber (11) until dimension (c) is
as follows.
a If the door is not locked easily or the
unlock lever is heavy, return stop-
per rubber (11) in the range that the
door does not have any play.
q Dimension (c) of stopper rub-
ber above cab: 35 ± 0.5 mm
q Dimension (c) of stopper rub-
ber under cab: 32 ± 0.5 mm
q Operating effort of door
unlock lever: 68.6 ± 19.6 Nm
{7 ± 2 kgm}
(3) After adjusting, tighten locknut (12).
58 D475A, D475ASD-5E0
Adjusting blade 1
a If the blade is removed and installed or disas-

sembled and reassemble, adjust it according 2) Adjust the shim of trunnion (2) (shim
to the following procedure. adjustment type).
1. Adjusting shims for assembly Adjusted Standard

Adjusted Standard clear-
1) Adjust the shim of center (1). clear- shim thick-
point ance
ance ness
Adjusted Adjusted Standard Standard shim 1.56 ± 0.65 mm
point clearance clearance thickness 2 c (Total thickness 12 mm
1 a See note 4.5 mm clearance)
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.
D475A, D475ASD-5E0 59
2. Adjusting blade tilt distance

1) Adjust dimension (d) of brace (4) with the
handle.
q 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) accord-
ing to the following procedure.
q (e1) > (e2): Increase dimension (d)
finely.
q (e1) < (e2): Decrease dimension (d)
finely.
60 D475A, D475ASD-5E0
SEN01818-00

© 2006 KOMATSU
All Rights Reserved
62
SEN01819-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Special functions of monitor panel (EMMS) ......................................................................................... 2
D475A, D475ASD-5E0 1

Special functions of monitor panel (EMMS) 1
Display section of special Operation section 1 of special Operation section 2 of special

functions functions (Basic operation) functions (Changeover opera-
tion)
1. Upper panel 3. Service switch 4. Buzzer cancel switch
(Gear speed display section) 5. Information switch
2. Lower panel 6. Shift-up switch
(Multi-information section) 7. Shift-down switch
a EMMS: Equipment Management Monitoring System
2 D475A, D475ASD-5E0
Normal function and special functions of monitor panel (EMMS)

The monitor panel (EMMS) has the normal and special functions, and displays information of various types
at the gear speed display section and the multi-information section of the center of the monitor panel.
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: Operator mode
With this function, an operator can view and change the items displayed normally or displayed by the
operation of the switches.
2. Special function 1: Service mode
With this function, a serviceman can display and change the displayed items by the specified switching
operation for testing, adjusting and troubleshooting.
Flow of each mode and function
D475A, D475ASD-5E0 3
Operation and display in operator mode 1. Maintenance mode

(Outline) (1-OIL, FILTER MAINTENANCE MODE)
a In this section, only the outline of the operation In this mode, the time up to the next replace-
mode is described. For the details of the con- ment of oils and filters is displayed on the
tents and operation method of each function multi-information section (2) and reset after the
and mode, see “Operation and maintenance replacement.
manual”. a Gear speed display section (1) keeps dis-
played normally.
Normal display mode (Default)
The monitor panel displays the following informa-
tion normally.
Gear speed display section (1):
q Left side: Travel direction (P·N·F·R)
q Right side: Gear speed (1·2·3)
q Graphics: Engine speed
Multi-information section (2):
a Information is displayed in 2 lines of 16 charac-
ters each.
q Left side:
Gear shift mode (F1-R1 ·F1-R2·F2-R2)
q Right side:
Service meter (Unit: 0.1h)
a To change the normal display mode to the
operator mode, hold buzzer cancel switch (4)
in the [U] position for 2.5 seconds.
4 D475A, D475ASD-5E0
Maintenance item list
Replacement interval (h)

No. Display Maintenance item 2nd time and more
1st time (fixed)
(changeable)
1 ENG OIL Engine oil 500 500
2 ENG FILT Engine oil filter 500 500
3 FUEL FILT Fuel main filter 1000 1000
4 HYD FILT Hydraulic oil filter 250 2000
5 CORR RES Corrosion resistor 1000 1000
5 DAMP OIL Damper oil 2000 2000
7 FNL OIL Final drive oil 250 2000
8 HYD OIL Hydraulic oil 250 2000
9 HSS FILT Charge filter (*1) 0 0
10 POWL OIL Power train oil 250 1000
11 POWL FLT Power train oil filter 250 500
12 F. PRE FLT Fuel pre-filter 500 500
(*1): Displayed on D475A-5 but not set.
2. Pm clinic auxiliary mode

(2-PM CLINIC MODE)
In this mode, the condition of the machine is Order Display Item
displayed on multi-information section (2) as
01 01-ENG. SPEED Engine speed
an auxiliary function of the periodic diagnoses
such as the Pm clinic, even if any measuring 02 02-COOLANT TEMP Coolant temperature
instrument is not connected. 03 03-ENG OIL PRESS Engine oil pressure
a Gear speed display section (1) keeps dis- 04 04-AMB PRESS Ambient pressure
played normally. 05 05-BOOST PRESS Engine boost pressure
06 06-BOOST TEMP Engine boost temperature
Power train oil tempera-
07 07-T/C TEMP
ture
08 08-HYD TEMP Hydraulic oil temperature
Hydraulic oil pressure
09 09-HYD. PRESS F
(F pump)
Hydraulic oil pressure
10 10-HYD. PRESS R
(R pump)
13 13-BATTERY VOLT Battery voltage
D475A, D475ASD-5E0 5
3. Failure code display mode 4. Adjustment mode (4-USER ADJUST MODE)

(3-FAULT CODE DISPLAY MODE) In this mode, the display condition of the moni-
In this mode, the contents of each fault in the tor panel can be adjusted and the fan speed
machine are displayed by a 6-character failure (for cleaning the radiator) can be changed on
code on the multi-information section (2). the multi-information section (2).
When the user or the operator needs to be a Gear speed display section (1) keeps dis-
notified of the failure code of each fault, this playing normally.
mode is applied.
a Gear speed display section (1) keeps dis-
played normally.
No. Display Item

Adjustment of LCD
1 01:LCD BRIGHTNESS
brightness
a When a serviceman needs to check the
Adjustment of dis-
failure codes for troubleshooting, the 2 02:DSP BRIGHTNESS
play brightness
“Electrical system failure code display
mode” and the “Mechanical system failure Adjustment of dis-
3 03:DSP CONTRAST
code display mode” should be used for play contrast
more detailed information. Fan 100% speed
a Method of checking failure code: 4 04:FAN 100% SPEED mode (For cleaning
Turn buzzer cancel switch (4) to the [U] radiator)
position on the screen shown above, and No injection crank-
5 05:NO INJECTION
the all failure codes detected currently are ing mode
displayed at the interval of about 2 sec- Tilt limit adjustment
6 06:TILT LIMIT
onds. (To finish displaying, turn the buzzer mode
cancel switch to the [ t ] position.) Pre-lubrication reset
7 07:PRE_LUB ON mode against pre-
lubrication trouble
6 D475A, D475ASD-5E0
1) Brightness of LCD 5) No injection cranking mode

This mode is to adjust brightness of the This mode is to circulate the engine oil
backup lamp at the liquid crystal gauge easily while applying no injection condi-
section. (See “Operation and maintenance tions to all engine cylinders before staring
manual”.) engine after an extended machine stor-
age.
2) Brightness of display 1] This mode is selected by operating
This mode is to adjust brightness of the the information switch.
backup lamp at the multi-information sec- 2] The mode is selected by turning the
tion. (See “Operation and maintenance buzzer cancel switch to the [U] position.
manual”.)
3) Contrast of display
This mode is to adjust contrast of the liquid
crystal at the multi-information section.
(See “Operation and maintenance man-
ual”.)
4) Fan 100% mode

This function is to control rotation speed of
the cooling fan forcedly at approximately
100% of the maximum speed.
1] This mode is selected by operating the
information switch.
2] The mode is selected by turning the
buzzer cancel switch to the [U] position. 3] In above 3 seconds, “WAIT” displayed
3] The function is effective under this con- on the lower line changes to “ACTIVE”
dition and the rotation speed of the and the mode becomes effective.
cooling fan is controlled to approxi-
mately 100% of the maximum speed.
a Exiting this mode disables the
function.
4] In this condition, turn the starting

switch to START position to apply no
injection cranking.
5] The mode is released by moving the
starting switch to ON position and
turning the buzzer cancel switch to
the [t] position.
k Do not continue no injection crack-
ing for more than 20 seconds in
order to protect the starting motor.
k For safety, this mode cannot be
operated while the engine is run-
ning.
D475A, D475ASD-5E0 7
a At this time, “NOT AVAILABLE” is dis- 7) Pre-lubrication mode

played on the lower line to indicate On this screen, operate the information
that the mode is ineffective. switch to display the Skip on the lower line
of the display section.
If this mode is finished under this condi-
tion, the engine can be started without
using the pre-lubrication system.
a This mode becomes ineffective once
the engine is stopped.
a Exiting from this mode disables this

function.
6) Tilt limit adjustment mode
a Refer to the section “Measurement
procedure for blade tilt control angle”
in Testing and adjusting, Part 2.
8 D475A, D475ASD-5E0
Action code display function

If a failure occurs in the machine during work which
the operator should be notified of, an action code
and a phone number are displayed on the multi-
information section (2).
a Gear speed display section (1) keeps dis-
played normally.
a The phone No. is displayed for only important
action codes. The display shown at right is an
example. (The form of the displayed phone No.
depends on the form of the input No.)
a If an important action code is displayed, the
caution 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 “Electrical system
failure code display mode” and “Mechanical system
failure code display mode” of the service mode.
Action codes table
Action
Indication method of fault Contents of fault Remedy
code
• Automatic function stops or normal
• Only action code is dis- • Torque converter is not locked up. function stops partially but machine
E01 played. • Blade dual tilt mechanism does not can work.
work. • Call your Komatsu distributor for
repair.
• Stop engine and start it again, and
• Action code is displayed. • Gear is not shifted up or down. you can operate machine without lim-
E02 • Caution lamp flashes. • Blade tilt is not limited. iting function. You must take care,
• Caution buzzer sounds. • Blade pitch mechanism does not however.
work. • Call your Komatsu distributor for
repair.
• Engine coolant temperature sensor
is defective.
• Action code is displayed. • Usable gear speeds are limited. • Move machine to safe place.
CALL E03 • Caution lamp flashes. • Engine speed does not rise fully. • Call your Komatsu distributor for
• Caution buzzer sounds. • Gear shifting shocks become large. repair.
• Steering performance lowers.
• Brake shocks become large.
• Action code is displayed. • Engine cannot be controlled. • Stop machine immediately.
CALL E04 • Caution lamp flashes. • Machine cannot travel. • Call your Komatsu distributor for
• Caution buzzer sounds. • Machine stops. repair.
D475A, D475ASD-5E0 9
Operation and display in service mode

Method of changing to service mode Gear
a When using the service mode, change the Order speed Display and item
display
screen by the following special operation.
5-EXCHG. INTVAL. INTERVAL MODE
1 1C
1) Special operation of switches Maintenance interval change mode
Set the monitor panel in the service mode by 6-ELEC. FAULT CODE MODE
operating service switch (3) and buzzer cancel 2 EE Electrical system failure code display
switch (4). mode
a Keeping the service switch in the ON posi-
7-MACHINE CHECK CODE MODE
tion, hold the buzzer cancel switch in the
[U] position for 2.5 seconds. 3 bE Mechanical system failure code display
a If the monitor panel is set in the service mode
mode, [1C] or [55] is displayed on the gear 8-SERVICE ADJUST MODE
4 Cb
speed display section (1). Adjustment mode
9-LOAD MAP 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
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).
q [ > ]: Next mode No.
q [ < ]: Previous mode No.
q [U]: Execute mode.
a For the details of operation in each mode,
see the following pages.
3) Finishing mode and function

The current mode and function can be finished
by either of the following method, regardless of
the current mode and hierarchy.
(1) When continuing the operation in another
mode or function or in the operator mode:
Return to the mode screen or function
screen to be used next by operating
buzzer cancel switch (4).
q [t]: Screen returns.
(2) When finishing the all operation:
Turn off the starting switch.
10 D475A, D475ASD-5E0
5. Maintenance interval change mode 2) Selecting and displaying maintenance

(5-EXCHG. INTVAL. INTERVAL MODE) item
In this mode, you can check and set the main- 1] Operate information switch (5) on the
tenance interval times of various filters and oils maintenance item selection screen to
which are the bases of the maintenance dis- select a maintenance item.
play function in the operator mode. q [ > ]: Next code
q [ < ]: Previous code
1) Selecting and executing mode 2] Display the maintenance item selec-
1] Select “Maintenance interval change tion screen by operating buzzer can-
mode” on the mode selection screen. cel switch (4).
a If the mode is selected, code q [U]: Execute item.
(1C) is displayed on gear speed
display section (1) and the title is
displayed on multi-information
section (2).
2] Display the maintenance item selec-
tion screen by operating buzzer can-
cel switch (4).
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 below are exam-
ples.
a If the replacement interval does not
need to be changed, finish the opera-
tion on this screen.
a If the replacement interval needs to
be changed, go to step 4).
D475A, D475ASD-5E0 11
4) Changing replacement interval time 2] If the input time is correct, enter the
1] Change the set time by operating change of setting by operating buzzer
information switch (5), shift-up switch cancel switch (4).
(6), and shift-down switch (7). q [U]: Enter change.
q [ > ]: Move cursor to right. a If the change is finished normally,
q [ < ]: Move cursor to left. the information display screen
q [UP]: Increase number. appears after the screen shown
q [DOWN]: Decrease number. below.
a If you do not use the mainte- a If the change does not finish nor-
nance function, set the all times mally, above message “SET-
to 0. TING NOW!!” is not displayed
but the replacement interval
change screen is kept displayed.
(The screen does not return to
the information display screen.)
12 D475A, D475ASD-5E0
Maintenance item list
Replacement interval (h)

No. Display Maintenance item 2nd time and more
1st time (fixed)
(changeable)
1 01: ENG OIL Engine oil 500 500
2 02: ENG FILT Engine oil filter 500 500
3 03: FUEL FILT Fuel main filter 1000 1000
4 04: HYD FILT Hydraulic oil filter 250 2000
5 06: CORR RES Corrosion resistor 1000 1000
6 07: DAMP OIL Damper oil 2000 2000
7 08: FNL OIL Final drive oil 250 2000
8 10: HYD OIL Hydraulic oil 250 2000
9 12: HSS FILT Charge filter (*1) 0 0
10 19: POWL OIL Power train oil 250 1000
11 20: POWL FILT Power train oil filter 250 500
12 41: F. PRE-FLT Fuel pre-filter 500 500
(*1): 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, D475ASD-5E0 13
6. Electrical system failure code display mode

(6-ELEC. FAULT CODE MODE)
In this mode, you can check the past electrical
system failure codes.
a Refer to the item “Failure code list” in
Troubleshooting, General.
1) Selecting and executing mode
1] Select “Electric system failure code dis-
play mode” on the mode selection
screen.
a If the mode is selected, code
(EE) is displayed on gear speed
section (2). 3) Display in the case where 1 or more codes
2] Display the failure code display are recorded
screen by operating buzzer cancel If any failure code has been output up to
switch (4). now, the information section displays as
q [U]: Execute mode. shown below.
(1) Record No. (Up to 20)
(2) Failure code (Code being output cur-
rently is flashing)
(3) Number of past occurrences
(4) Time measured by service meter after
first occurrence
last occurrence
a The items shown below are exam-
ples.
a Flashing and lighting of failure code

Flashing: Code is being output cur-
rently.
2) Display in the case where no codes are
Lighting: Code is not being output
recorded
currently.
If no failure codes have been output up to
now, the information section displays as
shown below.
14 D475A, D475ASD-5E0
a Condition for detecting and keeping 7. Mechanical system failure code display
failure code mode
If a failure code of any item other than (7-MACHINE CHECK CODE MODE)
communication and engine is output, In this mode, you can check the past mechani-
it keeps flashing until the starting cal system error codes.
switch is turned off. After the starting a Refer to the item “Failure code list” in
switch is turn on or the engine is Troubleshooting, General.
started again, the failure code keeps
lighting until the same fault is 1) Selecting and executing mode
detected. 1] Select “Mechanical system failure
A failure codes of communication and code display mode” on the mode
engine start lighting when the fault is selection screen.
solved, even if the starting switch is a If the mode is selected, code
not turned off. (bE) is displayed on gear speed
4) Operation to take when multiple codes are displayed on multi-information
recorded. section (2).
When multiple codes are recorded, they 2] Display the failure code display
can be displayed one by one by operating screen by operating buzzer cancel
information switch (5). switch (4).
q [ > ]: Next code q [U]: Execute mode.
a The failure codes are displayed from
the oldest one in order of length of
time after they were output.
5) Method of deleting failure code

While displaying a failure code to be
deleted, operate shift-up switch (6) or
shift-down switch (7).
q [UP] or [DOWN]: Delete failure code.
a A failure code which is being output
currently (which is flashing) cannot be
deleted.
D475A, D475ASD-5E0 15
2) Display in the case where no codes are a Flashing and lighting of failure code
recorded Flashing: Code is being output cur-
If no failure codes have been output up to rently.
now, the information section displays as Lighting: Code is not being output
shown below. currently.
a Condition for detecting and keeping
failure code
A failure code of mechanical system
starts lighting when the fault is solved,
even if the starting switch is not
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
information switch (5).
q [ > ]: Next code
a All the failure codes, including ones
3) Display in the case where 1 or more codes which have not been displayed, are
are recorded displayed in numeric order.
If any failure code has been output up to
now, the information section displays as 5) Method of deleting failure code
shown at right. The mechanical system failure codes can-
(1) Record No. (Up to 15) not be deleted.
(2) Failure code (Code being output cur-
rently is flashing)
(3) Number of past occurrences
first occurrence
last occurrence
a The item shown below is example.
16 D475A, D475ASD-5E0
8. Adjustment mode 2) Selecting adjustment items

(8-SERVICE ADJUST MODE) 1] On the adjustment code input screen,
In this mode, you can adjust the control system input the 4-digit code of the item to be
and various devices of the machine. adjusted by operating information
switch (5), shift up switch (6) and shift
1) Selecting and executing mode down switch (7).
i) Select “Adjustment mode” on the q [>]: Moves cursor rightward.
mode selection screen. q [<]: Moves cursor leftward.
a If the mode is selected, code q [UP]: Increases number.
(Cb) is displayed on gear speed q [DOWN]: Decreases number.
display section (1) and the title is 2] After inputting the code, operate
displayed on multi-information buzzer cancel switch (4) to display
section (2). the monitoring screen.
ii) Display the adjustment code input q [U]: Enters input mode.
screen by operating buzzer cancel
switch (4).
a If an incorrect code is input, the

adjustment code input screen
appears again after showing the
below screen. In this case, execute
the above operation again.
D475A, D475ASD-5E0 17
3) Contents of display on adjustment screen 5) Automatic selection of adjustment item

1] Code (Limited function)
2] Adjustment item After one of some adjustment items is
3] Related information selected, if the information switch is oper-
a For the detailed information and ated, the next adjustment item is selected
adjustment procedure, see “Adjust- automatically, even if the code of the next
ment modes list and adjustment pro- adjustment item is not input.
cedure”. q [ > ]: Code is increased
q [ < ]: Code is decreased
a This function is applied to only the
items having numbers in the Auto-
matic selection column of the “Adjust-
ment mode table and adjustment
procedure”. Those items are selected
in the order of their numbers.
a Note that this operation is not effec-
tive while the parking brake lever is in
the RESET position.
a You may return to the screen for
inputting codes and enter a code
without using this function.
4) When operating machine in adjustment

mode
If the parking brake lever is set in the
FREE position, gear speed display section
(1) displays normally and the machine can
be operated normally.
a At this time, even if the shift up or shift
down switch is pressed with the
PCCS lever in the neutral position,
the shift cannot be changed.
(The displayed number is the code of
adjustment mode selection.)
To change the shift, shift the PCCS
lever to the “forward” or “reverse”
position and press the shift up or shift
down switch while the machine is
traveling.
a To select another screen, return the
parking brake lever to the LOCK posi-
tion and perform the necessary pro-
cedure.
18 D475A, D475ASD-5E0
Adjustment modes list and adjustment procedure
Disassembly Sending
No. Code Adjustment 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
Transmission controller specification
[3] 0003 T/M S. CODE Code q 2
set
[4] 0004 BODY TYPE Machine specification set Code q 3
Brake potentiometer zero point adjust-
[5] 0005 BRAKE BASE Voltage q 4
ment
[6] 0007 ENG. FULL CH Engine deceleration cut mode Engine speed 5
Speed/Fuel injection
[7] 0008 INT-> 123456 Common rail reduced cylinder mode
rate
[8] 0009 PITCH SENS. Pitch angle sensor initialization set Voltage q 6
[9] 0010 FAN 70%MODE Fan speed 70% speed mode (Adjustment amount) 8
[10] 0022 VHMS INST VHMS specification set Set state 7
[11] 0530 STALL CHECK Stall speed check mode Engine speed
(Date of adjustment in
[12] 1005 FAN 100%MODE Fan speed 100% mode 9
factory)
[13] 1012 S/T N-SET Steering lever neutral set Voltage
[14] 1013 S/T M. L-SET Steering lever left set Voltage
[15] 1014 S/T M. R-SET Steering lever right set Voltage
[16] 1015 BRKLH. OFST Left brake oil pressure offset (set) Oil pressure
[17] 1016 BRKRH. OFST Right brake oil pressure offset (set) Oil pressure
[18] 1112 PRE LUB SEL Pre-lubrication set Set state
[19] 2223 R SLOW CUT Reverse slow stop set Set state
[20] 5535 CLUTCH OPEN Clutch disengagement mode Transmission speed
[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
Engine oil level display mode
[23] 9801 ENG. LEVEL Set state
(if equipped)
Hydraulic oil level display mode
[24] 9993 HYD. LEVEL Set state
(if equipped)
[25] 9995 LOCK BRAKE Electrical brake constantly ON mode Voltage
[26] 9996 MECHA BRAKE Electrical brake release mode Voltage
[27] 9997 HI IDLE SET High idle limit mode Revolving speed
[28] 9998 SFT INHIBIT 3rd speed cut set Permit
a 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”.)
a The numbers in “Sending in order” column can be displayed in order by setting the information switch in
[>] or [<] position.
D475A, D475ASD-5E0 19
[1] 0001: Phone number input mode [2] 0002: Steering controller specification set
q This code inputs or changes a phone number q This code is used to initialize the specification
to be displayed simultaneously when the user codes recognized by the steering controller
code is displayed. and the set values of the memory in the con-
q The lower part displays a phone number and troller.
symbols. q The specification code is displayed on the
q Available characters: lower line.
0123456789:;<=>? q Adjustment method
q Instructions for use: 1) Set buzzer cancel switch (4) in the [U]
1) By operating the information switch (5), position and check that the caution buzzer
shift up switch (6), and shift down switch sounds.
(7), input a phone number and symbols. 2) Check that the displayed specification
q [ > ]: Moves the cursor rightward. code has changed from [2*2] to [222].
q [ < ]: Moves the cursor leftward. a If specification code [222] is not displayed,
q [UP]: Advance the numeric character or the controller wiring harness or the con-
character (in the order of available charac- troller unit may be defective.
ters). a Even if this code is turned off, the setting
q [DOMN]: Reverse the numeric character is effective.
or character (in the reverse order of avail-
able characters).
2) Set buzzer cancel switch (4) in the [U]
position and check that the alarm buzzer
sounds.
a Sixteen digits of numeric characters are
provided. To avoid confusion, input sym-
bols other than numeric characters at dig-
its 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 con-
dition.)
a The setting is enabled even after ending
this code.
20 D475A, D475ASD-5E0
[3] 0003: Transmission controller specification set [4] 0004: Machine specification set
q This code is used to initialize the specifi- q This code is used to have the machine specifi-
cation codes recognized by the transmis- cation recognized by the controllers which
sion controller and the set values of the compose the system.
memory in the controller. q The machine specification code is displayed
q The specification code is displayed on the on the lower line.
lower line. q Adjustment method:
q Adjustment method: a Since this code is reset when “Transmis-
1) Set buzzer cancel switch (4) in the [U] sion controller specification set” is exe-
position and check that the alarm buzzer cuted, adjust it after that.
sounds. 1) Select the code of the machine specifica-
2) Check that the displayed specification tion by setting shift up switch (6), and shift
code has changed from [1*1] to [111]. down switch (7).
a If specification code [111] is not dis- a Be sure to select “SSC power setting
played, the controller wiring harness 1” as the SSC type.
or the controller unit may be defec- 2) Set buzzer cancel switch (4) in the [U]
tive. position and check that the caution buzzer
a Even if this code is turned off, the set- sounds.
ting is effective. k If the machine specification is different
from the setting in the controller, the
machine may move abnormally or an
error may be made. Accordingly, be
sure to match the setting to the
machine specification.
a Even if this code is turned off, the setting
is effective.
No. Type of work equipment Specification

800 Single tilt
801 Single tilt SSC power set 1
802 Single tilt SSC power set 2
810 Dual tilt
811 Dual tilt SSC power set 1
812 Dual tilt SSC power set 2
820 Superdozer
a Number “8” at the leftmost place of the

machine specification code indicates the
t r a v e l l e v e r ty p e . If t h e m a c h i n e i s
equipped with the OPT-type travel lever,
number “9” is displayed instead of “8”.
D475A, D475ASD-5E0 21
[5] 0005: Brake potentiometer zero-point adjust-

ment
q This code is used to adjust the zero point of the
brake pedal potentiometer.
q The deviation from the standard value is indi-
cated by voltage on the lower line (Indication
range: -2500 to 2500 mV).
q Adjustment method:
1) Check that the brake pedal is in neutral (it
is not pressed).
position and check that the alarm buzzer
sounds.
a This adjustment is performed to have the
zero point of the potentiometer recognized
by the controller. It is not performed to [7] 0008: Common rail reduced cylinder mode
adjust the effect of the brake. a When the engine common rail system seems
a Even if this adjustment is performed, the to be defective, this code is used to stop inject-
indication on the lower line does not ing fuel into 1 or more cylinders (reduce the
change. number of effective cylinders) while the engine
a Even if this code is turned off, the setting is running and find out a defective cylinder
is effective. from the change of the engine speed and the
fuel injection rate.
a Since this function diagnoses a failure based
on the differences of the engine speed and the
fuel injection rate in the reduced cylinder mode
operation from that in the normal mode opera-
tion, use this function while the engine is run-
ning.
q Engine speed (A) and fuel injection rate (B) are
displayed on the lower line.
q How to use:
Select the cylinders to be turned off for the
reduced cylinder mode operation by operating
information switch (5) and buzzer cancel
switch (4).
Use this method to turn on the selected cylin-
[6] 0007: Engine deceleration-cut mode ders again, too.
q This code is used to stop the auto-deceleration q [>]: Moves cursor rightward.
function of the engine and check the high idle q [<]: Moves cursor leftward.
speed of the engine singly. q [U]: Executes or stops reduced cylinder
q The engine speed is displayed on the lower mode operation.
line (Display range: 0 – 3000 rpm).
q Using method:
q 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.
22 D475A, D475ASD-5E0
a When the cursor is at cylinder “6”, if infor- [10] 0022: Setting of VHMS specification
mation switch (5) is operated to the right q This code is used to set the installation of
[>], the r ight ba nk c yli nders can be VHMS terminal. If the installation is not set, the
reduced. VHMS operation data is not set normally and
(L 1,2,3,4,5,6 o R 1,2,3,4,5,6) the data related to the VHMS cannot be moni-
tored.
[8] 0009: Pitch angle sensor initial set q The installation condition of the terminal is dis-
q This code is used to adjust the zero point and played on the lower line.
installation error of the pitch angle sensor. q ACTIVE: Setting of installation of VHMS
q The deviation from the standard neutral posi- q DEACTIVE: Setting of non-installation of
tion is displayed by voltage on the lower line VHMS
(Display range: -2500 to 2500 mV). q Setting method
q Adjustment method: 1) Select an installation condition of the
Set buzzer cancel switch (4) in the [U] position VHMS terminal with shift-up switch (6) and
and check that the caution buzzer sounds. shift-down switch (7).
a Even if this code is turned off, the setting 2) After selecting the condition of the termi-
is effective. nal, set buzzer cancel switch (4) in the [?]
position.
3) The buzzer sounds and the set condition
is saved.
a The setting is effective even after this
code is finished.
a After the control is replaced, be sure to set
(check) the condition.
[9] 0010: Fan 70% speed mode

q This code forcedly sets the rpm of cooling fan
at 70% of the maximum rotation.
q The lower part displays data for factory adjust-
ment.
q Instructions for use:
q The function is enabled with this code dis-
played to control the rpm of cooling fan to
approximately 70% of the maximum rotation.
a Ending this code disables the function.
D475A, D475ASD-5E0 23
[11] 0530: Stall speed check mode [12] 1005: Fan 100% mode
q This code is the function to make the cooling q This code forcedly sets the speed of cooling
fan speed maximum to check the torque con- fan at approximately 100% of the maximum
verter stall speed. speed.
k In this machine the cooling fan speed con- Also by this code, the adjustment value for the
trol function is installed in order to protect maximum speed can be set.
the radiator when the engine is not yet q The adjustment data is displayed on the lower
warmed up enough. However, in case that line.
this mode is in use, the protecting function q How to use:
does not work. So use the machine after a The function is effective with this code dis-
carrying out enough warming up. played to control the speed of cooling fan
q The engine speed is displayed on the lower line. to approximately 100% of the maximum
(Display range: 0 – 3000) speed.
q How to use i) When changing the adjustment value,
While this code is displayed, its function is operate shift up switch (6) and shift down
enabled and the cooling fan speed becomes switch (7) to set the adjustment value for
maximum. the maximum speed.
a If this code is turned off, its function is disabled. q [UP]: Adjustment value increases.
q [DOWN]: Adjustment value decreases.
ii) For confirming the adjustment value, set
buzzer cancel switch (4) in the [U] posi-
tion and check that the alarm buzzer
sounds.
a If this code is turned off, its function is dis-
abled. However, the adjustment value
once set is still effective.
24 D475A, D475ASD-5E0
[13] 1012: Steering lever neutral set

q This code is used to adjust the steering neutral
position of the PCCS lever.
q The deviation of the steering potentiometer
from the standard neutral position is displayed
by voltage on the lower line (Display range:
-2500 – 2500 mV).
1) Set the PCCS lever to the neutral position.
position and check that the caution buzzer
sounds.
a Even if adjustment is carried out, the dis-
play on the lower line does not change.
is effective. [15] 1014: Steering lever right set
a This code is not for adjusting the steering q This code is used to adjust the maximum right
performance. steering position of the PCCS lever.
from the standard maximum right position is
displayed by voltage on the lower line (Display
range: -2500 – 2500 mV).
1) Set the PCCS lever to the right steering
stroke end.
sounds.
is effective.
a This code is not for adjusting the steering
[14] 1013: Steering lever left set performance.
q This code is used to adjust the maximum left
steering position of the PCCS lever.
from the standard maximum left position is dis-
played by voltage on the lower line (Display
range: -2500 – 2500 mV).
1) Set the PCCS lever to the left steering
stroke end.
sounds.
is effective.
a This code is not for adjusting the steering
performance.
D475A, D475ASD-5E0 25
[16] 1015: Left brake oil pressure offset 2) Operate the buzzer cancel switch to [U]
q This code is used to adjust the left brake oil side and check that the caution buzzer
pressure manually. sounds.
q The offset oil pressure (Unit: MPa) is displayed a Even if this code is turned off, the setting
on the lower line (If it has been adjusted, its is effective.
value is displayed. It can be adjusted further
within the allowable range).
a The allowable adjustment range is ± 0.3
MPa {3 kg/cm2} (Displayed value: 0.3)
1) Operate the shift switch to set the offset oil
pressure.
q Shiftup switch (6): Increase oil pres-
sure
q Shiftdown switch (7): Decrease oil
pressure
a The offset pressure is increased or
decreased by 0.05 MPa {0.5 kg/cm2}
(Displayed value: 0.05).
position and check that the caution buzzer [18] 1112: Pre-lubrication set (if equipped)
sounds. q This code is used to set the machine equipped
a Even if this code is turned off, the setting with the pre-lubrication system.
is effective. q Installation or non-installation of the pre-lubri-
cation system is displayed on the lower line by
letters.
Operate information switch (5) to change the
setting.
q [ < ] [ > ]: Change display
q [Pre-Lub ON]: Machine is equipped with
pre-lubrication system
q [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
error may be detected.
is effective.
[17] 1016: Right brake oil pressure offset
q This code is used to adjust the right brake oil
pressure manually.
q The offset oil pressure (Unit: MPa) is displayed
on the lower line (If it has been adjusted, its
value is displayed. It can be adjusted further
within the allowable range).
a The allowable adjustment range is ± 0.3
MPa {3 kg/cm2} (Displayed value: 0.3)
1) Operate the shift switch to set the offset oil
pressure.
q Shiftup switch (6): Increase oil pres-
sure
q Shiftdown switch (7): Decrease oil
pressure
a The offset pressure is increased or
decreased by 0.05 MPa {0.5 kg/cm2}
(Displayed value: 0.05).
26 D475A, D475ASD-5E0
[19] 2223: Reverse slow stop set [20] 5535: Both steering clutches disengagement
q This code is used to turn off the reverse slow q This code is used to engage the transmission
function forcibly, regardless of the operation of clutch without driving the machine for testing,
the switches on the monitor panel. adjusting, troubleshooting, Pm Clinic, etc.
q The state of the reverse slow function is dis- q The transmission speed (Unit: rpm) is dis-
played on the lower line by letters. played on the lower line.
q Adjustment method: q Using method:
Operate information switch (5) to change the While this code is displayed, the function is
setting. effective and steering clutches on both sides
q [ < ] [ > ]: Change display are disengaged. Accordingly, the machine
q [DEACTIVE]: Turn reverse slow function does not travel even if the PCCS lever is oper-
OFF ated.
q [ACTIVE]: Turn reverse slow function ON a If this code is turned off, the function
a Once the reverse slow function is turned becomes ineffective.
OFF, the reverse speed is not lowered,
even if the reverse slow mode switch on
the monitor panel is turned ON.
is effective.
D475A, D475ASD-5E0 27
[21] 5537: Left steering clutch oil pressure offset [22] 5538: Right steering clutch oil pressure offset
q This code is used to adjust the left clutch oil q This code is used to adjust the right clutch oil
pressure manually. pressure manually.
q The offset oil pressure (Unit: MPa) is displayed q The offset oil pressure (Unit: MPa) is displayed
on the lower line (If it has been adjusted, its on the lower line (If it has been adjusted, its
value is displayed. It can be adjusted further value is displayed. It can be adjusted further
within the allowable range). within the allowable range).
q Adjustment method: q Adjustment method:
a The allowable adjustment range is ± 0.3 a The allowable adjustment range is ± 0.3
MPa {3 kg/cm2} (Displayed value: 0.3) MPa {3 kg/cm2} (Displayed value: 0.3)
1) Operate the shift switch to set the offset oil 1) Operate the shift switch to set the offset oil
pressure. pressure.
q Shiftup switch (6): Increase oil pres- q Shiftup switch (6): Increase oil pres-
sure sure
q Shiftdown switch (7): Decrease oil q Shiftdown switch (7): Decrease oil
pressure pressure
a The offset pressure is increased or a The offset pressure is increased or
decreased by 0.05 MPa {0.5 kg/cm2} decreased by 0.05 MPa {0.5 kg/cm2}
(Displayed value: 0.05). (Displayed value: 0.05).
2) Set buzzer cancel switch (4) in the [U] 2) Set buzzer cancel switch (4) in the [U]
position and check that the caution buzzer position and check that the caution buzzer
sounds. sounds.
a Even if this code is turned off, the setting a Even if this code is turned off, the setting
is effective. is effective.
28 D475A, D475ASD-5E0
[23] 9801: Engine oil level set (if equipped) [24] 9993: Hydraulic oil level set (if equipped)
q This code is used to set the machine equipped q This code is used to set the hydraulic oil level
with the engine oil level switch. caution.
q Installation or non-installation of the engine oil q The setting of the hydraulic oil level caution is
level switch is displayed on the lower line by displayed on the lower line by letters.
letters. q Adjustment method:
q Adjustment method: Operate information switch (5) to change the
Operate information switch (5) to change the setting.
setting. q [ < ] [ > ]: Change display
q [ < ] [ > ]: Change display q [ACTIVE]: Turn hydraulic oil level caution
q [ACTIVE]: Machine is equipped with function ON
engine oil level switch q [DEACTIVE]: Turn hydraulic oil level cau-
q [DEACTIVE]: Machine is not equipped tion function OFF
with engine oil level switch a To use this function, the hydraulic oil level
a To use this function, the engine oil level switch switch must be installed.
must be installed. a If [ACTIVE] is selected while the hydraulic oil
a If [ACTIVE] is selected while the engine oil level switch is not installed, the caution buzzer
level switch is not installed, the caution buzzer sounds. Take care.
sounds. Take care. a Even if this code is turned off, the setting is
effective.
D475A, D475ASD-5E0 29
[25] 9995: Electric brake constantly ON mode [27] 9997: High idle limit mode
q This code is used to see if the sudden stop q This code is used to limit the high idle speed.
prevent valve operates normally. q The engine speed (set value) is displayed on
q The voltage of the brake potentiometer is dis- the lower line.
played on the lower line. q Possible limiting range: High idle speed –400
q Using method: rpm
While this code is displayed, the function is q Using method:
effective and the electric brake is constantly 1) Set information switch (5) in the [ > ] or [ < ]
turned on. position to select the limit speed.
a If this code is turned off, the function 2) Set buzzer cancel switch (4) in the [U]
becomes ineffective. position and check that the caution buzzer
sounds.
a Once the high idle speed is limited, the
engine speed does not reach the original
high idle speed, even if the fuel control dial
is operated.
is effective.
[26] 9996: Electric brake release mode

q This code is used to check the operation of the
mechanical brake.
q The voltage of the brake potentiometer is dis-
played on the lower line.
q Using method:
While this code is displayed, the function is
effective and the electric brake is constantly
turned off.
a If this code is turned off, the function
becomes ineffective.
30 D475A, D475ASD-5E0
[28] 9998: 3rd speed cut set

q This code is used to prevent the gear from
shifting up to the 3rd gear speed.
q Available gear speeds are displayed on the
lower line by bits (in the order of the 3rd, 2nd,
and 1st from the left).
q Using method:
Operate information switch (5) and buzzer can-
cel switch (4) to limit or reset the maximum
gear speed.
q [ > ]: Move cursor to right
q [ < ]: Move cursor to left
q [U] Change setting
q Display of lower line [o]: Gear speed is
effective
q Display of lower line [_]: Gear speed is
ineffective
a Once a gear speed is limited, the gear
does not shift up to that gear speed, even
if the shiftup switch is operated.
is effective.
D475A, D475ASD-5E0 31
9. Load memory display mode 2) Changing information screen

(9-LOAD MAP DISPLAY MODE) Change the information screen by operat-
In this mode, you can check the load on the ing information switch (5).
machine, forward odometer, and reverse q [ > ]: Next screen.
odometer. q [ < ]: Previous screen.
1) Selecting and executing mode No. Display Item

1] Select “Load memory display mode”
1000 rpm service
on the mode selection screen. 1 01-1000 rpm SMR
data
a If the mode is selected, code (Ld)
Forward travel
is displayed on gear speed dis- 2 02-FOWARD ODO M
distance
play section (1) and the title is
displayed on multi-information Reverse travel
3 03-REVERSE ODO M
section (2). distance
2] Display the information screen by 4 04-F1 ODO Meter F1 travel distance
operating buzzer cancel switch (4). 5 05-F2 ODO Meter F2 travel distance
q [U]: Execute mode. 6 06-F3 ODO Meter F3 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.
32 D475A, D475ASD-5E0
4) Display of forward odometer (02) 7) Display of F2 odometer (05)

On this screen, the integrated forward On this screen, the integrated F2 (Forward
travel distance is displayed. 2nd gear) travel distance is displayed.
a The data cannot be reset. a The data cannot be reset.
5) Display of reverse odometer (03) 8) Display of F3 odometer (06)

On this screen, the integrated reverse On this screen, the integrated F3 (Forward
travel distance is displayed. 3rd gear) travel distance is displayed.
a The data cannot be reset. a The data cannot be reset.
6) Display of F1 odometer (04) 9) Display of R1 odometer (07)

On this screen, the integrated F1 (Forward On this screen, the integrated R1
1st gear) travel distance is displayed. (Reverse 1st gear) travel distance is dis-
a The data cannot be reset. played.
D475A, D475ASD-5E0 33
10) Display of R2 odometer (08) 12) Moving machine with saved load dis-
On this screen, the integrated R2 played
(Reverse 2nd gear) travel distance is dis- If the parking brake lever is set in the
played. FREE position, gear speed display unit (1)
a The data cannot be reset. is set in the normal display mode again
and the machine can operate normally.
load saving display mode.)
traveling.
tion temporarily, and then start the
11) Display of R3 odometer (09) operation.
On this screen, the integrated R3
(Reverse 3rd gear) travel distance is dis-
played.
34 D475A, D475ASD-5E0
10. Real-time monitoring mode q [ > ]: Move cursor to right.

(10-REAL TIME MONITORING MODE) q [ < ]: Move cursor to left.
In this mode, the speeds, oil pressures, oil q [UP]: Increase number.
temperatures, currents, voltages, etc. can be q [DOWN]: Decrease number.
monitored 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”.
1) Selecting and executing mode

1] Select “Real-time monitoring mode”
on the mode selection screen.
a If the mode is selected, code
(5R) is displayed on gear speed
section (2).
2] Display the monitoring code input
2] After inputting the code, display the
m on i to r in g s c r e en b y op er a ti n g
switch (4).
buzzer cancel switch (4).
q [ ]: Enter input code.
a If the input code is normal, the
monitoring screen shown at right
appears.
a If the input code is abnormal, the

code input screen appears again
after the screen shown at right.
2) Selecting and entering monitored items

1] On the code input screen, input the 5-
digit code of the item to be monitored
by operating information switch (5),
shift-up switch (6), and shift-down
switch (7).
D475A, D475ASD-5E0 35
3) Contents of display on monitoring screen 5) When operating machine in monitoring

(Figure below shows examples) mode
1] Code If the parking brake lever is set in the
2] Monitoring item FREE position, gear speed display section
3] Information displays normally and the machine can be
4] Unit (Not displayed for some items) operated normally.
a For the details, see the “Monitoring a At this time, even if the shift up or shift
mode table”. down switch is pressed with the
monitoring mode.)
traveling.
tion and perform the necessary pro-
cedure.
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).
q [U]: Hold and release.
a While the monitored item is held, the
letter “H” is displayed at the left end of
the lower line.
36 D475A, D475ASD-5E0
6) Automatic selection of monitoring item

(Limited 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.
q [ > ]: Code is increased
q [ < ]: Code is decreased
a This function is applied to only the
items having numbers in the “Sending
in order” column of the Monitoring
mode table. Those items are selected
in the order of their numbers.
a Note that this operation is not effec-
tive while the parking brake lever is in
the RESET position.
a You may return to the screen for
inputting codes and enter a code
without using this function.
D475A, D475ASD-5E0 37
Monitoring mode table
Auto-
No. Code Monitoring item Unit Remarks matic
selection
1 00201 ENG M ID L Engine controller model selection name, left bank Letter — —
2 00203 ENG M ID R Engine controller model selection name, right bank Letter — —
3 01002 ENG REV L Engine speed, left bank rpm — 1
4 01004 ENG REV R Engine speed, right bank rpm — 2
5 01603 Remote Th 2nd throttle position % — —
6 03000 FUEL DIAL Fuel control dial voltage mV — 25
7 03200 BATTERY Battery voltage mV — 39
8 03201 S/T ACC Steering controller ACC input voltage mV — —
9 03202 S/T PWR2 Steering controller load power supply voltage mV — —
10 03203 E-ECM PW L Engine controller power supply voltage, left bank mV — —
11 03206 E-ECM PW R Engine controller power supply voltage, right bank mV — —
12 03207 S/T PWR1 Steering controller unswitched power supply voltage mV — —
Transmission controller unswitched power supply volt-
13 03208 T/M PWR1 mV — —
age
14 03212 T/M ACC Transmission controller ACC input voltage mV — —
15 03216 T/M PWR2 Transmission controller load power supply voltage mV — —
16 04104 COOLANT TP Engine coolant temperature °C — 6
17 04105 COOLANT TP Engine coolant temperature sensor voltage mV — —
18 04200 FUEL SENS Fuel level sensor voltage mV — 37
19 04401 HYD.TEMP Hydraulic oil temperature °C — 7
20 08100 HSI BREAK HSI line break point rpm — —
21 08200 TQ Sel Torque curve selection Letter — —
22 08300 Droop Type Droop type selection Letter — —
23 08400 Droop SW Droop switch selection Letter — —
24 08500 Droop Trim Droop trim selection Letter — —
25 10500 S/T 5V PW1 Steering controller sensor 5V power supply voltage 1 mV — —
Transmission controller sensor 5V power supply voltage
26 10501 T/M 5V PW1 mV — —
1
27 10505 S/T 5V PW2 Steering controller sensor 5V power supply voltage 2 mV — —
Transmission controller sensor 5V power supply voltage
28 10506 T/M 5V PW2 mV — —
2
29 10700 S/T 24V PW Steering controller sensor 24V power supply voltage mV — —
Transmission controller sensor 24V power supply volt-
30 10701 T/M 24V PW mV — —
age
31 14200 FUEL TMP L Fuel temperature, left bank °C — —
32 14201 FUEL TMP L Fuel temperature sensor voltage, left bank mV — —
33 14202 FUEL TMP R Fuel temperature, right bank °C — —
34 14203 FUEL TMP R Fuel temperature sensor voltage, right bank mV — —
35 17201 PCV TMG L PCV closing timing, left bank CA — —
36 17202 PCV TMG R PCV closing timing, right bank CA — —
37 17500 ENG MODE Engine controller mode selection Letter — —
(See detailed
38 18300 ENG IVSW 1 Engine controller idle validation switch 1 bit —
information)
(See detailed
39 18301 ENG IVSW 1 Engine controller idle validation switch 2 bit —
information)
38 D475A, D475ASD-5E0
Auto-
selection
40 18400 INTAKE TEMP Intake air temperature °C — —
41 18401 INTAKE TEMP Intake air temperature sensor voltage mV — —
42 18500 BOOST TEMP Boost temperature °C — —
43 18501 BOOST TEMP Boost temperature sensor voltage mV — —
44 18600 INJECT CMD Final injection rate command mg/st — —
45 18700 ENG TRUQUE Engine output torque Nm — —
46 18900 E-ECM TP L Engine controller ECM inside temperature, left bank °C — —
47 18902 E-ECM TP R Engine controller ECM inside temperature, right bank °C — —
48 20201 T/M. PROGRM Transmission controller program version Letter — —
49 20202 S/T. PROGRM Steering controller program version Letter — —
50 20216 ENG BLD L Engine controller build version, left bank Letter — —
51 20217 ENG CAL L Engine controller calibration data version, left bank Letter — —
52 20218 ENG CAL R Engine controller calibration data version, right bank Letter — —
53 20219 ENG BLD R Engine controller build version, right bank Letter — —
54 20301 VHMS VHMS LED monitor LED — 40
55 20400 E-ECM SN L Engine controller ECM serial No., left bank Letter — —
56 20401 E-ECM SN R Engine controller ECM serial No., right bank Letter —
57 30100 T/C TEMP. Torque converter oil temperature °C — 8
58 31200 T/M IN Transmission input speed rpm —
59 31400 T/M OUT Transmission output speed rpm — 3
(See detailed
60 31520 T/M-FILL Transmission-related fill switch input state bit —
information)
(See detailed
61 31521 S/T FILL Steering-related fill switch input state bit —
information)
62 31602 1st CLUTCH 1st clutch ECMV current command value mA — —
63 31603 2nd CLUTCH 2nd clutch ECMV current command value mA — —
64 31604 3rd CLUTCH 3rd clutch ECMV current command value mA — —
65 31606 Rev CLUTCH Reverse clutch ECMV current command value mA — —
66 31608 Frd CLUTCH Forward clutch ECMV current command value mA — —
67 31612 1 CLUTCH F 1st clutch ECMV output feedback current mA — 33
68 31613 2 CLUTCH F 2nd clutch ECMV output feedback current mA — 34
69 31614 3 CLUTCH F 3rd clutch ECMV output feedback current mA — 35
70 31616 R CLUTCH F Reverse clutch ECMV output feedback current mA — 32
71 31618 BRAKE R.H. Right brake ECMV output feedback current mA — 27
72 31619 BRAKE L.H. Left brake ECMV output feedback current mA — 26
73 31620 BRAKE R.H. Right brake ECMV current command value mA — —
74 31621 BRAKE L.H. Left brake ECMV current command value mA — —
75 31622 F CLUTCH F Forward clutch ECMV output feedback current mA 31
76 31623 FAN PUMP. O Cooling fan pump solenoid output command current mA — —
77 31624 FAN PUMP. F Cooling fan pump solenoid output feedback current mA — —
78 31625 PITCH SOL. Blade pitch solenoid output feedback current mA — —
Torque converter lockup solenoid output feedback cur-
79 31627 L/U SOL mA — 36
rent
Sudden stop prevention solenoid output feedback cur-
80 31628 E. BRAKE SL mA — 28
rent
81 31633 FAN PMP2. O Cooling fan pump 2 solenoid output command current mA — —
D475A, D475ASD-5E0 39
Auto-
selection
82 31634 FAN PMP2. F Cooling fan pump 2 solenoid output feedback current mA — —
83 31701 DECEL Decelerator position % — 9
84 31703 DECEL Decelerator pedal potentiometer voltage mV — 24
85 31706 F THROTTLE Final accelerator position % — 10
86 32900 BODY ANGLE Machine pitch angle ° — 18
87 36001 Accel Adj Throttle correction value data % — —
88 36200 PRESS CMD Final common rail pressure command MPa — —
89 36300 INJECT CMD Final injection timing command CA — —
90 36400 RAIL PR L Common rail pressure, left bank MPa — 12
91 36401 RAIL PR L Common rail pressure sensor voltage, left bank mV — —
92 36403 RAIL PR R Common rail pressure, right bank MPa — 13
93 36404 RAIL PR R Common rail pressure sensor voltage, right bank mV — —
94 36500 BOOST PRS Boost pressure KPa — 14
95 36501 BOOST PRS Boost pressure sensor voltage mV — —
96 36700 ENG TORQUE Engine converted torque % — 15
97 37200 ENG OIL PRS Engine oil pressure KPa — 11
98 37201 ENG OIL PRS Engine oil pressure sensor voltage mV — —
99 37301 FUEL RATE Fuel injection rate L/h — —
100 37400 ABM PRESS Ambient pressure KPa — —
101 37401 ABM PRESS Ambient pressure sensor voltage mV — —
102 37500 ATM TEMP Ambient temperature °C — —
103 40001 VEHICLE SP Travel speed (Theoretical value) km/h — 4
(See detailed
104 40905 T/M-SW1 Transmission-related controller input signal 1 bit —
information)
(See detailed
105 40906 T/M-SW2 Transmission-related controller input signal 2 bit —
information)
(See detailed
106 40907 T/M OP SIG Transmission-related controller operation input signal bit —
information)
(See detailed
107 40908 T/M HYD SW Blade lever oil pressure switch input signal bit —
information)
(See detailed
108 40909 T/M SOL. 2 Transmission-related controller ON/OFF output 2 bit —
information)
(See detailed
109 40910 S/T-SW1 Steering-related controller switch input signal 1 bit —
information)
(See detailed
information)
(See detailed
information)
(See detailed
112 40914 S/T SOL. 1 Transmission-related controller ON/OFF output 1 bit —
information)
(See detailed
113 40915 S/T SOL. 2 Steering-related controller output signal 2 bit —
information)
114 42600 EXH TEMP LF Exhaust temperature, left front °C — —
115 42601 EXH TEMP RR Exhaust temperature, right rear °C — —
116 42602 EXH TEMP RF Exhaust temperature, right front °C — —
117 42603 EXH TEMP RF Exhaust temperature sensor voltage, right front mV — —
118 42604 EXH TEMP LF Exhaust temperature sensor voltage, left front mV — —
119 42605 EXH TEMP RR Exhaust temperature sensor voltage, right rear mV — —
40 D475A, D475ASD-5E0
Auto-
selection
120 42606 EXH TEMP LR Exhaust temperature, left rear °C — —
121 42607 EXH TEMP LR Exhaust temperature sensor voltage, left rear mV — —
122 42700 ENG OIL TMP Engine oil temperature °C — —
123 42701 ENG OIL TMP Engine oil pressure sensor voltage mV — —
124 42800 BLOWBY PRS Blow-by pressure KPa — —
125 43000 T/M PRESS Transmission main relief pressure MPa — —
(See detailed
126 43502 IdleCancel Warm-up operation cancel flag bit —
information)
127 44202 Accel Up Throttle upper limit value data % —
128 44203 Accel low Throttle lower limit value data % —
129 50200 T/M LEVR 1 Directional lever potentiometer 1 voltage mV 19
130 50201 T/M LEVR 2 Directional lever potentiometer 2 voltage mV 20
131 50300 S/T LEVR 1 Steering potentiometer 1 voltage mV 21
132 50301 S/T LEVR 2 Steering potentiometer 2 voltage mV 22
133 50400 BRAKE PEDL Brake pedal potentiometer voltage mV 23
134 50900 N-SAFTY Neutral safety relay drive voltage mV 38
135 51000 ENG REG Regulation command speed rpm —
136 51100 FUEL DIAL Fuel control dial command speed rpm
137 60000 TRACTION Traction force (Theoretical value) W 5
138 60100 BODY ANGLE Machine pitch angle sensor voltage mV —
139 60200 ACCELERATN Acceleration sensor voltage mV —
140 60300 SSC ORDER SSC command speed rpm —
(See detailed
141 60400 S/T-SW6 Steering-related controller input signal 6 bit —
information)
142 60500 ENG.CON. PW Engine controller drive voltage mV — —
143 60600 BR HOLD Battery relay drive voltage mV — —
144 60700 S/T MODE Steering state code Letter — —
145 60800 FILL MODE Fill condition setting variable Letter — —
146 60909 MOD MODE Modulation condition setting variable Letter — —
147 70000 CHG.P. MODE Gearshift point condition setting variable Letter — —
148 70200 T/M OUT Transmission speed sensor voltage mV — —
(See detailed
149 70300 B. KNOB SW Blade lever knob switch input signal bit —
information)
(See detailed
150 70305 T/M RIPER2 Ripper lever oil pressure switch input signal bit —
information)
151 70400 BACK ALARM Backup alarm relay drive voltage mV — —
152 70600 DUAL SOL. Dual tilt solenoid drive current mA — —
153 70700 HYD. PUMP 1 Work equipment pump oil pressure 1 MPa — 16
154 70701 HYD. PUMP 1 Work equipment oil pressure sensor 1 voltage mV — —
155 70702 HYD. PUMP 2 Work equipment pump oil pressure 2 MPa — 17
156 70703 HYD. PUMP 2 Work equipment oil pressure sensor 2 voltage mV — —
(See detailed
157 90000 T/M SOL. 3 Tilt and pitch solenoid output 3 bit output signal bit —
information)
(See detailed
158 90001 T/M SOL. 4 Dual tilt and pitch solenoid output 4 bit output signal bit —
information)
159 90002 BL YOKE L Left yoke angle sensor voltage mV — —
160 90003 BL YOKE R Right yoke angle sensor voltage mV — —
D475A, D475ASD-5E0 41
Auto-
selection
161 90600 S/T CLT LH Left clutch ECMV output feedback current mA — 29
162 90601 S/T CLT RH Right clutch ECMV output feedback current mA — 30
163 90602 S/T CLT LH Left clutch ECMV output current mA — —
164 90603 S/T CLT RH Right clutch ECMV output current mA — —
165 92100 F1 SMR F1 integrated travel hours h — —
168 92200 R1 SMR R1 integrated travel hours h — —
171 99901 TRIG T F Trigger time F msec — —
172 99902 TRIG T R Trigger time R msec — —
173 99903 TRIG T 1 Trigger time 1 msec — —
176 99906 TM SFT Transmission shift Letter — —
(See detailed
177 99907 LU Lockup state bit —
information)
178 99908 TM IN TRQ Transmission input torque Nm — —
179 99909 DOZING h Dozing hours h — —
180 99910 RIPPING h Ripping hours h — —
181 99911 PATH NUM Number of path path — —
182 99913 TC IN TRQ Torque converter input torque Nm — —
183 99914 H. P 1 TRQ Work equipment pump 1 input torque Nm — —
184 99915 H. P 2 TRQ Work equipment pump 2 input torque Nm — —
185 99917 BR L PRESS Left brake oil pressure MPa — —
186 99918 BR R PRESS Right brake oil pressure MPa — —
187 99919 CL L PRESS Left clutch oil pressure MPa — —
188 99920 CL R PRESS Right clutch oil pressure MPa — —
a The numbers in the Automatic selection column can be displayed in numeric order by setting the infor-
mation switch in the “>” or “<” position.
42 D475A, D475ASD-5E0
Detailed information on bit display 18301: Engine controller idle validation switch 2
codes 1: Idle validation switch 2: ON
2: (Unused)
Examples of display of bit information 3: (Unused)
a The display position of the bit information in the 4: (Unused)
“Real-time monitoring mode (Display of only 1 5: (Unused)
item)” is different from that in the “Dual display 6: (Unused)
monitoring mode (Simultaneous display of 2 7: (Unused)
items)”. 8: (Unused)
a The bit information is displayed by [ ] for OFF
and [o] for ON in the places 1 – 8.
a The state of each item shown below is the con-
dition for turning on the bit.
31520: Input state of transmission related fill

switch
1: Forward clutch fill switch: ON
2: Reverse clutch fill switch: ON
18300: Engine controller idle validation switch 1 3: 1st clutch fill switch: ON
1: Idle validation switch 1: ON 4: 2nd clutch fill switch: ON
2: (Unused) 5: 3rd clutch fill switch: ON
3: (Unused) 6: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
D475A, D475ASD-5E0 43
31521: Input state of steering related fill switch 40906: Transmission related controller input signal 2
1: Left brake fill switch: ON 1: Automatic gear shift-down switch: ON
2: Left clutch fill switch: ON 2: Neutral switch (OPT-type travel lever): OFF
3: (Unused) 3: Neutral switch (OPT-type travel lever): ON
4: (Unused) 4: Neutral switch (OPT-type travel lever): OFF
5: Right clutch fill switch: ON 5: Neutral switch (OPT-type travel lever): ON
6: Right brake fill switch: ON 6: Automatic pitch back switch: ON
40905: Transmission related controller input signal 1 40907: Transmission related controller function
1: Shift-up switch: OFF input signal
2: Shift-up switch: ON 1: ACC signal switch: ON
3: Shift-down switch: OFF 2: (Unused)
4: Shift-down switch: ON 3: R signal: ON
5: Parking brake switch: FREE 4: (Unused)
6: Parking brake switch: LOCK 5: (Unused)
8: (Unused)
44 D475A, D475ASD-5E0
40908: Blade lever oil pressure switch input signal 40910: Steering related controller input signal 1
1: Blade lift raise oil pressure switch: ON 1: (Unused)
2: Blade lift lower oil pressure switch: ON 2: (Unused)
5: Blade left tilt oil pressure switch: ON 5: Parking brake lever switch: FREE
6: Blade right tilt oil pressure switch: ON 6: Parking brake lever switch: LOCK
40909: Transmission related controller output 40911: Steering related controller input signal 2
signal 2 1: Buzzer cancel switch: t position
1: (Unused) 2: Buzzer cancel switch: U position
2: (Unused) 3: Information switch: > position
3: (Unused) 4: Information switch: < position
4: Backup alarm relay: ON 5: Service switch: ON
5: Neutral safety relay: ON 6: (Unused)
6: Lockup: ON 7: (Unused)
8: (Unused)
D475A, D475ASD-5E0 45
40913: Steering related controller input signal 5 40915: Steering related controller ON-OFF output
1: ACC signal: ON signal 2
2: Pre-lubrication oil pressure switch: ON 1: Pre-lubrication motor relay: ON
3: R signal: ON 2: Engine stop relay: ON
5: Fan reverse switch: ON 4: (Unused)
6: Fan cleaning switch: ON 5: (Unused)
8: (Unused)
40914: Steering related controller output signal 1

1: Pre-heater relay drive: ON 43502: Warm-up cancel flag
2: Snap shot switch: ON 1: Warm-up cancel flag: ON
3: Fan reverse solenoid: ON 2: (Unused)
4: Merge-divider selector solenoid valve: ON 3: (Unused)
5: Battery relay drive: ON 4: (Unused)
6: Sudden stop prevent solenoid: ON 5: (Unused)
7: LS solenoid: ON 6: (Unused)
8: (Unused)
46 D475A, D475ASD-5E0
60400: Steering related controller input signal 6 70305: Ripper lever oil pressure switch input signal
2: C signal: ON 2: Ripper lift raise oil pressure switch:
3: Engine low idle signal: ON ON (Operated)
4: Engine stop command signal: ON 3: Ripper lift lower oil pressure switch:
5: Hydraulic oil level switch signal: ON ON (Operated)
6: Pre-lubrication motor drive signal: ON 4: Ripper tilt in oil pressure switch: ON (Operated)
7: (Unused) 5: Ripper tilt out oil pressure switch: ON (Oper-
8: (Unused) ated)
6: (Unused)
7: (Unused)
8: (Unused)
70300: Blade lever knob switch input signal

1: Blade lever tilt switch: SINGLE
2: Blade lever tilt switch: DUAL
3: Blade lever pitch switch: OFF 90000: Tilt/Pitch solenoid output 3 bit output signal
4: Blade lever pitch switch: ON (Superdozer specification)
5: (Unused) 1: Left tilt limit solenoid: ON
6: (Unused) 2: Right tilt limit solenoid: ON
7: (Unused) 3: Pitch solenoid: ON
5: Pitch dump solenoid: ON
6: Pitch back solenoid: ON
7: (Unused)
8: (Unused)
D475A, D475ASD-5E0 47
90000: Dual/Pitch dump solenoid output 4 bit out- 99907: Lockup state
put signal (Other than superdozer specification) 1: Forward clutch output: ON
1: Left tilt limit solenoid: ON 2: Reverse clutch output: ON
2: Right tilt limit solenoid: ON 3: 1st clutch output: ON
3: (Unused) 4: 2nd clutch output: ON
4: (Unused) 5: 3rd clutch output: ON
5: (Unused) 6: Clutch modulation: Modulating
6: (Unused) 7: Lockup clutch output: ON
7: (Unused) 8: Clutch state: Neutral
8: (Unused)
90001: Transmission controller output signal

1: Dual tilt solenoid: ON
2: Pitch solenoid: ON
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
48 D475A, D475ASD-5E0
11. Dual display monitoring mode 2) Selecting and entering monitored items
(11-DUAL DISPLAY MONITORING MODE) 1] On the code input screen, input the 5-
In this mode, 2 monitored items can be dis- digit codes of the items to be moni-
played simultaneously. tored to the upper and lower lines by
a Note that only codes and monitoring infor- operating information switch (5), shift-
mation are displayed in this mode since up switch (6), and shift-down switch
the usable display columns are limited. (7).
(Item names and units cannot be dis- q [ > ]: Move cursor to right.
played.) q [ < ]: Move cursor to left.
q [UP]: Increase number.
1) Selecting and executing mode q [DOWN]: Decrease number.
1] Select “Dual display monitoring 2] After inputting the codes, display the
mode” on the mode selection screen. m on i to r in g s c r e en b y op er a ti n g
a If the mode is selected, code buzzer cancel switch (4).
(dR) is displayed on gear speed q [U]: Enter input code.
section (2).
2] Display the monitoring code input
switch (4).
a If the input codes are normal, the

monitoring screen shown below
appears.
D475A, D475ASD-5E0 49
a If the input codes are incorrect, 4) When operating machine in monitoring

the code input screen appears mode
again after the screen shown If the parking brake lever is set in the
below. FREE position, gear speed display section
(1) displays normally and the machine can
be operated normally.
monitoring mode.)
traveling.
3) Contents of display on monitoring screen tion and perform the necessary pro-
(Figure below shows examples) cedure.
(1) Code 1
(2) Information 1
(3) Code 2
(4) Information 2
a For the details, see the “Monitoring
mode table”.
50 D475A, D475ASD-5E0
12. Snap shot mode (12-SNAPSHOT MODE)

The VHMS specification has the manual snap
shot function and automatic snap shot func-
tion.
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
q 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 test-
ing, adjusting, etc., the operations of
the machine are not limited.
q To use the data saved with the man-
ual snap shot function, a personal
computer must be connected. For the
procedure for connecting the per-
sonal computer, see “Initialization
procedure for VHMS controller”. (The
personal computer may be connected
either before or after the snap shot
operation.)
(2) Automatic snap shot function
q While the automatic snap shot func-
tion is turned ON, if an item which the
VHMS controller monitors constantly
becomes abnormal (if the corre-
sponding failure code is displayed),
the snap shot data of that item in 7
minutes 30 seconds are saved in the
VHMS controller automatically.
q Since the VHMS controller automati-
cally performs the automatic snap
shot function according to the moni-
toring item data, the operator does
not need to operate the monitor.
q 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
intervals for the first 5 minutes, and at
1 second intervals for 2 minutes 30
seconds after the first 5 minutes.
D475A, D475ASD-5E0 51
SEN01819-00

© 2006 KOMATSU
All Rights Reserved
52
SEN01820-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up

Adjustment method when controller has been replaced ...................................................................... 2
Preparation work for troubleshooting for electrical equipment system................................................. 4
Inspection procedure of diode.............................................................................................................. 8
Handling of optional devices ................................................................................................................ 9
Initialization procedures for VHMS controller ..................................................................................... 10
Precautions for replacing VHMS controller ........................................................................................ 31
Pm Clinic service................................................................................................................................ 36
D475A, D475ASD-5E0 1

Adjustment method when 4. Adjusting transmission controller
controller has been replaced 1 Select Transmission controller specification set
(0003) and adjust the transmission controller.
a After the machine is assembled or transmis- a Execute this code only when the steering
sion controller or steering controller is controller is also replaced.
replaced, adjust the system according to the
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. Accord-
ingly, 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 a safe place and turn the starting switch OFF.
a Adjust the controller referring to the item 8.
Adjusting mode in "Special functions of monitor
panel (EMMS)". 5. Turning power on again
Turn the starting switch off (battery relay off)
1. Controller initial setting and leave it for 1 minute. Then turn the starting
After replacing controller, turn the switch ON switch on, then reset the monitor panel in the
temporarily (ACC position) and after approx. “Adjustment Mode” of the service mode.
10 seconds, turn the switch OFF.
q After turning the switch OFF, the controller 6. Adjusting machine specification
is initialized. Therefore leave it for approx. Select Machine specification set (0004) and
1 minute after turning the switch OFF adjust the machine specification.
even if the battery relay shuts down.
2. Setting system in service mode

After step 1, turn the starting switch ON again
and set the monitor panel in the “Adjustment
mode” of the service mode.
3. 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.
2 D475A, D475ASD-5E0
7. Adjusting brake potentiometer 10. Turning power on again

Select Brake potentiometer initial set (0005) Turn the starting switch OFF (battery relay off)
and adjust the brake potentiometer. and after leaving it for 1 minute, turn it ON
again.
11. Checking failure codes

1) Set the monitor panel in the “Electrical
system failure code display mode” of the
service mode.
2) Check if any active failure codes exist. If
not, delete all the failure codes recorded.
a If any active failure codes exist, elimi-
nate the cause of the incident by trou-
bleshooting, then carry out steps 10
and 11 again.
a Precautions after replacing controller:
If any controller is replaced, the ser-
vice meter in the oil and filter mainte-
8. Adjusting pitch angle sensor nance mode is reset to 0.
Select the initial setting (0009) of the pitch As a result, the replacement period
angle sensor and adjust the pitch angle sen- displayed on the monitor panel may
sor. be different from the actual operating
hours. To solve this problem, deter-
mine the first replacement periods of
the oils and filters after the replace-
ment of the controller according to the
replacement periods recorded before
the replacement of the controller.
9. VHMS system set

Set VHMS system using Adjustment mode
(0022).
(If not, take care that default is not-equipped
set.)
D475A, D475ASD-5E0 3
Preparation work for 2. Engine controller

troubleshooting for electrical 1) Open left and right side covers (1) and
remove side covers (2) and (3).
equipment system 1
a When performing troubleshooting for an elec-

trical circuit related to the monitor panel,
engine controller, transmission controller,
steering controller, or VHMS terminal, expose
the related connectors according to the follow-
ing procedure.
1. Monitor panel
1) Remove cover (1).
2) Remove the 2 mounting bolts and pull out
monitor panel (2) toward the operator’s
seat.
2) Remove cover (4) of engine controller.
3) Insert or connect T-adapters in or to con-

nectors S01, S02, S03, and S04 of moni-
tor panel (2). 3) Insert or connect the diagnostic T-adapter
in or to the connector (PWP, PWL, ENG,
OEMR or OEML) of engine controller (5).
a When disconnecting the connector,
loosen its screw.
a When connecting the connector,
tighten its screw to the specified
torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
4 D475A, D475ASD-5E0
k In order to prevent malfunction 2) Insert or connect T-adapters in or to con-

and mistaken system error warn- nectors TMC1, TMC2, and TMC3 of trans-
ing, be sure to completely remove mission controller (2).
foreign object (b) such as sand, a If the connectors cannot be discon-
dust, water, etc., from inside of nected and connected easily, remove
controller side connector (a) with the controller from the dashboard.
air blow etc., before connecting to a Since the connectors are secured
harness connector. with screws, loosen those screws
before disconnecting.
a When connecting the connectors
again, tighten their screws to the
specified torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
3. Transmission controller
1) Remove dashboard cover (1).
D475A, D475ASD-5E0 5
4. Steering controller 5. VHMS controller

1) Remove dashboard undercover (1). 1) Open the floor left side cover and remove
cover (1).

nectors STCN1, STCN2, and STCN3 of 2) Remove amplifier mounting cover (2).
steering controller (2).
a If the connectors cannot be discon-
nected and connected easily, remove
the controller from the dashboard.
a Since the connectors are secured
with screws, loosen those screws
before disconnecting.
a When connecting the connectors
again, tighten their screws to the
specified torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}

nectors V1, V2A, V2B, V3A, and V3B of
VHMS controller (3).
a If it is difficult to remove and install the
connectors, remove the controller for
the ease of work.
6 D475A, D475ASD-5E0
6. ORBCOMM terminal
1) Open the floor left side cover and remove
cover (1).
2) Referring to 5 above, remove VHMS con-

troller (3).
nectors CM29 and CM30 of ORBCOMM
terminal (4).
a If it is difficult to remove and install the
connectors, remove the terminal for
the ease of work.
D475A, D475ASD-5E0 7
Inspection procedure of diode 1 2. When using analog tester

1) Switch to resistance range.
a The direction of continuity of diode is marked 2) Check the deflection of needle while con-
on the surface of the diode. necting as follows.
i) Set red (+) test lead to diode anode
(P) side and black (–) test lead to
cathode (N) side.
ii) Set red (+) test lead to diode cathode
(N) side and black (–) test lead to
anode (P) side.
3) Based on the deflection of needle, judge
the quality of diode.
q Needle does not deflect with connec-
tion i) but deflects with connection ii):
Normal. (However deflection range
(resistance value) varies depending
on the type of tester and measuring
range.)
q Needle deflects with both connection
1. When using digital tester i) and ii): Defective (internal short cir-
1) Switch to diode range and check dis- cuit)
played value. q Needle does not deflect with either
a Voltage of internal battery is disconnection i) or ii): Defective (internal
played by normal tester. disconnection)
2) Set red (+) test lead to diode anode (P)
side and black (–) test lead to cathode (N)
side. Check displayed value.
3) Judge quality of diode from displayed
value.
q Displayed value does not change:
No continuity (defect)
q Displayed value changes:
Continue (normal) (note)
Note: In the case of silicon diode, the
value between 460 – 600 mV is dis-
played.
q Displayed value becomes 0 or near 0:
Short-circuiting of diode internal part
(defect)
8 D475A, D475ASD-5E0
Handling of optional devices 1
a D475A-5E0 has connectors to install optional

devices 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.
q 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-idle command

If it is required to keep the engine speed at low
idle for an optional device such as the engine
protector, connect the following connector pin
to the chassis ground.
q 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 idle, regardless of the fuel con-
trol 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.
q CN-PRS (2-pole heavy duty wire connec-
tor)
a Remove the connector installed when the
machine is shipped, and connector pin (1)
to the starting signal to be finally output by
the pre-lubricator and connector pin (2) to
the input signal from the starting switch.
4. Connecting external power source

If an external power source is necessary, con-
nect it through the following connectors.
q AUX1 (Plug connector)
q AUX2 (Plug connector)
a A 20A fuse is installed on the upstream
side of each of these connectors.
D475A, D475ASD-5E0 9
Initialization procedures for VHMS 1. Check of machine information, engine

controller 1 information and controller information
a This step is a work performed on the
a Initialization tools for VHMS controller whole machine.
Symbol Part No. Part name Check and record the machine information,
engine information, VHMS controller informa-
799-608-3211 Diskette tion and ORBCOMM terminal information.
1
No. Information to be checked
Z Notebook type personal com-
1 Machine model
Commercially puter (OS: Windows98/2000/
2
available NT/Me/XP Terminal 2 Machine serial No.
"RS232C" is with it)
3 Current service meter reading
a Before starting full operation after completion 4 Engine serial No.

of local assembly or before resuming operation 5 Transmission serial No.
after storage for a long period, initialize the 6 VHMS controller serial No.
VHMS controller according to the following
procedure. ORBCOMM terminal serial No.
7
[For ORBCOMM specification only]
a Machine data collected with the VHMS control-
ler are stored and managed in WebCARE
database. To process the data smoothly on the a The VHMS controller and ORBCOMM ter-
WebCARE, it is necessary to set the VHMS minal are in the VHMS controller box
controller consistently. If it is not set correctly, under the left side cover of the floor.
data will not be taken into the WebCARE and
data in the VHMS controller may not be uti-
lized. Accordingly, be sure to carry out the ini-
tialization.
a For the method of installing the VHMS Initial-
ization Program to the personal computer,
refer to the Operation and Maintenance Man-
ual contained in the package of diskette Z1.
a Since the service menu of the monitor panel
will be used in the following procedure, read
“Special functions of monitor panel” and under-
stand the operating procedure in advance.
a The initialization procedures cover both “ORB-
COMM Specification” and “ORBCOMMLESS
Specification”. In case of “ORBCOMMLESS”
Specification”, omit the procedures necessary 2. Connection of personal computer
for “ORBCOMM Specification” only. 1) Make sure that the starting switch is in the
a During the initialization work, confirm each OFF position.
k Be sure to connect and disconnect
work according to the “VHMS Initialization
Work Checklist”. the personal computer while start-
ing switch is in the OFF position.
2) Connect personal computer Z3 and down-
load connectors VDW and DL1 by wiring
harness Z2.
a The download connectors are
installed to the following places.
q VDW: Inside of cab (Left rear
lower part)
q DL1: Rear side of chassis (Hull
frame)
a Connect the personal computer to the
RS232C terminal.
10 D475A, D475ASD-5E0
2) Select “Service mode” and “Real-time

monitoring mode” in order on the monitor
panel.
3) Input ID = 20301.
4) If the central part of the lower line of the
multi-information display unit counts up,
the VHMS controller is normal.
a Execute initialization of VHMS from

the connector in the cab.
a Use the ground download connector
for only downloading.
5) Judge the operation of the ORBCOMM

controller by the state of the dot at the
right bottom of the LED digit of the VHMS
controller.
6) The dot at the right bottom of the LED digit
of the VHMS controller can be checked in
the multi-information display unit of the
monitor by the following method.
1] Set the starting switch in the ON posi-
tion.
2] For monitor panel specification:
Referring to 10. “Real-time monitoring
mode” or 11. “Dual display monitoring
mode”, input ID = 20301.
3. Check of operation and satellite capturing

condition of VHMS controller
a This step is a work performed in the oper-
ator's cab. 7) At least 3 minutes after starting the VHMS,
a Check of satellite capturing condition is check the decimal point at the right bottom
necessary o only [ORBCOMM specifica- of the LED of the VHMS controller or the
tion]. decimal point at the right bottom of the
1) Set the starting switch in the ON position. central part of the lower line of the multi-
information display unit.
D475A, D475ASD-5E0 11
9) Watch the decimal point LED on the right

of the right-hand 7 segments of the VHMS
controller to check that the ORBCOMM
controller is capturing the satellite [ORB-
COMM specification].
a Check the communication satellite
capturing condition of the ORBCOMM
controller on the VHMS controller
side.
a If the ORBCOMM controller is nor-
mal, the decimal point LED of the
right-hand 7 segments flashes.
Right decimal
Display
point
• Power is not supplied to ORB-
COMM controller.
OFF
• Communication line to VHMS
controller is abnormal.
• Satellite is not captured.
• Power is supplied to ORB-
ON COMM controller.
• Communication line to VHMS
controller is normal.
• Power is supplied to ORB-
4. Startup of VHMS initialization tool
COMM controller.
Blinking • Communication line to VHMS
controller is normal. ator's cab (on the personal computer).
• Satellite is captured. 1) Turn on the personal computer and start
the OS.
2) Click the icon of [VHMS Initialization Tool]
8) Check the controller for normal operation on the personal computer screen to start
referencing 7-segment LED of VHMS con- the VHMS initialization tool.
troller. a The setting screen varies with the
a VHMS controller is fed with switch version No. of the VHMS setting tool.
power supply. Thus, its operation is a When using a tool before Ver. 3.5.2.1
judged normal if its 7-segment LED (CD-ROM), set the VHMS in step 5.
starts flashing while rotating as the a When using an updated tool (Ver.
starting switch is turned on and then if 3.5.2.1 or after), set the VHMS in step
the controller starts counting in the 6.
ascending order. a It is recommended to download the
latest VHMS setting tool from the
WebCARE and update your tool.
(Related material: Servicemate SMP-
623)
3) Input the 10-digit service ID in [Service
ID].
a Service ID: 7286146000
4) Select [Data clear and Set up] in the
[Select Function] column.
5) Press the [OK] button to go to the setup
screen.
12 D475A, D475ASD-5E0
3) If information in the [Date/Time] box is not

correct, change it according to the follow-
ing procedures:
1] Press [Edit] button (1) on the right
lower part of the [Date/Time] box to
display the correction screen.
2] Correct the information and press the
[OK] button.
4) If information in the [Machine information]

box is not correct, change it according to
the following procedures:
1] Press the [Edit] button (2) on the right
lower part of the [Machine informa-
tion] box to display the correction
5. Initialization of VHMS controller (Tool screen.
before Ver. 3.5.2.1) 2] Correct the information and press the
a This step is a work performed in the oper- [OK] button.
ator's cab (on the personal computer).
a When initializing, do not change the data
of service meter [SMR].
[Machine information]
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.
5) After checking/changing all the data in

[Machine information], press [Apply] but-
ton (3) to settle the setting.
a Press the [Apply] button (3), and the
screen for checking the setting will
appear. Check the setting again and
press the [OK] button if the setting is
correct.
a In case of the ORBCOMM Specifica-
tion, execute [Communication Set-
ting] first and then settle the setting.
D475A, D475ASD-5E0 13
[Communication Setting] [For ORBCOMM spec-

ification only]
a Execute this setting after requesting for open-
ing of the ORBCOM terminal and finishing the
opening procedure.
6) Open the [Communication Setting] tab.
7) Check all the data.
8) To change the setting in [SHORT FAULT

HISTRY], follow the procedure below:
1] Select [SHORT FAULT HISTRY] on
the screen and press [Edit] button (5)
on the left lower part of the [File
Transfer Setting] block to display the
setting screen.
2] Change the setting and then press
the [OK] button.
a At initialization, select [Occur-
rence] at [Timing] and set the
function to [ON].
14 D475A, D475ASD-5E0
9) To change setting in [SHORT TREND 11) After checking/changing all the data in
ANALYSIS], follow the procedures below: [Communication Setting], press [Apply]
1] Select [SHORT TREND ANALYSIS] button to settle the setting.
on the screen and press [Edit] button a If the [Apply] button is pressed, the
on the left lower part of the [File s c r e e n f o r c h e c k in g t h e s e t t i n g
Transfer Setting] block to display the appears. Check the setting again and
setting screen. press the [OK] button if the setting is
2] Change the setting and then press correct.
the [OK] button.
a At initialization, input [20h] to
[SMR] and set the function to
[ON].
10) To change the setting of [Satellite Setting],

follow the procedure below. 12) After checking/changing the data of
1] Press the [Edit] button in the [Satellite [Machine Information] and [Communica-
Setting] block to display the setting tion Setting], press the [Exit] button at the
screen. right lower part of the screen to finish
2] Set the GCC Code to the applicable [VHMS Initialization Tool].
area and then press the [OK] button.
GCC codes and applicable areas

Applicable Applicable
Code Code
Area Area
1 U.S.A. 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
D475A, D475ASD-5E0 15
6. Initialization of VHMS controller (Ver. 3.5.2.1 3) Check the machine information. If it does
or after) not need to be corrected, press the “Next”
a This step is a work performed in the oper- button.
a When initializing, do not change the data
of service meter [SMR].
1) Select [VHMS Setting] and press the
“Next” button.
a If the VHMS was installed addition-

ally, the information of [Serial No.] etc.
must be input.
2) Select [Set up & All clear] and press the

“Next” button.
16 D475A, D475ASD-5E0
4) Select the time zone. 8) The contents of the setting are displayed
5) Input the local time. finally. If there is not a problem, press the
6) If the DST (Daylight Saving Time) is used “Apply” button.
now, select it and press the “Next” button.
a If the DST is selected, the clock is
advanced 1 hour automatically, thus
the time must be corrected again.
9) The system asks you if you save the data

before changing the setting. If you do not
need to save, select “NO”.
7) Set the GCC Code to the applicable area

and then press the “Next” button.
GCC codes and applicable areas

Applicable Applicable
Code Code
Area Area
1 U.S.A. 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
10) After finishing the work of changing the

contents of initialization, press the “OK”
button to finish the program.
D475A, D475ASD-5E0 17
7. Procedures for executing Quick Pm 2] Set the buzzer cancel switch in the
a The Quick Pm means the Pm Clinic exe- [U] position.
cuted with the manual snap shot function 3] “READY” is displayed and the system
of the monitor panel. is ready to start.
a Data in 7 minutes 30 seconds are saved in a On the lower line, 15 pieces of “-”
the VHMS controller. are displayed.
k Stop the machine on a flat place.
1) Start the engine.

2) Set the monitor panel to display the ser-
vice menu.
cial functions of monitor panel”.
3) Selection and execution of mode.
1] Select “Snap shot mode” on the mode
selection screen.
a If the mode is selected, code (55)
is displayed in gear speed dis-
play unit (1) and the title is dis-
played in multi-information unit
(2).
4] Set the buzzer cancel switch in the

[U] position, and the snap shot oper-
ation starts.
a After the snap shot operation
starts, the elapsed time is dis-
played on the upper line.
a On the lower line, 1 “ ” is added
every 30 seconds. While multiple
“ ” are displayed, the one at the
right end blinks.
a To interrupt the snap shot opera-
tion, set the buzzer cancel switch
in the [t] position.
18 D475A, D475ASD-5E0
5] After starting the snap shot operation,

operate the machine according to
Table 1.
a Check that the engine coolant
temperature and torque con-
verter oil temperature are in the
operating range.
a After 10 “ ” are displayed (After 5
minutes), “#” is added up to 5.
a “ ”: The data sampling interval is
10 seconds.
a “#”: The data sampling interval is
1 second.
D475A, D475ASD-5E0 19
Table 1 Operations of machine to be executed while snap shot is operated

Operation of machine
Time (sec)
Finish
Start
Fuel
No.
State of machine Steer- Decelera- Brake Parking

Transmission Work equipment control
ing tor pedal pedal brake
dial
1 0:00 0:25 25 N LH N LOW HI Released Released
Low idle
2 0:25 0:50 25 N RH N LOW HI Released Released
3 0:50 1:40 50 High idle N N N HI HI Released Released
4 1:40 2:30 50 Deceleration slow N N N HI LOW Released Released
High-pressure Right tilt (or
5 2:30 3:00 30 N N HI HI Released Released
relief & high idle pitch back in
High-pressure case of dual tilt
6 3:00 3:30 30 N N model) LOW HI Released Released
relief & low idle
Port relief &
7 3:30 4:00 30 N N Left tilt (or pitch HI HI Released Released
high idle
dump in case of
Port relief & dual tilt model)
8 4:00 4:30 30 N N LOW HI Released Released
low idle
NoF1oF2oF
Torque converter
9 4:30 5:10 40 3oNoR1oR2 N N LOW HI ON Released
stall & low idle
oR3oN
NoF3 (Shift to
Torque converter LOWo
F3, then run
10 5:10 6:00 50 stall (F3) & high N N HI Shift to F3, ON Released
engine at full
idle (Note 1) then HI
throttle)
11 6:00 6:30 30 High idle N N N HI HI Released Released
NoF3 (Shift to
Torque converter Left tilt (or pitch LOWo
F3, then run
12 6:30 7:10 40 stall + High-pres- N dump in case of HI Shift to F3, ON Released
engine at high
sure relief dual tilt model) then HI
idle)
High idleo HIo
13 7:10 7:30 20 N N N HI Released ON
Low idle (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 idle 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 idle.
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 idle to lower the oil temperature.)
20 D475A, D475ASD-5E0
6] The screen shown below appears 7 q Blowby Press

minutes 30 seconds after the snap q Exhaust Temp RB (Exhaust tem-
shot is started, and then the initial perature of right bank: 1, 2, 3, 4,
screen appears 5 seconds after. (End 5, 6)
of snap shot) q Exhaust Temp LB (Exhaust tem-
perature of left bank: 1, 2, 3, 4, 5,
6)
q Engine Oil Press
q Engine Oil Temp
q Eng Coolant Temp
q Ambient Temp
q Demand Eng Speed
(Engine speed demanded by
controller)
q T/C Oil Temp
(Torque converter oil tempera-
ture)
q T/M Main Press
(Transmission main relief pres-
Important sure)
The data of the Quick Pm is recorded only q T/M Output Speed
once. If the Quick Pm is executed again, (Transmission output speed)
the current data are overwritten. Accord- q Shift Position
ingly, be sure to save the data in the per- ( Tr a n s m i s s i o n , t r a v e l , g e a r
sonal computer after executing the Quick speed)
Pm, referring to “8. Downloading of set q S/T Clutch Pos.
data”. (Steering clutch position)
q S/T Brake Pos. (Steering brake
7] Using the analysis tool, read the data position)
of the Quick Pm. q Hydr Oil Temp
a For the usage of the analysis tool, (Hydraulic oil temperature)
see the operation manual. q Pump 1 Press
8] Open the data of the Quick Pm and (Work equipment pump 1 oil
translate them into a graph. pressure)
a Set the time to the X-axis and set the q Pump 2 Press
following items to the Y-axis. (Work equipment pump 2 oil
q Engine Speed pressure)
q Fuel Inject q Body Pitch Angle (Pitch angle)
D475A, D475ASD-5E0 21
9] Check “Click position graphic value

display”.
22 D475A, D475ASD-5E0
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
different from the actual graph.)
D475A, D475ASD-5E0 23
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 condi-
tions 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 idle Q Q Q Q Q Q Q

Engine at high idle 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
Q Q Q
throttle
Engine at full throttle
Torque converter stall & high-pressure relief Q
Engine at high idle o Engine at low idle Q Q
24 D475A, D475ASD-5E0
8. Downloading of set data

1) Connect personal computer Z3 and down-
load connectors VDW in the cab or ground
download connector DL1 by wiring har-
ness Z2.
2) When using download connector VDW in

the cab, set the starting switch in the ON
position.
3) When using ground download connector
DL1, turn switch (2) ON.
a Download connector VDW in the cab a The green LED lights up.
is installed to the left rear lower part of 4) Operate the icon of [VHMS Technical
the operator's seat. Analysis Tool] on the personal computer to
start the VHMS technical analysis tool.
a Input [User Name] and [Password].

a For the operation procedures, see the
Operation and Maintenance Manual
a Ground download connector DL1 is for VHMS Technical Analysis Tool.
installed in frame (1) at the rear of the
machine.
D475A, D475ASD-5E0 25
5) Use the [Download] function to download 10. Disconnection of Personal Computer

the data recorded in the VHMS controller 1) Make sure that the starting switch is in the
to the personal computer. OFF position.
a For the operation procedures, see the k Be sure to turn off the starting
Operation and Maintenance Manual switch before connecting or dis-
for VHMS Technical Analysis Tool. connecting the personal computer.
a Make sure that downloading has 2) Finish the OS of the personal computer
completed before proceeding to the and then turn the personal computer OFF.
next step.
9. Check of downloaded data

1) Check the set data with the [View] func- 3) If the data was downloaded in the cab,
tion. disconnect wiring harness Z2 from down-
a For the operation procedures, refer to load connector VDW.
the Operation and Maintenance Man-
ual for VHMS Technical Analysis Tool.
a Make sure that the [MFA0] code at
the time when the snapshot was
operated is displayed in [Fault His-
tory].
a Make sure that the snap shot data is
recorded.
4) If the data was downloaded on the

ground, turn switch (2) OFF and discon-
nect wiring harness Z2 from download
connector DL1.
2) After checking the set data, terminate
[VHMS Technical Analysis Tool].
26 D475A, D475ASD-5E0
11. Communication to Komatsu

After completing steps 1 to 9 successfully,
send the “VHMS/WebCARE setting notification
form” to VHMS/WebCARE Support Center of
Komatsu, Tokyo.
a Since Komatsu has to set the receiving
side of the satellite communication, be
sure to inform Komatsu of the completion
of the setting.
a Send the VHMS data by Notes (LAN) or
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
D475A, D475ASD-5E0 27
(Objective model: D475A-5E0 Bulldozer)
28 D475A, D475ASD-5E0
(Objective model: D475A-5E0 Bulldozer)
D475A, D475ASD-5E0 29
30 D475A, D475ASD-5E0
Precautions for replacing VHMS 2) Select “Save/Load” and press the “OK”
controller 1 button.
a Tools for replacing VHMS controller

799-608-3211 Diskette
1
Notebook type per-
Z sonal computer (OS:
Commercially
2 Windows98/2000/NT/
available
Me/XP Terminal
"RS232C" is with it)
a When the VHMS controller needs to be

replaced, set it before removing it and the
installed new VHMS controller according to the
a Machine data collected with the VHMS control-
ler are stored and managed in WebCARE
database. To process the data smoothly on the
WebCARE, it is necessary to set the VHMS
controller consistently. If it is not set correctly,
data will not be taken into the WebCARE and
data in the VHMS controller may not be uti- 3) Check all the information before replacing
lized. Accordingly, be sure to carry out the ini- the VHMS controller.
tialization. 4) Select [Save] from [File] in the menu.
a During the initialization work, confirm each
work according to the “VHMS Initialization
Work Checklist”.
a The information of model name etc. shown in
the figures is different from the actual machine.
[Work before replacing VHMS controller]

1. Downloading of remaining data
a Using the [Download] function, download
the data currently recorded in the VHMS
controller to the personal computer.
a For the operating procedures, see Initial-
ization procedures for VHMS controller,
“8. Downloading of set data”.
2. Check, saving and writing of information

set in VHMS controller (Before Ver. 3.5.2.1)
a Transfer the set data of the VHMS control-
ler to be replaced to the personal com-
puter and then write it in the newly
installed VHMS controller.
2-1. Check and saving of information set in VHMS
controller to be replaced
1) Connect the personal computer and start
the VHMS technical analysis tool.
a See “Initialization procedures for
VHMS controller”.
D475A, D475ASD-5E0 31
5) Check the information again and press the 3) Select [Load] from [File] in the menu.
“OK” button to save it.
4) The saved information is displayed. Press

the “OK” button.
6) Select [Exit] from [File] in the menu to fin-

ish the VHMS technical analysis tool.
7) Disconnect the personal computer.
a See Initialization procedures for
VHMS controller, “9. Disconnection of
Personal Computer”.
8) Turn the personal computer OFF.
9) Replace the VHMS controller.
2-2. Writing of set information in new VHMS con-

troller
1) Connect the personal computer again and
a See “Initialization procedures for 5) The saved information is displayed on
VHMS controller”. another screen.
2) Select “Save/Load” and press the “OK” 6) Press the [Edit] button to set the time.
button.
32 D475A, D475ASD-5E0
7) After setting the time, press the “OK” but- 9) The system asks you if you will save the
ton. previous data. Press the “NO” button.
a Usually, you do not need to save the
previous data.
8) Press the [Apply] button, and the contents

of the setting are displayed. Check the
contents again and press the [OK] button
if there is not a problem.

ish the VHMS setting tool.
3. Check, saving and writing of information

set in VHMS controller (Ver. 3.5.2.1 or after)
a Transfer the set data of the VHMS control-
ler to be replaced to the personal com-
puter and then write it in the newly
installed VHMS controller.
3-1. Check and saving of information set in VHMS

controller to be replaced
1) Connect the personal computer and start
the VHMS technical analysis tool.
VHMS controller”.
2) Select [When VHMS needs to be
replaced] and press the “Next” button.
D475A, D475ASD-5E0 33
3) Select [Save Current Setting before 3-2. Writing of set information in new VHMS con-
replacement of VHMS controller] and troller
press the “Next” button. 1) Connect the personal computer again and
VHMS controller”.
2) Select [When VHMS needs to be
replaced] and press the “Next” button.
4) Check all the information before replacing

the VHMS controller and press the “Save”
button.
3) Select [Use Previous setting after replace-

ment of VHMS controller] and press the
“Next” button.

ish the VHMS setting tool.
6) Disconnect the personal computer.
a See Initialization procedures for
VHMS controller, “9. Disconnection of
Personal Computer”.
7) Turn the personal computer OFF.
8) Replace the VHMS controller.
34 D475A, D475ASD-5E0
4) The saved information is displayed. Press 7) The above completes modification of the
the “Next” button. setting. Press [OK] button to end the
VHMS initial setting tool.
[Work after replacing VHMS controller]

a After replacing the VHMS controller, carry out
initialization according to the “Initialization Pro-
cedure for VHMS Controller”.
a Change the data to the information recorded
before the VHMS controller was replaced.
(Input the date and time when the VHMS con-
5) Set the time and press the “Apply” button. troller was replaced.)
a After completing the setting after the replace-
ment, send the check sheet to VHMS/Web-
CARE Support Center of Komatsu, Tokyo.
a Send the data downloaded before and after
replacing the VHMS controller by Notes (LAN)
or 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)
E-mail: webcare@komatsu.co.jp
6) The system asks you if you will save the

previous data. Press the “NO” button.
a Usually, you do not need to save the
previous data.
D475A, D475ASD-5E0 35
Pm Clinic service 1
Model Serial No. Service meter
T D475A-5E0
h
T D475ASD-5E0
User name Date of clinic Serviceman

/ /
Specifications
Blade Attachment Shoe width
T Semi U blade T Variable Multi-shank ripper T 710 mm %
T U blade T Variable giant ripper T 810 mm %
T Super blade T Counterweight ( kg) T 910 mm %
T T T %
Operating conditions
Quarry, mine Construction Type of soil (specific gravity) Type of work
T Construction, civil engi-
T Coal T Rock T Dozing
neering
T Gold T Roads T Gravel T Side cutting
T Limestone T Tunnels T Sand T Ripping
T T T Clay T Travel
Existence of abnormalities
Oil, coolant level check
T Engine coolant level When necessary
T Engine oil level T Power train T Damper case
T Hydraulic oil level T Final drive T( )
Ambient temperature Height above sea level

Max.
°C m
Min.
Operator's opinion
Visual check results
Failure code history

[ ] h [ ] h
Content: Content:
[ ] h [ ] h
Content: Content:
a Engine coolant temperature: Max. range a Power train oil temperature: Max. range
36 D475A, D475ASD-5E0
Measuring points for Pm clinic (1/3)
Reference pages for measurement procedures

1. Engine speed: Testing and adjusting (Part 1), Pages 5 – 7
2. Blow-by pressure: Testing and adjusting (Part 1), Pages 18 – 19
3. Engine oil pressure: Testing and adjusting (Part 1), Page 20
4. Boost pressure: Testing and adjusting (Part 1), Pages 8 – 9
5. Exhaust temperature: Testing and adjusting (Part 1), Pages 10 – 11
D475A, D475ASD-5E0 37

6. Torque converter parts: Testing and adjusting (Part 2), Pages 4 – 5
7. Transmission parts: Testing and adjusting (Part 2), Pages 6 – 8
8. Steering brake parts: Testing and adjusting (Part 2), Pages 9 – 10
38 D475A, D475ASD-5E0

9. Work equipment and HSS parts: Testing and adjusting (Part 2), Pages 22 – 32
10. Control circuits: Testing and adjusting (Part 2), Pages 33 – 39
11. Fan parts: Testing and adjusting (Part 2), Pages 48 – 49
D475A, D475ASD-5E0 39
40 D475A, D475ASD-5E0
D475A, D475ASD-5E0 41
42 D475A, D475ASD-5E0
Pm clinic T D475A-5E0 #
Serial number
Undercarriage check sheet T D475ASD-5E0 #
Work order Date Service meter Serviceman

/ / h
q Measure the bushing temperature immediately after operations

Left side of machine
Right side of machine
a Measurement results
Pass Fail
Left side of
machine
Right side of
machine
q Opening of track link
Left A: Clearance between Right A: Clearance between

track links track links
Pin No. 1.4 Pin No. 1.4
D475A, D475ASD-5E0 43
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
(Program form No.: SELA195001)
44 D475A, D475ASD-5E0
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
(Program form No.: SELA195001)
IMPACT
D475A, D475ASD-5E0 45
SEN01820-00

© 2006 KOMATSU
All Rights Reserved
46
SEN01821-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table and fuse locations ............................................................................................................. 2
Failure code table................................................................................................................................. 2
Fuse locations .................................................................................................................................... 12
D475A, D475ASD-5E0 1
SEN01821-00 40 Troubleshooting
Failure code table and fuse locations 1

Failure code table 1
Compo-
Failure Action Reference
Troubled part Trouble nent in Category of record
code code manual
charge
1500L0 Transmission clutch Double engagement T/M CALL E03 Electrical system
Command current is OFF and
15SAL1 Forward clutch oil pressure T/M CALL E03 Electrical system
fill signal is ON
Command current is ON and
15SALH Forward clutch oil pressure T/M CALL E03 Electrical system
fill signal is OFF
15SBL1 Reverse clutch oil pressure T/M CALL E03 Electrical system
fill signal is ON
15SBLH Reverse clutch oil pressure T/M CALL E03 Electrical system
fill signal is OFF
15SEL1 1st clutch oil pressure T/M CALL E03 Electrical system
fill signal is ON
15SELH 1st clutch oil pressure T/M CALL E03 Electrical system
fill signal is OFF
15SFL1 2nd clutch oil pressure T/M CALL E03 Electrical system
fill signal is ON
15SFLH 2nd clutch oil pressure T/M CALL E03 Electrical system
fill signal is OFF
15SGL1 3rd clutch oil pressure T/M CALL E03 Electrical system
fill signal is ON
15SGLH 3rd clutch oil pressure T/M CALL E03 Electrical system
fill signal is OFF
1800MW Power train clutch Clutch slip S/T — Electrical system
2201L1 Right clutch oil pressure S/T CALL E04 Electrical system
fill signal is ON
2201LH Right clutch oil pressure S/T CALL E04 Electrical system
fill signal is OFF
Command current is OFF and Troubleshoot-
2202L1 Left clutch oil pressure S/T CALL E04 Electrical system ing by failure
fill signal is ON
code (Display
2202LH Left clutch oil pressure S/T CALL E04 Electrical system of code)
fill signal is OFF
(Part 1)
2300NR Brake thermal load Abnormal heating S/T — Electrical system
Command current is OFF and SEN01823-00
2301L1 Right brake oil pressure S/T CALL E04 Electrical system
fill signal is ON
2301LH Right brake oil pressure S/T CALL E04 Electrical system
fill signal is OFF
2301NR Right steering brake thermal load Abnormal heating S/T CALL E04 Electrical system
2302L1 Left brake oil pressure S/T CALL E04 Electrical system
fill signal is ON
2302LH Left brake oil pressure S/T CALL E04 Electrical system
fill signal is OFF
2302NR Left steering brake thermal load Abnormal heating S/T CALL E04 Electrical system
AA10NX Air cleaner Clogging MON — Mechanical system
AB00MA Battery charge abnormality Malfunction MON — Mechanical system
B@BAZG Engine oil Oil pressure reduction ENG — Mechanical system
B@BAZK Engine oil Oil level reduction MON — Mechanical system
B@BCNS Radiator coolant Overheat ENG — Mechanical system
B@BCZK Radiator coolant Coolant level reduction MON — Mechanical system
B@CENS Power train oil Overheat MON — Mechanical system
B@CHZG HSS charge oil pressure Oil pressure reduction MON — Mechanical system
B@HANS Hydraulic oil Overheat MON — Mechanical system
B@HAZK Hydraulic oil Oil level reduction S/T — Mechanical system
2 D475A, D475ASD-5E0
Compo-
code code manual
charge
CA111 Engine controller (Left bank) Internal abnormality ENG CALL E04 Electrical system
CB111 Engine controller (Right bank) Internal abnormality ENG CALL E04 Electrical system
Engine NE/Bkup speed sensor
CA115 Speed sensor signal error ENG CALL E04 Electrical system
abnormality (Left bank)
Engine NE/Bkup speed sensor
CB115 Speed sensor signal error ENG CALL E04 Electrical system
abnormality (Right bank)
Charge pressure sensor abnormally
CA122 High voltage detection ENG CALL E03 Electrical system
high level (Only left bank)
Charge pressure sensor abnormally
CA123 Low voltage detection ENG CALL E03 Electrical system
low level (Only left bank)
Decelerator pedal sensor abnormally
high level (Only left bank)
Decelerator pedal sensor abnormally
low level (Only left bank)
Oil pressure sensor abnormally high
level (Only left bank)
Oil pressure sensor abnormally low
level (Only left bank)
Coolant temperature sensor abnor-
mally high level (Only left bank)
Coolant temperature sensor abnor-
mally low level (Only left bank)
Charge temperature sensor abnor-
Charge temperature sensor abnor-
Sensor power supply (2) abnormally
low level (Left bank) Troubleshoot-
Sensor power supply (2) abnormally ing by failure
CB187 Low voltage detection ENG CALL E03 Electrical system
low level (Right bank) code (Display
Engine oil temperature sensor of code)
abnormally high level (Only left bank) (Part 2)
Engine oil temperature sensor
abnormally low level (Only left bank) SEN01824-00
Ambient temperature sensor abnor-
Ambient temperature sensor abnor-
high level (Left bank)
CB227 High voltage detection ENG CALL E03 Electrical system
high level (Right bank)
CA234 Engine overspeed (Only left bank) Abnormally high speed ENG — Mechanical system
Ne speed sensor power supply
abnormality (Left bank)
Ne speed sensor power supply
abnormality (Right bank)
Fuel temperature sensor abnormally
CA263 Abnormally high speed ENG CALL E01 Electrical system
CB263 Abnormally high speed ENG CALL E01 Electrical system
low level (Left bank)
low level (Right bank)
CA271 PCV1 short circuit (Left bank) Short circuit ENG CALL E03 Electrical system
CB271 PCV1 short circuit (Right bank) Short circuit ENG CALL E03 Electrical system
CA272 PCV1 disconnection (Left bank) Disconnection ENG CALL E03 Electrical system
CB272 PCV1 disconnection (Right bank) Disconnection ENG CALL E03 Electrical system
D475A, D475ASD-5E0 3
Compo-
code code manual
charge
CA273 PCV2 short circuit (Left bank) Short circuit ENG CALL E03 Electrical system Troubleshoot-
ing by failure
CB273 PCV2 short circuit (Right bank) Short circuit ENG CALL E03 Electrical system code (Display
of code)
CA274 PCV2 disconnection (Left bank) Disconnection ENG CALL E03 Electrical system (Part 2)
CB274 PCV2 disconnection (Right bank) Disconnection ENG CALL E03 Electrical system
SEN01824-00
Injector #1 (L/B#1) system discon-
CA322 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Left bank)
Engine controller data mismatch
CA342 Mismatch ENG CALL E03 Electrical system
(Left bank)
Engine controller data mismatch
CB342 Mismatch ENG CALL E03 Electrical system
(Right bank)
Injector drive circuit abnormality
CA351 Circuit abnormality ENG CALL E03 Electrical system
(Left bank)
Injector drive circuit abnormality
CB351 Circuit abnormality ENG CALL E03 Electrical system
(Right bank)
low level (Left bank)
low level (Right bank)
Troubleshoot-
CB386 High voltage detection ENG CALL E03 Electrical system ing by failure
code (Display
Power supply voltage abnormally low
CA441 Low voltage detection ENG CALL E04 Electrical system of code)
level (Left bank)
(Part 3)
Power supply voltage abnormally low
level (Right bank)
SEN01825-00
Power supply voltage abnormally
Power supply voltage abnormally
Common rail abnormally high pres- Abnormally high pressure
CA449 ENG CALL E03 Electrical system
sure (2) (Left bank) occurrence
CB449 ENG CALL E03 Electrical system
sure (2) (Right bank) occurrence
Common rail pressure sensor abnor-
mally high level (Left bank)
mally high level (Right bank)
mally low level (Left bank)
mally low level (Right bank)
CA553 ENG E02 Electrical system
sure (1) (Left bank) occurrence
CB553 ENG E02 Electrical system
sure (1) (Right bank) occurrence
Common rail pressure sensor in-
CA554 In-range error occurrence ENG CALL E03 Electrical system
range error (Left bank)
Common rail pressure sensor in-
CB554 In-range error occurrence ENG CALL E03 Electrical system
range error (Right bank)
Supply pump low pressure (1)
CA559 Low pressure occurrence ENG E02 Electrical system
(Left bank)
4 D475A, D475ASD-5E0
Compo-
code code manual
charge
CB559 Low pressure occurrence ENG E02 Electrical system
(Right bank)
Engine Ne speed sensor abnormality
CA689 Signal error ENG CALL E03 Electrical system
(Left bank)
Troubleshoot-
Engine Ne speed sensor abnormality
CB689 Signal error ENG CALL E03 Electrical system ing by failure
(Right bank)
code (Display
Intake air temperature sensor abnor-
CA691 High voltage detection ENG E01 Electrical system of code)
(Part 3)
Intake air temperature sensor abnor-
CA692 Low voltage detection ENG E01 Electrical system
SEN01825-00
Engine Bkup speed sensor abnormal
CA731 Phase error ENG CALL E03 Electrical system
phase (Left bank)
Engine Bkup speed sensor abnormal
CB731 Phase error ENG CALL E03 Electrical system
phase (Right bank)
Engine controller all data loss
CA757 All data loss ENG CALL E04 Electrical system
(Left bank)
Engine controller all data loss
CB757 All data loss ENG CALL E04 Electrical system
(Right bank)
Engine Bkup speed sensor abnor-
CA778 Bkup signal error ENG CALL E03 Electrical system
mality (Left bank)
Engine Bkup speed sensor abnor-
CB778 Bkup signal error ENG CALL E03 Electrical system
mality (Right bank)
Inter-multicontroller communication
CA781 Communication error ENG CALL E03 Electrical system
error (Left bank)
Inter-multicontroller communication
CB781 Communication error ENG CALL E03 Electrical system
error (Right bank)
Multicontroller distinction wiring har-
CA1257 Distinction error ENG CALL E03 Electrical system
ness key error (Left bank)
Multicontroller distinction wiring har-
CB1257 Distinction error ENG CALL E03 Electrical system
ness key error (Right bank)
Injector #7 (R/B#1) system discon-
CB1548 Disconnection/Short circuit ENG CALL E03 Electrical system
nection/short circuit (Right bank)
Injector #11 (R/B#5) system discon- Troubleshoot-
nection/short circuit (Right bank) ing by failure
Injector #12 (R/B#6) system discon- code (Display
nection/short circuit (Right bank) of code)
Injector #19 (R/B#3) system discon- (Part 4)
CA1633 KOMNET abnormality (Left bank) Communication error ENG CALL E03 Electrical system SEN01826-00
Decelerator pedal sensor power sup-
CA2185 ply abnormally high level (Only left High voltage detection ENG CALL E03 Electrical system
bank)
Decelerator pedal sensor power sup-
CA2186 ply abnormally low level (Only left Low voltage detection ENG CALL E03 Electrical system
bank)
CA2249 Low pressure occurrence ENG CALL E03 Electrical system
(Left bank)
CB2249 Low pressure occurrence ENG CALL E03 Electrical system
(Right bank)
D110KA Battery relay Disconnection S/T — Electrical system
D110KB Battery relay Short circuit S/T — Electrical system
D130KA Neutral safety relay Disconnection T/M E02 Electrical system
D130KB Neutral safety relay Short circuit T/M E02 Electrical system
D161KA Backup alarm relay Disconnection T/M E01 Electrical system
D161KB Backup alarm relay Short circuit T/M E01 Electrical system
D182KZ Preheater relay Disconnection/short circuit S/T E01 Electrical system
D475A, D475ASD-5E0 5
Compo-
code code manual
charge
Engine controller ACC signal cut
D190KA Disconnection S/T — Electrical system
relay
Engine controller ACC signal cut
D190KB Short circuit S/T — Electrical system
relay
D5ZRKA Snap shot switch Disconnection S/T — Electrical system
D5ZRKB Snap shot switch Short circuit S/T — Electrical system

Monitor panel CAN communication
DAFRKR Communication error MON CALL E03 Electrical system
(MON)
dAFRKR Communication error T/M CALL E03 Electrical system
(T/M)
daFRKR Communication error S/T CALL E03 Electrical system Troubleshoot-
(S/T)
ing by failure
DAQ0KT Transmission controller Controller internal abnormality T/M E01 Electrical system code (Display
Transmission controller main power Power supply voltage reduc- of code)
DAQ1KK T/M CALL E04 Electrical system
supply tion (Input) (Part 4)
Transmission controller load power Power supply voltage reduc-
supply tion (Input) SEN01826-00
Transmission controller potentiome- Power supply voltage reduc-
ter power supply tion (Input)
Transmission controller sensor Power supply voltage reduc-
DAQ6KK T/M E01 Electrical system
power supply tion (Input)
Transmission controller sensor Power supply voltage reduc-
Transmission controller model selec- Model selection signal dis-
DAQ9KQ T/M CALL E04 Electrical system
tion agreement
Transmission controller CAN com-
DAQRKR Communication error T/M CALL E03 Electrical system
munication
Transmission controller S-NET com-
DAQSKR Communication error T/M E01 Electrical system
munication
Engine controller (Left bank) CAN
DB2RKR Communication error S/T CALL E03 Electrical system
communication
DB30KT Steering controller Controller internal abnormality S/T E01 Electrical system
Steering controller main power sup- Power supply voltage reduc-
DB31KK S/T CALL E04 Electrical system
ply tion (Input)
Power supply voltage reduc-
DB32KK Steering controller load power supply S/T CALL E04 Electrical system
tion (Input)
Steering controller potentiometer Power supply voltage reduc-
Steering controller sensor power Power supply voltage reduc-
supply tion (Input)
Steering controller sensor power Power supply voltage reduc-
DB37KK S/T CALL E03 Electrical system Troubleshoot-
supply tion (Input)
Model selection signal dis- ing by failure
DB39KQ Steering controller model selection S/T CALL E04 Electrical system code (Display
agreement
Steering controller CAN communica- of code)
dB3RKR Communication error S/T CALL E03 Electrical system (Part 5)
tion (T/M)
Steering controller S-NET communi-
DB3SKR Communication error S/T E01 Electrical system SEN01827-00
cation
DBB0KK Power supply voltage reduc-
VHMS controller VHMS — —
[n9 o 01] tion
DBB0KQ Model selection signal dis-
VHMS controller model selection VHMS — —
[nF o 11] agreement
DBB3KK
VHMS controller Direct source voltage reduction VHMS — —
[n9 o 05]
DBB5KP
VHMS sensor power supply (5 V) Output voltage reduction VHMS — —
[n9 o 04]
DBB6KP
[n9 o 02]
DBB7KP
[n9 o 03]
6 D475A, D475ASD-5E0
Compo-
code code manual
charge
DBBQKR
VHMS KOM-NET Communication error VHMS — —
[n8 o 02]
VHMS controller CAN communica-
dbBRKR Communication error S/T — Electrical system
tion
DD12KA Shift-up switch Disconnection T/M E02 Electrical system
DD12KB Shift-up switch Short circuit T/M E02 Electrical system
DD13KA Shift-down switch Disconnection T/M E02 Electrical system
DD13KB Shift-down switch Short circuit T/M E02 Electrical system
DD14KA Parking brake lever switch Disconnection T/M CALL E03 Electrical system
DD14KB Parking brake lever switch Short circuit T/M CALL E03 Electrical system
DDB9L4 Reverse switch Signal disagreement T/M E02 Electrical system
DDK3L4 Forward switch Signal disagreement T/M E02 Electrical system
DDK5KA Shift switch Disconnection T/M E02 Electrical system Troubleshoot-

ing by failure
DDK5KB Shift switch Short circuit T/M E02 Electrical system code (Display
of code)
Blade tilt right oil pressure switch
DDN2LD Switch ON for long time T/M E02 Electrical system (Part 5)
system
Blade tilt left oil pressure switch sys-
DDN3LD Switch ON for long time T/M E02 Electrical system SEN01827-00
tem
DDN7KA Blade pitch switch Disconnection T/M E02 Electrical system
DDN7KB Blade pitch switch Short circuit T/M E02 Electrical system
DDN9KA Blade tilt switch Disconnection T/M E01 Electrical system
DDN9KB Blade tilt switch Short circuit T/M E01 Electrical system
DDNALD Blade lift raise full oil pressure switch Switch ON for long time T/M — Electrical system
DDNBLD Ripper lift raise oil pressure switch Switch ON for long time T/M — Electrical system
DDNCLD Ripper lift lower oil pressure switch Switch ON for long time T/M — Electrical system
DDNDLD Ripper tilt in oil pressure switch Switch ON for long time T/M — Electrical system
DDNELD Ripper tilt back oil pressure switch Switch ON for long time T/M — Electrical system
Ripper lift lower full oil pressure
DDNFLD Switch ON for long time T/M — Electrical system
switch
DDQ2KA Parking brake lever switch Disconnection S/T CALL E03 Electrical system
DDQ2KB Parking brake lever switch Short circuit S/T CALL E03 Electrical system
DDQ2L4 Parking brake lever switch (S/T) Signal disagreement S/T CALL E03 Electrical system
dDQ2L4 Parking brake lever switch (T/M) Signal disagreement T/M CALL E03 Electrical system
DDT5KA Neutral switch Disconnection T/M CALL E04 Electrical system

Troubleshoot-
DDT5KB Neutral switch Short circuit T/M CALL E04 Electrical system ing by failure
Model selection signal dis- code (Display
DDT5KQ Lever specification selection error T/M CALL E04 Electrical system
agreement of code)
DGS1KX Hydraulic oil temperature sensor Out of input signal range T/M — Electrical system (Part 6)
DGT1KA Power train oil temperature sensor Disconnection MON E01 Electrical system SEN01828-00
DGT1KX Power train oil temperature sensor Out of input signal range MON E01 Electrical system
DGT5KA Left bank exhaust temperature sen-
Disconnection VHMS — —
[n3 o 12] sor system (Front)
dGT5KA Left bank exhaust temperature sen-
[n3 o 22] sor system (Rear)
DGT5KB Left bank exhaust temperature sen-
Short circuit VHMS — —
D475A, D475ASD-5E0 7
Compo-
code code manual
charge
dGT5KB Left bank exhaust temperature sen-
DGT6KA Right bank exhaust temperature sen-
dGT6KA Right bank exhaust temperature sen-
DGT6KB Right bank exhaust temperature sen-
dGT6KB Right bank exhaust temperature sen-
Work equipment pump oil pressure
DH22KA Disconnection T/M — Electrical system
sensor (F)
DH22KB Short circuit T/M — Electrical system
sensor (F)
DH23KA Disconnection T/M — Electrical system
sensor (R)
DH23KB Short circuit T/M — Electrical system
sensor (R)
DHE5KB
Blow-by pressure sensor system Disconnection VHMS — —
[n3 o 32]
Troubleshoot-
DHE5KY ing by failure
Blow-by pressure sensor system Hot short VHMS — —
[n3 o 31] code (Display
DHT3KX of code)
Transmission oil pressure sensor Out of input signal range VHMS — —
[n6 o 14] (Part 6)
DK01KA Left yoke angle sensor Disconnection T/M E02 Electrical system
SEN01828-00
DK01KB Left yoke angle sensor Short circuit T/M E02 Electrical system
DK03KA Right yoke angle sensor Disconnection T/M E02 Electrical system
DK03KB Right yoke angle sensor Short circuit T/M E02 Electrical system
DK10KA Fuel control dial Disconnection S/T CALL E03 Electrical system
DK10KB Fuel control dial Short circuit S/T CALL E03 Electrical system
DK30KA Steering potentiometer (1) Disconnection S/T CALL E03 Electrical system
DK30KB Steering potentiometer (1) Short circuit S/T CALL E03 Electrical system
DK30KX Steering potentiometer (1) Out of input signal range S/T CALL E04 Electrical system
DK30KZ Steering potentiometer (1) Disconnection or short circuit S/T CALL E04 Electrical system
DK30L8 Steering potentiometer (1) Analog signal disagreement S/T CALL E03 Electrical system
DK31KA Steering potentiometer (2) Disconnection S/T CALL E03 Electrical system
DK31KB Steering potentiometer (2) Short circuit S/T CALL E03 Electrical system
DK40KA Brake potentiometer Disconnection S/T CALL E03 Electrical system
DK40KB Brake potentiometer Short circuit S/T CALL E03 Electrical system
DK55KX Forward-reverse potentiometer Out of input signal range T/M CALL E04 Electrical system
DK55KZ Forward-reverse potentiometer Disconnection or short circuit T/M CALL E04 Electrical system
Troubleshoot-
DK55L8 Forward-reverse potentiometer Analog signal disagreement T/M CALL E03 Electrical system ing by failure
code (Display
DK56KA Forward-reverse potentiometer (1) Disconnection T/M CALL E03 Electrical system of code)
(Part 7)
DK56KB Forward-reverse potentiometer (1) Short circuit T/M CALL E03 Electrical system
DK57KA Forward-reverse potentiometer (2) Disconnection T/M CALL E03 Electrical system SEN01829-00
DK57KB Forward-reverse potentiometer (2) Short circuit T/M CALL E03 Electrical system
DK60KA Acceleration sensor Disconnection S/T E01 Electrical system
DK60KB Acceleration sensor Short circuit S/T E01 Electrical system
8 D475A, D475ASD-5E0
Compo-
code code manual
charge
DKH1KA Pitch angle sensor Disconnection S/T CALL E03 Electrical system
DKH1KB Pitch angle sensor Short circuit S/T CALL E03 Electrical system
DKH1KX Pitch angle sensor Out of input signal range S/T E01 Electrical system
Torque converter output speed sen-
DLF1KA Disconnection T/M — Electrical system
sor
DLT3KA Transmission output speed sensor Disconnection T/M E01 Electrical system
dLT3KA Transmission output speed sensor Disconnection T/M E01 Electrical system
DLT3KB Transmission output speed sensor Short circuit T/M E01 Electrical system
DV00KB Alarm buzzer Short circuit MON E02 Electrical system
DW55KA Blade pitch back solenoid Disconnection T/M CALL E03 Electrical system
DW55KB Blade pitch back solenoid Short circuit T/M CALL E03 Electrical system
DW56KA Blade pitch dump solenoid Disconnection T/M CALL E03 Electrical system
DW56KB Blade pitch dump solenoid Short circuit T/M CALL E03 Electrical system
DW56KY Blade pitch dump solenoid Hot short T/M CALL E03 Electrical system
DW57KA Left tilt limit solenoid Disconnection T/M E02 Electrical system
DW57KB Left tilt limit solenoid Short circuit T/M E02 Electrical system
DW57KY Left tilt limit solenoid Hot short T/M E02 Electrical system
DW58KA Right tilt limit solenoid Disconnection T/M E02 Electrical system
DW58KB Right tilt limit solenoid Short circuit T/M E02 Electrical system Troubleshoot-
ing by failure
DW58KY Right tilt limit solenoid Hot short T/M E02 Electrical system code (Display
of code)
DW59KA Dual tilt selector solenoid Disconnection T/M E01 Electrical system
(Part 7)
DW59KB Dual tilt selector solenoid Short circuit T/M E01 Electrical system
SEN01829-00
DW59KY Dual tilt selector solenoid Hot short T/M E01 Electrical system
DW5AKA Blade pitch selector solenoid Disconnection T/M E02 Electrical system
DW5AKB Blade pitch selector solenoid Short circuit T/M E02 Electrical system
DW5AKY Blade pitch selector solenoid Hot short T/M E02 Electrical system
Blade pitch dump solenoid
DW5DKA Disconnection T/M CALL E03 Electrical system
(Superdozer specification)
DW5DKB Short circuit T/M CALL E03 Electrical system
DW5DKY Hot short T/M CALL E03 Electrical system
DW7BKA Fan reverse solenoid Disconnection T/M E01 Electrical system
DW7BKB Fan reverse solenoid Short circuit T/M E01 Electrical system
DW7BKY Fan reverse solenoid Hot short T/M E01 Electrical system
DWJ0KA Pump merge-divider solenoid Disconnection S/T E02 Electrical system
DWJ0KB Pump merge-divider solenoid Short circuit S/T E02 Electrical system
DWJ0KY Pump merge-divider solenoid Hot short S/T E02 Electrical system
DWN3KA Sudden stop prevention solenoid Disconnection S/T CALL E04 Electrical system
DWN3KB Sudden stop prevention solenoid Short circuit S/T CALL E04 Electrical system
DWN3KY Sudden stop prevention solenoid Hot short S/T CALL E04 Electrical system
DWN5KA Fan pump solenoid (1) Disconnection T/M E01 Electrical system
D475A, D475ASD-5E0 9
Compo-
code code manual
charge
DWN5KB Fan pump solenoid (1) Short circuit T/M E01 Electrical system
Troubleshoot-
DWN5KY Fan pump solenoid (1) Hot short T/M E02 Electrical system ing by failure
code (Display
DWNCKA Fan pump solenoid (2) Disconnection T/M E01 Electrical system of code)
(Part 7)
DWNCKB Fan pump solenoid (2) Short circuit T/M E01 Electrical system
SEN01829-00
DWNCKY Fan pump solenoid (2) Hot short T/M E02 Electrical system
DXE0KA LS set solenoid Disconnection T/M E02 Electrical system
DXE0KB LS set solenoid Short circuit T/M E02 Electrical system
DXE0KY LS set solenoid Hot short T/M E02 Electrical system
DXH1KA Lockup solenoid Disconnection T/M E01 Electrical system
DXH1KB Lockup solenoid Short circuit T/M E01 Electrical system
DXH1KY Lockup solenoid Hot short T/M CALL E03 Electrical system
DXH4KA 1st clutch ECMV Disconnection T/M CALL E03 Electrical system
DXH4KB 1st clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH4KY 1st clutch ECMV Hot short T/M CALL E03 Electrical system
DXH5KA 2nd clutch ECMV Disconnection T/M CALL E03 Electrical system
DXH5KB 2nd clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH5KY 2nd clutch ECMV Hot short T/M CALL E03 Electrical system
DXH6KA 3rd clutch ECMV Disconnection T/M CALL E03 Electrical system
DXH6KB 3rd clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH6KY 3rd clutch ECMV Hot short T/M CALL E03 Electrical system
DXH7KA Reverse clutch ECMV Disconnection T/M CALL E03 Electrical system Troubleshoot-
ing by failure
DXH7KB Reverse clutch ECMV Short circuit T/M CALL E03 Electrical system code (Display
of code)
DXH7KY Reverse clutch ECMV Hot short T/M CALL E03 Electrical system (Part 8)
DXH8KA Forward clutch ECMV Disconnection T/M CALL E03 Electrical system
SEN01830-00
DXH8KB Forward clutch ECMV Short circuit T/M CALL E03 Electrical system
DXH8KY Forward clutch ECMV Hot short T/M CALL E03 Electrical system
DXH9KA Right steering clutch ECMV Disconnection S/T CALL E03 Electrical system
DXH9KB Right steering clutch ECMV Short circuit S/T CALL E03 Electrical system
DXH9KY Right steering clutch ECMV Hot short S/T CALL E04 Electrical system
DXHAKA Left steering clutch ECMV Disconnection S/T CALL E03 Electrical system
DXHAKB Left steering clutch ECMV Short circuit S/T CALL E03 Electrical system
DXHAKY Left steering clutch ECMV Hot short S/T CALL E04 Electrical system
DXHBKA Right brake ECMV Disconnection S/T CALL E04 Electrical system
DXHBKB Right brake ECMV Short circuit S/T CALL E04 Electrical system
DXHBKY Right brake ECMV Hot short S/T CALL E04 Electrical system
DXHCKA Left brake ECMV Disconnection S/T CALL E04 Electrical system
DXHCKB Left brake ECMV Short circuit S/T CALL E04 Electrical system
DXHCKY Left brake ECMV Hot short S/T CALL E04 Electrical system
F@BBZL Abnormality high pressure
Engine blow-by pressure sensor VHMS — —
[n3 o 38] occurrence
10 D475A, D475ASD-5E0
Compo-
code code manual
charge
F@BYNS Left front exhaust temperature sen- Exhaust temperature abnormal
VHMS — —
[n3 o 61] sor (1) rise
f@BYNS Left rear exhaust temperature sensor Exhaust temperature abnormal
VHMS — —
[n3 o 71] (1) rise
F@BZNS Right front exhaust temperature sen- Exhaust temperature abnormal
VHMS — — Troubleshoot-
ing by failure
f@BZNS Right rear exhaust temperature sen- Exhaust temperature abnormal
VHMS — — code (Display
of code)
F@BYNR Left front exhaust temperature sen- Exhaust temperature abnormal
VHMS — — (Part 8)
f@BYNR Left rear exhaust temperature sensor Exhaust temperature abnormal SEN01830-00
VHMS — —
[n3 o 72] (2) rise
F@BZNR Right front exhaust temperature sen- Exhaust temperature abnormal
VHMS — —
f@BZNR Right rear exhaust temperature sen- Exhaust temperature abnormal
VHMS — —
a The items in this table are arranged in the order of the failure codes.
a A component in charge is a controller or the monitor panel in charge of the system check.
MON : Monitor panel
ENG : Engine controller
T/M : Transmission controller
S/T : Steering controller
VHMS : VHMS controller
a The failure codes having no numbers in the action code column are not displayed on the ordinary
screen when abnormality related to them occurs. They are simply recorded in the fault history of the
service menu (Electrical equipment system or mechanical equipment system).
a The history classification column shows in which system each failure is classified, the electrical equip-
ment system or mechanical equipment system, when it is recorded in the failure history.
Since the failure codes of VHMS are special to the VHMS specification and saved only in the VHMS
controller, however, they are not recorded in the fault history. The 4-letter codes in [ ] among the VHMS
codes are the failure codes displayed on the 7-segment LED of the VHMS controller (They are divided
into 2 2-letter codes).
a Blinking and lighting of failure code
q Blinking : The trouble has not been repaired.
q Lighting : The trouble has been repaired.
D475A, D475ASD-5E0 11
Fuse locations 1
Connection table of fuse boxes
a This connection table shows the devices to which each power supply of the fuse box supplies power (An
accessory power supply is a device which supplies power while the starting switch is in the ON position
and an unswitched power supply is a device which supplies power while the starting switch is in the OFF
and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Fuse box A [FS12]

Fuse No. Type of power supply Fuse capacity (A) Destination of power
1 Accessory power supply 20 VHMS controller
2 20 VHMS controller
3 Unswitched power supply 20 Cab power supply
4 10 Converter operation support center
5 Accessory power supply 20 Converter operation support center
Fuse box B [FS22]

1 5 Backup alarm
2 20 Preheater power supply, pin puller, air suspension seat
3 Accessory power supply 20 Additional heater power supply
4 20 Working lamp
5 20 Rear lamp
Fuse box C [FS32]

1 5 ACC signal
2 20 Horn
3 Accessory power supply 20 Spare power supply (1)
4 20 Spare power supply (2)
5 20 Spare ACC signal
Cab fuse box D

1 10 Radio, cigarette lighter, room lamp
2 10 Rear wiper
3 10 Right wiper
4 10 Front wiper
5 10 Left wiper
Accessory power supply
6 20 Additional headlamp
7 20 Additional rear lamp, rotary lamp
8 — Spare
9 — Spare
10 10 Radio memory
12 D475A, D475ASD-5E0
Fuse locations and fuse Nos.

Inside of left console box in cab
Lower right part of cab overhead
D475A, D475ASD-5E0 13
Circuit breaker
No Connector No. Capacity (A) Circuit Remarks
1 F30 30 Cab unswitched power supply
2 F96 105 Main power supply
Electrical intake air heater main power supply
3 B105H2L 105 Installed in battery box at
(Right bank)
left of operator's seat
4 B105H1L 105 Electrical intake air heater main power supply
6 B7L 30 Engine controller unswitched power supply
7 B8L 30 Engine controller unswitched power supply
8 CB1 20 Steering controller
9 CB2 20 Monitor panel
10 CB3 20 Transmission controller Installed in console box at
11 CB4 20 Air conditioner left of operator's seat
12 CB5 20 Headlamp
13 CB6 20 Starting switch unswitched power supply
a Resetting operation of circuit breaker

Turn the starting switch OFF and push in projected reset button (14). If the reset button returns immedi-
ately, carry out troubleshooting to repair failed part.
14 D475A, D475ASD-5E0
SEN01821-00

© 2006 KOMATSU
All Rights Reserved
16
SEN01822-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting........................................................................................... 2
Sequence of events in troubleshooting ................................................................................................ 3
Checks before troubleshooting ............................................................................................................ 4
Classification and procedures of troubleshooting ................................................................................ 5
Contents of troubleshooting table......................................................................................................... 8
Wiring table for connector pin numbers ............................................................................................. 10
T-adapter box and T-adapter table ..................................................................................................... 39
D475A, D475ASD-5E0 1
General information on troubleshooting 1

Points to remember when troubleshooting 1
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 2 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 coolant 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 con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent 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 questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
2 D475A, D475ASD-5E0
Sequence of events in troubleshooting 1
D475A, D475ASD-5E0 3
Checks before troubleshooting 1
Judgement
Item Action
Value
1. Check fuel level — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check fuel filter — Replace
Checks before starting
Lubricating oil, coolant
4. Check hydraulic oil level — Add oil

5. Check oil level in damper case — Add oil
6. Check power train oil level — Add oil
7. Check engine oil level (engine oil pan level) — Add oil
8. Check coolant level — Add water
9. Check dust indicator for clogging — Clean or replace
10.Check travel of brake pedal — Adjust
1. Check for abnormal noise, smell — Repair
mechanical
equipment
Hydraulic,
2. Check for oil leakage — Repair

3. Carry out air bleeding — Bleed air
1. Check for looseness, corrosion of battery terminal, wiring 20 – 30 V Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wir- — Tighten or replace
ing
3. Check for looseness, corrosion of starting motor terminal, — Tighten or replace
wiring
Other check items
4. Check battery voltage (engine stopped) — Replace

Electrical equipment
5. Check battery electrolyte level — Add or replace

6. Check for discolored, burnt, exposed wiring — Replace
7. Check for missing wiring clamps, hanging wire — Repair
8. Check for water leaking on wiring (pay particularly careful — Disconnect con-
attention to water leaking on connectors or terminals) nector and dry
9. Check for blown, corroded fuses — Replace
10.Check alternator voltage (engine running at 1/2 throttle or After running Replace
above) for several
minutes:
27.5 – 29.5 V
11. Check operating sound of battery relay (starting switch — Replace
ON, OFF)
4 D475A, D475ASD-5E0
Classification and procedures of troubleshooting 1

Classification of troubleshooting
Mode Contents
Display of
Troubleshooting by failure code (Display of code)
code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
2. Procedure for troubleshooting to be taken when failure code is recorded:

If an action code is not displayed on the machine monitor, check for a failure code in the failure code dis-
play mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.“, and then carry out trouble-
shooting related to that phenomenon in the “E-mode“, “H-mode“, or “S-mode“.
D475A, D475ASD-5E0 5
Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
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 cranks but exhaust smoke does
5 The engine does not S-2b)
not come out
start
Exhaust smoke comes out but the engine does
6 S-2c)
not start
The engine speed does not rise sharply (Follow-up performance is
7 S-3
low)
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 Coolant 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
Time lag is large in shifting the gear speed or changing the travel
26 H-5
direction
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
6 D475A, D475ASD-5E0
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
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
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
The ripper pin puller cylinder does not operate (if the giant ripper is
42 H-21
installed)
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
D475A, D475ASD-5E0 7
Contents of troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code

Failure
Display of Trouble that appears in the machine
Display of panel symptom
panel
Failure content State where the monitor panel or controller detects the trouble
Controller's Action to be taken to protect the system and equipment when the monitor panel or controller
action detects a trouble
Symptoms that
Problem that appears as an abnormality in the main unit by the action taken by the monitor
appears
panel or controller (above)
on machine
General
Information related to troubles occurred 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)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Causes by which a trouble A harness of an independent circuit abnormally comes into
and standard is assumed to be defected contact with one of another circuit.
value in normal (The order number indi-
state cates a serial number, not <Notes on troubleshooting>
a priority sequence.) (1) Method of indicating connector numbers and handling of T-
adapter
For troubleshooting, insert or connect T-adapter shown
3 below unless especially specified.
• When “male” or “female” is not indicated for a connector
number, disconnect the connector, and insert the T-
adapters in both the male and female.
• When “male” or “female” is indicated for a connector
number, disconnect connector, and insert the T-adapter
in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• 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.
8 D475A, D475ASD-5E0
Related circuit diagram
This is the excerpted circuit diagram related to troubleshooting.

• Connector No.: Indicates (model – number of pins) (color)
• Arrow (io): Indicates the approximate mounting place on machine
D475A, D475ASD-5E0 9
Wiring table for connector pin numbers 1

a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
10 D475A, D475ASD-5E0
D475A, D475ASD-5E0 11
12 D475A, D475ASD-5E0
D475A, D475ASD-5E0 13
14 D475A, D475ASD-5E0
D475A, D475ASD-5E0 15
16 D475A, D475ASD-5E0
D475A, D475ASD-5E0 17
18 D475A, D475ASD-5E0
D475A, D475ASD-5E0 19
20 D475A, D475ASD-5E0
D475A, D475ASD-5E0 21
22 D475A, D475ASD-5E0
D475A, D475ASD-5E0 23
24 D475A, D475ASD-5E0
D475A, D475ASD-5E0 25
26 D475A, D475ASD-5E0
D475A, D475ASD-5E0 27
28 D475A, D475ASD-5E0
D475A, D475ASD-5E0 29
30 D475A, D475ASD-5E0
D475A, D475ASD-5E0 31
32 D475A, D475ASD-5E0
D475A, D475ASD-5E0 33
34 D475A, D475ASD-5E0
D475A, D475ASD-5E0 35
36 D475A, D475ASD-5E0
D475A, D475ASD-5E0 37
38 D475A, D475ASD-5E0
T-adapter box and T-adapter table 1

a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37
799-601-3200 T-box (for MS) 37
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4210 Adapter for DRC 50 DRC50 q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
D475A, D475ASD-5E0 39
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
40 D475A, D475ASD-5E0
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol

799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for DT/HD) 12 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410 Adapter for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q q
Adapter for engine (CRI-T3) PFUEL
799-601-9430 2 P q q
Adapter for engine (CRI-T3) PCV
799-601-9440 Adapter for engine (CRI-T2) 3 1,2,3 q
795-799-5520 Adapter for engine (HPI-T2) 2 S q
Adapter for engine (HPI-T2)
795-799-5530 Adapter for engine (CRI-T3) 2 C q q
Temperature sensor
Adapter for engine (HPI-T2)
795-799-5540 2 A q q
Adapter for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190 3 1,2,3L q q
Commonrail pressure
799-601-4230 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240 Adapter for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250 Adapter for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330 Adapter for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340 2 2,PA q q
Pump actuator
799-601-9020 Adapter for engine (CRI-T3) Injector 2 DT2 q q
799-601-9040 Adapter for engine (CRI-T3) SEGR, SBP 4 DT4 q q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4280 Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9370 Adapter for controller (HST) 26 HST26A q
D475A, D475ASD-5E0 41
SEN01822-00

© 2006 KOMATSU
All Rights Reserved
42
SEN01823-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Troubleshooting by failure code
(Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 1 .............................................................................. 3
Failure code [1500L0] Transmission clutch: Dual engagement ........................................................... 3
Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON .......... 4
Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF.......... 5
Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON.............................. 6
Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF ......... 7
Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON................... 8
Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF .................. 9
Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON................ 10
Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF ................11
Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON................ 12
Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF ............... 13
Failure code [1800MW] Power train clutch: Slip ................................................................................ 14
Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON.............. 15
D475A, D475ASD-5E0 1
Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF ............. 16
Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON ................ 17
Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF ................ 18
Failure code [2300NR] Brake thermal load: Abnormal heating .......................................................... 19
Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON .............. 20
Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF.............. 21
Failure code [2301NR] Right steering brake thermal load: Abnormal heating ................................... 22
Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON................. 23
Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF ................ 24
Failure code [2302NR] Left steering brake thermal load: Abnormal heating...................................... 25
Failure code [AA10NX] Air cleaner: Clogging .................................................................................... 26
Failure code [AB00MA] Battery charge abnormality: Malfunction ...................................................... 27
Failure code [B@BAZG] Engine oil: Oil pressure too low .................................................................. 28
Failure code [B@BAZK] Engine oil: Oil level reduction...................................................................... 29
Failure code [B@BCNS] Radiator coolant: Overheat......................................................................... 30
Failure code [B@BCZK] Radiator coolant: Level too low................................................................... 31
Failure code [B@CENS] Power train oil: Overheat ............................................................................ 32
Failure code [B@CHZG] Power train oil: Low oil pressure ................................................................ 33
Failure code [B@HANS] Hydraulic oil: Overheat ............................................................................... 34
Failure code [B@HAZK] Hydraulic oil: Level reduction ...................................................................... 35
2 D475A, D475ASD-5E0
Troubleshooting by failure code (Display of code), Part 1 1

Failure code [1500L0] Transmission clutch: Dual engagement 1
Action code Failure code Symptom Transmission clutch: Dual engagement

CALL E03 1500L0 of failure (Transmission controller system)
• Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Gear speed is limited.)
(1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
• Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Machine can not travel.)
(2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
Failure content (3) Either of [DXH6KA] or [DXH6KB] and (1) above
(4) [15SALH] and [15SBLH]
(5) Either [15SAL1] or [DXH8KY] and either [15SBL1] or [DXH7KY]
(6) [15SELH], [15SFLH], and [15SGLH]
(7) Either [15SEL1] or [DXH4KY] and either [15SFL1] or [DXH5KY]
(8) Either [15SEL1] or [DXH4KY] and either [15SGL1] or [DXH6KY]
(9) Either [15SFL1] or [DXH5KY] and either [15SGL1] or [DXH6KY]
Controller's • Flashes warning lamp and turns on alarm buzzer.
action • Limits operation of engine and transmission.
Symptoms that • Once machine is stopped, engine speed is limited to medium (half).
appear on • Once machine is stopped, traveling is limited to specific gear speeds.
machine • Machine cannot travel.
General
• Duplication of failure code: Engine start + travel
information
Cause Standard values when normal and remarks for troubleshooting

Possible Confirm the failure codes displayed at the same time, then carry out troubleshooting for the codes.
causes and the [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
standard values [15SGLH]
when normal [DXH4KA], [DXH4KB], [DXH4KY], [DXH5KA, [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB],
[DXH6KY], [DXH7KA, [DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]
D475A, D475ASD-5E0 3
Failure code [15SAL1] Forward clutch oil pressure: Command current

OFF and fill signal ON 1
Action code Failure code Symptom of Forward clutch oil pressure: Command current OFF and fill signal
CALL E03 15SAL1 failure ON (Transmission controller system)
Failure content • The fill switch signal is not set off at output stop of the transmission forward clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
Controller's
• Becomes N (neutral) at reverse operation.
action
• Limits operation of engine and transmission.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear 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.
General
(Code 31520: Transmission fill switch input state)
information
• Method of reproducing failure code: Engine start + Neutral running

a Prepare 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
a Prepare with starting switch OFF, then carry out troubleshooting
Defective harness ground-
Possible without turning starting switch ON.
2 ing (Contact with ground
causes and the Wiring harness between TMC1 (female) (5) – Resis-
circuit) Min. 1 Mz
standard values FFT2 (female) (1) with chassis ground tance
when normal a Prepare with starting switch OFF, then start the engine for trouble-
shooting.
Defective transmission
3 TMC1 PCCS lever Voltage
controller
Between (5) – N 5 – 11 V
chassis ground F (Forward) Max. 1 V
When no fault is detected in the electric system, the hydraulic pres-
Defective hydraulic pres-
4 sure system is assumed to be abnormal. Carry out the related trou-
sure system
bleshooting (H mode).
Circuit diagram related to transmission forward clutch ECMV
4 D475A, D475ASD-5E0
Failure code [15SALH] Forward clutch oil pressure: Command current

ON and fill signal OFF 1
Action code Failure code Symptom of Forward clutch oil pressure: Command current ON and fill signal OFF
CALL E03 15SALH failure (Transmission controller system)
Failure content • The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit.
Controller's
• Becomes neutral (N) at forward operation.
action
Symptoms that
appear 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.
General
information
• Method of reproducing failure 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 a Prepare with starting switch OFF, then carry out troubleshooting
Possible harness (Disconnection in without turning starting switch ON.
2
causes and the wiring or defective contact Wiring harness between TMC1 (female) (5) – Resis-
standard values in connector) Max. 1 z
FFT2 (female) (1) tance
shooting.
controller
Between (5) – N 5 – 11 V
chassis ground F (Forward) Max. 1 V
sure system
D475A, D475ASD-5E0 5
Failure code [15SBL1] Reverse clutch: Command current OFF and fill
signal ON 1
Action code Failure code Symptom of Reverse clutch: Command current OFF and fill signal ON
CALL E03 15SBL1 failure (Transmission controller system)
Failure content • The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.
Controller's
• Becomes neutral (N) at forward operation.
action
Symptoms that
appear 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.
General
information
• Method of reproducing failure code: Engine start + Neutral running

shooting.
Defective reverse clutch fill
1 FRT2 (male) PCCS lever Resistance
chassis ground R (Reverse) Max. 1 z
causes and the Wiring harness between TMC1 (female) (24) Resis-
circuit) Min. 1 Mz
standard values – FRT2 (female) (1) with chassis ground tance
shooting.
controller
Between (24) – N 5 – 11 V
chassis ground R (Reverse) Max. 1 V
sure system
Circuit diagram related to transmission reverse clutch ECMV
6 D475A, D475ASD-5E0
Failure code [15SBLH] Reverse clutch oil pressure: Command current

ON and fill signal OFF 1
Action code Failure code Symptom of Reverse clutch oil pressure: Command current ON and fill signal OFF
CALL E03 15SBLH failure (Transmission controller system)
Failure content • The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit.
Controller's
• Becomes neutral (N) at reverse operation.
action
Symptoms that
appear 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.
General
information
• Method of reproducing failure code: Engine start + Reverse running

shooting.
Defective reverse clutch fill
1 FRT2 (male) PCCS lever Resistance
chassis ground R (Reverse) Max. 1 z
2
causes and the wiring or defective contact Wiring harness between TMC1 (female) (24) Resis-
standard values in connector) Max. 1 z
– FRT2 (female) (1) tance
shooting.
controller
Between (24) – N 5 – 11 V
chassis ground R (Reverse) Max. 1 V
sure system
D475A, D475ASD-5E0 7
Failure code [15SEL1] 1st clutch oil pressure: Command current OFF
and fill signal ON 1
Action code Failure code Symptom of 1st clutch oil pressure: Command current OFF and fill signal ON
CALL E03 15SEL1 failure (Transmission controller system)
Failure content • The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit.
Controller's • Flashes caution lamp and turns on caution buzzer.
Symptoms that
appear 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.
General
information
• Method of reproducing failure code: Engine start + F1 or R1 o Neutral running

shooting.
Defective 1st clutch fill F1T8 (male) PCCS lever Resistance
1
Between (1) – Other than F1/R1 Min. 1 Mz
chassis ground F1·R1 Max. 1 z
circuit) Min. 1 Mz
standard values – F1T8 (female) (1) with chassis ground tance
shooting.
Defective transmission TMC1 PCCS lever Voltage
3
controller
Between (23) – Other than F1/R1 5 – 11 V
chassis ground F1·R1 Max. 1 V
sure system
Circuit diagram related to transmission level 1 clutch ECMV
8 D475A, D475ASD-5E0
Failure code [15SELH] 1st clutch oil pressure: Command current ON

and fill signal OFF 1
Action code Failure code Symptom of 1st clutch oil pressure: Command current ON and fill signal OFF
CALL E03 15SELH failure (Transmission controller system)
Failure content • The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
General
information
• Method of reproducing failure code: Engine start + F1 or R1 running

shooting.
Defective 1st clutch fill F1T8 (male) PCCS lever Resistance
1
2
Max. 1 z
standard values in connector) – F1T8 (female) (1) tance
shooting.
3
controller
sure system
Circuit diagram related to transmission 1st clutch ECMV
D475A, D475ASD-5E0 9
Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF
Action code Failure code Symptom of 2nd clutch oil pressure: Command current OFF and fill signal ON
CALL E03 15SFL1 failure (Transmission controller system)
Failure content • The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
General
information
• Method of reproducing failure code: Engine start + F2 or R2 running o Neutral running

shooting.
Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance
1
circuit) Min. 1 Mz
shooting.
3
controller
sure system
Circuit diagram related to transmission 2nd clutch ECMV
10 D475A, D475ASD-5E0
Failure code [15SFLH] 2nd clutch oil pressure: Command current ON

Action code Failure code Symptom of 2nd clutch oil pressure: Command current ON and fill signal OFF
CALL E03 15SFLH failure (Transmission controller system)
Failure content • The fill switch signal is not set on at output to the transmission level 2 clutch solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
General
information

shooting.
Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance
1
2
Max. 1 z
shooting.
3
controller
sure system
D475A, D475ASD-5E0 11
Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF
Action code Failure code Symptom of 3rd clutch oil pressure: Command current OFF and fill signal ON
CALL E03 15SGL1 failure (Transmission controller system)
Failure content • The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
General
information
• Method of reproducing failure code: Engine start + F3 or R3 running o Neutral running

shooting.
Defective 3rd clutch fill F3T4 (male) PCCS lever Resistance
1
circuit) Min. 1 Mz
shooting.
3
controller
sure system
Circuit diagram related to transmission 3rd clutch ECMV
12 D475A, D475ASD-5E0
Failure code [15SGLH] 3rd clutch oil pressure: Command current ON

Action code Failure code Symptom of 3rd clutch oil pressure: Command current ON and fill signal OFF
CALL E03 15SGLH failure (Transmission controller system)
Failure content • The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
General
information

shooting.
Defective 3rd clutch fill F3T4 (male) PCCS lever Resistance
1
2
Max. 1 z
shooting.
3
controller
sure system
D475A, D475ASD-5E0 13
Failure code [1800MW] Power train clutch: Slip 1

Action code Failure code Symptom of Power train clutch slip
E02 1800MW failure (Transmission controller system)
• At lock-up of the torque converter, the engine rotation is different from the torque converter rotation
Failure content
by 500 rpm or more.
Controller's
• None in particular.
action
Symptoms that
appear on • None in particular.
machine
• The engine rotation and the torque converter rotation can be checked in monitoring mode.
General (Code 01002: Engine rotation L, code 01004: Number of engine rotation R, code 31200: Transmis-
information sion input rotation (torque converter rotation)
• Method of reproducing failure code: Engine start + Lock-up switch ON + Actual running

Power train clutch slip
a Clutch slip was detected; check the cause and machine damage
1 (When the system is nor-
state, then repair the machine.
mal)
Possible
Defective engine rotation Check whether failure codes [CA689], [CB689], [CA778] and [CB778]
causes and the 2
sensor are displayed. If they are displayed, carry out the troubleshooting.
standard values
when normal Defective torque converter Check whether failure code [DLF1KA] is displayed. If it is displayed,
3
rotation sensor system carry out the troubleshooting.
Internally trouble; troubleshooting is impossible.
4 (If no visible abnormality is detected on the machine, the controller
controller
may be used continuously.)
14 D475A, D475ASD-5E0
Failure code [2201L1] Right clutch oil pressure: Command current OFF
Action code Failure code Symptom of Right clutch oil pressure: Command current OFF and fill signal OFF
CALL E04 2201L1 failure (Steering controller system)
Failure content • The fill switch signal is not set off at output stop of the right steering clutch solenoid circuit.
action • Limits operation of engine, transmission, and brake.
Symptoms that
appear 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
General mode.
information (Code 31521: Steering fill switch input state)
• Method of reproducing failure code: Engine start

a Prepare with starting switch OFF. Engine start for troubleshooting.
Defective right steering FRC8 (male) PCCS lever Resistance
1 clutch fill switch
(Internal short) Between (1) – N (Neutral) Min. 1 Mz
chassis ground Right steering Max. 1 z
without turning starting switch ON.
Possible 2 ing (Contact with ground
Wiring harness between STCN3 (female) (39) Resis-
causes and the circuit) Min. 1 Mz
standard values – FRC8 (female) (1) with chassis ground tance
when normal a Prepare with starting switch OFF. Engine start + Pivot turn switch
ON + Forward for troubleshooting.
Defective steering control- STCN3 PCCS lever Voltage
3
ler
Between (39) – N (Neutral) 5 – 11 V
chassis ground Right steering Max. 1 V
sure system
Circuit diagram related to right steering clutch ECMV
D475A, D475ASD-5E0 15
Failure code [2201LH] Right clutch oil pressure: Command current ON

Action code Failure code Symptom of Right clutch oil pressure: Command current ON and fill signal OFF
CALL E04 2201LH failure (Steering controller system)
Failure content • The fill switch signal is not set off at output to the right steering clutch solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring
General mode. (Code 31521: Steering fill switch input state)
information • Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever
operated (right steering)

Defective right steering FRC8 (male) PCCS lever Resistance
chassis ground Right steering Max. 1 z
2
causes and the wiring or defective contact Wiring harness between STCN3 (female) Resis-
Max. 1 z
standard values in connector) (39) – FRC8 (female) (1) tance
when normal a Prepare with starting switch OFF. Engine start for troubleshooting.
3
ler Between (39) – N (Neutral) 5 – 11 V
chassis ground Right steering Max. 1 V
sure system
16 D475A, D475ASD-5E0
Failure code [2202L1] Left clutch oil pressure: Command current OFF
Action code Failure code Symptom of Left clutch oil pressure: Command current OFF and fill signal ON
Failure content • The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring
General
mode. (Code 31521: Steering fill switch input state)
information

Defective left steering FLC6 (male) PCCS lever Resistance
chassis ground Left steering Max. 1 z
Defective harness ground- without turning starting switch ON.
Possible
causes and the Wiring harness between STCN3 (female) (29) Resis-
circuit) Min. 1 Mz
standard values – FLC6 (female) (1) with chassis ground tance
3
chassis ground Left steering Max. 1 V
sure system
Circuit diagram related to left clutch ECMV
D475A, D475ASD-5E0 17
Failure code [2202LH] Left clutch oil pressure: Command current ON

Action code Failure code Symptom of Left clutch oil pressure: Command current ON and fill signal OFF
Failure content • The fill switch signal is not set off at output to the left steering clutch solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring
General mode. (Code 31521: Steering fill switch input state)
information • Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever
operated (left steering)

Defective left steering FLC6 (male) PCCS lever Resistance
chassis ground Left steering Max. 1 z
2
causes and the wiring or defective contact Wiring harness between STCN3 (female) (29) Resis-
Max. 1 z
standard values in connector) – FLC6 (female) (1) tance
3
chassis ground Left steering Max. 1 V
sure system
Circuit diagram related to left clutch ECMV
18 D475A, D475ASD-5E0
Failure code [2300NR] Brake thermal load: Abnormal heating 1

Action code Failure code Symptom of Brake thermal load: abnormal heating
— 2300NR failure (Steering controller system)
• The steering controller added together the continuous operating times of the pitch angle sensor,
Failure content
travel speed, and brake potentiometer, and then judged that the brake was heating abnormally.
Controller's
action
Symptoms that
appear on
machine
General
information
Possible Cause Standard values when normal and remarks for troubleshooting
causes and the 1 Improper braking during downslope travel (Machine traveled down with brake pedal pressed)
standard values Defective steering control-
when normal 2 When the operation in cause 1 is not performed
ler
D475A, D475ASD-5E0 19
Failure code [2301L1] Right brake oil pressure: Command current OFF
Action code Failure code Symptom of Right brake oil pressure: Command current OFF and fill signal ON
Failure content • The fill switch signal is not set off at output stop of the right steering brake solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring
General mode.

a Prepare with starting switch OFF. Engine start + Pivot turn switch
Defective right steering ON + Forward for troubleshooting.
1 brake fill switch FRB4 (male) PCCS lever Resistance
(Internal short) Between (1) – N (Neutral) Max. 1 z
chassis ground Right steering Min. 1 Mz
circuit) Min. 1 Mz
standard values – FRB4 (female) (1) with chassis ground tance
when normal a Prepare with starting switch OFF. Engine start + Forward for trou-
bleshooting.
Defective steering control-
3 STCN2 PCCS lever Voltage
ler
Between (25) – N (Neutral) Max. 1V
chassis ground Right steering 5 – 11 V
sure system
Circuit diagram related to right steering brake ECMV
20 D475A, D475ASD-5E0
Failure code [2301LH] Right brake oil pressure: Command current ON

Action code Failure code Symptom of Right brake oil pressure: Command current ON and fill signal OFF
Failure content • The fill switch signal is not set off at output to the right steering brake solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring
General mode.
• Method of reproducing failure code: Engine start + Parking bake lever release

Defective right steering ON + Forward for troubleshooting.
1 clutch fill switch FRB4 (male) PCCS lever Resistance
2
causes and the wiring or defective contact Wiring harness between STCN2 (female) (25) Resis- Max. 1
standard values in connector) – FRB4 (female) (1) tance Mz
bleshooting.
3 STCN2 PCCS lever Voltage
ler
Between (25) – N (Neutral) Max. 1V
chassis ground Right steering 5 – 11 V
sure system
D475A, D475ASD-5E0 21
Failure code [2301NR] Right steering brake thermal load: Abnormal

heating 1
Action code Failure code Symptom of Right steering brake thermal load: Abnormal heating
Failure content travel speed and right steering potentiometer, and then judged that the right steering brake was
heating abnormally (Machine traveled down with brake pedal pressed).
Controller's
action
Symptoms that
appear on
machine
General
information

Possible
Improper steering during downslope travel (Machine traveled down and was steered to right con-
causes and the 1
tinuously)
standard values
when normal Defective steering control-
2 When the operation in cause 1 is not performed
ler
22 D475A, D475ASD-5E0
Failure code [2302L1] Left brake oil pressure: Command current OFF
Action code Failure code Symptom of Left brake oil pressure: Command current OFF and fill signal ON
Failure content • The fill switch signal is not set off at output stop of the left steering brake solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring
General
information

Defective left steering ON + Forward for troubleshooting.
1 brake fill switch FLB2 (male) PCCS lever Resistance
circuit) Min. 1 Mz
standard values – FLB2 (female) (1) with chassis ground tance
bleshooting.
3
ler
Between (35) – N (Neutral) Max. 1 V
chassis ground Left steering 5 – 11 V
sure system
Circuit diagram related to left steering brake ECMV
D475A, D475ASD-5E0 23
Failure code [2302LH] Left brake oil pressure: Command current ON

Action code Failure code Symptom of Left brake oil pressure: Command current ON and fill signal OFF
Failure content • The fill switch signal is not set on at output stop of the left steering brake solenoid circuit.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring
General
information
• Method of reproducing failure code: Engine start + Parking brake lever release

Defective left steering ON + Forward for troubleshooting.
1 brake fill switch FLB2 (male) PCCS lever Resistance
chassis ground Left steering Min. 1 Mz
2
causes and the wiring or defective contact Wiring harness between STCN2 (female) (35) Resis-
Max. 1 z
standard values in connector) – FLB2 (female) (1) tance
when normal a Prepare with starting switch OFF. Engine start + Pivot turn switch
ON + Forward for troubleshooting.
3
ler
Between (35) – N (Neutral) Max. 1 V
chassis ground Left steering 5 – 11 V
sure system
24 D475A, D475ASD-5E0
Failure code [2302NR] Left steering brake thermal load: Abnormal

heating 1
Action code Failure code Symptom of Left steering brake thermal load: Abnormal heating
Failure content travel speed and left steering potentiometer, and then judged that the left steering brake was heat-
ing abnormally (The machine traveled down with the foot brake pressed).
Controller's
action
Symptoms that
appear on
machine
General
information

Possible
Improper steering during downslope travel (Machine traveled down and was steered to left con-
causes and the 1
tinuously)
standard values
when normal Defective steering control-
2 When the operation in cause 1 is not performed
ler
D475A, D475ASD-5E0 25
Failure code [AA10NX] Air cleaner: Clogging 1

Action code Failure code Symptom of Air cleaner: Clogging
— AA10NX failure (Mechanical system)
Failure content • Clogging of air cleaner was detected while engine is running.
Controller's
• Blinks warning lamp and sounds alarm buzzer.
action
Symptoms that
appear on • If machine is used as it is, engine output may lower or engine may be damaged.
machine
General
• Air cleaner clogging caution symbol on monitor panel blinks and this failure code is recorded.
information

Clogged air cleaner
1 a Check air cleaner. If it is clogged, clean or replace it.
(When system is normal)
a Prepare with starting switch OFF, then start engine and carry out
Defective air cleaner clog- troubleshooting.
2 ging sensor (Internal dis- AF1, AF2 (male) Air cleaner Resistance
connection) When normal Max. 1z
Between (1) – (2)
When clogged Min. 1 Mz
Possible
causes and the
standard values Disconnection in wiring Wiring harness between S03 (female) (13) – Resis-
Max. 1z
when normal harness (Disconnection in AF1 (female) (1) tance
3
wiring or defective contact Wiring harness between AF1 (female) (2) – Resis-
in connector) Max. 1z
AF2 (female) (1) tance
Wiring harness between AF2 (female) (2) – Resis-
Max. 1z
chassis ground tance
troubleshooting.
4 Defective machine monitor S03 Air cleaner Voltage
Between (13) – When normal Max. 1V
chassis ground When clogged Min. 7 V
Electric circuit diagram related to air cleaner clogging
26 D475A, D475ASD-5E0
Failure code [AB00MA] Battery charge abnormality: Malfunction 1

Action code Failure code Symptom of Battery charge abnormality: Malfunction
— AB00MA failure (Mechanical system)
Failure content • Charge level circuit voltage lowered while engine is running.
Controller's
• Blinks warning lamp.
action
Symptoms that
appear on • If machine is used as it is, battery may be discharged.
machine
General • Charge level caution symbol on machine monitor blinks and this failure code is recorded.
information • Method of reproducing failure code: Start engine + Turn fuel control dial to full.

Possible
Battery charge defect Phenomenon causing battery charge defect may be occurring or
causes and the 1
(When system is normal) may have occurred. Check cause and damage condition and repair.
standard values
when normal Defective charge level Carry out troubleshooting for "Battery charge level caution lamp
2
caution lamp system blinks while engine is running" in E-mode.
D475A, D475ASD-5E0 27
Failure code [B@BAZG] Engine oil: Oil pressure too low 1

Action code Failure code Symptom of Engine oil: Oil pressure too low
— B@BAZG failure (Mechanical system)
Failure content • The engine oil pressure abnormality takes place during the engine running.
Controller's • Flashes warning lamp and turns on alarm buzzer. (Function of machine monitor)
action • Limits operation of engine.
Symptoms that • If the machine is operated in such a condition, the engine output may decrease and the engine
appear on may be damaged.
machine • After warning, engine speed is limited to medium (half).
• The engine oil pressure caution symbol on the machine monitor flashes and this failure code is
General
recorded.
information
• Duplication of failure code: Start the engine.

Reduction of engine oil It can be suspected that the problem causing the detection of engine
Possible
1 pressure oil pressure reduction is currently occurring or occurred in the past.
causes and the
(When system is normal) Investigate the cause and damage condition, and correct it.
standard values
when normal Carry out troubleshooting of engine oil pressure caution lamp sys-
Defective engine oil pres-
2 tem in accordance with‚ “While engine is running, emergency warn-
sure caution lamp circuit
ing item flashes” in E mode.
28 D475A, D475ASD-5E0
Failure code [B@BAZK] Engine oil: Oil level reduction 1

Action code Failure code Symptom of Engine oil: Oil level reduction
— B@BAZK failure (Mechanical system)
Failure content • During rotation of engine, engine oil level caution lamp flashes.
Controller's
• Flashes warning lamp and turns on caution buzzer. (Function of monitor panel)
action
Symptoms that
appear on • If machine is operated as it is, engine may be damaged.
machine
• The engine oil level caution symbol on the machine monitor flashes and this failure code is
General
recorded.
information
• Method of reproducing failure code: Start engine.

Engine oil level reduction It is suspected that problem causing engine oil level reduction is
Possible
1 (When system is in normal occurring at present or occurred in past. Investigate cause and dam-
causes and the
state) age condition, and correct it.
standard values
when normal Carry out troubleshooting of engine oil level caution lamp system in
Defective engine oil level
2 accordance with “During running of engine, emergency caution item
caution lamp system
flashes” in E mode.
D475A, D475ASD-5E0 29
Failure code [B@BCNS] Radiator coolant: Overheat 1

Action code Failure code Symptom of Radiator coolant: Overheat
— B@BCNS failure (Mechanical system)
Failure content • The radiator coolant becomes overheated during the engine running.
Controller's • Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel)
action • Limits operation of engine.
Symptoms that
• If the machine is operated in such a condition, engine may be damaged.
appear on
• After warning, engine output is limited to half of rated horsepower.
machine
• The engine coolant temperature caution symbol on the monitor panel flashes and this failure code
General
is recorded.
information
• Duplication of failure code: Start the engine.

It can be suspected that the problem causing a detection of coolant
Possible Coolant overheats
1 overheat is currently occurring or occurred in the past. Investigate
causes and the (When system is normal)
the cause and damage condition, and correct it.
standard values
when normal Defective engine coolant Carry out troubleshooting of coolant temperature caution lamp circuit
2 temperature caution lamp in accordance with “While engine is running, emergency warning
circuit item flashes” in E mode.
30 D475A, D475ASD-5E0
Failure code [B@BCZK] Radiator coolant: Level too low 1

Action code Failure code Symptom of Radiator coolant: Level too low
— B@BCZK failure (Mechanical system)
Failure content • Radiator coolant level decreases when starting switch is turned ON.
Controller's
• Flashes warning lamp and turns on alarm buzzer.
action
Symptoms that
appear on • If the machine is operated in such a condition, engine may be damaged.
machine
• The radiator coolant level caution symbol on the monitor panel flashes and this failure code is
General
recorded.
information
• Duplication of failure code: turn ON the starting switch.

Possible Radiator coolant level is It can be suspected that the problem causing the detection of radia-
causes and the 1 too low. tor coolant level too low is currently occurring or occurred in the past.
standard values (When system is normal) Investigate the cause and damage condition, and correct it.
when normal Defective radiator coolant Carry out troubleshooting in accordance with “When starting switch
2
level caution lamp circuit is turned ON, radiator coolant level caution flashes” in E mode.
D475A, D475ASD-5E0 31
Failure code [B@CENS] Power train oil: Overheat 1

Action code Failure code Symptom of Power train oil: Overheat
— B@CENS failure (Mechanical system)
Failure content • During rotation of engine, power train oil temperature caution lamp flashes.
Controller's
• Flashes warning lamp and turns on caution buzzer. (Function of machine monitor)
action
Symptoms that
appear on • If machine is operated as it is, power train may be damaged.
machine
General
information

Power train oil temperature It is suspected that problem causing power train oil temperature over-
Possible
1 overheat (When system is heat is occurring at present or occurred in past. Investigate cause and
causes and the
in normal state) damage condition, and correct it.
standard values
when normal 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
tion lamp system caution item flashes” in E mode.
32 D475A, D475ASD-5E0
Failure code [B@CHZG] Power train oil: Low oil pressure 1

Action code Failure code Symptom of Power train oil: Low oil pressure
— B@CHZG failure (Mechanical system)
Failure content • Power train oil pressure caution lamp blinks while engine is running.
Controller's
action
Symptoms that
appear on • If machine is used as it is, power train may be damaged.
machine
General
information

Possible Phenomenon causing power train oil pressure may be occurring or
1 lowers (When system is
causes and the may have occurred. Check cause and damage condition and repair.
normal)
standard values
when normal Defective power train oil
Carry out troubleshooting of power train oil pressure caution lamp in
2 pressure caution lamp sys-
"Emergency waning item blinks while engine is running" in E mode.
tem
D475A, D475ASD-5E0 33
Failure code [B@HANS] Hydraulic oil: Overheat 1

Action code Failure code Symptom of Hydraulic oil: Overheat
— B@HANS failure (Mechanical system)
Failure content • During rotation of engine, hydraulic oil caution lamp flashes.
Controller's
• Flashes warning lamp and turns on caution buzzer. (Function of machine monitor))
action
Symptoms that
appear on • If machine is operated as it is, work equipment circuit units may be damaged.
machine
• The hydraulic oil temperature caution symbol of the machine monitor flashes and this failure code
General
is recorded.
information

Hydraulic oil temperature It is suspected that problem causing hydraulic oil temperature over-
Possible
1 overheat (When system is heat is occurring at present or occurred in past. Investigate cause and
causes and the
in normal state) damage condition, and correct it.
standard values
when normal Defective hydraulic oil tem- Carry out troubleshooting of hydraulic oil temperature caution lamp
2 perature caution lamp sys- system in accordance with “During running of engine, emergency
tem caution item flashes” in E mode.
34 D475A, D475ASD-5E0
Failure code [B@HAZK] Hydraulic oil: Level reduction 1

Action code Failure code Symptom of Hydraulic oil: Level reduction
— B@HAZK failure (Mechanical system)
Failure content • During rotation of engine, hydraulic oil caution lamp flashes.
Controller's
• Flashes warning lamp and turns on caution buzzer. (Function of monitor panel)
action
Symptoms that
appear on • If machine is operated as it is, work equipment circuit units may be damaged.
machine
General
information

Hydraulic oil level reduc-It is suspected that problem causing hydraulic oil level reduction is
Possible
1 tion (When system is in occurring at present or occurred in past. Investigate cause and dam-
causes and the
normal state) age condition, and correct it.
standard values
when normal Carry out troubleshooting of hydraulic oil level caution lamp system in
Defective hydraulic oil
2 accordance with “During running of engine, emergency caution item
level caution lamp system
flashes” in E mode.
D475A, D475ASD-5E0 35
SEN01823-00

© 2006 KOMATSU
All Rights Reserved
36
SEN01824-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Failure code [CA111] Engine controller (Left bank): Internal abnormality ............................................ 4
Failure code [CB111] Engine controller (Right bank): Internal abnormality.......................................... 6
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank):
Abnormal speed sensor signal................................................................................................... 8
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank):
Abnormal speed sensor signal................................................................................................... 9
Failure code [CA122] Charge pressure sensor too high (At left bank only):
Excessively high voltage detected ........................................................................................... 10
Failure code [CA123] Charge pressure sensor too low (At left bank only):
Excessively low voltage detected ............................................................................................ 12
Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank):
High voltage detection ............................................................................................................. 13
D475A, D475ASD-5E0 1
Failure code [CA132] Decelerator pedal sensor too low (At left bank only):
Excessively low voltage detected............................................................................................. 15
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ...... 20
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Failure code [CA154] Charge temperature sensor too low (At left bank only):
Low voltage detection .............................................................................................................. 28
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank):
High voltage detection.............................................................................................................. 30
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank):
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Failure code [CA227] Sensor power source 2 too high (At left bank):
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed ...................... 40
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit..................................................... 50
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit .................................................. 51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection ............................................. 52
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection ........................................... 53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit..................................................... 54
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit .................................................. 55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection ............................................. 56
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection ........................................... 57
2 D475A, D475ASD-5E0

Failure code [CA111] Engine controller (Left bank): Internal
abnormality 1
Action code Failure code Symptom of Engine controller (Left bank): Internal abnormality
CALL E04 CA111 failure (Engine controller system)
Failure content • Controller has abnormality in it.
Controller's
action
Symptoms that
• Machine continues operation normally but may stop suddenly or may not able to start again once it
appear on
stops.
machine
General
information

Circuit breaker may be defective. Check it directly. (If fuse is broken
1 Defective circuit breaker
or circuit breaker is turned OFF, circuit probably has ground fault.)
Disconnection in wiring without turning starting switch ON.
harness (Disconnection Wiring harness between PW L (female) (3), Resis-
2 Max. 1 z
in wiring or defective (4) – battery (+) tance
Possible contact in connector) Wiring harness between PW L (female) (1), Resis-
causes and the Max. 1 z
(2) – ground tance
standard values
when normal a Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
3 harness (Contact with
GND circuit) Wiring harness between PW L (female) (3), Resis-
Min. 1 Mz
(4) – battery (+) tance
a Prepare with starting switch OFF, then turn starting switch ON and
Defective engine carry out troubleshooting.
4
controller PW L Voltage
Between (3), (4) – (1), (2) 20 – 30 V
4 D475A, D475ASD-5E0
Circuit diagram related to engine controller power supply
D475A, D475ASD-5E0 5
Failure code [CB111] Engine controller (Right bank): Internal

abnormality 1
Action code Failure code Symptom of Engine controller (Right bank): Internal abnormality
CALL E04 CB111 failure (Engine controller system)
Failure content • Controller has abnormality in it.
Controller's
action
Symptoms that
• Machine continues operation normally but may stop suddenly or may not able to start again once it
appear on
stops.
machine
General
information

Circuit breaker may be defective. Check it directly. (If fuse is broken
1 Defective circuit breaker
or circuit breaker is turned OFF, circuit probably has ground fault.)
harness (Disconnection Wiring harness between PW R (female) (3), Resis-
2 Max. 1 z
in wiring or defective (4) – battery (+) tance
Possible contact in connector) Wiring harness between PW R (female) (1), Resis-
(2) – ground tance
standard values
GND circuit) Wiring harness between PW R (female) (3), Resis-
Min. 1 Mz
(4) – battery (+) and ground tance
Defective engine carry out troubleshooting.
4
controller PW R Voltage
Between (3), (4) – (1), (2) 20 – 30 V
6 D475A, D475ASD-5E0
D475A, D475ASD-5E0 7
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At
left bank): Abnormal speed sensor signal 1
Action code Failure code Symptom of Abnormal engine Ne and Bkup speed sensors (At left bank): Abnor-
CALL E04 CA115 failure mal speed sensor signal (Engine controller system)
• Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
Failure content
cuit.
Controller's
action
Symptoms that
• Engine does not start (during engine stop).
appear on
• Engine stops (during engine running).
machine
General
information

Defective Ne speed
1 Carry out troubleshooting of [CA689].
sensor circuit
Defective Bkup speed
2 Carry out troubleshooting of [CA778].
sensor circuit
Since a mounting section of Ne speed sensor can be suspected to be
Defective Ne speed
3 defective, directly check the mounting section. (Defective installation
Possible sensor mounting section
of sensor itself, internal defect of flywheel, etc.)
causes and the
standard values Since a mounting section of Bkup speed sensor can be suspected to
Bkup speed sensor
when normal 4 be defective, directly check the mounting section. (Defective installa-
mounting section
tion of sensor itself, internal defect of supply pump, etc.)
Defective connection of
The defective (wrong) connections of Ne speed sensor and Bkup
5 sensor
speed sensor can be suspected. Directly check them.
(wrong connection)
Engine controller can be suspected to be defective if no problem is
Defective engine
6 found in causes 1 – 5 (since this is an internal defect, it cannot be
controller
diagnosed).
8 D475A, D475ASD-5E0
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At
right bank): Abnormal speed sensor signal 1
Action code Failure code Symptom of Abnormal engine Ne and Bkup speed sensors (At right bank): Abnor-
CALL E04 CB115 failure mal speed sensor signal (Engine controller system)
• Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
Failure content
cuit.
Controller's
action
Symptoms that
• Engine does not start (during engine stop).
appear on
• Engine stops (during engine running).
machine
General
information

Defective Ne speed
1 Carry out troubleshooting of [CB689].
sensor circuit
Defective Bkup speed
2 Carry out troubleshooting of [CB778].
sensor circuit
Since a mounting section of Ne speed sensor can be suspected to be
Defective Ne speed
3 defective, directly check the mounting section. (Defective installation
Possible sensor mounting section
of sensor itself, internal defect of flywheel, etc.)
causes and the
standard values Since a mounting section of Bkup speed sensor can be suspected to
Bkup speed sensor
when normal 4 be defective, directly check the mounting section. (Defective installa-
mounting section
tion of sensor itself, internal defect of supply pump, etc.)
Defective connection of
The defective (wrong) connections of Ne speed sensor and Bkup
5 sensor
speed sensor can be suspected. Directly check them.
(wrong connection)
Defective engine
controller
diagnosed).
D475A, D475ASD-5E0 9
Failure code [CA122] Charge pressure sensor too high (At left bank
only): Excessively high voltage detected 1
Action code Failure code Symptom of Charge pressure sensor too high (At left bank only): Excessively high
CALL E03 CA122 failure voltage detected (Engine controller system)
Failure content • Excessively high voltage is detected at circuit of charge pressure (boost pressure) sensor.
Controller's • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Acceleration performance of engine deteriorates.
machine
• The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
General
function. (Code: 36501 Boost pressure sensor voltage)
information

Defective sensor power If failure code [CA227] is displayed at the same time, carry out trou-
1
source circuit bleshooting for it first.
a Prepare with starting switch OFF, and diagnose with starting switch
ON or with engine started.
PIM Voltage
Defective charge pres-
2 sure (boost pressure) Between (1) – (2) Power source 4.75 – 5.25 V
sensor (internal defect) Since the sensor voltage is measured with the harness being con-
nected, if the voltage is abnormal, first check the harness and the con-
troller to make it sure if there is no other cause of the trouble, and then
judge the sensor voltage.
a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Disconnection in wiring Wiring harness between ENG (female) (37) – Resis-
harness Max. 1 z
PIM (female) (1) tance
3 (disconnection or defec-
Wiring harness between ENG (female) (44) – Resis-
tive contact of connec- Max. 1 z
tors) PIM (female) (3) tance
Max. 1 z
PIM (female) (2) tance
Possible a Prepare with starting switch OFF and diagnose with starting switch
causes and the still OFF.
standard values Defective harness Between ground and wiring harness between Resis-
when normal Min. 1 Mz
grounding ENG (female) (37) – PIM (female) (1) tance
4
(contact with ground Between ground and wiring harness between Resis-
Min. 1 Mz
circuit) ENG (female) (44) – PIM (female) (3) tance
Between ground and wiring harness between Resis-
Min. 1 Mz
ENG (female) (47) – PIM (female) (2) tance
still OFF.
Between wiring harness from ENG (female)
Resis-
(37) to PIM (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (44) to PIM (female) (3)
Harness short
5 Between wiring harness from ENG (female)
(Harness internal short) Resis-
tance
Resis-
tance
Defective engine ON or with engine started.
6
controller ENG Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
10 D475A, D475ASD-5E0
Circuit diagram related to charge pressure sensor
D475A, D475ASD-5E0 11
Failure code [CA123] Charge pressure sensor too low (At left bank
only): Excessively low voltage detected 1
Action code Failure code Symptom of Charge pressure sensor too low (At left bank only): Excessively low
CALL E03 CA123 failure voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at circuit of charge pressure (boost pressure) sensor.
Controller's • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
Symptoms that
appear on • Acceleration performance of engine deteriorates.
machine
• The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
General
function. (Code: 36501 Boost pressure sensor voltage)
information
causes and the
standard values Defective sensor power If failure code [CA187] is displayed at the same time, carry out trou-
1
when normal
12 D475A, D475ASD-5E0
Failure code [CA131] Decelerator pedal sensor abnormally high level

(Only left bank): High voltage detection 1
Action code Failure code Symptom of Decelerator pedal sensor abnormally high level (Only left bank): High
CALL E03 CA131 failure voltage detection (Engine controller system)
Failure content • High voltage was detected in decelerator pedal signal circuit.
• If abnormality occurs while starting switch is ON, controller fixes sensor to value just before occur-
rence of abnormality and continues operation.
Controller's
• If starting switch is turned ON while there is abnormality, controller fixes sensor to 100% value and
action
continues operation.
Symptoms that
appear on • Engine speed cannot be controlled with decelerator pedal.
machine
• Decelerator pedal signal voltage can be checked with monitoring function
General
(Code: 31703 Decelerator voltage)
information
• Method of reproducing failure code: Turn starting switch ON.

Defective decelerator
If failure code [CA2185] is also displayed, carry out troubleshooting
1 sensor power supply
for it first.
system
Defective decelerator DEC (male) Resistance
2
sensor (Internal defect) Between (A) – (C) 4.0 – 6.0 kz
Between (B) – (A) 0.25 – 5.0 kz
Between (B) – (C) 0.25 – 5.0 kz
Disconnection in wiring Wiring harness between OEM L (female) (22) Resis-
Max. 1z
harness (Disconnection – DEC (female) (A) tance
Possible 3
in wiring or defective con- Wiring harness between OEM L (female) (9) – Resis-
causes and the Max. 1z
tact in connector) DEC (female) (B) tance
standard values
when normal Wiring harness between OEM L (female) (23) Resis-
Max. 1z
– DEC (female) (C) tance
Wiring harness between OEM L (female) (22) Resis-
Ground fault in wiring Min. 1 Mz
– DEC (female) (A) tance
Wiring harness between OEM L (female) (9) – Resis-
GND circuit) Min. 1 Mz
DEC (female) (B) tance
Min. 1 Mz
carry out troubleshooting.
Defective engine OEM L Voltage
5
controller
Between (22) – (23) Power supply 4.75 – 5.25 V
Between (9) – (23) Signal 0.5 – 4.5 V
D475A, D475ASD-5E0 13
Circuit diagram related to decelerator pedal sensor
14 D475A, D475ASD-5E0
Failure code [CA132] Decelerator pedal sensor too low (At left bank
Action code Failure code Symptom of Decelerator pedal sensor too low: excessively low voltage detected
CALL E03 CA132 failure (At left bank only) (Engine controller system)
Failure content • Excessively low voltage is detected at signal circuit of decelerator pedal.
• Operates with the fixed value that is same as the value just before the abnormality is detected, if
abnormality occurs with the starting switch in the ON position.
Controller's
• If the starting switch is turned to the ON position in as-is abnormal condition, the controller oper-
action
ates with 100% value.
Symptoms that
appear on • Engine speed cannot be controlled by decelerator pedal.
machine
• The signal voltage of decelerator pedal can be checked in monitoring mode.
General
(Code: 31703 Decelerator voltage)
information
causes and the Defective decelerator
If failure code [CA2186] is displayed at the same time, carry out trou-
standard values 1 pedal sensor power sup-
when normal bleshooting for it first.
ply circuit
D475A, D475ASD-5E0 15
Excessively high voltage detected 1
Action code Failure code Symptom of Oil pressure sensor too high (At left bank only): Excessively high volt-
CALL E02 CA135 failure age detected (Engine controller system)
Failure content • Excessively high voltage is detected at oil pressure sensor circuit.
Controller's • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Symptoms that
appear on
machine
• The signal voltage of engine oil pressure sensor can be checked in monitoring function.
General
(Code: 37201 Engine oil pressure sensor voltage)
information

Defective sensor power If failure code [CA187] or [CA227] is displayed at the same time, carry
1
source circuit out troubleshooting for it first.
ON or with engine started.
POIL Voltage
Defective oil pressure
2 sensor Between (1) – (2) Power source 4.75 – 5.25 V
(internal defect) Since the sensor voltage is measured with the harness being con-
still OFF.
harness Max. 1 z
POIL (female) (1) tance
tors) POIL (female) (2) tance
Max. 1 z
POIL (female) (3) tance
standard values Defective harness Between ground and wiring harness between Resis-
grounding ENG (female) (37) – POIL (female) (1) tance
4
(contact with ground cir- Between ground and wiring harness between Resis-
Min. 1 Mz
cuit) ENG (female) (47) – POIL (female) (2) tance
Min. 1 Mz
ENG (female) (13) – POIL (female) (3) tance
still OFF.
Resis-
(37) to POIL (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (47) to POIL (female) (2)
Harness short
5
(Harness internal short) Between wiring harness from ENG (female) Resis-
tance
Resis-
tance
Defective engine control- ON or with engine started.
6
ler ENG Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
16 D475A, D475ASD-5E0
Circuit diagram related to oil pressure sensor
D475A, D475ASD-5E0 17
Excessively low voltage detected 1
Action code Failure code Symptom of Oil pressure sensor too low (At left bank only): Excessively low volt-
CALL E03 CA132 failure age detected (At left bank only) (Engine controller system)
Failure content • Excessively low voltage is detected at oil pressure sensor circuit.
Controller's • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Symptoms that
appear on
machine
• The signal voltage of engine oil pressure sensor can be checked in monitoring function.
General
(Code: 37201 Engine oil pressure sensor voltage)
information
causes and the
standard values Defective sensor power If failure code [CA187] is displayed at the same time, carry out trou-
1
when normal
18 D475A, D475ASD-5E0
Failure code [CA144] Coolant temperature sensor too high: Excessively

high voltage detected 1
Action code Failure code Symptom of Coolant temperature sensor too high: Excessively high voltage
E01 CA144 failure detected (Engine controller system)
Failure content • Excessively high voltage is detected at signal circuit of coolant temperature sensor.
Controller's • Operates with a fixed coolant temperature (90°C).
Symptoms that
appear on • Exhaust gas color becomes white.
machine
• The signal voltage of coolant temperature sensor can be checked in monitoring function.
General
(Code: 04105 Coolant temperature sensor voltage)
information

Defective coolant still OFF.
1 temperature sensor
TWTR (male) Coolant temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Disconnection in wiring still OFF.
harness
2 (disconnection or Max. 1 z
TWTR (female) (A) tance
defective contact of
connectors) Wiring harness among ENG (female) (38) – Resis-
Max. 1 z
JB – TWTR (female) (B) tance
Possible still OFF.
Harness short
causes and the 3 Between ENG (female) (15) – all pins of ENG
standard values (female) (with all connectors in the harness Min. 1 Mz
tance
when normal disconnected)
Since the connections among coolant temperature sensor – engine
harness – engine controller are suspected to be defective, check for a
defective connection.
Defective wiring harness
4 • Connector is loose, lock is broken, seal is broken
connector
• Pin is corroded, bent, broken, pushed in, expanded.
• Moisture in connector, entry of dirt or sand, etc., and insufficient
insulation
Defect in other locations still OFF.
5
than engine controller ENG (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
Defective engine Engine controller is possibly defective if no problem is found in causes
6
controller 1 – 5. (Since this is an internal defect, it cannot be diagnosed.)
20 D475A, D475ASD-5E0
Circuit diagram related to coolant temperature sensor
D475A, D475ASD-5E0 21
Failure code [CA145] Coolant temperature sensor too low (At left bank
Action code Failure code Symptom of Coolant temperature sensor too low (At left bank only): Excessively
E01 CA145 failure low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at signal circuit of coolant temperature sensor.
Controller's • Operates with a fixed coolant temperature (90°C).
Symptoms that
machine
General • The signal voltage of coolant temperature sensor can be checked in monitoring function.
information (Code: 04105 Coolant temperature sensor voltage)

Defective coolant still OFF.
1 temperature sensor
TWTR (male) Coolant temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Defective harness
still OFF.
2 grounding (contact with
ground circuit) Min. 1 Mz
ENG (female) (15) – TWTR (female) (A) tance
still OFF.
Harness short
Possible 3 Between ENG (female) (15) – all pins of ENG
causes and the (female) (with all connectors in the harness Min. 1 Mz
tance
standard values disconnected)
when normal Since the connections among coolant temperature sensor – engine
harness – engine controller are suspected to be defective, check for a
defective connection.
connector
insulation
5
than engine controller ENG (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
6
22 D475A, D475ASD-5E0
Circuit diagram related to coolant temperature sensor
D475A, D475ASD-5E0 23
Failure code [CA153] Charge temperature sensor too high (At left bank
only): Excessively high voltage detected 1
Action code Failure code Symptom of Charge temperature sensor too high (At left bank only): Excessively
E01 CA153 failure high voltage detected. (Engine controller system)
• Excessively high voltage is detected at signal circuit of charge temperature (boost temperature)
Failure content
sensor.
Controller's
• Operates with a fixed charge temperature (boost temperature) (70°C).
action
Symptoms that
machine
• The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
General
monitoring function. (Code: 18501 Boost temperature sensor voltage)
information

Defective charge temper- still OFF.
1 ature (boost temperature) TIM (male) Air boost temperature Resistance
sensor (internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground In all range Min. 1 Mz
harness (disconnection Wiring harness between ENG (female) (23) – Resis-
2 Max. 1 z
or defective contact of TIM (female) (A) tance
connectors) Wiring harness between ENG (female) (47) – Resis-
Max. 1 z
JB – TIM (female) (B) tance
Possible still OFF.
causes and the Harness short
3 Between ENG (female) (23) – all pins of ENG
standard values (Harness internal short) Resis-
(female) (with all connectors in the harness Min. 1 Mz
when normal tance
disconnected)
Since the connections among charge temperature (boost tempera-
ture) sensor – engine harness – engine controller are suspected to be
defective, check for a defective connection.
connector
insulation
5
than engine controller ENG (female) Air boost temperature Resistance
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
6
24 D475A, D475ASD-5E0
Circuit diagram related to charge temperature sensor
D475A, D475ASD-5E0 25
Failure code [CA154] Charge temperature sensor too low (At left bank
Action code Failure code Symptom of Charge temperature sensor too low (At left bank only): Excessively
E01 CA154 failure low voltage detected (Engine controller system)
• Excessively low voltage is detected at signal circuit of charge temperature (boost temperature)
Failure content
sensor.
Controller's
• Operates with a fixed charge temperature (boost temperature) (70°C).
action
Symptoms that
machine
• The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
General
monitoring function. (Code: 18501 Boost temperature sensor voltage)
information

Defective charge temper- still OFF.
1 ature (boost temperature) TIM (male) Air boost temperature Resistance
sensor (internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground In all range Min. 1 Mz
Defective harness
still OFF.
ground circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
ENG (female) (23) – TIM (female) (A) tance
still OFF.
Harness short
Possible 3 Between ENG (female) (23) – all pins of ENG
causes and the (female) (with all connectors in the harness Min. 1 Mz
tance
standard values disconnected)
when normal Since the connections among charge temperature (boost tempera-
ture) sensor – engine harness – engine controller are suspected to be
defective, check for a defective connection.
connector
insulation
still OFF.
Defect in other locations
5 ENG (female) Air boost temperature Resistance
than engine controller
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
Between (23) – ground In all range Min. 1 Mz
6
26 D475A, D475ASD-5E0
Circuit diagram related to charge temperature sensor
D475A, D475ASD-5E0 27
Failure code [CA187] Sensor power supply (2) abnormally low level
(Left bank): Low voltage detection 1
Action code Failure code Symptom of Sensor power supply (2) abnormally low level (Left bank): Low voltage
CALL E03 CA187 failure detection (Engine controller system)
Failure content • Low voltage was detected in sensor power supply (2) (5 V) circuit.
• Ambient pressure sensor sets ambient temperature to default value (52.44 kPa {0.5 kg/cm2}) and
• Oil pressure sensor sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues opera-
Controller's
tion.
action
• Charge pressure sensor fixes charge pressure to (400 kPa {4.1 kg/cm2}) and continues operation.
• Bkup sensor operates with Ne speed sensor signal.
Symptoms that
appear on • Output lowers.
machine
General
information
causes and the
standard values Carry out troubleshooting for failure code [CA227].
when normal
28 D475A, D475ASD-5E0
Failure code [CB187] Sensor power supply (2) abnormally low level
(Right bank): Low voltage detection 1
Action code Failure code Symptom of Sensor power supply (2) abnormally low level (Right bank): Low volt-
CALL E03 CA187 failure age detection (Engine controller system)
Controller's • Bkup sensor operates with Ne speed sensor signal.
action • Blinks warning lamp and sounds alarm buzzer.
Symptoms that
machine
General
information
causes and the
standard values Carry out troubleshooting for failure code [CB227].
when normal
D475A, D475ASD-5E0 29
Failure code [CA212] Engine oil temperature sensor abnormally high

level (Only left bank): High voltage detection 1
Action code Failure code Symptom of Engine oil temperature sensor abnormally high level (Only left bank):
E01 CA212 failure High voltage detection (Engine controller system)
Failure content • High voltage was detected in engine oil temperature sensor circuit.
Controller's
• Sets oil temperature to default value (100°C) and continues operation.
action
Symptoms that
appear on
machine
General
information

Defective oil temperature without turning starting switch ON.
1
sensor (Internal defect) TOIL (male) Oil temperature Resistance
Between (A) – (B) 0 – 100°C 0.5 – 36 kz
harness (Disconnection Wiring harness between ENG (female) (17) – Resis-
Possible 2 Max. 1 z
in wiring or defective con- TOIL (female) (A) tance
causes and the
tact in connector) Wiring harness between ENG (female) (47) – Resis-
standard values Max. 1 z
when normal TOIL (female) (B) tance
Ground fault in wiring
TOIL (female) (A) tance
Defective engine control- without turning starting switch ON.
4
ler ENG Oil temperature Resistance
(17) – (47) 0 – 100°C 0.5 – 36 kz
Circuit diagram related to engine oil temperature sensor
30 D475A, D475ASD-5E0
Failure code [CA213] Engine oil temperature sensor abnormally low

level (Only left bank): Low voltage detection 1
Action code Failure code Symptom of Engine oil temperature sensor abnormally low level (Only left bank):
E01 CA213 failure Low voltage detection (Engine controller system)
Failure content • Low voltage was detected in engine oil temperature sensor circuit.
Controller's
• Sets oil temperature to default value (100°C) and continues operation.
action
Symptoms that
appear on
machine
General
information
causes and the
when normal
D475A, D475ASD-5E0 31
Failure code [CA221] Atmospheric pressure sensor too high (At left
bank only): Excessively high voltage detected 1
Action code Failure code Symptom of Atmospheric pressure sensor too high (At left bank only): Excessively
CALL E03 CA213 failure high voltage detected (Engine controller system)
Failure content • Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
Controller's • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Symptoms that
appear on • Output decreases.
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
General
(Code: 37401 Atmospheric pressure sensor voltage)
information

Defective sensor power If failure code [CA352] or [CA386] is displayed at the same time, carry
1
source circuit out troubleshooting for it first.
ON.
PAMB Voltage
Defective atmospheric Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal 0.5 – 4.5 V
still OFF.
Max. 1 z
harness (disconnection PAMB (female) (1) tance
3
or defective contact of Wiring harness between ENG (female) (3) – Resis-
Max. 1 z
connectors) PAMB (female) (2) tance
Possible
causes and the Wiring harness between ENG (female) (38) – Resis-
Max. 1 z
standard values PAMB (female) (3) tance
when normal a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Defective harness Min. 1 Mz
ENG (female) (37) – PAMB (female) (1) tance
Min. 1 Mz
Min. 1 Mz
still OFF.
Resis-
(37) to PAMB (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (3) to PAMB (female) (2)
Harness short
5 Between wiring harness from ENG (female)
tance
Resis-
tance
32 D475A, D475ASD-5E0

Possible a Prepare with starting switch OFF, and diagnose with starting switch
causes and the ON or with engine started.
standard values Defective engine ENG Voltage
6
when normal controller
Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.5 – 4.5 V
Circuit diagram related to atmospheric pressure sensor
D475A, D475ASD-5E0 33
Failure code [CA222] Atmospheric pressure sensor too low (At left bank
Action code Failure code Symptom of Atmospheric pressure sensor too low (At left bank only): Excessively
CALL E03 CA222 failure low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
Controller's • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Symptoms that
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
General
(Code: 37401 Atmospheric pressure sensor voltage)
information
causes and the
standard values Carry out troubleshooting of failure code [CA221].
when normal
34 D475A, D475ASD-5E0
Failure code [CA227] Sensor power source (2) too high (At left bank):
Action code Failure code Symptom of Sensor power source (2) too high (At left bank): Excessively high volt-
CALL E03 CA227 failure age detected (Engine controller system)
Failure content • Excessively high voltage is detected in sensor power source (2) (5V) circuit.
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
• Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm2})
Controller's
• Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2})
action
• Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}).
Symptoms that
machine
General
information

Check the codes that are displayed at the same time. If any other
1 Defective related circuits
codes are displayed, carry out troubleshooting for those codes.
ON.
Bkup speed sensor G connector
Disconnect the
Engine oil pressure
Defective sensor devices on the right POIL connector
2 sensor
(internal defect) one at a time.
If the code disap- Atmospheric pressure
PAMB connector
pears, that device is sensor
internally defective. Charge pressure sen-
PIM connector
sor
harness
3 (disconnection or defec- Max. 1 z
Possible each sensor (female) tance
tive contact of connec-
causes and the tors) Wiring harness between ENG (female) (47) – Resis-
each sensor (female) tance
Defective harness still OFF.
grounding Between ground and wiring harness between Resis-
4 Min. 1 Mz
(contact with ground cir- ENG (female) (37) – each sensor (female) tance
cuit) Between ground and wiring harness between Resis-
Min. 1 Mz
ENG (female) (47) – each sensor (female) tance
still OFF.
Harness short Between wiring harness from ENG (female)
5
(Harness internal short) (37) to each sensor (female) and wiring har- Resis-
Min. 1 Mz
ness from ENG (female) (47) to each sensor tance
(female)
Defective engine control- ON.
6
ler ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
36 D475A, D475ASD-5E0
Circuit diagram related to sensor power source (2) (5V)
D475A, D475ASD-5E0 37
Failure code [CB227] Sensor power supply (2) abnormally high level
(Right bank): High voltage detection 1
Action code Failure code Symptom of Sensor power supply (2) abnormally high level (Right bank): High volt-
CALL E03 CB227 failure age detection (Engine controller system)
Failure content • High voltage was detected in sensor power supply (2) (5 V) circuit.
Controller's
• Bkup speed sensor operates with Ne speed sensor signal.
action
Symptoms that
machine
General
information

1 Related defective system If another code is also displayed, carry out troubleshooting for it.
Defective sensor (Inter- When device at right
2 is disconnected, if
nal defect) Bkup speed
error code disappears, G connector
sensor
that device has defect
in it.
3 Max. 1 z
in wiring or defective con- each sensor (female) tance
tact in connector) Wiring harness between ENG (female) (47) – Resis-
Possible Max. 1 z
causes and the
standard values
when normal Ground fault in wiring
4 harness (Contact with Min. 1 Mz
GND circuit)
Min. 1 Mz
Short circuit in wiring har-
5 ness (with another wiring Between wiring harness from ENG (female)
harness) (37) to each sensor (female) and wiring har- Resis-
Min. 1 Mz
ness from ENG (female) (47) to each sensor tance
(female)
Defective engine control- carry out troubleshooting.
6
ler ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
38 D475A, D475ASD-5E0
Circuit diagram related to sensor power source (2) (At right bank)
D475A, D475ASD-5E0 39
Failure code [CA234] Engine over speed (At left bank only): Excessively
high speed 1
Action code Failure code Symptom of Engine over speed (At left bank only): Excessively high speed
— CA234 failure (Engine controller system)
• The engine speed exceeds upper control limit speed.
Failure content
Controller's
• Stops operation of injector until the engine speed drops to the normal speed.
action
Symptoms that
appear on • Engine speed fluctuates.
machine
• The engine speed can be checked in monitoring function.
General
(Code: 01000 Engine speed)
information
• Duplication of failure code: Start engine and operate at high idle.

Possible codes are displayed, carry out troubleshooting for those codes.
causes and the The improper usage of equipped machine can be suspected. Instruct
standard values 2 Improper usage
the proper usage.
when normal Engine controller can be suspected to be defective if no problem is
Defective engine
controller
diagnosed).
40 D475A, D475ASD-5E0
Failure code [CA238] Abnormal power source for Ne speed sensor (At
left bank only): Excessively low voltage detected 1
Action code Failure code Symptom of Abnormal power source for Ne speed sensor (At left bank only):
CALL E03 CA238 failure Excessively low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controller's • Controls using Bkup speed sensor signal.
Symptoms that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information

still OFF.
Defective Ne speed sen- Disconnect a device
1 sor shown on the right.
(internal defect) If the failure code dis- Ne speed sensor Ne connector
appears, that device is
internally defective.
harness
Wiring harness between left bank ENG Resis-
(female) (16) – Ne (female) (1) tance
tors) Wiring harness between left bank ENG Resis-
Max. 1 z
Possible (female) (48) – Ne (female) (2) tance
causes and the a Prepare with starting switch OFF and diagnose with starting switch
standard values Defective harness still OFF.
when normal grounding Between ground and wiring harness between Resis-
3 Min. 1 Mz
(contact with ground cir- left bank ENG (female) (16) – Ne (female) (1) tance
Min. 1 Mz
left bank ENG (female) (48) – Ne (female) (2) tance
still OFF.
Harness short Between wiring harness from left bank ENG
4
(Harness internal short) (female) (16) to Ne (female) (1) and wiring Resis-
Min. 1 Mz
harness from left bank ENG (female) (48) to tance
Ne (female) (2)
5
ler Left bank ENG Voltage
Between (16) – (48) 4.75 – 5.25 V
42 D475A, D475ASD-5E0
Circuit diagram related to Ne speed sensor power source
D475A, D475ASD-5E0 43
Failure code [CB238] Abnormal power source for Ne speed sensor (At
right bank only): Excessively low voltage detected 1
Action code Failure code Symptom of Abnormal power source for Ne speed sensor (At right bank only):
CALL E03 CB238 failure Excessively low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controller's • Controls using Bkup speed sensor signal.
Symptoms that
appear on
machine
General
information

still OFF.
Defective Ne speed sen- Disconnect a device
1 sor shown on the right.
(internal defect) If the failure code dis- Ne speed sensor Ne connector
appears, that device is
internally defective.
harness
Wiring harness between left bank ENG Resis-
tors) Wiring harness between right bank ENG Resis-
Max. 1 z
Possible
standard values Defective harness
when normal Between ground and wiring harness between Resis-
grounding Min. 1 Mz
3 left bank ENG (female) (16) – Ne (female) (1) tance
(contact with ground cir-
cuit) Between ground and wiring harness between
Resis-
right bank ENG (female) (48) – Ne (female) Min. 1 Mz
tance
(2)
still OFF.
Harness short Between wiring harness from left bank ENG
4
(Harness internal short) (female) (16) to Ne (female) (1) and wiring Resis-
Min. 1 Mz
harness from right bank ENG (female) (48) to tance
Ne (female) (2)
5
ler Between left bank ENG (16) – Voltage
right bank ENG (48) 4.75 – 5.25 V
44 D475A, D475ASD-5E0
Circuit diagram related to Ne speed sensor power source
D475A, D475ASD-5E0 45
Action code Failure code Symptom of Fuel temperature sensor too high (At left bank): Excessively high volt-
E01 CA263 failure age detected (Engine controller system)
Failure content • Excessively high voltage is detected at fuel temperature sensor circuit.
Controller's
• Operates with a fixed fuel temperature (95°C).
action
Symptoms that
appear on
machine
General • The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
information (Code: 14201 Engine fuel temperature sensor voltage)

Defective fuel tempera- still OFF.
1 ture sensor (internal
TFUEL (male) Fuel temperature Resistance
defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
harness
Possible 2 (disconnection or defec- Max. 1 z
TFUEL (female) (A) tance
causes and the tive contact of connec-
tors) Wiring harness between ENG (female) (47) – Resis-
when normal TFUEL (female) (B) tance
3 Min. 1 Mz
(contact with ground cir- ENG (female) (30) – TFUEL (female) (A) tance
cuit) a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Defective engine control- ENG (female) Fuel temperature Resistance
4
ler Between (30) – (47) 10 – 100°C 0.6 – 20 kz
46 D475A, D475ASD-5E0
Circuit diagram related to fuel temperature sensor
D475A, D475ASD-5E0 47
Action code Failure code Symptom of Fuel temperature sensor too high (At right bank): Excessively high
E01 CB263 failure voltage detected (Engine controller system)
Failure content • Excessively high voltage is detected at fuel temperature sensor circuit.
Controller's
• Operates with a fixed fuel temperature (95°C).
action
Symptoms that
appear on
machine
General • The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
information (Code: 14201 Engine fuel temperature sensor voltage)

Defective fuel tempera- still OFF.
1 ture sensor (internal
TFUEL (male) Fuel temperature Resistance
defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
harness
Possible 2 (disconnection or defec- Max. 1 z
TFUEL (female) (A) tance
causes and the tive contact of connec-
tors) Wiring harness between ENG (female) (47) – Resis-
when normal TFUEL (female) (B) tance
3 Min. 1 Mz
(contact with ground cir- ENG (female) (30) – TFUEL (female) (A) tance
cuit) a Prepare with starting switch OFF and diagnose with starting switch
still OFF.
Defective engine control- ENG (female) Fuel temperature Resistance
4
ler Between (30) – (47) 10 – 100°C 0.6 – 20 kz
Circuit diagram related to fuel temperature sensor
48 D475A, D475ASD-5E0
Failure code [CA265] Fuel temperature sensor abnormally low level

Action code Failure code Symptom of Fuel temperature sensor abnormally low level (Left bank): Low volt-
E01 CA265 failure age detection (Engine controller system)
Failure content • Low voltage was detected in fuel temperature sensor circuit.
• Substitutes coolant temperature sensor.
Controller's
• If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and
action
Symptoms that
appear on
machine
General
information
causes and the
when normal
Failure code [CB265] Fuel temperature sensor abnormally low level

Action code Failure code Symptom of Fuel temperature sensor abnormally low level (Right bank): Low volt-
E01 CB265 failure age detection (Engine controller system)
Failure content • Low voltage was detected in fuel temperature sensor circuit.
• Substitutes coolant temperature sensor.
Controller's
• If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95°C) and
action
Symptoms that
appear on
machine
General
information
causes and the
when normal
D475A, D475ASD-5E0 49
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit 1
Action code Failure code Symptom of PCV1 short circuit (Left bank): Short circuit
Failure content • Short circuit occurred in supply pump PCV1 circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

Defective supply pump without turning starting switch ON.
1 PCV1 PCV1 (male) Resistance
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – ground Min. 1 Mz
PCV1 (female) (1) tance
Possible GND circuit)
causes and the Min. 1 Mz
standard values
when normal a Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Contact with
Wiring harness between ENG (female) (4) –
3 24V circuit) in wiring Voltage Max. 1 V
PCV1 (female) (1)
harness
Voltage Max. 1 V
PCV1 (female) (2)
Defective engine
4 ENG (female) Resistance
controller
Between (4) – (5) 2.3 – 5.3 z
Circuit diagram related to supply pump PCV1
50 D475A, D475ASD-5E0
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit 1
Action code Failure code Symptom of PCV1 short circuit (Right bank): Short circuit
Controller's
action
Symptoms that
appear on
machine
General
information

standard values
PCV1 (female) (1)
harness
Voltage Max. 1 V
PCV1 (female) (2)
Defective engine
controller
Between (4) – (5) 2.3 – 5.3 z
D475A, D475ASD-5E0 51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection 1

Action code Failure code Symptom of PCV1 disconnection (Left bank): Disconnection
Failure content • Disconnection occurred in supply pump PCV1 circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective PCV1 (female) (1) tance
Possible contact in connector) Wiring harness between ENG (female) (5) – Resis-
standard values
GND circuit)
Min. 1 Mz
Defective engine
controller
Between (4) – (5) 2.3 – 5.3 z
52 D475A, D475ASD-5E0
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection1

Action code Failure code Symptom of PCV1 disconnection (Right bank): Disconnection
Controller's
action
Symptoms that
appear on
machine
General
information

(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective PCV1 (female) (1) tance
Possible contact in connector) Wiring harness between ENG (female) (5) – Resis-
standard values
GND circuit)
Min. 1 Mz
Defective engine
controller
Between (4) – (5) 2.3 – 5.3 z
D475A, D475ASD-5E0 53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit 1
Action code Failure code Symptom of PCV2 short circuit (Left bank): Short circuit
Controller's
action
Symptoms that
appear on
machine
General
information

standard values
PCV2 (female) (1)
harness
Voltage Max. 1 V
PCV2 (female) (2)
Defective engine
controller
Between (9) – (10) 2.3 – 5.3 z
54 D475A, D475ASD-5E0
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit 1
Action code Failure code Symptom of PCV2 short circuit (Right bank): Short circuit
Controller's
action
Symptoms that
appear on
machine
General
information

standard values
PCV2 (female) (1)
harness
Voltage Max. 1 V
PCV2 (female) (2)
Defective engine
controller
Between (9) – (10) 2.3 – 5.3 z
D475A, D475ASD-5E0 55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection 1

Action code Failure code Symptom of PCV2 disconnection (Left bank): Disconnection
Controller's
action
Symptoms that
appear on
machine
General
information

1 PCV2 (Internal discon-
PCV2 (male) Resistance
nection)
Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective con- PCV2 (female) (1) tance
Possible tact in connector) Wiring harness between ENG (female) (10) – Resis-
Max. 1 z
causes and the PCV2 (female) (2) tance
standard values a Prepare with starting switch OFF, then carry out troubleshooting
when normal without turning starting switch ON.
GND circuit)
Min. 1 Mz
Defective engine control-
ler
Between (9) – (10) 2.3 – 5.3 z
56 D475A, D475ASD-5E0
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection1

Action code Failure code Symptom of PCV2 disconnection (Right bank): Disconnection
Controller's
action
Symptoms that
appear on
machine
General
information

1 PCV2 (Internal discon-
PCV2 (male) Resistance
nection)
Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
in wiring or defective con- PCV2 (female) (1) tance
Possible tact in connector) Wiring harness between ENG (female) (10) – Resis-
Max. 1 z
causes and the PCV2 (female) (2) tance
GND circuit)
Min. 1 Mz
Defective engine control-
ler
Between (9) – (10) 2.3 – 5.3 z
D475A, D475ASD-5E0 57
SEN01824-00

© 2006 KOMATSU
All Rights Reserved
58
SEN01825-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (At left bank):
Disconnection, short circuit ........................................................................................................ 4
Disconnection, short circuit ...................................................................................................... 10
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch.................................. 16
D475A, D475ASD-5E0 1
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch ............................... 17
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit ........................ 18
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality.................. 20
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank):
Failure code [CA441] Power supply voltage abnormally low level (Left bank):
Failure code [CB441] Power supply voltage abnormally low level (Right bank):
Failure code [CA442] Power supply voltage abnormally high level (Left bank):
Failure code [CB442] Power supply voltage abnormally high level (Right bank):
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank):
Abnormally high pressure occurrence...................................................................................... 30
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank):
Abnormally high pressure occurrence...................................................................................... 30
Failure code [CA451] Common rail pressure sensor too high (At left bank):
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank):
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank):
Abnormally low voltage detection............................................................................................. 36
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank):
Abnormally low voltage detection............................................................................................. 36
Excessively high pressure detected......................................................................................... 37
Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure
detected ................................................................................................................................... 38
Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error.....39
Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error ..39
Loss of pressure feed detected................................................................................................ 40
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal ................ 48
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal.............. 50
Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank):
Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank):
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase....55
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase .55
2 D475A, D475ASD-5E0

Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or
short circuit (At left bank): Disconnection, short circuit 1
Action code Failure code Symptom of Injector No. 1 (L/B No.1) system disconnection or short circuit (At left
CALL E03 CA322 failure bank): Disconnection, short circuit (Engine controller system)
Failure content • A disconnection or short circuit has occurred in injector No. 1 circuit.
Controller's
action
Symptoms that
• Output decreases.
appear on
• Speed is not stable.
machine
General
information

a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Defective injector No. 1
1 CN1 (male) Resistance
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
Between (1), (2) and ground Min. 1 Mz
Disconnection in wiring switch still OFF.
harness Wiring harness between ENG (female) (45) – Resis-
2 Max. 1 z
(disconnection or defective CN1 (female) (1) tance
contact of connectors) Wiring harness between ENG (female) (53) – Resis-
Possible Max. 1 z
CN1 (female) (2) tance
causes and the
standard values a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
when normal Defective harness
3 grounding (contact with Min. 1 Mz
ENG (female) (45) – CN1 (female) (1) tance
ground circuit)
Min. 1 Mz
Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry
4
injector or wiring harness out troubleshooting for them, too.
switch still OFF.
5 Defective engine controller ENG (female) Resistance
Between (45) – (53) 0.4 – 1.1 z
4 D475A, D475ASD-5E0
Circuit diagram related to injector No. 1
D475A, D475ASD-5E0 5

Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
Defective injector No. 5 CN5 (male) Resistance
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Possible Max. 1 z
causes and the
switch still OFF.
when normal Defective harness
3 grounding (contact with Min. 1 Mz
ground circuit)
Min. 1 Mz
4
switch still OFF.
Between (46) – (60) 0.4 – 1.1 z
6 D475A, D475ASD-5E0
D475A, D475ASD-5E0 7

Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Possible Max. 1 z
causes and the
switch still OFF.
when normal Defective harness ground-
3 ing (contact with ground Min. 1 Mz
circuit)
Min. 1 Mz
4
switch still OFF.
Between (55) – (52) 0.4 – 1.1 z
8 D475A, D475ASD-5E0
D475A, D475ASD-5E0 9

Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Possible Max. 1 z
causes and the
switch still OFF.
circuit)
Min. 1 Mz
4
switch still OFF.
Between (57) – (59) 0.4 – 1.1 z
10 D475A, D475ASD-5E0
D475A, D475ASD-5E0 11

Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Possible Max. 1 z
causes and the
switch still OFF.
circuit)
Min. 1 Mz
4
switch still OFF.
Between (54) – (51) 0.4 – 1.1 z
12 D475A, D475ASD-5E0
D475A, D475ASD-5E0 13

Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Possible Max. 1 z
causes and the
switch still OFF.
circuit)
Min. 1 Mz
4
switch still OFF.
Between (56) – (58) 0.4 – 1.1 z
14 D475A, D475ASD-5E0
D475A, D475ASD-5E0 15
Failure code [CA342] Engine controller data mismatch (Left bank):

Mismatch 1
Action code Failure code Symptom of Engine controller data mismatch (Left bank): Mismatch
Failure content • Data mismatch occurred in engine controller.
Controller's
action
Symptoms that
appear on • Engine cannot be started or operated.
machine
General
information
causes and the
when normal
16 D475A, D475ASD-5E0
Failure code [CB342] Engine controller data mismatch (Right bank):

Mismatch 1
Action code Failure code Symptom of Engine controller data mismatch (Right bank): Mismatch
Failure content • Data mismatch occurred in engine controller.
Controller's
action
Symptoms that
appear on • Engine cannot be started or operated.
machine
General
information
causes and the
when normal
D475A, D475ASD-5E0 17
Failure code [CA351] Abnormal injector drive circuit (At left bank):
Abnormal circuit 1
Action code Failure code Symptom of Abnormal injector drive circuit (At left bank): Abnormal circuit
Failure content • Abnormality has occurred in injector drive circuit.
Controller's • Operates with limited output. (Limits common rail pressure.)
Symptoms that
machine
General
information

Check the failure codes (codes for injector system trouble) that are
1 Defective related circuits displayed at the same time. If any other codes are displayed, carry
out troubleshooting for those codes.
Since a fuse or breaker of equipped machine side can be suspected
to be defective, directly check them.
2 Defective breaker
(If fuse is blown, or breaker is shut off, it is highly possible that a
defective grounding, etc. has occurred in the circuit.)
Possible Disconnection in wiring switch still OFF.
causes and the harness Wiring harness between PW L (female) (3) Resis-
3 Max. 1 z
standard values (disconnection or defective (4) – battery (+) tance
when normal contact of connectors) Wiring harness between PW L (female) (1) Resis-
Max. 1 z
(2) and ground tance
Defective harness switch still OFF.
Min. 1 Mz
PW L (female) (3) (4) – battery (+)Resistance tance
switch ON.
5 Defective engine controller
PW L Voltage
Between (3), (4) – (1), (2) 20 – 30 V
18 D475A, D475ASD-5E0
Circuit diagram related to controller power source
D475A, D475ASD-5E0 19
Failure code [CB351] Injector drive circuit abnormality (Right bank):

Circuit abnormality 1
Action code Failure code Symptom of Injector drive circuit abnormality (Right bank): Circuit abnormality
Failure content • Abnormality occurred in injector drive circuit.
Controller's • Limits output and continues operation (Limits common rail pressure).
Symptoms that
machine
General
information

If another code (code of injector system abnormality) is also dis-
1 Related defective system
played, carry out troubleshooting for it.
Fuse or circuit breaker on applicable machine side may be defective.
2 Defective circuit breaker Check them directly. (If fuse is broken or circuit breaker is turned
OFF, circuit probably has ground fault.)
Possible harness (Disconnection in Wiring harness between PW R (female) (3), Resis-
3 Max. 1 z
causes and the wiring or defective contact (4) – battery (+) tance
standard values in connector) Wiring harness between PW R (female) (1), Resis-
Max. 1 z
when normal (2) – ground tance
Wiring harness between PW R (female) (3), Resis-
(4) – battery (+) tance
PW R Voltage
Between (3), (4) – (1), (2) 20 – 30 V
20 D475A, D475ASD-5E0
D475A, D475ASD-5E0 21
Failure code [CA352] Sensor power supply (1) abnormally low level
Action code Failure code Symptom of Sensor power supply (1) abnormally low level (Left bank): Low volt-
Controller's • Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
Symptoms that
machine
General
information
causes and the
when normal
22 D475A, D475ASD-5E0
Failure code [CB352] Sensor power supply (1) abnormally low level
Action code Failure code Sensor power supply (1) abnormally low level (Right bank): Low volt-
Symptom of
age detection
CALL E03 CB352 failure
(Engine controller system)
Symptoms that
machine
General
information
causes and the
when normal
D475A, D475ASD-5E0 23
Failure code [CA386] Sensor power supply (1) abnormally high level
(Left bank): High voltage detection 1
Action code Failure code Symptom of Sensor power supply (1) abnormally high level (Left bank): High volt-
Symptoms that
machine
General
information

Defective sensor When device at right
(Internal defect) Left common rail
error code disap- PFUEL connector
pressure sensor
pears, that device has
defect in it.
Max. 1 z
harness (Disconnection in PFUEL (female) (1) tance
3
wiring or defective contact Wiring harness between ENG (female) (25) – Resis-
in connector) Max. 1 z
PFUEL (female) (2) tance
Max. 1 z
Possible Ground fault in wiring Min. 1 Mz
causes and the 4 harness (Contact with
standard values GND circuit) Wiring harness between ENG (female) (25) – Resis-
Min. 1 Mz
when normal PFUEL (female) (2) tance
Min. 1 Mz
Between wiring harness between ENG
(female) (33) – PFUEL (female) (1) and wir- Resis-
Min. 1 Mz
ing harness between ENG (female) (25) – tance
PFUEL (female) (2)
Short circuit in wiring
5 harness (with another
wiring harness) (female) (33) – PFUEL (female) (1) and wir- Resis-
Min. 1 Mz
PFUEL (female) (3)
Min. 1 Mz
PFUEL (female) (3)
ENG Voltage
Between (33) – (47) 4.75 – 5.25 V
24 D475A, D475ASD-5E0
Circuit diagram related to sensor power supply 1 (5V)
D475A, D475ASD-5E0 25
Failure code [CB386] Sensor power supply (1) abnormally high level
(Right bank): High voltage detection 1
Action code Failure code Sensor power supply (1) abnormally high level (Right bank): High
Symptom of
voltage detection
CALL E03 CB386 failure
(Engine controller system)
Symptoms that
machine
General
information

Defective sensor When device at right
(Internal defect) Right common rail
error code disap- PFUEL connector
pressure sensor
pears, that device has
defect in it.
Max. 1 z
3
Max. 1 z
Possible Ground fault in wiring har- Min. 1 Mz
causes and the 4 ness (Contact with GND
standard values circuit) Wiring harness between ENG (female) (25) – Resis-
Min. 1 Mz
when normal PFUEL (female) (2) tance
Min. 1 Mz
Min. 1 Mz
PFUEL (female) (2)
5 ness (with another wiring
harness) (female) (33) – PFUEL (female) (1) and wir- Resis-
Min. 1 Mz
PFUEL (female) (3)
Min. 1 Mz
PFUEL (female) (3)
ENG Voltage
Between (33) – (47) 4.75 – 5.25 V
26 D475A, D475ASD-5E0
Circuit diagram related to sensor power supply (1) (5V)
D475A, D475ASD-5E0 27
Failure code [CA441] Power supply voltage abnormally low level (Left
bank): Low voltage detection 1
Action code Failure code Symptom of Power supply voltage abnormally low level (Left bank): Low voltage
Failure content • Low voltage was detected in power supply voltage circuit.
Controller's
action
Symptoms that
• Machine continues operation normally but may stop suddenly or may not able to start again once
appear on
it stops.
machine
General
information
causes and the
when normal
Failure code [CB441] Power supply voltage abnormally low level (Right
bank): Low voltage detection 1
Action code Failure code Symptom of Power supply voltage abnormally low level (Right bank): Low voltage
CALL E04 CB441 failure detection (Engine controller system)
Failure content • Low voltage was detected in power supply voltage circuit.
Controller's
action
Symptoms that
appear on
it stops.
machine
General
information
causes and the
when normal
28 D475A, D475ASD-5E0
Failure code [CA442] Power supply voltage abnormally high level (Left
bank): High voltage detection 1
Action code Failure code Symptom of Power supply voltage abnormally high level (Left bank): High voltage
Failure content • High voltage was detected in power supply voltage circuit.
Controller's
action
Symptoms that
appear on
it stops.
machine
General
information
causes and the
when normal
Failure code [CB442] Power supply voltage abnormally high level (Right
bank): High voltage detection 1
Action code Failure code Symptom of Power supply voltage abnormally high level (Right bank): High volt-
CALL E04 CB442 failure age detection (Engine controller system)
Failure content • High voltage was detected in power supply voltage circuit.
Controller's
action
Symptoms that
appear on
it stops.
machine
General
information
causes and the
when normal
D475A, D475ASD-5E0 29
Failure code [CA449] Common rail abnormally high pressure (2) (Left
bank): Abnormally high pressure occurrence 1
Action code Failure code Symptom of Common rail abnormally high pressure (2) (Left bank): Abnormally
CALL E03 CA449 failure high pressure occurrence (Engine controller system)
Failure content • Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
Symptoms that
machine
General
information
causes and the
when normal
Failure code [CB449] Common rail abnormally high pressure (2) (Right
bank): Abnormally high pressure occurrence 1
Action code Failure code Symptom of Common rail abnormally high pressure (2) (Right bank): Abnormally
CALL E03 CB449 failure high pressure occurrence (Engine controller system)
Failure content • Common rail pressure sensor circuit detected abnormally high pressure (Level 2).
Symptoms that
machine
General
information
causes and the
when normal
30 D475A, D475ASD-5E0
Failure code [CA451] Common rail pressure sensor too high (At left
bank): Excessively high voltage detected 1
Action code Failure code Symptom of Common rail pressure sensor too high (At left bank): Excessively
CALL E03 CA451 failure high voltage detected (Engine controller system)
Failure content • Excessively high voltage has occurred in the common rail pressure sensor circuit.
Controller's • Operates with limited output.(Limits common rail pressure.)
Symptoms that
machine
General • The signal voltage of the common rail pressure sensor can be checked with the monitoring func-
information tion. (Code: 36401 Common rail pressure sensor voltage)

Defective sensor power If failure code [CA352] or [CA386] is displayed, carry out trouble-
1
source circuit shooting for it first.
a Prepare with starting switch OFF, and diagnose with starting
switch ON or with engine started.
PFUEL Voltage
Defective common rail Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal 0.25 – 4.6 V
nected, if the voltage is abnormal, first check the harness and the
controller to make it sure if there is no other cause of the trouble, and
then judge the sensor voltage.
switch still OFF.
Max. 1 z
harness (disconnection or PFUEL (female) (1) tance
3
defective contact of con- Wiring harness between ENG (female) (25) – Resis-
nectors) Max. 1 z
Possible Max. 1 z
causes and the a Prepare with starting switch OFF and diagnose with starting
standard values switch still OFF.
when normal
Defective harness ground- Min. 1 Mz
ENG (female) (33) – PFUEL (female) (1) tance
4 ing (contact with ground
circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
Min. 1 Mz
switch still OFF.
(33) to PFUEL (female) (1) and wiring har- Resis-
Min. 1 Mz
ness from ENG (female) (25) to PFUEL tance
(female) (2)
Harness short Between wiring harness from ENG (female)
5
(Harness internal short) (33) to PFUEL (female) (1) and wiring har- Resis-
Min. 1 Mz
(female) (3)
(25) to PFUEL (female) (2) and wiring har- Resis-
Min. 1 Mz
(female) (3)
32 D475A, D475ASD-5E0

Possible a Prepare with starting switch OFF, and diagnose with starting
causes and the switch ON or with engine started.
standard values 6 Defective engine controller ENG Voltage
when normal Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
D475A, D475ASD-5E0 33
Failure code [CB451] Common rail pressure sensor abnormally high

level (Right bank): High voltage detection 1
Action code Failure code Symptom of Common rail pressure sensor abnormally high level (Right bank):
CALL E03 CB451 failure High voltage detection (Engine controller system)
Failure content • High voltage was detected in common rail pressure sensor circuit.
Symptoms that
machine
General • Signal voltage of common rail pressure sensor can be checked with monitoring function
information (Code: 36404: Common rail pressure sensor voltage).

Defective sensor power If code [CB352] or [CB386] is displayed, carry out troubleshooting
1
supply system for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
PFUEL Voltage
Defective common rail
Between (1) – (3) Power supply 4.75 – 5.25 V
2 pressure sensor
(Internal defect) Between (2) – (3) Signal 0.25 – 4.6 V
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller, too,
for another cause of trouble, and then judge.
Max. 1 z
3
Max. 1 z
in connector) PFUEL (female) (2) tance
Max. 1 z
Possible PFUEL (female) (3) tance
causes and the a Prepare with starting switch OFF, then carry out troubleshooting
standard values without turning starting switch ON.
when normal Wiring harness between ENG (female) (33) – Resis-
Ground fault in wiring har- Min. 1 Mz
4 ness (Contact with GND
circuit) Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
PFUEL (female) (2)
5 ness (with another wiring Between wiring harness between ENG
harness) Min. 1 Mz
PFUEL (female) (3)
Min. 1 Mz
PFUEL (female) (3)
34 D475A, D475ASD-5E0

Possible a Prepare with starting switch OFF, then turn starting switch ON and
causes and the carry out troubleshooting.
standard values 6 Defective engine controller ENG Voltage
when normal Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
D475A, D475ASD-5E0 35
Failure code [CA452] Common rail pressure sensor abnormally low

level (Left bank): Abnormally low voltage detection 1
Action code Failure code Symptom of Common rail pressure sensor abnormally low level (Left bank):
CALL E03 CA452 failure Abnormally low voltage detection (Engine controller system)
Failure content • Low voltage was detected in common rail pressure sensor circuit.
Symptoms that
machine
causes and the
when normal
Failure code [CB452] Common rail pressure sensor abnormally low

level (Right bank): Abnormally low voltage detection 1
Action code Failure code Symptom of Common rail pressure sensor abnormally low level (Right bank):
CALL E03 CB452 failure Abnormally low voltage detection (Engine controller system)
Failure content • Low voltage was detected in common rail pressure sensor circuit.
Symptoms that
machine
causes and the
when normal
36 D475A, D475ASD-5E0
Excessively high pressure detected 1
Action code Failure code Symptom of Common rail pressure high trouble (1) (At left bank): Excessively
CALL E03 CA553 failure high pressure trouble occurred (Engine controller system)
Failure content • Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
Controller's
action
Symptoms that
machine
General • Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)

Improper fuel has been Since the use of improper fuel can be suspected, check the fuel.
2
used. (Viscosity is too high)
Defective electrical system Since an electrical defect of common rail pressure sensor is sus-
3 of common rail pressure pected, carry out troubleshooting for the following code.
Possible
sensor [CA451]
causes and the
Defective mechanical sys-
standard values Since a mechanical defect of common rail pressure sensor is sus-
when normal 4 tem of common rail pres-
pected, directly check the sensor.
sure sensor
Since a damage of spring, wear of seat or sticking of ball is sus-
5 Defective overflow valve
pected, directly check them.
Since an overflow piping is suspected to be clogged, directly check
6 Clogged overflow piping
it.
Since a mechanical defect of pressure limiter is suspected, directly
7 Defective pressure limiter
check the limiter.
D475A, D475ASD-5E0 37
Failure code [CB553] Common rail pressure too high (1) (At right bank):
Excessively high pressure detected 1
Action code Failure code Symptom of Common rail pressure high trouble (1) (At right bank): Excessively
CALL E03 CB553 failure high pressure trouble occurred (Engine controller system)
Failure content • Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
Controller's
action
Symptoms that
machine

Improper fuel has been Since the use of improper fuel can be suspected, check the fuel.
2
used. (Viscosity is too high)
Defective electrical system Since an electrical defect of common rail pressure sensor is sus-
3 of common rail pressure pected, carry out troubleshooting for the following code.
Possible
sensor [CB451]
causes and the
Defective mechanical sys-
standard values Since a mechanical defect of common rail pressure sensor is sus-
when normal 4 tem of common rail pres-
pected, directly check the sensor.
sure sensor
Since a damage of spring, wear of seat or sticking of ball is sus-
5 Defective overflow valve
pected, directly check them.
Since an overflow piping is suspected to be clogged, directly check
6 Clogged overflow piping
it.
Since a mechanical defect of pressure limiter is suspected, directly
7 Defective pressure limiter
check the limiter.
38 D475A, D475ASD-5E0
Failure code [CA554] In-range error in common rail pressure sensor (At
left bank): In-range error 1
Action code Failure code Symptom of In-range error in common rail pressure sensor (At left bank): In-
CALL E03 CA554 failure range error occurred (Engine controller system)
Failure content • In-range error has occurred in common rail pressure sensor circuit.
Symptoms that
machine
General
information
causes and the
standard values Carry out troubleshooting of [CA451].
when normal
Failure code [CB554] In-range error in common rail pressure sensor (At
right bank): In-range error 1
Action code Failure code Symptom of In-range error in common rail pressure sensor (At right bank): In-
CALL E03 CB554 failure range error occurred (Engine controller system)
Failure content • In-range error has occurred in common rail pressure sensor circuit.
Symptoms that
machine
General
information
causes and the
standard values Carry out troubleshooting of [CB451].
when normal
D475A, D475ASD-5E0 39
Failure code [CA559] Loss of pressure feed from supply pump (1) (At
left bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (1) (At left bank): Loss of
E02 CA559 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 1) from supply pump has occurred.
Controller's
• Limits common rail pressure.
action
Symptoms that
appear on
machine
General
information

Improper fuel has been
2 Since the use of improper fuel is suspected, directly check the fuel.
used.
a See “Note 1” for the contents of diagnosis. See Testing and
adjusting “Testing fuel pressure” for the pressure inspection of the
fuel low pressure circuit.
Defective low pressure
3 Pressure in fuel low pressure
circuit device
circuit Min. 0.15 MPa
(At high idle or under the load {Min. 1.5 kg/cm2}
equivalent to rating (stalling))
4 Clogged filter or strainer a See “Note 2” for the contents of diagnosis.
Since an electrical defect of supply pump PCV is suspected, carry
Defective electrical system
5 out troubleshooting for the following codes.
of supply pump PCV
[CA271], [CA272], [CA273], and [CA274]
Possible Defective common rail Since a defect of common rail pressure sensor is suspected, check
causes and the 6
pressure sensor for a damage in harnesses.
standard values
a As for testing an amount of pressure limiter leak, see testing and
when normal adjusting “Testing fuel return and leak amount”.
7 Defective pressure limiter Max. 10 cc/min.
Pressure limiter leak amount [Equivalent to rated operation
(stalling)]
a As for the test relating to return (spill) limit amount of injector, see
Testing and adjusting “Testing fuel return and leak amount”.
Speed under the conditions which
are equivalent to rated operation Injector return (spill) limit amount
(stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is
9 Defective supply pump
found in causes 1 – 8.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed”.
40 D475A, D475ASD-5E0
Note 1: When low-pressure circuit equipment is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D475A, D475ASD-5E0 41
Check sheet for no-pressure feed
Model Operation No.

Model and serial No. # Date inspected / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual inspections Pass Fail

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 660 – 700
*1 Engine speed High idle rpm 2,100 – 2,200
Equivalent to rating rpm 2,000
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
*4 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
*8 Low idle °C — — —
(high temperature)
Coolant temperature
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
Cylinder No. 1 Low idle rpm — — —
5 Cylinder No. 2 Low idle rpm — — —

*11
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
42 D475A, D475ASD-5E0
D. Inspection of strainer and filter Pass Fail

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual inspection of fuel filter
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return Standard value

Condition for inspection Unit Measured value Pass Fail
amount (reference value)
Pressure limiter Under the load equivalent to rating
11 cc/min Max 10
leak amount (stalling)
Equivalent to rating: 1,600 rpm cc/min 960
Equivalent to rating: 1,700 rpm cc/min 1,020 Rotation speed:
12 Injector return amount Equivalent to rating: 1,800 rpm cc/min 1,080
Equivalent to rating: 1,900 rpm cc/min 1,140 Return amount:
Equivalent to rating: 2,000 rpm cc/min 1,200
Inspection items *1 – *10 of B-4:

When inspecting with the monitoring function, see “Monitoring code table”.
Inspection items *11 of B-5:
When inspecting with the monitoring function, see “Adjustment mode table”.
Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
D475A, D475ASD-5E0 43
Failure code [CB559] Loss of pressure feed from supply pump (1) (At
right bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (1) (At right bank): Loss of
E02 CB559 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 1) from supply pump has occurred.
Controller's
• Limits common rail pressure.
action
Symptoms that
appear on
machine
General
information

Improper fuel has been
2 Since the use of improper fuel is suspected, directly check the fuel.
used.
a See “Note 1” for the contents of diagnosis. See Testing and
adjusting “Testing fuel pressure” for the pressure inspection of the
fuel low pressure circuit.
Defective low pressure
3 Pressure in fuel low pressure
circuit device
circuit Min. 0.15 MPa
(At high idle or under the load {Min. 1.5 kg/cm2}
equivalent to rating (stalling))
4 Clogged filter or strainer a See “Note 2” for the contents of diagnosis.
Since an electrical defect of supply pump PCV is suspected, carry
5 out troubleshooting for the following codes.
of supply pump PCV
[CB271], [CB272], [CB273], and [CB274]
Possible Defective common rail Since a defect of common rail pressure sensor is suspected, check
causes and the 6
pressure sensor for a damage in harnesses.
standard values
a As for testing an amount of pressure limiter leak, see testing and
when normal adjusting “Testing fuel return and leak amount”.
7 Defective pressure limiter Max. 10 cc/min.
Pressure limiter leak amount [Equivalent to rated operation
(stalling)]
a As for the test relating to return (spill) limit amount of injector, see
Testing and adjusting “Testing fuel return and leak amount”.
Speed under the conditions which
are equivalent to rated operation Injector return (spill) limit amount
(stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is
9 Defective supply pump
found in causes 1 – 8.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed”.
44 D475A, D475ASD-5E0
Note 1: When low-pressure circuit equipment is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D475A, D475ASD-5E0 45
Check sheet for no-pressure feed
Model Operation No.

Model and serial No. # Date inspected / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual inspections Pass Fail

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 660 – 700
*1 Engine speed High idle rpm 2,100 – 2,200
Equivalent to rating rpm 2,000
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
4 rail pressure
Fuel pressure in
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
(high temperature)
Coolant temperature
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
5 Cylinder No. 2 Low idle rpm — — —

*11
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
46 D475A, D475ASD-5E0
D. Inspection of strainer and filter Pass Fail

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual inspection of fuel filter
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return Standard value

Condition for inspection Unit Measured value Pass Fail
amount (reference value)
Pressure limiter Under the load equivalent to rating
11 cc/min Max 10
leak amount (stalling)
Equivalent to rating: 1,600 rpm cc/min 960
Equivalent to rating: 1,700 rpm cc/min 1,020 Rotation speed:
12 Injector return amount Equivalent to rating: 1,800 rpm cc/min 1,080
Equivalent to rating: 1,900 rpm cc/min 1,140 Return amount:
Equivalent to rating: 2,000 rpm cc/min 1,200
Inspection items *1 – *10 of B-4:

When inspecting with the monitoring function, see “Monitoring code table”.
Inspection items *11 of B-5:
When inspecting with the monitoring function, see “Adjustment mode table”.
Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
D475A, D475ASD-5E0 47
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank):
Abnormal signal 1
Action code Failure code Symptom of Abnormal engine Ne speed sensor (At left bank): Abnormal signal
Failure content • Abnormal signal of the engine Ne speed sensor has been detected.
Controller's • Operates using Bkup speed sensor signal.
Symptoms that
appear on
machine
General
information
Causes Standard values when normal and remarks for troubleshooting

Defective sensor power If failure code [CA238] is displayed at the same time, carry out trou-
1
switch still OFF.
Disconnection in wiring Wiring harness between left ENG (female) Resis-
Max. 1 z
harness (16) – NE (female) (1) tance
2
(disconnection or defective Wiring harness between left ENG (female) Resis-
Max. 1 z
contact of connectors) (48) – NE (female) (2) tance
Wiring harness between left ENG (female) Resis-
Max. 1 z
(27) – NE (female) (3) tance
switch still OFF.
Defective harness ground- Between ground and wiring harness between Resis-
Min. 1 Mz
ing left ENG (female) (16) – NE (female) (1) tance
3
Min. 1 Mz
cuit) left ENG (female) (48) – NE (female) (2) tance
Min. 1 Mz
left ENG (female) (27) – NE (female) (3) tance
Possible a Prepare with starting switch OFF and diagnose with starting
causes and the switch still OFF.
standard values
Between wiring harness from left ENG
when normal
(female) (16) to NE (female) (1) and wiring Resis-
Min. 1 Mz
harness from left ENG (female) (48) to NE tance
(female) (2)
Harness short Between wiring harness from left ENG
4
(Harness internal short) (female) (16) to NE (female) (1) and wiring Resis-
Min. 1 Mz
(female) (3)
Min. 1 Mz
(female) (3)
Defective mounting of sen- Since defective mounting of Ne speed sensor (improper gap) or
5 sor or defective parts for defective parts for speed detection (flywheel) can be suspected,
speed detection directly check it.
Engine Ne speed sensor can be suspected to be defective if no
Defective engine Ne
6 problem is found in causes 1 – 5 (since this is an internal defect, it
speed sensor
cannot be diagnosed).
7 Defective engine controller found in causes 1 – 6 (since this is an internal defect, it cannot be
diagnosed).
48 D475A, D475ASD-5E0
Circuit diagram related to engine Ne speed sensor
D475A, D475ASD-5E0 49
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank):
Abnormal signal 1
Action code Failure code Symptom of Abnormal engine Ne speed sensor (At right bank): Abnormal signal
Failure content • Abnormal signal of the engine Ne speed sensor has been detected.
Controller's • Operates using Bkup speed sensor signal.
Symptoms that
appear on
machine
General
information

Defective sensor power If failure code [CB238] is displayed at the same time, carry out trou-
1
switch still OFF.
Max. 1 z
harness (16) – NE (female) (1) tance
2
(disconnection or defective Wiring harness between right ENG (female) Resis-
Max. 1 z
contact of connectors) (48) – NE (female) (2) tance
Wiring harness between right ENG (female) Resis-
Max. 1 z
(27) – NE (female) (3) tance
switch still OFF.
Defective harness ground- Between ground and wiring harness between Resis-
Min. 1 Mz
ing left ENG (female) (16) – NE (female) (1) tance
3
Min. 1 Mz
cuit) right ENG (female) (48) – NE (female) (2) tance
Min. 1 Mz
right ENG (female) (27) – NE (female) (3) tance
standard values
when normal
Min. 1 Mz
harness from right ENG (female) (48) to NE tance
(female) (2)
4
(Harness internal short) (female) (16) to NE (female) (1) and wiring Resis-
Min. 1 Mz
(female) (3)
Between wiring harness from right ENG
Min. 1 Mz
(female) (3)
Defective mounting of sen- Since defective mounting of Ne speed sensor (improper gap) or
5 sor or defective parts for defective parts for speed detection (flywheel) can be suspected,
speed detection directly check it.
Engine Ne speed sensor can be suspected to be defective if no
Defective engine Ne
speed sensor
diagnosed).
50 D475A, D475ASD-5E0
Circuit diagram related to engine Ne speed sensor
D475A, D475ASD-5E0 51
Failure code [CA691] Intake air temperature sensor abnormally high

level (Only left bank): High voltage detection 1
Action code Failure code Symptom of Intake air temperature sensor abnormally high level (Only left bank):
E01 CA691 failure High voltage detection (Engine controller system)
Failure content • Intake air temperature sensor circuit detected high voltage.
Controller's
• Fixes intake air temperature (25°C) and continues operation.
action
Symptoms that
appear on
machine
General
information

Defective charge tempera- without turning starting switch ON.
1 ture sensor (Internal TAM1 Intake air temperature Resistance
defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground All range Min. 1 Mz
Possible harness (Disconnection in Wiring harness between ENG (female) (43) – Resis-
2 Max. 1z
causes and the wiring or defective contact TAM1 (female) (A) tance
standard values in connector) Wiring harness between ENG (female) (47) – Resis-
when normal Max. 1z
TAM1 (female) (B) tance
Ground fault in wiring har- without turning starting switch ON.
circuit) Wiring harness between ENG (female) (43) – Resis-
Min. 1 Mz
TAM1 (female) (A) tance
ENG (female) Intake air temperature Resistance
Between (43) – (47) 10 – 100°C 0.5 – 20 kz
52 D475A, D475ASD-5E0
Circuit diagram related to intake air temperature sensor
D475A, D475ASD-5E0 53
Failure code [CA692] Intake air temperature sensor abnormally low level
(Only left bank): Low voltage detection 1
Action code Failure code Symptom of Intake air temperature sensor abnormally low level (Only left bank):
E01 CA692 failure Low voltage detection (Engine controller system)
Failure content • Intake air temperature sensor circuit detected low voltage.
Controller's
• Fixes intake air temperature (25°C) and continues operation.
action
Symptoms that
appear on
machine
General
information
causes and the
when normal
54 D475A, D475ASD-5E0
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At
left bank): Abnormal phase 1
Action code Failure code Symptom of Abnormal engine Bkup speed sensor phase (At left bank): Abnormal
CALL E03 CA731 failure phase (Engine controller system)
Failure content • Abnormal phase has been detected in the engine Bkup sensor circuit.
Controller's • Operates using engine Ne speed sensor signal.
Symptoms that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
General
information

Since a defect of engine Ne speed sensor can be suspected, carry
Possible Defective engine Ne
1 out troubleshooting for the following code.
causes and the speed sensor circuit
[CA689]
standard values
when normal Since a defect of engine Bkup speed sensor can be suspected, carry
Defective engine Bkup
speed sensor system
[CA778]
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At
right bank): Abnormal phase 1
Action code Failure code Symptom of Abnormal engine Bkup speed sensor phase (At right bank): Abnor-
CALL E03 CB731 failure mal phase (Engine controller system)
Failure content • Abnormal phase has been detected in the engine Bkup sensor circuit.
Controller's • Operates using engine Ne speed sensor signal.
Symptoms that
appear on
machine
General
information

Since a defect of engine Ne speed sensor can be suspected, carry
Possible Defective engine Ne
causes and the speed sensor circuit
[CB689]
standard values
when normal Since a defect of engine Bkup speed sensor can be suspected, carry
speed sensor system
[CB778]
D475A, D475ASD-5E0 55
SEN01825-00

© 2006 KOMATSU
All Rights Reserved
56
SEN01826-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data ....................... 3
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data..................... 3
Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal ..... 4
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error .......... 6
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error .... 8
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error .. 10
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank):
Distinction error ........................................................................................................................ 11
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank):
Distinction error ........................................................................................................................ 12
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank):
Disconnection/Short circuit ...................................................................................................... 14
D475A, D475ASD-5E0 1
Disconnection/Short circuit....................................................................................................... 16
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error.............................. 26
Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level
(Only left bank): High voltage detection ................................................................................... 28
Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only):
Failure code [D110KA] Battery relay: Disconnection ......................................................................... 32
Failure code [D110KB] Battery relay: Short circuit ............................................................................. 34
Failure code [D130KA] Neutral safety relay: Disconnection............................................................... 36
Failure code [D130KB] Neutral safety relay: Short circuit .................................................................. 38
Failure code [D161KA] Back-up alarm relay: Disconnection.............................................................. 40
Failure code [D161KB] Back-up alarm relay: Short circuit ................................................................. 42
Failure code [D182KZ] Preheater relay: Disconnection or short circuit.............................................. 44
Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection ............................ 46
Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit................................ 48
Failure code [D5ZRKA] Snap shot switch: Disconnection.................................................................. 50
Failure code [D5ZRKB] Snap shot switch: Short circuit ..................................................................... 51
Failure code [DAFRKR] Monitor panel CAN communication: Communication error.......................... 52
Failure code [dAFRKR] Monitor panel CAN communication: Communication error .......................... 54
Failure code [daFRKR] Monitor panel CAN communication: Communication error........................... 56
Failure code [DAQ0KT] Transmission controller: Abnormality in controller ....................................... 58
Power supply voltage reduction (Input).................................................................................... 60
Failure code [DAQ5KK] Transmission controller potentiometer power supply:
Source voltage reduction (input) .............................................................................................. 64
Source voltage reduction (input) .............................................................................................. 65
Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency .... 67
Failure code [DAQRKR] Transmission controller sensor CAN communication:
Communication error (Objective component system abnormality) .......................................... 68
Defective communication (Abnormality in objective component system) ................................ 70
2 D475A, D475ASD-5E0

Failure code [CA757] Loss of all engine controller data (At left bank):
Loss of all data 1
Action code Failure code Symptom of Loss of all engine controller data (At left bank): Loss of all data
Failure content • Loss of all data in engine controller has been detected.
Controller's
action
Symptoms that
appear on • The engine cannot be started, or cannot be operated.
machine
General
information
causes and the
standard values Carry out troubleshooting of [CA111].
when normal
Failure code [CB757] Loss of all engine controller data (At right bank):
Loss of all data 1
Action code Failure code Symptom of Loss of all engine controller data (At right bank): Loss of all data
Failure content • Loss of all data in engine controller has been detected.
Controller's
action
Symptoms that
appear on • The engine cannot be started, or cannot be operated.
machine
General
information
causes and the
standard values Carry out troubleshooting of [CB111].
when normal
D475A, D475ASD-5E0 3
Failure code [CA778] Abnormal engine Bkup speed sensor (At left
bank): Abnormal Bkup signal 1
Action code Failure code Symptom of Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup
CALL E03 CA778 failure signal (Engine controller system)
Failure content • Abnormal engine Bkup speed sensor signal has been detected.
Controller's • Operates using Ne speed sensor signal.
Symptoms that
appear on
machine
General
information

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
source circuit shooting for it first.
switch still OFF.
Max. 1 z
harness (37) – left G (female) (1) tance
2
(disconnection or defective Wiring harness between left ENG (female) Resis-
Max. 1 z
contact of connectors) (47) – left G (female) (2) tance
Wiring harness between left ENG (female) Resis-
Max. 1 z
(26) – left G (female) (3) tance
switch still OFF.
Defective harness Min. 1 Mz
left ENG (female) (37) – left G (female) (1) tance
Min. 1 Mz
Min. 1 Mz
standard values
when normal
(female) (37) to left G (female) (1) and wiring Resis-
Min. 1 Mz
harness from left ENG (female) (47) to left G tance
(female) (2)
4
(Harness internal short) (female) (37) to left G (female) (1) and wiring Resis-
Min. 1 Mz
(female) (3)
(female) (47) to left G (female) (2) and wiring Resis-
Min. 1 Mz
(female) (3)
Defective mounting of sen- Since defective mounting of Bkup speed sensor (improper gap) or
5 sor or defective parts for defective parts for speed detection (in supply pump) can be sus-
speed detection pected, directly check it.
Engine Bkup speed sensor can be suspected to be defective if no
speed sensor
diagnosed).
4 D475A, D475ASD-5E0
Circuit diagram related to engine Bkup speed sensor
D475A, D475ASD-5E0 5
Failure code [CB778] Engine Bkup speed sensor abnormality (Right

bank): Bkup signal error 1
Action code Failure code Symptom of Engine Bkup speed sensor abnormality (Right bank): Bkup signal
CALL E03 CB778 failure error (Engine controller system)
Failure content • Engine Bkup speed sensor signal detected abnormality.
Controller's • Operates with Ne speed sensor signal
Symptoms that
• If engine has been running, it stops (when Ne speed sensor is also defective).
appear on
• If engine has been stopped, it cannot start (when Ne speed sensor is also defective).
machine
General
information

Defective sensor power If failure code [CB187] or [CB227] is displayed, carry out trouble-
1
supply system shooting for it first.
Disconnection in wiring Wiring harness between right ENG (female) Resis-
Max. 1 z
harness (Disconnection in (37) – right G (female) (1) tance
2
wiring or defective contact Wiring harness between right ENG (female) Resis-
Max. 1 z
in connector) (47) – right G (female) (2) tance
Max. 1 z
(26) – right G (female) (3) tance
circuit) Wiring harness between right ENG (female) Resis-
Min. 1 Mz
Min. 1 Mz
Possible (26) – right G (female) (3) tance
when normal Between wiring harness between right ENG
(female) (37) – right G (female) (1) and wiring Resis-
Min. 1 Mz
harness between right ENG (female) (47) – tance
right G (female) (2)
4 ness (with another wiring Between wiring harness between right ENG
harness) (female) (37) – right G (female) (1) and wiring Resis-
Min. 1 Mz
Between wiring harness between right ENG
(female) (47) – right G (female) (2) and wiring Resis-
Min. 1 Mz
Defective sensor installa- Bkup speed sensor may be installed defectively (improper clear-
5 tion or defective speed ance) or speed sensing part (in supply pump) may be defective.
sensing part Check them directly.
If causes 1 – 5 are not detected, engine Bkup speed sensor may be
6 defective. (Since trouble is in system, troubleshooting cannot be
speed sensor
carried out.)
If causes 1 – 6 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
6 D475A, D475ASD-5E0
Circuit diagram related to engine Bkup speed sensor
D475A, D475ASD-5E0 7
Failure code [CA781] Inter-multicontroller communication error (Left

bank): Communication error 1
Action code Failure code Symptom of Inter-multicontroller communication error (Left bank): Communica-
CALL E03 CA781 failure tion error (Engine controller system)
Failure content • Communication error occurred between engine controllers (Left bank).
Controller's
action
Symptoms that
• During operation: Engine continues operation with 1 bank.
appear on
• When key is ON: Engine cannot be started.
machine
General
information

harness (Disconnection in Wiring harness between left ENG (female) Resis-
1 Max. 1 z
wiring or defective contact (8) – right ENG (female) (8) tance
in connector) Wiring harness between left ENG (female) Resis-
Max. 1 z
(6) – right ENG (female) (6) tance
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and the without turning starting switch ON.
standard values Wiring harness between left ENG (female) (8) Resis-
when normal – right ENG (female) (8) tance
GND circuit)
Wiring harness between left ENG (female) (6) Resis-
Min. 1 Mz
– right ENG (female) (6) tance
3 Defective engine controller Left ENG (female) Resistance
Between (8) – (6) 108 – 132 z
8 D475A, D475ASD-5E0
Circuit diagram related to communication between multiple controller
D475A, D475ASD-5E0 9
Failure code [CB781] Inter-multicontroller communication error (Right

bank): Communication error 1
Action code Failure code Symptom of Inter-multicontroller communication error (Right bank): Communica-
CALL E03 CB781 failure tion error (Engine controller system)
Failure content • Communication error occurred between engine controllers (Right bank).
Controller's
action
Symptoms that
• During operation: Engine continues operation with 1 bank.
appear on
• When key is ON: Engine cannot be started.
machine
General
information
causes and the
when normal
10 D475A, D475ASD-5E0
Failure code [CA1257] Multicontroller distinction wiring harness key

error (Left bank): Distinction error 1
Action code Failure code Symptom of Multicontroller distinction wiring harness key error (Left bank): Dis-
CALL E03 CA1257 failure tinction error (Engine controller system)
Failure content • Controller of each bank disagrees with distinction wiring harness (Left bank).
Controller's • Stops operation.
Symptoms that
appear on • When key is ON: Engine cannot be started.
machine
General
information

harness (Disconnection in without turning starting switch ON.
1
wiring or defective contact Wiring harness between OEM L (female) (7) Resis-
Max. 1 z
in connector) – OEM L (female) (34) tance
Possible Ground fault in wiring har- without turning starting switch ON.
standard values circuit) Resis-
Between OEM L (female) (8) – ground Min. 1 Mz
tance
when normal
Resis-
3 Defective engine controller Between OEM L (female) (7) – ground Min. 1 Mz
tance
Resis-
Between OEM L (female) (8) – ground Min. 1 Mz
tance
Circuit diagram related to multicontroller distinction wiring harness key
D475A, D475ASD-5E0 11
Failure code [CB1257] Multicontroller distinction wiring harness key

error (Right bank): Distinction error 1
Action code Failure code Symptom of Multicontroller distinction wiring harness key error (Right bank): Dis-
CALL E03 CB1257 failure tinction error (Engine controller system)
Failure content • Controller of each bank disagrees with distinction wiring harness (Right bank).
Controller's • Stops operation.
Symptoms that
appear on • When key is ON: Engine cannot be started.
machine
General
information

1
wiring or defective contact Wiring harness between OEM R (female) (7) Resis-
Min. 1 Mz
in connector) – OEM R (female) (34) tance
Possible Ground fault in wiring har- without turning starting switch ON.
standard values circuit) Resis-
Between OEM R (female) (8) – ground Min. 1 Mz
tance
when normal
Resis-
3 Defective engine controller Between OEM R (female) (7) – ground Min. 1 Mz
tance
Resis-
Between OEM R (female) (8) – ground Min. 1 Mz
tance
Circuit diagram related to multicontroller distinction wiring harness key
12 D475A, D475ASD-5E0
Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short

circuit (Right bank): Disconnection/Short circuit 1
Action code Failure code Symptom of Injector #7 (R/B #1) system disconnection/short circuit (Right bank):
CALL E03 CB1548 failure Disconnection/Short circuit (Engine controller system)
Failure content • Disconnection or short circuit occurred in injector #7 circuit.
Controller's
action
Symptoms that
• Output lowers.
appear on
• Engine speed is unstable.
machine
General
information

Defective injector #7 CN1 (male) Resistance
1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
harness (Disconnection in Wiring harness between ENG (female) (45) – Resis-
2 Max. 1 z
wiring or defective contact CN1 (female) (1) tance
in connector) Wiring harness between ENG (female) (53) – Resis-
Max. 1 z
Possible CN1 (female) (2) tance
when normal Ground fault in wiring har-
3 ness (Contact with GND Min. 1 Mz
circuit)
Min. 1 Mz
Defective injector of
If failure codes of 1 or more injectors are displayed, carry out trou-
4 another cylinder or defec-
bleshooting for them.
tive wiring harness
Between (45) – (53) 0.4 – 1.1 z
14 D475A, D475ASD-5E0
Circuit diagram related to injector #7 (R/B #1)
D475A, D475ASD-5E0 15

Controller's
action
Symptoms that
• Output lowers.
appear on
machine
General
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (54) – (51) 0.4 – 1.1 z
16 D475A, D475ASD-5E0
D475A, D475ASD-5E0 17

Action code Failure code Symptom of Injector #10 (R/B #4) system disconnection/short circuit (Right
CALL E03 CB1551 failure bank): Disconnection/Short circuit (Engine controller system)
Controller's
action
Symptoms that
• Output lowers.
appear on
machine
General
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (56) – (58) 0.4 – 1.1 z
18 D475A, D475ASD-5E0
D475A, D475ASD-5E0 19

Controller's
action
Symptoms that
• Output lowers.
appear on
machine
General
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (46) – (60) 0.4 – 1.1 z
20 D475A, D475ASD-5E0
D475A, D475ASD-5E0 21

Action code Failure code Symptom of Injector #12 (R/B #6) system disconnection/short circuit (Right
CALL E03 CB1553 failure bank): Disconnection/Short circuit (Engine controller system)
Controller's
action
Symptoms that
• Output lowers.
appear on
machine
General
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (57) – (59) 0.4 – 1.1 z
22 D475A, D475ASD-5E0
D475A, D475ASD-5E0 23

Controller's
action
Symptoms that
• Output lowers.
appear on
machine
General
information

1
(Internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
circuit)
Min. 1 Mz
tive wiring harness
Between (55) – (52) 0.4 – 1.1 z
24 D475A, D475ASD-5E0
D475A, D475ASD-5E0 25
Failure code [CA1633] KOMNET abnormality (Left bank):

Communication error 1
Action code Failure code Symptom of KOMNET abnormality (Left bank): Communication error
Failure content • Abnormality occurred in KOMNET communication circuit to engine controller (Left bank).
Controller's • Continues normal control (Communication function cannot be used).
Symptoms that
• Information may not be transmitted or received normally through KOMNET communication system
appear on
and machine may not operate normally.
machine
General
information

Disconnection in wiring Wiring harness between OEM L (female) (46) Resis-
Max. 1 z
harness (Disconnection in – OEM R (female) (46) tance
1
wiring or defective contact Wiring harness between OEM L (female) (47) Resis-
Max. 1 z
in connector) – OEM R (female) (47) tance
Wiring harness between OEM L (female) (46) Resis- 108 –
– OEM L (female) (47) tance 132 z
Possible
causes and the
standard values Ground fault in wiring har-
– OEM R (female) (46) tance
circuit)
Min. 1 Mz
– OEM R (female) (47) tance
Wiring harness between OEM L (female) (46) Resis- 108 –
– OEM L (female) (47) tance 132 z
Wiring harness between OEM R (female) Resis- 108 –
(46) – OEM R (female) (47) tance 132 z
26 D475A, D475ASD-5E0
Circuit diagram related to KOMNET
D475A, D475ASD-5E0 27
Failure code [CA2185] Decelerator pedal sensor power supply

abnormally high level (Only left bank): High voltage detection 1
Action code Failure code Symptom of Decelerator pedal sensor power supply abnormally high level (Only
CALL E03 CA2185 failure left bank): High voltage detection
Failure content • High voltage (above 5.25 V) was detected in decelerator pedal sensor power supply circuit.
• If trouble occurs while starting switch is ON, controller fixes sensor to value just before occurrence
Controller's of abnormality and continues operation.
action • If starting switch is turned ON while there is trouble, controller operates at 100% value.
Symptoms that
appear on • Engine speed cannot be controlled with decelerator pedal.
machine
General
information

Defective decelerator sen- When device at right
sor (Internal defect)
code disappears, that Decelerator sensor DEC connector
device has trouble in
it.
harness (Disconnection in Wiring harness between OEM L (female) (22) Resis-
2 Max. 1 z
wiring or defective contact – DEC (female) (A) tance
in connector) Wiring harness between OEM L (female) (23) Resis-
Max. 1 z
Possible – DEC (female) (C) tance
Ground fault in wiring har-
– DEC (female) (A) tance
circuit)
Min. 1 Mz
4 ness (with another wiring Between wiring harness between OEM L
harness) (female) (22) – DEC (female) (A) and wiring Resis- 108 –
harness between OEM L (female) (23) – DEC tance 132 z
(female) (C)
OEM L Voltage
Between (22) – (23) 4.75 – 5.25 V
28 D475A, D475ASD-5E0
Circuit diagram related to decelerator pedal sensor power supply
D475A, D475ASD-5E0 29
Failure code [CA2186] Decelerator pedal sensor power source too low
(At left bank only): Excessively low voltage detected 1
Action code Failure code Symptom of Decelerator pedal sensor power source too low (At left bank only):
CALL E03 CA2186 failure Excessively low voltage detected (Engine controller system)
Failure content • Excessively low voltage is detected in the decelerator pedal sensor (5V) power source circuit.
• Operates with the fixed value that is same as the value just before the abnormality is detected, if
abnormality occurs with the starting switch in the ON position.
Controller's
• If the starting switch is turned to the ON position in as-is abnormal condition, the controller oper-
action
ates with 100% value.
Symptoms that
appear on • Engine speed cannot be controlled by decelerator pedal.
machine
General
information
causes and the
standard values 1 Carry out troubleshooting for failure code [CA2185].
when normal
30 D475A, D475ASD-5E0
Failure code [CA2249] Loss of pressure feed from supply pump (2) (At
left bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (2) (At left bank): Loss of
CALL E03 CA2249 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 2) occurred in the common rail circuit.
Controller's • Operates with limited output.
Symptoms that • Engine is hard to start.
appear on • Exhaust gas color becomes black.
machine • Output decreases.
causes and the
standard values 1 Carry out troubleshooting of [CA559].
when normal
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At
right bank): Loss of pressure feed detected 1
Action code Failure code Symptom of Loss of pressure feed from supply pump (2) (At right bank): Loss of
CALL E03 CB2249 failure pressure feed detected (Engine controller system)
Failure content • Loss of pressure feed (level 2) occurred in the common rail circuit.
Controller's • Operates with limited output.
Symptoms that • Engine is hard to start.
appear on • Exhaust gas color becomes black.
machine • Output decreases.
causes and the
standard values 1 Carry out troubleshooting of [CB559].
when normal
D475A, D475ASD-5E0 31
Failure code [D110KA] Battery relay: Disconnection 1

Action code Failure code Symptom of Battery relay: Disconnection
— D110KA failure (Steering controller system)
Failure content • Current does not flow when outputting it to battery relay circuit.
Controller's
• Stops output to battery relay circuit.
action
Symptoms that
appear 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.
General
(Code 60600: Battery relay drive voltage)
information
• Method of reproducing failure code: Switch starting switch from ON to OFF.

Defective battery relay
1 Battery relay Continuity
(Internal disconnection)
Between terminals BR –
Continue
ground terminal (E)
harness (Disconnection in Wiring harness between STCN3 (female) (4) Resis-
Possible 2 Max. 1 z
wiring or defective contact – battery relay SW tance
causes and the in connector)
standard values Wiring harness between battery relay ground Resis-
Max. 1 z
when normal terminal – chassis ground tance
Short circuit with chassis
ground in wiring harness
3 Short circuit of wiring harness between
(Contact with ground cir- Resis-
cuit) STCN3 (female) (4) – battery relay SW – Min. 1 Mz
tance
KEY (female) (4) with chassis ground
Defective steering control- without turning starting switch ON.
4
ler STCN3 (female) Continuity
Between (4) – chassis ground Continue
32 D475A, D475ASD-5E0
Circuit diagram related to battery relay
D475A, D475ASD-5E0 33
Failure code [D110KB] Battery relay: Short circuit 1

Action code Failure code Symptom of Battery relay: Short circuit
— D110KB failure (Steering controller system)
Failure content • Abnormal current flowed to battery relay circuit when outputting it.
Controller's
• Stops output to battery relay circuit.
action
Symptoms that
appear 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.
General
(Code 60600: Battery relay drive voltage)
information
• Method of reproducing failure code: Switch starting switch from ON to OFF.

Battery relay Continuity/resistance
1 Between terminals BR –
(Internal short circuit) Continue
ground terminal (E)
Between terminal BR –
Min. 1 Mz
Possible chassis ground
causes and the a Prepare with starting switch OFF, then turn starting switch ON and
standard values carry out troubleshooting.
when normal Hot short in wiring harness
(Contact with 24V circuit)
STCN3 (female) (4) – battery relay SW – Voltage Max. 1 V
KEY (female) (4) with chassis ground
3 STCN3 Starting switch Voltage
ler
Between (4) –
ON 20 – 30 V
chassis ground
34 D475A, D475ASD-5E0
Circuit diagram related to battery relay
D475A, D475ASD-5E0 35
Failure code [D130KA] Neutral safety relay: Disconnection 1

Action code Failure code Symptom of Neutral safety relay: Disconnection
E02 D130KA failure (Transmission controller system)
Failure content • 24 V is not generated when ground of neutral safety relay circuit is interrupted.
action • Stops ground output to neutral safety relay circuit.
Symptoms that
appear 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)
General • Method of reproducing failure code: Turn starting switch ON and operate parking brake lever (Lock
information position).
a This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in
secondary side (contact side)

Defective neutral safety without turning starting switch ON.
1 relay (Internal disconnec-
NSF (male) Resistance
tion)
Between (1) – (2) 200 – 400 z
Defective disconnection in without turning starting switch ON.
wiring harness (Discon- Wiring harness between TMC2 (female) (8) – Resis-
2 Max. 1 z
nection in wiring or defec- NSF (female) (2) tance
tive contact in connector) Wiring harness between NSF (female) (1) – Resis-
Max. 1 z
Possible starting switch ACC (270) tance
when normal Short circuit with chassis Short circuit of wiring harness between
Resis-
ground in wiring harness TMC2 (female) (8) – NSF (female) (2) with Min. 1 Mz
3 tance
(Contact with ground cir- chassis ground
cuit) Short circuit of wiring harness between NSF
Resis-
(female) (1) – starting switch ACC (270) with Min. 1 Mz
tance
chassis ground
4 TMC2 Parking brake lever Voltage
controller
Between (8) – Lock position Max. 1 V
chassis ground Free position 20 – 30 V
36 D475A, D475ASD-5E0
Circuit diagram related to neutral safety relay
D475A, D475ASD-5E0 37
Failure code [D130KB] Neutral safety relay: Short circuit 1

Action code Failure code Symptom of Neutral safety relay: Short circuit
E02 D130KB failure (Transmission controller system)
Failure content • Abnormal current flowed in neutral safety relay circuit at the time of ground output.
action • Stops ground output to neutral safety relay circuit.
Symptoms that
appear 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)
General • Method of reproducing failure code: Turn starting switch ON and operate parking brake lever (Free
a This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in

Defective neutral safety without turning starting switch ON.
1
relay (Internal short circuit) NSF (male) Resistance
Between (1) – (2) 200 – 400 z
Possible
causes and the Hot short in wiring harness
standard values (Contact with 24 V circuit)
when normal TMC2 (female) (8) – NSF (female) (2) with Voltage Max. 1 V
chassis ground
3 TMC2 Parking brake lever Voltage
controller
Between (8) – Lock position Max. 1 V
chassis ground Free position 20 – 30 V
38 D475A, D475ASD-5E0
Circuit diagram related to neutral safety relay
D475A, D475ASD-5E0 39
Failure code [D161KA] Back-up alarm relay: Disconnection 1

Action code Failure code Symptom of Back-up alarm relay: Disconnection
E01 D161KA failure (Transmission controller system)
Failure content • 24 V is not generated when ground output of neutral safety relay circuit is interrupted.
Controller's
• Stops output to back-up alarm relay circuit.
action
Symptoms that
appear 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)
General
• Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (reverse).
information
a This failure code detects abnormality in primary side (coil side) of back-up alarm relay, but not in

If fuse is burnout, circuit probably has short circuit with chassis
1 Defective fuse FS22-1
ground.
Defective back-up alarm without turning starting switch ON.
2 relay (Internal disconnec-
BKA (male) Resistance
tion)
Between (1) – (2) 200 – 400 z
Defective disconnection in without turning starting switch ON.
wiring harness (Discon- Wiring harness between TMC2 (female) (18) Resis-
3 Max. 1 z
nection in wiring or defec- –BKA (female) (2) tance
Possible tive contact in connector) Wiring harness between BKA (female) (1) – Resis-
Max. 1 z
causes and the FS22-1 outlet port tance
Short circuit with chassis Short circuit of wiring harness between
Resis-
ground in wiring harness TMC2 (female) (18) – BKA (female) (2) with Min. 1 Mz
4 tance
cuit) Short circuit of wiring harness between BKA
Resis-
(female) (1) – FS22-1 outlet port with chassis Min. 1 Mz
tance
ground
controller
Between (18) – Neutral position 20 – 30 V
chassis ground Reverse position Max. 1 V
40 D475A, D475ASD-5E0
Circuit diagram related to back-up alarm relay
D475A, D475ASD-5E0 41
Failure code [D161KB] Back-up alarm relay: Short circuit 1

Action code Failure code Symptom of Back-up alarm relay: Short circuit
E01 D161KB failure (Transmission controller system)
Failure content • Abnormal current flowed in back-up alarm relay circuit at the time of ground output.
Controller's
• Stops output to back-up alarm relay circuit.
action
Symptoms that
appear 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)
General • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (Reverse
a This failure code detects abnormality in primary side (coil side) of back-up alarm relay, but not in

Defective back-up alarm without turning starting switch ON.
1
relay (Internal short circuit) BKA (male) Resistance
Between (1) – (2) 200 – 400 z
Possible
causes and the Hot short in wiring harness
standard values (Contact with 24 V circuit)
when normal TMC2 (female) (18) – BKA (female) (2) with Voltage Max. 1 V
chassis ground
controller
Between (18) – Neutral position 20 – 30 V
chassis ground Reverse position Max. 1 V
42 D475A, D475ASD-5E0
Circuit diagram related to back-up alarm relay
D475A, D475ASD-5E0 43
Failure code [D182KZ] Preheater relay: Disconnection or short circuit 1

Action code Failure code Symptom of Preheater relay: Disconnection or short circuit
E01 D182KZ failure (Steering controller system)
Failure content • The upstream relay of the preheater relay does not operate.
Controller's
action
Symptoms that
• Automatic preheater system does not operate.
appear 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)
General
• Method of reproducing failure code: Turn the starting switch ON.
information
a This failure code detects abnormality on the primary (coil) side of the preheater relay and cannot
detect abnormality on the secondary (contact) side.

Defective preheater relay without turning starting switch ON.
1
(Internal disconnection) PHR (male) Resistance
Between (1) and (2) 200 – 400 z
harness
Wiring harness between STCN2 (female) Resis-
2 (Disconnection in wiring Max. 1 z
(19) and PHR (female) (2) tance
harness or defective con-
tact in connector) Wiring harness between PHR (female) (1) Resis-
Max. 1 z
Possible and starting switch ACC (270) tance
when normal Short circuit with chassis Between wiring harness between STCN2
Resis-
ground in wiring harness (female) (19) and RHR (female) (2) and Min. 1 Mz
3 tance
cuit) Between wiring harness between PHR
Resis-
(female) (1) and starting switch ACC (270) Min. 1 Mz
tance
and chassis ground
4 STCN2 Starting switch Voltage
ler
Between (19) chassis ON 20 – 30 V
ground OFF Max. 1 V
44 D475A, D475ASD-5E0
Circuit diagram related to preheater relay
D475A, D475ASD-5E0 45
Failure code [D190KA] Engine controller ACC signal cutout relay:

Disconnection 1
Action code Failure code Symptom of Engine controller ACC signal cutout relay: Disconnection
— D190KA failure (Steering controller system)
• The voltage 24 V of the engine controller ACC signal cutout relay circuit is not inconsistent with the
Failure content
output state of the controller.
Controller's
• Stops outputting power to ACC cut relay of engine controller.
action
Symptoms that
appear on
machine
• Output state (voltage) to engine controller ACC cut relay can be checked in monitoring mode.
(Code 60500: Voltage of engine controller ACC cut relay)
General
• Duplication of failure code: Turn on the starting switch.
information
a This failure code identifies a detected abnormality in primary side (coil side) of engine controller
ACC cut relay, but an abnormality in secondary side (contact side) can not be detected.

Defective engine controller switch still OFF.
1 ACC signal cutout relay
ACT (male) Resistance
(internal disconnection)
Between (1) – (2) 200 – 400 z
Possible
causes and the harness Wiring harness between STCN2 (female) (8) Resis-
2 Max. 1 z
standard values (disconnection or defective – ACT (female) (2) tance
contact of connectors) Wiring harness between ACT (female) (1) – Resis-
when normal Max. 1 z
starting switch ACC (270) tance
switch still OFF.
STCN2 (female) (8) – ACT (female) (2) tance
circuit)
Min. 1 Mz
ACT (female) (1) – starting switch ACC (270) tance
46 D475A, D475ASD-5E0
Circuit diagram related to engine controller ACC signal cut relay
D475A, D475ASD-5E0 47
Failure code [D190KB] Engine controller ACC signal cutout relay: Short
circuit 1
Action code Failure code Symptom of Engine controller ACC signal cutout relay: Short circuit
— D190KB failure (Steering controller system)
• Abnormal current flowed in the engine controller ACC signal cutout relay circuit at the time of
Failure content
ground output.
Controller's
• Stops the ground output of the engine controller ACC signal cutout relay circuit.
action
Symptoms that
appear on • Engine cannot be stopped by steering controller.
machine
General a This failure code identifies a detected abnormality in primary side (coil side) of engine controller
information ACC signal cutout relay, but an abnormality in secondary side (contact side) can not be detected.

Defective engine controller switch still OFF.
Possible 1 ACC signal cutout relay
ACT (male) Resistance
causes and the (internal disconnection)
standard values Between (1) – (2) 200 – 400 z
when normal a Prepare with starting switch OFF and diagnose with starting
switch ON.
2 ing (contact with ground
circuit) Between ground and wiring harness between
Voltage 20 – 30 V
STCN2 (female) (19) – ACT (female) (2)
48 D475A, D475ASD-5E0
Circuit diagram related to engine controller ACC signal cut relay
D475A, D475ASD-5E0 49
Failure code [D5ZRKA] Snap shot switch: Disconnection 1

Action code Failure code Symptom of Snap shot switch: Disconnection
— D5ZRKA failure (Steering controller system)
Failure content • When the snap shot switch circuit is disconnected from the chassis ground, 24 V is not generated.
Controller's
action
Symptoms that
appear on
machine
General
• Enter the snap shot mode and apply a trigger.
information

1
wiring harness or defective Wiring harness between STCN2 (female) (9)
contact in connector) Voltage Max. 1 V
and V3B (female) (6)
2 Between wiring harness between STCN2
Possible cuit) (female) (9) and V3B (female) (6) and chas- Min. 1 Mz
tance
causes and the sis ground
standard values a Prepare with starting switch OFF, then turn starting switch ON and
when normal carry out troubleshooting.
Defective steering STCN2 Snap shot switch Voltage
3
controller Trigger Max. 1 V
Between (9) and
Out of period just
chassis ground 20 – 30 V
after trigger
4 Defective VHMS controller
V3B Voltage
Between (6) and chassis ground 20 – 30 V
Circuit diagram related to snap shot switch
50 D475A, D475ASD-5E0
Failure code [D5ZRKB] Snap shot switch: Short circuit 1

Action code Failure code Symptom of Snap shot switch: Short circuit
— D5ZRKB failure (Steering controller system)
Failure content • Abnormal current flowed in snap shot switch circuit at the time of ground output.
Controller's
action
Symptoms that
appear on
machine
General
• 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 chas- Voltage Max. 1 V
sis ground
standard values Defective steering control- STCN2 Snap shot switch Voltage
2
when normal ler Trigger Max. 1 V
Between (9) and
Out of period
chassis ground 20 – 30 V
just after trigger
V3B Voltage
Between (6) and chassis ground 20 – 30 V
Circuit diagram related to snap shot switch
D475A, D475ASD-5E0 51
Failure code [DAFRKR] Monitor panel CAN communication:

Action code Failure code Symptom of Monitor panel CAN communication: Communication error
CALL E03 DAFRKR failure (Machine monitor system)
Failure content • Monitor panel cannot recognize steering controller in CAN communication circuit.
Controller's • Blinks warning lamp and sounds alarm buzzer.
action • Limits operations of engine and transmission.
Symptoms that • System may not operate normally.
appear on • Once machine is stopped, engine speed is limited to medium (half).
machine • Once machine is stopped, gear speed is limited to F1 and R1.
General
information

Wiring harness between S04 (female) (1), (2)
– STCN2 (female) (32) or TMC2 (female)
(32) or OEM L (female) (46) or OEM R Resis-
Max. 1 z
Disconnection in wiring (female) (46) or CT1 (female) (A) or V4A tance
harness (Disconnection in (female) (4) or RES (female) (A) or SRV
1
wiring or defective contact (male) (3)
in connector) Wiring harness between S04 (female) (3), (4)
Max. 1 z
(female) (47) or CT1 (female) (B) or V4A tance
(female) (12) or RES (female) (B) or SRV
(male) (10)
Possible Min. 1 Mz
causes and the (female) (46) or CT1 (female) (A) or V4A tance
standard values (female) (4) or RES (female) (A) or SRV
(male) (3)
when normal circuit)
Min. 1 Mz
(male) (10)
(32) or OEM L (female) (46) or OEM R
Voltage Max. 1 V
(female) (46) or CT1 (female) (A) or V4A
(female) (4) or RES (female) (A) or SRV
3 24V circuit) in wiring har-
(male) (3)
ness
Voltage Max. 1 V
(female) (47) or CT1 (female) (B) or V4A
(male) (10)
52 D475A, D475ASD-5E0

Possible Defective CAN terminal without turning starting switch ON.
4
causes and the resistor CT1 (male), RES (male) Resistance
standard values Between (A) – (B) 100 – 140 z
when normal If causes 1 – 4 are not detected, monitor panel or steering controller
Defective monitor panel or
5 may be defective. (Since trouble is in system, troubleshooting can-
steering controller
not be carried out.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0 53
Failure code [dAFRKR] Monitor panel CAN communication:

CALL E03 dAFRKR failure (Transmission controller system)
Failure content • Transmission cannot recognize monitor panel in CAN communication circuit.
action • Limits operations of engine, transmission and brake.
General
information

Max. 1 z
1
Max. 1 z
(male) (10)
Possible Min. 1 Mz
(male) (3)
Min. 1 Mz
(male) (10)
Voltage Max. 1 V
(male) (3)
ness
Voltage Max. 1 V
(male) (10)
54 D475A, D475ASD-5E0

4
when normal If causes 1 – 4 are not detected, monitor panel or transmission con-
5 troller may be defective. (Since trouble is in system, troubleshooting
transmission controller
cannot be carried out.)
D475A, D475ASD-5E0 55
Failure code [daFRKR] Monitor panel CAN communication:

CALL E03 daFRKR failure (Steering controller system)
Failure content • Steering controller cannot recognize monitor panel in CAN communication circuit.
General
information

Max. 1 z
1
Max. 1 z
(male) (10)
Possible Min. 1 Mz
(male) (3)
Min. 1 Mz
(male) (10)
Voltage Max. 1 V
(male) (3)
ness
Voltage Max. 1 V
(male) (10)
56 D475A, D475ASD-5E0

4
when normal If causes 1 – 4 are not detected, monitor panel or steering controller
steering controller
D475A, D475ASD-5E0 57
Failure code [DAQ0KT] Transmission controller: Abnormality in

controller 1
Action code Failure code Symptom of Transmission controller: Abnormality in controller
E01 DAQ0KT failure (Transmission controller system)
Failure content • Information of ROM (nonvolatile storage) of transmission controller is not normal.
Controller's
action
Symptoms that
appear on • Gear shift feeling of transmission may become worse.
machine
General
• Method of reproducing error code: Turn starting switch ON.
information
causes and the Troubleshooting cannot be carried out since it is internal defect.
standard values 1 (It is no problem even if you use controller unless no visible problem
when normal controller
appears on machine.)
58 D475A, D475ASD-5E0

Power supply voltage reduction (Input) 1
Action code Failure code Symptom of Transmission controller main power supply: Power supply voltage
CALL E04 DAQ1KK failure reduction (Input) (Transmission controller system)
Failure content • Transmission controller power supply voltage is below 17 V.
• Monitor panel may not display normally.
Symptoms that
• Relays and solenoids may not be driven and system may not operate normally.
appear on
machine
• Once machine is stopped, it cannot travel at all.
• Charge level (Voltage) of battery can be checked in monitoring mode
General
(Code 03200: Battery voltage).
information

Defective circuit breaker If circuit breaker CB6 is turned OFF, circuit probably has ground
1
CB6 (20 A) fault.
2
CB30 (30 A) fault.
Wiring harness between TMC3 (female) (1), Resis-
Max. 1 z
Disconnection in wiring (11) – CB6 (2) tance
harness (Disconnection in Resis-
3 Wiring harness between CB6 (1) – F30 Max. 1 z
wiring or defective contact tance
in connector) Wiring harness between B30S – battery relay Resis-
Max. 1 z
Possible BRB terminal tance
causes and the Wiring harness between TMC3 (female) (21), Resis-
Max. 1 z
standard values (31), (32), (33) – ground tance
(11) – CB6 (2) tance
circuit) Resis-
Wiring harness between CB6 (1) – F30 Min. 1 Mz
tance
Wiring harness between B30S – battery relay Resis-
Min. 1 Mz
BRB terminal tance
5 TMC3 Voltage
controller
Between (1), (11) – (21), (31),
20 – 30 V
(32), (33)
60 D475A, D475ASD-5E0
Circuit diagram related to transmission controller power supply
D475A, D475ASD-5E0 61

Action code Failure code Symptom of Transmission controller load power supply: Power supply voltage
Failure content • Power supply voltage of transmission controller load (relays, solenoids, etc.) is below 17 V.
Symptoms that • Relays and solenoids may not be driven and system may not operate normally.
machine • Once machine is stopped, it cannot travel at all.
• Charge level (Voltage) of battery can be checked in monitoring mode
General
(Code 03200: Battery voltage).
information

1
CB3 (20 A) fault.
2
CB105 (105 A) fault.
Max. 1 z
Disconnection in wiring (12), (22) – CB3 (2) tance
in connector) Wiring harness between B105S – battery Resis-
Max. 1 z
Possible relay BRC terminal tance
Max. 1 z
(12), (22) – CB3 (2) tance
Resis-
circuit) Wiring harness between CB3 (1) – F96 Min. 1 Mz
tance
Wiring harness between B105S – battery Resis-
Min. 1 Mz
relay BRC terminal tance
5 TMC3 Voltage
controller
Between (2), (12), (22) – (21),
20 – 30 V
(31), (32), (33)
62 D475A, D475ASD-5E0
Circuit diagram related to transmission controller power supply
D475A, D475ASD-5E0 63
Failure code [DAQ5KK] Transmission controller potentiometer power

supply: Source voltage reduction (input) 1
Action code Failure code Symptom of Transmission controller potentiometer power supply: Source voltage
CALL E03 DAQ5KK failure reduction (input) (Transmission controller system)
• Voltage of 5 V power supply circuit of transmission controller sensor is below 4.5 V or above 5.5 V.
Failure content
• Abnormal current flowed in 5 V power supply circuit of transmission controller sensor.
Controller's
• Stops output to 5 V power supply circuit if abnormal voltage flows.
action
machine • Once machine is stopped, travel is limited to F1 an R1.
General
information

Defective forward-reverse
TL2 (male) Resistance
1 potentiometer (Internal
Between (4) – (1) 3.2 kz ± 20%
short circuit)
Sensor Between (1) –
Min. 1 Mz
chassis ground
Short circuit with chassis without turning starting switch ON.
Possible ground in wiring harness
causes and the (Contact with ground cir- Resis-
TMC1 (female) (22) – TL2 (female) (4) with Min. 1 Mz
standard values cuit) tance
when normal chassis ground
Hot short in wiring harness
(Contact with 24 V circuit)
TMC1 (female) (22) – TL2 (female) (4) with Voltage Max. 1 V
chassis ground
Defective transmission carry out troubleshooting.
4
controller TMC1 Voltage
Between (22) – (21) 4.5 – 5.5 V
Circuit diagram related to transmission controller potentiometer power supply
64 D475A, D475ASD-5E0

Source voltage reduction (input) 1
Action code Failure code Symptom of Transmission controller sensor power supply: Source voltage reduc-
E01 DAQ6KK failure tion (input) (Transmission controller system)
• Voltage of 24 V power supply circuit of transmission controller sensor is below 12 V or above 30 V.
Failure content
• Abnormal current flowed in 24 V power supply circuit of transmission controller sensor.
Controller's
• Stops output to 24 V power supply circuit if abnormal voltage flows
action
Symptoms that
appear on
machine
General • Method of reproducing failure code: Turn starting switch ON
information (Then wire is not connected since this power supply is not used).

causes and the
standard values 1
when normal
(16) – (21) 20 – 30 V
D475A, D475ASD-5E0 65

Action code Failure code Symptom of Transmission controller sensor power supply: Power supply voltage
• Voltage of 5V power supply circuit for transmission controller sensors is below 4.5 V or above 5.5 V.
Failure content
• Abnormal current flowed in 5V power supply circuit for transmission controller sensors.
Controller's
• If abnormal current flows, controller stops output of 5V power supply circuit.
action
Symptoms that
appear on • System may not operate normally.
machine
General
information

Defective work equip- When device at right is disconnected, if failure code
HP1 or
ment pump oil pressure lights up (to indicate resetting), sensor has trouble in it.
1 HP2 con-
sensor (Internal short cir- a Turn starting switch OFF, disconnect connector, turn
nector
cuit) starting switch ON and carry out troubleshooting.
Possible 2 ness (Contact with GND
circuit) Wiring harness between TMC3 (female) (34) Resis-
– HP1 or HP2 (female) (B) tance
standard values
when normal Hot short (Contact with carry out troubleshooting.
ness Wiring harness between TMC3 (female) (34)
Voltage Max. 1 V
– HP1 or HP2 (female) (B)
Defective steering or carry out troubleshooting.
4
transmission controller TMC3, TMC1 Voltage
Between TMC3 (34) – TMC1 (21) 4.5 – 5.5 V
Circuit diagram related to transmission controller sensor power supply
66 D475A, D475ASD-5E0
Failure code [DAQ9KQ] Transmission controller type collation: Type

select signal inconsistency 1
Action code Failure code Symptom of Transmission controller type collation: Type select signal inconsis-
CALL E04 DAQ9KQ failure tency (Transmission controller system)
Failure content • Internal spec. setting of transmission controller is inconsistent with spec. set signal.
Symptoms that • Machine does not operate at all.
machine • Once machine is stopped, it cannot travel any more.
General
information

It is normal if error code lights on (reset display) after carrying out
1 adjustment mode.
controller adjustment
• Adjustment code: 0003: Transmission controller spec.
Possible Disconnection in wiring a Prepare with starting switch OFF, carry out troubleshooting with-
causes and the harness (Disconnection in out turning starting switch ON.
2
standard values wiring or defective contact Short circuit of wiring harness between Resis-
Max. 1 z
when normal in connector) TMC3 (female) (10) with chassis ground tance
3
Between (10) – chassis ground Max. 1 V
Circuit diagram related to transmission controller type select
D475A, D475ASD-5E0 67
Failure code [DAQRKR] Transmission controller sensor CAN

communication: Communication error (Objective component system
abnormality) 1
Action code Failure code Transmission controller CAN communication: Communication error
Symptom of
(Objective component system abnormality)
CALL E03 DAQRKR failure
(Transmission controller system)
• Transmission controller cannot recognize monitor panel, steering controller, engine controller or
Failure content
VHMS controller in CAN communication circuit.
General
information

Max. 1 z
1
Max. 1 z
(male) (10)
Possible (32) or OEM L (female) (46) or OEM R Resis-
Min. 1 Mz
(female) (46) or CT1 (female) (A) or V4A tance
causes and the Ground fault in wiring har-
when normal (male) (3)
circuit)
Min. 1 Mz
(male) (10)
Voltage Max. 1 V
(male) (3)
ness
Voltage Max. 1 V
(male) (10)
68 D475A, D475ASD-5E0

Defective CAN terminal without turning starting switch ON.
4
Possible resistor CT1 (male), RES (male) Resistance
causes and the Between (A) – (B) 100 – 140 z
standard values Defective monitor panel,
when normal If causes 1 – 4 are not detected, monitor panel, engine controller,
engine controller, trans-
transmission controller, steering controller or VHMS controller may
5 mission controller, steering
be defective. (Since trouble is in system, troubleshooting cannot be
controller or VHMS con-
carried out.)
troller
D475A, D475ASD-5E0 69

Defective communication (Abnormality in objective component
system) 1
Action code Failure code Transmission controller S-NET communication: Defective communi-
Symptom of
cation (Abnormality in objective component system)
E01 DAQSKR failure
(Transmission controller system)
Failure content • Transmission controller cannot recognize S-NET.
Controller's
• Takes no particular action.
action
Symptoms that
appear on • Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine
General
information

1
wiring or defective contact Wiring harness between TMC2 (female) (21) Resis-
Max. 1 z
in connector) – S01 (female) (8) tance
cuit) TMC2 (female) (21) – S01 (female) (8) with Min. 1 Mz
tance
chassis ground
standard values Hot short in wiring harness
when normal (Contact with 24 V circuit)
TMC2 (female) (21) – S01 (female) (8) with Voltage Max. 1 V
chassis ground
Defective monitor panel carry out troubleshooting.
4
(Switch module) S01 Voltage
Between (8) – chassis ground 6–9V
5
Between (21) – (31) 6–9V
70 D475A, D475ASD-5E0
Circuit diagram related to S-NET communication
D475A, D475ASD-5E0 71
SEN01826-00

© 2006 KOMATSU
All Rights Reserved
72
SEN01827-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error .... 4
Failure code [DB30KT] Steering controller: Abnormality in controller .................................................. 6
Failure code [DB31KK] Steering controller main power supply:
Power supply voltage reduction (Input)...................................................................................... 8
Failure code [DB32KK] Steering controller load power supply:
Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input).. 14
Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input).. 15
Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency ............ 16
Failure code [dB3RKR] Steering controller CAN communication: Communication error ................... 18
D475A, D475ASD-5E0 1

Defective communication (Abnormality in objective component system) ................................ 20
VHMS controller: Lowering of source voltage .......................................................................... 22
Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o "11")
Check of VHMS controller model: Disagreement of model selection....................................... 23
VHMS controller: Lowering of direct source voltage ................................................................ 24
VHMS sensor power supply (5 V): Lowering of output voltage ................................................ 25
VHMS sensor power supply (24 V): Lowering of output voltage .............................................. 26
VHMS sensor power supply (12 V): Lowering of output voltage .............................................. 28
Failure code [DBBQKR] (or VHMS_LED display "n8" o "02")
VHMS KOM-NET: Communication error .................................................................................. 30
Failure code [dbBRKR] VHMS controller CAN communication: Communication error ...................... 32
Failure code [DD12KA] Shift up switch: Disconnection...................................................................... 34
Failure code [DD12KB] Shift up switch: Short circuit ......................................................................... 36
Failure code [DD13KA] Shift down switch: Disconnection ................................................................. 38
Failure code [DD13KB] Shift down switch: Short circuit..................................................................... 40
Failure code [DD14KA] Parking brake lever switch: Disconnection ................................................... 42
Failure code [DD14KB] Parking brake lever switch: Short circuit....................................................... 44
Failure code [DDB9L4] Reverse switch: Signal disagreement........................................................... 46
Failure code [DDK3L4] Forward switch: Signal disagreement ........................................................... 48
Failure code [DDK5KA] Gearshift switch: Disconnection ................................................................... 50
Failure code [DDK5KB] Gearshift switch: Short circuit....................................................................... 52
Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time........ 54
Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time ........... 55
Failure code [DDN7KA] Blade pitch switch: Disconnection................................................................ 56
Failure code [DDN7KB] Blade pitch switch: Short circuit ................................................................... 58
Failure code [DDN9KA] Blade tilt switch: Disconnection.................................................................... 60
Failure code [DDN9KB] Blade tilt switch: Short circuit ....................................................................... 62
Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time ............. 64
Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time ................... 65
Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time .................. 66
Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time........................ 67
Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time.................. 68
Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time .............. 69
2 D475A, D475ASD-5E0

Failure code [DB2RKR] Engine controller (Left bank) CAN
communication: Communication error 1
Action code Failure code Symptom of Engine controller CAN communication: Communication error
CALL E03 DB2RKR failure (Steering controller system)
Failure content • Steering controller cannot recognize engine controller (Left bank) in CAN communication circuit.
General
information

Wiring harness between OEM L (female) (46)
– CT1 (female) (A) – STCN2 (female) (32) or
Resis-
TMC2 (female) (32) or RES (female) (A) or Max. 1 z
tance
Disconnection in wiring S04 (female) (1), (2) or V4A (female) (4) or
harness (Disconnection in SRV (male) (3)
1
wiring or defective contact Wiring harness between OEM L (female) (47)
in connector) – CT1 (female) (B) – STCN2 (female) (22) or
Resis-
TMC2 (female) (22) or RES (female) (B) or Max. 1 z
tance
S04 (female) (3), (4) or V4A (female) (12) or
SRV (male) (10)
Max. 1 z
– ACT (female) (6) tance
Possible Resis-
causes and the TMC2 (female) (32) or RES (female) (A) or Min. 1 z
tance
standard values S04 (female) (1), (2) or V4A (female) (4) or
Ground fault in wiring SRV (male) (3)
when normal 2 harness
(Contact with GND circuit) Wiring harness between OEM L (female) (47)
– CT1 (female) (B) – STCN2 (female) (22) or
Resis-
TMC2 (female) (22) or RES (female) (B) or Min. 1 z
tance
SRV (male) (10)
Min. 1 z
– ACT (female) (6) tance
TMC2 (female) (32) or RES (female) (A) or Voltage Max. 1 V
3 24V circuit) in wiring
SRV (male) (3)
harness
– CT1 (female) (B) – STCN2 (female) (22) or
TMC2 (female) (22) or RES (female) (B) or Voltage Max. 1 V
SRV (male) (10)
4 D475A, D475ASD-5E0

Defective CAN terminal without turning starting switch ON.
4
Possible resistor CT1 (male), ERS (male) Resistance
causes and the Between (A) – (B) 100 – 140 z
standard values Defective engine controller If engine cannot be started, engine controller power supply may be
when normal 5
power supply defective. Carry out troubleshooting for failure code [CA111].
If causes 1 – 5 are not detected, engine controller or steering con-
Defective engine controller
6 troller may be defective. (Since trouble is in system, troubleshooting
or steering controller
D475A, D475ASD-5E0 5
Failure code [DB30KT] Steering controller: Abnormality in controller 1

Action code Failure code Symptom of
Steering controller: Abnormality in controller
E01 DB30KT failure
Failure content • Information of ROM (nonvolatile storage) of steering controller is not normal.
Controller's
action
Symptoms that
• Steering performance may be reduced.
appear on
• Brake performance may be reduced.
machine
General
information
causes and the Troubleshooting cannot be carried out since it is internal defect.
standard values Defective steering
1 (It is no problem even if you use controller unless no visible problem
controller
when normal appears on machine.)
6 D475A, D475ASD-5E0
Failure code [DB31KK] Steering controller main power supply: Power

supply voltage reduction (Input) 1
Action code Failure code Symptom of Steering controller main power supply: Power supply voltage reduc-
CALL E04 DB31KK failure tion (Input) (Steering controller system)
Failure content • Steering controller power supply voltage is below 17 V.
• Monitor panel may not display normally.
Symptoms that
• Relays and solenoids may not be driven and system may not operate normally.
appear on
machine
General • Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage).
information • Method of reproducing failure code: Turn starting switch ON.

1
CB6 (20 A) fault.
2
CB30 (30 A) fault.
Wiring harness between STCN3 (female) (1), Resis-
Max. 1 z
Disconnection in wiring (11) – CB6 (2) tance
in connector) Wiring harness between B30S – battery relay Resis-
Max. 1 z
Possible BRB terminal tance
causes and the Wiring harness between STCN3 (female) Resis-
Max. 1 z
standard values (21), (31), (32), (33) – ground tance
when normal Prepare with starting switch OFF, then carry out troubleshooting
(11) – CB6 (2) tance
4 harness
Resis-
(Contact with GND circuit) Wiring harness between CB6 (1) – F30 Min. 1 Mz
tance
Wiring harness between B30S – battery relay Resis-
Min. 1 Mz
BRB terminal tance
Prepare with starting switch OFF, then turn starting switch ON and
Defective steering
5 STCN3 Voltage
controller
Between (1), (11) – (21), (31),
20 – 30 V
(32), (33)
8 D475A, D475ASD-5E0
Circuit diagram related to steering controller power supply
D475A, D475ASD-5E0 9
Failure code [DB32KK] Steering controller load power supply: Power

supply voltage reduction (Input) 1
Action code Failure code Symptom of Steering controller load power supply: Power supply voltage reduc-
CALL E04 DB32KK failure tion (Input) (Steering controller system)
Failure content • Power supply voltage of steering controller load (relays, solenoids, etc.) is below 17 V.
Symptoms that • Relays and solenoids may not be driven and system may not operate normally.
machine • Once machine is stopped, it cannot travel at all.
General • Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage).

1
CB1 (20 A) fault.
2
CB105 (105 A) fault.
Max. 1 z
Disconnection in wiring (12), (22) – CB1 (2) tance
in connector) Wiring harness between B105S – battery Resis-
Max. 1 z
Possible relay BRC terminal tance
Max. 1 z
when normal Prepare with starting switch OFF, then carry out troubleshooting
(12), (22) – CB3 (2) tance
4 harness
(Contact with GND circuit) Wiring harness between CB1 (1) – F96 Resis-
Min. 1 Mz
tance
Wiring harness between B105S – battery Resis-
Min. 1 Mz
relay BRC terminal tance
Prepare with starting switch OFF, then turn starting switch ON and
Defective steering
5 STCN3 Voltage
controller
Between (2), (12), (22) – (21),
20 – 30 V
(31), (32), (33)
10 D475A, D475ASD-5E0
Circuit diagram related to steering controller power supply
D475A, D475ASD-5E0 11

Action code Failure code Symptom of Steering controller potentiometer power supply: Power supply volt-
CALL E03 DB35KK failure age reduction (Input) (Steering controller system)
• Voltage of 5V power supply circuit for steering controller sensors is below 4.5 V or above 5.5 V.
Failure content
• Abnormal current flowed in 5V power supply circuit for steering controller sensors.
Controller's
• If abnormal current flows, controller stops output of 5V power supply circuit.
action
• Limits operations of engine and transmission.
General
information

Defective brake without turning starting switch ON.
1 potentiometer BRK (male) Resistance
(Internal short circuit) Between (C) – (A) 5 kz ± 20%
Sensor
Between (C) – ground Min. 1 Mz
Defective fuel control dial without turning starting switch ON.
2 potentiometer DIAL (male) Resistance
(Internal short circuit) Between (1) – (3) 5 kz ± 15%
Sensor
Between (1) – ground Min. 1 Mz
Defective steering without turning starting switch ON.
Possible 3 potentiometer TL2 (male) Resistance
causes and the (Internal short circuit) Between (5) – (8) 3.2 kz ± 20%
standard values
when normal
4 harness Wiring harness between STCN1 (female)
(Contact with GND circuit) (22) – TL2 (female) (5) or BRK (female) (C) Resis-
Min. 1 Mz
tance
or DIAL (female) (1)
Hot short (Contact with carry out troubleshooting.
5 24V circuit) in wiring Wiring harness between STCN1 (female)
harness (22) – TL2 (female) (5) or BRK (female) (C) Voltage Max. 1 V
or DIAL (female) (1)
Defective steering carry out troubleshooting.
6
controller STCN1 Voltage
Between (22) – (21) 4.5 – 5.5 V
12 D475A, D475ASD-5E0
Circuit diagram related to steering controller potentiometer power supply
D475A, D475ASD-5E0 13

Action code Failure code Symptom of Steering controller sensor power supply: Source voltage reduction
CALL E03 DB36KK failure (input) (Steering controller system)
• Voltage of 24 V power supply circuit of steering controller sensor is below 12 V or above 30 V.
Failure content
• Abnormal current flowed in 24 V power supply circuit of steering controller sensor.
machine • Once machine is stopped, travel is limited to F1 and R1.
General
information

It is internal defect if error code lights on (reset display)
Defective blade pitch
when disconnecting right connector. PT1
1 angle sensor (Internal
a Disconnect connector with starting switch OFF, then connector
short circuit)
turn starting switch ON and carry out troubleshooting.
causes and the ground in wiring harness
standard values 2 Short circuit of wiring harness between
when normal STCN1 (female) (16) – PT1 (female) (C) with Min. 1 Mz
cuit) tance
chassis ground
a Prepare with starting switch OFF, turn starting switch ON and
Defective steering control- carry out troubleshooting.
3
ler STCN1 Voltage
Between (16) – (21) 20 – 30 V
Circuit diagram related to steering controller sensor power supply
14 D475A, D475ASD-5E0

Action code Failure code Symptom of Steering controller sensor power supply: Source voltage reduction
CALL E03 DB37KK failure (input) (Steering controller system)
• Voltage of 5 V power supply circuit of steering controller sensor is below 4.5 V or above 5.5 V.
Failure content
• Abnormal current flowed in 5 V power supply circuit of steering controller sensor.
action • Stops output of 5 V power supply circuit if abnormal voltage flows.
Symptoms that
machine
General
information

It is internal defect if error code lights on (reset display)
Defective acceleration
when disconnecting right connector. SSA
1 sensor
a Disconnect connector with starting switch OFF, then connector
(Internal short circuit)
turn starting switch ON and carry out troubleshooting.
Possible STCN3 (female) (34) – SSA (female) (C) with Min. 1 Mz
cuit) tance
causes and the chassis ground
standard values a Prepare with starting switch OFF, turn starting switch ON and
STCN3 (female) (34) – SSA (female) (1) with Voltage Max. 1 V
chassis ground
Defective steering
4 STCN1, STCN3 Voltage
controller
Between STCN3 (34) –
20 – 30 V
STCN1 (21)
Circuit diagram related to steering controller sensor power supply
D475A, D475ASD-5E0 15
Failure code [DB39KQ] Steering controller type selection: Type select

signal inconsistency 1
Action code Failure code Symptom of Steering controller type selection: Type select signal inconsistency
CALL E04 DB39KQ failure (Steering controller system)
Failure content
• Internal spec. setting of steering controller is inconsistent with spec. set signal.
Controller's
• Stops all outputs of steering controller.
action
• Limits operation of engine, transmission, and brake.
Symptoms that • Problem that appears on machineMachine does not operate at all.
General
information

It is normal if failure code indicates (reset display) after carrying out
Defective steering
1 adjustment mode.
controller adjustment
• Adjustment code: 0002 (Steering controller spec. set)
Possible Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
causes and the harness (Disconnection in without turning starting switch ON.
2
standard values wiring or defective contact Wiring harness between STCN3 (female) Resis-
when normal (20) – chassis ground tance
3
Between (20) – chassis ground Max. 1 V
Circuit diagram related to steering controller type select
16 D475A, D475ASD-5E0
Failure code [dB3RKR] Steering controller CAN communication:

Action code Failure code Symptom of Steering controller CAN communication: Communication error
CALL E03 dB3RKR failure (Transmission controller system)
Failure content • Transmission controller cannot recognize steering controller in CAN communication circuit.
General
information

Max. 1 z
1
Max. 1 z
(male) (10)
Possible Min. 1 Mz
2 harness
(male) (3)
when normal (Contact with GND circuit)
Min. 1 Mz
(male) (10)
Voltage Max. 1 V
(male) (3)
harness
Voltage Max. 1 V
(male) (10)
18 D475A, D475ASD-5E0

4
when normal Defective steering If causes 1 – 4 are not detected, steering controller or transmission
5 controller or transmission controller may be defective. (Since trouble is in system, trouble-
controller shooting cannot be carried out.)
D475A, D475ASD-5E0 19

Defective communication (Abnormality in objective component system)1
Action code Failure code Steering controller S-NET communication: Defective communication
Symptom of
(Abnormality in objective component system)
E01 DB3SKR failure
(Steering controller system)
Failure content • Transmission controller cannot recognize S-NET.
Controller's
• Takes no particular action.
action
Symptoms that
appear on • Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine
General
information

1
wiring or defective contact Wiring harness between STCN2 (female) Resis-
Max. 1 z
in connector) (21) – S01 (female) (8) tance
(Contact with ground Resis-
STCN2 (female) (21) – S01 (female) (8) with Min. 1 Mz
circuit) tance
chassis ground
Possible a Prepare with starting switch OFF, turn starting switch ON and
when normal (Contact with 24 V circuit)
STCN2 (female) (21) – S01 (female) (8) with Voltage Max. 1 V
chassis ground
Defective monitor panel carry out troubleshooting.
4
(Switch module) S01 Voltage
Between (8) – chassis ground 6–9V
5
Between (21) – (31) 6–9V
20 D475A, D475ASD-5E0
Circuit diagram related to S-NET communication
D475A, D475ASD-5E0 21
Failure code [DBB0KK] (or LED of VHMS controller indicates "n9" o

"01") VHMS controller: Lowering of source voltage 1
Action code Failure code Symptom of VHMS controller: Lowering of source voltage
— DBB0KK failure (VHMS controller system)
Failure content • The switch source voltage is below 19.5 V.
Controller's
action
Symptoms that
appear on • The system may not operate normally.
machine
• The machine monitor does not display the failure code. (If the data saved in the VHMS controller
General
are downloaded to a personal computer, however, the failure code can be checked.)
information
• The LED of the VHMS controller indicates "n9" o "01".

harness (Disconnection in Wiring harness between V1 (female) (8), (9) Resis-
1 Max. 1 z
wiring harness or defective and FS12 (fuse) (1) tance
contact in connector) Wiring harness between V1 (female) (11) and Resis-
Max. 1 z
Possible GND 01 tance
standard values Short circuit with chassis
when normal ground in wiring harness
2 Between wiring harness between V1
circuit) (female) (8), (9) and FS12 (fuse) (1) and Min. 1 Mz
tance
chassis ground
Between V1 (female) (8), (9) and V1 (female)
Voltage 20 – 30 V
(11), (12) or chassis ground
Circuit diagram related to VHMS controller power supply
22 D475A, D475ASD-5E0
Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o

"11") Check of VHMS controller model: Disagreement of model
selection 1
Action code Failure code Symptom of VHMS controller model selection: Disagreement of model selection
— DBB0KQ failure signals (VHMS controller system)
Failure content • Wrong connection of connectors is displayed.
Controller's
action
Symptoms that
machine
General
information
• The LED of the VHMS controller indicates "nF" o "11".

Wrong connection of
VHMS controller connec- Check that the couple of connectors V2A and V3A and that of con-
1
tors (When system is nor- nectors V2B and V3B are connected correctly. If not, correct.
mal)
Possible harness (Disconnection in Between wiring harness V1 (female) (11), Resis-
causes and the 2 Max. 1 z
wiring harness or defective (12) and chassis ground tance
standard values
contact in connector) Between wiring harness V3A (female) (9) Resis-
and chassis ground tance
Between V1 (female) (11), (12) and chassis
3 Defective VHMS controller Voltage Max. 1 V
ground
Between V3A (female) (9) and chassis
Voltage Max. 1 V
ground
Circuit diagram related to model selection power supply
D475A, D475ASD-5E0 23
Failure code [DBB3KK] (or LED of VHMS controller indicates "n9" o

"05") VHMS controller: Lowering of direct source voltage 1
Action code Failure code Symptom of VHMS controller: Lowering of direct source voltage
— DBB3KK failure (VHMS controller system)
Failure content • The direct source voltage is below 19.5 V.
Controller's
action
Symptoms that
machine
General
information

harness (Disconnection in Wiring harness between V1 (female) (6), (7) Resis-
1 Max. 1 z
wiring harness or defective and FS12 (fuse) (2) tance
contact in connector) Wiring harness between V1 (female) (11) and Resis-
Max. 1 z
Possible GND 01 tance
standard values Short circuit with chassis
2 Between wiring harness between V1
circuit) (female) (6), (7) and FS12 (fuse) (2) and Min. 1 Mz
tance
chassis ground
Between V1 (female) (6), (7) and V1 (female)
Voltage 20 – 30 V
(11), (12) or chassis ground
Circuit diagram related to VHMS controller power supply
24 D475A, D475ASD-5E0
Failure code [DBB5KP] (or LED of VHMS controller indicates "n9" o

"04") VHMS sensor power supply (5 V): Lowering of output voltage 1
Action code Failure code Symptom of Sensor power supply (5 V): Lowering of output voltage
— DBB5KP failure (Disconnection or short circuit)
Failure content • The sensor source voltage (5 V) is out of the normal range (4.5 – 5.5 V).
Controller's
action
Symptoms that
machine
General
information

1 Short circuit of wiring harness between V1
cuit) (female) (4) – ENBP (female) (B) and chassis Min. 1 Mz
tance
Possible ground
causes and the Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
standard values harness (Disconnection in without turning starting switch ON.
when normal 2
wiring harness or defective Between wiring harness V1 (female) (4) and Resis-
contact in connector) Max. 1 z
ENBP (female) (B) tance
Between V1 (female) (4) and V2A (female) 4.5 –
Voltage
(12) 5.5 V
Circuit diagram related to sensor power supply 5 V
D475A, D475ASD-5E0 25

Action code Failure code Symptom of VHMS sensor power supply (24 V): Lowering of output voltage
— DBB6KP failure (Disconnection or short circuit) (VHMS controller system)
Failure content • The sensor source voltage (24 V) is out of the normal range (20 – 30 V).
Controller's
action
Symptoms that
machine
General
information

Disconnection in wiring
harness (Disconnection in Wiring harness between V1 (female) (2) –
1 EXA1 (female) (A), V1 (female) (2) – EXA2
wiring harness or defective Resis-
contact in connector) (female) (A), V1 (female) (2) – EXA3 (female) Max. 1 z
tance
(A), V1 (female) (2) – EXA4 (female) (A) – V1
(female) (2) – TMMD (female) (B)
Possible
causes and the
standard values
Short circuit with chassis Short circuit of wiring harness between V1
when normal
ground in wiring harness (female) (2) – EXA1 (female) (A), V1 (female)
2
(Contact with ground cir- (2) – EXA2 (female) (A), V1 (female) (2) – Resis-
cuit) Min. 1 Mz
EXA3 (female) (A), V1 (female) (2) – EXA4 tance
(female) (A) – V1 (female) (2) – TMMD
(female) (B) with chassis ground
3 Defective VHMS controller carry out troubleshooting.
Between V1 (2) and V2A (13) Voltage 20 – 30 V
26 D475A, D475ASD-5E0
D475A, D475ASD-5E0 27

Action code Failure code Symptom of VHMS sensor power supply (12 V): Lowering of output voltage
— DBB7KP failure (Disconnection or short circuit) (VHMS controller system)
Failure content • The sensor source voltage (12 V) is out of the normal range (11.5 – 12.5 V).
Controller's
action
Symptoms that
machine
General
information

1
wiring harness or defec- Between wiring harness V1 (female) (3) and Resis-
Max. 1 z
tive contact in connector) DLT (female) (1) tance
standard values 2 Short circuit of wiring harness between V1
when normal (female) (3) and DLT (female) (1) with chas- Min. 1 Mz
cuit) tance
sis ground
V1 Voltage
Between (3) and (11), (12) 11.5 – 12.5 V
28 D475A, D475ASD-5E0
Failure code [DBBQKR] (or VHMS_LED display "n8" o "02") VHMS

KOM-NET: Communication error 1
Action code Failure code Symptom of VHMS KOM-NET: Communication error
CALL E03 DBBQKR failure (VHMS controller system)
Failure content • Communication (CAN) information cannot be received from each controller.
Controller's
action
Symptoms that
machine
• Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
General
saved in VHMS controller into personal computer).
information
• "n8" on VHMS controller LED changes from "n8" to "02".

Max. 1 z
1
Max. 1 z
(male) (10)
Possible (32) or OEM L (female) (46) or OEM R Resis-
Min. 1 Mz
standard values 2 ness (Contact with GND
when normal (male) (3)
circuit)
Min. 1 Mz
(male) (10)
Voltage Max. 1 V
(male) (3)
ness
Voltage Max. 1 V
(male) (10)
30 D475A, D475ASD-5E0

causes and the
Defective CAN terminal CT1 (male), RES (male),
standard values 4
resistor RES L (male), RES R (male), Resistance
when normal
CTV (male)
Between (A) – (B) 100 – 140 z
D475A, D475ASD-5E0 31
Failure code [dbBRKR] VHMS controller CAN communication:

Action code Failure code Symptom of VHMS controller CAN communication: Communication error
— dbBRKR failure (Steering controller system)
Failure content • Steering controller cannot recognize VHMS controller in CAN communication circuit.
Controller's
action
Symptoms that
appear on • Data related to VHMS cannot be monitored.
machine
General • Data related to VHMS may not be obtained normally.

Max. 1 z
1
Max. 1 z
(male) (10)
Possible Min. 1 Mz
(male) (3)
when normal GND circuit)
Min. 1 Mz
(male) (10)
Voltage Max. 1 V
(male) (3)
harness
Voltage Max. 1 V
(male) (10)
32 D475A, D475ASD-5E0

4
when normal If causes 1 – 4 are not detected, steering controller or VHMS control-
5 ler may be defective. (Since trouble is in system, troubleshooting
ler or VHMS controller
D475A, D475ASD-5E0 33
Failure code [DD12KA] Shift up switch: Disconnection 1

Shift up switch: Disconnection (Transmission controller system)
E02 DD12KA failure
Failure content • Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time.
action • Recognizes that switch is not pressed.
Symptoms that
• Shift up is not possible.
appear 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.
General • 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 failure 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 Wiring harness between TMC1 (female) (6) – Resis-
Max. 1 z
harness (Disconnection in TL3 (female) (3) tance
2
– TL3 (female) (1) tance
Possible Wiring harness between TMC1 (female) (4) – Resis-
Max. 1 z
causes and the TL3 (female) (2) tance
Short circuit of wiring harness between
Hot short in wiring harness TMC1 (female) (6) – TL3 (female) (3) with Voltage Max. 1 V
3
(Contact with 24 V circuit) chassis ground
TMC2 (female) (37) – TL3 (female) (1) with Voltage Max. 1 V
chassis ground
Shift up switch
TMCN1,TMCN2
OFF (Release) ON (Press)
Defective transmission Voltage between
4
controller TMC1 (6) – TMC1 Max. 1 V 5 – 11 V
(10)
Voltage between
TMC2 (37) – TMC1 5 – 11 V Max. 1 V
(10)
34 D475A, D475ASD-5E0
Circuit diagram related to shift up switch and shift down switch
D475A, D475ASD-5E0 35
Failure code [DD12KB] Shift up switch: Short circuit 1

Shift up switch: Short circuit (Transmission controller system)
E02 DD12KB failure
Failure content • Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time.
Symptoms that
• Shift up is not possible.
appear on
machine
General • Input state (ON/OFF) from shift up switch can be checked in monitoring mode.

Shift up switch
TL3 (male)
1
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
Possible Short circuit with chassis Short circuit of wiring harness between
Resis-
causes and the ground in wiring harness TMC1 (female) (6) – TL3 (female) (3) with Min. 1 Mz
2 tance
standard values
when normal cuit) Short circuit of wiring harness between
Resis-
tance
chassis ground
Shift up switch
TMC1,TMC2
3
(10)
Voltage between
TMC2 (37) – TMC1 5 – 11 V Max. 1 V
(10)
36 D475A, D475ASD-5E0
D475A, D475ASD-5E0 37
Failure code [DD13KA] Shift down switch: Disconnection 1

Action code Failure code Symptom of Shift down switch: Disconnection
E02 DD13KA failure (Transmission controller system)
Failure content • Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time.
Symptoms that
• Shift down is not possible.
appear on
machine
General • 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 failure code: Turn starting switch ON and operate shift down switch.

Shift down switch
Defective shift down TL3 (male)
1 switch
Max. 1 z Min. 1 Mz
(5) – (6)
Resistance between
Min. 1 Mz Max. 1 z
(5) – (4)
Disconnection in wiring Wiring harness between TMC3 (female) (19) Resis-
Max. 1 z
harness (Disconnection in – TL3 (male) (6) tance
2
– TL3 (male) (4) tance
Possible Wiring harness between TMC1 (female) (10) Resis-
Max. 1 z
causes and the – TL3 (male) (5) tance
Hot short in wiring harness TMC3 (female) (19) – TL3 (male) (6) with Voltage Max. 1 V
3
TMC3 (female) (29) – TL3 (male) (4) with Voltage Max. 1 V
chassis ground
Shift down switch
TMC1, TMC3
4
(10)
Voltage between
TMC3 (29) – TMC1 5 – 11 V Max. 1 V
(10)
38 D475A, D475ASD-5E0
D475A, D475ASD-5E0 39
Failure code [DD13KB] Shift down switch: Short circuit 1

Action code Failure code Symptom of Shift down switch: Short circuit
E02 DD13KB failure (Transmission controller system)
Failure content • Signals of two systems of shift down switch circuit were turned ON (CLOSE)
Symptoms that
• Shift down is not possible.
appear on
machine
General • 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)
Resis-
causes and the ground in wiring harness TMC3 (female) (19) – TL3 (male) (6) with Min. 1 Mz
2 tance
standard values
Resis-
TMC3 (female) (29) – TL3 (male) (4) with Min. 1 Mz
tance
chassis ground
Shift down switch
TMC1, TMC3
3
(10)
Voltage between
TMC3 (29) – TMC1 5 – 11 V Max. 1 V
(10)
40 D475A, D475ASD-5E0
D475A, D475ASD-5E0 41
Failure code [DD14KA] Parking brake lever switch: Disconnection 1

Action code Failure code Symptom of Parking brake lever switch: Disconnection
E02 DD14KA failure (Transmission controller system)
• Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same
Failure content
time.
Controller's
• Recognizes parking brake lever is in Free position.
action
Symptoms that
appear on
• Once machine is stopped, travel is limited to F1 and R1.
machine
a Signals of parking brake switch are commonly used by transmission controller and steering con-
troller. Depending on where problem occurs, related codes may be displayed at the same time.
(Related code: DDQ2KA, DDQ2L4).
General
• Of signals of two systems of switch, NC is for operation detection and NO is for error detection.
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 failure code: Turn starting switch ON and operate parking brake lever.
When failure code [DD14KA] occurred alone

harness (Disconnection in Wiring harness between TMC1 (female) (18) Resis-
1 Max. 1 z
wiring or defective contact – branched point of circuit JF2 tance
in connector) Wiring harness between TMC1 (female) (12) Resis-
Possible Max. 1 z
– branched point of circuit JF1 tance
causes and the
standard values
when normal
Parking brake lever
TMC1
Defective transmission Free position Lock position
2
controller Between (18) –
Max. 1 V 5 – 11 V
chassis ground
Between (12) –
5 – 11 V Max. 1 V
chassis ground
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Parking brake lever switch Parking brake lever
1 NSW (male)
(Internal disconnection) Free position Lock position
Between (A) – (B) Max. 1 z Min. 1 Mz
Possible
Between (A) – (B) Min. 1 Mz Max. 1 z
causes and the
Disconnection in wiring Wiring harness between NSW (female) (B) – Resis-
Max. 1 z
harness (Disconnection in TMC1 (female) (18), – STCN2 (female) (5) tance
2
wiring or defective contact Wiring harness between NSW (female) (C) – Resis-
Max. 1 z
in connector) TMC1 (female) (12), – STCN2 (female) (15) tance
Wiring harness between NSW (female) (A) – Resis-
Max. 1 z
42 D475A, D475ASD-5E0
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Possible
causes and the Short circuit of wiring harness between NSW
Hot short in wiring harness (female) (B) – TMC1 (female) (18), – STCN2 Voltage Max. 1 V
standard values 3
(Contact with 24 V circuit) (female) (5) with chassis ground
when normal
Short circuit of wiring harness between NSW
(female) (C) – TMC1 (female) (12), – STCN2 Voltage Max. 1 V
(female) (15) with chassis ground
Circuit diagram related to parking brake switch
D475A, D475ASD-5E0 43
Failure code [DD14KB] Parking brake lever switch: Short circuit 1

Action code Failure code Symptom of Parking brake lever switch: Short circuit
E02 DD14KB failure (Transmission controller system)
• Signals of two systems of parking brake lever switch circuit were turned ON (CLOSE) at the same
Failure content
time.
Controller's
action
Symptoms that
appear on
machine
a Signals 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: DDQ2KB, DDQ2L4).
General
information
• Method of reproducing failure code: Turn starting switch ON and operate parking brake lever.

Parking brake lever switch Parking brake lever
1 NSW (male)
(Internal disconnection) Free position Lock position
Between (A) – (C) Min. 1 Mz Max. 1 z
a Prepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Possible Short circuit with chassis Wiring harness between NSW (female) (B) –
Resis-
causes and the ground in wiring harness TMC1 (female) (18), – STCN2 (female) (5) with Min. 1 Mz
2 tance
standard values
when normal cuit) Wiring harness between NSW (female) (C) –
Resis-
TMC1 (female) (12), – STCN2 (female) (15) Min. 1 Mz
tance
with chassis ground
Parking brake lever
TMC1
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
44 D475A, D475ASD-5E0
D475A, D475ASD-5E0 45
Failure code [DDB9L4] Reverse switch: Signal disagreement 1

Action code Failure code Symptom of Reverse switch: Signal disagreement
E03 DDB9L4 failure (Transmission controller system)
Failure content • Signals of 2 reverse switch circuit systems disagree with each other.
Controller's
• Assumes that switch is not pressed.
action
• Limits operations of engine, transmission and brake.
Symptoms that
appear on
• Once machine is stopped, gear speed is limited to F1.
machine
• Input state (ON/OFF) from reverse switch can be checked in monitoring mode (Code 40905: Trans-
General
mission controller input signal 1).
information
• Method of reproducing failure code: Turn starting switch ON (+ Operate reverse switch).

Reverse switch
TL3 (male)
Defective reverse switch OFF (Released) ON (Pressed)
1
Min. 1 Mz Max. 1 z
(6) – (5)
Resistance between
Min. 1 Mz Max. 1 z
(4) – (2)
Max. 1 z
harness (Disconnection in – TL3 (female) (6) tance
2
Wiring harness between TMC1 (female) (10) Resis-
Max. 1 z
Possible
causes and the Ground fault in wiring
standard values Wiring harness between TMC3 (female) (19) Resis-
when normal – TL3 (female) (6) tance
GND circuit)
Min. 1 Mz
Wiring harness between TMC3 (female) (19)
– TL3 (female) (6)
harness
Voltage Max. 1 V
Reverse switch
Reverse switch
OFF (Released) ON (Pushed)
5
controller TMC3 (19) – TMC1 5 – 11 V Max. 1 V
(10)
Voltage between
TMC3 (29) – TMC1 5 – 11 V Max. 1 V
(10)
46 D475A, D475ASD-5E0
Circuit diagram related to forward-reverse switch
D475A, D475ASD-5E0 47
Failure code [DDK3L4] Forward switch: Signal disagreement 1

Action code Failure code Symptom of Forward switch: Signal disagreement
E03 DDK3L4 failure (Transmission controller system)
Failure content • Signals of 2 forward switch circuit systems disagree with each other.
Controller's
• Assumes that switch is not pressed.
action
• Limits operations of engine, transmission and brake.
Symptoms that
appear on
• Once machine is stopped, gear speed is limited to F1.
machine
• Input state (ON/OFF) from forward switch can be checked in monitoring mode (Code 40905: Trans-
General
mission controller input signal 1).
information
• Method of reproducing failure code: Turn starting switch ON (+ Operate forward) switch.

Forward switch
TL3 (male)
Defective forward switch OFF (Released) ON (Pressed)
1
Min. 1 Mz Max. 1 z
(3) – (5)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
Wiring harness between TMC1 (female) (6) –
Disconnection in wiring Resis-
TL3 (female) (3) Max. 1 z
harness (Disconnection in 19–1. Resistance tance
2
wiring or defective contact
Max. 1 z
Max. 1 z
standard values Ground fault in wiring har-
Wiring harness between TMC1 (female) (6) – Resis-
when normal 3 ness (Contact with GND Min. 1 Mz
TL3 (female) (3) tance
circuit)
Min. 1 Mz
4 24V circuit) in wiring har- Voltage Max. 1 V
TL3 (female) (3)
ness
Voltage Max. 1 V
Forward switch
TMC1, TMC2
OFF (Released) ON (Pushed)
5
(10)
Voltage between
TMC2 (37) – TMC1 5 – 11 V Max. 1 V
(10)
48 D475A, D475ASD-5E0
Circuit diagram related to forward-reverse switch
D475A, D475ASD-5E0 49
Failure code [DDK5KA] Gearshift switch: Disconnection 1

Action code Failure code Symptom of Gearshift switch: Disconnection
E02 DDK5KA failure (Transmission controller system)
Failure content • Signals of 2 gearshift switch circuit systems are turned OFF (opened) simultaneously.
action • Assumes that switch is not pressed.
Symptoms that
• Gear cannot be shifted up or down (1st o 2nd).
appear on
• Auto shift-down function does not work.
machine
• Input state (ON/OFF) from gearshift switch can be checked in monitoring mode (40906: Transmis-
General
sion controller input signal 2).
information
• Method of reproducing failure code: Turn starting switch ON (+ operate gearshift switch).

Shift switch
SNC (female)
1
Max. 1 z Min. 1 Mz
(3) – (1)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
Disconnection in wiring Wiring harness between TMC2 (female) (7) – Resis-
Max. 1 z
harness (Disconnection in SNL (male) (2) tance
2
Max. 1 z
in connector) – SNC (male) (3) tance
Possible Max. 1 z
causes and the – SNC (male) (1) tance
Hot short in wiring harness TMC2 (female) (7) – SNC (male) (2) with Voltage Max. 1 V
3
TMC2 (female) (10) – SNC (male) (3) with Voltage Max. 1 V
chassis ground
Shift switch
TMC1,TMC2
4
(10)
Voltage between
TMC2 (10) – TMC1 Max. 1 V 5 – 11 V
(10)
50 D475A, D475ASD-5E0
Circuit diagram related to shift switch
D475A, D475ASD-5E0 51
Failure code [DDK5KB] Gearshift switch: Short circuit 1

Action code Failure code Symptom of Gearshift switch: Short circuit
E03 DDK5KB failure (Transmission controller system)
Failure content • Signals of 2 gearshift switch circuit systems are turned ON (closed) simultaneously.
action • Assumes that switch is not pressed.
Symptoms that
• Gear cannot be shifted up or down (1st o 2nd).
appear on
machine
• Input state (ON/OFF) from gearshift switch can be checked in monitoring mode (40906: Transmis-
General
sion controller input signal 2).
information
• Method of reproducing failure code: Turn starting switch ON (+ operate gearshift switch).

Shift switch
SNC (female)
1
Max. 1 z Min. 1 Mz
(3) – (1)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
Possible Resis-
causes and the ground in wiring harness TMC2 (female) (7) – SNC (male) (2) with Min. 1 Mz
2 tance
standard values (Contact with ground cir- chassis ground
cuit) Short circuit of wiring harness between
when normal Resis-
TMC2 (female) (10) – SNC (male) (3) with Min. 1 Mz
tance
chassis ground
Shift switch
TMC1,TMC2
3
(10)
Voltage between
TMC2 (10) – TMC1 Max. 1 V 5 – 11 V
(10)
52 D475A, D475ASD-5E0
Circuit diagram related to shift switch
D475A, D475ASD-5E0 53
Failure code [DDN2LD] (Blade tilt right oil pressure switch system:
Switch is ON for long time 1
Action code Failure code Symptom of Blade tilt right oil pressure switch system: Switch is ON for long time
E02 DDN2LD failure (Transmission controller system)
Failure content • The signal of the blade tilt right oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's • Flashes the caution lamp and turns on the caution buzzer.
action • Recognizes that the oil pressure switch is turned OFF.
Symptoms that • During right dual tilt operation, tilting is not limited.
appear on • Blade tilt right operation becomes slow.
machine • VHMS data is not always correct.
• The input state (ON/OFF) from the blade tilt right oil pressure switch can be checked in the moni-
General toring mode. (Code 40908: Blade lever oil pressure switch input state)
information • Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 sec-
onds).

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
normal) was operated to cause an error.
Defective blade tilt right oil troubleshooting.
2 pressure switch TRS (male) Blade lever Resistance
(Internal short circuit) Neutral Min. 1 Mz
Possible Between (1) and (2)
Right tilt Max. 1 z
causes and the
3 Between wiring harness between TMC2
(female) (6) and TRS (female) (1) and chas- Min. 1 Mz
cuit) tance
sis ground
troubleshooting.
Defective transmission TMC2, TMC1 Blade lever Voltage
4
controller
Between TMC2 (6) Neutral 5 – 11 V
and TMC1 (4) Right tilt Max. 1 V
Circuit diagram related to blade tilt right oil pressure switch
54 D475A, D475ASD-5E0
Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch
is ON for long time 1
Action code Failure code Symptom of Blade tilt left oil pressure switch system: Switch is ON for long time
E02 DDN3LD failure (Transmission controller system)
Failure content • The signal of the blade tilt left oil pressure switch circuit is kept turned ON for 60 seconds.
action • Recognizes that the oil pressure switch is turned OFF.
Symptoms that • During left dual tilt operation, tilting is not limited.
appear on • Blade tilt left operation becomes slow.
machine • VHMS data is not always correct.
• The input state (ON/OFF) from the blade tilt left oil pressure switch can be checked in the monitor-
General ing mode. (Code 40908: Blade lever oil pressure switch input state)
onds).

1 (When electrical system is reproductive operation is performed, it is suspected that the lever
Defective blade tilt left oil troubleshooting.
2 pressure switch (Internal TLS (male) Blade lever Resistance
short circuit) Neutral Min. 1 Mz
Left tilt Max. 1 z
causes and the
(female) (16) and TLS (female) (1) and chas- Min. 1 Mz
cuit) tance
sis ground
troubleshooting.
Defective transmission TMC2, TMC1 Blade lever Voltage
4
controller
and TMC1 (4) Left tilt Max. 1 V
Circuit diagram related to blade tilt left oil pressure switch
D475A, D475ASD-5E0 55
Failure code [DDN7KA] Blade pitch switch: Disconnection 1

Action code Failure code Symptom of Blade pitch switch: Disconnection
E02 DDN7KA failure (Transmission controller system)
Failure content • The signals of the 2 blade pitch switch circuit systems are turned OFF (opened) simultaneously.
action • Recognizes that the switch is not pressed.
Symptoms that
appear 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.
General
• 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 failure code: Turn the starting switch ON + (Operate blade tilt switch).

Blade pitch switch
Defective blade pitch P03 (male)
OFF (Released) ON (Pressed)
1 switch (Internal disconnec-
tion) Resistance between
Max. 1 z Min. 1 Mz
(1) and (5)
Resistance between
Min. 1 Mz Max. 1 z
(1) and (2)
Max. 1 z
harness (Disconnection in and P03 (female) (5) tance
2
wiring harness or defec- Wiring harness between TMC2 (female) (5) Resis-
Max. 1 z
tive contact in connector) and P03 (female) (2) tance
Max. 1 z
and P03 (female) (1) tance
causes and the
standard values a Prepare with starting switch OFF, then turn starting switch ON and
Between wiring harness between TMC2
Short circuit with power
(female) (15) and P03 (female) (5) and chas- Voltage Max. 1 V
3 source in wiring harness
sis ground
(Contact with 24-V circuit)
(female) (5) and P03 (female) (2) and chas- Voltage Max. 1 V
sis ground
Blade pitch switch
TMC1, TMC2
OFF (Released) ON (Pressed)
4
controller TMC2 (15) and Max. 1 V 5 – 11 V
TMC1 (4)
Voltage between
TMC2 (5) and 5 – 11 V Max. 1 V
TMC1 (4)
56 D475A, D475ASD-5E0
Circuit diagram related to blade pitch switch and blade tilt switch
D475A, D475ASD-5E0 57
Failure code [DDN7KB] Blade pitch switch: Short circuit 1

Action code Failure code Symptom of Blade pitch switch: Short circuit
E02 DDN7KB failure (Transmission controller system)
Failure content • Signals of two systems of blade pitch switch circuit were turned ON (CLOSE) at the same time.
Symptoms that
appear on • Blade pitch does not function (Operating blade pitch causes tilt operation.)
machine
General • 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 failure code: Turn starting switch ON and operate blade tilt switch.

Blade pitch switch
Defective blade pitch P03 (male)
1 switch (Internal disconnec-
tion) Resistance between
Max. 1 z Min. 1 Mz
(1) – (5)
Resistance between
Min. 1 Mz Max. 1 z
(1) – (2)
causes and the ground in wiring harness TMC2 (female) (15) – P03 (female) (5) with Voltage Max. 1 V
2
standard values (Contact with ground cir- chassis ground
TMC2 (female) (5) – P03 (female) (2) with Voltage Max. 1 V
chassis ground
Blade pitch switch
TMC1, TMC2
3 Voltage between
controller
TMC2 (15) – Max. 1 V 5 – 11 V
TMC1 (4)
Voltage between
5 – 11 V Max. 1 V
TMC2 (5) – TMC1 (4)
58 D475A, D475ASD-5E0
Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0 59
Failure code [DDN9KA] Blade tilt switch: Disconnection 1

Action code Failure code Symptom of Blade tilt switch: Disconnection
E01 DDN9KA failure (Transmission controller system)
Failure content • Signals of two systems of blade tilt switch circuit were turned OFF (OPEN) at the same time.
Controller's
• Recognizes switch is set at SINGLE side.
action
Symptoms that
appear on • Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.)
machine
General • 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 failure 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)
Max. 1 z
harness (Disconnection in – P03 (female) (6) tance
2
– P03 (female) (4) tance
Possible Wiring harness between TMC1 (female) (4) – Resis-
Max. 1 z
causes and the P03 (female) (3) tance
Hot short in wiring harness TMC2 (female) (35) – P03 (female) (6) with Voltage Max. 1 V
3
chassis ground
Blade tilt switch
TMC1, TMC2
SINGLE DUAL
4
controller TMC2 (35) – Max. 1 V 5 – 11 V
TMC1 (4)
Voltage between
TMC2 (25) – 5 – 11 V Max. 1 V
TMC1 (4)
60 D475A, D475ASD-5E0
D475A, D475ASD-5E0 61
Failure code [DDN9KB] Blade tilt switch: Short circuit 1

Blade tilt switch: Short circuit (Transmission controller system)
E01 DDN9KB failure
Failure content • Signals of two systems of blade tilt switch circuit were turned ON (CLOSE) at the same time.
Controller's
• Recognizes switch is set at SINGLE side.
action
Symptoms that
appear on • Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.)
machine
General • 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 failure 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)
causes and the ground in wiring harness TMC2 (female) (35) – P03 (female) (6) with Voltage Max. 1 V
2
standard values
chassis ground
Blade tilt switch
TMC1, TMC2
SINGLE DUAL
3
TMC1 (4)
Voltage between
TMC2 (25) – 5 – 11 V Max. 1 V
TMC1 (4)
62 D475A, D475ASD-5E0
D475A, D475ASD-5E0 63
Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch
Action code Failure code Symptom of Blade lift raise full oil pressure switch: Switch is ON for long time
— DDNALD failure (Transmission controller system)
Failure content • The signal of the blade lift raise full oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
• Recognizes that the oil pressure switch is turned OFF.
action
Symptoms that
• The data of the VHMS may become abnormal.
appear on
• Blade lift raise operation becomes slow.
machine
• The input state (ON/OFF) from the blade lift raise full oil pressure switch can be checked in the
General monitoring mode. (Code 40908: Ripper lever oil pressure switch input signal)
onds).

Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after
1 (When electrical system is the resetting operation is performed, it is suspected that the lever
Defective blade lift raise troubleshooting.
2 full oil pressure switch BLU (male) Blade lever Resistance
Raise Max. 1 z
causes and the
(female) (36) and BLU (female) (1) and chas- Min. 1 Mz
cuit) tance
sis ground
troubleshooting.
Defective transmission TMC1, TMC2 Ripper lever Voltage
4
controller
and TMC1 (10) Tilt in Max. 1 V
Circuit diagram related to blade lift raise full oil pressure switch
64 D475A, D475ASD-5E0
Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is
ON for long time 1
Action code Failure code Symptom of Ripper lift raise oil pressure switch: Switch is ON for long time
— DDNBLD failure (Transmission controller system)
Failure content • The signal of the ripper lift raise oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
action
Symptoms that • The shoe slip control (SSC) function does not operate normally.
appear on • Ripper lift raise operation becomes slow.
machine • The data of the VHMS may become abnormal.
• The input state (ON/OFF) from the ripper lift raise oil pressure switch can be checked in the moni-
General toring mode. (Code 70305: Steering controller input signal 3)
onds).

1 (When electrical system is resetting operation is performed, it is suspected that the lever was
normal) operated to cause an error.
Defective ripper lift raise oil troubleshooting.
2 pressure switch RPU (male) Ripper lever Resistance
Raise Max. 1 z
causes and the
(female) (13) and RPU (female) (1) and Min. 1 Mz
cuit) tance
chassis ground
troubleshooting.
4
controller
and TMC1 (4) Raise Max. 1 V
Circuit diagram related to ripper lift raise oil pressure switch
D475A, D475ASD-5E0 65
Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is
ON for long time 1
Action code Failure code Symptom of Ripper lift lower oil pressure switch: Switch is ON for long time
— DDNCLD failure (Transmission controller system)
Failure content • The signal of the ripper lift lower oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
action
appear on • The data of the VHMS may become abnormal.
machine • Ripper lift lower operation becomes slow.
• The input state (ON/OFF) from the ripper lift lower oil pressure switch can be checked in the moni-
General toring mode. (Code 70305: Steering controller input signal 3)
onds).

Defective ripper lift lower troubleshooting.
2 oil pressure switch RPD (male) Ripper lever Resistance
Lower Max. 1 z
causes and the
(female) (3) and RPD (female) (1) and chas- Min. 1 Mz
cuit) tance
sis ground
troubleshooting.
4
controller
and TMC1 (4) Lower Max. 1 V
Circuit diagram related to ripper lift lower oil pressure switch
66 D475A, D475ASD-5E0
Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON

for long time 1
Action code Failure code Symptom of Ripper tilt in oil pressure switch: Switch is ON for long time
— DDNDLD failure (Transmission controller system)
Failure content • The signal of the ripper tilt in oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
action
appear on • The data of the VHMS may become abnormal.
machine • Ripper tilt in operation becomes slow.
• The input state (ON/OFF) from the ripper tilt in oil pressure switch can be checked in the monitor-
General ing mode. (Code 70305: Ripper lever oil pressure switch input signal)
onds).

Defective ripper tilt in oil troubleshooting.
2 pressure switch (Internal RT1 (male) Ripper lever Resistance
short circuit) Neutral Min. 1 Mz
Tilt in Max. 1 z
causes and the
(female) (2) and RT1 (female) (1) and chas- Min. 1 Mz
cuit) tance
sis ground
troubleshooting.
4
controller
and TMC1 (4) Tilt in Max. 1 V
Circuit diagram related to ripper tilt in oil pressure switch
D475A, D475ASD-5E0 67
Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is
ON for long time 1
Action code Failure code Symptom of Ripper tilt back oil pressure switch: Switch is ON for long time
— DDNELD failure (Transmission controller system)
Failure content • The signal of the ripper tilt back oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
action
appear on • The tilt back speed of the ripper lowers.
machine • The data of the VHMS may become abnormal.
• The input state (ON/OFF) from the ripper tilt back oil pressure switch can be checked in the moni-
General toring mode. (Code 70305: Ripper lever oil pressure switch input signal)
onds).

Defective ripper tilt back oil troubleshooting.
2 pressure switch RT8 (male) Ripper lever Resistance
Tilt back Max. 1 z
causes and the
(female) (38) and RT8 (female) (1) and chas- Min. 1 Mz
cuit) tance
sis ground
troubleshooting.
4
controller
and TMC1 (4) Tilt back Max. 1 V
Circuit diagram related to ripper tilt back oil pressure switch
68 D475A, D475ASD-5E0
Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch
Action code Failure code Symptom of Blade lift lower full pressure switch: Switch is ON for long time
— DDNFLD failure (Transmission controller system)
Failure content • The signal of the blade lift lower full oil pressure switch circuit is kept turned ON for 60 seconds.
Controller's
action
Symptoms that
• The lift lower speed of the blade lowers.
appear on
• The data of the VHMS may become abnormal.
machine
• The input state (ON/OFF) from the blade lift lower full oil pressure switch can be checked in the mon-
General itoring mode. (Code 40908: Ripper lever oil pressure switch input signal)
onds).

Defective blade lift lower troubleshooting.
2 full oil pressure switch BLD (male) Blade lever Resistance
Lower full Max. 1 z
causes and the
(female) (26) and BLD (female) (1) and chas- Min. 1 Mz
cuit) tance
sis ground
troubleshooting.
4
controller
TMC2 (26) – Neutral 5 – 11 V
TMC1 (4) Tilt in Max. 1 V
Circuit diagram related to blade lift lower full oil pressure switch
D475A, D475ASD-5E0 69
SEN01827-00

© 2006 KOMATSU
All Rights Reserved
70
SEN01828-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Failure code [DDQ2KA] Parking brake lever switch: Disconnection .................................................... 4
Failure code [DDQ2KB] Parking brake lever switch: Short circuit........................................................ 6
Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals ..................................... 8
Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals ..................................... 9
Failure code [DDT5KA] Neutral switch: Disconnection ...................................................................... 10
Failure code [DDT5KB] Neutral switch: Short circuit.......................................................................... 12
Failure code [DDT5KQ] Lever specification selection: Model selection signal disagreement............ 14
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range......... 15
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection...................................... 16
Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range ...... 18
Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front):
Disconnection (or LED of VHMS controller indicates "n3" o "12") .......................................... 20
D475A, D475ASD-5E0 1
Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear):
Disconnection (or LED of VHMS controller indicates "n3" o "22") .......................................... 22
Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front):
Short circuit (or LED of VHMS controller indicates "n3" o "11") .............................................. 24
Left bank exhaust temperature sensor system (Rear): Short circuit ........................................ 26
Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o "24")
Right bank exhaust temperature sensor system (Front): Disconnection ................................. 28
Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o "26")
Right bank exhaust temperature sensor system (Rear): Disconnection .................................. 30
Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o "23")
Right bank exhaust temperature sensor system (Front): Short circuit ..................................... 32
Right bank exhaust temperature sensor system (Rear): Short circuit...................................... 34
Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection .................... 36
Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit ....................... 37
Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection ................... 38
Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit ....................... 39
Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o "32")
Blow-by pressure sensor system: Disconnection..................................................................... 40
Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o "31")
Blow-by pressure sensor system: Hot short............................................................................. 41
Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o "14")
Transmission oil pressure sensor: Out of input signal range ................................................... 42
Failure code [DK01KA] Left yoke angle sensor: Disconnection ......................................................... 43
Failure code [DK01KB] Left yoke angle sensor: Short circuit............................................................. 44
Failure code [DK03KA] Right yoke angle sensor: Disconnection....................................................... 45
Failure code [DK03KB] Right yoke angle sensor: Short circuit .......................................................... 46
Failure code [DK10KA] Fuel dial: Disconnection................................................................................ 47
Failure code [DK10KB] Fuel dial: Short circuit ................................................................................... 48
Failure code [DK30KA] Steering potentiometer (1): Disconnection.................................................... 49
Failure code [DK30KB] Steering potentiometer (1): Short circuit ....................................................... 50
Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range .................... 51
Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit ............................ 52
Failure code [DK30L8] Steering potentiometer (1): See table............................................................ 53
Failure code [DK31KA] Steering potentiometer (2): Disconnection.................................................... 54
Failure code [DK31KB] Steering potentiometer (2): Short circuit ....................................................... 55
2 D475A, D475ASD-5E0

Failure code [DDQ2KA] Parking brake lever switch: Disconnection 1
Action code Failure code Symptom of Parking brake lever switch: Disconnection
CALL E03 DDQ2KA failure (Steering controller system)
• Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same
Failure content
time.
Controller's
action
Symptoms that
appear on
machine
a Signals of parking brake switch are commonly used by transmission controller and steering con-
troller. Depending on where problem occurs, related codes may be displayed at the same time.
(Related code: DD14KA, DDQ2L4).
General
information
(Code 40910: Steering controller input signal 1)
• Method of reproducing failure code: Turn starting switch ON (and operate parking brake lever).
When failure code [DDQ2KA] occurred alone

harness (Disconnection Wiring harness between STCN2 (female) (5) Resis-
1 Max. 1 z
in wiring or defective con- – branched point of circuit JF2 tance
tact in connector) Wiring harness between STCN2 (female) (15) Resis-
Possible Max. 1 z
– branched point of circuit JF1 tance
causes and the
standard values
when normal
Parking brake lever
STCN2
Defective steering Free position Lock position
2
Max. 1 V 5 – 11 V
chassis ground
Between (15) –
5 – 11 V Max. 1 V
chassis ground
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time
Parking brake lever Parking brake lever
1 switch NSW
Free position Lock position
Possible
causes and the
Disconnection in wiring Wiring harness between NSW (female) (B) – Resis-
Max. 1 z
harness (Disconnection TMC1 (female) (18), – STCN2 (female) (5) tance
2
in wiring or defective con- Wiring harness between NSW (female) (C) – Resis-
Max. 1 z
tact in connector) TMC1 (female) (12), – STCN2 (female) (15) tance
Wiring harness between NSW (female) (A) – Resis-
Max. 1 z
4 D475A, D475ASD-5E0
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time
Possible
causes and the Short circuit of wiring harness between NSW
Hot short in wiring har-
(female) (B) – TMC1 (female) (18) – STCN2 Voltage Max. 1 V
standard values 3 ness (Contact with 24 V
Short circuit of wiring harness between NSW
(female) (C) – TMC1 (female) (12) – STCN2 Voltage Max. 1 V
D475A, D475ASD-5E0 5
Failure code [DDQ2KB] Parking brake lever switch: Short circuit 1

Action code Failure code Symptom of Parking brake lever switch: Short circuit
CALL E03 DDQ2KB failure (Steering controller system)
Failure content • Signals of both parking brake lever switch circuit systems are turned ON (closed) simultaneously.
Controller's
• Recognizes that parking brake lever is at FREE position.
action
Symptoms that
appear on
machine
a Since 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)
General
• NC and NO signals of both switch systems are for detecting operation and error respectively.
information
• Inputting from parking brake switch (ON/OFF) can be checked in monitoring mode.
When failure codes [DDQ2KA] and [DD14KA] are displayed simultaneously

Defective parking brake Parking brake lever
1 lever switch (Internal NSW (male)
At FREE At LOCK
short circuit)
Possible Short circuit with chassis Short circuit of wiring harness between NSW
Resis-
ground in wiring harness (female) (B) – TMC1 (female) (18) – STCN2 Min. 1 Mz
causes and the 2 tance
standard values (Contact with ground cir- (female) (5) with chassis ground
when normal cuit) Short circuit of wiring harness between NSW
Resis-
(female) (C) – TMC1 (female) (12) – STCN2 Min. 1 Mz
tance
Parking brake lever
STCN2
Defective steering At FREE At LOCK
3
Max. 1 V 5 – 11 V
chassis ground
Between (15) –
5 – 11 V Max. 1 V
chassis ground
6 D475A, D475ASD-5E0
D475A, D475ASD-5E0 7
Failure code [DDQ2L4] Parking brake lever switch: Disagreement of

signals 1
Action code Failure code Symptom of Parking brake lever switch: Disagreement of signals
CALL E03 DDQ2L4 failure (Steering controller system)
• Switch input signal of steering controller disagrees with communication signal from transmission
Failure content
controller.
Symptoms that
appear on
machine
a Since 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 simulta-
neously, depending on troubled part. (Related codes: DAFRKR, DB2RKR, DB3RKR, DAQRKR,
General
DD14KA, DD14KB, DDQ2KA, DDQ2KB)
information
• Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode.

See if failure codes [DAFRKR], [DBBQKR], [DB3RKR], and
Defective CAN communi-
1 [DAQRKR] are displayed. If they are displayed, carry out trouble-
Possible cation signal system
shooting for them first.
causes and the
Defective parking brake See if failure codes [DD14KA], [DD14KB], [DDQ2KA], and
standard values
when normal 2 lever switch signal sys- [DDQ2KB] are displayed. If they are displayed, carry out trouble-
tem shooting for them first.
Defective steering con-
3 Since trouble is in system, troubleshooting cannot be carried out.
troller
8 D475A, D475ASD-5E0
Failure code [dDQ2L4] Parking brake lever switch: Disagreement of

signals 1
Action code Failure code Symptom of Parking brake lever switch: Disagreement of signals
CALL E03 dDQ2L4 failure (Transmission controller system)
• Switch input signal of steering controller disagrees with communication signal from transmission
Failure content
controller.
Symptoms that
appear on
machine
a Since 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 simulta-
neously, depending on troubled part. (Related codes: DAFRKR, DB2RKR, DB3RKR, DAQRKR,
General
DD14KA, DD14KB, DDQ2KA, DDQ2KB)
information
• Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode.

See if failure codes [DAFRKR], [DBBQKR], [DB3RKR], and
Defective CAN communi-
1 [DAQRKR] are displayed. If they are displayed, carry out trouble-
Possible cation signal system
shooting for them first.
causes and the
Defective parking brake See if failure codes [DD14KA], [DD14KB], [DDQ2KA], and
standard values
when normal 2 lever switch signal sys- [DDQ2KB] are displayed. If they are displayed, carry out trouble-
tem shooting for them first.
Defective steering con-
3 Since trouble is in system, troubleshooting cannot be carried out.
troller
D475A, D475ASD-5E0 9
Failure code [DDT5KA] Neutral switch: Disconnection 1

Neutral switch: Disconnection (Transmission controller system)
CALL E04 DDT5KA failure
Failure content • Signals of two systems of neutral switch circuit were turned OFF (OPEN) at the same time.
action • Recognizes that switch is pressed.
Symptoms that
appear on
• Once machine is stopped, it cannot travel any more.
machine
• Input state (ON/OFF) from neutral switch can be checked in monitoring mode.
General
information
• Method of reproducing failure code: Turn starting switch ON (and operate neutral switch).

Neutral switch
SNC (male)
Defective neutral switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(4) – (6)
Resistance between
Min. 1 Mz Max. 1 z
(4) – (5)
Max. 1 z
harness (Disconnection – SNC (female) (6) tance
2
in wiring or defective con- Wiring harness between TMC2 (female) (17) Resis-
Max. 1 z
tact in connector) – SNC (female) (5) tance
Possible Max. 1 z
causes and the – SNC (female) (4) tance
standard values a Prepare with starting switch OFF, turn starting switch ON and carry
when normal out troubleshooting.
Short circuit of wiring harness between TMC2
(female) (27) – SNC (female) (6) with chassis Voltage Max. 1 V
3 ness (Contact with 24 V
ground
circuit)
Short circuit of wiring harness between TMC2
(female) (17) – SNC (female) (5) with chassis Voltage Max. 1 V
ground
Shift up switch
TMC1,TMC2
4
TMC1 (10)
Voltage between
TMC2 (17) – 5 – 11 V Max. 1 V
TMC1 (10)
10 D475A, D475ASD-5E0
Circuit diagram related to neutral switch
D475A, D475ASD-5E0 11
Failure code [DDT5KB] Neutral switch: Short circuit 1

Neutral switch: Short circuit (Transmission controller system)
CALL E04 DDT5KB failure
Failure content • Signals of two systems of neutral switch circuit were turned ON (CLOSE) at the same time.
action • Recognizes that switch is pressed.
Symptoms that
appear on
machine
• Input state (ON/OFF) from neutral switch can be checked in monitoring mode.
General
information
• Method of reproducing failure code: Turn starting switch ON (and operate neutral switch).

Neutral switch
SNC (male)
Defective neutral switch OFF (Release) ON (Press)
1
Max. 1 z Min. 1 Mz
(4) – (6)
Resistance between
Min. 1 Mz Max. 1 z
(4) – (5)
Short circuit with chassis Short circuit of wiring harness between TMC2
Possible Resis-
causes and the ground in wiring harness (female) (27) – SNC (female) (6) with chassis Min. 1 Mz
2 tance
standard values (Contact with ground cir- ground
cuit) Short circuit of wiring harness between TMC2
when normal Resis-
(female) (17) – SNC (female) (5) with chassis Min. 1 Mz
tance
ground
Shift up switch
TMC1, TMC2
3
TMC1 (10)
Voltage between
TMC2 (17) – 5 – 11 V Max. 1 V
TMC1 (10)
12 D475A, D475ASD-5E0
Circuit diagram related to neutral switch
D475A, D475ASD-5E0 13
Failure code [DDT5KQ] Lever specification selection: Model selection

signal disagreement 1
Action code Failure code Symptom of Lever specification selection: Model selection signal disagreement
CALL E04 DDT5KQ failure (Transmission controller system)
Failure content • Travel lever cannot select PCCS standard specification.
Controller's
action
Symptoms that
appear on
machine
• Input state (ON/OFF) from neutral switch can be checked in monitoring mode
General
information

causes and the – SNC (female) (5) tance
GND circuit)
– SNC (female) (6) tance
Defective engine
If cause 1 is not detected, transmission controller may be defective.
2 controller or transmis-
(Since trouble is in system, troubleshooting cannot be carried out.)
sion controller
Circuit diagram related to lever specification selection
14 D475A, D475ASD-5E0
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is

out of normal range 1
Action code Failure code Symptom of Hydraulic oil temperature sensor: Input signal is out of normal range
CALL E04 DGS1KX failure (Transmission controller system)
Failure content • Hydraulic oil temperature sensor signal is out of normal range.
Controller's
• Does not take any particular action.
action
Symptoms that
appear on • Hydraulic oil temperature gauge of monitor panel may not display normally.
machine
• Hydraulic oil temperature (temperature) can be checked in monitoring mode.
General
(Code 04401: Hydraulic oil temperature)
information
• Method of reproducing failure code: Turn starting switch ON or start engine.

Defective hydraulic oil without turning starting switch ON.
temperature sensor SDS (male) Resistance
1
(Internal disconnection or
short circuit) Between (1) – (2) 3.5 k – 90 kz (10 – 100°C)
Between (1) – chassis ground Min. 1 Mz
harness (Disconnection Wiring harness between TMC1 (female) (14) Resis-
2 Max. 1 z
in wiring or defective con- – SDS (female) (1) tance
tact in connector) Wiring harness between TMC1 (female) (21) Resis-
Max. 1 z
– SDS (female) (2) tance
Possible
causes and the Short circuit with chassis
when normal 3 Short circuit of wiring harness between TMC1
cuit) (female) (14) – SDS (female) (1) with chassis Min. 1 Mz
tance
ground
Short circuit with power out troubleshooting.
4 source in wiring harness Short circuit of wiring harness between TMC1
(Contact with 24 V circuit) (female) (14) – SDS (female) (1) with chassis Voltage Max. 1 V
ground
5 TMC1 (female) Resistance
controller
Between (14) – (21) 3.5 k – 90 kz (10 – 100°C)
Circuit diagram related to hydraulic oil temperature sensor
D475A, D475ASD-5E0 15
Failure code [DGT1KA] Power train oil temperature sensor:

Disconnection 1
Action code Failure code Symptom of Power train oil temperature sensor: Disconnection
E01 DGT1KA failure (Machine monitor system)
Failure content • The power train temperature sensor signal is lower than the specified value.
Controller's
• Nothing particular.
action
Symptoms that • Power train oil temperature on machine monitor is not displayed properly.
appear on • Fan speed is limited to half.
machine • Gear shift shock of transmission is large.
• Power train temperature state (temperature) can be checked in monitoring mode.
General
(Code 30100: Power train oil temperature)
information
• Duplication of failure code: Turn starting switch ON or start engine.

Defective power train oil still OFF.
1 temperature sensor 453 (male) Resistance
(Short circuit) Between (1) – (2) 3.5 kz – 90 kz (10 – 100°C)
a a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Wiring harness between S04 (female) (12) – Resis-
Defective harness Max. 1 z
453 (female) (1) tance
Wiring harness between S03 (female) (3) – Resis-
Possible ground circuit) Max. 1 z
causes and the 453 (female) (2) tance
standard values Wiring harness between S03 (female) (4) – Resis-
Max. 1 z
when normal 453 (female) (2) tance
Hot short of wiring
still OFF.
3 harness
Between ground and wiring harness between
(contact with 24 V circuit) Voltage Max. 1V
S04 (female) (12) – 453 (female) (1)
Defective machine moni- ON.
4
tor panel Between ground and wiring harness between
Voltage Max. 1V
S04 (female) (12) – 453 (female) (1)
Machine monitor can be suspected to defective if no problem is found
Defective machine
5 in causes 1 – 4 (since this is an internal defect, it cannot be diag-
monitor
nosed).
16 D475A, D475ASD-5E0
Circuit diagram related to power train oil temperature sensor
D475A, D475ASD-5E0 17
Failure code [DGT1KX] Power train oil temperature sensor: Input signal
is out of normal range 1
Action code Failure code Symptom of Power train oil temperature sensor: Input signal out of range
E01 DGT1KX failure (Machine monitor system)
Failure content • Power train temperature sensor signal is out of normal range.
Controller's
• Nothing particular.
action
Symptoms that • Power train oil temperature on machine monitor is not displayed properly.
appear on • Fan speed is limited to half.
machine • Gear shift shock of transmission is large.
• Power train temperature state (temperature) can be checked in monitoring mode.
General
(Code 30100: Power train oil temperature)
information
• Duplication of failure code: Turn starting switch ON or start engine.

Defective power train oil still OFF.
1 temperature sensor 453 (male) Resistance
(Short circuit) Between (1) – (2) 3.5 kz – 90 kz (10 – 100°C)
causes and the Defective harness
still OFF.
standard values 2 grounding (contact with
when normal ground circuit) Min. 1 Mz
S04 (female) (12) – 453 (female) (1) tance
Hot short of wiring
ON.
3 harness
(contact with 24 V circuit) Voltage Max. 1V
S04 (female) (12) – 453 (female) (1)
Defective machine
4 Since this is an internal defect, it cannot be diagnosed.
monitor
Circuit diagram related to power train oil temperature sensor
18 D475A, D475ASD-5E0
Failure code [DGT5KA] Left bank exhaust temperature sensor system

(Front): Disconnection (or LED of VHMS controller indicates "n3" o
"12") 1
Action code Failure code Symptom of Left bank exhaust temperature sensor system (Front): Disconnection
E01 DGT5KA failure (VHMS controller system)
Failure content • The signal voltage of the left bank exhaust temperature sensor is below 0.5 V.
Controller's
action
Symptoms that
appear on • The left bank exhaust temperature cannot be monitored with the monitoring function.
machine
General
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 sen-
Defective left bank Exhaust temperature
sor (Front) is replaced, the condition does not
2 exhaust temperature sensor is normal
become normal.
sensor
Exhaust temperature
sor (Front) is replaced, the condition becomes
sensor is defective
normal.
troubleshooting.
Between (A) and (C) Voltage 20 – 30 V
Before
Possible Defective left bank Approx.
exhaust temperature engine is 20°C Voltage
causes and the 3 0.9 – 1.2 V
sensor EXA2 – started
standard values Between
V1, V2A After
when normal amplifier (B) and
line engine is
(C) Approx.
started 500°C Voltage
2.6 – 3.5 V
(with no
load)
Wiring harness between V1 (female) (2) and Resis-
Max. 1 z
EXA2 (female) (A) tance
Disconnection in wiring Wiring harness between V2A (female) (7) and Resis-
Max. 1 z
harness (Disconnection EXA2 (female) (B) tance
4
in wiring harness or Wiring harness between V2A (female) (13) Resis-
defective contact) Max. 1 z
and EXA2 (female) (C) tance
Wiring harness between EXT2 (female) (1) Resis-
Max. 1 z
and EXTLF (female) (1) tance
Wiring harness between EXT2 (female) (2) Resis-
Max. 1 z
and EXTLF (female) (2) tance
20 D475A, D475ASD-5E0

troubleshooting.
Possible
causes and the
Defective VHMS troubleshooting.
standard values 5
controller V2A Exhaust temperature Voltage
when normal
Before engine is
Between 20°C Approx. 0.9 – 1.2 V
started
(7) and
After engine is started
(13) 500°C Approx. 2.6 – 3.5 V
(with no load)
Circuit diagram related to left bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0 21
Failure code [dGT5KA] Left bank exhaust temperature sensor system

(Rear): Disconnection (or LED of VHMS controller indicates "n3" o
"22") 1
Action code Failure code Symptom of Left bank exhaust temperature sensor system (Rear): Disconnection
E01 dGT5KA failure (VHMS controller system)
Failure content • The signal voltage of the left bank exhaust temperature sensor is below 0.5 V.
Controller's
action
Symptoms that
machine
General
information

Abnormal rise of left bank
1 exhaust temperature Check the engine, then repair it if it has any abnormality.
sor (Rear) is replaced, the condition does not
become normal.
sensor
Exhaust temperature
sor (Rear) is replaced, the condition becomes
sensor is defective
normal.
troubleshooting.
Before
Possible Defective left bank Approx.
causes and the 3 0.9 – 1.2 V
sensor EXA4 – started
standard values Between
V1, V2A After
when normal amplifier (B) and
line engine is
(C) Approx.
2.6 – 3.5 V
(with no
load)
Max. 1 z
Max. 1 z
4
defective contact) Max. 1 z
and EXA4 (female) (C) tance
Wiring harness between EXT4 (male) (1) and Resis-
Max. 1 z
EXTLR (female) (1) tance
Max. 1 z
EXTLR (female) (2) tance
22 D475A, D475ASD-5E0

troubleshooting.
Possible
causes and the
standard values 5
when normal
Before engine is
started
(6) and
(13) 500°C Approx. 2.6 – 3.5 V
(with no load)
Circuit diagram related to left bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0 23
Failure code [DGT5KB] Left bank exhaust temperature sensor system

(Front): Short circuit (or LED of VHMS controller indicates "n3" o "11")1
Action code Failure code Symptom of Left bank exhaust temperature sensor system (Front): Short circuit
— DGT5KB failure (VHMS controller system)
Failure content • The signal voltage of the left bank exhaust temperature sensor is above 4.9 V.
Controller's
action
Symptoms that
machine
General
information

sor is replaced, the condition does not
become normal.
sensor
Exhaust temperature
sor is replaced, the condition becomes nor-
sensor is defective
mal.
troubleshooting.
Defective left bank Before
Approx.
0.9 – 1.2 V
2 EXA2 – started
sensor Between
amplifier V1, V2A After
(B) and
line engine is
Possible (C) Approx.
causes and the 2.6 – 3.5 V
(with no
standard values
load)
when normal
Between wiring harness between V1 (female) Resis-
Min. 1 Mz
(2) and EXA2 (female) (A) and chassis ground tance
Between wiring harness between V2A
Short circuit with chassis Resis-
(female) (7) and EXA2 (female) (B) and chas- Min. 1 Mz
ground in wiring harness tance
3 sis ground
(Contact with ground cir-
cuit) Between wiring harness between EXT2
Resis-
(male) (1) and EXTLF (female) (1) and chas- Min. 1 Mz
tance
sis ground
Between wiring harness between EXT2
Resis-
(male) (2) and EXTLF (female) (2) and chas- Min. 1 Mz
tance
sis ground
Short circuit with power a Prepare with starting switch OFF, then carry out troubleshooting
source in wiring harness without turning starting switch ON.
4
(Contact with 24-V cir- Between wiring harness between V1 (female) Resis-
Min. 1 Mz
cuit) (2) and EXA2 (female) (B), (C) tance
24 D475A, D475ASD-5E0

troubleshooting.
Possible
causes and the
Defective VHMS control- troubleshooting.
standard values 5
ler V2A Exhaust temperature Voltage
when normal
Before engine is
started
(7) and
(13) 500°C Approx. 2.6 – 3.5 V
(with no load)
Circuit diagram related to left bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0 25
Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" o

"21") Left bank exhaust temperature sensor system (Rear): Short
circuit 1
Action code Failure code Symptom of Left bank exhaust temperature sensor system (Rear): Short circuit
— dGT5KB failure (VHMS controller system)
Failure content • The signal voltage of the left bank exhaust temperature sensor is above 4.9 V.
Controller's
action
Symptoms that
machine
General
information

sor is replaced, the condition does not
become normal.
sensor
Exhaust temperature
sor is replaced, the condition becomes nor-
sensor is defective
mal.
troubleshooting.
Defective left bank Before
Approx.
engine is 20°C Voltage
exhaust temperature 0.9 – 1.2 V
2 EXA4 – started
sensor Between
amplifier V1, V2A After
line (B) and
(C) engine is
Possible Approx.
(with no
standard values
load)
when normal
Min. 1 Mz
3 sis ground
Resis-
(male) (1) and EXTLR (female) (1) and chas- Min. 1 Mz
tance
sis ground
Resis-
(male) (2) and EXTLR (female) (2) and chas- Min. 1 Mz
tance
sis ground
Short circuit with power a Prepare with starting switch OFF, then carry out troubleshooting
source in wiring harness without turning starting switch ON.
4
(Contact with 24-V cir- Between wiring harness between V1 (female) Resis-
Min. 1 Mz
cuit) (2) and EXA4 (female) (B), (C) tance
26 D475A, D475ASD-5E0

troubleshooting.
Possible
causes and the
Defective VHMS control- troubleshooting.
standard values 5
ler V2A Exhaust temperature Voltage
when normal
Before engine is
started
(6) and
(13) 500°C Approx. 2.6 – 3.5 V
(with no load)
Circuit diagram related to left bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0 27
Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o

"24") Right bank exhaust temperature sensor system (Front):
Disconnection 1
Action code Failure code Symptom of Right bank exhaust temperature sensor system (Front): Disconnec-
— DGT6KA failure tion (VHMS controller system)
Failure content • The signal voltage of the right bank exhaust temperature sensor is below 0.5 V.
Controller's
action
Symptoms that
appear on • The right bank exhaust temperature cannot be monitored with the monitoring function.
machine
General
information

Abnormal rise of right
bank exhaust tempera-
1 Check the engine, then repair it if it has any abnormality.
ture
When the right bank exhaust temperature
Defective right bank Exhaust temperature
sensor (Front) is replaced, the condition does
not become normal.
sensor
Exhaust temperature
sensor (Front) is replaced, the condition
sensor is defective
becomes normal.
troubleshooting.
Possible Before
Defective right bank Approx.
causes and the engine is 20°C Voltage
0.9 – 1.2 V
standard values 3 exhaust temperature EXA1 – started
sensor amplifier Between
when normal V1, V2A After
(B) and
line engine is
(C) Approx.
2.6 – 3.5 V
(with no
load)
Max. 1 z
Max. 1 z
4
Max. 1 z
defective contact) and EXA1 (female) (C) tance
Max. 1 z
EXTRF (female) (1) tance
Max. 1 z
EXTRF (female) (2) tance
28 D475A, D475ASD-5E0

troubleshooting.
Possible
causes and the
standard values 5
when normal
Before engine is
started
(5) and
(13) 500°C Approx. 2.6 – 3.5 V
(with no load)
Circuit diagram related to right bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0 29
Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o

"26") Right bank exhaust temperature sensor system (Rear):
Disconnection 1
Action code Failure code Symptom of Right bank exhaust temperature sensor system (Rear): Disconnection
— dGT6KA failure (VHMS controller system)
Failure content • The signal voltage of the right bank exhaust temperature sensor is below 0.5 V.
Controller's
action
Symptoms that
machine
General
information

Abnormal rise of right
bank exhaust tempera-
1 Check the engine, then repair it if it has any abnormality.
ture
sensor (Rear) is replaced, the condition does
not become normal.
sensor
Exhaust temperature
sensor (Rear) is replaced, the condition
sensor is defective
becomes normal.
troubleshooting.
Possible Before
Defective right bank Approx.
causes and the engine is 20°C Voltage
0.9 – 1.2 V
standard values 3 exhaust temperature EXA3 – started
when normal V1, V2A After
(B) and
line engine is
(C) Approx.
2.6 – 3.5 V
(with no
load)
Max. 1 z
Disconnection in wiring Wiring harness between V2A (female) (16) Resis-
Max. 1 z
harness (Disconnection and EXA3 (female) (B) tance
4
Max. 1 z
defective contact) and EXA3 (female) (C) tance
Max. 1 z
EXTRR (female) (1) tance
Max. 1 z
EXTRR (female) (2) tance
30 D475A, D475ASD-5E0

troubleshooting.
Possible
causes and the
standard values 5
when normal
Before engine is
started
(16) and
(13) 500°C Approx. 2.6 – 3.5 V
(with no load)
Circuit diagram related to right bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0 31
Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o

"23") Right bank exhaust temperature sensor system (Front): Short
circuit 1
Action code Failure code Symptom of Right bank exhaust temperature sensor system (Front): Short circuit
— DGT6KB failure (VHMS controller system)
Failure content • The signal voltage of the right bank exhaust temperature sensor is above 4.9 V.
Controller's
action
Symptoms that
machine
General
information

sensor (Front) is replaced, the condition does
not become normal.
sensor
Exhaust temperature
sensor (Front) is replaced, the condition
sensor is defective
becomes normal.
troubleshooting.
Before
Approx.
Defective right bank engine is 20°C Voltage
0.9 – 1.2 V
2 exhaust temperature EXA1 – started
V1, V2A After
line (B) and
(C) engine is
Possible Approx.
(with no
standard values
load)
when normal
Min. 1 Mz
3 sis ground
Resis-
(male) (1) and EXTRF (female) (1) and chas- Min. 1 Mz
tance
sis ground
Resis-
(male) (2) and EXTRF (female) (2) and chas- Min. 1 Mz
tance
sis ground
4 ness (Contact with 24-V
circuit) Min. 1 Mz
(2) and EXA1 (female) (B), (C) tance
32 D475A, D475ASD-5E0

troubleshooting.
Between V1 (2) and chassis ground Voltage 20 – 30 V
Possible
causes and the
standard values 5
when normal
Before engine is
started
(5) and
(13) 500°C Approx. 2.6 – 3.5 V
(with no load)
Circuit diagram related to right bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0 33
Failure code [dGT6KB] (or LED of VHMS controller indicates "n3" o

"25") Right bank exhaust temperature sensor system (Rear): Short
circuit 1
Action code Failure code Symptom of Right bank exhaust temperature sensor system (Rear): Short circuit
— dGT6KB failure (VHMS controller system)
Failure content • The signal voltage of the right bank exhaust temperature sensor is above 4.9 V.
Controller's
action
Symptoms that
machine
General
information

sensor (Rear) is replaced, the condition does
not become normal.
sensor
Exhaust temperature
sensor (Rear) is replaced, the condition
sensor is defective
becomes normal.
troubleshooting.
Before
Approx.
Defective right bank engine is 20°C Voltage
0.9 – 1.2 V
2 exhaust temperature EXA3 – started
V1, V2A After
line (B) and
(C) engine is
Possible Approx.
(with no
standard values
load)
when normal
Min. 1 Mz
(female) (16) and EXA3 (female) (B) and Min. 1 Mz
3 chassis ground
Resis-
(male) (1) and EXTRR (female) (1) and chas- Min. 1 Mz
tance
sis ground
Resis-
(male) (2) and EXTRR (female) (2) and chas- Min. 1 Mz
tance
sis ground
4 ness (Contact with 24-V
circuit) Min. 1 Mz
(2) and EXA3 (female) (B), (C) tance
34 D475A, D475ASD-5E0

troubleshooting.
Between V1 (2) and chassis ground Voltage 20 – 30 V
Possible
causes and the
standard values 5
when normal
Before engine is
started
(16) and
(13) 500°C Approx. 2.6 – 3.5 V
(with no load)
Circuit diagram related to right bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0 35
Failure code [DH22KA] Work equipment pump oil pressure sensor (F):
Disconnection 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (F): Disconnection
— DH22KA failure (Transmission controller system)
Failure content • Signal voltage of work equipment pump oil pressure sensor (F) circuit is below 0.2 V.
Controller's
action
Symptoms that
appear 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
General
mode. (Code 70701: Voltage of work equipment pump oil sensor (F))
information

Defective 5 V power See if error code [DAQ7KK] is displayed. If it is displayed, carry out
1
source system troubleshooting for it first.
Defective work equip- a Prepare with starting switch OFF, turn starting switch ON and carry
ment pump oil pressure out troubleshooting.
2
sensor (F) (Internal trou- HP1 Voltage
ble) Between (C) – (A) 0.5 – 6.0 V
Possible Disconnection in wiring Wiring harness between TMC3 (female) (34) Resis-
Max. 1 z
causes and the harness (Disconnection – HP1 (female) (B) tance
3
standard values in wiring or defective con- Wiring harness between TMC1 (female) (9) – Resis-
tact in connector) Max. 1 z
when normal HP1 (female) (C) tance
Max. 1 z
– HP1 (female) (A) tance
4 Short circuit of wiring harness between TMC1
cuit) (female) (9) – HP1 (female) (C) with chassis Min. 1 Mz
tance
ground
Transmission controller can be suspected to be defective if no prob-
5 lem is found in causes 1 – 4 (since this is an internal defect, it cannot
controller
be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (F)
36 D475A, D475ASD-5E0
Failure code [DH22KB] Work equipment pump oil pressure sensor (F):
Short circuit 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (F): Short circuit
— DH22KB failure (Transmission controller system)
Failure content • Signal voltage of work equipment pump oil pressure sensor (F) circuit is above 4.8 V
Controller's
action
Symptoms that
appear 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
General mode.
information (Code 70701: Voltage of work equipment pump oil pressure sensor (F))

1
2
sensor (F) (Internal trou- HP1 Voltage
Possible
ble) Between (C) – (A) 0.5 – 6.0 V
causes and the
when normal Hot short in wiring har- out troubleshooting.
3 ness (Contact with 24 V Short circuit of wiring harness between TMC1
circuit) (female) (9) – HP1 (female) (C) with chassis Voltage Max. 1 V
ground
controller
be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (F)
D475A, D475ASD-5E0 37
Failure code [DH23KA] Work equipment pump oil pressure sensor (R):
Disconnection 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (R): Disconnection
— DH23KA failure (Transmission controller system)
Failure content • Signal voltage of work equipment pump oil pressure sensor (R) circuit is below 0.2 V.
Controller's
action
Symptoms that
appear 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
General
mode. (Code 70703: Voltage of work equipment pump oil sensor (R))
information

1
2
sensor (R) (Internal trou- HP2 Voltage
ble) Between (C) – (A) 0.5 – 6.0 V
Possible Disconnection in wiring Wiring harness between TMC3 (female) (34) Resis-
Max. 1 z
causes and the harness (Disconnection – HP2 (female) (B) tance
3
standard values in wiring or defective con- Wiring harness between TMC1 (female) (3) – Resis-
tact in connector) Max. 1 z
when normal HP2 (female) (C) tance
Max. 1 z
– HP2 (female) (A) tance
cuit) (female) (3) – HP2 (female) (C) with chassis Min. 1 Mz
tance
ground
controller
be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (R)
38 D475A, D475ASD-5E0
Failure code [DH23KB] Work equipment pump oil pressure sensor (R):
Short circuit 1
Action code Failure code Symptom of Work equipment pump oil pressure sensor (R): Short circuit
— DH23KB failure (Transmission controller system)
Failure content • Signal voltage of work equipment pump oil pressure sensor (R) circuit is above 4.8 V
Controller's
action
Symptoms that
appear 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
General mode.
information (Code 70703: Voltage of work equipment pump oil pressure sensor (R))

1
2
sensor (R) (Internal trou- HP2 Voltage
Possible
ble) Between (C) – (A) 0.5 – 6.0 V
causes and the
when normal Hot short in wiring har- out troubleshooting.
3 ness (Contact with 24 V Short circuit of wiring harness between TMC1
circuit) (female) (3) – HP2 (female) (C) with chassis Voltage Max. 1 V
ground
controller
be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (R)
D475A, D475ASD-5E0 39
Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o

"32") Blow-by pressure sensor system: Disconnection 1
Action code Failure code Symptom of Blow-by pressure sensor system: Disconnection
— DHE5KB failure (VHMS controller system)
Failure content • The signal voltage of the blow-by pressure sensor is below 0.1 V.
Controller's
action
Symptoms that
appear on • The blow-by pressure cannot be monitored with the monitoring function.
machine
General
are downloaded to a personal computer, however, the error code can be checked.)
information

Defective blow-by pres- ENBP Voltage
1
sure sensor
Between (B) and (A) 4.5 – 5.5 V
Between (C) and (A) 0.3 – 0.7 V
Possible Disconnection in wiring without turning starting switch ON.
causes and the harness (Disconnection Wiring harness between V1 (female) (4) and Resis-
standard values 2 Max. 1 z
in wiring harness or ENBP (female) (B) tance
when normal defective contact) Wiring harness between 2A (female) (18) and Resis-
Max. 1 z
ENBP (female) (C) tance
Defective VHMS control- Between V1 (female) (4) and V2A (female)
3 Voltage 4.5 – 5.5 V
ler (12)
Between V2A (female) (18) and V2A (female)
Voltage 0.3 – 0.7 V
(12)
Circuit diagram related to blow-by pressure sensor
40 D475A, D475ASD-5E0
Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o

"31") Blow-by pressure sensor system: Hot short 1
Action code Failure code Symptom of Blow-by pressure sensor system: Hot short
— DHE5KY failure (VHMS controller system)
Failure content • The signal voltage of the blow-by pressure sensor is above 4.7 V.
Controller's
action
Symptoms that
appear on • The blow-by pressure cannot be monitored with the monitoring function.
machine
General
are downloaded to a personal computer, however, the error code can be checked.)
information

Defective blow-by pres- ENBP Voltage
1
sure sensor
Between (B) and (A) 4.5 – 5.5 V
Between (C) and (A) 0.3 – 0.7 V
causes and the Hot short in wiring har-
standard values 2 ness (Contact with 24-V
Wiring harness between V2 (female) (18) and
when normal circuit) Voltage Max. 1 V
ENBP (female) (C)
Defective VHMS control- Between V1 (female) (4) and V2A (female)
3 Voltage 4.5 – 5.5 V
ler (12)
Between V2A (female) (18) and V2A (female)
Voltage 0.3 – 0.7 V
(12)
D475A, D475ASD-5E0 41
Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o

"14") Transmission oil pressure sensor: Out of input signal range 1
Action code Failure code Symptom of Transmission oil pressure sensor: Out of input signal range
— DHT3KX failure (VHMS controller system)
Failure content • The transmission oil pressure signal cannot be obtained.
Controller's
action
Symptoms that
machine
General
information

harness (Disconnection Wiring harness between V1 (female) (2) and Resis-
1 Max. 1 z
in wiring harness or TMMD (female) (B) tance
defective contact) Wiring harness between V2A (female) (15) Resis-
Max. 1 z
and TMMD (female) (C) tance
Short circuit with chassis Between wiring harness between V1 (female)
Resis-
Possible ground in wiring harness (2) and TMMD (female) (B) and chassis Min. 1 Mz
2 tance
causes and the (Contact with ground cir- ground
standard values cuit) Between wiring harness between V2A
when normal Resis-
(female) (15) and TMMD (female) (C) and Min. 1 Mz
tance
chassis ground
Hot short in wiring har- carry out troubleshooting.
3 ness (Contact with 24-V Short circuit of wiring harness between V2A
circuit) (female) (15) and TMMD (female) (C) with Voltage Max. 1 V
chassis ground
Defective VHMS carry out troubleshooting.
4
controller V1 and V2A Voltage
Between V1 (2) and V2A (12) Below 20 – 30 V
Circuit diagram related to transmission oil pressure sensor
42 D475A, D475ASD-5E0
Failure code [DK01KA] Left yoke angle sensor: Disconnection 1

Action code Failure code Symptom of Left yoke angle sensor: Disconnection
— DK01KA failure (Transmission controller system)
Failure content • The signal voltage of the left yoke angle sensor circuit is lower than the specified value.
Controller's
• Flashes the caution lamp and turns on the caution buzzer.
action
Symptoms that
appear 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.
General
(Code 90002: Left yoke angle sensor voltage)
information

Defective sensor 5-V If error code [DAQ7KK] is displayed, carry out troubleshooting for it
1
power supply system first.
Defective left yoke angle without 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
causes and the harness (Disconnection
3 in wiring harness or Max. 1 z
when normal and CSL (female) (A) tance
defective contact in con-
nector) Wiring harness between TMC1 (female) (7) Resis-
Max. 1 z
and CSL (female) (B) tance
cuit) (female) (7) and CSL (female) (B) and chassis Min. 1 Mz
tance
ground
controller
be diagnosed).
Circuit diagram related to left yoke angle sensor
D475A, D475ASD-5E0 43
Failure code [DK01KB] Left yoke angle sensor: Short circuit 1

Action code Failure code Symptom of Left yoke angle sensor: Short circuit
— DK01KB failure (Transmission controller system)
Failure content • The signal voltage of the left yoke angle sensor circuit is higher than the specified value.
Controller's
action
Symptoms that
machine
• The input state (voltage) from the left yoke angle sensor can be checked in the monitoring mode.
General
(Code 90002: Left yoke angle sensor voltage)
information

1
Defective left yoke angle without turning starting switch ON.
sensor CSL (male) Resistance
2
Possible
causes and the
standard values Between (B) and (C) 0.25 – 7.0 kz
source in wiring harness
(Contact with 24-V cir-
cuit) (female) (7) and CSL (female) (B) and chassis Voltage Max. 1 V
ground
controller
be diagnosed).
Circuit diagram related to left yoke angle sensor
44 D475A, D475ASD-5E0
Failure code [DK03KA] Right yoke angle sensor: Disconnection 1

Action code Failure code Symptom of Right yoke angle sensor: Disconnection
— DK03KA failure (Transmission controller system)
Failure content • The signal voltage of the right yoke angle sensor circuit is lower than the specified value.
Controller's
action
Symptoms that
machine
• The input state (voltage) from the right yoke angle sensor can be checked in the monitoring mode.
General
(Code 90003: Right yoke angle sensor voltage)
information

1
Defective right yoke without turning starting switch ON.
angle sensor CSR (male) Resistance
2
Between (B) and (C) 0.25 – 7.0 kz
causes and the harness (Disconnection
3 in wiring harness or Max. 1 z
when normal and CSR (female) (A) tance
defective contact in con-
nector) Wiring harness between TMC1 (female) (13) Resis-
Max. 1 z
and CSR (female) (B) tance
cuit) (female) (13) and CSR (female) (B) and chas- Min. 1 Mz
tance
sis ground
controller
be diagnosed).
Circuit diagram related to right yoke angle sensor
D475A, D475ASD-5E0 45
Failure code [DK03KB] Right yoke angle sensor: Short circuit 1

Action code Failure code Symptom of Right yoke angle sensor: Short circuit
— DK03KB failure (Transmission controller system)
Failure content • The signal voltage of the right yoke angle sensor circuit is higher than the specified value.
Controller's
action
Symptoms that
machine
• The input state (voltage) from the right yoke angle sensor can be checked in the monitoring mode.
General
(Code 90003: Right yoke angle sensor voltage)
information

1
Defective right yoke without turning starting switch ON.
angle sensor CSR (male) Resistance
2
Possible
causes and the
standard values Between (B) and (C) 0.25 – 7.0 kz
source in wiring harness
(Contact with 24-V cir-
cuit) (female) (13) and CSR (female) (B) and chas- Voltage Max. 1 V
sis ground
controller
be diagnosed).
Circuit diagram related to right yoke angle sensor
46 D475A, D475ASD-5E0
Failure code [DK10KA] Fuel dial: Disconnection 1

Action code Failure code Symptom of Fuel dial: Disconnection
CALL E03 DK10KA failure (Steering controller system)
Failure content • Signal voltage of fuel dial circuit is lower than the specified value.
Controller's
• Continues to control with decelerator pedal potentiometer signal.
action
• Operation of engine and transmission is limited.
Symptoms that
appear on
machine
• Input state (voltage) from fuel dial can be checked in monitoring mode.
General
(Code 03000: Fuel dial voltage)
information

Defective sensor 5V Check if failure code [DAQ7KK] is displayed. If it is displayed, carry
1
power supply circuit out troubleshooting for it first.
still OFF.
Defective fuel dial DIAL (male) Resistance
2 (internal disconnection
Between (1) – (3) 4.0 – 6.0 kz
and short circuit)
Between (1) – (2) 0.5 – 4.5 kz
Between (2) – (3) 0.5 – 4.5 kz
still OFF.
Disconnection in wiring
harness Max. 1 z
Possible – DIAL (female) (1) tance
standard values – DIAL (female) (2) tance
tors)
when normal Wiring harness between STCN1 (female) (21) Resis-
Max. 1 z
– DIAL (female) (3) tance
4 Min. 1 Mz
(contact with ground cir- STCN1 (female) (22) – DIAL (female) (1) tance
Min. 1 Mz
STCN1 (female) (8) – DIAL (female) (2) tance
ON.
Defective steering and
5 STCN1 Voltage
Between (22) – (21) 4.6 – 5.4 V
Between (8) – (21) 0.5 – 4.5 V
Circuit diagram related to fuel dial
D475A, D475ASD-5E0 47
Failure code [DK10KB] Fuel dial: Short circuit 1

Action code Failure code Symptom of Fuel dial: Short circuit
CALL E03 DK10KB failure (Steering controller system)
Failure content • Signal voltage of fuel dial circuit is higher than the specified value.
Controller's
• Continues to control with decelerator pedal potentiometer signal.
action
• Operation of engine and transmission is limited.
Symptoms that
appear on
machine
• Input state (voltage) from fuel dial can be checked in monitoring mode.
General
(Code 03000: Fuel dial voltage)
information

Defective sensor 5 V Check if failure code [DAQ7KK] is displayed. If it is displayed, carry
1
power supply circuit out troubleshooting for it first.
still OFF.
Defective fuel dial DIAL (male) Resistance
2 (internal disconnection
Between (1) – (3) 4.0 – 6.0 kz
and short circuit)
Between (1) – (2) 0.5 – 4.5 kz
Between (2) – (3) 0.5 – 4.5 kz
Disconnection in wiring a Prepare with starting switch OFF and diagnose with starting switch
harness still OFF.
Possible Wiring harness between STCN1 (female) (21) Resis-
causes and the tors) – DIAL (female) (3) tance
standard values
ON.
Hot short of wiring har- Voltage Max. 1V
STCN1 (female) (22) – DIAL (female) (1)
4 ness
(contact with 24 V circuit) Between ground and wiring harness between Voltage Max. 1V
Voltage Max. 1V
ON.
Defective steering and
5 STCN1 Voltage
Between (22) – (21) 4.6 – 5.4 V
Between (8) – (21) 0.5 – 4.5 V
Circuit diagram related to fuel dial
48 D475A, D475ASD-5E0
Failure code [DK30KA] Steering potentiometer (1): Disconnection 1

Action code Failure code Symptom of Steering potentiometer (1): Disconnection
Failure content • Signal voltage of steering potentiometer (1) system (L) is lower than the specified value.
Controller's
• Continues controlling with signal of steering potentiometer (2) system (R).
action
Symptoms that
appear on
machine
• Input (Voltage) from steering potentiometer (1) (L) can be checked in monitoring mode.
General (Code 50300: Voltage of steering potentiometer (1))
information • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steer-
ing).

Defective 5 V sensor See if error code [DB35KK] is displayed. If it is displayed, carry out
1
power source system troubleshooting for it first.
Defective steering poten- without turning starting switch ON.
tiometer (1) TL2 (male) Resistance
2
(Internal disconnection or Between (5) – (8) 3.2 kz ± 20%
short circuit) Between (7) – (5) 1 – 6 kz (Right – left steering)
Between (7) – (8) 6 – 1 kz (Right – left steering)
Possible 3 Max. 1 z
causes and the in wiring or defective – TL2 (female) (5) tance
standard values contact in connector) Wiring harness between STCN1 (female) (2) Resis-
Max. 1 z
Resis-
ground in wiring harness STCN1 (female) (22) – TL2 (female) (5) with Min. 1 Mz
4 tance
(Contact with ground chassis ground
circuit) Short circuit of wiring harness between
Resis-
STCN1 (female) (2) – TL2 (female) (7) with Min. 1 Mz
tance
chassis ground
5
Between (2) – (21) 0.5 – 4.5 V
Circuit diagram related to steering potentiometer
D475A, D475ASD-5E0 49
Failure code [DK30KB] Steering potentiometer (1): Short circuit 1

Action code Failure code Symptom of Steering potentiometer (1): Short circuit
Failure content • Signal voltage of steering potentiometer (1) system (L) is higher than specified value.
Controller's
• Continues controlling with signal of steering potentiometer (2) system (R).
action
Symptoms that
appear on
machine
• Input (Voltage) from steering potentiometer (1) (L) can be checked in monitoring mode.
ing).

1
tiometer 1 TL2 (male) Resistance
2
Possible
when normal Short circuit of wiring harness between
STCN1 (female) (22) – TL2 (female) (5) with Voltage Max. 1 V
3 source in wiring harness
chassis ground
chassis ground
4
Between (2) – (21) 0.5 – 4.5 V
50 D475A, D475ASD-5E0
Failure code [DK30KX] Steering potentiometer (1): Input signal is out of

normal range 1
Action code Failure code Symptom of Steering potentiometer (1): Input signal is out of normal range
CALL E04 DK30KX failure (Steering controller system)
• Either of failure codes [DK30KA] and [DK30KB] of steering potentiometer systems (1) and (2) and
Failure content
failure codes [DK31KA] and [DK31KB] are displayed simultaneously.
Symptoms that
appear on
machine
• Input (Voltage) from steering potentiometers can be checked in monitoring mode.
(Code 50300: Voltage of steering potentiometer (1))
General
information
• Method of reproducing failure code: Turn starting switch ON and operate PCCS lever
(for steering).
Possible Causes Standard values when normal and remarks for troubleshooting
causes and the
standard values Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
when normal
D475A, D475ASD-5E0 51
Failure code [DK30KZ] Steering potentiometer (1): Disconnection or

short circuit 1
Action code Failure code Symptom of Steering potentiometer (1): Disconnection or short circuit
CALL E04 DK30KZ failure (Steering controller system)
• When starting switch is turned ON, either of steering potentiometer systems (1) and (2) is abnor-
Failure content mal, then either of failure codes [DK30KA] and [DK30KB] and failure codes [DK31KA] and
[DK31KB] are displayed simultaneously.
Symptoms that
appear on
machine
General
information
• Method of reproducing failure code: Turn starting switch ON and operate PCCS lever
(for steering).
causes and the
when normal
52 D475A, D475ASD-5E0
Failure code [DK30L8] Steering potentiometer (1): See table 1

Action code Failure code Symptom of Steering potentiometer (1): See table
CALL E03 DK30L8 failure (Steering controller system)
• Total signal voltage of each of steering potentiometer (1) system (ST1) and (2) system (ST2) is out
Failure content
of the specified range.
Controller's • Continues controlling with signal of normal one of steering potentiometer (1) system (ST1) and (2)
action (ST2).
Symptoms that
appear on
machine
General
information
• Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steer-
ing).
causes and the
when normal
D475A, D475ASD-5E0 53
Failure code [DK31KA] Steering potentiometer (2): Disconnection 1

Action code Failure code Symptom of Steering potentiometer (2): Disconnection
Failure content • Signal voltage of steering potentiometer (2) system (R) is lower than the specified value.
Controller's
• Continues controlling with signal of steering potentiometer (1) system (L).
action
Symptoms that
appear on
machine
• Input (Voltage) from steering potentiometer (2) (R) can be checked in monitoring mode.
ing).

Defective sensor 5V See if error code [DB35KK] is displayed. If it is displayed, carry out
1
tiometer (2) TL2 (male) Resistance
2
Possible 3 Max. 1 z
causes and the in wiring or defective – TL2 (female) (5) tance
standard values contact in connector) Wiring harness between STCN1 (female) (19) Resis-
Max. 1 z
Resis-
ground in wiring harness STCN1 (female) (22) – TL2 (female) (5) with Min. 1 Mz
4 tance
(Contact with ground chassis ground
circuit) Short circuit of wiring harness between
Resis-
STCN1 (female) (19) – TL2 (female) (6) with Min. 1 Mz
tance
chassis ground
5
Between (19) – (21) 0.5 – 4.5 V
54 D475A, D475ASD-5E0
Failure code [DK31KB] Steering potentiometer (2): Short circuit 1

Action code Failure code Symptom of Steering potentiometer (2): Short circuit
Failure content • Signal voltage of steering potentiometer (2) system (R) is higher than the specified value.
Controller's
• Continues controlling with signal of steering potentiometer (1) system (L).
action
Symptoms that
appear on
machine
• Input (Voltage) from steering potentiometer (2) (R) can be checked in monitoring mode.
ing).

Defective sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out
1
tiometer (2) (Internal dis- TL2 (male) Resistance
2
connection or short Between (5) – (8) 3.2 kz ± 20%
circuit) Between (6) – (5) 1 – 6 kz (Right – left steering)
Possible
3 ness (Contact with 24 V
chassis ground
circuit)
chassis ground
Defective steering con- carry out troubleshooting.
4
troller STCN1 Voltage
Between (19) – (21) 0.5 – 4.5 V
D475A, D475ASD-5E0 55
SEN01828-00

© 2006 KOMATSU
All Rights Reserved
56
SEN01829-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Failure code [DK40KA] Brake potentiometer: Disconnection............................................................... 3
Failure code [DK40KB] Brake potentiometer: Short circuit .................................................................. 4
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range .............. 5
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit ...................... 6
Failure code [DK55L8] Forward-reverse potentiometer: See table...................................................... 7
Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection ........................................ 8
Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit ........................................ 10
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection ...................................... 12
Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit ........................................ 14
Failure code [DK60KA] Acceleration sensor: Disconnection ............................................................. 16
Failure code [DK60KB] Acceleration sensor: Short circuit ................................................................. 18
Failure code [DKH1KA] Pitch angle sensor: disconnection ............................................................... 19
Failure code [DKH1KB] Pitch angle sensor: Short circuit .................................................................. 20
D475A, D475ASD-5E0 1
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range .............................................. 21
Failure code [DLF1KA] Torque converter output speed sensor: Disconnection ................................ 22
Failure code [DLT3KA] Transmission output speed sensor: Disconnection ...................................... 23
Failure code [dLT3KA] Transmission output speed sensor: Disconnection ....................................... 24
Failure code [DLT3KB] Transmission output speed sensor: Short circuit .......................................... 26
Failure code [DV00KB] Caution buzzer: Short circuit......................................................................... 27
Failure code [DW55KA] Blade pitch back solenoid: Disconnection ................................................... 28
Failure code [DW55KB] Blade pitch back solenoid: Short circuit ....................................................... 29
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection .................................................. 30
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit...................................................... 31
Failure code [DW56KY] Blade pitch dump solenoid: Hot short .......................................................... 32
Failure code [DW57KA] Left tilt limit solenoid: Disconnection............................................................ 33
Failure code [DW57KB] Left tilt limit solenoid: Short circuit ............................................................... 34
Failure code [DW57KY] Left tilt limit solenoid: Hot short.................................................................... 35
Failure code [DW58KA] Right tilt limit solenoid: Disconnection ......................................................... 36
Failure code [DW58KB] Right tilt limit solenoid: Short circuit ............................................................. 37
Failure code [DW58KY] Right tilt limit solenoid: Hot short ................................................................. 38
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection .................................................... 39
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit........................................................ 40
Failure code [DW59KY] Dual tilt selector solenoid: Hot short ............................................................ 41
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection .............................................. 42
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit.................................................. 43
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short ...................................................... 44
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification): Disconnection.... 45
Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification): Short circuit....... 46
Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification): Hot short ........... 47
Failure code [DW7BKA] Fan reverse solenoid: Disconnection .......................................................... 48
Failure code [DW7BKB] Fan reverse solenoid: Short circuit.............................................................. 49
Failure code [DW7BKY] Fan reverse solenoid: Hot short .................................................................. 50
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection.............................................. 51
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit ................................................. 52
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short...................................................... 53
Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection ....................................... 54
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit........................................... 55
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short ............................................... 56
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection .......................................................... 57
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit.............................................................. 58
Failure code [DWN5KY] Fan pump solenoid 1: Hot short .................................................................. 59
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection ......................................................... 60
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit ............................................................. 61
Failure code [DWNCKY] Fan pump solenoid 2: Hot short ................................................................. 62
2 D475A, D475ASD-5E0

Failure code [DK40KA] Brake potentiometer: Disconnection 1
Action code Failure code Symptom of Brake potentiometer: Disconnection
Failure content • Signal voltage of brake potentiometer circuit is lower than the specified value.
Controller's
• Does not control with signal of brake potentiometer (Brake can be operated with pedal).
action
Symptoms that • Brake control performance of brake pedal lowers.
• Input (Voltage) from brake potentiometer can be checked in monitoring mode.
General
(Code 50400: Voltage of brake potentiometer)
information
• Method of reproducing failure code: Turn starting switch ON and operate brake pedal.

1
Defective brake potenti- BRK (male) Resistance
2 ometer (Internal discon-
Between (A) – (C) 4.0 – 6.0 kz
nection or short circuit)
Between (A) – (B) 1.5 – 4.5 kz (Free – full stroke)
Between (B) – (C) 4.5 – 1.5 kz (Free – full stroke)
Possible harness (Disconnection in Wiring harness between STCN1 (female) Resis-
3 Max. 1 z
wiring or defective contact (22) – BRK (female) (C) tance
causes and the
standard values in connector) Wiring harness between STCN1 (female) (3) Resis-
Max. 1 z
when normal – BRK (female) (B) tance
Resis-
ground in wiring harness STCN1 (female) (22) – BRK (female) (C) with Min. 1 Mz
4 tance
Resis-
STCN1 (female) (3) – BRK (female) (B) with Min. 1 Mz
tance
chassis ground
5
ler STCN1 Voltage
Between (3) – (21) 1.5 – 4.5 V
Circuit diagram related to brake potentiometer
D475A, D475ASD-5E0 3
Failure code [DK40KB] Brake potentiometer: Short circuit 1

Action code Failure code Symptom of Brake potentiometer: Short circuit
Failure content • Signal voltage of brake potentiometer circuit is higher than specification value.
Controller's
• Does not control brake with brake potentiometer signal (Brake can be controlled with pedal).
action
Symptoms that • Brake cannot be controlled well with brake pedal.
• Input state (Voltage) from brake potentiometer can be checked in monitoring mode
General
(Code 50400: Brake potentiometer voltage).
information
• Method of reproducing failure code: Turn starting switch ON (+ Operate brake pedal).

Defective sensor 5V If failure code [DB35KK] is displayed, carry out troubleshooting for it
1
Defective brake potenti- BRK (male) Resistance
2 ometer (Internal discon-
Between (A) – (C) 4.0 – 6.0 kz
nection or short circuit)
Between (A) – (B) 1.5 – 4.5 kz (Free – full stroke)
Between (B) – (C) 4.5 – 1.5 kz (Free – full stroke)
Possible
causes and the Hot short (Contact with
standard values Wiring harness between STCN1 (female)
3 24V circuit) in wiring har- Voltage Max. 1 V
when normal (22) – BRK (female) (C)
ness
Max. 1 V
– BRK (female) (B) tance
4
Max. 1 z
in connector) (21) – BRK (female) (A) tance
5
ler STCN1 Voltage
Between (3) – (21) 1.5 – 4.5 V
Circuit diagram related to brake potentiometer
4 D475A, D475ASD-5E0
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is

out of normal range 1
Action code Failure code Symptom of Forward-reverse potentiometer: Input signal is out of normal range
CALL E04 DK55KX failure (Transmission controller system)
• Either of failure codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and
Failure content
2 and either of failure codes [DK57KA] and [DK57KB] are displayed simultaneously.
Symptoms that
appear on
machine
• Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
General
information
• Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/
reverse travel).
causes and the
when normal
D475A, D475ASD-5E0 5
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection

or short circuit 1
Action code Failure code Symptom of Forward-reverse potentiometer: Disconnection or short circuit
CALL E04 DK55KZ failure (Transmission controller system)
• When starting switch is turned ON, either of forward-reverse potentiometer systems 1 and 2 is
Failure content abnormal, then either of failure codes [DK56KA] and [DK56KB] and either of failure codes
[DK57KA] and [DK57KB] are displayed simultaneously.
Symptoms that
appear on
machine
General • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/
information reverse travel).
causes and the
when normal
6 D475A, D475ASD-5E0
Failure code [DK55L8] Forward-reverse potentiometer: See table 1

Action code Failure code Symptom of Forward-reverse potentiometer: See table
CALL E03 DK55L8 failure (Transmission controller system)
• Total signal voltage of each of forward-reverse potentiometer 1 system (FR3) and 2 system (FR4)
Failure content
is out of the specified range.
Controller's • Continues controlling with signal of normal one of forward-reverse potentiometer 1 system (FR3)
action and 2 (FR4).
Symptoms that
appear on
machine
General
information
• Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/
reverse travel).
causes and the
when normal
D475A, D475ASD-5E0 7
Failure code [DK56KA] Forward-reverse potentiometer (1):

Disconnection 1
Action code Failure code Symptom of Forward-reverse potentiometer (1): Disconnection
CALL E04 DK56KA failure (Transmission controller system)
Failure content • Signal voltage of forward-reverse potentiometer (1) system (R) is lower than the specified value.
Controller's
• Continues controlling with signal of forward-reverse potentiometer (2) system (F).
action
Symptoms that
appear on
machine
• Input (Voltage) from forward-reverse potentiometer (1) (R) can be checked in monitoring mode.
General (Code 50200: Voltage of forward-reverse potentiometer (1))
information • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/
reverse travel).

Defective 5 V sensor See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
Defective forward-reverse without turning starting switch ON.
potentiometer (1) (Internal TL2 (male) Resistance
2
disconnection or short cir- Between (4) – (1) 3.2 kz ± 20%
cuit) Between (3) – (4) 5.5 – 1.5 kz (Forward – reverse)
Between (3) – (1) 1.5 – 5.5 kz (Forward – reverse)
Possible harness (Disconnection in Wiring harness between TMC1 (female) (22) Resis-
3 Max. 1 z
causes and the wiring or defective contact – TL2 (female) (4) tance
in connector) Wiring harness between TMC1 (female) (2) – Resis-
when normal TL2 (female) (3) tance
Resis-
ground in wiring harness TMC1 (female) (2) – TL2 (female) (3) with Min. 1 Mz
4 tance
Resis-
tance
chassis ground
5
Between (2) – (21) 0.5 – 4.5 V
8 D475A, D475ASD-5E0
Circuit diagram related to forward-reverse potentiometer
D475A, D475ASD-5E0 9
Failure code [DK56KB] Forward-Reverse potentiometer (1): Short

circuit 1
Action code Failure code Symptom of Forward-Reverse potentiometer (1): Short circuit
CALL E03 DK56KB failure (Transmission controller system)
• Signal voltage of forward-reverse potentiometer (1) system (R) circuit is higher than specified
Failure content
value.
Controller's
• Continues control with signal of forward-reverse potentiometer (2) system (F).
action
Symptoms that
appear on
• Once machine is stopped, gear speed is limited to F1 and R1.
machine
• Input state (Voltage) from forward-reverse potentiometer (1) (R) can be checked in monitoring
General mode (Code 50200: Forward-Reverse potentiometer (1) voltage).
information • Method of reproducing failure code: Turn starting switch ON (+ Operate PCCS lever (Forward and
reverse)).

Defective sensor 5V If failure code [DAQ5KK] is displayed, carry out troubleshooting for it
1
2
Possible
causes and the Wiring harness between TMC1 (female) (2) –
Hot short (Contact with Voltage Max. 1 V
TL2 (female) (3)
standard values 3 24V circuit) in wiring har-
when normal ness Wiring harness between TMC1 (female) (22)
Voltage Max. 1 V
Voltage Max. 1 V
4
Max. 1 z
in connector) – TL2 (female) (1) tance
5
Between (2) – (21) 0.5 – 4.5 V
10 D475A, D475ASD-5E0
D475A, D475ASD-5E0 11
Failure code [DK57KA] Forward-reverse potentiometer (2):

Disconnection 1
Action code Failure code Symptom of Forward-reverse potentiometer (2): Disconnection

CALL E03 DK57KA failure (Transmission controller system)
Failure content • Signal voltage of forward-reverse potentiometer (2) system (F) is lower than the specified value.
Controller's
• Continues controlling with signal of forward-reverse potentiometer (1) system (R).
action
Symptoms that
appear on
machine
• Input (Voltage) from forward-reverse potentiometer (2) (F) can be checked in monitoring mode.
General (Code 50201: Voltage of forward-reverse potentiometer (2))
information • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/
reverse travel).

Defective 5 V sensor See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
2
3 Max. 1 z
causes and the wiring or defective contact – TL2 (female) (4) tance
Resis-
ground in wiring harness TMC1 (female) (19) – TL2(female) (2) with Min. 1 Mz
4 tance
Resis-
tance
chassis ground
5
Between (19) – (21) 0.5 – 4.5 V
12 D475A, D475ASD-5E0
D475A, D475ASD-5E0 13
Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit1
Action code Failure code Symptom of Forward-Reverse potentiometer (2): Short circuit
CALL E03 DK57KB failure (Transmission controller system)
• Signal voltage of forward-reverse potentiometer (2) system (F) circuit is higher than specified
Failure content
value.
Controller's
• Continues control with signal of forward-reverse potentiometer (1) system (R).
action
Symptoms that
appear on
• Once machine is stopped, gear speed is limited to F1 and R1.
machine
• Input state (Voltage) from forward-reverse potentiometer (2) (F) can be checked in monitoring
General mode (Code 50201: Forward-Reverse potentiometer (2) voltage).
information • Method of reproducing failure code: Turn starting switch ON (+ Operate PCCS lever (Forward and
reverse)).

Defective sensor 5V If failure code [DAQ5KK] is displayed, carry out troubleshooting for it
1
2
Possible
causes and the Wiring harness between TMC1 (female) (19)
Hot short (Contact with Voltage Max. 1 V
standard values – TL2 (female) (2)
when normal ness Wiring harness between TMC1 (female) (22)
Voltage Max. 1 V
Voltage Max. 1 V
4
5
controller TCM1 Voltage
Between (19) – (21) 0.5 – 4.5 V
14 D475A, D475ASD-5E0
D475A, D475ASD-5E0 15
Failure code [DK60KA] Acceleration sensor: Disconnection 1

Action code Failure code Symptom of Acceleration sensor: Disconnection
E01 DK60KA failure (Steering controller system)
Failure content • Signal voltage of acceleration sensor is below 0.5 V.
Controller's
• Turns shoe slip control (SSC) function OFF.
action
Symptoms that
appear on • Even if shoe slips, engine speed does not change.
machine
• Input (Voltage) from acceleration sensor can be checked in monitoring mode.
General
(Code 60200: Voltage of acceleration sensor)
information

Defective 5 V power See if failure code [DB37KK] is displayed. If it is displayed, carry out
1
Defective acceleration carry out troubleshooting.
2
sensor (Internal trouble) SSA Voltage
Between (2) – (3) 0.75 – 4.25 V
harness (Disconnection in Wiring harness between STCN3 (female) Resis-
3 Max. 1 z
wiring or defective contact (34) – SSA (female) (1) tance
Possible
in connector) Wiring harness between STCN1 (female) (1) Resis-
standard values – SSA (female) (2) tance
Resis-
ground in wiring harness STCN3 (female) (34) – SSA (female) (1) with Min. 1 Mz
4 tance
Resis-
STCN1 (female) (1) – SS3 (female) (2) with Min. 1 Mz
tance
chassis ground
5
ler STCN1 Voltage
Between (1) – (21) 0.75 – 4.25 V
16 D475A, D475ASD-5E0
Circuit diagram related to acceleration sensor
D475A, D475ASD-5E0 17
Failure code [DK60KB] Acceleration sensor: Short circuit 1

Action code Failure code Symptom of Acceleration sensor: Short circuit
E01 DK60KB failure (Steering controller system)
Failure content • Acceleration sensor signal voltage is above 4.5 V.
Controller's
• Stops shoe slip control (SSC) function.
action
Symptoms that
appear on • Engine speed does not change even if shoe slips.
machine
• Input state (Voltage) from acceleration sensor can be checked in monitoring mode (Code 60200:
General
Acceleration sensor voltage).
information

Defective 5V power supply If failure code [DB37KK] is displayed, carry out troubleshooting for it
1
system first.
Defective acceleration carry out troubleshooting.
2
sensor (Internal defect) SSA Voltage
Between (2) – (3) 0.75 – 4.25 V
Wiring harness between STCN1 (female) (1)
Possible Hot short (Contact with Voltage Max. 1 V
– SSA (female) (2)
causes and the 3 24V circuit) in wiring har-
Wiring harness between STCN3 (female)
standard values ness Voltage Max. 1 V
when normal (34) – SSA (female) (1)
Voltage Max. 1 V
(21) – SSA (female) (3)
4
Max. 1 z
in connector) (21) – SSA (female) (3) tance
5
ler STCN1 Voltage
Between (1) – (21) 0.75 – 4.25 V
Circuit diagram related to acceleration sensor
18 D475A, D475ASD-5E0
Failure code [DKH1KA] Pitch angle sensor: disconnection 1

Action code Failure code Symptom of Pitch angle sensor: Disconnection
CALL E03 DKH1KA failure (Steering controller system)
Failure content • Signal voltage of pitch angle sensor is lower than the specified value.
Controller's
• Cannot recognize pitch angle.
action
Symptoms that • Gear shift shock is large.
• Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
General
(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
harness (Disconnection in Wiring harness between STCN1 (female) Resis-
Possible 3 Max. 1 z
wiring or defective contact (16) – PT1 (female) (C) tance
causes and the in connector) Wiring harness between STCN1 (female) Resis-
(13) – PT1 (female) (B) tance
when normal
Resis-
ground in wiring harness STCN1 (female) (16) – PT1 (female) (C) with Min. 1 Mz
4 tance
Resis-
STCN1 (female) (13) – PT1 (female) (B) with Min. 1 Mz
tance
chassis ground
Steering controller can be suspected to be defective if no problem is
ler
diagnosed).
Circuit diagram related to pitch angle sensor
D475A, D475ASD-5E0 19
Failure code [DKH1KB] Pitch angle sensor: Short circuit 1

Action code Failure code Symptom of Pitch angle sensor: Short circuit
CALL E03 DKH1KB failure (Steering controller system)
Failure content • Signal voltage of pitch angle sensor is higher than the specified value.
Controller's
action
Symptoms that • Gear shift shock is large.
• Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
General
(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 Short circuit of wiring harness between
causes and the Hot short in wiring harness STCN1 (female) (13) – PT1 (female) (B) with Voltage Max. 1 V
standard values 3
STCN1 (female) (21) – PT1 (female) (A) with Voltage Max. 1 V
chassis ground
4
Max. 1 z
in connector) (21) – PT1 (female) (A) tance
ler
diagnosed).
Circuit diagram related to pitch angle sensor
20 D475A, D475ASD-5E0
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range 1
Action code Failure code Symptom of Pitch angle sensor: Out of input signal range
E01 DKH1KX failure (Steering controller system)
• Either of pitch angle sensor errors [DKH1KA] and [DKH1KB] occurred or steering controller CAN
Failure content
communication error [DB3RKR] occurred.
Controller's
action
Symptoms that
appear on • Gear speed is not changed automatically.
machine
• Input state (Voltage) from pitch angle sensor can be checked in monitoring mode
General
(Code 60100: Pitch angle sensor voltage).
information
causes and the
standard values Carry out troubleshooting for disconnection [DKH1KA] and short circuit [DKH1KB] in pitch angle
sensor and steering controller CAN communication [DB3RKR].
when normal
D475A, D475ASD-5E0 21
Failure code [DLF1KA] Torque converter output speed sensor:

Disconnection 1
Action code Failure code Symptom of Torque converter output speed sensor: Disconnection
CALL E03 DLF1KA failure (Transmission controller system)
Failure content • Signals from the torque converter output speed sensor are not input.
Controller's
• Recognizes torque converter output speed is 0 rpm.
action
Symptoms that
appear 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 moni-
General
toring mode. (Code 31200: Torque converter speed)
information
• Method of reproducing failure code: Start the engine + Drive the machine actually.

Defective torque con- without turning starting switch ON.
verter output speed sensor TC1 (male) Resistance
1
short circuit) Between (1) and (2) 500 – 1,000 z
Between (1) and chassis ground Min. 1 Mz
causes and the 2 Max. 1 z
wiring harness or defective and TC1 (female) (1) tance
standard values contact in connector) Wiring harness between TMC2 (female) (39) Resis-
and TC1 (female) (2) tance
cuit) (female) (20) and TC1 (female) (1) and chas- Min. 1 Mz
tance
sis ground
If causes 1 – 3 are not detected, transmission controller may be
controller
carried out.)
Circuit diagram related to torque converter output speed sensor
22 D475A, D475ASD-5E0
Failure code [DLT3KA] Transmission output speed sensor:

Disconnection 1
Action code Failure code Symptom of Transmission output speed sensor: Disconnection
E01 DLT3KA failure (Transmission controller system)
• Transmission output speed sensor error [dLT3KA] occurred or transmission CAN communication
Failure content
error [DAQRKR] occurred.
Controller's
• Assumes transmission output speed to be 0 rpm.
action
• Transmission speed cannot be monitored.
Symptoms that
• Traction force cannot be calculated.
appear on
• Auto-shift down operation is defective.
machine
• Gear shift shock is large.
• Input voltage from transmission output speed sensor can be checked in monitoring mode
General
(Code 31400: Transmission output speed).
information
• Method of reproducing failure code: Turn starting switch ON + Drive machine actually.
causes and the
Carry out troubleshooting for disconnection [dLT3KA] and transmission CAN communication error
standard values
when normal [DAQRKR].
D475A, D475ASD-5E0 23
Failure code [dLT3KA] Transmission output speed sensor:

Disconnection 1
Action code Failure code Symptom of Transmission output speed sensor: Disconnection
E01 dLT3KA failure (Transmission controller system)
Failure content • Signal is not input from transmission output speed sensor.
Controller's
• Assumes that transmission output speed is 0 rpm.
action
Symptoms that
appear on
• Auto-shift down operation is defective.
machine
• Gear shift shock is large.
• Input (rpm) from transmission output speed sensor can be checked in monitoring mode.
General
(Code 31400: Transmission speed
information
• Method of reproducing failure code: Start engine and travel machine actually.

output speed sensor TM1 (male) Resistance
1
(Internal disconnection or Between (1) – (2) 500 – 1,000 z
short circuit) Between (1), (2) – chassis
Min. 1 Mz
ground
harness (Disconnection in Wiring harness between TMC2 (female) (30) Resis-
2 Max. 1 z
wiring or defective contact – TM1 (female) (1) tance
Max. 1 z
– TM1 (female) (2) tance
Possible
ground in wiring harness Resis-
3 TMC2 (female) (30) – TM1 (female) (1) with Min. 1 Mz
(Contact with ground cir- tance
chassis ground
cuit)
Min. 1 Mz
and TM1 (female) (2) and chassis ground tance
Hot short in wiring harness Wiring harness between TMC2 (female) (30)
4 Voltage Max. 1 V
(Contact with 24-V circuit) and TM1 (female) (1) and chassis ground
Voltage Max. 1 V
and TM1 (female) (2) and chassis ground
controller
be diagnosed).
24 D475A, D475ASD-5E0
Circuit diagram related to transmission output speed sensor
D475A, D475ASD-5E0 25
Failure code [DLT3KB] Transmission output speed sensor: Short

circuit 1
Action code Failure code Symptom of Transmission output speed sensor: Short circuit
E01 DLT3KB failure (Transmission controller system)
Failure content • Signal from transmission output speed sensor does not change while machine is traveling.
Controller's
• Assumes transmission output speed to be 0 rpm.
action
Symptoms that
appear on
machine
• Gearshift shocks are increased.
• Input voltage from transmission output speed sensor can be checked in monitoring mode
General
(Code 31400: Transmission output speed).
information
• Method of reproducing failure code: Turn starting switch ON + Drive machine actually.

Defective installation of
Carry out adjustment according to Testing and adjusting, "Adjusting
1 transmission output speed
transmission speed sensor".
sensor
Defective transmission without turning starting switch ON.
output speed sensor
2 TM1 (male) Resistance
Possible short circuit) Between (1) – (2) 500 – 1,000 z
causes and the Between (1) – ground Min. 1 Mz
– TM1 (female) (1) tance
circuit)
Min. 1 Mz
and TM1 (female) (1) and chassis ground tance
controller
carried out.)
Circuit diagram related to transmission output speed sensor
26 D475A, D475ASD-5E0
Failure code [DV00KB] Caution buzzer: Short circuit 1

Action code Failure code Symptom of Caution buzzer: Short circuit
E01 DV00KB failure (Machine monitor system)
Failure content • Abnormal current flowed when caution buzzer circuit output ground signal.
Controller's • Flashes caution lamp.
action • Stops caution buzzer circuit from outputting ground signal.
Symptoms that
appear on • Caution buzzer does not sound.
machine
General • Method of reproducing failure code: Turn starting switch ON (When it is turned ON, buzzer sounds
information for 1 second).

Defective caution buzzer without turning starting switch ON.
1
(Internal short circuit) 217 (male) Resistance
Between (1) – (2) 200 z
2 Short circuit of wiring harness between 217
Possible (female) (1) – S03 (female) (18) with chassis Voltage Max. 1 V
causes and the ground
Wiring harness between 217 (female) (1) and Resis-
circuit) Min. 1 Mz
S03 (female) (18) and chassis ground tance
S03 Caution buzzer Voltage
4 Defective monitor panel
When turned OFF 20 – 30 V
Between (18) –
chassis ground When turned ON
Max. 3 V
(sounding)
Circuit diagram related to caution buzzer
D475A, D475ASD-5E0 27
Failure code [DW55KA] Blade pitch back solenoid: Disconnection 1

Action code Failure code Symptom of Blade pitch back solenoid: Disconnection
CALL E03 DW55KA failure (Transmission controller system)
• Flashes warning lamp and turns on warning alarm.
Failure content
• When the signal is output to the blade pitch back solenoid circuit, no current flows.
Controller's
• Stops outputting the signal to the blade pitch back solenoid circuit.
action
Symptoms that
appear 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
General
mode. (Code 90000: Tilt pitch solenoid output 3)
information
• Method of reproducing failure code: Turn the starting switch ON. + Pitch back blade.

Defective blade pitch back without turning starting switch ON.
1 solenoid
PPB (male) Resistance
Between (1) and (2) 20 – 60 z
causes and the Disconnection in wiring without turning starting switch ON.
standard values harness (Disconnection in Wiring harness between TMC3 (female) (26) Resis-
when normal 2 Max. 1 z
wiring harness or defective and PPB (female) (1) tance
contact in connector) Wiring harness between TMC3 (female) (3) Resis-
Max. 1 z
and PPB (female) (2) tance
controller
carried out.)
Circuit diagram related to blade pitch back solenoid
28 D475A, D475ASD-5E0
Failure code [DW55KB] Blade pitch back solenoid: Short circuit 1

Action code Failure code Symptom of Blade pitch back solenoid: Short circuit
CALL E03 DW55KB failure (Transmission controller system)
Failure content • When signal was output to blade pitch back solenoid circuit, abnormal current flowed.
action • Stops outputting signal to blade pitch back solenoid.
Symptoms that
appear on • Blade does not pitch back.
machine
• Output state (ON/OFF) to blade pitch back solenoid can be checked in monitoring mode
General
(Code 90000: Tilt/Pitch solenoid output 3).
information
• Method of reproducing failure code: Turn starting switch ON + Perform blade pitch back operation.

Defective blade pitch back without turning starting switch ON.
1 solenoid (Internal short cir- PPB (male) Resistance
cuit) Between (1) – (2) 20 – 60 z
causes and the circuit) Wiring harness between TMC3 (female) (26) Resis-
Min. 1 Mz
standard values – PPB (female) (1) tance
3 ness (with another wiring Between wiring harness between TMC3
(female) (26) – PPB (female) (1) and wiring Resis-
harness) Min. 1 Mz
harness between TMC3 (female) (3) – PPB tance
(female) (2)
controller
carried out.)
Circuit diagram related to blade pitch back solenoid
D475A, D475ASD-5E0 29
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection 1

Action code Failure code Symptom of Blade pitch dump solenoid: Disconnection
CALL E03 DW56KA failure (Transmission controller system)
• Flashes warning lamp and turns on warning alarm.
Failure content
• When the signal is output to the blade pitch dump solenoid circuit, no current flows.
Controller's
• Stops outputting the signal to the blade pitch dump solenoid circuit.
action
Symptoms that
appear 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
General mode.
information (Code 90000: Tilt/pitch solenoid output 3)
• Method of reproducing failure code: Turn the starting switch ON. + Pitch the blade forward.

Defective blade pitch without turning starting switch ON.
1 dump solenoid
PPD (male) Resistance
Between (1) and (2) 20 – 60 z
2 Max. 1 z
wiring harness or defective and PPD (female) (1) tance
causes and the
standard values contact in connector) Wiring harness between TMC3 (female) (3) Resis-
Max. 1 z
when normal and PPD (female) (2) tance
(female) (16) and PPD (female) (1) and chas- Voltage Max. 1 V
sis ground
controller
carried out.)
Circuit diagram related to blade pitch dump solenoid
30 D475A, D475ASD-5E0
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit 1

Action code Failure code Symptom of Blade pitch dump solenoid: Short circuit
CALL E03 DW56KB failure (Transmission controller system)
Failure content • When signal was output to blade pitch dump solenoid circuit, abnormal current flowed.
action • Stops outputting signal to blade pitch dump solenoid circuit.
Symptoms that
appear on • Blade does not pitch dump.
machine
• Output state (ON/OFF) to blade pitch dump solenoid can be checked in monitoring mode
General (Code 90000: Tilt/Pitch solenoid output 3).
information • Method of reproducing failure code: Turn starting switch ON + Perform blade pitch dump opera-
tion.

1 dump solenoid (Internal PPD (male) Resistance
short circuit) Between (1) – (2) 20 – 60 z
circuit) Min. 1 Mz
standard values – PPD (female) (1) tance
harness) (female) (16) – PPD (female) (1) and wiring Resis-
Min. 1 Mz
harness between TMC3 (female) (3) – PPD tance
(female) (2)
controller
carried out.)
D475A, D475ASD-5E0 31
Failure code [DW56KY] Blade pitch dump solenoid: Hot short 1

Action code Failure code Symptom of Blade pitch dump solenoid: Hot short
CALL E03 DW56KY failure (Transmission controller system)
Failure content • Some current keeps flowing to blade pitch dump solenoid circuit.
Symptoms that
appear on • Blade pitch dump solenoid keeps operating.
machine
• Output state (ON/OFF) to blade pitch dump solenoid can be checked in monitoring mode
General (Code 90000: Tilt/Pitch solenoid output 3).
tion.

1 dump solenoid (Internal
PPD (male) Resistance
short circuit)
Possible Between (1) – (2) 20 – 60 z
standard values Hot short (Contact with
when normal 2 24V circuit) in wiring har-
Voltage Max. 1 V
– PPD (female) (1).
controller
carried out.)
32 D475A, D475ASD-5E0
Failure code [DW57KA] Left tilt limit solenoid: Disconnection 1

Action code Failure code Symptom of Left tilt limit solenoid: Disconnection
E02 DW57KA failure (Transmission controller system)
Failure content • When the signal is output to the left tilt limit solenoid circuit, no current flows.
action • Stops outputting the signal to the left tilt limit solenoid circuit.
Symptoms that
• The blade is not pitched forward.
appear 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.
General
(Code 90000: Tilt/pitch solenoid output 3)
information
• Method of reproducing failure code: Turn the starting switch ON. + Execute the left tilt mode.

Defective left tilt limit without turning starting switch ON.
1 solenoid
TLL (male) Resistance
Between (1) and (2) 20 – 60 z
wiring harness or defective and TLL (female) (1) tance
Max. 1 z
and TLL (female) (2) tance
controller
carried out.)
Circuit diagram related to left tilt limit solenoid
D475A, D475ASD-5E0 33
Failure code [DW57KB] Left tilt limit solenoid: Short circuit 1

Action code Failure code Symptom of Left tilt limit solenoid: Short circuit
E02 DW57KB failure (Transmission controller system)
Failure content • When signal was output to left tilt limit solenoid circuit, abnormal current flowed.
action • Stops outputting signal to left tilt limit solenoid circuit.
Symptoms that
• Blade does not pitch dump.
appear on
• Left tilt limit function does not work.
machine
• Output state (ON/OFF) to left tilt limit solenoid can be checked in monitoring mode
General
information
• Method of reproducing failure code: Turn starting switch ON + Perform left tilt limit mode.

Defective left tilt limit sole- TLL (male) Resistance
1
noid (Internal short circuit)
Between (1) – (2) 20 – 60 z
Min. 1 Mz
standard values – TLL (female) (1) tance
(female) (27) – TLL (female) (1) and wiring Resis-
harness) Min. 1 Mz
harness between TMC3 (female) (3) – TLL tance
(female) (2)
controller
carried out.)
34 D475A, D475ASD-5E0
Failure code [DW57KY] Left tilt limit solenoid: Hot short 1

Action code Failure code Symptom of Left tilt limit solenoid: Hot short
E02 DW57KY failure (Transmission controller system)
Failure content • Some current keeps flowing to left tilt limit solenoid circuit.
Controller's
• Stops outputting signal to left tilt limit solenoid circuit.
action
Symptoms that
appear on • Left tilt limit solenoid keeps operating.
machine
• Output state (ON/OFF) to left tilt limit solenoid can be checked in monitoring mode
General
information
• Method of reproducing failure code: Turn starting switch ON + Perform left tilt mode.

Defective left tilt limit sole- without turning starting switch ON.
1
noid (Internal short circuit) TLL (male) Resistance
ness Voltage Max. 1 V
– TLL (female) (1).
controller
carried out.)
D475A, D475ASD-5E0 35
Failure code [DW58KA] Right tilt limit solenoid: Disconnection 1

Action code Failure code Symptom of Right tilt limit solenoid: Disconnection
Failure content • When the signal is output to the right tilt limit solenoid circuit, no current flows.
action • Stops outputting the signal to the right tilt limit solenoid circuit.
Symptoms that
• The blade is not pitched back.
appear 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.
General
(Code 90000: Tilt/pitch solenoid output 3)
information
• Method of reproducing failure code: Turn the starting switch ON. + Execute the right tilt mode.

Defective right tilt limit without turning starting switch ON.
1 solenoid
TLR (male) Resistance
Between (1) and (2) 20 – 60 z
wiring harness or defective and TLR (female) (1) tance
Max. 1 z
and TLR (female) (2) tance
controller
carried out.)
Circuit diagram related to right tilt limit solenoid
36 D475A, D475ASD-5E0
Failure code [DW58KB] Right tilt limit solenoid: Short circuit 1

Action code Failure code Symptom of Right tilt limit solenoid: Short circuit
Failure content • When signal was output to right tilt limit solenoid circuit, abnormal current flowed.
action • Stops outputting signal to right tilt limit solenoid circuit.
Symptoms that
appear on • Blade does not pitch back.
machine
• Output state (ON/OFF) to right tilt limit solenoid can be checked in monitoring mode
General
information
• Method of reproducing failure code: Turn starting switch ON + Perform right tilt limit mode.

1 solenoid (Internal short cir- TLR (male) Resistance
cuit) Between (1) – (2) 20 – 60 z
Min. 1 Mz
standard values – TLR (female) (1) tance
(female) (37) – TLR (female) (1) and wiring Resis-
harness) Min. 1 Mz
harness between TMC3 (female) (3) – TLR tance
(female) (2)
controller
carried out.)
D475A, D475ASD-5E0 37
Failure code [DW58KY] Right tilt limit solenoid: Hot short 1

Action code Failure code Symptom of Right tilt limit solenoid: Hot short
Failure content • Some current keeps flowing to right tilt limit solenoid circuit.
Controller's
• Stops outputting signal to right tilt limit solenoid circuit.
action
Symptoms that
appear on • Right tilt limit solenoid keeps operating.
machine
• Output state (ON/OFF) to right tilt limit solenoid can be checked in monitoring mode
General
information
• Method of reproducing failure code: Turn starting switch ON + Perform right tilt mode.

1 solenoid (Internal discon-
TLR (male) Resistance
nection)
– TLR (female) (1).
controller
carried out.)
38 D475A, D475ASD-5E0
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection 1

Action code Failure code Symptom of Dual tilt selector solenoid: Disconnection
Failure content • When signal is output to dual tilt selector solenoid circuit, any current does not flow.
Controller's
• Stops outputting to dual tilt selector solenoid circuit.
action
Symptoms that
appear on • Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works).
machine
• Output (Current) to dual tilt selector solenoid can be checked in monitoring mode.]
General
(Code 70600: Dual tilt solenoid drive current)
information
• Method of reproducing failure code: Turn starting switch ON and perform blade dual tilt operation.

Defective dual tilt selector without turning starting switch ON.
DUL (male) Resistance
nection)
Between (1) – (2) 10 – 40 z
standard values harness (Disconnection in Wiring harness between TMC3 (female) (6) – Resis-
wiring or defective contact DUL (female) (1) tance
Max. 1 z
– DUL (female) (2) tance
controller
carried out.)
Circuit diagram related to dual tilt selector solenoid
D475A, D475ASD-5E0 39
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit 1

Action code Failure code Symptom of Dual tilt selector solenoid: Short circuit
Failure content • When signal was output to dual tilt selector solenoid circuit, abnormal current flowed.
Controller's
• Stops outputting signal to dual tilt selector solenoid circuit.
action
Symptoms that
appear on • Dual tilt unit does not operate (When dual tilt operation is performed, single tilt unit operates).
machine
• Output state (Current) to dual tilt selector solenoid can be checked in monitoring mode
General
(Code 70600: Dual tilt solenoid drive current).
information
• Method of reproducing failure code: Turn starting switch ON + Perform dual tilt operation.

1 solenoid (Internal short cir- DUL (male) Resistance
cuit) Between (1) – (2) 10 – 40 z
causes and the circuit) Wiring harness between TMC3 (female) (6) – Resis-
Min. 1 Mz
standard values DUL (female) (1) tance
(female) (6) – DUL (female) (1) and wiring Resis-
harness) Min. 1 Mz
harness between TMC3 (female) (13) – DUL tance
(female) (2)
controller
carried out.)
40 D475A, D475ASD-5E0
Failure code [DW59KY] Dual tilt selector solenoid: Hot short 1

Action code Failure code Symptom of Dual tilt selector solenoid: Hot short
Failure content • Some current keeps flowing to dual tilt selector solenoid circuit.
Controller's
• Stops outputting signal to dual tilt selector solenoid circuit.
action
Symptoms that
appear on • Dual tilt selector solenoid keeps operating.
machine
• Output state (Current) to dual tilt selector solenoid can be checked in monitoring mode
General
(Code 70600: Dual tilt solenoid drive current).
information
• Method of reproducing failure code: Turn starting switch ON + Perform dual tilt operation.

DUL (male) Resistance
nection)
DUL (female) (1).
If causes 1 – 2 are not detected, steering or transmission controller
Defective steering or
D475A, D475ASD-5E0 41
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection 1

Action code Failure code Symptom of Blade pitch selector solenoid: Disconnection
E02 DW5AKA failure (Transmission controller system)
Failure content • When the signal is output to the blade pitch selector solenoid circuit, no current flows.
action • Stops outputting the signal to the blade pitch selector solenoid circuit.
Symptoms that
• The blade is not pitched back. (When the pitch back operation is performed, the blade may be
appear on
tilted.)
machine
• The output state (current) to the blade pitch selector solenoid can be checked in the monitoring
General mode.
information (Code 31625: Pitch solenoid current)
• Method of reproducing failure code: Turn the starting switch ON. + Pitch the blade back.

1 selector solenoid
PTH (male) Resistance
Between (1) and (2) 10 – 40 z
wiring harness or defective and PTH (female) (1) tance
Max. 1 z
and PTH (female) (2) tance
controller
carried out.)
Circuit diagram related to blade pitch selector solenoid
42 D475A, D475ASD-5E0
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit 1

Action code Failure code Symptom of Blade pitch selector solenoid: Short circuit
E02 DW5AKB failure (Transmission controller system)
Failure content • When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.
action • Stops outputting signal to blade pitch selector solenoid circuit.
Symptoms that
appear on • Blade pitch back unit does not operate (When pitch back operation is performed, tilt unit operates).
machine
• Output state (Current) to blade pitch selector solenoid can be checked in monitoring mode
General
(Code 31625: Pitch solenoid current).
information

1 selector solenoid (Internal PTH (male) Resistance
Min. 1 Mz
standard values – PTH (female) (1) tance
(female) (28) – PTH (female) (1) and wiring Resis-
harness) Min. 1 Mz
harness between TMC3 (female) (13) – PTH tance
(female) (2)
controller
carried out.)
D475A, D475ASD-5E0 43
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short 1

Action code Failure code Symptom of Blade pitch selector solenoid: Hot short
E02 DW5AKY failure (Transmission controller system)
Failure content • Some current keeps flowing to blade pitch selector solenoid circuit.
Symptoms that
appear on • Blade pitch selector solenoid keeps operating.
machine
General
information

1 selector solenoid (Internal
short circuit)
– PTH (female) (1).
controller
carried out.)
44 D475A, D475ASD-5E0
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer

specification): Disconnection 1
Action code Failure code Symptom of Blade pitch selector solenoid (Superdozer specification): Disconnec-
CALL E03 DW5DKA failure tion (Transmission controller system)
Failure content • When the signal is output to the blade pitch selector solenoid circuit, no current flows.
action • Stops outputting the signal to the blade pitch selector solenoid circuit.
Symptoms that
• The blade is not pitched back. (When the pitch back operation is performed, the blade may be
appear on
tilted.)
machine
• The output state (current) to the blade pitch selector solenoid can be checked in the monitoring
General mode.
information (Code 31625: Pitch solenoid current)
• Method of reproducing failure code: Turn the starting switch ON. + Pitch the blade back.

1 dump solenoid
Between (1) and (2) 10 – 40 z
wiring harness or defective and PTH (female) (1) tance
Max. 1 z
and PTH (female) (2) tance
controller
carried out.)
Circuit diagram related to blade pitch dump solenoid (Superdozer)
D475A, D475ASD-5E0 45
Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer

specification): Short circuit 1
Action code Failure code Symptom of Blade pitch selector solenoid (Superdozer specification): Short cir-
CALL E03 DW5DKB failure cuit (Transmission controller system)
Failure content • When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.
Symptoms that
appear on • Blade pitch back unit does not operate (When pitch back operation is performed, tilt unit operates).
machine
General
information

1 dump solenoid (Internal PTH (male) Resistance
circuit) Min. 1 Mz
standard values – PTH (female) (1) tance
harness) (female) (28) – PTH (female) (1) and wiring Resis-
Min. 1 Mz
harness between TMC3 (female) (13) – PTH tance
(female) (2)
controller
carried out.)
Circuit diagram related to blade pitch dump solenoid (Superdozer specification)
46 D475A, D475ASD-5E0
Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer

specification): Hot short 1
Action code Failure code Symptom of Blade pitch selector solenoid (Superdozer specification): Hot short
CALL E03 DW5DKY failure (Transmission controller system)
Failure content • Some current keeps flowing to blade pitch dump solenoid circuit.
Symptoms that
appear on • Blade pitch dump solenoid keeps operating.
machine
• Output state (Current) to blade pitch dump solenoid can be checked in monitoring mode
General (Code 31625: Pitch solenoid current).
tion.

1 dump solenoid (Internal
short circuit)
standard values Hot short (Contact with carry out troubleshooting.
Voltage Max. 1 V
– PTH (female) (1).
controller
carried out.)
Circuit diagram related to blade pitch dump solenoid (Superdozer specification)
D475A, D475ASD-5E0 47
Failure code [DW7BKA] Fan reverse solenoid: Disconnection 1

Action code Failure code Symptom of Fan reverse solenoid: Disconnection
E01 DW7BKA failure (Steering controller system)
Failure content • When the signal is output to the fan reverse solenoid circuit, no current flows.
Controller's
• Stops outputting the signal to the fan reverse solenoid circuit.
action
Symptoms that
appear 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.
General (Code 40914: Steering-related controller ON/OFF output 1)
information • Method of reproducing failure code: Turn the starting switch ON. + Reverse the fan rotation direc-
tion.

Defective fan reverse without turning starting switch ON.
1 solenoid
FAR (male) Resistance
Between (1) and (2) 34 – 44 z
standard values harness (Disconnection in Wiring harness between STCN3 (female) Resis-
wiring harness or defective (17) and FAR (female) (1) tance
contact in connector) Wiring harness between STCN3 (female) (3) Resis-
Max. 1 z
and FAR (female) (2) tance
Defective steering
3 found in causes 1 – 2 (Since this is an internal defect, it cannot be
controller
diagnosed).
Circuit diagram related to fan reverse solenoid
48 D475A, D475ASD-5E0
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 1

Action code Failure code Symptom of Fan reverse solenoid: Short circuit
E01 DW7BKB failure (Steering controller system)
Failure content • When the signal is output to the fan reverse solenoid circuit, an abnormal current flows.
Controller's
• Stops outputting the signal to the fan reverse solenoid.
action
Symptoms that
appear 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.
General
(Code 40914: Steering-related controller ON/OFF output 1)
information
• Method of reproducing error code: Turn the starting switch ON. + Reverse the fan rotation direction.

Defective fan reverse without turning starting switch ON.
1 solenoid FAR (male) Resistance
(Internal short circuit) Between (1) and (2) 34 – 44 z
(female) (17) and FAR (female) (1) and chas- Min. 1 Mz
sis ground
when normal
Short circuit in wiring without turning starting switch ON.
harness Between wiring harness between STCN3
3
(Short circuit between (female) (17) and FAR (female) (1) and wir- Resis-
wiring harnesses) Min. 1 Mz
ing harness between STCN3 (female) (13) tance
and FAR (female) (2)
Defective steering
controller
diagnosed).
D475A, D475ASD-5E0 49
Failure code [DW7BKY] Fan reverse solenoid: Hot short 1

Action code Failure code Symptom of Fan reverse solenoid: Hot short
E02 DW7BKY failure (Steering controller system)
Failure content • Some current keeps flowing to fan reverse solenoid circuit.
action • Stops outputting signal to fan reverse solenoid circuit.
Symptoms that
appear on • Fan keeps running in reverse.
machine
• Output state (ON/OFF) to fan reverse solenoid can be checked in monitoring mode
General
(Code 40914: Steering-related controller ON/OFF output 1).
information
• Method of reproducing failure code: Turn starting switch ON + Operate fan in reverse.

Defective fan reverse sole- without turning starting switch ON.
1 noid (Internal disconnec-
FAR (male) Resistance
tion)
(17) – FAR (female) (1).
If causes 1 – 2 are not detected, steering controller may be defec-
3 tive. (Since trouble is in system, troubleshooting cannot be carried
ler
out.)
50 D475A, D475ASD-5E0
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection 1

Action code Failure code Symptom of Pump merge-divider solenoid: Disconnection
E02 DWJ0KA failure (Steering controller system)
Failure content • When the signal is output to the pump merge-divider solenoid circuit, no current flows.
action • Stops outputting the signal to the pump merge-divider solenoid circuit.
Symptoms that
appear on • Blade tilt/pitch work may not be performed normally.
machine
• The output state (ON/OFF) to the pump merge-divider solenoid can be checked in the monitoring
General mode.
information (Code 40914: Steering-related controller ON/OFF output 1)
• Method of reproducing failure code: Turn the starting switch ON. + Execute the dual tilt mode.

Defective pump without turning starting switch ON.
1 merge-divider solenoid
MFD (male) Resistance
Between (1) and (2) 20 – 60 z
standard values harness (Disconnection in Wiring harness between STCN3 (female) Resis-
wiring harness or defective (27) and MFD (female) (1) tance
Max. 1 z
and MFD (female) (2) tance
ler
diagnosed).
Circuit diagram related to pump merge-divider solenoid
D475A, D475ASD-5E0 51
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit 1

Action code Failure code Symptom of Pump merge-divider solenoid: Short circuit
E02 DWJ0KB failure (Steering controller system)
Failure content • When signal was output to pump merge-divider solenoid circuit, abnormal current flowed.
action • Stops outputting signal to pump merge-divider solenoid circuit.
Symptoms that
appear on • Blade may not be tilted or pitched normally.
machine
• Output state (ON/OFF) to pump merge-divider solenoid can be checked in monitoring mode
General
(Code 40914: Steering-related controller ON/OFF output 1).
information
• Method of reproducing failure code: Turn starting switch ON + Perform dual tilt mode.

Defective pump merge- without turning starting switch ON.
1 divider solenoid (Internal MFD (male) Resistance
causes and the circuit) Wiring harness between STCN3 (female) Resis-
Min. 1 Mz
standard values (27) – MFD (female) (1) tance
3 ness (with another wiring Between wiring harness between STCN3
(female) (27) – MFD (female) (1) and wiring Resis-
harness) Min. 1 Mz
harness between STCN3 (female) (3) – MFD tance
(female) (2)
If causes 1 – 3 are not detected, steering controller may be defec-
4 tive. (Since trouble is in system, troubleshooting cannot be carried
ler
out.)
52 D475A, D475ASD-5E0
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short 1

Action code Failure code Symptom of Pump merge-divider solenoid: Hot short
E02 DWJ0KY failure (Steering controller system)
Failure content • Current keeps flowing to the pump merge-divider solenoid circuit.
action • Stops outputting the signal to the pump merge-divider solenoid circuit.
Symptoms that
appear on • Blade tilt/pitch work may not be performed normally.
machine
• The output state (ON/OFF) to the pump merge-divider solenoid can be checked in the monitoring
General
mode. (Code 40914: Steering-related controller ON/OFF output 1)
information
• Method of reproducing failure code: Turn the starting switch ON. + Execute the dual tilt mode.

Defective pump without turning starting switch ON.
1 merge-divider solenoid
MFD (male) Resistance
Between (1) and (2) 20 – 60 z
Possible
when normal 2 Between wiring harness between STCN3
(female) (27) and MFD (female) (1) and Voltage Max. 1 V
chassis ground
ler
diagnosed).
D475A, D475ASD-5E0 53
Failure code [DWN3KA] Sudden stop prevention solenoid:

Disconnection 1
Action code Failure code Symptom of Sudden stop prevention solenoid: Disconnection
CALL E04 DWN3KA failure (Steering controller system)
Failure content • When signal is output to sudden stop prevention solenoid circuit, any current does not flow.
Symptoms that
appear on
machine
• Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode.
General
(Code 31628: Sudden stop prevention solenoid drive current)
information

Defective sudden stop without turning starting switch ON.
1 prevention solenoid (Inter-
ST8 (male) Resistance
nal disconnection)
Between (1) – (2) 5 – 25 z
standard values harness (Disconnection in Wiring harness between STCN3 (female) (7) Resis-
wiring or defective contact – ST8 (female) (1) tance
in connector) Wiring harness between STCN3 (female) Resis-
Max. 1 z
(13) – ST8 (female) (2) tance
ler
diagnosed).
Circuit diagram related to sudden stop prevention solenoid
54 D475A, D475ASD-5E0
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit1

Action code Failure code Symptom of Sudden stop prevention solenoid: Short circuit
CALL E04 DWN3KB failure (Steering controller system)
Failure content • When signal was output to sudden stop prevention solenoid circuit, abnormal current flowed.
Symptoms that
appear on
machine
General
information

1 prevention solenoid (Inter- ST8 (male) Resistance
nal short circuit) Between (1) – (2) 5 – 25 z
STCN3 (female) (7) – ST8 (female) (1) with Min. 1 Mz
chassis ground
when normal
Short circuit in wiring harness between
harness) STCN3 (female) (7) – ST8 (female) (1) with Resis-
Min. 1 Mz
wiring harness between STCN3 (female) (13) tance
– ST8 (female) (2)
ler
diagnosed).
D475A, D475ASD-5E0 55
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short 1

Action code Failure code Symptom of Sudden stop prevention solenoid: Hot short
CALL E04 DWN3KY failure (Steering controller system)
Failure content • Current keeps flowing to sudden stop prevention solenoid circuit.
Symptoms that • Function of emergency sudden stop prevention does not operate.
General
information

1 prevention solenoid (Inter-
ST8 (male) Resistance
nal disconnection)
Between (1) – (2) 5 – 25 z
Possible
when normal 2 Short circuit of wiring harness between
STCN3 (female) (7) – ST8 (female) (1) with Voltage Max. 1 V
chassis ground
ler
diagnosed).
56 D475A, D475ASD-5E0
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection 1

Action code Failure code Symptom of Fan pump solenoid 1: Disconnection
E01 DWN5KA failure (Transmission controller system)
Failure content • When signal is output to fan pump solenoid circuit, any current does not flow.
Controller's
• Stops outputting to fan pump solenoid circuit.
action
Symptoms that
appear on • Output of the fan pump (LPV90) becomes maximum.
machine
• Output (Current) to fan pump solenoid can be checked in monitoring mode.
General
(Code 31623, 31624: Cooling fan solenoid output command current, output current)
information

Defective fan pump sole- without turning starting switch ON.
FA1 (male) Resistance
tion)
Between (1) – (2) 5 – 15 z
wiring or defective contact – FA1 (female) (1) tance
Max. 1 z
– FA1 (female) (2) tance
3 lem is found in causes 1 – 2 (Since this is an internal defect, it can-
controller
not be diagnosed).
Circuit diagram related to fan pump solenoid
D475A, D475ASD-5E0 57
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit 1

Action code Failure code Symptom of Fan pump solenoid 1: Short circuit
E01 DWN5KB failure (Transmission controller system)
Failure content • When signal was output to fan pump solenoid circuit, abnormal current flowed.
Controller's
• Stops outputting to fan pump solenoid circuit.
action
Symptoms that
machine
General
information

Defective fan pump sole- FA1 (male) Resistance
1
Between (1) – (2) 15 – 25 z
TMC3 (female) (17) – FA1 (female) (1) with Min. 1 Mz
chassis ground
when normal
Short circuit in wiring harness between TMC3
harness) (female) (17) – FA1 (female) (1) with wiring Resis-
Min. 1 Mz
harness between TMC3 (female) (23) – FA1 tance
(female) (2)
controller
be diagnosed).
58 D475A, D475ASD-5E0
Failure code [DWN5KY] Fan pump solenoid 1: Hot short 1

Action code Failure code Symptom of Fan pump solenoid 1: Hot short
E02 DWN5KY failure (Transmission controller system)
Failure content • Current keeps flowing to fan pump solenoid circuit.
Controller's • Flashes warning lamp and turns on warning alarm.
action • Stops outputting to fan pump solenoid circuit.
Symptoms that
• Output of the fan pump (LPV90) becomes minimum.
appear on
• Fan speed does not increase.
machine
General
information

Defective fan pump sole- without turning starting switch ON.
tion)
Between (1) – (2) 5 – 15 z
Possible
TMC3 (female) (17) – FA1 (female) (1) with Voltage Max. 1 V
chassis ground
controller
not be diagnosed).
D475A, D475ASD-5E0 59
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection 1

Action code Failure code Symptom of Fan pump solenoid 2: Disconnection
E01 DWNCKA failure (Transmission controller system)
Failure content • When the signal is output to the fan pump solenoid circuit, no current flows.
Controller's
• Stops outputting the signal to the fan pump solenoid circuit.
action
Symptoms that
machine
• The output state (current) to the fan pump solenoid can be checked in the monitoring mode.
General
information

Prepare with starting switch OFF, then carry out troubleshooting
Defective fan pump without turning starting switch ON.
1 solenoid 2
Between (1) and (2) 5 – 15 z
Possible Prepare with starting switch OFF, then carry out troubleshooting
wiring harness or defective and FA2 (female) (1) tance
Max. 1 z
and FA2 (female) (2) tance
controller
not be diagnosed).
60 D475A, D475ASD-5E0
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit 1

Action code Failure code Symptom of Fan pump solenoid 2: Short circuit
E01 DWNCKB failure (Transmission controller system)
Failure content • When the signal is output to the fan pump solenoid circuit, an abnormal current flows.
Controller's
• Stops outputting the signal to the fan pump solenoid.
action
Symptoms that
machine
• The output state (ON/OFF) to the fan pump solenoid can be checked in the monitoring mode.
General
information

1 solenoid 2 FA2 (male) Resistance
(Internal short circuit) Between (1) and (2) 5 – 15 z
(female) (7) and FA2 (female) (1) and chas- Min. 1 Mz
sis ground
when normal
harness Between wiring harness between TMC3
3
(Short circuit between (female) (7) and FA2 (female) (1) and wiring Resis-
harness between TMC3 (female) (23) and tance
FA2 (female) (2)
controller
be diagnosed).
D475A, D475ASD-5E0 61
Failure code [DWNCKY] Fan pump solenoid 2: Hot short 1

Action code Failure code Symptom of Fan pump solenoid 2: Hot short
E02 DWNCKY failure (Transmission controller system)
Failure content • Current keeps flowing to the fan pump solenoid circuit.
Controller's • Flashes warning lamp and turns on warning alarm.
action • Stops outputting the signal to the fan pump solenoid circuit.
Symptoms that
• Output of the fan pump (LPV30) becomes minimum.
appear on
• Fan speed does not increase.
machine
• The output state (current) to the fan pump solenoid can be checked in the monitoring mode.
General
information

Prepare with starting switch OFF, then carry out troubleshooting
1 solenoid 2
Between (1) and (2) 15 – 25 z
Possible
causes and the Prepare with starting switch OFF, then turn starting switch ON and
when normal 2 Between wiring harness between TMC3
(female) (7) and FA2 (female) (1) and chas- Voltage Max. 1 V
sis ground
controller
not be diagnosed).
62 D475A, D475ASD-5E0
SEN01829-00

© 2006 KOMATSU
All Rights Reserved
64
SEN01830-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Failure code [DXE0KA] LS set solenoid: Disconnection ...................................................................... 3
Failure code [DXE0KB] LS set solenoid: Short circuit.......................................................................... 4
Failure code [DXE0KY] LS set solenoid: Hot short .............................................................................. 5
Failure code [DXH1KA] Lock-up solenoid: Disconnection ................................................................... 6
Failure code [DXH1KB] Lock-up solenoid: Short circuit....................................................................... 7
Failure code [DXH1KY] Lockup solenoid: Hot short ............................................................................ 8
Failure code [DXH4KA] 1st clutch ECMV: Disconnection.................................................................... 9
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ..................................................................... 10
Failure code [DXH4KY] 1st clutch ECMV: Hot short.......................................................................... 11
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection................................................................. 12
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit .................................................................... 13
Failure code [DXH5KY] 2nd clutch ECMV: Hot short......................................................................... 14
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ................................................................. 15
D475A, D475ASD-5E0 1
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ..................................................................... 16

Failure code [DXH6KY] 3rd clutch ECMV: Hot short.......................................................................... 17
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection ......................................................... 18
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit ............................................................. 19
Failure code [DXH7KY] Reverse clutch ECMV: Hot short ................................................................. 20
Failure code [DXH8KA] Forward clutch ECMV: Disconnection.......................................................... 21
Failure code [DXH8KB] Forward clutch ECMV: Short circuit ............................................................. 22
Failure code [DXH8KY] Forward clutch ECMV: Hot short.................................................................. 23
Failure code [DXH9KA] Right steering clutch ECMV: Disconnection................................................. 24
Failure code [DXH9KB] Right steering clutch ECMV: Short circuit .................................................... 25
Failure code [DXH9KY] Right steering clutch ECMV: Hot short......................................................... 26
Failure code [DXHAKA] Left steering clutch ECMV: Disconnection................................................... 27
Failure code [DXHAKB] Left steering clutch ECMV: Short circuit ...................................................... 28
Failure code [DXHAKY] Left steering clutch ECMV: Hot short........................................................... 29
Failure code [DXHBKA] Right brake ECMV: Disconnection .............................................................. 30
Failure code [DXHBKB] Right brake ECMV: Short circuit .................................................................. 31
Failure code [DXHBKY] Right brake ECMV: Hot short ...................................................................... 32
Failure code [DXHCKA] Left brake ECMV: Disconnection................................................................. 33
Failure code [DXHCKB] Left brake ECMV: Short circuit .................................................................... 34
Failure code [DXHCKY] Left brake ECMV: Hot short......................................................................... 35
Failure code [F@BBZL] (or VHMS_LED display "n3" o "38")
Engine blow-by pressure sensor: Abnormally high pressure occurrence ................................ 36
Failure code [F@BYNS] (or VHMS_LED display "n3" o "61")
Left front exhaust temperature sensor (1): Exhaust temperature abnormal rise...................... 38
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71")
Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise ...................... 40
Failure code [F@BZNS] (or VHMS_LED display "n3" o "38")
Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise ................... 42
Failure code [f@BZNS] (or VHMS_LED display "n3" o "39")
Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise .................... 44
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62")
Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise...................... 46
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72")
Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise ...................... 48
Failure code [F@BZNR] (or VHMS_LED display "n3" o "82")
Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise ................... 50
Failure code [f@BZNR] (or VHMS_LED display "n3" o "92")
Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise .................... 52
2 D475A, D475ASD-5E0

Failure code [DXE0KA] LS set solenoid: Disconnection 1
Action code Failure code Symptom of LS set solenoid: Disconnection
E02 DXE0KA failure (Steering controller system)
Failure content • When the signal is output to the LS set solenoid circuit, no current flows.
Controller's • Stops outputting the signal to the LS set solenoid circuit.
action • Flashes the caution lamp and turns on the caution buzzer.
Symptoms that
appear 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.
General
(Code 40914: Steering-related controller ON/OFF output signal 1)
information

Defective LS set solenoid without turning starting switch ON.
1
(Internal short circuit) LSV (male) Resistance
Between (1) and (2) 5 – 15 z
wiring harness or defective and LSV (female) (1) tance
Max. 1 z
and LSV (female) (2) tance
ler
diagnosed).
Circuit diagram related to LS set solenoid
D475A, D475ASD-5E0 3
Failure code [DXE0KB] LS set solenoid: Short circuit 1

Action code Failure code Symptom of LS set solenoid: Short circuit
E02 DXE0KB failure (Steering controller system)
Failure content • When the signal is output to the LS set solenoid circuit, an abnormal current flows.
Symptoms that
machine
General
information

Defective LS set solenoid LSV (male) Resistance
1
Between (1) and (2) 15 – 25 z
(female) (37) and LSV (female) (1) and chas- Min. 1 Mz
sis ground
when normal
harness Between wiring harness between STCN3
3
(Short circuit between (female) (37) and LSV (female) (1) and wiring Resis-
harness between STCN3 (female) (3) and tance
LSV (female) (2)
ler
diagnosed).
4 D475A, D475ASD-5E0
Failure code [DXE0KY] LS set solenoid: Hot short 1

Action code Failure code Symptom of LS set solenoid: Hot short
E02 DXE0KY failure (Steering controller system)
Failure content • Current keeps flowing to the LS set solenoid circuit.
Symptoms that
machine
General
information

Defective LS set solenoid without turning starting switch ON.
1
(Internal short circuit) LSV (male) Resistance
Between (1) and (2) 15 – 25 z
Possible
when normal 2 Between wiring harness between STCN3
(female) (37) and LSV (female) (1) and chas- Voltage Max. 1 V
sis ground
ler
diagnosed).
D475A, D475ASD-5E0 5
Failure code [DXH1KA] Lock-up solenoid: Disconnection 1

Action code Failure code Symptom of Lock-up solenoid: Disconnection
E01 DXH1KA failure (Transmission controller system)
Failure content • When signal is output to torque converter lock-up solenoid circuit, any current does not flow.
Controller's
• Stops outputting to torque converter lock-up solenoid circuit.
action
Symptoms that
appear on • Torque converter is not locked-up.
machine
• Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode.
General
(Code 31627: Torque converter lock-up solenoid drive current)
information
• Method of reproducing failure code: Start engine and turn lock-up switch ON and drive machine.

Defective torque converter without turning starting switch ON.
1 lock-up solenoid (Internal
653 (male) Resistance
short circuit)
Between (1) – (2) 30 – 80 z
wiring or defective contact – 653 (female) (1) tance
Max. 1 z
– 653 (female) (2) tance
controller
not be diagnosed).
Circuit diagram related to torque converter lock-up solenoid
6 D475A, D475ASD-5E0
Failure code [DXH1KB] Lock-up solenoid: Short circuit 1

Action code Failure code Symptom of Lock-up solenoid: Short circuit
E01 DXH1KB failure (Transmission controller system)
Failure content • When signal was output to torque converter lock-up solenoid circuit, abnormal current flowed.
Controller's
• Stops outputting to torque converter lock-up solenoid circuit.
action
Symptoms that
appear on • Torque converter is not locked-up.
machine
• Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode.
General
(Code 31627: Torque converter lock-up solenoid drive current)
information
• Method of reproducing failure code: Start engine and turn lock-up switch ON and drive machine.

1 lock-up solenoid (Internal 653 (male) Resistance
(female) (38) – 653 (female) (1) with chassis Min. 1 Mz
ground
when normal
Short circuit in wiring harness between TMC3
harness) (female) (38) – 653 (female) (1) with wiring Resis-
Min. 1 Mz
harness between TMC3 (female) (23) – 653 tance
(female) (2)
controller
be diagnosed).
Circuit diagram related to torque converter lock-up solenoid
D475A, D475ASD-5E0 7
Failure code [DXH1KY] Lockup solenoid: Hot short 1

Action code Failure code Symptom of Lockup solenoid: Hot short
CALL E03 DXH1KY failure (Transmission controller system)
Failure content • Some current keeps flowing to torque converter lockup solenoid circuit.
action • Stops outputting signal to torque converter lockup solenoid circuit.
Symptoms that • Torque converter lockup solenoid keeps operating.
machine • Once machine is stopped, gear speed is limited to F1 and R1 (Engine may stop).
• Output state (Current) to torque converter lockup solenoid can be checked in monitoring mode
General (Code 31627: Torque converter lockup solenoid drive current).
information • Method of reproducing failure code: Turn starting switch ON + Turn lockup switch ON + Drive
machine.

1 lockup solenoid (Internal
653 (male) Resistance
short circuit)
Voltage Max. 1 V
– 653 (female) (1).
controller
carried out.)
Circuit diagram related to torque converter lockup solenoid
8 D475A, D475ASD-5E0
Failure code [DXH4KA] 1st clutch ECMV: Disconnection 1

Action code Failure code Symptom of 1st clutch ECMV: Disconnection
CALL E03 DXH4KA failure (Transmission controller system)
Failure content • When signal is output to 1st clutch solenoid circuit, any current does not flow.
Controller's
• Stops outputting to transmission 1st clutch solenoid circuit.
action
Symptoms that • Automatic shift-down function does not work.
• Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
General
(Code 31602, 31612: Output command current, output current of 1st clutch ECMV)
information
• Method of reproducing failure code: Start engine and drive machine in F1 or R1.

Defective 1st clutch sole- without turning starting switch ON.
S1T7 (male) Resistance
tion)
Between (1) – (2) 5 – 15 z
wiring or defective contact – S1T7 (female) (1) tance
Max. 1 z
S1T7 (female) (2) tance
controller
not be diagnosed).
D475A, D475ASD-5E0 9
Failure code [DXH4KB] 1st clutch ECMV: Short circuit 1

Action code Failure code Symptom of 1st clutch ECMV: Short circuit
CALL E03 DXH4KB failure (Transmission controller system)
Failure content • When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.
Controller's
action
General
information

Defective 1st clutch sole- S1T7 (male) Resistance
1
Between (1) – (2) 5 – 15 z
cuit) (female) (15) – S1T7 (female) (1) with chassis Min. 1 Mz
standard values tance
ground
when normal
3 ness (with another wiring Short circuit in wiring harness between TMC3
harness) (female) (15) – S1T7 (female) (1) with wiring Resis-
Min. 1 Mz
harness between TMC3 (female) (3) – S1T7 tance
(female) (2)
controller
be diagnosed).
10 D475A, D475ASD-5E0
Failure code [DXH4KY] 1st clutch ECMV: Hot short 1

Action code Failure code Symptom of 1st clutch ECMV: Hot short
Failure content • Current keeps flowing to 1st clutch solenoid circuit.
Controller's
action
General
information

Defective 1st clutch sole- without turning starting switch ON.
1
noid (Internal short circuit) S1T7 (male) Resistance
Between (1) – (2) 5 – 15 z
Possible
(female) (15) – S1T7 (female) (1) with chassis Voltage Max. 1 V
ground
controller
not be diagnosed).
D475A, D475ASD-5E0 11
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection 1

Action code Failure code Symptom of 2nd clutch ECMV: Disconnection
Failure content • When signal is output to 2nd clutch solenoid circuit, any current does not flow.
Controller's
• Stops outputting to transmission 2nd clutch solenoid circuit.
action
Symptoms that
appear on
machine
• Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
General
(Code 31603, 31613: Output command current, output current of 2nd clutch ECMV)
information

Defective 2nd clutch sole- without turning starting switch ON.
tion)
Between (1) – (2) 5 – 15 z
wiring or defective contact – S2T5 (female) (1) tance
Max. 1 z
– S2T5 (female) (2) tance
controller
not be diagnosed).
12 D475A, D475ASD-5E0
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit 1

Action code Failure code Symptom of 2nd clutch ECMV: Short circuit
Failure content • When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.
Controller's
action
Symptoms that
appear on
machine
General
information

Defective 2nd clutch sole- S2T5 (male) Resistance
1
Between (1) – (2) 5 – 15 z
ground
when normal
Min. 1 Mz
(female) (2)
controller
be diagnosed).
D475A, D475ASD-5E0 13
Failure code [DXH5KY] 2nd clutch ECMV: Hot short 1

Action code Failure code Symptom of 2nd clutch ECMV: Hot short
Failure content • Current keeps flowing to 2nd clutch solenoid circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

Defective 2nd clutch sole- without turning starting switch ON.
1
Between (1) – (2) 5 – 15 z
Possible
(female) (36) – S2T5 (female) (1) with chassis Voltage Max. 1 V
ground
controller
not be diagnosed).
14 D475A, D475ASD-5E0
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection 1

Action code Failure code Symptom of 3rd clutch ECMV: Disconnection
Failure content • When signal is output to 3rd clutch solenoid circuit, any current does not flow.
Controller's
• Stops outputting to transmission 3rd clutch solenoid circuit.
action
Symptoms that
appear on
machine
• Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
General
(Code 31604, 31614: Output command current, output current of 3rd clutch ECMV)
information

Defective 3rd clutch sole- without turning starting switch ON.
tion)
Between (1) – (2) 5 – 15 z
standard values harness (Disconnection in Wiring harness between TMC3 (female) (5) – Resis-
wiring or defective contact S3T3 (female) (1) tance
Max. 1 z
S3T3 (female) (2) tance
controller
not be diagnosed).
D475A, D475ASD-5E0 15
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit 1

Action code Failure code Symptom of 3rd clutch ECMV: Short circuit
Failure content • When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.
Controller's
action
Symptoms that
appear on
machine
General
information

Defective 3rd clutch sole- S3T3 (male) Resistance
1
Between (1) – (2) 5 – 15 z
ground
when normal
Min. 1 Mz
(female) (2)
controller
be diagnosed).
16 D475A, D475ASD-5E0
Failure code [DXH6KY] 3rd clutch ECMV: Hot short 1

Action code Failure code Symptom of 3rd clutch ECMV: Hot short
Failure content • Current keeps flowing to 3rd clutch solenoid circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

Defective 3rd clutch sole- without turning starting switch ON.
1
Between (1) – (2) 5 – 15 z
Possible
TMCN3 (female) (5) – S3T3 (female) (1) with Voltage Max. 1 V
chassis ground
controller
not be diagnosed).
D475A, D475ASD-5E0 17
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection 1

Action code Failure code Symptom of Reverse clutch ECMV: Disconnection
Failure content • When signal is output to reverse clutch solenoid circuit, any current does not flow.
Controller's
• Stops outputting to transmission reverse clutch solenoid circuit.
action
Symptoms that
appear on
• Once machine is stopped, travel is limited to F1.
machine
• Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
General
(Code 31606, 31616: Output command current, output current of reverse clutch ECMV)
information
• Method of reproducing failure code: Start engine and drive machine in reverse.

Defective reverse clutch without turning starting switch ON.
SRT1 (male) Resistance
nection)
Between (1) – (2) 5 – 15 z
wiring or defective contact – SRT1 (female) (1) tance
Max. 1 z
– SRT1 (female) (2) tance
3 lem is found in causes 1 – 2 (Since this is an internal defect, it cannot
controller
be diagnosed).
18 D475A, D475ASD-5E0
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit 1

Action code Failure code Symptom of Reverse clutch ECMV: Short circuit
Failure content • When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.
Controller's
action
Symptoms that
appear on
machine
General
information
• Method of reproducing failure code: Start engine and drive machine in reverse.

1 solenoid (Internal short cir- SRT1 (male) Resistance
cuit) Between (1) – (2) 5 – 15 z
cuit) (female) (25) – SRT1 (female) (1) with chas- Min. 1 Mz
sis ground
when normal
harness) (female) (25) – SRT1 (female) (1) with wiring Resis-
Min. 1 Mz
harness between TMC3 (female) (13) – SRT1 tance
(female) (2)
controller
be diagnosed).
D475A, D475ASD-5E0 19
Failure code [DXH7KY] Reverse clutch ECMV: Hot short 1

Action code Failure code Symptom of Reverse clutch ECMV: Hot short
Failure content • Current keeps flowing to reverse clutch solenoid circuit.
Controller's
action
Symptoms that
appear on
• Once machine is stopped, travel is limited to R1.
machine
General
information
• Method of reproducing failure code: Start engine and drive machine in forward.

1 solenoid (Internal short cir-
SRT1 (male) Resistance
cuit)
Between (1) – (2) 5 – 15 z
Possible
(female) (25) – SRT1 (female) (1) with chas- Voltage Max. 1 V
sis ground
3 lem is found in causes 1 – 2 (Since this is an internal defect, it cannot
controller
be diagnosed).
20 D475A, D475ASD-5E0
Failure code [DXH8KA] Forward clutch ECMV: Disconnection 1

Action code Failure code Symptom of Forward clutch ECMV: Disconnection
Failure content • When signal is output to forward clutch solenoid circuit, any current does not flow.
Controller's
• Stops outputting to transmission forward clutch solenoid circuit.
action
Symptoms that
appear on
machine
• Output (Current) to forward clutch solenoid can be checked in monitoring mode.
General
(Code 31608, 31622: Output command current, output current of forward clutch ECMV)
information
• Method of reproducing failure code: Start engine and drive machine forward.

Defective forward clutch without turning starting switch ON.
SFT1 (male) Resistance
nection)
Between (1) – (2) 5 – 15 z
wiring or defective contact – SFT1 (female) (1) tance
Max. 1 z
– SFT1 (female) (2) tance
controller
not be diagnosed).
D475A, D475ASD-5E0 21
Failure code [DXH8KB] Forward clutch ECMV: Short circuit 1

Action code Failure code Symptom of Forward clutch ECMV: Short circuit
Failure content • When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.
Controller's
action
Symptoms that
appear on
machine
General
information
• Method of reproducing failure code: Start engine and drive machine forward.

1 solenoid (Internal short cir- SFT1 (male) Resistance
cuit) Between (1) – (2) 5 – 15 z
cuit) (female) (35) – SFT1 (female) (1) with chassis Min. 1 Mz
ground
when normal
harness) (female) (35) – SFT1 (female) (1) with wiring Resis-
Min. 1 Mz
harness between TMC3 (female) (13) – SFT1 tance
(female) (2)
controller
be diagnosed).
22 D475A, D475ASD-5E0
Failure code [DXH8KY] Forward clutch ECMV: Hot short 1

Action code Failure code Symptom of Forward clutch ECMV: Hot short
Failure content • Current keeps flowing to forward clutch solenoid circuit.
Controller's
action
Symptoms that
appear on
machine
General
information
• Method of reproducing failure code: Start engine and drive machine reverse.

1 solenoid (Internal short cir-
SFT1 (male) Resistance
cuit)
Between (1) – (2) 5 – 15 z
Possible
(female) (35) – SFT1 (female) (1) with chassis Voltage Max. 1 V
ground
controller
not be diagnosed).
D475A, D475ASD-5E0 23
Failure code [DXH9KA] Right steering clutch ECMV: Disconnection 1

Action code Failure code Symptom of Right steering clutch ECMV: Disconnection
CALL E03 DXH9KA failure (Steering controller system)
Failure content • When signal is output to right steering clutch solenoid circuit, current does not flow.
Controller's
• Stops outputting to right steering clutch solenoid circuit.
action
Symptoms that • Machine cannot be steered to right.
• Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
General (Code 90601, 90603: Right steering clutch ECMV (E-POCV) output current, command current)
information • Method of reproducing failure code:
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).

Defective right steering without turning starting switch ON.
1 clutch solenoid
SRC7 (male) Resistance
Between (1) – (2) 5 – 15 z
wiring or defective contact – SRC7 (female) (1) tance
Max. 1 z
– SRC7 (female) (2) tance
ler
diagnosed).
24 D475A, D475ASD-5E0
Failure code [DXH9KB] Right steering clutch ECMV: Short circuit 1

Action code Failure code Symptom of Right steering clutch ECMV: Short circuit
CALL E03 DXH9KB failure (Steering controller system)
Failure content • When signal was output to right steering clutch solenoid circuit, abnormal current flowed.
Controller's
action
Symptoms that • Machine cannot be steered to right.

1 clutch solenoid SRC7 (male) Resistance
(Internal short circuit) Between (1) – (2) 5 – 15 z
cuit) STCN3 (female) (35) – SRC7 (female) (1) Min. 1 Mz
with chassis ground
when normal
3 harness (with another wir- Short circuit of wiring harness between
STCN3 (female) (35) – SRC7 (female) (1) Resis-
ing harness) Min. 1 Mz
with wiring harness between STCN3 (female) tance
(23) – SRC7 (female) (2)
ler
diagnosed).
D475A, D475ASD-5E0 25
Failure code [DXH9KY] Right steering clutch ECMV: Hot short 1

Action code Failure code Symptom of Right steering clutch ECMV: Hot short
CALL E04 DXH9KY failure (Steering controller system)
Failure content • Current keeps flowing to right steering clutch solenoid circuit.
Controller's
action
Symptoms that • Machine cannot be steered to right. (Right clutch cannot be disconnected.)
machine • Once machine is stopped, machine cannot travel any more.

1 clutch solenoid
SRC7 (male) Resistance
Between (1) – (2) 5 – 15 z
Possible
STCN3 (female) (35) – SRC7 (female) (1) Voltage Max. 1 V
with chassis ground
ler
diagnosed).
26 D475A, D475ASD-5E0
Failure code [DXHAKA] Left steering clutch ECMV: Disconnection 1

Action code Failure code Symptom of Left steering clutch ECMV: Disconnection
CALL E03 DXHAKA failure (Steering controller system)
Failure content • When signal is output to left steering clutch solenoid circuit, current does not flow.
Controller's
• Stops outputting to left steering clutch solenoid circuit.
action
Symptoms that • Machine cannot be steered to left.
• Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
General (Code 90600, 90602: Left steering clutch ECMV (E-POCV) output current, command current)
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).

Defective left steering without turning starting switch ON.
1 clutch solenoid
SLC5 (male) Resistance
Between (1) – (2) 5 – 15 z
wiring or defective contact – SLC5 (female) (1) tance
Max. 1 z
– SLC5 (female) (2) tance
ler
diagnosed).
Circuit diagram related to left steering clutch ECMV
D475A, D475ASD-5E0 27
Failure code [DXHAKB] Left steering clutch ECMV: Short circuit 1

Action code Failure code Symptom of Left steering clutch ECMV: Short circuit
CALL E03 DXHAKB failure (Steering controller system)
Failure content • When signal was output to left steering clutch solenoid circuit, abnormal current flowed.
Controller's
action

1 clutch solenoid SLC5 (male) Resistance
(Internal short circuit) Between (1) – (2) 5 – 15 z
cuit) STCN3 (female) (25) – SLC5 (female) (1) with Min. 1 Mz
chassis ground
when normal
3 harness (with another wir- Short circuit of wiring harness between
STCN3 (female) (25) – SLC5 (female) (1) with Resis-
ing harness) Min. 1 Mz
– SLC5 (female) (2)
ler
diagnosed).
28 D475A, D475ASD-5E0
Failure code [DXHAKY] Left steering clutch ECMV: Hot short 1

Action code Failure code Symptom of Left steering clutch ECMV: Hot short
CALL E04 DXHAKY failure (Steering controller system)
Failure content • Current keeps flowing to left steering clutch solenoid circuit.
Controller's
action
machine • Once machine is stopped, machine cannot travel any more.

1 clutch solenoid
SLC5 (male) Resistance
Between (1) – (2) 5 – 15 z
Possible
STCN3 (female) (25) – SLC5 (female) (1) with Voltage Max. 1 V
chassis ground
ler
diagnosed).
D475A, D475ASD-5E0 29
Failure code [DXHBKA] Right brake ECMV: Disconnection 1

Action code Failure code Symptom of Right brake ECMV: Disconnection
CALL E04 DXHBKA failure (Steering controller system)
Failure content • When signal is output to right steering brake solenoid circuit, any current does not flow.
Controller's
• Stops outputting to right steering brake solenoid circuit.
action
• Limits operation of engine, transmission and brake.
• Sudden stop prevention valve is applied during travel.
Symptoms that
appear on
machine
• Right brake is kept applied.
• Output (Current) to right steering brake solenoid can be checked in monitoring mode.
General
(Code 31620, 31618: Command current, output current of right steering brake ECMV)
information
• Method of reproducing failure code: Turn starting switch ON and release parking brake lever.

1 brake solenoid (Internal
SR83 (male) Resistance
short circuit)
Between (1) – (2) 5 – 15 z
wiring or defective contact – SR83 (female) (1) tance
Max. 1 z
– SR83 (female) (2) tance
ler
diagnosed).
30 D475A, D475ASD-5E0
Failure code [DXHBKB] Right brake ECMV: Short circuit 1

Action code Failure code Symptom of Right brake ECMV: Short circuit
CALL E04 DXHBKB failure (Steering controller system)
Failure content • When signal was output to right steering brake solenoid circuit, abnormal current flowed.
Controller's
action
Symptoms that
appear on
machine
General
information
• Method of reproducing failure code: Start engine and release parking brake lever.

1 brake solenoid (Internal SR83 (male) Resistance
cuit) STCN3 (female) (15) – SR83 (female) (1) with Min. 1 Mz
chassis ground
when normal
3 ness (with another wiring Short circuit in wiring harness between
STCN3 (female) (15) – SR83 (female) (1) with Resis-
harness) Min. 1 Mz
– SR83 (female) (2)
ler
diagnosed).
D475A, D475ASD-5E0 31
Failure code [DXHBKY] Right brake ECMV: Hot short 1

Action code Failure code Symptom of Right brake ECMV: Hot short
CALL E04 DXHBKY failure (Steering controller system)
Failure content • Current keeps flowing to right steering brake solenoid circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

SR83 (male) Resistance
short circuit)
Between (1) – (2) 5 – 15 z
Possible
STCN3 (female) (15) – SR83 (female) (1) with Voltage Max. 1 V
chassis ground
ler
diagnosed).
32 D475A, D475ASD-5E0
Failure code [DXHCKA] Left brake ECMV: Disconnection 1

Action code Failure code Symptom of Left brake ECMV: Disconnection
CALL E04 DXHCKA failure (Steering controller system)
Failure content • When signal is output to left steering brake solenoid circuit, any current does not flow.
Controller's
• Stops outputting to left steering brake solenoid circuit.
action
Symptoms that
appear on
machine
• Left brake is kept applied.
• Output (Current) to left steering brake solenoid can be checked in monitoring mode.
General
(Code 31621, 31619: Command current, output current of left steering brake ECMV)
information

SL81 (male) Resistance
short circuit)
Between (1) – (2) 5 – 15 z
wiring or defective contact – SL81 (female) (1) tance
Max. 1 z
– SL81 (female) (2) tance
ler
diagnosed).
D475A, D475ASD-5E0 33
Failure code [DXHCKB] Left brake ECMV: Short circuit 1

Action code Failure code Symptom of Left brake ECMV: Short circuit
CALL E04 DXHCKB failure (Steering controller system)
Failure content • When signal was output to left steering brake solenoid circuit, abnormal current flowed.
Controller's
action
Symptoms that
appear on
machine
• Left brake is kept applied.
General
information
• Method of reproducing failure code: Start engine and release parking brake lever.

1 brake solenoid (Internal SL81 (male) Resistance
cuit) STCN3 (female) (5) – SL81 (female) (1) with Min. 1 Mz
chassis ground
when normal
3 ness (with another wiring Short circuit in wiring harness between
STCN3 (female) (5) – SL81 (female) (1) with Resis-
harness) Min. 1 Mz
– SL81 (female) (2)
ler
diagnosed).
34 D475A, D475ASD-5E0
Failure code [DXHCKY] Left brake ECMV: Hot short 1

Action code Failure code Symptom of Left brake ECMV: Hot short
CALL E04 DXHCKY failure (Steering controller system)
Failure content • Current keeps flowing to left steering brake solenoid circuit.
Controller's
action
Symptoms that • Sudden stop prevention valve is applied during travel.
General
information

SL81 (male) Resistance
short circuit)
Between (1) – (2) 5 – 15 z
Possible
STCN3 (female) (5) – SL81 (female) (1) with Voltage Max. 1 V
chassis ground
ler
diagnosed).
D475A, D475ASD-5E0 35
Failure code [F@BBZL] (or VHMS_LED display "n3" o "38") Engine

blow-by pressure sensor: Abnormally high pressure occurrence 1
Action code Failure code Symptom of Engine blow-by pressure sensor: Abnormally high pressure occur-
— F@BBZL failure rence (VHMS controller system)
Failure content • Blow-by pressure sensor signal circuit detected pressure higher than 4.71 kPa {480 mmAq}.
Controller's
action
Symptoms that
appear on • If machine is used as it is, engine may be broken.
machine
General
information
• "n3" on VHMS controller LED changes to "38".

Abnormal rise of blow-by
1 pressure (When system is Check engine and repair, if there is abnormality.
Possible normal)
causes and the Defective blow-by pres- If failure code [DHE5KB] or [DHE5KY] is displayed, carry out trou-
2
standard values sure sensor system bleshooting for it.
when normal a Prepare with starting switch OFF, then turn starting switch ON or
Between V2A (female) (18) – V2A (female) 0.3 –
Voltage
(12) 0.7 V
36 D475A, D475ASD-5E0
Failure code [F@BYNS] (or VHMS_LED display "n3" o "61") Left front
exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure code Left front exhaust temperature sensor (1): Exhaust temperature
Symptom of
abnormal rise
— F@BYNS failure
(VHMS controller system)
• Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Failure content perature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700°C
in range above rated output speed and 750°C in range below maximum torque speed)
Controller's
action
Symptoms that
machine
General
information

Abnormal rise of left front
1 exhaust temperature Check engine and repair, if there is abnormality.
Possible Defective left front exhaust If failure code [DGT5KA] or [DGT5KB] is displayed, carry out trou-
causes and the 2
temperature sensor bleshooting for it.
standard values
when normal
3 Defective VHMS controller V2A Exhaust temperature Voltage
20°C Approx. 0.9 – 1.2 V
(7) – (13)
500°C Approx. 2.6 – 3.5 V
38 D475A, D475ASD-5E0
Circuit diagram related to exhaust temperature sensor (1)
D475A, D475ASD-5E0 39
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear
Action code Failure code Symptom of Left rear exhaust temperature sensor (1): Exhaust temperature
— f@BYNS failure abnormal rise (VHMS controller system)
• Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Controller's
action
Symptoms that
machine
General
information

Abnormal rise of left rear
Possible Defective left rear exhaust If failure code [dGT5KA] or [dGT5KB] is displayed, carry out trouble-
causes and the 2
temperature sensor shooting for it.
standard values
when normal
20°C Approx. 0.9 – 1.2 V
(6) – (13)
500°C Approx. 2.6 – 3.5 V
40 D475A, D475ASD-5E0
D475A, D475ASD-5E0 41
Failure code [F@BZNS] (or VHMS_LED display "n3" o "38") Right front
Action code Failure code Symptom of Right front exhaust temperature sensor (1): Exhaust temperature
— F@BZNS failure abnormal rise (VHMS controller system)
• Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust
Failure content temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between
700°C in range above rated output speed and 750°C in range below maximum torque speed)
Controller's
action
Symptoms that
machine
• Failure code is not displayed on machine monitor (It can be checked, however, by downloading
General
data saved in VHMS controller into personal computer).
information

Abnormal rise of right front
Possible Defective right front
If failure code [DGT6KA] or [DGT6KB] is displayed, carry out trou-
causes and the 2 exhaust temperature sen-
bleshooting for it.
standard values sor
20°C Approx. 0.9 – 1.2 V
(5) – (13)
500°C Approx. 2.6 – 3.5 V
42 D475A, D475ASD-5E0
D475A, D475ASD-5E0 43
Failure code [f@BZNS] (or VHMS_LED display "n3" o "39") Right rear
Action code Failure code Right rear exhaust temperature sensor (1): Exhaust temperature
Symptom of
abnormal rise
— f@BZNS failure
(VHMS controller system)
• Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust
Controller's
action
Symptoms that
machine
General
information

Abnormal rise of right rear
Possible Defective right rear
If failure code [dGT6KA] or [dGT6KB] is displayed, carry out trouble-
shooting for it.
standard values sor
20°C Approx. 0.9 – 1.2 V
(16) – (13)
500°C Approx. 2.6 – 3.5 V
44 D475A, D475ASD-5E0
D475A, D475ASD-5E0 45
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front
Action code Failure code Symptom of Left front exhaust temperature sensor (2): Exhaust temperature
— F@BYNR failure abnormal rise (VHMS controller system)
• Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Controller's
action
Symptoms that
machine
General
information

Abnormal rise of left front
Possible Defective left front exhaust If failure code [DGT5KA] or [DGT5KB] is displayed, carry out trou-
causes and the 2
temperature sensor bleshooting for it.
standard values
when normal
20°C Approx. 0.9 – 1.2 V
(7) – (13)
500°C Approx. 2.6 – 3.5 V
46 D475A, D475ASD-5E0
D475A, D475ASD-5E0 47
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear
Action code Failure code Symptom of Left rear exhaust temperature sensor (2): Exhaust temperature
— f@BYNR failure abnormal rise (VHMS controller system)
• Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust tem-
Controller's
action
Symptoms that
machine
General
information

Abnormal rise of left rear
Possible Defective left rear exhaust If failure code [dGT5KA] or [dGT5KB] is displayed, carry out trouble-
causes and the 2
temperature sensor shooting for it.
standard values
when normal
20°C Approx. 0.9 – 1.2 V
(6) – (13)
500°C Approx. 2.6 – 3.5 V
48 D475A, D475ASD-5E0
D475A, D475ASD-5E0 49
Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front
Action code Failure code Symptom of Right front exhaust temperature sensor (2): Exhaust temperature
— F@BZNR failure abnormal rise (VHMS controller system)
• Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust
Controller's
action
Symptoms that
machine
General
information

Abnormal rise of right front
Possible Defective right front
If failure code [DGT6KA] or [DGT6KB] is displayed, carry out trou-
bleshooting for it.
standard values sor
20°C Approx. 0.9 – 1.2 V
(5) – (13)
500°C Approx. 2.6 – 3.5 V
50 D475A, D475ASD-5E0
D475A, D475ASD-5E0 51
Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear
Action code Failure code Symptom of Right rear exhaust temperature sensor (2): Exhaust temperature
— f@BZNR failure abnormal rise (VHMS controller system)
• Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust
Controller's
action
Symptoms that
machine
General
information

Abnormal rise of right rear
Possible Defective right rear
If failure code [dGT6KA] or [dGT6KB] is displayed, carry out trouble-
shooting for it.
standard values sor
20°C Approx. 0.9 – 1.2 V
(16) – (13)
500°C Approx. 2.6 – 3.5 V
52 D475A, D475ASD-5E0
D475A, D475ASD-5E0 53
SEN01830-00

© 2006 KOMATSU
All Rights Reserved
54
SEN01831-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Troubleshooting of electrical system
(E-mode)
Troubleshooting of electrical system (E-mode)............................................................................................... 2
Contents of troubleshooting table......................................................................................................... 2
E-1 The engine does not start. ............................................................................................................. 3
E-2 The preheater does not operate. ................................................................................................... 7
D475A, D475ASD-5E0 1
Troubleshooting of electrical system (E-mode) 1

Contents of troubleshooting table 1
Trouble Problem that appears on machine
Related
Information related to detected trouble or troubleshooting
information

<Described contents>
• Standard value in normal state required to judge the
assumed cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Causes by which a trouble A harness of an independent circuit abnormally comes into
and standard is assumed to be defected contact with one of another circuit.
value in normal (The order number indi-
state cates a serial number, not <Notes on troubleshooting>
a priority sequence.) (1) Method of indicating connector numbers and handling of T-
adapter
For troubleshooting, insert or connect T-adapter shown
3 below unless especially specified.
• When “male” or “female” is not indicated for a connector
number, disconnect the connector, and insert the T-
adapters in both the male and female.
• When “male” or “female” is indicated for a connector
number, disconnect connector, and insert the T-adapter
in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• 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 troubleshooting.

• Connector No.: Indicates (Model – No. of pins) (Color).
• “Connector No. and pin No.” from each branching/merging point: indi-
cate the ends of branch or source of merging within the parts of the
same wiring harness
• Arrow (io): Roughly indicates mounting place on machine.
2 D475A, D475ASD-5E0
E-1 The engine does not start. 1

Symptom of
• The engine does not start.
failure (1)
• The engine start circuit has the neutral safety function, and the engine does not start unless the
parking brake lever is set to the lock position.
• If “the monitor panel does not come on” or “the battery relay does not cause operating sound” when
General the starting switch is set to ON, the main electric power supply system is supposed to be out of
information order. So, inspect the main electric power supply system.
• Before starting the troubleshooting, validate that the related failure code is not displayed.
(If the failure code [D130KA], [D130KB], [DD14KA], [DD14KB], [DDQ2KA] or [DDQ2KB] is dis-
played, conduct troubleshooting for the displayed code first.)

Battery voltage Battery specific gravity
1 Insufficient battery capacity
Min. 24 V Min. 1.26
a Prepare with the starting switch OFF, then carry out troubleshoot-
ing without turning the starting switch ON.
Defective starting switch KEY (male) Switch position Resistance
2
OFF Min. 1 Mz
Between (5) and (3)
START Max. 1 z
a Prepare with the starting switch OFF, then start the engine and
Defective neutral safety carry out troubleshooting.
3 relay (internal disconnec- If the engine starts in accordance with the engine starting arrange-
tion) ment after the neutral safety relay (NSF) is replaced with another
one while the starting switch is set to OFF, the relay is defective.
a Prepare with the starting switch OFF, then turn the starting switch
Defective alternator (inter- ON and carry out troubleshooting.
4
nal short-circuit) Alternator Voltage
Possible Between Terminal R and ground Max. 1 V
causes and the a Prepare with the starting switch OFF, then start the engine and
when normal Starting motor A, B Voltage
Electric power supply : between
20 – 30 V
Terminal B and ground
Detective starting motor Charge : between Terminal R
5 Max. 1 V
(internal defect) and ground
Starting : between Terminal S
20 – 30 V
and ground
When the voltages of electric power supply, for charging and start-
ing are normal but the starting motor does not rotate, the starting
motor is defective.
a Prepare with the starting switch OFF, then carry out troubleshoot-
ing without turning the starting switch ON.
Disconnection in wiring har- Wiring harness between KEY (female) (3) Resis-
Max. 1 z
ness (disconnection in wir- and NFS (female) (3) tance
6
ing or defective contact in Wiring harness between NSF (female) (5) Resis-
connector) Max. 1 z
and ST1 (female) (1) tance
Wiring harness between NSF (female) (5) Resis-
Max. 1 z
and ST2 (female) (1) tance
D475A, D475ASD-5E0 3

a Prepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Hot short of wiring harness between alterna-
Possible tor R terminal and ST1 (female) (2) or ST2 Voltage Max. 1 V
causes and the (female) (2) with ground
7
when normal (Contact with 24 V circuit) Hot short of wiring harness between STCN1
(female) (23) and pre-lubrication motor sig- Voltage Max. 1 V
nal terminal with ground
Hot short of wiring harness between S03
(female) (9) and pre-heater relay HTRIC ter- Voltage Max. 1 V
minal with ground
4 D475A, D475ASD-5E0
Symptom of • Trouble (1) is not detected but the engine does not start (When the machine is equipped with pre-
failure (2) lubricator).
• "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 "o" on the right
General
side flashes, the engine oil pressure is not heightened. (In this case, the pre-lubrication motor and
information
the engine oil pressure switch for pre-lubrication may be defective. Accordingly, carry out the fol-
lowing troubleshooting.)

a Prepare with starting switch OFF, then keep starting switch OFF
Defective engine oil pres- or start engine and carry out troubleshooting.
sure switch for pre-lubrica- STCN2 Starting switch Resistance
1
tion (Internal disconnection
or short circuit) Between (3) and OFF Max. 1 z
chassis ground Start engine Min. 1 Mz
When 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 dis-
2
relay (PLUB) play unit and "E" on the right side flashes after the starting switch is
turned ON.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective pre-lubrication
3 Pre-lubrication motor Voltage
motor
Between signal terminal
20 – 30 V
and chassis ground
Possible Wiring harness between engine oil pressure Resis-
switch terminal POP and STCN2 (female) (3) tance
standard values
when normal Disconnection in wiring Wiring harness between KEY (female) (1) Resis-
Max. 1 z
harness (Disconnection in and pre-lubrication relay (PLUB) (female) (1) tance
4
wiring harness or defective Wiring harness between pre-lubrication relay
contact in connector) Resis-
(PLUB) (female) (2) and STCN2 (female) Max. 1 z
tance
(18)
Wiring harness between pre-lubrication
Resis-
motor signal terminal and STCN1 (female) Max. 1 z
tance
(23)
Between wiring harness between KEY
Resis-
(female) (1) and pre-lubrication relay (PLUB) Min. 1 Mz
Short circuit with chassis tance
(female) (1) and chassis ground
5 Between wiring harness between pre-lubri-
cuit) cation relay (PLUB) (female) (2) and STCN2 Min. 1 Mz
tance
Between wiring harness between pre-lubri-
Resis-
cation motor signal terminal and STCN1 Min. 1 Mz
tance
D475A, D475ASD-5E0 5
Engine start/charge-related circuit diagram
6 D475A, D475ASD-5E0
E-2 The preheater does not operate. 1

Symptom of
• The preheater does not operate.
failure
a This troubleshooting describes the procedures to be followed when the automatic and manual pre-
heating does not function to heat the electrical intake air heater mounting section.
(When only the preheating lamp does not light up, carry out the troubleshooting of “E-8 While the
preheater is operating, the preheating pilot lamp does not light up”)
• For preheating, both the “Automatic preheating function” and “Manual preheating function” are
General
available. When either function is performed, the preheating lamp comes on.
information
• If “the monitor panel does not light up” or “the battery relay does not make operating noise” when
turning the starting switch ON, the main electric power supply system can be suspected to be
defective. So, check the main electric power supply system.
• Before starting the troubleshooting, validate that the related failure code is not displayed.
(If the failure code [D182KZ] is displayed, firstly conduct this troubleshooting.)

switch still OFF.
Defective starting switch Starting switch Switch position Resistance
1
Between 250 (B) – OFF Min. 1 Mz
255 (R1) HEAT (R1) Max. 1 z
Defective fuse If the fuse is burnt, it is highly possible that a defective grounding,
2
(FS22) etc. has occurred in the circuit.
Defective circuit breaker If the breaker is cutout, it is highly possible that a defective ground-
3
(CB30, CB6) ing, etc. has occurred in the circuit.
switch ON.
Defective preheater relay
4 If preheating starts normally at the intake air temperature below
minus 5°C after the preheater relay PHR is replaced with another
one, the preheater relay PHR is defective.
Possible a Prepare with the starting switch OFF and diagnose with the start-
causes and the ing switch HEAT.
standard values Heater relay Voltage
when normal
Electric power supply: between
Defective heater relay terminal HTR1A, HTR2A and 20 – 30V
5
(internal defect) ground
Signal: between terminal
20 – 30V
HTR1C, HTR2C and ground
When the both voltages of electric power supply and signal are nor-
mal and no operating noise is heard, the heater relay is defective.
switch still OFF.
Defective diode
6 Diagnose diode HTD1, HTD2 (male)
(internal short circuit)
• See the “Inspection procedure of diode” in the “Testing and
adjusting” section.
Defective electrical intake switch still OFF.
7
air heater (internal defect) Electrical intake air heater Continuity
Between terminals Continue
D475A, D475ASD-5E0 7

switch still OFF.
Wiring harnesses between FS22 (2) – PHR Resis-
Max. 1 z
(female) (5) tance
Wiring harness between PHR (female) (3) – Resis-
Max. 1 z
Disconnection in wiring terminal HTR1C – terminal HTR2C tance
harness Wiring harness between starting switch 255 Resis-
8 Max. 1 z
(disconnection or defective (R1) – terminal HTR1C – terminal HTR2C tance
contact of connectors) Wiring harness between terminal BRC of
Resis-
battery relay – terminal HTR1A and terminal Max. 1 z
tance
HTR1A
Wiring harness between terminal REL1,
Resis-
REL2 of heater relay – electrical intake air Max. 1 z
Possible tance
heater HT1
causes and the
when normal switch still OFF.
Between ground and wiring harness Resis-
Min. 1 Mz
between FS22 (2) – PHR (female) (5) tance
Between ground and wiring harness
Resis-
between PHR (female) (3) – terminal HTR1C Min. 1 Mz
tance
– terminal HTR2C
Defective harness
9 grounding Between ground and wiring harness
Resis-
(contact with ground circuit) between starting switch 255 (R1) – terminal tance
Min. 1 Mz
HTR1C – terminal HTR2C
Resis-
between terminal BRC of battery relay – ter- Min. 1 Mz
tance
minal HTR1A and terminal HTR2A
Resis-
between terminal REL1, REL2 of heater Min. 1 Mz
tance
relay – electrical intake air heater HT1
8 D475A, D475ASD-5E0
Engine preheat-related circuit diagram
D475A, D475ASD-5E0 9
SEN01831-00

© 2006 KOMATSU
All Rights Reserved
10
SEN01832-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Information in troubleshooting table ..................................................................................................... 3
H-1 No force (no drawbar pull)............................................................................................................. 4
H-2 No travel (at 2nd or 3rd speed) ..................................................................................................... 6
H-3 No travel at all gear speeds........................................................................................................... 7
H-4 Machine travels only in one direction forward or in reverse .......................................................... 8
H-5 Large time lag at gear speed shifting or forward-reverse shifting ................................................. 9
H-6 Steering is not possible ............................................................................................................... 10
H-7 Steering is possible only on one side .......................................................................................... 11
H-8 Steering overrun occurs .............................................................................................................. 12
H-9 Brake does not work.................................................................................................................... 13
H-10 Torque converter is not lock-up................................................................................................. 14
H-11 Power train oil is overheated ..................................................................................................... 15
H-12 All work equipment speeds are slow ......................................................................................... 16
D475A, D475ASD-5E0 1
H-13 Work equipment does not move................................................................................................ 17

H-14 Blade lift speed is slow or lacks power ...................................................................................... 18
H-15 Blade tilt speed is slow or lacks power ...................................................................................... 19
H-16 Ripper lift speed is slow or lacks power..................................................................................... 20
H-17 Ripper tilt speed is slow or lacks power..................................................................................... 21
H-18 Excessive hydraulic drift of blade lift.......................................................................................... 22
H-19 Excessive hydraulic drift of blade tilt.......................................................................................... 23
H-20 Excessive hydraulic drift of ripper lift ......................................................................................... 24
H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine)............................. 24
H-22 Blade pitch does not work (dual tilt attachment machine) ......................................................... 25
H-23 Abnormal sound comes out from around work equipment pump .............................................. 25
2 D475A, D475ASD-5E0
Troubleshooting of hydraulic and mechanical system (H-mode)1

Information in troubleshooting table 1
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>
(Given numbers are refer-
value in normal • Standard value in normal state to judge possible causes
state ence numbers, which do not
• Remarks on judgment
indicate priority)
3
D475A, D475ASD-5E0 3
H-1 No force (no drawbar pull) 1

Symptom of
• No force (No drawbar pull)
failure
General
• 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.
a Prepare with starting switch OFF, then drive the engine in high
idle mode for troubleshooting (after checking that the transmis-
sion 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 0.39 – 0.64 MPa
Full neutral
{8.0 – 10.0 kg/cm2} {4.0 – 6.5 kg/cm2}
Incorrect pressure set to idle mode 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}
Defective operation of without turning starting switch ON.
valve Check it directly that the spring free length (120.3 mm) is normal
and that the spool moves smoothly.
Possible a Prepare with starting switch OFF, then drive the engine in low idle
causes and the mode for troubleshooting (after checking that the transmission
standard values main relief pressure is normal).
when normal Transmission clutch Clutch pressure
Defective operation of FWD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
5
transmission valve (ECMV) REV 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
1ST 1.86 – 2.35 MPa {19.0 – 24.0 kg/cm2}
2ND 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
3RD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
idle mode for troubleshooting.
Internal defect of transmis- Measuring conditions Engine speed
6
sion F3 stall Min. 1,590 rpm
F3 stall + Work equipment relief
Min. 1,450 rpm
(pitch back)
a Move the machine to a flat ground and start the engine for trou-
bleshooting.
Defective operation (drag-
7 Drive the engine in low idle mode and operate F2. Unless the
ging) of brake
machine moves, the brake is being dragged. (Execute the trouble-
shooting of “Brake does not work.”)
4 D475A, D475ASD-5E0

PCCS lever Left stroke end Right stroke end
Min. 2.45 MPa 0 MPa
Possible Left clutch pressure
{Min. 25 kg/cm2} {0 kg/cm2}
causes and the
0 MPa Min. 2.45 MPa
standard values 8 Defective steering clutch Right clutch pressure
{0 kg/cm2} {Min. 25 kg/cm2}
when normal
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, D475ASD-5E0 5
H-2 No travel (at 2nd or 3rd speed) 1

Symptom of
• No travel (at 2nd or 3rd speed)
failure
General • 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 0.39 – 0.64 MPa
Full neutral
{8.0 – 10.0 kg/cm2} {4.0 – 6.5 kg/cm2}
a Prepare with starting switch OFF, then drive the engine in low idle
mode for troubleshooting.
Defective operation of Transmission clutch Clutch pressure
2
transmission valve (ECMV)
2ND 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
3RD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is sup-
3
sion clutch posed to be defective. Check it directly.
4 Defective operation (dragging) is supposed, check linkage valves.
Possible ging) of parking brake
causes and the a Move the machine to a flat ground and start the engine for trou-
standard values bleshooting.
when normal Defective operation (drag-
ging) of brake
Min. 2.45 MPa 0 MPa
Left clutch pressure
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
When the oil pressure is abnormal, execute the troubleshooting of
“Steering is not possible.”
6 D475A, D475ASD-5E0
H-3 No travel at all gear speeds 1

Symptom of
• No travel at all gear speeds
failure
General
information

Incorrect pressure set to
Transmission main relief
2 transmission main relief PCCS lever
pressure
valve
2.55 – 3.04 MPa
Full neutral
{26.0 – 31.0 kg/cm2}
Defective operation of without turning starting switch ON.
Check it directly that the spring free length (120.3 mm) is normal
valve
mode for troubleshooting (after checking that the transmission
main relief pressure is normal).
Transmission clutch Clutch pressure
Defective operation of FWD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
4
transmission valve (ECMV) REV 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
1ST 1.86 – 2.35 MPa {19.0 – 24.0 kg/cm2}
2ND 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
3RD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
Possible Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is sup-
5
causes and the sion clutch posed to be defective. Check it directly.
standard values a Prepare with starting switch OFF, then drive the engine in high
when normal idle mode for troubleshooting (after checking that the transmis-
Defective operation of sion main relief pressure is normal).
6 Brake pedal Brake oil pressure (right and left)
brake
Release Min. 2.45 MPa {Min. 25 kg/cm2}
Step on 0 MPa {0 kg/cm2}
Min. 2.45 MPa 0 MPa
Left clutch pressure 2
Defective seal of steering {Min. 25 kg/cm } {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
8
clutch it directly.
Perform troubleshooting for failure codes [DDQ2KA], [DDQ2KB],
Defective operation of park- [DDQ2L4] and [dDQ2L4].
9
ing brake lever switch Even if the failure code does not appear, confirm that the switch
input is changed properly.
D475A, D475ASD-5E0 7
H-4 Machine travels only in one direction forward or in reverse 1

Symptom of
• Machine travels only in one direction Forward or in Reverse.
failure
General
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
Check it directly that the spring free length (120.3 mm) is normal
valve
Possible Transmission clutch Clutch pressure
causes and the Defective operation of
4 FWD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
standard values transmission valve (ECMV)
when normal REV 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
1ST 1.86 – 2.35 MPa {19.0 – 24.0 kg/cm2}
2ND 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
3RD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
Defective seal of transmis- When the cause 4 is not applicable, the clutch seal is supposed to
5
sion clutch be defective. Check it directly.
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective,
6
sion clutch check it directly.
bleshooting.
ging) of brake
Defective operation of for-
8 ward-reverse potentiome- Perform troubleshooting related to forward-reverse potentiometer.
ter of travel lever
8 D475A, D475ASD-5E0
H-5 Large time lag at gear speed shifting or forward-reverse shifting 1

Symptom of
• Large time lag at gear speed shifting or forward-reverse shifting
failure
General
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 Transmission clutch Clutch pressure
causes and the Defective operation of FWD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
3
standard values transmission valve (ECMV) REV 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
when normal
1ST 1.86 – 2.35 MPa {19.0 – 24.0 kg/cm2}
2ND 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
3RD 2.25 – 2.74 MPa {23.0 – 28.0 kg/cm2}
Defective seal of transmis- When the cause 3 is not applicable, the clutch seal is supposed to
4
sion clutch be defective. Check it directly.
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective,
5
sion clutch check it directly.
bleshooting.
ging) of brake
D475A, D475ASD-5E0 9
H-6 Steering is not possible 1

Symptom of
• Steering is not possible.
failure

Prepare with starting switch OFF, then drive the engine in low idle
1 Lift the machine with the blade and the ripper and steer the wheel
brake
for F3 travel (or R3 travel). If the track shoe stops, the brake is
defective. (Execute the troubleshooting of “Brake does not work.”)
Min. 2.45 MPa 0 MPa
Possible Defective operation of {Min. 25 kg/cm2} {0 kg/cm2}
causes and the 2 steering clutch valve 0 MPa Min. 2.45 MPa
standard values (ECMV) {0 kg/cm2} {Min. 25 kg/cm2}
when normal 0 MPa Min. 2.45 MPa
Left brake pressure 2
{0 kg/cm } {Min. 25 kg/cm2}
Min. 2.45 MPa 0 MPa
Defective seal of steering When the cause 2 is not applicable, the clutch seal is supposed to
3
clutch be defective. Check it directly.
4
clutch it directly.
5 steering potentiometer of Perform the troubleshooting related to steering potentiometer.
travel lever
10 D475A, D475ASD-5E0
H-7 Steering is possible only on one side 1

Symptom of
• Steering is possible only on one side.
failure

Min. 2.45 MPa 0 MPa
Defective operation of {Min. 25 kg/cm2} {0 kg/cm2}
1 steering clutch valve 0 MPa Min. 2.45 MPa
(ECMV) {0 kg/cm2} {Min. 25 kg/cm2}
Possible
0 MPa Min. 2.45 MPa
causes and the Left brake pressure
standard values {0 kg/cm2} {Min. 25 kg/cm2}
when normal Min. 2.45 MPa 0 MPa
Defective seal of steering When the cause 1 is not applicable, the clutch seal is supposed to
2
clutch be defective. Check it directly.
3
clutch it directly.
4 steering potentiometer of Perform the troubleshooting related to steering potentiometer.
travel lever
D475A, D475ASD-5E0 11
H-8 Steering overrun occurs 1

Symptom of
• Steering overrun occurs.
failure

a Prepare with starting the engine, then drive the engine in low idle
Possible Defective operation of
1 Lift the machine with the blade and the ripper and steer the wheel
causes and the brake
standard values for F3 travel (or R3 travel). If the track shoe stops, the brake is
defective. (Execute the troubleshooting of “Brake does not work.”)
when normal
When the track shoe does not stop in the troubleshooting of the
2 cause 1, the steering clutch is defective. (Execute the troubleshoot-
steering clutch
ing of “Steering is not possible.”)
12 D475A, D475ASD-5E0
H-9 Brake does not work 1

Symptom of
• Brake does not work.
failure

a Start the engine for troubleshooting.
Step on the brake pedal, shift the gear to F2 and drive the engine in
1 Degradation of brake
high idle mode. When the machine moves, the brake performance
is degraded.
Defective operation of The brake pedal and the brake valve are supposed not to work nor-
2
brake pedal mally. Check them directly.
Possible Min. 2.45 MPa 0 MPa
causes and the Left clutch pressure
Defective operation of {Min. 25 kg/cm2} {0 kg/cm2}
standard values
when normal 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
4 Defective brake seal cause 3, the brake seal is supposed to be defective. Check it
directly.
The inside of the brake is supposed to be defective. Check it
5 Internal defect of brake
directly.
D475A, D475ASD-5E0 13
H-10 Torque converter is not lock-up 1

Symptom of
• The torque converter is not lock-up.
failure

Defective operation of idle mode for troubleshooting.
2 torque converter lock-up Torque converter Clutch pressure
valve Min. 1.13 – 1.42 MPa
At lock-up time
{Min. 11.5 – 14.5 kg/cm2}
Possible
Defective seal of lock-up When the troubleshooting of the case 2 is not normal, the lock-up
causes and the 3
clutch clutch seal is supposed to be defective. Check it directly.
standard values
when normal Internal defect of lock-up The inside of the lock-up clutch is supposed to be defective. Check
4
clutch it directly.
Internal defect of torque Measuring conditions Engine speed
5
converter F3 stall Min. 1,590 rpm
F3 stall + Work equipment relief
Min. 1,450 rpm
(pitch back)
14 D475A, D475ASD-5E0
H-11 Power train oil is overheated 1

Symptom of
• The power train oil is overheated.
failure
• Before troubleshooting, check that the indication of the power train oil temperature gauge agrees
General with actual temperature of the power train oil. (When the indication does not agree with actual tem-
information perature, execute the troubleshooting of “The indication of power train 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. Trouble-
1 Rise of engine output
shoot referring to the shop manual for engine.
Defective power train pump The power train pump is supposed to be defective, or air is sup-
2
or air entry in suction circuit posed to have entered from the suction circuit. Check them directly.
Internal defect of torque Torque converter Torque converter
Possible 3 PCCS lever
converter inlet pressure outlet pressure
causes and the
0.8 – 1.0 MPa 0.39 – 0.64 MPa
standard values Full neutral
when normal {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
4
of transmission clutch (the clutch slides). Check it directly.
a Start the engine for troubleshooting.
Defective operation (drag- Drive the engine in low idle mode and operate F2. Unless the
5
ging) of brake machine moves, the brake is being dragged. (Execute the trouble-
Defective operation (slide) The inside of the steering clutch is supposed to be defective (the
6
of steering clutch clutch slides). Check it directly.
D475A, D475ASD-5E0 15
H-12 All work equipment speeds are slow 1

Symptom of
• All work equipment speeds are slow.
failure
General
• 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
1
unit of work equipment) defective; directly check it.
Defective work equipment The pump of the work equipment is assumed to be defective;
2
pump directly check it.
Defective unload valve
3 Work equipment lever Unload pressure
function
2.94 – 4.9 MPa
Full neutral
{30 – 50 kg/cm2}
Possible
causes and the
Defective set pressure or idle mode for troubleshooting.
standard values
when normal 4 defective function of main Work equipment lever Main relief pressure
relief valve Stroke end 27.4 ± 1.4 MPa
(Except blade cylinder) {280 ± 14 kg/cm2}
Defective function of self-
Original pressure of control cir-
5 pressure reducing valve Work equipment lever
cuit
(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.
16 D475A, D475ASD-5E0
H-13 Work equipment does not move 1

Symptom of
• Work equipment does not move.
failure
General
information

Defective PTO (Pump drive The PTO pump drive unit of the work equipment is assumed to be
1
unit of work equipment) defective; directly check it.
Defective work equipment The work equipment pump is assumed to be defective; directly
2
pump check it.
Defective unload valve
3 Work equipment lever Unload pressure
function
2.94 – 4.9 MPa
Full neutral
{30 – 50 kg/cm2}
Possible a Prepare with starting switch OFF, then drive the engine in high
causes and the Defective set pressure or idle mode for troubleshooting.
standard values 4 defective function of main Work equipment lever Main relief pressure
when normal relief valve 27.4 ± 1.4 MPa
Stroke end
{280 ± 14 kg/cm2}
Defective function of self-
Original pressure of control cir-
5 pressure reducing valve Work equipment lever
cuit
(PPC original pressure)
Min. 3.72 MPa
Full neutral
{Min. 38 kg/cm2}
Defective function of work
Check that the PPC lock valve works properly when the work equip-
6 equipment lock lever and
ment lock lever is moved up and down.
PPC lock valve
D475A, D475ASD-5E0 17
H-14 Blade lift speed is slow or lacks power 1

Symptom of
• Blade lift speed is slow or lacks power.
failure
General • 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 1 Blade lever PPC valve output pressure
tion
causes and the Min. 3.72 MPa
standard values Lift stroke end
{Min. 38 kg/cm2}
when normal Defective function of blade The spool function of the blade lift control valve is assumed to be
2
lift control valve (Spool) defective; directly check it.
The blade lift cylinder is assumed to be aired; carry out the air bleed
3 Aired blade lift cylinder
and observe how the phenomenon changes.
18 D475A, D475ASD-5E0
H-15 Blade tilt speed is slow or lacks power 1

Symptom of
• Blade tilt speed is slow or lacks power.
failure
information • When the hydraulic drift rate of the blade tilt is also high, carry out troubleshooting “High Hydraulic
Drift Rate of Blade Tilt.”

Possible 1 Blade lever PPC valve output pressure
tion
Lift stroke end
standard values {Min. 38 kg/cm2}
when normal Defective function of blade The spool function of the blade tilt control valve is assumed to be
2
tilt control valve (Spool) defective; directly check it.
The blade tilt cylinder is assumed to be aired; carry out the air bleed
3 Aired blade tilt cylinder
D475A, D475ASD-5E0 19
H-16 Ripper lift speed is slow or lacks power 1

Symptom of
• Ripper lift speed is slow or lacks power.
failure
General • 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.”

1 Ripper lever PPC valve output pressure
tion
Min. 3.72 MPa
Possible Lift stroke end
{Min. 38 kg/cm2}
causes and the
standard values Defective function of ripper The spool function of the ripper lift control valve is assumed to be
2
when normal lift control valve (Spool) defective; directly check it.
Defective function of ripper
The function of the suction valve of the ripper lift control valve is
3 lift control valve (suction
assumed to be defective, directly check it.
valve)
The ripper lift cylinder is assumed to be aired; carry out the air bleed
4 Aired ripper lift cylinder
20 D475A, D475ASD-5E0
H-17 Ripper tilt speed is slow or lacks power 1

Symptom of
• Ripper tile speed is slow or lacks power.
failure
General • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information • Confirm whether the ripper is remodeled.

Possible 1 Ripper lever PPC valve output pressure
tion
Tilt stroke end
standard values {Min. 38 kg/cm2}
when normal Defective function of ripper The spool function of the ripper tilt control valve is assumed to be
2
tilt control valve (Spool) defective; directly check it.
The ripper tilt cylinder is assumed to be aired; carry out the air bleed
3 Aired ripper tilt cylinder
D475A, D475ASD-5E0 21
H-18 Excessive hydraulic drift of blade lift 1

Symptom of
• Excessive hydraulic drift of blade lift.
failure
information • Confirm that no oil leaks the circuits in the work equipment before troubleshooting.

Prepare with starting the engine, then stop the engine for trouble-
shooting.
Follow the procedure below for troubleshooting. If the hydraulic drift
Possible speed becomes high, the spool seal of the blade lift control valve is
Defective seal of blade lift assumed to be defective.
causes and the 1
control valve (Spool) 1) Prop up the machine using the blade lift, and lift the front of the
standard values
when normal machine.
2) Stop the engine, and release the lock lever.
3) Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of blade lift The seal of the blade lift cylinder is assumed to be defective; directly
2
cylinder check it.
22 D475A, D475ASD-5E0
H-19 Excessive hydraulic drift of blade tilt 1

Symptom of
• Excessive hydraulic drift of blade tilt.
failure

a Prepare with starting the engine, then stop the engine for trouble-
shooting.
speed becomes high, the spool seal of the blade tilt control valve is
Defective seal of blade tilt assumed to be defective.
Possible 1
control valve (Spool) 1) Prop up the machine using the blade tilt, and lift the right of the
causes and the
machine.
standard values 2) Stop the engine, and release the lock lever.
when normal 3) Set the blade lever to the right tilt side, and confirm how the phe-
nomenon changes.
Defective seal of blade tilt idle mode for troubleshooting.
2
cylinder Blade tilt cylinder Cylinder leak quantity
Right tilt stroke end 20 cc/min
D475A, D475ASD-5E0 23
H-20 Excessive hydraulic drift of ripper lift 1

Symptom of
• Excessive hydraulic drift of ripper lift.
failure
General • Confirm whether the ripper is remodeled.

a Prepare with starting the engine, then stop the engine for trouble-
shooting.
speed becomes high, the spool seal of the ripper lift control valve
Defective seal of ripper lift (Hi) is assumed to be defective.
Possible 1
control valve (Spool) 1) Prop up the machine using the blade tilt, and lift the rear of the
causes and the
machine.
standard values 2) Stop the engine, and release the lock lever.
when normal 3) Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of ripper lift idle mode for troubleshooting.
2
cylinder Ripper lift cylinder Cylinder leak quantity
Lowering stroke end 20 cc/min
H-21 Ripper pin puller cylinder does not work (giant ripper attachment
machine) 1
Symptom of
• The ripper pin puller cylinder does not work.
failure
General
• Confirm that the main relief pressure for transmission is normal before troubleshooting.
information

Defective function of pin Measurement Pin puller working
1 Pin puller switch
Possible puller solenoid position pressure
causes and the Push-in Cylinder bottom side Min. 2.55 MPa
standard values Pull-in Cylinder head side {Min. 26 kg/cm2}
when normal Internally defective pin The pin puller cylinder is assumed to be defective internally; directly
2
puller cylinder check it.
Check that the fuse is not melted.
Defective fuse FS2-2 (20A)
3 If melted, the short circuit is probably assumed, check the harness
for pin puller
of the related circuit.
24 D475A, D475ASD-5E0
H-22 Blade pitch does not work (dual tilt attachment machine) 1
Symptom of
• The blade pitch does not work.
failure
General
information

Defective function of blade
The spool of the blade pitch operation valve is assumed to be defec-
1 pitch selection solenoid
tive; directly check it.
valve
Possible
Defective function of blade The function of the blade pitch cylinder is assumed to be defective;
causes and the 2
pitch control valve (Spool) directly check it.
standard values
when normal Defective function of blade The function of the blade pitch selection solenoid valve is assumed
3
pitch cylinder to be defective; directly check it.
Perform the troubleshooting related to the blade pitch.
Defective function of blade
4 Even if the failure code does not appear, confirm that the switch
pitch switch
input is changed properly.
H-23 Abnormal sound comes out from around work equipment pump 1
Symptom of
• Abnormal noise from around work equipment pump.
failure
General
information

1 Inappropriate oil The oil used is assumed to be inappropriate; directly check it.
Possible Clogged hydraulic oil tank The strainer of the hydraulic oil tank is assumed to be clogged;
2
causes and the strainer directly check it.
standard values Air is assumed to be inhaled in the suction circuit of the work
when normal 3 Air inhaled in suction circuit
machine pump; directly check the pipes.
Internally defective work The work equipment pump is assumed to be defective internally;
4
equipment pump directly check it.
D475A, D475ASD-5E0 25
SEN01832-00

© 2006 KOMATSU
All Rights Reserved
26
SEN01833-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)............................................................................................................... 3
Method of using troubleshooting chart ................................................................................................. 3
S-1 Starting performance is poor ......................................................................................................... 6
S-2 Engine does not start..................................................................................................................... 7
S-3 Engine does not pick up smoothly............................................................................................... 10
S-4 Engine stops during operations ....................................................................................................11
S-5 Engine does not rotate smoothly ................................................................................................. 12
S-6 Engine lacks output (or lacks power)........................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 16
S-9 Oil becomes contaminated quickly .............................................................................................. 17
S-10 Fuel consumption is excessive.................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 19
S-12 Oil pressure drops ..................................................................................................................... 20
S-13 Oil level rises (Entry of coolant or fuel)...................................................................................... 21
S-14 Coolant temperature becomes too high (overheating) .............................................................. 22
D475A, D475ASD-5E0 1
S-15 Abnormal noise is made ............................................................................................................ 23

S-16 Vibration is excessive ................................................................................................................ 24
2 D475A, D475ASD-5E0
Troubleshooting of engine (S-mode) 1

Method of using troubleshooting chart 1
The troubleshooting chart consists of “questions”, “check items”, “causes”, and “troubleshooting” blocks.
The “questions” and “check items” narrow down the causes to highly probable “causes” by simple inspection
or from symptoms without using a diagnostic tool.
Then, the final verifications of “causes” are carried out by checking the narrowed down “causes” in the order
of their probability with diagnostic tools or by direct inspection following the “troubleshooting” procedure.
Questions:
Information to be obtained by questioning the user
or operator, and which corresponds to the sections
A and B in the right chart.
Section A includes basic information, and section B
contains items which can be obtained depending
on the level of the user or operator.
Check items:
Items checked by the serviceman in order to nar-
row down the causes, section C of the right chart is
corresponding to them.
Causes:
Items to be narrowed down by the questions and
check items.
The serviceman narrows down the causes to highly
probable causes according to the information from
A, B and C.
Troubleshooting:
Items to be verified at the end in order to check if
the narrowed down causes are the true factors
causing the failure. The verification is carried out
by applying diagnostic tools or implementing direct
inspection in the order of probability.
This troubleshooting chart marks the content of the

questions and check items with E, Q or w accord-
ing to their closer relationship with the causes.
E : A cause that can be referred to in relation to
the question or check item.
Q : A cause that is related the question or check
item.
w : A cause particularly probable among those
marked with Q above.
a Count the priority level of each marking as w >
Q when determining the cause.
Don't count E when determining the cause.
The item with this marking may be counted,
however, if no difference is present than this
and the cause cannot be determined.
D475A, D475ASD-5E0 3
<Example of troubleshooting> Exhaust smoke is black

Let us assume that [Clogged air cleaner element] is taken to be the cause of black exhaust gas. Three symp-
toms have causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was
lost gradually], and [Air cleaner clogging caution lamp is flashing].
4 D475A, D475ASD-5E0
If we look for the linkage of these three phenomena to possible causes, we find that they have causal rela-
tionship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
D475A, D475ASD-5E0 5
S-1 Starting performance is poor 1

General causes for poor starting performance are Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Insufficient supply of fuel
Defective alternator (generator section)

q
Defective alternator (regulator section)

Stuck or seized supply pump plunger
q Insufficient intake of air
Defective intake air heater system

q Improper selection of fuel (particularly during winter)
Defective or deteriorated battery

Clogged feed pump gauze filter
Coolant in exhaust pipe
Worn piston ring and cylinder

q
Clogged air cleaner element

a The common rail fuel injection system (CRI) recognizes
Clogged fuel filter element

the fuel injection timing electrically. Accordingly, even if
the starting operation is carried out, the engine may not
Defective injector
start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of
machine operation
Operated for long period E E E E
Starting perfor- Became worse gradually Q w w Q Q

mance Engine starts easily when warm w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters not carried out according to Operation and Maintenance
Manual w w w Q Q
Engine oil replenished more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed)
w
During operation, charge level monitor indicates abnormal charge (if monitor is
installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy E w Q Q
Starting motor cranks engine slowly w
Fuel does not flow out if air bleeding plug of fuel filter is
While engine is removed w w
cranked with start-
ing motor, If spill hose from injector is disconnected,
Q w
Check items
little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter and strainer directly q
Inspect feed pump gauze filter directly q
Troubleshooting
Carry out troubleshooting of the failure code for "No-pressure feed by supply pump
(*1)"
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change on some cylinders q
When starting switch is turned to HEAT, intake air heater mount does not become
warm
q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q

engine at low idle? None q
When specific gravity of electrolyte and voltage of battery are measured, they are
low
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
6 D475A, D475ASD-5E0
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective starting motor (safety relay section)

q Engine seized inside
Defective connection of battery terminal
Defective starting motor (motor section)

o See "S-4 Engine stops during operations".
q Water hammer caused by coolant which entered cylinder

q
Defective steering circuit wiring

q Malfunction of hydraulic pump
Broken flywheel ring gear
Defective starting switch

Questions
Degree of machine opera- Operated for long period

tion
E E
Condition of horn when Horn does not sound Q Q
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages w
Makes rattling noise and does not turn Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting

When specific gravity of electrolyte and voltage of battery are measured, they are low q
Troubleshooting
There is not voltage (20 - 30 V) between battery relay terminal B and

terminal E q
Turn starting switch OFF, When terminal B and terminal C of starting switch are connected,
engine starts q
connect cord, turn the
switch ON and carry out
in E-mode
When terminal B and terminal C at safety relay outlet are connected,
troubleshooting engine starts q
When terminal B and terminal C at safety relay outlet are connected,
engine does not start q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
D475A, D475ASD-5E0 7
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke
Defective operation of overflow valve (Does not close)

comes out
q Fuel is not being supplied
Leaking, clogging and entry of air to fuel piping

q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Wrong connection of supply pump PCV

Seized, abnormally worn feed pump
Defective operation of flow damper

Broken supply pump shaft spline
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Use of improper fuel
Defective injector
Degree of
Operated for long period E E E
Questions
machine operation
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Non-specified fuel is being used w
w w E E Q
Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is no fuel in it w Q w
w
Check items
Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy w Q Q
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q Q Q w Q
cranked with out
starting motor, If spill hose from injector is disconnected, little fuel spills Q w w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting of failure code for "No-pressure feed by supply pump
q q q
error (*1)"
Carry out troubleshooting of failure code for "Abnormality in PCV1 (*2) or Abnor-
q
mality in PCV2 (*3)"
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
8 D475A, D475ASD-5E0
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Defective coolant temperature sensor and/or wiring harness

General causes why exhaust smoke comes out but engine
Worn dynamic valve system (Valve, rocker lever, etc.)

does not start
q Lack of rotating force due to defective electrical system
Leaking, clogging of fuel system, and entry of air

q Insufficient supply of fuel
Stuck and/or seized supply pump plunger

Improper selection of fuel
Clogged injector and/or defective spray

q
Worn piston ring and/or cylinder liner
Defective intake air heater system

Clogged fuel filter and/or strainer

Use of improper fuel

Degree of machine
operation Operated for long period E E E E
Suddenly failed to start w w Q
Questions

Manual w w w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is no fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
While engine is Fuel does not flow out if air bleeding plug of fuel filter is
removed Q Q w w
cranked with start-
ing motor, If spill hose from injector is disconnected, little fuel spills Q Q w
some cylinders is low w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
q
Troubleshooting
Inspect fuel filter, strainer directly

Carry out troubleshooting of failure code for "No-pressure feed by supply pump error
(*1)" q
When injector unit is tested, spray condition is bad q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally (if coolant temperature
gauge is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become
warm
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
D475A, D475ASD-5E0 9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Defective operation of flow damper (Maximum leakage from injector)

q Defective spray condition of fuel
q Improper selection of fuel
q Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electri-
Seized turbocharger or interference of turbocharger

cal system)
Leaking, clogging of or entry of air to fuel piping

Clogged injector and/or defective spray


Improper valve clearance

Degree of
machine operation Operated for long period E E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters not carried out according to Operation and Maintenance Manual w w w
some cylinders is low Q w
Color of exhaust Blue under light load w

Check items
gas is Black w Q w w
When engine is cranked, interference sound is emitted from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q

Inspect valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

Inspect feed pump gauze filter directly
Carry out troubleshooting of failure code for "No-pressure feed by supply pump error
(*1)" q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change on some cylinders q q
Adjusting
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
10 D475A, D475ASD-5E0
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
q Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)
Broken auxiliary equipment (pump, compressor, etc.)

q There is overheating
Broken or seized piston and/or connecting rod

q Malfunction of hydraulic pump

Broken or seized crankshaft bearing
Leaking and/or clogged fuel piping

Broken supply pump shaft spline

Malfunction of hydraulic pump

Broken or seized feed pump
Broken or seized gear train
Degree of machine
operation
Operated for long period EE
Abnormal noise was heard and engine stopped sud-
denly w w w w Q w Q w w
Questions
Condition when engine Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q
Engine stopped after hunting w Q Q Q Q
Manual w w
Fuel level monitor indicates low level (if monitor is installed) w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is Turns in opposite direction w
cranked by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Inspect piston and connecting rod directly q
Inspect crankshaft bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect feed pump directly q
in H-mode
Carry out troubleshooting of failure code for "No-pressure feed by supply

pump error (*1)"
q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
removed
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
D475A, D475ASD-5E0 11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Defective operation of flow damper (Maximum leakage from injector)

q Defective speed sensor (Error at degree that it is not indicated)
Clogged injector and/or defective spray (dirt in injector)
Defective G (Bkup) speed sensor or wiring harness

Defective Ne speed sensor and/or wiring harness
Leaking or clogging or entry of air to fuel piping

Low setting of low idle speed
Clogged fuel filter or strainer

Degree of machine
operation Operated for long period E E
Questions
Occurs at a certain speed range Q Q Q

Occurs at low idle w Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w Q Q
Replacement of filters not carried out according to Operation and Maintenance Manual w w
Check items
Rust and water are found when fuel tank is drained Q Q


Troubleshooting

change on some cylinders
q q
Carry out troubleshooting of failure code for "Abnormality in engine Ne speed sensor (*1)" q
Carry out troubleshooting of failure code for "Abnormality in engine Bkup speed sensor (*2)" q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Remedy
Add
*1: Failure code [CA689] and failure [CB689]

*2: Failure code [CA778] and failure [CB778]
1
12 D475A, D475ASD-5E0
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Defective installation of boost pressure sensor (air leakage)

Insufficient supply of fuel
Defective fuel temperature sensor and/or wiring harness

q
Defective boost pressure sensor and/or wiring harness

Clogged injector or defective spray (dirt in injector)

Defective drive of injector (signal and/or solenoid)
q Overheat
o See "S-14 Coolant temperature becomes too

high (Overheating)"

Air leakage from air intake piping

(limiting injection rate (output) because of an
Leaking or clogged fuel piping

error in electrical system)

Degree of machine
operation Operated for long period E E E E E
Q Q Q Q
Questions
Suddenly
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation and Mainte-
nance Manual w Q
Engine oil replenished more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
w
w
Check items
When engine is cranked, interference sound is emitted from around turbocharger

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when
load is applied
w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w Q
There is hunting from engine (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

Carry out troubleshooting of failure code for "No-pressure feed by supply
pump error (*1)" q
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change on some cylinders
q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting of failure code for "Abnormality in charge pres-
sure sensor (*2)" q
Carry out troubleshooting of failure code for "Abnormality in fuel tempera-
ture sensor (*3)"
q
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Clean
Clean
Clean
D475A, D475ASD-5E0 13
*2: Failure code [CA122] and failure code[CA123]
14 D475A, D475ASD-5E0
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Defective coolant temperature sensor or wiring harness

Leakage of air between turbocharger and cylinder head
q Excessive injection of fuel

Clogged fuel spill piping (on cylinder head side)

q Overheat

o See "S-14 Coolant temperature becomes too high

(Overheating)"
Improper fuel injection pressure

(limiting injection rate (output) because of an error in
Crushed or clogged muffler
Clogged or seized injector

electrical system)
Abnormally worn injector
Improper injection timing

Degree of
machine operation Operated for long period E E E E
Suddenly became black w Q Q Q
Questions
Color of exhaust Gradually became black

gas w Q Q
Blue under light load w
Non-specified fuel is being used Q Q
Oil replenished more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, and clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Q w
Check items

Torque converter stall speed or pump relief speed is high
(Fuel is injected excessively)
Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is fount to be heavy q
q
Troubleshooting
Inspect valve clearance directly

When muffler is removed, exhaust sound improves q
Carry out troubleshooting of failure code for "No-pressure feed by supply pump
error (*1)" q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change on some cylinder
q
Inspect fuel spill piping (on cylinder head side) directly q q
Carry out troubleshooting of failure code for "Abnormality in coolant temperature
sensor error (*2)"
Adjusting
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
D475A, D475ASD-5E0 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal combustion of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

Worn or damaged valve (stem, guide, seal)
q Long-time operation of engine at low idle or high idle
(Do not run engine continuously at idle without load for

more than 20 minutes)
Clogged breather or breather hose

Dust sucked in from intake system
q External leakage of oil
Worn seal at turbocharger end
Worn or damaged rear oil seal
Oil leakage from oil drain plug

q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of machine oper- Operated for long period
E E E E
Questions
ation
Oil consumption suddenly increased w Q
Oil replenished more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is contaminated with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is increasing w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found contaminated abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
16 D475A, D475ASD-5E0
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
Clogged breather and/or breather hose

q Use of improper fuel

q Use of improper oil
q Operation under excessive load
Worn valve and/or valve guide
Defective oil filter safety valve
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of machine operation Operated for long period E E E
Questions
Non-specified fuel is being used Q

Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is
installed) w Q
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check items
Color of exhaust gas

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

q q
Troubleshooting
When compression pressure is measured, it is found to be low

Inspect breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy Clean
—
D475A, D475ASD-5E0 17
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel
Defective coolant temperature sensor or wiring harness

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of
E E E
Questions
Operated for long period

machine operation
More than other machines of same model Q Q Q Q
Condition of fuel
consumption
Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
ders is low w
Check items
Low idle speed is high Q

Torque converter stall speed or hydraulic pump relief speed is high Q
Color of exhaust Black Q Q Q Q
gas White Q
Remove and inspect head cover directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
change on some cylinders q
If spill hose from injector is disconnected and measured, much fuel spills q
Carry out troubleshooting of failure code for "Abnormality in coolant temperature sensor (*2)" q
Confirm with monitoring function of machine monitor q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
18 D475A, D475ASD-5E0
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant Causes
q Internal leakage in lubrication system
Damaged cylinder liner O-ring and/or hole caused by pitting

q Internal leakage in cooling system
Broken cylinder head and/or head gasket
Insufficient protrusion of cylinder liner

Broken oil cooler core and/or O-ring
Cracks inside cylinder block
Degree of machine
Operated for long period E E
Questions
operation
Suddenly increased Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w

Check items
There are excessive air bubbles in radiator, coolant spurts back w w
Pressure-tightness test of cylinder head shows there is leakage q

Troubleshooting
Inspect cylinder block and liner directly q q
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
D475A, D475ASD-5E0 19
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, and/or wear of lubrication system
Defective oil pressure sensor and/or defective wiring harness

q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Defective oil level sensor and/or wiring harness

Leaking, crushed, clogged hydraulic piping
Clogged and/or broken pipe in oil pan
Defective oil pump relief valve

Coolant and fuel mixing in oil
Clogged strainer in oil pan
Worn journal of bearing
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Degree of
E E E
Questions
machine operation Operated for long period

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters not carried according to Operation and Maintenance Manual w
Indicates pressure drop at low idling time w Q
Oil pressure Indicates pressure drop at low and high idling times Q w w w Q
monitor
(if installed) Indicates pressure drop on slopes w
Indicates pressure drop occasionally w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

q q
Troubleshooting
Inspect oil pan strainer and pipe directly

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of oil pump relief valve are fatigued and damaged q
Inspect oil filter directly q
Carry out troubleshooting of failure code for "Abnormality in oil pressure sensor (*1)" q
If oil level sensor is replaced, oil level monitor indicates normally q
Adjusting
Replace
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Clean
—
Add
20 D475A, D475ASD-5E0
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) and/or defective seal
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in cool-

ant".
Defective seal of auxiliary equipment (pump, compressor)

Broken oil cooler core and/or O-ring

Fuel leakage inside head cover
Worn or damaged rear oil seal

Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions
Degree of
machine operation
Operated for long period E E E E
Fuel consumption increasing w w
Coolant replenished more frequently Q w
There is oil mixed in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles
appears, or coolant spurts back w Q
Check items
Exhaust smoke is white Q Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant comes out w
Oil level in damper chamber of machine is low w
Oil level in hydraulic tank is low w

Remove and inspect head cover directly q
q q
Troubleshooting
Inspect cylinder block and/or liner directly

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
D475A, D475ASD-5E0 21
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation, and/or damages of fan)
Rise in power train oil temperature on applicable machine side

Drop in heat dissipation efficiency

q
q Problem in coolant circulation system
q Oil temperature of power train is rising
Slipping fan belt and/or worn fan pulley

Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Defective operation of thermostat
Clogged or crushed radiator fins
Clogged or broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of
E E E E
Questions
Sudden overheated Q w Q
Condition for
Persistent overheating Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator and coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on applicable machine side are clogged with
Check items
dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature gauge enters red range faster than engine coolant tem-
perature gauge (if oil temperature gauge and coolant temperature gauge are w
installed) on the installed machine side

Inspect cylinder liner directly q
q
Inspect oil cooler directly

Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation of thermostat is tested, it does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
in H-mode
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt and pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
22 D475A, D475ASD-5E0
S-15 Abnormal noise is made 1

General causes why abnormal noise is emitted Causes
q Abnormality due to defective parts
Improper fuel injection timing (abnormality in coolant temperature sensor)

q Abnormal combustion
q Air leakage from air intake system
Deformed cooling fan and/or looseness or interference of fan belt

a Judge if the noise is an internal noise or an external noise
before starting troubleshooting.
a While the engine is not sufficiently warmed up, it is operated
Defective inside of muffler (dividing board out of position)

Broken dynamic valve system (valve and/or rocker lever)
Leakage of air between turbocharger and cylinder head
in the low-temperature mode. Accordingly, the engine sound
rises slightly higher. This is no abnormality, however.
Excessive wear of piston ring and/or cylinder liner

a When the engine is accelerated, the engine sound rises
slightly for approx. 3 seconds maximum. This is no abnor-
mality, however.
Interference or seizure of turbocharger
Removed or seized gear train bushing

Improper gear train backlash
Clogged or seized injector

Dirt caught in injector

Degree of
machine operation Operated for long period E
Questions
Condition of Gradually increased Q Q

abnormal noise Suddenly increased Q Q Q
Non-specified fuel is being used Q
Oil replenished more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is emitted around muffler w
Check items

some cylinders is low w Q
Color of exhaust Blue under light load w

gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is fount to be heavy q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
change on some cylinders q q
Abnormal noise is heard only when engine is started q
Confirm with monitoring function of machine monitor q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
D475A, D475ASD-5E0 23
S-16 Vibration is excessive 1

General causes why vibration occurs Causes
q Defective parts (abnormal wear, breakage, etc.)
Broken output shaft and/or parts in damper on installed machine side

Misalignment between engine and devices on installed machine side
q Misalignment between installed machine
q Abnormal combustion
a If abnormal noise vibration occur, carry out troubleshooting for "S-15
Abnormal noise is emitted", too.
Stuck dynamic valve system (valve, rocker lever, etc.)
Loose engine mounting bolts and/or broken cushions

Worn main bearing and/or connecting rod bearing
Worn front support spigot joint portion

Improper gear train backlash

Worn camshaft bushing
Degree of
E E E E
Questions

Condition of vibra- Suddenly increased Q Q
tion Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
q
Troubleshooting
Inspect gear train directly

Inspect camshaft bushing directly q
Confirm with monitoring function of machine monitor q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly q
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
24 D475A, D475ASD-5E0
SEN01833-00

© 2006 KOMATSU
All Rights Reserved
26
SEN02013-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
General information on disassembly and assembly ....................................................................................... 2
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 4
Special tool list ..................................................................................................................................... 7
Sketches of special tools.................................................................................................................... 14
D475A, D475ASD-5E0 1
SEN02013-00 50 Disassembly and assembly
General information on disassembly and assembly 1

How to read this manual 1 Installation
q Except where otherwise instructed, installation
1. Removal and installation of assemblies of parts is done in the r evers e order of
Special tools removal.
q As to the special tools needed for removal q Instructions and precautions for installing parts
and installation, symbols such A1···X1 are are shown with [*1] mark in the “Removal” sec-
attached in the table along with respective tion, identifying which step the instructions are
part numbers, part names and quantity. intended for.
q In addition to the above, the list of special q As to the multi purpose tools used in installa-
tools contains the following information. tion, the numbers such [1], [2]··· are given.
1) Necessity Their part numbers, part names and quantity
t: Special tools that cannot be substi- are not described.
tuted and should always be used q Marks shown in the “Installation” section stand
(installed). for the following.
k : Precautions related to safety in execution
q: Special tools that will be useful if
available and are substitutable with of work.
commercially available tools. a : This mark gives guidance or precautions
2) Distinction of new and existing special when doing the procedure.
2 : Type of coating material
tools
3 : Tightening torque
N: Tools newly developed for this model.
They respectively have a new part
5 : Quantity of oil or coolant to be added
number.
R: Tools with upgraded part numbers.
They are remodeled from already Sketches of special tools
available tools for other models. q Various special tools are illustrated for the con-
Blank: Tools already available for other venience of local manufacture.
models. They can be used without
any modification.
3) Circle mark (Q) in sketch column:
q A circle mark means that a sketch of
the special tool is presented in the
section of Sketches of special tools.
q Part No. of special tools starting with
79*T means that they are locally
made parts and as such not inter-
changeable with those made by
Komatsu in Japan, e.g. 79*T-***-****.
Removal
q The “Removal” section contains procedures,
precautions and the amount of oil or coolant to
be drained.
q As to the multi purpose tools used in removal,
the numbers such [1], [2]··· are given. Their
part numbers, part names and quantity are not
described.
q Various symbols used in the “Removal” section
are explained and listed below.
of work.
a : This mark gives guidance or precautions
when doing the procedure.
[*1] : This mark shows that there are instructions
or precautions for installing parts.
6 This mark shows oil or coolant to be drained.
4 : Weight of part or component
2 D475A, D475ASD-5E0
2. Disassembly and assembly of assem- Assembly

blies q In “Assembly” section, the work procedures,
Special tools precautions and know-how for carrying out
q As to the special tools needed for disas- those procedures, and quantity of the oil and
sembly and assembly, symbols such coolant added are described.
A1···X1 are attached along with respective q As to the multi purpose tools used in assembly,
part numbers, part names and quantity. the numbers such [1], [2]··· are given. Their
q In addition to the above, the list of special part numbers, part names and quantity are not
tools contains the following information. described.
1) Necessity q Various symbols used in “Assembly” section
t: Special tools that cannot be substi- are explained and listed below.
tuted and should always be used k : Precautions related to safety in execution
(installed). of work
q: Special tools that will be useful if a : This mark gives guidance or precautions
available and are substitutable with when doing the procedure.
commercially available tools. 2 : Type of coating material
2) Distinction of new and existing special 3 : Tightening torque
tools 5 : Quantity of oil or coolant to be added
N: Tools newly developed for this model.
They respectively have a new part
Sketches of special tools
number.
R: Tools with upgraded part numbers. q Various special tools are illustrated for the con-
They are remodeled from already venience of local manufacture.
available tools for other models.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark (Q) in sketch column:
q A circle mark means that a sketch of
the special tool is presented in the
section of Sketches of special tools.
q Part No. of special tools starting with
79*T means that they are locally
made parts and as such not inter-
changeable with those made by
Komatsu in Japan, e.g. 79*T-***-****.
Disassembly
q In “Disassembly” section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q As to the multi purpose tools used in disas-
sembly, the numbers such [1], [2]··· are given.
Their part numbers, part names and quantity
are not described.
q Various symbols used in the “Disassembly”
section are explained and listed below.
of work.
a : This mark gives guidance or precautions
when doing the procedure.
6 This mark shows oil or coolant to be drained.
D475A, D475ASD-5E0 3
Coating materials list 1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• Used to prevent falling off of rubber gaskets, rub-
LT-1A 790-129-9030 150 g Tube
ber cushions, and cork plugs.
• Used for plastic (except polyethylene, polypropy-
20 g Polyethylene lene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene • Features: Resistant to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
Adhesive:
790-129-9060
1 kg
LT-3 Set of adhesive Can • Used to stick and seal metal, glass, and plastics.
Hardener:
and hardener
500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs for drilled holes.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant sealant used to repair engines.
• Quick-setting adhesive.
Three Bond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics, and
woods.
• Quick-setting adhesive.
Aron-alpha Polyethylene • Quick-hardening type. (max. strength is obtained
790-129-9130 2g
201 container after 30 minutes of application)
• Used mainly to stick rubbers, plastics, and metals.
Loctite Polyethylene • Features: Resistant to heat and chemicals.
79A-129-9110 50 cc
648-50 container • Used for fitted portions of high temperatures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nipples of
hydraulic pipes.
• Features: Silicon-based heat and cold-resistant
Gasket sealant
sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flanged surfaces and threaded por-
tions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-hardening sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
Three Bond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat-resistant, vibration-
Three Bond
419-15-18131 100 g Tube resistant and impact-resistant sealant.
1207B
• Used to seal transfer case, etc.
4 D475A, D475ASD-5E0
Cate- Komatsu
gory code
• Used to lubricate sliding portions (for preventing
disulfide lubricant
LM-G 09940-00051 60 g Can

Molybdenum
squeaking)
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI
SYG2-400LI-A
G0-LI(*)
SYG2-160LI Various Various • General purpose type.
*: For cold
SYGA-160CNLI
districts
SYG0-400LI-A(*)
SYG0-16CNLI(*)
SYG2-400CA
SYG2-350CA
• Used for bearings used at normal temperature
G2-CA SYG2-400CA-A Various Various
under light load in contact with water or steam.
SYG2-160CA
SYGA-160CNCA
• Used for parts under heavy load.
Molybdenum Caution:
SYG2-400M 400 g × 10
disulfide lubri- Bellows-type • Do not use this grease for ball bearings such
Grease
SYG2-400M-A 400 g × 20
cant LM-G as swing circle bearing.
SYGA-16CNM 16 kg Can
(G2-M) • Apply this grease to work equipment pins only
when installing but do not use it after then.
SYG2-400T-A
Hyper white
SYG2-16CNT • Seizure resistance and heat resistance higher
grease
SYG0-400T-A 400 g Bellows-type than molybdenum disulfide grease.
G2-T, G0-T(*)
(*) 16 kg Can • Not conspicuous on machine since its color is
*: For cold
SYG0-16CNT white.
districts
(*)
Bio grease
SYG2-400B
G2-B, G2-
SYGA-16CNB
BT(*) • Since this grease is decomposed by natural bacte-
SYG2-400BT 400 g Bellows-type
*For use at ria in short period, its impacts on microorganisms,
(*) 16 kg Can
high tempera- animals, and plants are minimized.
SYGA-16CNBT
ture under
(*)
high load
SUNSTAR
• Used as primer for cab side.
PAINT Glass
20 ml (Using limit: 4 months after date of manufac-
PRIMER 580 container
ture)
SUPER
417-926-3910
SUNSTAR
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manufac-
PRIMER 580 container
Adhesive for cab glass
ture)
SUPER
SUNSTAR • Used as primer for painted surface on cab
Primer
PAINT Glass side.

22M-54-27230 20 ml
PRIMER 435- container (Using limit: 4 months after date of manufac-
95 ture)
SUNSTAR • Used as primer for black ceramic-coated sur-
GLASS face on glass side and for hard polycarbon-
22M-54-27240 150 ml Steal can
PRIMER 435- ate-coated surface. (Using limit: 4 months
41 after date of manufacture)
SUNSTAR
• Used as primer for sash (processing of Alu-
SASH Glass
22M-54-27250 20 ml mite surface) (Using limit: 4 months after date
PRIMER GP- container
of manufacture)
402
D475A, D475ASD-5E0 5
Cate- Komatsu
gory code
SUNSTAR • “S” is used for high-temperature season (April
PENGUINE – October) and “W” for low-temperature sea-
Polyethylene
SEAL 580 417-926-3910 320 ml son (October – April) as adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manufac-
“W” ture)
Adhesive
Sika Ltd., • Used as adhesive for glass.

Polyethylene
Japan, Sikaf- 20Y-54-39850 310 ml (Using limit: 6 months after date of manufac-
container
lex 256HV ture)
Adhesive for cab glass

SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manufac-
SUPER 560 container) ture)
SUNSTAR
• Used to seal joint of glasses.
PENGUINE Polyethylene
417-926-3920 320 ml (Using limit: 4 months after date of manufac-
SEAL No. container
ture)
Caulking material
2505
SEKISUI SIL- • Used to seal front window.
Polyethylene
ICON SEAL- 20Y-54-55130 333 ml (Using limit: 6 months after date of manufac-
container
ANT ture)
GE TOSHIBA • Used to seal joint of glasses
SILICON Translucent white seal
22M-54-27220 333 ml Cartridge
TOSSEAL (Using limit: 12 months after date of manufac-
381 ture)
6 D475A, D475ASD-5E0
Special tool list 1

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t ........... Cannot be substituted, must always be installed (used)

q ........... Extremely useful if available or can be substituted with commercially available
part
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, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See
"Sketches of special tools").
Necessity
remodel
Sketch
New/
Q'ty
Component Symbol Part No. Part Name Nature of work, remarks
790-431-1120 Adapter t 1
791-520-4140 Screw t 1
791-181-1020 Sleeve t 1
Removal and instal- 791-765-1150 Plate t 1
Pulling out pin or radiator
lation of radiator 1 791-112-1180 Nut t 1 guard
guard assembly
790-101-2540 Washer t 1
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Removal, installation
Tightening of cylinder
of cylinder head 2 790-331-1110 Wrench q 1
head bolt
assembly A
3 795-931-1100 Seal puller t 1 Extraction of oil seal
795T-621-1430 Plate t 1 N Q
Removal, installation 795T-621-1440 Push tool t 1 N Q
of engine front seal 4 01050-32240 • Bolt t 3 Press fitting of oil seal
01050-32225 • Bolt t 3
01640-02232 • Washer t 3
3 795-931-1100 Seal puller assem- t 1 Extraction of oil seal

bly
Removal, installation 795T-621-1540 Push tool t 1 N Q
of engine rear seal
5 01050-32060 • Bolt t 5 Press fitting of oil seal
01640-02032 • Washer t 5
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, assembly of
Disassembly and
790-501-5000 Repair stand t 1 transmission
assembly of trans- D
Checking actuation of pis-
mission 799-301-1600 Oil leak tester t 1 ton
D475A, D475ASD-5E0 7
Necessity
remodel
Sketch
New/
Q'ty
791-622-1110 Bracket t 1
Removal, installation of
1 01016-51690 Bolt t 1
clutch, brake assembly
01011-81600 Bolt t 1
Disassembly and
E 791T-822-1810 Push tool t 1 Q
assembly of steering 2 Press fitting of bearing
791T-822-1820 Push tool t 1 Q
3 791-822-1830 Wrench t 1
bearing round nut
790-337-1032 Lifting tool t 1
1 791-827-1910 Plate t 1
final drive assembly
01011-83015 Bolt t 3
790-431-1081 Guide t 1
790-431-1031 Block t 1
790-101-2350 Leg t 2
790-101-2430 Adapter t 2
Pulling out sprocket bear-
2 790-101-2360 Plate t 4 ing
02215-11622 Nut t 2
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
790-431-1101 Installer assembly t 1
Puller Press fitting of sprocket
Disassembly and 3 790-101-2102 t 1
(294 kN {30 ton}) bearing
assembly of final J
drive assembly 790-101-1102 Pump t 1
4 791-585-1510 Installer t 1 Installation of floating seal
790-431-1220 Remover assembly t 1
Puller
5 790-101-2102 t 1 Pulling out center hub
(294 kN {30 ton})
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
7 790-101-2102 t 1
(294 kN {30 ton}) carrier pin
790-101-1102 Pump t 1
8 790-431-1240 Guide t 1 Assembly of No. 1 pinion
8 D475A, D475ASD-5E0
Necessity
remodel
Sketch
New/
Q'ty
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
Press fitting of idler bush-
1 01580-01613 Nut t 2 ing
01643-31645 Washer t 2
Assembly of Idler
Puller
790-101-2102 t 2
(294 kN {30 ton})
790-101-1102 Pump t 1
3 791-830-1480 Push tool t 1 Press fitting of seal guide
4 791-601-1000 Oil pump t 1 Filling with oil
Disassembly and Press fitting of floating seal
6 790-830-1770 Push tool t 1 N
assembly of carrier collar
roller Removal, installation of
7 791-630-1270 Wrench t 1
round nut
8 791-830-1740 Plate t 1 N Press fitting of bushing
10 791-830-1730 Push tool t 1 N Press fitting of seal ring
Assembly of track 11 791-601-1000 Oil pump t 1 Filling with oil
roller 790-401-1700 Lifting tool t 1
L
790-401-1761 Adapter t 1 Removal, installation of
12
790-401-1540 Shackle t 2 track roller assembly
790-401-1770 T-bolt t 2
Disassembly and 791T-830-1780 Plate t 3 N Q

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})
Disassembly and 7 790-101-1102 Pump t 1
assembly of bogie 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 Pulling out ring
5 01580-13629 Nut t 2
6 01643-33690 Washer t 1
Puller
7 790-101-4000 t 1
(490 kN {50 ton})
D475A, D475ASD-5E0 9
Necessity
remodel
Sketch
New/
Q'ty
Pulling out ring

15 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 assem-
Puller bly
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
19 791-601-1000 Oil pump t 1 Filling with oil
Disassembly and
L 791-630-1860 Bracket t 1
assembly of bogie
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
791T-830-1700 Lifting tool t 1 N Q
791T-830-1710 • Bar 1 N Q
791T-830-1720 • Plate 1 N Q
Removal of No. 1 bogie
21 07283-31079 • Grip 1
track roller
01582-01210 • Nut 2
01643-31232 • Washer 2
04530-11628 • Eye bolt 1
Puller Pulling out idler cushion
1 790-101-2102 t 1
(294 kN {30 ton}) guide pin
790-101-1102 Pump t 1
791-685-8502 Compressor t 1
Disassembly and 791-635-3160 Extension t 1

assembly of recoil M 790-201-2790 Spacer t 1 Disassembly, assembly of
2
spring Cylinder recoil spring
790-101-1300 t 1
(980 kN {100 ton})
790-101-1102 Pump t 1
791-730-1120 Bolt t 6
Removal of recoil spring
3 01580-13326 Nut t 6
assembly
01643-33380 Washer t 6
792-900-1610 Adapter t 1
792-900-1530 Screw t 1
Disassembly and 791-775-1110 Sleeve t 1
assembly of N 1 Pulling out center pin
equalizer bar 791T-850-1150 Plate t 1 Q
01582-53024 Nut t 1
01643-33080 Washer t 1
10 D475A, D475ASD-5E0
Necessity
remodel
Sketch
New/
Q'ty
Puller
790-101-2102 t 1 Pulling out center pin
1 (294 kN {30 ton})
790-101-1102 Pump t 1
791T-850-1160 Bracket t 1 Q
Disassembly and 791T-850-1170 Bracket t 1 Q

assembly of N 790-438-1110 Screw t 1
equalizer bar 790-101-2540 Washer t 2 Pulling out side pin bush-
2
791-112-1180 Nut t 2 ing
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
791T-850-1180 Sleeve t 1 Q
791T-850-1190 Plate t 1 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 check-
5 and t 1
ing air 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
Disassembly and
assembly of track R 5 01010-62050 Bolt t 2
shoe 6 791-832-1220 Plate t 1
7 791-832-1230 Shaft t 2
8 791-832-1210 Frame t 1
Pulling out and press fit-
8 9 791-832-1240 Nut t 2
ting of pin and bush
10 04530-11628 Eye bolt t 2
11 791-832-1310 Adapter t 1
12 791-832-1280 Adapter t 1
13 791-832-1320 Guide t 1
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
D475A, D475ASD-5E0 11
Necessity
remodel
Sketch
New/
Q'ty
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 Pulling out and press fit-
ting of pin and bush
22 791-832-1630 Guide t 1
23 791-832-1470 Guide t 1 N
24 791-832-1410 Extension t 1
8 25 791-832-1350 Pusher t 1
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 fit-
29 790-101-1102 Pump t 1 ting of pin and bush
Puller
30 790-101-4200 t 1
(294 kN {30 ton})
31 790-685-9230 Spacer t 1
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
Disassembly and 5 791-685-5680 • Ring 1 N
assembly of track Press fitting ring
R 9 6 791-685-5690 • Push tool 1 N
shoe (For large 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
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 1 N
2 791-685-5650 • Adapter 1 N
3 791-685-5660 • Ring 1 N Press fitting ring
4 791-685-5670 • Plate 1 N (For small plug)
5 791-685-5680 • Ring 1 N
6 791-685-5690 • Push tool 1 N
12
7 791-685-5710 • Adapter 1 N
8 791-685-5720 • Spring 1 N Press fitting ring
9 791-685-5730 • Bar 1 N (For small plug)
10 01252-30655 • Bolt 1
Press fitting ring
11 01580-01210 • Nut 1
(For small plug)
13 791-685-5750 Push tool t 1 N Press fitting ring
12 D475A, D475ASD-5E0
Necessity
remodel
Sketch
New/
Q'ty
Cylinder repair Disassembly, assembly of

1 790-502-1003 q 1
stand cylinder
790-201-1702 Push tool kit t 1 Press fitting of coil bushing
• Blade tilt
(standard specification)
• Blade pitch
790-201-1881 • Push tool 1 (superdozer specifica-
tion)
2 • Ripper tilt
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
• Blade pitch
3 790-201-1690 • Plate 1 (superdozer specifica-
Disassembly, assem- tion)
bly of hydraulic cylin- U • Ripper tilt
der 790-201-1530 • Plate 1 • Pin puller
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Installation of all cylinder
4 790-720-1000 Expander t 1
piston rings
796-720-1690 Ring t 1 Blade lift (standard specifi-
07281-01919 Clamp t 1 cation)
796-720-1690 Ring t 1 Blade lift (superdozer
07281-02169 Clamp t 1 specification)
Ripper tilt, lift
796-720-1710 Ring t 1 Blade tilt
5
Blade pitch
07281-02709 Clamp t 1 (superdozer specifica-
tion)
796-720-1630 Ring t 1
Pin puller
07281-00709 Clamp t 1
Removal and installation
6 790-102-2303 Wrench t 1
of pin puller cylinder head
799-703-1200 Service tool kit t 1 Charging with refrigerant
799-703-1100 Vacuum pump t 1 (100 V specification)
Air conditioner
X 799-703-1111 Vacuum pump t 1 (220 V specification)
related
799-703-1121 Vacuum pump t 1 (240 V specification)
799-703-1401 Gas leak detector t 1
D475A, D475ASD-5E0 13
Sketches of special tools 1
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A4 Plate
A4 Push tool
14 D475A, D475ASD-5E0
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A5 Push tool
E2 Push tool
D475A, D475ASD-5E0 15
E2 Push tool
L13 Plate
16 D475A, D475ASD-5E0
L17 Guide
L20 Spacer
D475A, D475ASD-5E0 17
L21 Lifting tool
L21 Bar
18 D475A, D475ASD-5E0
L-21 Plate
N1 Plate
D475A, D475ASD-5E0 19
N2 Bracket
N2 Bracket
20 D475A, D475ASD-5E0
P Sleeve
P Plate
D475A, D475ASD-5E0 21
SEN02013-00

© 2007 KOMATSU
All Rights Reserved
22
SEN02014-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
50 Disassembly and assembly1

Engine and cooling system (SAA12V140E-3)
Engine and cooling system (SAA12V140E-3) ................................................................................................ 2
Removal and installation of engine assembly ...................................................................................... 2
Removal and installation of radiator assembly..................................................................................... 6
Removal and installation of aftercooler assembly ................................................................................ 8
Removal and installation of radiator guard assembly ........................................................................ 10
Removal and installation of fuel tank assembly ................................................................................. 12
Removal and installation of engine hood assembly ........................................................................... 13
Removal and installation of fan drive assembly ................................................................................. 15
Removal and installation of fan motor assembly................................................................................ 16
D475A, D475ASD-5E0 1
Engine and cooling system (SAA12V140E-3) 1

Removal and installation of 3. Lift off radiator upper cover (2).
engine assembly 1 4 Radiator upper cover assembly: 85 kg
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
799-703-1111 Vacuum pump t 1
X
799-703-1121 Vacuum pump t 1
Gas leak detec-
799-703-1401 t 1
tor
4. Remove engine hood assembly (3). For
Removal details, see "Removal and installation of
k Lower the work equipment to the ground engine hood assembly".
and stop the engine.
k Set the parking brake lever and work equip-
ment lock lever in the lock position.
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Drain the coolant.
6 Coolant: 210 l
2. Remove right and left potentiometer wiring

grommets (1) from the cover.
5. Remove right and left engine side covers (4)

and right and left covers (5).
2 D475A, D475ASD-5E0
6. Remove undercovers (1st, 2nd and 3rd ones 9. Disconnect radiator outlet tube (11).
from the front) (33).
10. Disconnect torque converter oil cooler tubes
(12) and (13).
11. Disconnect heater hose (14).
7. Disconnect radiator inlet hoses (6) and aera-

tion hoses (7).
12. Lift off the right and left aftercooler outlet piping
assemblies.
a Loosen hose clamp (15).
a Remove pipe mounting bolt (16).
a Remove piping fixing bracket (17).
8. Lift off the right and left aftercooler inlet piping

assemblies.
a Loosen hose clamps (8).
a Remove pipe mounting bolt (9).
a Remove piping fixing bracket (10).
D475A, D475ASD-5E0 3
13. Disconnect air conditioner hose (15) and 16. Disconnect engine rear-side air conditioner
remove the compressor assembly. hoses (23) and wiring connectors (24).
a Collect the air conditioner refrigerant
(R134a) from the air conditioner circuit.
a Cover the hoses so that dirt, water, etc.
will not enter them.
a Disconnect all the clamps of hose (11).
17. Disconnect fuel filter hose (25), 4 hoses (26)

and heater hose (27) between the valve and
engine.
14. Remove engine lubricating oil pump hose (18),

pump mounting bracket mounting bolts (19),
and pump and bracket assembly (20).
a Remove cables (21).
18. Remove damper rubber shield (28).
15. Remove cables (22) from the starting motor.
4 D475A, D475ASD-5E0
19. Sling universal joint (29), remove the mounting Installation

bolts, and lift off the universal joint. q Carry out installation in the reverse order to
4 Universal joint: 65 kg removal.
q 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 Coolant: 210 l
20. Remove front mounting bolt (30) and rear

mounting bolt (31).
21. Remove engine assembly (32).

4 Engine assembly: 3,900 kg
a When removing the engine assembly,
check that all the wirings and pipings are
disconnected and the engine assembly
does not interfere with other parts.
D475A, D475ASD-5E0 5
Removal and installation of 4. Disconnect radiator inlet hoses (3) (right and
radiator assembly 1 left) and aeration hoses (4) (right and left).
5. Disconnect sub-tank hose (5).

Removal
1. Drain the coolant. 6. Disconnect power line cooler aeration hose
(6).
6 Coolant: 210 l

a Remove the fan motor assembly. For

details, see "Removal and installation of
fan motor assembly".
3. Lift off radiator upper cover (2). 7. Remove isolator bolts (7) (2 each on the right
and left sides).
4 Radiator upper cover assembly: 85 kg
8. Remove wind breaker panels (8) (upper, lower,
right and left).
9. Disconnect headlamp connectors (9).
6 D475A, D475ASD-5E0
10. Disconnect radiator upper wiring harness (10) 13. Remove tube (15).
and radiator coolant level sensor connector
(11). 14. Lift off lower mounting bolts (16) (right and left).
11. Sling radiator assembly (12) and remove upper 15. Lift off radiator assembly (12).
mounting bolts (13) (2 each on the right and a When removing the radiator assembly,
left sides). take care not to damage its core.
4 Radiator assembly: 485 kg
12. Remove undercover (14).
Installation
q Carry out installation in the reverse order to
removal.

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant: 210 l
D475A, D475ASD-5E0 7
Removal and installation of 3. Disconnect radiator upper clamp (3) and after-
aftercooler assembly 1 cooler upper clamp (4).
4. Remove mounting bolt (6) of aftercooler upper

Removal pipe (5).
5. Remove lower cover bolts (7) and open lower

cover (8).
2. Lift off radiator upper cover (2).
6. Remove mounting bolt (10) of aftercooler lower

pipe (9) and aftercooler lower mounting bolt
(13).
8 D475A, D475ASD-5E0
7. Sling aftercooler (11) and remove upper

mounting bolts (12).
8. Move aftercooler upper pipe (5) and lower pipe

(9) toward the engine and lift off aftercooler
(11), taking care that the aftercooler will not
interfere with the pipes.
Installation
removal.
D475A, D475ASD-5E0 9
Removal and installation of 3. Sling blade lift cylinder assembly (4), then fit
radiator guard assembly 1 cylinder holder tool and secure to radiator
guard.
Special tools 4. Drain coolant.

6 Coolant: 210 l
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 1 791-112-1180 Nut t 1
790-101-2540 Washer t 1
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
5. Disconnect radiator inlet and outlet hoses, aer-
ation hose, and wiring harness clip.
Removal For details, see "Removal and installation of
1. Remove lock plate (1) of the lift cylinder rod radiator assembly".
pin, then remove pin (2). [*1]
a Start the engine and retract the piston rod 6. Disconnect hydraulic cooler hose (5).
fully, then tie the piston rod with wire to Disconnect fan motor hose (6).
k Release the remaining pressure from
prevent it from coming out.
a Tie the piston rod on the opposite side in the hydraulic circuit.
the same way. For details, see Testing and adjusting,
Releasing residual pressure from work
equipment circuit.
a Fit a cover to prevent dirt from entering the
piping.
2. Remove hood assembly.

For details, see "Removal and installation of
hood assembly".
Remove engine side covers (left and right).
10 D475A, D475ASD-5E0
7. Disconnect work equipment hoses (7) and (8). Installation

removal.
[*1]
a Standard shim thickness: 4 mm

5 Coolant: 210 l
8. Sling radiator guard assembly and remove lock

bolt, then using tool A1, push rear pin (11) to
inside of radiator guard and remove.
9. Remove lock plate, then using tool A1, 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
wiring and piping when removing.
4 Radiator guard assembly: 4,700 kg
D475A, D475ASD-5E0 11
Removal and installation of fuel 6. Remove fuel tank mounting bolt (9).
tank assembly 1
Removal
1. Disconnect hose (1).
a Before disconnecting the hose, close the
fuel valve.
2. Remove case (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.
12 D475A, D475ASD-5E0
Removal and installation of 3. Disconnect wiring connectors (3) (201 and

engine hood assembly 1 209) and remove clamp (4).
4. Disconnect hose (5) to the sub-tank and

Removal remove hose clamp (4).

5. Open right and left covers (6) and (7).
6. Remove right and left side covers (8).
2. Lift off radiator upper cover (2).

D475A, D475ASD-5E0 13
7. Loosen clamps (9) and disconnect air cleaner 11. Remove hood mounting bolts (16) and (17).
hoses (10). [*1]
8. Remove sub-tank drain hose clamp (11).
9. Disconnect wiring connectors (12) (HR1 and

HR2 at the right rear of the hood).
12. Lift off hood assembly (18).

4 Hood assembly: 600 kg
10. Loosen the mounting bolts of cover (13) and

remove covers (14) and (15).
Installation
removal.
[*1]
Hose inserted length: Min. 40 mm
3 Hose clamp:
8.83 ± 0.5 Nm {0.9 ± 0.05 kgm}
14 D475A, D475ASD-5E0
Removal and installation of fan 5. Remove wiring harness clamp (5) and discon-
drive assembly 1 nect connector (6).
6. Bracket (7).
Removal
1. Drain the hydraulic oil.
6 Hydraulic tank: Approx. 340 l
2. Remove 8 mounting bolts (2) of radiator mask

(1) and open the radiator mask.
7. Disconnect fan motor hoses (8), (9) and (10).
8. Sling fan drive assembly (11) and remove

bracket mounting bolts (12).
9. Lift off fan drive assembly (11).

4 Fan drive assembly: 250 kg
3. Remove net (3).
a Loosen mounting bolts (13) of the lower
4. Remove fan blade (4). right and left shrouds.
a Move the fan to the position shown in the
photo.
Installation
removal.
q 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, D475ASD-5E0 15
Removal and installation of fan motor assembly 1
Removal
1. Remove the fan drive assembly. For details,
see "Removal and installation of fan drive 3. Remove nut (2). [*2]
assembly".
4. Remove fan (3).
2. Remove the mounting bolt and lock plate (1).
[*1] 5. Remove the 4 mounting bolts and fan motor
assembly (4). [*3]
4 Fan motor assembly: 65 kg
16 D475A, D475ASD-5E0
Installation
removal.
[*1]
Be sure to adjust the hole of lock plate (1) by
turning nut (2) in the tightening direction.
[*2]
3 Mounting nut (2):
1,080 – 1,275 Nm {110 – 130 kgm}
a After tightening the nut, check dimension
(d) shown below.
q MIN: 2.0 mm
q MAX: 4.0 mm
[*3]
a When fitting the fan motor and fan, clean
and degrease them thoroughly.
D475A, D475ASD-5E0 17
SEN02014-00

© 2007 KOMATSU
All Rights Reserved
18
SEN02338-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
50 Disassembly and assembly 1
Engine (SAA12V140E-3)
Engine (SAA12V140E-3) ................................................................................................................................ 2
Removal and installation of fuel supply pump assembly...................................................................... 2
Removal and installation of cylinder head assembly ........................................................................... 8
Removal and installation of fuel injector assembly ............................................................................ 19
Removal and installation of engine front seal .................................................................................... 25
Removal and installation of engine rear seal ..................................................................................... 26
D475A, D475ASD-5E0 1
Engine (SAA12V140E-3) 1
Removal and installation of fuel 4. Remove fuel hose clamp (4) and bracket (5).
supply pump assembly 1
5. Remove high-pressure pipe clamp (6) and
high-pressure pipe (7).
Removal of fuel supply pump on left bank
side 6. Remove clamp (8) and fuel tube (9). [*1]
k Lower the work equipment to the ground
and stop the engine. 7. Remove lubrication tube (10).
a Do not remove the undercover.
1. Close the fuel valve under the fuel tank.
2. Remove left side cover (1) and left cover (2).
3. Remove 2 main fuel filters (3).

a Use a filter wrench etc. to remove the fil-
ters.
8. Remove common rail cover (11).
2 D475A, D475ASD-5E0
9. Disconnect wiring connectors (12). Removal of fuel supply pump on right bank
a Connectors: PCV1, PCV2 and G side
a Do not remove the undercover.
2. Remove right side cover (1) and right cover

(2).
10. Remove the mounting bolts of fuel supply

pump assembly (13) and pull out the fuel sup-
ply pump assembly and mounting bracket
together.
a Wind a rope around the fuel supply pump
and sling it.
a Remove the high-pressure pipe clamp just
under the fuel supply pump without fail.
4 Left fuel supply pump assembly: 17 kg
3. Remove 4 engine oil filters (3).

a Use a filter wrench etc. to remove the fil-
ters.
4. Remove heat insulation plate (4).
a After the fuel supply pump is removed, the

coupling on the drive case moves out of posi-
tion. Accordingly, rotate the crankshaft to set
the drive case in position when installing the
fuel supply pump.
D475A, D475ASD-5E0 3
5. Disconnect wiring clamp (5) and fuel hose 7) Disconnect 6 upper high-pressure pipes
clamps (6). (13) of the common rail and high-pressure
pipes (14) on this side.
6. Remove hose clamp (7) of the fuel air bleeding

valve. 8) Disconnect common rail wiring connector
(15).
7. Remove the common rail according to the fol-

lowing procedure. 9) Remove right and left mounting bolts (16)
1) Remove clamp (8). to remove common rail (17).
2) Remove the common rail cover mounting
bolts to drop cover (9).
3) Remove clamp (10).
4) Remove high-pressure pipe (11).
5) Remove bracket (12).
6) Remove common rail cover (9).
4 D475A, D475ASD-5E0
8. Remove brackets (18) and (19). Installation

a The following is the installation procedure for
the left bank fuel supply pump assembly. The
basic installation procedure for the right fuel
supply pump assembly is the same.
1. Install supply pump assembly (13) temporarily.

2 Supply pump assembly mounting bolt:
Adhesive (LT-2)
a Before tightening the mounting bolt on the
pump side and mounting bolt (14) on the
engine mounting bracket side to the speci-
fied torque, tighten the sleeve nuts of the
high-pressure pipe (between the supply
pump and common rail).
9. Remove clamp (20) and fuel tube (21).
10. Remove lubrication tube (22).
11. Disconnect wiring connectors (23).

a Connectors: PCV1, PCV2 and G
12. Remove the mounting bolts of fuel supply

pump assembly (24) and pull out the fuel sup-
ply pump assembly and mounting bracket
together.
a Wind a rope around the fuel supply pump
and sling it.
a Remove the high-pressure pipe clamp just
under the fuel supply pump without fail. 2. Connect the wiring connector (12).
4 Right fuel supply pump assembly: 17 kg
3. Remove common rail cover (11).
a After the fuel supply pump is removed, the

coupling on the drive case moves out of posi-
tion. Accordingly, rotate the crankshaft to set
the drive case in position when installing the
fuel supply pump.
D475A, D475ASD-5E0 5
High-pressure pipe 3 Bracket mounting bolt (14):

k When handling the high-pressure pipe and 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
clamp, observe the following. 4) Install lubrication tube (10).
q Never bend the high-pressure pipe to cor- 3 Lubrication tube joint bolt:
rect before installing or use it for another 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
section. 5) Install high-pressure pipe clamp (6)
q Install the specified clamp to the specified according to the following procedure.
position securely and tighten it to the 1] Finger tighten all the mounting bolts
specified torque. of high-pressure pipe clamp (6) and
q Do not apply lubricant to the high-pressure bracket (16).
pipe sleeve nut and the threads of the 2] Tighten the high-pressure pipe clamp
mating part. (6) mounting bolts permanently.
a If lubricant is applied, the axial tension a When tightening the high-pres-
is increased too much and the high- sure pipe clamp mounting bolts,
pressure pipe may be broken when the ta k e c a re e x t r e me l y t ha t a n
sleeve nut is tightened. excessive force will not be
k Before installing the high-pressure pipe, applied to the mounting area on
check it. If it has any defect, replace it the supply pump side.
since fuel may leak. 3 Clamp bolt:
q Check the taper seal of the connecting 9.8 ± 1 Nm {1 ± 0.1 kgm}

part (Part "a": Part of 2 mm from the end) 3] Tighten bracket (16) mounting bolts
for visible lengthwise slit "b" and dent "c". permanently.
q Check part "d" (End of the taper seal: Part 6) Install 4 rubber covers (15) to the high-
at 2 mm from the end) for stepped-type pressure pipe sleeve nuts.
wear (fatigue) which your nail can feel. a Install the rubber covers so that their
slits will be directed as follows.
q Supply pump side: Down
q Common rail side: Inward (Fac-
ing each other)
4. Install the high-pressure pipe according to the

1) Install high-pressure pipe assembly (7)
and then tighten the sleeve nuts to the
specified torque.
a Using a spanner-type torque wrench
(commercially available), control the
tightening torque.
3 High-pressure pipe sleeve nut
(Supply pump side):
39.2 – 49 Nm {4 – 5 kgm}
High-pressure pipe sleeve nut
(Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
2) Tighten the supply pump assembly mount-
ing bolts.
3) Tighten supply pump assembly bracket
(14) mounting bolts.
6 D475A, D475ASD-5E0
q Carry out the following installation in the

reverse order to removal.
[*1]
3 Joint bolt on main fuel filter (upper) side:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Joint bolt on fuel supply pump side:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
k Check that each high-pressure pipe is at

least 10 mm apart from the wiring harness
around it.
D475A, D475ASD-5E0 7
Removal and installation of 4. Remove mounting bands (3) and connector

cylinder head assembly 1
nuts and then wind a rope around muffler
assembly (4) and lift it off.
4 Muffler assembly: 60 kg (1 piece)
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
A 2 790-331-1110 Wrench q 1
Removal
terminal of the battery. 5. Remove the piping and then remove the corro-
sion resistor, air bleeding valve and mounting
1. Close the fuel valve under the fuel tank. bracket (5) together.
2. Remove the engine hood. For details, see 4 Corrosion resistor, air bleeding valve
"Removal and installation of engine hood". and mounting bracket: Approx. 35 kg

and right and left covers (2).
6. Remove muffler mounting bracket (6).

4 Muffler mounting bracket: 38 kg
8 D475A, D475ASD-5E0
7. Remove aftercooler inlet pipe (7) and after-

cooler outlet pipe (8). [*1] 14. Remove the common rail cover. For details,
see "Removal and installation of fuel supply
8. Remove bracket (9) and turbocharger intake pump assembly".
connector (10) together. [*2]
15. Remove right and left rubber covers (17) and
9. Remove turbocharger exhaust connector (11). (18).
16. Remove right and left high-pressure pipes

(19).
10. Disconnect right and left main wirings (12).
11. Remove engine oil filter assembly (13).
17. Remove right and left air intake manifolds (20).

4 Air intake manifold: 35 kg
12. Disconnect fuel hose and piping (14). [*3]
13. Remove main fuel filter assembly (15) and fuel

prefilter assembly (16).
D475A, D475ASD-5E0 9
18. Remove each tube of the turbocharger. 19. Remove heat insulation cover (25).
q Lubrication tube (21)
q Lubricating oil drain tube (22)
q Coolant tube (23) [*4]
q Coolant drain tube (24) [*4]
20. Sling turbocharger and exhaust manifold

assembly (26), remove the mounting bolts, and
lift off the turbocharger and exhaust manifold
assembly. [*5]
4 Turbocharger and exhaust manifold
assembly: 60 kg
10 D475A, D475ASD-5E0
21. Removal of injector external wiring 25. Removal of rocker arm assembly
1) Remove cover plate (27). 1) Loosen locknuts (34) and then loosen
2) Disconnect connector (28) from each cyl- adjustment screws (35) fully.
inder head and disconnect wiring harness a Check that the rocker arm is not
(29). affected by the valve tension but it is
free.
22. Remove air vent tubes (30) and (31). [*6] 2) Remove rocker arm assembly (36).
a Put a location tag to each rocker arm
23. Remove spill tube (32). assembly before storing.
24. Remove head cover (33).
26. Remove push rods (37).
27. Remove crossheads (38).
28. Removal of fuel injector

1) Remove injector terminal mounting nuts
(39).
2) Remove clamp mounting bolt (40).
3) Push connector (41) into the cylinder head
and remove injector wiring harness (42).
4) Remove holder mounting bolt (43).
D475A, D475ASD-5E0 11
5) Insert small L-bar [B] under the fuel con- Installation

nector and pry out fuel injector (44) slowly.
a Do not grip the solenoid valve at the Cylinder head assembly
top of the injector with pliers to pull
out the injector. 1. Install the cylinder head gasket.
2. Sling and install cylinder head assembly (45).

4 Cylinder head assembly: 30 kg
29. Lift off cylinder head assembly (45).

4 Cylinder head assembly: 30 kg
a If the cylinder head assembly is removed
without removing the fuel injector, the a If there are 5 punch marks on the head of
injector tip projects from the bottom of the a bolt, do not reuse that bolt but replace it.
cylinder head. Accordingly, use a block, a Tighten the mounting bolts in the order
etc. to prevent the injector from interfering shown in the figure.
with the floor. 2 Cylinder head assembly mounting bolt:
Molybdenum disulfide grease (LM-P)
3 Cylinder head assembly mounting bolts
(1) – (6):
1st time: 137 – 157 Nm {14 – 16 kgm}
2nd time: 284 – 294 Nm {29 – 30 kgm}
3rd time: Retighten by 90 – 120°
3 Cylinder head assembly mounting bolt (7):
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
30. Remove the cylinder head gasket.
12 D475A, D475ASD-5E0
a Use tool A2 (See the tool table) to

retighten the mounting bolts. When not
using tool A2, make marks on the bolts
and cylinder head, and then retighten
each bolt by 90 – 120°
6. Install spherical washer (50) to injector holder

mounting bolt (43) and tighten injector holder
(49) temporarily.
2 Spherical washer: Engine oil (EO30)
a Tighten injector holder (49) permanently
a After tightening the bolts, make punch after tightening the high-pressure pipe
mark "a" on the main bolt head (Do not temporarily.
make it when new bolts are used, how-
ever).
Crosshead
7. Install crossheads (38).
Fuel injector 2 Sliding parts of crosshead:
a Check that there is no dirt in the injector Engine oil (EO30)
sleeve.
2 O-ring: Engine oil (EO30)
3. Fit O-rings (46) and (47) to fuel injector (44).

a Take care not to fit O-ring (47) to center
groove (A).
4. Install gasket (48) to fuel injector (44).
5. Insert fuel injector (44) and injector holder (49)

together in the cylinder head.
D475A, D475ASD-5E0 13
8. Adjust the crosshead according to the follow- 10. Install push rods (37).
ing procedure. a Check that each push rod end is fitted in
1) Loosen locknut (102) and then loosen the receiving area of the cam follower.
adjustment screw (103) to a position 2 Both ends of push rod:
where it will not touch valve stem (104). Engine oil (EO30)
2) Hold the contact face to the rocker arm
with the finger to keep crosshead in con-
tact with valve stem (105) on the push rod
side.
3) Tighten adjustment screw (103) slowly
and check the point at which adjustment
screw (103) touches valve stem (104).
4) Tighten adjustment screw (103) further by
20 – 30° from the above point.
5) While holding adjustment screw (103),
tighten locknut (102).
3 Locknut:
58.8 ± 5.9 Nm {6.0 ± 0.6 kgm}
11. Install rocker arm assembly (36).

2 Rocker shaft: Engine oil (EO30)
2 Threaded part and seat of rocker arm
assembly mounting bolt:
Engine oil (EO30)
a Check that the ball of adjustment screw
(35) is fitted in the push rod socket.
a When tightening the mounting bolt, check
that adjustment screw (35) does not press
the push rod.
3 Rocker arm assembly mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
9. Injector wiring harness a Tighten locknut (34) after adjusting the
1) Push out connector (41) from inside of the valve clearance.
cylinder head and install injector wiring a Adjust the valve clearance. For details,
harness (42) in the cylinder head. see Testing and adjusting, "Testing and
2) Tighten injector terminal mounting nuts adjusting valve clearance".
(39) and clamp mounting bolt (40).
a Tighten injector terminal mounting
nuts (39) alternately.
3 Injector terminal mounting nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a After tightening the injector terminal
mounting nuts, press the wiring har-
ness against the injector body to take
up the slack.
14 D475A, D475ASD-5E0
3 Tightening torque for locknut: 14. Fuel injector and high-pressure pipe (between
52.9 – 64.7 Nm {5.4 – 6.6 kgm} common rail and fuel injector)
a After tightening the locknut, check the k When handling the high-pressure pipe
valve clearance again. and clamp, observe the following.
q Never bend the high-pressure pipe to
correct before installing or use it for
another section.
q Install the specified clamp to the
specified position securely and
tighten it to the specified torque.
q Do not apply lubricant to the high-
pressure pipe sleeve nut and the
threads of the mating part.
a If lubricant is applied, the axial ten-
sion is increased too much and the
high-pressure pipe may be broken
when the sleeve nut is tightened.
k Before installing the high-pressure
pipe, check it. If it has any defect,
replace it since fuel may leak.
12. Install spill tube (32). q Check the taper seal of the connect-
3 Joint bolt: ing part (Part "a": Part of 2 mm from
9.8 – 12.7 Nm {1.0 – 1.3 kgm} the end) for visible lengthwise slit "b"
and dent "c".
13. Place cylinder head cover (33). (Place it to q Check part "d" (End of the taper seal:
prevent dirt from entering. It will need to be Part at 2 mm from the end) for
removed again.) stepped-type wear (fatigue) which
your nail can feel.
D475A, D475ASD-5E0 15
1) Fit O-ring (52) to the high-pressure pipe 6) Install the cylinder head cover.
sleeve nut (51). 3 Cylinder head cover mounting bolt:
2 O-ring: Engine oil (EO30) 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
2) Tighten sleeve nut (51) temporarily into 7) Install rubber covers (17) and (18) to the
fuel injector (44). sleeve nuts of high-pressure pipes (19).
a If sleeve nut (51) does not catch the a Install the rubber covers so that their
threads, press its end with a small slits will be directed as follows.
rod, etc. toward the injector and turn q Injector side (17): Down
the spanner. q Common rail side (18):
3) Tighten sleeve nut (53) on the common Cylinder block side
rail side temporarily, too.
4) Tighten injector holder (49) permanently.
3 Injector holder mounting bolt (43):
58.9 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten the sleeve nut to the specified
torque.
(commercially available), control the
tightening torque.
3 High-pressure pipe (19) sleeve nut
(Injector side):
39.2 – 49 Nm {4 – 5 kgm}
3 High-pressure pipe (19) sleeve nut
(Common rail side):
39.2 – 49 Nm {4 – 5 kgm}
a After tightening each sleeve nut (51), 15. Air intake manifold assembly
check that O-rings (46) and (52) are 1) Install the gasket.
not projected from the sleeve nut. a Direct the side having the mark of
"UP" up and direct it toward the air
intake manifold.
2 Threaded part and seat of mount-
ing bolt:
Molybdenum disulfide grease (LM-P)
a Tighten the mounting bolts according
3 Air intake manifold mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
16 D475A, D475ASD-5E0
16. Install the high-pressure pipe clamps (between [*2]

the common rail and fuel injector). For details, 3 Air intake connector mounting bolt:
see "Removal and installation of fuel supply 49 – 68.6 Nm {5.0 – 7.0 kgm}
pump assembly".
[*3]
17. Install the high-pressure pipes (between the 3 Fuel tube joint bolt:
common rail and fuel supply pump). For 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
details, see "Removal and installation of fuel 3 Fuel hose joint bolt:
supply pump assembly". 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
a For precautions, see the section of the 3 Spill tube joint bolt
high-pressure pipe (between the common Cylinder head side:
rail and fuel injector). 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
a Using a spanner-type torque wrench Air intake manifold side:
(commercially available), control the tight- 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
ening torque.
[*4]
q Carry out the following installation in the 3 Turbocharger coolant tube joint bolt (upper
reverse order to removal. side): 24.5 – 34.3 Nm {2.3 – 3.5 kgm}
3 Turbocharger coolant tube sleeve nut (lower
[*1] side): 24.5 – 59 Nm {2.3 – 6 kgm}
q Air hose 3 Turbocharger coolant hose:
a Use a new MIKALOR clamp. 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
1) Set the hose to the original position
(marked position). (Insertion depth of air [*5]
hose: Min. 80 mm) Exhaust manifold assembly
2) Set the bridge (BR) under the clamp bolt 1) Install the gasket.
and lap it over the band at least 3 mm (b). a Direct the side having the mark of "OUT"
Dimension (b): Min. 3 mm toward the exhaust manifold.
2 Threaded part (BC) of clamp bolt: a Tighten the mounting bolts in the numeric
Lubricating oil (Threebond PANDO 18B) order shown in the figure.
a After tightening the mounting bolts, tighten
a Do not use an impact wrench. them again to the same torque.
2 Threaded part and seat of mounting bolt:
q When reusing used hose Molybdenum disulfide grease (LM-P)
3) Set the clamp to the trace of the clamp on 3 Exhaust manifold mounting bolt:
the hose. 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
3 Clamp bolt: Min. 6 Nm {0.6 kgm}
q When using new hose

4) Tighten until dimension BDG becomes as
follows.
BDG: 17 – 20 mm
D475A, D475ASD-5E0 17
Reference
Turbocharger assembly
2 Turbocharger assembly mounting bolt and
nut: Molybdenum disulfide grease (LM-P)
3 Turbocharger assembly mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
[*6]
3 Air vent tube mounting bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.

around it.
18 D475A, D475ASD-5E0
Removal and installation of fuel 4 Corrosion resistor, air bleeding valve

injector assembly 1
and mounting bracket: Approx. 35 kg
Removal
2. Remove the engine hood. For details, see

"Removal and installation of engine hood".

and right and left covers (2). 6. Remove muffler mounting bracket (6).
4 Muffler mounting bracket: 38 kg
4. Remove mounting bands (3) and connector

nuts and then wind a rope around muffler
assembly (4) and lift it off. 7. Remove aftercooler inlet pipe (7) and after-
4 Muffler assembly: 60 kg (1 piece) cooler outlet pipe (8). [*1]
8. Remove bracket (9) and turbocharger intake

connector (10) together. [*2]
9. Remove turbocharger exhaust connector (11).
5. Remove the piping and then remove the corro-

sion resistor, air bleeding valve and mounting
bracket (5) together.
D475A, D475ASD-5E0 19
10. Disconnect right and left main wirings (12).
11. Remove engine oil filter assembly (13).
17. Remove right and left air intake manifolds (20).

4 Air intake manifold: 35 kg
12. Disconnect fuel hose and piping (14). [*3]
13. Remove main fuel filter assembly (15) and fuel

prefilter assembly (16).
18. Removal of injector external wiring

1) Remove cover plate (27).
2) Disconnect connector (28) from each cyl-
inder head and disconnect wiring harness
14. Remove the common rail cover. For details, (29).
see "Removal and installation of fuel supply
pump assembly". 19. Remove head cover (30).
15. Remove right and left rubber covers (17) and

(18).
16. Remove right and left high-pressure pipes

(19).
20 D475A, D475ASD-5E0
20. Removal of rocker arm assembly 5) Insert small L-bar [B] under the fuel con-
1) Loosen locknuts (34) and then loosen nector and pry out fuel injector (44) slowly.
adjustment screws (35) fully. a Do not grip the solenoid valve at the
a Check that the rocker arm is not top of the injector with pliers to pull
affected by the valve tension but it is out the injector.
free.
2) Remove rocker arm assembly (36).
a Put a location tag to each rocker arm
assembly before storing.
Installation
Fuel injector
a Check that there is no dirt in the injector
21. Removal of fuel injector sleeve.
1) Remove injector terminal mounting nuts 2 O-ring: Engine oil (EO30)
(39).
2) Remove clamp mounting bolt (40). 1. Fit O-rings (46) and (47) to fuel injector (44).
3) Push connector (41) into the cylinder head a Take care not to fit O-ring (47) to center
and remove injector wiring harness (42). groove (A).
4) Remove holder mounting bolt (43).
2. Install gasket (48) to fuel injector (44).
3. Insert fuel injector (44) and injector holder (49)

together in the cylinder head.
D475A, D475ASD-5E0 21
4. Install spherical washer (50) to injector holder 6. Install rocker arm assembly (36).
mounting bolt (43) and tighten injector holder 2 Rocker shaft: Engine oil (EO30)
(49) temporarily. 2 Threaded part and seat of rocker arm
2 Spherical washer: Engine oil (EO30) assembly mounting bolt:
a Tighten injector holder (49) permanently Engine oil (EO30)
after tightening the high-pressure pipe a Check that the ball of adjustment screw
temporarily. (35) is fitted in the push rod socket.
a When tightening the mounting bolt, check
that adjustment screw (35) does not press
the push rod.
3 Rocker arm assembly mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
a Tighten locknut (34) after adjusting the
valve clearance.
a Adjust the valve clearance. For details,
see Testing and adjusting, "Testing and
adjusting valve clearance".
5. Injector wiring harness

1) Push out connector (41) from inside of the
cylinder head and install injector wiring
harness (42) in the cylinder head.
2) Tighten injector terminal mounting nuts
(39) and clamp mounting bolt (40).
a Tighten injector terminal mounting
nuts (39) alternately.
3 Injector terminal mounting nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a After tightening the injector terminal 3 Tightening torque for locknut:
mounting nuts, press the wiring har- 52.9 – 64.7 Nm {5.4 – 6.6 kgm}
ness against the injector body to take a After tightening the locknut, check the
up the slack. valve clearance again.
22 D475A, D475ASD-5E0
7. Place the cylinder head cover. (Place it to pre- 1) Fit O-ring (52) to the high-pressure pipe
vent dirt from entering. It will need to be sleeve nut (51).
removed again.) 2 O-ring: Engine oil (EO30)
2) Tighten sleeve nut (51) temporarily into
8. Fuel injector and high-pressure pipe (between fuel injector (44).
common rail and fuel injector) a If sleeve nut (51) does not catch the
k When handling the high-pressure pipe threads, press its end with a small
and clamp, observe the following. rod, etc. toward the injector and turn
q Never bend the high-pressure pipe to the spanner.
correct before installing or use it for 3) Tighten sleeve nut (53) on the common
another section. rail side temporarily, too.
q Install the specified clamp to the 4) Tighten injector holder (49) permanently.
specified position securely and 3 Injector holder mounting bolt (43):
tighten it to the specified torque. 58.9 – 73.5 Nm {6.0 – 7.5 kgm}
q Do not apply lubricant to the high- 5) Tighten the sleeve nut to the specified
pressure pipe sleeve nut and the torque.
threads of the mating part. a Using a spanner-type torque wrench
a If lubricant is applied, the axial ten- (commercially available), control the
sion is increased too much and the tightening torque.
high-pressure pipe may be broken 3 High-pressure pipe (19) sleeve nut
when the sleeve nut is tightened. (Injector side):
k Before installing the high-pressure 39.2 – 49 Nm {4 – 5 kgm}
pipe, check it. If it has any defect, 3 High-pressure pipe (19) sleeve nut
replace it since fuel may leak. (Common rail side):
q Check the taper seal of the connect- 39.2 – 49 Nm {4 – 5 kgm}
ing part (Part "a": Part of 2 mm from a After tightening each sleeve nut (51),
the end) for visible lengthwise slit "b" check that O-rings (46) and (52) are
and dent "c". not projected from the sleeve nut.
q Check part "d" (End of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.
D475A, D475ASD-5E0 23
6) Install the cylinder head cover. Removal

3 Cylinder head cover mounting bolt: q Carry out the following installation in the
14.7 – 34.3 Nm {1.5 – 3.5 kgm} reverse order to removal.
7) Install rubber covers (17) and (18) to the
sleeve nuts of high-pressure pipes (19). [*1]
a Install the rubber covers so that their q Air hose
slits will be directed as follows. a Use a new MIKALOR clamp.
q Injector side (17): Down 1) Set the hose to the original position
q Common rail side (18): (marked position). (Insertion depth of air
Cylinder block side hose: Min. 80 mm)
2) Set the bridge (BR) under the clamp bolt
and lap it over the band at least 3 mm (b).
Dimension (b): Min. 3 mm
2 Threaded part (BC) of clamp bolt:
Lubricating oil (Threebond PANDO 18B)
a Do not use an impact wrench.
q When reusing used hose

3) Set the clamp to the trace of the clamp on
the hose.
3 Clamp bolt: Min. 6 Nm {0.6 kgm}
q When using new hose

9. Install the high-pressure pipe clamps (between 4) Tighten until dimension BDG becomes as
the common rail and fuel injector). For details, follows.
see "Removal and installation of fuel supply BDG: 17 – 20 mm
pump assembly".
10. Install the high-pressure pipes (between the

common rail and fuel supply pump). For
details, see "Removal and installation of fuel
supply pump assembly".
a For precautions, see the section of the
high-pressure pipe (between the common
rail and fuel injector).
(commercially available), control the tight-
ening torque.
[*2]
3 Air intake connector mounting bolt:
49 – 68.6 Nm {5.0 – 7.0 kgm}
[*3]
3 Fuel tube joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Fuel hose joint bolt:

24.5 – 34.3 Nm {2.5 – 3.5 kgm}

around it.
24 D475A, D475ASD-5E0
Removal and installation of Installation

engine front seal 1 q Carry out installation in the reverse order to
removal.
Special tools [*1]
a Align the dowel pin when installing the crank-
New/remodel
Necessity
shaft pulley.
Symbol
Sketch
Q'ty
Part No. Part Name a Tighten the mounting bolts in the order shown
in the diagram below.
3 Crankshaft pulley mounting bolt:
3 795-931-1100 Seal puller t 1 1st step: 73.5 ± 19.6 Nm {7.5 ± 2 kgm}
795T-621-1430 Plate t 1 N Q 2nd step: 245 ± 19.6 Nm {25 ± 2 kgm}
3rd step: 744.8 ± 19.6 Nm {76 ± 2 kgm}
795T-621-1440 Push tool t 1 N Q
A
4 01050-32240 • Bolt t 3
01050-32225 • Bolt t 3
01640-02232 • Washer t 3
Removal
1. Remove radiator guard assembly.
radiator guard assembly".
2. Remove crankshaft pulley (1). [*1]
[*2]
a Do as follows according to the wear of the
crankshaft seal contact surface.
1) When crankshaft is a new part or when
there is no wear of oil seal contact sur-
face.
1] Press fit by tool A4
2] After press fitting, check mounting
dimension (a).
Front seal mounting dimension (a):
17.5 mm
3] Install dust seal (3).
Dust seal mounting dimension (b):
3. Remove front seal (2). [*2] approx. 7 mm
D475A, D475ASD-5E0 25
Removal and installation of Installation

engine rear seal 1 1. Using guide bolt, and install flywheel (2).
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
3 795-931-1100 Seal puller t 1

795T-621-1540 Plate t 1 N Q
A
5 01050-32060 • Bolt t 5
01640-02032 • Washer t 5
Removal 2. Secure flywheel (2) and housing with plate [3].

1. Remove damper assembly.
damper assembly".
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 the diagram below.
3 Flywheel mounting bolt:
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]
26 D475A, D475ASD-5E0
3. After installing flywheel, use dial gauge [4] to

measure radial and face runout of flywheel.
q Face runout: Max. 0.30 mm
q Radial runout: Max. 0.30 mm
[*1]
a Do as follows according to the wear of the
crankshaft seal contact surface.
1) When crankshaft is a new part or when
there is no wear of oil seal contact sur-
face.
1] Press fit by tool A5.
2] After press fitting, check mounting
dimension (a).
Front seal mounting dimension (a):
18.5 mm
D475A, D475ASD-5E0 27
SEN02338-00

© 2007 KOMATSU
All Rights Reserved
28
SEN02015-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Power train, Part 1

Power train, Part 1 .......................................................................................................................................... 2
Removal and installation of damper assembly..................................................................................... 2
Disassembly and assembly of damper assembly ................................................................................ 4
Removal and installation of power train unit assembly ........................................................................ 7
Removal and installation of PTO, torque converter assembly ........................................................... 10
Disconnection and connection of PTO, torque converter assembly................................................... 12
Disassembly and assembly of torque converter assembly ................................................................ 14
Disassembly and assembly of PTO assembly ................................................................................... 23
Removal and installation of TORQFLOW transmission assembly ..................................................... 29
Disassembly and assembly of TORQFLOW transmission assembly................................................. 30
D475A, D475ASD-5E0 1
Removal and installation of 6. Remove holder (4) and coupling (5). [*2]
damper assembly
7. Remove retainer (6).
Removal 8. Sling damper cover (7), then use forcing screw

1. Remove hood assembly. [1] (12mm, P=1.75) to remove damper cover.
For details, see Removal and installation of k Install guide bolts (12 mm, P = 1.75, l =
hood assembly. 100) in 2 mounting bolt holes in the top
of the damper cover so that the damper
2. Open underguard (3rd from front of machine). cover does not come out suddenly.
4 Damper cover: 50 kg
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] (16 mm, 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
2 D475A, D475ASD-5E0
Installation
removal.
[*1]
3 Universal joint mounting bolt:
156.8 – 196 Nm {16 – 20 kgm}
[*2]
2 Holder mounting bolt thread:
Thread tightener (LT-2)
490 – 607.6 Nm {50 – 62 kgm}
q Refilling with oil (damper case)

level, and run the engine to circulate the oil
through the system. Then check the oil level
again.
D475A, D475ASD-5E0 3
Disassembly and assembly of Assembly

damper assembly 1. Using push tool, press fit bearing (9).
2 Flywheel pilot portion: Grease (G2-U)
a Fill 50% (approx. 55 g) of clearance (a).
Disassembly
1. Remove bolt (1), then remove flange (2).
2. Remove seal (3).
3. Remove shaft (4).
4. Remove rubber (5).
5. Remove flange (6) from body (7).
6. Remove seal (8).
7. Remove bearing (9).

2. Install seal (8) to flange (6), and seal (3) to
flange (2).
a Install the seal with the lip facing the inside
as shown in the diagram.
Disassembly of damper cover assembly

8. Remove bearing (10) and seal (11) from cover
(12).
3. Align the bolt holes with body (7), then install
9. Remove oil seal (13) from retainer (14). flange (6).
2 Flange mating surface:
a Check that there are no dents, rust, oil or
grease, or water on the mating surface,
then coat both the flange and body sur-
faces with gasket sealant.
a Coat with a thickness of about 0.1 – 0.2
mm, leave to dry for 2 – 3 minutes, then
tighten.
4 D475A, D475ASD-5E0
7. Tighten bolt (1).
4. Set shaft (4) to flange and body assembly in

position. Assembly of damper cover assembly
8. Using push tool [1], press fit oil seal (13) to
5. Assemble rubber (5). retainer (14).
a When assembling the rubber, coat the 2 Oil seal press-fitting surface:
whole surface of the rubber, the outside Gasket sealant (LG-1)
circumference of the shaft, and the inside a Coat the inside surface of the retainer
circumference of the body with grease thinly with gasket sealant and wipe off any
(G2-LI). sealant that is forced out.
a After assembling the rubber, fill approx. 2 Lip of oil seal: Grease (G2-LI)
50% (approx. 400 g) of the space ((b) por-
tion: 16 places) between the shaft and
body with grease (G2-LI).
9. Using push tool [2], press fit bearing (10) to

cover (12).
6. Install flange (2).

2 Flange mating surface:
a Check that there are no dents, rust, oil or
grease, or water on the mating surface,
then coat both the flange and body sur-
faces with gasket sealant.
a Coat with a thickness of about 0.1 – 0.2
mm, leave to dry for 2 – 3 minutes, then
tighten.
D475A, D475ASD-5E0 5
10. Using push tool [1], press fit oil seal (11) to
cover (12).
2 Oil seal press-fitting surface:
a Coat the inside surface of the cover thinly
with gasket sealant and wipe off any seal-
ant that is forced out.
2 Lip of oil seal: Grease (G2-LI)
6 D475A, D475ASD-5E0
Removal and installation of power 8. Remove hydraulic pump inlet tube coupling (5)
train unit assembly and hydraulic tank side coupling (6), and
remove tube (7).
Removal 9. Disconnect fan motor hose (8).

1. Drain oil from hydraulic tank and power train
case. 10. Disconnect hoses (9) and (10).
6 Power train case: Approx. 150 l
2. Remove floor frame assembly.

floor frame assembly".
3. Remove fuel tank assembly.

fuel tank assembly".
4. Remove brake rod (1).
5. Disconnect cable (2). 11. Disconnect steering hose (11).
12. Disconnect hoses (12) and (13).
6. Disconnect lubrication hose (3).
7. Disconnect fan motor pump tube coupling (4). 13. Remove hydraulic pump inlet tube (14).
14. Disconnect hydraulic pump PPC hoses (15)

and (16).
D475A, D475ASD-5E0 7
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,
21. Remove rear mount bolt (25), then remove
PL3).
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).
8 D475A, D475ASD-5E0
24. Remove shaft (30). Installation

a Pull out the shaft with forcing screws [2]. q Carry out installation in the reverse order to
a If the shaft will not come out, set jack [3] removal.
on the ground and push the shoe grouser
up, then move the sprocket to the front or [*1]
rear to a position where the shaft will 3 Universal joint mounting bolt:
come out, and remove the shaft. 156.8 – 196 Nm {16 – 20 kgm}
[*2]
3 Front mount bolt:
1,519 – 1,911 Nm {155 – 195 kgm}
[*3]
3 Rear mount bolt:
823.2 – 1,029 Nm {84 – 105 kgm}
[*4]
a Check that the housing clip is fitted
securely in the flange.
3 Housing clip:
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
assembly, pay attention to the mating sur-
face of the coupling, and be careful not to
damage the seal of the rear mount cou-
pling.
q Refilling with oil

again.
5 Power train case: Approx. 210 l
D475A, D475ASD-5E0 9
Removal and installation of PTO, 6. Sling filter assembly (6), then remove.
torque converter assembly 4 Transmission filter assembly: 40 kg
4 Torque converter, transmission lubrica-
Removal tion filter assembly: Approx. 80 kg
1. Remove power train unit assembly.
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 together with the strainer.
4 Power train pump, strainer assembly:
100 kg
8. Lift off mount bracket (9). [*2]

3. Remove brake rod (2). [*1]
4 Mount bracket: 70 kg
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
hoses, mark them with tags to prevent any
mistake in the mounting position when
installing.
5. Remove oil filler tube (5).
10 D475A, D475ASD-5E0
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
assembly, 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]
2 PTO boss rotating portion:
Grease (G2-LI)
[*3]
a Using a lever block, raise the PTO and
13. Remove oil pan (18). torque converter assembly horizontally,
a Remove the block under the oil pan, sling align it with the spline of the shaft at the
the oil pan, then remove the mounting steering case end, then install.
bolts and disconnect the oil pan.
4 Oil pan: 120 kg
D475A, D475ASD-5E0 11
Disconnection and connection of 5. Remove oil seal (6). [*2]

PTO, torque converter assembly
6. Remove spacer (7).
a Remove snap ring (8), then remove the
Special tools spacer.
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 assem-
bly, then disconnect it from the torque con-
verter 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,
retainer assembly, and shims.
a Check the number and thickness of the
shims, and keep in a safe place.
12 D475A, D475ASD-5E0
Connection 3) Measure shim thickness.

q Carry out connection in the reverse order to q (a) – (0 to 0.05 mm)
disconnection. 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
as follows. specified torque.
1) Assemble the oil seal to the retainer 3 Retainer mounting bolt:
assembly, then install the cover, and 58.8 – 73.5 Nm {6 – 7.5 kgm}
tighten to 9.8 Nm {1 kgm}. a Assemble the shim as shown in the dia-
2) Using a clearance gauge, measure clear- gram below so that it does not come at
ance (a) between the retainer and the position (b) of the retainer removal tap.
housing.
a Measure clearance (a) at four points
(A, B, C, D) around the circumfer-
ence, and take the average as clear-
ance (a).
[*2]
2 Outer circumference of oil seal:
D475A, D475ASD-5E0 13
Disassembly and assembly of 2) Using eyebolts [1], remove lockup clutch

torque converter assembly and drive case assembly (4).
a Disassemble the lockup clutch and
drive case assembly as follows.
Special tools 1] Remove seal ring (5), and using forc-
ing 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
q Set the torque converter assembly to tool C.
2] Remove snap ring (7), then remove

plate (8).
3] 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.
14 D475A, D475ASD-5E0
4] Set clutch housing at top, then using 9] Remove 3 discs (16) and 2 plates
eyebolts [4], remove housing and pis- (17) from drive case (18).
ton assembly (10). a After removing the discs and
a When the assembly is removed, plates, keep them in a flat place
the piston will fall out, so support to prevent them from becoming
it by hand when removing. distorted.
5] Remove piston (11) from housing
(12).
4. Stator assembly
1) Remove snap ring (19), then remove sta-
6] Remove seal ring (13) from piston. tor assembly (20).
7] Remove seal ring (14) from housing. 2) Disassemble stator assembly as follows.
race (22) from stator (23).
8] Using push tool [5], remove bearing

(15) from housing.
2] Remove snap ring (24) from stator
(23).
D475A, D475ASD-5E0 15
5. Pump assembly 9. Pin

1) Remove snap ring (25). Remove pin (37).
2) Remove pump assembly (26).
3) Disassemble pump assembly as follows.
1] Remove retainer (27).
2] Remove bearing and guide assembly
(28) from pump (29).
10. Inner gear

Remove snap ring (38), then remove inner
gear (39).
11. Piston
3] Remove bearing outer race (30) from 1) Remove piston (40) from case (41).
guide (31).

Set stator clutch housing at top and remove
stator 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
becoming distorted.
16 D475A, D475ASD-5E0
12. Stator shaft assembly 5] Using push tool [7], remove bearing
1) Tap stator shaft assembly (44) with a plas- (55), then remove plate (56).
tic hammer, and remove from case (45).
2) Disassemble stator shaft assembly as fol-
lows.
1] Using push tool [6], remove shaft
as se mbly ( 46) from stato r s haft
assembly.

bearing inner race (48), bushing (49),
and seal ring (50) from shaft.
3] Remove seal ring (51) from stator
shaft (52).
plate (54).
D475A, D475ASD-5E0 17
Assembly 7) Install snap ring (47), and secure inner

a Wash all parts in clean flushing oil (in particu- race.
lar, oil holes, etc.), then dry them, and check
for dirt or damage. Coat the sliding surfaces of
all parts with engine oil before installing.
q Set case (41) to tool C.
1. Stator shaft assembly

1) Assemble plate (56) to stator shaft (52),
and using push tool, press fit bearing (55).
a Put drops (approx. 6 cc) of engine oil
(SAE10W-CD or SAE30-CD) on the
bearing and rotate about 10 times.
2) Install plate (54), and secure with snap
ring (53).
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 8) Tap stator shaft (52) with a plastic hammer
shaft securely. and press fit bearing portion to case.
9) Set shaft (46) to stator shaft, then using
push tool, press fit bearing portion.
10) Turn over case and tighten mounting bolts
of shaft from case end.
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 securely.
5) Using push tool [9], press fit bushing (49) 2 Mounting bolt:
to shaft. Thread tightener (LT-2)
a Be careful not to deform the bushing 3 Mounting bolt:
when press fitting. 58.8 – 73.5 Nm {6 – 7.5 kgm}
6) Using push tool [10], press fit inner race
(48) to shaft.
18 D475A, D475ASD-5E0
2. Piston 6. Spring
1) Install seal ring (43) to case. Install spring (33).
2 Outer circumference of seal ring:
Grease (G2-LI)
a Be careful to assemble the seal ring
facing in the direction shown in the
diagram below.
2) Install seal ring (42) to piston.
2 Outer circumference of seal ring:
Grease (G2-LI)
a Be careful to assemble the seal ring
facing in the direction shown in the
diagram below.

Install stator clutch housing (32).
a Check that the springs are fitted securely
in the holes in the housing and piston.
2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
8. Pump assembly
1) Assemble pump assembly as follows.
1] Using push tool, press fit bearing
3) Install piston (40) to case (41). outer race (30) to guide (31).
2 Contact surface of seal ring: a Put drops (approx. 6 cc) of
Grease (G2-LI) engine oil (SAE10W-CD or
SAE30-CD) on the bearing and
3. Inner gear rotate about 10 times.
Install inner gear (39) and secure with snap
ring (38).
2] Set bearing and guide assembly (28)

to pump (29), then tap with a plastic
4. Pin hammer and press fit bearing portion.
Install pin (37). 3] Install retainer (27).
2 Mounting bolt:
5. Plate, discs, springs Thread tightener (LT-2)
Install 1 plate (36), 2 discs (35), and springs 3 Mounting bolt:
(34). 58.8 – 74.5 Nm {6 – 7.5 kgm}
D475A, D475ASD-5E0 19
2) Install pump assembly (26). 10. Lock-up clutch, drive case assembly
a When installing the pump, be careful 1) Assemble lock-up clutch and drive case
not to damage the seal ring assem- assembly as follows.
bled to the shaft. 1] Set turbine (9) to block [11], and set
3) Install snap ring (25). drive case (18) to turbine.
9. Stator assembly 2] Install 3 discs (16) and 2 plates (17).

1) Assemble stator assembly as follows.
1] Install snap ring (24) to stator (23).
3] Install seal ring (14) to housing.

2 Outer circumference of seal
2] Assemble race (22) to stator (23), and ring: Grease (G2-LI)
secure with snap ring (21). 4] Install seal ring (13) to piston.
2) Install stator assembly (20) to stator shaft, 2 Outer circumference of seal
and secure with snap ring (19). ring: Grease (G2-LI)
20 D475A, D475ASD-5E0
5] Install piston (11) to housing (12). 2) Using eyebolt [1], install lock-up clutch
2 Contact surface of seal ring: and drive case assembly (4).
Grease (G2-LI) a Align the positions of the turbine oil
a When installing, be careful not to groove ( mark) and drain plug (2)
damage the seal ring. when installing.
6] Using eyebolts [4], install housing and
piston assembly (10).
a Support the piston assembly by
hand to prevent it from falling out
when installing.
2 Mounting bolt:
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
3) Tighten mounting bolts (3).

a Check that drain plug (2) is tightened.
3 Mounting bolt:
49 – 58.8 Nm {5 – 6 kgm}
3 Drain plug:
9.8 – 12.7 Nm {1 – 1.3 kgm}

(15).
a Put drops (approx. 6 cc) of
engine oil (SAE10W-CD or
SAE30-CD) on the bearing and
rotate about 10 times.
8] Install plate (8), and secure with snap
ring (7).
9] Install input shaft (6).
2 Mounting bolt:
3 Mounting bolt:
156.8 – 196 Nm {16 – 20 kgm}
10] Install 2 seal rings (5).
D475A, D475ASD-5E0 21
11. Torque converter valve assembly

Install torque converter valve assembly (1).
a Tighten the mounting bolts uniformly in
turn and be careful not to tighten them
unevenly.
3 Mounting bolt:
43.1 – 53.9 Nm {4.4 – 5.5 kgm}
22 D475A, D475ASD-5E0
Disassembly and assembly of 3) Using puller [2], remove bearings (5) and
PTO assembly (6) from gear (7).
Disassembly
1. PTO lubrication tube
Sling PTO assembly and remove lubrication
tube (1).
a Remove the 3 lubrication tubes on the
opposite side also, set the torque con-
verter end at the bottom, then lower.
3. Power train and 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).
D475A, D475ASD-5E0 23
4. Scavenging drive gear 6. Idler gear assembly

Remove snap ring (13) from bottom of PTO 1) Remove idler gear assembly (19) and
case, then remove gear (14). bearing (20) from bottom of PTO case.
2) Remove outer race (21).
5. Shaft assembly
1) Remove plate (15) of idler gear.
7. PTO case
1) Remove race assembly (24) together with
2) Turn over PTO case, then using forcing bearing outer race (25).
screw [1], remove shaft assembly (16).
a The bearing outer race and key
assembly will come out from the bot-
tom of the PTO case, so place a
wooden block in position and be care-
ful 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.
2) Remove bearing inner races (26) and (27)

from race (28).
24 D475A, D475ASD-5E0
3) Remove bearing outer race (29). Assembly

4) Remove sleeve (30). 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.
bearing and rotate about 10 turns.
2) Install snap ring (22).
8. Bearing
1) Remove snap ring (22).
2) Remove bearing (23).
2. PTO case
1) Install sleeve (30) to case.
a Install the sleeve with the chamfered
inside circumference facing down.
a Expand-fit the sleeve.
2) Using push tool, press fit bearing outer
race (29).
D475A, D475ASD-5E0 25
3) Using push tool, press fit bearing inner 4. Shaft assembly

races (27) and (26) to race (28). 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.
4) Install race assembly (24).

2 Internal surface of race:
Anti-friction compound (LM-P)
5) Using push tool, press fit bearing outer 5. Bearing
race (25). 1) Turn over PTO case, and press fit bearing
a Put drops (approx. 6 cc) of engine oil spacer (31) and bearing inner race (20) to
(SAE10W-CD or SAE30-CD) on the shaft, then tighten mounting bolts of shaft
bearing and rotate about 10 turns. assembly.
bearing, then rotate approx. 10 turns.
3. Idler gear
1) Using push tool [5], press fit bearing outer
race (21) to gear (19).
2) Position idler gear to PTO case.
26 D475A, D475ASD-5E0
2) Install plate (15). 2) Using push tool [8], press fit boss (11) and
2 Mounting bolt: bearing (12) to cover.
Thread tightener (LT-2) a Expand fit the bearing.
3 Mounting bolt: 2 Boss spline portion:
98 – 123 Nm {10 – 12.5 kgm} Grease (G2-LI)
3) Install gear (10).
6. Scavenging drive gear 2 Gear spline portion:
1) Install gear (14). Grease (G2-LI)
2 Spline portion: Grease (G2-LI) 2 Gear mounting bolt:
3 Gear mounting bolt:
98 – 122.6 Nm {10 – 12.5 kgm}
2) Install snap ring (13) from bottom of PTO

case.
7. Power train, PPC pump gear assembly 4) Using push tool [7], press fit bearing (9) to
1) Using push tool [7], press fit bearing (12) gear (10).
to boss (11). 5) Raise cover assembly (8) and install.
a If the cover assembly is stiff and does
not enter the case, use a plastic ham-
mer and tap evenly on the side face
to install.
D475A, D475ASD-5E0 27
8. Hydraulic pump gear assembly 9. Lubrication tube

1) Using push tool [7], press fit bearings (5) Sling PTO assembly, then install lubrication
and (6) to gear (7). tube (1).
a Install 3 lubrication tubes also on the
opposite side.
3 Mounting bolt:
19.6 – 29.4 Nm {2 – 3 kgm}
2) Using push tool [8], press fit gear assem-

bly (3) to cover (4).
a Expand fit the bearing.
a Set the end where the bearing end
face and gear end face are level so
that it faces the cover.
2 Gear spline portion:
Grease (G2-LI)
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 ham-
mer and tap evenly on the side face
to install.
28 D475A, D475ASD-5E0
Removal and installation of

TORQFLOW transmission
assembly
Removal
q Remove PTO and torque converter assembly.
PTO, torque converter assembly".
1. Remove TORQFLOW transmission assembly

(1). [*1]
k Sling the transmission assembly, then
remove the mounting bolts.
a Using a lever block, raise the transmission
horizontally, then remove from the steer-
ing.
4 TORQFLOW transmission assembly:
1,330 kg
Installation
removal.
[*1]
a Using a lever block, sling transmission
assembly (1) horizontally, align with spline
of shaft at steering case end, then install.
D475A, D475ASD-5E0 29
Disassembly and assembly of 3. Transmission case

TORQFLOW transmission 1) Turn over transmission assembly, and
remove plate (10).
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
q Set the transmission assembly on the block.
4. Housing
1. Control valve assembly
1) Remove 17 tie bolts (12).
2) Using eyebolts, remove housing (13).
2) Remove control valve assembly (2)
3) Remove seal ring (14) from housing.
together with seat.
2. Sleeve
1) Remove plug (8).
2) Using eyebolts [1], pull out sleeve (9).
30 D475A, D475ASD-5E0
5. Spring 11. Sleeve, guide pin

Remove spring (15). 1) Remove sleeve (27).
2) Remove guide pin (28).
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.
7. No. 1 ring gear

Remove ring gear (19).
12. Shaft, No. 1, 2, 3 carrier assembly

Using eyebolts, remove No. 1, 2, and 3 carrier
assembly (29).
4 Shaft, No. 1, 2, 3 carrier assembly:
200 kg
1) Disassemble the shaft and carrier assem-
bly as follows.
1] Remove snap ring (130), then
8. No. 1 housing, piston
remove sun gear (30).
1) Using eyebolts, remove No. 1 housing and
2) Remove piston (22) from housing (21).
2] Using eyebolts, remove shaft and No.

1 carrier assembly (31) from No. 2
and 3 carrier assembly (32).
9. Spring
Remove spring (23).

(26) in turn.
D475A, D475ASD-5E0 31
2) Disassemble the shaft and No. 1 carrier 3) Disassemble the No. 2, No.3 carrier
assembly as follows. assembly as follows.
1] Raise the assembly, then using forc- 1] Remove sun gear (48).
ing screw [2], remove shaft and cage 2] Using eyebolts, remove plate and
assembly (33). gear assembly (49).
2] Using plastic hammer, remove cage
assembly (34), spacer (35), and bear-
ing (36).
3] Remove seal ring (37) from cage
assembly.
4] Remove seal ring (38) from cage.
5] Remove seal ring (40) from shaft
(39).
3] Remove ring (50), and disassemble

plate (51) and gear (52).
4] Remove plate (54) from No. 2, 3 car-
rier assembly (53).
5] Remove seal ring (55) from plate.
6] Remove shaft (42), ball (43), thrust

washer (44), gear (45), and bearing
(46) from No. 1 carrier assembly (41).
7] Remove seal rings (47) and (131).

washer (58), gear (59), and bearing
(60).
32 D475A, D475ASD-5E0
7] Using push tool, remove collar and 15. No. 3 piston

bearing assembly (61) from carrier. Remove No. 3 piston (71).
8] Using push tool, remove bearing (62).
16. Spring
Remove spring (72).

(75) in turn.
9] Using puller and push tool, remove

bearing (63) and spacer (64) from col-
lar (65).
10] 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
4 No. 2 housing, piston: 80 kg
2) Remove piston (70) from housing (69).
21. Spring
Remove spring (79).

(82) in turn.
D475A, D475ASD-5E0 33
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.
1] Remove 2 mounting bolts, then install
guide bolts.
2] Remove remaining mounting bolts,
then loosen guide bolts [5] slowly, and
remove No. 4 carrier assembly (96)
from No. 5 clutch assembly (97).
4 No. 4 carrier assembly, No. 5
clutch assembly: 160 kg
34 D475A, D475ASD-5E0
9] Remove piston (112) from No. 5

housing (111).
10] Remove spacer (113) and seal ring
(114) from No. 5 housing.
29. Shaft
Remove shaft (115).

washer (100), gear (101), and bear-
ing (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 fol-
lows.
1] Remove snap ring, then using eye-
bolts, sling shaft assembly, knock out
bearing portion, and remove shaft
4] Remove spring (103) and pin (104). assembly (118).
5] Remove discs (105), plates (106),
and springs (107).
a Keep the discs and plates in a
flat place to prevent them from
becoming deformed.
6] Remove guide pin (108).
7] Remove inner gear (109).
8] Remove seal ring (110) from inner
gear.
D475A, D475ASD-5E0 35
2] Remove cage (119). 9] Remove snap ring (135), then

3] Using stand [6], remove bearing remove boss and bearing (127).
(120). 10] Remove snap ring (136), then using
push tool, remove bearing (129) from
boss (128).
4] Remove snap ring (134), then

remove bearing (121) from cage
(133).
5] Remove seal ring (122). Assembly
6] Remove cover (123). a Wash all parts in clean flushing oil (in particu-
lar, oil holes, etc.), then dry them, and check
for dirt or damage. Coat the sliding surfaces of
all parts with engine oil before installing.
a Set the seal ring facing its pressure receiving
side for the housing, then coat with grease
(G2-LI) and install uniformly so that it is posi-
tioned correctly.
a Align the notches of the oil groove when install-
ing the discs.
7] Remove bearing (124).

8] Remove seal ring (126).
36 D475A, D475ASD-5E0
1. Shaft assembly 8] Using eyebolts, sling shaft assembly

1) Assemble the shaft assembly as follows. (118), then press fit bearing, and
1] Install seal ring (126). secure with snap ring.
2] Using push tool, install baring (124).
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).
3] Install cover (123).

4] Install seal ring (122).
5] Install bearing (121) to cage (133)
and secure with snap ring (134).
2. No. 4 carrier, No. 5 clutch assembly
1) Assemble the No. 4 carrier and No. 5
clutch assembly as follows.
1] Using push tool, install spacer (113)
to No. 5 housing (111).
2] Install seal ring (114).
3] Install piston assembly (112) to No. 5
housing (111).

(120).
7] Fit seal ring and install cage (119).
D475A, D475ASD-5E0 37
4] Install seal ring (110) to inner gear. 11] Set No. 4 carrier assembly (96) to No.
5] Install inner gear (109). 5 clutch assembly (97), and using 2
6] Install guide pin (108). guide bolts [5], compress spring, then
7] Install springs (107), plates (106), and tighten mounting bolts.
discs (105) in turn. a Check that the spring is fitted
8] Install pin (104) and spring (103). securely in the hole of the hous-
a Free length of spring: 103.5 mm ing, then tighten the mounting
bolts.
2 Mounting bolt:
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
9] Assemble bearing (102) in gear

(101), and fit thrust washers (100) to
both sides, then set in position in car-
rier.
10] Assemble ball (99) to shaft (98), and
push shaft into carrier. 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 the correct direction, check the bolt
hole, then knock in the dowel pin por-
tion with a plastic hammer until there
is no clearance at the mating surface.
2) Install ring gear (94).
38 D475A, D475ASD-5E0
4. No. 3 ring gear

1) Install ring gear (92).
2) Install No. 3 ring gear (91).
5. Plate, bearing
1) Using push tool, press fit bearing (90) in
collar (89).
2) Using push tool, press fit bearing (88).
6. Sun gear
Install sun gear (84), and secure with snap ring
(132).
7. Guide pin
Install guide pin (83).
3) Using push tool, press fit bearing (87) in 8. Discs, plates, springs
plate (86). Install springs (82), plates (81), and discs (80)
a Set the large protrusion of the bearing in turn.
assembly on top as shown in the dia-
gram below, and install to the plate. 9. Spring
4) Using eyebolts, install plate and bearing Install spring (79).
assembly (85). a Free length of spring: 81.7 mm
D475A, D475ASD-5E0 39
10. No. 4 piston 17. No. 2 ring gear

Fit seal ring and install No. 4 piston (78). Install ring gear (67).
11. No. 3 housing

Using eyebolts, fit seal ring and install No. 3
housing (77).
12. Seat
Install seat (76).
18. Shaft, No. 1, 2, 3 carrier assembly

1) Assemble the No. 2, No. 3 carrier as fol-
lows.
1] Install seal ring (66) to carrier.
2] Using push tool, press fit spacer (64)
and bearing (63) in collar (65).

Install springs (75), plates (74), and discs (73)
in turn.
14. Spring
Install spring (72).
a Free length of spring: 84 mm
15. No. 3 piston

Fit seal ring and install No. 3 piston (71).

(62).
4] Using push tool, press fit collar and
bearing (61) in carrier.

1) Fit seal ring, and install piston (70) to
housing (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.
40 D475A, D475ASD-5E0
5] Assemble bearing (60) in gear (59), 2) Assemble the shaft and No. 1 carrier
then fit thrust washers (58) to both assembly as follows.
sides, and set in carrier. 1] Install seal rings (47), (131) to carrier.
6] Assemble ball (57) to shaft (56), and 2] Assemble bearing (46) in gear (45),
push shaft into carrier. then fit thrust washers (44) to both
sides, and set in carrier.
3] Assemble ball (43) to shaft (42), and
push shaft into carrier case (41).
7] Install seal ring (55) to plate.

8] Install plate (54) to No. 2, 3 carrier
assembly (53).
9] Set plate (51) to gear (52), and install 4] Install seal ring (40) to shaft (39).
ring (50). 5] Install seal ring (38) to cage.
10] Using eyebolts, install plate and gear 6] Using push tool, press fit bearing (37)
assembly (49). in cage.
11] Install sun gear (48), and secure with 7] Press fit bearing (36) in shaft.
snap ring.
D475A, D475ASD-5E0 41
8] Set spacer (35) to bearing and cage 2] Set carrier assembly on its side, then
assembly (34), and press fit shaft install sun gear (30), and secure with
(39). snap ring (130).
Using eyebolts, install shaft and No.
1, 2, 3 carrier assembly (29) to hous-
ing.
9] Using eyebolts, install shaft and cage

assembly (33).
3) Assemble the shaft and carrier assembly
as follows. 19. Sleeve, guide pin
1] Using eyebolts, install shaft and No. 1 1) Install guide pin (28).
carrier assembly (31) to No. 2, 3 car- 2) Install sleeve (27).
rier assembly (32).
a Align the sun gear with the tooth 20. Discs, plates, springs
face of the planetary gear, and Install springs (26), plates (25), and discs (24)
tap with a plastic hammer to in turn.
install.
21. Spring
42 D475A, D475ASD-5E0
22. No. 1 housing, piston 26. Housing

1) Fit seal ring and install piston (22) to hous- 1) Install seal ring (14) to housing.
ing (21). 2) Using eyebolts, set housing (13) in posi-
2) Using eyebolts, install No. 1 housing and tion.
piston (20). 3) Tighten 17 tie bolts (12) in turn.
a Check that the spring is fitted 3 Tie bolts:
securely in the hole of the housing. 353 – 392 Nm {36 – 40 kgm}
23. No. 1 ring gear 27. Checking piston stroke

Install ring gear (19). Using tool D, check each piston stroke.
a Air pressure: 0.5 – 0.6 MPa {5 – 6 kg/cm2}
24. Discs, plates, springs. Unit: mm
Install springs (18), plates (17), and discs (16)
Piston Standard stroke
in turn.
No. 1 (R) 7.4
25. Spring No. 2 (F) 8.4
No. 3 (3) 4.8
No. 4 (2) 5.0
No. 5 (1) 7.1
D475A, D475ASD-5E0 43
28. Transmission case 2) Using push tool, install bearing (129) to

1) Using eyebolts, install transmission case boss (128), and secure with snap ring
(11). (136).
2) Install plate (10). 3) Install boss and bearing assembly (127) to
output shaft, and secure with snap ring
(135).
a Install the bearing slowly and be care-
ful that shaft (115) is mated with the
lock portion of boss (128).
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 mat- 30. Sleeve
ing boss. 1) Install sleeve (9).
2) Install plug (8).
31. Control valve assembly

1) Install control valve assembly (2) together
with seat.
2) Install cover (1).
44 D475A, D475ASD-5E0
D475A, D475ASD-5E0 45
SEN02015-00

© 2007 KOMATSU
All Rights Reserved
46
SEN02016-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Power train, Part 2

Power train, Part 2 .......................................................................................................................................... 2
Disassembly and assembly of steering case assembly ....................................................................... 2
Disassembly and assembly of steering clutch, brake assembly ........................................................ 14
Disassembly and assembly of transfer gear housing assembly ........................................................ 20
Removal and installation of power train pump assembly ................................................................... 24
Removal and installation of scavenging pump assembly................................................................... 24
Removal and installation of torque converter oil cooler ..................................................................... 25
Removal and installation of torque converter valve assembly ........................................................... 26
Disassembly and assembly of torque converter valve assembly ....................................................... 27
Removal and installation of transmission control valve assembly ..................................................... 31
Disassembly and assembly of transmission control valve assembly (ECMV assembly) ................... 32
Removal and installation of steering control valve assembly ............................................................. 35
Disassembly and assembly of steering control valve assembly ........................................................ 36
Removal and installation of final drive assembly ............................................................................... 38
Disassembly and assembly of final drive assembly ........................................................................... 40
D475A, D475ASD-5E0 1
Disassembly and assembly of 2. Clutch, brake assembly

steering case assembly Using tool E1, sling clutch and brake assembly,
then remove mounting bolts, and remove
clutch and brake assembly (3).
Special tools a Remove the clutch and brake assembly
on the opposite side in the same way.
New/remodel
When pulling out the clutch and brake
Necessity
Symbol
Sketch
assembly, be careful not to damage the
Q'ty
Part No. Part Name
discs and plates.
791-622-1110 Bracket t 1
1 01016-51690 Bolt t 1
E 01011-81600 Bolt t 1
791T-822-1810 Push tool t 1 Q
2
791T-822-1820 Push tool t 1 Q
Disassembly
1. Steering rod bracket
2) Remove tube (2).
3) Remove brake rod bracket (20).
3. Shafts
Remove left and right shafts (4).
4. Lubrication tube
Remove lubrication tubes (5).
4) Remove transmission output shaft speed

sensor (75) and flange (76) together.
2 D475A, D475ASD-5E0
5. Pipes, steering valve 7. Transfer and gear housing assembly

1) Remove left and right pipes (6). 1) Install a guide bolt and tighten forcing
2) Remove pipe (7). screws [1] to remove housing assembly
(10).
3) Remove steering valve assembly (21) with

seat. 2) Disassemble the transfer and gear hous-
ing assembly according to the following
procedure.
1] Set the transfer and gear housing
assembly on the block.
2] Take out lubrication tube (51).
6. Input shaft
1) Remove cage assembly (8).
2) Remove snap ring, and pull out input shaft
(9) from case.
D475A, D475ASD-5E0 3
3] Reverse the transfer and gear hous-

ing assembly and remove lubrication
tube (56).
4] Using eyebolts [11], remove pinion
housing assembly (57).
a Check the quantity and thickness
of the inserted shims and then
keep them.
10] Remove collar (63) from gear (64).

11] Using push tool [13], remove bearing
outer races (65) and (69), bearing
inner races (66) and (67), and collar
(68).
5] Using forcing screws, remove cover

(58).
a Check the quantity and thickness
of the inserted shims and then
keep them.
6] Remove holder (59).
12] Remove the bolts and remove hous-

ing (76) from case (78).
13] Remove drive gear and bearing
assembly (77).
7] Push pinion shaft (60) out of pinion

housing assembly (57) with a press.
8] Remove the holder. Using puller [12],
remove bearing inner race (61) from
pinion shaft (60).
9] Remove cage and bearing assembly
(62).
4 D475A, D475ASD-5E0
14] Remove bearing outer race (79) from 8. Cage

case (78). 1) Turn over so that right cage is at top, then
remove bearing cage (11).
a Check the number and thickness of
the shims, and keep in a safe place.
15] Remove bearing inner races (81) and

(82) from the drive gear.
2) Using eyebolts [2], remove cage (12).
9. Bevel gear, shaft assembly

1) Using eyebolts, remove bevel gear and
shaft assembly (13).
16] Remove bearing outer race (70) from

housing (76).
17] Remove snap ring (83), and then
remove bearing outer race (71) from
housing (76).
2) Disassemble the bevel gear and shaft

assembly as follows.
1] Pull out reamer bolt, and remove
bevel gear (14) from shaft (15).
2] Using puller [3], remove bearings (16)
and (17) from shaft.
D475A, D475ASD-5E0 5
10. Cage 2. Bevel gear, shaft assembly

1) Turn over steering case, and remove 1) Assemble bevel gear and shaft as follows.
bearing cage (18). 1] Using tool E2, press fit bearings (17)
a Check the number and thickness of and (16).
the shims, and keep in a safe place. 2] Set bevel gear (14) to shaft (15), and
2) Remove outer race (19) from bearing tighten reamer bolt.
cage. 3 Reamer bolt:
490 – 607.6 Nm {50 – 62 kgm}
Assembly 2) Using eyebolts, install bevel gear and

a Wash all parts, then dry them, and check for shaft assembly (13).
dirt or damage. Coat the sliding surfaces of all
parts with engine oil before installing. 3. Cage
1) Using eyebolts [2], install cage (12).
1. Cage 3 Mounting bolt:
1) Using push tool, press fit outer race (19). 245 – 308.7 Nm {25 – 31.5 kgm}
2) Assemble shim, and install bearing cage
(18).
3 Mounting bolt:
245 – 308.7 Nm {25 – 31.5 kgm}
6 D475A, D475ASD-5E0
2) Assemble shim, and install bearing cage 3] Using the push tool, press fit bearing
(11). inner races (81) and (82).
3 Mounting bolt:
245 – 308.7 Nm {25 – 31.5 kgm}
4. Adjusting preload
Rotate bevel gear 10 – 20 turns, and fit push-
pull scale [4] to tip of teeth, then measure rotat-
ing torque of bevel gear shaft.
a Measure while the bevel pinion is not
engaged.
a Standard rotating torque:
9.8 – 11.8 Nm {1.0 – 1.2 kgm}
q Rotating force at outside of bevel
gear:
51.0 – 61.8 Nm {5.2 – 6.3 kgm} 4] Using the push tool, press fit bearing
outer race (79) to case (78).
5. Transfer and gear housing assembly

1) Assemble the transfer and gear housing 5] Install drive gear and bearing assem-
assembly according to the following pro- bly (77) to the case.
cedure. 6] Install housing (76), matching it to the
1] Using the push tool, press fit bearing dowel pin, and tighten the bolts.
outer race (71) on the drive gear side 3 Mounting bolt:
and install snap ring (83). 277 ± 32 Nm {28.3 ± 3.2 kgm}
2] Press fit bearing outer race (70) on
the pinion side to housing (76).
D475A, D475ASD-5E0 7
7] Using push tool [18], press fit inner 12] Tighten the mounting bolts of cover
race (61) to pinion shaft (60). (58) temporarily in the following order.
8] Install the holder. 3 Mounting bolt: 49 Nm {5 kgm}
Adhesive (LT-2)
276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
9] Install pinion gear (64) and collar (63)
to the pinion shaft.
13] Loosen the mounting bolts and

tighten them again temporarily in the
above order.
3 Mounting bolt: 49 Nm {5 kgm}
14] Check clearance (A) between the
cover and cage and adjust it to the
10] Using push tool [19], press fit cage following range with the shims.
and bearing assembly (62). a Clearance (A): 0.05 – 0.15 mm
11] Install holder (59). a Check that the dispersion of the
2 Holder mounting bolt: clearance is 0.05 mm or less
Adhesive (LT-2) through the periphery and the
3 Holder mounting bolt: bearing is press fitted perfectly
276.85 ± 31.85 Nm {28.25 ± 3.25 kgm} and is not leaning.
8 D475A, D475ASD-5E0
15] Tighten the mounting bolts of cover 2) Install guide bolt [5] to the steering case
(58) permanently in the following and install housing assembly (10).
order. 3 Mounting bolt:
3 Mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm}
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
6. Adjusting tooth contact, backlash

16] Install the shim to pinion housing 1) Adjusting backlash
assembly (57). Using eyebolts [11], Put the probe of dial gauge [6] in contact
install pinion housing assembly (57). with the tip of the bevel gear teeth at right
a Standard shim thickness: 2 mm angles. Hold the bevel pinion in position,
17] Install lubrication tube (56). and read the measurement when the
bevel gear is moved forward and back-
ward.
a Standard value for backlash:
0.3 – 0.4 mm
a Measure at a minimum of 3 points on
diagonally opposite sides.
18] Install lubrication tube (51) and block

as a unit.
D475A, D475ASD-5E0 9
Adjusting 2) Adjusting tooth contact

If correct backlash pattern is not obtained Testing
from the result of inspection, adjust as fol- 1] Coat the tooth face of the bevel pinion
lows. lightly with red lead (minimum).
1] If backlash is too small: Rotate the bevel gear in both the for-
Adjust the shim thickness at the bevel ward and reverse directions, and
pinion end to move the bevel pinion in inspect the pattern left on the teeth.
direction (A), or adjust the shim thick- 2] The standard tooth contact should be
ness at the bearing cage of the bevel as follows:
gear shaft to move the bevel gear in (from small end of pinion)
direction (B). a) Width of tooth contact: 30 – 50%
b) Center 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
s ame pos it ion when the ge ar is
rotated in forward or reverse.
2] 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 direction (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 bearing. Adjust by moving shims
between the bearing cage and the
bevel pinion. Always keep the same
total thickness of shims.
10 D475A, D475ASD-5E0
Adjusting
If the result of the inspection shows that
the correct tooth contact is not being
obtained, adjust again as follows.
1] 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 the bearing cage of the bevel gear
shaft to move the bevel gear in direc-
tion (B), then check the tooth contact
pattern and backlash again.
2] If bevel pinion is too close to center
line of bevel gear.
Contact is at the big end of the con-
vex 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
7. Transmission output shaft and input shaft
direction from (A) above).
1) Install the speed sensor and flange
Or adjust the thickness of the shims
at the bearing cage of the bevel gear
1] Install flange (76).
shaft to move the bevel gear in direc-
a Remove the speed sensor.
tion (B) (the opposite direction from
2] Looking at transfer gear (85) through
(B) above), then check the tooth con-
the hole of the flange, check that a
tact pattern and backlash again.
tooth of the gear is at the center of the
a When adjusting the movement in or
hole.
out of the bevel gear, do not change
a If a tooth is not seen, turn the
the preload of the bearing. Adjust by
transfer gear to bring a tooth to
moving shims between the bearing
the center of the hole.
cage and the bevel pinion. Always
3] Remove locknut (84) from speed sen-
keep the same total thickness of
sor (75). Apply gasket sealant to the
shims.
threaded portion of speed sensor (75)
and install speed sensor (75) to
flange (76).
a Tighten the speed sensor until its
tip touches the transfer gear, and
then return it by 1/2 – 1 turn.
2 Threaded portion of speed
sensor: Gasket sealant (LG-6)
D475A, D475ASD-5E0 11
4] Remove the speed sensor and flange 8. Steering valve and pipe
as a unit and tighten locknut (84). 1) Install steering valve assembly (21) and
a Take care that the speed sensor seat as unit.
will not turn when the locknut is
tightened.
2 Threaded portion of locknut
and its contact surface against
flange: Gasket sealant (LG-6)
3 Locknut:
49 – 68.6 Nm {5 – 7 kgm}
5] Install speed sensor (75) and flange
(76) as a unit.
2 Flange mounting bolt hole and
flange mounting surface:
6] After installing the speed sensor,
rotate the transfer gear slowly and
check that the speed sensor does not 2) Install pipe (7).
interfere with the gear. 3) Install left and right pipes (6).
a Coat the O-rings thinly with grease (G2-
LI), and be careful not to damage them
when installing.
2) Install input shaft (9) to the case and fix it

with the snap ring.
3) Install cage assembly (8).
9. Lubrication tube
Install lubrication tubes (5).
10. Clutch, brake assembly

Using tool E1, install clutch and brake assem-
bly (3).
3 Mounting bolt:
279 ± 30 Nm {28.5 ± 3 kgm}
12 D475A, D475ASD-5E0
11. Shafts
Install left and right shafts (4).
a If it is difficult to insert the shafts with the
bevel 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.
12. Steering rod, bracket

1) Install brake rod bracket (20).
2) Install tube (2).
3) Install cover (1).
D475A, D475ASD-5E0 13
Disassembly and assembly of 3. Clutch, brake assembly

steering clutch, brake assembly Turn over clutch and brake assemblies, and
using eyebolts [3], disconnect clutch 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
Disassembly
Disconnection of clutch, brake assembly

1. Collar
Remove plate (1), then remove collar (2).
2. Sleeve Disassembly of clutch assembly

1) Remove plate (3). 1. Stopper
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.
14 D475A, D475ASD-5E0
3. Torque pin 7. Spacer

Remove torque pin (12). Remove spacer (22).
4. Clutch hub 8. Clutch cage, piston

Using eyebolts, remove clutch hub (13). 1) Using eyebolts, remove clutch cage (23).
2) Remove piston (24).
5. Plate
1) Using forcing screws [4], remove flange
(14).
3) Remove outer race (25) from clutch cage.
9. Belleville springs
2) Remove outer race (15) from flange. Remove Belleville springs (26).
6. Bearing cage
1) Remove bearing cage assembly (16).
10. Brake hub

1) Using eyebolts [5], remove brake hub
(27).
2) Remove plate (18) and nut (19), then 2) Remove bearing (28) from brake hub.
remove bearings (20) and (21) from cage
(17).
D475A, D475ASD-5E0 15
Disassembly of brake assembly 4. Torque pin

1. Stopper Remove torque pin (36).
Remove stopper (29).
5. Piston
2. Discs, plates, springs Remove piston (37) and seal ring (38).
Remove discs (30), springs (31), and plates
(32) in turn.
Remove Belleville springs (39).
3. Brake cage
1) Using eyebolts [6], remove brake cage
(33).
2) Remove outer race (34) and seal ring (35)
from brake cage.
16 D475A, D475ASD-5E0
Assembly 4. Brake cage

1) Using push tool, install outer race (34) to
Assembly of brake assembly brake cage.
1. Belleville springs 2) Install seal ring (35).
Install Belleville springs (39). 3) Using eyebolts [6], install brake cage (33).
3 Mounting bolt:
a Fit the Belleville springs back to back
when installing. 245 – 308.7 Nm {25 – 31.5 kgm}
2. Piston 5. Discs, plates, springs

Fit seal ring (38) and install piston (37). Install plates (32), springs (31), and discs (30)
in turn.
3. Torque pin a Check the mating surfaces of the discs
Install torque pin (36). and plates for dirt or damage, and coat
them thinly with engine oil before assem-
bling.
6. Stopper
Install stopper (29).
3 Mounting bolt:
245 – 308.7 Nm {35 – 31.5 kgm}
D475A, D475ASD-5E0 17
Assembly of clutch assembly 2) Install piston (24).

1. Brake hub 3) Using eyebolts, fit seal ring and install
1) Using push tool, press fit bearing (28) in clutch cage (23) to housing.
brake hub. 4. Spacer
2) Using eyebolts [5], install brake hub (27) Install spacer (22).
to clutch housing.
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
hook wrench (tool E3), tighten the
nut.
3 Nut:
490 – 607.6 Nm {50 – 62 kgm}
Install Belleville springs (26).
a Fit the Belleville springs back to back
when installing.
3. Clutch cage, piston

1) Install outer race (25) to clutch cage.
2) Install bearing cage (16).
6. Plate
1) Using push tool, press fit outer race (15) to
flange.
18 D475A, D475ASD-5E0
2) Install flange (14).

3 Mounting bolt:
245 – 308.7 Nm {25 – 31.5 kgm}
7. Clutch hub
Set guide bolts to housing, and using eyebolts,
install clutch hub (13).
8. Torque pin
Install torque pin (12).
2) Set sleeve (4) to clutch and brake assem-

blies.

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 thinly with engine oil before assem-
bling.
3) Install plate (3).
3 Mounting bolt:
10. Stopper
Install stopper (8). 112 ± 9.8 Nm {11.5 ± 1.0 kgm}
3 Mounting bolt:
245 – 308.7 Nm {25 – 31.5 kgm} 3. Collar
Fit collar (2) and install plate (1).
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.
D475A, D475ASD-5E0 19
Disassembly and assembly of 4. Pinion housing

transfer gear housing assembly 1) Remove lubrication tube (7).
2) Using eyebolts [2], remove pinion housing
assembly (8).
Disassembly a Check the number and thickness of
a Set the transfer gear housing assembly on a the slims, and keep in a safe place.
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.
20 D475A, D475ASD-5E0
5) Remove cage, bearing assembly (13). Assembly

6) Remove collar (14) from transfer gear 1. Pinion assembly
(15). 1) Using push tool, press fit outer race (20) in
bearing cage.
2) Assemble collar (19), bearing inner races
(17) and (18).
3) Using push tool, press fit bearing outer
race (16).
7) Using push tool [4], remove outer race

(16), bearings (17) and (18), collar (19),
and outer race (20).
4) Using push tool [5], press fit inner race

(12) in pinion gear (11), and install holder.
245 – 308.7 Nm {25 – 31.5 kgm}
5) Install transfer gear (15) and collar (14) to
pinion gear.
D475A, D475ASD-5E0 21
6) Using push tool [6], press fit cage, bearing 2. Pinion housing
assembly (13). 1) Assemble shim, and using eyebolts [2],
7) Install holder (10). install pinion housing assembly (8).
3 Holder mounting bolt: a Standard shim thickness: 2 mm
245 – 308.7 Nm {25 – 31.5 kgm} 2) Install lubrication tube (7).
8) Install cover (9) as follows. 3. Transfer gear

q Tighten cover mounting bolts tempo- 1) Using push tool [7], press fit inner races
rarily in the order shown in diagram (6) on both sides.
below. (Approx. 49 Nm {5 kgm}) 2) Set transfer gear (5) in case.
q Check clearance (A) between cover
and cage, and check that it is as fol-
lows.
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
completely press fitted and is not at
an angle.
q After checking the above, tighten the
mounting bolts of cover (9) in the
order shown in the diagram below.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
22 D475A, D475ASD-5E0
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) Install bearing cage assembly (2) to case.
3 Mounting bolt:
245 – 308.7 Nm {25 – 31.5 kgm}
5. Lubrication tube
Install lubrication tube (1) together with block.
D475A, D475ASD-5E0 23
Removal and installation of power Removal and installation of

train pump assembly scavenging pump assembly
Removal Removal
1. Remove oil strainer inspection cover at front 1. Open undercover. (3rd from front of machine).
left of operator’s platform.
2. Disconnect inlet tube (1).
2. Open undercover. (3rd from front of machine). a Oil will leak out from inside the piping, so
prepare a container to catch the oil.
3. Remove oil strainer (1).
a Disconnect coupling (2) and remove 3. Disconnect outlet tube (2).
strainer mounting bolts.
4. Remove scavenging pump assembly (3).
4. Disconnect hose (3). 4 Scavenging pump assembly: 25 kg
5. Lift off power train pump assembly (4).

4 Power train pump assembly: 64 kg
Installation
removal.
Installation
q Carry out installation in the reverse order to q Refilling with oil (power train case)
removal. Add oil through the oil filler to the specified
again.
24 D475A, D475ASD-5E0
Removal and installation of 7. Sling torque converter oil cooler assembly (8),
torque converter oil cooler then lower assembly to remove.
4 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).
5. Remove oil inlet tube (5) and outlet tube (6).
6. Disconnect aeration hose (7).
D475A, D475ASD-5E0 25
Removal and installation of 7. Remove hose clamp (6).

torque converter valve assembly
8. Remove torque converter valve assembly (7).
[*2]
4
Removal Torque converter valve assembly:
1. Remove operator’s cab assembly. 33 kg
operator’s cab assembly".
2. Remove operator’s seat and floor frame cover.

a Use turnbuckle (1) when disconnecting
the brake rod. Check the mounting dimen-
sions of the rod before disconnecting. [*1]
Installation
removal.
[*1]
a Adjust the brake pedal linkage.
3. Disconnect connector of solenoid valve (2).
For details, see Testing and adjusting,
Adjusting brake pedal and parking brake
4. Disconnect hose clamp (3).
lever.
3 Turnbuckle locknut:
5. Disconnect central pressure detection hose
34.3 – 58.8 Nm {3.5 – 6 kgm}
(4).
a Before removing the pressure detection
[*2]
3
hoses, mark them with tags to prevent any
Torque converter valve assembly
mistake in the mounting position when
mounting bolt:
installing.
43.1 – 53.9 Nm {4.4 – 5.5 kgm}
6. Disconnect hose (5).
26 D475A, D475ASD-5E0
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). ring 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

solenoid valve (14) and install.
D475A, D475ASD-5E0 27
28 D475A, D475ASD-5E0
Disassembly of torque converter relief

valve, main relief valve, stator clutch modu-
lating 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).
2) Remove cover (24), then remove valve
(21), spring (22), and valve (23).
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, D475ASD-5E0 29
Assembly of lock-up modulating valve, sta-

tor clutch modulating valve, main relief
valve and torque converter relief valve
a Clean all parts, and check for dirt or damage.

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

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

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 D475A, D475ASD-5E0
Removal and installation of 5. Disconnect wiring harness connector (4). (8

transmission control valve places)
assembly 6. Disconnect central pressure detection hose
(5). (4 places)
Removal a Before removing the pressure detection
1. Remove operator’s cab assembly. hoses, mark them with tags to prevent any
For details, see "Removal of operator’s cab mistake in the mounting position when
assembly". installing.
2. Remove operator’s seat and floor frame cover. 7. Remove transmission control valve assembly
a Use turnbuckle (1) when disconnecting (6). (4 places)
the brake rod. Check the mounting dimen-
sions of the rod before disconnecting. [*1]
Installation
3. Disconnect hose clamp (2). q Carry out installation in the reverse order to
removal.
4. Remove valve cover (3).
[*1]
a Adjust the brake pedal linkage.
Adjusting brake pedal and parking brake
lever.
3 Turnbuckle locknut:
34.3 – 58.8 Nm {3.5 – 6 kgm}
D475A, D475ASD-5E0 31
Disassembly and assembly of transmission control valve assembly

(ECMV assembly)
Disassembly of ECMV assembly 2. Pressure control valve

q 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.
q 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
1) Remove bracket (20) and switch assem- it moves smoothly.
bly (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
3) Remove sleeve (18), spring (17), and pin (10).
(16).
32 D475A, D475ASD-5E0
Assembly of ECMV assembly a Install the shim securely and do not drop it
a If the pressure control valve was disassembled in the valve.
or any part of it was replaced, be sure to check a After adjusting the shim, test the oil pres-
the oil pressure. sure again.
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with
engine oil before installing.

1) Install shims (9) and (10) and spring (8) to
spool (7), and then install the spool to
body (1).
q Standard number of shims: 3
q Standard shim thickness: 1.5 mm
(Thickness of 1 shim: 0.2 mm, 0.5
mm)
a Check that the spool moves smoothly.
2) Put ball (4) in valve (3), fit O-ring (5), and
install them.
3) Fit O-ring (6) to the solenoid and install
them to body (1).
a When reusing all of valve body (1),
spring (8), spool (7), solenoid (2), and
valve (3), install the standard number
of the shims.
a When replacing solenoid valve (2),
check that spring (8) is installed
securely.
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).
3. Testing ECMV oil pressure

Check the ECMV oil pressure. For details, see
Testing and adjusting, Testing ECMV oil pres-
sure.
4. Adjusting ECMV oil pressure

As a result of testing, if the oil pressure is out
of the standard range, adjust it with shims (9)
and (10).
Quantity of adjustment
0.06 MPa
per shim (0.5 mm thick)
{Approx. 0.65 kg/cm2}
714-23-15580
0.025 MPa
714-28-15590
a If the shim is increased, the oil pressure is

heightened. If the former is decreased, the
latter is lowered.
D475A, D475ASD-5E0 33
Disassembly of priority valve Assembly of priority valve

q 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 assem-
bly, clean around it so that dirt will not 2. Fit the O-ring to plug (10) and install them to
enter the transmission assembly. body (1).
q Keep the removed parts so that they will not be 3 Plug: 58.8 – 78.4 Nm {6 – 8 kgm}
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
a Check the quantity of shim (4). plug (8) and install them to body (1).
3 Plug: 58.8 – 78.4 Nm {6 – 8 kgm}
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 pres-
sure again.
34 D475A, D475ASD-5E0

steering control valve assembly
Removal
1. Remove fuel tank assembly.
For details, see Removal and installation 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).
Installation
removal.
D475A, D475ASD-5E0 35
Disassembly and assembly of steering control valve assembly
Disassembly of ECMV assembly 2. Pressure control valve

q 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.
q 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
1) Remove bracket (25), switch assembly it moves smoothly.
(17), and cover (28) from valve body (1). 4) Remove spring (13) and shims (14) and
2) Remove springs (18) and (19) and spring (15) from spool (7). Then, remove ring
seat (20). (12), sleeve (10), spring (9), and poppet
3) Remove sleeve (23), spring (22), and pin (8).
(21). a Check the quantity of shims (14) and
(15).
36 D475A, D475ASD-5E0
Assembly of ECMV assembly a If the shim is increased, the oil pressure is

a If the pressure control valve was disassembled heightened. If the former is decreased, the
or any part of it was replaced, be sure to check latter is lowered.
the oil pressure. a Install the shim securely and do not drop it
a Clean the all parts and check them for dirt or in the valve.
damage. Coat their sliding surfaces with a After adjusting the shim, test the oil pres-
engine oil before installing. sure again.

1) Install poppet (8), spring (9), O-ring (11),
sleeve (10), and ring (12) to spool (7).
2) Install shims (14) and (15) and spring (13)
to spool (7), and then install the spool to
body (1).
q Standard number of shims: 3
q Standard shim thickness: 1.5 mm
(Thickness of 1 shim: 0.2 mm, 0.5
mm)
a Check that the spool moves smoothly.
3) Fit the O-ring to valve (3), install the ball,
fit the O-ring to the solenoid, and install
them to body (1).
a When reusing all of valve body (1),
spring (13), spool (7), solenoid (2),
valve (3), sleeve (10), and spring (9),
install the standard number of the
shims.
a When replacing solenoid valve (2),
check that spring (13) is installed
securely.
2. Flow control valve

1) Install sleeve (23), spring (22), and pin
(21) to body (1).
2) Install springs (19) and (18) to spring seat
(20) and put them in cover (28). Fit O-
rings (26) and (27) and install switch
assembly (17) and bracket (25) with bolts
(24).
3. Testing ECMV oil pressure

Check the ECMV oil pressure. For details, see
Testing and adjusting, Testing ECMV oil pres-
sure.
4. Adjusting ECMV oil pressure

As a result of testing, if the oil pressure is out
of the standard range, adjust it with shims (14)
and (15).
0.06 MPa
714-23-15580
0.025 MPa
714-23-15590
D475A, D475ASD-5E0 37
Removal and installation of final 4. Remove cover (3), then using forcing screw,
drive assembly pull out drive shaft (4). [*1]
a If the shaft will not come out, set a jack on
the ground and push the shoe grouser up,
Special tools then move the sprocket to the front or rear
to a position where the shaft will come out,
New/remodel
and remove the shaft.
Necessity
Symbol
Sketch
a Pull the shaft out to a position where it
Q'ty
Part No. Part Name
contacts the sprocket.

J 1 791-827-1910 Plate t 1
01011-83015 Bolt t 3
Removal
1. Remove track shoe assembly.
For details, see "Expansion and installation of
track shoe assembly".
2. Raise chassis with jack or ripper and set stand

[1] under frame.
3. Remove covers (1) and (2). 5. Remove 3 bolts of final drive and install tool J1.
6. Sling final drive assembly (5), then remove

mounting bolts, and lift off. [*2]
4 Final drive assembly: 3,600 kg
38 D475A, D475ASD-5E0
Installation
removal.
[*1]
a If the shaft will not go in, set a jack on the
ground and push the shoe grouser up,
then move the sprocket to the front or rear
to a position where the shaft will go in, and
install the shaft.
[*2]
2 Final drive assembly mounting bolt:
3 Final drive assembly mounting bolt:
1,960 – 2,450 Nm (200 – 250 kgm)
q Refilling with oil (final drive case)

level.
5 Final drive case: 71 l (GO140)
D475A, D475ASD-5E0 39
Disassembly and assembly of Disassembly

final drive assembly 1. Draining oil
Remove drain plug and drain oil from final
drive case.
Special tools
6 Final drive case: Approx. 71 l
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name 2. Sprocket
1) Set final drive assembly to block (height:
approx. 50 mm).
790-431-1081 Guide t 1 2) Remove sprocket (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
(294 kN {30 ton})
790-101-1102 Pump t 1 3. Cover
t 1 Using eyebolts [1], remove cover (2).
J 4 791-585-1510 Installer
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
Remover &
790-431-1230 t 1
installer
7 Puller
790-101-2102 t 1
(294 kN {30 ton})
4. Hub
790-101-1102 Pump t 1 1) Remove plate (3).
8 790-431-1240 Guide t 1 2) Using eyebolts [2], lift off hub (4).
40 D475A, D475ASD-5E0
5. Sprocket hub assembly 4) Remove bearing inner race (8) from

1) Remove holder (5). sprocket hub assembly.
a Check the number and thickness of
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
3) Using eyebolts [3], remove sprocket hub seal 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).
D475A, D475ASD-5E0 41
2) Disassemble cover assembly as follows. 2) Disassemble carrier assembly as follows.

1] Remove floating seal cover (15). 1] Set carrier assembly on block (height:
2] Remove floating seal (16) from float- approx. 100mm).
ing seal cover. 2] Remove holder (21).
a Keep the floating seal in a safe 3] Using tool J7, remove planetary gear
place to protect it from damage. shaft (22).
3] Remove spacer (17) and bearing 4] Remove planet gear (23), bearing
inner race (18). inner races (24A) and (24B), and
spacer (24C).
4] Remove plate, then remove ring gear

(19). 5] Remove bearing outer race (24D).
8. Carrier assembly
1) Using eyebolts [5], remove carrier assem-
bly (20).
42 D475A, D475ASD-5E0
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 fol-

4) Remove holder (51) from sun gear shaft lows.
assembly, and pull out sun gear (52) 1] Remove gear (32) from hub (33).
2] 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.
1] Remove collar (36).
2] Remove bearing inner race (37) and
collar (38).
D475A, D475ASD-5E0 43
11. Cage assembly 13. Outer race, oil seals

1) Using eyebolts [7], remove cage assembly 1) Using puller [10], remove bearing outer
(39). race (48).
2) Remove shims (40). 2) Remove oil seals (49) and (50) from
a Check the number and thickness of cover.
3) Disassemble cage assembly as follows. Assembly

1] Using puller [8], remove bearing outer a Clean all parts, and check for dirt or damage.
race (41). Coat the sliding surfaces of all parts with
2] Remove oil seals (42) and (43). engine oil before installing.
1. Hub, shaft assembly

1) Assemble shaft assembly as follows.
1] Install collar (38).
2] Using push tool [17], press fit bearing
inner race (37).
3] 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).
44 D475A, D475ASD-5E0
2) Using eyebolts [6], install shaft assembly 5) Install plate (28).

(31) to case. 2 Mounting bolt:
3) Assemble hub assembly as follows. Thread tightener (LT-2)
1] Using push tool, press fit bearing 3 Mounting bolt:
outer races (34A) and (34B) to hub 490 – 608 Nm{50 – 62 kgm}
(33).
2. Carrier assembly
2] Set gear (32) to hub (33). 1) Assemble carrier assembly as follows.
2 Mounting bolt: a The planetary gear bearing forms a
Thread tightener (LT-2) set, so align the mating marks on the
3 Mounting bolt: inner race, outer race, and spacer
823 – 1,029 Nm {84 – 105 kgm} when assembling.
4) Set shaft assembly (31) and hub assem-
bly (29) in position, then using tool J6,
press fit bearing (30) portion.
1] Install ring and spacer to planet gear,

then using push tool [18], press fit top
and bottom bear ing outer races
(24D).
D475A, D475ASD-5E0 45
2] Assemble spacer (24C) and bearing 3. Sun gear

inner races (24B) and (24A) to planet 1) Press fit sun gear (52) to sun gear shaft,
gear (23), then set to carrier. and install holder (51).
a Set so that the protruding part at 2 Holder mounting bolt:
the end face of the planet gear Thread tightener (LT-2)
faces the outside of the machine. 2) Assemble sun gear shaft assembly (27) to
carrier (53), then install holder (26) and
spacer (25).
3] 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. 4. Carrier, sun gear assembly
4] Install holder (21). Using eyebolts [5], install carrier and sun gear
2 Mounting bolt: assembly (20).
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
a After tightening the bolts, check
that the gear rotates smoothly.
46 D475A, D475ASD-5E0
5. Cover assembly
1) Assemble cover assembly as follows.
1] Using push tools [11] and [12], install
oil seals (50) and (49).
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.
6] Using tool J4, press fit floating seal
(16) to floating seal cover.
a Remove all oil and grease from
the O-ring and O-ring contact
surface, and dry before installing.
a After installing the floating seal,
check that the angle of the seal is
less than 1 mm.

outer race (48) to cover.
7] Install floating seal cover (15).

a Fit a cork plug in the forcing tap.
3] Fit ring gear (19) and install plate.

a Fit so that the notched part of the
end face of the gear faces the
inside of the machine.
4] Install spacer (54), then using tool J3,
press fit bearing inner race (18).
5] Install spacer (17).
D475A, D475ASD-5E0 47
a Install so that the cut-out portion 7. Sprocket hub assembly

of the floating seal cover is facing 1) Using tool J4, install floating seal (12) to
the bottom as shown in the dia- floating seal cover.
gram below. a Remove all oil and grease from the
O-ring and O-ring contact surface,
and dry before installing.
a After installing the floating seal, check
that the angle of the seal is less than
1 mm.
2) Using eyebolts, raise cover assembly (14)

and install.
2 Case mating surface:
Gasket sealant (Three Bond 1216)
a Check that there are no dents, rust,
oil, grease, or water on the mating 2) Using push tool, press fit bearing outer
surface of the case and cover. races (11) and (10).
a Coat the whole circumference of the 3) Install floating seal cover (9).
mating surface of the case (one side)
with gasket sealant without any
break.
a Install the cover assembly within 20
minutes after coating with gasket
sealant.
3 Mounting bolt:
1,715 – 1,911 Nm {175 – 195 kgm}
6. Wear guard
1) Raise wear guard (13) and install.
2) Install wear guard plate (13a).
3 Mounting bolt:
823 – 1,029 Nm {84 – 105 kgm}
4) Set bearing (8) to sprocket hub assembly.
48 D475A, D475ASD-5E0
5) Using eyebolts [3], sling sprocket hub

assembly (6) and set to cover.
a Check that there is no dirt on the slid-
ing surface of the floating seal, then
coat thinly with engine oil.
8. Hub
1) Using eyebolts [2], raise hub (4) and
install.
2) Install plate (3).
2 Mounting bolt:
6) Using tool J3, press fit bearing (7) portion. Thread tightener (LT-2)
a Rotate the sprocket hub assembly 3 Mounting bolt:
when press fitting. 245 – 309 Nm {25 – 31.5 kgm}
7) Install holder (5). 9. Cover

a Tighten 6 mounting bolts temporarily Using eyebolts [1], install cover (2).
at equal distances around the circum-
ference, then adjust with shims so
that clearance (X) between cover (14)
and holder (5) is within the standard
value.
Clearance (X): 0.1 – 0.3 mm
3 Mounting bolt (temporary tight-
ening):
Approx. 74 Nm {7.5 kgm}
2 Mounting bolt:
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
D475A, D475ASD-5E0 49
10. Sprocket 12. Cage assembly

Install sprocket (1). 1) Assemble cage assembly as follows.
3 Mounting bolt: 1] Using push tools [11] and [12], install
2,500 – 2,794 Nm {255 – 285 kgm} 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 pres-
sure at the top.
a Coat the inside surface of the
case thinly with gasket sealant
and wipe off any sealant that is
forced out.
11. Gear assembly

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.

outer race (41).
50 D475A, D475ASD-5E0
2) Using eyebolt [7], set cage assembly (39)

to case, and remove tool J8.
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, 13. Refilling with oil
then tighten mounting bolts of cage (A) Tighten drain plug and add engine oil through
uniformly. the oil filler to the specified level.
3 Mounting bolts:
5 Final drive case:
319 – 608 Nm {32.5 – 62 kgm}
Approx. 71 l (GO140)
D475A, D475ASD-5E0 51
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
52 D475A, D475ASD-5E0
D475A, D475ASD-5E0 53
SEN02016-00

© 2007 KOMATSU
All Rights Reserved
54
SEN02017-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Undercarriage and frame, Part 1

Undercarriage and frame, Part 1 .................................................................................................................... 2
Removal and installation of track frame assembly ............................................................................... 2
Disassembly and assembly of idler assembly...................................................................................... 4
Removal and installation of recoil spring assembly ............................................................................. 7
Disassembly and assembly of recoil spring assembly ........................................................................11
Removal and installation of track roller assembly .............................................................................. 13
Disassembly and assembly of track roller assembly.......................................................................... 15
Removal and installation of carrier roller assembly............................................................................ 17
Disassembly and assembly of carrier roller assembly ....................................................................... 18
Removal and installation of bogie assembly ...................................................................................... 21
Disassembly and assembly of bogie assembly.................................................................................. 25
Removal and installation of No.1 bogie assembly ............................................................................. 27
D475A, D475ASD-5E0 1
Undercarriage and frame, Part 1 1
Removal and installation of track 7. Using eyebolts [3], pull out pin (3). [*1]
frame assembly 1
a It is difficult to remove the pin if the centers
of the equalizer bar hole and track frame
hole are not aligned, so adjust the height
Removal of the track frame before removing.
1. Remove track shoe assembly.
For details, see "Expansion and installation of
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).
2 D475A, D475ASD-5E0
12. Lift off track frame assembly (10). [*3] Installation

a Oil will flow out from the pivot case, so q Carry out installation in the reverse order to
catch it in an oil container. removal.
6 Pivot case: 26 l
[*1]
4 Track frame assembly: 11,180 kg 2 Inside surface of bushing:
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
outside of the machine.
[*2]
a After removing the grease from the press-
fitting 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
twisting.
q Refilling with oil (pivot case)

Add oil through oil filler to the specified level.
5 Pivot case: 26 l (SAE30)
D475A, D475ASD-5E0 3
Disassembly and assembly of 6. Using puller [4], remove seal guide (6) and
idler assembly retainer (7) and plate (8).
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 Nut t 2
7. Remove seal guides (2) and (6) from retainers
01643-31645 Washer t 2 (3) and (7).
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
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
screws [2], remove seal guide (2) together with protect 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
protect it from damage.
4. Turn over idler assembly.
5. Remove mounting bolts, then using eyebolts

[3], remove shaft (5) together with retainer.
4 D475A, D475ASD-5E0
10. Remove bushings (11) from idler (12). 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.
Assembly
1. Set bushing (11) and tool L1 to idler (12), and
press fit bushing (11).
a First, center the bushing with a plastic
hammer, then press fit with a puller. 4. Using eyebolts [3], set idler (12) to shaft (5).
a Press fit so that press-fitting dimension (a) a Set block (height: approx. 200 mm) under
from the end face of the idler to the top the idler.
surface of the bushing is the dimension
given below. 5. Turn over idler assembly.
q Press-fitting dimension (a): 17 ± 0.5 a Tie with wire to prevent the shaft from fall-
mm ing out.
6. Fit O-ring and install retainer (7) and plate (8)

to idler.
D475A, D475ASD-5E0 5
7. Using tool L2, install floating seal (9) to seal 9. Using tool L4, fill with oil to specified level, then
guides (2) and (6). tighten oil filler plug.
5 Idler: 1.4 – 1.5 l (GO140)
3 Oil filler plug:
156.8 – 254.8 Nm {16 – 26 kgm}
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}
a Press fit the seal guide so that press-fitting

dimension (a) from the end face of the
shaft to the top surface of the seal guide is
the dimension given below.
q Press-fitting dimension (a):
124.5 ± 0.2 mm
a Turn over the idler assembly and repeat
the same procedure to press fit the seal
guide (6) on the opposite side.
6 D475A, D475ASD-5E0
Removal and installation of recoil 5. Lift off trunnion (3).

spring assembly 4 Trunnion: 140 kg
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

Puller
M 1 790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
Removal 6. Remove covers (4).

1. Remove track shoe assembly. a Remove both the inside and outside cov-
For details, see "Expansion and installation of ers.
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
7. Using tool M1, remove pins (5). [*1]

a Remove both the inside and outside pins.
D475A, D475ASD-5E0 7
8. Lift off idler and recoil spring assembly (6). [*2] 2) Loosen idler yoke mounting bolts (9) grad-
a Using a lever block, keep the assembly ually in turn on diagonally opposite sides.
horizontal, and be careful not to damage [*4]
the oil seal at the track frame end.
4 Idler, recoil spring assembly: 3,500 kg
k To prevent danger, never stand in front

of the idler yoke assembly or behind
9. Disconnect recoil cylinder assembly (7) from the recoil cylinder assembly.
idler yoke assembly (8) as follows. [*3] k The recoil spring inside the recoil cylin-
1) Put idler yoke assembly (8) in contact with der is applying a pushing force of
ground, then raise recoil cylinder assem- approx. 788 kN {approx. 81 tons} on the
bly (7). idler yoke, so be careful not to loosen
a When doing this, check that there is the mounting bolts suddenly. Loosen
no damage to the weld of recoil cylin- the mounting bolts gradually until
der assembly (7). clearance (a) between the flange of the
a Wrap cloth around the chrome plated recoil cylinder and idler yoke is 8 – 12
bushing to protect it. mm.
3) When the bolts are loosened, the torque

will suddenly drop. Check that the
installed load of the recoil spring is not
applying any pushing force on the mount-
ing bolts, then remove all bolts.
a If the torque increases (the installed
load of the recoil spring is applied)
during the loosening operation, stop
the loosening operation and disas-
semble as follows.
8 D475A, D475ASD-5E0
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 dam-
age 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.
k When disconnecting the idler yoke

assembly and recoil cylinder assembly,
do not stand in front of the idler yoke
assembly or behind the recoil cylinder
assembly until safety has been con-
firmed and the recoil spring assembly
has been removed.
1] Prepare the following parts.
q Bolt [1] (x 6): 791-730-1120
q Nut [2] (x 6): 01580-13326
q Washer [3] (x 6):
01643-33380 (use again)
2] 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 con-
tact the bottom of the yoke (Y)
thread.
10. Remove ring (12).
3] Remove remaining 12 bolts (those
not marked ).
4] Hold bolts [1] with a wrench to pre-
vent 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.
5] When recoil spring is fully extended
and torque has completely dropped in
loosening direction of nut [2], remove
bolt [1].
a When clearance (b) is approx.
280 mm, the spring is fully
extended.
D475A, D475ASD-5E0 9
11. Pump in grease through lubricator (13), and 14. Remove holder (20) from recoil spring assem-
remove cylinder (14) and piston assembly (15). bly.
[*5]
12. Disassemble piston assembly (15) as follows. Installation

1) Remove wear ring (16) from piston. q Carry out installation in the reverse order to
2) Remove snap ring (17), then remove removal.
packing (18).
[*1]
a Before installing the pin, align the center
of the hole in the track frame and the
dowel pin at the recoil cylinder end with a
bar.
[*2]
a Using a lever block, keep horizontal and
be careful not to damage the oil seal at the
track frame end when installing.
a Adjust the clearance.
Adjusting clearance of idler.
13. Remove recoil spring assembly (19). [*3]

4 Recoil spring assembly: 780 kg a If the recoil spring set bolt is broken or the
nut at the tip of the shaft has fallen off, see
Assembly of recoil spring assembly when
assembling.
[*4]
2 Idler yoke assembly mounting bolt:
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.
1] Fill the inside of the cylinder with
approx. 2.0 l of grease.
2] Set with the cylinder drain hole facing
up, then loosen the lubricator.
3] Push the piston until it contacts the
stopper. This will push out the air and
any extra grease.
10 D475A, D475ASD-5E0
Disassembly and assembly of 2. Apply hydraulic pressure slowly to compress

recoil spring assembly spring, then remove lock plate (2) and remove
nut (3).
Special tools 3. Release hydraulic pressure gradually and

relieve tension of spring.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
791-685-8502 Compressor t 1
791-635-3160 Extension t 1
790-201-2790 Spacer t 1
M 2
Cylinder (980 kN
790-101-1300 t 1
{100 ton})
790-101-1102 Pump t 1
Disassembly
1. Remove recoil spring assembly (1) with tool
4. Remove rear pilot (5), spacer (6), bolt (7), and
M2.
k The spring is under high installed load,
front pilot (8) from spring (4).
so be careful to set it correctly.
a Installed load of spring:
Approx. 788 kN {approx. 81 ton}
D475A, D475ASD-5E0 11
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.
2. Apply hydraulic pressure slowly to compress

spring, and set so that installed length of spring
is specified value.
a Installed length (a) of spring: 1,461 mm
a Installed load of spring:
Approx. 788 kN {approx. 81 ton}
3. Fit nut (3), then install lock plate (2).

a When securing the recoil spring mounting
nut, make a clearance (b) of 0 – 1 mm
between lock plate (2) and nut (3), then
bring lock plate (2) and bolt (7) into tight
contact, and secure in position.
2 Lock plate mounting bolt:
4. Gradually release hydraulic pressure to com-

pletely release tension of spring, then remove
recoil spring assembly (1) from tool M2.
12 D475A, D475ASD-5E0
Removal and installation of track

roller assembly
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q’ty
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 5. Remove the mounting bolts and place track
791T-830-1780 Plate t 3 N Q roller assembly (2) on steel plate [1]. [*2]
13 01011-62700 Bolt t 6
01673-32780 Washer t 6 6. Operate the blade and ripper to lift the machine
body until track roller assembly (2) separates
from the bogie.
Removal
1. Loosen the track shoe. For details, see
"Expansion and installation of track shoe
assembly".
2. Install tool L13 and secure bogie assembly (1).

[*1]
7. Pull track roller assembly (2) out of the

machine body from the top of the steel plate
with a bar, etc. [*3]
4 Track roller assembly: 240 kg
3. Operate the blade and ripper to lift the machine

body until track roller assembly (2) separates
from the track shoe.
4. Place steel plate [1] on the track shoe and

operate the blade and ripper to lower the
machine body until the track roller assembly
comes in contact with the steel plate.
a Operate the blade and ripper slowly, run-
ning the engine at the low idling speed.
D475A, D475ASD-5E0 13
Installation a Install the track roller assembly with the oil

q Carry out installation in the reverse order to filler plug out.
removal. a After installing the track roller assembly,
set the position of dowel pin (4).
[*1] 2 Track roller assembly mounting bolt:
After removing tool L13, replace the mounting Adhesive (LT-2)

bolts of cover (3) with the regular parts. 3 Track roller assembly mounting bolt:
3 Cover mounting bolt: 2,205 – 2,695 Nm {222 – 275 kgm}

883 – 1,470 Nm {90 – 150 kgm}
[*3]
[*2] When using the assembling tool
Install S to the first and last track rollers and Set tool L12 under the track roller assem-
install D to the other track rollers. bly (2) and lift up and set track roller
S: Single flange assembly (2) to the track frame.
D: Double flange
14 D475A, D475ASD-5E0
Disassembly and assembly of 6. Using press, remove seal guide (6) together
track roller assembly with retainer (7) and plate (8) from shaft.
7. Remove seal guides (2) and (6) from retainers

Special tools (3) and (7).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
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 Track roller: 1.4 – 1.5 l 8. Remove floating seal (9) from seal guides (2)
and (6).
2. Set track roller assembly (1) on block [1]. a Keep the floating seal in a safe place to
protect it from damage.
3. Remove mounting bolts, then using forcing
screws [2], remove seal guide (2) together with 9. Remove floating seal (10) from retainers (3)
retainer (3) and plate (4). and (7).
a Keep the floating seal in a safe place to
4. Turn over track roller assembly. protect it from damage.
5. Remove mounting bolts, then using eyebolts

[3], remove shaft (5) together with retainer.
10. Remove bushing (11) from roller (12).
D475A, D475ASD-5E0 15
Assembly
1. Set roller (12) to press, then using tool L8,
press fit bushing (11).
a First, center the bushing with a plastic
hammer, 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
surface of the bushing is the dimension
given below.
q Press-fitting dimension (a):
17 ± 0.5 mm
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 dimension given below.
q 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 Track roller: 1.4 – 1.5 l (GO140)
3 Oil filler plug:
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}
16 D475A, D475ASD-5E0

carrier roller assembly
Removal
1. Loosen the track shoe. For details, see
Expanding track shoe assembly.
2. Lift up the track shoe with hydraulic jack [1].
3. Lift off carrier roller assembly (1). [*1]

4 Carrier roller assembly: 105 kg
Installation
removal.
[*1]
a Make a clearance (a) of 5 mm between
the carrier roller and support as shown
below.
2 Carrier roller assembly mounting bolt:
Adhesive (LT-2)
3 Carrier roller assembly mounting bolt:
744.8 ± 83.3 Nm {76 ± 8.5 kgm}
D475A, D475ASD-5E0 17
Disassembly and assembly of 5. Using tool L7, remove nut (4).

carrier roller assembly
6. Remove the fitted part of the seal guide with
puller [2] and remove bearing (5) and roller (6)
Special tools as one unit by using eyebolts.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
4 791-601-1000 Oil pump t 1

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.
7. Remove bearing outer race (7) from the roller.
6 Carrier roller: Approx. 13 l
8. Remove seal guide (8) and bearing inner race
2. Set carrier roller assembly (1) to block [1]. (9) as one unit with puller [3].
3. Remove the mounting bolts and cover (2).
4. Remove ring (3).
9. Remove floating seal (10) from seal guide (8).
18 D475A, D475ASD-5E0
10. Remove seal guide (11) with push tool [4]. a Press fit the bearing inner race, turning
the roller, until the roller becomes a little
11. Remove floating seal (12) from seal guide (11). hard to turn.
5. Tighten nut (4) with tool L7.

Assembly 3 Nut: 98 Nm {10 kgm}
a Clean the all parts and check them for dirt. a After the nut is tightened, if its hole is not
matched to the hole of the shaft, match its
1. Press fit bearing inner race (9) with push tool hole by loosening the nut.
[5].
6. Install ring (3).
2. Press fit bearing outer race (7) with push tool
[6].
7. Fit the O-ring to cover (2) and install them.
3. Set roller (6) and bearing inner race (5) to the

shaft.
4. Press fit bearing inner race (5) to the shaft with

push tool [7].
D475A, D475ASD-5E0 19
8. Install floating seal (10) to seal guide (8) with 12. Supply specified quantity of oil by using tool L4
tool L5. and tighten the oil filler plug.
5 Carrier roller: 1.25 – 1.35 l (GO140)
9. Fit the O-ring to seal guide (8) and install them, 3 Oil filler plug:
matching them to the dowel pin. 157 – 255 Nm {16 – 26 kgm}
10. Install floating seal (12) to seal guide (11) with

tool L5.
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.
20 D475A, D475ASD-5E0
Removal and installation of bogie Removal

assembly 1. Loosen the track shoe. For details, see Expan-
sion and installation of track shoe assembly.
Special tools 2. Install tool L13 and secure the bogie assembly.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
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
5 01630-32780 Washer t 3
Puller 3. Operate the blade and ripper to lift the machine
6 790-101-4000 t 1 body until the track roller assembly separates
(490 kN {50 ton})
7 790-101-1102 Pump t 1 from the track link.
k Set a block between the track roller and
1 791-830-1650 Plate t 1 N
track link so that the machine body will
2 791-830-1660 Spacer t 1 N not lower.
3 796-670-1120 Plate t 1
4 790-434-1070 Screw t 1 N 4. Set block [1] out of the track shoe, matching it
L
15 5 01580-13629 Nut t 2 to the height of the track link.
6 01643-33690 Washer t 1
5. Set steel plate [2] on the track shoe and block
Puller
7 790-101-4000 t 1 [1].
(490 kN {50 ton})
8 790-101-1102 Pump t 1
6. Operate the blade and ripper to lower the
1 791-830-1620 Plate t 1 N machine body until the track roller of bogie
2 791-830-1640 Screw t 3 N assembly (1) comes in contact with steel plate
3 01580-12722 Nut t 3 [2].
16 4 01643-32780 Washer t 3 a Operate the blade and ripper slowly, run-
ning the engine at the low idling speed.
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
18 791-530-1510 Installer t 1
19 791-601-1000 Oil pump t 1
D475A, D475ASD-5E0 21
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 oppo-
site side according to above steps 1) – 7).
3) Remove floating seals (5) from the end

faces of rings (4) and (7).
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.
track link so that the machine body will
not lower.
22 D475A, D475ASD-5E0
12. Sling bogie assembly (1) and pull it out, sliding 2) Press fit shaft (3) to ring (8).
it on steel plate [2]. 3) Install spacer (9).
4 Bogie assembly: 1,200 kg 4) Press fit ring (7) to shaft (3).
5) Install spacer (6).
6) Press fit ring (4) to shaft (3).
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
rings (4) and (7) and install floating seals
bogie assembly (1) and the bogie assembly on
(10) to the opposite side of ring (7) and
the opposite side. Slide bogie assembly (1) on
ring (8).
the steel plate to set it to the mounting position.
a When installing the floating seals,
completely degrease the O-rings and
O-ring contacting surfaces.
a Check that each floating seal is not
inclined more than 1 mm.
3. Match the pin hole of the track frame to that of

the bogie and set guide tool L17.
D475A, D475ASD-5E0 23
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).
a Push in the pin assembly with cover 6. Press fit the pin assembly on the opposite side
(2). of the bogie according to above steps 3 and 4.
a Push in the pin assembly to machined
face (b) of the bogie. 7. Tighten the mounting bolts of pin assembly
2 Apply lubricant (LM-P) all over the cover (2) (2 places on inside and outside).
side of the pin assembly. 3 Cover mounting bolt:
a Total press fitting force of pin assem- 883 – 1,470 Nm {90 – 150 kgm}
bly: 294.2 – 490.5 kN {30 – 50 tons}
8. Adjust the tension of the track shoe. For detail,

see Testing and adjusting, "Testing and adjust-
ing track shoe tension".
24 D475A, D475ASD-5E0
Disassembly and assembly of 3. Disassemble the pin assembly according to

bogie assembly Removal and installation of bogie assembly
(Step 8).
Special tools 4. Disconnection of bogie

Disconnect inner bogie (4) and outer bogie (5).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
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
Puller
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
Disassembly
Assembly
1. Track roller assembly
Turn over bogie assembly (1) and lift off 2 track
Assemble the pin assembly according to
roller assemblies (2).
Removal and installation of bogie assembly
(Steps 3 – 5 of Installation).
2. Set inner bogie (4) to outer bogie (5).
3. Press fitting of pin assembly

1) Set tool L16 and cover (3).
D475A, D475ASD-5E0 25
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 of the bogie according to above steps 3 and 4.
pin assembly up (when the pin a After press fitting the pin assembly, rock
assembly is installed to the machine). the small bogie so that it can be moved
a Push in the pin assembly with cover with light force.
(3).
a Push in the pin assembly to the 6. Tighten the mounting bolts of pin assembly
machined face (b) of the bogie and cover (3) (2 places on inside and outside).
secure the level difference of 5 mm 3 Cover mounting bolt:
between the bogie and pin assembly. 883 – 1,470 Nm {90 – 150 kgm}
2 Apply lubricant (LM-P) all over
the side of the pin assembly. 7. Track roller assembly
a Total press fitting force of pin assem- Sling and install 2 track roller assemblies (2) to
bly: bogie assembly (1).
294.2 – 490.5 kN {30 – 50 tons} 2 Track roller mounting bolt:
Adhesive (LT-2)
3 Track roller mounting bolt:
2,205 – 2,695 Nm {225 – 275 kgm}
4. Refilling with oil

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 (GO140)
26 D475A, D475ASD-5E0
Removal and installation of No.1 Removal

bogie assembly 1. Loosen track shoe tension.
For details, see Expansion and installation of
track shoe assembly.
Special tools
2. Operate blade and ripper, and raise chassis to
New/Remodel
a position where track roller of No. 2 bogie
Necessity
Symbol
Sketch
assembly is separated from track link.
Q’ty
Part No. Part Name
the track link to prevent the chassis
1 791-830-1620 Plate t 1 N from coming down.
2 791-830-1630 Spacer t 1 N
3. Fit eyebolts to holes of pad mounting bolt (M12
3 791-830-1640 Screw t 3 N
x 2) portion at rear of No. 1 bogie assembly,
4 01580-12722 Nut t 3 and raise No. 1 bogie assembly (1).
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})
8 790-101-1102 Pump t 1
1 791-830-1620 Plate t 1 N 4. Put steel plate between track shoe and roller,
then loosen roller cap bolts (2) approx. 20 mm.
2 791-830-1640 Screw t 3 N
(Both inside and outside)
L 3 01580-12722 Nut t 3
16 4 01643-32780 Washer t 3 5. Tap end face of shaft (3) with hammer and
5 790-101-4000
Puller
t 1
remove track roller assembly (4).
(490 kN {50 ton}) q There is a dowel pin on the near side of
6 790-101-1102 Pump t 1 the track roller assembly, so be careful not
17 791T-830-1670 Guide t 2 N Q to break it.
18 791-530-1510 Installer t 1 (Dowel pin insertion tolerance: 5 – 6 mm)
19 791-601-1000 Oil pump t 1
6. Remove roller cap bolt (2), then put track roller
791-630-1860 Bracket t 1 assembly (4) on steel plate, and pull out.
4
791-630-1870 Bracket t 1
Track roller assembly: 240 kg
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 Q
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
D475A, D475ASD-5E0 27
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). will 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 inter-
feres with the idler. Accordingly, sup-
ply 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).
28 D475A, D475ASD-5E0
10. Lower bogie (5) on the steel plate and pull it 2) Press fit shaft (7) to ring (13).
out. 3) Install spacer (14).
4 Bogie assembly: 180 kg 4) Press fit ring (12) to shaft (7).
5) Install spacer (11).
6) Press fit ring (8) to shaft (7).
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
2. Slide bogie (5) on steel plate [1] to the center.
rings (8) and (12) and install floating seals
(10) to the opposite side of ring (12) and
3. Set bogie (5) to the mounting position with tool
ring (13).
L20.
a When installing the floating seals,
completely degrease the O-rings and
O-ring contacting surfaces.
a Check that each floating seal is not
inclined more than 1 mm.
4. Match the pin hole of the track frame to that of

the bogie and insert guide tool L17.
D475A, D475ASD-5E0 29
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.
a Oil supplying pressure: 0.49 MPa {5 kg/
cm2}
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.
a Push in the pin assembly with cover 7. Press fit the pin assembly on the opposite side
(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 8. Install covers (6) (2 places on inside and out-
level difference of 5 mm between the side).
bogie and pin assembly.
2 Apply lubricant (LM-P) all over 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 assem- hold the bogie.
bly:
294.2 – 490.5 kN {30 – 50 tons}
30 D475A, D475ASD-5E0
10. Insert tool L21 in the shaft of track roller

assembly (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

clearance between bogie (5) and shaft (3)
becomes about 20 mm, install cap (15) and
secure it with bolts (2) temporarily.
12. Matching the dowel pin holes, tighten bolts (2).

2 Cap mounting bolt: Adhesive (LT-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 adjust-
ing track shoe tension.
D475A, D475ASD-5E0 31
SEN02017-00

© 2007 KOMATSU
All Rights Reserved
32
SEN02018-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Undercarriage and frame, Part 2

Undercarriage and frame, Part 2 .................................................................................................................... 2
Expansion and installation of track shoe assembly.............................................................................. 2
Overall disassembly and overall assembly of track shoe..................................................................... 5
Press-fitting jig dimension table for link press .................................................................................... 21
Field disassembly and assembly of one link ...................................................................................... 22
Disassembly and assembly of master link ......................................................................................... 27
Removal and installation of pivot shaft assembly............................................................................... 31
Removal and installation of equalizer bar .......................................................................................... 32
Disassembly and assembly of equalizer bar bushing ........................................................................ 35
D475A, D475ASD-5E0 1
Undercarriage and frame, Part 2 1
Expansion and installation of Expansion of track shoe assembly (Normal)

track shoe assembly 1 a If Checking before expansion of track shoe
assembly shows that there is no abnormality,
do as follows.
Expansion 1. Set master link in position.
a Bring the master link above the idler (just
Checking before expansion of track shoe behind the center).
assembly a Set blocks [1] and [2] at the front end of
k In some cases, it may be extremely danger- the idler and between the carrier rollers so
ous to expand the track shoe assembly. To that the mating faces of the master link will
prevent danger, carry out the following not open until the master bolt is removed.
checks before expansion of the track shoe
assembly.
k Never loosen the lubricator more than one
turn.
q Loosen lubricator (1) at the adjustment cylin-
der, release the grease, then move the
machine backwards and forwards a short dis-
tance, and check that the track tension is
relieved.
a If the shoe tension is relieved, go to "Expan-
sion of track shoe assembly (Normal)".
2. Relieve track shoe tension. [*1]

k Never loosen lubricator (1) more than
one turn.
a If the track is not relieved by loosening the
lubricator, move the machine backwards
and forwards.
q If the above procedure does not relieve the

track tension and the track shoe assembly
remains tense, there may be an abnormality
inside the track frame (the recoil spring case is
broken, the recoil spring set bolt is broken, or
the nut at the end of shaft has fallen off).
a If the shoe tension is not relieved, go to
"Expansion of track shoe assembly (when
there is abnormality inside track frame)".
2 D475A, D475ASD-5E0
3. Remove track shoe (2). [*2] 1. Remove work equipment assembly.

a Loosen each of the 4 bolts by 1 – 2 turns. For details, see "Removal and installation of
Check that the 4 bolts can be turned work equipment assembly".
lightly, then pull them out. Do not pull out
only 1 bolt without loosening the other 2. Loosen lubricator (1), then move machine
three. backwards and forwards to remove grease.
a If a bolt is turned forcibly while it cannot be k Never loosen lubricator (1) more than
turned lightly, the threads of it and master one turn.
link (3) may be damaged. a Check that all the grease has been
removed.
4. Raise tip of master link, move machine

towards rear slowly, and lay out track shoe 3. Drive slowly forward to put track shoe at idler
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
k To prevent danger, never stand in front as the machine being repaired is available, put
of the idler yoke assembly. in 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.
Expansion of track shoe assembly (when

there is abnormality inside track frame)
a When "Checking before expansion of track

shoe assembly" shows any abnormality, 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 assembly is removed.
This may lead to serious injury, so expand
the track shoe assembly as follows.
D475A, D475ASD-5E0 3
Installation
expansion (normal).
[*1]
a For details of the track shoe tension, see
Testing and adjusting, Testing and adjust-
ing 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
master 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 in the order shown in the diagram
below.
2 Shoe mounting bolt:
Seizure prevention compound
(Maruzen Molymax No. 2 or
equivalent)
3 Shoe mounting bolt:
1st step:
980 ± 98 Nm {100 ± 10 kgm}
2nd step:
Tighten a further 180 ± 10°
4 D475A, D475ASD-5E0
Overall disassembly and overall Overall disassembly

assembly of track shoe a When disassembling the track shoe, see shop
manual – Guidance for reusable parts – Lubri-
cated tracks (III) (Form No.: SEBG4092).
Special tools a Check that the track press has protective cover
(1).
New/remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
1 791-646-7531 Plug remover t 1

2 791-660-7460 Pin brush t 1
3 791-646-7900 Push tool t 1
4 791-932-1110 Push tool t 1
790-701-3000 Seal checker
5 and t 1
791-601-1000 Oil pump
6 791-632-1010 Installer t 1
Push tool
1 791-685-5600 t 1 N a When removing the pin, totally cover pin end
assembly
push tool (2) and link wedge with thick cloth (3)
2 791-685-5640 • Adapter 1 N so that the broken pieces of wedge ring (4) will
3 791-685-5660 • Ring 1 N not be scattered.
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 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
D475A, D475ASD-5E0 5
2. Disassembly of link
1) Set the link assembly on the link press
and hit it with a hammer so that the bush-
ing will be fitted to the jaw.
a If the link tread, outside of the bush-
ing, etc. are worn, adjust the height of
the jaw or guide plate to align the dis-
assembly jig with the pin and bushing
so that the link hole will not be dam-
aged during disassembly.
a If the above parts are not aligned per-
fectly, the link hole may be damaged
and the pin and bushing may be bro-
ken during disassembly.
a The track press operator and other workers a Drive the small plug of the pin inward
must put on helmets, safety glasses and ear- with tool R1 after disassembly to
plugs. avoid making the workshop dirty.
1. Removal of shoe
Sling the shoe assembly and set it on a floor
with the shoe up. Remove the shoe with a
shoe bolt impact wrench.
a If a shoe bolt is still hard (If its torque is not
lowered to 0) after it is unscrewed by 1
turn, loosen the other bolts, and it can be
removed easily.
a If a bolt is unscrewed forcibly while its
torque is not 0, it will stick to the link and
will need to be repaired.
a When moving the shoe assembly, take
care not to damage the master link.
a If it is obliged to cut a shoe nut with gas,
keep the temperature of the sealing parts
below 80°C and prevent the spatters from
entering the clearance of the link so that
the sealing parts will not be deteriorated
by the heat.
6 D475A, D475ASD-5E0
2) Operate the left cylinder to pull out the fit- 4) Return the right cylinder and take out the
ted parts of the left link, pin, and bushing links, pins, bushings, and spacers on both
simultaneously. sides, then send the next link assembly to
a Check the pulling out force of the pin the jaw.
and bushing to see if the necessary a If the end faces of the bushings and
fitting force of the pin and bushing is sealing surfaces are damaged, oil will
obtained when they are turned over leak. Accordingly, handle them with
and assembled. care.
a When the wedge link is cut, it bangs. a Take care not to scratch your hands
This phenomenon is normal. with the sharp edges of a cut wedge
link.
3) Return the left cylinder and operate the

right cylinder to pull out the right link, pin,
and bushing simultaneously.
D475A, D475ASD-5E0 7
3. Inspection a Precautions for storage

Inspect the following items to see if the parts 3) Store the seal without removing it from the
can be reused for an oil lubricated track or a link to prevent rusting of the counterbore
grease lubricated track, then generally exam- of the link, taking care not to damage the
ine whether the link assembly should be recy- seal lip.
cled as an oil lubricated track or as an grease 4) Apply rust-preventive oil to the pin and
lubricated 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 reusable 5) Apply rust-preventive oil all over the pin,
parts – Lubricated tracks (III) (Form No.: bushing, and spacer. In particular, take
SEBG4092). care not to damage the end faces of the
1) Check the parts visually for damage, then bushing.
apply a dye penetrant test or a magnetic
flaw test to the parts which seem to be
damaged. Discard a cracked part since it
cannot be reused.
2) Measure the outside diameters of the fit-
ting 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 standard interference.
a If the allowable interference is not
obtained, replace the parts with new
ones.
a For the criteria, see “Maintenance Overall assembly
standard”.
a When assembling the track shoe, see shop
manual – Guidance for reusable parts – Lubri-
cated 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
deteriorated easily by cleaning liquid
(trichloroethylene, etc.), clean them
quickly. After cleaning them, wipe off
the cleaning liquid.
8 D475A, D475ASD-5E0
2) When reusing the pin, chamfer the cor- 1] Insert the plug in the hole of the guide
ners of its end smoothly with a grinder. through the plug inserting hole.
Remove the projections of the fitting parts 2] Push the bar with the hand and insert
with the grinder. the plug until it stops.
a If the corners of the pin end are worn 3] Push the plug with the bar to press
and sharpened, they may scuff the fit- the guide against the pin.
ting parts to cause oil leakage. 4] Drive the bar with a hammer.
a Driving distance (a) from pin end:
10 ± 1 mm
a If the edge of the pin hole is worn
and sharpened, chamfer it with a
small grinder (wheel tip angle: 45
– 60°) so that the plug will not be
damaged.
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 them just before assembling
them.
a Do not repair the end faces of the
bushing with a grinder, etc. since that
can cause oil leakage.
4) If the large plug has been driven out, drive
it with tool R3. 5) Installation of seal assembly
Clean the pin hole with tool R2 in Clean the counterbore of the link carefully
advance. and push in the seal to the bottom with
tool R6.
a If any oil sticks to the counterbore of
the link and seal assembly, the seal
turns and its sealing performance is
lowered. Accordingly, do not apply
any oil. Take care that oil will not stick
to the seal when the seal is inserted
in the counterbore.
D475A, D475ASD-5E0 9
6) Adjust the dimensions of the fitting jig of 2. Assembly of link

the link press to keep the projection dis- 1) Apply oil (GO90) between the pin and
tance of the pin and bushing constant and bushing with a clean brush, then set them
keep the fitting dimensions of the seal on this side of the link press jaw.
within the limits when those parts are a When reusing (turning) the bushing,
assembled. set its worn side to the shoe fitting
a For the standard dimensions, see face of the link (which is directed up
“Press-fitting jig dimension table for on the link press).
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 spacer may be broken or it and
bushing end may be worn abnormally.
a Press cutting force of pin and bush-
ing: 1,274 kN {130 tons}
Press cutting force C
1.8 x Average press fitting force
(Set the press cutting force by adjust-
ing the relief pressure of the link 3) Measure the distance between the shoe
press.) bolt holes of both links with a shoe bolt
hole pitch gauge. Press fit the master link
until the specified shoe bolt hole pitch is
obtained.
a Remove the all chips made when the
bushing is press fitted by blowing air
against them.
10 D475A, D475ASD-5E0
4) Turn over the master links and check that 7) Apply gasket sealant (198-32-19890) to
they are press fitted in parallel. the pin fitting hole of the link to prevent oil
from oozing through the scuffs of the pin
fitting parts.
5) Measure the projections of the bushing on

both sides with a depth gauge.
a Adjust the fitting jig of the link press 8) Set the right link and install the spacer to
so that the bushing will be projected the pin.
by the same distance on both sides. a Check that the sealing surface and
bush ends are free from dirt and
apply oil (GO90) to them with a clean
cloth or brush.
a Clean the spacer with a clean cloth
before 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 simi-
larly to a new one. If it is not installed
in this direction, its strength may
lower. Accordingly, make a mark of
the side hole on the end face of the
pin.
D475A, D475ASD-5E0 11
9) Set the right jig on the receiving side and 11) Set the left link and install the spacer to
the left jig on the pushing side and press the pin.
fit the pin and bushing simultaneously. a Apply oil similarly to the right link.
a If the jigs shake while the pin and
bushing are press fitted, the seal may
come off the 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}
12) Set the left jig on the receiving side and

the right jig on the pushing side and press
fit the 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}
10) Using the spacer for fine adjustment,

press fit the pin until it is fitted to the lower
part of the pin end receiving jig.
a Adjust the depth of the receiving jig
so that the pin will be projected by the
same distance on both sides.
12 D475A, D475ASD-5E0
13) Press fit until the link, spacer, and bushing 15) Install the ring to jig R12.
are fitted to each other.
a Actually, you cannot see from outside
if the above parts are fitted. Accord-
ingly, control the hydraulic pressure of
the link press. Set the relief pressure
to a proper level and heighten the
hydraulic pressure to that level.
For setting of the relief pressure, see
Preparation work.
a Check that adjacent 2 links can turn
around each other.
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
inserted in the pin hole.
14) Measure the distance between the shoe

bolt 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, disas-
semble and check for abnormality,
then press fit again. 17) Similarly, insert the ring in the pin groove
a If the distance between the shoe bolt on the opposite side with jig R9.
holes is shorter than the limit and the
shoe cannot be installed, the spacer
or bushing end may be worn more
than the allowable limit. In this case,
disassemble and replace the parts.
D475A, D475ASD-5E0 13
18) Push in the ring with jig R13. 20) Supply oil (GO90) with tool R5 until the oil
Pushing force of ring: supply pressure rises to 196 – 294 kPa {2
392 – 490 kN {40 – 50 tons} – 3 kg/cm2}.
a In a cold or very cold district, supply
Komatsu genuine oil (150-09-19270
or 195-32-61990) having better low-
temperature characteristics instead of
GO90.
a If the oil pressure is heightened too
much, it has bad effects on the seal.
Take care.
19) After each link is assembled, bleed air

from 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, disassem-
ble and check the seal. If the seal is a Supply oil so that the depth L of the
free from abnormality, assemble hollow of the pin hole will be in the fol-
again. lowing 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
14 D475A, D475ASD-5E0
21) After supplying oil, drive in the small plug 2) When installing a double track, place the
to the specified position with tool R4. assembled double shoes on a level place
a Apply GO90 around the small plug. in 1 line with the shoe side up. Pull pin-
a Drive in the plug to the following side master link (1) and bushing-side mas-
depth. ter link (2) together and set them to each
Driving depth from end: 7.5 ± 1 mm other by the mating faces. Place shoe (3)
22) Assemble the master link on the pin side on the links and check that master bolts
at last. (4) can be tightened easily by hands until
a Check that the master links on both the mating faces of the links are fitted
sides are press fitted in parallel. together, and then connect the master
links.
3. Installation of shoe
1) Set the link assembly on the bed and 2 Shoe bolt:
install the shoe with a shoe bolt impact Lubricant containing molybde-
wrench and a torque wrench. num disulfide (LM-P)
2 Shoe bolt: 3 Shoe bolt (Master link)
Lubricant containing Initial torque:
molybdenum disulfide (LM-P) 980 ± 98 Nm {100 ± 10 kgm}
3 Shoe bolt (Regular link) Retightening angle: 180 ± 10°
Initial torque: a Tighten the bolts in the order of [1] –
784 ± 78 Nm {80 ± 8 kgm} [4].
Retightening angle: 180 ± 10°
D475A, D475ASD-5E0 15
When recycling for grease lubricated track 4) Clean the outside of the pin, surfaces of
1. Preparation work the spacer, and end faces and inside of
1) Cleaning of seal assembly the bushing, if they are dirty.
Take the seal assembly out of the link and 5) Apply grease to the outside of the pin and
divide it into the seal ring and load ring, surfaces of the spacer.
then clean them.
a Since the seal ring and load ring are
deteriorated 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.
a If any grease sticks to the counter-
2) When reusing the pin, chamfer the cor- bore of the link and seal assembly,
ners of its end carefully with a grinder so the seal turns and its sealing perfor-
that it will be press fitted smoothly. mance is lowered. Accordingly, do not
apply any grease.
3) Drive the large plug and small plug with

tools R3 and R4.
1] Insert each plug in the hole of the
guide through the plug inserting hole.
(Apply oil to the plug.)
2] Push the bar with the hand and insert
the plug until it stops.
3] Push the plug with the bar to press
the guide against the pin.
4] 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 as they are.
16 D475A, D475ASD-5E0
7) Adjust the dimensions of the fitting jig of 2) Press fit both bushing-side master links to
the link press to keep the projection dis- the bushings with the shoe fitting faces up.
tance of the pin and bushing constant and a At this time, use the pin-side master
keep the fitting dimensions of the seal links as supports.
within the limits when those parts are a Fitting force of bushing:
assembled. 245 – 382 kN {25 – 39 tons}
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
3) Measure the distance between the shoe

bolt holes of both links with a shoe bolt
hole pitch gauge. Press fit the master link
until the specified shoe bolt hole pitch is
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
2. Assembly of link they are press fitted in parallel.
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).
D475A, D475ASD-5E0 17
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
7) Set both links and operate both pushing

jigs to press fit the pin and bushing simul-
taneously.
a If the jigs shake while the pin and
bushing are press fitted, the seal may
6) Send out the master link and set the next come off the link. Accordingly, press
pin and bushing. fit smoothly. If the seal comes off the
a When reusing the pin, install it with its link, stop press fitting and install the
side hole on the link tread side simi- seal to the link correctly, then start
larly to a new one. If it is not installed press fitting again.
in this direction, its strength may a Press cutting force of pin and bush-
lower. Accordingly, make a mark of ing: 1,274 kN {130 tons}
the side hole on the end face of the Press cutting force C
pin. 1.8 x Average press fitting force
a If the outside of the pin is worn, set it (Set the press cutting force by adjust-
with the un-worn part on the traction ing the relief pressure of the link
side. In this case, install it with its side press.)
hole on the link tread side, too. 8) Measure the distance between the shoe
bolt holes with a shoe bolt hole pitch
gauge. If the result is within the limits, stop
press fitting.
18 D475A, D475ASD-5E0
9) Install the ring to jig R12. 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
torque wrench.
2 Shoe bolt:
Lubricant containing molybdenum
disulfide (LM-P)
3 Shoe bolt (Regular link)
Initial torque:
784 ± 78 Nm {80 ± 8 kgm}
10) Match the jig to the pin hole and push it in Retightening angle: 180 ± 10°
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
inserted in the pin.
11) Push in the ring with jig R13.

Pushing force of ring:
392 – 490 kN {40 – 50 tons}
D475A, D475ASD-5E0 19
4. Assembly of 1/2 track

Place the assembled 2 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 master bolts (4) can be tightened
easily by hands until the mating faces of the
links are fitted together, and then connect the
master links.
2 Shoe bolt:
Lubricant containing molybdenum
disulfide (LM-P)
3 Shoe bolt (Master link)
Initial torque:
980 ± 98 Nm {100 ± 10 kgm}
a Tighten the bolts in the order of [1] – [4].
20 D475A, D475ASD-5E0
Press-fitting jig dimension table for link press
Jig dimension (mm)

a 4.6
b 2.0
c 59.1
D475A, D475ASD-5E0 21
Field disassembly and assembly

of one link
Special tools
New/Remodel
New/Remodel
Necessity
Necessity
Symbol
Symbol
Sketch
Sketch
Q’ty
Q’ty
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 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)
18 791-832-1480 Adapter t 1 N
with 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
22 D475A, D475ASD-5E0
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 1) Set tools R8-13, R8-14, and R8-15 to R8-
it is not aligned, retighten R8-5 and adjust 11, then apply hydraulic pressure to push
the 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
Install tools R8-2 and R8-3 to tool R8-1. repeat 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 hori-
zontal.
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, D475ASD-5E0 23
7. Repeat steps 1 – 5 to remove pin (4) on the Assembly

opposite side. 1. Assemble the link sub-assembly according to
the following procedure.
1) Set tool R8-17 to the bushing-side end of
link (6) and press fit bushing (7).
a Press fitting force of bushing:
245 – 382 kN {25 – 39 tons}
8. Repeat step 6 to remove link (5).
2) Set tool R8-18 to the pin-side end of the

link 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}
2. Set link sub-assembly (9) to the link to be con-

nected.
24 D475A, D475ASD-5E0
3. Set link (10) on the opposite side and support it 6. Similarly to the disassembly procedure, push
with tool R8-19. open link (11) to be connected by using tools
R8-30 and R8-31.
4. Similarly to the disassembly procedure, set

tools R8-29, R8-6 – R8-11, and R8-24 to the 7. Set link (12) to be connected to link (11) and
link. connect them with tool R8-22, then remove
tools R8-30 and R8-31.
5. Use R8-18 and R8-23 to press fit the pin. Use
tools R8-21, R8-17, R8-20, and R8-14 to press
fit the bushing. Press fit the pin and bushing
alternately.
a Press fit the pin first. After the bushing is
engaged with the link, remove tool R8-19
installed in step 3, then press fit the bush-
ing.
333 – 451 kN {34 – 46 tons}
a Press fitting force of bushing:
245 – 382 kN {25 – 39 tons}
D475A, D475ASD-5E0 25
8. Press fitting of pin

1) Set tools R8-28, R8-6 – R8-12, R8-26,
R8-27, R8-14, and R8-22 and apply
hydraulic pressure to press fit pin (13).
2) After the cylinder reaches the stroke end,
remove tools R8-26, R8-27, and R8-14
and repeat the work with tools R8-16, R8-
14, R8-25, and R8-14.
3) After the cylinder reaches the stroke end
again, remove tools R8-12, R8-16, R8-25,
R8-14, and R8-22 and press fit the pin
with tools R8-18, R8-23, and R8-24.
2 Pin fitting hole of link:
Gasket sealant (198-32-19890)
link tread side.
666 – 902 kN {68 – 92 tons}
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".
26 D475A, D475ASD-5E0
Disassembly and assembly of

master link
Special tools
New/Remodel
New/Remodel
Necessity
Necessity
Symbol
Symbol
Sketch
Sketch
Q’ty
Q’ty
Part No. Part Name Part No. Part Name
1 791-832-1610 Plate t 1 8 791-685-5720 • Spring 1 N

2 791-832-1270 Bracket t 1 9 791-685-5730 • Bar 1 N
9
3 01010-81495 Bolt t 1 10 01252-30655 • Bolt 1
4 791-832-1250 Bracket t 1 11 01580-01210 • Nut 1
5 01010-62050 Bolt t 2 1 791-832-1490 Push tool t 1 N
11
6 791-832-1220 Plate t 1 2 791-832-1510 Push tool t 1 N
7 791-832-1230 Shaft t 2 Push tool
1 791-685-5700 1 N
8 791-832-1210 Frame t 1 assembly
9 791-832-1240 Nut t 2 2 791-685-5650 • Adapter 1 N
10 04530-11628 Eye bolt t 2 R 3 791-685-5660 • Ring 1 N
11 791-832-1310 Adapter t 1 4 791-685-5670 • Plate 1 N
12 791-832-1280 Adapter t 1 5 791-685-5680 • Ring 1 N
12
13 791-832-1320 Guide t 1 6 791-685-5690 • Push tool 1 N
14 01320-41030 Screw t 5 7 791-685-5710 • Adapter 1 N
15 791-832-1640 Pusher t 1 8 791-685-5720 • Spring 1 N
16 791-832-1340 Extension t 2 9 791-685-5730 • Bar 1 N
8 17 791-832-1650 Adapter t 1 10 01252-30655 • Bolt 1
18 791-832-1480 Adapter t 1 N 11 01580-01210 • Nut 1
19 791-832-1670 Guide t 1 13 791-685-5750 Push tool t 1 N
20 791-832-1330 Guide t 1
R 21 791-832-1660 Adapter t 1
Disassembly
22 791-832-1630 Guide t 1
a For the method of using tool R8, see Field dis-
23 791-832-1470 Guide t 1 N
assembly of one link.
24 791-832-1410 Extension t 1
25 791-832-1350 Pusher t 1 1. Removal of track shoe assembly
26 791-832-1620 Guide t 1 Remove the track shoe assembly from the
27 04530-11018 Eye bolt t 1 track frame. For details, see Expanding track
Cylinder shoe assembly.
28 791-101-4500 t 1
(1960 kN {200 ton}
29 790-101-1102 Pump t 1 2. Disassembly of shoe
Disconnect the all master links and divide the
Puller (294 kN
30 790-101-4200 t 1 shoes into 4 parts.
{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
D475A, D475ASD-5E0 27
3. Removal of master link q Master link type

q Master pin type 1) Cutting and removal of master link on
1) Cutting of regular link with gas bushing 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
q Necessary special tool: master links (5) and (6) in the direction of
Gas cutting machine and to pull them out. Then, push
pins (8) and (9) out of regular link (7) in the
directions of and with a press.
q 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).
q Necessary special tools:
1. Gas cutting machine
2. Tool R8
28 D475A, D475ASD-5E0
Assembly 2) Set spacer (3) and seal assembly (4) to

a For the method of using tool R8, see "Field dis- the counterbore of the link of the connect-
assembly of one link". ing 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
3) Match the pin hole and bushing hole to
D2 33 x 2.0
each other and connect the pin and bush-
ing 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
bushing-side master link (1).
tool R8 as shown in the figure. (Expand
2 Apply gasket sealant (198-32-
the link end by 10 mm.)
19890) to the pin hole of the link.
link tread side.
D475A, D475ASD-5E0 29
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)
6) Install the shoe to the link of the connect- from both sides with tool R8.
ing part. 3) Install the ring with tools R8, R9, R11,
7) Drive large plug (7) with tool R3 and sup- R12, and R13.
ply oil with tool R5, then drive small plug 4) Drive large plug (13) with tool R3 and sup-
(8) with tool R4. ply oil with tool R5, then drive small plug
a When press fitting both master links, (14) 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 bush-
ing, 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
mating faces. Place the shoe on the links and
check that master bolts can be tightened easily
by hands until the mating faces of the links are
fitted together, and then connect the master
links.
3. Assembly of link on pin side 2 Shoe bolt:
1) Set spacer (3) and seal assembly (4) to Lubricant containing molybdenum
the counterbore of the master link. disulfide (LM-P)
3 Shoe bolt (Master link)
Initial torque:
980 ± 98 Nm {100 ± 10 kgm}
30 D475A, D475ASD-5E0
Removal and installation of pivot 3. Remove seal (2), then remove cover (3). [*2]
shaft assembly
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791T-850-1180 Sleeve t 1 Q
791T-850-1190 Plate t 1 Q
791-730-1130 Bolt t 2
791-101-3310 Plate t 1
P
01643-32060 Washer t 2
Installation
01580-02016 Nut t 2
790-105-2300 Jack assembly t 1 removal.
790-101-1102 Pump t 1
[*1]
2 Pivot shaft press-fitting surface:
Removal
Anti-friction compound (LM-P)
1. Remove track frame assembly.
For details, see "Removal of track frame [*2]
assembly". a Using tool P, press fit seal (2) to the pivot
shaft.
2 Seal press-fitting surface:
2. Sling pivot shaft assembly (1) and remove
mounting bolts, then using forcing screw [1], Gasket sealant (LG-6)
pull out pivot shaft assembly. [*1] a Check that press-fitting dimension (a) of
4 Pivot shaft assembly: 390 kg the seal from the end face of the shaft is
the specified dimension.
q Press-fitting dimension (a): 665 ± 1.0 mm
D475A, D475ASD-5E0 31
Removal and installation of 5. Set stand and hydraulic jack [1] (294 kN {30
equalizer bar ton}) under radiator guard.
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 Q
N 1 01582-53024 Nut t 1
01643-33080 Washer t 1
Puller 7. Remove cover (7).
790-101-2102 t 1
(294 kN {30t on})
790-101-1102 Pump t 1 8. Remove main bolt (8) of side pin.
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 hose at the tilt cylinder end.
9. Using eyebolt [2], remove side pin (9). [*3]
3. Remove seal (2) together with washer (3). [*1] a It is difficult to remove the pin if the centers
of the equalizer bar hole and track frame
4. Remove washer (4), then remove spacer (5). hole are not aligned, so use hydraulic jack
a Oil will flow out from the pivot case, so [1] to adjust the height at the equalizer bar
catch it in an oil container. end before removing.
6 Pivot case: 26 l a Repeat Steps 6 to 9 to remove the side pin
on the opposite side.
32 D475A, D475ASD-5E0
10. Operate hydraulic jack [1] slowly and lower 14. Operate blade and raise front of chassis, and
chassis to point where equalizer bar contacts set hydraulic jack under radiator guard.
left and right track frames.
15. Raise equalizer bar (13), move it past main
11. Disconnect lubrication tube (10). frame and track frame, and remove.
k After removing the equalizer bar, do
12. Remove lock plate (11). [*4] not lower the chassis.
4 Equalizer bar assembly: 600 kg
13. Using tool N1, remove center pin (12). [*5]

a It is difficult to remove the pin if the centers
of the equalizer bar hole and main frame Installation
hole are not aligned, so use hydraulic jack
[1] to adjust the height at the main frame
removal.
end before removing.
[*1]
a After removing the grease from the press-
fitting 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.
[*2]
3 Main mounting bolt of side pin:
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).
D475A, D475ASD-5E0 33
[*3]
2 Inside surface of bushing:
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
outside of the machine.
[*4]
Tread tightener (LT-2)
1,519 – 1,911 Nm {155 – 195 kgm}
[*5]
2 Equalizer bar bushing and main frame
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.
q Refilling with oil (pivot case)

5 Pivot case: 26 l (SAE30)
34 D475A, D475ASD-5E0
Disassembly and assembly of 3) Set tool N2 in position and remove side

equalizer bar bushing bushing (4) from equalizer bar (5).
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791T-850-1160 Bracket t 1 Q
791T-850-1170 Bracket t 1 Q
790-438-1110 Screw t 1
790-101-2540 Washer t 2
N 2
791-112-1180 Nut t 2
Puller Assembly
790-101-2102 t 1
(294 kN {30 ton})
1. Side bushing
790-101-1102 Pump t 1 1) Set side bushing (4) and tool N2 in posi-
tion, then press fit side bushing (4) to
Disassembly equalizer bar (5).
1. Center bushing 2 Outer circumference of bushing:
Remove center bushings (1). Anti-friction compound (LM-P)
2. Side bushing
1) Remove seals (2).
2) Remove snap ring (3).
D475A, D475ASD-5E0 35
a Align the direction of installation of the 2. Center bushing

side bushing as shown in the diagram Using press, press fit bushing (1).
below. 2 Outer circumference of center bushing:
1] Make split surface (mating surface) Anti-friction compound (LM-P)
(a) of outer bushing horizontal. a Center bushing press-fitting force:
2] Set inner bushing and outer bushing 68.6 – 233.2 kN {7 – 23.8 ton}
grease hole (b) at an angle.
a Side bushing press-fitting force:
47 – 96 kN {4.8 – 9.8 ton}
2) Install snap ring (3).

a After installing the snap ring, fill front
and rear portion C of side bushing
with grease (G2-LI).
2 Amount of grease to fill side
bushing: 0.45 l
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.
36 D475A, D475ASD-5E0
D475A, D475ASD-5E0 37
SEN02018-00

© 2007 KOMATSU
All Rights Reserved
38
SEN02019-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Hydraulic system
Hydraulic system............................................................................................................................................. 2
Removal and installation of hydraulic pump assembly ........................................................................ 2
Removal and installation of hydraulic valve assembly ......................................................................... 4
Disassembly and assembly of control valve ........................................................................................ 5
Disassembly and assembly of merge divider valve and self pressure reducing valve assembly ........ 9
Removal and installation of PPC relief valve assembly ......................................................................11
Disassembly and assembly of hydraulic cylinder assembly............................................................... 12
Disassembly and assembly of ripper pin puller cylinder assembly .................................................... 17
D475A, D475ASD-5E0 1
Hydraulic system 1
Removal and installation of 5. Disconnect hoses (5).

hydraulic pump assembly 1
Removal
and stop the engine. Release the remaining
pressure in the hydraulic piping.
" R e l e a s i ng r e m a i n i n g p re s s u re f r o m
hydraulic circuit".
Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic
tank.
terminal of the battery. 6. Remove tube coupling (6).
1. Drain oil from hydraulic tank.

6 Hydraulic tank: 170 l
2. Remove floor frame assembly.

For details, see "Removal of floor frame
assembly".
3. Disconnect pump outlet hoses (1) and (2).
4. Disconnect PPC hoses (3) and (4).
7. Remove pump inlet tube (7).
8. Disconnect PPC hoses (8) and (9).
9. Disconnect wiring clamp at the top of pump

(10) and wiring harness connector (11).
10. Sling hydraulic assembly (12), then remove

mounting bolts, and remove.
2 D475A, D475ASD-5E0
Installation
removal.
q Refilling with oil (hydraulic tank)

again.
D475A, D475ASD-5E0 3
Removal and installation of 6. Disconnect 5 PPC hoses (5) from bottom side.
hydraulic valve assembly a PPC hoses are distinguished by color
bands.
Removal 7. Disconnect ripper hoses (6) and (7).

" R e l e a s i ng r e m a i n i n g p re s s u re f r o m
hydraulic circuit".
tank.
1. Drain oil from hydraulic tank.

6 Hydraulic tank: 170 l
8. Disconnect tubes (8) and (9).
2. Remove right cover of operator cab. 9. Disconnect hose (10).
3. Remove hose (1). 10. Disconnect wiring connectors (11) and (12),
and clamp (13).
4. Disconnect 5 PPC hoses (2) from upper side.
11. Sling control valve assembly (14), and then
remove.
4 Main control valve assembly: 195 kg
5. Disconnect blade lift hoses (3) and blade tilt

hoses (4).
Installation
removal.

again.
q Bleeding air in the hydraulic piping

For detail, see Testing and adjusting, Air bleed-
ing from hydraulic cylinder.
4 D475A, D475ASD-5E0
Disassembly and assembly of control valve
D475A, D475ASD-5E0 5
6 D475A, D475ASD-5E0
Disassembly Assembly
1. Ripper lift valve q Coat the sliding surface of each part with
1) Remove case (1), spring (12), and retainer engine 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).
a Do not disassemble spool assembly Fit the O-ring to case (1) and install them.
(2). 3) Install retainer (9) and spring (12). Fit the
O-ring to case (1) and install them.
2. Blade right tilt valve 3 Case mounting bolt:
1) Remove case (1), spring (15), and retainer 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
(9).
2) Remove lower case (1), spring (15), and 2. Blade left tilt valve
3) Remove spool (3). 2) Install lower retainer (9) and spring (15).
a Do not disassemble spool assembly Fit the O-ring to case (1) and install them.
(3). 3) Install retainer (9) and spring (15). Fit the
3. Blade lift valve 3 Case mounting bolt:
1) Remove case (3), loosen bolt (8), and 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
remove retainer (7) and spring (6).
2) Remove plate (2), spring (13), and 3. Blade lift valve
3) Remove lower case (1), plate (2), spring 2) Install lower retainer (11), spring (14), and
(14), and retainer (11). plate (2). Fit the O-ring to case (1) and
4) Remove spool (4). install them.
a Do not disassemble spool assembly 3) Install retainer (10), spring (13), and plate
(4). (2).
4) Install spring (6) and retainer (7) to case
4. Blade lift valve (3) and secure them with bolt (8). Fit the
1) Remove case (3), loosen bolt (8), and O-ring to case (3) and install them.
remove retainer (7) and spring (6). 3 Retainer mounting bolt:
2) Remove plate (2), spring (13), and 11.8 – 14.6 Nm {1.2 – 1.5 kgm}
retainer (10). 3 Case mounting bolt:
3) Remove lower case (1), plate (2), spring 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
(14), and retainer (11).
4) Remove spool (4). 4. Blade lift valve
a Do not disassemble spool assembly 1) Install spool (4) to the valve body.
(4). 2) Install lower retainer (11), spring (14), and
plate (2). Fit the O-ring to case (1) and
5. Blade left tilt valve install them.
1) Remove case (1), spring (15), and retainer 3) Install retainer (10), spring (13), and plate
(9). (2).
2) Remove lower case (1), spring (15), and 4) Install spring (6) and retainer (7) to case
retainer (9). (3) and secure them with bolt (8). Fit the
3) Remove spool (3). O-ring to case (3) and install them.
a Do not disassemble spool assembly 3 Retainer mounting bolt:
(3). 11.8 – 14.6 Nm {1.2 – 1.5 kgm}
3 Case mounting bolt:
6. Ripper tilt valve 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
1) Remove case (1), spring (12), and retainer
(9).
2) Remove lower case (1), spring (12), and
retainer (9).
a Do not disassemble spool assembly
(2).
D475A, D475ASD-5E0 7
5. Blade right tilt valve

1) Install spool (3) to the valve body.
2) Install lower retainer (9) and spring (15).
Fit the O-ring to case (1) and install them.
3) Install retainer (9) and spring (15). Fit the
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 the O-ring to case (1) and install them.
3) Install retainer (9) and spring (12). Fit the
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
8 D475A, D475ASD-5E0
Disassembly and assembly of merge divider valve and self pressure

reducing valve assembly
D475A, D475ASD-5E0 9
Disassembly Assembly
1. Remove case (7) from valve body (1). Loosen q Coat the sliding surface of each part with
bolt (6) and remove retainer (8), spring (5), engine oil before installing.
retainer (4), plug (3), and spool (2).
1. Fit the O-ring and install ball (37), spring (36),
2. Remove plug (14), spring (12), and spool (11). and seat (35) to block (30).
3 Seat: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3. Remove plug (18), spring (17), and spool (16).
2. Fit the O-ring and install valve assembly (20) to
4. Remove plug (33), spring (32), and spool (31) block (30).
from block (30). 3 Valve assembly:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
5. Remove valve assembly (20) from block (30).
3. Install spool (31) and spring (32). Fit the O-ring
6. Remove seat (35), spring (36), and ball (37) and install plug (33).
from block (30). 3 Plug assembly:
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,
replace the whole merge divider valve 4. Install spool (16) and spring (17). Fit the O-ring
assembly. to plug (18) and install them to valve body (1).
3 Plug assembly:
147.1 – 186.3 Nm {15 – 19 kgm}
5. Install spring (12) to spool (11). Fit the O-ring to

plug (14) and install them.
3 Plug assembly:
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). Fit the O-ring and install case (7).
3 Mounting bolt of case (7):
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
10 D475A, D475ASD-5E0
Removal and installation of PPC

relief valve assembly
Removal
Releasing remaining pressure from hydrau-
lic circuit.
tank.
1. Remove operator’s cab right cover.
2. Remove hoses (1), (2), and (3).
3. Disconnect connector (4).
4. Remove PPC relief valve assembly (5).
Installation
removal.
D475A, D475ASD-5E0 11
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1. Cylinder tube
Remove cylinder tube.
Special tools 2. Quick drop valve assembly
a Blade lift cylinder only.
New/remodel
Necessity
1) Remove quick drop valve assembly (1).
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
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 2) Disassemble quick drop valve assembly
as follows.
790-201-1680 • Plate 1 1] Remove elbow (2).
3 790-201-1690 • Plate 1 2] Remove spring (3), washer (4), and
790-201-1530 • Plate 1 valves (5) and (6), and pull out collar
U
(7).
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
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
12 D475A, D475ASD-5E0
3. Piston rod assembly 6) Disassemble piston assembly as follows.

1) Set cylinder assembly (8) to tool U1. 1] Remove wear ring (17).
2) Remove head assembly (9). 2] Remove piston ring (18).
3) Pull out piston rod assembly (10).
a Put an oil container under the cylinder
to catch the oil.
5. Head assembly
1) Remove head assembly (19) from piston
rod.
4. Piston assembly
1) Set piston rod assembly (10) to tool U1.
2) Disassemble head assembly as follows.

1] Remove O-ring (20) and backup ring
2) Remove spacer (11). (21).
3) Remove piston assembly (12).
4) Remove backup rings (13) and (14), and
O-ring (15).
5) Remove retainer (16).
D475A, D475ASD-5E0 13

seal (23).
3] Remove packing (24), then remove
bushing (25).
5] Install backup ring (21) and O-ring

(20).
Assembly
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 installing.
1. Head assembly
1) Assemble head assembly as follows.
1] Using tool U2, press fit bushing (25)
to head.
2] Install packing (24).
3] Using tool U3, press fit seal (23). 2) Install head assembly (19) to piston rod.
4] Install snap ring (22).
14 D475A, D475ASD-5E0
2. Piston assembly 2) Install retainer (16).

1) Assemble piston assembly as follows. 3) Install O-ring (15) and backup rings (14)
1] Using tool U4, expand piston ring and (13).
(18). a Coat the O-ring and backup ring por-
a Set the piston ring on the tion with grease, and secure the
expander and turn the handle 8 – backup ring to prevent it from open-
10 times to expand the ring. ing.
2] Remove piston ring (18) from tool U4, 4) Install piston assembly (12).
then install to piston. 5) Assemble spacer (11) and tighten mount-
3] Set tool U5 in position and compress ing bolts.
piston ring (18). 2 Mounting bolt:
4] Install wear ring (17) to piston. Thread tightener (LT-2)
3 Mounting bolt:
Blade lift:
98 – 123 Nm {10 – 12.5 kgm}
Blade lift, ripper lift, ripper tilt:
157 – 196 Nm {16 – 20 kgm}
3. Piston rod assembly

1) Set cylinder (8) to tool U1.
D475A, D475ASD-5E0 15
2) Assemble piston rod (10) to cylinder (8). 2) Install quick drop valve assembly (1).
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.
3 Mounting bolt:
Blade lift:
490 ± 49 Nm {50 ± 5 kgm}
Blade tilt, ripper lift, ripper tilt:
1,320 ± 140 Nm {135 ± 15 kgm}
5. Cylinder tube
Install cylinder tube.
4. Quick drop valve assembly

a Blade lift cylinder only.
1) Assemble quick drop valve assembly as
follows.
1] Assemble collar (7), and install valves
(6) and (5), washer (4), and spring
(3).
2] Install elbow (2).
16 D475A, D475ASD-5E0
Disassembly and assembly of a Put an oil container under the cylinder

ripper pin puller cylinder to catch the oil.
assembly
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
Cylinder repair
1 790-502-1003 q 1
stand
790-201-1881 • Push tool 1
790-201-1871 • Push tool 1 2. Cylinder head assembly
2 1) Remove cylinder head assembly (2) from
790-201-1721 • Push tool 1
piston rod (3).
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
4 790-720-1000 Expander t 1
796-720-1690 Ring t 1
07281-01919 Clamp t 1 2) Remove O-ring (5) and backup ring (6).
3) Remove O-ring (7).
796-720-1690 Ring t 1
4) Remove snap ring (8), then remove dust
07281-02169 Clamp t 1 seal (9).
5
796-720-1710 Ring t 1 5) Remove rod packing (10), then remove
bushing (11).
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
assembly (2).
3) Remove piston rod (3) together with cylin-
der head assembly (2).
D475A, D475ASD-5E0 17

Remove piston ring (12) from piston rod (3).
2. Cylinder head assembly

1) Using tool U2, press fit bushing (11) to cyl-
inder head (4).
Assembly
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 installing.

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).
2) Using tool U3, press fit dust seal (9) to cyl-
inder head (4).
18 D475A, D475ASD-5E0
3) Install snap ring (8) and rod packing (10). 3. Cylinder assembly
4) Install O-ring (7). 1) Set cylinder to tool U1 and support with
5) Install backup ring (6) and O-ring (4). 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
assembly (2).
3 Cylinder head assembly:
441 ± 44.1 Nm {45 ± 4.5 kgm}
6) Install cylinder head assembly (2) to pis-

ton rod (3).
D475A, D475ASD-5E0 19
SEN02019-00

© 2007 KOMATSU
All Rights Reserved
20
SEN02020-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Work equipment
Work equipment .............................................................................................................................................. 2
Removal and installation of blade assembly ........................................................................................ 2
Disassembly and assembly of giant ripper assembly .......................................................................... 4
D475A, D475ASD-5E0 1
Work equipment 1
Removal and installation of blade k Release the remaining pressure from the
assembly 1
hydraulic circuit.
" R e l e a s i n g re m a i ni n g pr e s s ur e f ro m
Removal hydraulic circuit".
k Lower the work equipment to the ground in Then loosen the oil filler cap slowly to
a horizontal place, and set blocks [1] release the pressure inside the hydraulic
securely under the left and right straight tank.
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
entering 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.
q Repeat the same procedure to disconnect 6. Remove blade assembly (7).
the cylinder from the blade on the oppo- a Start the engine, drive the machine slowly
site side. in reverse, and disconnect the blade
assembly from the trunnions.
2 D475A, D475ASD-5E0
Installation
removal.
[*1]
a Adjust with block [1] so that height (b) and
width (c) of the left and right straight frames are
the dimensions given below.
q Height (b) of trunnion portion:
Approx. 981 mm
q Brace width (c): Approx. 3,840 mm

Run the engine to circulate the oil through the
system. Then check the oil level again.
D475A, D475ASD-5E0 3
Disassembly and assembly of 7. Disconnect 4 lift cylinder hoses (4), 4 tilt cylin-
giant ripper assembly der hoses (5), and 2 pin-puller cylinder hoses
(6).
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
4. Set stand [2] under arm and beam.

8. Sling tilt cylinder assembly (7), then remove
pin (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, and lower on top of the arm.
6. Sling lift cylinder assembly and remove pin (3). 9. Sling lift cylinder assembly (9), then remove
a Start the engine, retract the piston rod pin (10) and lift off lift cylinder assembly (9).
4
fully, and lower on top of the lift cylinder. Lift cylinder assembly: 400 kg
k Release the remaining pressure from
the hydraulic circuit.
"Releasing remaining pressure from
hydraulic circuit".
4 D475A, D475ASD-5E0
10. Sling beam (11), then remove left and right 2. Sling beam (11) and set in mounting position,
pins (12) and lift off beam (11). then fit left and right pins (12) and secure with
4 Beam: 2,450 kg lock plate.
4 Arm: 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 Arm: 1,800 kg 3. Sling lift cylinder assembly (9) and set in
mounting 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 4. Sling tilt cylinder assembly (7) and set in
lock plate. mounting position, then fit pin (8) and secure
4
with lock plate.
Arm: 1,800 kg
a Set a stand under the arm. 4 Tilt cylinder assembly: 410 kg
D475A, D475ASD-5E0 5
5. Connect 2 pin-puller cylinder hoses (6), 4 tilt 8. Mount machine on block [1] and lower blade to
cylinder 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.

For details, see Testing and adjusting, "Bleed
air from hydraulic cylinder".
6 D475A, D475ASD-5E0
D475A, D475ASD-5E0 7
SEN02020-00

© 2007 KOMATSU
All Rights Reserved
8
SEN02021-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Cab and its attachments

Cab and its attachments ................................................................................................................................. 2
Removal and installation of ROPS guard............................................................................................. 2
Removal and installation of operator’s cab assembly .......................................................................... 3
Removal and installation of floor frame assembly................................................................................ 4
D475A, D475ASD-5E0 1
Cab and its attachments 1
Removal and installation of ROPS

guard 1
Removal
1. Sling ROPS guard (1) and remove 16 mount-
ing bolts (2). [*1]
2. Lift off ROPS guard (1).

4 ROPS guard: 918 kg
Installation
removal.
[*1]
3 ROPS guard mounting bolt:
1,960 – 2,450 Nm {200 – 250 kgm}
2 D475A, D475ASD-5E0
Removal and installation of 6. Remove front covers (8), (9) and (10).
operator’s cab assembly
7. Remove 3 mounting bolts (11), 6 bolts (12) and
15 bolts (13).
Removal
1. Remove ROPS guard.

For details, see Removal of ROPS guard.
2. Remove left cover (1) of operator’s cab.
3. Disconnect wiring connectors (12V, 21 and 20)

(2).
4. Disconnect 4 washer hoses (3) and 19 washer

wires (4).
Washer hose 8. Sling operator’s cab assembly (14), then
Red : Right door Black : Rear window remove.
4
Blue : Left door – : Front window Operator’s assembly: 500 kg
5. Remove garnishes (5), (6) and (7).

Installation
removal.
D475A, D475ASD-5E0 3
Removal and installation of floor 4. Remove sidecover (5).

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
799-703-1401 Gas leak detector t 1 5. Disconnect brake pedal linkage (6). [*4]
a Check the mounting dimensions of brake
rod before disconnection.
Removal
1. Remove operator’s cab assembly.
For details, see "Removal of operator’s 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 Operator’s seat: 64 kg
4 D475A, D475ASD-5E0
7. Remove wiring connector (12) (CN2-SSA-PT1) 11. Remove brake rod (17).
and the clamp.
12. Disconnect parking brake cable (18). [*3]
8. Disconnect wiring connector (13) (995-111-
VFD) and remove the connector bracket. 13. Disconnect air conditioner hose (19). [*1]
a Collect the refrigerant (R134a) from the air
conditioner circuit.
14. Disconnect heater hose (20).
9. Disconnect blade PPC hose (14A), hose (14B)

and ripper PPC hose (15). [*2]
10. Disconnect wiring connector and clamp (16).

15. Disconnect wiring connector (21) and clamp
(22).
16. Remove floor frame bracket bolt (23) on right

side.
17. Disconnect ground wiring (24).
18. Remove floor frame bracket bolt (25) on left

side.
D475A, D475ASD-5E0 5
19. Remove 8 floor frame rear mounting bolts (26). Installation

removal.
[*1]
a Install the hoses without twisting or inter-
ference.
a Install the air conditioner circuit hoses
carefully to prevent dirt, dust, or water
from getting inside the hoses.
a Check that there are O-rings at the piping
connection of the air conditioner hoses
before installing.
Coat the O-rings thoroughly with compres-
sor oil (Shell Suniso 4G or 5G).
20. Lift off floor frame assembly (27).
4 Floor frame assembly: 500 kg
a Use a chain block to adjust the balance in all
directions (front, rear, left, and right), and lift off
slowly.
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)
M6 bolt
9.8 ± 1.96 {1.0 ± 0.2}
(compressor portion)
6 D475A, D475ASD-5E0
[*2]
a The connecting positions of the PPC
hoses are indicated by the band colors on
their quick couplers. When connecting
them, confirm them by the band colors.
[*3]
a Adjust installed length of parking brake
cable. For details, see Testing and adjust-
ing, Adjusting brake pedal and parking
brake lever.
[*4]
a Adjust installed length of brake rod.
"Adjusting brake pedal and parking brake
lever".
3 Brake pedal linkage turnbuckle:
34.3 – 58.8 Nm {3.5 – 6 kgm}
q Charging with air conditioner gas

Using tool X, charge the air conditioner circuit
with air conditioner gas (R134a).

D475A, D475ASD-5E0 7
SEN02021-00

© 2007 KOMATSU
All Rights Reserved
8
SEN02339-00
D475A-5E0
D475ASD-5E0

D475A-5E0 30001 and up
Electrical system
Electrical system ............................................................................................................................................. 2
Removal and installation of controller assembly .................................................................................. 2
Removal and installation of engine controller assembly (left) .............................................................. 3
Removal and installation of air conditioner condenser assembly ........................................................ 4
Removal and installation of air conditioner compressor assembly ...................................................... 5
Removal and installation of air conditioner unit.................................................................................... 7
D475A, D475ASD-5E0 1
Electrical system 1
Removal and installation of 5. Disconnect wiring connectors of engine con-

controller assembly 1
troller (6).
(CN-LE1, CN-LE32, CN-LE31, CN-LE4, CN-
LE2, CN-LE52, CN-LE51)
Removal
k Disconnect the cable from the negative (–) 6. Remove engine controller (6).
7. Remove engine controller mounting bracket
1. Remove cover (1). (7).
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-

troller (9). (CN-STCN1, CN-STCN2, 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.
2 D475A, D475ASD-5E0
Removal and installation of 3. Disconnect wirings (3), (4) and (5).

engine controller assembly (left) 1
Removal
1. Remove undercover (1).
4. Remove ground cable fixing bolt (6) and con-

troller (7).
2. Remove the 4 controller cover mounting bolts

and remove cover (2).
a Remove the fan motor piping clamps to
make a space for work.
a The cover mounting bolts are used to fix
the controller, too.
5. Remove the right controller similarly to the left

one.
Installation
removal.
D475A, D475ASD-5E0 3
Removal and installation of air 3. Remove air conditioner condenser assembly

conditioner condenser assembly (5) from right side of chassis.
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

799-703-1100 Vacuum pump t 1
799-703-1121 Vacuum pump t 1
Installation
Removal
1. Open engine right side cover (1) and remove removal.
side covers (2) and (3).
[*1]
before installing.
3 Air conditioner hose sleeve nut:
Outside:
22.05 ± 2.45 Nm {2.25 ± 0.25 kgm}
Inside:
13.25 ± 1.47 Nm {1.35 ± 0.15 kgm}
2. Disconnect hoses (4). [*1]

a Fit blind plugs to prevent dirt or moisture
from entering the hoses.
a Be careful not to damage or drop the O-
rings.
4 D475A, D475ASD-5E0
Removal and installation of air 2. Disconnect air conditioner compressor clutch

conditioner compressor connector (CN-351) (4).
assembly 3. Disconnect 2 compressor hoses (5). [*1]
Special tools conditioner circuit.
a Fit blind plugs to prevent dirt or moisture
New/remodel
from entering the hoses.
Necessity
Symbol
Sketch
a Be careful not to damage or drop the O-
Q'ty
Part No. Part Name
rings.

799-703-1100 Vacuum pump t 1
799-703-1121 Vacuum pump t 1
Removal
terminal 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

conditioner compressor assembly (8).
D475A, D475ASD-5E0 5
Installation
removal.
[*1]
before installing.
3 Air conditioner hose mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
[*2]
a Adjust the belt tension.
"Testing and adjusting tension of air condi-
tioner compressor belt".

6 D475A, D475ASD-5E0
Removal and installation of air 6. Disconnect air hose (7).

conditioner unit
Special tools
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name

799-703-1100 Vacuum pump t 1
799-703-1121 Vacuum pump t 1
799-703-1401 Gas leak detector t 1 7. Remove fresh air filter bracket (8).
8. Disconnect 2 air conditioner hoses (9).

Removal
1. Remove operator's seat (1). 9. Disconnect heater hose (10).
10. Disconnect wire and wiring connector (11).
11. Remove air conditioner unit (12).

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).
D475A, D475ASD-5E0 7
Installation
removal.
[*1]
a Install the hoses without twisting or inter-
ference.
before installing.
3 Tighten the air conditioner gas pip-
ing 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)
M6 bolt (compres-
9.8±1.96 {1.0±0.2}
sor portion)


8 D475A, D475ASD-5E0
D475A, D475ASD-5E0 9
SEN02339-00

© 2007 KOMATSU
All Rights Reserved
10
SEN00225-00
D475A-5E0
D475ASD-5E0
Machine Model Serial Number

D475A-5E0 30001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic diagrams and drawings................................................................................................................... 3
Power train hydraulic circuit diagram ................................................................................................... 3
Hydraulic circuit diagram (1/3) ............................................................................................................. 5
D475A, D475ASD-5E0 1
Hydraulic diagrams and drawings Power train hydraulic circuit diagram

D475A, D475ASD-5E0
Power train hydraulic circuit diagram
D475A, D475ASD-5E0 3
Hydraulic circuit diagram (1/3) Hydraulic circuit diagram (1/3)
D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0 5
D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0 7
D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0 9
SEN00225-00

© 2006 KOMATSU
All Rights Reserved
12
SEN00226-01
D475A-5E0
D475ASD-5E0
Machine Model Serial Number

D475A-5E0 30001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical diagrams and drawings ................................................................................................................... 3
Electrical circuit diagram (1/13)............................................................................................................ 3
Electrical circuit diagram (5/13)...........................................................................................................11
Electrical circuit diagram (6/13).......................................................................................................... 13
Electrical circuit diagram (10/13)........................................................................................................ 21
Electrical circuit diagram (11/13) ........................................................................................................ 23
Electrical circuit diagram of inside cab ............................................................................................... 29
Connector arrangement diagram ....................................................................................................... 31
D475A, D475ASD-5E0 1
Electrical diagrams and drawings Electrical circuit diagram (1/13)
D475A, D475ASD-5E0
Electrical circuit diagram (1/13)
SEN00226-01
D475A, D475ASD-5E0 3
Electrical circuit diagram (2/13) Electrical circuit diagram (2/13)
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 5
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 7
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 9
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 11
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 13
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 15
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 17
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 19
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 21
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 23
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 25
D475A, D475ASD-5E0
SEN00226-01
D475A, D475ASD-5E0 27
Electrical circuit diagram of inside cab Electrical circuit diagram of inside cab
D475A, D475ASD-5E0
D475A, D475ASD-5E0 29
Connector arrangement diagram
D475A, D475ASD-5E0
Connector arrangement diagram D475A, D475ASD-5E0
Connector Number Address of Connector Number Address of Connector Number Address of Connector Number Address of
Model Component name Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram No. of pins stereogram
1 Giboshi 1 Lamp outlet connector (Cab) J-9 BRE Terninal 1 Battery relay (Right) (Terminal E) E-8 GND4 Terninal 1 Ground (Engine) AT-3 SFTU — 3 PCCS lever shift-up switch V-9
2 Terninal 1 Rear left speaker (Cab) J-9 BRE Terninal 1 Battery relay (Left) (Terminal E) I-2 H01 Giboshi 1 Additional heater switch (If equipped) Y-2 SL81 DT 2 Left brake ECMV (Solenoid) BB-6
3 Terninal 1 Rear left speaker (Cab) J-9 BRK DT 3 Brake potentiometer U-2 H02 Giboshi 1 Additional heater switch (If equipped) Y-2 SLC5 DT 2 Left clutch ECMV (Solenoid) BA-6
4 — 4 Rear wiper motor (Cab) I-9 BSW HD-18 14 Intermediate connector (BULGA specification) X-2 HLS DT 2 Hydraulic oil level switch (If equipped) H-9 SLS — 2 Daylight sensor AF-8
5 Terninal 1 Rear right speaker (Cab) I-9 BUA DT 2 Backup alarm I-9 HP1 DT 3 Work equipment pump oil pressure (F) F-9 SR83 DT 2 Right brake ECMV (Solenoid) BB-6
6 Terninal 1 Rear right speaker (Cab) I-9 BUZ KES-1 3 Buzzer switch AH-7 HP2 DT 3 Work equipment pump oil pressure (R) F-9 SRC7 DT 2 Right clutch ECMV (Solenoid) BA-7
9 — 6 Front wiper motor (Cab) G-9 CB1 Terninal 1 Circuit breaker (20 A) (Steering controller) AK-4 HR1 DT-B 12 Intermediate connector (Hood) P-4 SRT1 DT 2 Reverse clutch ECMV (Solenoid) AX-5
10 — 9 Radio (Cab) K-9 CB2 Terninal 1 Circuit breaker (20 A) (Monitor panel) AK-4 HR2 DT-A 12 Intermediate connector (Hood) P-4 SRV DT-A 12 Service connector AH-2
11 KES1 6 Left wiper switch (Cab) J-1 CB3 Terninal 1 Circuit breaker (20 A) (Transmission controller) AK-4 HRN1 Terninal 1 Horn (415 Hz) D-1 SSA DT 4 Acceleration sensor (SSC model) R-1
12 KES1 6 Front wiper switch (Cab) J-2 CB4 Terninal 1 Circuit breaker (20 A) (Air conditioner) AK-3 HRN2 Terninal 1 Horn (350 Hz) C-7 ST/B2 Terninal 1 Safety relay (Terminal B) AV-4
13 KES1 6 Right wiper switch (Cab) K-2 CB5 Terninal 1 Circuit breaker (20 A) (Headlamp) AK-3 HT1 Terninal 1 Electrical intake air heater (Left bank) AV-6 ST1 DT 3 Intermediate connector (Starting motor A) AV-5
14 KES1 6 Rear wiper switch (Cab) K-2 CB6 Terninal 1 Circuit breaker (20 A) (Starting switch terminal B) AK-3 HT2 Terninal 1 Electrical intake air heater (Right bank) AR-8 ST2 DT 2 Intermediate connector (Starting motor B) AV-5
15 M 2 Lamp switch (Cab) K-2 CM29 AMP070 10 ORBCOMM terminal AK-9 HTR1A Terninal 1 Preheater relay (Left) AR-1 ST8 DT 2 Emergency stop valve BB-6
17 YAZAKI 4 Right door wiper motor (Cab) G-9 CM30 AMP070 14 ORBCOMM terminal AJ-8 HTR1C Terninal 1 Preheater relay (Left) AR-1 STB Terninal 1 Safety relay (Terminal B) AV-5
18 YAZAKI 4 Left door wiper motor (Cab) L-4 CN1 DT 2 Injector #1 (Left bank) AS-9 HTR2A Terninal 1 Preheater relay (Right) AQ-1 STCN1 DRC26 24 Steering controller AD-2
19 DT 4 Intermediate connector (Window washer) K-3 CN1 DT 2 Injector #1 (Right bank) AQ-7 HTR2C Terninal 1 Preheater relay (Right) AQ-2 STCN2 DRC26 40 Steering controller AE-2
20 DTHD#8 1 Cab power supply Z-4 CN2 DT 2 Injector #2 (Left bank) AV-4 J1939 DT-A 8 Intermediate connector AU-2 STCN3 DRC26 40 Steering controller AE-1
21 DTHD#12 1 Cab unswitched power supply Z-3 CN2 DT 2 Injector #2 (Right bank) AR-8 KEY DT 6 Starting switch AH-8 STF X 4 Steering controller write connector AD-4
22 Terninal 1 Cigarette lighter (Cab) L-9 CN3 DT 2 Injector #3 (Left bank) AV-5 L.P. HD-18 14 Intermediate connector (Injector left bank) AS-2 SW Terninal 1 Battery relay (Right) (Terminal BR) F-9
25 Giboshi 1 Rotary lamp outlet connector (Cab) K-9 CN3 DT 2 Injector #3 (Right bank) AR-8 L.S. HD-18 14 Intermediate connector (Injector left bank) AS-2 SW Terninal 1 Battery relay (Left) (Terminal BR) I-1
26 M 2 Rotary lamp switch (Cab) K-2 CN4 DT 2 Injector #4 (Left bank) AV-5 LMFL Relay 5 Front lamp relay (Left) AK-1 SX8 Terninal 1 Ground L-4
81 — 2 Room lamp (Cab) H-9 CN4 DT 2 Injector #4 (Right bank) AS-8 LMFR Relay 5 Front lamp relay (Right) AL-1 TAM1 PACKARD 2 Intake air temperature sensor AV-8
101 DT-B 12 Intermediate connector (Bulkhead wiring harness) P-3 CN5 DT 2 Injector #5 (Left bank) AV-6 LMRP Relay 5 Ripper point lamp relay AL-1 TC1 DT 2 Torque converter outlet speed sensor BB-5
102 DT-A 12 Intermediate connector (Bulkhead wiring harness) P-3 CN5 DT 2 Injector #5 (Right bank) AS-9 LMW Relay 5 Working lamp relay AL-1 TFUEL PACKARD 2 Fuel temperature sensor (Left bank) AU-4
201 DT-B 12 Intermediate connector (Yoke angle sensor) D-7 CN6 DT 2 Injector #6 (Left bank) AV-6 LSV DT 2 Pump LS selector solenoid AW-5 TFUEL PACKARD 2 Fuel temperature sensor (Right bank) AQ-6
203 DT 2 Right headlamp C-7 CN6 DT 2 Injector #6 (Right bank) AU-9 MFD DT 2 Merge-divider solenoid valve R-7 TIM PACKARD 2 Intake air temperature sensor AQ-4
204 DT 2 Left headlamp C-7 CONV DT 6 Converter X-8 MMS DT-C 12 Intermediate connector AO-6 TL1 HD-24 23 Intermediate connector (PCCS lever) Y-2
207 DT 2 Left headlamp D-7 CSL DT 3 Left yoke angle sensor E-1 NE SUMITOMO 3 Ne sensor AV-8 TL2 DT-B 8 PCCS lever potentiometer W-8
208 DT 2 Right headlamp C-7 CSR DT 3 Right yoke angle sensor B-3 NSF Relay 5 Neutral safety relay AM-1 TL3 DT 6 Intermediate connector (Console) W-9
209 DT-A 12 Intermediate connector (Small hood) E-1 CT1 DT 3 CAN terminal resistor AF-8 NSW DT 3 Parking brake switch AM-4 TLL DT 2 Left tilt limit solenoid valve Q-7
217 DT 2 Caution buzzer AE-6 CTV DT 3 CAN terminal resistor AN-6 OEM HD-24 21 Intermediate connector AR-3 TLR DT 2 Right tilt limit solenoid valve Q-7
221 DT 2 Left working lamp H-1 CUR KES-1 3 Cursor switch AI-7 OEM L DRC-50 50 Engine controller (Left bank) AV-1 TLS DT 2 Blade tilt left oil pressure switch Q-8
223 DT 2 Ripper point lamp (If equipped) L-6 DEC DT 3 Decelerator pedal T-2 OEM R DRC-50 50 Engine controller (Right bank) AU-2 TM1 DT 2 Transmission outlet speed sensor BB-5
226 DT 2 Left rear working lamp L-7 DIAL M 3 Fuel control dial W-9 OLLV DT 2 Engine oil level switch AR-3 TMC1 DRC26 24 Transmission controller AI-5
241 DT-A 12 Intermediate connector (Right fender) G-9, P-6 DL1 BENDIX 5 Download connector (ORBCOM specification) M-3 OLV1 DT 2 Intermediate connector (Engine oil level) AU-9 TMC2 DRC26 40 Transmission controller AI-5
242 DT 2 Right working lamp D-8 DLT DT 2 Download right (ORBCOM specification) L-2 OLV2 — 2 Intermediate connector (Engine oil level) AS-8 TMC3 DRC26 40 Transmission controller AI-4
243 DT 2 Right rear working lamp H-9 DPNL DT 2 Diode AX-8 P03 DT 6 Intermediate connector (Work equipment knob switch) Q-9 TMF X 4 Transmission write connector AD-4
244 DT 2 Pin puller solenoid L-5 DUL DT 2 Dual tilt selector solenoid valve R-8 PAMB AMP 3 Ambient pressure sensor AV-6 TMMD DT 3 Transmission main oil pressure AW-5
250 Terninal 1 Starting switch (Terminal B) AI-9 EG1 DTP 4 Intermediate connector (Engine) AQ-1 PCV1 SUMITOMO 2 Supply pump #1 (Left bank) AU-3 TOIL PACKARD 2 Engine oil temperature sensor AV-4
255 Terninal 1 Starting switch (Terminal R1) AI-8 EG2 HD-24 23 Intermediate connector (Engine) AV-7 PCV1 SUMITOMO 2 Supply pump #1 (Right bank) AQ-5 TRS DT 2 Blade tilt right oil pressure switch P-8
256 Terninal 1 Starting switch (Terminal R2) AI-8 EHL Relay 5 Engine hold relay AK-1 PCV2 SUMITOMO 2 Supply pump #2 (Left bank) AU-4 TS1 DT-C 12 Intermediate connector (Monitor panel) AI-3
260 Terninal 1 Starting switch (Terminal BR) AH-8 ENBP DT 3 Blow-by pressure AQ-3 PCV2 SUMITOMO 2 Supply pump #2 (Right bank) AQ-5 TS1F DT-C 12 Intermediate connector (Steering controller) AI-3
262 X 2 Intermediate connector (Horn switch) S-9 ENG DRC-60 60 Engine controller (Left bank) AV-1 PFUEL AMP 3 Common rail pressure sensor (Left bank) AU-4 TS2 DT-D 12 Intermediate connector (Monitor panel) AD-3
263 X 2 Pin puller switch U-9 ENG DRC-60 60 Engine controller (Right bank) AU-2 PFUEL AMP 3 Common rail pressure sensor (Right bank) AU-9 TS2F DT-D 12 Intermediate connector (Steering controller) AD-3
265 Terninal 1 Horn switch T-9 ENGL HD-18 21 Intermediate connector (Engine sensor) AS-2 PHR Relay 5 Preheater relay AM-1 TTM DT-B 12 Intermediate connector (Monitor panel) AD-5
266 Terninal 1 Horn switch T-9 ESD DT 3 Intermediate connector (Fuse box) AN-1 PIM SUMITOMO 3 Boost pressure sensor AR-3 TTMF DT-B 12 Intermediate connector (Transmission controller) AD-5
270 Terninal 1 Starting switch (Terminal ACC) AH-9 EXA1 DT 3 Exhaust temperature sensor amplifier (Left 1) AN-6 PL1 HD-24 23 Intermediate connector (Power train) BB-4 TWTR PACKARD 2 Coolant temperature sensor AR-3
280 Terninal 1 Starting switch (Terminal C) AI-9 EXA2 DT 3 Exhaust temperature sensor amplifier (Left 2) AL-5 PL1F HD-24 23 Intermediate connector (Emergency escape device) (If equipped) AY-8 USB DTHD#8 1 Intermediate connector (Fuse) Z-4
360 DT 6 Washing tank motor K-3 EXA3 DT 3 Exhaust temperature sensor amplifier (Right 1) AN-8 PL1M HD-24 23 Intermediate connector (Emergency escape device) (If equipped) AY-8 V1 AMP070 20 VHMS controller AK-6
369 DT 6 Washing tank motor L-3 EXA4 DT 3 Exhaust temperature sensor amplifier (Right 2) AJ-7 PL2 HD-24 31 Intermediate connector (Power train) AY-8, BB-4 V2A AMP070 18 VHMS controller AL-9
422 DT 2 Fuel level gauge L-5 EXTLF DT 2 Exhaust temperature sensor (Left front) AU-9 PL3 HD-18 14 Intermediate connector (Power train) BB-4 V2B AMP070 12 VHMS controller AM-9
453 DT 2 Torque converter oil temperature sensor AZ-2 EXTLR DT 2 Exhaust temperature sensor (Left rear) AT-9 PLUB Relay 5 Pre-lubricator relay AK-3 V3A AMP070 18 VHMS controller AM-5
599 DT-A 12 Intermediate connector (Left fender) Z-4 EXTRF DT 2 Exhaust temperature sensor (Right front) AT-9 PM1 Terninal 1 Pre-lubricator motor (If equipped) F-1 V3B AMP070 12 VHMS controller AL-5
653 DT 2 Lockup solenoid AX-5 EXTRR DT 2 Exhaust temperature sensor (Right rear) AT-9 PNL HD-24 31 Intermediate connector (Emergency escape device) (If equipped) AW-9 V4A AMP070 14 VHMS controller AO-8
800 Giboshi 1 Intermediate connector (Spare power supply 1) AN-2 EXT1 DT 2 Exhaust temperature sensor amplifier (Left 1) AM-5 POIL FRAMATOME 3 Engine oil pressure sensor AV-4 V4B AMP070 10 VHMS controller AO-7
801 Giboshi 1 Intermediate connector (Spare power supply 2) AN-2 EXT2 DT 2 Exhaust temperature sensor amplifier (Left 2) AN-9 POP Terninal 1 Pre-lubricator pressure switch (If equipped) AV-5 VDA HD-18 14 Intermediate connector (Download) M-3
810 Giboshi 1 Spare power supply 1 Z-5 EXT3 DT 2 Exhaust temperature sensor amplifier (Right 1) AJ-7 PPB DT 2 Pitch back solenoid valve R-8 VDB DT-A 8 Intermediate connector (Left fender) Z-4
811 Giboshi 1 Spare power supply 2 Z-5 EXT4 DT 2 Exhaust temperature sensor amplifier (Right 2) AN-9 PPD DT 2 Pitch dump solenoid valve R-8 VDW BENDIX 5 VHMS download (ORBCOM specification) Y-8
12S1 YAZAKI 2 Accessory socket X-8 F1T8 DT 2 1st clutch ECMV (Fill switch) AY-6 PPV DT 2 Pitch priority solenoid valve S-8 VEG HD-24 21 Intermediate connector (Engine) AV-7
12S2 YAZAKI 2 Accessory socket X-8 F2T6 DT 2 2nd clutch ECMV (Fill switch) AY-6 PR1 Terninal 1 Pre-lubricator relay (If equipped) E-8 VF1 HD-24 21 Intermediate connector (Floor) AJ-6
12V DT 3 Intermediate connector (Cab) Z-3 F3T4 DT 2 3rd clutch ECMV (Fill switch) AZ-6 PR2 Terninal 1 Pre-lubricator relay (If equipped) E-8 VF2 HD-24 23 Intermediate connector (Floor) AK-5
AC DT 2 Air conditioner compressor AQ-7 F30 — 1 Circuit breaker (30 A) B-9 PR3 Terninal 1 Pre-lubricator relay (If equipped) F-1 WLD DT 2 Coolant level sensor C-2
AC1 DT-A 12 Intermediate connector (Air conditioner) W-8 F96 — 1 Circuit breaker (105 A) B-9 PR4 Terninal 1 Pre-lubricator relay (If equipped) G-1 a The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles, 12 poles) are as follows.
AC2 HD-24 31 Intermediate connector (Air conditioner) Z-6 FA1 DT 2 Fun pump solenoid AZ-2 PRE DT 2 Pre-lubricator AN-3 DT-A = Gray, DT-B = Black, DT-C = Green, DT-D = Brown
ACT DT 2 Air conditioner external air sensor E-8 FA2 DT 2 Fun pump solenoid BA-3 PRS DT 2 Pre-lubricator AN-4
ACT Relay 5 ACC cut relay AK-2 FAN1 KES1 3 Fan clean mode switch AI-7 PT1 DT 3 Pitch angle sensor R-1
ACU S 12 Air conditioner unit Z-7 FAN2 KES1 4 Fan reverse mode switch AI-6 PTH DT 2 Pitch selector solenoid valve R-8
ADH KES1 4 Additional heater switch AI-6 FAR DT 2 Fan reverse solenoid D-2 PW L DTP 4 Engine controller (Left bank) AV-1
AF1 DT 2 Air cleaner clogging sensor G-1 FD5 DT-B 12 Fuse wiring harness W-1 PW R DTP 4 Engine controller (Right bank) AT-2
AF2 DT 2 Air cleaner clogging sensor H-1 FFT2 DT 2 Forward clutch ECMV (Fill switch) AZ-6 PWR1 DTHD#4 1 Intermediate connector (fuse) Z-5
ANB Terninal 1 Alternator (Terminal B) AQ-7 FL82 DT 2 Left brake ECMV (Fill switch) BB-6 PWR2 DTHD#4 1 Intermediate connector (fuse) Z-5
ANR Terninal 1 Alternator (Terminal R) AQ-7 FLC6 DT 2 Left clutch ECMV (Fill switch) BA-7 R.P. HD-18 14 Intermediate connector AQ-5
AP1 AMP040 16 Air conditioner control panel U-2 FR84 DT 2 Right brake ECMV (Fill switch) BA-6 R.S. HD-18 14 Intermediate connector (Injector right bank) AQ-5
AP2 AMP040 20 Air conditioner control panel U-2 FRC8 DT 2 Right clutch ECMV (Fill switch) BA-7 REL1 Terninal 1 Preheater relay (Left) AR-2
AP3 SWP 12 Air conditioner unit Y-7 FRT2 DT 2 Reverse clutch ECMV (Fill switch) AY-6 REL2 Terninal 1 Preheater relay (Right) AQ-2
AP4 SWP 16 Air conditioner unit Z-7 FS11 — — Fuse box AL-4 RES DT 2 Left bank resistor (Pull-up) AT-3
AP5 SWP 8 Air conditioner unit Y-7 FS12 — — Fuse box AL-4 RES DT 2 Right bank resistor (Pull-up) AQ-4
ASD KES1 4 Auto shift-down switch AH-8 FS21 — — Fuse box AL-4 RES L DT 3 CAN terminal resistor (Left bank) AU-1
ASUS DT 2 Intermediate connector (Air suspension seat) U-9 FS22 — — Fuse box AL-4 RES R DT 3 CAN terminal resistor (Right bank) AQ-3
B7L — 1 Circuit breaker (30 A) C-9 FS31 — — Fuse box AM-4 RPD DT 2 Ripper lower oil pressure switch P-9
B7S — 1 Circuit breaker (30 A) C-8 FS32 — — Fuse box AM-4 RPNL X 2 Resistor AY-9
B8L — 1 Circuit breaker (30 A) C-8 FSB HD-24 31 Intermediate connector (Fuse box) W-1 RPU DT 2 Ripper raise oil pressure switch Q-9
B8S — 1 Circuit breaker (30 A) C-8 FTU KES-1 4 Auto pitch back switch AH-8 RSD DT 2 Diode P-6
B30S — 1 Circuit breaker (30 A) B-9 FWL KES-1 4 Front working lamp switch AI-6 RTB DT 2 Ripper tilt back oil pressure switch Q-8
B105H1L — 1 Circuit breaker (105 A) C-9 G SUMITOMO 3 G sensor (Left bank) AU-3 RTI DT 2 Ripper tilt in oil pressure switch P-9
B105H1S — 1 Circuit breaker (105 A) C-9 G SUMITOMO 3 G sensor (Right bank) AQ-5 RWL KES-1 4 Rear working lamp switch AI-7
B105H2L — 1 Circuit breaker (105 A) B-9 GND Terninal 1 Ground (Engine) AT-3 S01 AMP040 12 Monitor panel AG-8
B105H2S — 1 Circuit breaker (105 A) B-9 GND01 Terninal 1 Ground (Floor) X-1 S02 M 2 Monitor panel AF-8
B105S — 1 Circuit breaker (105 A) B-9 GND02 Terninal 1 Ground (Floor) X-1 S03 AMP070 20 Monitor panel AG-8
BKA Relay 5 Backup alarm relay AK-2 GND03 Terninal 1 Ground (Left fender) J-2 S04 AMP070 12 Monitor panel AG-8
BLD DT 2 Blade lower oil pressure switch Q-8 GND04 Terninal 1 Ground (Right fender) E-8 S1T7 DT 2 1st clutch ECMV (Solenoid) AY-6
BLMT YAZAKI 2 Air conditioner additional blower X-8 GND05 Terninal 1 Ground (Bulkhead) P-3 S21 DT 3 Intermediate connector (Monitor) AG-8
BLSW KES1 4 Additional blower motor switch AI-6 GND06 Terninal 1 Ground (Heater relay) AQ-2 S24 — — Service switch AD-6
BLU DT 2 Blade raise oil pressure switch Q-8 GND07 Terninal 1 Ground (Floor) AG-1 S2T5 DT 2 2nd clutch ECMV (Solenoid) AY-6
BRB Terninal 1 Battery relay (Right) (Terminal B) F-9 GND09 Terninal 1 Ground (Left fender) J-2 S3T3 DT 2 3rd clutch ECMV (Solenoid) AZ-6
BRB Terninal 1 Battery relay (Left) (Terminal B) J-2 GND1 Terninal 1 Ground (Engine) AS-2 SDS DT 2 Hydraulic oil temperature sensor AZ-2
BRC Terninal 1 Battery relay (Right) (Terminal M) F-8 GND2 Terninal 1 Ground (Engine) AS-2 SFT1 DT 2 Forward clutch ECMV (Solenoid) AZ-6
BRC Terninal 1 Battery relay (Left) (Terminal M) H-1 GND3 Terninal 1 Ground (Engine) AT-3 SFTD — 3 PCCS lever shift-down switch V-9
SEN00226-01
D475A, D475ASD-5E0 31
SEN00226-01

© 2006 KOMATSU
All Rights Reserved
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Shop Manual D475a-5

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SEN00203-02

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual................................................................................................................ 2

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00203-02

00 Index and foreword SEN00204-02

10 Structure, function and maintenance standard SEN00209-00

20 Standard value table SEN00220-00

30 Testing and adjusting SEN00221-00

Troubleshooting by failure code (Display of code), Part 4 SEN01826-00

50 Disassembly and assembly SEN00223-00

90 Diagrams and drawings SEN00224-01

Foreword and general information SEN00206-01

10 Structure, function and maintenance standard

Cab and its attachments SEN00218-00

20 Standard value table

30 Testing and adjusting

Emergency escape method when power train has trouble...................................................... 18

Failure code [15SBLH] Reverse clutch oil pressure:

Failure code [CB781] Inter-multicontroller communication error (Right bank):

Troubleshooting by failure code (Display of code), Part 5 SEN01827-00

Troubleshooting by failure code (Display of code), Part 6 SEN01828-00

Failure code [DXE0KB] LS set solenoid: Short circuit ............................................................. 4

Troubleshooting of hydraulic and mechanical system (H-mode) SEN01832-00

50 Disassembly and assembly

Removal and installation of aftercooler assembly ................................................................... 8

Overall disassembly and overall assembly of track shoe ........................................................ 5

90 Diagrams and drawings

Connector arrangement diagram............................................................................................. 31

D475A, D475ASD-5E0 Bulldozer

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2006/09)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of