D475a Bulldozer

SEN00203-04
BULLDOZER
-5E0 D475A D475ASD -5E0

SERIAL NUMBERS
D475A30001 and up D475ASD- 30001
SEN00205-04
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
30001 and up 30001 and up
00 Index and foreword

Index
Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
D475A, D475ASD-5E0
SEN00205-04
Composition of shop manual

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 accordingly. Section Title Shop Manual, contents binder, binder label and tabs 00 Index and foreword Index Foreword and general information 01 Specification Specification and technical data 10 Structure, function and maintenance standard Engine and cooling system Power train, Part 1 Power train, Part 2 Undercarriage and frame Hydraulic system, Part 1 Hydraulic system, Part 2 Hydraulic system, Part 3 Work equipment Cab and its attachments Electrical system 20 Standard value table Standard service value table 30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3 Testing and adjusting, Part 4 40 Troubleshooting Failure code table and fuse locations General information on troubleshooting Troubleshooting by failure code, Part 1 Troubleshooting by failure code, Part 2 Troubleshooting by failure code, Part 3 Form Number SEN00203-04 SEN00204-04 SEN00205-04 q SEN00206-02 SEN00207-01 SEN00208-01 SEN00209-01 SEN00210-00 SEN00211-00 SEN00212-00 SEN00213-01 SEN00214-00 SEN00215-00 SEN00216-00 SEN00217-00 SEN00218-00 SEN00219-00 SEN00220-01 SEN01816-01 SEN00221-02 SEN01817-01 SEN01818-01 SEN01819-02 q SEN01820-01 SEN00222-01 SEN01821-01 SEN01822-01 SEN01823-01 SEN01824-01 SEN01825-01 D475A, D475ASD-5E0
SEN00205-04
Troubleshooting by failure code, Part 4 Troubleshooting by failure code, Part 5 Troubleshooting by failure code, Part 6 Troubleshooting by failure code (Display of code), Part 7 Troubleshooting by failure code (Display of code), Part 8 Troubleshooting of electrical system (E-mode) Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode) 50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system (SAA12V140E-3) Engine (SAA12V140E-3) Power train, Part 1 Power train, Part 2 Undercarriage and frame, Part 1 Undercarriage and frame, Part 2 Hydraulic system Work equipment Cab and its attachments Electrical system 90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings
SEN01826-01 SEN01827-01 SEN01828-01 SEN01829-00 SEN01830-00 SEN01831-01 SEN01832-00 SEN01833-00 SEN00223-01 SEN02013-01 SEN02014-00 SEN02338-01 SEN02015-00 SEN02016-00 SEN02017-00 SEN02018-00 SEN02019-00 SEN02020-00 SEN02021-00 SEN02339-01 SEN00224-02 SEN00225-00 SEN00226-02 q
D475A, D475ASD-5E0
SEN00205-04
Table of contents
00 Index and foreword Index SEN00205-04 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 Foreword and general information SEN00206-02 Safety notice ............................................................................................................................ 2 How to read the shop manual.................................................................................................. 7 Explanation of terms for maintenance standard ...................................................................... 9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 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 SEN00208-01 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 SEN00211-00 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 SEN00212-00 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
D475A, D475ASD-5E0
SEN00205-04
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 SEN00213-01 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 SEN00214-00 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 Hydraulic system, Part 2 SEN00215-00 Hydraulic system, Part 2 ............................................................................................................. 2 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 system, Part 3 SEN00216-00 Hydraulic system, Part 3 ............................................................................................................. 2 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 SEN00217-00 Work equipment .......................................................................................................................... 2 Cylinder stay ............................................................................................................................ 2 Blade ....................................................................................................................................... 4 Ripper equipment .................................................................................................................... 8
D475A, D475ASD-5E0
SEN00205-04
Cab and its attachments SEN00218-00 Cab and its attachments.............................................................................................................. 2 Cab mount ............................................................................................................................... 2 Cab .......................................................................................................................................... 3 Air conditioner.......................................................................................................................... 6 Electrical system SEN00219-00 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 SEN01816-01 Standard value table for engine ............................................................................................... 2 Standard value table for chassis .............................................................................................. 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN01817-01 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 SEN01818-01 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
D475A, D475ASD-5E0
SEN00205-04
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 SEN01819-02 Special functions of monitor panel (EMMS)............................................................................. 2 Testing and adjusting, Part 4 SEN01820-01 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 SEN01821-01 Failure code table .................................................................................................................... 2 Fuse locations ......................................................................................................................... 12 General information on troubleshooting SEN01822-01 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 Connection table for connector pin numbers ........................................................................... 10 T- branch box and T- branch adapter table ............................................................................. 45 Troubleshooting by failure code, Part 1 SEN01823-01 Failure code [1380MW] Lockup clutch: Clutch slip.................................................................. 3 Failure code [1500L0] Transmission clutch: Dual engagement............................................... 4 Failure code [15E0MW] Transmission clutch: Clutch slip........................................................ 5 Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON............................................................................ 6 Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF............................................................................ 7 Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON ................. 8 Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF............................................................................ 9 Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON ...... 10 Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF ..... 11 Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON ..... 12 Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF .... 13 Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON ..... 14 Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF..... 15 Failure code [1800MW] Power train clutch: Slip ...................................................................... 16 D475A, D475ASD-5E0
SEN00205-04
Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON ... 17 Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF... 18 Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON ...... 19 Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF ..... 20 Failure code [2300NR] Brake thermal load: Abnormal heating ............................................... 21 Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON.... 22 Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF ... 23 Failure code [2301NR] Right steering brake thermal load: Abnormal heating......................... 24 Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON ...... 25 Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF...... 26 Failure code [2302NR] Left steering brake thermal load: Abnormal heating ........................... 27 Failure code [6001ZK] Failure code for design........................................................................ 28 Failure code [A000NS] Engine: Overheat................................................................................ 29 Failure code [AA10NX] Air cleaner: Clogging.......................................................................... 30 Failure code [AB00MA] Battery charge abnormality: Malfunction ........................................... 31 Failure code [B@BAZG] Engine oil: Oil pressure too low........................................................ 32 Failure code [B@BAZK] Engine oil: Oil level reduction ........................................................... 33 Failure code [B@BCNS] Engine coolant: Overheat ................................................................ 34 Failure code [B@BCZK] Engine coolant: Level too low........................................................... 35 Failure code [B@CENS] Power train oil: Overheat ................................................................. 38 Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure...................................... 39 Failure code [B@CHZK] Power train oil: Oil level reduction.................................................... 39 Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction ......................... 40 Failure code [B@HANS] Hydraulic oil: Overheat..................................................................... 40 Failure code [B@HAZK] Hydraulic oil: Level reduction ........................................................... 41 Troubleshooting by failure code, Part 2 SEN01824-01 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): Excessively low voltage detected......................................................................................... 15 Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 16 Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 18 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): Excessively low voltage detected......................................................................................... 22 Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 24 Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected......................................................................................... 26 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): Low voltage detection .......................................................................................................... 29 Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection.......................................................................................................... 30
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SEN00205-04
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection .......................................................................................................... 31 Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected ....................................................................................... 32 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): Excessively high voltage detected ....................................................................................... 36 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): Excessively low voltage detected ........................................................................................ 42 Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected ........................................................................................ 44 Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected ....................................................................................... 46 Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected ....................................................................................... 48 Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection .......................................................................................................... 49 Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection .......................................................................................................... 49 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 Troubleshooting by failure code, Part 3 SEN01825-01 Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 4 Failure code [CA323] Injector #5 (L/B #5) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 6 Failure code [CA324] Injector #3 (L/B #3) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 8 Failure code [CA325] Injector #6 (L/B #6) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 10 Failure code [CA331] Injector #2 (L/B #2) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 12 Failure code [CA332] Injector #4 (L/B #4) system disconnection or short circuit (At left bank): Disconnection, short circuit............................................................................ 14 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 Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection .......................................................................................................... 22 Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection .......................................................................................................... 23 Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection ......................................................................................................... 24 Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection ......................................................................................................... 26 Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection .......................................................................................................... 28 D475A, D475ASD-5E0
SEN00205-04
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection .......................................................................................................... 28 Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection.......................................................................................................... 29 Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection.......................................................................................................... 29 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): Excessively high voltage detected ....................................................................................... 32 Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection.......................................................................................................... 34 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): Loss of pressure feed detected............................................................................................ 44 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 Troubleshooting by failure code, Part 4 SEN01826-01 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
10
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SEN00205-04
Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit............................................................................. 16 Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit............................................................................. 18 Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit............................................................................. 20 Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit............................................................................. 22 Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit............................................................................. 24 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 [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected............................................................................................ 31 Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected............................................................................................ 31 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: Power supply voltage reduction (Input)................................................................................ 62 Failure code [DAQ5KK] Transmission controller potentiometer power supply: Source voltage reduction (input) .......................................................................................... 64 Failure code [DAQ6KK] Transmission controller sensor power supply: Source voltage reduction (input) .......................................................................................... 65 Failure code [DAQ7KK] Transmission controller sensor power supply: Power supply voltage reduction (Input)................................................................................ 66 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 Troubleshooting by failure code, Part 5 SEN01827-01 Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error ........................................................................................................... 4 Failure code [dB2RKR] Engine controller (Left bank) CAN communication: Communication error ........................................................................................................... 6 Failure code [db2RKR] Engine controller (Right bank) CAN communication: Communication error ........................................................................................................... 8 Failure code [DB30KT] Steering controller: Abnormality in controller...................................... 10 D475A, D475ASD-5E0
11
SEN00205-04
Failure code [DB31KK] Steering controller main power supply: Power supply voltage reduction (Input)................................................................................ 12 Failure code [DB32KK] Steering controller load power supply: Power supply voltage reduction (Input)................................................................................ 14 Failure code [DB35KK] Steering controller potentiometer power supply: Power supply voltage reduction (Input)................................................................................ 16 Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input) .......................................................................................... 18 Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input) .......................................................................................... 19 Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency .......................................................................................... 20 Failure code [dB3RKR] Steering controller CAN communication: Communication error......... 22 Failure code [DB3SKR] Steering controller S-NET communication: Defective communication (Abnormality in objective component system) ............................ 24 Failure code [DBB0KK] (or LED of VHMS controller indicates "n9" o "01") VHMS controller: Lowering of source voltage ...................................................................... 26 Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o "11") Check of VHMS controller model: Disagreement of model selection................................... 27 Failure code [DBB3KK] (or LED of VHMS controller indicates "n9" o "05") VHMS controller: Lowering of direct source voltage ............................................................ 28 Failure code [DBB5KP] (or LED of VHMS controller indicates "n9" o "04") VHMS sensor power supply (5 V): Lowering of output voltage............................................ 29 Failure code [DBB6KP] (or LED of VHMS controller indicates "n9" o "02") VHMS sensor power supply (24 V): Lowering of output voltage.......................................... 30 Failure code [DBB7KP] (or LED of VHMS controller indicates "n9" o "03") VHMS sensor power supply (12 V): Lowering of output voltage.......................................... 32 Failure code [DBBQKR] (or VHMS_LED display "n8" o "02") VHMS KOM-NET: Communication error .............................................................................. 34 Failure code [dbBRKR] VHMS controller CAN communication: Communication error ........... 36 Failure code [DD12KA] Shift up switch: Disconnection ........................................................... 38 Failure code [DD12KB] Shift up switch: Short circuit............................................................... 40 Failure code [DD13KA] Shift down switch: Disconnection....................................................... 42 Failure code [DD13KB] Shift down switch: Short circuit .......................................................... 44 Failure code [DD14KA] Parking brake lever switch: Disconnection ........................................ 46 Failure code [DD14KB] Parking brake lever switch: Short circuit ............................................ 48 Failure code [DDB9L4] Reverse switch: Signal disagreement ................................................ 50 Failure code [DDK3L4] Forward switch: Signal disagreement ................................................ 52 Failure code [DDK5KA] Gearshift switch: Disconnection ........................................................ 54 Failure code [DDK5KB] Gearshift switch: Short circuit ............................................................ 56 Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time.................................................................................................... 58 Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time .. 59 Failure code [DDN7KA] Blade pitch switch: Disconnection ..................................................... 60 Failure code [DDN7KB] Blade pitch switch: Short circuit......................................................... 62 Failure code [DDN9KA] Blade tilt switch: Disconnection ......................................................... 64 Failure code [DDN9KB] Blade tilt switch: Short circuit............................................................. 66 Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time ... 68 Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time ........ 69 Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time ....... 70 Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time ............. 71 Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time ....... 72 Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time ... 73 Troubleshooting by failure code, Part 6 SEN01828-01 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
12
D475A, D475ASD-5E0
SEN00205-04
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 Failure code [dGT6KB] (or LED of VHMS controller indicates "n3" o "25") 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 Troubleshooting by failure code (Display of code), Part 7 SEN01829-00 Troubleshooting by failure code (Display of code), Part 7........................................................... 3 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 D475A, D475ASD-5E0
13
SEN00205-04
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 Troubleshooting by failure code (Display of code), Part 8 SEN01830-00 Troubleshooting by failure code (Display of code), Part 8........................................................... 3 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
14
D475A, D475ASD-5E0
SEN00205-04
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) SEN01831-01 Contents of troubleshooting table ............................................................................................ 3 E-1 The engine does not start ................................................................................................. 4 E-2 The preheater does not operate ....................................................................................... 8 E-3 The ripper pin puller cylinder does not operate................................................................. 12 E-4 The monitor panel does not come on at all when the starting switch is turned on............ 14 E-5 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out.......................................................................................................... 16 E-6 When the starting switch is turned on, the basic check items flash .................................. 17 E-7 While the engine is operating, any caution item flashes ................................................... 18 E-8 An emergency caution item flashes while the engine is running ...................................... 21 E-9 While the preheater is operating, the preheating pilot lamp does not come on ................ 24 E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)............................................................................................ 26 D475A, D475ASD-5E0
15
SEN00205-04
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on............................................................................................................ 26 E-12 The engine coolant temperature gauge does not indicate normally ............................... 27 E-13 Indication of the power train (torque converter) temperature gauge is abnormal ........... 28 E-14 The hydraulic oil temperature gauge does not indicate normally.................................... 29 E-15 Indication of the fuel gauge is abnormal ......................................................................... 30 E-16 Indications of gear speed and engine speed are abnormal ............................................ 31 E-17 Indication of the shift mode service meter is abnormal ................................................... 31 E-18 The switch module cannot be operated .......................................................................... 32 E-19 The warning lamp does not flash or does not go out ...................................................... 33 E-20 The alarm buzzer does not sound or does not stop........................................................ 34 E-21 Auto shift down is not possible or is not released ........................................................... 35 E-22 The automatic pitch back system does not operate (only superdozer specification) ...... 36 E-23 The alarm buzzer cannot be cancelled ........................................................................... 37 E-24 The operator mode cannot be operated.......................................................................... 38 E-25 The service mode cannot be operated............................................................................ 40 E-26 The back-up alarm does not sound................................................................................. 42 E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on ............................................................................................................... 44 E-28 Troubleshooting for air conditioner system ..................................................................... 50 E-29 Orbcomm terminal does not operate normally (Data are not transmitted) ...................... 65 E-30 Fan does not reverse ...................................................................................................... 67 E-31 Gear cannot be shifted.................................................................................................... 69 E-32 Electric priming pump does not operate or does not stop automatically......................... 70 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
16
D475A, D475ASD-5E0
SEN00205-04
S-5 Engine does not rotate smoothly ...................................................................................... S-6 Engine lacks output (or lacks power) ................................................................................ S-7 Exhaust smoke is black (incomplete combustion) ............................................................ S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. S-9 Oil becomes contaminated quickly ................................................................................... S-10 Fuel consumption is excessive ....................................................................................... S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. S-12 Oil pressure drops........................................................................................................... S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... S-14 Coolant temperature becomes too high (overheating).................................................... S-15 Abnormal noise is made ................................................................................................. S-16 Vibration is excessive .....................................................................................................
12 13 15 16 17 18 19 20 21 22 23 24
50 Disassembly and assembly General information on disassembly and assembly SEN02013-01 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 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) SEN02338-01 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 ....................................................................... 27 Power train, Part 1 SEN02015-00 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 SEN02016-00 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 D475A, D475ASD-5E0
17
SEN00205-04
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 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 SEN02020-00 Work equipment .......................................................................................................................... 2 Removal and installation of blade assembly............................................................................ 2 Disassembly and assembly of giant ripper assembly .............................................................. 4 Cab and its attachments SEN02021-00 Cab and its attachments.............................................................................................................. 2 Removal and installation of ROPS guard ................................................................................ 2 Removal and installation of operators cab assembly.............................................................. 3 Removal and installation of floor frame assembly ................................................................... 4 Electrical system SEN02339-01 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
18
D475A, D475ASD-5E0
SEN00205-04
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 Hydraulic circuit diagram (2/3)................................................................................................. 7 Hydraulic circuit diagram (3/3)................................................................................................. 9 Electrical diagrams and drawings SEN00226-02 Electrical diagrams and drawings ............................................................................................... 3 Electrical circuit diagram (1/13) ............................................................................................... 3 Electrical circuit diagram (2/13) ............................................................................................... 5 Electrical circuit diagram (3/13) ............................................................................................... 7 Electrical circuit diagram (4/13) ............................................................................................... 9 Electrical circuit diagram (5/13) ............................................................................................... 11 Electrical circuit diagram (6/13) ............................................................................................... 13 Electrical circuit diagram (7/13) ............................................................................................... 15 Electrical circuit diagram (8/13) ............................................................................................... 17 Electrical circuit diagram (9/13) ............................................................................................... 19 Electrical circuit diagram (10/13) ............................................................................................. 21 Electrical circuit diagram (11/13) ............................................................................................. 23 Electrical circuit diagram (12/13) ............................................................................................. 25 Electrical circuit diagram (13/13) ............................................................................................. 27 Electrical circuit diagram of inside cab .................................................................................... 29 Connector arrangement diagram............................................................................................. 31
D475A, D475ASD-5E0
19
SEN00205-04
D475A, D475ASD-5E0 Bulldozer Form No. SEN00205-04
2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
20
SEN00206-02
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Foreword and general information
Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 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-5E0
SEN00206-02
Safety notice
(Rev. 2007/03)
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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition.
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Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5 Prohibition of operation and handling by unlicensed workers Wearing protective goggles (for cleaning or grinding work) Wearing shielding goggles and protectors (for welding work) Precautions against work which you are not used to or you are used to too much
6 Safety check before starting work 7 8
9 Good physical condition and preparation 10
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Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
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When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the 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 machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
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Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative () terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still 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 electrical wiring. Damaged wiring may cause electrical fires.
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When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check 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 installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
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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. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding 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 forming 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 allowable 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 sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
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11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
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If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
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13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
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Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the 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 immediately in an emergency.
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Wire ropes (Standard Z twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
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Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant and put on protective goggles. 2) Connection 1] When installing the air conditioner circuit 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 damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.
Example of O-ring (Fitted to every joint of hoses and tubes)
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
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How to read the shop manual

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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. Materials and specifications are subject to change without notice. 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. 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 disassembly 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.
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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.
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Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table.
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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 ) Revisions Revised brochures are shown in the shop manual composition table.
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Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol k a 4 3 2 5 6 Item Safety Caution Weight Tightening torque Coat Oil, coolant Drain Remarks Special safety precautions are necessary when performing work. Special technical precautions or other precautions for preserving standards are necessary when performing work. Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
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Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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Explanation of terms for maintenance standard
The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1. Standard size and tolerance 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 temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the standard size and the range of difference 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.
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Example: Standard size 120 a
Tolerance 0.022 0.126
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) Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
Example: Standard size 60 Tolerance Shaft Hole 0.030 +0.046 0.076 +0
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Standard clearance and standard value The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the standard value, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
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Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the clearance limit. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
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Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance 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. Repair limit and allowable value 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 product 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 various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
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Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the interference limit. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
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Handling of electric equipment and hydraulic component
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, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted 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 (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
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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 soldering may be damaged, or the wiring may be broken.
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High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), 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-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface 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 compressed 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 compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
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Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. 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 connectors apart. a Never pull with one hand. 2]
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When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
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Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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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 damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the 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 breakage, 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 stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected 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.
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Heavy duty wire connector (DT 8-pole, 12pole) 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) horizontally 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
Disconnection
Connection (Example of incomplete setting of (a))
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Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 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 oi l a nd wa ter fr om t he c om 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 connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
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Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control 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 controller. 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 connectors connected to the controller. Fit an arc welding ground close to the welding point.
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Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
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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. 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 performance should be checked with special test equipment. 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. 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 cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
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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. Flushing operations After disassembling and assembling the equipment, 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.
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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 circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
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Handling of connectors newly used for engines

a Mainly, following engines are object for following connectors. q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 107 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (107, 114 engines) Ne speed sensor of flywheel housing: NE (107 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines) Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you. 2.
q
1.
Pull lock type (PACKARD-2) 107 170, 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
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3.
Push lock type q 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow.
q
114 engine
107, 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04) While pressing lock (D), pull out connector (4) in the direction of the arrow.
3)
107 engine
2)
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
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4)
125 170, 12V140 engine While pressing lock (E) of the connector, pullout connector (5) in the direction of the arrow. Example) Fuel pressure in common rail: PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc. Disconnect connector (6) according to the 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 harness side.
1)
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.
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How to read electric wire code

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 symbols. 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 nominal 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 indicated.)
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) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile Symbol AV Conductor Insulator Conductor Insulator Conductor Insulator Material Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Heat-resistant crosslinked polyethylene Using temperature range (C) Example of use General wiring (Nominal No. 5 and above) 30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely 50 to +110 cold district, wiring at high-temperature place
AVS
Heat-resistant low-voltAEX age wire for automobile
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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 CovAV Standard 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8 50/0.45 7.95 3.7 5.5 5.3
15 84/0.45 13.36 4.8 7.0 7.0
20 41/0.80 20.61 6.0 8.2 8.2
30 70/0.80 35.19 8.0 10.8 10.8
40 85/0.80 42.73 8.6 11.4 11.4
50
60
85
100
108/0.80 127/0.80 169/0.80 217/0.80 54.29 9.8 13.0 13.0 63.84 10.4 13.6 13.6 84.96 12.0 16.0 16.0 109.1 13.6 17.6 17.6
f of nominal No. denotes flexible.
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3.
Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red 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 Charge Ground Start Light Instrument Signal Type of circuit Others
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch WG

AEX R B R D Y G L

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

YW GL

Gr Br

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Precautions when carrying out operation
[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.
q q q q q q q q q q
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. 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 number 02 03 04 05 06 10 12 2) Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234 Sleeve nut (elbow end) 02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 07371-30400 07371-30500
3)
If the part is not under hydraulic pressure, the following corks can be used. Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34
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2.
q q q q q q q q q q q q q
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. 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. When using the machine for the first time after repair or long storage, follow the same procedure. 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 specified 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. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
a 3.
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4)
5)
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. 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.
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Method of disassembling and connecting push-pull type coupler

k 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. 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.
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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 hexagonal 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 disconnect it. (Fig. 8)
2.
Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
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Type 3 1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect 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 hexagonal portion at the male end. (Fig. 13)
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Standard tightening torque table

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. Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Tightening torque Nm kgm 11.8 14.7 1.2 1.5 27 34 2.8 3.5 59 74 6.0 7.5 98 123 10.0 12.5 153 190 15.5 19.5 235 285 23.5 29.5 320 400 33.0 41.0 455 565 46.5 58.0 610 765 62.5 78.0 785 980 80.0 100.0 1,150 1,440 118 147 1,520 1,910 155 195 1,960 2,450 200 250 2,450 3,040 250 310 2,890 3,630 295 370
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
The following table corresponds to the bolts in Fig. B. Width across flats mm 10 13 14 27 Tightening torque Nm 5.9 9.8 13.7 23.5 34.3 46.1 74.5 90.2
a Fig. B
Thread diameter of bolt mm 6 8 10 12

a Fig. A
kgm 0.6 1.0 1.4 2.4 3.5 4.7 7.6 9.2
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2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Width across flats mm 14 17 22 Tightening torque Nm kgm 59 74 6.0 7.5 98 123 10.0 12.5 235 285 23.5 29.5
Thread diameter of bolt mm 10 12 16
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 mm 14 20 24 33 42 Tightening torque Nm {kgm} Range Target 35 63 { 3.5 6.5} 44 { 4.5} 84 132 { 8.5 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 186 {13.0 19.0} tor. 363 480 {37.0 49.0} 422 {43.0} 746 1,010 {76.0 103} 883 {90.0} Width across flats mm
Nominal No. 02 03,04 05,06 10,12 14
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 No. 08 10 12 14 16 18 20 24 30 33 36 42 52 Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52 Width across flats mm 14 17 19 22 24 27 30 32 32 36 Tightening torque Nm {kgm} Range Target 5.88 8.82 {0.6 0.9} 7.35 {0.75} 9.81 12.74 {1.0 1.3} 11.27 {1.15} 14.7 19.6 {1.5 2.0} 17.64 {1.8} 19.6 24.5 {2.0 2.5} 22.54 {2.3} 24.5 34.3 {2.5 3.5} 29.4 {3.0} 34.3 44.1 {3.5 4.5} 39.2 {4.0} 44.1 53.9 {4.5 5.5} 49.0 {5.0} 58.8 78.4 {6.0 8.0} 68.6 {7.0} 93.1 122.5 { 9.5 12.5} 107.8 {11.0} 107.8 147.0 {11.0 15.0} 127.4 {13.0} 127.4 176.4 {13.0 18.0} 151.9 {15.5} 181.3 240.1 {18.5 24.5} 210.7 {21.5} 274.4 367.5 {28.0 37.5} 323.4 {33.0}
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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 Thread size (mm) 14 18 22 24 30 33 36 42 Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2
Nominal No. of hose 02 03 04 05 06 (10) (12) (14)
Width across flats 19 22 24 27 32 36 41 46 55
Range 34 54 { 3.5 5.5} 34 63 { 3.5 6.5} 54 93 { 5.5 9.5} 59 98 { 6.0 10.0} 84 132 { 8.5 13.5} 128 186 {13.0 19.0} 177 245 {18.0 25.0} 177 245 {18.0 25.0} 197 294 {20.0 30.0} 246 343 {25.0 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
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. Thread size mm 6 8 10 12 14 Nm 10 2 24 4 43 6 77 12 Tightening torque Bolts and nuts kgm 1.02 0.20 2.45 0.41 4.38 0.61 7.85 1.22
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 mm 6 8 10 12 14 Tightening torque Nm 82 10 2 12 2 24 4 36 5 kgm 0.81 0.20 1.02 0.20 1.22 0.20 2.45 0.41 3.67 0.51
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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 inch 1/16 1/8 1/4 3/8 1/2 3/4 1 Tightening torque Nm 31 82 12 2 15 2 24 4 36 5 60 9 kgm 0.31 0.10 0.81 0.20 1.22 0.20 1.53 0.20 2.45 0.41 3.67 0.51 6.12 0.92
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Conversion table
Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1. Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 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.
2.
Millimeters to inches 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
(B) 5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898
0 10 20 30 40 (A) 50 60 70 80 90
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Millimeters to inches 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701 5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929 2.244 2.638 3.032 3.425 3.819 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898
0 10 20 30 40 50 60 70 80 90
Kilogram to pound 0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42 1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62 2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83 3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03 4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24 5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44 1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03 123.46 145.51 167.55 189.60 211.64 125.66 147.71 169.76 191.80 213.85 127.87 149.91 171.96 194.01 216.05 130.07 152.12 174.17 196.21 218.26
0 10 20 30 40 50 60 70 80 90
Liters to U.S. Gallons 0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095 13.209 15.850 18.492 21.134 23.775 13.473 16.115 18.756 21.398 24.040 13.737 16.379 19.020 21.662 24.304 3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568 4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832 1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944 14.529 17.171 19.813 22.455 25.096 14.795 17.435 20.077 22.719 25.361 15.058 17.700 20.341 22.983 25.625 15.322 17.964 20.605 23.247 25.889 15.586 18.228 20.870 23.511 26.153
0 10 20 30 40 50 60 70 80 90
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Liters to U.K. Gallons 0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797 1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017 2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237 3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457 4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677 5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897 1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778 12.318 14.518 16.718 18.917 21.117 12.528 14.738 16.938 19.137 21.337 12.758 14.958 17.158 19.357 21.557 12.978 15.178 17.378 19.577 21.777
0 10 20 30 40 50 60 70 80 90
kgm to ft.lb 0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 1 kgm = 7.233 ft.lb 7 8 9 50.6 57.9 65.1 123.0 130.2 137.4 195.3 202.5 209.8 267.6 274.9 282.1 340.0 347.2 354.4 412.3 484.6 556.9 629.3 701.6 419.5 491.8 564.2 636.5 708.8 426.8 499.1 571.4 643.7 716.1
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7 1084.9 1157.3 1129.6 1301.9 1374.3 1092.2 1164.5 1236.8 1309.2 1381.5 1099.4 1171.7 1244.1 1316.4 1388.7 1106.6 1179.0 1251.3 1323.6 1396.0 1113.9 1186.2 1258.5 1330.9 1403.2 1121.1 1193.4 1265.8 1338.1 1410.4 1128.3 1200.7 1273.0 1345.3 1417.7 1135.6 1207.9 1280.1 1352.6 1424.9 1142.8 1215.1 1287.5 1359.8 1432.1 1150.0 1222.4 1294.7 1367.0 1439.4
38
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kg/cm2 to lb/in2 0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414 1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428 2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442 3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456 4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470 5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485 6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499 1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 953.0 1,095 1,237 1,380 1,522 1,664 1,806 1,949 2,091 2,233 2,375 2,518 2,660 2,802 2,944 3,086 3,229 3,371 3,513 825.0 967.2 1,109 1,252 1,394 1,536 1,678 1,821 1,963 2,105 2,247 2,389 2,532 2,674 2,816 2,958 3,101 3,243 3,385 3,527 839.2 981.4 1,124 1,266 1,408 1,550 1,693 1,835 1,977 2,119 2,262 2,404 2,546 2,688 2,830 2,973 3,115 3,257 3,399 3,542
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
D475ASD-5E0
39
SEN00206-02
Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade 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 Fahrenheit 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 Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1C = 33.8F F 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
C 40.4 37.2 34.4 31.7 28.9 28.3 27.8 27.2 26.7 26.1 25.6 25.0 24.4 23.9 23.3 22.8 22.2 21.7 21.1 20.6 20.0 19.4 18.9 18.3 17.8 17.2 16.7 16.1 15.6 15.0 14.4 13.9 13.3 12.8 12.2 40 35 30 25 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10
F 40.0 31.0 22.0 13.0 4.0 2.2 0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0
C 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0
C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0
C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4
40
D475ASD-5E0
SEN00206-02
D475ASD-5E0
41
SEN00206-02
42
SEN00208-01
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
01 Specification
Specification and technical data
Specification drawings .................................................................................................................................... 2 Specifications .................................................................................................................................................. 3 Weight table .................................................................................................................................................. 12 Fuel, coolant and lubricants .......................................................................................................................... 16
D475A, D475ASD-5E0
SEN00208-01
01 Specification
Specification drawings
Dimensions
Symbol A B C Overall length
Item
Unit mm mm mm
Semi-U tiltdozer + giant ripper 11,565 4,646 5,265
Full-U tiltdozer + giant ripper 12,065 4,646 6,205
Superdozer + counterweight 10,525 4,646 6,465
Overall height (including ROPS) Overall width
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Specifications
Semi-U tiltdozer and full-U tiltdozer specifications

Machine model Serial Number Machine weight Weight Tractor Above + Semi-U tiltdozer Above + Variable giant ripper Above + ROPS cab + Air conditioner Min. turning radius Gradeability Stability (Front, Rear, Left, Right) Forward 1st 2nd 3rd 1st 2nd 3rd km/h km/h m deg. deg. kg 83,510 100,010 107,370 108,310 4.6 30 35 0 3.5 0 6.3 0 10.9 0 4.7 0 8.4 0 14.3 127.5 {1.30} 152.7 {1.56} kPa {kg/cm }
2
D475A-5E0 30001 and up
Performance
Gear speeds Ground pressure
Tractor Semi-U dozer Semi-U dozer + Variable giant ripper Above + ROPS cab + Air conditioner + Perforated side cover Tractor Overall length Semi-U dozer Semi-U dozer + Variable giant ripper Full-U dozer + Variable giant ripper Overall width Tractor Semi-U dozer Full-U dozer Up to ROPS top Up to exhaust pipe end Up to exhaust duct top mm mm mm
Reverse
163.9 {1.67} 165.3 {1.69}
6,680 8,705 11,565 12,065 3,620 5,265 6,205 4,646 4,546 3,861 2,770 mm 4,524 710 711
Dimensions
Overall height
Track gauge Length of track on ground Track shoe width Minimum ground clearance
D475A, D475ASD-5E0
SEN00208-01
01 Specification
Machine model Serial Number Model name Type Number of cylinderBore x Stroke Total displacement Rated output Max. torque High idle Low idle Min. fuel consumption ratio (at rated output) Performance mm l {cc} kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}
D475A-5E0 30001 and up Komatsu SAA12V140E-3 4-cycle, water-cooled, V-type, direct-injection engine with turbocharger and aftercooler 12140 x 165 30.48 {30,480} 664/2,000 {890/2,000} 3,825/1,400 {390/1,400} 2,150 600 215 {160} 24 V, 7.5 kW x 2 24 V, 100 A 12V, 220 Ah x 4 D-type 3-element, 1-stage, 1-phase type (With lockup clutch) Planetary gear, multiple disc clutch, hydraulic, pump-forced lubrication, 3 forward/reverse gear speeds type Spiral bevel gear, splash lubrication type Wet, multiple disc clutch, spring-actuated, hydraulic (hand-operated) type interlocked with brake Wet, multiple disc clutch, spring-actuated, hydraulic (foot/hand-operated) type interlocked with brake 1-stage spur gear and 1-stage planetary gear, splash lubrication type Hard, equalizing beam type 2 pieces on each side 8 pieces on each side Assembly type single grouser shoe, 41 pieces on each side, Pitch: 317.5 mm, Width: 710 mm Gear type (BAL 160 + 160 + 112) Gear (BAR 63 + 320)
Engine Power train Undercarriage
Starting motor Alternator Battery Type of radiator core Torque converter
Transmission Bevel gear shaft Steering clutch
Steering brake
Final drive Type of suspension Carrier roller Track roller Track shoe
Power train + Lubricating oil pump (Tandem) Scavenging pump (Tandem)
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Machine model Serial Number Max. pressure Work equipment pump Type MPa {kg/cm2}
D475A-5E0 30001 and up 27.5 {280} Variable swash plate type: 2 pcs. (HPV 125 + 125)
Capacity (at engine speed of 2,000 rpm)
l/min
542
Variable swash plate type: 2 pcs. (LPV 90 + 30) Cooling fan pump MPa {kg/cm }
2
Max. discharge pressure: 17.5 {178} Theoretical discharge pressure: 178/1,934 Fixed swash plate type (LMF 180)
l/min/rpm Work equipment hydraulic system Cooling fan motor Work equipment valve Type For blade lift For blade tilt For ripper lift For ripper tilt Type Dimensions of blade lift cylinder Bore of cylinder Outside diameter of piston rod Stroke of piston Max. distance between pins Min. distance between pins Bore of cylinder Outside diameter of piston rod Stroke of piston Max. distance between pins Min. distance between pins mm mm
MPa {kg/cm }
2
Max. using pressure: 17.5 {178}
6-spool type: 1 pc. Hydraulic
Double acting piston 180 110 1,925 3,155 1,230 250 140 293 1,988 1,695
Hydraulic cylinders
Dimensions of blade tilt cylinder
D475A, D475ASD-5E0
SEN00208-01
01 Specification
Machine model Serial Number Bore of cylinder (Both of right and left) Outside diameter of piston rod (Both of right and left) Stroke of piston (Both of right and left) Max. distance between pins (Both of right and left) Min. distance between pins (Both of right and left) Bore of cylinder Outside diameter of piston rod Stroke of piston Max. distance between pins Min. distance between pins Bore of cylinder Outside diameter of piston rod Stroke of piston Max. distance between pins Min. distance between pins mm mm
D475A-5E0 30001 and up 250 140 mm 293 1,988 1,695 225 120 645 2,175 1,530 225 140 540 2,020 1,480 Box type (External control valve type)
Work equipment hydraulic system
Hydraulic cylinders
Hydraulic tank
Dimensions of ripper tilt cylinder
Dimensions of ripper lift cylinder
Dimensions of blade dual tilt cylinder
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Machine model Serial Number Type Blade supporting method Max. lift above ground Max. drop below ground Max. tilting distance Changing range of blade cutting edge angle Capacity of blade Width of blade Height of blade Angle of blade cutting edge Max. lift above ground Max. drop below ground Max. tilting distance Changing range of blade cutting edge angle Capacity of blade Width of blade Height of blade Angle of blade cutting edge Max. tilting distance Max. pitch angle Max. pitch back angle
Performance
D475A-5E0 30001 and up Hydraulic semi-U tiltdozer Hydraulic full-U tiltdozer Brace type (Right tilt cylinder) mm mm mm deg. m3 mm mm deg. mm mm mm deg. m3 mm mm deg. mm deg. deg. 1,676 954 770 6 38.1 <SAE 27.2> 5,265 2,690 52 1,676 954 905 6 42.3 <SAE 34.4> 3,640 1,580 52 1,145 6 6
Semi-U dozer Full-U dozer Work equipment Semi-U dozer + Pitch Full-U dozer + Pitch
Performance
Performance
Dimensions
Performance
Dimensions
Max. tilting distance Max. pitch angle Max. pitch back angle Max. digging depth Max. lift Digging angle (Standard) Length of beam Number of shanks Max. digging depth Max. lift Digging angle (Standard) Length of beam Number of shanks
mm deg. deg. mm mm deg. mm pcs. mm mm deg. mm pcs.
1,350 6 6 1,124 1,196 45 (Adjustable steplessly to 32.5 54) 3,085 3 1,744 1,196 45 (Adjustable steplessly to 34 56) 1,477 1
Multi-ripper Giant ripper
Dimensions
Performance
Dimensions
Performance
D475A, D475ASD-5E0
SEN00208-01
01 Specification
Superdozer specification
Machine model Serial Number Machine weight Weight Tractor Superdozer + ROPS cab + Air conditioner + Counterweight Min. turning radius Gradeability Stability (Front, Rear, Left, Right) Forward 1st 2nd 3rd 1st 2nd 3rd km/h km/h m deg. deg. 4.6 30 35 0 3.5 0 6.3 0 10.9 0 4.7 0 8.4 0 14.3 113.0 {1.15} kPa {kg/cm }
2
D475ASD-5E0 30001 and up
kg
84,430 113,120
Performance
Gear speeds Ground pressure
Tractor Superdozer + ROPS cab + Air conditioner + Counterweight Tractor Superdozer + Counterweight Tractor Superdozer Up to ROPS top Up to exhaust pipe end Up to exhaust duct top mm mm
Reverse
151.4 {1.54}
Overall length
6,680 10,525 3,620 6,465 4,646 4,546 3,861 2,770
Overall width
mm
Dimensions
Overall height
Track gauge Length of track on ground Track shoe width Minimum ground clearance mm
4,524 810 711
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Machine model Serial Number Model name Type Number of cylinderBore x Stroke Total displacement Rated output Performance Engine Max. torque High idle Low idle Min. fuel consumption ratio (at rated output) Starting motor Alternator Battery Type of radiator core Torque converter mm l {cc} kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}
D475ASD-5E0 30001 and up Komatsu SAA12V140E-3 4-stroke, water-cooled, V-type, direct-injection engine with turbocharger and aftercooler 12140 x 165 30.48 {30,480} 677/2,000 {908/2,000} 3,825/1,400 {390/1,400} 2,150 600 215 {160}
24 V, 7.5 kW x 2 24 V, 100 A 12 V, 220 Ah x 4 D-type 3-element, 1-stage, 1-phase type (With lockup clutch) Planetary gear, multiple disc clutch,
Transmission
hydraulic, pump-forced lubrication, 3 forward/reverse gear speeds type
Power train
Bevel gear shaft
Spiral bevel gear, splash lubrication type Wet, multiple disc clutch, spring-actuated,
Steering clutch
hydraulic (hand-operated) type interlocked with brake Wet, multiple disc clutch, spring-actuated,
Steering brake
hydraulic (foot/hand-operated) type interlocked with brake
Final drive Type of suspension Undercarriage Carrier roller Track roller
1-stage spur gear and 1-stage planetary gear, splash lubrication type Hard, equalizing beam type 2 pieces on each side 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) Scavenging pump (Tandem)
Gear type (BAL 160 + 160 + 112) Gear (BAR 63 + 320)
D475A, D475ASD-5E0
SEN00208-01
01 Specification
Machine model Serial Number Max. pressure Work equipment pump Type Capacity (at engine speed of 2,000 rpm) l/min MPa {kg/cm2}
D475ASD-5E0 30001 and up 27.5 {280} Variable swash plate type: 2 pcs. (HPV 125 + 125) 542
Variable swash plate type: 2 pcs. (LPV 90 + 30) Cooling fan pump MPa {kg/cm }
2
Max. discharge pressure: 17.5 {178} Theoretical discharge pressure: 178/1,934 Fixed swash plate type (LMF 180)
l/min/rpm Cooling fan motor Work equipment valve Type For blade lift For blade tilt For ripper lift For ripper tilt Type Dimensions of blade lift cylinder Bore of cylinder Outside diameter of piston rod Stroke of piston Max. distance between pins Min. distance between pins Bore of cylinder Outside diameter of piston rod Stroke of piston Max. distance between pins Min. distance between pins mm mm
Work equipment hydraulic system
MPa {kg/cm2}
Max. using pressure: 17.5 {178}
6-spool type: 1 pc. Hydraulic
Double acting piston 180 110 1,925 3,155 1,230 250 140 660 2,154 1,494 Box type (External control valve type)
Hydraulic cylinders
Hydraulic tank
10
Dimensions of blade pitch cylinder
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Machine model Serial Number Type Blade supporting method Work equipment Max. lift above ground Max. drop below ground Max. tilting distance Max. pitch dump angle Max. pitch back angle Capacity of blade Width of blade Height of blade Angle of blade cutting edge mm mm mm deg. deg. m3 mm mm deg. Performance
D475ASD-5E0 30001 and up Hydraulic superdozer (Pitchdozer) Cylinder type 2,016 804 900 (at cutting edge angle of 52) 15 15 45.0 <SAE 36.6> 6,465 2,690 42 67
Superdozer
Dimensions
D475A, D475ASD-5E0
11
SEN00208-01
01 Specification
Weight table
k
This weight table is a reference for handling and transportation of components.
Semi-U tiltdozer and full-U tiltdozer specifications

Unit: kg Machine model Serial Number Engine and damper assembly Engine assembly Damper assembly Main radiator assembly Aftercooler assembly Oil cooler assembly Fuel tank assembly [When full] Power train unit (Including work equipment pump and fan pump) Torque converter and PTO assembly Transmission assembly Transmission valve assembly Steering clutch and brake assembly Steering valve assembly Work equipment pump Cooling fan pump Power train and lubricating oil pump Scavenging pump Power train filter assembly (3 pcs.) Final drive assembly (Each side) Main frame assembly Track group assembly (Each side) Track frame Idler assembly (Each side) Track roller assembly (1 single flange) Track roller assembly (1 double flange) Carrier roller assembly (1 pc.) Track shoe assembly (710 mm) Pivot shaft assembly (each side) Equalizer bar Hydraulic tank assembly Control valve Blade lift cylinder assembly (Each side) Blade tilt cylinder assembly Tiltdozer assembly Blade Straight frame (Left) Straight frame (Right) Tilt cylinder assembly Variable giant ripper assembly Shank assembly Ripper lift cylinder assembly Ripper tilt cylinder assembly D475A-5E0 30001 and up 4,115 3,900 215 485 30 129 863 [2,335] 5,350 830 1,335 40 2,290 75 180 72 64 25 100 3,575 9,120 13,190 2,976 708 248 237 106 13,530 370 733 290 195 509 504 16,500 (18,500) 8,550 (9,760) 1,770 (1,770) 1,770 (1,770) 504 (504) 7,300 1,040 389 394
Values in ( ) are for full-U blade.
12
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Unit: kg Machine model Serial Number Radiator guard assembly Radiator guard Blade lift cylinder assembly (Each side) Cooling fan motor Radiator mask (Including grille) (Each side) Engine underguard (Front) Engine underguard (Rear) Power train underguard (Front) Power train underguard (Rear) Hood Fender (Left) Fender (Right) ROPS mount assembly (Left) ROPS mount assembly (Right) ROPS assembly Floor frame assembly Cab assembly Operator's seat assembly D475A-5E0 30001 and up 4,550 2,530 509 65 100 267 324 340 448 197 474 570 527 520 934 600 455 64
D475A, D475ASD-5E0
13
SEN00208-01
01 Specification
Superdozer specification
Unit: kg Machine model Serial Number Engine and damper assembly Engine assembly Damper assembly Main radiator assembly Aftercooler assembly Oil cooler assembly Fuel tank assembly [When full] Power train unit (Including work equipment pump and fan pump) Torque converter and PTO assembly Transmission assembly Transmission valve assembly Steering clutch and brake assembly Steering valve assembly Work equipment pump Cooling fan pump Power train and lubricating oil pump Scavenging pump Power train filter assembly (3 pcs.) Final drive assembly (Each side) Main frame assembly Track group assembly (Each side) Track frame Idler assembly (Each side) Track roller assembly (1 single flange) Track roller assembly (1 double flange) Carrier roller assembly (1 pc.) Track shoe assembly (810 mm) Pivot shaft assembly (each side) Equalizer bar Hydraulic tank assembly Control valve Blade lift cylinder assembly (Each side) Blade pitch cylinder assembly (Each side) Superdozer assembly Blade Straight frame (Left) Straight frame (Right) Pitch cylinder assembly (Each side) Counterweight Radiator guard assembly Radiator guard Blade lift cylinder assembly (Each side) Cooling fan motor D475ASD-5E0 30001 and up 4,115 3,900 215 485 30 129 863 [2,335] 5,350 830 1,335 40 2,290 75 180 72 64 25 100 3,575 9,120 13,190 2,976 708 248 237 106 14,450 370 733 290 195 509 508 21,200 11,950 1,770 1,770 508 6,400 4,640 2,530 509 65
14
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Unit: kg Machine model Serial Number Radiator mask (Including grille) (Each side) Engine underguard (Front) Engine underguard (Rear) Power train underguard (Front) Power train underguard (Rear) Hood Fender (Left) Fender (Right) ROPS mount assembly (Left) ROPS mount assembly (Right) ROPS assembly Floor frame assembly Cab assembly Operator's seat assembly D475ASD-5E0 30001 and up 100 267 324 340 448 197 474 570 527 520 934 600 455 64
D475A, D475ASD-5E0
15
SEN00208-01
01 Specification
Fuel, coolant and lubricants

a For details of the notes (Note 1, Note 2 - - -) in the table, see Operation and Maintenance Manual.
16
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Unit: l Refilling points Engine oil pan Damper case Power train case Final drive case (each) Hydraulic system (with blade, without ripper) Cooling system (including reservoir tank) Fuel tank D475A, D475ASD-5E0 Specified capacity 126 2.2 410 75 420 210 1670 Refill capacity 121 2.2 210 75 170
D475A, D475ASD-5E0
17
SEN00208-01
18
SEN00210-00
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
10 Structure, function and maintenance standard

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
SEN00210-00
Engine and cooling system

Radiator and oil cooler
1
1
1. Main radiator 2. Sub radiator 3. Turbocharger 4. Engine 5. Power train oil cooler 6. Water pump
D475A, D475ASD-5E0
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Engine mount
Unit: mm
No. Check item Standard size 78 2 3 Clearance between bracket and bushing Free height of rubber mount 200 Criteria Tolerance Shaft 0.030 0.060 0.043 0.083 Standard size 118 Hole +0.006 0.048 +0.072 +0.072 Standard clearance 0.018 0.066 0.043 0.155 Repair limit 116 Clearance limit 0.1 Replace 0.1 Remedy
Clearance between bracket and cushion
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Cooling fan pump

Type: LPV90 + 30
DC: Discharge port SC: Suction port 1. 2. LPV90 Hydraulic pump LPV30 Hydraulic pump
D475A, D475ASD-5E0
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1.
LPV90 Hydraulic pump
DC: Discharge port SC: Suction port
D475A, D475ASD-5E0
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IM: PA: PD1: PD2: PDA: PEN: PEPC: PS:
Control current input connector Pump discharge port Drain port Drain port (Plug) Breather Control pressure pick-up port (Plug) EPC basic pressure input port Pump suction port
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Shaft Cradle Case Rocker cam Shoe Piston Cylinder block Valve plate Spring Servo piston
D475A, D475ASD-5E0
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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 (C). 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 rocker cam (4) and slid circularly. Rocker cam (4) receives high-pressure oil and forms a static pressure bearing and slides on cylindrical 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 maintained properly. q The oil in each cylinder of cylinder block (7) can be sucked and discharged through valve plate (8).
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Operation 1) Operation of pump q Cylinder block (7) rotates together with shaft (1). Shoe (5) slides on plane (A). At this time, rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (7) changes. Angle (a) is called the swash plate angle.
If center line (X) of rocker cam (4) is equal to the axial of cylinder block (7) (the swash plate angle is 0), there is not a difference between volumes (E) and (F) in cylinder block (7) and the oil is not sucked or discharged. (The swash plate angle is not set to 0 actually, however.)
In short, swash plate angle (a) is in proportion to the pump discharge.
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). 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). 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.]
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2)
q
Control of discharge If swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, or discharge (Q) is increased. Swash plate angle (a) is changed with servo piston (1). Servo piston (1) reciprocates straight according to the signal pressure of the PC valve. This straight motion is transmitted to rocker cam (4). Then, rocker cam (4) supported on the cylindrical surface of cradle (2) slides in the rotating direction. The pressure receiving area of the top of servo piston (1) is different from that of the bottom. Main pump discharge pressure (self-pressure) (PA) is kept led in the pressure chamber on the small-diameter piston side (upper side). PC valve output pressure (PEN) is led in the pressure chamber on the large-diameter piston side (lower side). The movement of servo piston (1) is controlled according to the difference between pressure (PA) on the small-diameter piston side and pressure (PEN) on the large-diameter piston side and the ratio of the pressure receiving area of the small-diameter piston to that of the large-diameter piston.
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3)
PC valve, EPC valve, and servo piston
IM: PA: PEPC:
Control current input connector Pump discharge port EPC basic pressure input port PC valve 4. Piston 5. Seat 6. Spring 7. Spool 8. Sleeve 9. Plug EPC valve 10. EPC valve
Servo piston 1. Servo piston 2. Lever 3. Spring
D475A, D475ASD-5E0
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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.
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(1) When EPC output pressure is high [When EPC current (i) is large]
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Operation q The relationship between the EPC valve input current (i) and EPC valve output pressure (F) is as shown in the figure below.
If the EPC discharge pressure rises, spool (7) is pushed to the left because of the difference in sectional areas between parts (S1) and (S2) of the spool (S1 > S2). Port (f) is connected to port (g) and pump discharge pressure (PA) flows through port (g) to port (f). Port (f) is disconnected from the drain circuit. Pump discharge pressure (PA) from port (f) of the PC valve enters chamber (X) on the large diameter side of servo piston (1). Pump pressure (PA) is also constantly applied to chamber (Y) on the small diameter side of servo piston (1). Since a larger force is applied to the large diameter side because of the difference in area between both ends of servo piston (1), however, servo piston (1) moves toward the minimum swash plate angle side (upper side). If servo piston (1) moves up, piston (4) is moved to the right through lever (2). Accordingly, spring (6) is compressed and spool (7) moves to the right. If spool (7) moves to the right and port (f) is disconnected from port (g), servo piston (1) stops moving up. At this time, servo piston (1) stops at a place higher (nearer to the minimum swash plate angle) than when the EPC discharge pressure is low.
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(2) When EPC output pressure is low [When EPC current (i) is small]
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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.
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2.
LPV30 Hydraulic pump
P1: PAEPC: PDA2: PEPC: PS: TO:
Pump discharge port EPC output pressure pickup port Breather EPC valve basic pressure input port Pump suction port Drain port
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Shaft Oil seal Case Rocker cam Shoe Piston Cylinder block Valve plate Spring Servo piston Ball
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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 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 maintained properly. q The oil in each cylinder of cylinder block (7) can be sucked and discharged through valve plate (8).
q
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Operation 1) Operation of pump q Cylinder block (7) rotates together with shaft (1). Shoe (5) slides on plane (A). At this time, rocker cam (4) tilts around ball (11). As a result, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (7) changes. Angle (a) is called the swash plate angle. 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.]
If center line (X) of rocker cam (4) is equal to the axial of cylinder block (7) (the swash plate angle is 0), there is not a difference between volumes (E) and (F) in cylinder block (7) and the oil is not sucked or discharged. (The swash plate angle is not set to 0 actually, however.) In short, swash plate angle (a) is in proportion to the pump discharge.
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2)
q
Control of discharge If swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, or discharge (Q) is increased. Swash plate angle (a) is changed with servo piston (10). Servo piston (10) reciprocates straight according to the signal pressure of the servo valve. This straight motion is transmitted to rocker cam (4). Then, rocker cam (4) supported on ball (11) rocks around ball (11).
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3)
Servo valve
P: PE: PH: T: 1. 2. 3. 4. 5. 6. 7.
EPC valve basic pressure input port Control piston pressure output port Pump discharge pressure input port Drain port Plug Lever Retainer Seat Spool Piston Sleeve
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A: Drain side B: Pump discharge 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.
D: EPC output pressure side P: EPC basic pressure input side
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The relationship between the EPC valve input current (i) and EPC valve output pressure (F) is as shown in the figure below.
Operation The output oil of the EPC valve flows in the piston 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 discharge 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 discharge circuit and the servo piston circuit are shut off. The pressure in the servo piston chamber lowers and the rocker cam returns toward the maximum swash plate angle. q These processes are repeated until the swash plate is fixed to a position where the EPC output 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.
q
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Cooling fan motor

Type: LMF180
P: From fan pump T: From cooler to tank TC: To tank Specifications Type : LMF180 Capacity : 180 cc/rev Rated speed : 982 rpm Rated flow : 178 l/min Check valve cracking pressure: 0.07 MPa {0.7 kg/cm2}
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Output shaft Case Thrust plate Shoe Piston Cylinder block Valve plate End cover Center spring Safety-suction valve
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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 generates 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 output shaft by means of spline, the output shaft revolves to transmit the torque.
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2.
Safety-suction valve
1. 2. 3. 4. 5. 6. 7. 8. 9.
Piston Main valve Piston spring Valve seat Poppet Poppet spring Suction valve Suction valve spring 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)
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Operation 1) Operation as safety valve q Port (A) is connected to port (P) of the motor and port (B) is connected through port (MB) to port (T). 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 sections is (d5) > (d4) > (d1) > (d3) > (d2).
If poppet (5) opens, the pressure in port (C) lowers and piston (1) moves to the right. Piston (1) comes in contact with the tip of poppet (5) and the hydraulic oil is drained through throttle (b) and port (D).
If abnormal pressure generated in port (A) reaches the set pressure of spring (6), poppet (5) opens and the hydraulic oil in port (C) is drained through port (D) and periphery (a) of suction valve (7).
Since the pressure in port (C) is lower than that in port (A), main valve (2) moves to the right and the hydraulic oil flows through port (A) to port (B), thus generation of abnormal pressure is prevented. Even if abnormal pressure is generated, suction valve (7) having a large section diameter does not operate since (d1) < (d4).
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2)
q
Operation as suction valve If negative pressure is generated in port (P) of the motor, the pressure in ports (A) and (C) becomes negative since those ports are connected. A right force caused by the hydraulic pressure equivalent to the area difference between (d4) and (d1) is applied to suction valve (7). If the differential pressure between ports (B) and (A) increases above the set pressure, it moves suction valve (7) to the right. Accordingly, hydraulic oil flows from port (B) to port (A) to prevent generation of negative pressure in port (A).
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3. 1)
Operation for forward and reverse revolution Forward revolution (Counterclockwise revolution)
If ON-OFF solenoid (1) for selector valve is deenergized, the hydraulic oil in port (MA) is sent to chamber (E) and spool (5) moves to the left. The hydraulic oil in port (MB) is returned to the tank through passage (a) on the periphery of spool (5). If ON-OFF solenoid (1) for selector valve is deenergized, the hydraulic oil from the pump is blocked by ON-OFF selector valve (2) and port (C) is connected to the tank circuit. Accordingly, selector spool (3) is pushed by spring (4) to the right to open motor port (MA) and then the hydraulic oil flows in the motor to revolve the motor forward (counterclockwise).
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2)
Reverse revolution (Clockwise revolution)
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. The hydraulic oil in port (MA) is returned from chamber (E) to the tank through passage (a) on the periphery of spool (5). If ON-OFF solenoid (1) for selector valve is energized, ON-OFF selector valve (2) changes to let the hydraulic oil from the pump flow through port (C) into spool chamber (D). The hydraulic oil in chamber (D) pushes selector spool (3) to the left against spring (4). As a result, motor port (MB) opens and the hydraulic oil flows in the motor to revolve the motor in reverse (clockwise).
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

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
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Power train, Part 1

Power train
1
1
Outline q The power generated by engine (1) has its torsional vibration dampened by damper (2), and then passes through universal joint (3), and is transmitted to torque converter (7). The power from the engine is transmitted through oil by torque converter (7) to the input shaft (turbine shaft) of transmission (8) in accordance with the change in the load. There is a lockup clutch assembled to the torque converter, and when the rotating speed beyond the torque converter becomes higher, the lockup clutch is engaged. When this happens, the drive case and turbine form one unit, so the power from the engine is transmitted directly to the transmission input shaft. Transmission (8) uses a combination of a planetary gear system and hydraulic equipment to reduce the speed and shift the gears (forward: 3 gears, reverse: 3 gears). It connects two sets of clutches selected with the gear shift lever according to the change in the load, and transmits the power from the transmission to transfer (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
shaft, and it is then divided at right angles to the left and right and transmitted to the respective steering clutches (9). The power transmitted from the bevel gear shaft to the final drive is used to steer the machine by engaging or disengaging steering clutch (9). The steering lever is operated to disengage the steering clutch on the side to which the machine is to be steered in order to change the direction of travel. The size of the turning radius is controlled by steering brake (10) installed to the outside of the steering clutch. Steering brake (10) uses the same disc system that is used for the steering clutch. The power output from the steering clutch enters final drive (11), where it is reduced, and rotates sprocket (12). Final drive is a double reduction type consisting of a single stage spur gear and single stage planetary gear system. It rotates the sprocket to drive track shoe (13) and moves the machine.
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1. 2. 3. 4. 5.
Engine (SAA12V140E-3) Damper Universal joint Power train, lubrication pump (BAL160+160+112) Work equipment pump (HPV125+125)
6. 7. 8. 9. 10. 11. 12.
Fan pump (LPV90+30) Torque converter Transmission Steering clutch Steering brake Final drive Sproket
13. 14. 15. 16. 17. 18. 19.
Track shoe Transfer Transfer drive gear Bevel pinion Bevel gear PTO Scavenging pump
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Power train hydraulic equipment arrangement diagram
1. 2. 3. 4. 5. 6. 7. 8. 9.
Torque converter oil filter Transmission lubricating oil filter Transmission oil filter Torque converter valve Transmission control valve Steering control valve Power train oil strainer Oil tank Power train, lubrication pump (BAL160+160+112) 10. Scavenging pump 11. Power train oil cooler
A. B. C. D. E. F. G. H. J. K. L. M. N. P.
Transmission main relief pressure pickup port (TM) Transmission R clutch pressure pickup port (REV) Transmission F clutch pressure pickup port (FWD) Torque converter inlet pressure pickup port (IN) Lockup clutch pressure pickup port (LU) Left clutch pressure pickup port (LC) Left brake pressure pickup port (LB) Right brake pressure pickup port (RB) Right clutch pressure pickup port (RC) Stator clutch pressure pickup port (SC) Torque converter outlet pressure pickup port (OUT) Transmission 1st clutch pressure pickup port (1ST) Transmission 2nd clutch pressure pickup port (2ND) Transmission 3rd clutch pressure pickup port (3RD)
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Damper and universal joint
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Output shaft Flywheel Outer body Flange Oil level gauge Breather Cover Coupling Universal joint Rubber coupling Drain plug
Outline The damper damps the tensional vibration caused by fluctuation of the engine torque and the impact torque caused by sudden acceleration and heavy digging work to protect the torque converter, transmission, and other power train components. q Since this damper employs rubber coupling (10), vibrations are damped by the compressive damping effect of the rubber and less component parts are used.
q
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 transmitted to output shaft (1), and then transmitted through universal joint (9) to the torque converter and transmission.
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Unit: mm
No. Check item Standard size 647.7 13 14 15 Clearance between flywheel housing and damper Outer diameter of oil seal contact face on coupling Outer diameter of bearing contact face on output shaft 571.5 Criteria Tolerance Shaft 0.024 0.104 0.022 0.092 Standard size 120 55 Hole +0.080 +0.080 +0.070 +0.070 Standard clearance 0.024 0.184 0.022 0.162 Repair limit 119.9 54.9 Clearance limit 0.2 0.2 Replace Remedy
12
Clearance between flywheel housing and cover
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Power train system 1 General view of power train unit
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A: B: C: D:
Main relief pressure pickup port (TM) R clutch pressure pickup port (REV) F clutch pressure pickup port (FWD) Torque converter inlet pressure pickup port (IN) E: Lockup clutch pressure pickup port (LU) F: Left steering clutch pressure pickup port (LC) G: Left steering brake pressure pickup port (LB) H: Right steering brake pressure pickup port (RB) J: Right steering clutch pressure pickup port (RC) K: Stator clutch pressure pickup port (SC) L: Torque converter outlet pressure pickup port (OUT) M: 1st clutch pressure pickup port (1ST) N: 2nd clutch pressure pickup port (2ND) P: 3rd clutch pressure pickup port (3RD) 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.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Oil filler port Centralized pressure pickup port Oil level gauge Torque converter and PTO Torque converter valve Transmission control valve Transmission Steering control valve Steering unit Torque converter oil filter Transmission lubricating oil filter Power train oil filter Torque converter, power train, and lubricating oil pump 14. Power train oil strainer 15. Scavenging pump
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Torque converter, PTO

a PTO: Abbreviation for Power Take Off
10
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A: B: C: D: E: F: G: H: J: K: L: M: N: P: R: S:
To transmission control valve To transmission lubrication circuit To transmission oil pan From steering case From power train pump From lubricating oil pump To transmission oil pan To scavenging pump To scavenging pump To power train oil filter To transmission lubricating oil filter From power train oil filter From transmission lubricating oil filter Torque converter outlet oil temperature pickup port Torque converter outlet oil pressure pickup port (OUT) To power train oil cooler
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42.
Cooling fan pump mounting port Hydraulic pump mounting port Power train, torque converter, and lubricating oil pump mounting port Scavenging pump mounting port Torque converter valve Coupling Retainer Input shaft (number of teeth: 59) Front housing PTO idler gear (number of teeth: 74) PTO idler gear shaft Lockup clutch housing Drive case Turbine Rear housing Stator Pump Stator shaft Guide Retainer Pump shaft Transmission input shaft Stator clutch hub gear Stator clutch housing Return spring Stator clutch plate Stator clutch disc Stator clutch piston Turbine boss Lockup clutch plate Lockup clutch disc Lockup clutch piston Scavenging pump drive gear (number of teeth: 65) Sleeve Bearing race Power train, torque converter, lubricating oil pump, and cooling fan pump drive gear (number of teeth: 61) Drive gear boss Cover Cover Hydraulic pump drive gear (number of teeth: 61) Cover Strainer
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Outline q The torque converter is a 3-element, 1-stage, and 1-phase type, which is integral with the transmission. q The torque converter is equipped with a wet multiple disc clutch type torque converter lockup device and a wet double disc clutch type stator clutch in order to reduce fuel consumption, to increase the operability, and to reduce the horsepower consumption by the engine. q For higher efficiency of continuous light dozing and leveling operation, the torque converter is locked up and the engine power is transferred directly to the transmissions input shaft. q When the torque converter is locked up (the pump and turbine is integrated into 1 unit), the oil is still supplied to the torque converter. Accordingly, the oil flowing from the pump through the turbine to the stator is obstructed by the stator blades and cannot flow in any direction. As a result, this oil resists the rotation of the pump and turbine (it is agitated). q To reduce the rotating resistance of the pump and turbine, the stator clutch is disengaged simultaneously with lockup of the torque converter so that the stator can rotate freely. As the stator is dragged and turned by the pump and turbine, the oil returns from the turbine to the pump smoothly against less resistance. 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.
Structure q Pump (17) is integral with coupling (6), input shaft (8), lockup clutch housing (12), and drive case (13), and rotated by the engine power. q Turbine (14) is integral with turbine boss (29) and transmission input shaft (22), and rotated by the oil from pump (17). q Stator (16) is integral with stator shaft (18) and stator clutch hub gear (23), and fixed to rear housing (15) through the stator clutch unit. q The lockup clutch unit consists of clutch plate (30) meshed with drive case (13), clutch disc (31) meshed with turbine boss (29), and clutch piston (32) which slides inside clutch housing (12) integral with drive case (13). q The stator clutch unit consists of clutch hub gear (23) attached to stator shaft (18) with spline, clutch disc (27) meshed with clutch hub gear (23), clutch plate (26) supported by the pins on clutch housing (24) and rear housing (15), and clutch piston (28) which slides inside rear housing (15). q The PTO unit consists of input shaft (8), PTO idler gear (10), and pump drive gears (33), (36) and (40).
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Unit: mm
No. 1 2 3 4 5 6 7 8 9 Check item Outside diameter of oil seal contact surface of input coupling Inside diameter of seal ring contact surface of sleeve Inside diameter of seal ring contact surface of retainer Inside diameter of seal ring contact surface of pump shaft Backlash between input shaft and PTO idler gear Backlash between PTO idler gear and power train, torque converter, lubricating oil pump, and cooling fan pump drive gear Backlash between PTO idler gear and hydraulic pump drive gear Backlash between input shaft and scavenging pump drive gear Wear of input shaft seal ring Width Thickness 4 4.5 5.4 5.0 26.2 5.4 5.0 15.8 Standard size 12 Fitting tolerance of PTO idler gear bearing Outside diameter Inside diameter Fitting tolerance of power train, torque converter, lubricating oil pump, and cooling fan pump drive gear bearing Outside diameter (cover side) Outside diameter (case side) Inside diameter Outside diameter (cover side) Fitting tolerance of hydraulic pump drive gear bearing Outside diameter (case side) Inside diameter (cover side) Inside diameter (case side) 15 Fitting tolerance of scavenging pump drive gear bearing Outside diameter Inside diameter 140 80 140 140 65 160 140 75 65 72 35 Standard size 16 Stator clutch return spring Free length Installed length Installed load 54.1 37.0 125.4 N {12.8 kg} Standard size 125 115 190 120 Criteria Tolerance 0 0.063 +0.035 0 +0.046 0 +0.035 0 0.198 0.484 0.198 0.484 0.198 0.484 0.198 0.484 0.01 0.03 0.12 0.1 0.1 0.22 0.1 0.05 0.15 Tolerance Shaft 0 0.018 0 0.019 0 0.018 0 0.018 +0.030 +0.011 0 0.025 0 0.018 +0.030 +0.011 +0.030 +0.011 0 0.013 +0.025 +0.009 Free length 50.9 Hole 0.008 0.033 0 0.015 +0.012 0.028 +0.015 0.010 0 0.015 +0.012 0.028 +0.015 0.010 0 0.015 0 0.015 +0.009 0.021 0 0.010 Repair limit Installed load 106.9 N {10.9 kg} Replace 3.6 4.05 4.9 4.5 24.6 4.9 4.5 14.7 Repair limit 124.8 115.1 190.5 120.5 Repair by hard chrome plating or replace Remedy
Thickness of lockup clutch disc 10 Thickness of lockup clutch plate Overall thickness of lockup clutch assembly Thickness of stator clutch disc 11 Thickness of stator clutch plate Overall thickness of stator clutch assembly
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Power transmitting route When lockup clutch is disengaged and stator clutch is engaged When lockup clutch is engaged and stator clutch is disengaged
If lockup clutch (3) is disengaged, drive case (5) and turbine (7) are disconnected from each other. If stator clutch (9) is engaged at this time, rear housing (10) and stator shaft (11) are connected to each other to fix stator (8). Therefore, the torque converter works as an ordinary torque converter. The power from the engine is transmitted to coupling (1) through the damper and the universal joint. The power transmitted to coupling (1) rotates input shaft (2), clutch housing (4), drive case (5) and pump (6) integrally. The power transmitted to pump (6) rotates turbine (7) through the medium of oil and is transferred to transmission input shaft (12) attached to turbine (7) with spline.
If lockup clutch (3) is engaged, drive case (5) and turbine (7) are connected to each other. If stator clutch (9) is disengaged at this time, rear housing (10) and stator shaft (11) are disconnected from each other, and stator (8) is dragged and turned by pump (6) and turbine (7). Therefore, the torque converter works as a lockup torque converter. The power from the engine is transmitted to coupling (1) through the damper and the universal joint. The power transmitted to coupling (1) rotates input shaft (2), clutch housing (4), drive case (5) and pump (6) integrally. The power transmitted to drive case (5) rotates turbine (7) directly since lockup clutch (3) is fixed, and is transferred to transmission input shaft (12) attached to turbine (7) with spline.
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Oil flow
The oil flows through the main relief valve and its pressure is reduced to below the set pressure by the torque converter relief valve. It then flows in inlet port (A), goes through the oil passages of rear housing (1), pump shaft (2) and guide (3), and flows into pump (4). The oil is given a centrifugal force by pump (4), and then it enters turbine (5) to transmit its energy to turbine (5). The oil from turbine (5) is sent to stator (6) and flows in pump (4) again. A part of the oil, however, is sent through outlet port (B) to the power train oil cooler.
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Torque converter valve
PTF: TCF: TC : SC : LC : drT: dr: P3 : P8 : PSC: PPL:
From power train oil filter From torque converter oil filter To torque converter To stator clutch To lockup clutch Drain (Torque converter relief) Drain Lockup clutch oil pressure pickup port (LU) Main relief oil pressure pickup port (TM) Stator clutch oil pressure pickup port (SC) Pilot oil pressure pickup port
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Valve body Torque converter relief valve Cover Main relief valve Piston Piston Stator clutch modulating valve Piston Piston Cover Piston Piston Lockup clutch modulating valve Shaft Stopper Load piston Cover
18. 19. 20. 21. 22.
Plug Valve body Lockup selector valve Piston Cover
Lockup solenoid valve 23. Cap 24. Coil 25. Valve 26. Ball 27. Valve 28. Base 29. Shaft 30. Case 31. Plunger
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Unit: mm No. Check item Clearance between main relief valve and valve body Clearance between torque converter relief valve and valve body Clearance between stator clutch modulating valve and valve body Clearance between lockup clutch modulating valve and valve body Clearance between lockup selector valve and valve body Standard size 40 Shaft 0.035 0.045 0.035 0.045 0.035 0.045 0.035 0.045 0.035 0.045 Standard size Installed length 101.5 86.3 95.2 88.7 80.5 54 Criteria Tolerance Hole +0.016 0 +0.016 0 +0.013 0 +0.013 0 +0.013 0 Installed load 1,455 N {148.5 kg} 645.6 N {65.83 kg} 151.9 N {15.5 kg} 158.6 N {16.18 kg} Standard clearance 0.035 0.061 0.035 0.061 0.035 0.058 0.035 0.058 0.035 0.058 Clearance limit 0.081 0.081 0.078 0.078 0.078 Remedy
2 3 4 5
40 25 25 25
Repair limit Free length 116.7 113.4 100.4 137.2 78.1 64.0 Installed load 1,383 N {141.1 kg} 613 N {62.5 kg} 144 N {14.7 kg} 151 N {15.4 kg} Replace
Main relief valve spring
Free length 120.3
7 8 9 10
Torque converter relief valve spring Stator clutch modulating valve spring Lockup clutch modulating valve spring (outside) Lockup clutch modulating valve spring (inside)
116.92 103.5 141.4 80.5 66
55.9 N {5.7 kg}
53.0 N {5.4 kg}
11 Lockup selector valve spring
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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 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 protect the torque converter from abnormally high pressure. Set pressure: 1.00 MPa {10.2 kg/cm2} Lockup solenoid valve 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 disengaged. Stator clutch modulating valve 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 abnormally high pressure, as well as raising the clutch pressure gradually to the set pressure. Set pressure: 1.3 MPa {13 kg/cm2}
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Operation of main relief valve
Operation of torque converter relief valve
The oil from the hydraulic pump flows through the filter, port (A) of the torque converter valve, and orifice (a) of torque converter relief valve (1) to chamber (B).
The oil from the main relief valve flows through port (C) to the torque converter, and at the same time, also flows through orifice (b) of torque converter relief valve (3) to chamber (D). 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.
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.
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Operation of lockup solenoid valve and lockup selector valve When traveling in torque converter range
While the machine is in the torque converter range, the lockup solenoid valve is de-energized and therefore plunger (1) is pushed back upward by the oil pressure from the pump. As the seats of valve (2) and ball (3) are opened, the drain circuit of port (B) is opened and the oil in port (A) and port (C) is drained. Lockup selector valve (5) is pushed back to the right by the tension of spring (6). As a result, the passages between port (D) and port (F) and between port (E) and port (G) are closed, while the passages between port (D) and port (E) and between port (F) and port (H) are opened.
The oil from the pump flows through port (D) into port (E) and applies back pressure to stator clutch piston (7). It turns engaged the stator clutch as the oil pressure in the circuit is raised. At the same time, the oil which applied back pressure to lockup clutch piston (8) is drained through port (F) into port (H) to turn the lockup clutch disengaged. The oil from the pump flows into port (A) and port (D). The oil in port (A) is drained as the lockup solenoid valve is de-energized, while the oil pressure in port (D) is secured by orifice (a) and adjusted by modulating valve (9).
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When traveling in direct range
While the machine is in the direct range, the lockup solenoid valve is energized and therefore plunger (1) moves downward. As the seats of valve (2) and ball (3) are closed, the drain circuit of port (B) is closed and the oil in port (A) flows to port (C) The oil from port (C) pushes piston (4) to move lockup selector valve (5) to the left. As a result, the passages between port (D) and port (E) and between port (F) and port (H) are closed, while the passages between port (D) and port (F) and between port (E) and port (G) are opened.
The oil from the pump flows through port (D) into port (F) and applies back pressure to stator clutch piston (8). It turns the lockup clutch engaged as the oil pressure in the circuit is raised. At the same time, the oil which had applied back pressure to stator clutch piston (7) is drained through port (E) into port (G) to turn the stator clutch disengaged. The pressure of the oil which flows from the pump into port (D) is adjusted by modulating valve (10).
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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-energized 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 passages 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 intermittently, 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.
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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 piston (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), modulating 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.
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Torque converter lockup control system

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 selection panel. q The machine controller receives the gear speed information from the transmission controller and the transmission outlet speed sensor signal from the shoe slip controller and turns ON and OFF the lockup system by connecting 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.
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Scavenging pump
Type: BAR(3)63+320
A: B: C: 1. 2.
Suction port from torque converter Suction port from steering unit Discharge port Front pump Rear pump
Outline q The scavenging pump is installed to the PTO case and driven by the power from the engine. q Front pump (1) sucks the oil collected in the torque converter case through the filter and 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 Nominal delivery amount (cc/rev) Front Rear Tandem gear pump 63.3 319.4 0.98 {10} 1,997
Maximum discharge pressure (MPa {kg/cm2}) Maximum speed (rpm)
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Transmission control
a a
PCCS: Abbreviation for Palm Command Control System For steering operation concerned to operation of the Palm Command Control System lever (PCCS lever), see Steering and brake control.
1. 2. 3. 4. 5. 6. 7. 8.
Brake pedal Lock lever PCCS lever (Forward-Reverse, Gear shift) Transmission neutral switch Cable Transmission control valve UP switch (Gear is shifted up each time this switch is pressed.) DOWN switch (Gear is shifted down each time this switch is pressed.)
Lever positions A: Neutral B: Forward C: Reverse D: Free E: Lock Outline q The transmission is controlled with PCCS lever (3). The PCCS lever is used to select the travel direction and shift the gear. 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).
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Transmission
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A: B: C: D: E: F: G: H: J: K: L: M: N: P: dr: 1. 2. 3. 4.
To transmission lubrication circuit To priority valve To scavenging pump (from steering case) From scavenging pump (to transmission oil pan) From power train oil filter To lubricating oil relief valve From 1st clutch ECMV From 2nd clutch ECMV From F clutch ECMV From 3rd clutch ECMV From R clutch ECMV Air vent (from steering case) To steering control valve From steering case (to scavenging pump) Drain Transmission input shaft Transmission control valve Front case Rear case
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5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42.
Front cover R sun gear (number of teeth: 32) R ring gear (hub) (number of internal teeth: 89) Pinion shaft R planetary pinion (number of teeth: 25) R ring gear (number of teeth: 82) Pinion shaft F ring gear (number of internal teeth: 89) F planetary pinion (number of teeth: 25) F sun gear (number of teeth: 39) 3rd ring gear (number of internal teeth: 89) 3rd planetary pinion (number of teeth: 25) 3rd sun gear (number of teeth: 39) 2nd ring gear (number of internal teeth: 89) 2nd planetary pinion (number of teeth: 21) 2nd sun gear (number of teeth: 47) Pinion shaft 1st clutch inner drum Output shaft Collar Drive shaft (for sensor) 1st clutch piston housing 1st clutch piston 2nd carrier 2nd clutch piston 2nd clutch piston housing F and 3rd carrier 3rd clutch piston F and 3rd clutch piston housing F clutch piston R carrier R clutch piston housing R clutch piston Tie rod pin Washer spring Clutch spring Clutch plate Clutch disc
Outline q The transmission adopted is a forward 3-gear speed and reverse 3-gear speed transmission which consists of the planetary gear mechanisms and the disc clutches. q Out of the 5 sets of planetary gear mechanisms and disc clutches, 2 clutches are fixed hydraulically by the operation of ECMV to select 1 rotation direction and 1 speed. q The transmission transmits the power received by the transmission input shaft to the output shaft while changing the gear speed (forward 1st-3rd or reverse 1st-3rd) by any combination of the F, R clutches and 3 speed clutches. Number of plates and discs used
Clutch No. R clutch F clutch 3rd clutch 2nd clutch 1st clutch Number of plates 6 6 4 3 5 Number of discs 7 7 5 4 6
Combinations of clutches at respective gear speeds and reduction ratio

Gear speed Forward 1st speed Forward 2nd speed Forward 3rd speed Neutral Reverse 1st speed Reverse 2nd speed Reverse 3rd speed Clutch used F 1st F 2nd F 3rd 1st (*) R 1st R 2nd R 3rd Reduction ratio 3.282 1.789 1.000 2.563 1.397 0.781
*: Filled with oil at low pressure. (Except for low temperature and abnormal conditions.)
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Unit: mm No. Check item Standard size Installed length 90.0 94.0 72.0 63.0 76.0 Criteria Repair limit Installed load 140.5 N {14.3 kg} 84.3 N {8.5 kg} 150.5 N {15.4 kg} 119.1 N {12.2 kg} 238.7 N {24.4 kg} Tolerance 0.36 0.36 0.30 0.26 0.43 0.1 0.15 0.1 0.01 0.03 0.12 0.01 0.03 0.15 0.01 0.03 0.15 0.01 0.03 0.15 0.01 0.04 0.15 0.01 0.04 0.15 0.16 0.35 0.18 0.38 Free length 94.0 94.0 79.0 76.8 97.3 Installed load 119.6 N {12.2 kg} 70.6 N {7.2 kg} 128.5 N {13.1 kg} 102.0 N {10.4 kg} 203.0 N {20.7 kg} 68.9 68.9 47.5 36.9 58.2 4.9 4.9 5.2 2.70 3.85 3.60 4.85 3.60 4.85 5.50 6.65 3.60 4.85 3.60 3.85 Replace Remedy
R clutch spring (12 pcs.)
Free length 100.0
2 3 4 5 6 7 8 9 10
F clutch spring (12 pcs.) 3rd clutch spring (12 pcs.) 2nd clutch spring (12 pcs.) 1st clutch spring (12 pcs.) Total assembled thickness of 7 discs and 6 plates of R clutch Total assembled thickness of 7 discs and 6 plates of F clutch Total assembled thickness of 5 discs and 4 plates of 3rd clutch Total assembled thickness of 4 discs and 3 plates of 2nd clutch Total assembled thickness of 6 discs and 5 plates of 1st clutch F, R,
100.0 84.0 81.7 103.5 Standard size 72.6 72.6 50.2 39.0 61.4 5.4 5.4 5.8 Width Thickness Width Thickness Width Thickness Width Thickness Width Thickness Width Thickness 3.0 4.0 4.0 5.0 4.0 5.0 6.0 6.8 4.0 5.0 4.0 4.0
Repair limit
11 Thickness of clutch disc 2nd, 3rd

1st
12 Thickness of clutch plate 13

Wear of seal ring (1 place) Wear of seal ring (4 places) Wear of seal ring (2 places) Wear of seal ring (2 places) Wear of seal ring (1 place) Wear of seal ring (3 places)
14
15
16
17
18
Backlash between 19 sun gear and planetary pinion
20
Backlash between planetary pinion and ring gear
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Disc clutch Structure Operation When clutch is engaged (fixed)
q q
The disc clutch consists of piston (2), plates (3), discs (4), pin (5), return spring (6) etc. to fix ring gear (1). Inside teeth of disc (4) are engaged with outside teeth of ring gear (1). Plate (3) is assembled to clutch housing (7) with pin (5).
The oil from ECMV is sent with pressure to the rear side of piston (2) through the oil passage of housing (7) and pushes piston (2) leftward. Piston (2) contacts plate (3) closely against disc (4) to stop rotation of disc (4) by use of the friction force generated between them. 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 q
As the oil from ECMV is stopped, piston (2) is pushed back rightward by return spring (6). Plate (3) and disc (4) are released from the frictional force and ring gear (1), as the result, is also released.
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Power transmitting route Forward 1st speed
When the transmission is set to the forward 1st 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 engaged. The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (20). The F clutch is actuated by the oil pressure applied to the F clutch piston, and fixes F ring gear (4). The 1st clutch is actuated by the oil pressure applied to the 1st clutch piston, and fixes 1st clutch inner drum (16). The power from the torque converter is transmitted to F planetary pinion (3) through input shaft (1) and F sun gear (2). 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).
The rotation of F and 3rd carrier (10) is transmitted through 3rd planetary pinion (11) to 3rd ring gear (12). 3rd ring gear (12) and 2nd carrier (13) are meshed with each other and rotate integrally. Accordingly, the rotation of 3rd ring gear (12) is transmitted through 2nd carrier (13) to 1st clutch piston housing (14). As 1st clutch inner drum (16) is fixed by the 1st clutch, the power transmitted to 1st clutch piston housing (14) is transmitted through 1st clutch inner drum (16) to output shaft (20).
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Forward 2nd speed
When the transmission is set to the forward 2nd speed, the F clutch and 2nd clutch are engaged.The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (20). The F clutch is actuated by the oil pressure applied to the F clutch piston, and fixes F ring gear (4). The 2nd clutch is actuated by the oil pressure applied to the 2nd clutch piston, and fixes 2nd ring gear (17). The power from the torque converter is transmitted to F planetary pinion (3) through input shaft (1) and F sun gear (2). 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).
The rotation of F and 3rd carrier (10) is transmitted through 3rd planetary pinion (11) to 3rd ring gear (12). 3rd ring gear (12) and 2nd carrier (13) are meshed with each other and rotate integrally. Accordingly, the rotation of 2nd carrier (13) is transmitted to 2nd planetary pinion (15). As 2nd ring gear (17) is fixed by the 2nd clutch, the power transmitted to 2nd planetary pinion (15) is transmitted through 2nd sun gear (18) to output shaft (20).
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Forward 3rd speed
When the transmission is set to the forward 3rd 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 engaged. The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (20). The F clutch is actuated by the 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). The power from the torque converter is transmitted to F planetary pinion (3) through input shaft (1) and F sun gear (2). 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).
As 3rd ring gear (12) is fixed by the 3rd clutch, the power transmitted to F and 3rd carrier (10) is transmitted through 3rd planetary pinion (11) and 3rd sun gear (19) to output shaft (20).
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Reverse 1st speed
When the transmission is set to the reverse 1st 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 engaged. The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (20). The R clutch is actuated by the oil pressure applied to the R clutch piston, and fixes ring gear (7). The 1st clutch is actuated by the oil pressure applied to the 1st clutch piston, and fixes 1st clutch inner drum (16). The power from the torque converter is transmitted to R planetary pinion (6) through input shaft (1) and R sun gear (5). 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 carrier (10).
The rotation of F and 3rd carrier (10) is transmitted through 3rd planetary pinion (11) to 3rd ring gear (12). 3rd ring gear (12) and 2nd carrier (13) are meshed with each other and rotate integrally. Accordingly, the rotation of 3rd ring gear (12) is transmitted through 2nd carrier (13) to 1st clutch piston housing (14). As 1st clutch inner drum (16) is fixed by the 1st clutch, the power transmitted to 1st clutch piston housing (14) is transmitted through 1st clutch inner drum (16) to output shaft (20).
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44
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

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
SEN00212-00
Power train, Part 2

Transmission control valve
1
1
D475A, D475ASD-5E0
SEN00212-00
PF: F clutch oil pressure pickup port (FWD) PR: R clutch oil pressure pickup port (REV) P1: 1st clutch pressure pickup port (1ST) P2: 2nd clutch pressure pickup port (2ND) P3: 3rd clutch pressure pickup port (3RD) PV: To priority valve LV: To lubricating oil relief valve LD: Drain (from lubricating oil relief valve) CF: To F clutch CR: To R clutch C1: To 1st clutch C2: To 2nd clutch C3: To 3rd clutch dr: Drain 1. 2. 3. 4. 5. 6. 7. 8. 9. Filter Priority valve Lubricating oil relief valve 1st clutch ECMV 2nd clutch ECMV 3rd clutch ECMV F clutch ECMV R clutch ECMV Valve seat
Operation table of ECMV

ECMV Gear speed
F Q Q Q
1st Q
2nd
3rd
Forward 1st Forward 2nd Forward 3rd Reverse 1st Reverse 2nd Reverse 3rd * Neutral
Q Q Q Q Q Q Q Q Q
*: Filled with oil at low pressure. (Except for low temperature and abnormal conditions.)
D475A, D475ASD-5E0
SEN00212-00
Transmission clutch ECMV

a a
ECMV: Abbreviation for Electronic Control Modulation Valve Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: P: T: Dr: P1: 1. 2. 3. 4. 5. 6. 7.
To clutch From pump Drain Drain Clutch oil pressure pickup port Fill switch connector Proportional solenoid connector Flow rate pickup valve Fill switch Proportional solenoid Pressure control valve Nameplate (*1)
*1: Clutch used F, R, 1st, 2nd, 3rd Stamp of the nameplate A*******
D475A, D475ASD-5E0
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Outline of ECMV q The ECMV consists of 1 pressure control valve and 1 fill switch. q Pressure control valve This valve receives the current sent from the transmission controller with a proportional solenoid, and then converts it into oil pressure. q Fill switch This switch detects that the clutch is filled with oil and has the following functions. 1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil. 2. Keeps outputting signals (fill signals) to the controller to notify whether oil pressure is applied or not while oil pressure is applied to the clutch.
ECMV and proportional solenoid q For each ECMV, 1 proportional solenoid is installed. The proportional solenoid generates thrust shown below according to the command current from the controller. The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Accordingly, the thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil. Current propulsion force characteristics of proportional solenoid
Propulsion force Hydraulic pressure characteristics of proportional solenoid
Range A: Before shifting gear (When draining) 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).
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 ON by the pressure of the clutch. The oil pressure is built up according to this signal.
D475A, D475ASD-5E0
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Operation of ECMV q ECMV is controlled with the command current 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.
Before shifting gear (when draining) (Range A in chart)
Range A: Before shifting gear (When draining) 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).
Under the condition where any current is not sent to proportional solenoid (1), pressure control 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 detection valve (4).
D475A, D475ASD-5E0
SEN00212-00
During filling (Range B in chart)
Pressure regulation (Range C in chart)
If current is applied to proportional solenoid (1) with no oil in the clutch, the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left. This opens pump port (P) and clutch port (A) to feed oil in the clutch. When the clutch is filled with oil, pressure detection valve (4) actuates to turn ON fill switch (5).
If current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the tension of pressure control valve spring (2), and then the pressure is settled.
D475A, D475ASD-5E0
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Priority valve
Unit: mm No. Check item Clearance between spool and valve body Standard size 22 Shaft 0.035 0.045 Standard size Installed length 28.5 Criteria Tolerance Hole +0.013 0 Installed load 84.7 kN {8.6 kg} Standard clearance 0.035 0.058 Clearance limit 0.078 Replace Remedy
Repair limit Free length 37.6 Installed load 80.4 kN {8.2 kg}
Return spring
Free length 38.8
3. 4. 5.
Valve body Spool Piston
Outline The priority valve is installed in the circuit 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 pressure 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. Set pressure: 1.56 MPa {16 kg/cm2}
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Operation from start to finish of gear shifting
Operation right after finishing of gear shifting
q q
The oil from the pump flows through port (A) and orifice (a) to chamber (C). If the oil flow from the pump increases and the oil pressure rises, the oil in chamber (C) pushes piston (1). Then, the reaction force of piston (1) compresses spring (2) and moves valve (3) to the left. If valve (3) moves, port (A) and port (B) are connected and the oil from the pump flows through port (B) to the ECMV. The oil pressure at this time is the set pressure of the priority valve. Then, the oil pressure transmitted from port (B) to the ECMV rises to the set pressure of the clutch.
If the gear shift lever is operated, the oil pressure in port (B) decreases sharply nearing 0 MPa { 0 kg/cm2} as a result of the ECMV operation. Then, the oil pressure in port (A) also decreases, but valve (3) is pushed back to the right by the tension of spring (2). As a result, the oil pressure in port (A) (pilot pressure) is kept to the set pressure.
D475A, D475ASD-5E0
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Lubricating oil relief valve
Unit: mm No. Check item Clearance between spool and valve body Standard size 22 Shaft 0.035 0.045 Standard size Installed length 37 Criteria Tolerance Hole +0.013 0 Installed load 91.9 N {9.37 kg} Standard clearance 0.035 0.058 Clearance limit 0.078 Replace Remedy
Repair limit Free length 66.5 Installed load 87.3 N {8.9 kg}
Return spring
Free length 68.5
3. 4. 5.
Lubricating oil pressure pickup port Spool Valve body
Outline The lubricating oil relief valve is installed to the transmission control valve. It keeps the lubricating oil circuit below the set pressure. Set pressure: 0.26 MPa {2.7 kg/cm2}
10
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Torque converter, power train, lubricating oil pump

Type: BAL(4)160+(4)160+(4)112
Unit: mm No. Check item Type Side clearance BAL(4)160 BAL(4)112 BAL(4)160 BAL(4)112 Type BAL(4)160 BAL(4)112 Criteria Standard clearance 0.04 0.10 0.060 0.145 Standard size 14 Tolerance 0 0.5 5.9 Nm {0.6 kgm} Speed (rpm) 2,000 2,000 Discharge pressure (MPa{kg/ cm2}) 2.94 {30} 2.94 {30} Standard delivery amount (ll/min) 288 205 Delivery amount limit (ll/min) 266 188 Clearance limit 0.13 0.20 Repair limit Replace Remedy
Clearance between plain bearing inner diameter and gear shaft
3 4
Depth to knock in pin Rotating torque of spline shaft
Delivery amount Oil: SAE10WCD Oil temperature: 45 55 C
Type
BAL(4)160 BAL(4)112
5. 6. 7. A: B: C: D:
Lubricating oil pump Power train pump Torque converter pump Suction port Lubricating oil pump discharge port Power train pump discharge port Torque converter pump discharge port
Outline The torque converter pump, power train pump and lubricating oil pump are installed to the PTO case. They are driven by the power from the engine to supply the oil pressure to the torque converter, transmission and steering unit.
D475A, D475ASD-5E0
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SEN00212-00
Steering, brake control

a a
PCCS: Abbreviation for Palm Command Control System Regarding the transmission related description of operation of the PCCS lever, refer to Transmission control.
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Brake pedal Lock lever PCCS lever (Steering) Limit switch Steering ECMV Brake valve Parking brake lever (From lock lever) Cable Rod (From brake pedal) Potentiometer Steering controller Transmission controller Engine controller
Positions of lever and pedal A: Neutral B: Forward straight-travel C: Reverse straight-travel D: Left clutch OFF E: Left clutch OFF Left brake ON F: Right clutch OFF G: Right clutch OFF Right brake ON H: Brake RELEASE J: Brake ON K: Free L: Lock
Outline q PCCS lever (3) sends an electric signal to steering controller (11). After receiving it, steering controller (11) sends a proportional current to steering ECMV (5) to operate the steering clutch and brake. q The brake pedal (1) sends an electric signal to steering controller (11) through potentiometer (10). After receiving it, steering controller (11) sends a proportional current to steering ECMV (5) to operate the brake. In this case, the right and left brakes operate at the same time to activate braking. Rod (9) operates the brake through brake valve (6) for redundant use. (Only at the time of complete braking) q If you slightly tilt PCCS lever (3) towards the left, the left steering clutch is partially disengaged, causing the machine to make a slow left turn. q If you completely tilt PCCS lever (3) towards the left, the left steering clutch is turned disengaged and the left steering brake is turned engaged, causing the machine to make a sudden left turn. q Lock lever (2) is connected to parking brake lever (7) and it also serves as a parking brake.
D475A, D475ASD-5E0
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Final drive
Outline q The final drive is a single stage spur gear, single 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 sliding portion of the sprocket to prevent the entry of dirt or sand and to prevent leakage of lubricating oil.
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Floating seal Sun gear Carrier Hub Cover Sprocket hub Sprocket teeth Floating seal guard Cover Planetary pinion
11. 12. 13. 14. 15. 16. 17. 18. 19.
Ring gear Cover No. 1 gear No. 1 gear hub No. 1 pinion Final drive case Bearing cage Shaft Wear guard
D475A, D475ASD-5E0
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SEN00212-00
Unit: mm
No. 20 21 22 Check item Backlash between No.1 pinion and No.1 gear Backlash between sun gear and planet pinion Backlash between planetary pinion and ring gear Outside diameter of No.1 pinion oil seal contact surface Thickness of thrust collar of inner body roller bearing Thickness of thrust coller of No.1 gear boss roller bearing Height of button Clearance between planetary pinion shaft and carrier (small end) Clearance between planetary pinion shaft and carrier (large end) Standard shim thickness for No.1 pinion bearing cage Dimension of end face of final drive cover and end face of bearing Clearance of floating seal guard Wear of wear guard Standard size 47.5 Standard size 110 Standard clearance 0.26 0.96 0.25 0.70 0.26 0.83 Standard size 120.0 24.8 14.0 20 Tolerance Shaft 0.035 0.054 0.035 0.054 Hole 0.024 0.059 0.067 0.107 2 Criteria Clearance limit 0.96 0.70 0.83 Repair limit 119.9 24.75 13.95 18.5 Standard clearance 0.024 0.030 0.072 0.013 Clearance limit 0.030 Remedy
23
24 25 26
Replace
27
28
135
0.013
29
30
7.3 8.3
Adjust
31 32
3.1 4.7 Repair limit 17 Rebuild or replace
16
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Path of power transmission
The power from the bevel gear shaft and steering clutch is transmitted to No. 1 pinion (15). It then passes through No. 1 gear (13), which is meshed with the No. 1 pinion, and is transmitted to sun gear (2) to rotate it. The rotation of sun gear (2) is transmitted to planetary pinion (10), but ring gear (11), which is meshed with the planetary pinion, is fixed to cover (9), so the planetary pinion rotates on its own axis and moves around the sun gear along the ring gear.
Then, the rotating force of sun gear (2) forms the rotating force of carrier (3), which supports the planetary pinion, and is transmitted to sprocket hub (6). The rotation direction of carrier (3) is the same as sun gear (2). The rotating force transmitted to sprocket hub (6) is transmitted to sprocket teeth (7).
D475A, D475ASD-5E0
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Sprocket
Unit: mm
No. 1 2 Check item Wear of tooth tip Thickness of tooth root Standard size 486 32.5 Criteria Repair limit 470 26.5 Remedy Replace or overlaying welding
18
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Full-scale drawing of sprocket tooth profile
D475A, D475ASD-5E0
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Steering unit
A: B: C: D: E: F: G:
To steering control valve Air vent (To transmission case) To scavenging pump To pin puller solenoid valve From pin puller solenoid valve From power train oil cooler Torque converter output speed sensor mounting 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
1. 2. 3. 4. 5.
Transmission Steering control valve Steering unit Breather Drain plug
21
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22
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6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Output shaft Sleeve Pin Clutch piston Pin Clutch plate Clutch disc Stopper Clutch hub Clutch cage Flange Bevel gear (number of teeth: 37) Cage Steering shaft Clutch spring Housing Stopper Brake plate Brake disc
25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42.
Brake hub Brake cage Brake piston Brake spring Case Input shaft Drive shaft Drive gear (number of teeth: 27) Transmission output speed sensor Case Cage Torque converter output speed sensor Cage Drum Cover Cage Driven gear (number of teeth: 30) Bevel pinion (number of teeth: 22)
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Outline Transfer q The transfer transmits the output power from the transmission to the bevel pinion with reduced speed. q The transfer consists of input shaft (30) meshed with the transmission output shaft, drive gear (32), driven gear (41) and bevel pinion (42). Bevel gear shaft q The bevel gear shaft changes the direction of the power transmitted to the bevel pinion by a right angle to the left-and-right direction by using a bevel pinion and a bevel gear, and also decelerates the output speed. q The bevel gear shaft has spiral gears for a bevel pinion and a bevel gear, and adopts the forced lubrication by the pressurized oil for the lubrication. q The bevel gear shaft consists of bevel gear (17) meshed with the bevel pinion, steering shaft (19) and the bearing to support the steering shaft. Steering clutch The steering clutch is connected to the bevel gear shaft through the spline. It transmits and cuts out the power from the bevel gear shaft to the final drive to change the turning direction of the machine. q The steering clutch has a wet-type multipledisc hydraulic clutch and is driven hydraulically, together with the brake by the steering 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 steering case to the cage and hub, and eventually to the discs and plates. q The steering clutch consists of hub (14) connected 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 transmitted to output shaft (6) through hub (25).
q
Steering brake q The steering brakes are connected to the L.H. and R.H. steering clutch respectively. They control the power transmitted from the steering clutches to the final drive to change the turning direction of the machine and to brake the machine. q The steering brakes have wet-type multipledisc hydraulic clutches and are driven hydraulically together with the clutches by the brake pedal and steering control valve operated with the PCCS lever. q As for the lubrication, the steering brakes adopt the forced lubrication system where the oil from the power train lubricating pump is sent through the hydraulic circuit in the steering case to the cage, and eventually to the discs and plates. q While the engine is stopped, even if the brake pedal is not depressed, the back pressure of the brake piston decreases and the steering brakes become applied. When restarting the engine, if the parking brake lever is not in locked position, the engine does not start. q The steering brakes consist of hub (25) connected to housing (21), discs (24) engaged with the hub, plates (23) fixed to piston (27) by pin (8), piston (27) to press the discs and plates against each other, cage (26) to support these parts, case (29), the bearing and output shaft (6) connected to the hub by the spline. And piston (27) and case (29) are fixed to the steering case.
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Unit: mm No. Check item Standard size Criteria Tolerance 0.1 Max. 0.3 0.1 Max. 0.3 0.41 0.1 Max. 0.3 0.1 Max. 0.4 0.40 +0.046 0 +0.089 0 +0.052 0 +0.089 0 +0.052 0 Standard size Repair limit 3.8 0.4 4.3 0.4 72.6 3.8 0.4 4.5 0.5 69.3 190.5 Repair or replace Replace Repair or replace Remedy Replace Repair or replace Replace Repair or replace Replace
Brake plate
Thickness Strain
4.2
5.4
2 3 4 5 6 7
Brake disc
Thickness Strain
82.2 4.2
Total assembled thickness of 8 brake plates and 9 discs Clutch plate Thickness Strain Thickness Strain
5.4
Clutch disc
76.8 190
Total assembled thickness of 8 clutch plates and 8 discs Inside diameter of seal ring contact surface of sleeve Large diameter parts Small diameter parts Large diameter parts Small diameter parts
Inside diameter of seal ring contact surface of brake piston
350
350.1
300
300.1
Inside diameter of seal ring contact face of clutch piston
350
350.1
300
300.1 Repair limit Replace
10 Brake spring
Free length 19.7
Installed length 12.9 12.9
Installed load 46.97 kN {4,790 kg} 55.7 kN {5,680 kg}
Free length 19.1 20.0 Standard clearance 0.023 0.031 1.0 1.0 0.75
Installed load 44.62 kN {4,550 kg} 52.96 kN {5,400 kg} Clearance limit Max. 0.031
11 Clutch spring
20.4 Standard size 20
Tolerance Shaft +0.023 +0.002 0.4 0.7 0.4 0.7 0.30 0.40 Hole +0.033 0
Clearance between bevel gear 12 and reamer bolt
13 14 15 16 17
Backlash between brake hub and disc Backlash between clutch hub and disc Backlash between bevel pinion and bevel gear Preload of bevel gear shaft taper roller bearing Standard shim thickness of bearing cage
Standard clearance
Clearance limit
Adjust or replace
Standard rotating torque: 9.8 11.8 Nm {1.0 1.2 kgm}
(When bevel pinion and gear are not meshed: 51 61.8 Nm {5.2 6.3 kgm} at bevel gear end )
2.0
Adjust
Adjust shim
D475A, D475ASD-5E0
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Unit: mm No. Check item Standard clearance 0.26 0.67 Standard size 19.3 Tolerance 0.1 2.0 Criteria Clearance limit 0.75 Repair limit 18.9 Remedy Adjust or replace Replace Adjust shim
18 Backlash between transfer gears 19 20

Thickness of collar between transfer gear and bearing Standard shim thickness of bearing cage
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Operation of steering clutch When steering clutch is turned engaged When steering clutch is turned disengaged
When the PCCS lever is in the neutral position, the oil in the back side of clutch piston (1) is drained by the steering control valve. At this time, clutch piston (1) is pushed back to the right by the tension of clutch spring (2) to press discs (3) and plates (4) against stopper (5). The power from steering shaft (6) is transmitted through clutch hub (7), pressed discs (3) and plates (4) to housing (8). Since housing (8) is connected to brake hub (9) and output shaft (10), the power is transmitted through output shaft (10 ) to the final drive.
If the PCCS lever is operated to the left or right, the oil pressure is applied to the back of clutch piston (1) by the steering control valve. As the oil pressure rises, clutch piston (1) compress clutch spring (2) and moves to the left to eliminate the pressing force between discs (3) and plates (4). The power from steering shaft (6) is not transmitted after housing (8) and accordingly is not transmitted to the final drive. If the PCCS lever is released, the oil in the back side of clutch piston (1) is drained by the steering control valve, thus the steering clutch is turned engaged. If the L.H. steering clutch is turned disengaged, the power is transmitted only to the R.H. steering clutch, and consequently the machine turns to the left.
D475A, D475ASD-5E0
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Operation of steering brake When steering brake is released When steering brake is applied (When PCCS lever is operated)
When the PCCS lever is in the neutral position and the brake pedal is released, the steering control valve only sets the brake pressure to the maximum. Accordingly, the steering clutch is turned engaged and the oil pressure is applied to the back of brake piston (1). As the oil pressure rises, brake piston (1) compresses brake spring (2) and moves to the left to eliminate the pressing force between discs (3) and plates (4). The power transmitted from the steering shaft (6) through the steering clutch to brake hub (7) is further transmitted through output shaft (8) to the final drive.
q q
If the PCCS lever is operated to the left or right, the steering control valve turns the steering clutch disengaged and the oil in the back side of piston (1) starts to be drained. At this time, brake piston (1) is pushed back to the right by the tension of brake spring (2) to press discs (3) and plates (4) against stopper (5). Brake piston (1) and stopper (5) are fixed to the steering case by the pin. Brake hub (7) and output shaft (8), which tend to rotate by the inertia force even after the steering clutch is turned disengaged, can be stopped by pressing discs (3) and plates (4) to each other. The turning radius and speed can be adjusted by the brake force controlled by the oil pressure in the back side of piston (1) according to the stroke of the PCCS lever to the left and right.
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When steering brake is applied (When PCCS lever is in neutral and brake pedal is depressed)
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). 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
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Steering control valve
32
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P: L: PS: LC: LL: LB: LBL:
From power train pump From power train oil cooler To pin puller solenoid valve To L.H. steering clutch To L.H. steering lubrication circuit To L.H. steering brake To L.H. bevel gear shaft bearing lubrication circuit RC: To R.H. steering clutch RL: To R.H. steering lubrication circuit RB: To R.H. steering brake RBL: To R.H. bevel gear shaft bearing lubrication circuit BPL: To bevel pinion bearing lubrication circuit DPS: From pin puller solenoid valve DLC: Drain (L.H. steering clutch) DLC: Drain (L.H. steering clutch pilot) DLB: Drain (L.H. steering brake) DRC:Drain (R.H. steering clutch) DRP: Drain (R.H. steering clutch pilot) DRB: Drain (R.H. steering brake) DB: Drain (Sudden stop prevention valve) DBP: Drain (Sudden stop prevention valve pilot) DPB: Drain (Parking brake) 1. 2. 3. 4. 5. 6. 7. 8. Filter R.H. steering clutch ECMV L.H. steering clutch ECMV Sudden stop prevention valve R.H. steering brake ECMV L.H. steering brake ECMV Parking brake valve Valve seat
Outline q The steering control valve consists of 4 ECMV's installed on the valve seat, to control the steering clutch and steering brake. q The steering control valve is located in the circuit between the power train pump and pistons of the steering clutch and steering brake. It consists of 2 sets of the steering clutch ECMV (L.H. and R.H.) and 2 sets of the steering brake ECMV (L.H. and R.H.). q The steering control valve sends the oil from the power train pump to the steering clutch and steering brake to control each disc clutch. q If the PCCS lever is leaned to the right or left, the steering clutch is disengaged. The steering brake will operate by further leaning the PCCS lever. q The controller sends commands to each ECMV according to the right or left stroke of the PCCS lever and adjusts the gradual or sharp turns. q If the brake pedal is depressed, the controller sends commands to the steering brake ECMV 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 PCCS lever and brake pedal operates the steering clutch and steering brake by controlling each ECMV. q The sudden stop prevention valve is installed to prevent the machine from stopping suddenly, when an abnormality takes place in the electrical system. 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 piston to operate the brake. Also the parking brake valve is connected to the brake pedal by the linkage.
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Steering clutch ECMV, Steering brake ECMV

a a ECMV: Abbreviation for Electronic Control Modulation Valve Dont try to disassemble it since adjustment for maintaining the performance will be needed.
A: P: T: Dr: P1: 1. 2. 3. 4. 5. 6. 7.
To clutch or brake From pump Drain Drain To clutch or brake pressure pickup port Fill switch connector Proportional solenoid connector Pressure detection valve Fill switch Proportional solenoid Pressure control valve Nameplate (*1)
*1: Clutch used Steering clutch, Steering brake Stamp of the nameplate R*******
Outline Each ECMV keeps the steering clutch oil pressure and steering brake oil pressure to the set pressure and furthermore changes the circuit to the piston chamber of the steering clutch and steering brake.
34
D475A, D475ASD-5E0
SEN00212-00
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 signal (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 according to the command current from the controller. 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 controlled. ECMV and fill switch 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 according to this signal. Operation of ECMV The ECMV is controlled by the command current from the controller to the proportional solenoid and the fill switch output signal.
D475A, D475ASD-5E0
35
SEN00212-00
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.)
When the PCCS lever is in neutral position and the brake pedal is released, proportional solenoid (1) of the clutch ECMV is de-energized and the sealing part of ball (2) is opened. The oil from the power train pump flows through port (Pc) of the clutch ECMV to orifice (a), then it is drained through the sealing part of ball (2). Valve (3) is moved to the right by the tension of spring (4) to disconnect port (Pc) from port (C), and connect port (C) with port (Dr). At this time, the oil from the back pressure port of the clutch piston is drained through port (C) and the clutch is turned engaged by the tension of the clutch spring. The oil pressure in the brake circuit, etc. is secured by orifice (a).
Proportional solenoid (5) of the brake ECMV is energized and pushes ball (6) to the left and closes the sealing part. The oil in port (Pb) of the brake ECMV flows in port (E) and pushes valve (7) to the left to connect port (Pb) with port (B) and disconnect port (B) from port (Dr). At this time, the oil flows in the back pressure port of the brake piston. As the oil pressure rises, the brake piston is pushed to the left to compress the brake spring, then the brake is released. When the parking brake lever is in free position, as the parking brake valve is closed, the oil in the brake circuit is not drained.
36
D475A, D475ASD-5E0
SEN00212-00
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.)
When the PCCS lever is operated to left halfway and the brake pedal is released, proportional solenoid (1) of the L.H. clutch ECMV is energized and the sealing part of ball (2) is closed. The oil from the power train pump flows through port (Pc) of the clutch EMCV and orifice (a) to port (F) and pushes valve (3) to the left to connect port (Pc) with port (C) and disconnect port (C) from port (Dr). At this time, the oil flows in the back pressure port of the clutch piston. As the oil pressure rises, the clutch piston is pushed to the left to compress the clutch spring, then the clutch is turned disengaged. Proportional solenoid (5) of the brake ECMV is energized and pushes ball (6) to the left and closes the sealing part. The oil in port (Pb) of the brake ECMV flows in 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.
Proportional solenoid (5) generates the propulsion force in proportion to the command current. This propulsion force is balanced with the sum of the propulsion force generated by the oil pressure in the back pressure port of the brake piston and the tension of spring (8), then the brake pressure is set up to adjust the brake force. Accordingly, if the stroke of the PCCS lever is short, the oil pressure after port (B) is set high and the brake is turned from released to semi-released. If the stroke of the PCCS lever is long, the oil pressure after port (B) is set low and the brake is turned from semireleased to applied. When the parking brake lever is in free position, as the parking brake valve is closed, the oil in the brake circuit is not drained.
D475A, D475ASD-5E0
37
SEN00212-00
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.)
When the PCCS lever is shifted from operated to left halfway to operated to left fully, proportional solenoid (5) of the L.H. brake ECMV is de-energized and the sealing part of ball (6) is fully opened. 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. The oil from the power train pump flows through port (Pb) of the brake ECMV and orifice (b), then it is drained through sealing part of ball (6). The oil pressure in the clutch circuit, etc. is secured by orifice (b).
When the parking brake lever is in free position, as the parking brake valve is closed, the oil in the brake circuit is not drained.
38
D475A, D475ASD-5E0
SEN00212-00
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.)
When the brake pedal is depressed fully, proportional solenoids (5) of L.H. and R.H. brake ECMV are de-energized to open the sealing part of ball (6). The controller outputs the command current to proportional solenoid (5) according to the brake pedal stroke. Proportional solenoid (5) generates the propulsion force in proportion to the command current. This propulsion force is balanced with the sum of the propulsion force generated by the oil pressure in the back pressure port of the brake piston and the tension of spring (8), then the brake pressure is set up to adjust the brake force. 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.
If the brake pedal is depressed, the parking brake valve connected by the linkage operates to open the brake circuit and drain the oil.
D475A, D475ASD-5E0
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SEN00212-00
Parking brake valve
Unit: mm No. Check item Clearance between spool and valve body Standard size 14 Outside diameter of dust seal contact surface of spool Standard size 14 Standard size Shaft 0.020 0.030 Criteria Tolerance Hole +0.011 0 Tolerance 0.020 0.030 Installed length 47.7 Installed load 38.2 N {3.9 kg} Standard clearance 0.020 0.041 Clearance limit 0.05 Repair by hard chrome plating or replace Remedy
Replace
Repair limit 13.9 Repair limit Free length 63 Installed load 36.3 N {3.7 kg}
Return spring
Free length 65
Replace
4. 5.
Spool Valve body
Outline 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 position, the brake operates by draining the operating pressure of the L.H. and R.H. steering brake.
40
D475A, D475ASD-5E0
SEN00212-00
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.)
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). The oil which had flown into the brake piston back pressure port is drained through ports (A), (B) and (C). 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. When the engine is started again, as ports (A), (B) and (C) are still opened, the brake is continuously applied. If the parking brake lever is shifted to free position, spool (1) moves to the right to disconnect ports (A), (B) and (C). Then the oil pressure from the brake ECMV is applied to the back pressure port of the brake piston and the brake becomes released.
D475A, D475ASD-5E0
41
SEN00212-00
Sudden stop prevention valve
Outline q The sudden stop prevention valve is installed to prevent the machine from stopping suddenly when an abnormality takes place in the electrical 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 consequently the sudden brake can be avoided. q If an abnormality takes place in the electrical system, also solenoid (3) of sudden stop prevention 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
44
SEN00213-01
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Undercarriage and frame
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
SEN00213-01
Track frame
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Idler Recoil spring assembly Carrier roller Track frame Sprocket Sprocket guard Track roller bogie Track roller Cap Idler yoke Cylinder Guide
Track roller, bogie (Semi U, full U, superdozer specification)

Track roller flange type arrangement 1st S 2nd D 3rd D 4th D 5th D 6th D 7th D 8th S
S: Single D: Double
D475A, D475ASD-5E0
SEN00213-01
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 surfaces, 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
No. Check item Item 4 Deformation of track frame outer cylinder Curvature Twisting Dents (cylinder portion) Standard size 70 14 15 Clearance between idler bogie and guide Press-fitting force for cartridge Tolerance Shaft 0.15 0.35 Hole +0.3 +0.3 Criteria Repair limit 7 (for length of 3,000) 3 (for level length of 3,000) 12 Standard clearance 0.15 0.65 Clearance limit 3.0 Clearance limit 2.0 Adjust Repair or Replace Remedy
13
Clearance between inner cylinder and guide
Replace
Standard clearance 0 0.5
294.20 490.33 kN {30 50 ton}
D475A, D475ASD-5E0
SEN00213-01
Recoil spring
1. 2. 3. 4. 5. 6. 7. 8. 9.
Yoke Nut Retainer Rod Spring cylinder Retainer Piston Lubricator (for supplying and discharging grease) Grease chamber cylinder
Outline q Recoil spring (10) damps sudden shocks applied to the idler. q The recoil spring is also used to adjust the track shoe tension by supplying or discharging grease through lubricator (8) and moving rod (4) forward or in reverse.
D475A, D475ASD-5E0
SEN00213-01
Unit: mm
No. Check item Standard size 10 Recoil spring Free length 1,713 Standard size 445 Installation length 1,425 Criteria Repair limit Installation Installation Free length load load 725.7 kN {74,000 kg} 1,696 Standard clearance 0.128 0.488 683.1 kN {69,700 kg} Replace Clearance limit 0.8 Remedy
Tolerance Shaft 0.068 0.165 Hole +0.323 +0.600
11
Clearance between inner cylinder and outer cylinder of outer cylinder bushing Press-fitting force for outer cylinder bushing (inner cylinder side) Clearance between recoil spring mount nut and lock plate
12
129.4 389.1 kN {13.2 39.7 ton} Adjust 0 1.0
13
D475A, D475ASD-5E0
SEN00213-01
Idler
D475A, D475ASD-5E0
SEN00213-01
Unit: mm No. 1 2 3 4 5 6 Check item Outside diameter of protruding part Outside diameter of tread surface Depth of tread Thickness of tread Overall width Width of tread Standard size 180 8 Width of shaft flange Standard size 1,043 990 26.5 36 347 96 Tolerance Shaft 0.350 0.413 Standard size 335.0 Standard size 115 10 End play Tolerance Shaft +0.046 +0.046 Standard size 0.52 0.98 Hole 0.15 0.20 Hole +0.168 +0.003 Criteria Repair limit 959 42 20.5 105 Standard clearance 0.353 0.581 Repair limit Standard Interference interference limit 0.15 0.246 Repair limit Replace ring Clearance limit Rebuild or replace Replace bushing Rebuild or replace Remedy
Clearance between shaft and bushing
Interference between ring and shaft
D475A, D475ASD-5E0
SEN00213-01
Track roller
D475A, D475ASD-5E0
SEN00213-01
2nd 7th track rollers (double flanged roller)

No. 1 2 3 4 5 6 7 8 9 Check item Outside diameter of flange (outside) Outside diameter of flange (inside) Outside diameter of tread Thickness of tread Overall width Width of tread Width of flange (Outside of flange) Width of flange (Inside of flange) Width of shaft flange Standard size 147 Standard size 84 12 End play Standard size 344 332 300 71.5 423 99.5 34.5 27.5 379 Tolerance Shaft 0.350 0.413 Hole +0.170 +0.170 Criteria Repair limit 246 44.5 19.5 12.5 Standard clearance 0.350 0.583 Clearance limit
Unit: mm
Remedy
Rebuild or replace
10
Replace bushing
Tolerance Shaft +0.046 +0.046 Hole 0.15 0.20
11
Interference between shaft and seal ring
Standard Interference interference limit 0.150 0.246 Clearance limit
Replace
Standard size 0.44 0.91
Adjust or replace
D475A, D475ASD-5E0
SEN00213-01
1st and 8th track rollers (single flanged roller)

No. 1 3 4 5 6 7 9 Check item Outside diameter of flange Outside diameter of tread Thickness of tread Overall width Width of tread Width of flange Width of shaft flange Standard size 157 Standard size 95 12 End play Standard size 349 315 74 423 99.5 34.5 379 Tolerance Shaft 0.350 0.413 Hole +0.171 +0.007 Criteria Repair limit 240 36.5 19.5 Standard clearance 0.350 0.583 Standard interference 0.15 0.246
Unit: mm
Remedy
Rebuild or replace
10
Clearance limit Replace bushing Interference limit Adjust or replace
Tolerance Shaft +0.046 0 Hole 0.15 0.20
11
Interference between shaft and seal guide
Replace
0.44 0.91
10
D475A, D475ASD-5E0
SEN00213-01
D475A, D475ASD-5E0
11
SEN00213-01
Carrier roller
Unit: mm
No. 1 2 3 4 5 Check item Outside diameter of flange Outside diameter of carrier roller tread Width of carrier roller tread Thickness of tread Width of flange Standard size 95 7 8 Clearance between shaft and support Play in axial direction of roller 90 Standard size 275 240 96 49.5 25 Tolerance Shaft +0.046 +0.046 0.2 0.2 Standard size 0 0.22 Hole 0.15 0.20 +0.35 +0.35 Criteria Repair limit 215 37 14 Standard interference 0.150 0.246 Standard clearance Replace 0 0.55 Rebuild or replace Remedy
Interference between shaft and ring
Clearance limit
12
D475A, D475ASD-5E0
SEN00213-01
Track roller bogie
Outline q The track rollers are installed to small bogie (6). The track rollers and track shoes are always in contact. q The vibration of the machine from the ground surface is absorbed by rubber mount (5).
1. 2. 3. 4. 5. 6. 7. 8. 9.
Guide Cap Track roller assembly (double) Large bogie Rubber mount Small bogie Track roller assembly (single) Cover Cartridge pin
D475A, D475ASD-5E0
13
SEN00213-01
Track shoe
Portion P shows the link on the side where the bushing is pressed fitted.
14
D475A, D475ASD-5E0
SEN00213-01
Unit: mm
No. 1 Check item Link pitch Standard size 317.8 Standard size 116 3 4 5 6 Thickness of bushing Height of link Thickness of link (bushing press-fitting portion) Clearance between links One side Both sides 22.5 Standard size 199 53.5 1.6 3.2 Standard size 113 8 Interference between regular pin and link a. Regular link b. Master link 70 Tolerance Shaft +0.652 +0.552 +0.496 +0.436 Hole +0.087 +0.087 +0.124 +0.050 Criteria Repair limit 320.8 Turning Load 107.5 14 Heavy load 110 16.5 Repair limit 181 (*1) 35.5 (*2) Standard interference 0.465 0.652 0.312 0.446 Adjust or replace Rebuild or replace Turn or replace Remedy Turn or replace
Outside diameter of bushing
Interference between bushing and link
Tightening torque (Nm {kgm}) 785 78 {80 8} 980 98 {100 10}
Tightening angle (deg) 180 10 180 10 Retighten
Shoe bolt
*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
SEN00213-01
Single grouser shoe
Unit: mm
No. 1 2 Check item Height of grouser Overall height of shoe Standard size 105 133 Criteria Repair limit 35 63 Remedy Repair by build-up welding or replace
16
D475A, D475ASD-5E0
SEN00213-01
D475A, D475ASD-5E0
17
SEN00213-01
Main frame
18
D475A, D475ASD-5E0
SEN00213-01
Unit: mm
No. Check item Standard size Standard size Tolerance Shaft 0.108 +0.056 0.018 0.075 0.030 0.060 0.043 0.106 0.036 0.090 0.036 0.090 0.043 0.106 0.043 0.083 Standard size 1 118 58 Hole +0.052 +0.052 +0.057 +0.057 +0.006 0.048 +0.210 +0.050 +0.301 +0.118 +0.164 +0.062 +0.140 +0.031 +0.208 +0.131 Criteria Repair limit Standard clearance (Std.interference) 0.004 0.108 0.018 0.132 0.018 0.066 0.093 0.316 0.154 0.371 0.298 0.454 0.274 0.446 0.174 0.291 Repair limit 0.5 116 56 Clearance limit Remedy
Interference between steering case and bushing
315
Min. 0
2 3
Clearance between steering frame and final drive cage Clearance between bracket and cushion Clearance between ripper arm mounting pin and bushing Clearance between ripper cylinder mounting pin and bushing Clearance between radiator guard mounting pin and bushing Clearance between radiator guard mounting pin and bushing Clearance between equalizer bar shaft and bushing Protrusion of rubber at end face of seal Free height of front mount rubber Free height of rear mount rubber Press-fitting force for ripper arm mounting bushing Press-fitting force for ripper cylinder mounting bushing Press-fitting force for radiator guard mounting bushing Press-fitting force for radiator guard mounting bushing Press-fitting force for equalizer bar shaft mounting bushing
390 78
0.2 0.1
140
1.5
110
1.5
Replace
Hole 100.2 Shaft 100 Hole 115.2 Shaft 115 140
1.5
1.5
8 9 10 11 12 13 14 15
1.5
126.5 253 kN {12.9 25.8 ton} 111.8 267.7 kN {11.4 27.3 ton} 62.8 142.2 kN {6.4 14.5 ton} 53.9 106.9 kN {5.5 10.9 ton}
Adjust
16
65.7 153 kN {6.7 15.6 ton}
D475A, D475ASD-5E0
19
SEN00213-01
Suspension
20
D475A, D475ASD-5E0
SEN00213-01
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Equalizer bar Pivot shaft assembly Cover Thrust plate Thrust plate Pivot shaft Seal cage Cover Seal cage Side pin Center pin
Outline q The front part of the track frame moves up and down around pivot shaft (6) at its rear end. Equalizer bar (1) rocks around center pin (11) and is connected to the right and left track frames by side pins (10).
D475A, D475ASD-5E0
21
SEN00213-01
Unit: mm
No. 12 13 14 Check item Press-fitting force for side pin bushing Press-fitting force for side pin bushing Press-fitting force for center pin bushing Standard size 140 16 17 18 Clearance between side pin and bushing Clearance between pivot shaft and bushing Clearance between pivot shaft and bushing 115 260 220 Standard size 200 20 21 22 Interference between thrust washer and seal Interference between thrust washer and seal Interference between pivot shaft and seal 270 194 263 Criteria 47.0 96.0 kN {4.8 9.8 ton} 121.5 294 kN {12.4 30 ton} 68.6 232.2 kN {7 23.8 ton} Tolerance Shaft 0.043 0.083 0.048 0.078 0.190 0.271 0.145 0.208 Hole +0.225 +0.143 +0.015 0.015 +0.138 +0.026 +0.114 +0.038 Standard clearance 0.186 0.308 0.033 0.093 0.216 0.409 0.204 0.340 Clearance limit 1.0 1.0 1.0 1.0 Replace bushing Remedy
15
Clearance between center pin and bushing
Tolerance Shaft +0.051 +0.031 +0.216 +0.086 +0.096 +0.050 +0.108 +0.056 Hole 0.033 0.079 0.234 0.286 0.075 0.147 0.122 0.203
19
Interference between side pin boss and bushing
Standard Interference interference limit 0.064 0.130 0.320 0.502 0.125 0.243 0.178 0.311 Replace
22
D475A, D475ASD-5E0
SEN00213-01
D475A, D475ASD-5E0
23
SEN00213-01
24
SEN00214-00
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

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
SEN00214-00

Work equipment hydraulic equipment arrangement diagram
Semi U-dozer (single tilt)
1
1
1. 2. 3. 4. 5. 6.
Blade tilt cylinder R.H. blade lift cylinder Main control valve Accumulator Dual tilt solenoid valve Hydraulic tank
7. 8. 9. 10. 11.
Fan pump Work equipment pump L.H. blade lift cylinder Fan motor Oil cooler
D475A, D475ASD-5E0
SEN00214-00
Superdozer (full U-dozer + dual tilt)
1. 2. 3. 4. 5. 6.
Blade tilt cylinder R.H. blade lift cylinder Main control valve Accumulator Dual tilt solenoid valve Hydraulic tank
7. 8. 9. 10. 11. 12.
Fan pump Work equipment pump L.H. blade lift cylinder Blade pitch cylinder Fan motor Oil cooler
D475A, D475ASD-5E0
SEN00214-00
Multi-shank ripper
1. 2. 3. 4. 5. 6.
Main control valve Divider block Ripper tilt cylinder (right) Ripper lift cylinder (right) Ripper lift cylinder (left) Ripper tift cylinder (left)
D475A, D475ASD-5E0
SEN00214-00
Giant ripper
q
The diagram shows a machine equipped with a pin puller cylinder
1. 2. 3. 4. 5.
Main control valve Divider block Ripper tilt cylinder (right) Ripper lift cylinder (right) Pin puller cylinder
6. 7. 8. 9.
Ripper lift cylinder (left) Ripper tilt cylinder (left) Pin puller solenoid valve Brake valve
D475A, D475ASD-5E0
SEN00214-00
PPC control piping diagram

Blade and ripper control
1. 2. 3. 4. 5. 6. 7.
Blade control PPC valve Main control valve Accumulator Ripper control PPC valve PPC lock valve Work equipment lock lever Work equipment pump
D475A, D475ASD-5E0
SEN00214-00
Work equipment control

q
The diagram shows a machine equipped with pitch dozer and pin puller cylinder.
1. 2. 3. 4.
Work equipment lock lever Blade control lever Pitch button Tilt switch
5. 6. 7.
Ripper control lever Pin puller switch PPC lock valve
D475A, D475ASD-5E0
SEN00214-00
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 interconnected with PPC lock valve (7), and at the LOCK position (N), the oil in the PPC circuit is stopped.
D475A, D475ASD-5E0
SEN00214-00
Work equipment pump

Type: HPV125 + 125 (140 cm /rev specification)
3
DC: Discharge SC: Suction
Outline q This pump consists of two variable-capacity swash plate-type piston pumps, CO valve, LS valve, and EPC valve.
10
D475A, D475ASD-5E0
SEN00214-00
A B C D E F G H J K 1. 2. 3. 4. 5. 6. 7. 8. 9.
PBF PAF PLSC PBR PENR PAR PENF PD1F PEPB PRC
: Front pump pressure input port : Front pump discharge port : LS set selector pressure pickup port : Rear pump pressure input port : Control pressure pickup port : Rear pump discharge port : Control pressure pickup port : Case drain port : EPC basic pressure pickup port : Rear pump discharge pressure pickup port
L PLSR : Load pressure input port M PLSRC: Load pressure pickup port N PLSFC : Load pressure pickup port P PLSF : Load pressure input port Q PEPC : EPC basic pressure port R PFC : Front pump discharge pressure pickup port S PD2F : Drain plug T ISIG : LS set selector current U PS : Pump suction port V PD2R : Air breather mounting port 10. 11. 12. 13. 14. 15. 16. 17. Shoe Piston Cylinder block Valve plate End cap Rear shaft Rear case Servo piston
Front main pump Rear main pump LS valve CO valve LS-EPC valve Front shaft Cradle Front case Rocker cam
D475A, D475ASD-5E0
11
SEN00214-00
Function q The rotation and torque transmitted to the pump shaft are converted into hydraulic pressure, and pressurized oil is discharged according to the load. q It is possible to change the discharge amount by changing the swash plate angle.
Structure q Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings. q The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) 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 cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure 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 pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8). D475A, D475ASD-5E0
12
SEN00214-00
Operation
1. Operation of pump
q
Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle (a) is called the swash plate angle.)
If center line (X) of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.)
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). 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. 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
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2. Control of delivery amount

q
q q
If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and delivery amount (Q) increases. Swash plate angle (a) is changed by servo piston (12). Servo piston (12) moves in a reciprocal movement according to the signal pressure 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. 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. Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter end. The relationship 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 pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).
14
D475A, D475ASD-5E0
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3. LS valve
A. B. C. D. E. F. G.
PLS : LS pressure input port PP : Pump port PLP : LS control pressure output port PPL : CO control pressure input port PDP : Drain port PSIG : LS mode selection pilot port PA : Pump port
1. 2. 3. 4. 5. 6. 7. 8.
Sleeve Piston Spool Spring Seat Sleeve Plug Locknut
4. CO valve
A. PPL : CO control pressure output port B. PA : Pump port A. PDP : Drain port 1. 2. Plug Servo piston assembly
3. 4. 5. 6. 7. 8.
Ball Spool Spring Retainer Cover Spring
D475A, D475ASD-5E0
15
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Function 1) LS valve q The LS (Load Sensing) valve detects the load and controls the discharge amount. q This valve controls main pump delivery amount (Q) according to differential pressure (dPLS) between main pump pressure (PP) and control valve outlet port pressure (PLS) (= PP 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 proportional 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}.
2)
q
CO valve When the pump pressure in the hydraulic circuit becomes maximum, the CO (Cut-OFF) valve minimizes the pump swash plate angle to limit the pressure and protect the circuit. Since the pump swash plate angle is minimized, the pump absorption torque is reduced and the fuel consumption is reduced.
16
D475A, D475ASD-5E0
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Operation
1) LS valve
(1) When control valve is at neutral position
The LS valve is a three-way selector valve, with pressure (PLS) (LS pressure) from the inlet port of the control valve brought to spring chamber (B), and main pump discharge pressure (PP) brought to port (H) of sleeve (8). The size of this LS pressure (PLS) + force of spring (4) and the main pump pressure (self pressure) (PP) determines the position of spool (6). However, the size of the output pressure (PSIG) (the LS selection pressure) of the EPC valve for the LS valve entering port (G) also changes the position of spool (6). (The set pressure of the spring changes). Before the engine is started, servo piston (12) is pushed to the right. (See the diagram on the right) When the engine is started and the control lever is at the neutral position, LS pressure (PLS) is 0 MPa {0 kg/cm2}. (It is interconnected with the drain circuit through the control valve spool.)
At this point, spool (6) is pushed to the right, and port (C) and port (D) are connected. Pump pressure (PP) enters the large diameter end of the piston from port (K) and the same pump pressure (PP) also enters port (J) at the small diameter end of the piston, so the swash plate is moved to the minimum angle by the difference in the area of piston (12).
D475A, D475ASD-5E0
17
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(2) Operation in direction of maximum pump delivery amount
q q
When the difference between main pump pressure (PP) and LS pressure (PLS), or LS differential pressure (dPLS), becomes smaller (for example, when the area of opening of the control valve becomes larger and LS pressure (PLS) increases), the combined force of LS pressure (PLS) and force of spring (4) pushes spool (6) to the right. As spool (6) moves, ports (D) and (E) are connected to each other and to the CO valve. At this time, the CO valve is connected to the drain port and the pressure in circuit (D) (K) becomes drain pressure (PT). (Operation of the CO valve will be explained later.) Accordingly, the pressure on the large diameter 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.
If the output pressure of the EPC valve for the LS valve is applied to port (G) at this time, it pushes piston (7) to the left. If piston (7) is pushed to the left, the set force of spring (4) is reduced and LS differential pressure (d PLS) [the difference between oil pressures (PLS) and (PP)] changes when ports (D) and (E) of spool (6) are connected.
18
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(3) Operation in direction of minimum pump delivery amount
The following explains the case where servo piston (12) moves to the right (where the delivery amount becomes smaller). When LS differential pressure ( d PLS) increases [for example, when the area of opening of the control valve becomes smaller and LS pressure (PLS) lowers], pump pressure (PP) pushes spool (6) to the left. As spool (6) moves, main pump pressure (PP) flows from port (C) to port (D), and then it enters the large diameter end of the piston through port (K). Main pump pressure (PP) also enters port (J) on the small diameter end of servo piston (12), but servo piston (12) is pushed to the right because of the difference in area between its large diameter end and small diameter end. As a result, the swash plate angle is reduced.
D475A, D475ASD-5E0
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(4) When servo piston is balanced
Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN). When main pump pressure (PP) of the LS valve is balanced with the combined force of LS pressure (PLS) and the force of spring (4) and their relationship is (A0) (PP) = (A1) (PEN), servo piston (12) stops in the current position. Then, swash plate is kept at an intermediate position. [It stops at a position where the opening between ports (D) and (E) of spool (6) and that between ports (C) and (D) are approximately the same.]
At this time, the relationship between the areas receiving the pressure at both ends of servo piston (12) is (A0) : (A1) = 1 : 2. Accordingly, the relationship between the pressures applied to both ends of the piston when the piston is balanced becomes (PP) : (PEN) C 2 : 1. The position where spool (6) is balanced and stopped is the standard center. The force of spring (4) is so adjusted that the standard center will be decided when (PP) (PLS) = 2.5 MPa {25 kg/cm2}. When the input current to the LS-EPC valve changes from 0 to 0.9A and (PSIG) (the output pressure of the LS-EPC valve varying from 0 to 2.9 MPa {0 to 30 kg/cm2}) is applied to port (G), however, the balancing and stopping position 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
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The operation of the LS valve is shown in the following table.
Solenoid drive table

Single specification Lift Raise Lower Left tilt Single tilt Left tilt limit Right tilt Right tilt limit Left tilt Dual tilt Left tilt limit Right tilt Right tilt limit Pitch Rear pitch Forward pitch Raise Lower Raise Lower Dual specification Superdozer specification
q q
q q q q q q q q
q q q q
Blade
Lift Ripper Tilt
D475A, D475ASD-5E0
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2) CO valve
(1) When actuator load is small and pump pressure (PP) is low
q 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). Port (C) of the CO valve is connected to port (E) of the LS valve. Pump pressure (PP) is applied to port (B) and small diameter side of servo piston (9). The pressure in port (E) of the LS valve is drain pressure (PT). If ports (E) and (G) of the LS valve are connected 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. As a result, the pump swash plate angle is increased to increase the pump delivery amount.
22
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(2) When actuator load is large and pump discharge pressure reaches maximum
q q 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. Port (C) of the CO valve is connected to port (E) of the LS valve. Pump pressure (PP) is applied to port (B) and small diameter side of servo piston (9). Then, the pressure applied through port (C) to the LS valve is main pump pressure (PP) from port (B). If ports (E) and (G) of the LS valve are connected at this time, main pump pressure (PP) is applied to the large diameter side of servo piston (9). Main pump pressure (PP) is applied to the small diameter side of the piston, too. Servo piston (9) is pushed to the right, however, because of the difference in area between the large diameter side and small diameter side of the piston. As a result, the pump swash plate angle is decreased to decrease the pump delivery amount.
D475A, D475ASD-5E0
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5. LS-EPC valve
A. PSIG : To LS valve B. PT : To tank C. PEPC: From self pressure reducing valve
1. 2. 3. 4. 5. 6. 7.
Coil Body Spring Spool Rod Plunger Connector
24
D475A, D475ASD-5E0
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Function q The EPC valve consists of the solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the LS valve.
Operation 1)
q q q
When signal current is 0 (coil de-energized) When there is no signal current flowing from the controller to coil (1), coil (1) is de-energized. For this reason, spool (4) is pushed to the right in the direction of the arrow by spring (3). As a result, port (C) (PEPC) closes and the pressurized oil from the main pump does not flow to the LS valve. At the same time, the pressurized oil from the LS valve passes from port (A) (PSIG) through port (B) (PT) and is drained to the tank.
D475A, D475ASD-5E0
25
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2)
q
q q
When signal current is small (Coil is energized) If a small signal current flows in coil (1), coil (1) is energized and a thrust to the right is generated in plunger (6). Rod (5) pushes spool (2) to the right and the oil from port (C) (PEPC) flows in port (A) (PSIG). The pressure in port (A) (PSIG) rises. If the total of the force applied to spool (2) and the load of spring (3) exceeds the thrust of plunger (6), spool (2) is pushed to the left. Then, port (C) (PEPC) and port (A) (PSIG) are disconnected and port (A) (PSIG) and port (B) (PT) are connected simultaneously. As a result, spool (2) moves up and down until the thrust of plunger (6) is balanced with the total of the pressure in port (A) (PSIG) and the load of spring (3). Accordingly, the pressure in the circuit between the EPC valve and LS valve is controlled in proportion to the signal current.
3)
q q q q
When signal current is maximum (Coil is energized) If the signal current flows in coil (1), coil (1) is energized. Since the signal current is at the maximum, the thrust in plunger (6) becomes maximum. Accordingly, rod (5) presses spool (2) to the right. As a result, the maximum oil flows from port (C) (PEPC) to port (A) (PSIG) and the pressure in the circuit between the EPC valve and LS valve becomes highest. At this time, port (C) (PT) is closed and the oil does not flow in the tank.
26
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PPC valve
1. Blade PPC valve
P : From self pressure reducing valve P1 : To blade lift valve (LOWER) PPC port P2 : To blade lift valve (RAISE) PPC port
P3 : To blade tilt valve (LEFT TILT) PPC port P4 : To blade tilt valve (RIGHT TILT) PPC port T : To hydraulic tank
D475A, D475ASD-5E0
27
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1. 2. 3. 4. 5. 6.
Spool Metering spring Centering spring Piston Disc Nut (For connecting lever)
7. 8. 9. 10. 11.
Joint Plate Retainer Body Filter
28
D475A, D475ASD-5E0
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Unit: mm
No. Check item Standard size Centering spring (For port P1) Free length x Outside diameter 34.0 x 15.5 13 14 15 16 17 Centering spring (For port P2) Centering spring (For ports P3 and P4) Metering spring (For port P1) Metering spring (For port P2) Metering spring (For ports P3 and P4) 43.2 x 15.5 48.57 x 15.5 29.27 x 8.15 26.3 x 8.15 26.53 x 8.15 Installed length 31.9 34.0 32.5 25.4 24.1 24.9 Installed load 94 N {9.6 kg} 78.5 N {8 kg} 107.9 N {11 kg} 16.7 N {1.70 kg} 16.7 N {1.70 kg} 16.7 N {1.70 kg} Criteria Repair limit Free length Installed load 75.2 N {7.68 kg} 62.8 N {6.4 kg} 86.3 N {8.8 kg} 13.3 N {1.36 kg} 13.3 N {1.36 kg} 13.3 N {1.36 kg} If spring is damaged or deformed, replace it Remedy
12
D475A, D475ASD-5E0
29
SEN00214-00
Operation
1) When in neutral
(1) For lifting blade q Ports (A) and (B) of the blade lift valve of the control valve and ports (P1) and (P2) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D). (2) For tilting blade q Ports (C) and (D) of the blade tilt valve of the control valve and ports (P3) and (P4) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
30
D475A, D475ASD-5E0
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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). Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port (P1) through fine control hole (f) to port (B). If the pressure in port (P1) rises, spool (1) is pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and connected to drain chamber (D) almost simultaneously to release the pressure in port (P1). 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 relationship 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). 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. 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
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3) When in fine control (When control lever is returned)

q
4) When lever is operated to stroke end

q
If lever (5) begins to return, the force of centering spring (3) and the pressure in port (P1) push up spool (1). As a result, fine control hole (f) is connected to drain chamber (D) and the oil in port (P1) is released. If the pressure in port (P1) lowers too much, spool (1) is pushed down by metering spring (2) and fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously. Then, the pump pressure is applied until the pressure in port (P1) is restored to the level corresponding to the position of the lever. When the control valve spool returns, the oil in drain chamber (D) flows in through fine control hole (f) of the valve which is not in operation and then flows through port (P2) into port (A).
If disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (B) and pushes the control valve spool. The oil returning from port (A) flows through port (P2) and fine control (f) into drain chamber (D).
32
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5) When blade is floated

q
6) When FLOAT state of blade is reset

q
q q
q q
If piston (4) on the LOWER side of port (P1) is pushed down by disc (5), ball (11) touches projection (a) of the piston in the middle of the stroke (The detent starts to operate). If piston (4) is pushed in further, ball (11) pushes up collar (12) supported on detent spring (13) and escapes out to go over projection (a) of the piston. At this time, piston (4') on the opposite side is pushed up by spring (14). As a result, the oil in chamber (F) flows through (b) and (c) to chamber (E) and piston (4') follows disc (5). Since passage (d) is connected to port (P1), almost the same pressure is applied to passage (d) and port (P1). 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. At this time, the control valve moves to the FLOAT position and the blade is floated. Since piston (4') is pushed up by the pressure in chamber (E), the FLOAT state is kept even if the lever is released.
Disc (5) is pushed down with a force larger than the oil pressure in chamber (E) to return from the FLOAT position. As a result, chamber (E) is disconnected from passage (d) and connected to the drain chamber. Accordingly, the oil pressure in chamber (E) is lost and the FLOAT state is reset.
D475A, D475ASD-5E0
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2. Ripper PPC valve
P P1 P2 P3 P4 T
: From self pressure reducing valve : To ripper tilt valve PPC port : To ripper tilt valve PPC port : To ripper lift valve PPC port : To ripper lift valve PPC port : To tank
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Spool Metering spring Centering spring Piston Disc Nut (For connecting lever) Joint Plate Retainer Body Filter
34
D475A, D475ASD-5E0
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Unit: mm
No. Check item Standard size Centering spring (For ports P3 and P4) Free length x Outside diameter 50.4 x 15.5 13 14 Centering spring (For ports P1 and P2) Metering spring 50.1 x 15.5 26.5 x 8.20 Installed length 34.0 34.0 24.9 Installed load 55.9 N {5.7 kg} 71.4 N {7.28 kg} 16.7 N {1.70 kg} Criteria Repair limit Free length Installed load 44.7 N {4.56 kg} 56.9 N {5.8 kg} 13.3 N {1.36 kg} If spring is damaged or deformed, replace it Remedy
12
D475A, D475ASD-5E0
35
SEN00214-00
Operation
1) When in neutral
q
Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected through fine control hole (f) of spool (1) to drain chamber (D).
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. Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the pressure in port (P1)] is balanced with the force of the control valve spool return spring.
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). Accordingly, fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously, and then the pilot oil flows from port (P1) through fine control hole (f) to port (A). If the pressure in port (P1) rises, spool (1) is pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and connected to drain chamber (D) almost simultaneously to release the pressure in port (P1). 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 relationship 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). D475A, D475ASD-5E0
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3) When in fine control (When control lever is returned)

q
4) When lever is operated to stroke end

q
If disc (5) begins to return, the force of centering spring (3) and the pressure in port (P1) push up spool (1). As a result, fine control hole (f) is connected to drain chamber (D) and the oil in port (P1) is released. If the pressure in port (P1) lowers too much, spool (1) is pushed down by metering spring (2) and fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously. Then, the pump pressure is applied until the pressure in port (P1) is restored to the level corresponding to the position of the lever. When the control valve spool returns, the oil in drain chamber (D) flows in through fine control hole (f) of the valve which is not in operation and then flows through port (P2) into chamber (B).
If disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber (PP). Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into chamber (A) and pushes the control valve spool. The oil returning from chamber (B) flows through port (P2) and fine control (f) into drain chamber (D).
D475A, D475ASD-5E0
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PCCS lever
Travel and steering PCCS lever
a
Do not disassemble the PCCS lever. If it is disassembled, the output voltage characteristics and operating effort characteristics will need to be adjusted.
1. 2. 3. 4.
Bellows Bracket Plate Bolt
5. 6. 7.
Screw Lever Connector
38
D475A, D475ASD-5E0
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Function
1. Operating effort characteristics

1)
q
Operation for forward and reverse travel The control lever is held at 3 positions of Forward, Neutral, and Reverse.
2)
q
Operation for steering Free return.
D475A, D475ASD-5E0
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2. Output voltage characteristics

q
The control unit is installed to the left control stand and the control lever is installed directly onto it. The operating angle (stroke) of the control lever is sensed with potentiometers and signal voltages are output to the transmission and steering controller. A potentiometer is installed in each of longitudinal direction and lateral direction. Each potentiometer outputs 2 signal voltages which are opposite to each other as shown in the figure at right.
40
D475A, D475ASD-5E0
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42
SEN00215-00
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Hydraulic system, Part 2 ................................................................................................................................. 2 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
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Control valve
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 maintain. A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6 P1 P2 P3 P4 P7 P8 P9 1. 2. 3. 4. : To ripper lift cylinder head : To blade tilt right cylinder head : To blade lift cylinder head : To blade lift cylinder head : To blade tilt left cylinder head : To ripper tilt cylinder head : To ripper lift cylinder bottom : To blade tilt right cylinder bottom : To blade lift cylinder bottom : To blade lift cylinder bottom : To blade tilt left cylinder bottom : To ripper tilt cylinder bottom : From ripper lift PPC valve : From ripper lift PPC valve : From blade tilt PPC valve : From blade tilt PPC valve : From blade lift PPC valve : From blade lift PPC valve : From blade tilt PPC valve 6-spool valve Cover 1 Cover 2 Merge-divider valve
1
1
P10 : From blade tilt PPC valve P11 : From ripper tilt PPC valve P12 : From ripper tilt PPC valve PLS1 : To rear pump control PLS2 : To front pump control PP1 : From rear main pump PP2 : From front main pump PPS1: To rear pump control PPS2: To front pump control PR : To solenoid valve, PPC valve, and EPC valve PS : From merge-divider solenoid valve PST : From port PR SA : Pressure sensor mounting port SB : Pressure sensor mounting port T : To tank TS : To tank
D475A, D475ASD-5E0
SEN00215-00
6-spool valve
(1/8)
D475A, D475ASD-5E0
SEN00215-00
(2/8)
D475A, D475ASD-5E0
SEN00215-00
(3/8)
1. 2. 3. 4. 5. 6. 7.
Unload valve Pressure compensation valve (on ripper tilt head side) Pressure compensation valve (on blade left tilt head side) Pressure compensation valve (on blade lift head side) Pressure compensation valve (on blade lift head side) Pressure compensation valve (on blade right tilt head side) Pressure compensation valve (on ripper lift head side)
8. 9. 10. 11. 12. 13. 14.
Pressure compensation valve (on ripper lift bottom side) Pressure compensation valve (on blade right tilt bottom side) Pressure compensation valve (on blade lift bottom side) Pressure compensation valve (on blade lift bottom side) Pressure compensation valve (on blade left tilt bottom side) Pressure compensation valve (on ripper tilt bottom side) Main relief valve
D475A, D475ASD-5E0
SEN00215-00
(4/8)
D475A, D475ASD-5E0
SEN00215-00
1. 2. 3. 4. 5. 6. 7. 8.
No.
Spool (Ripper tilt) Spool (Blade left tilt) Spool (Blade lift) Spool (Blade lift) Spool (Blade right tilt) Spool (Ripper lift) Unload valve Main relief valve Unit: mm
Check item Standard size Free length x Outside diameter 54.5 x 34.8 Installed length 51.2 50.5 65 65.5 33 Installed load 393 N {40.1 kg} 377 N {38.4 kg} 390 N {39.8 kg} 354 N {36.1 kg} 274 N {27.9 kg} Criteria Repair limit Free length Installed load 315 N {32.1 kg} 301 N {30.7 kg} 312 N {31.8 kg} 283 N {28.9 kg} 219 N {22.3 kg} Remedy
Spool return spring
10 11 12 13
Spool return spring Spool return spring Spool return spring Spool return spring
54 x 34.8 69.9 x 34.8 72.3 x 37.0 52.9 x 22.3
If spring is damaged or deformed, replace it.
D475A, D475ASD-5E0
SEN00215-00
(5/8)
D475A, D475ASD-5E0
SEN00215-00
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Safety-suction valve (Blade left tilt head) Safety-suction valve (Blade lift head) Plug (Superdozer Spec.) Safety-suction valve (Blade lift head) Plug (Superdozer Spec.) Safety-suction valve (Blade right tilt head) Suction valve (Ripper lift head) Safety-suction valve (Ripper lift bottom) Safety-suction valve (Blade right tilt bottom) Safety valve (Blade lift bottom) Safety valve (Blade lift bottom) Safety-suction valve (Blade left tilt bottom) LS shuttle valve (Arm and right travel) LS shuttle valve (Boom, left travel, and bucket) LS check valve Pressure release plug Unit: mm
No.
Check item Standard size Free length x Outside diameter 11.5 x 4.6 Installed length 8.5
Criteria Repair limit Installed load 1.5 N {0.15 kg} Free length Installed load 1.2 N {0.12 kg}
Remedy
15
Check valve spring
D475A, D475ASD-5E0
SEN00215-00
(6/8)
10
D475A, D475ASD-5E0
SEN00215-00
1. 2.
Unload valve Main relief valve
Ripper tilt valve 3. Spool 4. Pressure compensation valve (Head) 5. LS shuttle valve 6. Pressure compensation valve (Bottom) Blade left tilt valve 7. Safety-suction valve 8. Spool 9. Pressure compensation valve (Head) 10. LS shuttle valve 11. Pressure compensation valve (Bottom) 12. Safety-suction valve Unit: mm
No. Check item Standard size Free length x Outside diameter 36.9 x 11.1 Installed length 28 Installed load 29.4 N {3 kg} Criteria Repair limit Free length Installed load 23.5 N {2.4 kg} If spring is damaged or deformed, replace it. Remedy
13
Piston return spring
D475A, D475ASD-5E0
11
SEN00215-00
(7/8)
12
D475A, D475ASD-5E0
SEN00215-00
Blade lift valve 1. Safety-suction valve Plug (Superdozer Spec.) 2. Spool 3. Pressure compensation valve (Right) 4. Pressure compensation valve (Left) 5. Suction valve Blade lift valve 6. Safety-suction valve Plug (Superdozer Spec.) 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) 16. LS shuttle valve 17. Pressure compensation valve (Forward) 18. Suction valve Ripper lift valve 19. Suction valve 20. Spool 21. Pressure compensation valve (Curl) 22. LS shuttle valve 23. Pressure compensation valve (Dump) 24. Safety-suction valve Unit: mm
No. Check item Standard size Free length x Outside diameter 31.5 x 10.3 26 Piston return spring 36.9 x 11.1 Installed length 19.5 28 Installed load 6.2 N {0.6 kg} 29.4 N {3 kg} Criteria Repair limit Free length Installed load 4.9 N {0.5 kg} 23.5 N {2.4 kg} If spring is damaged or deformed, replace it. Remedy
25
Regeneration valve spring
D475A, D475ASD-5E0
13
SEN00215-00
(8/8)
14
D475A, D475ASD-5E0
SEN00215-00
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Unload valve Main relief valve Merge-divider valve (For main) Spool return spring Merge-divider valve (For LS) Spool return spring Valve (Sequence valve) Spring (Sequence valve) LS bypass plug Spring (Safety valve) Ball Valve (Pressure reducing valve) Spring (Main pressure reducing valve) Spring (Pilot pressure reducing valve) Poppet Screw Spring (Safety valve) Ball Unit: mm
No.
Check item Standard size Free length x Outside diameter 11.5 x 4.6 Installed length 8.5 33 63 59
Criteria Repair limit Installed load 1.5 N {0.15 kg} 156.8 N {16.0 kg} 177.5 N {18.1 kg} 199.8 N {20.4 kg} Free length Installed load 1.2 N {0.12 kg} 125.5 N {12.8 kg} 142.0 N {14.5 kg} 160.0 N {16.3 kg}
Remedy
19
Check valve spring
20 21 22
Spool return spring Spool return spring Sequence valve spring
46.6 x 21.8 64.5 x 32.3 70.9 x 18
D475A, D475ASD-5E0
15
SEN00215-00
Main relief valve
1. 2.
Spring 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
SEN00215-00
CLSS
1. Outline of CLSS
Features CLSS stands for Closed center Load Sensing System, and has the following features. q Fine control not influenced by load q Control enabling digging even with fine control q Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations q Energy saving using variable pump control
Structure q The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment. q The work equipment pump body consists of the pump itself, CO valve and LS valve.
D475A, D475ASD-5E0
17
SEN00215-00
2. Basic principle
1)
q
Control of pump swash plate The pump swash plate angle (pump delivery amount) is controlled so that LS differential pressure (dPLS) [the difference between pump pressure (PP) and control valve outlet port LS pressure (PLS)] (load pressure of actuator) is constant. [LS pressure (dPLS) = Pump discharge pressure (PP) LS pressure (PLS)]
If LS differential pressure (dPLS) becomes lower than the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate moves towards the maximum position; if it becomes higher than the set pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towards the minimum position.
18
D475A, D475ASD-5E0
SEN00215-00
2)
q
Pressure compensation A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. When two actuators are operated together, this valve acts to make pressure difference (dP) between the upstream (inlet port) and downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure). In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of openings (S1) and (S2) of each valve.
D475A, D475ASD-5E0
19
SEN00215-00
Unload valve
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 pressure 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
SEN00215-00
Introduction of LS pressure
(LS shuttle valve)
1. 2. 3.
Main pump Main spool Pressure compensation valve
4. 5.
Check valve LS shuttle valve
Function q LS pressure (PLS) is the actuator load pressure at the output side of the control valve. q The upstream pressure (= spool meter-in downstream pressure) of pressure compensation valve (3) is taken inside main spool (2) and goes to LS shuttle valve (5). q When this happens, it connects actuator circuit (A) and LS circcuit (PLS) through check valve (4), and sets so that LS pressure (PLS) C actuator load pressure. q Introduction hole (a) inside main spool (2) has a small diameter, so it also acts as a throttle.
Operation q When main spool (2) is operated, pump discharge pressure (PP) starts to flow to actuator circuit (A). q First, this pump discharge pressure (PP) passes through introduction hole (a) of main spool (2), and is taken to LS circuit (PLS). q When actuator circuit pressure (A) rises to the necessary pressure, pump pressure (PP) rises and check valve (4) inside main spool (2) opens. The high pressure of LS circuit (PLS) then flows to actuator circuit (A). q In this way, LS pressure (PLS) becomes almost the same as actuator circuit pressure (A).
D475A, D475ASD-5E0
21
SEN00215-00
LS bypass plug
1. 2. 3. 4. 5.
Main pump Main spool Pressure compensation valve LS shuttle valve LS bypass plug
Function The residual pressure in LS circuit (PLS) is released from orifices (b) and (c). q This reduces the speed of the rise in the LS 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.
q
22
D475A, D475ASD-5E0
SEN00215-00
Pressure compensation valve

1. When the load pressure is higher than other actuators
1. 2. 3. 4. 5. 6.
Main pump Valve Shuttle valve Piston Spring LS shuttle valve
Function q When the maximum load pressure is generated during compound operations and during independent operations, and the load pressure is higher than other actuators, the pressure compensation valve acts as a load check valve to prevent reverse flow in the circuit. Operation 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).
q
D475A, D475ASD-5E0
23
SEN00215-00
2. When the load pressure is lower than other actuators
Function q During compound operations, if the load pressure is lower than the other actuators and the flow of oil starts to increase, the pressure compensation valve carries out compensation. In this case, it tries to make the load pressure for the other actuators greater and reduce the flow of oil.
Operation q During compound operations, if the load pressure for the other actuators rises, the oil flow in actuator circuit (B) tries to increase. q When this happens, LS pressure (PLS) for the other actuator also increases, so this LS pressure (PLS) pushes shuttle valve (3) of the pressure compensation valve to the right in the direction of the arrow, passes through the passage inside piston (4), and flows to spring chamber (C). 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 pressure (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 pressure (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
SEN00215-00
Blade lift valve

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
SEN00215-00
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
SEN00215-00
2. When blade lift lever is set in RAISE position
28
D475A, D475ASD-5E0
SEN00215-00
Operation q If the blade lift lever is set in the RAISE position, the pilot pressure is applied through the blade PPC valve to chamber (E) and spool (3) moves to the left. 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
SEN00215-00
3. When blade lift lever is set in LOWER position
30
D475A, D475ASD-5E0
SEN00215-00
Operation q If the blade lift lever is set in the LOWER position, the pilot pressure is applied through the blade PPC valve to chamber (F) and spool (3) moves to the right. 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
SEN00215-00
4. When blade lift lever is set in FLOAT position
32
D475A, D475ASD-5E0
SEN00215-00
Operation q If the blade lift lever is moved from the LOWER position to the FLOAT position, the pilot pressure is applied through the blade PPC valve to 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
SEN00215-00
Merge-divider valve
1. 2. 3. 4.
Main spool Spring LS spool Spring
Function q The merge-divider valve merges or divides oils (PP1) and (PP2) discharged from 2 pumps (It distributes those oils to each control valve group). q This valve also merges and divides the LS circuit pressures.
Operation 1. When oils from pumps are merged (When pilot pressure (PS) is turned OFF) q Since pilot pressure (PS) is turned OFF, main spool (1) is pressed to the left by spring (2) and ports (E) and (F) are connected. q Accordingly, oils (PP1) and (PP2) discharged from the 2 pumps are merged in ports (E) and (F) and sent to the control valves which need them. q Similarly, LS spool (3) is pressed to the left by spring (4) and the connection of the LS circuit changes as follows. Connection of circuit: (A) is connected to (D). (B) is connected to (C). 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 pressure compensation valves and other hydraulic equipment.
34
D475A, D475ASD-5E0
SEN00215-00
2.
q
When oils from pumps are divided (When pilot pressure (PS) is turned ON) When pilot pressure (PS) is turned ON, main spool (1) is pressed to the right by the (PS) pressure and ports (E) and (F) are disconnected. 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 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. 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
SEN00215-00
Self pressure reducing valve
Function q The self pressure reducing valve lowers the discharge pressure of the main pump and supplies it as the control pressure for the solenoid valves, PPC valves, etc. Operation 1. When engine is stopped
Poppet (11) is pressed by spring (12) against the seat and the passage between port (PR) and (TS) is closed. Valve (14) is pressed to the left by spring (13) and the passage between ports (P2) and (PR) is open. Valve (7) is pressed to the left by spring (8) and the passage between ports (P2) and (A2) is closed. D475A, D475ASD-5E0
36
SEN00215-00
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 Valve (7) is pressed by spring (8) and (PR) pressure (which is 0 MPa {0 kg/cm2} while the engine is stopped) to close the passage between ports (P2) and (A2). If hydraulic oil flows in through port (P2), however, (d area x pressure P2) = force of spring (8) + (d area x PR pressure), and they are balanced. Then, the passage between ports (P2) and (A2) is so 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).
q
Accordingly, differential pressure is generated over orifice (a) in spool (14), and spool (14) moves in the direction to close the passage between ports (P2) and (PR). The P2 pressure is lowered and controlled to a constant pressure (set pressure) by the opening ratio of the passage at this time and supplied as the PR pressure.
D475A, D475ASD-5E0
37
SEN00215-00
3.
When load pressure (P2) is high
Operation q If load pressure (A2) is heightened and the pump delivery amount is increased because of digging operation, etc., the P2 pressure rises {(d area P2 pressure) > force of spring (8) + (d area PR pressure)}, then valve (7) moves to the right stroke end. q As a result, the opening ratio of the passage between ports (P2) and (A2) is increased and the passage resistance is reduced. Consequently, 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).
Accordingly, differential pressure is generated over orifice (a) in spool (14) and spool (14) moves in the direction to close the passage between ports (P2) and (PR). The P2 pressure is lowered and controlled to a constant pressure (set pressure) by the opening ratio of the passage at this time and supplied as the PR pressure.
38
D475A, D475ASD-5E0
SEN00215-00
4.
When abnormally high pressure is generated
Operation q If the PR pressure of the self pressure reducing valve is raised abnormally, ball (16) separates from the seat against the force of spring (15). As a result, the hydraulic oil flows from output port (PR) to (TS) and the PR pressure lowers. Accordingly, the devices receiving the oil pressure (PPC valves, solenoid valves, etc.) are protected from abnormally high pressure.
D475A, D475ASD-5E0
39
SEN00215-00
Pilot solenoid valve
PPB : PPD : TLL : TLR : PTH : DUL : PPV : MFD:
Rear pitch solenoid Forward pitch solenoid Left tilt limit solenoid Right tilt limit solenoid Pitch changeover solenoid Dual changeover solenoid Pitch priority solenoid Merge-divider solenoid
40
D475A, D475ASD-5E0
SEN00215-00
The operation of the pilot solenoid valve is shown in the following table.
Solenoid drive table (Dual tilt specification)

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

PPB Lift Raise Lower Left tilt Blade Single tilt Left tilt limit Right tilt Right tilt limit Pitch Rear pitch Forward pitch Raise Lower Raise Lower PPD TLL TLR PTH DUL PPV MFD
q q q q q q q q q q
Lift Ripper Tilt
D475A, D475ASD-5E0
41
SEN00215-00
42
SEN00216-00
BULLDOZER
1SHOP MANUAL 2SHOP
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Hydraulic system, Part 3 ................................................................................................................................. 2 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
SEN00216-00

Hydraulic tank, hydraulic filter
1
1
1. 2. 3. 4. 5.
Pressure valve Cover Sight gauge Cover Hydraulic tank
6. 7. 8. 9. 10. 11. 12.
Oil filler cap Hydraulic filter element Spring Suction valve Strainer Drain plug Drain valve
D475A, D475ASD-5E0
SEN00216-00
Specified value Tank capacity Hydraulic tank (l) 310 210 170 140 38.2 6.9 {0.39 0.07} 0 0.49 {0 0.005 } High (l ) Level inside Center (l) tank Low (l ) Cracking pressure (kPa {kg/cm2}) Vacuum valve actuating pressure (kPa {kg/cm2})
Breather cap
Specified value Cracking pressure (kPa {kg/cm2}) Hydraulic Mesh size filter Filtering area Filtering oil flow Strainer Mesh size Filtering area (m) (cm )
2
150 30 {1.53 0.3} 30/8 17,600 703 105 3,600
(l/min) (m) (cm )

2
D475A, D475ASD-5E0
SEN00216-00
Accumulator
For PPC valve
1
Operation q After the engine is stopped, when the PPC valve is at neutral, chamber (A) inside the bladder is compressed by the oil pressure in chamber (B). q When the PPC valve is operated, the oil pressure in chamber (B) goes below 2.9 MPa {30 kg/cm2}, and the pressure of the nitrogen gas in chamber (A) expands the bladder, so the oil in chamber (B) acts as the pilot pressure and actuates the main control valve.
1. 2. 3. 4. 5. 6.
Glass plug Shell Poppet Holder Bladder 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 pressure 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 actuate it and enable the work equipment to move down under its own weight.
D475A, D475ASD-5E0
SEN00216-00
Work equipment cylinder

q
Blade lift cylinder
Blade tilt cylinder, superdozer pitch cylinder
Ripper lift cylinder, ripper tilt cylinder
D475A, D475ASD-5E0
SEN00216-00
Pin puller cylinder
Unit: mm
No. Check item Standard size Blade lift Clearance between piston rod and bushing Blade tilt Ripper lift Ripper tilt Pin puller Blade lift Blade tilt 2 Clearance between piston rod support shaft and bushing Ripper lift Ripper tilt Pin puller Clearance between cylinder support shaft bushing and yoke Clearance between cylinder bottom support shaft and bushing 110 140 120 140 30 65 90 110 110 Ball 29 145 0.100 0.200 0.145 0.245 +0.457 +0.370 +0.207 +0.120 +0.195 +0.122 +0.1 1.0 1.0 1.0 Criteria Tolerance Shaft 0.036 0.090 0.043 0.106 0.036 0.090 0.043 0.106 0.065 0.117 0.300 0.200 Hole +0.261 +0.047 +0.263 +0.047 +0.263 +0.048 +0.263 +0.047 +0.133 +0.007 +0.5 +0.2 +0.100 +0.013 +0.207 +0.120 +0.207 +0.120 Standard clearance 0.083 0.351 0.090 0.369 0.084 0.353 0.090 0.369 0.072 0.250 0.200 0.400 Clearance limit 0.65 0.67 0.65 0.67 0.55 1.0 1.0 1.0 1.0 Replace Remedy
Blade lift
Blade tilt 4 Ripper lift Ripper tilt 5 Clearance between cylinder bottom support shaft and boss
90 110 110 26
D475A, D475ASD-5E0
SEN00216-00
Piston valve
For blade lift cylinder Outline q The piston valve is installed to the piston of the blade lift cylinder. When the piston moves to the stroke end, the piston valve relieves the oil sent from the work equipment pump to lower the oil pressure applied to the piston. The piston valve also relieves the oil before the piston reaches the bottom or head of the cylinder to reduce the impact made at the stroke end and lower the surge pressure generated by the impact. Operation 1. When piston valve is closed The oil from the work equipment pump acts on piston (2) and piston valve (3). Then, piston valve (3) is pushed to the right to seal the tapered part of piston valve seat (4). As a result, the oil pressure in the cylinder rises to move piston (2) to the right. 2.
1
When piston valve is open The end of valve (6) touches the cylinder bottom before piston rod (1) reaches the stroke end, and then valve (6) and piston valve (3) do not move any more and only piston (2) continues moving. At this time, the oil on the cylinder head side which has been stopped by piston valve (3) is relieved through piston valve seats (4) and (5), thus the oil pressure in the cylinder does not rise any more.
D475A, D475ASD-5E0
SEN00216-00
Quick drop valve

For blade lift cylinder Outline The quick drop valve is installed to each of the right and left blade lift cylinders. It increases the lowering speed of the blade and prevents a vacuum on the cylinder bottom side during the lowering stroke and shortens the time lag in starting digging. The blade lowering speed is almost determined by the pump delivery amount. It can be heightened, however, by the quick drop valve. 2.
1
While lowering blade The oil pushed out of the cylinder head side flows through port (B) to port (C). At this time, a pressure difference is made between before and after orifice (a). If the pressure difference becomes larger than the tension of spring (4), it compresses the spring and moves spool (2) and check valve (3) to the right. Then, ports (B) and (A) are connected and a part of the oil which has been flowing from the head side to port (C) flows in port (A) on the bottom side and merges with the oil from the control valve and flows into the bottom side. Accordingly, the blade lowering speed is increased by the quantity of the oil flowing into the cylinder bottom side and a vacuum on the bottom side is prevented.
1. 2.
Valve body Spool
3. 4.
Check valve 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
SEN00216-00
Unit: mm
No. Check item Standard size 38.0 Criteria Tolerance Shaft 0.011 0.016 Standard size 2 Valve spring Free length 75.2 Installed length 55.9 Installed load 136.3 N {13.9 kg} Hole +0.010 +0.016 Standard clearance 0.011 0.026 Clearance limit 0.03 Replace Remedy
Clearance between spool and valve body
Repair limit Free length 67.7 Installed load 122.6 N {12.5 kg}
D475A, D475ASD-5E0
11
SEN00216-00
Blade control knob (Dual tilt specification)
1. 2. 3. 4. 5.
Switch (dual-single selector switch) Switch (pitch) Cover Connector (male) Connector (female)
Outline q If the blade control knob is tilted forward, backward, to the right, or to the left, the blade is raised, lowered, tilted to the right, or tilted to the left. If switch (1) is set to the DUAL position and the lever is tilted to the right or left, dual tilt operation is carried out. If the lever is tilted to the right or left while switch (2) is pressed and held, pitching operation is carried out.
If switch (2) is pressed and the lever is operated, the blade is pitched. If the lever is tilted to the left, the blade is pitched back. If the former is tilted to the right, the latter is pitched forward. If switch (1) is set to the DUAL position and the lever is operated, blade carries out dual tilt operation. If the lever is tilted to the left, the blade carries out left dual tilt operation. If the lever is tilted to the right, the blade carries out right dual tilt operation. If switch (1) is set in either DUAL or SINGLE position and the lever is tilted to the right or left while switch (2) is pressed and held, the blade is pitched.
12
D475A, D475ASD-5E0
SEN00216-00
Blade control knob (Superdozer specification)
1. 2. 3. 4. 5.
Forward pitch switch Rear pitch switch Cover Connector (male) Connector (female)
Outline The blade is raised and lowered by leaning the blade control knob forward and backward. q If switch (1) is pressed, the blade is pitched forward. If switch (2) is pressed, the blade is pitched back.
q
D475A, D475ASD-5E0
13
SEN00216-00
Pitch and dual solenoid valve
1. 2. 3. 4. 5. A: B: P: T:
Connector Solenoid (a) Valve Solenoid (b) Manual push pin Port A Port B Port P Port T
Outline q The pitch and dual solenoid valve is installed between the PPC valve and main control valve and used to select the PPC pilot pressure. q Operation of the pitch switch of the blade control lever (or the rear pitch switch or forward pitch switch of the superdozer specification), pilot pressure can be applied so the right and left pitch cylinders will move similarly and the tilt operation can be changed to the pitch operation. 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 operated by the controller.
14
D475A, D475ASD-5E0
SEN00216-00
Pin puller hydraulic circuit diagram
1. 2. 3. 4. 5. 6. 7.
Power train oil tank Oil strainer Power train pump Oil filter Main relief valve (Set pressure: 2.45 MPa {25 kg/cm2}) Steering control valve Pin-puller solenoid valve
8. Pin-puller cylinder 9. Steering case 10. Scavenging pump A: B: C: To transmission lubrication circuit To torque converter circuit To transmission valve circuit and torque converter lockup circuit
D475A, D475ASD-5E0
15
SEN00216-00
Pin puller solenoid valve
1. 2. 3. 4. 5. 6. 7. 8. 9.
Plug Spring Spring retainer Valve body Spool Spring retainer Spring Push pin Solenoid assembly
A. B. C. D.
To pin puller cylinder head From power train pump To pin puller cylinder bottom To steering case
16
D475A, D475ASD-5E0
SEN00216-00
Operation 1. Pin puller switch at PUSH IN position When the pin-puller switch is turned to the PUSH IN position, no current flows to solenoid (9) and it is deactivated. When this happens, spool (5) opens ports (A) and (B) and ports (C) and (D), and the oil from the power train pump flows from port (A) to port (B) and enters the bottom of pin puller cylinder (10). The oil entering the bottom end of the cylinder increases the hydraulic pressure in the circuit and extends the cylinder. Shank mounting pin (11) is pushed into shank (12).
2.
Pin-puller switch at PULL OUT position When the pin puller switch is turned to the PULL OUT position, current flows to solenoid (9) and it is excited. When this happens, the solenoid pushes out push pin (8), and spool (5) moves to the left in the direction of the arrow. Ports (A) and (B) and ports (C) and (D) close, and ports (A) and (C) and ports (B) and (D) open. The oil from the power train pump flows from port (A) to port (C) and enters the head of pin puller cylinder (10). The oil entering the head end of the cylinder increases the hydraulic pressure in the circuit and retracts the cylinder. Shank mounting pin (11) is pulled out of shank (12).
D475A, D475ASD-5E0
17
SEN00216-00
18
SEN00217-00
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Work equipment
Work equipment .............................................................................................................................................. 2 Cylinder stay ........................................................................................................................................ 2 Blade .................................................................................................................................................... 4 Ripper equipment................................................................................................................................. 8
D475A, D475ASD-5E0
SEN00217-00
Work equipment
Cylinder stay
1
1
Unit: mm
No. Check item Standard size 210 160 145 Criteria Tolerance Shaft 0.050 0.122 0.043 0.106 0.145 0.245 Hole +0.167 +0.005 +0.192 +0.129 +0.040 +0.016 Standard clearance 0.145 0.289 0.172 0.298 0.145 0.285 Clearance limit 0.5 0.5 0.5 Replace Remedy
Clearance between cylinder yoke and bushing Clearance between cylinder yoke and bushing Clearance between lift cylinder supporting shaft and bushing
2 3
D475A, D475ASD-5E0
SEN00217-00
Blade
Full U-dozer, Semi U-dozer, Superdozer
Unit: mm
D475A, D475ASD-5E0
SEN00217-00
No.
Check item Standard size 90
Criteria Tolerance Shaft 0.2 0.3 0.2 0.3 0.3 0.4 0.3 0.4 0.2 0.3 0.2 0.4 0.3 0.5 0.3 0.5 +0.206 +0.166 0.5 1.0 0.2 0.4 0.3 0.5 0.3 0.5 0.043 0.108 0.043 0.108 0.2 0.8 0.2 0.3 0.3 0.5 0.3 0.5 0.3 0.5 0.3 0.5 Hole +0.3 +0.1 +0.3 +0.1 +0.1 +0.6 +0.1 +0.6 +0.3 +0.6 +1.5 +1.0 +0.3 +0.6 +0.207 +0.120 0.014 0.060 +1.0 +0.6 +0.3 +0.1 +0.3 +0.6 +0.208 +0.118 +0.225 +0.106 +0.225 +0.106 +0.3 +0.6 +0.3 +0.6 +0.5 +0.2 +0.3 +0.6 +0.3 +0.6 +0.5 +0.2 Standard clearance 0.3 0.6 0.3 0.6 0.3 0.5 0.3 0.5 0.2 0.6 1.2 1.9 0.3 0.8 0.420 0.707 0.152 0.266 0.5 2.0 0.3 0.7 0.3 0.8 0.418 0.708 0.149 0.333 0.149 0.333 0.2 1.1 0.2 0.6 0.5 1.0 0.3 0.8 0.3 0.8 0.5 1.0 Clearance limit 2 2 1 1 1 3 3 2 8 3 3 2 2 2 2 1 2 2
Remedy
Clearance between brace pin and brace Clearance between brace pin and bracket Clearance between brace pin and bracket Clearance between brace pin and bushing Clearance between center brace and cap spherical surface Clearance between joint and bracket Clearance between frame pin and joint Clearance between frame pin and bracket Clearance between straight frame joint bushings Clearance between trunnion and cap spherical surface Clearance between joint and bracket Clearance between blade pin and joint Clearance between blade pin and bracket Clearance between center link pin and blade bracket Clearance between center link pin and center link Clearance between center link and blade bracket Clearance between center brace spherical surface and cap Clearance between lift cylinder head pin and cylinder Clearance between lift cylinder head pin and cross joint Clearance between bracket and lateral pin Clearance between cross joint and lateral pin
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
90 90 90 200 240 120 120 185 250 240 120 120 145 145 550 200 65 65 65 65
Replace
Adjust shim or replace
Replace
Adjust shim or replace
Replace 2 2
D475A, D475ASD-5E0
SEN00217-00
Cutting edge, end bit
Unit: mm
No. 1 2 3 4 Check item Height of end bit outside Width of end bit Height of end bit inside Height of cutting edge Standard size 510 720 393 405 Criteria Repair limit 383 635 330 351 (240 after turned) Replace or turn Replace Remedy
D475A, D475ASD-5E0
SEN00217-00
Ripper equipment
Variable giant ripper
D475A, D475ASD-5E0
SEN00217-00
Unit: mm
No. Check item Clearance between bushing and bracket and arm mount pin Clearance between bushing and beam and arm mount pin Clearance between cylinder mount pin and bushing Outside diameter of shank mount pin Wear of point Wear of protector Standard size 140 140 110 Criteria Tolerance Shaft 0.043 0.106 0.043 0.106 0.036 0.090 100 Standard size 460 224 Hole +0.193 +0.050 +0.500 +0.300 +0.289 +0.123 Tolerance 0.3 300 184 Standard clearance 0.093 0.299 0.343 0.606 0.159 0.379 Repair limit Clearance limit 1.5 1.5 1.5 Replace Remedy
2 3 4 5 6
Standard size
Repair limit
D475A, D475ASD-5E0
SEN00217-00
D475A, D475ASD-5 Bulldozer Form No. SEN00217-00
10
SEN00218-00
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Cab and its attachments
Cab and its attachments ................................................................................................................................. 2 Cab mount............................................................................................................................................ 2 Cab....................................................................................................................................................... 3 Air conditioner ...................................................................................................................................... 6
D475A, D475ASD-5E0
SEN00218-00

Cab mount
1
1
1. 2. 3.
Support Damper mount (front) Damper mount (rear)
Outline q Mounts are installed at two places at the front 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.
D475A, D475ASD-5E0
SEN00218-00
Cab
Cab assembly
1. 2. 3. 4.
Front wiper Front glass Rear wiper Door
D475A, D475ASD-5E0
SEN00218-00
ROPS guard
1.
ROPS guard
D475A, D475ASD-5E0
SEN00218-00
Air conditioner
Air conditioner piping
D475A, D475ASD-5E0
SEN00218-00
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. A. B. C.
Condenser Air conditioner compressor Refrigerant piping Window defroster Side defroster Vent Hot water pickup piping Valve (hot water outlet) Receiver tank Hot water return piping Valve (hot water inlet) Air conditioner unit Additional blower motor Fresh air Recirculated air Hot air/cold air
D475A, D475ASD-5E0
SEN00218-00
SEN00219-00
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

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
SEN00219-00
Electrical system
Engine control
1
1
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Battery relay (Right) Steering controller Battery (Right) Transmission controller Engine throttle controller Decelerator pedal Starting switch Decelerator pedal potentiometer Fuel control dial Battery (left) Battery relay (left) Starting motor Fuel supply pump
Outline Engine control is carried out in the following two systems. 1. When the fuel control dial and decelerator pedal are operated, it controls the fuel injection pump with an electric signal. 2. When mode selection system is actuated. The throttle signal and fuel control dial signal enter the machine controller, are processed together with other data, and are sent to the electronic engine throttle controller as the throttle command. The electronic engine throttle controller controls the fuel supply pump according to the command. This machine uses CRI system.
D475A, D475ASD-5E0
SEN00219-00
Engine control system
Outline q The engine throttle controller receives the manual signals of the 1st throttle, 2nd throttle and the 3rd throttle signals which is the control signals from the machine body, then selects the lower engine speed and controls the fuel supply pump. The 3rd throttle control signals contain the following. 1) High idle speed control 2) SSC (Shoe Slip Control) 3) Automatic deceleration (F3, R3, R2)
The steering controller sends the most suitable for engine speed from informations 1) and 2) and transmits it as the 3rd throttle to the engine throttle controller. Information of the engine throttle controller is commonly used by all the controllers throughout the network, for optimum control of the engine and machine body. The automatic deceleration function sets the engine speed to 1,000 rpm temporarily when the travel direction is changed from F3, R3, or R2 (to protect the transmission clutch).
D475A, D475ASD-5E0
SEN00219-00
Deceleration potentiometer
1. 2. 3. 4. 5. 6. 7.
Connector Lever Body Potentiometer Coupling Shaft Stopper
Outline q The deceleration potentiometer is installed to the front lower part of the operators cab and connected to the decelerator pedal by linkage. q If the decelerator pedal is pressed, the throttle potentiometer shaft rotates by the linkage and the potentiometer resistance changes. Constant voltage is applied between pins (A) and (C) of the potentiometer and an electric signal is sent through pin (B) to the engine throttle controller according to the position of the decelerator pedal.
D475A, D475ASD-5E0
SEN00219-00
CRI engine control system

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 controller and output to each actuator to control the fuel injection rate and fuel injection timing.
D475A, D475ASD-5E0
SEN00219-00
1. 2.
Fuel tank Fuel supply pump assembly 2A. PCV 2B. High pressure pump 2C. Priming pump 2D. Feed pump 2E. Bypass valve 2F. G speed sensor 3. Fuel filter 4. Overflow valve 5. Common rail 6. Pressure limiter 7. Flow damper 8. Injector assembly 8A. Orifice 8B. Control chamber 8C. Hydraulic piston 8D. Injector 8E. Nozzle 9. Engine throttle controller 10. NE speed sensor
System configuration The CRI system consists of the fuel supply pump (2), common rail (5), injector (8), engine throttle controller (9) to control them, and sensors. q The fuel supply pump generates fuel pressure in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply pump. The discharge rate is controlled by turning on and off PCV (discharge control valve) (2A) of the fuel supply pump according to the electric signals from the engine throttle controller. The common rail receives the pressurized fuel from the fuel supply pump and distributes it to the cylinders. The fuel pressure is sensed by the common rail fuel pressure sensor installed to the common rail and controlled by the feedback method so that the actual fuel pressure will 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 highpressure 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.
q
D475A, D475ASD-5E0
SEN00219-00
Monitor system
The monitor system monitors the machine condition with sensors installed to various parts of the machine, and quickly processes and displays obtained information on the monitor panel, to notify the operator of machine condition. The function of the monitor system is as follows. 1) Function which turns on the alarm when the machine has a trouble on the monitor. 2) Function which constantly displays the machine condition (coolant temperature, torque converter oil temperature, fuel level, hydraulic oil level, etc.) on the gauge. 3) Function of displaying error codes. 4) Function of monitoring the current and voltage of the sensors and solenoids.
In the monitor panel, there are various mode selector switches of the SSC (Shoe Slip Control), which are used to operate the machine control system (with SSC). The monitor panel has the functions of displaying data and selecting the SSC mode (with SSC). The CPU (Central Processing Unit) in it processes, displays, and outputs the information. The display unit is LCD (Liquid Crystal Display) and the switches are seat switches.
D475A, D475ASD-5E0
SEN00219-00
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. F1, R3, etc. are notified by CAN according to information of transmission controller. 2) Display of engine speed in gauge number. The number of pulses the engine rotation is converted into a gauge number and notified to the monitor panel by CAN.
Transmission controller o Steering CAN controller o Monitor panel (Controller Area Network) CAN Engine speed sensor o Steering controller o Monitor panel
3) Display of failure When the machine has a failure, the corresponding CAN failure code is notified to the monitor panel by CAN. Which one should be turned on, the buzzer or the caution lamp, is notified, too. i) In normal state User code ii) In fault history display mode The service code (6-digit code) and the following items are displayed 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. Contents and conditions of processing 2. Method
Engine sensor/solenoid o Steering controller or transmission controller o Monitor panel
Sensors and solenoids o Engine throttle controller o Steering controller o Monitor panel
3. Flow of signals
1) The communication conditions of each sensor, each solenoid, and CAN are displayed. The item Nos. and device conditions are notified to the monitor panel by CAN. The monitor panel displays the items and each value on its multi-information section. 2) Each items is selected by using the cursor switches, selector switches, buzzer cancel switch, and shift UP/DOWN switches. Other items
1. Contents and conditions of processing
CAN
Each sensor o Steering controller or transmission controller o Monitor panel Sensors o Engine throttle controller o Steering controller o Monitor panel Monitor panel o Controller o Monitor panel
2. Method
3. Flow of signals
1) Function selection mode (Displayed each time 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
CAN
Steeging controller o Monitor panel
D475A, D475ASD-5E0
SEN00219-00
Monitor panel
Monitor portion
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Engine coolant temperature gauge Power train oil temperature gauge Hydraulic oil temperature gauge Fuel gauge Radiator coolant level check lamp Hydraulic oil level check lamp Engine oil level check lamp Charge level monitor Engine oil pressure caution lamp Engine coolant temperature caution lamp Power train oil temperature caution lamp Hydraulic oil temperature caution lamp Air cleaner clogging caution lamp
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 2.
Engine preheating pilot lamp Maintenance caution lamp Warming lamp Filter, oil change interval lamp Display panel A (Speed range, Engine speed) Display panel B (Multi-information) Dual/single tilt selector display lamp Lockup mode switch Economy mode selector switch Reverse slow mode selector switch Shoe slip selection mode switch (with SSC) Rock selection mode selector switch (with SSC) Fan operation confirmation lamp Start-up inspection 1) After all lighting of Section 1 is terminated, if there is an error in a start-up inspection item, the item flashes. 2) If the engine is started, the check items before starting go off. (If the engine running is judged by the signal (CAN) from the engine controller.) Cautions Caution items are checked until the engine stops after the engine starts. If an error occurs, the error is displayed by flashing and the alarm lamp synchronously flashes. Further, if an emergency item flashes, the alarm buzzer also sounds synchronously. Flashing of the monitor and alarm lamp is repeated. They come on and off for about 0.8 second. The flashing period of the monitor slightly changes when atmospheric temperature is low (below about 10C), but this case is not abnormal.
Outline q The monitor potion consists of a monitor that issues an alarm when an error occurred in a vehicle, a gauge that always displays the state of the vehicle, and the service meter. The monitor portion installs a microcomputer and processes and displays signals from each sensor. Besides, the items displayed on the monitor portion and gauge portion are listed in the table on the next page. Operation 1. When the power turns on (When the starting switch is ON) 1) All items of the gauge and monitor portions come on for three seconds. 2) The alarm lamp comes on for two seconds.
3.
a a
D475A, D475ASD-5E0
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SEN00219-00
Monitor panel display

Display category Symbol Display item Display range Display method Displays when engine is stopped and starting switch is ON Display when normal: OFF Display when abnormal: Flashes
Radiator coolant level
Below low level
Engine oil level
When sensor is abnormal or when wiring harness is disconnected Display when normal: OFF Display when abnormal: ON
Check
Hydraulic oil level
Below low level
Battery charge Caution 1

SAP00522
When charge is defective
Air clever clogging
When clogged: Less than 6.37 kPa {650 mmH2O}
Displays when starting switch is ON and engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes
Engine oil pressure
Below 49.0kPa {0.5kg/cm2}
Radiator coolant level
Below low level
Engine coolant temperature
When at highest level (108C or above) on engine coolant temperature gauge Displays when starting switch is ON and engine is running Display when normal: OFF Display when abnormal: Flashes CAUTION lamp flashes Alarm buzzer sounds
Caution 2
Torque converter oil temperature
When at highest level (130C or above) on engine coolant temperature gauge
Hydraulic oil temperature
1053C or above
Hydraulic oil level
Below low level
Maintenance
When replacement time of filter or oil has been passed
12
D475A, D475ASD-5E0
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Display category
Symbol
Display item
Display range
Display method Lights according to required time determined by engine controller based. It also lights at the time of manual preheat by setting starting switch at preheat position (turning it counterclockwise). Display lights at the time of operation. It goes off at the time of nonoperation.
Preheating Pilot
When preheating
Dual tilt
At the time of operation
Engine coolant temperature
Torque converter oil temperature Gauges
One place lights up to show applicable level
Hydraulic oil temperature
Fuel level
All lamps light up below applicable level
Multi information
Service meter (Hours meter)
From 0 to 99999
Actuated when the engine is rotating
D475A, D475ASD-5E0
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SEN00219-00
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
Without SSC specifications
2.
Initial Setup at key ON The function the operator desires according to the situation of an operating place is selected and all functions shall be set to the OFF state.
Economy Mode Function In a field, such as a rock-bed place where many shoe slips are generated, the following power is output in each mode so that the frequency of decelerator 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
SEN00219-00
Sensors
Type of sensor Engine oil pressure Engine coolant temperature Torque converter oil temperature Hydraulic oil temperature Radiator coolant level Fuel level Engine oil level All cleaner clogging Sensor method Contact Resistance Resistance Resistance Contact Resistance Contact Contact When normal OFF ON ON ON When abnormal ON OFF OFF OFF
Engine oil pressure sensor
1. 2. 3.
Plug Contact ring Contact
4. 5. 6.
Diaphragm Spring Terminal
Engine coolant temperature sensor Torque converter oil temperature sensor Hydraulic oil temperature sensor
1. 2. 3.
Thermistor Body Tube
4. 5. 6.
Tube Wire Connector
D475A, D475ASD-5E0
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SEN00219-00
Radiator coolant level sensor
1. 2. 3.
Float Sensor Tube
4. 5.
Wire Connector
Fuel level sensor
1. 2. 3. 4. 5. 6. 7.
Connector Float Arm Body Spring Contact Spacer
Function q The fuel level sensor is installed to the side face of the fuel tank. The float moves up and down according to the fuel level. This movement of the float is transmitted by the arm and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level. When the display on the monitor panel reaches a certain level, a warning lamp flashes. D475A, D475ASD-5E0
16
SEN00219-00
Engine oil level sensor
1. 2. 3.
Float Sensor Tube
4. 5.
Wire Connector
Air cleaner clogging sensor
1. 2. 3.
Boss Switch Conduit
4. 5.
Wire Connector
D475A, D475ASD-5E0
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SEN00219-00
Mode selection system

(SSC (Shoe Slip Control) System)
System diagram
Outline q The mode selection system automatically carries out engine control to match the operating mode selected by the operator, and acts to reduce fuel consumption, extend the life of the track shoes, and reduce the frequency of operation of the deceleration. q The engine control modes consist of the economy 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.
The lockup control mode is the same as the conventional lockup function. It cannot be selected in combination with the above modes.
18
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Function of mode selection system The system consists of the mode selection panel (containing a microcomputer) to select working condition, steering controller (containing a microcomputer) to control the engine, engine controller to receive the commands from the steering controller and controls the fuel injection pump, transmission 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 transmission 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 transmission 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 signal to the lockup solenoid valve, judging from input gear speed information from the transmission 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 potentiometer, manual signal of the throttle dial, and the SSC command signal.
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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 switch selection Mode work conditions ON/OFF switching is automatically performed in accordance with the load. Speed number of gear ratios Low ON T/C speed OFF output side shaft High ON speed speed side OFF Lock-up F1, F2, F3, R1, R2, R3 1,360 rpm or more 1,330 rpm or more 2,570 rpm or more 2,600 rpm or more 1. When the economy mode (1 or 2) and SSC are 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 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. The engine speed can be suppressed without performing the decelerator operation of the engine. 2. Target travel speed at reverse time R1 R2 70% at full operation R3 1. At start, to prevent rashing out, the modulating valve is actuated. At this time, the steering controller performs index characteristic down of about 40% and performs the engine output control if a ripper down signal is input. 2. The steering controller performs the engine output control in accordance with the index 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. 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. Mode operation, characteristic 1. When the torque converter approaches to the 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. 2. Can be used in all number of gear ratios. 3. Simultaneous selection disabled with another mode 4. Suitable for dozing work of comparatively a few load fluctuations.
Dozing
1. When F1 is shifted with the economy mode switch 1) or 2) ON Economy
Reverse slow
1. When R1, R2, and R3 are shifted
Rock-bed selection
SSC (Shoe Slip Control)
The following conditions are satisfied: 1) When F1 is shifted. 2) After the ripper down, ripper tilt levers are actuated and the switch is set to ON
Ripping
Set to ON in connection with SSC
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.
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Sensors
Transmission output shaft speed sensor
1. 2. 3.
Magnet Terminal Case
4. 5.
Boots Connector
Torque converter speed sensor
1. 2. 3.
Connector Flange Sensor
D475A, D475ASD-5E0
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Acceleration sensor
1. 2. 3.
q q
Sensor portion Wire Connector The acceleration sensor is installed under the front of the operators cab. With the acceleration sensor, the position of the ball inside the sensor changes according to the acceleration. Inside the sensor, there is a coil that detects the position of the ball. This is amplified by the amp and is sent as a voltage change to the SSC controller. The input and output characteristics of the sensor are shown in the diagram below.
22
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Pitch angle sensor
1. 2. 3. 4.
q
Body Tube Wire Connector The sensor is filled with electrolyte. If sensor leans, the electrolyte surface slants. If electrolyte surface slants, the contact area of two electrodes installed in the sensor with electrolyte changes. As a result, electrostatic capacity between the two electrode changes. The change of electrostatic capacity is output as a change of voltage. The input and output characteristics of the sensor are shown in the figure at right.
D475A, D475ASD-5E0
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Electrical equipment
Relay box
24
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Operation of lamp system
Lamp system circuit diagram
D475A, D475ASD-5E0
25
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Preheating (Electrical intake air heater) control
Preheating circuit
26
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Steering electronic control system
1. 2. 3. 4. 5.
Monitor panel (Multi information) Auto shift down switch Engine controller Transmission controller Steering controller
6. 7. 8. 9.
Steering control valve Transmission output shaft speed sensor Transmission control valve Engine speed sensor
D475A, D475ASD-5E0
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Shift mode function Function If you shift the lever to the forward or reverse, the gear speed selected from the shift mode is turned on. Type of modes q F1-R1 (Manual mode) q F1-R2 (Shift mode 1) q F2-R2 (Shift mode 2) Selecting method Shift the PCCS lever to N. Select the shift mode using UP or DOWN switch. Display The selected shift mode is displayed on the monitor panel.
Auto-shift-down function Function If the load is increased while the machine is traveling or working at the 2nd or 3rd gear speed, the gear speed is shifted down automatically. q The drawbar pull (load on the machine) is calculated from the engine speed, travel speed, and throttle information from the steering controller, and the gear speed is shifted down automatically according to the load and travel speed. q Once the gear speed is automatically shifted down, it is not automatically shifted up to the former position. (Gear speed can be shifted up with the manual switch.) q This function is applicable to both forward and reverse travels. 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
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VHMS controller
D475A, D475ASD-5E0
29
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Input and output signals

CN1 [CN 1]
Pin No. CN1-1 NC CN1-2 Sensor power supply (24V) CN1-3 Sensor power supply (12V) CN1-4 Sensor power supply (5V) CN1-5 Sensor power supply (5V) CN1-6 Power supply (Constant power supply) (24V) Signal name Input/ Output Input Output Output Output Output Input Input Input Input Input Input Input Input Input Input Input
CN2 [CN2 A, B]
Pin No. CN2-A1 CN2-A2 NC CN2-A3 CN2-A4 NC CN2-A5 Exhaust temperature (Right 1) CN2-A6 Exhaust temperature (Left 2) CN2-A7 Exhaust temperature (Left 1) CN2-A8 NC CN2-A9 NC CN2-A10 CN2-A11 NC CN2-A12 Sensor GND CN2-A13 Sensor GND CN2-A14 NC CN2-A15 Transmission, main CN2-A16 Exhaust temperature (Right 2) CN2-A17 WAKE UP (Low) CN2-A18 Blow-by pressure CN2-B1 NC CN2-B2 NC CN2-B3 NC CN2-B4 NC CN2-B5 NC CN2-B6 Wake up HI CN2-B7 NC CN2-B8 NC CN2-B9 GND CN2-B10 NC CN2-B11 NC CN2-B12 CONNECTOR (GND) Signal name Input/ Output Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input
Power supply (Constant power supply) CN1-7 (24V) CN1-8 BR power supply (24V) CN1-9 BR power supply (24V) CN1-10 NC CN1-11 GND CN1-12 GND CN1-13 NC CN1-14 NC CN1-15 NC CN1-16 NC CN1-17 Start signal CN1-18 NC CN1-19 GND CN1-20 GND
30
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CN3 [CN 3 A, B]
Pin No. CN3-A1 CN3-A2 CAB out D/L Sw CN3-A3 NC CN3-A4 NC CN3-A5 Model selection (See ORB connection) Signal name Input/ Output Input Input Input Output Input Input Input Input/ Output Input Input Input Input Input Input Input Input Input Input/ Output Input Input
CN4 [CN 4 A, B]
Pin No. CN4-A1 NC CN4-A2 NC CN4-A3 RS232C GND CN4-A4 CAN (1) H (KOM-NET/c) CN4-A5 CAN (0) shield CGC CN4-A6 CAN (0) H CGC CN4-A7 NC CN4-A8 NC CN4-A9 GND CN4-A10 RS232C RX0 (PC Tool) CN4-A11 RS232C TX0 (PC Tool) CN4-A12 CAN (1) L (KOM-NET/c) CN4-A13 CAN (1) SH (KOM-NET/c) CN4-A14 CAN (0) L CGC CN4-B1 NC CN4-B2 NC CN4-B3 RS232C GND CN4-B4 RS232C TX1 (Orbcom) CN4-B5 NC CN4-B6 NC CN4-B7 NC CN4-B8 NC CN4-B9 GND CN4-B10 RS232C RX1 (Orbcom) Signal name Input/ Output Input/ Output Input/ Output Input Input/ Output Input Input Output Input/ Output Input Input/ Output Input Output Input Input
CN3-A6 NC CN3-A7 CN3-A8 CN3-A9 CONNECTOR SEL2 (OPEN) CN3-A10 NC CN3-A11 NC CN3-A12 NC CN3-A13 NC CN3-A14 NC CN3-A15 NC CN3-A16 NC CN3-A17 NC CN3-A18 NC CN3-B1 NC CN3-B2 NC CN3-B3 NC CN3-B4 NC CN3-B5 NC CN3-B6 Snap shot Sw data clear CN3-B7 NC CN3-B8 NC CN3-B9 NC CN3-B10 NC CN3-B11 NC CN3-B12 NC
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SEN00219-00
Sensors
Engine oil temperature sensor Specifications Type of sensor: Measurement range: Thermistor 40 130C 80 130C (Assured accuracy: 2C) 4.9 MPa {50 kg/cm2} 30C to +140C Exhaust temperature sensor/amplifier Specifications Rated voltage: DC 24 V Sensed temperature range: 100 1,000C 300 800C (Assured accuracy: 10C) Output voltage characteristics (Ambient temperature: 20C) Reference values
Sensed temperature (C) 50 100 1.397 400 2.626 700 3.899 800 4.316
Max. power consumption: 0.5 mW Pressure resistance: Using temperature: Performance table
Temper- Resis- Temper- Resis- Temper- Resisature tance ature tance ature tance (C) (kz) (C) (kz) (C) (kz) 30 40 50 60 70 35.27 24.28 17.05 12.20 8.884 80 85 90 95 100 6.571 5.682 4.931 4.293 3.750 110 115 120 125 130 2.887 2.544 2.248 1.992 1.769
Output voltage 1.191 (V)
Operating temperature range: 40 to +110C Current consumption: Max. 30 mA a: b: c: d: Heat sensing part of sensor Outside diameter of mounting part: R1/8 Amplifier Connector (Power supply side) Connector (Sensor side)
a:
Heat sensing part of sensor Outside diameter of mounting part: R1/4
Function The engine oil temperature sensor is installed to the engine oil filter. It inputs the change of the temperature as the change of the thermistor resistance to the VHMS controller.
Function The exhaust temperature sensor/amplifier is a thermocouple-type temperature sensor, which is installed to the turbocharger inlet. It outputs the exhaust temperature data to the VHMS controller.
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Atmospheric temperature sensor Specifications Power consumption: Pressure resistance: Max. 0.5 mW 0.98 MPa {10 kg/cm2}
Sensed temperature range (ambient): 30 to +120C Storage temperature range: 50 to +140C Performance table
Sensed temperature (C) Resistance (kz)
20
10
10
20
50
30.32 18.58 11.74 7.623 5.077 1.712
a.
Heat sensing part of sensor Outside diameter of mounting part: 16 x 1.5
Function The atmospheric temperature sensor inputs the change of the atmospheric temperature as the change of the thermistor resistance to the VHMS controller.
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Engine blow-by pressure sensor
1. 2. 3. A. B. C.
Sensor Connector Atmospheric pressure intake tube GND (Black) Power supply (Red) Output (White)
Specifications and function Pressure range: 0 20 kPa {0 2,040 mmH2O} Allowable pressure: Source voltage:
q
20 to 100 kPa {2,040 to 10,200 mmH2O} 5 0.25 V
Output characteristics:See graph. The blow-by pressure sensor is a fine relative pressure sensor which measures the difference between the pressure in the crankcase and the atmospheric pressure. The pressure in the crankcase is applied to the tip side of the sensor and the atmospheric pressure is applied to the wiring harness side.
Transmission main oil pressure sensor
1. 2.
Sensor Connector
34
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Communication (ORB: ORBCOMM) controller/antenna

Controller Specifications Source voltage: DC 12 V DC 30 V Size: W306 x D152 x H52 (mm) Connectors CN1A (ORB-A): AMP070-14 CN1B (ORB-B): AMP070-10 CN2: Communication antenna cable connector Antenna Specifications Type: Helical whip antenna (1) Impedance: 50 z Input terminal:N-P type Length: 165 20 mm a. Communication antenna mounting part
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
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
20 Standard value table

Standard service value table
Standard value table for engine ...................................................................................................................... 2 Standard value table for chassis ..................................................................................................................... 3
D475A, D475ASD-5E0
SEN01816-01
Standard value table for engine

Machine model Engine Item Measurement conditions High idle (*1) Low idle Rated speed At rated output Whole speed range (Outside air temperature: 20C) At sudden acceleration At high idle (*1) Intake valve Exhaust valve Oil temperature: 40 60 C (Engine speed) Coolant temperature: Within operating range At rated output At high idle SAE0W30EOS SAE5W40EOS SAE10W30DH SAE15W40DH SAE30DH At low idle SAE0W30EOS SAE5W40EOS SAE10W30DH SAE15W40DH SAF30DH Whole speed range (In oil pan) Deflection under finger pressure of 58.8 N {6 kg} Deflection under finger pressure of 58.8 N {6 kg} Unit D475A, D475ASD-5E0 SAA12V140E-3 Standard value for new machine 2,150 (+25/50) 650 50 2,000 Min. 132.30 {1000} Max. 650 Max. 4.5 Max. 1.0 0.35 0.02 0.57 0.02 Min. 4.1 {42} (200 250)
Service limit value 2,150 (+25/50) 650 50 Max. 700 Max. 5.5 Max. 2.0 Min. 2.0 {20} (200 250)
Speed Intake air pressure (Boost pressure) Exhaust temperature Exhaust gas color Valve clearance (At normal temperature) Compression pressure (Engine oil: SAE15W-40 or SAE30) Blow-by pressure (Engine oil: SAE15W-40 or SAE30)
rpm
kPa {mmHg} C Bosch index mm MPa {kg/cm2} (rpm) kPa {mmH2O}
Max. 2.94 {300}
Max. 5.88 {600}
0.29 0.44 {3.0 4.5} MPa {kg/cm2} Min. 0.08 {0.8}
Min. 0.20 {2.0}
Oil pressure (oil temperature: 90 110C)
Min. 0.07 {0.7}
Oil temperature Tension of alternator belt Tension of air conditioner compressor belt
C mm mm
80 110 20 2 20 2
Max. 120
(*1): Refer to the item 3. of Measuring engine speed in Testing and adjusting, Part 1.
D475A, D475ASD-5E0
SEN01816-01
Standard value table for chassis

Machine model Category Measurement item Deceleration low idle speed Engine speed Deceleration high idle speed Torque converter stall speed Measurement conditions Unit D475A, D475ASD-5E0 Standard value for new machine 900 50 2,000 50 Service limit value 900 50 2,000 50
Engine coolant temperature: Within operating range Power train oil temperature: Within operating range Hydraulic oil temperature: Within operating range Deceleration low idle: Press decelerator pedal Deceleration high idle: Set forward-reverse rpm lever in neutral + Set work equipment control lever in neutral Torque converter stall: Stall at F3
1,690 50
Min. 1,590
Torque converter stall + Torque converter stall + Work equipment relief Work equipment relief speed: Stall at F3 + Raise ripper or relieve pitch back circuit speed Decelerator pedal Forward, reverse PCCS lever Control lever and pedal stroke Steering Neutral o Right Run engine at low idle Press pedal to center Full stroke Stroke to oil pressure of 0 Neutral o Float Neutral o Raise/Lower Neutral o Left/Right tilt Neutral o Raise/Lower Neutral o Tilt in/out mm mm Stop engine Set lever to center Stop engine Press pedal to center Neutral o Forward Neutral o Reverse Neutral o Left mm mm
1,615 75 45 15 30 5 30 5 40 5 (Play: Max. 3) 40 5 (Play: Max. 3) 78 10 58 10 90 10 60 10 60 10 78 10 mm 81 10 N{kg} 59 9.8 {6.0 1.0} 56.9 6.9 {5.8 0.7} 51 6.9 {5.2 0.7} N{kg} 25.5 4.9 {2.6 0.5} 28.4 4.9 {2.9 0.5}
Min. 1,450 45 15 30 5 30 5 40 5 (Play: Max. 3) 40 5 (Play: Max. 3) 78 10 58 10 90 10 60 10 60 10 78 10 81 10 59 9.8 {6.0 1.0} 56.9 6.9 {5.8 0.7} 51 6.9 {5.2 0.7} 25.5 4.9 {2.6 0.5} 28.4 4.9 {2.9 0.5}
Brake pedal
Blade control lever
Run engine at low idle Hydraulic oil temperature: Within operating range Set lever to center Run engine at low idle Hydraulic oil temperature: Within operating range Set lever to center Stop engine Press pedal to center
Ripper control lever
Control lever and pedal operating effort
Decelerator pedal
Forward, reverse PCCS lever Steering Stop engine Set lever to center
Neutral o Forward, Reverse Forward, Reverse o Neutral Neutral o Left Neutral o Right
D475A, D475ASD-5E0
SEN01816-01
Machine model Category Measurement item Measurement conditions Run engine at low idle Press pedal to center Neutral o Raise Run engine at low idle Hydraulic oil tempera- Neutral o Lower ture: Within operating range Neutral o Float Set lever to center Neutral o Left/Right tilt Run engine at low idle Hydraulic oil temperature: Within operating range Set lever to center Neutral o Raise/Lower Neutral o Tilt in/out Engine at low idle Unit
D475A, D475ASD-5E0 Standard value for new machine 490.3 49.0 {50.0 5.0} 39.2 9.8 {4.0 1.0} 39.2 9.8 {4.0 1.0} 82.4 13.7 {8.4 1.4} 28.4 9.8 {2.9 1.0} 21.6 4.9 {2.2 0.5} 20.6 4.9 {2.1 0.5} 400 30 rpm 980 50 MPa {kg/cm2} 15.2 2.5 {155 25} 0.78 0.98 {8 10} 0.03 0.20 {0.3 2} 0.39 0.64 {4 6.5} 0.03 0.15 {0.3 0.15} 1.3 1.42 {11.5 14.5} 2.55 2.74 {26.0 28.0} MPa {kg/cm2} 2.55 2.74 {26.0 28.0} 2.65 2.98 {27.0 30.4} 2.35 2.89 {24.0 29.5} 2.35 2.74 {24.0 28.0} 2.35 2.74 {24.0 28.0} 1.96 2.35 {20.0 24.0} 2.35 2.74 {24.0 28.0} Min. 880 15.2 2.5 {155 25} 0.78 0.98 {8 10} 0.03 0.20 {0.3 2} 0.39 0.64 {4 6.5} 0.03 0.15 {0.3 0.15} 1.3 1.42 {11.5 14.5} Min. 2.55 {Min. 26.0} Min. 2.45 {Min. 25.0} 2.55 3.04 {26.0 31.0} 2.45 3.04 {25.0 31.0} 2.25 2.74 {23.0 28.0} 2.25 2.74 {23.0 28.0} 1.86 2.35 {19.0 24.0} 2.25 2.74 {23.0 28.0} Service limit value 490.3 49.0 {50.0 5.0} 39.2 9.8 {4.0 1.0} 39.2 9.8 {4.0 1.0} 82.4 13.7 {8.4 1.4} 28.4 9.8 {2.9 1.0} 21.6 4.9 {2.2 0.5} 20.6 4.9 {2.1 0.5} Min. 350
Control lever and pedal operating effort
Brake pedal
N{kg}
Blade control lever
N{kg}
Ripper control lever
N{kg}
Min. speed Fan Max. speed Circuit oil pressure
Hydraulic oil temperature: Within operating Engine at high range idle Fan 100% mode Engine at high idle High idle Low idle High idle Low idle High idle High idle Power train oil temperature: Within operating Low idle range High idle Low idle Low idle Low idle Low idle Low idle
Torque converter inlet pressure
Torque converter outlet pressure Torque converter lock-up clutch pressure Torque converter stator clutch pressure
Power train oil pressure
Transmission main relief pressure Transmission F clutch pressure Transmission R clutch pressure Transmission 1st clutch pressure Transmission 2nd clutch pressure
D475A, D475ASD-5E0
SEN01816-01
Machine model Category Measurement item Transmission 3rd clutch pressure Transmission lubricating pressure Measurement conditions Unit
D475A, D475ASD-5E0 Standard value for new machine 2.35 2.74 {24.0 28.0} 0.15 0.29 {1.5 3.0} 2.65 2.98 {27.0 30.4} 2.35 2.89 {24.0 29.5} 2.65 2.98 {27.0 30.4} MPa {kg/cm2} 2.35 2.89 {24.0 29.5} 2.65 2.98 {27.0 30.4} 2.35 2.89 {24.0 29.5} 2.65 2.98 {27.0 30.4} 2.35 2.89 {24.0 29.5} 2.65 3.03 {27.0 30.9} 3.3 0.3 6.2 0.3 11.2 0.6 4.2 0.3 8.0 0.4 km/h 14.0 0.7 3.4 0.3 6.3 0.3 11.6 0.6 4.4 0.3 8.4 0.4 14.3 0.7 Service limit value 2.25 2.74 {23.0 28.0} 0.15 0.29 {1.5 3.0} Min. 2.45 Min. {25} 2.26 2.89 {23.0 29.5} Min. 2.45 {Min. 25} 2.26 2.89 {23.0 29.5} Min. 2.45 {Min. 25} 2.26 2.89 {23.0 29.5} Min. 2.45 {Min. 25} 2.26 2.89 {23.0 29.5} Min. 2.55 {Min. 26} 3.3 0.3 6.2 0.3 11.2 0.6 4.2 0.3 8.0 0.4 14.0 0.7 3.4 0.3 6.3 0.3 11.6 0.6 4.4 0.3 8.4 0.4 14.3 0.7
Low idle High idle High idle
Steering left clutch pressure Low idle Power train oil pressure High idle Steering left brake pressure Power train oil temperature: Within Low idle operating range High idle Low idle High idle Low idle Low idle When lockup switch is OFF When lockup switch is ON Forward 1st Forward 2nd Forward 3rd Reverse 1st Reverse 2nd Reverse 3rd Forward 1st Forward 2nd Forward 3rd Reverse 1st Reverse 2nd Reverse 3rd
Steering right clutch pressure
Steering right brake pressure
Ripper pin puller pressure
Travel speed
Stop machine on flat and level place Run engine at high idle Engine coolant temperature: Within operating range Economy mode: OFF Reverse slow mode: OFF Run-up distance: 10 30 m Measuring distance: 20 m
Power train
D475A, D475ASD-5E0
SEN01816-01
Machine model Item Category Standard value for new machine Engine speed Unit
D475A, D475ASD-5E0 Service limit value Standard value for new machine Service limit value
Measurement
Specification
Work equipment
Pump merge Measurement /divide conditions (ReferRelieving ence) method
Work equipment pump Work equipment pump outlet pressure (F) outlet pressure (R) 26.5 1.4 26.5 1.4 26.5 1.4 26.5 1.4 {270 14} {270 14} {270 14} {270 14} 22.1 1.4 22.1 1.4 22.1 1.4 22.1 1.4 {225 14} {225 14} {225 14} {225 14} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4 {280 14} {280 14} {280 14} {280 14} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4 {280 14} {280 14} {280 14} {280 14} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4 {280 14} {280 14} {280 14} {280 14} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4 {280 14} {280 14} {280 14} {280 14} 24.5 1.4 24.5 1.4 24.5 1.4 24.5 1.4 {250 14} {250 14} {250 14} {250 14} 23.0 1.4 23.0 1.4 23.0 1.4 23.0 1.4 {235 14} {235 14} {235 14} {235 14} 24.0 1.4 24.0 1.4 27.4 1.4 27.4 1.4 {245 14} {245 14} {280 14} {280 14} 21.1 1.4 21.1 1.4 27.4 1.4 27.4 1.4 {215 14} {215 14} {280 14} {280 14} 27.4 1.4 27.4 1.4 24.0 1.4 24.0 1.4 {280 14} {280 14} {245 14} {245 14} 27.4 1.4 27.4 1.4 21.1 1.4 21.1 1.4 {280 14} {280 14} {215 14} {215 14} 24.5 1.4 24.5 1.4 24.5 1.4 24.5 1.4 {250 14} {250 14} {250 14} {250 14} 21.1 1.4 21.1 1.4 21.1 1.4 21.1 1.4 {215 14} {215 14} {215 14} {215 14} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4 {280 14} {280 14} {280 14} {280 14} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4 {280 14} {280 14} {280 14} {280 14} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4 {280 14} {280 14} {280 14} {280 14} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4 {280 14} {280 14} {280 14} {280 14} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4 {280 14} {280 14} {280 14} {280 14} 27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4 {280 14} {280 14} {280 14} {280 14}
Raise relief Blade Lower relief
High Merge Low High Merge Low High Merge Low High Merge Low High
Blade single tilt
Left steering tilt Right steering tilt
Work equipment oil pressure
Relief pressure
Left dual tilt Dual tilt
Blade dual tilt
Divide Hydraulic oil temperature: Low MPa 45 55C Relieve {kg/cm2} only circuit High Right dual to be meaDivide sured tilt Low High Divide Low High Divide Low High Merge Low High Merge Low
Pitch dump
Pitch back
Raise relief Ripper Lower relief
D475A, D475ASD-5E0
SEN01816-01
Measurement
Specification
Work equipment
High Tilt in Dual tilt Ripper High Tilt back Merge Low High Merge Low High Merge Low High Hydraulic Merge oil temperature: Low MPa 45 55C Relieve {kg/cm2} only circuit High to be meaMerge sured Low High Merge Low High Merge Low High Tilt in Merge Low High Tilt back Merge Low Merge Low
Raise relief Blade Lower relief Work equipment oil pressure
Relief pressure
Blade single tilt Single tilt
Left steering tilt Right steering tilt
Raise relief
Lower relief Ripper
D475A, D475ASD-5E0
SEN01816-01
Measurement
Specification
Work equipment
Raise relief Blade Lower relief
High Merge Low High Merge Low High Low High Merge Low High
Left steerMerge ing tilt Blade single tilt
Right steering tilt
Relief pressure
Pitch dump Super Blade dual tilt Pitch back
Divide Hydraulic oil temperature: Low MPa 45 55C Relieve {kg/cm2} only circuit High to be meaDivide sured Low High Merge Low High Merge Low High
Raise relief
Lower relief Ripper Tilt in
Merge Low High
Tilt back
Merge Low
D475A, D475ASD-5E0
SEN01816-01
Machine model Item Measurement Category Specification Work equipment Relieving method Measurement conditions Unit
D475A, D475ASD-5E0
Standard value for new machine
Service limit value
Raise relief Blade Lower relief Left steering tilt Right steering tilt Left dual tilt Dual tilt Blade dual tilt Right dual tilt Pitch dump Pitch back Work equipment oil pressure LS differential pressure Raise relief Lower relief Tilt in Tilt back Raise relief Blade Lower relief Left steering tilt Right steering tilt Raise relief Lower relief Tilt in Tilt back Hydraulic oil temperature: Within operating range Run engine at high idle
2.45 0.2 {25 2} 2.45 0.2 {25 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 2.45 0.2 {25 2} MPa {kg/cm2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2}
2.45 0.2 {25 2} 2.45 0.2 {25 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2}
Blade single tilt
Ripper
Single tilt
Blade single tilt
Ripper
D475A, D475ASD-5E0
SEN01816-01
Machine model Item Measurement Category Specification Work equipment Relieving method Measurement conditions Unit
D475A, D475ASD-5E0
Standard value for new machine
Service limit value
Raise relief Blade Lower relief Left steering tilt Right steering tilt Pitch dump Pitch back Raise relief Lower relief Tilt in Tilt back Hydraulic oil temperature: 45 55 C Set all work equipment control levers in neutral Hydraulic oil temperature: Within operating range Set all work equipment control levers in neutral Engine at high idle Hydraulic oil temperature: Within operating range Set lever at stroke end Engine at high idle Hydraulic oil temperature: Within operating range Run engine at high idle Measure leakage for 1 minute while relieving cylinder MPa {kg/cm2} Hydraulic oil temperature: Within operating range Run engine at high idle
2.45 0.2 {25 2} 2.45 0.2 {25 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.94 4.9 {30 50}
2.45 0.2 {25 2} 2.45 0.2 {25 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 1.76 0.2 {18 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.45 0.2 {25 2} 2.94 4.9 {30 50}
LS differential pressure
Blade single tilt
Super
Blade dual tilt
Ripper
Unload pressure
Work equipment control oil pressure
3.92 4.51 {40 46}
Min. 3.72 {Min. 38}
PPC valve output pressure Work equipment Blade tilt cylinder Leakage Blade pitch cylinder from Ripper shift cylinder cylinder Ripper tilt cylinder
3.92 4.51 {40 46} 5 cc/min 5 5 5
Min. 3.72 {Min. 38} 20 20 20 20
10
D475A, D475ASD-5E0
SEN01816-01
Machine model Category Measurement item Measurement conditions Measuring posture Raise Blade lift (Single tiltdozer specification) (Dual tiltdozer specification) High idle sec Hydraulic oil temperature: Within operating range Apply no load on blade. Between blade on ground and raising stroke end Measuring posture Raise Blade lift (Superdozer specification) Hydraulic oil temperature: Within operating range Apply no load on blade. Between blade on ground and raising stroke end Measuring posture Left tilt Blade tilt (Single tiltdozer specification) Hydraulic oil temperature: Within operating range Apply no load on blade. Between left tilt end and right tilt end Measuring posture Left tilt Blade tilt (Dual tiltdozer specification) Hydraulic oil temperature: Within operating range Apply no load on blade. Between left tilt end and right tilt end Right tilt High idle High idle sec Low idle Right tilt High idle Low idle High idle sec Low idle Lower High idle Low idle High idle sec Low idle Low idle Lower High idle Low idle
D475A, D475ASD-5E0 Standard Service limit Unit value for new value machine Low idle 14 3.5 Max. 20.0
5.0 0.5
Max. 6.0
1.8 0.3
Max. 2.5
1.8 0.3
Max. 2.5
15.8 3.5
Max. 22.0
5.1 0.5
Max. 7.0
1.7 0.3
Max. 3.0
Work equipment
Blade speed
1.7 0.3
Max. 2.2
4.0 1.5
Max. 6.5
3.3 0.5
Max. 6.0
4.4 1.5
Max. 6.0
3.6 0.5
Max. 6.0
5.5 1.5
Max. 8.0
3.1 0.5
Max. 5.0
5.5 1.5
Max. 8.0
3.1 0.5
Max. 5.0
D475A, D475ASD-5E0
11
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Machine model Category Measurement item Measurement conditions Measuring posture Left tilt Blade tilt (Superdozer specification) Hydraulic oil temperature: Within operating range Apply no load on blade. Between left tilt end and right tilt end Measuring posture Pitch dump Blade speed Blade pitch (Dual tiltdozer specification) Hydraulic oil temperature: Within operating range Apply no load on blade. Between pitch back end and pitch dump end Measuring posture Pitch dump Blade pitch (Superdozer specification) Hydraulic oil temperature: Within operating range Apply no load on blade. Between pitch back end and pitch dump end Measuring posture Raise Ripper speed High idle Ripper lift Hydraulic oil temperature: Within operating range Lower Select lowest shank hole. Between ripper on ground and raising stroke end Low idle High idle sec Pitch back Pitch back Right tilt High idle Low idle High idle sec Low idle High idle Low idle High idle sec Low idle High idle Low idle High idle sec Low idle
D475A, D475ASD-5E0 Standard Service limit Unit value for new value machine Low idle 4.0 1.5 Max. 6.0
3.3
+0.5 -0.8
Max. 6.0
4.4 1.5
Max. 6.5
3.6
+0.5 -0.8
Max. 6.0
9.6 1.5
13.0
4.4 0.5
6.0
6.6 1.6
Max. 10.0
Work equipment
4.1 0.5
Max. 6.0
23.0 3.0
Max. 30
7.8 1.0
Max. 10
16.0 2.0
Max. 23.0
7.2 1.0
Max. 9.5
7.7 1.0
Max. 12.0
3.0 0.5
Max. 4.0
3.0 0.5
Max. 5.0
3.0 0.5
Max. 4.0
12
D475A, D475ASD-5E0
SEN01816-01
Machine model Category Measurement item Measurement conditions Measuring posture Tilt in Ripper speed High idle Ripper tilt Hydraulic oil temperature: Within operating range Select lowest shank hole. Between forward tilt end and rear tilt end Blade (Single tiltdozer specification) (Dual tiltdozer specification) Time lag Blade (Superdozer specification) Low idle Tilt out High idle Low idle High idle Low idle High idle High idle sec
D475A, D475ASD-5E0 Standard Service limit Unit value for new value machine Low idle 15.6 1.5 Max. 22.0
5.2 0.5
Max. 7.0
9.1 1.5
Max. 14.0
3.3 0.5 Max. 2.5 sec Max. 2.7
Max. 4.5 3.2 3.5
Hydraulic oil temperature: Within operating range Lower blade from max. rising position and measure time after blade comes in contact with ground until idler is lifted. Hydraulic oil temperature: Within operating range Lower blade from max. rising position and measure time after blade comes in contact with ground until idler is lifted. Hydraulic oil temperature: Within operating range Lower ripper from max. rising position and measure time after ripper comes in contact with ground until sprocket is lifted. Measuring posture
Work equipment
Ripper
sec
Max. 1.0
1.5
Hydraulic drift of lifted blade Hydraulic oil temperature: Within operating range Stop engine. Raise blade to max. rising position and then measure reduction of blade bottom height (h) in 15 minutes. Measuring posture
mm/ Max. 150/15 Max. 300/15 min
Hydraulic drift Hydraulic drift of machine tilted by blade
mm/ min Hydraulic oil temperature: Within operating range Stop engine. Tilt blade to maximum to push up shoe on either side and then measure reduction of shoe height (h) in 5 minutes.
Max. 50/5
Max. 100/5
D475A, D475ASD-5E0
13
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Machine model Category Measurement item Measurement conditions Measuring posture
D475A, D475ASD-5E0 Standard Service limit Unit value for new value machine
Hydraulic drift of machine lifted by blade Hydraulic oil temperature: Within operating range Stop engine. Push up front part of machine with blade and then measure reduction of idler center height (h) in 5 minutes. Measuring posture Work equipment
mm/ min
Max. 50/5
Max. 100/5
Hydraulic drift
Hydraulic drift of lifted ripper Hydraulic oil temperature: Within operating range Stop engine. Raise ripper to max. rising position and then measure reduction of shank bottom height (h) in 15 minutes. Measuring posture
mm/ Max. 80/15 min
Max. 160/15
Hydraulic drift of machine lifted by ripper Hydraulic oil temperature: Within operating range Stop engine. Push up rear part of machine with ripper and then measure reduction of sprocket center height (h) in 5 minutes.
mm/ min
Max. 30/5
Max. 60/5
14
D475A, D475ASD-5E0
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D475A, D475ASD-5E0
15
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16
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
30 Testing and adjusting

Testing and adjusting, Part 1
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
D475A, D475ASD-5E0
SEN01817-01
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
D475A, D475ASD-5E0
SEN01817-01
Tools for testing, adjusting, and troubleshooting

Testing or adjusting item Air boost pressure (boost pressure) Coolant temperature, oil temperature and exhaust temperature Exhaust gas color C Part No. Part name Quantity Symbol Remarks
799-201-2202 Boost gauge kit 790-401-2220 Hose 799-101-1502 Digital temperature gauge 1 2 799-201-9001 Handy smoke checker Commercial item Commercial item 1 Smoke meter Thickness gauge
1 101 200 kPa {760 1,500 mmHg} 1 1 99.9 1,299C 1 1 1 1 1 1 1 0 5 kPa {0 500 mmH2O} 1 Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} 0 7 MPa {0 70 kg/cm2} KIT Part No.: 795-502-1205 Bosch index: 0 9
Valve clearance
795-502-1590 Compression gauge 795-471-1310 Adapter 6217-71-6150 Gasket 799-201-1504 Blow-by checker 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester
Compression pressure
2 3 F
Blow-by pressure
Engine oil pressure
1 Pressure gauge: 60 MPa {600 kg/cm2} 1 Pressure gauge: 1.0 MPa {10 kg/cm2} 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 *As common as G1 *As common as G1
2 1 Testing fuel pressure H 2 3 4 1 2 3 Testing fuel return and leak amount J 4 5 6 7 1 Power train oil pressure K 2 3
799-401-2320 Hydraulic tester 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic tester 795-471-1450 Adapter 07005-00812 Gasket 6151-51-8490 Spacer 6206-71-1770 Joint Commercial item Commercial item Commercial item Commercial item Hose Hose Measuring cylinder Stopwatch
1 *As common as G2
07376-70315 Plug 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic tester 799-101-5220 Nipple (10 x 1.25 mm) 07002-11023 O-ring
1 *As common as G2
D475A, D475ASD-5E0
SEN01817-01
Testing or adjusting item
Part No.
Part name
Quantity
Symbol
Remarks
1 Emergency escape method when power train has trouble L 2 3 1 2 M 3 4 5 Testing control circuit basic pressure N 1 1 P 2 3 Measuring ripper pin puller solenoid valve output pressure Measuring internal leakage of work equipment cylinder Measuring fan motor speed Measuring fan pump circuit pressure Adjusting blade tilt angle control Operating effort Stroke and hydraulic drift Work equipment speed Voltage and resistance Q 1 2 R S T 1 U V W X Y 1 Initializing VHMS controller Z 2 3
19M-06-32820 Switch assembly 17M-06-41530 Wiring harness 799-101-5220 Nipple (10 x 1.25 mm) 07002-11023 O-ring 790-190-1601 Pump assembly 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 566-35-43561 Nipple (18 x 1.5 mm) 07002-11823 O-ring 799-101-5160 Nipple (R1/8) 799-101-5220 Nipple (10 x 1.25 mm) 07002-11023 O-ring 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-3100 Adapter (size 02) 799-401-3200 Adapter (size 03) 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-3200 Adapter (size 03) Commercial item Measuring cylinder
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 *As common as G1 *As common as G1 *As common as G1 *As common as G1
Testing and adjusting work equipment and HSS oil pressure
799-401-2701 Differential pressure gauge 1
Measuring PPC valve output pressure
1 *As common as P3 1 1 1 1 1 1 1 1 1 1 1 1 1 OS: Windows 98/2000/Me/XP Terminal "RS232C" is with it *As common as G1
799-205-1100 Tachometer KIT 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-402-3800 Angle gauge 79A-264-0021 0 294 N {0 30 kg} 79A-264-0091 0 490 N {0 50 kg} Commercial item Commercial item Commercial item Scale Stopwatch Tester
799-608-3211 Diskette 799-608-3220 Harness Commercial item Notebook type personal computer
D475A, D475ASD-5E0
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Testing or adjusting item
Part No.
Part name
Quantity
Symbol
Remarks
799-601-7400 T-adapter assembly 799-601-7500 T-adapter assembly 799-601-9100 T-adapter assembly 799-601-9200 T-adapter assembly 799-601-9300 T-adapter assembly 799-601-7310 Adapter 799-601-7320 Adapter 799-601-7360 Adapter 799-601-3450 Adapter 799-601-4101 T-adapter assembly 799-601-4130 T-adapter 799-601-4150 T-adapter Diagnosis of sensor and harness 799-601-4211 T-adapter 799-601-4220 T-adapter 799-601-4240 Socket 799-601-4250 Socket 799-601-4260 T-adapter 799-601-4330 Socket 799-601-4350 T-adapter box 799-601-9020 T-adapter 799-601-9420 T-adapter 799-601-9430 Socket 795-799-5530 Socket 795-799-5540 Socket 799-601-9310 Plate 799-601-9320 T-adapter box
1 For AMP040 1 For AMP070 1 For HD30 1 For DT connector 1 For DRC26-24 (40 pins) 1 For SWP 12 pins 1 For SWP 16 pins 1 For relay (5 pins) 1 For VHMS download harness 1 Connector for engine 1 Ne sensor 1 Oil pressure sensor 1 Controller (50-pole) 1 Controller (60-pole) 1 Ambient pressure sensor 1 Boost pressure sensor 1 Controller (4-pole) 1 G (Bkup) sensor 1 60-pole 1 Injector 1 Common rail pressure 1 Supply pump PCV 1 Coolant, fuel and oil temperature sensor
1 Boost and intake temperature sensor 1 For 24-pole 1 For 24-pole
D475A, D475ASD-5E0
SEN01817-01
Measuring engine speed

a
3.
Measure the engine speed under the following condition. q Coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range q Power train oil temperature: Within operating range Preparatory work Turn the starting switch ON and set the monitor panel in the Monitoring mode to prepare for 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.
1.
Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle position. 2) Set the PCCS lever and work equipment control lever in neutral and measure the engine speed. a The high idle speed measured in the Monitoring mode or in the Pm Clinic auxiliary mode is the auto-deceleration speed. a When measuring the high idle speed of the engine, use the Adjustment mode. Adjustment code: 0007 (Engine decelerator cut mode)
4.
Measuring decelerator pedal speed 1) Start the engine and set the fuel control 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 1) Start the engine and set the fuel control dial in the low idle position. 2) Set the PCCS lever and work equipment control lever in neutral and measure the engine speed.
D475A, D475ASD-5E0
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5.
Measuring torque converter stall speed a Use Adjustment mode to measure. q Adjustment mode: 0530 (Stall speed check mode) k This machine is equipped with the cooling fan speed control function to protect the radiator when the engine is not fully warmed up. Since that function does not work while this mode is used, warm up the engine fully before using this mode. 1) Start the engine and set the fuel control dial in the low idle position. 2) With the brake pedal depressed securely and the parking brake lever in the free position, set the PCCS lever in the forward and 3rd gear speed position. a Before going to the next step, check that the upper display unit of the monitor panel is set in the normal display state and it displays [F3]. a Keep the steering unit in neutral. 3) Press the decelerator pedal and set the fuel control dial in the high idle position. 4) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 5) Just after the power train oil temperature gauge reaches position (a) of the green range, return the direction of the PCCS lever into neutral.
7)
Perform steps 2) 4) again 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.
6.
Measuring torque converter stall + work equipment relief speed (full stall speed) a Use Adjustment mode to measure. q Adjustment mode: 0530 (Stall speed check mode) 1) Start the engine and set the fuel control dial in the low idle position. 2) With the brake pedal depressed securely and the parking brake lever in the free position, set the PCCS lever in the forward and 3rd gear speed position. a Before going to the next step, check that the upper display unit of the monitor panel is set in the normal display state and it displays [F3]. a Keep the steering unit in neutral. 3) Press the decelerator pedal and set the fuel control dial in the high idle position. 4) Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. k Keep pressing the brake pedal 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
SEN01817-01
7) 8)
Repeat above steps 2) 6) 3 times. Perform steps 2) 4) and also operate ripper 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, measure the high idle speed of the engine in the Adjustment mode).
D475A, D475ASD-5E0
SEN01817-01
Measuring intake air pressure (boost pressure)

a
2.
Measuring instruments for intake air pressure (boost pressure)

Part No. 799-201-2202 790-401-2220 Hose Part name Boost gauge kit
Symbol A
k
Remove air intake connector boost pressure pickup plugs (2) and (3) (R1/8). a If nipple [1] is installed as standard to the intake air pressure (boost pressure) measuring port, install gauge [2] without installing anything to the port. q Plug (2): For left bank q Plug (3): For right bank
When installing and removing the measuring instrument, take care not to touch a hot part of the engine. Measure the intake air pressure (boost pressure) under the following condition. q Coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range q Power train oil temperature: Within operating range Open the left and right side covers of the engine.
1.
3.
Install nipple [1] of boost gauge kit A and connect gauge [2]. q Left bank
D475A, D475ASD-5E0
SEN01817-01
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 halfway 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. Measure the intake air pressure (boost pressure) 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 converter.
5.
6.
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
10
D475A, D475ASD-5E0
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Measuring exhaust temperature 1

a Measuring instrument for exhaust temperature
Symbol B Part No. 799-101-1502 Name Digital thermometer
2)
Remove exhaust temperature measuring plugs. q Plug (2): For left bank front q Plug (3): For left bank rear q Plug (4): For right bank front q Plug (5): For right bank rear
Measure the exhaust temperature under the following condition. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range Check the exhaust temperature with the monitor 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 q Monitoring code (Left bank front): 42600 q Monitoring code (Left bank rear): 42606 q Unit: C a For the operating method, see Special functions of monitor panel. 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.
1.
3.
Install sensor [1] to the measuring plugs and connect them to digital thermometer B. a Clamp the wiring harness of the digital thermometer so that it will not touch a hot part during measurement. a Example of the right bank rear
2.
D475A, D475ASD-5E0
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4.
Procedure for measuring maximum exhaust temperature for troubleshooting. Operate the machine and measure the maximum exhaust temperature. a Use the PEAK mode of the digital thermometer. a The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, correct it by the following calculation. q Corrected value [C] = Measured value + 2 x (20 Outside air temperature)
2)
3)
k
Stop relieving the ripper or pitch back, and lower the exhaust temperature by only stalling the torque converter (Condition (b) in the figure). a If the temperature does not lower but rises, set the temperature to high in step 1). After the temperature lowers and is stabilized, measure it (Condition (c) in the figure). Just after the power train oil temperature gauge reads the red range, return the direction of the PCCS lever into neutral and lower the power train oil temperature.
5.
Procedure for measuring exhaust temperature periodically for preventive maintenance a If the torque converter is stalled, the torque converter oil temperature is overheated before the exhaust temperature is stabilized. Measure according to the following procedure. 1) Completely stall the torque converter to raise the exhaust temperature to about 650C according to the following procedure (Condition (a) in the figure). i) Start the engine and set the fuel control dial to the low 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.
6.
After finishing measurement, remove the measuring instrument and return the removed parts.
12
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Measuring exhaust gas color

a Measuring instrument for exhaust gas color
Part No. 799-201-9001 Commercial item Part name Handy smoke checker Smoke meter Symbol 1 C
k
2.
Measuring with smoke meter C2 1) Insert probe [1] of smoke meter C2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip.
When installing and removing the measuring instrument, take care not to touch a hot part. 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. Measure the exhaust gas color under the following condition. q Coolant temperature: Within operating range Measuring with handy smoke checker C1 1) Stock a sheet of filter paper to smoke checker C1. 2) Insert the exhaust gas intake pipe in the exhaust pipe. 3) Start the engine. 4) As increasing the engine speed rapidly or running it at high idle, operate the handle of smoke checker C1 so that the filter paper will absorb the exhaust gas.
2)
1.
3)
4)
5)
Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter C2. a Restrict the supplied air pressure below 1.5 MPa {15 kg/cm2}. Connect the power cable to a receptacle of AC100V power source. a Before connecting the cable, check that the power switch of the smoke meter is turned off. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. Turn on the power switch of smoke meter C2.
5) 6)
Remove the filter paper and compare it with the attached scale to make a judgement. After finishing measurement, remove the measuring instrument and reinstall the removed parts.
6) 7)
Start the engine. As increasing the engine speed rapidly or running it at high idle, press the accelerator pedal of smoke meter C2 and collect the exhaust gas with the filter paper.
D475A, D475ASD-5E0
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8)
9)
Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. After finishing measurement, remove the measuring instrument and reinstall the removed parts.
14
D475A, D475ASD-5E0
30 Testing and adjusting a
SEN01817-01
Adjusting valve clearance

a Adjusting tool for valve clearance
Part No. Commercially available Part name Thickness gauge
At near the compression top dead center of the RH No. 1 cylinder, the intake valve of RH No. 6 cylinder moves.(opens).
Symbol D
1.
Remove cylinder head cover. a For details, see Removal and installation of cylinder head assembly in Disassembly and assembly. 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 RH No. 6 cylinder.
2.
3.
Loosen locknut (6) of RH No. 1 cylinder adjust screw (5). Insert a clearance gauge D of specified 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
Crank the engine using the barring tool (B) mounted to the front right-hand side of the flywheel housing.
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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 After finishing adjustment, return the removed parts. 3 Cylinder head cover mounting bolt: 14.7 34.3 Nm {1.5 3.5 kgm}
6.
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Testing compression pressure

a Testing tools for compression pressure
Part No. 795-502-1590 795-471-1310 6261-71-6150 Adapter Gasket Part name Compression gauge 1 E
k
4.
Symbol
When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure after the engine is warmed up. (Engine oil temperature: 40 60C). 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 Disassembly and assembly. Bring the cylinder to be tested to the compression top dead center and remove rocker arm assembly (2). a See Adjusting valve clearance. Disconnect fuel high-pressure tube (3) and injector wiring harness and remove injector (4). a Disconnect the terminal of the injector wiring harness on the injector side and the 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).
Install adapter E2 to the mounting hole on the injector and compression gauge E1. a Fit the gasket to the injector end without fail a Fix the adapter with the injector holder. 3 Holder mounting bolt: 58.8 73.5 Nm {6.0 7.5 kgm} a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so that air will not leak easily. Install rocker arm assembly (2) and adjust the valve clearance. 3 Rocker arm assembly mounting bolt: 93 103 Nm {9.5 10.5 kgm} a See Adjusting valve clearance.
5.
1.
2.
3.
6.
Disconnect engine controller connectors (1) (PW R) and (2) (PW L).
If these connectors are not disconnected, the engine may start while you are measuring, and that is dangerous. Accordingly, be sure to disconnect these connectors. 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.
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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 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) temporarily. 2 Spherical part of washer: Engine oil 3) Tighten sleeve nut (15) of the fuel highpressure tube temporarily. 4) Tighten bolt (13) permanently. 3 Bolt: 58.8 73.5 Nm {6.0 7.5 kgm} 5) Tighten sleeve nut (15) permanently. 3 Sleeve nut: 39.2 49.0 Nm {4 5 kgm}
8.
Tighten the clamp and spacer with the bolt. 5) Install rocker arm assembly. 3 Rocker arm assembly mounting bolt: 93 103 Nm {9.5 10.5 kgm} a Adjust the valve clearance. For details, see Adjusting valve clearance. 6) Install head cover. 3 Cylinder head cover mounting bolt: 29.4 34.3 Nm {3.0 3.5 kgm}
4)
Install the injector wiring harness according 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
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Measuring blow-by pressure

a Measuring instrument for blow-by pressure
Symbol F Part No. 799-201-1504 Name Blow-by checker
Measure the blow-by pressure under the following condition. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range Check the blow-by pressure with the monitor panel since the machine of standard specification is equipped with crankcase pressure sensors for the VHMS. q Monitoring code: 42800 (Blow-by pressure) q Unit: kPa a For the operating method, see Special functions of monitor panel (EMMS). a The monitor indicates the absolute value. If the VHMS is not installed, measure by the following method. 1) Remove right and left covers (2) of engine undercover (1).
3)
1.
Install nozzle [2] of blow-by checker F and hose [3] to blow-by hose (4) of the left bank and connect blow-by checker F.
2.
4)
2)
Install nozzle [1] of blow-by checker F to blow-by hose (3) of the right bank and block the hose joint. a Connect a short hose and tie the outlet. a Either of the right and left blow-by hoses may be blocked.
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 measured 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. In this case, the blow-by value will be about 80% of the value at rated output.
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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 consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil.
5)
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Measuring engine oil pressure

a
3) 4)
Measuring instruments for engine oil pressure

Symbol G 1 2 Part No. Name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic tester
Install nipple [1] and joint (M14 1.5 mm) of hydraulic tester G1 and connect them to hydraulic tester G2. Run the engine at low idle and high idle and measure the engine oil pressure at each speed.
Measure the engine oil pressure under the following condition. q Engine coolant temperature: Within operating range Check the engine oil pressure with the monitor panel since the machine is equipped with engine oil pressure sensors for the VHMS. q Monitoring code: 37200 (Engine oil pressure) q Unit: MPa a For the operating method, see Special functions of monitor panel (EMMS). 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 temperature sensor (1) on the LH side of the cylinder block. Keep the removed oil temperature sensor and the wiring harness connector connected to each other. a Dont remove the oil pressure sensor from the block because the engine controller detects abnormal low pressure error of the oil pressure sensor.
1.
5)
2.
After finishing measurement, remove the measuring instruments and return the removed parts.
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Handling of fuel system devices 1

a Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
Releasing residual pressure from fuel system 1

a Pressure is generated in the low pressure circuit and high pressure circuit of the fuel system while the engine is running. Low pressure circuit: Feed pump Fuel main filter Fuel supply pump High-pressure circuit: Fuel supply pump Common rail Fuel injector The pressure in both low pressure circuit and high pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed or installed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system, or removing or installing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
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Testing fuel pressure

a Measuring tools for fuel pressure
Part No. 799-101-5002 790-261-1204 799-401-2320 795-471-1450 07005-00812 Part name Hydraulic tester Digital hydraulic tester Hydraulic tester Adapter Gasket Symbol 1 H 2 3 4
4.
Start the engine and inspect the fuel pressure with the engine running at high idle or at the equivalent of rated output speed (stall load). a If the fuel pressure is in the following range, it is normal.
Engine speed At high idle or at the equivalent of rated output speed Fuel pressure 0.15 0.3 MPa {1.5 3 kg/cm2}
a
k
Measure the fuel pressure only for the low pressure circuit between the feed pump fuel filter fuel supply pump. Since the pressure in the high pressure circuit from the fuel supply pump through the common rail to the injector is very high, it cannot be measured. Open the left upper side cover of the engine and remove fuel pressure inspection plug (1) (M8 X 1.25) of fuel filter head.
1.
5.
Since the fuel circuits of the right and left banks after the priming pump are independent from each other, check them separately. After finishing testing, remove the testing tools and return the removed parts.
6.
2. 3.
Install adapter H3 and gasket H4 to the plug hole. Install nipple [1] of hydraulic tester H1, and connect to hydraulic tester H2.
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Handling of reduced cylinder mode operation

a
Handling of no injection cranking operation 1

a No injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. Before the engine is started after it or the engine unit has been stored for a long period, the no injection cranking is performed to lubricate the engine parts and protect them from seizure. Use the no-injection cranking function for only the above purposes while the engine is mounted on the machine. To implement no injection cranking operation, see Special functions of monitor panel (EMMS).
1. 2.
3.
Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). When engine speed and output do not change from the normal operation (all cylinder operating mode) even though the fuel injection has been cut out for any cylinder, the cylinder is suspected to be defective. The following problems can be considered: q Leaking of cylinder head gasket q Defective injection of injector q Defective piston, piston ring or cylinder liner q Defective valve mechanism (valve system) q Defective electrical system 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 easily. a To implement reduced cylinder mode operation, see Special functions of monitor panel (EMMS). a Use the reduced cylinder mode for only the purpose of troubleshooting.
a a
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Testing fuel return and leak amount
Testing tools for fuel return and leak amount

Part No. 6151-51-8490 6206-71-1770 Commercially available Commercially available Commercially available Commercially available 07376-70315 Spacer Joint Hose Hose Measuring cylinder Stopwatch Plug Part name
1.
Symbol 1 2 3 J 4 5 6 7
Preparation work (example for left bank) 1) Remove tube (3) between common rail (1) and supply pump (2). 2) Insert spacer J1 to supply pump (2) side and retighten it with the currently removed joint bolt. a Be sure to fit the gaskets to both ends of the spacer. 3) Connect the return piping to the fuel tank side again. a Be sure to fit the gaskets to both ends of the spacer.
Prepare an oil pan of about 20 l to receive the fuel flowing out during the test.
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4)
5)
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. 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) 3. After finishing testing, stop the engine.
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 checking the engine speed. 3) Start the engine and operate at the equivalent 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 limiter is in the following range, it is normal.
Engine speed (rpm) Equivalent to rated operation Leaking amount (cc/min) Max. 10
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2)
3)
Connect inspection hose J4 to joint (5) side. a Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. Adjust routing to prevent its slacking of inspection hose J4 and insert the hose end to the oil pan (container).
Rated output speed (rpm) 1,600 1,700 1,800 1,900 2,000
Return (Spill) limit (cc/min) 960 1,020 1,080 1,140 1,200
7) 4.
After finishing testing, stop the engine.
Work after finishing testing After finishing all testing, remove the testing tools and return the removed parts. Check the right bank similarly.
5.
4) 5) 6)
Referencing Measuring engine speed, set up the condition necessary for checking the engine speed. Start the engine and operate at the equivalent to rated operation (torque converter stall load). 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 injector is in the following range, it is normal.
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Bleeding air from fuel circuit
If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. 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).
Don't fill fuel directly after removing main filter (2).
1.
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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} 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} Bleed the air from the RH bank according to the above procedure. 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.
4.
5. 6.
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Testing fuel circuit for leakage

k
9.
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing and installing its components, check for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can inspect it easily for fuel leakage. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. Run the engine at a speed less than 1,000 rpm and stop it after its rotation is stabilized. 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. Run the engine at low idle. 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. Run the engine at high idle. 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. Run the engine at high idle to apply load to the engine. a Relieve by tilting the blade or raising the ripper.
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. a If any fuel leakage is not detected, inspection is completed.
1.
2. 3.
4. 5.
6. 7.
8.
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Testing and adjusting alternator belt tension 1

Testing Press the intermediate point of the belt between alternator pulley and drive pulley with a finger and measure deflection (a) of the belt. a Pressing force: Approx. 59 Nm {Approx. 6 kg} a Deflection (a): 20 2 mm
Adjusting a If the deflection is out of the standard range, adjust it according to the following procedure. 1. 2. 3. Loosen nut (B) and bolt (2) alternately. Adjust belt tension using nut (A). Tighten bolt (2) to have adjust bolt (1) and plate (3) made orthogonal to each other. 3 Bolt: 53.9 122.6 Nm {5.5 12.5 kgm} Tighten nut (B) to fix plate (3). a After adjusting, test the belt tension again.
4.
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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. 2. Loosen 3 mounting bolts and nuts (1) and locknuts (2) and (3). Turn locknut (3) and move air conditioner compressor (4) together with the bracket to adjust the tension of the belt. Tighten locknuts (2), (3) and 3 mounting bolts and nuts (1).
3.
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Adjusting fuel control dial and decelerator pedal
1.
Outline of fuel control system The following signals are inputted as rotation command signals to the engine controller. q Decelerator pedal potentiometer signal q 3rd throttle signal The engine controller controls the fuel control system of the engine (CRI system) according to the lowest engine speed signal among those input signals. q Adjust the deceleration slow speed by adjusting the decelerator pedal linkage.
q
[1] [2] [3] [4] [5] [6] [7]
Fuel control dial (2nd throttle signal) Engine controller Steering controller Decelerator pedal (1st throttle signal) Decelerator potentiometer Engine (CRI system) Machine control signal (3rd throttle signal) [8] Rod [9] Stopper bolt
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2.
Preparatory work 1) Start the engine, set the monitor panel in the Adjustment mode, and prepare to measure the engine speed. a For the operation method, see Special functions of monitor panel (EMMS). q Adjustment code: 0007 (Engine deceleration cut mode) a The engine speed is displayed by 1 rpm.
4.
Adjusting high idle speed Set the fuel control dial to the high idle position and check that the high idle speed is correct. q High idle speed: 2000 50 rpm a When engine speed is high: Lower the engine speed to below 1,900 rpm temporarily with stopper bolt (9) to eliminate the play of the decelerator pedal, and then adjust the engine speed to the high idle speed. a When engine speed is low: Adjust the engine speed to the high idle speed with stopper bolt (9). 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 displayed position. q The decelerator position can be checked while the engine is stopped. Check of final accelerator position a Measure the final accelerator position in the monitoring mode. q Monitoring mode: 31706 (Final accelerator 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 the PCCS lever in the F or R position, and check that the displayed position is 100%. (Finish the check in 5 above in advance.) If the displayed position is less than 100%, check the voltage signal of the fuel circuit for error. If this adjustment is not made perfectly, the engine control function etc. may not operate normally. Accordingly, be sure to check the displayed position. q The accelerator position can be checked while the engine is stopped.
5.
6.
3.
Adjusting decelerator pedal speed Set the fuel control dial at the high idle position, depress decelerator pedal (4) until it contacts the stopper, and check that the decelerator pedal speed is normal. q Decelerator pedal speed: 900 50 rpm a If the engine speed is not correct, adjust installation dimension (a) of rod (8). q Installation dimension (a): 283 mm q Installation dimension (b): 67.5 mm
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

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 Releasing residual pressure from work equipment cylinder ......................................................................... 44
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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
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Measuring power train oil pressure

a
Measuring instruments for power train oil pressure

Symbol 1 K 2 3 Part No. Name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic tester 799-101-5220 Nipple (10 x 1.25 mm) 07002-11023 O-ring
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. Measure the power train oil pressure under the following condition. q Power train oil temperature: Within operating range Centralized pressure pickup ports (1) (14) are installed inside the inspection cover on the right outside of the operators cab and transmission lubricating oil pressure pickup port (15) is installed to the top of the power train filter. Table of locations of centralized pressure pickup points for measuring oil pressure and gauges to use
Measured oil pressure T/C inlet pressure T/C stator clutch pressure T/C lockup clutch pressure T/M main relief pressure Gauge (MPa {kg/cm2}) 2.5 {25} 1.0 {10} 6 {60} 2.5 {25} 6 {60} 6 {60} 6 {60} 6 {60} 6 {60} 6 {60} 6 {60} 6 {60} 6 {60} 6 {60} 1.0 {10}
No. Stamp 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 IN SC LU TM
OUT T/C outlet pressure
FWD T/M F clutch pressure REV T/M R clutch pressure 1ST T/M 1st clutch pressure 2ND T/M 2nd clutch pressure 3RD T/M 3rd clutch pressure LB RB LC RC S/T left brake pressure S/T right brake pressure Left clutch pressure Right clutch pressure T/M lubricating pressure
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1.
Measuring torque converter inlet pressure (IN) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pick-up nipple (1). a Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}.
2.
Measuring torque converter outlet pressure (OUT) 1) Connect hydraulic tester K2 to oil pressure pick-up nipple (2). a Use an oil pressure gauge of 1.0 MPa {10 kg/cm2}.
2) 2) 3) Start the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle. 3)
Start the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle.
4)
4)
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3.
Measuring torque converter stator clutch pressure (SC) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pick-up nipple (3). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
4.
Measuring torque converter lock-up clutch pressure (LU) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pick-up nipple (4). a Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}.
2) 3)
Run the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle.
2)
Start the engine and set the monitor panel in the Adjustment mode and disengage both steering clutches. a For the operating method, see Special functions of monitor panel (EMMS). a Adjustment code: 5535 (Disengagement of both steering clutches) a The transmission speed is displayed on the lower display section (Unit: 1 rpm).
4)
3) 4) 5) 6)
Turn on the lock-up mode switch. Set the PCCS lever in the FORWARD and 2nd gear speed position and make the transmission run idle. Raise the engine speed gradually and measure the oil pressure when the lock-up pilot lamp lights up. After finishing measurement, remove the measuring instrument and return the removed parts.
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5.
Measuring transmission main relief pressure (TM) a Check the transmission main relief pressure with the monitor panel since the machine is equipped with a transmission main relief pressure sensor for the VHMS. q Monitoring code: 43000 (Transmission main relief pressure) q Unit: MPa a For the operating method, see Special functions of monitor panel (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 hydraulic tester K1 to oil pressure pick-up nipple (5). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
6.
Measuring transmission F clutch pressure (FWD) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (6). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2)
3) 4) 2) 3) Run the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle.
5)
Run the engine, set the monitor panel in the Adjustment mode, and disengage both steering clutches. a For the operating method, see Special functions of monitor panel (EMMS). a Adjustment code: 5535 (Both steering clutches disengagement) a The lower message display displays the transmission speed (Unit: 1 rpm). Set the parking brake lever in the FREE position. Set the PCCS lever in the FORWARD 3rd gear speed position, and run the transmission idle. k Keep ready to press the brake pedal at any time for safety. Measure the oil pressure while the engine is running at low idle.
4)
6)
After finishing measurement, remove the measuring instrument and return the removed parts. D475A, D475ASD-5E0
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Measuring transmission R clutch pressure (R) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (7). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
8.
Measuring transmission 1st clutch pressure (1ST) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (8). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2)
3) 4)
5)
Run the engine, set the monitor panel in the Adjustment mode, and disengage both steering clutches. a For the operating method, see Special functions of monitor panel (EMMS). a Adjustment code: 5535 (Both steering clutches disengagement) a The lower message display displays the transmission speed (in rpm). Set the parking brake lever in the FREE position. Set the PCCS lever in the REVERSE 3rd gear speed position, and run the transmission idle. k Keep ready to press the brake pedal at any time for safety. Measure the oil pressure while the engine is running at low idle.
2)
3) 4)
5)
Run the engine, set the monitor panel in the Adjustment mode, and disengage both steering clutches. a For the operating method, see Special functions of monitor panel (EMMS). a Adjustment code: 5535 (Both steering clutches disengagement) a The lower message display displays the transmission speed (Unit: 1 rpm). Set the parking brake lever in the FREE position. Set the PCCS lever in the FORWARD 1st gear speed position, and run the transmission idle. k Keep ready to press the brake pedal at any time for safety. Measure the oil pressure while the engine is running at low idle.
6)
6)
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9.
Measuring transmission 2nd clutch pressure (2ND) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (9). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
10. Measuring transmission 3rd clutch pressure (3RD) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (10). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2)
3) 4)
5)
Run the engine, set the monitor panel in the Adjustment mode, and disengage both steering clutches. a For the operating method, see Special functions of monitor panel (EMMS). a Adjustment code: 5535 (Both steering clutches disengagement) a The lower message display displays the transmission speed (in rpm). Set the parking brake lever in the FREE position. Set the PCCS lever in the FORWARD 2nd gear speed position, and run the transmission idle. k Keep ready to press the brake pedal at any time for safety. Measure the oil pressure while the engine is running at low idle.
2)
3) 4)
5)
Run the engine, set the monitor panel in the Adjustment mode, and disengage both steering clutches. a For the operating method, see Special functions of monitor panel (EMMS). a Adjustment code: 5535 (Both steering clutches disengagement) a The message display displays the transmission speed (in rpm). Set the parking brake lever in the FREE position. Set the PCCS lever in the FORWARD 3rd gear speed position, and run the transmission idle. k Keep ready to press the brake pedal at any time for safety. Measure the oil pressure while the engine is running at low idle.
6)
6)
After finishing measurement, remove the measuring instrument and return the removed parts. D475A, D475ASD-5E0
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11. Measuring steering left brake pressure (LB) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (11). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
12. Measuring steering right brake pressure (RB) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (12). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2) 3)
Run the engine and set the parking brake lever in the FREE position. Measure the oil pressure while the engine is running at low idle and high idle. a Check that the oil pressure becomes 0 when the PCCS lever is set to the steering left stroke end. a Check that the oil pressure becomes 0 when the brake pedal is pressed fully or when the parking brake lever is set in the LOCK position.
2) 3)
Run the engine and set the parking brake lever in the FREE position. Measure the oil pressure while the engine is running at low idle and high idle. a Check that the oil pressure becomes 0 when the PCCS lever is set to the steering right stroke end. a Check that the oil pressure becomes 0 when the brake pedal is pressed fully or when the parking brake lever is set in the LOCK position.
4)
4)
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13. Measuring steering left clutch pressure (LC) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (13). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
14. Measuring steering right clutch pressure (RC) 1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure pickup nipple (14). a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2) 3)
4)
Run the engine and set the parking brake lever in the FREE position. Set the PCCS lever to the steering left stroke end. a Set the direction of the PCCS lever in neutral. Measure the oil pressure while the engine is running at low idle and high idle. a Check that the oil pressure becomes 0 when the steering of the PCCS lever is returned to the neutral position.
2) 3)
4)
Run the engine and set the parking brake lever in the FREE position. Set the PCCS lever to the steering right stroke end. a Set the direction of the PCCS lever in neutral. Measure the oil pressure while the engine is running at low idle and high idle. a Check that the oil pressure becomes 0 when the steering of the PCCS lever is returned to the neutral position.
5)
5)
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15. Measuring transmission lubricating oil pressure 1) Connect hydraulic tester K2 to oil pressure pickup nipple (15). a Use an oil pressure gauge of 1.0 MPa {10 kg/cm2}.
2)
Run the engine at high idle and measure the oil pressure.
3)
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Adjusting transmission speed sensor

a 1.
6.
The torque converter output speed sensor for the VHMS is not adjustable. Remove the fuel tank undercover, and then remove transmission output speed sensor (1) and the flange together. a Before adjusting transmission speed sensor (1), remove it temporarily and check that its tip is free from a steel chip and a flaw. a Before installing the transmission speed sensor, separate sensor (1), flange (2), and nut (3). 7.
Remove sensor (1) and flange (2) together and secure them with nut (3). a Take care that the adjustment angle of the sensor will not change. 3 Nut: 49.0 68.6 Nm {5 7 kgm} Install flange (2) and the sensor together to the steering case. 2 Flange and mounting bolt: Gasket sealant (LG-6) 3 Mounting bolt: 59 74 Nm {6 7.5 kgm}
8.
2. 3.
Install flange (2) to the steering case temporarily. Looking at bevel gear (4) through the hole of flange (2), check that the tooth tip is at the center of the hole. a If the tooth tip is not at the center, run the engine and move the machine forward or in reverse a little to set the tooth tip to the center. Tighten sensor (1) until its tip touches the tooth tip of gear (4). 2 Threads of sensor: Gasket sealant (LG-6) 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.
After finishing adjustment, set the monitor panel in the Monitoring display mode and check that the transmission speed is displayed normally. a For the operating method, see Special functions of monitor panel (EMMS). a Monitoring code: 31400 (Transmission speed)
4.
5.
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Simple method to test brake performance

a
Implement simple method to test brake performance under the following condition. q Power train oil temperature: Within operating range Set the blade and ripper in the travel posture on a level place.
1.
2. 3.
Run the engine and set the parking brake lever in free position. 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 position. 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. Press the decelerator pedal and set the fuel control dial in the high idle position. 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 finished.
4. 5.
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Adjusting brake pedal and parking brake lever

Brake pedal side
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Parking brake lever side
Adjusting brake pedal side 3. 1. Adjusting brake pedal stroke Adjust stroke (a) of brake pedal (1) by adjusting installed dimension (b) of stopper bolt (2). a Adjust the brake pedal stroke with the brake rod separated from the pedal. q Pedal stroke (a): 78 mm q Installed dimension (b) of stopper bolt: 36.5 mm Adjusting installed length of brake rod 1) Connect small rod (3), brake rod (4), and turnbuckle (6). q Screwing distance (c), (d), (e), and (f): 23 mm 2) Adjust the installed length of brake rod (4) with turnbuckle (6) so that the spool of brake valve (5) will be at the OFF position. a The threads on the brake pedal side of the turnbuckle locknut are inverted. 3 Locknut: 34.3 58.8 Nm {3.5 6.0 kgm} 4. Checking brake pedal stroke 1) Press brake pedal (1) and check that its stroke is as set in step 1 above. 2) Press brake pedal (1) and check that it is stopped by stopper (7). 3) Press brake pedal (1) and check that spool stroke (g) of brake valve (5) is in the normal range. q Spool stroke (g): 20 24 mm Checking brake oil pressure 1) Start the engine and set the monitor panel in the adjustment mode. a For the operating method in the adjustment mode, see Special functions of monitor panel (EMMS). a Adjustment code: 9996 (Mechanical brake release mode) 2) With the parking brake lever in the FREE position, press the brake pedal fully and check that the brake oil pressures on both sides become 0. a For the measuring points of the brake oil pressure, see Measuring power train oil pressure.
2.
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5.
Initializing brake potentiometer Turn the starting switch ON, set the monitor panel to the Adjustment mode, and initialize the brake potentiometer. a For the operating method in the adjustment mode, see Special functions of monitor panel (EMMS). a Adjustment code: 0005 (Initialization of brake potentiometer)
Adjusting parking brake lever side 6. Assembly and installation of lever assembly 1) Assemble lever assembly (7) and adjust the operation of limit switch (8). a Assemble the lever assembly with the parking cable disconnected from the lever. 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). 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 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 follows. a For the measuring point of the brake oil pressure, see Measuring power train oil pressure. q LOCK position: 0, FREE position: Specified pressure Checking limit switch 1) Turn the starting switch ON, set the monitor panel to the Monitoring display mode. a For the operating method in the monitoring display mode, see Special functions of monitor panel (EMMS). 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.
7.
8.
9.
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Adjusting PCCS lever console position
1. 2.
Set operators seat (1) in the forward (dozing) position. Under this condition, check that console (2) is in parallel with operators seat (1). a If the console is not parallel with the operators seat, adjust dimension (a) of rod (4). q Standard dimensions (a): 179 mm a The locknut on the rear side of the turnbuckle is a left-handed (reversing) screw.
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Emergency escape method when power train has trouble 1

a Devices used for emergency escape
Symbol 1 2 Part No. Part name
Since the female side of connector PL2 is kept disconnected, mask it with a vinyl sheet, etc. Put switch assembly [1] in the cab through the cab window.
19M-06-32820 Switch assembly L 7824-66-6430 Register 195-06-71220 Wiring harness 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 following procedure. If the engine cannot be started, see Emergency escape with brake releasing device. 1) Connect switch assembly [1] and register [2] to wiring harness [3] of emergency escape device L1. k Since register [2] controls the drive voltage of the solenoid, connect it to the wiring harness before connecting to the machine. k Set the all gear speed switches of switch assembly [1] in the OFF position and the direction switch in the P position to prevent the machine from starting suddenly.
3)
Disconnect neutral safety relay (NSF) in the fuse room and connect pins [3] and [5] of the connector on the wiring harness side. a Perform this operation only when the engine does not start electrically because of a trouble in the neutral safety relay or the transmission controller. k If the engine is started by this method, the neutral safety function does not work. Accordingly, before starting the engine, set the parking brake lever in the LOCK position and set the PCCS lever in the full neutral position. k Start the engine by this method only in an emergency. If the engine does not start in another case, be sure to carry out troubleshooting and repair the trouble.
2)
Open the left fender inspection cover and connect wiring harness [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. D475A, D475ASD-5E0
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4) 5)
Start the engine and set the parking brake lever in the FREE position. 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 travels in reverse, since the steering direction is reversed.
3) 4)
Remove the fuel tank undercover and disconnect supply hose (3) of the pin puller solenoid valve. 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) 6)
2)
Install volume pump [4] of pump assembly L2 to the outside of the operators cab.
Turn the starting switch ON and set the parking brake lever in the FREE position. 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} a Since an accumulator is installed in the circuit, the handle must be operated 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.
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7)
Tow the machine to a safe place. a The brake releasing oil pressure lowers gradually because of internal leakage and the brake is applied again about 1 minutes after. Accordingly, work quickly. a If the brake releasing pressure lowers to about 1.57 MPa {16 kg/cm 2 }, the brake is applied. In this case, operate the volume pump again to raise the brake releasing pressure to the initial pressure.
Inspecting wear of sprocket

a
Use the Full-scale dimensions drawing of sprocket profile in Sprocket in Structure, function, and maintenance standard as a gauge for measuring wear of the sprocket. Make a copy of the Full-scale dimensions drawing of sprocket profile on a transparent paper or sheet and apply it directly to the sprocket to see if the sprocket can be used.
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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 according to the following procedure. 1. 2. Remove cover (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} 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.
3.
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Testing and adjusting work equipment oil pressure

a
3)
Testing and adjusting instruments for work equipment oil pressure

Symbol 1 2 M 3 4 5 Part No. Name
Install nipples M2, M3, and connect them to oil pressure gauge [1] of hydraulic tester M1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 566-35-43561 Nipple (18 x 1.5 mm) 07002-11823 O-ring 799-101-5160 Nipple (R1/8) 799-401-2701 Differential pressure gauge 799-101-5220 Nipple (10 x 1.25 mm) 07002-11023 O-ring
Measuring k Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the LOCK position. a Measure the work equipment oil pressure under the following condition. q Hydraulic oil temperature: Within operating range 1. Measuring unload pressure 1) Remove the main valve cover above the right fender. 2) Remove work equipment oil pressure sensors (1) and (2) from the work equipment control valve. q (1): Front pump oil pressure sensor q (2): Rear pump oil pressure sensor
4)
Run the engine at high idle and set the blade lever and ripper lever in neutral, and measure the oil pressure.
5)
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2.
Measuring main relief pressure (Single tilt specification) a Measure the main relief pressure at the same point as the unload pressure. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}. a Since the oils from the 2 pumps are merged in the work equipment circuit of the single tilt specification, the oil pressure of the divided oil cannot be measured. 1) Start the engine and set the work equipment 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.
After finishing measurement, remove the measuring instrument and return the removed parts. The unload pressure, main relief pressure, blade tilt relief pressure, blade pitch relief pressure, and blade raise relief pressure can also be measured in the PM clinic auxiliary mode of the operator mode of the monitor panel. The pressures of both the front and rear pumps can be measured simultaneously in the Dual display monitoring mode of the service mode.
3)
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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. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}. a The oil pressure of the divided oil can be measured by measuring while pitching back the ripper. 1) Start the engine and set the work equipment lock lever in the FREE position. 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.
3)
The unload pressure, main relief pressure, blade tilt relief pressure, blade pitch relief pressure, and blade raise relief pressure can also be measured in the PM clinic auxiliary mode of the operator mode of the monitor panel. The pressures of both the front and rear pumps can be measured simultaneously in the Dual display monitoring mode of the service mode.
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4.
Measuring blade tilt relief pressure (Single tilt specification) a Measure the blade tilt relief pressure at the same point as the unload pressure. a Use an oil pressure gauge of 40 MPa {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. 1) Start the engine and set the work equipment lock lever in the FREE position. 2) Run the engine at high idle, tilt the blade to the left to relieve the cylinder at a stroke end, and measure the oil pressure.
3)
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5.
Measuring blade pitch relief pressure (Dual tilt specification and superdozer specification) a Measure the blade pitch dump relief pressure at the same point as the unload pressure. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}. a Measure the pressure of the divided oil from the 2 pumps during pitch dump operation. 1) Start the engine and set the work equipment lock lever in the FREE position. 2) Run the engine at high idle, pitch dump the blade to relieve the cylinder at a stroke end, and measure the oil pressure.
3)
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6.
Measuring blade raise relief pressure a Measure the blade raise relief pressure at the same point as the unload pressure. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}. 1) Block the return side hose of the blade lift cylinder. 2) Start the engine and set the work equipment lock lever in the FREE position.
3) 4)
Run the engine at high idle, raise the blade to relieve the cylinder at a stroke end, and measure the oil pressure. After finishing measurement, remove the measuring instrument and return the 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.
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7.
Measuring LS differential pressure a Measure the pump discharge pressure and LS pressure (actuator load pressure) at the same time and calculate the difference between them. 1) Remove work equipment oil pressure sensors (1) and (2) from the work equipment control valve.
When using differential pressure gauge: Connect the pump discharge pressure side to the high pressure side (back side) and connect the LS pressure side to the low pressure side (lower side). Since the differential pressure gauge needs a 12 V power source, connect it to a battery.
2)
Remove oil pressure pickup plugs (3) and (4) from the work equipment pump. q (1): Front pump discharge oil pressure sensor q (2): Rear pump discharge oil pressure sensor q (3): Front pump LS pressure plug q (4): Rear pump LS pressure plug
3)
4)
Install nipple M2, M3 to the work equipment control valve and connect it to oil pressure gauge [1] of hydraulic tester M1 or differential pressure gauge M4. (Pump discharge pressure) Install nipple M5 to the work equipment pump side and connect it to oil pressure gauge [1] of hydraulic tester M1 or differential pressure gauge M4. (LS pressure: Low pressure side)
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When using oil pressure gauge: Use the oil pressure gauge of 40 MPa {400 kg/cm2}. Since the differential pressure is about 3.9 MPa {40 kg/cm2} at maximum, measure it by installing the same gauge to the pickup plugs alternately.
8.
Measuring LS valve output pressure (servo piston inlet pressure) 1) Open the inspection cover of the cross bar front undercover. 2) Remove oil pressure pickup plugs (5) and (6) from the work equipment pump. 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 pressure gauge [1] of hydraulic tester M1. a Use the oil pressure gauge of 40 MPa {400 kg/cm2}.
5)
a 6)
Operate the blade lever and ripper lever and measure the pump discharge pressure and LS pressure (actuator load pressure) at the same time while each cylinder is moving. Calculation of LS differential pressure: LS differential pressure = Pump discharge pressure LS pressure After finishing measurement, remove the measuring instruments and return the removed parts.
4)
Start the engine and set the work equipment lock lever in the FREE position.
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5)
Run the engine at high idle, perform the operations shown in the following table, and measure the LS valve output pressure.
Operation LS valve output pressure (MPa {kg/cm2}) 0 {0}
Adjusting a The unload valve cannot be adjusted. 1. Adjusting main relief pressure a If the work equipment relief pressure is abnormal, adjust main relief valve (7) or (8) according to the following procedure. a When the main relief pressure of the dual tilt specification and superdozer specification is measured, if it is abnormal in either or both of the front pump circuit and rear p um p c i rc ui t, ad jus t the m ain r el ie f valve(s) of the abnormal circuit(s). a The main relief pressure of the divided oil 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
Specification
Common to all Raise blade specifications Dual tilt and superdozer Single tilt Raise ripper or pitch back to relieve Raise ripper or tilt to right to relieve
1.4 27.4 + 2.74 + 14 {280 28}
6)
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}
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a a
Loosen locknut (18) of the blade tilt relief valve and turn adjustment nut (17) to adjust the pressure. If the adjustment nut is q turned to the right, the pressure rises. q turned to the left, the pressure lowers. Quantity of adjustment per turn of adjustment 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, adjust blade tilt relief valve (15) or (16) according to the following procedure. a When the blade tilt relief pressure of the dual tilt specification and superdozer specification is measured, if it is abnormal in either or both of the front pump circuit and rear pump circuit, adjust the blade tilt relief valve(s) of the abnormal circuit(s). a The blade tilt relief pressure of the divided oil of the single tilt specification cannot be measured. Accordingly, measure the 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
3.
Adjusting blade lift relief pressure a If the blade lift relief pressure is abnormal, adjust blade lift relief valve (19) or (20) according to the following procedure. a The blade lift relief pressure of the divided oil cannot be measured. Accordingly, measure the blade lift relief pressure on either side or both sides. q (19): Blade lift relief valve for front pump circuit q (20): Blade lift relief valve for rear pump circuit
Loosen locknut (21) of the blade tilt relief valve and turn adjustment nut (22) to adjust the pressure. If the adjustment nut is q turned to the right, the pressure rises. q turned to the left, the pressure lowers.
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Quantity of adjustment per turn of adjustment nut: 25.3 MPa {258 kg/cm2} 3 Locknut: 39 49 Nm {4 5 kgm}
2) 4. Adjusting LS differential pressure a If the LS differential pressure is abnormal, adjust LS valves (11) and (12) according to the following procedure. q (11): LS valve for front pump circuit q (12): LS valve for rear pump circuit
After finishing adjustment, check again that the oil pressure is normal according to the procedure for measurement described above.
1)
Loosen locknut (13) and turn adjustment screw (14) to adjust the differential pressure. a If the adjustment screw is q turned to the right, the LS differential pressure rises. q turned to the left, the LS differential 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}
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Testing and adjusting control circuit basic pressure

a
3.
Run the engine at high idle, set the blade lever and ripper lever in neutral, and measure the oil pressure.
Measuring instruments for control circuit basic pressure

Symbol N 1 Part No. Part name
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester
The control circuit basic pressure is the pressure 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. 4. After finishing measurement, remove the measuring instrument and return the removed parts.
Measuring k Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the LOCK position. a Measure the control circuit basic pressure under the following condition. q Hydraulic oil temperature: Within operating range 1. 2. Remove the right ROPS front cover. Connect oil pressure gauge [1] of hydraulic tester N1 to oil pressure pickup nipple (1). a Use the oil pressure gauge of 6 MPa {60 kg/cm2}.
Adjusting a The self-pressure reducing valve cannot be adjusted.
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Measuring PPC valve output pressure and solenoid valve output pressure
a
Measuring instruments for PPC valve output pressure and solenoid valve output pressure
Symbol 1 P Part No. Part name
The PPC valve output pressure of the following circuits is the basic pressure of the solenoid valve (Dual tilt specification and superdozer specification). q Blade right tilt/left tilt: Pitch/Tilt solenoid valve basic pressure
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (02) 3 799-401-3200 Adapter (03)
Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the LOCK position. Before measuring the PPC valve output pressure and pitch/tilt control valve pressure, check that the control circuit basic pressure is normal. Measure the PPC valve output pressure and pitch/tilt control valve pressure under the following condition. q Hydraulic oil temperature: Within operating range Measuring PPC valve output pressure (solenoid valve basic pressure) a Measure the pressure of the following circuits at the PPC valve. q Blade lift raise circuit q Blade tilt circuit before entering pitch/ 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]. 3) Start the engine and set the work equipment lock lever in the FREE position. 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 measured on the work equipment control side. a When measuring the blade-lower circuit, operate the lever until the blade floats.
2.
1.
Measuring solenoid valve output pressure (Dual tilt specification and superdozer specification) a Measure the following solenoid valve output pressures on the solenoid valve block (3) side. (It is difficult to measure on the work equipment control valve side.) q Blade left tilt circuit (Left tilt/pitch back circuit) (4) after passing through solenoid valve q Blade right tilt circuit (Right dual tilt/ pitch back circuit) (5) after passing through solenoid valve
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1) 2)
Disconnect the piping of the circuit to be measured and install oil pressure pickup adapter P2 or P3. Install nipple [1] of hydraulic tester P1 and connect oil pressure gauge [2].
Measure the following solenoid valve output pressures on the work equipment control side. 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 through solenoid valve 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 through solenoid valve
3) 4)
Start the engine and set the work equipment lock lever in the FREE position. Run the engine at high idle, operate the control lever or knob switch of the circuit to be measured, and measure the oil pressure. a Measure the oil pressure with the lever at a stroke end. a When measuring the output pressure of the pitch dump solenoid valve or pitch back solenoid valve of the superdozer specification, set the blade lever in 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.
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1) 2)
Disconnect the piping of the circuit to be measured and install oil pressure pickup adapter P2 or P3. Install nipple [1] of hydraulic tester P1 and connect oil pressure gauge [2].
3) 4)
Start the engine and set the work equipment lock lever in the FREE position. Run the engine at high idle, operate the control lever or knob switch of the circuit to be measured, and measure the oil pressure. a Measure the oil pressure with the lever at a stroke end. a When measuring the output pressure of the pitch dump solenoid valve or pitch back solenoid valve of the superdozer specification, set the blade lever in 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.
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Single tilt specification
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Dual tilt specification and superdozer specification
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Adjusting play of PPC valve

a a
q
If the end play of the blade lever and ripper lever is excessive, adjust it with their PPC valves according to the following procedure. This figure shows the PPC valve for the ripper. Standard play (a): 0.5 3.0mm at 200mm from revolution center of lever (in both longitudinal and lateral directions) Remove boot (1). Loosen locknut (2) and turn disc (3) to adjust the play. a Do not move the piston at this time. Fix disc (3) and tighten locknut (2). 3 Locknut: 98 127 Nm {10 13 kgm} Install boot (1).
1. 2.
3. 4.
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Measuring outlet pressure of ripper pin puller solenoid valve 1

a Measuring instruments for outlet pressure of ripper pin puller solenoid valve
Symbol 1 Q 2
k
Part No.
Name
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-3200 Oil pressure pickup adapter (Size 03)
Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the outlet pressure of the ripper pin puller solenoid valve under the following condition. q Power train oil temperature: Within operating range Disconnect pin puller cylinder hose (1) or (2).
4.
Run the engine at high idle and operate the ripper pin puller switch and measure the oil pressure.
1.
5.
2. 3.
Install oil pressure pickup adapter Q2 and connect the disconnected hose again. Install nipple [1] of hydraulic tester Q1 and connect oil pressure gauge [2]. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
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Checking parts which caused hydraulic drift of blade and ripper

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 procedure. Stop the engine with the cylinder at the following 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.
3)
Ripper lift cylinder Tens e r ipp er to pus h u p the re ar of machine.
1.
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 cylinder 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.
2)
Blade tilt cylinder Retract the tilt cylinder to the stroke end and tense blade further to push up the right side of the machine.
[Reference] In case of the hydraulic drift is caused by defective cylinder packing, the reason why the drift speed becomes faster by above mentioned operation is as follows: 1) When work equipment is set in the above 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 press 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.
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Measuring internal leakage of work equipment cylinder

a
3.
Measuring instruments for internal leakage of work equipment cylinder

Symbol L Part No. Purchased Name Measuring cylinder
Run the engine at high idle and apply the relief pressure to the cylinder bottom side. q Blade tilt cylinder: Operate to extend the cylinder to be measured. q Ripper lift cylinder: Operate to lower ripper. q Ripper Tilt cylinder: Operate to tilt ripper forward. After 30 seconds, measure leakage for 1 minute. After finishing removed parts. measurement, return the
a a
Measure the internal leakage of work equipment cylinder under the following condition. q Hydraulic oil temperature: 45 55C Since the blade lift cylinder is equipped with a piston valve, its internal leakage cannot be measured. Extend the cylinder to be measured to the stroke end and set the machine in the measuring 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. 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.
4. 5.
1.
2.
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Releasing residual pressure from work equipment cylinder 1

a When disconnecting the piping between the control valve and work equipment cylinder, release the residual pressure from the circuit according to the following procedure. Loosen the hydraulic tank oil filler cap gradually to release the residual pressure from the tank. Set the work equipment lock lever in the FREE position and operate the work equipment control lever to each direction. a If the work equipment control lever is operated 2 3 times, the residual pressure in the accumulator is released. Run the engine at low idle for about 5 seconds, then stop it. Repeat steps 2 3 above 2 3 times.
Bleeding air from work equipment cylinder 1

a If the work equipment cylinder is removed and installed or its piping is disconnected and connected, bleed air from its circuit according to the following procedure. Run the engine at low idle for about 5 minutes. Running the engine at low idle, extend and retract the cylinder to be bled 4 5 times. a Move the piston rod to about 100mm before the stroke end and never relieve the oil. Running the engine at high idle and carry out the operation in 2. Running the engine at low idle, move the cylinder to the stroke end to relieve the oil.
1.
1. 2.
2.
3. 4.
3. 4.
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Adjusting ripper lever position
a a
Adjust the ripper lever to the best position according to the following procedure. The ripper lever can be adjusted forward and in reverse within the range of 40mm from the center of the lever shaft. 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). 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).
1.
2.
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Adjusting work equipment lock lever
1. 2.
Adjust dimension (a) between pins of rod (1). Dimension (a) between pins: 442.6 mm
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.
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Measuring fan motor speed

a Measuring instruments for fan motor speed
Symbol S Part No. 799-205-1100 Name Tachometer kit
4.
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.
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 The probe tip cannot be inserted in an opening of the fan net, but it can measure the fan motor speed. Remove all obstacles between the lighting part of the probe and the reflecting tape.
5.
2.
Make clearance (a) by shifting fan net (1) and stick reflecting tape [1] to the fan through clearance (a). a Stick the reflecting tape near the outside of the fan (where the distance between the fan net and fan is short).
Start the engine and set the monitor panel in the adjustment mode. a For the operating method in the adjustment mode, see Special functions of monitor panel (EMMS). a Adjustment code: 1005 (Fan 100% speed mode) Run the engine at low idle and high idle and measure the fan motor speed.
6.
3.
Install fan net (1) and close the radiator mask. k Be sure to close the fan net and the radiator mask before starting measurement. Do not start the engine with the radiator mask open.
7.
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Measuring fan circuit oil pressure1

a Measuring instruments for fan circuit oil pressure
Symbol T
k
Part No. 799-101-5002 790-261-1204
Name Hydraulic tester Digital hydraulic tester
Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the fan circuit oil pressure under the following condition. q Hydraulic oil temperature: Within operating range Open the radiator mask. 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 40 MPa {400 kg/cm2}.
5.
1. 2.
3.
Start the engine and set the monitor panel in the adjustment mode. a For the operating method in the adjustment mode, see Special functions of monitor panel (EMMS). a Adjustment code: 1005 (Fan 100% speed mode) Run the engine at high idle and measure the fan circuit oil pressure.
4.
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Bleeding air from fan pump

a
a 1. 2.
If the fan pump is removed and installed or its piping is disconnected and connected, bleed air from the pump case according to the following procedure. Before bleeding air, check that the hydraulic oil level is proper. Remove the floor inspection cover. Loosen air bleeders (1) and (2), and leave it for 15 minutes.
3. 4.
After 15 minutes, run the engine at low idle. After oil flows out of air bleeder, tighten air bleeders (1) and (2).
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Measurement procedure for blade tilt control angle (Dual tiltdozer specification) 1
a Measuring instrument for blade tilt control angle
Symbol U Part No. 799-402-3800 Name Angle gauge
2.
Run the engine at low idle, set the toggle switch of the blade lever to the dual tilt position, and set the blade in the following standard posture. 1) Set the blade horizontally (Set it to 0). 2) Pitch back the blade to the maximum. 3) Raise the blade at 100 mm above the ground.
a 1.
When the blade and blade cylinder potentiometer are removed and installed or when the machine controller is replaced, adjust the blade tilt limit angle according to the following procedure. If this adjustment is not performed, the blade may not tilt sufficiently or may tilt too much and interfere with the track shoe. Be sure to perform this adjustment. Perform this adjustment on a level ground. Adjust installed length (a) of rod (1) and connect it to potentiometer lever (2) and yoke (3). q Installed length (a): 425 mm 3. Hold the buzzer cancel switch in the select position [ U ] for 2.5 seconds to display the maintenance mode. Set the information switch in the [>] position to select the adjustment mode.
4.
5.
Set the buzzer cancel switch in the select position [ U ] to select the adjustment selection screen.
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6.
Operate information switches [<] and [>] to select the tilt limit setting screen.
10. Operate the blade lever to tilt the blade to the 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.
7. 8.
Set the buzzer cancel switch in the select position [U] to select the tilt limit adjustment mode. Press the pitch switch of the blade lever, and the buzzer sounds and the work equipment position in the standard posture is saved. Raise the blade tip to about 1 m above the ground. 11. Set the toggle switch of the blade lever in the single tilt position and then set it in the dual tilt 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 adjustment mode temporarily. 13. Set the blade in the maximum pitch dump posture (Keep the work equipment horizontal).
9.
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14. Set the buzzer cancel switch in the select position [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. 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.
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.
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Measurement procedure for blade tilt control angle (Superdozer specification) 1

a Measuring instrument for blade tilt control angle
Symbol U Part No. 799-402-3800 Name Angle gauge
a 1.
When the blade and blade cylinder potentiometer are removed and installed or when the machine controller is replaced, adjust the blade tilt limit angle according to the following procedure. If this adjustment is not performed, the blade may not tilt sufficiently or may tilt too much and interfere with the track shoe. Be sure to perform this adjustment. Perform this adjustment on a level ground. Adjust installed length (a) of rod (1) and connect it to potentiometer lever (2) and yoke (3). q Installed length (a): 425 mm
3.
Hold the buzzer cancel switch in the select position [ U ] for 2.5 seconds to display the maintenance mode. Set the information switch in the [>] position to select the adjustment mode.
4.
5.
Set the buzzer cancel switch in the select position [ U ] to select the adjustment selection screen. Operate information switches [<] and [>] to select the tilt limit setting screen.
2.
Run the engine at low idle and set the blade in the following standard posture. 1) Set the blade horizontally (Set it to 0). 2) Pitch back the blade to the maximum. 3) Raise the blade at 100 mm above the ground.
6.
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7. 8.
Set the buzzer cancel switch in the select position [U] to select the tilt limit adjustment mode. Press the pitch back button (lower button) of the work equipment lever, and the buzzer sounds and the work equipment position in the standard posture is saved. Set the buzzer cancel switch in the cancel position [t] once to cancel the tilt limit adjustment mode temporarily.
9.
13. Press the pitch dump button (upper button), and the buzzer sounds and the left limit position is saved. a Since the tilt limiting function does not work at this time, operate the lever slowly and take care not to increase the tilting angle too much. a Adjust the tilting angle accurately with angle gauge U. 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.
11. Set the buzzer cancel switch in the select position [U] again to select the tilt limit adjustment mode. 12. Raise the work equipment tip to about 1 m above the ground and tilt it to the left by 7.
15. Press the pitch dump button (upper button), and the buzzer sounds and the right limit position is saved. a Since the tilt limiting function does not work at this time, operate the lever slowly and take care not to increase the tilting angle too much. a Adjust the tilting angle accurately with angle gauge U. 16. Set the buzzer cancel switch in the cancel position [t] to cancel the tilt limit adjustment mode. 17. Lower the work equipment to the ground and stop the engine. 18. Start the engine again, tilt the blade to the right and left, and check that the blade stops automatically in the following range at any height. q Automatic tilt stopping angle: 7 1
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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 position q Fan: Adjustment code:1005 (Fan 100% mode) a If the measured value is lower than the standard value, check the following. (1) Plug of control box (2) Air filters (recirculated air filter and fresh air filter) of air conditioner for clogging 1) A simple method of measuring the internal pressure is as follows. 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].
5]
Seal the mounting holes of lock lever (1) with tape (2).
6] 7]
Set the coolant level in the vinyl hose out of the cab to that in the cab. 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)
Secure the end of hose [1] to the operator's seat with tape.
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2.
Check of sealing performance 1) Close the all openings of the cab. 2) Splash coolant around the hatched part of the cab at the rate of about 19 l/min for 10 minutes. q At this time, it is not necessary to splash pressurized coolant. 3) Splash coolant horizontally from a hose over sealing surface (3). 4) Check around the dashboard carefully. a If coolant leaks, caulk the leaking part and check again.
3.
Testing door lock Close the door and check the relationship between the operator's cab and door. If there is any fault, repair it. 1) Check of condition 1] Check the installed height of damper rubbers (4). (Check 4 pieces on each side.) Stick adhesive tape [1] to the contact face of damper rubber (4), open and close the door 2 3 times. Then, 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.
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2]
Check the relationship between the door latch and striker (on both sides). q Close door (5) and check the engaging condition of latch (6) and striker (7). q Normal: Deviation (a) is 0.5 mm or less. a Check deviation (a) of latch center (y) and striker center (x) from each other from the direction of (A).
2)
Adjusting 1] Adjusting height of damper rubbers q Loosen the mounting bolt of damper rubber (4). q The shim can be removed or installed without removing the mounting bolt. q Increase or decrease the number of shim (8) installed at the bottom of damper rubber (4) to properly adjust the height of damper rubber (4).
2]
3]
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 unlocked 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} Apply grease (G2-LI) to latch (6). a If latch (6) is not sufficiently gr ease d, the knob bec omes heavy.
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4.
Testing open lock Lock the door open and check the relationship between the operator's cab and door. If there is any fault, repair it. 1) Check of condition 1] Check the relationship between open lock latch (9) and striker (10) from the direction of B. 2)
ii)
Check the installed height of the stopper rubbers. (Check both sides, 4 pieces on each.) Lock the door open and shake it in the forward and reverse directions to see if it has any play. Check that the operating effort of the unlock lever is not heavy.
Open the door and check the engaging condition of the open latch and striker. Check that the claw of open latch (9) does not ride over the bent part of striker (10). Check that the body of open latch (9) does not interfere with striker (10).
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 clearance (b) between striker (7) and open latch (9) is reduced to 0, loosen mounting nut (12) of stopper rubber (11) and extend stopper rubber (11) in the pushing direction to adjust.
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 stopper rubber (11) in the range that the door does not have any play. q Dimension (c) of stopper rubber above cab: 35 0.5 mm q Dimension (c) of stopper rubber 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). D475A, D475ASD-5E0
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Adjusting blade
If the blade is removed and installed or disassembled and reassemble, adjust it according to the following procedure. Adjusting shims for assembly 1) Adjust the shim of center (1).
Adjusted point 1 Adjusted clearance a Standard clearance See note Standard shim thickness 4.5 mm
2)
Adjust the shim of trunnion (2) (shim adjustment type).

Adjusted Standard clearclearance ance c 1.56 0.65 mm (Total thickness clearance) Standard shim thickness 12 mm
1.
Adjusted point 2
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.
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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 Right tilt distance (e1) Left tilt distance (e2) U Approx. 900 mm Approx. 900 mm Semi-U Approx. 750 mm Approx. 750 mm
3)
If both tilt distances are not the same, adjust dimension (d) of brace (4) according to the following procedure. q (e1) > (e2): Increase dimension (d) finely. q (e1) < (e2): Decrease dimension (d) finely.
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Special functions of monitor panel (EMMS) .................................................................................................... 2
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Special functions of monitor panel (EMMS)
Display section of special functions 1. 2. Upper panel (Gear speed display section) Lower panel (Multi-information section)
Operation section 1 of special functions (Basic operation) 3. Service switch
Operation section 2 of special functions (Changeover operation) 4. Buzzer cancel switch 5. Information switch 6. Shift-up switch (STD steering lever) Shift switch (ONE-WAY steering lever) 7. Shift-down switch (STD steering lever) Neutral switch (ONE-WAY steering lever)
EMMS: Equipment Management Monitoring System
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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
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Operation and display in operator mode (Outline)

a In this section, only the outline of the operation mode is described. For the details of the contents and operation method of each function and mode, see Operation and maintenance manual.
1.
Maintenance mode (1-OIL, FILTER MAINTENANCE MODE) In this mode, the time up to the next replacement of oils and filters is displayed on the multi-information section (2) and reset after the replacement. a Gear speed display section (1) keeps displayed normally.
Normal display mode (Default) The monitor panel displays the following information 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 characters 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.
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Maintenance item list

Replacement interval (h) No. 1 2 3 4 5 5 7 8 9 10 11 12 Display ENG OIL ENG FILT FUEL FILT HYD FILT CORR RES DAMP OIL FNL OIL HYD OIL HSS FILT POWL OIL POWL FLT F. PRE FLT Maintenance item Engine oil Engine oil filter Fuel main filter Hydraulic oil filter Corrosion resistor Damper oil Final drive oil Hydraulic oil Charge filter (*1) Power train oil Power train oil filter Fuel pre-filter 1st time (fixed) 500 500 1000 250 1000 2000 250 250 0 250 250 500 2nd time and more (changeable) 500 500 1000 2000 1000 2000 2000 2000 0 1000 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 displayed on multi-information section (2) as an auxiliary function of the periodic diagnoses such as the Pm clinic, even if any measuring instrument is not connected. a Gear speed display section (1) keeps displayed normally.
Order 01 02 03 04 05 06 07 08 09 10 13
Display 01-ENG. SPEED
Item Engine speed
02-COOLANT TEMP Coolant temperature 03-ENG OIL PRESS Engine oil pressure 04-AMB PRESS 05-BOOST PRESS 06-BOOST TEMP 07-T/C TEMP 08-HYD TEMP 09-HYD. PRESS F 10-HYD. PRESS R 13-BATTERY VOLT Ambient pressure Engine boost pressure Engine boost temperature Power train oil temperature Hydraulic oil temperature Hydraulic oil pressure (F pump) Hydraulic oil pressure (R pump) Battery voltage
The ambient pressure and boost pressure is displayed in absolute value.
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3.
Failure code display mode (3-FAULT CODE DISPLAY MODE) In this mode, the contents of each fault in the machine are displayed by a 6-character failure code on the multi-information section (2). When the user or the operator needs to be notified of the failure code of each fault, this mode is applied. a Gear speed display section (1) keeps displayed normally.
4.
Adjustment mode (4-USER ADJUST MODE) In this mode, the display condition of the monitor panel can be adjusted and the fan speed (for cleaning the radiator) can be changed on the multi-information section (2). a Gear speed display section (1) keeps displaying normally.
No. 1
Display
Item
When a serviceman needs to check the failure codes for troubleshooting, the Electrical system failure code display mode and the Mechanical system failure code display mode should be used for more detailed information. Method of checking failure code: Turn buzzer cancel switch (4) to the [U] position on the screen shown above, and the all failure codes detected currently are displayed at the interval of about 2 seconds. (To finish displaying, turn the buzzer cancel switch to the [ t ] position.)
Adjustment of LCD 01:LCD BRIGHTNESS brightness 02:DSP BRIGHTNESS 03:DSP CONTRAST 04:FAN 100% SPEED 05:NO INJECTION 06:TILT LIMIT 07:PRE_LUB ON Adjustment of display brightness Adjustment of display contrast Fan 100% speed mode (For cleaning radiator) No injection cranking mode Tilt limit adjustment mode Pre-lubrication reset mode against prelubrication trouble
2 3 4 5 6 7
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1)
Brightness of LCD This mode is to adjust brightness of the backup lamp at the liquid crystal gauge section. (See Operation and maintenance manual.) Brightness of display This mode is to adjust brightness of the backup lamp at the multi-information section. (See Operation and maintenance manual.) Contrast of display This mode is to adjust contrast of the liquid crystal at the multi-information section. (See Operation and maintenance manual.) 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] The function is effective under this condition and the rotation speed of the cooling fan is controlled to approximately 100% of the maximum speed. a Exiting this mode disables the function.
5)
2)
No injection cranking mode This mode is to circulate the engine oil easily while applying no injection conditions to all engine cylinders before staring engine after an extended machine storage. 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)
4)
3]
In above 3 seconds, WAIT displayed on the lower line changes to ACTIVE and the mode becomes effective.
4] 5]
In this condition, turn the starting switch to START position to apply no injection cranking. The mode is released by moving the starting switch to ON position and turning the buzzer cancel switch to the [t] position. Do not continue no injection cracking for more than 20 seconds in order to protect the starting motor. For safety, this mode cannot be operated while the engine is running.
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At this time, NOT AVAILABLE is displayed on the lower line to indicate that the mode is ineffective.
7)
Pre-lubrication mode On this screen, operate the information switch to display the Skip on the lower line of the display section. If this mode is finished under this condition, the engine can be started without using the pre-lubrication system. a This mode becomes ineffective once the engine is stopped.
6)
Exiting from this mode disables this function. Tilt limit adjustment mode a Refer to the section Measurement procedure for blade tilt control angle in Testing and adjusting, Part 2.
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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 multiinformation section (2). a Gear speed display section (1) keeps displayed 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 code Indication method of fault Contents of fault Torque converter is not locked up. Blade dual tilt mechanism does not work. Remedy Automatic function stops or normal function stops partially but machine can work. Call your Komatsu distributor for repair. Stop engine and start it again, and you can operate machine without limiting function. You must take care, however. Call your Komatsu distributor for repair.
E01
Only action code is displayed.
E02
Gear is not shifted up or down. Action code is displayed. Blade tilt is not limited. Caution lamp flashes. Blade pitch mechanism does not Caution buzzer sounds. work.
Engine coolant temperature sensor is defective. Move machine to safe place. Action code is displayed. Usable gear speeds are limited. Call your Komatsu distributor for Engine speed does not rise fully. CALL E03 Caution lamp flashes. repair. Caution buzzer sounds. Gear shifting shocks become large. Steering performance lowers. Brake shocks become large. Action code is displayed. Engine cannot be controlled. CALL E04 Caution lamp flashes. Machine cannot travel. Caution buzzer sounds. Machine stops. Stop machine immediately. Call your Komatsu distributor for repair.
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Operation and display in service mode

Method of changing to service mode a When using the service mode, change the screen by the following special operation. 1) Special operation of switches Set the monitor panel in the service mode by operating service switch (3) and buzzer cancel switch (4). a Keeping the service switch in the ON position, hold the buzzer cancel switch in the [U] position for 2.5 seconds. a If the monitor panel is set in the service mode, [1C] or [55] is displayed on the gear speed display section (1).
Gear Order speed display
Display and item 5-EXCHG. INTVAL. INTERVAL MODE Maintenance interval change mode 6-ELEC. FAULT CODE MODE Electrical system failure code display mode 7-MACHINE CHECK CODE MODE Mechanical system failure code display mode 8-SERVICE ADJUST MODE Adjustment mode 9-LOAD MAP DISPLEY MODE Load memory display mode 10-REAL TIME MONITORING MODE Real time monitoring mode 11-DUAL DISPLAY MONITORING MODE Dual display monitoring mode 12-SNAP SHOT MODE Snap shot mode *
1C
EE
bE
4 5 6 7 8
Cb Ld 5R dR 55
* 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
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5.
Maintenance interval change mode (5-EXCHG. INTVAL. INTERVAL MODE) In this mode, you can check and set the maintenance interval times of various filters and oils which are the bases of the maintenance display function in the operator mode. 1) Selecting and executing mode 1] Select Maintenance interval change mode on the mode selection screen. a If the mode is selected, code (1C) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). 2] Display the maintenance item selection screen by operating buzzer cancel switch (4). q [U]: Execute mode.
2)
Selecting and displaying maintenance item 1] Operate information switch (5) on the maintenance item selection screen to select a maintenance item. q [ > ]: Next code q [ < ]: Previous code 2] Display the maintenance item selection screen by operating buzzer cancel switch (4). q [U]: Execute item.
3)
Contents of information section The following items are displayed on the information section. (1) Code (2) Maintenance item (3) Replacement interval time (Set time) a The items shown below are examples. a If the replacement interval does not need to be changed, finish the operation on this screen. a If the replacement interval needs to be changed, go to step 4).
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4)
Changing replacement interval time 1] Change the set time by operating information switch (5), shift-up switch (6), and shift-down switch (7). q [ > ]: Move cursor to right. q [ < ]: Move cursor to left. q [UP]: Increase number. q [DOWN]: Decrease number.
2]
If the input time is correct, enter the change of setting by operating buzzer cancel switch (4). q [U]: Enter change. a If the change is finished normally, the information display screen appears after the screen shown below.
If you do not use the maintenance function, set the all times to 0.
If the change does not finish normally, above message SETTING NOW!! is not displayed but the replacement interval change screen is kept displayed. (The screen does not return to the information display screen.)
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Maintenance item list

Replacement interval (h) No. 1 2 3 4 5 6 7 8 9 10 11 12 Display 01: ENG OIL 02: ENG FILT 03: FUEL FILT 04: HYD FILT 07: DAMP OIL 08: FNL OIL 10: HYD OIL 12: HSS FILT 19: POWL OIL Maintenance item Engine oil Engine oil filter Fuel main filter Hydraulic oil filter Damper oil Final drive oil Hydraulic oil Charge filter (*1) Power train oil 1st time (fixed) 500 500 1000 250 1000 2000 250 250 0 250 250 500 2nd time and more (changeable) 500 500 1000 2000 1000 2000 2000 2000 0 1000 500 500
06: CORR RES Corrosion resistor
20: POWL FILT Power train oil filter 41: F. PRE-FLT Fuel pre-filter
(*1): Displayed on D475A-5 but not set.
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.
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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 display mode on the mode selection screen. a If the mode is selected, code (EE) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). 2] Display the failure code display screen by operating buzzer cancel switch (4). q [U]: Execute mode.
3)
Display in the case where 1 or more codes are recorded If any failure code has been output up to now, the information section displays as shown below. (1) Record No. (Up to 20) (2) Failure code (Code being output currently is flashing) (3) Number of past occurrences (4) Time measured by service meter after first occurrence (5) Time measured by service meter after last occurrence a The items shown below are examples.
a 2) Display in the case where no codes are recorded If no failure codes have been output up to now, the information section displays as shown below.
Flashing and lighting of failure code Flashing: Code is being output currently. Lighting: Code is not being output currently.
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Condition for detecting and keeping failure code If a failure code of any item other than communication and engine is output, it keeps flashing until the starting switch is turned off. After the starting switch is turn on or the engine is started again, the failure code keeps lighting until the same fault is detected. A failure codes of communication and engine start lighting when the fault is solved, even if the starting switch is not turned off.
7.
Mechanical system failure code display mode (7-MACHINE CHECK CODE MODE) In this mode, you can check the past mechanical system error codes. a Refer to the item Failure code list in Troubleshooting, General. 1) Selecting and executing mode 1] Select Mechanical system failure code display mode on the mode selection screen. a If the mode is selected, code (bE) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). 2] Display the failure code display screen by operating buzzer cancel switch (4). q [U]: Execute mode.
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 q [ < ]: Previous code a The failure codes are displayed from the oldest one in order of length of time after they were output. 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.
5)
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2)
Display in the case where no codes are recorded If no failure codes have been output up to now, the information section displays as shown below.
Flashing and lighting of failure code Flashing: Code is being output currently. Lighting: Code is not being output currently. 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)
3)
Display in the case where 1 or more codes are recorded If any failure code has been output up to now, the information section displays as shown at right. 1] Record No. (Up to 15) 2] Failure code (Code being output currently is flashing) 3] Number of past occurrences 4] Service meter reading at first occurrence 5] Service meter reading at last occurrence a The item shown below is example.
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) described in the monitor illustration on page 2. q [ > ]: Next code q [ < ]: Previous code a All the failure codes, including ones which have not been displayed, are displayed in numeric order. Method of deleting failure code The mechanical system failure codes cannot be deleted.
5)
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8.
Adjustment mode (8-SERVICE ADJUST MODE) In this mode, you can adjust the control system and various devices of the machine. 1) Selecting and executing mode i) Select Adjustment mode on the mode selection screen. a If the mode is selected, code (Cb) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). ii) Display the adjustment code input screen by operating buzzer cancel switch (4). q [U]: Execute mode.
2)
Selecting adjustment items 1] On the adjustment code input screen, input the 4-digit code of the item to be adjusted by operating information switch (5), shift up switch (6) and shift down switch (7). q [>]: Moves cursor rightward. q [<]: Moves cursor leftward. q [UP]: Increases number. q [DOWN]: Decreases number. 2] After inputting the code, operate buzzer cancel switch (4) to display the monitoring screen. q [U]: Enters input mode.
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.
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3)
Contents of display on adjustment screen 1] Code 2] Adjustment item 3] Related information a For the detailed information and adjustment procedure, see Adjustment modes list and adjustment procedure.
5)
Automatic selection of adjustment item (Limited function) After one of some adjustment items is selected, if the information switch is operated, the next adjustment item is selected automatically, even if the code of the next adjustment 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 Automatic selection column of the Adjustment mode table and adjustment procedure. Those items are selected in the order of their numbers. a Note that this operation is not effective while the parking brake lever is in the RESET position. a You may return to the screen for 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 position and perform the necessary procedure.
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Adjustment modes list and adjustment procedure

No. Code [1] 0001 INP TEL NO. [2] 0002 S/T S. CODE [3] 0003 T/M S. CODE [4] 0004 BODY TYPE [5] 0005 BRAKE BASE [6] 0007 ENG. FULL CH [7] 0008 INT-> 123456 [8] 0009 PITCH SENS. [9] 0010 FAN 70%MODE [10] 0022 VHMS INST [11] 0530 STALL CHECK Adjustment item Phone No. input mode Steering controller specification set Transmission controller specification set Machine specification set Related information Numerals and symbols Code Code Code q q q q 1 2 3 4 5 Disassembly Sending and assembly in order
Brake potentiometer zero point adjustVoltage ment Engine deceleration cut mode Common rail reduced cylinder mode Pitch angle sensor initialization set Fan speed 70% speed mode VHMS specification set Stall speed check mode Engine speed Speed/Fuel injection rate Voltage (Adjustment amount) Set state Engine speed (Date of adjustment in factory) Voltage Voltage Voltage Oil pressure Oil pressure Set state Set state Transmission speed Oil pressure Oil pressure Set state Set state Voltage Voltage Revolving speed Permit
6 8 7
[12] 1005 FAN 100%MODE Fan speed 100% mode [13] 1012 S/T N-SET [14] 1013 S/T M. L-SET [15] 1014 S/T M. R-SET [16] 1015 BRKLH. OFST [17] 1016 BRKRH. OFST [18] 1112 PRE LUB SEL [19] 2223 R SLOW CUT [20] 5535 CLUTCH OPEN [21] 5537 CLT LH. OFST [22] 5538 CLT RH. OFST [23] 9801 ENG. LEVEL [24] 9993 HYD. LEVEL [25] 9995 LOCK BRAKE [27] 9997 HI IDLE SET [28] 9998 SFT INHIBIT Steering lever neutral set Steering lever left set Steering lever right set Left brake oil pressure offset (set) Right brake oil pressure offset (set) Pre-lubrication set Reverse slow stop set Clutch disengagement mode Left clutch oil pressure offset (set) Right clutch oil pressure offset (set) Engine oil level display mode (if equipped) Hydraulic oil level display mode (if equipped) Electrical brake constantly ON mode High idle limit mode 3rd speed cut set
[26] 9996 MECHA BRAKE Electrical brake release mode
a 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.) The numbers in Sending in order column can be displayed in order by setting the information switch in [>] or [<] position.
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[1] 0001: Phone number input mode q This code inputs or changes a phone number to be displayed simultaneously when the user code is displayed. q The lower part displays a phone number and symbols. q Available characters: 0123456789:;<=>? q Instructions for use: 1) By operating the information switch (5), shift up switch (6), and shift down switch (7), input a phone number and symbols. q [ > ]: Moves the cursor rightward. q [ < ]: Moves the cursor leftward. q [UP]: Advance the numeric character or character (in the order of available characters). q [DOMN]: Reverse the numeric character or character (in the reverse order of available 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 symbols other than numeric characters at digits you will not use. a 0 (zero) is input at all places of the lower part before shipment from our factory. (No phone number is displayed under this condition.) a The setting is enabled even after ending this code.
[2] 0002: Steering controller specification set q This code is used to initialize the specification codes recognized by the steering controller and the set values of the memory in the controller. q The specification code is displayed on the lower line. q Adjustment method 1) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. 2) Check that the displayed specification code has changed from [2*2] to [222]. a If specification code [222] is not displayed, the controller wiring harness or the controller unit may be defective. a Even if this code is turned off, the setting is effective.
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[3] 0003: Transmission controller specification set q This code is used to initialize the specification codes recognized by the transmission controller and the set values of the memory in the controller. q The specification code is displayed on the lower line. q Adjustment method: 1) Set buzzer cancel switch (4) in the [U] position and check that the alarm buzzer sounds. 2) Check that the displayed specification code has changed from [1*1] to [111]. a If specification code [111] is not displayed, the controller wiring harness or the controller unit may be defective. a Even if this code is turned off, the setting is effective.
[4] 0004: Machine specification set a STD STEERING q This code is used to have the machine specification recognized by the controllers which compose the system. q The machine specification code is displayed on the lower line. q Adjustment method: a Since this code is reset when Transmission controller specification set is executed, adjust it after that. 1) Select the code of the machine specification by setting shift up switch (6). a Be sure to select SSC power setting 1 as the SSC type. 2) Operate shift-down switch (7) and set the travel lever code. 3) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. 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. 800 801 802 810 811 812 820
Type of work equipment Single tilt Single tilt Single tilt Dual tilt Dual tilt Dual tilt Superdozer
Specification SSC power set 1 SSC power set 2 SSC power set 1 SSC power set 2
a a
Number 8 at the leftmost place of the machine specification code indicates the travel lever type. If the optional-type travel lever is employed, set 9 at the above place.
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q
q q
ONE-WAY STEERING LEVER This code is used to have the machine specification recognized by the controllers which compose the system. The machine specification code is displayed on the lower line. Adjustment method: a Since this code is reset when Transmission controller specification set is executed, adjust it after that. 1) Select the code of the machine specification by setting shift up switch (6). a Be sure to select SSC power setting 1 as the SSC type. 2) Operate shift-down switch (7) and set the travel lever code. 3) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. 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.
[5] 0005: Brake potentiometer zero-point adjustment q This code is used to adjust the zero point of the brake pedal potentiometer. q The deviation from the standard value is indicated 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). 2) Set buzzer cancel switch (4) in the [U] 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 adjust the effect of the brake. a Even if this adjustment is performed, the indication on the lower line does not change. a Even if this code is turned off, the setting is effective.
Code X00 X01 X02 X10 X11 X12
Work equipment specification Single tilt Single tilt Single tilt Dual tilt Dual tilt Dual tilt
SSC specification Without SSC SSC power setting 1 SSC power setting 2 Without SSC SSC power setting 1 SSC power setting 2
[6] 0007: Engine deceleration-cut mode q This code is used to stop the auto-deceleration function of the engine and check the high idle speed of the engine singly. q The engine speed is displayed on the lower 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.
Note: "X" indicates a travel lever code. "8": STD STEERING "9": ONE-WAY STEERING LEVER
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When the cursor is at cylinder 6, if information switch (5) is operated to the right [>], the right bank cylinders can b e reduced. (L 1,2,3,4,5,6 o R 1,2,3,4,5,6)
[7] 0008: Common rail reduced cylinder mode a When the engine common rail system seems to be defective, this code is used to stop injecting fuel into 1 or more cylinders (reduce the number of effective cylinders) while the engine is running and find out a defective cylinder 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 operation, use this function while the engine is running. 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 cylinders again, too. q [>]: Moves cursor rightward. q [<]: Moves cursor leftward. q [U]: Executes or stops reduced cylinder mode operation.
[8] 0009: Pitch angle sensor initial set This code is used to adjust the zero point and installation error of the pitch angle sensor. q The deviation from the standard neutral position is displayed by voltage on the lower line (Display range: -2500 to 2500 mV). q Adjustment method: Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if this code is turned off, the setting is effective.
q
[9] 0010: Fan 70% speed mode This code forcedly sets the rpm of cooling fan at 70% of the maximum rotation. q The lower part displays data for factory adjustment. q Instructions for use: q The function is enabled with this code displayed to control the rpm of cooling fan to approximately 70% of the maximum rotation. a Ending this code disables the function.
q
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[10] 0022: Setting of VHMS specification q This code is used to set the installation of VHMS terminal. If the installation is not set, the VHMS operation data is not set normally and the data related to the VHMS cannot be monitored. q The installation condition of the terminal is displayed on the lower line. q ACTIVE: Setting of installation of VHMS q DEACTIVE: Setting of non-installation of VHMS q Setting method 1) Select an installation condition of the VHMS terminal with shift-up switch (6) and shift-down switch (7). 2) After selecting the condition of the terminal, 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.
[11] 0530: Stall speed check mode q This code is the function to make the cooling fan speed maximum to check the torque converter stall speed. k In this machine the cooling fan speed control function is installed in order to protect the radiator when the engine is not yet warmed up enough. However, in case that this mode is in use, the protecting function does not work. So use the machine after carrying out enough warming up. q The engine speed is displayed on the lower line. (Display range: 0 3000) q How to use While this code is displayed, its function is enabled and the cooling fan speed becomes maximum. a If this code is turned off, its function is disabled.
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[12] 1005: Fan 100% mode q This code forcedly sets the speed of cooling fan at approximately 100% of the maximum speed. Also by this code, the adjustment value for the maximum speed can be set. q The adjustment data is displayed on the lower line. q How to use: a The function is effective with this code displayed to control the speed of cooling fan to approximately 100% of the maximum speed. i) When changing the adjustment value, operate shift up switch (6) and shift down switch (7) to set the adjustment value for the maximum speed. q [UP]: Adjustment value increases. q [DOWN]: Adjustment value decreases. ii) For confirming the adjustment value, set buzzer cancel switch (4) in the [U] position and check that the alarm buzzer sounds. a If this code is turned off, its function is disabled. However, the adjustment value once set is still effective.
[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). q Adjustment method: 1) Set the PCCS lever to the neutral position. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if adjustment is carried out, the display on the lower line does not change. a Even if this code is turned off, the setting is effective. a This code is not for adjusting the steering performance.
[14] 1013: Steering lever left set q This code is used to adjust the maximum left steering position of the PCCS lever. q The deviation of the steering potentiometer from the standard maximum left position is displayed by voltage on the lower line (Display range: -2500 2500 mV). q Adjustment method: 1) Set the PCCS lever to the left steering stroke end. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if adjustment is carried out, the display on the lower line does not change. a Even if this code is turned off, the setting is effective. a This code is not for adjusting the steering performance.
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[15] 1014: Steering lever right set q This code is used to adjust the maximum right steering position of the PCCS lever. q The deviation of the steering potentiometer from the standard maximum right position is displayed by voltage on the lower line (Display range: -2500 2500 mV). q Adjustment method: 1) Set the PCCS lever to the right steering stroke end. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if adjustment is carried out, the display on the lower line does not change. a Even if this code is turned off, the setting is effective. a This code is not for adjusting the steering performance.
[16] 1015: Left brake oil pressure offset q This code is used to adjust the left 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). q Adjustment method: 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 pressure 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). 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if this code is turned off, the setting 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). q Adjustment method: 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 pressure 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).
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30 Testing and adjusting Operate the buzzer cancel switch to [U] side and check that the caution buzzer sounds. Even if this code is turned off, the setting is effective.
SEN01819-02
2) a
[19] 2223: Reverse slow stop set q This code is used to turn off the reverse slow function forcibly, regardless of the operation of the switches on the monitor panel. q The state of the reverse slow function is displayed on the lower line by letters. q Adjustment method: Operate information switch (5) to change the setting. q [ < ] [ > ]: Change display q [DEACTIVE]: Turn reverse slow function OFF q [ACTIVE]: Turn reverse slow function ON a Once the reverse slow function is turned OFF, the reverse speed is not lowered, even if the reverse slow mode switch on the monitor panel is turned ON. a Even if this code is turned off, the setting is effective.
[18] 1112: Pre-lubrication set (if equipped) q This code is used to set the machine equipped with the pre-lubrication system. q Installation or non-installation of the pre-lubrication system is displayed on the lower line by letters. q Adjustment method: 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. a Even if this code is turned off, the setting is effective.
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[20] 5535: Both steering clutches disengagement q This code is used to engage the transmission clutch without driving the machine for testing, adjusting, troubleshooting, Pm Clinic, etc. q The transmission speed (Unit: rpm) is displayed on the lower line. q Using method: While this code is displayed, the function is effective and steering clutches on both sides are disengaged. Accordingly, the machine does not travel even if the PCCS lever is operated. a If this code is turned off, the function becomes ineffective.
[21] 5537: Left steering clutch oil pressure offset q This code is used to adjust the left clutch 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). q Adjustment method: 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 pressure 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). 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if this code is turned off, the setting is effective.
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[22] 5538: Right steering clutch oil pressure offset q This code is used to adjust the right clutch 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). q Adjustment method: 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 pressure 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). 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if this code is turned off, the setting is effective.
[23] 9801: Engine oil level set (if equipped) This code is used to set the machine equipped with the engine oil level switch. q Installation or non-installation of the engine oil level switch is displayed on the lower line by letters. q Adjustment method: Operate information switch (5) to change the setting. q [ < ] [ > ]: Change display q [ACTIVE]: Machine is equipped with engine oil level switch q [DEACTIVE]: Machine is not equipped with engine oil level switch a To use this function, the engine oil level switch must be installed. a If [ACTIVE] is selected while the engine oil level switch is not installed, the caution buzzer sounds. Take care.
q
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[24] 9993: Hydraulic oil level set (if equipped) q This code is used to set the hydraulic oil level caution. q The setting of the hydraulic oil level caution is displayed on the lower line by letters. q Adjustment method: Operate information switch (5) to change the setting. q [ < ] [ > ]: Change display q [ACTIVE]: Turn hydraulic oil level caution function ON q [DEACTIVE]: Turn hydraulic oil level caution function OFF a To use this function, the hydraulic oil level switch must be installed. a If [ACTIVE] is selected while the hydraulic oil level switch is not installed, the caution buzzer sounds. Take care. a Even if this code is turned off, the setting is effective.
[25] 9995: Electric brake constantly ON mode q This code is used to see if the sudden stop prevent valve operates normally. q The voltage of the brake potentiometer is displayed on the lower line. q Using method: While this code is displayed, the function is effective and the electric brake is constantly turned on. a If this code is turned off, the function becomes ineffective.
[26] 9996: Electric brake release mode This code is used to check the operation of the mechanical brake. q The voltage of the brake potentiometer is displayed 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.
q
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[27] 9997: High idle limit mode q This code is used to limit the high idle speed. q The engine speed (set value) is displayed on the lower line. q Possible limiting range: High idle speed 400 rpm q Using method: 1) Set information switch (5) in the [ > ] or [ < ] position to select the limit speed. 2) Set buzzer cancel switch (4) in the [U] 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. a Even if this code is turned off, the setting is effective.
[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 cancel 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. a Even if this code is turned off, the setting is effective.
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9.
Load memory display mode (9-LOAD MAP DISPLAY MODE) In this mode, you can check the load on the machine, forward odometer, and reverse odometer. 1) Selecting and executing mode 1] Select Load memory display mode on the mode selection screen. a If the mode is selected, code (Ld) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). 2] Display the information screen by operating buzzer cancel switch (4). q [U]: Execute mode.
2)
Changing information screen Change the information screen by operating information switch (5). q [ > ]: Next screen. q [ < ]: Previous screen.
Display 01-1000 rpm SMR 02-FOWARD ODO M 03-REVERSE ODO M 04-F1 ODO Meter 05-F2 ODO Meter 06-F3 ODO Meter 07-R1 ODO Meter 08-R2 ODO Meter 09-R3 ODO Meter Item 1000 rpm service data Forward travel distance Reverse travel distance F1 travel distance F2 travel distance F3 travel distance R1 travel distance R2 travel distance R3 travel distance
No. 1 2 3 4 5 6 7 8 9
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.
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4)
Display of forward odometer (02) On this screen, the integrated forward travel distance is displayed. a The data cannot be reset.
7)
Display of F2 odometer (05) On this screen, the integrated F2 (Forward 2nd gear) travel distance is displayed. a The data cannot be reset.
5)
Display of reverse odometer (03) On this screen, the integrated reverse travel distance is displayed. a The data cannot be reset.
8)
Display of F3 odometer (06) On this screen, the integrated F3 (Forward 3rd gear) travel distance is displayed. a The data cannot be reset.
6)
Display of F1 odometer (04) On this screen, the integrated F1 (Forward 1st gear) travel distance is displayed. a The data cannot be reset.
9)
Display of R1 odometer (07) On this screen, the integrated R1 (Reverse 1st gear) travel distance is displayed. a The data cannot be reset.
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10) Display of R2 odometer (08) On this screen, the integrated R2 (Reverse 2nd gear) travel distance is displayed. a The data cannot be reset.
11) Display of R3 odometer (09) On this screen, the integrated R3 (Reverse 3rd gear) travel distance is displayed. a The data cannot be reset.
12) Moving machine with saved load displayed If the parking brake lever is set in the FREE position, gear speed display unit (1) is set in the normal display mode again and the machine can operate 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 load saving display mode.) 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 position temporarily, and then start the operation.
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10. Real-time monitoring mode (10-REAL TIME MONITORING MODE) In this mode, the speeds, oil pressures, oil temperatures, currents, voltages, etc. can be 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 display section (1) and the title is displayed on multi-information section (2). 2] Display the monitoring code input screen by operating buzzer cancel switch (4). q [U]: Execute mode.
q q q q
[ > ]: Move cursor to right. [ < ]: Move cursor to left. [UP]: Increase number. [DOWN]: Decrease number.
2]
After inputting the code, display the m on ito rin g scree n b y op erating buzzer cancel switch (4). q [ ]: Enter input code. a If the input code is normal, the monitoring screen shown at right appears.
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 5digit code of the item to be monitored by operating information switch (5), shift-up switch (6), and shift-down switch (7).
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3)
Contents of display on monitoring screen (Figure below shows examples) 1] Code 2] Monitoring item 3] Information 4] Unit (Not displayed for some items) a For the details, see the Monitoring mode table.
5)
When operating machine in monitoring mode If the parking brake lever is set in the FREE position, gear speed display section 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 monitoring mode.) 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 position and perform the necessary procedure.
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.
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6)
Automatic selection of monitoring item (Limited function) After one of some monitoring items is selected, if the information switch is operated, 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 effective 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.
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Monitoring mode table

No. Code 1 2 3 4 5 6 7 8 9 00201 ENG M ID L 00203 ENG M ID R 01002 ENG REV L 01004 ENG REV R 01603 Remote Th 03000 FUEL DIAL 03200 BATTERY 03201 S/T ACC 03202 S/T PWR2 Monitoring item Engine controller model selection name, left bank Engine controller model selection name, right bank Engine speed, left bank Engine speed, right bank 2nd throttle position Fuel control dial voltage Battery voltage Steering controller ACC input voltage Steering controller load power supply voltage Engine controller power supply voltage, left bank Engine controller power supply voltage, right bank Steering controller unswitched power supply voltage Transmission controller unswitched power supply voltage Transmission controller ACC input voltage Transmission controller load power supply voltage Engine coolant temperature Engine coolant temperature sensor voltage Fuel level sensor voltage Hydraulic oil temperature HSI line break point Torque curve selection Droop type selection Droop switch selection Droop trim selection Steering controller sensor 5V power supply voltage 1 Transmission controller sensor 5V power supply voltage 1 Steering controller sensor 5V power supply voltage 2 Transmission controller sensor 5V power supply voltage 2 Steering controller sensor 24V power supply voltage Transmission controller sensor 24V power supply voltage Fuel temperature, left bank Fuel temperature sensor voltage, left bank Fuel temperature, right bank Fuel temperature sensor voltage, right bank PCV closing timing, left bank PCV closing timing, right bank Engine controller mode selection Engine controller idle validation switch 1 Engine controller idle validation switch 2 Unit Letter Letter rpm rpm % mV mV mV mV mV mV mV mV mV mV C mV mV C rpm Letter Letter Letter Letter mV mV mV mV mV mV C mV C mV CA CA Letter bit bit Remarks (See detailed information) (See detailed information) Automatic selection 1 2 25 39 6 37 7
10 03203 E-ECM PW L 11 03206 E-ECM PW R 12 03207 S/T PWR1 13 03208 T/M PWR1 14 03212 T/M ACC 15 03216 T/M PWR2 16 04104 COOLANT TP 17 04105 COOLANT TP 18 04200 FUEL SENS 19 04401 HYD.TEMP 20 08100 HSI BREAK 21 08200 TQ Sel 22 08300 Droop Type 23 08400 Droop SW 24 08500 Droop Trim 25 10500 S/T 5V PW1 26 10501 T/M 5V PW1 27 10505 S/T 5V PW2 28 10506 T/M 5V PW2 29 10700 S/T 24V PW 30 10701 T/M 24V PW 31 14200 FUEL TMP L 32 14201 FUEL TMP L 33 14202 FUEL TMP R 34 14203 FUEL TMP R 35 17201 PCV TMG L 36 17202 PCV TMG R 37 17500 ENG MODE 38 18300 ENG IVSW 1 39 18301 ENG IVSW 1
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No. Code
Monitoring item
Unit C mV C mV mg/st Nm C C Letter Letter Letter Letter Letter Letter LED Letter Letter C rpm rpm bit bit mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA
Remarks (See detailed information) (See detailed information)
Automatic selection 40 8 3 33 34 35 32 27 26 31 36 28
40 18400 INTAKE TEMP Intake air temperature 41 18401 INTAKE TEMP Intake air temperature sensor voltage 42 18500 BOOST TEMP Boost temperature 43 18501 BOOST TEMP Boost temperature sensor voltage 44 18600 INJECT CMD 46 18900 E-ECM TP L 47 18902 E-ECM TP R 48 20201 T/M. PROGRM 49 20202 S/T. PROGRM 50 20216 ENG BLD L 51 20217 ENG CAL L 52 20218 ENG CAL R 53 20219 ENG BLD R 54 20301 VHMS 55 20400 E-ECM SN L 56 20401 E-ECM SN R 57 30100 T/C TEMP. 58 31200 T/M IN 59 31400 T/M OUT 60 31520 T/M-FILL 61 31521 S/T FILL 62 31602 1st CLUTCH 63 31603 2nd CLUTCH 64 31604 3rd CLUTCH 65 31606 Rev CLUTCH 66 31608 Frd CLUTCH 67 31612 1 CLUTCH F 68 31613 2 CLUTCH F 69 31614 3 CLUTCH F 70 31616 R CLUTCH F 71 31618 BRAKE R.H. 72 31619 BRAKE L.H. 73 31620 BRAKE R.H. 74 31621 BRAKE L.H. 75 31622 F CLUTCH F 76 31623 FAN PUMP. O 77 31624 FAN PUMP. F 78 31625 PITCH SOL. 79 31627 L/U SOL 80 31628 E. BRAKE SL 81 31633 FAN PMP2. O Final injection rate command Engine controller ECM inside temperature, left bank Engine controller ECM inside temperature, right bank Transmission controller program version Steering controller program version Engine controller build version, left bank Engine controller calibration data version, left bank Engine controller calibration data version, right bank Engine controller build version, right bank VHMS LED monitor Engine controller ECM serial No., left bank Engine controller ECM serial No., right bank Torque converter oil temperature Transmission input speed Transmission output speed Transmission-related fill switch input state Steering-related fill switch input state 1st clutch ECMV current command value 2nd clutch ECMV current command value 3rd clutch ECMV current command value Reverse clutch ECMV current command value Forward clutch ECMV current command value 1st clutch ECMV output feedback current 2nd clutch ECMV output feedback current 3rd clutch ECMV output feedback current Reverse clutch ECMV output feedback current Right brake ECMV output feedback current Left brake ECMV output feedback current Right brake ECMV current command value Left brake ECMV current command value Forward clutch ECMV output feedback current Cooling fan pump solenoid output command current Cooling fan pump solenoid output feedback current Blade pitch solenoid output feedback current Torque converter lockup solenoid output feedback current Sudden stop prevention solenoid output feedback current Cooling fan pump 2 solenoid output command current 45 18700 ENG TRUQUE Engine output torque
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No. Code 82 31634 FAN PMP2. F 83 31701 DECEL 84 31703 DECEL 85 31706 F THROTTLE 87 36001 Accel Adj 88 36200 PRESS CMD 89 36300 INJECT CMD 90 36400 RAIL PR L 91 36401 RAIL PR L 92 36403 RAIL PR R 93 36404 RAIL PR R 94 36500 BOOST PRS 95 36501 BOOST PRS 97 37200 ENG OIL PRS 98 37201 ENG OIL PRS 99 37301 FUEL RATE 100 37400 ABM PRESS 101 37401 ABM PRESS 102 37500 ATM TEMP 103 40001 VEHICLE SP 104 40905 T/M-SW1 105 40906 T/M-SW2 106 40907 T/M OP SIG 107 40908 T/M HYD SW 108 40909 T/M SOL. 2 109 40910 S/T-SW1 110 40911 S/T-SW2 111 40913 S/T-SW5 112 40914 S/T SOL. 1 113 40915 S/T SOL. 2 114 42600 EXH TEMP LF
Monitoring item Cooling fan pump 2 solenoid output feedback current Decelerator position Decelerator pedal potentiometer voltage Final accelerator position Throttle correction value data Final common rail pressure command Final injection timing command Common rail pressure, left bank Common rail pressure sensor voltage, left bank Common rail pressure, right bank Common rail pressure sensor voltage, right bank Boost pressure Boost pressure sensor voltage Engine oil pressure Engine oil pressure sensor voltage Fuel injection rate Ambient pressure Ambient pressure sensor voltage Ambient temperature Travel speed (Theoretical value) Transmission-related controller input signal 1 Transmission-related controller input signal 2 Transmission-related controller operation input signal Blade lever oil pressure switch input signal Transmission-related controller ON/OFF output 2 Steering-related controller switch input signal 1 Steering-related controller switch input signal 2 Steering-related controller switch input signal 5 Transmission-related controller ON/OFF output 1 Steering-related controller output signal 2 Exhaust temperature, left front
Unit mA % mV % % MPa CA MPa mV MPa mV kPa mV % kPa mV L/h kPa mV C km/h bit bit bit bit bit bit bit bit bit bit C C C mV
Remarks (Absolute pressure) (Absolute pressure) (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information)
Automatic selection 9 24 10 18 12 13 14 15 11 4
86 32900 BODY ANGLE Machine pitch angle
96 36700 ENG TORQUE Engine converted torque
115 42601 EXH TEMP RR Exhaust temperature, right rear 116 42602 EXH TEMP RF Exhaust temperature, right front 117 42603 EXH TEMP RF Exhaust temperature sensor voltage, right front
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No. Code 118 42604 EXH TEMP LF
Monitoring item Exhaust temperature sensor voltage, left front
Unit mV mV C mV C mV kPa MPa bit % % mV mV mV mV mV mV rpm rpm W mV mV rpm bit mV mV Letter Letter Letter Letter mV bit bit mV mA MPa mV MPa mV bit bit
Remarks (See detailed information)
Automatic selection 19 20 21 22 23 38 5
119 42605 EXH TEMP RR Exhaust temperature sensor voltage, right rear 120 42606 EXH TEMP LR Exhaust temperature, left rear 121 42607 EXH TEMP LR Exhaust temperature sensor voltage, left rear 122 42700 ENG OIL TMP 123 42701 ENG OIL TMP 124 42800 BLOWBY PRS 125 43000 T/M PRESS 126 43502 IdleCancel 127 44202 Accel Up 128 44203 Accel low 129 50200 T/M LEVR 1 130 50201 T/M LEVR 2 131 50300 S/T LEVR 1 132 50301 S/T LEVR 2 133 50400 BRAKE PEDL 134 50900 N-SAFTY 135 51000 ENG REG 136 51100 FUEL DIAL 137 60000 TRACTION 138 60100 BODY ANGLE 139 60200 ACCELERATN 140 60300 SSC ORDER 141 60400 S/T-SW6 142 60500 ENG.CON. PW 143 60600 BR HOLD 144 60700 S/T MODE 145 60800 FILL MODE 146 60909 MOD MODE 147 70000 CHG.P. MODE 148 70200 T/M OUT 149 70300 B. KNOB SW 150 70305 T/M RIPER2 151 70400 BACK ALARM 152 70600 DUAL SOL. 153 70700 HYD. PUMP 1 154 70701 HYD. PUMP 1 155 70702 HYD. PUMP 2 156 70703 HYD. PUMP 2 157 90000 T/M SOL. 3 158 90001 T/M SOL. 4 Engine oil temperature Engine oil pressure sensor voltage Blow-by pressure Transmission main relief pressure Warm-up operation cancel flag Throttle upper limit value data Throttle lower limit value data Directional lever potentiometer 1 voltage Directional lever potentiometer 2 voltage Steering potentiometer 1 voltage Steering potentiometer 2 voltage Brake pedal potentiometer voltage Neutral safety relay drive voltage Regulation command speed Fuel control dial command speed Traction force (Theoretical value) Machine pitch angle sensor voltage Acceleration sensor voltage SSC command speed Steering-related controller input signal 6 Engine controller drive voltage Battery relay drive voltage Steering state code Fill condition setting variable Modulation condition setting variable Gearshift point condition setting variable Transmission speed sensor voltage Blade lever knob switch input signal Ripper lever oil pressure switch input signal Backup alarm relay drive voltage Dual tilt solenoid drive current Work equipment pump oil pressure 1 Work equipment oil pressure sensor 1 voltage Work equipment pump oil pressure 2 Work equipment oil pressure sensor 2 voltage Tilt and pitch solenoid output 3 bit output signal Dual tilt and pitch solenoid output 4 bit output signal
(See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information)
16 17
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No. Code 159 90002 BL YOKE L 160 90003 BL YOKE R 161 90600 S/T CLT LH 162 90601 S/T CLT RH 163 90602 S/T CLT LH 164 90603 S/T CLT RH 165 92100 F1 SMR 166 92101 F2 SMR 167 92102 F3 SMR 168 92200 R1 SMR 169 92201 R2 SMR 170 92202 R3 SMR 171 99901 TRIG T F 172 99902 TRIG T R 173 99903 TRIG T 1 174 99904 TRIG T 2 175 99905 TRIG T 3 176 99906 TM SFT 177 99907 LU 178 99908 TM IN TRQ 179 99909 DOZING h 180 99910 RIPPING h 181 99911 PATH NUM 182 99913 TC IN TRQ 183 99914 H. P 1 TRQ 184 99915 H. P 2 TRQ 185 99917 BR L PRESS 186 99918 BR R PRESS 187 99919 CL L PRESS 188 99920 CL R PRESS
Monitoring item Left yoke angle sensor voltage Right yoke angle sensor voltage Left clutch ECMV output feedback current Right clutch ECMV output feedback current Left clutch ECMV output current Right clutch ECMV output current F1 integrated travel hours F2 integrated travel hours F3 integrated travel hours R1 integrated travel hours R2 integrated travel hours R3 integrated travel hours Trigger time F Trigger time R Trigger time 1 Trigger time 2 Trigger time 3 Transmission shift Lockup state Transmission input torque Dozing hours Ripping hours Number of path Torque converter input torque Work equipment pump 1 input torque Work equipment pump 2 input torque Left brake oil pressure Right brake oil pressure Left clutch oil pressure Right clutch oil pressure
Unit mV mV mA mA mA mA h h h h h h msec msec msec msec msec Letter bit Nm h h path Nm Nm Nm MPa MPa MPa MPa
Remarks (See detailed information)
Automatic selection 29 30
The numbers in the Automatic selection column can be displayed in numeric order by setting the information switch in the > or < position.
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Detailed information on bit display codes

Examples of display of bit information a The display position of the bit information in the Real-time monitoring mode (Display of only 1 item) is different from that in the Dual display monitoring mode (Simultaneous display of 2 items). a The bit information is displayed by [ ] for OFF and [o] for ON in the places 1 8. a The state of each item shown below is the condition for turning on the bit.
18301: Engine controller idle validation switch 2 1: Idle validation switch 2: ON 2: (Unused) 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
18300: Engine controller idle validation switch 1 1: Idle validation switch 1: ON 2: (Unused) 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
31520: Input state of transmission related fill switch 1: Forward clutch fill switch: ON 2: Reverse clutch fill switch: ON 3: 1st clutch fill switch: ON 4: 2nd clutch fill switch: ON 5: 3rd clutch fill switch: ON 6: (Unused) 7: (Unused) 8: (Unused)
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31521: Input state of steering related fill switch 1: Left brake fill switch: ON 2: Left clutch fill switch: ON 3: (Unused) 4: (Unused) 5: Right clutch fill switch: ON 6: Right brake fill switch: ON 7: (Unused) 8: (Unused)
40906: Transmission related controller input signal 2 1: Automatic gear shift-down switch: ON 2: Neutral switch (OPT-type travel lever): OFF 3: Neutral switch (OPT-type travel lever): ON 4: Neutral switch (OPT-type travel lever): OFF 5: Neutral switch (OPT-type travel lever): ON 6: Automatic pitch back switch: ON 7: (Unused) 8: (Unused)
40905: Transmission related controller input signal 1 1: Shift-up switch: OFF 2: Shift-up switch: ON 3: Shift-down switch: OFF 4: Shift-down switch: ON 5: Parking brake switch: FREE 6: Parking brake switch: LOCK 7: (Unused) 8: (Unused)
40907: Transmission related controller function input signal 1: ACC signal switch: ON 2: (Unused) 3: R signal: ON 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
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40908: Blade lever oil pressure switch input signal 1: Blade lift raise oil pressure switch: ON 2: Blade lift lower oil pressure switch: ON 3: (Unused) 4: (Unused) 5: Blade left tilt oil pressure switch: ON 6: Blade right tilt oil pressure switch: ON 7: (Unused) 8: (Unused)
40910: Steering related controller input signal 1 1: (Unused) 2: (Unused) 3: (Unused) 4: (Unused) 5: Parking brake lever switch: FREE 6: Parking brake lever switch: LOCK 7: (Unused) 8: (Unused)
40909: Transmission related controller output signal 2 1: (Unused) 2: (Unused) 3: (Unused) 4: Backup alarm relay: ON 5: Neutral safety relay: ON 6: Lockup: ON 7: (Unused) 8: (Unused)
40911: Steering related controller input signal 2 1: Buzzer cancel switch: t position 2: Buzzer cancel switch: U position 3: Information switch: > position 4: Information switch: < position 5: Service switch: ON 6: (Unused) 7: (Unused) 8: (Unused)
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40913: Steering related controller input signal 5 1: ACC signal: ON 2: Pre-lubrication oil pressure switch: ON 3: R signal: ON 4: (Unused) 5: Fan reverse switch: ON 6: Fan cleaning switch: ON 7: (Unused) 8: (Unused)
40915: Steering related controller ON-OFF output signal 2 1: Pre-lubrication motor relay: ON 2: Engine stop relay: ON 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
40914: Steering related controller output signal 1 1: Pre-heater relay drive: ON 2: Snap shot switch: ON 3: Fan reverse solenoid: ON 4: Merge-divider selector solenoid valve: ON 5: Battery relay drive: ON 6: Sudden stop prevent solenoid: ON 7: LS solenoid: ON 8: (Unused)
43502: Warm-up cancel flag 1: Warm-up cancel flag: ON 2: (Unused) 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
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60400: Steering related controller input signal 6 1: (Unused) 2: C signal: ON 3: Engine low idle signal: ON 4: Engine stop command signal: ON 5: Hydraulic oil level switch signal: ON 6: Pre-lubrication motor drive signal: ON 7: (Unused) 8: (Unused)
70305: Ripper lever oil pressure switch input signal 1: (Unused) 2: Ripper lift raise oil pressure switch: ON (Operated) 3: Ripper lift lower oil pressure switch: ON (Operated) 4: Ripper tilt in oil pressure switch: ON (Operated) 5: Ripper tilt out oil pressure switch: ON (Operated) 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 4: Blade lever pitch switch: ON 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
90000: Tilt/Pitch solenoid output 3 bit output signal (Superdozer specification) 1: Left tilt limit solenoid: ON 2: Right tilt limit solenoid: ON 3: Pitch solenoid: ON 4: (Unused) 5: Pitch dump solenoid: ON 6: Pitch back solenoid: ON 7: (Unused) 8: (Unused)
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90000: Dual/Pitch dump solenoid output 4 bit output signal (Other than superdozer specification) 1: Left tilt limit solenoid: ON 2: Right tilt limit solenoid: ON 3: (Unused) 4: (Unused) 5: (Unused) 6: (Unused) 7: (Unused) 8: (Unused)
99907: Lockup state 1: Forward clutch output: ON 2: Reverse clutch output: ON 3: 1st clutch output: ON 4: 2nd clutch output: ON 5: 3rd clutch output: ON 6: Clutch modulation: Modulating 7: Lockup clutch output: ON 8: Clutch state: Neutral
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)
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11. Dual display monitoring mode (11-DUAL DISPLAY MONITORING MODE) In this mode, 2 monitored items can be displayed simultaneously. a Note that only codes and monitoring information are displayed in this mode since the usable display columns are limited. (Item names and units cannot be displayed.) 1) Selecting and executing mode 1] Select Dual display monitoring mode on the mode selection screen. a If the mode is selected, code (dR) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). 2] Display the monitoring code input screen by operating buzzer cancel switch (4). q [U]: Execute mode.
2)
Selecting and entering monitored items 1] On the code input screen, input the 5digit codes of the items to be monitored to the upper and lower lines by operating information switch (5), shiftup switch (6), and shift-down switch (7). q [ > ]: Move cursor to right. q [ < ]: Move cursor to left. q [UP]: Increase number. q [DOWN]: Decrease number. 2] After inputting the codes, display the m on ito rin g scree n b y op erating buzzer cancel switch (4). q [U]: Enter input code.
If the input codes are normal, the monitoring screen shown below appears.
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If the input codes are incorrect, the code input screen appears again after the screen shown below.
4)
3)
Contents of display on monitoring screen (Figure below shows examples) (1) Code 1 (2) Information 1 (3) Code 2 (4) Information 2 a For the details, see the Monitoring mode table.
When operating machine in monitoring 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 monitoring mode.) 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 position and perform the necessary procedure.
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12. Snap shot mode (12-SNAPSHOT MODE) The VHMS specification has the manual snap shot function and automatic snap shot function. While the manual snap shot function is turned ON, various data in 7 minutes 30 seconds for the Pm clinic, testing, and adjusting can be saved in the VHMS controller. 1) Select Snap shot mode on the mode selection screen. a If the mode is selected, code (55) is displayed 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 testing, adjusting, etc., the operations of the machine are not limited. q To use the data saved with the manual snap shot function, a personal computer must be connected. For the procedure for connecting the personal computer, see Initialization procedure for VHMS controller. (The personal computer may be connected either before or after the snap shot operation.) (2) Automatic snap shot function q While the automatic snap shot function is turned ON, if an item which the VHMS controller monitors constantly becomes abnormal (if the corresponding failure code is displayed), the snap shot data of that item in 7 minutes 30 seconds are saved in the VHMS controller automatically. q Since the VHMS controller automatically performs the automatic snap shot function according to the monitoring 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.
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

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
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Adjustment method when controller has been replaced

a
4.
a a
After the machine is assembled or transmiss i on c o ntr o ll e r o r s t ee ri n g c on tr ol l er i s replaced, adjust the system according to the following procedure. If the system is not adjusted, the machine may not operate normally and may move suddenly. Accordingly, be sure to adjust it. Precautions for replacing a controller: If a controller is replaced, the memory of the oil and filter maintenance mode is reset. Accordingly, take a record of the next replacement periods of the oils and filters. Precautions for replacing a controller: When replacing a controller, stop the machine in a safe place and turn the starting switch OFF. Adjust the controller referring to the item 8. Adjusting mode in "Special functions of monitor panel (EMMS)". Controller initial setting After replacing controller, turn the switch ON temporarily (ACC position) and after approx. 10 seconds, turn the switch OFF. q After turning the switch OFF, the controller is initialized. Therefore leave it for approx. 1 minute after turning the switch OFF even if the battery relay shuts down. 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. Adjusting steering controller Select Steering controller specification set (0002) and adjust the steering controller. a Execute this code only when the transmission controller is also replaced.
Adjusting transmission controller Select Transmission controller specification set (0003) and adjust the transmission controller. a Execute this code only when the steering controller is also replaced.
5.
1.
Turning power on again Turn the starting switch off (battery relay off) and leave it for 1 minute. Then turn the starting switch on, then reset the monitor panel in the Adjustment Mode of the service mode. Adjusting machine specification Select Machine specification set ( 0004) and adjust the machine specification.
6.
2.
3.
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7.
Adjusting brake potentiometer Select Brake potentiometer initial set (0005) and adjust the brake potentiometer.
10. Turning power on again Turn the starting switch OFF (battery relay off) 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, eliminate the cause of the incident by troubleshooting, then carry out steps 10 and 11 again. a Precautions after replacing controller: If any controller is replaced, the service meter in the oil and filter maintenance mode is reset to 0. As a result, the replacement period displayed on the monitor panel may be different from the actual operating hours. To solve this problem, determine the first replacement periods of the oils and filters after the replacement of the controller according to the replacement periods recorded before the replacement of the controller.
8.
Adjusting pitch angle sensor Select the initial setting ( 0009 ) of the pitch angle sensor and adjust the pitch angle sensor.
9.
VHMS system set Set VHMS system using Adjustment mode (0022). (If not, take care that default is not-equipped set.)
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Preparation work for troubleshooting for electrical equipment system

a
2.
Engine controller 1) Open left and right side covers (1) and remove side covers (2) and (3).
When performing troubleshooting for an electrical circuit related to the monitor panel, engine controller, transmission controller, steering controller, or VHMS terminal, expose the related connectors according to the following procedure. Monitor panel 1) Remove cover (1). 2) Remove the 2 mounting bolts and pull out monitor panel (2) toward the operators seat. 2) Remove cover (4) of engine controller.
1.
3)
Insert or connect T-adapters in or to connectors S01, S02, S03, and S04 of monitor 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}
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In order to prevent malfunction and mistaken system error warning, be sure to completely remove foreign object (b) such as sand, dust, water, etc., from inside of controller side connector (a) with air blow etc., before connecting to harness connector.
2)
Insert or connect T-adapters in or to connectors TMC1, TMC2, and TMC3 of transmission controller (2). a If the connectors cannot be disconnected 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}
3.
Transmission controller 1) Remove dashboard cover (1).
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4.
Steering controller 1) Remove dashboard undercover (1).
5.
VHMS controller 1) Open the floor left side cover and remove cover (1).
2)
Insert or connect T-adapters in or to connectors STCN1 , STCN2 , and STCN3 of steering controller (2). a If the connectors cannot be disconnected 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}
2)
Remove amplifier mounting cover (2).
3)
Insert or connect T-adapters in or to connectors 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.
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6.
ORBCOMM terminal 1) Open the floor left side cover and remove cover (1).
2) 3)
Referring to 5 above, remove VHMS controller (3). Insert or connect T-adapters in or to connectors KOM1 of ORBCOMM terminal (4). a If it is difficult to remove and install the connectors, remove the terminal for the ease of work.
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Inspection procedure of diode

a
2.
The direction of continuity of diode is marked on the surface of the diode.
1.
When using digital tester 1) Switch to diode range and check displayed value. a Voltage of internal battery is displayed by normal tester. 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 displayed. q Displayed value becomes 0 or near 0: Short-circuiting of diode internal part (defect)
When using analog tester 1) Switch to resistance range. 2) Check the deflection of needle while connecting 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 connection 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 i) and ii): Defective (internal short circuit) q Needle does not deflect with either connection i) or ii): Defective (internal disconnection)
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Handling of optional devices

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. 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. 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 control dial position. 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 following connector pin. q CN-PRS (2-pole heavy duty wire connector) a Remove the connector installed when the machine is shipped, and connector pin (1) to the starting signal to be finally output by the pre-lubricator and connector pin (2) to the input signal from the starting switch. Connecting external power source If an external power source is necessary, connect 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.
1.
2.
3.
4.
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Initialization procedures for VHMS controller 1

a Initialization tools for VHMS controller
Part No. 799-608-3211 799-608-3220 Commercially available Diskette Wiring harness Notebook type personal computer (OS: Windows98/2000/ NT/Me/XP Terminal "RS232C" is with it) Part name Symbol 1 Z 2
1.
Check of machine information, engine information and controller information a This step is a work performed on the whole machine. Check and record the machine information, engine information, VHMS controller information and ORBCOMM terminal information.
No. 1 2 3 4 5 6 7 Information to be checked Machine model Machine serial No. Current service meter reading Engine serial No. Transmission serial No. VHMS controller serial No. ORBCOMM terminal serial No. [For ORBCOMM specification only]
Before starting full operation after completion of local assembly or before resuming operation after storage for a long period, initialize the VHMS controller according to the following procedure. Machine data collected with the VHMS controller 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 utilized. Accordingly, be sure to carry out the initialization. For the method of installing the VHMS Initialization Program to the personal computer, refer to the Operation and Maintenance Manual contained in the package of diskette Z1. Since the service menu of the monitor panel will be used in the following procedure, read Special functions of monitor panel and understand the operating procedure in advance. The initialization procedures cover both ORBCOMM Specification and ORBCOMMLESS Specification. In case of ORBCOMMLESS Specification, omit the procedures necessary for ORBCOMM Specification only. During the initialization work, confirm each work according to the VHMS Initialization Work Checklist.
The VHMS controller and ORBCOMM terminal are in the VHMS controller box under the left side cover of the floor.
2.
Connection of personal computer 1) Make sure that the starting switch is in the OFF position. k Be sure to connect and disconnect the personal computer while starting switch is in the OFF position. 2) Connect personal computer Z3 and download 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.
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2) 3) 4)
Select Service mode and Real-time monitoring mode in order on the monitor panel. Input ID = 20301. If the central part of the lower line of the multi-information display unit counts up, the VHMS controller is normal.
a a
Execute initialization of VHMS from the connector in the cab. Use the ground download connector for only downloading.
5)
6)
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. 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 position. 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 operator's cab. a Check of satellite capturing condition is necessary o only [ORBCOMM specification]. 1) Set the starting switch in the ON position.
7)
At least 3 minutes after starting the VHMS, check the decimal point at the right bottom of the LED of the VHMS controller or the decimal point at the right bottom of the central part of the lower line of the multiinformation display unit.
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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 [ORBCOMM specification]. a Check the communication satellite capturing condition of the ORBCOMM controller on the VHMS controller side. a If the ORBCOMM controller is normal, the decimal point LED of the right-hand 7 segments flashes.
Right decimal point OFF
Display Power is not supplied to ORBCOMM controller. Communication line to VHMS controller is abnormal. Satellite is not captured. Power is supplied to ORBCOMM controller. Communication line to VHMS controller is normal. Power is supplied to ORBCOMM controller. Communication line to VHMS controller is normal. Satellite is captured.
ON
4.
Blinking
8)
Check the controller for normal operation referencing 7-segment LED of VHMS controller. a VHMS controller is fed with switch power supply. Thus, its operation is judged normal if its 7-segment LED starts flashing while rotating as the starting switch is turned on and then if the controller starts counting in the ascending order.
Startup of VHMS initialization tool a This step is a work performed in the operator's cab (on the personal computer). 1) Turn on the personal computer and start the OS. 2) Click the icon of [VHMS Initialization Tool] on the personal computer screen to start the VHMS initialization tool. a The setting screen varies with the version No. of the VHMS setting tool. a When using a tool before Ver. 3.5.2.1 (CD-ROM), set the VHMS in step 5. a When using an updated tool (Ver. 3.5.2.1 or after), set the VHMS in step 6. a It is recommended to download the latest VHMS setting tool from the WebCARE and update your tool. (Related material: Servicemate SMP623) 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.
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3)
If information in the [Date/Time] box is not correct, change it according to the following 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)
5.
Initialization of VHMS controller (Tool before Ver. 3.5.2.1) a This step is a work performed in the operator'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 displayed first in the [Data clear and Set up] menu. 2) Check all the data.
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 information] box to display the correction screen. 2] Correct the information and press the [OK] button.
5)
After checking/changing all the data in [Machine information], press [Apply] button (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 Specification, execute [Communication Setting] first and then settle the setting.
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[Communication Setting] [For ORBCOMM specification only] a Execute this setting after requesting for opening 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 [Occurrence] at [Timing] and set the function to [ON].
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9)
To change setting in [SHORT TREND ANALYSIS], follow the procedures below: 1] Select [SHORT TREND ANALYSIS] on the screen and press [Edit] button 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, input [20h] to [SMR] and set the function to [ON].
11) After checking/changing all the data in [Communication Setting], press [Apply] button to settle the setting. a If the [Apply] button is pressed, the s c r e e n f or c h e c k in g th e s e t ti n g appears. Check the setting again and press the [OK] button if the setting is correct.
10) To change the setting of [Satellite Setting], follow the procedure below. 1] Press the [Edit] button in the [Satellite Setting] block to display the setting screen. 2] Set the GCC Code to the applicable area and then press the [OK] button.
12) After checking/changing the data of [Machine Information] and [Communication Setting], press the [Exit] button at the right lower part of the screen to finish [VHMS Initialization Tool].
GCC codes and applicable areas Code 1 120 121 Applicable Area U.S.A. Italy Malaysia Code 122 123 130 Applicable Area Korea Brazil Japan
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6.
Initialization of VHMS controller (Ver. 3.5.2.1 or after) a This step is a work performed in the operator's cab (on the personal computer). a When initializing, do not change the data of service meter [SMR]. 1) Select [VHMS Setting] and press the Next button.
3)
Check the machine information. If it does not need to be corrected, press the Next button.
If the VHMS was installed additionally, the information of [Serial No.] etc. must be input.
2)
Select [Set up & All clear] and press the Next button.
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4) 5) 6)
Select the time zone. Input the local time. If the DST (Daylight Saving Time) is used 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.
8)
The contents of the setting are displayed finally. If there is not a problem, press the Apply button.
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
Code 1 120 121
Applicable Area U.S.A. Italy Malaysia
Code 122 123 130
Applicable Area Korea Brazil Japan
10) After finishing the work of changing the contents of initialization, press the OK button to finish the program.
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7.
Procedures for executing Quick Pm a The Quick Pm means the Pm Clinic executed with the manual snap shot function of the monitor panel. a Data in 7 minutes 30 seconds are saved in the VHMS controller. k Stop the machine on a flat place. 1) 2) Start the engine. Set the monitor panel to display the service menu. a For the operating method, see Special functions of monitor panel. 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 display unit (1) and the title is displayed in multi-information unit (2).
2] 3]
Set the buzzer cancel switch in the [U] position. READY is displayed and the system is ready to start. a On the lower line, 15 pieces of - are displayed.
3)
4]
Set the buzzer cancel switch in the [U] position, and the snap shot operation starts. a After the snap shot operation starts, the elapsed time is displayed 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 operation, set the buzzer cancel switch in the [t] position.
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5]
After starting the snap shot operation, operate the machine according to Table 1. a Check that the engine coolant temperature and torque converter 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.
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Table 1 Operations of machine to be executed while snap shot is operated

Time (sec) Operation of machine State of machine Transmission N N N N N N N N NoF1oF2oF 3oNoR1oR2 oR3oN NoF3 (Shift to F3, then run engine at full throttle) N NoF3 (Shift to F3, then run engine at high idle) N Fuel SteerWork equipment control ing dial LH RH N N N N N N N N N N Right tilt (or pitch back in case of dual tilt model) Left tilt (or pitch dump in case of dual tilt model) LOW LOW HI HI HI LOW HI LOW Decelerator pedal HI HI HI LOW HI HI HI HI Brake pedal Parking brake Finish Start
No. 1 2 3 4 5 6 7 8
0:00 0:25 25 0:25 0:50 25 0:50 1:40 50
Low idle High idle
Released Released Released Released Released Released Released Released Released Released Released Released Released Released Released Released
1:40 2:30 50 Deceleration slow 2:30 3:00 30 3:00 3:30 30 3:30 4:00 30 4:00 4:30 30 High-pressure relief & high idle High-pressure relief & low idle Port relief & high idle Port relief & low idle Torque converter stall & low idle
4:30 5:10 40
LOW
HI LOWo Shift to F3, then HI HI LOWo Shift to F3, then HI HI
ON
Released
Torque converter 10 5:10 6:00 50 stall (F3) & high idle (Note 1) 11 6:00 6:30 30 High idle
HI
ON
Released
N Left tilt (or pitch dump in case of dual tilt model) N
HI
Released Released
Torque converter 12 6:30 7:10 40 stall + High-pressure relief 13 7:10 7:30 20 High idleo Low idle (Note 2)
HI HIo LOW
ON
Released
Released
ON
(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
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6]
The screen shown below appears 7 minutes 30 seconds after the snap shot is started, and then the initial screen appears 5 seconds after. (End of snap shot)
q q
q q q q q
Important The data of the Quick Pm is recorded only once. If the Quick Pm is executed again, the current data are overwritten. Accordingly, be sure to save the data in the personal computer after executing the Quick Pm, referring to 8. Downloading of set data. 7] a 8] a Using the analysis tool, read the data of the Quick Pm. For the usage of the analysis tool, see the operation manual. Open the data of the Quick Pm and translate them into a graph. Set the time to the X-axis and set the following items to the Y-axis. q Engine Speed q Fuel Inject
q q
q q q q
Blowby Press Exhaust Temp RB (Exhaust temperature of right bank: 1, 2, 3, 4, 5, 6) Exhaust Temp LB (Exhaust temperature of left bank: 1, 2, 3, 4, 5, 6) Engine Oil Press Engine Oil Temp Eng Coolant Temp Ambient Temp Demand Eng Speed (Engine speed demanded by controller) T/C Oil Temp (Torque converter oil temperature) T/M Main Press (Transmission main relief pressure) T/M Output Speed (Transmission output speed) Shift Position ( Tr a n s m i s s i o n , t r a v e l , g e a r speed) S/T Clutch Pos. (Steering clutch position) S/T Brake Pos. (Steering brake position) Hydr Oil Temp (Hydraulic oil temperature) Pump 1 Press (Work equipment pump 1 oil pressure) Pump 2 Press (Work equipment pump 2 oil pressure) Body Pitch Angle (Pitch angle)
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9]
Check Click position graphic value display.
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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.)
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11] Enter the above value in the Pm Clinic Inspection Sheet. a The relationship between the data necessary for the Pm Clinic and the measurement conditions is as follows.
Measurement items Transmission main relief pressure
Steering right clutch fill switch
Steering right brake fill switch Q Q Q
Steering left clutch fill switch
Steering left brake fill switch
2nd clutch fill switch
Engine at low idle Engine at high idle Deceleration slow High-pressure relief & engine at full throttle High-pressure relief & engine at slow Port relief & engine at full throttle Port relief & engine at slow Torque converter stall & engine at slow Torque converter stall (F3) & engine at full throttle Engine at full throttle Torque converter stall & high-pressure relief Engine at high idle o Engine at low idle
Q Q Q Q Q
Q Q
Q Q
3rd clutch fill switch
Engine oil pressure
1st clutch fill switch
State of machine Blow-by pressure Engine speed
Q Q Q Q
Q Q
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Work equipment pump (FR) Q Q Q Q
Front clutch fill switch
Rear clutch fill switch
Exhaust temperature
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8.
Downloading of set data 1) Connect personal computer Z3 and download connectors VDW in the cab or ground download connector DL1 by wiring harness Z2.
2) 3) a Download connector VDW in the cab is installed to the left rear lower part of the operator's seat. 4)
When using download connector VDW in the cab, set the starting switch in the ON position. When using ground download connector DL1, turn switch (2) ON. a The green LED lights up. Operate the icon of [VHMS Technical Analysis Tool] on the personal computer to start the VHMS technical analysis tool.
a a a Ground download connector DL1 is installed in frame (1) at the rear of the machine.
Input [User Name] and [Password]. For the operation procedures, see the Operation and Maintenance Manual for VHMS Technical Analysis Tool.
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5)
Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. a For the operation procedures, see the Operation and Maintenance Manual for VHMS Technical Analysis Tool. a Make sure that downloading has completed before proceeding to the next step.
10. Disconnection of Personal Computer 1) Make sure that the starting switch is in the OFF position. k Be sure to turn off the starting switch before connecting or disconnecting the personal computer. 2) Finish the OS of the personal computer and then turn the personal computer OFF.
9.
Check of downloaded data a This step is a work performed in the operator's cab (on the personal computer). 1) Check the set data with the [View] function. a For the operation procedures, refer to the Operation and Maintenance Manual for VHMS Technical Analysis Tool. a Make sure that the [MFA0] code at the time when the snapshot was operated is displayed in [Fault History]. a Make sure that the snap shot data is recorded.
3)
If the data was downloaded in the cab, disconnect wiring harness Z2 from download connector VDW.
4)
2)
After checking the set data, terminate [VHMS Technical Analysis Tool].
If the data was downloaded on the ground, turn switch (2) OFF and disconnect wiring harness Z2 from download connector DL1.
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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
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(Objective model: D475A-5E0 Bulldozer)
28
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(Objective model: D475A-5E0 Bulldozer)
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Precautions for replacing VHMS controller 1

a Tools for replacing VHMS controller
Symbol 1 Z 2 Part No. 799-608-3211 799-608-3220 Commercially available Diskette Wiring harness Notebook type personal computer (OS: Windows98/2000/NT/ Me/XP Terminal "RS232C" is with it) Name
2)
Select Save/Load and press the OK button.
a a
When the VHMS controller needs to be replaced, set it before removing it and the installed new VHMS controller according to the following procedure. Machine data collected with the VHMS controller 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 utilized. Accordingly, be sure to carry out the initialization. During the initialization work, confirm each work according to the VHMS Initialization Work Checklist. The information of model name etc. shown in the figures is different from the actual machine.
3) 4)
Check all the information before replacing the VHMS controller. Select [Save] from [File] in the menu.
[Work before replacing VHMS controller] 1. Downloading of remaining data a This step is a work performed in the operator's cab (on the personal computer). a Using the [Download] function, download the data currently recorded in the VHMS controller to the personal computer. a For the operating procedures, see Initialization procedures for VHMS controller, 8. Downloading of set data. Check, saving and writing of information set in VHMS controller (Before Ver. 3.5.2.1) a This step is a work performed in the operator's cab (on the personal computer). a Transfer the set data of the VHMS controller to be replaced to the personal computer a nd th en wr ite 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. 2.
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5)
Check the information again and press the OK button to save it.
3)
Select [Load] from [File] in the menu.
4)
The saved information is displayed. Press the OK button.
6) 7)
8) 9)
Select [Exit] from [File] in the menu to finish the VHMS technical analysis tool. Disconnect the personal computer. a See Initialization procedures for VHMS controller, 9. Disconnection of Personal Computer. Turn the personal computer OFF. Replace the VHMS controller.
2-2. Writing of set information in new VHMS controller 1) Connect the personal computer again and start the VHMS technical analysis tool. a See Initialization procedures for VHMS controller. 2) Select Save/Load and press the OK button.
5) 6)
The saved information is displayed on another screen. Press the [Edit] button to set the time.
32
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7)
After setting the time, press the OK button.
9)
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.
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.
10) Select [Exit] from [File] in the menu to finish the VHMS setting tool. 3. Check, saving and writing of information set in VHMS controller (Ver. 3.5.2.1 or after) a This step is a work performed in the operator's cab (on the personal computer). a Transfer the set data of the VHMS controller to be replaced to the personal comp uter an d the n wr ite it in the n ewly 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. a See Initialization procedures for VHMS controller. 2) Select [When VHMS needs to be replaced] and press the Next button.
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3)
Select [Save Current Setting before replacement of VHMS controller] and press the Next button.
3-2. Writing of set information in new VHMS controller 1) Connect the personal computer again and start the VHMS technical analysis tool. a See Initialization procedures for 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 replacement of VHMS controller] and press the Next button.
5) 6)
7) 8)
Select [Exit] from [File] in the menu to finish the VHMS setting tool. Disconnect the personal computer. a See Initialization procedures for VHMS controller, 9. Disconnection of Personal Computer. Turn the personal computer OFF. Replace the VHMS controller.
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4)
The saved information is displayed. Press the Next button.
7)
The above completes modification of the setting. Press [OK] button to end the VHMS initial setting tool.
5)
Set the time and press the Apply button.
[Work after replacing VHMS controller] a After replacing the VHMS controller, carry out initialization according to the Initialization Procedure 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 controller was replaced.) a After completing the setting after the replacement, send the check sheet to VHMS/WebCARE 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.
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Pm Clinic service
Model T D475A-5E0 T D475ASD-5E0 User name
1
Serial No. Service meter h
Date of clinic / /
Serviceman
Specifications Blade T Semi U blade T U blade T Super blade T Attachment T Variable Multi-shank ripper T Variable giant ripper T Counterweight ( kg) T Operating conditions Quarry, mine T Coal T Gold T Limestone T Construction T Construction, civil engineering T Roads T Tunnels T Type of soil (specific gravity) T Rock T Gravel T Sand T Clay Existence of abnormalities Oil, coolant level check T Engine coolant level T Engine oil level T Hydraulic oil level When necessary T Power train T Final drive Ambient temperature Max. Min. C T Damper case T( ) Type of work T Dozing T Side cutting T Ripping T Travel T 710 mm T 810 mm T 910 mm T Shoe width % % % %
Height above sea level m
Operator's opinion
Visual check results
Failure code history [ Content: [ Content: ] h ] h [ Content: [ Content: ] h ] h
Engine coolant temperature: Max. range
Power train oil temperature: Max. range
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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
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Reference pages for measurement procedures 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
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Reference pages for measurement procedures 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
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Decelerator low idle Decelerator high idle
1,950 2,050
1,950 2,050
Low idle High idle
Low idle
Transmission: Neutral Oil temperature: Within operating range High idle
Low idle Transmission: Neutral High idle High idle Transmission: F3 (Adjustment code: 5535) Transmission: R3 (Adjustment code: 5535) Transmission: F1 (Adjustment code: 5535) Transmission: F2 (Adjustment code: 5535) Transmission: F3 (Adjustment code: 5535) Low idle Low idle Low idle Low idle Low idle
40
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Low idle
High idle Transmission: Neutral Low idle
High idle
Engine speed high idle, F2, brake applied
Low idle
High idle
Low idle
High idle
High idle
Low idle High idle High idle
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Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle Low idle High idle
42
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Pm clinic Undercarriage check sheet

Work order /
q
Serial number Date /
T D475A-5E0 # T D475ASD-5E0 # Serviceman h
Service meter
Measure the bushing temperature immediately after operations Left side of machine
Right side of machine
Measurement results
Pass Fail
Left side of machine Right side of machine

q
Opening of track link

Left track Pin No. A: Clearance between links 1.6 Right track Pin No. A: Clearance between links 1.6
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UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)

(Program form No.: SELA195001)
44
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UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)

(Program form No.: SELA195001)
IMPACT
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2 Fuse locations............................................................................................................................................... 12
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40 Troubleshooting
Failure code table

Failure code Troubled part Clutch slip Double engagement Clutch slip Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Clutch slip Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Abnormal heating Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Abnormal heating Command current is OFF and fill signal is ON Command current is ON and fill signal is OFF Abnormal heating Overheat Clogging Malfunction Oil pressure reduction Oil level reduction Overheat Coolant level reduction Water in fuel Trouble Component in charge T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M S/T S/T S/T S/T S/T S/T S/T S/T S/T S/T S/T S/T MON MON MON ENG MON ENG MON MON Action code Category of record Electrical system Reference manual
1380MW Lockup clutch 1500L0 Transmission clutch
CALL E03 Electrical system Electrical system
15E0MW Transmission clutch 15SAL1 Forward clutch oil pressure 15SALH Forward clutch oil pressure 15SBL1 Reverse clutch oil pressure 15SBLH Reverse clutch oil pressure 15SEL1 1st clutch oil pressure 15SELH 1st clutch oil pressure 15SFL1 2nd clutch oil pressure 15SFLH 2nd clutch oil pressure 15SGL1 3rd clutch oil pressure 15SGLH 3rd clutch oil pressure 1800MW Power train clutch 2201L1 Right clutch oil pressure
CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system Electrical system
CALL E04 Electrical system CALL E04 Electrical system TroubleshootCALL E04 Electrical system ing by failure code, Part 1 CALL E04 Electrical system SEN01823-01 Electrical system CALL E04 Electrical system CALL E04 Electrical system CALL E04 Electrical system CALL E04 Electrical system CALL E04 Electrical system CALL E04 Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system
2201LH Right clutch oil pressure 2202L1 Left clutch oil pressure
2202LH Left clutch oil pressure 2300NR Brake thermal load 2301L1 Right brake oil pressure
2301LH Right brake oil pressure 2301NR Right steering brake thermal load 2302L1 Left brake oil pressure
2302LH Left brake oil pressure 2302NR Left steering brake thermal load 6001ZK Failure code for design A000NS Engine AA10NX Air cleaner AB00MA Battery charge abnormality B@BAZG Engine oil B@BAZK Engine oil B@BCNS Engine coolant B@BCZK Engine coolant B@BEBF Fuel
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Failure code B@BFZK Fuel level
Troubled part Reduction Overheat
Trouble
Component in charge MON MON MON MON MON MON S/T
Action code
Category of record Mechanical system Mechanical system
Reference manual
B@CENS Power train oil B@CHZG HSS charge oil pressure B@CHZK Power train B@GAZK Battery electrolyte level B@HANS Hydraulic oil B@HAZK Hydraulic oil CA111 CB111 CA115 CB115 CA122 CA123 CA131 CA132 CA135 CA141 CA144 CA145 CA153 CA154 CA187 CB187 CA212 CA213 CA221 CA222 CA227 CB227 CA234 CA238 CB238 CA263 CB263 CA265 Engine controller (Left bank) Engine controller (Right bank) Engine NE/Bkup speed sensor abnormality (Left bank) Engine NE/Bkup speed sensor abnormality (Right bank) Charge pressure sensor abnormally high level (Only left bank) Charge pressure sensor abnormally 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 abnormally high level (Only left bank) Coolant temperature sensor abnormally low level (Only left bank) Charge temperature sensor abnormally high level (Only left bank) Charge temperature sensor abnormally low level (Only left bank) Sensor power supply (2) abnormally low level (Left bank) Sensor power supply (2) abnormally low level (Right bank) Engine oil temperature sensor abnormally high level (Only left bank) Engine oil temperature sensor abnormally low level (Only left bank) Ambient temperature sensor abnormally high level (Only left bank) Ambient temperature sensor abnormally low level (Only left bank) Sensor power supply (2) abnormally high level (Left bank) Sensor power supply (2) abnormally high level (Right bank) Engine overspeed (Only left bank) Ne speed sensor power supply abnormality (Left bank) Ne speed sensor power supply abnormality (Right bank) Fuel temperature sensor abnormally high level (Left bank) Fuel temperature sensor abnormally high level (Right bank) Fuel temperature sensor abnormally low level (Left bank)
Low oil pressure Oil level reduction Electrolyte level reduction Overheat Oil level reduction Internal abnormality Internal abnormality Speed sensor signal error Speed sensor signal error High voltage detection Low voltage detection High voltage detection Low voltage detection High voltage detection Low voltage detection High voltage detection Low voltage detection High voltage detection Low voltage detection Low voltage detection Low voltage detection High voltage detection Low voltage detection High voltage detection Low voltage detection High voltage detection High voltage detection Abnormally high speed Low voltage detection Low voltage detection Abnormally high speed Abnormally high speed Low voltage detection
Mechanical system Troubleshooting by failure Mechanical system code, Part 1 Mechanical system SEN01823-01 Mechanical system Mechanical system
ENG CALL E04 Electrical system ENG CALL E04 Electrical system ENG CALL E04 Electrical system ENG CALL E04 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E02 Electrical system ENG CALL E02 Electrical system ENG CALL E02 Electrical system ENG CALL E02 Electrical system ENG CALL E01 Electrical system TroubleshootENG CALL E01 Electrical system ing by failure code, Part 2 ENG CALL E03 Electrical system SEN01824-01 ENG CALL E03 Electrical system ENG CALL E01 Electrical system ENG CALL E01 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG Mechanical system
ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E01 Electrical system ENG CALL E01 Electrical system ENG CALL E01 Electrical system
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40 Troubleshooting
Failure code CB265 CA271 CB271 CA272 CB272 CA273 CB273 CA274 CB274 CA322 CA323 CA324 CA325 CA331 CA332 CA342 CB342 CA351 CB351 CA352 CB352 CA386 CB386 CA441 CB441 CA442 CB442 CA449 CB449 CA451 CB451 CA452 CB452 CA553 CB553
Troubled part
Trouble
Component in charge
Action code
Category of record
Reference manual
Fuel temperature sensor abnormally Low voltage detection low level (Right bank) PCV1 short circuit (Left bank) PCV1 short circuit (Right bank) PCV1 disconnection (Left bank) PCV1 disconnection (Right bank) PCV2 short circuit (Left bank) PCV2 short circuit (Right bank) PCV2 disconnection (Left bank) PCV2 disconnection (Right bank) Injector #1 (L/B#1) system disconnection/short circuit (Left bank) Injector #5 (L/B#5) system disconnection/short circuit (Left bank) Injector #3 (L/B#3) system disconnection/short circuit (Left bank) Injector #6 (L/B#6) system disconnection/short circuit (Left bank) Injector #2 (L/B#2) system disconnection/short circuit (Left bank) Injector #4 (L/B#4) system disconnection/short circuit (Left bank) Engine controller data mismatch (Left bank) Engine controller data mismatch (Right bank) Injector drive circuit abnormality (Left bank) Injector drive circuit abnormality (Right bank) Sensor power supply (1) abnormally low level (Left bank) Sensor power supply (1) abnormally low level (Right bank) Sensor power supply (1) abnormally high level (Left bank) Sensor power supply (1) abnormally high level (Right bank) Power supply voltage abnormally low level (Left bank) Power supply voltage abnormally low level (Right bank) Power supply voltage abnormally high level (Left bank) Power supply voltage abnormally high level (Right bank) Common rail abnormally high pressure (2) (Left bank) Common rail abnormally high pressure (2) (Right bank) Common rail pressure sensor abnormally high level (Left bank) Common rail pressure sensor abnormally high level (Right bank) Common rail pressure sensor abnormally low level (Left bank) Common rail pressure sensor abnormally low level (Right bank) Common rail abnormally high pressure (1) (Left bank) Common rail abnormally high pressure (1) (Right bank) Short circuit Short circuit Disconnection Disconnection Short circuit Short circuit Disconnection Disconnection Disconnection/Short circuit Disconnection/Short circuit Disconnection/Short circuit Disconnection/Short circuit Disconnection/Short circuit Disconnection/Short circuit Mismatch Mismatch Circuit abnormality Circuit abnormality Low voltage detection Low voltage detection High voltage detection High voltage detection Low voltage detection Low voltage detection High voltage detection High voltage detection Abnormally high pressure occurrence Abnormally high pressure occurrence High voltage detection High voltage detection Low voltage detection Low voltage detection Abnormally high pressure occurrence Abnormally high pressure occurrence
ENG CALL E01 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system Troubleshooting by failure ENG CALL E03 Electrical system code, Part 2 ENG CALL E03 Electrical system SEN01824-01 ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system TroubleshootENG CALL E03 Electrical system ing by failure code, Part 3 ENG CALL E03 Electrical system SEN01825-01 ENG CALL E04 Electrical system ENG CALL E04 Electrical system ENG CALL E04 Electrical system ENG CALL E04 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG ENG E02 E02 Electrical system Electrical system
D475A, D475ASD-5E0
40 Troubleshooting
SEN01821-01
Failure code CA554 CB554 CA559 CB559 CA689 CB689 CA691 CA692 CA731 CB731 CA757 CB757 CA778 CB778 CA781 CB781 CA1257 CB1257 CB1548 CB1549 CB1551 CB1552 CB1553 CB1622
Troubled part Common rail pressure sensor inrange error (Left bank) Common rail pressure sensor inrange error (Right bank) Supply pump low pressure (1) (Left bank) Supply pump low pressure (1) (Right bank) Engine Ne speed sensor abnormality (Left bank) Engine Ne speed sensor abnormality (Right bank) Intake air temperature sensor abnormally high level (Only left bank) Intake air temperature sensor abnormally low level (Only left bank) Engine Bkup speed sensor abnormal phase (Left bank) Engine Bkup speed sensor abnormal phase (Right bank) Engine controller all data loss (Left bank) Engine controller all data loss (Right bank) Engine Bkup speed sensor abnormality (Left bank) Engine Bkup speed sensor abnormality (Right bank) Inter-multicontroller communication error (Left bank) Inter-multicontroller communication error (Right bank) Multicontroller distinction wiring harness key error (Left bank) Multicontroller distinction wiring harness key error (Right bank) Injector #7 (R/B#1) system disconnection/short circuit (Right bank) Injector #8 (R/B#2) system disconnection/short circuit (Right bank) Injector #10 (R/B#4) system disconnection/short circuit (Right bank) Injector #11 (R/B#5) system disconnection/short circuit (Right bank) Injector #12 (R/B#6) system disconnection/short circuit (Right bank) Injector #19 (R/B#3) system disconnection/short circuit (Right bank)
Trouble In-range error occurrence In-range error occurrence Low pressure occurrence Low pressure occurrence Signal error Signal error High voltage detection Low voltage detection Phase error Phase error All data loss All data loss Bkup signal error Bkup signal error Communication error Communication error Distinction error Distinction error Disconnection/Short circuit Disconnection/Short circuit Disconnection/Short circuit Disconnection/Short circuit Disconnection/Short circuit Disconnection/Short circuit Communication error High voltage detection Low voltage detection Low pressure occurrence Low pressure occurrence Disconnection Short circuit Disconnection Short circuit Disconnection
Component in charge
Action code
Category of record
Reference manual
ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG ENG E02 E02 Electrical system Electrical system
TroubleshootENG CALL E03 Electrical system ing by failure code, Part 3 ENG CALL E03 Electrical system SEN01825-01 ENG E01 Electrical system ENG E01 Electrical system
ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E04 Electrical system ENG CALL E04 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system Troubleshooting by failure ENG CALL E03 Electrical system code, Part 4 ENG CALL E03 Electrical system SEN01826-01 ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system ENG CALL E03 Electrical system S/T S/T T/M T/M T/M E02 E02 E01 Electrical system Electrical system Electrical system Electrical system Electrical system
CA1633 KOMNET abnormality (Left bank) Decelerator pedal sensor power supCA2185 ply abnormally high level (Only left bank) Decelerator pedal sensor power supCA2186 ply abnormally low level (Only left bank) Supply pump low pressure (2) CA2249 (Left bank) Supply pump low pressure (2) CB2249 (Right bank) D110KA Battery relay D110KB Battery relay D130KA Neutral safety relay D130KB Neutral safety relay D161KA Backup alarm relay
D475A, D475ASD-5E0
SEN01821-01
40 Troubleshooting
Failure code
Troubled part
Trouble Short circuit Disconnection/short circuit Disconnection Short circuit Disconnection Short circuit Communication error Communication error Communication error Controller internal abnormality Power supply voltage reduction (Input) Power supply voltage reduction (Input) Power supply voltage reduction (Input) Power supply voltage reduction (Input) Power supply voltage reduction (Input) Model selection signal disagreement Communication error Communication error Communication error Communication error Communication error Controller internal abnormality
Component in charge T/M S/T S/T S/T S/T S/T
Action code E01 E01
Category of record Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Reference manual
D161KB Backup alarm relay D182KZ Preheater relay Engine controller ACC signal cut relay Engine controller ACC signal cut D190KB relay D190KA D5ZRKA Snap shot switch D5ZRKB Snap shot switch DAFRKR Monitor panel CAN communication (MON) Monitor panel CAN communication dAFRKR (T/M) Monitor panel CAN communication daFRKR (S/T)
MON CALL E03 Electrical system T/M S/T T/M T/M T/M T/M T/M T/M T/M T/M T/M S/T T/M S/T S/T S/T S/T S/T S/T S/T S/T S/T S/T VHMS VHMS VHMS VHMS VHMS CALL E03 Electrical system TroubleshootCALL E03 Electrical system ing by failure code, Part 4 E01 Electrical system SEN01826-01 CALL E04 Electrical system CALL E04 Electrical system CALL E03 Electrical system E01 Electrical system
DAQ0KT Transmission controller DAQ1KK DAQ2KK DAQ5KK DAQ6KK DAQ7KK DAQ9KQ DAQRKR DAQSKR DB2RKR dB2RKR db2RKR Transmission controller main power supply Transmission controller load power supply Transmission controller potentiometer power supply Transmission controller sensor power supply Transmission controller sensor power supply Transmission controller model selection Transmission controller CAN communication Transmission controller S-NET communication Engine controller (Left bank) CAN communication Engine controller (Left bank) CAN communication Engine controller (Right bank) CAN communication
CALL E03 Electrical system CALL E04 Electrical system CALL E03 Electrical system E01 Electrical system
CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system E01 Electrical system
DB30KT Steering controller DB31KK DB32KK DB35KK DB36KK DB37KK DB39KQ dB3RKR DB3SKR Steering controller main power supply
DBB0KK [n9 o 01] DBB0KQ [nF o 11] DBB3KK [n9 o 05] DBB5KP VHMS sensor power supply (5 V) [n9 o 04] DBB6KP VHMS sensor power supply (24 V) [n9 o 02]
Power supply voltage reduction (Input) Power supply voltage reducSteering controller load power supply tion (Input) Steering controller potentiometer Power supply voltage reducpower supply tion (Input) Steering controller sensor power Power supply voltage reducsupply tion (Input) Steering controller sensor power Power supply voltage reducsupply tion (Input) Model selection signal disSteering controller model selection agreement Steering controller CAN communicaCommunication error tion (T/M) Steering controller S-NET communiCommunication error cation Power supply voltage reducVHMS controller tion Model selection signal disVHMS controller model selection agreement Direct source voltage reducVHMS controller tion Output voltage reduction Output voltage reduction
CALL E04 Electrical system CALL E04 Electrical system CALL E03 Electrical system CALL E03 Electrical system Troubleshooting by failure CALL E03 Electrical system code, Part 5 CALL E04 Electrical system SEN01827-01 CALL E03 Electrical system E01 Electrical system
D475A, D475ASD-5E0
40 Troubleshooting
SEN01821-01
Failure code
Troubled part
Trouble Output voltage reduction Communication error Communication error Disconnection Short circuit Disconnection Short circuit Disconnection Short circuit Signal disagreement Signal disagreement Disconnection Short circuit
Component in charge VHMS VHMS S/T T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M S/T S/T S/T T/M T/M T/M T/M T/M MON MON
Action code E02 E02 E02 E02
Category of record Electrical system Electrical system Electrical system Electrical system Electrical system
Reference manual
DBB7KP VHMS sensor power supply (12 V) [n9 o 03] DBBQKR VHMS KOM-NET [n8 o 02] VHMS controller CAN communicadbBRKR tion DD12KA Shift-up switch DD12KB Shift-up switch DD13KA Shift-down switch DD13KB Shift-down switch DD14KA Parking brake lever switch DD14KB Parking brake lever switch DDB9L4 Reverse switch DDK3L4 Forward switch DDK5KA Shift switch DDK5KB Shift switch DDN2LD
CALL E03 Electrical system CALL E03 Electrical system E02 E02 E02 E02 E02 E02 E02 E02 E01 E01 Electrical system Electrical system Electrical system Troubleshooting by failure Electrical system code, Part 5 Electrical system SEN01827-01 Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Blade tilt right oil pressure switch Switch ON for long time system Blade tilt left oil pressure switch sysDDN3LD Switch ON for long time tem DDN7KA Blade pitch switch DDN7KB Blade pitch switch DDN9KA Blade tilt switch DDN9KB Blade tilt switch Disconnection Short circuit Disconnection Short circuit
DDNALD Blade lift raise full oil pressure switch Switch ON for long time DDNBLD Ripper lift raise oil pressure switch DDNCLD Ripper lift lower oil pressure switch DDNDLD Ripper tilt in oil pressure switch DDNELD Ripper tilt back oil pressure switch DDNFLD Ripper lift lower full oil pressure switch Switch ON for long time Switch ON for long time Switch ON for long time Switch ON for long time Switch ON for long time Disconnection Short circuit Signal disagreement Signal disagreement Disconnection Short circuit Model selection signal disagreement Out of input signal range Disconnection Out of input signal range
DDQ2KA Parking brake lever switch DDQ2KB Parking brake lever switch DDQ2L4 Parking brake lever switch (S/T) dDQ2L4 Parking brake lever switch (T/M) DDT5KA Neutral switch DDT5KB Neutral switch DDT5KQ Lever specification selection error DGS1KX Hydraulic oil temperature sensor DGT1KA Power train oil temperature sensor DGT1KX Power train oil temperature sensor
CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system TroubleshootCALL E04 Electrical system ing by failure code, Part 6 CALL E04 Electrical system SEN01828-01 CALL E04 Electrical system E01 E01 Electrical system Electrical system Electrical system
D475A, D475ASD-5E0
SEN01821-01
40 Troubleshooting
Failure code DGT5KA [n3 o 12] dGT5KA [n3 o 22] DGT5KB [n3 o 11] dGT5KB [n3 o 21] DGT6KA [n3 o 24] dGT6KA [n3 o 26] DGT6KB [n3 o 23] dGT6KB [n3 o 25] DH22KA DH22KB DH23KA DH23KB
Troubled part Left bank exhaust temperature sensor system (Front) Left bank exhaust temperature sensor system (Rear) Left bank exhaust temperature sensor system (Front) Left bank exhaust temperature sensor system (Rear) Right bank exhaust temperature sensor system (Front) Right bank exhaust temperature sensor system (Rear) Right bank exhaust temperature sensor system (Front) Right bank exhaust temperature sensor system (Rear) Work equipment pump oil pressure sensor (F) Work equipment pump oil pressure sensor (F) Work equipment pump oil pressure sensor (R) Work equipment pump oil pressure sensor (R)
Trouble Disconnection Disconnection Short circuit Short circuit Disconnection Disconnection Short circuit Short circuit Disconnection Short circuit Disconnection Short circuit Disconnection Hot short Out of input signal range Disconnection Short circuit Disconnection Short circuit Disconnection Short circuit Disconnection Short circuit Out of input signal range Disconnection or short circuit Analog signal disagreement Disconnection Short circuit Disconnection Short circuit Out of input signal range Disconnection or short circuit Analog signal disagreement Disconnection Short circuit
Component in charge VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS T/M T/M T/M T/M VHMS VHMS VHMS T/M T/M T/M T/M S/T S/T S/T S/T S/T S/T S/T S/T S/T S/T S/T T/M T/M T/M T/M T/M
Action code E02 E02 E02 E02
Category of record Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Reference manual
DHE5KB Blow-by pressure sensor system [n3 o 32] DHE5KY Blow-by pressure sensor system [n3 o 31] DHT3KX Transmission oil pressure sensor [n6 o 14] DK01KA Left yoke angle sensor DK01KB Left yoke angle sensor DK03KA Right yoke angle sensor DK03KB Right yoke angle sensor DK10KA Fuel control dial DK10KB Fuel control dial DK30KA Steering potentiometer (1) DK30KB Steering potentiometer (1) DK30KX Steering potentiometer (1) DK30KZ Steering potentiometer (1) DK30L8 Steering potentiometer (1) DK31KA Steering potentiometer (2) DK31KB Steering potentiometer (2) DK40KA Brake potentiometer DK40KB Brake potentiometer DK55KX Forward-reverse potentiometer DK55KZ Forward-reverse potentiometer DK55L8 Forward-reverse potentiometer DK56KA Forward-reverse potentiometer (1) DK56KB Forward-reverse potentiometer (1)
Troubleshooting by failure code, Part 6 SEN01828-01
CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E04 Electrical system CALL E04 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E04 Electrical system Troubleshooting by failure code (Display CALL E04 Electrical system of code), Part 7 CALL E03 Electrical system SEN01829-00 CALL E03 Electrical system CALL E03 Electrical system
D475A, D475ASD-5E0
40 Troubleshooting
SEN01821-01
Failure code
Troubled part
Trouble Disconnection Short circuit Disconnection Short circuit Disconnection Short circuit Out of input signal range
Component in charge T/M T/M S/T S/T S/T S/T S/T T/M T/M T/M T/M MON T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M
Action code
Category of record
Reference manual
DK57KA Forward-reverse potentiometer (2) DK57KB Forward-reverse potentiometer (2) DK60KA Acceleration sensor DK60KB Acceleration sensor DKH1KA Pitch angle sensor DKH1KB Pitch angle sensor DKH1KX Pitch angle sensor
CALL E03 Electrical system CALL E03 Electrical system E01 E01 Electrical system Electrical system
CALL E03 Electrical system CALL E03 Electrical system E01 E01 E01 E01 E02 Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Torque converter output speed senDLF1KA Disconnection sor DLT3KA Transmission output speed sensor dLT3KA Transmission output speed sensor DLT3KB Transmission output speed sensor DV00KB Alarm buzzer DW55KA Blade pitch back solenoid DW55KB Blade pitch back solenoid DW56KA Blade pitch dump solenoid DW56KB Blade pitch dump solenoid DW56KY Blade pitch dump solenoid DW57KA Left tilt limit solenoid DW57KB Left tilt limit solenoid DW57KY Left tilt limit solenoid DW58KA Right tilt limit solenoid DW58KB Right tilt limit solenoid DW58KY Right tilt limit solenoid DW59KA Dual tilt selector solenoid DW59KB Dual tilt selector solenoid DW59KY Dual tilt selector solenoid DW5AKA Blade pitch selector solenoid DW5AKB Blade pitch selector solenoid DW5AKY Blade pitch selector solenoid Blade pitch dump solenoid (Superdozer specification) Blade pitch dump solenoid DW5DKB (Superdozer specification) Blade pitch dump solenoid DW5DKY (Superdozer specification) DW5DKA DW7BKA Fan reverse solenoid DW7BKB Fan reverse solenoid DW7BKY Fan reverse solenoid Disconnection Disconnection Short circuit Short circuit Disconnection Short circuit Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short
CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system Troubleshooting by failure code (Display E02 Electrical system of code), Part 7 E02 E02 E02 E02 E02 E01 E01 E01 E02 E02 E02 Electrical system SEN01829-00 Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system E01 E01 E01 Electrical system Electrical system Electrical system
D475A, D475ASD-5E0
SEN01821-01
40 Troubleshooting
Failure code
Troubled part
Trouble Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit
Component in charge S/T S/T S/T S/T S/T S/T T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M T/M S/T S/T
Action code E02 E02 E02
Category of record Electrical system Electrical system Electrical system
Reference manual
DWJ0KA Pump merge-divider solenoid DWJ0KB Pump merge-divider solenoid DWJ0KY Pump merge-divider solenoid DWN3KA Sudden stop prevention solenoid DWN3KB Sudden stop prevention solenoid DWN3KY Sudden stop prevention solenoid DWN5KA Fan pump solenoid (1) DWN5KB Fan pump solenoid (1) DWN5KY Fan pump solenoid (1) DWNCKA Fan pump solenoid (2) DWNCKB Fan pump solenoid (2) DWNCKY Fan pump solenoid (2) DXE0KA LS set solenoid DXE0KB LS set solenoid DXE0KY LS set solenoid DXH1KA Lockup solenoid DXH1KB Lockup solenoid DXH1KY Lockup solenoid DXH4KA 1st clutch ECMV DXH4KB 1st clutch ECMV DXH4KY 1st clutch ECMV DXH5KA 2nd clutch ECMV DXH5KB 2nd clutch ECMV DXH5KY 2nd clutch ECMV DXH6KA 3rd clutch ECMV DXH6KB 3rd clutch ECMV DXH6KY 3rd clutch ECMV DXH7KA Reverse clutch ECMV DXH7KB Reverse clutch ECMV DXH7KY Reverse clutch ECMV DXH8KA Forward clutch ECMV DXH8KB Forward clutch ECMV DXH8KY Forward clutch ECMV DXH9KA Right steering clutch ECMV DXH9KB Right steering clutch ECMV
CALL E04 Electrical system TroubleshootCALL E04 Electrical system ing by failure code (Display of code), Part 7 E01 Electrical system SEN01829-00 E01 Electrical system E02 E01 E01 E02 E02 E02 E02 E01 E01 Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system CALL E04 Electrical system
CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system Troubleshooting by failure code (Display CALL E03 Electrical system of code), Part 8 CALL E03 Electrical system SEN01830-00 CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E03 Electrical system
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01821-01
Failure code
Troubled part Hot short
Trouble
Component in charge S/T S/T S/T S/T S/T S/T S/T S/T S/T S/T VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS
Action code
Category of record
Reference manual
DXH9KY Right steering clutch ECMV DXHAKA Left steering clutch ECMV DXHAKB Left steering clutch ECMV DXHAKY Left steering clutch ECMV DXHBKA Right brake ECMV DXHBKB Right brake ECMV DXHBKY Right brake ECMV DXHCKA Left brake ECMV DXHCKB Left brake ECMV DXHCKY Left brake ECMV F@BBZL [n3 o 38] F@BYNS [n3 o 61] f@BYNS [n3 o 71] F@BZNS [n3 o 81] f@BZNS [n3 o 91] F@BYNR [n3 o 62] f@BYNR [n3 o 72] F@BZNR [n3 o 82] f@BZNR [n3 o 92] Engine blow-by pressure sensor Left front exhaust temperature sensor (1) Left rear exhaust temperature sensor (1) Right front exhaust temperature sensor (1) Right rear exhaust temperature sensor (1) Left front exhaust temperature sensor (2) Left rear exhaust temperature sensor (2) Right front exhaust temperature sensor (2) Right rear exhaust temperature sensor (2)
CALL E04 Electrical system CALL E03 Electrical system CALL E03 Electrical system CALL E04 Electrical system CALL E04 Electrical system CALL E04 Electrical system CALL E04 Electrical system CALL E04 Electrical system CALL E04 Electrical system Troubleshooting by failure code (Display CALL E04 Electrical system of code), Part 8 SEN01830-00
Disconnection Short circuit Hot short Disconnection Short circuit Hot short Disconnection Short circuit Hot short Abnormality high pressure occurrence Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise Exhaust temperature abnormal rise
a a
a a
The items in this table are arranged in the order of the failure codes. 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 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). The history classification column shows in which system each failure is classified, the electrical equipment 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). 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
SEN01821-01
40 Troubleshooting
Fuse locations
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 fusible links to see if the power is supplied normally.
Fuse box A [FS12]

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

Fuse No. 1 2 3 4 5 Accessory power supply Type of power supply Fuse capacity (A) 5 20 20 20 20 Backup alarm Preheater power supply, pin puller, air suspension seat Additional heater power supply Working lamp Rear lamp Destination of power
Fuse box C [FS32]

Fuse No. 1 2 3 4 5 Accessory power supply Type of power supply Fuse capacity (A) 5 20 20 20 20 ACC signal Horn Spare power supply (1) Spare power supply (2) Spare ACC signal Destination of power
Cab fuse box D

Fuse No. 1 2 3 4 5 6 7 8 9 10 Accessory power supply Type of power supply Fuse capacity (A) 10 10 10 10 10 20 20 10 Rear wiper Right wiper Front wiper Left wiper Additional headlamp Additional rear lamp, rotary lamp Spare Spare Radio memory Destination of power Radio, cigarette lighter, room lamp
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01821-01
Fuse locations and fuse Nos.

Inside of left console box in cab
Lower right part of cab overhead
D475A, D475ASD-5E0
13
SEN01821-01
40 Troubleshooting
Circuit breaker
No 1 2 3 4 6 7 8 9 10 11 12 13 Connector No. F30 F96 B105H2L B105H1L B7L B8L CB1 CB2 CB3 CB4 CB5 CB6 Capacity (A) 30 105 105 105 30 30 20 20 20 20 20 20 Main power supply Electrical intake air heater main power supply Installed in battery box at (Right bank) left of operator's seat Electrical intake air heater main power supply Engine controller unswitched power supply Engine controller unswitched power supply Steering controller Monitor panel Transmission controller Air conditioner Headlamp Starting switch unswitched power supply Installed in console box at left of operator's seat Circuit Cab unswitched power supply Remarks
Resetting operation of circuit breaker Turn the starting switch OFF and push in projected reset button (14). If the reset button returns immediately, carry out troubleshooting to repair failed part.
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01821-01
D475A, D475ASD-5E0
15
SEN01821-01
16
SEN01822-01
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
General information on troubleshooting
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 Connection table for connector pin numbers ................................................................................................ 10 T- branch box and T- branch adapter table ................................................................................................... 45
D475A, D475ASD-5E0
SEN01822-01
40 Troubleshooting
Points to remember when troubleshooting

k k k k k k
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. 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. 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. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative () terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and 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 symptoms. 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 procedure. 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? 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. 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 investigation or measurement that may make the problem worse. 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. 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.
3.
4.
5.
6.
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Sequence of events in troubleshooting
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Checks before troubleshooting 1

Item Judgement Value 20 30 V After running for several minutes: 27.5 29.5 V Action Add fuel Clean, drain Replace Add oil Add oil Add oil Add oil Add water Clean or replace Adjust Repair Repair Bleed air Tighten or replace Tighten or replace Tighten or replace Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace
1. Check fuel level 2. Check for impurities in fuel

Checks before starting Lubricating oil, coolant Hydraulic, mechanical equipment Other check items Electrical equipment
3. Check fuel filter 4. Check hydraulic oil level 5. Check oil level in damper case 6. Check power train oil level 7. Check engine oil level (engine oil pan level) 8. Check coolant level 9. Check dust indicator for clogging 10.Check travel of brake pedal 1. Check for abnormal noise, smell 2. Check for oil leakage 3. Carry out air bleeding 1. Check for looseness, corrosion of battery terminal, wiring 2. Check for looseness, corrosion of alternator terminal, wiring 3. Check for looseness, corrosion of starting motor terminal, wiring 4. Check battery voltage (engine stopped) 5. Check battery electrolyte level 6. Check for discolored, burnt, exposed wiring 7. Check for missing wiring clamps, hanging wire 8. Check for water leaking on wiring (pay particularly careful attention to water leaking on connectors or terminals) 9. Check for blown, corroded fuses 10.Check alternator voltage (engine running at 1/2 throttle or above) 11. Check operating sound of battery relay (starting switch ON, OFF)
Replace
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Classification and procedures of troubleshooting

Classification of troubleshooting
Mode Display of code E-mode H-mode S-mode Contents Troubleshooting by failure code (Display of code) Troubleshooting of electrical system Troubleshooting of hydraulic and mechanical system 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 troubleshooting in [Display of code]). 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 display 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 troubleshooting in [Display of code]). 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 troubleshooting related to that phenomenon in the E-mode, H-mode, or S-mode.
2.
3.
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Phenomena looking like troubles and troubleshooting Nos.

Troubleshooting No. Phenomena looking like trouble Code display E-mode H-mode S-mode
Phenomena related to action code or error code 1 Action codes are displayed on the monitor panel 2 Error codes are displayed in the error code display mode Phenomena related to engine 3 The engine does not start easily (It always takes time to start) 4 The engine does not crank E-1 The engine cranks but exhaust smoke does 5 The engine does not not come out start Exhaust smoke comes out but the engine does 6 not start 7 The engine speed does not rise sharply (Follow-up performance is low) S-1 S-2a) S-2b) S-2c) S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16 E-2 Phenomena related to power train 22 Power is low (Drawbar pull is low) 23 The machine does not travel (in the 2nd or 3rd gear speed) 24 The machine does not travel start in any gear speed 25 The machine can travel in only forward or reverse direction Time lag is large in shifting the gear speed or changing the travel 26 direction 27 The machine cannot be steered 28 The machine can be steered in only 1 direction 29 The machine overruns when steered 30 The brake does not operate 31 The torque converter is not locked up 32 The torque converter oil is overheated Phenomena related to work equipment 33 Speed of the whole work equipment is low 34 Any part of the equipment does not move 35 Blade lifting speed or power is low 36 Blade tilting speed or power is low 37 Ripper lifting speed or power is low H-12 H-13 H-14 H-15 H-16 H-1 H-2 H-3 H-4 H-5 H-6 H-7 H-8 H-9 H-10 H-11 S-6 q Check the error code
8 The engine stops during operation 9 Engine rotation is abnormal (The engine hunts) 10 Output is insufficient or power is low 11 Exhaust gas color is bad (Incomplete combustion) 12 Oil is consumed much or exhaust gas color is bad 13 Oil becomes dirty quickly 14 Fuel is consumed much 15 Coolant contains oil (or it blows back or reduces) 16 The engine oil pressure caution lamp lights up (Oil pressure lowers) 17 Oil level rises 18 Coolant temperature rises too high (Overheating) 19 Abnormal sound comes out 20 Vibration is excessive 21 The preheater does not operate
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Troubleshooting No. Phenomena looking like trouble Code display E-mode H-mode H-17 H-18 H-19 H-20 H-21 H-22 H-23 S-mode
38 Ripper tilting speed or power is low 39 Hydraulic drift of blade lifting is large 40 Hydraulic drift of blade tilting is large 41 Hydraulic drift of ripper lifting is large The ripper pin puller cylinder does not operate (if the giant ripper is 42 installed) 43 The blade does not pitch (if the dual tilt system installed) 44 Abnormal sound comes out from around hydraulic pump Phenomena related to monitor panel (Operator mode: Ordinary screen) 45 46 When the starting switch is turned ON, no items are displayed on monitor panel When the starting switch is turned ON, all items are kept displayed on monitor panel E-4 E-5 E-6 E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-21 E-22 E-23 E-24 E-25 Other phenomena 67 The backup alarm does not sound The night lamp of the panel, headlamp, working lamp, and rear lamp 68 do not light up 69 The air conditioner does not operate 70 The ORBCOMM terminal does not operate normally 71 Fan does not reverse 72 Gear cannot be shifted 73 Electric priming pump does not operate or does not stop E-26 E-27 E-28 E-29 E-30 E-31 E-32
47 When the starting switch is turned ON, the basic check items flash 48 Caution items flash while the engine is running 49 Emergency warning items flash while the engine is started When the preheater is operated, the preheater pilot lamp does not 50 light up 51 52 When the dual tilt is selected, the dual/single tilt selector lamp does not light up (if the dual tilt system is equipped) When the torque converter is locked up, the torque converter lockup pilot lamp does not light up
53 Display of the engine coolant temperature gauge is abnormal 54 Display of the power train oil temperature gauge is abnormal 55 Display of the hydraulic oil temperature gauge is abnormal 56 Display of the fuel level gauge is abnormal 57 Display of the gear speed and engine speed is abnormal 58 Display of the shift mode and service meter is abnormal 59 The switch module cannot be operated 60 The caution lamp does not flash or go off 61 The caution buzzer does not sound or go off 62 The auto shift-down system does not operate or reset 63 The auto pitch-back system does not operate or reset 64 The caution buzzer cannot be canceled 65 The operator mode does not operate 66 The service mode does not operate
Phenomena related to monitor panel (Service mode: Special function screen)
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Contents of troubleshooting table

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 Display of panel Controller's action Failure code Display of panel Failure Trouble that appears in the machine symptom
Failure content State where the monitor panel or controller detects the trouble Action to be taken to protect the system and equipment when the monitor panel or controller 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 Information related to troubles occurred or troubleshooting
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 A harness not connected to the power (24 V) circuit comes 2 into contact with the power (24 V) circuit. Short circuit Causes by which a trouble A harness of an independent circuit abnormally comes into is assumed to be defected contact with one of another circuit. (The order number indicates a serial number, not <Notes on troubleshooting> (1) Method of indicating connector numbers and handling of Ta priority sequence.) 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 Tadapters 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 () leads as shown below unless especially specified. 4 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.
Possible causes and standard value in normal state
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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
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Connection table for connector pin numbers

a
(Rev. 2007.8)
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
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11
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12
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13
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14
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15
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16
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17
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18
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19
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20
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21
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22
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23
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24
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25
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26
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27
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29
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30
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31
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32
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33
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34
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35
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36
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43
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T- branch box and T- branch adapter table

a
(Rev. 2007.8) 1
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.
Number of pins T-adapter kit 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 799-601-4101 q q 1 2 3 4 6 8 12 14 16 1 2 3 M2P M3P X2P X3P X4P SW6P SW8P SW12P SW14P SW16P q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q 799-601-4201 Identification symbol Out of kit q q q 24 24 17 17 5 10 5 17 19 14 5 13 17 21 9 2 3 4 8 8 12 16 MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5S MS-17P MS-19P MS-14P MIC-5P MIC-13P MIC-17P MIC-21P MIC-9P ECONO2P ECONO3P ECONO4P ECONO8P DLI-8P DLI-12P DLI-16P q q q q q q q q q q q q q q q q 60 q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
799-601-2600 T-box (for ECONO) 799-601-3100 T-box (for MS) 799-601-3200 T-box (for MS) 799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS) 799-601-3420 Adapter for BENDIX (MS) 799-601-3430 Adapter for BENDIX (MS) 799-601-3440 Adapter for BENDIX (MS) 799-601-3450 Adapter for BENDIX (MS) 799-601-3460 Adapter for BENDIX (MS) 799-601-3510 Adapter for BENDIX (MS) 799-601-3520 Adapter for BENDIX (MS) 799-601-3530 Adapter for BENDIX (MS) 799-601-2910 Adapter for BENDIX (MS) 799-601-3470 Case 799-601-2710 Adapter for MIC 799-601-2720 Adapter for MIC 799-601-2730 Adapter for MIC 799-601-2740 Adapter for MIC 799-601-2950 Adapter for MIC 799-601-2750 Adapter for ECONO 799-601-2760 Adapter for ECONO 799-601-2770 Adapter for ECONO 799-601-2780 Adapter for ECONO 799-601-2790 Adapter for ECONO 799-601-2810 Adapter for DLI 799-601-2820 Adapter for DLI 799-601-2830 Adapter for DLI 799-601-2840 Extension cable (ECONO type) 799-601-2850 Case 799-601-4350 T-box (for DRC 60, ECONO) 799-601-4360 Case 799-601-7010 Adapter for X (T-adapter) 799-601-7020 Adapter for X 799-601-7030 Adapter for X 799-601-7040 Adapter for X 799-601-7050 Adapter for SWP 799-601-7060 Adapter for SWP 799-601-7310 Adapter for SWP 799-601-7070 Adapter for SWP 799-601-7320 Adapter for SWP 799-601-7080 Adapter for M (T-adapter) 799-601-7090 Adapter for M 799-601-7110 Adapter for M
21 37 37
q q
12 ECONO12P q q
12 ECONO12P q q
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Number of pins
T-adapter kit 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 799-601-4101 799-601-4201 Identification symbol Out of kit q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
799-601-7120 Adapter for M 799-601-7130 Adapter for M 799-601-7340 Adapter for M 799-601-7140 Adapter for S 799-601-7150 Adapter for S (White) 799-601-7160 Adapter for S (Blue) 799-601-7170 Adapter for S (Blue) 799-601-7330 Adapter for S (White) 799-601-7350 Adapter for S (White) 799-601-7180 Adapter for AMP040 799-601-7190 Adapter for AMP040 799-601-7210 Adapter for AMP040 799-601-7220 Adapter for AMP040 799-601-7230 Short connector for X 799-601-7240 Case 799-601-7270 Case 799-601-7510 Adapter for 070 799-601-7520 Adapter for 070 799-601-7530 Adapter for 070 799-601-7540 Adapter for 070 799-601-7550 Adapter for 070 799-601-7360 Adapter for relay 799-601-7370 Adapter for relay 799-601-7380 Adapter for JFC 799-601-9010 Adapter for DTM 799-601-9020 Adapter for DT 799-601-9030 Adapter for DT 799-601-9040 Adapter for DT 799-601-9050 Adapter for DT 799-601-9060 Adapter for DT (Gray) 799-601-9070 Adapter for DT (Black) 799-601-9080 Adapter for DT (Green) 799-601-9090 Adapter for DT (Brown) 799-601-9110 Adapter for DT (Gray) 799-601-9120 Adapter for DT (Black) 799-601-9130 Adapter for DT (Green) 799-601-9140 Adapter for DT 799-601-9210 Adapter for HD30-18 799-601-9220 Adapter for HD30-18 799-601-9230 Adapter for HD30-18 799-601-9240 Adapter for HD30-18 799-601-9250 Adapter for HD30-24 799-601-9260 Adapter for HD30-24 799-601-9270 Adapter for HD30-24 799-601-9280 Adapter for HD30-24 799-601-9290 Adapter for HD30-24 799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO)
4 6 8 8 10 12 16 16 12 8 12 16 20 2
M4P M6P M8P S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P
q q q q q q
q q
10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21 23 31 24
07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21 D24-23 D24-31
q q q q q
46
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Number of pins
T-adapter kit 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 799-601-4101 q q q q q q q q 799-601-4201 Identification symbol Out of kit q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
799-601-9330 Case 799-601-9340 Case 799-601-9350 Adapter for DRC 799-601-9360 Adapter for DRC 799-601-9410* Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor 799-601-9430* Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV 40 24 2 3 2 3 2 2 2 3 3 3 4 3 3 3 2 3 3 4 3 3 3 2 4 4 50 60 60 121 16 16 26 2, 3, 4, DRC-40 DRC-24 G A3 P 1,2,3 S C A ITT3N FCIN FCIG FCIB 4160 4180 1,2,3L 1,2,3,4C 1,2,3A 1,2,3B 1,2,3,G 2,PA 1,2,3,4T DTP4 DRC50 DRC60 HST16A HST16B HST26A
q q q q
799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2) Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor 795-799-5540* Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 795-799-5470 Cable for engine (HPI-T2) 795-799-5480 Cable for engine (HPI-T2) 799-601-4110 Adapter for engine (140-T3) PIM 799-601-4130 Adapter for engine (CRI-T3) NE, CAM 799-601-4140 Adapter for engine (CRI-T3) Atomosphere pressure Adapter for engine (CRI-T3) Oil pressure switch
799-601-4150 Adapter for engine (CRI-T3) POIL 799-601-4160
799-601-4180 Adapter for engine (CRI-T3) PEVA Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure 799-601-4230* Socket for engine (CRI-T3) Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 799-601-4250* Socket for engine (CRI-T3) PIM 799-601-4330* Socket for engine (CRI-T3) G Socket for engine (CRI-T3) 799-601-4340* Pump actuator 799-601-4380* Socket for engine (CRI-T3)(95) Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 799-601-4211 Adapter for controller (ENG) 799-601-4220 Adapter for controller (ENG) 799-601-4390* Socket for controller (95 ENG) 799-601-4280 Box for controller (PUMP) 799-601-9720 Adapter for controller (HST) 799-601-9710 Adapter for controller (HST) 799-601-9730 Adapter for controller (HST) 799-601-9890 Multi-adapter for DT2 4 and DTM2
* Shows not T-adapter but socket. D475A, D475ASD-5E0
47
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
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Serial number
40 Troubleshooting
Troubleshooting by failure code, Part 1
Failure code [1380MW] Lockup clutch: Clutch slip ......................................................................................... 3 Failure code [1500L0] Transmission clutch: Dual engagement ...................................................................... 4 Failure code [15E0MW] Transmission clutch: Clutch slip ............................................................................... 5 Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON ..................... 6 Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF .................... 7 Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON ........................................ 8 Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF .................... 9 Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON ........................... 10 Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF ............................11 Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON .......................... 12 Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF .......................... 13 Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON........................... 14 Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF .......................... 15 Failure code [1800MW] Power train clutch: Slip ........................................................................................... 16 Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON......................... 17 Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF ........................ 18
D475A, D475ASD-5E0
SEN01823-01
40 Troubleshooting
Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON ........................... 19 Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF........................... 20 Failure code [2300NR] Brake thermal load: Abnormal heating..................................................................... 21 Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON ......................... 22 Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF......................... 23 Failure code [2301NR] Right steering brake thermal load: Abnormal heating .............................................. 24 Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON............................ 25 Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF ........................... 26 Failure code [2302NR] Left steering brake thermal load: Abnormal heating ................................................ 27 Failure code [6001ZK] Failure code for design ............................................................................................. 28 Failure code [A000NS] Engine: Overheat ..................................................................................................... 29 Failure code [AA10NX] Air cleaner: Clogging ............................................................................................... 30 Failure code [AB00MA] Battery charge abnormality: Malfunction................................................................. 31 Failure code [B@BAZG] Engine oil: Oil pressure too low ............................................................................. 32 Failure code [B@BAZK] Engine oil: Oil level reduction................................................................................. 33 Failure code [B@BCNS] Engine coolant: Overheat...................................................................................... 34 Failure code [B@BCZK] Engine coolant: Level too low ................................................................................ 35 Failure code [B@BEBF] Fuel: Water in fuel .................................................................................................. 36 Failure code [B@BFZK] Fuel level: Reduction.............................................................................................. 37 Failure code [B@CENS] Power train oil: Overheat....................................................................................... 38 Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure ........................................................... 39 Failure code [B@CHZK] Power train oil: Oil level reduction ......................................................................... 39 Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction .............................................. 40 Failure code [B@HANS] Hydraulic oil: Overheat .......................................................................................... 40 Failure code [B@HAZK] Hydraulic oil: Level reduction................................................................................. 41
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [1380MW] Lockup clutch: Clutch slip

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Lockup clutch: Clutch slip failure (Transmission controller system) 1380MW When torque converter is locked up, sensed engine speed does not match with sensed torque converter output speed. None in particular. None in particular. Engine speed and torque converter speed can be checked in real-time monitoring mode. (Code 01002: Engine speed (Left bank), Code 01004: Engine speed (Right bank)) (Code 31200: Transmission input speed (Torque converter output speed)) Method of reproducing failure code: Start engine, turn lockup clutch ON and drive machine. Cause Lockup clutch slip (When system is normal) Defective engine speed sensor system Defective torque converter speed sensor Defective transmission controller Standard values when normal and remarks for troubleshooting Check for cause of lockup clutch slip and damage of machine. If failure code [CA689], [CB689] or [CA778], [CB778] is displayed, carry out troubleshooting for it. If failure code [DLF1KA] is displayed, carry out troubleshooting for it. Since trouble is in system, troubleshooting cannot be carried out.
1 Possible causes and the standard values when normal 2 3 4
D475A, D475ASD-5E0
SEN01823-01
40 Troubleshooting
Failure code [1500L0] Transmission clutch: Dual engagement

Action code CALL E03 Failure code 1500L0 Symptom Transmission clutch: Dual engagement 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 action Flashes warning lamp and turns on alarm buzzer. 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 information Duplication of failure code: Engine start + travel Cause Possible causes and the standard values when normal Standard values when normal and remarks for troubleshooting
Confirm the failure codes displayed at the same time, then carry out troubleshooting for the codes. [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1], [15SGLH] [DXH4KA], [DXH4KB], [DXH4KY], [DXH5KA, [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB], [DXH6KY], [DXH7KA, [DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [15E0MW] Transmission clutch: Clutch slip

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Transmission clutch: Clutch slip failure (Transmission controller system) 15E0MW Sensed torque converter output speed does not match with sensed transmission output speed. None in particular. None in particular. Torque converter speed and transmission speed can be checked in real-time monitoring mode. (Code 31200: Transmission input speed (Torque converter output speed)) (Code 31400: Transmission output speed) Method of reproducing failure code: Start engine and drive machine. Cause Transmission clutch slip (When system is normal) Defective torque converter speed sensor system Defective transmission speed sensor Defective transmission controller Standard values when normal and remarks for troubleshooting Check for cause of transmission clutch slip and damage of machine. If failure code [DLF1KA] is displayed, carry out troubleshooting for it. If failure code [DLT3KA], [dLT3KA] or [DLT3KB] is displayed, carry out troubleshooting for it. Since trouble is in system, troubleshooting cannot be carried out.
1 Possible causes and the standard values when normal 2 3 4
D475A, D475ASD-5E0
SEN01823-01
40 Troubleshooting
Failure code [15SAL1] Forward clutch oil pressure: Command current OFF and fill signal ON
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Forward clutch oil pressure: Command current OFF and fill signal failure ON (Transmission controller system) 15SAL1 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. Becomes N (neutral) at reverse operation. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F1. The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) Method of reproducing failure code: Engine start + Neutral running Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective forward clutch fill FFT2 (male) PCCS lever Resistance 1 switch (Internal short) N Min. 1 Mz Between (1) chassis ground F (Forward) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. 2 ing (Contact with ground Wiring harness between TMC1 (female) (5) Resiscircuit) Min. 1 Mz FFT2 (female) (1) with chassis ground tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage 3 controller N 5 11 V Between (5) chassis ground F (Forward) Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trou4 sure system bleshooting (H mode). Cause
Possible causes and the standard values when normal
Circuit diagram related to transmission forward clutch ECMV
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [15SALH] Forward clutch oil pressure: Command current ON and fill signal OFF
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Forward clutch oil pressure: Command current ON and fill signal OFF failure (Transmission controller system) 15SALH The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Becomes neutral (N) at forward operation. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to R1. The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) Method of reproducing failure code: Engine start + Forward running Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective forward clutch fill FFT2 (male) PCCS lever Resistance switch (Internal short) N Min. 1 Mz Between (1) chassis ground F (Forward) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between TMC1 (female) (5) ResisMax. 1 z in connector) FFT2 (female) (1) tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage controller N 5 11 V Between (5) chassis ground F (Forward) Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
D475A, D475ASD-5E0
SEN01823-01
40 Troubleshooting
Failure code [15SBL1] Reverse clutch: Command current OFF and fill signal ON
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Reverse clutch: Command current OFF and fill signal ON failure (Transmission controller system) 15SBL1 The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Becomes neutral (N) at forward operation. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to R1. The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) Method of reproducing failure code: Engine start + Neutral running Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective reverse clutch fill FRT2 (male) PCCS lever Resistance 1 switch (Internal short) N Min. 1 Mz Between (1) chassis ground R (Reverse) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. 2 ing (Contact with ground Wiring harness between TMC1 (female) (24) Resiscircuit) Min. 1 Mz FRT2 (female) (1) with chassis ground tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage 3 controller N 5 11 V Between (24) chassis ground R (Reverse) Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trou4 sure system bleshooting (H mode). Cause
Circuit diagram related to transmission reverse clutch ECMV
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [15SBLH] Reverse clutch oil pressure: Command current ON and fill signal OFF
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Reverse clutch oil pressure: Command current ON and fill signal OFF failure (Transmission controller system) 15SBLH The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Becomes neutral (N) at reverse operation. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F1. The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) Method of reproducing failure code: Engine start + Reverse running Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective reverse clutch fill FRT2 (male) PCCS lever Resistance switch (Internal short) N Min. 1 Mz Between (1) chassis ground R (Reverse) Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between TMC1 (female) (24) ResisMax. 1 z in connector) FRT2 (female) (1) tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage controller N 5 11 V Between (24) chassis ground R (Reverse) Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
D475A, D475ASD-5E0
SEN01823-01
40 Troubleshooting
Failure code [15SEL1] 1st clutch oil pressure: Command current OFF and fill signal ON
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 1st clutch oil pressure: Command current OFF and fill signal ON failure (Transmission controller system) 15SEL1 The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F1 and R1. The input state (ON/OFF) from the level 1 clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) Method of reproducing failure code: Engine start + F1 or R1 o Neutral running Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 1st clutch fill F1T8 (male) PCCS lever Resistance switch (Internal short) Other than F1/R1 Min. 1 Mz Between (1) chassis ground F1 R1 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between TMC1 (female) (23) Resiscircuit) Min. 1 Mz F1T8 (female) (1) with chassis ground tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage controller Other than F1/R1 5 11 V Between (23) chassis ground F1 R1 Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
Circuit diagram related to transmission level 1 clutch ECMV
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [15SELH] 1st clutch oil pressure: Command current ON and fill signal OFF
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 1st clutch oil pressure: Command current ON and fill signal OFF failure (Transmission controller system) 15SELH The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F2 and R2. The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) Method of reproducing failure code: Engine start + F1 or R1 running Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 1st clutch fill F1T8 (male) PCCS lever Resistance 1 switch (Internal short) Other than F1/R1 Min. 1 Mz Between (1) chassis ground F1 R1 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 2 wiring or defective contact Wiring harness between TMC1 (female) (23) ResisMax. 1 z in connector) F1T8 (female) (1) tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage 3 controller Other than F1/R1 5 11 V Between (23) chassis ground F1 R1 Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pres4 sure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
Circuit diagram related to transmission 1st clutch ECMV
D475A, D475ASD-5E0
11
SEN01823-01
40 Troubleshooting
Failure code [15SFL1] 2nd clutch oil pressure: Command current OFF and fill signal ON
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 2nd clutch oil pressure: Command current OFF and fill signal ON failure (Transmission controller system) 15SFL1 The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F2 and R2. The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) Method of reproducing failure code: Engine start + F2 or R2 running o Neutral running Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance switch (Internal short) Other than F2/R2 Min. 1 Mz Between (1) chassis ground F2 R2 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between TMC1 (female) (17) Resiscircuit) Min. 1 Mz F2T6 (female) (1) with chassis ground tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage controller Other than F2/R2 5 11 V Between (17) chassis ground F2 R2 Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
Circuit diagram related to transmission 2nd clutch ECMV
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [15SFLH] 2nd clutch oil pressure: Command current ON and fill signal OFF
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 2nd clutch oil pressure: Command current ON and fill signal OFF failure (Transmission controller system) 15SFLH The fill switch signal is not set on at output to the transmission level 2 clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F1 and R1. The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) Method of reproducing failure code: Engine start + F2 or R2 running Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance 1 switch (Internal short) Other than F2/R2 Min. 1 Mz Between (1) chassis ground F2 R2 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 2 wiring or defective contact Wiring harness between TMC1 (female) (17) ResisMax. 1 z in connector) F2T6 (female) (1) tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage 3 controller Other than F2/R2 5 11 V Between (17) chassis ground F2 R2 Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pres4 sure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
D475A, D475ASD-5E0
13
SEN01823-01
40 Troubleshooting
Failure code [15SGL1] 3rd clutch oil pressure: Command current OFF and fill signal ON
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 3rd clutch oil pressure: Command current OFF and fill signal ON failure (Transmission controller system) 15SGL1 The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F3 and R3. The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) Method of reproducing failure code: Engine start + F3 or R3 running o Neutral running Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 3rd clutch fill F3T4 (male) PCCS lever Resistance switch (Internal short) Other than F3/R3 Min. 1 Mz Between (1) chassis ground F3 R3 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between TMC1 (female) (11) Resiscircuit) Min. 1 Mz F3T4 (female) (1) with chassis ground tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage controller Other than F3/R3 5 11 V Between (11) chassis ground F3 R3 Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
Circuit diagram related to transmission 3rd clutch ECMV
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [15SGLH] 3rd clutch oil pressure: Command current ON and fill signal OFF
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 3rd clutch oil pressure: Command current ON and fill signal OFF failure (Transmission controller system) 15SGLH The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F1 and R1. The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode. (Code 31520: Transmission fill switch input state) Method of reproducing failure code: Engine start + F3 or R3 running Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective 3rd clutch fill F3T4 (male) PCCS lever Resistance 1 switch (Internal short) Other than F3/R3 Min. 1 Mz Between (1) chassis ground F3 R3 Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 2 wiring or defective contact Wiring harness between TMC1 (female) (11) ResisMax. 1 z in connector) F3T4 (female) (1) tance a Prepare with starting switch OFF, then start the engine for troubleshooting. Defective transmission TMC1 PCCS lever Voltage 3 controller Other than F3/R3 5 11 V Between (11) chassis ground F3 R3 Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pres4 sure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
D475A, D475ASD-5E0
15
SEN01823-01
40 Troubleshooting
Failure code [1800MW] Power train clutch: Slip

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Power train clutch slip failure (Transmission controller system) 1800MW At lock-up of the torque converter, the engine rotation is different from the torque converter rotation by 500 rpm or more. None in particular. None in particular. The engine rotation and the torque converter rotation can be checked in monitoring mode. (Code 01002: Engine rotation L, code 01004: Number of engine rotation R, code 31200: Transmission input rotation (torque converter rotation) Method of reproducing failure code: Engine start + Lock-up switch ON + Actual running Cause Power train clutch slip 1 (When the system is normal) Defective engine rotation 2 sensor Defective torque converter 3 rotation sensor system 4 Defective transmission controller Standard values when normal and remarks for troubleshooting a Clutch slip was detected; check the cause and machine damage state, then repair the machine. Check whether failure codes [CA689], [CB689], [CA778] and [CB778] are displayed. If they are displayed, carry out the troubleshooting. Check whether failure code [DLF1KA] is displayed. If it is displayed, carry out the troubleshooting. Internally trouble; troubleshooting is impossible. (If no visible abnormality is detected on the machine, the controller may be used continuously.)
16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [2201L1] Right clutch oil pressure: Command current OFF and fill signal ON
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right clutch oil pressure: Command current OFF and fill signal OFF failure (Steering controller system) 2201L1 The fill switch signal is not set off at output stop of the right steering clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) Method of reproducing failure code: Engine start Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. Defective right steering FRC8 (male) PCCS lever Resistance clutch fill switch N (Neutral) Min. 1 Mz Between (1) (Internal short) chassis ground Right steering Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between STCN3 (female) (39) Resiscircuit) Min. 1 Mz FRC8 (female) (1) with chassis ground tance a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective steering controlSTCN3 PCCS lever Voltage ler N (Neutral) 5 11 V Between (39) chassis ground Right steering Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
Circuit diagram related to right steering clutch ECMV
D475A, D475ASD-5E0
17
SEN01823-01
40 Troubleshooting
Failure code [2201LH] Right clutch oil pressure: Command current ON and fill signal OFF
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right clutch oil pressure: Command current ON and fill signal OFF failure (Steering controller system) 2201LH The fill switch signal is not set off at output to the right steering clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever operated (right steering) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. Defective right steering FRC8 (male) PCCS lever Resistance clutch fill switch N (Neutral) Min. 1 Mz Between (1) (Internal short) chassis ground Right steering Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between STCN3 (female) ResisMax. 1 z in connector) (39) FRC8 (female) (1) tance a Prepare with starting switch OFF. Engine start for troubleshooting. STCN3 PCCS lever Voltage Defective steering controller N (Neutral) 5 11 V Between (39) chassis ground Right steering Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [2202L1] Left clutch oil pressure: Command current OFF and fill signal ON
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left clutch oil pressure: Command current OFF and fill signal ON failure (Steering controller system) 2202L1 The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) Method of reproducing failure code: Engine start Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. Defective left steering FLC6 (male) PCCS lever Resistance clutch fill switch N (Neutral) Min. 1 Mz Between (1) (Internal short) chassis ground Left steering Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between STCN3 (female) (29) Resiscircuit) Min. 1 Mz FLC6 (female) (1) with chassis ground tance a Prepare with starting switch OFF. Engine start for troubleshooting. STCN3 PCCS lever Voltage Defective steering controller N (Neutral) 5 11 V Between (29) chassis ground Left steering Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
Circuit diagram related to left clutch ECMV
D475A, D475ASD-5E0
19
SEN01823-01
40 Troubleshooting
Failure code [2202LH] Left clutch oil pressure: Command current ON and fill signal OFF
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left clutch oil pressure: Command current ON and fill signal OFF failure (Steering controller system) 2202LH The fill switch signal is not set off at output to the left steering clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever operated (left steering) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start for troubleshooting. Defective left steering FLC6 (male) PCCS lever Resistance clutch fill switch N (Neutral) Min. 1 Mz Between (1) (Internal short) chassis ground Left steering Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between STCN3 (female) (29) ResisMax. 1 z in connector) FLC6 (female) (1) tance a Prepare with starting switch OFF. Engine start for troubleshooting. STCN3 PCCS lever Voltage Defective steering controller N (Neutral) 5 11 V Between (29) chassis ground Left steering Max. 1 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
Circuit diagram related to left clutch ECMV
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [2300NR] Brake thermal load: Abnormal heating

Action code Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Brake thermal load: abnormal heating failure (Steering controller system) 2300NR The steering controller added together the continuous operating times of the pitch angle sensor, travel speed, and brake potentiometer, and then judged that the brake was heating abnormally. None in particular.
Cause Standard values when normal and remarks for troubleshooting 1 Improper braking during downslope travel (Machine traveled down with brake pedal pressed) Defective steering control2 When the operation in cause 1 is not performed ler
D475A, D475ASD-5E0
21
SEN01823-01
40 Troubleshooting
Failure code [2301L1] Right brake oil pressure: Command current OFF and fill signal ON
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right brake oil pressure: Command current OFF and fill signal ON failure (Steering controller system) 2301L1 The fill switch signal is not set off at output stop of the right steering brake solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) Method of reproducing failure code: Engine start Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective right steering FR84 (male) PCCS lever Resistance brake fill switch (Internal short) N (Neutral) Max. 1 z Between (1) chassis ground Right steering Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between STCN2 (female) (25) Resiscircuit) Min. 1 Mz FR84 (female) (1) with chassis ground tance a Prepare with starting switch OFF. Engine start + Forward for troubleshooting. Defective steering controlSTCN2 PCCS lever Voltage ler N (Neutral) Max. 1V Between (25) chassis ground Right steering 5 11 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
Circuit diagram related to right steering brake ECMV
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [2301LH] Right brake oil pressure: Command current ON and fill signal OFF
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right brake oil pressure: Command current ON and fill signal OFF failure (Steering controller system) 2301LH The fill switch signal is not set off at output to the right steering brake solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) Method of reproducing failure code: Engine start + Parking bake lever release Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective right steering FR84 (male) PCCS lever Resistance clutch fill switch (Internal short) N (Neutral) Max. 1 z Between (1) chassis ground Right steering Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between STCN2 (female) (25) ResisMax. 1 in connector) FR84 (female) (1) tance Mz a Prepare with starting switch OFF. Engine start + Forward for troubleshooting. Defective steering controlSTCN2 PCCS lever Voltage ler N (Neutral) Max. 1V Between (25) chassis ground Right steering 5 11 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
D475A, D475ASD-5E0
23
SEN01823-01
40 Troubleshooting
Failure code [2301NR] Right steering brake thermal load: Abnormal heating
Action code Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Right steering brake thermal load: Abnormal heating failure (Steering controller system) 2301NR The steering controller added together the continuous operating times of the pitch angle sensor, travel speed and right steering potentiometer, and then judged that the right steering brake was heating abnormally (Machine traveled down with brake pedal pressed). None in particular.
Cause Standard values when normal and remarks for troubleshooting Improper steering during downslope travel (Machine traveled down and was steered to right con1 tinuously) Defective steering control2 When the operation in cause 1 is not performed ler
24
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [2302L1] Left brake oil pressure: Command current OFF and fill signal ON
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left brake oil pressure: Command current OFF and fill signal ON failure (Steering controller system) 2302L1 The fill switch signal is not set off at output stop of the left steering brake solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) Method of reproducing failure code: Engine start Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective left steering FL82 (male) PCCS lever Resistance brake fill switch (Internal short) N (Neutral) Max. 1 z Between (1) chassis ground Right steering Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Defective harness groundwithout turning starting switch ON. ing (Contact with ground Wiring harness between STCN2 (female) (35) Resiscircuit) Min. 1 Mz FL82 (female) (1) with chassis ground tance a Prepare with starting switch OFF. Engine start + Forward for troubleshooting. Defective steering controlSTCN2 PCCS lever Voltage ler N (Neutral) Max. 1 V Between (35) chassis ground Left steering 5 11 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
Circuit diagram related to left steering brake ECMV
D475A, D475ASD-5E0
25
SEN01823-01
40 Troubleshooting
Failure code [2302LH] Left brake oil pressure: Command current ON and fill signal OFF
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left brake oil pressure: Command current ON and fill signal OFF failure (Steering controller system) 2302LH The fill switch signal is not set on at output stop of the left steering brake solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it never runs. The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring mode. (Code 31521: Steering fill switch input state) Method of reproducing failure code: Engine start + Parking brake lever release Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective left steering FL82 (male) PCCS lever Resistance brake fill switch (Internal short) N (Neutral) Max. 1 z Between (1) chassis ground Left steering Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between STCN2 (female) (35) ResisMax. 1 z in connector) FL82 (female) (1) tance a Prepare with starting switch OFF. Engine start + Pivot turn switch ON + Forward for troubleshooting. Defective steering controlSTCN2 PCCS lever Voltage ler N (Neutral) Max. 1 V Between (35) chassis ground Left steering 5 11 V When no fault is detected in the electric system, the hydraulic presDefective hydraulic pressure system is assumed to be abnormal. Carry out the related trousure system bleshooting (H mode). Cause
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [2302NR] Left steering brake thermal load: Abnormal heating
Action code Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Left steering brake thermal load: Abnormal heating failure (Steering controller system) 2302NR The steering controller added together the continuous operating times of the pitch angle sensor, travel speed and left steering potentiometer, and then judged that the left steering brake was heating abnormally (The machine traveled down with the foot brake pressed). None in particular.
Cause Standard values when normal and remarks for troubleshooting Improper steering during downslope travel (Machine traveled down and was steered to left con1 tinuously) Defective steering control2 When the operation in cause 1 is not performed ler
D475A, D475ASD-5E0
27
SEN01823-01
40 Troubleshooting
Failure code [6001ZK] Failure code for design

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code 6001ZK Symptom of Failure code for design failure
None in particular. None in particular. Since this failure code is for design, it does not occur actually. It appears in mechanical system error code list, however.
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [A000NS] Engine: Overheat

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Engine: Overheat failure (Mechanical system) A000NS While engine was running, engine overheat lamp blinked. None in particular. None in particular. Since lighting of above caution lamp is not set for this machine, above failure code is not displayed. Above failure code is listed in the mechanical system failure code table [B@BCNS], however.
D475A, D475ASD-5E0
29
SEN01823-01
40 Troubleshooting
Failure code [AA10NX] Air cleaner: Clogging

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Air cleaner: Clogging failure (Mechanical system) AA10NX Clogging of air cleaner was detected while engine is running. Blinks warning lamp and sounds alarm buzzer. If machine is used as it is, engine output may lower or engine may be damaged. Air cleaner clogging caution symbol on monitor panel blinks and this failure code is recorded. Cause Clogged air cleaner 1 (When system is normal) Defective air cleaner clog2 ging sensor (Internal disconnection) Standard values when normal and remarks for troubleshooting a Check air cleaner. If it is clogged, clean or replace it. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. AF1, AF2 (male) Air cleaner Resistance When normal Max. 1z Between (1) (2) When clogged Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S03 (female) (13) ResisMax. 1z AF1 (female) (1) tance ResisWiring harness between AF1 (female) (2) Max. 1z AF2 (female) (1) tance Wiring harness between AF2 (female) (2) ResisMax. 1z chassis ground tance a Prepare with starting switch OFF, then start engine and carry out troubleshooting. S03 Air cleaner Voltage When normal Max. 1V Between (13) chassis ground When clogged Min. 7 V
Disconnection in wiring harness (Disconnection in 3 wiring or defective contact in connector)
4 Defective machine monitor
Electric circuit diagram related to air cleaner clogging
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [AB00MA] Battery charge abnormality: Malfunction

Action code Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Battery charge abnormality: Malfunction failure (Mechanical system) AB00MA Charge level circuit voltage lowered while engine is running. Blinks warning lamp. If machine is used as it is, battery may be discharged. Charge level caution symbol on machine monitor blinks and this failure code is recorded. Method of reproducing failure code: Start engine + Turn fuel control dial to full. Cause Battery charge defect 1 (When system is normal) Defective charge level 2 caution lamp system Standard values when normal and remarks for troubleshooting Phenomenon causing battery charge defect may be occurring or may have occurred. Check cause and damage condition and repair. Carry out troubleshooting for "Battery charge level caution lamp blinks while engine is running" in E-mode.
D475A, D475ASD-5E0
31
SEN01823-01
40 Troubleshooting
Failure code [B@BAZG] Engine oil: Oil pressure too low

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code B@BAZG Symptom of Engine oil: Oil pressure too low failure (Mechanical system)
The engine oil pressure abnormality takes place during the engine running. Flashes warning lamp and turns on alarm buzzer. (Function of machine monitor) Limits operation of engine. If the machine is operated in such a condition, the engine output may decrease and the engine may be damaged. 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 recorded. Duplication of failure code: Start the engine. Cause Standard values when normal and remarks for troubleshooting It can be suspected that the problem causing the detection of engine oil pressure reduction is currently occurring or occurred in the past. Investigate the cause and damage condition, and correct it. If cause 1 is not detected, engine oil sensor system may be detective. Carry out troubleshooting for the failure codes [CA135] and [CA141].
Reduction of engine oil 1 pressure (When system is normal) 2 Defective engine oil pressure caution lamp circuit
32
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [B@BAZK] Engine oil: Oil level reduction

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Engine oil: Oil level reduction failure (Mechanical system) B@BAZK During rotation of engine, engine oil level caution lamp flashes. Flashes warning lamp and turns on caution buzzer. (Function of monitor panel) If machine is operated as it is, engine may be damaged. The engine oil level caution symbol on the machine monitor flashes and this failure code is recorded. Method of reproducing failure code: Start engine. Cause Standard values when normal and remarks for troubleshooting Engine oil level reduction It is suspected that problem causing engine oil level reduction is 1 (When system is in normal occurring at present or occurred in past. Investigate cause and damstate) age condition, and correct it. 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
33
SEN01823-01
40 Troubleshooting
Failure code [B@BCNS] Engine coolant: Overheat

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code B@BCNS Symptom of Engine coolant: Overheat failure (Mechanical system)
Engine coolant overheats while engine is running. Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel) Limits output and continues operation. Engine output lowers. If the machine is operated in such a condition, engine may be damaged. The engine coolant temperature caution symbol on the monitor panel flashes and this failure code is recorded. Duplication of failure code: Start the engine. Cause Standard values when normal and remarks for troubleshooting Engine coolant may be overheating. Check it directly and remove cause if it is overheating.
1 Engine coolant overheat 2
If cause 1 is not detected, coolant temperature sensor system may Defective coolant be detective. Carry out troubleshooting for the failure codes [CA144] temperature sensor system and [CA145].
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [B@BCZK] Engine coolant: Level too low

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code B@BCZK Symptom of Engine coolant: Level too low failure (Mechanical system)
Engine coolant level decreases when starting switch is turned ON. Flashes warning lamp and turns on alarm buzzer. If the machine is operated in such a condition, engine may be damaged. The engine coolant level caution symbol on the monitor panel flashes and this failure code is recorded. Duplication of failure code: turn ON the starting switch. Cause Standard values when normal and remarks for troubleshooting
Engine coolant level is too It can be suspected that the problem causing the detection of engine 1 low. coolant level too low is currently occurring or occurred in the past. (When system is normal) Investigate the cause and damage condition, and correct it. 2 Defective engine coolant level caution lamp circuit Carry out troubleshooting in accordance with When starting switch is turned ON, engine coolant level caution flashes in E mode.
D475A, D475ASD-5E0
35
SEN01823-01
40 Troubleshooting
Failure code [B@BEBF] Fuel: Water in fuel

Action code Failure code Symptom of Fuel: Water in fuel failure (Mechanical system) B@BEBF Failure content There was water in fuel and water separator lamp lighted up. Controller's None in particular. action Symptoms that appear on None in particular. machine General Since above caution lamp is not set for this machine, above failure code is not displayed. information Above failure code is listed in the mechanical system failure code table, however.
36
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [B@BFZK] Fuel level: Reduction

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fuel level: Reduction failure (Mechanical system) B@BFZK Fuel level reduced and fuel level caution lamp lighted up. None in particular. None in particular. Since above caution lamp is not set for this machine, above failure code is not displayed. Above failure code is listed in the mechanical system failure code table, however.
D475A, D475ASD-5E0
37
SEN01823-01
40 Troubleshooting
Failure code [B@CENS] Power train oil: Overheat

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Power train oil: Overheat failure (Mechanical system) B@CENS During rotation of engine, power train oil temperature caution lamp flashes. Flashes warning lamp and turns on caution buzzer. (Function of machine monitor) If machine is operated as it is, power train may be damaged. Method of reproducing failure code: Start engine. Cause Power train oil temperature 1 overheat (When system is in normal state) Defective power train oil 2 temperature overheat caution lamp system Standard values when normal and remarks for troubleshooting It is suspected that problem causing power train oil temperature overheat is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. Carry out troubleshooting of power train oil temperature caution lamp system in accordance with During running of engine, emergency caution item flashes in E mode.
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [B@CHZG] HSS charge oil pressure: Low oil pressure
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of HSS charge oil pressure: Low oil pressure failure (Mechanical system) B@CHZG Power train oil pressure caution lamp blinks while engine is running. Blinks warning lamp and sounds alarm buzzer. If machine is used as it is, power train may be damaged. Method of reproducing failure code: Start engine. Cause Power train oil pressure 1 lowers (When system is normal) Defective power train oil 2 pressure caution lamp system Standard values when normal and remarks for troubleshooting Phenomenon causing power train oil pressure may be occurring or may have occurred. Check cause and damage condition and repair. Carry out troubleshooting of power train oil pressure caution lamp in "Emergency waning item blinks while engine is running" in E mode.
Failure code [B@CHZK] Power train oil: Oil level reduction

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Power train oil: Oil level reduction failure (Mechanical system) B@CHZK While engine was running, power train oil caution lamp blinked. None in particular. None in particular. Since above caution lamp is not set for this machine, above failure code is not displayed. Above failure code is listed in the mechanical system failure code table, however.
D475A, D475ASD-5E0
39
SEN01823-01
40 Troubleshooting
Failure code [B@GAZK] Battery electrolyte level: Electrolyte level reduction

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Battery electrolyte level: Electrolyte level reduction failure (Mechanical system) B@GAZK Battery electrolyte level reducted and battery electrolyte level reduction lamp lighted. None in particular. None in particular. Since above caution lamp is not set for this machine, above failure code is not displayed. Above failure code is listed in the mechanical system failure code table, however.
Failure code [B@HANS] Hydraulic oil: Overheat

Action code Failure code Symptom of Hydraulic oil: Overheat failure (Mechanical system) B@HANS 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 Method of reproducing failure code: Start engine. Cause Hydraulic oil temperature 1 overheat (When system is in normal state) Defective hydraulic oil tem2 perature caution lamp system Standard values when normal and remarks for troubleshooting It is suspected that problem causing hydraulic oil temperature overheat is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. Carry out troubleshooting of hydraulic oil temperature caution lamp system in accordance with During running of engine, emergency caution item flashes in E mode.
40
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-01
Failure code [B@HAZK] Hydraulic oil: Level reduction

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Hydraulic oil: Level reduction failure (Mechanical system) B@HAZK During rotation of engine, hydraulic oil caution lamp flashes. Flashes warning lamp and turns on caution buzzer. (Function of monitor panel) If machine is operated as it is, work equipment circuit units may be damaged. Method of reproducing failure code: Start engine. Cause Hydraulic oil level reduc1 tion (When system is in normal state) Standard values when normal and remarks for troubleshooting It is suspected that problem causing hydraulic oil level reduction is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. 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
41
SEN01823-01
42
SEN01824-01
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
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): Excessively low voltage detected .......................................................................................................... 15 Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected ......................................................................................................... 16
D475A, D475ASD-5E0
SEN01824-01
40 Troubleshooting
Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected .......................................................................................................... 18 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): Excessively low voltage detected .......................................................................................................... 22 Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected ......................................................................................................... 24 Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected .......................................................................................................... 26 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): Low voltage detection ............................................................................................................................ 29 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): Low voltage detection ............................................................................................................................ 31 Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected ......................................................................................................... 32 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): Excessively high voltage detected ......................................................................................................... 36 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): Excessively low voltage detected .......................................................................................................... 42 Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected .......................................................................................................... 44 Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected ......................................................................................................... 46 Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected ......................................................................................................... 48 Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection ............................................................................................................................ 49 Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection ............................................................................................................................ 49 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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
D475A, D475ASD-5E0
SEN01824-01
40 Troubleshooting
Failure code [CA111] Engine controller (Left bank): Internal abnormality

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Engine controller (Left bank): Internal abnormality failure (Engine controller system) CA111 Controller has abnormality in it. Blinks warning lamp and sounds alarm buzzer. Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Cause 1 Defective circuit breaker Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector) Ground fault in wiring 3 harness (Contact with GND circuit) Defective engine controller
Standard values when normal and remarks for troubleshooting Circuit breaker may be defective. Check it directly. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between PW L (female) (3), ResisMax. 1 z (4) battery (+) tance Wiring harness between PW L (female) (1), ResisMax. 1 z (2) ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz PW L (female) (3), (4) battery (+) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PW L Voltage Between (3), (4) (1), (2) 20 30 V
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Circuit diagram related to engine controller power supply
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Failure code [CB111] Engine controller (Right bank): Internal abnormality

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Engine controller (Right bank): Internal abnormality failure (Engine controller system) CB111 Controller has abnormality in it. Blinks warning lamp and sounds alarm buzzer. Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Cause 1 Defective circuit breaker Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector)
Ground fault in wiring 3 harness (Contact with GND circuit)
Defective engine controller
Standard values when normal and remarks for troubleshooting Circuit breaker may be defective. Check it directly. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between PW R (female) (3), ResisMax. 1 z (4) battery (+) tance Wiring harness between PW R (female) (1), ResisMax. 1 z (2) ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz PW R (female) (3), (4) battery (+) and tance ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PW R Voltage Between (3), (4) (1), (2) 20 30 V
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Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Abnormal engine Ne and Bkup speed sensors (At left bank): Abnorfailure mal speed sensor signal (Engine controller system) CA115 Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor circuit. Flashes warning lamp and turns on alarm buzzer. Engine does not start (during engine stop). Engine stops (during engine running).
Cause Defective Ne speed 1 sensor circuit Defective Bkup speed 2 sensor circuit Possible causes and the standard values when normal 3
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CA689]. Carry out troubleshooting of [CA778].
Since a mounting section of Ne speed sensor can be suspected to be Defective Ne speed defective, directly check the mounting section. (Defective installation sensor mounting section of sensor itself, internal defect of flywheel, etc.) Since a mounting section of Bkup speed sensor can be suspected to Bkup speed sensor 4 be defective, directly check the mounting section. (Defective installamounting 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).
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Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Abnormal engine Ne and Bkup speed sensors (At right bank): Abnorfailure mal speed sensor signal (Engine controller system) CB115 Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor circuit. Flashes warning lamp and turns on alarm buzzer. Engine does not start (during engine stop). Engine stops (during engine running).
Cause Defective Ne speed 1 sensor circuit Defective Bkup speed 2 sensor circuit Possible causes and the standard values when normal 3
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CB689]. Carry out troubleshooting of [CB778].
Since a mounting section of Ne speed sensor can be suspected to be Defective Ne speed defective, directly check the mounting section. (Defective installation sensor mounting section of sensor itself, internal defect of flywheel, etc.) Since a mounting section of Bkup speed sensor can be suspected to Bkup speed sensor 4 be defective, directly check the mounting section. (Defective installamounting 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).
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Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Charge pressure sensor too high (At left bank only): Excessively high failure voltage detected (Engine controller system) CA122 Excessively high voltage is detected at circuit of charge pressure (boost pressure) sensor. Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}). Flashes warning lamp and turns on alarm buzzer. Acceleration performance of engine deteriorates. The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring function. (Code: 36501 Boost pressure sensor voltage) Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source circuit Standard values when normal and remarks for troubleshooting If failure code [CA227] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. PIM Voltage Between (1) (2) Power source 4.75 5.25 V Since the sensor voltage is measured with the harness being connected, 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. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (37) ResisMax. 1 z PIM (female) (1) tance Wiring harness between ENG (female) (44) ResisMax. 1 z PIM (female) (3) tance Wiring harness between ENG (female) (47) ResisMax. 1 z PIM (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (37) PIM (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (44) PIM (female) (3) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) PIM (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (female) ResisMin. 1 Mz (37) to PIM (female) (1) and wiring harness tance from ENG (female) (44) to PIM (female) (3) Between wiring harness from ENG (female) ResisMin. 1 Mz (37) to PIM (female) (1) and wiring harness tance from ENG (female) (47) to PIM (female) (2) Between wiring harness from ENG (female) Resis(44) to PIM (female) (3) and wiring harness Min. 1 Mz tance from ENG (female) (47) to PIM (female) (2) a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. ENG Voltage Between (37) (47) Power source 4.75 5.25 V
Defective charge pres2 sure (boost pressure) sensor (internal defect)
Disconnection in wiring harness 3 (disconnection or defective contact of connectors) Possible causes and the standard values when normal
Defective harness grounding 4 (contact with ground circuit)
Harness short (Harness internal short)
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Circuit diagram related to charge pressure sensor
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Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Charge pressure sensor too low (At left bank only): Excessively low failure voltage detected (Engine controller system) CA123 Excessively low voltage is detected at circuit of charge pressure (boost pressure) sensor. Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}). Flashes warning lamp and turns on alarm buzzer. Acceleration performance of engine deteriorates. The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring function. (Code: 36501 Boost pressure sensor voltage) Duplication of failure code: turn ON the starting switch. Cause 1 Defective sensor power source circuit Standard values when normal and remarks for troubleshooting If failure code [CA187] is displayed at the same time, carry out troubleshooting for it first.
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Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank): High voltage detection
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Decelerator pedal sensor abnormally high level (Only left bank): High failure voltage detection (Engine controller system) CA131 High voltage was detected in decelerator pedal signal circuit. If abnormality occurs while starting switch is ON, controller fixes sensor to value just before occurrence of abnormality and continues operation. If starting switch is turned ON while there is abnormality, controller fixes sensor to 100% value and continues operation. Blinks warning lamp and sounds alarm buzzer.
Engine speed cannot be controlled with decelerator pedal. Decelerator pedal signal voltage can be checked with monitoring function (Code: 31703 Decelerator voltage) Method of reproducing failure code: Turn starting switch ON. Cause Defective decelerator 1 sensor power supply system Standard values when normal and remarks for troubleshooting If failure code [CA2185] is also displayed, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. DEC (male) Resistance Defective decelerator 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 a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (22) ResisDisconnection in wiring Max. 1z tance harness (Disconnection DEC (female) (A) in wiring or defective con- Wiring harness between OEM L (female) (9) ResisMax. 1z tact in connector) DEC (female) (B) tance Wiring harness between OEM L (female) (23) ResisMax. 1z DEC (female) (C) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring OEM L (female) (22) DEC (female) (A) tance harness (Contact with Between ground and wiring harness between ResisGND circuit) Min. 1 Mz OEM L (female) (9) DEC (female) (B) tance Between ground and wiring harness between ResisMin. 1 Mz OEM L (female) (23) DEC (female) (C) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine OEM L Voltage controller Between (22) (23) Power supply 4.75 5.25 V Between (9) (23) Signal 0.5 4.5 V
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Circuit diagram related to decelerator pedal sensor
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Failure code [CA132] Decelerator pedal sensor too low (At left bank only): Excessively low voltage detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Decelerator pedal sensor too low: excessively low voltage detected failure (At left bank only) (Engine controller system) CA132 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. If the starting switch is turned to the ON position in as-is abnormal condition, the controller operates with 100% value. Flashes warning lamp and turns on alarm buzzer.
Engine speed cannot be controlled by decelerator pedal. The signal voltage of decelerator pedal can be checked in monitoring mode. (Code: 31703 Decelerator voltage) Duplication of failure code: turn ON the starting switch. Cause Standard values when normal and remarks for troubleshooting Defective decelerator If failure code [CA2186] is displayed at the same time, carry out trou1 pedal sensor power supbleshooting for it first. ply circuit
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Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected
Action code CALL E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Oil pressure sensor too high (At left bank only): Excessively high voltfailure age detected (Engine controller system) CA135 Excessively high voltage is detected at oil pressure sensor circuit. Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2}) Flashes warning lamp and turns on alarm buzzer.
The signal voltage of engine oil pressure sensor can be checked in monitoring function. (Code: 37201 Engine oil pressure sensor voltage) Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source circuit Standard values when normal and remarks for troubleshooting If failure code [CA187] or [CA227] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. POIL Voltage Defective oil pressure Between (1) (2) Power source 4.75 5.25 V sensor Since the sensor voltage is measured with the harness being con(internal defect) 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. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring Wiring harness between ENG (female) (37) ResisMax. 1 z harness POIL (female) (1) tance (disconnection or defecWiring harness between ENG (female) (47) Resistive contact of connecMax. 1 z POIL (female) (2) tance tors) Wiring harness between ENG (female) (13) ResisMax. 1 z POIL (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisDefective harness Min. 1 Mz ENG (female) (37) POIL (female) (1) tance grounding (contact with ground cir- Between ground and wiring harness between ResisMin. 1 Mz cuit) ENG (female) (47) POIL (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (13) POIL (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (female) ResisMin. 1 Mz (37) to POIL (female) (1) and wiring harness tance from ENG (female) (47) to POIL (female) (2) Harness short (Harness internal short) Between wiring harness from ENG (female) ResisMin. 1 Mz (37) to POIL (female) (1) and wiring harness tance from ENG (female) (13) to POIL (female) (3) Between wiring harness from ENG (female) Resis(47) to POIL (female) (2) and wiring harness Min. 1 Mz tance from ENG (female) (13) to POIL (female) (3) a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. Defective engine controller ENG Voltage Between (37) (47) Power source 4.75 5.25 V
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Circuit diagram related to oil pressure sensor
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Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Oil pressure sensor too low (At left bank only): Excessively low voltfailure age detected (At left bank only) (Engine controller system) CA132 Excessively low voltage is detected at oil pressure sensor circuit. Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2}) Flashes warning lamp and turns on alarm buzzer.
The signal voltage of engine oil pressure sensor can be checked in monitoring function. (Code: 37201 Engine oil pressure sensor voltage) Duplication of failure code: turn ON the starting switch. Cause 1 Defective sensor power source circuit Standard values when normal and remarks for troubleshooting If failure code [CA187] is displayed at the same time, carry out troubleshooting for it first.
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Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Coolant temperature sensor too high: Excessively high voltage failure detected (Engine controller system) CA144 Excessively high voltage is detected at signal circuit of coolant temperature sensor. Operates with a fixed coolant temperature (90C). Flashes warning lamp and turns on alarm buzzer. Exhaust gas color becomes white. The signal voltage of coolant temperature sensor can be checked in monitoring function. (Code: 04105 Coolant temperature sensor voltage) Duplication of failure code: turn ON the starting switch. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch Defective coolant still OFF. 1 temperature sensor TWTR (male) Coolant temperature Resistance (Internal defect) Between (A) (B) 10 100C 0.6 20 kz a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between ENG (female) (15) Resis2 (disconnection or Max. 1 z TWTR (female) (A) tance defective contact of Wiring harness among ENG (female) (38) Resisconnectors) Max. 1 z JB TWTR (female) (B) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 Between ENG (female) (15) all pins of ENG (Harness internal short) ResisMin. 1 Mz (female) (with all connectors in the harness tance 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 Connector is loose, lock is broken, seal is broken 4 connector Pin is corroded, bent, broken, pushed in, expanded. Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations 5 than engine controller ENG (female) Coolant temperature Resistance Between (15) (38) 10 100C 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.) Cause
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Circuit diagram related to coolant temperature sensor
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Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Coolant temperature sensor too low (At left bank only): Excessively failure low voltage detected (Engine controller system) CA145 Excessively low voltage is detected at signal circuit of coolant temperature sensor. Operates with a fixed coolant temperature (90C). Flashes warning lamp and turns on alarm buzzer. Exhaust gas color becomes white. The signal voltage of coolant temperature sensor can be checked in monitoring function. (Code: 04105 Coolant temperature sensor voltage) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch Defective coolant still OFF. 1 temperature sensor TWTR (male) Coolant temperature Resistance (Internal defect) Between (A) (B) 10 100C 0.6 20 kz a Prepare with starting switch OFF and diagnose with starting switch Defective harness still OFF. 2 grounding (contact with Between ground and wiring harness between Resisground circuit) Min. 1 Mz ENG (female) (15) TWTR (female) (A) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 Between ENG (female) (15) all pins of ENG (Harness internal short) Resis(female) (with all connectors in the harness Min. 1 Mz tance 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 a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations 5 than engine controller ENG (female) Coolant temperature Resistance Between (15) (38) 10 100C 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.) Cause
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Circuit diagram related to coolant temperature sensor
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Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Charge temperature sensor too high (At left bank only): Excessively failure high voltage detected. (Engine controller system) CA153 Excessively high voltage is detected at signal circuit of charge temperature (boost temperature) sensor. Operates with a fixed charge temperature (boost temperature) (70C). Exhaust gas color becomes white. The signal voltage of the charge temperature (boost temperature) sensor can be checked with the monitoring function. (Code: 18501 Boost temperature sensor voltage) Duplication of failure code: turn ON the starting switch. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective charge temperTIM (male) Air boost temperature Resistance 1 ature (boost temperature) sensor (internal defect) Between (A) (B) 10 100C 0.5 20 kz Between (A) ground In all range Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring harness (disconnection Wiring harness between ENG (female) (23) Resis2 Max. 1 z or defective contact of TIM (female) (A) tance connectors) Wiring harness between ENG (female) (47) ResisMax. 1 z JB TIM (female) (B) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 Between ENG (female) (23) all pins of ENG (Harness internal short) ResisMin. 1 Mz (female) (with all connectors in the harness tance disconnected) Since the connections among charge temperature (boost 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 a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations 5 than engine controller ENG (female) Air boost temperature Resistance Between (23) (47) 10 100C 0.5 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.) Cause
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Circuit diagram related to charge temperature sensor
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Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Charge temperature sensor too low (At left bank only): Excessively failure low voltage detected (Engine controller system) CA154 Excessively low voltage is detected at signal circuit of charge temperature (boost temperature) sensor. Operates with a fixed charge temperature (boost temperature) (70C). Exhaust gas color becomes white. The signal voltage of the charge temperature (boost temperature) sensor can be checked with the monitoring function. (Code: 18501 Boost temperature sensor voltage) Duplication of failure code: turn ON the starting switch. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective charge temperTIM (male) Air boost temperature Resistance 1 ature (boost temperature) sensor (internal defect) Between (A) (B) 10 100C 0.5 20 kz Between (A) ground In all range Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch Defective harness still OFF. 2 grounding (contact with Between ground and wiring harness between Resisground circuit) Min. 1 Mz ENG (female) (23) TIM (female) (A) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short 3 Between ENG (female) (23) all pins of ENG (Harness internal short) ResisMin. 1 Mz (female) (with all connectors in the harness tance disconnected) Since the connections among charge temperature (boost temperature) sensor engine harness engine controller are suspected to be defective, check for a defective connection. Defective wiring harness Connector is loose, lock is broken, seal is broken 4 connector Pin is corroded, bent, broken, pushed in, expanded. Moisture in connector, entry of dirt or sand, etc., and insufficient insulation a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defect in other locations ENG (female) Air boost temperature Resistance 5 than engine controller Between (23) (47) 10 100C 0.5 20 kz Between (23) ground In all range Min. 1 Mz 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.) Cause
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Circuit diagram related to charge temperature sensor
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Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection
Action code CALL E03 Failure content Failure code Symptom of Sensor power supply (2) abnormally low level (Left bank): Low voltage failure detection (Engine controller system) CA187 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 continues operation. Oil pressure sensor sets oil pressure to default value (250 kPa {2.5 kg/cm2}) and continues operation. Charge pressure sensor fixes charge pressure to (400 kPa {4.1 kg/cm2}) and continues operation. Bkup sensor operates with Ne speed sensor signal. Blinks warning lamp and sounds alarm buzzer.
Controller's action
Symptoms that appear on machine General information Possible causes and the standard values when normal
Output lowers.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA227].
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Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Sensor power supply (2) abnormally low level (Right bank): Low voltfailure age detection (Engine controller system) CA187 Low voltage was detected in sensor power supply (2) (5 V) circuit. Bkup sensor operates with Ne speed sensor signal. Blinks warning lamp and sounds alarm buzzer. Output lowers.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CB227].
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Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Engine oil temperature sensor abnormally high level (Only left bank): failure High voltage detection (Engine controller system) CA212 High voltage was detected in engine oil temperature sensor circuit. Sets oil temperature to default value (100C) and continues operation.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective oil temperature 1 sensor (Internal defect) TOIL (male) Oil temperature Resistance Between (A) (B) 0 100C 0.5 36 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between ENG (female) (17) Resis2 Max. 1 z in wiring or defective con- TOIL (female) (A) tance tact in connector) Wiring harness between ENG (female) (47) ResisMax. 1 z TOIL (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring without turning starting switch ON. 3 harness (Contact with Between ground and wiring harness between ResisGND circuit) Min. 1 Mz ENG (female) (17) TOIL (female) (A) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine control4 ler ENG Oil temperature Resistance (17) (47) 0 100C 0.5 36 kz
Cause
Circuit diagram related to engine oil temperature sensor
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Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Engine oil temperature sensor abnormally low level (Only left bank): failure Low voltage detection (Engine controller system) CA213 Low voltage was detected in engine oil temperature sensor circuit. Sets oil temperature to default value (100C) and continues operation.
Cause
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Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Atmospheric pressure sensor too high (At left bank only): Excessively failure high voltage detected (Engine controller system) CA213 Excessively high voltage is detected at signal circuit of atmospheric pressure sensor. Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}). Flashes warning lamp and turns on alarm buzzer. Output decreases. The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode. (Code: 37401 Atmospheric pressure sensor voltage) Duplication of failure code: turn ON the starting switch. Cause Defective sensor power 1 source circuit Standard values when normal and remarks for troubleshooting If failure code [CA352] or [CA386] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch ON. PAMB Voltage Between (1) (3) Power source 4.75 5.25 V Between (2) (3) Signal 0.5 4.5 V Since the sensor voltage is measured with the harness being connected, 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. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (37) ResisMax. 1 z PAMB (female) (1) tance Wiring harness between ENG (female) (3) ResisMax. 1 z PAMB (female) (2) tance Wiring harness between ENG (female) (38) ResisMax. 1 z PAMB (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (37) PAMB (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (3) PAMB (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (38) PAMB (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (female) Resis(37) to PAMB (female) (1) and wiring harness Min. 1 Mz tance from ENG (female) (3) to PAMB (female) (2) Between wiring harness from ENG (female) ResisMin. 1 Mz (37) to PAMB (female) (1) and wiring harness tance from ENG (female) (38) to PAMB (female) (3) Between wiring harness from ENG (female) ResisMin. 1 Mz (3) to PAMB (female) (2) and wiring harness tance from ENG (female) (38) to PAMB (female) (3)
Defective atmospheric 2 pressure sensor (internal defect)
Disconnection in wiring harness (disconnection 3 or defective contact of connectors)
Defective harness 4 grounding (contact with ground circuit)
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Cause Possible causes and the standard values when normal Defective engine controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. ENG Voltage 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
SEN01824-01
40 Troubleshooting
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Atmospheric pressure sensor too low (At left bank only): Excessively failure low voltage detected (Engine controller system) CA222 Excessively low voltage is detected at signal circuit of atmospheric pressure sensor. Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}). Flashes warning lamp and turns on alarm buzzer. Output decreases. The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode. (Code: 37401 Atmospheric pressure sensor voltage) Duplication of failure code: turn ON the starting switch. Cause Standard values when normal and remarks for troubleshooting Carry out troubleshooting of failure code [CA221].
34
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D475A, D475ASD-5E0
35
SEN01824-01
40 Troubleshooting
Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Sensor power source (2) too high (At left bank): Excessively high voltfailure age detected (Engine controller system) CA227 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}) Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2}) Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}). Flashes warning lamp and turns on alarm buzzer.
Output decreases.
Standard values when normal and remarks for troubleshooting 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. a Prepare with starting switch OFF and diagnose with starting switch ON. Bkup speed sensor G connector Disconnect the Engine oil pressure Defective sensor POIL connector devices on the right 2 sensor (internal defect) one at a time. Atmospheric pressure If the code disapPAMB connector sensor pears, that device is Charge pressure seninternally defective. PIM connector sor a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between ENG (female) (37) Resis3 (disconnection or defecMax. 1 z each sensor (female) tance tive contact of connecWiring harness between ENG (female) (47) Resistors) Max. 1 z each sensor (female) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding Between ground and wiring harness between Resis4 Min. 1 Mz tance (contact with ground cir- ENG (female) (37) each sensor (female) cuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) each sensor (female) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short Between wiring harness from ENG (female) 5 (Harness internal short) (37) to each sensor (female) and wiring harResisMin. 1 Mz ness from ENG (female) (47) to each sensor tance (female) a Prepare with starting switch OFF and diagnose with starting switch ON. Defective engine control6 ENG Voltage ler Between (37) (47) 4.75 5.25 V
Cause
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Circuit diagram related to sensor power source (2) (5V)
D475A, D475ASD-5E0
37
SEN01824-01
40 Troubleshooting
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection
Action code Failure code Symptom of Sensor power supply (2) abnormally high level (Right bank): High voltfailure age detection (Engine controller system) CALL E03 CB227 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 appear on Output lowers. machine General information Cause Standard values when normal and remarks for troubleshooting 1 Related defective system If another code is also displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When device at right Defective sensor (Inter2 is disconnected, if nal defect) Bkup speed error code disappears, G connector sensor that device has defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between ENG (female) (37) Resis3 Max. 1 z in wiring or defective con- each sensor (female) tance tact in connector) ResisWiring harness between ENG (female) (47) Max. 1 z each sensor (female) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between Resis4 harness (Contact with Min. 1 Mz ENG (female) (37) each sensor (female) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) each sensor (female) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness from ENG (female) 5 ness (with another wiring (37) to each sensor (female) and wiring harResisharness) Min. 1 Mz ness from ENG (female) (47) to each sensor tance (female) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine control6 ler ENG Voltage Between (37) (47) 4.75 5.25 V
38
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Circuit diagram related to sensor power source (2) (At right bank)
D475A, D475ASD-5E0
39
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Failure code [CA234] Engine over speed (At left bank only): Excessively high speed
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Engine over speed (At left bank only): Excessively high speed failure (Engine controller system) CA234 The engine speed exceeds upper control limit speed. Flashes warning lamp and turns on alarm buzzer. Stops operation of injector until the engine speed drops to the normal speed. Engine speed fluctuates. The engine speed can be checked in monitoring function. (Code: 01000 Engine speed) Duplication of failure code: Start engine and operate at high idle. Standard values when normal and remarks for troubleshooting 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. The improper usage of equipped machine can be suspected. Instruct 2 Improper usage the proper usage. Engine controller can be suspected to be defective if no problem is Defective engine 3 found in causes 1 2 (since this is an internal defect, it cannot be controller diagnosed). Cause
40
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D475A, D475ASD-5E0
41
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40 Troubleshooting
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Abnormal power source for Ne speed sensor (At left bank only): failure Excessively low voltage detected (Engine controller system) CA238 Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit. Controls using Bkup speed sensor signal. Flashes warning lamp and turns on alarm buzzer. Engine stops during operation (when Bkup speed sensor is defective at the same time). Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective Ne speed sen- Disconnect a device 1 sor shown on the right. (internal defect) If the failure code disNe speed sensor Ne connector appears, that device is internally defective. a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between left bank ENG Resis2 (disconnection or defecMax. 1 z (female) (16) Ne (female) (1) tance tive contact of connecWiring harness between left bank ENG Resistors) Max. 1 z (female) (48) Ne (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between Resisgrounding Min. 1 Mz 3 tance (contact with ground cir- left bank ENG (female) (16) Ne (female) (1) cuit) Between ground and wiring harness between ResisMin. 1 Mz left bank ENG (female) (48) Ne (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short Between wiring harness from left bank ENG 4 (Harness internal short) (female) (16) to Ne (female) (1) and wiring ResisMin. 1 Mz harness from left bank ENG (female) (48) to tance Ne (female) (2) a Prepare with starting switch OFF and diagnose with starting switch ON. Defective engine control5 ler Left bank ENG Voltage Between (16) (48) 4.75 5.25 V
Cause
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Circuit diagram related to Ne speed sensor power source
D475A, D475ASD-5E0
43
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40 Troubleshooting
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Abnormal power source for Ne speed sensor (At right bank only): failure Excessively low voltage detected (Engine controller system) CB238 Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit. Controls using Bkup speed sensor signal. Flashes warning lamp and turns on alarm buzzer. Engine stops during operation (when Bkup speed sensor is defective at the same time). Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective Ne speed sen- Disconnect a device 1 sor shown on the right. (internal defect) If the failure code disNe speed sensor Ne connector appears, that device is internally defective. a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between left bank ENG Resis2 (disconnection or defecMax. 1 z (female) (16) Ne (female) (1) tance tive contact of connecWiring harness between right bank ENG Resistors) Max. 1 z (female) (48) Ne (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between ResisMin. 1 Mz grounding left bank ENG (female) (16) Ne (female) (1) tance 3 (contact with ground cirBetween ground and wiring harness between cuit) Resisright bank ENG (female) (48) Ne (female) Min. 1 Mz tance (2) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Harness short Between wiring harness from left bank ENG 4 (Harness internal short) (female) (16) to Ne (female) (1) and wiring ResisMin. 1 Mz harness from right bank ENG (female) (48) to tance Ne (female) (2) a Prepare with starting switch OFF and diagnose with starting switch ON. Defective engine control5 ler Voltage Between left bank ENG (16) right bank ENG (48) 4.75 5.25 V
Cause
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Circuit diagram related to Ne speed sensor power source
D475A, D475ASD-5E0
45
SEN01824-01
40 Troubleshooting
Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fuel temperature sensor too high (At left bank): Excessively high voltfailure age detected (Engine controller system) CA263 Excessively high voltage is detected at fuel temperature sensor circuit. Operates with a fixed fuel temperature (95C).
The signal voltage of engine fuel temperature sensor can be checked in monitoring function. (Code: 14201 Engine fuel temperature sensor voltage) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch Defective fuel temperastill OFF. ture sensor (internal TFUEL (male) Fuel temperature Resistance defect) Between (A) (B) 10 100C 0.6 20 kz a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between ENG (female) (30) Resis(disconnection or defecMax. 1 z TFUEL (female) (A) tance tive contact of connecWiring harness between ENG (female) (47) Resistors) Max. 1 z TFUEL (female) (B) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding Between ground and wiring harness between ResisMin. 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. ENG (female) Fuel temperature Resistance Defective engine controller Between (30) (47) 10 100C 0.6 20 kz Cause
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Circuit diagram related to fuel temperature sensor
D475A, D475ASD-5E0
47
SEN01824-01
40 Troubleshooting
Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fuel temperature sensor too high (At right bank): Excessively high failure voltage detected (Engine controller system) CB263 Excessively high voltage is detected at fuel temperature sensor circuit. Operates with a fixed fuel temperature (95C).
The signal voltage of engine fuel temperature sensor can be checked in monitoring function. (Code: 14201 Engine fuel temperature sensor voltage) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch Defective fuel temperastill OFF. ture sensor (internal TFUEL (male) Fuel temperature Resistance defect) Between (A) (B) 10 100C 0.6 20 kz a Prepare with starting switch OFF and diagnose with starting switch Disconnection in wiring still OFF. harness Wiring harness between ENG (female) (30) Resis(disconnection or defecMax. 1 z TFUEL (female) (A) tance tive contact of connecWiring harness between ENG (female) (47) Resistors) Max. 1 z TFUEL (female) (B) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness grounding Between ground and wiring harness between ResisMin. 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. ENG (female) Fuel temperature Resistance Defective engine controller Between (30) (47) 10 100C 0.6 20 kz Cause
Circuit diagram related to fuel temperature sensor
48
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Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Cause Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA263]. Failure code Symptom of Fuel temperature sensor abnormally low level (Left bank): Low voltfailure age detection (Engine controller system) CA265 Low voltage was detected in fuel temperature sensor circuit. Substitutes coolant temperature sensor. If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95C) and continues operation.
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Cause Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CB263]. Failure code Symptom of Fuel temperature sensor abnormally low level (Right bank): Low voltfailure age detection (Engine controller system) CB265 Low voltage was detected in fuel temperature sensor circuit. Substitutes coolant temperature sensor. If coolant temperature sensor is also abnormal, sets fuel temperature to default value (95C) and continues operation.
D475A, D475ASD-5E0
49
SEN01824-01
40 Troubleshooting
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit
Action code Failure code Symptom of PCV1 short circuit (Left bank): Short circuit failure (Engine controller system) CALL E03 CA271 Failure content Short circuit occurred in supply pump PCV1 circuit. Controller's Blinks warning lamp and sounds alarm buzzer. action Symptoms that appear on machine General While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse information voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV1 (Internal short circuit) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV1 (male) Resistance Between (1) (2) 2.3 5.3 z Between (1), (2) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (4) PCV1 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (5) PCV1 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between ground and wiring harness between Voltage Max. 1 V ENG (female) (4) PCV1 (female) (1) Between ground and wiring harness between Voltage Max. 1 V ENG (female) (5) PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (4) (5) 2.3 5.3 z Between (4), (5) ground Min. 1 Mz
Hot short (Contact with 3 24V circuit) in wiring harness
Circuit diagram related to supply pump PCV1
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Failure code [CB271] PCV1 short circuit (Right bank): Short circuit
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of PCV1 short circuit (Right bank): Short circuit failure (Engine controller system) CB271 Short circuit occurred in supply pump PCV1 circuit. Blinks warning lamp and sounds alarm buzzer.
While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV1 (Internal short circuit) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV1 (male) Resistance Between (1) (2) 2.3 5.3 z Between (1), (2) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (4) PCV1 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (5) PCV1 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between ground and wiring harness between Voltage Max. 1 V ENG (female) (4) PCV1 (female) (1) Between ground and wiring harness between Voltage Max. 1 V ENG (female) (5) PCV1 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (4) (5) 2.3 5.3 z Between (4), (5) ground Min. 1 Mz
D475A, D475ASD-5E0
51
SEN01824-01
40 Troubleshooting
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of PCV1 disconnection (Left bank): Disconnection failure (Engine controller system) CA272 Disconnection occurred in supply pump PCV1 circuit. Blinks warning lamp and sounds alarm buzzer.
While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV1 (Internal disconnection) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV1 (male) Resistance Between (1) (2) 2.3 5.3 z Between (1), (2) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (4) ResisMax. 1 z PCV1 (female) (1) tance Wiring harness between ENG (female) (5) ResisMax. 1 z PCV1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (4) PCV1 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (5) PCV1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (4) (5) 2.3 5.3 z Between (4), (5) ground Min. 1 Mz
Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector)
52
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Failure code [CB272] PCV1 disconnection (Right bank): Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of PCV1 disconnection (Right bank): Disconnection failure (Engine controller system) CB272 Disconnection occurred in supply pump PCV1 circuit. Blinks warning lamp and sounds alarm buzzer.
While engine is running normally, pulse voltage of about 24 V is applied to PCV1 (1). This pulse voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV1 (Internal disconnection) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV1 (male) Resistance Between (1) (2) 2.3 5.3 z Between (1), (2) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (4) ResisMax. 1 z PCV1 (female) (1) tance Wiring harness between ENG (female) (5) ResisMax. 1 z PCV1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (4) PCV1 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (5) PCV1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (4) (5) 2.3 5.3 z Between (4), (5) ground Min. 1 Mz
D475A, D475ASD-5E0
53
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Failure code [CA273] PCV2 short circuit (Left bank): Short circuit
Action code Failure code Symptom of PCV2 short circuit (Left bank): Short circuit failure (Engine controller system) CALL E03 CA273 Failure content Short circuit occurred in supply pump PCV2 circuit. Controller's Blinks warning lamp and sounds alarm buzzer. action Symptoms that appear on machine General While engine is running normally, pulse voltage of about 24 V is applied to PCV2 (1). This pulse information voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV2 (Internal short circuit) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV2 (male) Resistance Between (1) (2) 2.3 5.3 z Between (1), (2) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (9) PCV2 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (10) PCV2 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between ground and wiring harness between Voltage Max. 1 V ENG (female) (9) PCV2 (female) (1) Between ground and wiring harness between Voltage Max. 1 V ENG (female) (10) PCV2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (9) (10) 2.3 5.3 z Between (9), (10) ground Min. 1 Mz
54
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40 Troubleshooting
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Failure code [CB273] PCV2 short circuit (Right bank): Short circuit
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of PCV2 short circuit (Right bank): Short circuit failure (Engine controller system) CB273 Short circuit occurred in supply pump PCV2 circuit. Blinks warning lamp and sounds alarm buzzer.
While engine is running normally, pulse voltage of about 24 V is applied to PCV2 (1). This pulse voltage cannot be measured with circuit tester. Cause Defective supply pump 1 PCV2 (Internal short circuit) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV2 (male) Resistance Between (1) (2) 2.3 5.3 z Between (1), (2) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (9) PCV2 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (10) PCV2 (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between ground and wiring harness between Voltage Max. 1 V ENG (female) (9) PCV2 (female) (1) Between ground and wiring harness between Voltage Max. 1 V ENG (female) (10) PCV2 (female) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Between (9) (10) 2.3 5.3 z Between (9), (10) ground Min. 1 Mz
D475A, D475ASD-5E0
55
SEN01824-01
40 Troubleshooting
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of PCV2 disconnection (Left bank): Disconnection failure (Engine controller system) CA274 Disconnection occurred in supply pump PCV2 circuit. Blinks warning lamp and sounds alarm buzzer.
While engine is running normally, pulse voltage of about 24 V is applied to PCV2 (1). This pulse voltage cannot be measured with circuit tester. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective supply pump without turning starting switch ON. PCV2 (Internal disconPCV2 (male) Resistance nection) Between (1) (2) 2.3 5.3 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection Wiring harness between ENG (female) (9) Max. 1 z tance in wiring or defective con- PCV2 (female) (1) tact in connector) Wiring harness between ENG (female) (10) ResisMax. 1 z PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between ResisMin. 1 Mz harness (Contact with ENG (female) (9) PCV2 (female) (1) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (10) PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine controlENG (female) Resistance ler Between (9) (10) 2.3 5.3 z Between (9), (10) ground Min. 1 Mz Cause
2 Possible causes and the standard values when normal 3
56
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of PCV2 disconnection (Right bank): Disconnection failure (Engine controller system) CB274 Disconnection occurred in supply pump PCV2 circuit. Blinks warning lamp and sounds alarm buzzer.
While engine is running normally, pulse voltage of about 24 V is applied to PCV2 (1). This pulse voltage cannot be measured with circuit tester. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective supply pump without turning starting switch ON. PCV2 (Internal disconPCV2 (male) Resistance nection) Between (1) (2) 2.3 5.3 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection Wiring harness between ENG (female) (9) Max. 1 z tance in wiring or defective con- PCV2 (female) (1) tact in connector) Wiring harness between ENG (female) (10) ResisMax. 1 z PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between ResisMin. 1 Mz harness (Contact with ENG (female) (9) PCV2 (female) (1) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (10) PCV2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine controlENG (female) Resistance ler Between (9) (10) 2.3 5.3 z Between (9), (10) ground Min. 1 Mz Cause
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57
SEN01824-01
58
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank): Disconnection, short circuit ......................................................................................................................... 4 Failure code [CA323] Injector #5 (L/B #5) system disconnection or short circuit (At left bank): Disconnection, short circuit ......................................................................................................................... 6 Failure code [CA324] Injector #3 (L/B #3) system disconnection or short circuit (At left bank): Disconnection, short circuit ......................................................................................................................... 8 Failure code [CA325] Injector #6 (L/B #6) system disconnection or short circuit (At left bank): Disconnection, short circuit ....................................................................................................................... 10 Failure code [CA331] Injector #2 (L/B #2) system disconnection or short circuit (At left bank): Disconnection, short circuit ....................................................................................................................... 12 Failure code [CA332] Injector #4 (L/B #4) system disconnection or short circuit (At left bank): Disconnection, short circuit ....................................................................................................................... 14 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
SEN01825-01
40 Troubleshooting
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection.......22 Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection ....23 Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection ....24 Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection ..26 Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection............28 Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection .........28 Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection .........29 Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection.......29 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): Excessively high voltage detected ............................................................................................................32 Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection...............................................................................................................................34 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): Loss of pressure feed detected.................................................................................................................44 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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
D475A, D475ASD-5E0
SEN01825-01
40 Troubleshooting
Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank): Disconnection, short circuit
Action code Failure code Symptom of Injector #1 (L/B #1) system disconnection or short circuit (At left failure bank): Disconnection, short circuit (Engine controller system) CALL E03 CA322 Failure content A disconnection or short circuit has occurred in injector #1 circuit. Controller's Flashes warning lamp and turns on alarm buzzer. action Symptoms that Output decreases. appear on Speed is not stable. machine General While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of information injector. This pulse voltage cannot be measured with circuit tester. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective injector #1 CN1 (male) Resistance (internal defect) Between (1) (2) 0.4 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring Wiring harness between ENG (female) (45) Resisharness Max. 1 z tance (disconnection or defective CN1 (female) (1) contact of connectors) Wiring harness between ENG (female) (53) ResisMax. 1 z CN1 (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between ResisMin. 1 Mz grounding (contact with ENG (female) (45) CN1 (female) (1) tance ground circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (53) CN1 (female) (2) tance Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry injector or wiring harness out troubleshooting for them, too. a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Resistance Defective engine controller Between (45) (53) 0.4 1.1 z Between (45), (53) and ground Min. 1 Mz Cause
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
Circuit diagram related to injector #1
D475A, D475ASD-5E0
SEN01825-01
40 Troubleshooting
Action code Failure code Symptom of Injector #5 (L/B #5) system disconnection or short circuit (At left failure bank): Disconnection, short circuit (Engine controller system) CALL E03 CA323 Failure content A disconnection or short circuit has occurred in injector #5 circuit. Controller's Flashes warning lamp and turns on alarm buzzer. action Symptoms that Output decreases. appear on Speed is not stable. machine General While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of information injector. This pulse voltage cannot be measured with circuit tester. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective injector #5 CN5 (male) Resistance (internal defect) Between (1) (2) 0.4 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring Wiring harness between ENG (female) (46) Resisharness Max. 1 z tance (disconnection or defective CN5 (female) (1) contact of connectors) Wiring harness between ENG (female) (60) ResisMax. 1 z CN5 (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective harness Between ground and wiring harness between ResisMin. 1 Mz grounding (contact with ENG (female) (46) CN5 (female) (1) tance ground circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (60) CN5 (female) (2) tance Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry injector or wiring harness out troubleshooting for them, too. a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Resistance Defective engine controller Between (46) (60) 0.4 1.1 z Between (46), (60) and ground Min. 1 Mz Cause
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
D475A, D475ASD-5E0
SEN01825-01
40 Troubleshooting
Action code Failure code Symptom of Injector #3 (L/B #3) system disconnection or short circuit (At left failure bank): Disconnection, short circuit (Engine controller system) CALL E03 CA324 Failure content A disconnection or short circuit has occurred in injector #3 circuit. Controller's Flashes warning lamp and turns on alarm buzzer. action Symptoms that Output decreases. appear on Speed is not stable. machine General While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of information injector. This pulse voltage cannot be measured with circuit tester. Cause Defective injector #3 (internal defect) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. CN3 (male) Resistance Between (1) (2) 0.4 1.1 z Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (55) ResisMax. 1 z CN3 (female) (1) tance Wiring harness between ENG (female) (52) ResisMax. 1 z CN3 (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (55) CN3 (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (52) CN3 (female) (2) tance If multiple failure codes are displayed for injector malfunction, carry out troubleshooting for them, too. a Prepare with starting switch OFF and diagnose with starting switch still OFF. ENG (female) Resistance Between (55) (52) 0.4 1.1 z Between (55), (52) and ground Min. 1 Mz
Disconnection in wiring harness 2 (disconnection or defective contact of connectors)
Defective harness ground3 ing (contact with ground circuit) Defective another cylinder injector or wiring harness
5 Defective engine controller
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40 Troubleshooting
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11
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12
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13
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40 Troubleshooting
14
D475A, D475ASD-5E0
40 Troubleshooting
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D475A, D475ASD-5E0
15
SEN01825-01
40 Troubleshooting
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Engine controller data mismatch (Left bank): Mismatch failure (Engine controller system) CA342 Data mismatch occurred in engine controller. Blinks warning lamp and sounds alarm buzzer. Engine cannot be started or operated.
Cause
16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Engine controller data mismatch (Right bank): Mismatch failure (Engine controller system) CB342 Data mismatch occurred in engine controller. Blinks warning lamp and sounds alarm buzzer. Engine cannot be started or operated.
Cause
D475A, D475ASD-5E0
17
SEN01825-01
40 Troubleshooting
Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit
Action code Failure code Symptom of Abnormal injector drive circuit (At left bank): Abnormal circuit failure (Engine controller system) CALL E03 CA351 Failure content Abnormality has occurred in injector drive circuit. Controller's Operates with limited output. (Limits common rail pressure.) action Flashes warning lamp and turns on alarm buzzer. Symptoms that appear on Output decreases. machine General information Standard values when normal and remarks for troubleshooting Check the failure codes (codes for injector system trouble) that are 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. 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.) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Disconnection in wiring Wiring harness between PW L (female) (3) Resisharness Max. 1 z tance (disconnection or defective (4) battery (+) contact of connectors) Wiring harness between PW L (female) (1) ResisMax. 1 z (2) and ground tance a Prepare with starting switch OFF and diagnose with starting Defective harness switch still OFF. grounding (contact with Between ground and wiring harness between Resisground circuit) Min. 1 Mz PW L (female) (3) (4) battery (+)Resistance tance a Prepare with starting switch OFF and diagnose with starting switch ON. Defective engine controller PW L Voltage Between (3), (4) (1), (2) 20 30 V Cause
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
Circuit diagram related to controller power source
D475A, D475ASD-5E0
19
SEN01825-01
40 Troubleshooting
Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality
Action code Failure code Symptom of Injector drive circuit abnormality (Right bank): Circuit abnormality failure (Engine controller system) CALL E03 CB351 Failure content Abnormality occurred in injector drive circuit. Controller's Limits output and continues operation (Limits common rail pressure). action Blinks warning lamp and sounds alarm buzzer. Symptoms that appear on Output lowers. machine General information Standard values when normal and remarks for troubleshooting If another code (code of injector system abnormality) is also disRelated defective system played, carry out troubleshooting for it. Fuse or circuit breaker on applicable machine side may be defective. Defective circuit breaker Check them directly. (If fuse is broken or circuit breaker is turned OFF, circuit probably has ground fault.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between PW R (female) (3), ResisMax. 1 z wiring or defective contact (4) battery (+) tance in connector) Wiring harness between PW R (female) (1), ResisMax. 1 z (2) ground tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring without turning starting switch ON. harness (Contact with Between ground and wiring harness between ResisGND circuit) Min. 1 Mz PW R (female) (3), (4) battery (+) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine controller PW R Voltage Between (3), (4) (1), (2) 20 30 V Cause
1 2
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
D475A, D475ASD-5E0
21
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40 Troubleshooting
Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection
Action code Failure code Symptom of Sensor power supply (1) abnormally low level (Left bank): Low voltfailure age detection (Engine controller system) CALL E03 CA352 Failure content Low voltage was detected in sensor power supply (1) (5 V) circuit. Controller's Common rail pressure sensor limits output and continues operation (Limits common rail pressure). action Blinks warning lamp and sounds alarm buzzer. Symptoms that appear on Output lowers. machine General information Possible causes and the standard values when normal Cause Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA386].
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Sensor power supply (1) abnormally low level (Right bank): Low voltSymptom of age detection failure CB352 (Engine controller system) Low voltage was detected in sensor power supply (1) (5 V) circuit. Common rail pressure sensor limits output and continues operation (Limits common rail pressure). Blinks warning lamp and sounds alarm buzzer. Output lowers. Failure code
Cause
D475A, D475ASD-5E0
23
SEN01825-01
40 Troubleshooting
Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection
Action code Failure code Symptom of Sensor power supply (1) abnormally high level (Left bank): High voltfailure age detection (Engine controller system) CALL E03 CA386 Failure content High voltage was detected in sensor power supply (1) (5 V) circuit. Controller's Common rail pressure sensor limits output and continues operation (Limits common rail pressure). action Blinks warning lamp and sounds alarm buzzer. Symptoms that appear on Output lowers. machine General information Cause 1 Related defective system Standard values when normal and remarks for troubleshooting If another code is also displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When device at right Defective sensor is disconnected, if (Internal defect) Left common rail error code disapPFUEL connector pressure sensor pears, that device has defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in PFUEL (female) (1) wiring or defective contact Wiring harness between ENG (female) (25) ResisMax. 1 z in connector) PFUEL (female) (2) tance Wiring harness between ENG (female) (47) ResisMax. 1 z PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring ENG (female) (33) PFUEL (female) (1) tance harness (Contact with Between ground and wiring harness between ResisGND circuit) Min. 1 Mz ENG (female) (25) PFUEL (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between ENG (female) (33) PFUEL (female) (1) and wirResisMin. 1 Mz ing harness between ENG (female) (25) tance PFUEL (female) (2) Short circuit in wiring Between wiring harness between ENG harness (with another (female) (33) PFUEL (female) (1) and wirResiswiring harness) Min. 1 Mz ing harness between ENG (female) (47) tance PFUEL (female) (3) Between wiring harness between ENG (female) (25) PFUEL (female) (2) and wirResisMin. 1 Mz ing harness between ENG (female) (47) tance PFUEL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective engine controller ENG Voltage Between (33) (47) 4.75 5.25 V
24
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
Circuit diagram related to sensor power supply 1 (5V)
D475A, D475ASD-5E0
25
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40 Troubleshooting
Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Sensor power supply (1) abnormally high level (Right bank): High Symptom of voltage detection failure CB386 (Engine controller system) High voltage was detected in sensor power supply (1) (5 V) circuit. Common rail pressure sensor limits output and continues operation (Limits common rail pressure). Blinks warning lamp and sounds alarm buzzer. Output lowers. Failure code
Cause 1 Related defective system
Defective sensor (Internal defect)
Ground fault in wiring har4 ness (Contact with GND circuit)
Short circuit in wiring har5 ness (with another wiring harness)
Standard values when normal and remarks for troubleshooting If another code is also displayed, carry out troubleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When device at right is disconnected, if Right common rail error code disapPFUEL connector pressure sensor pears, that device has defect in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) ResisMax. 1 z PFUEL (female) (1) tance Wiring harness between ENG (female) (25) ResisMax. 1 z PFUEL (female) (2) tance Wiring harness between ENG (female) (47) ResisMax. 1 z PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (33) PFUEL (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (25) PFUEL (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between ENG (female) (33) PFUEL (female) (1) and wirResisMin. 1 Mz ing harness between ENG (female) (25) tance PFUEL (female) (2) Between wiring harness between ENG (female) (33) PFUEL (female) (1) and wirResisMin. 1 Mz ing harness between ENG (female) (47) tance PFUEL (female) (3) Between wiring harness between ENG (female) (25) PFUEL (female) (2) and wirResisMin. 1 Mz ing harness between ENG (female) (47) tance PFUEL (female) (3) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ENG Voltage Between (33) (47) 4.75 5.25 V
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
Circuit diagram related to sensor power supply (1) (5V)
D475A, D475ASD-5E0
27
SEN01825-01
40 Troubleshooting
Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Power supply voltage abnormally low level (Left bank): Low voltage failure detection (Engine controller system) CA441 Low voltage was detected in power supply voltage circuit. Blinks warning lamp and sounds alarm buzzer. Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Cause
Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Power supply voltage abnormally low level (Right bank): Low voltage failure detection (Engine controller system) CB441 Low voltage was detected in power supply voltage circuit. Blinks warning lamp and sounds alarm buzzer. Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Cause
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Power supply voltage abnormally high level (Left bank): High voltage failure detection (Engine controller system) CA442 High voltage was detected in power supply voltage circuit. Blinks warning lamp and sounds alarm buzzer. Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Cause
Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Power supply voltage abnormally high level (Right bank): High voltfailure age detection (Engine controller system) CB442 High voltage was detected in power supply voltage circuit. Blinks warning lamp and sounds alarm buzzer. Machine continues operation normally but may stop suddenly or may not able to start again once it stops.
Cause
D475A, D475ASD-5E0
29
SEN01825-01
40 Troubleshooting
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Common rail abnormally high pressure (2) (Left bank): Abnormally failure high pressure occurrence (Engine controller system) CA449 Common rail pressure sensor circuit detected abnormally high pressure (Level 2). Limits output and continues operation (Limits common rail pressure). Blinks warning lamp and sounds alarm buzzer. Output lowers.
Cause
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Common rail abnormally high pressure (2) (Right bank): Abnormally failure high pressure occurrence (Engine controller system) CB449 Common rail pressure sensor circuit detected abnormally high pressure (Level 2). Limits output and continues operation (Limits common rail pressure). Blinks warning lamp and sounds alarm buzzer. Output lowers.
Cause
30
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40 Troubleshooting
Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Common rail pressure sensor too high (At left bank): Excessively failure high voltage detected (Engine controller system) CA451 Excessively high voltage has occurred in the common rail pressure sensor circuit. Operates with limited output.(Limits common rail pressure.) Flashes warning lamp and turns on alarm buzzer. Output decreases. The signal voltage of the common rail pressure sensor can be checked with the monitoring function. (Code: 36401 Common rail pressure sensor voltage) Cause Defective sensor power 1 source circuit Standard values when normal and remarks for troubleshooting If failure code [CA352] or [CA386] is displayed, carry out troubleshooting 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 pressure sensor Between (2) (3) Signal 0.25 4.6 V (internal defect) Since the sensor voltage is measured with the harness being connected, 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. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between ENG (female) (33) ResisDisconnection in wiring Max. 1 z tance harness (disconnection or PFUEL (female) (1) defective contact of con- Wiring harness between ENG (female) (25) ResisMax. 1 z nectors) PFUEL (female) (2) tance Wiring harness between ENG (female) (47) ResisMax. 1 z PFUEL (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz Defective harness groundENG (female) (33) PFUEL (female) (1) tance ing (contact with ground Between ground and wiring harness between Resiscircuit) Min. 1 Mz ENG (female) (25) PFUEL (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) PFUEL (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from ENG (female) (33) to PFUEL (female) (1) and wiring harResisMin. 1 Mz ness from ENG (female) (25) to PFUEL tance (female) (2) Harness short Between wiring harness from ENG (female) (Harness internal short) (33) to PFUEL (female) (1) and wiring harResisMin. 1 Mz ness from ENG (female) (47) to PFUEL tance (female) (3) Between wiring harness from ENG (female) (25) to PFUEL (female) (2) and wiring harResisMin. 1 Mz ness from ENG (female) (47) to PFUEL tance (female) (3)
Possible causes and the standard values when normal 4
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Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, and diagnose with starting switch ON or with engine started. ENG Voltage 6 Defective engine controller Between (33) (47) 4.75 5.25 V Between (25) (47) 0.25 4.6 V
Cause
Circuit diagram related to common rail pressure sensor
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Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Common rail pressure sensor abnormally high level (Right bank): failure High voltage detection (Engine controller system) CB451 High voltage was detected in common rail pressure sensor circuit. Limits output and continues operation (Limits common rail pressure). Blinks warning lamp and sounds alarm buzzer. Output lowers. Signal voltage of common rail pressure sensor can be checked with monitoring function (Code: 36404: Common rail pressure sensor voltage). Cause Defective sensor power 1 supply system Standard values when normal and remarks for troubleshooting If code [CB352] or [CB386] is displayed, carry out troubleshooting 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 pressure sensor Between (2) (3) Signal 0.25 4.6 V (Internal defect) Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in PFUEL (female) (1) wiring or defective contact Wiring harness between ENG (female) (25) ResisMax. 1 z in connector) PFUEL (female) (2) tance Wiring harness between ENG (female) (47) ResisMax. 1 z PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring harENG (female) (33) PFUEL (female) (1) tance ness (Contact with GND Between ground and wiring harness between Resiscircuit) Min. 1 Mz ENG (female) (25) PFUEL (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (47) PFUEL (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between ENG (female) (33) PFUEL (female) (1) and wirResisMin. 1 Mz ing harness between ENG (female) (25) tance PFUEL (female) (2) Short circuit in wiring harBetween wiring harness between ENG ness (with another wiring (female) (33) PFUEL (female) (1) and wirResisharness) Min. 1 Mz ing harness between ENG (female) (47) tance PFUEL (female) (3) Between wiring harness between ENG (female) (25) PFUEL (female) (2) and wirResisMin. 1 Mz ing harness between ENG (female) (47) tance PFUEL (female) (3)
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Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. ENG Voltage 6 Defective engine controller Between (33) (47) 4.75 5.25 V Between (25) (47) 0.25 4.6 V
Cause
Circuit diagram related to common rail pressure sensor
D475A, D475ASD-5E0
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Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Common rail pressure sensor abnormally low level (Left bank): failure Abnormally low voltage detection (Engine controller system) CA452 Low voltage was detected in common rail pressure sensor circuit. Limits output and continues operation (Limits common rail pressure). Blinks warning lamp and sounds alarm buzzer. Output lowers. Signal voltage of common rail pressure sensor can be checked with monitoring function (Code: 36401: Common rail pressure sensor voltage). Cause Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA451].
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Common rail pressure sensor abnormally low level (Right bank): failure Abnormally low voltage detection (Engine controller system) CB452 Low voltage was detected in common rail pressure sensor circuit. Limits output and continues operation (Limits common rail pressure). Blinks warning lamp and sounds alarm buzzer. Output lowers. Signal voltage of common rail pressure sensor can be checked with monitoring function (Code: 36404: Common rail pressure sensor voltage). Cause Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CB451].
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Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Common rail pressure high trouble (1) (At left bank): Excessively failure high pressure trouble occurred (Engine controller system) CA553 Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit. Flashes warning lamp and turns on alarm buzzer. Output decreases. Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure) Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other Defective related circuits codes are displayed, carry out troubleshooting for those codes. Improper fuel has been Since the use of improper fuel can be suspected, check the fuel. used. (Viscosity is too high) Defective electrical system Since an electrical defect of common rail pressure sensor is susof common rail pressure pected, carry out troubleshooting for the following code. sensor [CA451] Defective mechanical sysSince a mechanical defect of common rail pressure sensor is sustem of common rail prespected, directly check the sensor. sure sensor Since a damage of spring, wear of seat or sticking of ball is susDefective overflow valve pected, directly check them. Since an overflow piping is suspected to be clogged, directly check Clogged overflow piping it. Since a mechanical defect of pressure limiter is suspected, directly Defective pressure limiter check the limiter. Cause
1 2 3
4 5 6 7
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Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Common rail pressure high trouble (1) (At right bank): Excessively failure high pressure trouble occurred (Engine controller system) CB553 Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit. Flashes warning lamp and turns on alarm buzzer. Output decreases. Common rail pressure can be checked with the monitoring function. (Code: 36403 Common rail pressure) Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other Defective related circuits codes are displayed, carry out troubleshooting for those codes. Improper fuel has been Since the use of improper fuel can be suspected, check the fuel. used. (Viscosity is too high) Defective electrical system Since an electrical defect of common rail pressure sensor is susof common rail pressure pected, carry out troubleshooting for the following code. sensor [CB451] Defective mechanical sysSince a mechanical defect of common rail pressure sensor is sustem of common rail prespected, directly check the sensor. sure sensor Since a damage of spring, wear of seat or sticking of ball is susDefective overflow valve pected, directly check them. Since an overflow piping is suspected to be clogged, directly check Clogged overflow piping it. Since a mechanical defect of pressure limiter is suspected, directly Defective pressure limiter check the limiter. Cause
1 2 3
4 5 6 7
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Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of In-range error in common rail pressure sensor (At left bank): Infailure range error occurred (Engine controller system) CA554 In-range error has occurred in common rail pressure sensor circuit. Operates with limited output.(Limits common rail pressure.) Flashes warning lamp and turns on alarm buzzer. Output decreases.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CA451].
Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of In-range error in common rail pressure sensor (At right bank): Infailure range error occurred (Engine controller system) CB554 In-range error has occurred in common rail pressure sensor circuit. Operates with limited output.(Limits common rail pressure.) Flashes warning lamp and turns on alarm buzzer. Output decreases.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CB451].
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Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected
Action code Failure code Symptom of Loss of pressure feed from supply pump (1) (At left bank): Loss of failure pressure feed detected (Engine controller system) E02 CA559 Failure content Loss of pressure feed (level 1) from supply pump has occurred. Controller's Limits common rail pressure. action Symptoms that Output decreases. appear on Flashes warning lamp and turns on alarm buzzer. machine General information Cause 1 Defective related circuits 2 Improper fuel has been used. Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. Since the use of improper fuel is suspected, directly check the fuel.
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 Min. 0.15 MPa circuit (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] Defective common rail Since a defect of common rail pressure sensor is suspected, check 6 pressure sensor for a damage in harnesses. a As for testing an amount of pressure limiter leak, see testing and 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 nopressure feed.
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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.
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Check sheet for no-pressure feed

Model Model and serial No. Engine Engine serial No. # # Operation No. Date inspected Service meter Worker's name / / h
A. Visual inspections 1 2 Fuel leakage to outside Clogged fuel tank breather
Pass Fail
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) 3 Checking failure codes Checking monitoring information Code Display item Condition for inspection Low idle *1 Engine speed High idle Equivalent to rating *2 *3 *4 *5 Throttle speed Command for fuel injection rate Command for common rail pressure Fuel pressure in common rail Command for fuel injection timing Boost pressure Coolant temperature (high temperature) Coolant temperature (low temperature) Fuel temperature Low idle High idle Equivalent to rating Equivalent to rating Equivalent to rating Low idle *6 High idle Equivalent to rating *7 *8 *9 *10 Equivalent to rating Low idle Low idle Low idle Unit rpm rpm rpm % % mm3 MPa MPa CA CA CA kPa C C C Standard value (reference value) 600 700 2,100 2,200 2,000 0 100 Measured value / / / /
Pass Fail
Pass Fail
Checking reduced cylinder mode operation (engine speed) Function Cut-out cylinder Cylinder No. 1 5 *11 Cylinder No. 2 Cylinder No. 3 Cylinder No. 4 Cylinder No. 5 Cylinder No. 6 Condition for inspection Low idle Low idle Low idle Low idle Low idle Low idle Unit rpm rpm rpm rpm rpm rpm Standard value (reference value) Measured value Pass Fail
C. Inspection of pressure in fuel circuit 6 Pressure in fuel low pressure circuit
Condition for inspection At high idle or under the load equivalent to rating (stalling)
Unit MPa {kg/cm2}
Standard value (reference value) Min. 0.15 {Min. 1.5}
Measured value
Pass Fail
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D. Inspection of strainer and filter 7 8 9 Visual inspection of strainer Visual inspection of gauze filter Visual inspection of fuel filter
Pass Fail
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return amount 11 Pressure limiter leak amount
Condition for inspection Under the load equivalent to rating (stalling) Equivalent to rating: 1,600 rpm Equivalent to rating: 1,700 rpm
Unit cc/min cc/min cc/min cc/min cc/min cc/min
Standard value (reference value) Max 10 960 1,020 1,080 1,140 1,200
Measured value
Pass Fail
Rotation speed:
12 Injector return amount
Equivalent to rating: 1,800 rpm Equivalent to rating: 1,900 rpm Equivalent to rating: 2,000 rpm
Return amount:
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
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Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected
Action code Failure code Symptom of Loss of pressure feed from supply pump (1) (At right bank): Loss of failure pressure feed detected (Engine controller system) E02 CB559 Failure content Loss of pressure feed (level 1) from supply pump has occurred. Controller's Limits common rail pressure. action Symptoms that Output decreases. appear on Flashes warning lamp and turns on alarm buzzer. machine General information Cause 1 Defective related circuits 2 Improper fuel has been used. Standard values when normal and remarks for troubleshooting Check the codes that are displayed at the same time. If any other codes are displayed, carry out troubleshooting for those codes. Since the use of improper fuel is suspected, directly check the fuel.
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 Min. 0.15 MPa circuit (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 [CB271], [CB272], [CB273], and [CB274] Defective common rail Since a defect of common rail pressure sensor is suspected, check 6 pressure sensor for a damage in harnesses. a As for testing an amount of pressure limiter leak, see testing and 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 nopressure feed.
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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.
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Check sheet for no-pressure feed

Model Model and serial No. Engine Engine serial No. # # Operation No. Date inspected Service meter Worker's name / / h
A. Visual inspections 1 2 Fuel leakage to outside Clogged fuel tank breather
Pass Fail
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) 3 Checking failure codes Checking monitoring information Code Display item Condition for inspection Low idle *1 Engine speed High idle Equivalent to rating *2 *3 *4 *5 Throttle speed Command for fuel injection rate Command for common rail pressure Fuel pressure in common rail Command for fuel injection timing Boost pressure Coolant temperature (high temperature) Coolant temperature (low temperature) Fuel temperature Low idle High idle Equivalent to rating Equivalent to rating Equivalent to rating Low idle *6 High idle Equivalent to rating *7 *8 *9 *10 Equivalent to rating Low idle Low idle Low idle Unit rpm rpm rpm % % mm3 MPa MPa CA CA CA kPa C C C Standard value (reference value) 600 700 2,100 2,200 2,000 0 100 Measured value / / / /
Pass Fail
Pass Fail
Checking reduced cylinder mode operation (engine speed) Function Cut-out cylinder Cylinder No. 1 5 *11 Cylinder No. 2 Cylinder No. 3 Cylinder No. 4 Cylinder No. 5 Cylinder No. 6 Condition for inspection Low idle Low idle Low idle Low idle Low idle Low idle Unit rpm rpm rpm rpm rpm rpm Standard value (reference value) Measured value Pass Fail
C. Inspection of pressure in fuel circuit 6 Pressure in fuel low pressure circuit
Condition for inspection At high idle or under the load equivalent to rating (stalling)
Unit MPa {kg/cm2}
Standard value (reference value) Min. 0.15 {Min. 1.5}
Measured value
Pass Fail
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D. Inspection of strainer and filter 7 8 9 Visual inspection of strainer Visual inspection of gauze filter Visual inspection of fuel filter
Pass Fail
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return amount 11 Pressure limiter leak amount
Condition for inspection Under the load equivalent to rating (stalling) Equivalent to rating: 1,600 rpm Equivalent to rating: 1,700 rpm
Unit cc/min cc/min cc/min cc/min cc/min cc/min
Standard value (reference value) Max 10 960 1,020 1,080 1,140 1,200
Measured value
Pass Fail
Rotation speed:
12 Injector return amount
Equivalent to rating: 1,800 rpm Equivalent to rating: 1,900 rpm Equivalent to rating: 2,000 rpm
Return amount:
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
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Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Abnormal engine Ne speed sensor (At left bank): Abnormal signal failure (Engine controller system) CA689 Abnormal signal of the engine Ne speed sensor has been detected. Operates using Bkup speed sensor signal. Flashes warning lamp and turns on alarm buzzer. Engine stops during operation (when Bkup speed sensor is defective at the same time). Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Causes Defective sensor power 1 source circuit
Defective mounting of sen5 sor or defective parts for speed detection 6 Defective engine Ne speed sensor
Standard values when normal and remarks for troubleshooting If failure code [CA238] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between left ENG (female) ResisMax. 1 z (16) NE (female) (1) tance Wiring harness between left ENG (female) ResisMax. 1 z (48) NE (female) (2) tance Wiring harness between left ENG (female) ResisMax. 1 z (27) NE (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (16) NE (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (48) NE (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (27) NE (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from left ENG (female) (16) to NE (female) (1) and wiring ResisMin. 1 Mz harness from left ENG (female) (48) to NE tance (female) (2) Between wiring harness from left ENG (female) (16) to NE (female) (1) and wiring ResisMin. 1 Mz harness from left ENG (female) (27) to NE tance (female) (3) Between wiring harness from left ENG (female) (48) to NE (female) (2) and wiring ResisMin. 1 Mz harness from left ENG (female) (27) to NE tance (female) (3) Since defective mounting of Ne speed sensor (improper gap) or defective parts for speed detection (flywheel) can be suspected, directly check it. Engine Ne speed sensor can be suspected to be defective if no problem is found in causes 1 5 (since this is an internal defect, it cannot be diagnosed). Engine controller can be suspected to be defective if no problem is found in causes 1 6 (since this is an internal defect, it cannot be diagnosed).
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Circuit diagram related to engine Ne speed sensor
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Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Abnormal engine Ne speed sensor (At right bank): Abnormal signal failure (Engine controller system) CB689 Abnormal signal of the engine Ne speed sensor has been detected. Operates using Bkup speed sensor signal. Flashes warning lamp and turns on alarm buzzer. Engine stops during operation (when Bkup speed sensor is defective at the same time). Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Causes Defective sensor power 1 source circuit
Defective mounting of sen5 sor or defective parts for speed detection 6 Defective engine Ne speed sensor
Standard values when normal and remarks for troubleshooting If failure code [CB238] is displayed at the same time, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between left ENG (female) ResisMax. 1 z (16) NE (female) (1) tance Wiring harness between right ENG (female) ResisMax. 1 z (48) NE (female) (2) tance Wiring harness between right ENG (female) ResisMax. 1 z (27) NE (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (16) NE (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz right ENG (female) (48) NE (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz right ENG (female) (27) NE (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from left ENG (female) (16) to NE (female) (1) and wiring ResisMin. 1 Mz harness from right ENG (female) (48) to NE tance (female) (2) Between wiring harness from left ENG (female) (16) to NE (female) (1) and wiring ResisMin. 1 Mz harness from right ENG (female) (27) to NE tance (female) (3) Between wiring harness from right ENG (female) (48) to NE (female) (2) and wiring ResisMin. 1 Mz harness from right ENG (female) (27) to NE tance (female) (3) Since defective mounting of Ne speed sensor (improper gap) or defective parts for speed detection (flywheel) can be suspected, directly check it. Engine Ne speed sensor can be suspected to be defective if no problem is found in causes 1 5 (since this is an internal defect, it cannot be diagnosed). Engine controller can be suspected to be defective if no problem is found in causes 1 6 (since this is an internal defect, it cannot be diagnosed).
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Circuit diagram related to engine Ne speed sensor
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Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Intake air temperature sensor abnormally high level (Only left bank): failure High voltage detection (Engine controller system) CA691 Intake air temperature sensor circuit detected high voltage. Fixes intake air temperature (25C) and continues operation.
Cause Defective charge tempera1 ture sensor (Internal defect)
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Ground fault in wiring har3 ness (Contact with GND circuit)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TAM1 Intake air temperature Resistance Between (A) (B) 10 100C 0.5 20 kz Between (A) ground All range Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (43) ResisMax. 1z TAM1 (female) (A) tance Wiring harness between ENG (female) (47) ResisMax. 1z TAM1 (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (43) TAM1 (female) (A) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Intake air temperature Resistance Between (43) (47) 10 100C 0.5 20 kz
52
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
Circuit diagram related to intake air temperature sensor
D475A, D475ASD-5E0
53
SEN01825-01
40 Troubleshooting
Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Intake air temperature sensor abnormally low level (Only left bank): failure Low voltage detection (Engine controller system) CA692 Intake air temperature sensor circuit detected low voltage. Fixes intake air temperature (25C) and continues operation.
Cause
54
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-01
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Abnormal engine Bkup speed sensor phase (At left bank): Abnormal failure phase (Engine controller system) CA731 Abnormal phase has been detected in the engine Bkup sensor circuit. Operates using engine Ne speed sensor signal. Flashes warning lamp and turns on alarm buzzer. Engine stops during operation (when Ne speed sensor is defective at the same time). Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
Cause Possible causes and the standard values when normal 1 Defective engine Ne speed sensor circuit Defective engine Bkup speed sensor system
Standard values when normal and remarks for troubleshooting Since a defect of engine Ne speed sensor can be suspected, carry out troubleshooting for the following code. [CA689] Since a defect of engine Bkup speed sensor can be suspected, carry out troubleshooting for the following code. [CA778]
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Abnormal engine Bkup speed sensor phase (At right bank): Abnorfailure mal phase (Engine controller system) CB731 Abnormal phase has been detected in the engine Bkup sensor circuit. Operates using engine Ne speed sensor signal. Flashes warning lamp and turns on alarm buzzer. Engine stops during operation (when Ne speed sensor is defective at the same time). Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
Cause Possible causes and the standard values when normal 1 Defective engine Ne speed sensor circuit Defective engine Bkup speed sensor system
Standard values when normal and remarks for troubleshooting Since a defect of engine Ne speed sensor can be suspected, carry out troubleshooting for the following code. [CB689] Since a defect of engine Bkup speed sensor can be suspected, carry out troubleshooting for the following code. [CB778]
D475A, D475ASD-5E0
55
SEN01825-01
56
SEN01826-01
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
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 Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 16 Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 18 Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 20
D475A, D475ASD-5E0
SEN01826-01
40 Troubleshooting
Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 22 Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit .................................................................................................................... 24 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 [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected.............................................................................................................. 31 Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected.............................................................................................................. 31 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: Power supply voltage reduction (Input).................................................................................................. 62 Failure code [DAQ5KK] Transmission controller potentiometer power supply: Source voltage reduction (input) ............................................................................................................ 64 Failure code [DAQ6KK] Transmission controller sensor power supply: Source voltage reduction (input) ............................................................................................................ 65 Failure code [DAQ7KK] Transmission controller sensor power supply: Power supply voltage reduction (Input).................................................................................................. 66 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
40 Troubleshooting
SEN01826-01
Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data 1
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Loss of all engine controller data (At left bank): Loss of all data failure (Engine controller system) CA757 Loss of all data in engine controller has been detected. Flashes warning lamp and turns on alarm buzzer. The engine cannot be started, or cannot be operated.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CA111].
Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data 1
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Loss of all engine controller data (At right bank): Loss of all data failure (Engine controller system) CB757 Loss of all data in engine controller has been detected. Flashes warning lamp and turns on alarm buzzer. The engine cannot be started, or cannot be operated.
Cause
Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CB111].
D475A, D475ASD-5E0
SEN01826-01
40 Troubleshooting
Failure code [CA778] Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup signal
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Abnormal engine Bkup speed sensor (At left bank): Abnormal Bkup failure signal (Engine controller system) CA778 Abnormal engine Bkup speed sensor signal has been detected. Operates using Ne speed sensor signal. Flashes warning lamp and turns on alarm buzzer. Engine stops during operation (when Ne speed sensor is defective at the same time). Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
Standard values when normal and remarks for troubleshooting If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between left ENG (female) ResisDisconnection in wiring Max. 1 z (37) left G (female) (1) tance harness 2 (disconnection or defective Wiring harness between left ENG (female) ResisMax. 1 z contact of connectors) (47) left G (female) (2) tance Wiring harness between left ENG (female) ResisMax. 1 z (26) left G (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz Defective harness left ENG (female) (37) left G (female) (1) tance 3 grounding (contact with Between ground and wiring harness between Resisground circuit) Min. 1 Mz left ENG (female) (47) left G (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (26) left G (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between wiring harness from left ENG (female) (37) to left G (female) (1) and wiring ResisMin. 1 Mz harness from left ENG (female) (47) to left G tance (female) (2) Harness short Between wiring harness from left ENG 4 (Harness internal short) (female) (37) to left G (female) (1) and wiring ResisMin. 1 Mz harness from left ENG (female) (26) to left G tance (female) (3) Between wiring harness from left ENG (female) (47) to left G (female) (2) and wiring ResisMin. 1 Mz harness from left ENG (female) (26) to left G tance (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 susspeed detection pected, directly check it. Engine Bkup speed sensor can be suspected to be defective if no Defective engine Bkup 6 problem is found in causes 1 5 (since this is an internal defect, it speed sensor cannot be diagnosed). Engine controller can be suspected to be defective if no problem is 7 Defective engine controller found in causes 1 6 (since this is an internal defect, it cannot be diagnosed).
Cause Defective sensor power 1 source circuit
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to engine Bkup speed sensor
D475A, D475ASD-5E0
SEN01826-01
40 Troubleshooting
Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Engine Bkup speed sensor abnormality (Right bank): Bkup signal failure error (Engine controller system) CB778 Engine Bkup speed sensor signal detected abnormality. Operates with Ne speed sensor signal Blinks warning lamp and sounds alarm buzzer. If engine has been running, it stops (when Ne speed sensor is also defective). If engine has been stopped, it cannot start (when Ne speed sensor is also defective).
Cause Defective sensor power 1 supply system
Defective sensor installa5 tion or defective speed sensing part 6 Defective engine Bkup speed sensor
Standard values when normal and remarks for troubleshooting If failure code [CB187] or [CB227] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between right ENG (female) ResisMax. 1 z (37) right G (female) (1) tance Wiring harness between right ENG (female) ResisMax. 1 z (47) right G (female) (2) tance Wiring harness between right ENG (female) ResisMax. 1 z (26) right G (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz right ENG (female) (37) right G (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz right ENG (female) (47) right G (female) (2) tance Between ground and wiring harness between ResisMin. 1 Mz right ENG (female) (26) right G (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between right ENG (female) (37) right G (female) (1) and wiring ResisMin. 1 Mz harness between right ENG (female) (47) tance right G (female) (2) Between wiring harness between right ENG (female) (37) right G (female) (1) and wiring ResisMin. 1 Mz harness between right ENG (female) (26) tance right G (female) (3) Between wiring harness between right ENG (female) (47) right G (female) (2) and wiring ResisMin. 1 Mz harness between right ENG (female) (26) tance right G (female) (3) Bkup speed sensor may be installed defectively (improper clearance) or speed sensing part (in supply pump) may be defective. Check them directly. If causes 1 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to engine Bkup speed sensor
D475A, D475ASD-5E0
SEN01826-01
40 Troubleshooting
Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error
Action code Failure code Symptom of Inter-multicontroller communication error (Left bank): Communicafailure tion error (Engine controller system) CALL E03 CA781 Failure content Communication error occurred between engine controllers (Left bank). Controller's Blinks warning lamp and sounds alarm buzzer. action Symptoms that During operation: Engine continues operation with 1 bank. appear on When key is ON: Engine cannot be started. machine General information
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between left ENG (female) Resis1 Max. 1 z wiring or defective contact (8) right ENG (female) (8) tance in connector) Wiring harness between left ENG (female) ResisMax. 1 z (6) right ENG (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between Resis2 harness (Contact with Min. 1 Mz left ENG (female) (8) right ENG (female) (8) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz left ENG (female) (6) right ENG (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Left ENG (female) Resistance 3 Defective engine controller Between (8) (6) 108 132 z Between (8), (6) ground Min. 1 Mz
Cause
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to communication between multiple controller
D475A, D475ASD-5E0
SEN01826-01
40 Troubleshooting
Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error 1
Action code Failure code Symptom of Inter-multicontroller communication error (Right bank): Communicafailure tion error (Engine controller system) CALL E03 CB781 Failure content Communication error occurred between engine controllers (Right bank). Controller's Blinks warning lamp and sounds alarm buzzer. action Symptoms that During operation: Engine continues operation with 1 bank. appear on When key is ON: Engine cannot be started. machine General information Possible causes and the standard values when normal Cause Standard values when normal and remarks for troubleshooting Carry out troubleshooting for failure code [CA781].
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Multicontroller distinction wiring harness key error (Left bank): Disfailure tinction error (Engine controller system) CA1257 Controller of each bank disagrees with distinction wiring harness (Left bank). Stops operation. Blinks warning lamp and sounds alarm buzzer. When key is ON: Engine cannot be started.
Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 1 wiring or defective contact Wiring harness between OEM L (female) (7) ResisMax. 1 z in connector) OEM L (female) (34) tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND Resiscircuit) Between OEM L (female) (8) ground Min. 1 Mz tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisMin. 1 Mz 3 Defective engine controller Between OEM L (female) (7) ground tance ResisMin. 1 Mz Between OEM L (female) (8) ground tance
Circuit diagram related to multicontroller distinction wiring harness key
D475A, D475ASD-5E0
11
SEN01826-01
40 Troubleshooting
Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error
Failure code Symptom of Multicontroller distinction wiring harness key error (Right bank): Disfailure tinction error (Engine controller system) CB1257 Controller of each bank disagrees with distinction wiring harness (Right bank). Stops operation. Blinks warning lamp and sounds alarm buzzer. When key is ON: Engine cannot be started.
Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 1 wiring or defective contact Wiring harness between OEM R (female) (7) ResisMin. 1 Mz in connector) OEM R (female) (34) tance a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND Resiscircuit) Between OEM R (female) (8) ground Min. 1 Mz tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisMin. 1 Mz 3 Defective engine controller Between OEM R (female) (7) ground tance ResisMin. 1 Mz Between OEM R (female) (8) ground tance
Circuit diagram related to multicontroller distinction wiring harness key
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
13
SEN01826-01
40 Troubleshooting
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): failure Disconnection/Short circuit (Engine controller system) CALL E03 CB1548 Failure content Disconnection or short circuit occurred in injector #7 circuit. Controller's Blinks warning lamp and sounds alarm buzzer. action Symptoms that Output lowers. appear on Engine speed is unstable. machine General While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of information injector. This pulse voltage cannot be measured with circuit tester. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #7 CN1 (male) Resistance (Internal defect) Between (1) (2) 0.4 1.1 z Between (1), (2) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between ENG (female) (45) Max. 1 z tance wiring or defective contact CN1 (female) (1) in connector) Wiring harness between ENG (female) (53) ResisMax. 1 z CN1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between ResisMin. 1 Mz ness (Contact with GND ENG (female) (45) CN1 (female) (1) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (53) CN1 (female) (2) tance Defective injector of If failure codes of 1 or more injectors are displayed, carry out trouanother cylinder or defecbleshooting for them. tive wiring harness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Defective engine controller Between (45) (53) 0.4 1.1 z Between (45), (53) ground Min. 1 Mz Cause
2 Possible causes and the standard values when normal
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to injector #7 (R/B #1)
D475A, D475ASD-5E0
15
SEN01826-01
40 Troubleshooting
16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
17
SEN01826-01
40 Troubleshooting
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Injector #10 (R/B #4) system disconnection/short circuit (Right failure bank): Disconnection/Short circuit (Engine controller system) CB1551 Disconnection or short circuit occurred in injector #10 circuit. Blinks warning lamp and sounds alarm buzzer. Output lowers. Engine speed is unstable. While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #10 CN4 (male) Resistance (Internal defect) Between (1) (2) 0.4 1.1 z Between (1), (2) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between ENG (female) (56) Max. 1 z tance wiring or defective contact CN4 (female) (1) in connector) Wiring harness between ENG (female) (58) ResisMax. 1 z CN4 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between ResisMin. 1 Mz ness (Contact with GND ENG (female) (56) CN4 (female) (1) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (58) CN4 (female) (2) tance Defective injector of If failure codes of 1 or more injectors are displayed, carry out trouanother cylinder or defecbleshooting for them. tive wiring harness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Defective engine controller Between (56) (58) 0.4 1.1 z Between (56), (58) ground Min. 1 Mz Cause
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
19
SEN01826-01
40 Troubleshooting
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Injector #11 (R/B #5) system disconnection/short circuit (Right bank): failure Disconnection/Short circuit (Engine controller system) CB1552 Disconnection or short circuit occurred in injector #11 circuit. Blinks warning lamp and sounds alarm buzzer. Output lowers. Engine speed is unstable. While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #11 CN5 (male) Resistance (Internal defect) Between (1) (2) 0.4 1.1 z Between (1), (2) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between ENG (female) (46) Max. 1 z tance wiring or defective contact CN5 (female) (1) in connector) Wiring harness between ENG (female) (60) ResisMax. 1 z CN5 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between ResisMin. 1 Mz ness (Contact with GND ENG (female) (46) CN5 (female) (1) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (60) CN5 (female) (2) tance Defective injector of If failure codes of 1 or more injectors are displayed, carry out trouanother cylinder or defecbleshooting for them. tive wiring harness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Defective engine controller Between (46) (60) 0.4 1.1 z Between (46), (60) ground Min. 1 Mz Cause
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
21
SEN01826-01
40 Troubleshooting
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Injector #12 (R/B #6) system disconnection/short circuit (Right failure bank): Disconnection/Short circuit (Engine controller system) CB1553 Disconnection or short circuit occurred in injector #12 circuit. Blinks warning lamp and sounds alarm buzzer. Output lowers. Engine speed is unstable. While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective injector #12 CN6 (male) Resistance (Internal defect) Between (1) (2) 0.4 1.1 z Between (1), (2) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between ENG (female) (57) Max. 1 z tance wiring or defective contact CN6 (female) (1) in connector) Wiring harness between ENG (female) (59) ResisMax. 1 z CN6 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between ResisMin. 1 Mz ness (Contact with GND ENG (female) (57) CN6 (female) (1) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz ENG (female) (59) CN6 (female) (2) tance Defective injector of If failure codes of 1 or more injectors are displayed, carry out trouanother cylinder or defecbleshooting for them. tive wiring harness a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ENG (female) Resistance Defective engine controller Between (57) (59) 0.4 1.1 z Between (57), (59) ground Min. 1 Mz Cause
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
23
SEN01826-01
40 Troubleshooting
24
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
25
SEN01826-01
40 Troubleshooting
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error
Action code Failure code Symptom of KOMNET abnormality (Left bank): Communication error failure (Engine controller system) CALL E03 CA1633 Failure content Abnormality occurred in KOMNET communication circuit to engine controller (Left bank). Controller's Continues normal control (Communication function cannot be used). action Blinks warning lamp and sounds alarm buzzer. 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 Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) ResisMax. 1 z OEM R (female) (46) tance Wiring harness between OEM L (female) (47) ResisMax. 1 z OEM R (female) (47) tance Wiring harness between OEM L (female) (46) Resis108 OEM L (female) (47) tance 132 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz OEM L (female) (46) OEM R (female) (46) tance Between ground and wiring harness between ResisMin. 1 Mz OEM L (female) (47) OEM R (female) (47) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) Resis108 OEM L (female) (47) tance 132 z Wiring harness between OEM R (female) Resis108 (46) OEM R (female) (47) tance 132 z
Disconnection in wiring harness (Disconnection in 1 wiring or defective contact in connector) Possible causes and the standard values when normal
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Circuit diagram related to KOMNET
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27
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Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level (Only left bank): High voltage detection
Failure code Symptom of Decelerator pedal sensor power supply abnormally high level (Only failure left bank): High voltage detection CA2185 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 of abnormality and continues operation. If starting switch is turned ON while there is trouble, controller operates at 100% value. Blinks warning lamp and sounds alarm buzzer.
Engine speed cannot be controlled with decelerator pedal.
Cause
Defective decelerator sensor (Internal defect)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. When device at right is disconnected, if code disappears, that Decelerator sensor DEC connector device has trouble in it. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (22) ResisMax. 1 z DEC (female) (A) tance Wiring harness between OEM L (female) (23) ResisMax. 1 z DEC (female) (C) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz OEM L (female) (22) DEC (female) (A) tance Between ground and wiring harness between ResisMin. 1 Mz OEM L (female) (23) DEC (female) (C) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between OEM L (female) (22) DEC (female) (A) and wiring Resis108 harness between OEM L (female) (23) DEC tance 132 z (female) (C) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. OEM L Voltage Between (22) (23) 4.75 5.25 V
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Circuit diagram related to decelerator pedal sensor power supply
D475A, D475ASD-5E0
29
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Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only): Excessively low voltage detected 1
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Decelerator pedal sensor power source too low (At left bank only): failure Excessively low voltage detected (Engine controller system) CA2186 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. If the starting switch is turned to the ON position in as-is abnormal condition, the controller operates with 100% value. Flashes warning lamp and turns on alarm buzzer.
Engine speed cannot be controlled by decelerator pedal.
Cause 1
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Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected 1
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Loss of pressure feed from supply pump (2) (At left bank): Loss of failure pressure feed detected (Engine controller system) CA2249 Loss of pressure feed (level 2) occurred in the common rail circuit. Operates with limited output. Flashes warning lamp and turns on alarm buzzer. Engine is hard to start. Exhaust gas color becomes black. Output decreases. Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure) Cause 1 Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CA559].
Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected 1
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Loss of pressure feed from supply pump (2) (At right bank): Loss of failure pressure feed detected (Engine controller system) CB2249 Loss of pressure feed (level 2) occurred in the common rail circuit. Operates with limited output. Flashes warning lamp and turns on alarm buzzer. Engine is hard to start. Exhaust gas color becomes black. Output decreases. Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure) Cause 1 Standard values when normal and remarks for troubleshooting Carry out troubleshooting of [CB559].
D475A, D475ASD-5E0
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Failure code [D110KA] Battery relay: Disconnection

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Battery relay: Disconnection failure (Steering controller system) D110KA Current does not flow when outputting it to battery relay circuit. Stops output to battery relay circuit. Problem may occur in data writing to ROM (nonvolatile storage) of each controller. Output state (voltage) to battery relay can be checked in monitoring mode. (Code 60600: Battery relay drive voltage) Method of reproducing failure code: Switch starting switch from ON to OFF.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective battery relay Battery relay Continuity (Internal disconnection) Between terminals BR Continue ground terminal (E) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) (4) ResisMax. 1 z wiring or defective contact battery relay SW tance in connector) Wiring harness between battery relay ground ResisMax. 1 z terminal chassis ground tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisMin. 1 Mz STCN3 (female) (4) battery relay SW cuit) tance KEY (female) (4) with chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering controlSTCN3 (female) Continuity ler Between (4) chassis ground Continue
Cause
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Circuit diagram related to battery relay
D475A, D475ASD-5E0
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Failure code [D110KB] Battery relay: Short circuit

Action code Failure code Symptom of Battery relay: Short circuit failure (Steering controller system) D110KB 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.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Battery relay Continuity/resistance Defective battery relay 1 Between terminals BR (Internal short circuit) Continue ground terminal (E) Between terminal BR Min. 1 Mz chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24V circuit) STCN3 (female) (4) battery relay SW Voltage Max. 1 V KEY (female) (4) with chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controlSTCN3 Starting switch Voltage 3 ler Between (4) ON 20 30 V chassis ground
Cause
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Circuit diagram related to battery relay
D475A, D475ASD-5E0
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Failure code [D130KA] Neutral safety relay: Disconnection
Action code Failure code Symptom of Neutral safety relay: Disconnection failure (Transmission controller system) E02 D130KA Failure content 24 V is not generated when ground of neutral safety relay circuit is interrupted. Controller's Flashes caution lamp and turns on caution buzzer. 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) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective neutral safety without turning starting switch ON. 1 relay (Internal disconnecNSF (male) Resistance tion) Between (1) (2) 200 400 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective disconnection in wiring harness (DisconWiring harness between TMC2 (female) (8) Resis2 Max. 1 z nection in wiring or defec- NSF (female) (2) tance tive contact in connector) Wiring harness between NSF (female) (1) ResisMax. 1 z starting switch ACC (270) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness TMC2 (female) (8) NSF (female) (2) with Min. 1 Mz 3 tance (Contact with ground circhassis ground cuit) Short circuit of wiring harness between NSF ResisMin. 1 Mz (female) (1) starting switch ACC (270) with tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission TMC2 Parking brake lever Voltage 4 controller Lock position Max. 1 V Between (8) chassis ground Free position 20 30 V Cause
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Circuit diagram related to neutral safety relay
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Failure code [D130KB] Neutral safety relay: Short circuit
Action code Failure code Symptom of Neutral safety relay: Short circuit failure (Transmission controller system) E02 D130KB Failure content Abnormal current flowed in neutral safety relay circuit at the time of ground output. Controller's Flashes caution lamp and turns on caution buzzer. 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 information position). a This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in secondary side (contact side) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective neutral safety 1 relay (Internal short circuit) NSF (male) Resistance Between (1) (2) 200 400 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) TMC2 (female) (8) NSF (female) (2) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission TMC2 Parking brake lever Voltage 3 controller Lock position Max. 1 V Between (8) chassis ground Free position 20 30 V Cause
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Circuit diagram related to neutral safety relay
D475A, D475ASD-5E0
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Failure code [D161KA] Back-up alarm relay: Disconnection

Action code Failure code Symptom of Back-up alarm relay: Disconnection failure (Transmission controller system) E01 D161KA 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 secondary side (contact side)
Standard values when normal and remarks for troubleshooting If fuse is burnout, circuit probably has short circuit with chassis 1 Defective fuse FS22-1 ground. a Prepare with starting switch OFF, then carry out troubleshooting Defective back-up alarm without turning starting switch ON. 2 relay (Internal disconnecBKA (male) Resistance tion) Between (1) (2) 200 400 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective disconnection in Wiring harness between TMC2 (female) (18) Resiswiring harness (DisconMax. 1 z 3 tance nection in wiring or defec- BKA (female) (2) tive contact in connector) Wiring harness between BKA (female) (1) ResisMax. 1 z FS22-1 outlet port tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness TMC2 (female) (18) BKA (female) (2) with Min. 1 Mz tance 4 (Contact with ground circhassis ground cuit) Short circuit of wiring harness between BKA Resis(female) (1) FS22-1 outlet port with chassis Min. 1 Mz tance ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission TMC2 PCCS lever Voltage 5 controller Neutral position 20 30 V Between (18) chassis ground Reverse position Max. 1 V
Cause
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Circuit diagram related to back-up alarm relay
D475A, D475ASD-5E0
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Failure code [D161KB] Back-up alarm relay: Short circuit

Action code Failure code Symptom of Back-up alarm relay: Short circuit failure (Transmission controller system) E01 D161KB 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 information position). a This failure code detects abnormality in primary side (coil side) of back-up alarm relay, but not in secondary side (contact side)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective back-up alarm 1 relay (Internal short circuit) BKA (male) Resistance Between (1) (2) 200 400 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) TMC2 (female) (18) BKA (female) (2) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission TMC2 PCCS lever Voltage 3 controller Neutral position 20 30 V Between (18) chassis ground Reverse position Max. 1 V
Cause
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Circuit diagram related to back-up alarm relay
D475A, D475ASD-5E0
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Failure code [D182KZ] Preheater relay: Disconnection or short circuit 1

Action code Failure code Symptom of Preheater relay: Disconnection or short circuit failure (Steering controller system) E01 D182KZ 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. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective preheater relay PHR (male) Resistance (Internal disconnection) Between (1) and (2) 200 400 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness Wiring harness between STCN2 (female) Resis(Disconnection in wiring Max. 1 z (19) and PHR (female) (2) tance harness or defective conWiring harness between PHR (female) (1) Resistact in connector) Max. 1 z and starting switch ACC (270) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Between wiring harness between STCN2 Resisground in wiring harness (female) (19) and RHR (female) (2) and Min. 1 Mz tance (Contact with ground circhassis ground cuit) Between wiring harness between PHR Resis(female) (1) and starting switch ACC (270) Min. 1 Mz tance and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controlSTCN2 Starting switch Voltage ler ON 20 30 V Between (19) chassis ground OFF Max. 1 V Cause
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Circuit diagram related to preheater relay
D475A, D475ASD-5E0
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Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Engine controller ACC signal cutout relay: Disconnection failure (Steering controller system) D190KA Voltage of engine controller ACC cut relay circuit does not match controller output. Stops outputting signal to engine controller ACC cut relay. Engine stop function of steering controller does not work.
Output state (voltage) to engine controller ACC cut relay can be checked in real-time monitoring mode (Code 60500: Engine controller ACC cut relay voltage). Method of reproducing failure code: Turn starting switch ON. a This failure code detects abnormality on primary side (coil side) of engine controller ACC cut relay but does not detect abnormality on secondary side (contact side). Cause 1 Defective fuse FS31 (1) 2 Standard values when normal and remarks for troubleshooting If fuse is broken, circuit probably has ground fault etc. a Prepare with starting switch OFF, then carry out troubleshooting Defective engine controller without turning starting switch ON. ACC cut relay ACT (male) Resistance (Internal disconnection) Between (1) (2) 200 400 z a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness Wiring harness between STCN2 (female) (8) Resis(Disconnection in wiring Max. 1 z ACT (female) (2) tance harness or defective Wiring harness between ACT (female) (1) Resiscontact in connector) Max. 1 z starting switch ACC (270) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Resisground in wiring harness Between ground and wiring harness between Min. 1 Mz STCN2 (female) (8) ACT (female) (2) tance (Contact with ground circuit) Between ground and wiring harness between ResisMin. 1 Mz ACT (female) (1) starting switch ACC (270) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering STCN2 Starting switch Voltage controller Between (8) ON Max. 1 V chassis ground
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Circuit diagram related to engine controller ACC signal cut relay
D475A, D475ASD-5E0
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Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Engine controller ACC signal cutout relay: Short circuit failure (Steering controller system) D190KA When signal was output to engine controller ACC cut relay, abnormal current flowed. Stops outputting signal to engine controller ACC cut relay. Engine stop function of steering controller does not work. Output state (voltage) to engine controller ACC cut relay can be checked in real-time monitoring mode (Code 60500: Engine controller ACC cut relay voltage). Method of reproducing failure code: Turn starting switch ON. a This failure code detects abnormality on primary side (coil side) of engine controller ACC cut relay but does not detect abnormality on secondary side (contact side). Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective engine controller without turning starting switch ON. 1 ACC cut relay ACT (male) Resistance (Internal disconnection) Between (1) (2) 200 400 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 24 2 V circuit) in wiring harness Wiring harness between STCN2 (female) (8) Voltage Max. 1 V ACT (female) (2) and chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering 3 STCN2 Starting switch Voltage controller Between (8) ON Max. 1 V chassis ground Cause
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Circuit diagram related to engine controller ACC signal cut relay
D475A, D475ASD-5E0
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Failure code [D5ZRKA] Snap shot switch: Disconnection

Action code Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Snap shot switch: Disconnection failure (Steering controller system) D5ZRKA When the snap shot switch circuit is disconnected from the chassis ground, 24 V is not generated. None in particular.
Enter the snap shot mode and apply a trigger. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring harness or defective Wiring harness between STCN2 (female) (9) Voltage Max. 1 V contact in connector) and V3B (female) (6) a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Between wiring harness between STCN2 (Contact with ground cirResisMin. 1 Mz (female) (9) and V3B (female) (6) and chascuit) tance sis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN2 Snap shot switch Voltage Defective steering controller Trigger Max. 1 V Between (9) and Out of period just chassis ground 20 30 V after trigger a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective VHMS controller V3B Voltage Between (6) and chassis ground 20 30 V Cause
Circuit diagram related to snap shot switch
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Failure code [D5ZRKB] Snap shot switch: Short circuit

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Snap shot switch: Short circuit failure (Steering controller system) D5ZRKB Abnormal current flowed in snap shot switch circuit at the time of ground output. None in particular.
Enter the snap shot mode and apply a trigger. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit with power 1 source in wiring harness Between wiring harness between STCN2 (Contact with 24-V circuit) (female) (9) and V3B (female) (6) and chasVoltage Max. 1 V sis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN2 Snap shot switch Voltage Defective steering control2 ler Trigger Max. 1 V Between (9) and Out of period chassis ground 20 30 V just after trigger a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller V3B Voltage Between (6) and chassis ground 20 30 V Cause
Circuit diagram related to snap shot switch
D475A, D475ASD-5E0
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Failure code [DAFRKR] Monitor panel CAN communication: Communication error

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Monitor panel CAN communication: Communication error failure (Machine monitor system) DAFRKR Monitor panel cannot recognize steering controller in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 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) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMax. 1 z (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMin. 1 Mz (female) (46) or CT1 (female) (A) or V4A tance Ground fault in wiring har(female) (4) or RES (female) (A) or SRV 2 ness (Contact with GND (male) (3) and ground circuit) Wiring harness between S04 (female) (3), (4) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMin. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring har(male) (3) and ground ness Wiring harness between S04 (female) (3), (4) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground Cause
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Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) (B) 100 140 z 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 cansteering controller not be carried out.)
Cause
Circuit diagram related to CAN communication
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Failure code [dAFRKR] Monitor panel CAN communication: Communication error

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Monitor panel CAN communication: Communication error failure (Transmission controller system) dAFRKR Transmission cannot recognize monitor panel in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine, transmission and brake. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
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Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) (B) 100 140 z If causes 1 4 are not detected, monitor panel or transmission conDefective monitor panel or 5 troller may be defective. (Since trouble is in system, troubleshooting transmission controller cannot be carried out.)
Cause
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40 Troubleshooting
Failure code [daFRKR] Monitor panel CAN communication: Communication error

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Monitor panel CAN communication: Communication error failure (Steering controller system) daFRKR Steering controller cannot recognize monitor panel in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine, transmission and brake. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
56
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) (B) 100 140 z 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 cansteering controller not be carried out.)
Cause
D475A, D475ASD-5E0
57
SEN01826-01
40 Troubleshooting
Failure code [DAQ0KT] Transmission controller: Abnormality in controller

Action code Failure code Symptom of Transmission controller: Abnormality in controller failure (Transmission controller system) E01 DAQ0KT 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 Possible causes and the standard values when normal Cause 1 Defective transmission controller
Standard values when normal and remarks for troubleshooting Troubleshooting cannot be carried out since it is internal defect. (It is no problem even if you use controller unless no visible problem appears on machine.)
58
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
59
SEN01826-01
40 Troubleshooting
Failure code [DAQ1KK] Transmission controller main power supply: Power supply voltage reduction (Input)
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Transmission controller main power supply: Power supply voltage failure reduction (Input) (Transmission controller system) DAQ1KK Transmission controller power supply voltage is below 17 V. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. Monitor panel may not display normally. Relays and solenoids may not be driven and system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage). Method of reproducing failure code: Turn starting switch ON.
Standard values when normal and remarks for troubleshooting If circuit breaker CB6 is turned OFF, circuit probably has ground fault. If circuit breaker CB30 is turned OFF, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (1), ResisMax. 1 z (11) CB6 (2) tance Disconnection in wiring harness (Disconnection in Resis3 Wiring harness between CB6 (1) F30 Max. 1 z wiring or defective contact tance in connector) Wiring harness between B30S battery relay ResisMax. 1 z BRB terminal tance Wiring harness between TMC3 (female) (21), ResisMax. 1 z (31), (32), (33) ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring harTMC3 (female) (1), (11) CB6 (2) tance 4 ness (Contact with GND Between ground and wiring harness between Resiscircuit) Min. 1 Mz CB6 (1) F30 tance Between ground and wiring harness between ResisMin. 1 Mz B30S battery relay BRB terminal tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission 5 TMC3 Voltage controller Between (1), (11) (21), (31), 20 30 V (32), (33)
Cause Defective circuit breaker 1 CB6 (20 A) Defective circuit breaker 2 CB30 (30 A)
60
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to transmission controller power supply
D475A, D475ASD-5E0
61
SEN01826-01
40 Troubleshooting
Failure code [DAQ2KK] Transmission controller load power supply: Power supply voltage reduction (Input)
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Transmission controller load power supply: Power supply voltage failure reduction (Input) (Transmission controller system) DAQ2KK Power supply voltage of transmission controller load (relays, solenoids, etc.) is below 17 V. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. Relays and solenoids may not be driven and system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage). Method of reproducing failure code: Turn starting switch ON.
Standard values when normal and remarks for troubleshooting If circuit breaker CB3 is turned OFF, circuit probably has ground fault. If circuit breaker CB105 is turned OFF, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (2), ResisMax. 1 z (12), (22) CB3 (2) tance Disconnection in wiring harness (Disconnection in Resis3 Wiring harness between CB3 (1) F96 Max. 1 z wiring or defective contact tance in connector) Wiring harness between B105S battery ResisMax. 1 z relay BRC terminal tance Wiring harness between TMC3 (female) (21), ResisMax. 1 z (31), (32), (33) ground tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring harTMC3 (female) (2), (12), (22) CB3 (2) tance 4 ness (Contact with GND Between ground and wiring harness between Resiscircuit) Min. 1 Mz CB3 (1) F96 tance Between ground and wiring harness between ResisMin. 1 Mz B105S battery relay BRC terminal tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission 5 TMC3 Voltage controller Between (2), (12), (22) (21), 20 30 V (31), (32), (33)
Cause Defective circuit breaker 1 CB3 (20 A) Defective circuit breaker 2 CB105 (105 A)
62
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to transmission controller power supply
D475A, D475ASD-5E0
63
SEN01826-01
40 Troubleshooting
Failure code [DAQ5KK] Transmission controller potentiometer power supply: Source voltage reduction (input) 1
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Transmission controller potentiometer power supply: Source voltage failure reduction (input) (Transmission controller system) DAQ5KK Voltage of 5 V power supply circuit of transmission controller sensor is below 4.5 V or above 5.5 V. Abnormal current flowed in 5 V power supply circuit of transmission controller sensor. Flashes caution lamp and turns on caution buzzer. Stops output to 5 V power supply circuit if abnormal voltage flows. Limits operation of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 an R1.
Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward-reverse TL2 (male) Resistance potentiometer (Internal Between (4) (1) 3.2 kz 20% short circuit) Sensor Between (1) Min. 1 Mz chassis ground a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisTMC1 (female) (22) TL2 (female) (4) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness Short circuit of wiring harness between (Contact with 24 V circuit) TMC1 (female) (22) TL2 (female) (4) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission controller TMC1 Voltage Between (22) (21) 4.5 5.5 V Cause
Circuit diagram related to transmission controller potentiometer power supply
64
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Failure code [DAQ6KK] Transmission controller sensor power supply: Source voltage reduction (input) 1
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Transmission controller sensor power supply: Source voltage reducfailure tion (input) (Transmission controller system) DAQ6KK Voltage of 24 V power supply circuit of transmission controller sensor is below 12 V or above 30 V. Abnormal current flowed in 24 V power supply circuit of transmission controller sensor. Stops output to 24 V power supply circuit if abnormal voltage flows
Method of reproducing failure code: Turn starting switch ON (Then wire is not connected since this power supply is not used). Cause 1 Defective transmission controller Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMC1 Voltage (16) (21) 20 30 V
D475A, D475ASD-5E0
65
SEN01826-01
40 Troubleshooting
Failure code [DAQ7KK] Transmission controller sensor power supply: Power supply voltage reduction (Input) 1
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Transmission controller sensor power supply: Power supply voltage failure reduction (Input) (Transmission controller system) DAQ7KK Voltage of 5V power supply circuit for transmission controller sensors is below 4.5 V or above 5.5 V. Abnormal current flowed in 5V power supply circuit for transmission controller sensors. If abnormal current flows, controller stops output of 5V power supply circuit. System may not operate normally. Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting When device at right is disconnected, if failure code HP1 or lights up (to indicate resetting), sensor has trouble in it. HP2 cona Turn starting switch OFF, disconnect connector, turn nector starting switch ON and carry out troubleshooting. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har2 ness (Contact with GND Between ground and wiring harness between Resiscircuit) TMC3 (female) (34) HP1 or HP2 (female) Min. 1 Mz tance (B) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 3 24V circuit) in wiring har- Between ground and wiring harness between ness TMC3 (female) (34) HP1 or HP2 (female) Voltage Max. 1 V (B) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering or 4 transmission controller TMC3, TMC1 Voltage Between TMC3 (34) TMC1 (21) 4.5 5.5 V Cause Defective work equipment pump oil pressure 1 sensor (Internal short circuit)
Circuit diagram related to transmission controller sensor power supply
66
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Transmission controller type collation: Type select signal inconsisfailure tency (Transmission controller system) DAQ9KQ Internal spec. setting of transmission controller is inconsistent with spec. set signal. Flashes caution lamp and turns on caution buzzer. Limits operations of engine, transmission and brake. Machine does not operate at all. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more.
Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting It is normal if error code lights on (reset display) after carrying out Defective transmission 1 adjustment mode. controller adjustment Adjustment code: 0003: Transmission controller spec. a Prepare with starting switch OFF, carry out troubleshooting withDisconnection in wiring out turning starting switch ON. harness (Disconnection in 2 wiring or defective contact Short circuit of wiring harness between ResisMax. 1 z in connector) TMC3 (female) (10) with chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission 3 controller TMC3 Voltage Between (10) chassis ground Max. 1 V Cause
Circuit diagram related to transmission controller type select
D475A, D475ASD-5E0
67
SEN01826-01
40 Troubleshooting
Failure code [DAQRKR] Transmission controller sensor CAN communication: Communication error (Objective component system abnormality) 1
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Transmission controller CAN communication: Communication error Symptom of (Objective component system abnormality) failure DAQRKR (Transmission controller system) Transmission controller cannot recognize monitor panel, steering controller, engine controller or VHMS controller in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 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) STCN2 (female) (22) or TMC2 (female) Resis(22) or OEM L (female) (47) or OEM R Max. 1 z (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMin. 1 Mz (female) (46) or CT1 (female) (A) or V4A tance Ground fault in wiring har(female) (4) or RES (female) (A) or SRV 2 ness (Contact with GND (male) (3) and ground circuit) Wiring harness between S04 (female) (3), (4) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMin. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring har(male) (3) and ground ness Wiring harness between S04 (female) (3), (4) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground Cause
68
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Cause 4 Defective CAN terminal resistor
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CT1 (male), RES (male) Resistance Between (A) (B) 100 140 z If causes 1 4 are not detected, monitor panel, engine controller, transmission controller, steering controller or VHMS controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective monitor panel, engine controller, trans5 mission controller, steering controller or VHMS controller
D475A, D475ASD-5E0
69
SEN01826-01
40 Troubleshooting
Failure code [DAQSKR] Transmission controller S-NET communication: Defective communication (Abnormality in objective component system) 1
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Transmission controller S-NET communication: Defective communiSymptom of cation (Abnormality in objective component system) failure DAQSKR (Transmission controller system) Transmission controller cannot recognize S-NET. Takes no particular action. Machine may not acquire switch signal of monitor panel, not allowing normal operation of system. Method of reproducing failure code: Turn starting switch ON. Cause Disconnection in wiring harness (Disconnection in 1 wiring or defective contact in connector) Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit) Possible causes and the standard values when normal Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC2 (female) (21) ResisMax. 1 z S01 (female) (8) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisTMC2 (female) (21) S01 (female) (8) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC2 (female) (21) S01 (female) (8) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. S01 Voltage Between (8) chassis ground 69V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMC2 Voltage Between (21) (31) 69V Failure code
Hot short in wiring harness (Contact with 24 V circuit)
Defective monitor panel (Switch module)
Defective transmission controller
70
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to S-NET communication
D475A, D475ASD-5E0
71
SEN01826-01
72
SEN01827-01
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error ............... 4 Failure code [dB2RKR] Engine controller (Left bank) CAN communication: Communication error................ 6 Failure code [db2RKR] Engine controller (Right bank) CAN communication: Communication error.............. 8 Failure code [DB30KT] Steering controller: Abnormality in controller ........................................................... 10 Failure code [DB31KK] Steering controller main power supply: Power supply voltage reduction (Input) ..... 12 Failure code [DB32KK] Steering controller load power supply: Power supply voltage reduction (Input) ...... 14 Failure code [DB35KK] Steering controller potentiometer power supply: Power supply voltage reduction (Input) ................................................................................................. 16 Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input) ............ 18 Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input) ............ 19 Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency....................... 20 Failure code [dB3RKR] Steering controller CAN communication: Communication error .............................. 22 Failure code [DB3SKR] Steering controller S-NET communication: Defective communication (Abnormality in objective component system) .............................................. 24 Failure code [DBB0KK] (or LED of VHMS controller indicates "n9" o "01") VHMS controller: Lowering of source voltage........................................................................................ 26
D475A, D475ASD-5E0
SEN01827-01
40 Troubleshooting
Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o "11") Check of VHMS controller model: Disagreement of model selection .................................................... 27 Failure code [DBB3KK] (or LED of VHMS controller indicates "n9" o "05") VHMS controller: Lowering of direct source voltage .............................................................................. 28 Failure code [DBB5KP] (or LED of VHMS controller indicates "n9" o "04") VHMS sensor power supply (5 V): Lowering of output voltage.............................................................. 29 Failure code [DBB6KP] (or LED of VHMS controller indicates "n9" o "02") VHMS sensor power supply (24 V): Lowering of output voltage............................................................ 30 Failure code [DBB7KP] (or LED of VHMS controller indicates "n9" o "03") VHMS sensor power supply (12 V): Lowering of output voltage............................................................ 32 Failure code [DBBQKR] (or VHMS_LED display "n8" o "02") VHMS KOM-NET: Communication error ..... 34 Failure code [dbBRKR] VHMS controller CAN communication: Communication error................................. 36 Failure code [DD12KA] Shift up switch: Disconnection................................................................................. 38 Failure code [DD12KB] Shift up switch: Short circuit .................................................................................... 40 Failure code [DD13KA] Shift down switch: Disconnection ............................................................................ 42 Failure code [DD13KB] Shift down switch: Short circuit................................................................................ 44 Failure code [DD14KA] Parking brake lever switch: Disconnection.............................................................. 46 Failure code [DD14KB] Parking brake lever switch: Short circuit ................................................................. 48 Failure code [DDB9L4] Reverse switch: Signal disagreement...................................................................... 50 Failure code [DDK3L4] Forward switch: Signal disagreement...................................................................... 52 Failure code [DDK5KA] Gearshift switch: Disconnection.............................................................................. 54 Failure code [DDK5KB] Gearshift switch: Short circuit ................................................................................. 56 Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time................... 58 Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time ...................... 59 Failure code [DDN7KA] Blade pitch switch: Disconnection .......................................................................... 60 Failure code [DDN7KB] Blade pitch switch: Short circuit .............................................................................. 62 Failure code [DDN9KA] Blade tilt switch: Disconnection .............................................................................. 64 Failure code [DDN9KB] Blade tilt switch: Short circuit .................................................................................. 66 Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time ........................ 68 Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time.............................. 69 Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time............................. 70 Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time .................................. 71 Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time............................. 72 Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time ......................... 73
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
D475A, D475ASD-5E0
SEN01827-01
40 Troubleshooting
Failure code [DB2RKR] Engine controller (Left bank) CAN communication: Communication error
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Engine controller CAN communication: Communication error failure (Steering controller system) DB2RKR Steering controller cannot recognize engine controller (Left bank) in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine, transmission and brake. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) CT1 (female) (A) STCN2 (female) (32) or ResisTMC2 (female) (32) or RES (female) (A) or Max. 1 z tance S04 (female) (1), (2) or V4A (female) (4) or Disconnection in wiring 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 ResisTMC2 (female) (22) or RES (female) (B) or Max. 1 z tance S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) ResisWiring harness between OEM L (female) (39) Max. 1 z ACT (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) CT1 (female) (A) STCN2 (female) (32) or ResisTMC2 (female) (32) or RES (female) (A) or Min. 1 Mz tance S04 (female) (1), (2) or V4A (female) (4) or Ground fault in wiring SRV (male) (3) and ground 2 harness (Contact with GND circuit) Wiring harness between OEM L (female) (47) CT1 (female) (B) STCN2 (female) (22) or ResisTMC2 (female) (22) or RES (female) (B) or Min. 1 Mz tance S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground Wiring harness between OEM L (female) (39) ResisMin. 1 Mz ACT (female) (6) and ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between OEM L (female) (46) CT1 (female) (A) STCN2 (female) (32) or TMC2 (female) (32) or RES (female) (A) or Voltage Max. 1 V Hot short (Contact with S04 (female) (1), (2) or V4A (female) (4) or 3 24V circuit) in wiring SRV (male) (3) and ground harness Wiring harness between OEM L (female) (47) CT1 (female) (B) STCN2 (female) (22) or TMC2 (female) (22) or RES (female) (B) or Voltage Max. 1 V S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground Cause
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) (B) 100 140 z Defective engine controller If engine cannot be started, engine controller power supply may be 5 power supply defective. Carry out troubleshooting for failure code [CA111]. If causes 1 5 are not detected, engine controller or steering conDefective engine controller 6 troller may be defective. (Since trouble is in system, troubleshooting or steering controller cannot be carried out.)
Cause
D475A, D475ASD-5E0
SEN01827-01
40 Troubleshooting
Failure code [dB2RKR] Engine controller (Left bank) CAN communication: Communication error
Failure code Symptom of Engine controller CAN communication: Communication error failure (Transmission controller system) dB2RKR Transmission controller cannot recognize engine controller (Left bank) in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine, transmission and brake. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) CT1 (female) (A) STCN2 (female) (32) or ResisTMC2 (female) (32) or RES (female) (A) or Max. 1 z tance S04 (female) (1), (2) or V4A (female) (4) or Disconnection in wiring 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 ResisTMC2 (female) (22) or RES (female) (B) or Max. 1 z tance S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) Wiring harness between OEM L (female) (39) ResisMax. 1 z ACT (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM L (female) (46) CT1 (female) (A) STCN2 (female) (32) or ResisMin. 1 Mz TMC2 (female) (32) or RES (female) (A) or tance S04 (female) (1), (2) or V4A (female) (4) or Ground fault in wiring SRV (male) (3) and ground 2 harness Wiring harness between OEM L (female) (47) (Contact with GND circuit) CT1 (female) (B) STCN2 (female) (22) or ResisTMC2 (female) (22) or RES (female) (B) or Min. 1 Mz tance S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground Wiring harness between OEM L (female) (39) ResisMin. 1 Mz ACT (female) (6) and ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between OEM L (female) (46) CT1 (female) (A) STCN2 (female) (32) or TMC2 (female) (32) or RES (female) (A) or Voltage Max. 1 V Hot short (Contact with S04 (female) (1), (2) or V4A (female) (4) or 3 24V circuit) in wiring SRV (male) (3) and ground harness Wiring harness between OEM L (female) (47) CT1 (female) (B) STCN2 (female) (22) or TMC2 (female) (22) or RES (female) (B) or Voltage Max. 1 V S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground Cause
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) (B) 100 140 z Defective engine controller If engine cannot be started, engine controller power supply may be 5 power supply defective. Carry out troubleshooting for failure code [CA111]. If causes 1 5 are not detected, engine controller or transmission Defective engine controller 6 controller may be defective. (Since trouble is in system, troubleor transmission controller shooting cannot be carried out.)
Cause
D475A, D475ASD-5E0
SEN01827-01
40 Troubleshooting
Failure code [db2RKR] Engine controller (Right bank) CAN communication: Communication error
Action code Failure code Symptom of Engine controller CAN communication: Communication error failure (Steering controller system) CALL E03 db2RKR Failure content Steering controller cannot recognize engine controller (Right bank) in CAN communication circuit. Controller's Takes no particular action. action Symptoms that appear on System may not operate normally. machine General Method of reproducing failure code: Turn starting switch ON. information Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM R (female) (46) CT1 (female) (A) STCN2 (female) ResisDisconnection in wiring (32) or TMC2 (female) (32) or RES (female) Max. 1 z tance harness (Disconnection in (A) or S04 (female) (1), (2) or V4A (female) 1 wiring or defective contact (4) or SRV (male) (3) in connector) Wiring harness between OEM R (female) (47) CT1 (female) (B) STCN2 (female) Resis(22) or TMC2 (female) (22) or RES (female) Max. 1 z tance (B) or S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between OEM R (female) (46) CT1 (female) (A) STCN2 (female) Resis(32) or TMC2 (female) (32) or RES (female) Min. 1 Mz tance Ground fault in wiring (A) or S04 (female) (1), (2) or V4A (female) 2 harness (4) or SRV (male) (3) and ground (Contact with GND circuit) Wiring harness between OEM R (female) (47) CT1 (female) (B) STCN2 (female) Resis(22) or TMC2 (female) (22) or RES (female) Min. 1 Mz tance (B) or S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between OEM R (female) (46) CT1 (female) (A) STCN2 (female) (32) or TMC2 (female) (32) or RES (female) Voltage Max. 1 V Hot short (Contact with (A) or S04 (female) (1), (2) or V4A (female) 3 24V circuit) in wiring (4) or SRV (male) (3) and ground harness Wiring harness between OEM R (female) (47) CT1 (female) (B) STCN2 (female) (22) or TMC2 (female) (22) or RES (female) Voltage Max. 1 V (B) or S04 (female) (3), (4) or V4A (female) (12) or SRV (male) (10) and ground Cause
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) (B) 100 140 z Defective engine controller If engine cannot be started, engine controller power supply may be 5 power supply defective. Carry out troubleshooting for failure code [CB111]. If causes 1 5 are not detected, engine controller or steering conDefective engine controller 6 troller may be defective. (Since trouble is in system, troubleshooting or steering controller cannot be carried out.)
Cause
D475A, D475ASD-5E0
SEN01827-01
40 Troubleshooting
Failure code [DB30KT] Steering controller: Abnormality in controller

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Steering controller: Abnormality in controller failure DB30KT Information of ROM (nonvolatile storage) of steering controller is not normal.
Steering performance may be reduced. Brake performance may be reduced. Method of reproducing failure code: Turn starting switch ON. Cause 1 Defective steering controller Standard values when normal and remarks for troubleshooting Troubleshooting cannot be carried out since it is internal defect. (It is no problem even if you use controller unless no visible problem appears on machine.)
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
D475A, D475ASD-5E0
11
SEN01827-01
40 Troubleshooting
Failure code [DB31KK] Steering controller main power supply: Power supply voltage reduction (Input) 1
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering controller main power supply: Power supply voltage reducfailure tion (Input) (Steering controller system) DB31KK Steering controller power supply voltage is below 17 V. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. Monitor panel may not display normally. Relays and solenoids may not be driven and system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage). Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting If circuit breaker CB6 is turned OFF, circuit probably has ground fault. If circuit breaker CB30 is turned OFF, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN3 (female) (1), ResisMax. 1 z (11) CB6 (2) tance Disconnection in wiring harness (Disconnection in Resis3 Wiring harness between CB6 (1) F30 Max. 1 z wiring or defective contact tance in connector) Wiring harness between B30S battery relay ResisMax. 1 z BRB terminal tance Wiring harness between STCN3 (female) ResisMax. 1 z (21), (31), (32), (33) ground tance Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring STCN3 (female) (1), (11) CB6 (2) tance 4 harness Between ground and wiring harness between Resis(Contact with GND circuit) Min. 1 Mz CB6 (1) F30 tance Between ground and wiring harness between ResisMin. 1 Mz B30S battery relay BRB terminal tance Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering 5 STCN3 Voltage controller Between (1), (11) (21), (31), 20 30 V (32), (33) Cause Defective circuit breaker 1 CB6 (20 A) Defective circuit breaker 2 CB30 (30 A)
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Circuit diagram related to steering controller power supply
D475A, D475ASD-5E0
13
SEN01827-01
40 Troubleshooting
Failure code [DB32KK] Steering controller load power supply: Power supply voltage reduction (Input) 1
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering controller load power supply: Power supply voltage reducfailure tion (Input) (Steering controller system) DB32KK Power supply voltage of steering controller load (relays, solenoids, etc.) is below 17 V. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine and transmission. Relays and solenoids may not be driven and system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage). Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting If circuit breaker CB1 is turned OFF, circuit probably has ground fault. If circuit breaker CB105 is turned OFF, circuit probably has ground fault. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN3 (female) (2), ResisMax. 1 z (12), (22) CB1 (2) tance Disconnection in wiring harness (Disconnection in Resis3 Wiring harness between CB1 (1) F96 Max. 1 z wiring or defective contact tance in connector) Wiring harness between B105S battery ResisMax. 1 z relay BRC terminal tance Wiring harness between TMC3 (female) (21), ResisMax. 1 z (31), (32), (33) ground tance Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz Ground fault in wiring TMC3 (female) (2), (12), (22) CB3 (2) tance 4 harness Resis(Contact with GND circuit) Between ground and wiring harness between Min. 1 Mz CB1 (1) F96 tance Between ground and wiring harness between ResisMin. 1 Mz B105S battery relay BRC terminal tance Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering STCN3 Voltage 5 controller Between (2), (12), (22) (21), 20 30 V (31), (32), (33) Cause Defective circuit breaker 1 CB1 (20 A) Defective circuit breaker 2 CB105 (105 A)
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Circuit diagram related to steering controller power supply
D475A, D475ASD-5E0
15
SEN01827-01
40 Troubleshooting
Failure code [DB35KK] Steering controller potentiometer power supply: Power supply voltage reduction (Input) 1
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering controller potentiometer power supply: Power supply voltfailure age reduction (Input) (Steering controller system) DB35KK Voltage of 5V power supply circuit for steering controller sensors is below 4.5 V or above 5.5 V. Abnormal current flowed in 5V power supply circuit for steering controller sensors. Blinks warning lamp and sounds alarm buzzer. If abnormal current flows, controller stops output of 5V power supply circuit. Limits operations of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective brake BRK (male) Resistance 1 potentiometer (Internal short circuit) Between (C) (A) 5 kz 20% Sensor Between (C) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fuel control dial DIAL (male) Resistance 2 potentiometer (Internal short circuit) Between (1) (3) 5 kz 15% Sensor Between (1) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering TL2 (male) Resistance 3 potentiometer (Internal short circuit) Between (5) (8) 3.2 kz 20% Between (8) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 4 harness Between ground and wiring harness between Resis(Contact with GND circuit) STCN1 (female) (22) TL2 (female) (5) or Min. 1 Mz tance BRK (female) (C) or DIAL (female) (1) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with 5 24V circuit) in wiring Between ground and wiring harness between harness STCN1 (female) (22) TL2 (female) (5) or Voltage Max. 1 V BRK (female) (C) or DIAL (female) (1) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering 6 controller STCN1 Voltage Between (22) (21) 4.5 5.5 V Cause
16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Circuit diagram related to steering controller potentiometer power supply
D475A, D475ASD-5E0
17
SEN01827-01
40 Troubleshooting
Failure code [DB36KK] Steering controller sensor power supply: Source voltage reduction (input)
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering controller sensor power supply: Source voltage reduction failure (input) (Steering controller system) DB36KK Voltage of 24 V power supply circuit of steering controller sensor is below 12 V or above 30 V. Abnormal current flowed in 24 V power supply circuit of steering controller sensor. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting 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. a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between (Contact with ground cirResisSTCN1 (female) (16) PT1 (female) (C) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Defective steering control3 ler STCN1 Voltage Between (16) (21) 20 30 V Cause
Circuit diagram related to steering controller sensor power supply
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Failure code [DB37KK] Steering controller sensor power supply: Source voltage reduction (input)
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering controller sensor power supply: Source voltage reduction failure (input) (Steering controller system) DB37KK Voltage of 5 V power supply circuit of steering controller sensor is below 4.5 V or above 5.5 V. Abnormal current flowed in 5 V power supply circuit of steering controller sensor. Flashes caution lamp and turns on caution buzzer. Stops output of 5 V power supply circuit if abnormal voltage flows.
System may not operate normally. Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting It is internal defect if error code lights on (reset display) Defective acceleration when disconnecting right connector. SSA sensor a Disconnect connector with starting switch OFF, then connector (Internal short circuit) turn starting switch ON and carry out troubleshooting. a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisSTCN3 (female) (34) SSA (female) (C) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Hot short in wiring harness Short circuit of wiring harness between (Contact with 24 V circuit) STCN3 (female) (34) SSA (female) (1) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Defective steering STCN1, STCN3 Voltage controller Between STCN3 (34) 20 30 V STCN1 (21) Cause
Circuit diagram related to steering controller sensor power supply
D475A, D475ASD-5E0
19
SEN01827-01
40 Troubleshooting
Failure code [DB39KQ] Steering controller type selection: Type select signal inconsistency 1
Action code CALL E04 Failure content Failure code Symptom of Steering controller type selection: Type select signal inconsistency failure (Steering controller system) DB39KQ Internal spec. setting of steering controller is inconsistent with spec. set signal. Flashes caution lamp and turns on caution buzzer. Stops all outputs of steering controller. Limits operation of engine, transmission, and brake. Problem that appears on machineMachine does not operate at all. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more.
Controller's action Symptoms that appear on machine General Method of reproducing failure code: Turn starting switch ON. information Cause
Standard values when normal and remarks for troubleshooting 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) a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 2 wiring or defective contact Wiring harness between STCN3 (female) ResisMax. 1 z in connector) (20) chassis ground tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Defective steering 3 controller STCN3 Voltage Between (20) chassis ground Max. 1 V
Circuit diagram related to steering controller type select
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
D475A, D475ASD-5E0
21
SEN01827-01
40 Troubleshooting
Failure code [dB3RKR] Steering controller CAN communication: Communication error

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering controller CAN communication: Communication error failure (Transmission controller system) dB3RKR Transmission controller cannot recognize steering controller in CAN communication circuit. Blinks warning lamp and sounds alarm buzzer. Limits operations of engine, transmission and brake. System may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1.
Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 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) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMax. 1 z (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMin. 1 Mz (female) (46) or CT1 (female) (A) or V4A tance Ground fault in wiring (female) (4) or RES (female) (A) or SRV 2 harness (male) (3) and ground (Contact with GND circuit) Wiring harness between S04 (female) (3), (4) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMin. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring (male) (3) and ground harness Wiring harness between S04 (female) (3), (4) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground Cause
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Cause Possible causes and the standard values when normal 4 Defective CAN terminal resistor
Defective steering 5 controller or transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CT1 (male), RES (male) Resistance Between (A) (B) 100 140 z If causes 1 4 are not detected, steering controller or transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
D475A, D475ASD-5E0
23
SEN01827-01
40 Troubleshooting
Failure code [DB3SKR] Steering controller S-NET communication: Defective communication (Abnormality in objective component system)1
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Steering controller S-NET communication: Defective communication Symptom of (Abnormality in objective component system) failure DB3SKR (Steering controller system) Transmission controller cannot recognize S-NET. Takes no particular action. Machine may not acquire switch signal of monitor panel, not allowing normal operation of system. Method of reproducing failure code: Turn starting switch ON. Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 1 wiring or defective contact Wiring harness between STCN2 (female) ResisMax. 1 z in connector) (21) S01 (female) (8) tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between (Contact with ground ResisSTCN2 (female) (21) S01 (female) (8) with Min. 1 Mz circuit) tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 3 Short circuit of wiring harness between (Contact with 24 V circuit) STCN2 (female) (21) S01 (female) (8) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Defective monitor panel 4 (Switch module) S01 Voltage Between (8) chassis ground 69V a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Defective steering 5 STCN2 Voltage controller Between (21) (31) 69V Failure code
24
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Circuit diagram related to S-NET communication
D475A, D475ASD-5E0
25
SEN01827-01
40 Troubleshooting
Failure code [DBB0KK] (or LED of VHMS controller indicates "n9" o "01") VHMS controller: Lowering of source voltage
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of VHMS controller: Lowering of source voltage failure (VHMS controller system) DBB0KK The switch source voltage is below 19.5 V. None in particular. The system may not operate normally.
The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n9" o "01". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between V1 (female) (8), (9) Resis1 Max. 1 z wiring harness or defective and FS12 (fuse) (1) tance contact in connector) Wiring harness between V1 (female) (11) and ResisMax. 1 z GND 01 tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Between wiring harness between V1 (Contact with ground Resis(female) (8), (9) and FS12 (fuse) (1) and Min. 1 Mz circuit) tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller Between V1 (female) (8), (9) and V1 (female) Voltage 20 30 V (11), (12) or chassis ground Cause
Circuit diagram related to VHMS controller power supply
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o "11") Check of VHMS controller model: Disagreement of model selection
Failure code Symptom of VHMS controller model selection: Disagreement of model selection failure signals (VHMS controller system) DBB0KQ Wrong connection of connectors is displayed. None in particular. The system may not operate normally. The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "nF" o "11". Cause Standard values when normal and remarks for troubleshooting Wrong connection of VHMS controller connec- Check that the couple of connectors V2A and V3A and that of con1 tors (When system is nor- nectors V2B and V3B are connected correctly. If not, correct. mal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Between wiring harness V1 (female) (11), Resis2 Max. 1 z wiring harness or defective (12) and chassis ground tance contact in connector) Between wiring harness V3A (female) (9) ResisMax. 1 z and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 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
27
SEN01827-01
40 Troubleshooting
Failure code [DBB3KK] (or LED of VHMS controller indicates "n9" o "05") VHMS controller: Lowering of direct source voltage
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of VHMS controller: Lowering of direct source voltage failure (VHMS controller system) DBB3KK The direct source voltage is below 19.5 V. None in particular. The system may not operate normally.
The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n9" o "05". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between V1 (female) (6), (7) Resis1 Max. 1 z wiring harness or defective and FS12 (fuse) (2) tance contact in connector) Wiring harness between V1 (female) (11) and ResisMax. 1 z GND 01 tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Between wiring harness between V1 (Contact with ground Resis(female) (6), (7) and FS12 (fuse) (2) and Min. 1 Mz circuit) tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller Between V1 (female) (6), (7) and V1 (female) Voltage 20 30 V (11), (12) or chassis ground Cause
Circuit diagram related to VHMS controller power supply
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Failure code [DBB5KP] (or LED of VHMS controller indicates "n9" o "04") VHMS sensor power supply (5 V): Lowering of output voltage
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Sensor power supply (5 V): Lowering of output voltage failure (Disconnection or short circuit) DBB5KP The sensor source voltage (5 V) is out of the normal range (4.5 5.5 V). None in particular. The system may not operate normally.
The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n9" o "04". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 1 Short circuit of wiring harness between V1 (Contact with ground cirResis(female) (4) ENBP (female) (B) and chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 2 wiring harness or defective Between wiring harness V1 (female) (4) and ResisMax. 1 z contact in connector) ENBP (female) (B) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller Between V1 (female) (4) and V2A (female) 4.5 Voltage (12) 5.5 V Cause
Circuit diagram related to sensor power supply 5 V
D475A, D475ASD-5E0
29
SEN01827-01
40 Troubleshooting
Action code Failure code Symptom of VHMS sensor power supply (24 V): Lowering of output voltage failure (Disconnection or short circuit) (VHMS controller system) DBB6KP Failure content The sensor source voltage (24 V) is out of the normal range (20 30 V). Controller's None in particular. 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 "02". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 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(female) (A), V1 (female) (2) EXA3 (female) Max. 1 z contact in connector) tance (A), V1 (female) (2) EXA4 (female) (A) V1 (female) (2) TMMD (female) (B) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between V1 ground in wiring harness (female) (2) EXA1 (female) (A), V1 (female) 2 (Contact with ground cir- (2) EXA2 (female) (A), V1 (female) (2) ResisMin. 1 Mz cuit) EXA3 (female) (A), V1 (female) (2) EXA4 tance (female) (A) V1 (female) (2) TMMD (female) (B) with chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller Between V1 (2) and V2A (13) Voltage 20 30 V Cause
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
D475A, D475ASD-5E0
31
SEN01827-01
40 Troubleshooting
Action code Failure code Symptom of VHMS sensor power supply (12 V): Lowering of output voltage failure (Disconnection or short circuit) (VHMS controller system) DBB7KP Failure content The sensor source voltage (12 V) is out of the normal range (11.5 12.5 V). Controller's None in particular. 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 "03". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 1 wiring harness or defecBetween wiring harness V1 (female) (3) and ResisMax. 1 z tive contact in connector) DLT (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between V1 (Contact with ground cirResis(female) (3) and DLT (female) (1) with chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective VHMS controller V1 Voltage Between (3) and (11), (12) 11.5 12.5 V Cause
32
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
D475A, D475ASD-5E0
33
SEN01827-01
40 Troubleshooting
Failure code [DBBQKR] (or VHMS_LED display "n8" o "02") VHMS KOM-NET: Communication error
Action code Failure code Symptom of VHMS KOM-NET: Communication error failure (VHMS controller system) CALL E03 DBBQKR Failure content Communication (CAN) information cannot be received from each controller. Controller's None in particular. action Symptoms that appear on System may not operate normally. 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". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 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) STCN2 (female) (22) or TMC2 (female) Resis(22) or OEM L (female) (47) or OEM R Max. 1 z tance (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMin. 1 Mz (female) (46) or CT1 (female) (A) or V4A tance Ground fault in wiring har(female) (4) or RES (female) (A) or SRV 2 ness (Contact with GND (male) (3) and ground circuit) Wiring harness between S04 (female) (3), (4) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMin. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring har(male) (3) and ground ness Wiring harness between S04 (female) (3), (4) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground Cause
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Cause Possible causes and the standard values when normal
Defective CAN terminal resistor
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CT1 (male), RES (male), RES L (male), RES R (male), Resistance CTV (male) Between (A) (B) 100 140 z
D475A, D475ASD-5E0
35
SEN01827-01
40 Troubleshooting
Failure code [dbBRKR] VHMS controller CAN communication: Communication error

Action code Failure code Symptom of VHMS controller CAN communication: Communication error failure (Steering controller system) dbBRKR Failure content Steering controller cannot recognize VHMS controller in CAN communication circuit. Controller's None in particular. action Symptoms that appear on Data related to VHMS cannot be monitored. machine General Data related to VHMS may not be obtained normally. information Method of reproducing failure code: Turn starting switch ON.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMax. 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) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMax. 1 z (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R ResisMin. 1 Mz (female) (46) or CT1 (female) (A) or V4A tance Ground fault in wiring (female) (4) or RES (female) (A) or SRV 2 harness (Contact with (male) (3) and ground GND circuit) Wiring harness between S04 (female) (3), (4) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R ResisMin. 1 Mz (female) (47) or CT1 (female) (B) or V4A tance (female) (12) or RES (female) (B) or SRV (male) (10) and ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between S04 (female) (1), (2) STCN2 (female) (32) or TMC2 (female) (32) or OEM L (female) (46) or OEM R Voltage Max. 1 V (female) (46) or CT1 (female) (A) or V4A Hot short (Contact with (female) (4) or RES (female) (A) or SRV 3 24V circuit) in wiring (male) (3) and ground harness Wiring harness between S04 (female) (3), (4) STCN2 (female) (22) or TMC2 (female) (22) or OEM L (female) (47) or OEM R Voltage Max. 1 V (female) (47) or CT1 (female) (B) or V4A (female) (12) or RES (female) (B) or SRV (male) (10) and ground
Cause
36
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective CAN terminal 4 resistor CT1 (male), RES (male) Resistance Between (A) (B) 100 140 z If causes 1 4 are not detected, steering controller or VHMS controlDefective steering control5 ler may be defective. (Since trouble is in system, troubleshooting ler or VHMS controller cannot be carried out.)
Cause
D475A, D475ASD-5E0
37
SEN01827-01
40 Troubleshooting
Failure code [DD12KA] Shift up switch: Disconnection

Action code Failure code Symptom of Shift up switch: Disconnection (Transmission controller system) failure E02 DD12KA Failure content Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time. Controller's Flashes caution lamp and turns on caution buzzer. 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. Cause
Defective shift up switch (Internal disconnection)
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Possible causes and the standard values when normal 3 Hot short in wiring harness (Contact with 24 V circuit)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift up switch TL3 (male) OFF (Release) ON (Press) Resistance between Max. 1 z Min. 1 Mz (2) (3) Resistance between Min. 1 Mz Max. 1 z (2) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (6) ResisMax. 1 z TL3 (female) (3) tance Wiring harness between TMC2 (female) (37) ResisMax. 1 z TL3 (female) (1) tance Wiring harness between TMC1 (female) (4) ResisMax. 1 z TL3 (female) (2) tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC1 (female) (6) TL3 (female) (3) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between TMC2 (female) (37) TL3 (female) (1) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift up switch TMCN1,TMCN2 OFF (Release) ON (Press) Voltage between TMC1 (6) TMC1 Max. 1 V 5 11 V (10) Voltage between TMC2 (37) TMC1 5 11 V Max. 1 V (10)
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Circuit diagram related to shift up switch and shift down switch
D475A, D475ASD-5E0
39
SEN01827-01
40 Troubleshooting
Failure code [DD12KB] Shift up switch: Short circuit

Action code Failure code Symptom of Shift up switch: Short circuit (Transmission controller system) failure E02 DD12KB Failure content Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time. Controller's Flashes caution lamp and turns on caution buzzer. 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. Cause
Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift up switch TL3 (male) OFF (Release) ON (Press) Resistance between Max. 1 z Min. 1 Mz (2) (3) Resistance between Min. 1 Mz Max. 1 z (2) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisMin. 1 Mz TMC1 (female) (6) TL3 (female) (3) with tance chassis ground Short circuit of wiring harness between ResisTMC2 (female) (37) TL3 (female) (1) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift up switch TMC1,TMC2 OFF (Release) ON (Press) Voltage between TMC1 (6) TMC1 Max. 1 V 5 11 V (10) Voltage between TMC2 (37) TMC1 5 11 V Max. 1 V (10)
40
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
D475A, D475ASD-5E0
41
SEN01827-01
40 Troubleshooting
Failure code [DD13KA] Shift down switch: Disconnection

Action code Failure code Symptom of Shift down switch: Disconnection failure (Transmission controller system) E02 DD13KA Failure content Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time. Controller's Flashes caution lamp and turns on caution buzzer. action Recognizes that switch is not pressed. Symptoms that Shift down 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 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. Cause
Defective shift down 1 switch (Internal disconnection)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift down switch TL3 (male) OFF (Release) ON (Press) Resistance between Max. 1 z Min. 1 Mz (5) (6) Resistance between Min. 1 Mz Max. 1 z (5) (4) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (19) ResisMax. 1 z TL3 (male) (6) tance Wiring harness between TMC3 (female) (29) ResisMax. 1 z TL3 (male) (4) tance Wiring harness between TMC1 (female) (10) ResisMax. 1 z TL3 (male) (5) tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC3 (female) (19) TL3 (male) (6) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between TMC3 (female) (29) TL3 (male) (4) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift down switch TMC1, TMC3 OFF (Release) ON (Press) Voltage between TMC3 (29) TMC1 Max. 1 V 5 11 V (10) Voltage between TMC3 (29) TMC1 5 11 V Max. 1 V (10)
42
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
D475A, D475ASD-5E0
43
SEN01827-01
40 Troubleshooting
Failure code [DD13KB] Shift down switch: Short circuit

Action code Failure code Symptom of Shift down switch: Short circuit failure (Transmission controller system) E02 DD13KB Failure content Signals of two systems of shift down switch circuit were turned ON (CLOSE) Controller's Flashes caution lamp and turns on caution buzzer. action Recognizes that switch is not pressed. Symptoms that Shift down 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 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 up switch.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift down switch TL3 (male) Defective shift down switch OFF (Release) ON (Press) 1 (Internal disconnection) Resistance between Max. 1 z Min. 1 Mz (5) (6) Resistance between Min. 1 Mz Max. 1 z (5) (4) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between ResisMin. 1 Mz ground in wiring harness TMC3 (female) (19) TL3 (male) (6) with tance 2 (Contact with ground circhassis ground cuit) Short circuit of wiring harness between ResisTMC3 (female) (29) TL3 (male) (4) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift down switch TMC1, TMC3 OFF (Release) ON (Press) Defective transmission Voltage between 3 controller TMC3 (19) TMC1 Max. 1 V 5 11 V (10) Voltage between TMC3 (29) TMC1 5 11 V Max. 1 V (10)
Cause
44
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
D475A, D475ASD-5E0
45
SEN01827-01
40 Troubleshooting
Failure code [DD14KA] Parking brake lever switch: Disconnection

Action code E02 Failure content Controller's action Symptoms that appear on machine
Failure code Symptom of Parking brake lever switch: Disconnection failure (Transmission controller system) DD14KA Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same time. Flashes caution lamp and turns on caution buzzer. Recognizes parking brake lever is in Free position. Limits operation of engine, transmission, and brake.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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: DDQ2KA, DDQ2L4). Of signals of two systems of switch, NC is for operation detection and NO is for error detection. 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 Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC1 (female) (18) Resis1 Max. 1 z wiring or defective contact branched point of circuit JF2 tance in connector) Wiring harness between TMC1 (female) (12) ResisMax. 1 z branched point of circuit JF1 tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. 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 Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Parking brake lever Parking brake lever switch NSW (male) 1 (Internal disconnection) Free position Lock position Between (A) (B) Max. 1 z Min. 1 Mz Between (A) (B) Min. 1 Mz Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between NSW (female) (B) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in TMC1 (female) (18), STCN2 (female) (5) 2 wiring or defective contact Wiring harness between NSW (female) (C) ResisMax. 1 z in connector) TMC1 (female) (12), STCN2 (female) (15) tance Wiring harness between NSW (female) (A) ResisMax. 1 z chassis ground tance
General information
46
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NSW Hot short in wiring harness (female) (B) TMC1 (female) (18), STCN2 Voltage Max. 1 V 3 (Contact with 24 V circuit) (female) (5) with chassis ground 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
47
SEN01827-01
40 Troubleshooting
Failure code [DD14KB] Parking brake lever switch: Short circuit

Action code E02 Failure content Controller's action Symptoms that appear on machine
Failure code Symptom of Parking brake lever switch: Short circuit failure (Transmission controller system) DD14KB Signals of two systems of parking brake lever switch circuit were turned ON (CLOSE) at the same time. Flashes caution lamp and turns on caution buzzer. Recognizes parking brake lever is in Free position. Limits operation of engine, transmission, and brake.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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). Of signals of two systems of switch, NC is for operation detection and NO is for error detection. 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. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Parking brake lever Parking brake lever switch NSW (male) 1 Free position Lock position (Internal disconnection) Between (A) (B) Max. 1 z Min. 1 Mz Between (A) (C) Min. 1 Mz Max. 1 z a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit with chassis Wiring harness between NSW (female) (B) ResisMin. 1 Mz ground in wiring harness TMC1 (female) (18), STCN2 (female) (5) with tance 2 (Contact with ground circhassis ground cuit) Wiring harness between NSW (female) (C) ResisTMC1 (female) (12), STCN2 (female) (15) Min. 1 Mz tance with chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking brake lever TMC1 Free position Lock position Defective transmission con3 troller Between (18) Max. 1 V 5 11 V chassis ground Between (12) 5 11 V Max. 1 V chassis ground Cause
General information
48
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
D475A, D475ASD-5E0
49
SEN01827-01
40 Troubleshooting
Failure code [DDB9L4] Reverse switch: Signal disagreement

Action code E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Reverse switch: Signal disagreement failure (Transmission controller system) DDB9L4 Signals of 2 reverse switch circuit systems disagree with each other. Blinks warning lamp and sounds alarm buzzer. Assumes that switch is not pressed. Limits operations of engine, transmission and brake.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1. Input state (ON/OFF) from reverse switch can be checked in monitoring mode (Code 40905: Transmission controller input signal 1). Method of reproducing failure code: Turn starting switch ON (+ Operate reverse switch). Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Reverse switch TL3 (male) Defective reverse switch OFF (Released) ON (Pressed) (Internal disconnection) Resistance between Min. 1 Mz Max. 1 z (6) (5) Resistance between Min. 1 Mz Max. 1 z (4) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (19) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in TL3 (female) (6) wiring or defective contact Wiring harness between TMC3 (female) (29) ResisMax. 1 z in connector) TL3 (female) (4) tance Wiring harness between TMC1 (female) (10) ResisMax. 1 z TL3 (female) (5) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring Between ground and wiring harness between Resisharness (Contact with Min. 1 Mz TMC3 (female) (19) TL3 (female) (6) tance GND circuit) Between ground and wiring harness between ResisMin. 1 Mz TMC3 (female) (29) TL3 (female) (4) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with Between ground and wiring harness between 24V circuit) in wiring Voltage Max. 1 V TMC3 (female) (19) TL3 (female) (6) harness Between ground and wiring harness between Voltage Max. 1 V TMC3 (female) (29) TL3 (female) (4) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Reverse switch Reverse switch OFF (Released) ON (Pushed) Defective transmission Voltage between controller TMC3 (19) TMC1 5 11 V Max. 1 V (10) Voltage between TMC3 (29) TMC1 5 11 V Max. 1 V (10) Cause
50
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Circuit diagram related to forward-reverse switch
D475A, D475ASD-5E0
51
SEN01827-01
40 Troubleshooting
Failure code [DDK3L4] Forward switch: Signal disagreement

Action code E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Forward switch: Signal disagreement failure (Transmission controller system) DDK3L4 Signals of 2 forward switch circuit systems disagree with each other. Blinks warning lamp and sounds alarm buzzer. Assumes that switch is not pressed. Limits operations of engine, transmission and brake.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1. Input state (ON/OFF) from forward switch can be checked in monitoring mode (Code 40905: Transmission controller input signal 1). Method of reproducing failure code: Turn starting switch ON (+ Operate forward) switch. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Forward switch TL3 (male) Defective forward switch OFF (Released) ON (Pressed) 1 (Internal disconnection) Resistance between Min. 1 Mz Max. 1 z (3) (5) Resistance between Min. 1 Mz Max. 1 z (1) (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (6) ResisDisconnection in wiring Max. 1 z TL3 (female) (3) tance harness (Disconnection in 191. Resistance 2 wiring or defective contact Wiring harness between TMC2 (female) (37) Resisin connector) Max. 1 z TL3 (female) (1) tance Wiring harness between TMC1 (female) (10) ResisMax. 1 z TL3 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harBetween ground and wiring harness between ResisMin. 1 Mz 3 ness (Contact with GND TMC1 (female) (6) TL3 (female) (3) tance circuit) Between ground and wiring harness between ResisMin. 1 Mz TMC2 (female) (37) TL3 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with Between ground and wiring harness between 4 24V circuit) in wiring harVoltage Max. 1 V TMC1 (female) (6) TL3 (female) (3) ness Between ground and wiring harness between Voltage Max. 1 V TMC2 (female) (37) TL3 (female) (1) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Forward switch TMC1, TMC2 OFF (Released) ON (Pushed) Defective transmission Voltage between 5 controller TMC1 (6) TMC1 5 11 V Max. 1 V (10) Voltage between TMC2 (37) TMC1 5 11 V Max. 1 V (10) Cause
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Circuit diagram related to forward-reverse switch
D475A, D475ASD-5E0
53
SEN01827-01
40 Troubleshooting
Failure code [DDK5KA] Gearshift switch: Disconnection

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Gearshift switch: Disconnection failure (Transmission controller system) DDK5KA Signals of 2 gearshift switch circuit systems are turned OFF (opened) simultaneously. Blinks warning lamp and sounds alarm buzzer. Assumes that switch is not pressed. Gear cannot be shifted up or down (1st o 2nd). Auto shift-down function does not work.
Input state (ON/OFF) from gearshift switch can be checked in monitoring mode (40906: Transmission controller input signal 2). Method of reproducing failure code: Turn starting switch ON (+ operate gearshift switch). Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift switch SNC (female) OFF (Release) ON (Press) Resistance between Max. 1 z Min. 1 Mz (3) (1) Resistance between Min. 1 Mz Max. 1 z (2) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisWiring harness between TMC2 (female) (7) Max. 1 z SNL (male) (2) tance Wiring harness between TMC2 (female) (10) ResisMax. 1 z SNC (male) (3) tance Wiring harness between TMC1 (female) (10) ResisMax. 1 z SNC (male) (1) tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC2 (female) (7) SNC (male) (2) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between TMC2 (female) (10) SNC (male) (3) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift switch TMC1,TMC2 OFF (Release) ON (Press) Voltage between TMC2 (7) TMC1 5 11 V Max. 1 V (10) Voltage between TMC2 (10) TMC1 Max. 1 V 5 11 V (10)
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D475A, D475ASD-5E0
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SEN01827-01
Circuit diagram related to shift switch
D475A, D475ASD-5E0
55
SEN01827-01
40 Troubleshooting
Failure code [DDK5KB] Gearshift switch: Short circuit

Action code E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Gearshift switch: Short circuit failure (Transmission controller system) DDK5KB Signals of 2 gearshift switch circuit systems are turned ON (closed) simultaneously. Blinks warning lamp and sounds alarm buzzer. Assumes that switch is not pressed. Gear cannot be shifted up or down (1st o 2nd). Auto shift-down function does not work.
Input state (ON/OFF) from gearshift switch can be checked in monitoring mode (40906: Transmission controller input signal 2). Method of reproducing failure code: Turn starting switch ON (+ operate gearshift switch). Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Shift switch SNC (female) OFF (Release) ON (Press) Resistance between Max. 1 z Min. 1 Mz (3) (1) Resistance between Min. 1 Mz Max. 1 z (2) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisTMC2 (female) (7) SNC (male) (2) with Min. 1 Mz tance chassis ground Short circuit of wiring harness between ResisMin. 1 Mz TMC2 (female) (10) SNC (male) (3) with tance chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift switch TMC1,TMC2 OFF (Release) ON (Press) Voltage between TMC2 (7) TMC1 5 11 V Max. 1 V (10) Voltage between TMC2 (10) TMC1 Max. 1 V 5 11 V (10)
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D475A, D475ASD-5E0
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SEN01827-01
Circuit diagram related to shift switch
D475A, D475ASD-5E0
57
SEN01827-01
40 Troubleshooting
Failure code [DDN2LD] (Blade tilt right oil pressure switch system: Switch is ON for long time
Action code E02 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Blade tilt right oil pressure switch system: Switch is ON for long time failure (Transmission controller system) DDN2LD The signal of the blade tilt right oil pressure switch circuit is kept turned ON for 60 seconds. Flashes the caution lamp and turns on the caution buzzer. Recognizes that the oil pressure switch is turned OFF. During right dual tilt operation, tilting is not limited. Blade tilt right operation becomes slow. VHMS data is not always correct. The input state (ON/OFF) from the blade tilt right oil pressure switch can be checked in the monitoring mode. (Code 40908: Blade lever oil pressure switch input state) Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting 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. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective blade tilt right oil TRS (male) Blade lever Resistance 2 pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Right tilt Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (6) and TRS (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC2, TMC1 Blade lever Voltage 4 controller Neutral 5 11 V Between TMC2 (6) and TMC1 (4) Right tilt Max. 1 V
Circuit diagram related to blade tilt right oil pressure switch
58
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-01
Failure code [DDN3LD] Blade tilt left oil pressure switch system: Switch is ON for long time 1
Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade tilt left oil pressure switch system: Switch is ON for long time failure (Transmission controller system) DDN3LD The signal of the blade tilt left oil pressure switch circuit is kept turned ON for 60 seconds. Flashes the caution lamp and turns on the caution buzzer. Recognizes that the oil pressure switch is turned OFF. During left dual tilt operation, tilting is not limited. Blade tilt left operation becomes slow. VHMS data is not always correct. The input state (ON/OFF) from the blade tilt left oil pressure switch can be checked in the monitoring mode. (Code 40908: Blade lever oil pressure switch input state) Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting 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. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective blade tilt left oil TLS (male) Blade lever Resistance 2 pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Left tilt Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (16) and TLS (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC2, TMC1 Blade lever Voltage 4 controller Neutral 5 11 V Between TMC2 (16) and TMC1 (4) Left tilt Max. 1 V
Circuit diagram related to blade tilt left oil pressure switch
D475A, D475ASD-5E0
59
SEN01827-01
40 Troubleshooting
Failure code [DDN7KA] Blade pitch switch: Disconnection

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch switch: Disconnection failure (Transmission controller system) DDN7KA The signals of the 2 blade pitch switch circuit systems are turned OFF (opened) simultaneously. Flashes the caution lamp and turns on the caution buzzer. Recognizes that the switch is not pressed. The blade is not pitched (When pitching operation is performed, the blade is tilted). "NO" of the 2 switch system signals is for detection of operations and "NC" is for detection of errors. The input state (ON/OFF) from the blade pitch switch can be checked in the monitoring mode. (Code 70300: Blade lever knob switch input signal) Method of reproducing failure code: Turn the starting switch ON + (Operate blade tilt switch).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade pitch switch P03 (male) Defective blade pitch OFF (Released) ON (Pressed) 1 switch (Internal disconnecResistance between tion) Max. 1 z Min. 1 Mz (1) and (5) Resistance between Min. 1 Mz Max. 1 z (1) and (2) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC2 (female) (15) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in and P03 (female) (5) 2 wiring harness or defecWiring harness between TMC2 (female) (5) ResisMax. 1 z tive contact in connector) and P03 (female) (2) tance Wiring harness between TMC2 (female) (4) ResisMax. 1 z and P03 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 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) Between wiring harness between TMC2 (female) (5) and P03 (female) (2) and chasVoltage Max. 1 V sis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Blade pitch switch TMC1, TMC2 OFF (Released) ON (Pressed) Defective transmission Voltage between 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)
Cause
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SEN01827-01
Circuit diagram related to blade pitch switch and blade tilt switch
D475A, D475ASD-5E0
61
SEN01827-01
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Failure code [DDN7KB] Blade pitch switch: Short circuit

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch switch: Short circuit failure (Transmission controller system) DDN7KB Signals of two systems of blade pitch switch circuit were turned ON (CLOSE) at the same time. Flashes caution lamp and turns on caution buzzer. Recognizes that switch is not pressed. Blade pitch does not function (Operating blade pitch causes tilt operation.) Of signals of two systems of switch, NO is for operation detection and NC is for error detection. Input state (ON/OFF) from blade pitch switch can be checked in monitoring mode. (Code 70300: Blade lever knob switch input) Method of reproducing failure code: Turn starting switch ON and operate blade tilt switch.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade pitch switch P03 (male) Defective blade pitch OFF (Release) ON (Press) 1 switch (Internal disconnecResistance between tion) Max. 1 z Min. 1 Mz (1) (5) Resistance between Min. 1 Mz Max. 1 z (1) (2) a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit with chassis Short circuit of wiring harness between ground in wiring harness TMC2 (female) (15) P03 (female) (5) with Voltage Max. 1 V 2 (Contact with ground circhassis ground cuit) Short circuit of wiring harness between TMC2 (female) (5) P03 (female) (2) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Blade pitch switch TMC1, TMC2 OFF (Release) ON (Press) Defective transmission 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)
Cause
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SEN01827-01
Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0
63
SEN01827-01
40 Troubleshooting
Failure code [DDN9KA] Blade tilt switch: Disconnection

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade tilt switch: Disconnection failure (Transmission controller system) DDN9KA Signals of two systems of blade tilt switch circuit were turned OFF (OPEN) at the same time. Recognizes switch is set at SINGLE side. Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.) Of signals of two systems of switch, NO is for operation detection and NC is for error detection. Input state (ON/OFF) from blade tilt switch can be checked in monitoring mode. (Code 70300: Blade lever knob switch input signal) Method of reproducing failure code: Turn starting switch ON (and operate blade tilt switch).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade tilt switch P03 (male) Defective blade tilt switch SINGLE DUAL (Internal disconnection) Resistance between Max. 1 z Min. 1 Mz (3) (6) Resistance between Min. 1 Mz Max. 1 z (3) (4) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC2 (female) (35) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection in P03 (female) (6) wiring or defective contact Wiring harness between TMC2 (female) (25) ResisMax. 1 z in connector) P03 (female) (4) tance Wiring harness between TMC1 (female) (4) ResisMax. 1 z P03 (female) (3) tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Voltage Max. 1 V Hot short in wiring harness TMC2 (female) (35) P03 (female) (6) with (Contact with 24 V circuit) chassis ground Short circuit of wiring harness between TMC2 (female) (25) P03 (female) (4) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Blade tilt switch TMC1, TMC2 SINGLE DUAL Defective transmission Voltage between controller TMC2 (35) Max. 1 V 5 11 V TMC1 (4) Voltage between TMC2 (25) 5 11 V Max. 1 V TMC1 (4)
Cause
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SEN01827-01
D475A, D475ASD-5E0
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Failure code [DDN9KB] Blade tilt switch: Short circuit

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade tilt switch: Short circuit (Transmission controller system) failure DDN9KB Signals of two systems of blade tilt switch circuit were turned ON (CLOSE) at the same time. Recognizes switch is set at SINGLE side. Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.) Of signals of two systems of switch, NO is for operation detection and NC is for error detection. Input state (ON/OFF) from blade tilt switch can be checked in monitoring mode. (Code 70300: Blade lever knob switch input state) Method of reproducing failure code: Turn starting switch ON (and operate blade tilt switch). Cause
Defective blade tilt switch (Internal disconnection)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Blade tilt switch P03 (male) SINGLE DUAL Resistance between Max. 1 z Min. 1 Mz (3) (6) Resistance between Min. 1 Mz Max. 1 z (3) (4) a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC2 (female) (35) P03 (female) (6) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between TMC2 (female) (25) P03 (female) (4) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Blade tilt switch TMC1, TMC2 SINGLE DUAL Voltage between TMC2 (35) Max. 1 V 5 11 V TMC1 (4) Voltage between TMC2 (25) 5 11 V Max. 1 V TMC1 (4)
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D475A, D475ASD-5E0
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Failure code [DDNALD] (Blade lift raise full oil pressure switch: Switch is ON for long time 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade lift raise full oil pressure switch: Switch is ON for long time failure (Transmission controller system) DDNALD The signal of the blade lift raise full oil pressure switch circuit is kept turned ON for 60 seconds. Recognizes that the oil pressure switch is turned OFF. The data of the VHMS may become abnormal. Blade lift raise operation becomes slow. The input state (ON/OFF) from the blade lift raise full oil pressure switch can be checked in the monitoring mode. (Code 40908: Ripper lever oil pressure switch input signal) Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting 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 normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective blade lift raise BLU (male) Blade lever Resistance 2 full oil pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Raise Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between STCN2 (Contact with ground cirResis(female) (36) and BLU (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC1, TMC2 Ripper lever Voltage 4 controller Neutral 5 11 V Between TMC2 (36) and TMC1 (10) Tilt in Max. 1 V
Circuit diagram related to blade lift raise full oil pressure switch
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SEN01827-01
Failure code [DDNBLD] Ripper lift raise oil pressure switch: Switch is ON for long time 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Ripper lift raise oil pressure switch: Switch is ON for long time failure (Transmission controller system) DDNBLD The signal of the ripper lift raise oil pressure switch circuit is kept turned ON for 60 seconds. Recognizes that the oil pressure switch is turned OFF. The shoe slip control (SSC) function does not operate normally. Ripper lift raise operation becomes slow. 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 monitoring mode. (Code 70305: Steering controller input signal 3) Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting Wrong operation of lever If the error code lamp still lights up (resetting is still urged) after the 1 (When electrical system is resetting operation is performed, it is suspected that the lever was normal) operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective ripper lift raise oil RPU (male) Ripper lever Resistance 2 pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Raise Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (13) and RPU (female) (1) and Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC2, TMC1 Ripper lever Voltage 4 controller Neutral 5 11 V Between TMC2 (13) and TMC1 (4) Raise Max. 1 V
Circuit diagram related to ripper lift raise oil pressure switch
D475A, D475ASD-5E0
69
SEN01827-01
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Failure code [DDNCLD] Ripper lift lower oil pressure switch: Switch is ON for long time 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Ripper lift lower oil pressure switch: Switch is ON for long time failure (Transmission controller system) DDNCLD The signal of the ripper lift lower oil pressure switch circuit is kept turned ON for 60 seconds. Recognizes that the oil pressure switch is turned OFF. The shoe slip control (SSC) function does not operate normally. The data of the VHMS may become abnormal. Ripper lift lower operation becomes slow. The input state (ON/OFF) from the ripper lift lower oil pressure switch can be checked in the monitoring mode. (Code 70305: Steering controller input signal 3) Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting 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 normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective ripper lift lower RPD (male) Ripper lever Resistance 2 oil pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Lower Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (3) and RPD (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC1, TMC2 Ripper lever Voltage 4 controller Neutral 5 11 V Between TMC2 (3) and TMC1 (4) Lower Max. 1 V
Circuit diagram related to ripper lift lower oil pressure switch
70
D475A, D475ASD-5E0
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SEN01827-01
Failure code [DDNDLD] Ripper tilt in oil pressure switch: Switch is ON for long time 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Ripper tilt in oil pressure switch: Switch is ON for long time failure (Transmission controller system) DDNDLD The signal of the ripper tilt in oil pressure switch circuit is kept turned ON for 60 seconds. Recognizes that the oil pressure switch is turned OFF. The shoe slip control (SSC) function does not operate normally. The data of the VHMS may become abnormal. Ripper tilt in operation becomes slow. The input state (ON/OFF) from the ripper tilt in oil pressure switch can be checked in the monitoring mode. (Code 70305: Ripper lever oil pressure switch input signal) Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting 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 normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective ripper tilt in oil RT1 (male) Ripper lever Resistance 2 pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Tilt in Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (2) and RT1 (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC1, TMC2 Ripper lever Voltage 4 controller Neutral 5 11 V Between TMC2 (2) and TMC1 (4) Tilt in Max. 1 V
Circuit diagram related to ripper tilt in oil pressure switch
D475A, D475ASD-5E0
71
SEN01827-01
40 Troubleshooting
Failure code [DDNELD] (Ripper tilt back oil pressure switch: Switch is ON for long time 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Ripper tilt back oil pressure switch: Switch is ON for long time failure (Transmission controller system) DDNELD The signal of the ripper tilt back oil pressure switch circuit is kept turned ON for 60 seconds. Recognizes that the oil pressure switch is turned OFF. The shoe slip control (SSC) function does not operate normally. The tilt back speed of the ripper lowers. 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 monitoring mode. (Code 70305: Ripper lever oil pressure switch input signal) Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 60 seconds). Cause Standard values when normal and remarks for troubleshooting 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 normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective ripper tilt back oil RT8 (male) Ripper lever Resistance 2 pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Tilt back Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (38) and RT8 (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC1, TMC2 Ripper lever Voltage 4 controller Neutral 5 11 V Between TMC2 (38) and TMC1 (4) Tilt back Max. 1 V
Circuit diagram related to ripper tilt back oil pressure switch
72
D475A, D475ASD-5E0
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SEN01827-01
Failure code [DDNFLD] Blade lift lower full oil pressure switch: Switch is ON for long time 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade lift lower full pressure switch: Switch is ON for long time failure (Transmission controller system) DDNFLD The signal of the blade lift lower full oil pressure switch circuit is kept turned ON for 60 seconds. Recognizes that the oil pressure switch is turned OFF. The lift lower speed of the blade lowers. The data of the VHMS may become abnormal. The input state (ON/OFF) from the blade lift lower full oil pressure switch can be checked in the monitoring mode. (Code 40908: Ripper lever oil pressure switch input signal) Method of reproducing failure code: Turn the starting switch ON (Error is reproduced after 180 seconds). Cause Standard values when normal and remarks for troubleshooting 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 normal) was operated to cause an error. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective blade lift lower BLD (male) Blade lever Resistance 2 full oil pressure switch (Internal short circuit) Neutral Min. 1 Mz Between (1) and (2) Lower full Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 3 Between wiring harness between TMC2 (Contact with ground cirResis(female) (26) and BLD (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective transmission TMC1, TMC2 Ripper lever Voltage 4 controller Neutral 5 11 V TMC2 (26) TMC1 (4) Tilt in Max. 1 V
Circuit diagram related to blade lift lower full oil pressure switch
D475A, D475ASD-5E0
73
SEN01827-01
74
SEN01828-01
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
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
D475A, D475ASD-5E0
SEN01828-01
40 Troubleshooting
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 Failure code [dGT6KB] (or LED of VHMS controller indicates "n3" o "25") 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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
D475A, D475ASD-5E0
SEN01828-01
40 Troubleshooting
Failure code [DDQ2KA] Parking brake lever switch: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine
Failure code Symptom of Parking brake lever switch: Disconnection failure (Steering controller system) DDQ2KA Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same time. Flashes caution lamp and turns on caution buzzer. Recognizes parking brake lever is in Free position. Limits operation of engine, transmission, and brake.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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: DD14KA, DDQ2L4). Of signals of two systems of switch, NC is for operation detection and NO is for error detection. Input state (ON/OFF) from parking brake switch can be checked in monitoring mode. (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 Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between STCN2 (female) (5) Resis1 Max. 1 z in wiring or defective con- branched point of circuit JF2 tance tact in connector) Wiring harness between STCN2 (female) (15) ResisMax. 1 z branched point of circuit JF1 tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking brake lever STCN2 Defective steering Free position Lock position 2 controller Between (5) 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 Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Parking brake lever Parking brake lever NSW 1 switch Free position Lock position (Internal disconnection) Between (A) (B) Max. 1 z Min. 1 Mz Between (A) (B) Min. 1 Mz Max. 1 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between NSW (female) (B) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection TMC1 (female) (18), STCN2 (female) (5) 2 in wiring or defective con- Wiring harness between NSW (female) (C) ResisMax. 1 z tact in connector) TMC1 (female) (12), STCN2 (female) (15) tance Wiring harness between NSW (female) (A) ResisMax. 1 z chassis ground tance
General information
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between NSW Hot short in wiring har(female) (B) TMC1 (female) (18) STCN2 Voltage Max. 1 V 3 ness (Contact with 24 V (female) (5) with chassis ground circuit) Short circuit of wiring harness between NSW (female) (C) TMC1 (female) (12) STCN2 Voltage Max. 1 V (female) (15) with chassis ground
D475A, D475ASD-5E0
SEN01828-01
40 Troubleshooting
Failure code [DDQ2KB] Parking brake lever switch: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine
Failure code Symptom of Parking brake lever switch: Short circuit failure (Steering controller system) DDQ2KB Signals of both parking brake lever switch circuit systems are turned ON (closed) simultaneously. Flashes caution lamp and turns on caution buzzer. Recognizes that parking brake lever is at FREE position. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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) NC and NO signals of both switch systems are for detecting operation and error respectively. Inputting from parking brake switch (ON/OFF) can be checked in monitoring mode. (Code 40910: Steering controller input signal 1) Method of reproducing failure code: Turn starting switch ON (and operate parking brake lever). When failure codes [DDQ2KA] and [DD14KA] are displayed simultaneously Cause Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective parking brake Parking brake lever NSW (male) 1 lever switch (Internal At FREE At LOCK short circuit) Between (A) (B) Max. 1 z Min. 1 Mz Between (A) (B) Min. 1 Mz Max. 1 z a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit with chassis Short circuit of wiring harness between NSW Resisground in wiring harness (female) (B) TMC1 (female) (18) STCN2 Min. 1 Mz tance 2 (Contact with ground cir- (female) (5) with chassis ground cuit) Short circuit of wiring harness between NSW Resis(female) (C) TMC1 (female) (12) STCN2 Min. 1 Mz tance (female) (15) with chassis ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Parking brake lever STCN2 Defective steering At FREE At LOCK 3 controller Between (5) Max. 1 V 5 11 V chassis ground Between (15) 5 11 V Max. 1 V chassis ground
General information
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
D475A, D475ASD-5E0
SEN01828-01
40 Troubleshooting
Failure code [DDQ2L4] Parking brake lever switch: Disagreement of signals

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine Failure code Symptom of Parking brake lever switch: Disagreement of signals failure (Steering controller system) DDQ2L4 Switch input signal of steering controller disagrees with communication signal from transmission controller. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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 simultaneously, depending on troubled part. (Related codes: DAFRKR, DB2RKR, DB3RKR, DAQRKR, DD14KA, DD14KB, DDQ2KA, DDQ2KB) Inputting from parking brake switch (ONOFF) can be checked in monitoring mode. (Code 40910: Steering controller input signal 1) Method of reproducing failure code: Turn starting switch ON (and operate parking brake lever). Standard values when normal and remarks for troubleshooting See if failure codes [DAFRKR], [DBBQKR], [DB3RKR], and Defective CAN communi1 [DAQRKR] are displayed. If they are displayed, carry out troublecation signal system shooting for them first. Defective parking brake See if failure codes [DD14KA], [DD14KB], [DDQ2KA], and 2 lever switch signal sys[DDQ2KB] are displayed. If they are displayed, carry out troubletem shooting for them first. Defective steering con3 Since trouble is in system, troubleshooting cannot be carried out. troller Cause
General information
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [dDQ2L4] Parking brake lever switch: Disagreement of signals

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine Failure code Symptom of Parking brake lever switch: Disagreement of signals failure (Transmission controller system) dDQ2L4 Switch input signal of steering controller disagrees with communication signal from transmission controller. Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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 simultaneously, depending on troubled part. (Related codes: DAFRKR, DB2RKR, DB3RKR, DAQRKR, DD14KA, DD14KB, DDQ2KA, DDQ2KB) Inputting from parking brake switch (ONOFF) 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). Standard values when normal and remarks for troubleshooting See if failure codes [DAFRKR], [DBBQKR], [DB3RKR], and Defective CAN communi1 [DAQRKR] are displayed. If they are displayed, carry out troublecation signal system shooting for them first. Defective parking brake See if failure codes [DD14KA], [DD14KB], [DDQ2KA], and 2 lever switch signal sys[DDQ2KB] are displayed. If they are displayed, carry out troubletem shooting for them first. Defective steering con3 Since trouble is in system, troubleshooting cannot be carried out. troller Cause
General information
D475A, D475ASD-5E0
SEN01828-01
40 Troubleshooting
Failure code [DDT5KA] Neutral switch: Disconnection

Action code Failure code Symptom of Neutral switch: Disconnection (Transmission controller system) failure CALL E04 DDT5KA Failure content Signals of two systems of neutral switch circuit were turned OFF (OPEN) at the same time. Controller's Flashes caution lamp and turns on caution buzzer. action Recognizes that switch is pressed. Symptoms that Once machine is stopped, engine speed is limited to medium (half). 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 (Code 40906: Transmission controller input signal 2) information Method of reproducing failure code: Turn starting switch ON (and operate neutral switch).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Neutral switch SNC (male) Defective neutral switch OFF (Release) ON (Press) (Internal disconnection) Resistance between Max. 1 z Min. 1 Mz (4) (6) Resistance between Min. 1 Mz Max. 1 z (4) (5) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisWiring harness between TMC2 (female) (27) Disconnection in wiring Max. 1 z tance harness (Disconnection SNC (female) (6) in wiring or defective con- Wiring harness between TMC2 (female) (17) ResisMax. 1 z tact in connector) SNC (female) (5) tance Wiring harness between TMC1 (female) (10) ResisMax. 1 z SNC (female) (4) tance a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC2 Hot short in wiring har(female) (27) SNC (female) (6) with chassis Voltage Max. 1 V 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 a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift up switch TMC1,TMC2 OFF (Release) ON (Press) Defective transmission Voltage between controller TMC2 (27) Max. 1 V 5 11 V TMC1 (10) Voltage between TMC2 (17) 5 11 V Max. 1 V TMC1 (10)
Cause
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Circuit diagram related to neutral switch
D475A, D475ASD-5E0
11
SEN01828-01
40 Troubleshooting
Failure code [DDT5KB] Neutral switch: Short circuit

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Neutral switch: Short circuit (Transmission controller system) failure DDT5KB Signals of two systems of neutral switch circuit were turned ON (CLOSE) at the same time. Flashes caution lamp and turns on caution buzzer. Recognizes that switch is pressed. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Input state (ON/OFF) from neutral switch can be checked in monitoring mode. (Code 40906: Transmission controller input signal 2) Method of reproducing failure code: Turn starting switch ON (and operate neutral switch).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Neutral switch SNC (male) Defective neutral switch OFF (Release) ON (Press) 1 (Internal disconnection) Resistance between Max. 1 z Min. 1 Mz (4) (6) Resistance between Min. 1 Mz Max. 1 z (4) (5) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between TMC2 Resisground in wiring harness (female) (27) SNC (female) (6) with chassis Min. 1 Mz 2 tance (Contact with ground cir- ground cuit) Short circuit of wiring harness between TMC2 ResisMin. 1 Mz (female) (17) SNC (female) (5) with chassis tance ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Shift up switch TMC1, TMC2 OFF (Release) ON (Press) Defective transmission Voltage between 3 controller TMC2 (27) Max. 1 V 5 11 V TMC1 (10) Voltage between TMC2 (17) 5 11 V Max. 1 V TMC1 (10)
Cause
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Circuit diagram related to neutral switch
D475A, D475ASD-5E0
13
SEN01828-01
40 Troubleshooting
Failure code [DDT5KQ] Lever specification selection: Model selection signal disagreement 1
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Lever specification selection: Model selection signal disagreement failure (Transmission controller system) DDT5KQ Travel lever cannot select PCCS standard specification. Blinks warning lamp and sounds alarm buzzer. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel at all. Input state (ON/OFF) from neutral switch can be checked in monitoring mode (Code 40906: Transmission controller input signal 2) Method of reproducing failure code: Turn starting switch ON. Cause Ground fault in wiring 1 harness (Contact with GND circuit) Defective engine 2 controller or transmission controller 3 Defective transmission controller Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between ground and wiring harness between ResisMin. 1 Mz TMC2 (female) (17) SNC (female) (5) tance Between ground and wiring harness between ResisMin. 1 Mz TMC2 (female) (27) SNC (female) (6) tance If cause 1 is not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.) If causes 1 and 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to lever specification selection
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range 1
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Hydraulic oil temperature sensor: Input signal is out of normal range failure (Transmission controller system) DGS1KX Hydraulic oil temperature sensor signal is out of normal range. Does not take any particular action. Hydraulic oil temperature gauge of monitor panel may not display normally. Hydraulic oil temperature (temperature) can be checked in monitoring mode. (Code 04401: Hydraulic oil temperature) Method of reproducing failure code: Turn starting switch ON or start engine. Cause Defective hydraulic oil temperature sensor 1 (Internal disconnection or short circuit) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. SDS (male) Resistance Between (1) (2) 3.5 k 90 kz (10 100C) Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (14) ResisMax. 1 z SDS (female) (1) tance Wiring harness between TMC1 (female) (21) ResisMax. 1 z SDS (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMC1 Resis(female) (14) SDS (female) (1) with chassis Min. 1 Mz tance ground a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC1 (female) (14) SDS (female) (1) with chassis Voltage Max. 1 V ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TMC1 (female) Resistance Between (14) (21) 3.5 k 90 kz (10 100C) Between (14) chassis ground Min. 1 Mz
Disconnection in wiring harness (Disconnection 2 in wiring or defective contact in connector) Possible causes and the standard values when normal Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit) Short circuit with power 4 source in wiring harness (Contact with 24 V circuit)
Circuit diagram related to hydraulic oil temperature sensor
D475A, D475ASD-5E0
15
SEN01828-01
40 Troubleshooting
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Power train oil temperature sensor: Disconnection failure (Machine monitor system) DGT1KA The power train temperature sensor signal is lower than the specified value. Nothing particular. Power train oil temperature on machine monitor is not displayed properly. Fan speed is limited to half. Gear shift shock of transmission is large. Power train temperature state (temperature) can be checked in monitoring mode. (Code 30100: Power train oil temperature) Duplication of failure code: Turn starting switch ON or start engine.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective power train oil 453 (male) Resistance temperature sensor (Short circuit) Between (1) (2) 3.5 kz 90 kz (10 100C) Between (1), (2) and ground Min. 1 Mz a a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between S04 (female) (12) ResisMax. 1 z Defective harness 453 (female) (1) tance grounding (contact with Wiring harness between S03 (female) (3) Resisground circuit) Max. 1 z 453 (female) (2) tance Wiring harness between S03 (female) (4) ResisMax. 1 z 453 (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch Hot short of wiring still OFF. harness Between ground and wiring harness between (contact with 24 V circuit) Voltage Max. 1V S04 (female) (12) 453 (female) (1) a Prepare with starting switch OFF and diagnose with starting switch ON. Defective machine monitor 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 in causes 1 4 (since this is an internal defect, it cannot be diagmonitor nosed).
Causes
16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Circuit diagram related to power train oil temperature sensor
D475A, D475ASD-5E0
17
SEN01828-01
40 Troubleshooting
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 failure (Machine monitor system) E01 DGT1KX 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. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Defective power train oil 453 (male) Resistance temperature sensor (Short circuit) Between (1) (2) 3.5 kz 90 kz (10 100C) Between (1), (2) and ground Min. 1 Mz a Prepare with starting switch OFF and diagnose with starting switch Defective harness still OFF. grounding (contact with Between ground and wiring harness between Resisground circuit) Min. 1 Mz S04 (female) (12) 453 (female) (1) tance a Prepare with starting switch OFF and diagnose with starting switch Hot short of wiring ON. harness Between ground and wiring harness between (contact with 24 V circuit) Voltage Max. 1V S04 (female) (12) 453 (female) (1) Defective machine Since this is an internal defect, it cannot be diagnosed. monitor Causes
Circuit diagram related to power train oil temperature sensor
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
D475A, D475ASD-5E0
19
SEN01828-01
40 Troubleshooting
Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front): Disconnection (or LED of VHMS controller indicates "n3" o "12")
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left bank exhaust temperature sensor system (Front): Disconnection failure (VHMS controller system) DGT5KA The signal voltage of the left bank exhaust temperature sensor is below 0.5 V. None in particular. The left bank exhaust temperature cannot be monitored with the monitoring function. The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n3" o "12". Causes Standard values when normal and remarks for troubleshooting Abnormal rise of left bank 1 exhaust temperature Check the engine, then repair it if it has any abnormality. (When system is normal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the left bank exhaust temperature senDefective left bank Exhaust temperature sor (Front) is replaced, the condition does not 2 exhaust temperature sensor is normal become normal. sensor When the left bank exhaust temperature senExhaust temperature sor (Front) is replaced, the condition becomes sensor is defective normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 30 V Before Defective left bank Approx. engine is 20C Voltage exhaust temperature 0.9 1.2 V 3 EXA2 started sensor Between V1, V2A After amplifier (B) and line engine is (C) Approx. started 500C Voltage 2.6 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between V1 (female) (2) and ResisMax. 1 z EXA2 (female) (A) tance Wiring harness between V2A (female) (7) and ResisDisconnection in wiring Max. 1 z tance harness (Disconnection EXA2 (female) (B) 4 in wiring harness or Wiring harness between V2A (female) (13) ResisMax. 1 z defective contact) and EXA2 (female) (C) tance Wiring harness between EXT2 (female) (1) ResisMax. 1 z and EXTLF (female) (1) tance Wiring harness between EXT2 (female) (2) ResisMax. 1 z and EXTLF (female) (2) tance
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Causes
Defective VHMS controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and V2A (13) Voltage 20 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. V2A Exhaust temperature Voltage Before engine is 20C Approx. 0.9 1.2 V Between started (7) and After engine is started (13) 500C Approx. 2.6 3.5 V (with no load)
Circuit diagram related to left bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
21
SEN01828-01
40 Troubleshooting
Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear): Disconnection (or LED of VHMS controller indicates "n3" o "22") 1
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left bank exhaust temperature sensor system (Rear): Disconnection failure (VHMS controller system) dGT5KA The signal voltage of the left bank exhaust temperature sensor is below 0.5 V. None in particular. The left bank exhaust temperature cannot be monitored with the monitoring function. The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n3" o "12". Causes Standard values when normal and remarks for troubleshooting Abnormal rise of left bank 1 exhaust temperature Check the engine, then repair it if it has any abnormality. (When system is normal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the left bank exhaust temperature senDefective left bank Exhaust temperature sor (Rear) is replaced, the condition does not 2 exhaust temperature sensor is normal become normal. sensor When the left bank exhaust temperature senExhaust temperature sor (Rear) is replaced, the condition becomes sensor is defective normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 30 V Before Defective left bank Approx. engine is 20C Voltage exhaust temperature 0.9 1.2 V 3 EXA4 started sensor Between V1, V2A After amplifier (B) and line engine is (C) Approx. started 500C Voltage 2.6 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between V1 (female) (2) and ResisMax. 1 z EXA4 (female) (A) tance Wiring harness between V2A (female) (6) and ResisDisconnection in wiring Max. 1 z tance harness (Disconnection EXA4 (female) (B) 4 in wiring harness or Wiring harness between V2A (female) (13) ResisMax. 1 z defective contact) and EXA4 (female) (C) tance Wiring harness between EXT4 (male) (1) and ResisMax. 1 z EXTLR (female) (1) tance Wiring harness between EXT4 (male) (2) and ResisMax. 1 z EXTLR (female) (2) tance
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Causes
Circuit diagram related to left bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
23
SEN01828-01
40 Troubleshooting
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 content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left bank exhaust temperature sensor system (Front): Short circuit failure (VHMS controller system) DGT5KB The signal voltage of the left bank exhaust temperature sensor is above 4.9 V. None in particular. The left bank exhaust temperature cannot be monitored with the monitoring function. The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n3" o "11". Causes Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the left bank exhaust temperature senExhaust temperature sor is replaced, the condition does not sensor is normal become normal. When the left bank exhaust temperature senExhaust temperature sor is replaced, the condition becomes norsensor is defective mal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 30 V Before Approx. engine is 20C Voltage 0.9 1.2 V EXA2 started Between V1, V2A After (B) and line engine is (C) Approx. started 500C Voltage 2.6 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA2 (female) (A) and chassis ground tance Between wiring harness between V2A Resis(female) (7) and EXA2 (female) (B) and chasMin. 1 Mz tance sis ground Between wiring harness between EXT2 Resis(male) (1) and EXTLF (female) (1) and chasMin. 1 Mz tance sis ground Between wiring harness between EXT2 ResisMin. 1 Mz (male) (2) and EXTLF (female) (2) and chastance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA2 (female) (B), (C) tance
Defective left bank 1 exhaust temperature sensor
Defective left bank exhaust temperature 2 sensor amplifier Possible causes and the standard values when normal
Short circuit with power source in wiring harness 4 (Contact with 24-V circuit)
24
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and V2A (13) Voltage 20 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective VHMS control5 ler V2A Exhaust temperature Voltage Before engine is 20C Approx. 0.9 1.2 V Between started (7) and After engine is started (13) 500C Approx. 2.6 3.5 V (with no load)
Causes
Circuit diagram related to left bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
25
SEN01828-01
40 Troubleshooting
Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" o "21") Left bank exhaust temperature sensor system (Rear): Short circuit
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left bank exhaust temperature sensor system (Rear): Short circuit failure (VHMS controller system) dGT5KB The signal voltage of the left bank exhaust temperature sensor is above 4.9 V. None in particular. The left bank exhaust temperature cannot be monitored with the monitoring function.
The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n3" o "21". Causes Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the left bank exhaust temperature senExhaust temperature sor is replaced, the condition does not sensor is normal become normal. When the left bank exhaust temperature senExhaust temperature sor is replaced, the condition becomes norsensor is defective mal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 30 V Before Approx. engine is 20C Voltage 0.9 1.2 V started EXA4 Between V1, V2A After (B) and line engine is (C) Approx. started 500C Voltage 2.6 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA4 (female) (A) and chassis ground tance Between wiring harness between V2A Resis(female) (6) and EXA4 (female) (B) and chasMin. 1 Mz tance sis ground Between wiring harness between EXT4 ResisMin. 1 Mz (male) (1) and EXTLR (female) (1) and chastance sis ground Between wiring harness between EXT4 Resis(male) (2) and EXTLR (female) (2) and chasMin. 1 Mz tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA4 (female) (B), (C) tance
Defective left bank 1 exhaust temperature sensor
Defective left bank exhaust temperature 2 sensor amplifier Possible causes and the standard values when normal
Short circuit with power source in wiring harness 4 (Contact with 24-V circuit)
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and V2A (13) Voltage 20 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective VHMS control5 ler V2A Exhaust temperature Voltage Before engine is 20C Approx. 0.9 1.2 V Between started (6) and After engine is started (13) 500C Approx. 2.6 3.5 V (with no load)
Causes
Circuit diagram related to left bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
27
SEN01828-01
40 Troubleshooting
Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o "24") Right bank exhaust temperature sensor system (Front): Disconnection
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right bank exhaust temperature sensor system (Front): Disconnecfailure tion (VHMS controller system) DGT6KA The signal voltage of the right bank exhaust temperature sensor is below 0.5 V. None in particular. The right bank exhaust temperature cannot be monitored with the monitoring function.
The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n3" o "24". Causes Standard values when normal and remarks for troubleshooting Abnormal rise of right bank exhaust tempera1 Check the engine, then repair it if it has any abnormality. ture (When system is normal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the right bank exhaust temperature Defective right bank Exhaust temperature sensor (Front) is replaced, the condition does 2 exhaust temperature sensor is normal not become normal. sensor When the right bank exhaust temperature Exhaust temperature sensor (Front) is replaced, the condition sensor is defective becomes normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 30 V Before Approx. Defective right bank engine is 20C Voltage 0.9 1.2 V 3 exhaust temperature EXA1 started Between sensor amplifier V1, V2A After (B) and line engine is (C) Approx. started 500C Voltage 2.6 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between V1 (female) (2) and ResisMax. 1 z EXA1 (female) (A) tance Wiring harness between V2A (female) (5) and ResisDisconnection in wiring Max. 1 z tance harness (Disconnection EXA1 (female) (B) 4 in wiring harness or Wiring harness between V2A (female) (13) ResisMax. 1 z defective contact) and EXA1 (female) (C) tance Wiring harness between EXT1 (male) (1) and ResisMax. 1 z EXTRF (female) (1) tance Wiring harness between EXT1 (male) (2) and ResisMax. 1 z EXTRF (female) (2) tance
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Causes
Circuit diagram related to right bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
29
SEN01828-01
40 Troubleshooting
Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o "26") Right bank exhaust temperature sensor system (Rear): Disconnection
Failure code Symptom of Right bank exhaust temperature sensor system (Rear): Disconnection failure (VHMS controller system) dGT6KA The signal voltage of the right bank exhaust temperature sensor is below 0.5 V. None in particular. The right bank exhaust temperature cannot be monitored with the monitoring function. The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n3" o "26". Causes Standard values when normal and remarks for troubleshooting Abnormal rise of right bank exhaust tempera1 Check the engine, then repair it if it has any abnormality. ture (When system is normal) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the right bank exhaust temperature Defective right bank Exhaust temperature sensor (Rear) is replaced, the condition does 2 exhaust temperature sensor is normal not become normal. sensor When the right bank exhaust temperature Exhaust temperature sensor (Rear) is replaced, the condition sensor is defective becomes normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 30 V Before Approx. Defective right bank engine is 20C Voltage 0.9 1.2 V 3 exhaust temperature EXA3 started Between sensor amplifier V1, V2A After (B) and line engine is (C) Approx. started 500C Voltage 2.6 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between V1 (female) (2) and ResisMax. 1 z EXA3 (female) (A) tance Wiring harness between V2A (female) (16) ResisDisconnection in wiring Max. 1 z tance harness (Disconnection and EXA3 (female) (B) 4 in wiring harness or Wiring harness between V2A (female) (13) ResisMax. 1 z defective contact) and EXA3 (female) (C) tance Wiring harness between EXT3 (male) (1) and ResisMax. 1 z EXTRR (female) (1) tance Wiring harness between EXT3 (male) (2) and ResisMax. 1 z EXTRR (female) (2) tance
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Causes
Circuit diagram related to right bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
31
SEN01828-01
40 Troubleshooting
Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o "23") Right bank exhaust temperature sensor system (Front): Short circuit
Failure code Symptom of Right bank exhaust temperature sensor system (Front): Short circuit failure (VHMS controller system) DGT6KB The signal voltage of the right bank exhaust temperature sensor is above 4.9 V. None in particular. The right bank exhaust temperature cannot be monitored with the monitoring function. The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n3" o "23". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the right bank exhaust temperature Defective right bank Exhaust temperature sensor (Front) is replaced, the condition does 1 exhaust temperature sensor is normal not become normal. sensor When the right bank exhaust temperature Exhaust temperature sensor (Front) is replaced, the condition sensor is defective becomes normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 30 V Before Approx. Defective right bank engine is 20C Voltage 0.9 1.2 V 2 exhaust temperature started EXA1 Between sensor amplifier V1, V2A After (B) and line engine is (C) Approx. started 500C Voltage 2.6 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA1 (female) (A) and chassis ground tance Between wiring harness between V2A Short circuit with chassis Resis(female) (5) and EXA1 (female) (B) and chasMin. 1 Mz ground in wiring harness tance 3 sis ground (Contact with ground cirBetween wiring harness between EXT1 cuit) ResisMin. 1 Mz (male) (1) and EXTRF (female) (1) and chastance sis ground Between wiring harness between EXT1 Resis(male) (2) and EXTRF (female) (2) and chasMin. 1 Mz tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting Hot short in wiring harwithout turning starting switch ON. 4 ness (Contact with 24-V Between wiring harness between V1 (female) Resiscircuit) Min. 1 Mz (2) and EXA1 (female) (B), (C) tance Causes
32
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Causes
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and chassis ground Voltage 20 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. V2A Exhaust temperature Voltage Before engine is 20C Approx. 0.9 1.2 V Between started (5) and After engine is started (13) 500C Approx. 2.6 3.5 V (with no load)
Circuit diagram related to right bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
33
SEN01828-01
40 Troubleshooting
Failure code [dGT6KB] (or LED of VHMS controller indicates "n3" o "25") Right bank exhaust temperature sensor system (Rear): Short circuit
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right bank exhaust temperature sensor system (Rear): Short circuit failure (VHMS controller system) dGT6KB The signal voltage of the right bank exhaust temperature sensor is above 4.9 V. None in particular. The right bank exhaust temperature cannot be monitored with the monitoring function.
The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n3" o "25". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. When the right bank exhaust temperature Defective right bank Exhaust temperature sensor (Rear) is replaced, the condition does 1 exhaust temperature sensor is normal not become normal. sensor When the right bank exhaust temperature Exhaust temperature sensor (Rear) is replaced, the condition sensor is defective becomes normal. a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between (A) and (C) Voltage 20 30 V Before Approx. Defective right bank engine is 20C Voltage 0.9 1.2 V 2 exhaust temperature started EXA3 Between sensor amplifier V1, V2A After (B) and line engine is (C) Approx. started 500C Voltage 2.6 3.5 V (with no load) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between V1 (female) ResisMin. 1 Mz (2) and EXA3 (female) (A) and chassis ground tance Between wiring harness between V2A Short circuit with chassis Resis(female) (16) and EXA3 (female) (B) and Min. 1 Mz ground in wiring harness tance 3 chassis ground (Contact with ground cirBetween wiring harness between EXT3 cuit) ResisMin. 1 Mz (male) (1) and EXTRR (female) (1) and chastance sis ground Between wiring harness between EXT3 Resis(male) (2) and EXTRR (female) (2) and chasMin. 1 Mz tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting Hot short in wiring harwithout turning starting switch ON. 4 ness (Contact with 24-V Between wiring harness between V1 (female) Resiscircuit) Min. 1 Mz (2) and EXA3 (female) (B), (C) tance Causes
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Causes
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Between V1 (2) and chassis ground Voltage 20 30 V a Prepare with starting switch OFF, then start engine and carry out troubleshooting. V2A Exhaust temperature Voltage Before engine is 20C Approx. 0.9 1.2 V Between started (16) and After engine is started (13) 500C Approx. 2.6 3.5 V (with no load)
Circuit diagram related to right bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
35
SEN01828-01
40 Troubleshooting
Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Work equipment pump oil pressure sensor (F): Disconnection failure (Transmission controller system) DH22KA Signal voltage of work equipment pump oil pressure sensor (F) circuit is below 0.2 V. Does not take any particular action. Work equipment pump (F) oil pressure cannot be monitored. Input (Voltage) from work equipment pump oil pressure sensor (F) can be checked in monitoring mode. (Code 70701: Voltage of work equipment pump oil sensor (F)) Method of reproducing failure code: Turn starting switch ON. Causes Defective 5 V power 1 source system Defective work equipment pump oil pressure 2 sensor (F) (Internal trouble) Standard values when normal and remarks for troubleshooting See if error code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. HP1 Voltage Between (C) (A) 0.5 6.0 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (34) ResisMax. 1 z HP1 (female) (B) tance ResisWiring harness between TMC1 (female) (9) Max. 1 z HP1 (female) (C) tance Wiring harness between TMC1 (female) (21) ResisMax. 1 z HP1 (female) (A) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMC1 ResisMin. 1 Mz (female) (9) HP1 (female) (C) with chassis tance ground Transmission controller can be suspected to be defective if no problem is found in causes 1 4 (since this is an internal defect, it cannot be diagnosed).
Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit) 5 Defective transmission controller
Circuit diagram related to work equipment pump oil pressure sensor (F)
36
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Work equipment pump oil pressure sensor (F): Short circuit failure (Transmission controller system) DH22KB Signal voltage of work equipment pump oil pressure sensor (F) circuit is above 4.8 V Does not take any particular action. Work equipment pump (F) oil pressure cannot be monitored. Input (Voltage) from work equipment pump oil pressure sensor (F) can be checked in monitoring mode. (Code 70701: Voltage of work equipment pump oil pressure sensor (F)) Method of reproducing failure code: Turn starting switch ON. Causes Defective 5 V power 1 source system Standard values when normal and remarks for troubleshooting See if error code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, turn starting switch ON and carry Defective work equipout troubleshooting. ment pump oil pressure 2 sensor (F) (Internal trouHP1 Voltage ble) Between (C) (A) 0.5 6.0 V a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Hot short in wiring har3 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 Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (F)
D475A, D475ASD-5E0
37
SEN01828-01
40 Troubleshooting
Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Work equipment pump oil pressure sensor (R): Disconnection failure (Transmission controller system) DH23KA Signal voltage of work equipment pump oil pressure sensor (R) circuit is below 0.2 V. Does not take any particular action. Work equipment pump (R) oil pressure cannot be monitored. Input (Voltage) from work equipment pump oil pressure sensor (R) can be checked in monitoring mode. (Code 70703: Voltage of work equipment pump oil sensor (R)) Method of reproducing failure code: Turn starting switch ON. Causes Defective 5 V power 1 source system Defective work equipment pump oil pressure 2 sensor (R) (Internal trouble) Standard values when normal and remarks for troubleshooting See if error code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. HP2 Voltage Between (C) (A) 0.5 6.0 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (34) ResisMax. 1 z HP2 (female) (B) tance ResisWiring harness between TMC1 (female) (3) Max. 1 z HP2 (female) (C) tance Wiring harness between TMC1 (female) (21) ResisMax. 1 z HP2 (female) (A) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between TMC1 ResisMin. 1 Mz (female) (3) HP2 (female) (C) with chassis tance ground Transmission controller can be suspected to be defective if no problem is found in causes 1 4 (since this is an internal defect, it cannot be diagnosed).
Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit) 5 Defective transmission controller
Circuit diagram related to work equipment pump oil pressure sensor (R)
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Work equipment pump oil pressure sensor (R): Short circuit failure (Transmission controller system) DH23KB Signal voltage of work equipment pump oil pressure sensor (R) circuit is above 4.8 V Does not take any particular action. Work equipment pump (R) oil pressure cannot be monitored. Input (Voltage) from work equipment pump oil pressure sensor (R) can be checked in monitoring mode. (Code 70703: Voltage of work equipment pump oil pressure sensor (R)) Method of reproducing failure code: Turn starting switch ON. Causes Defective 5 V power 1 source system Standard values when normal and remarks for troubleshooting See if error code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, turn starting switch ON and carry Defective work equipout troubleshooting. ment pump oil pressure 2 sensor (R) (Internal trouHP2 Voltage ble) Between (C) (A) 0.5 6.0 V a Prepare with starting switch OFF, turn starting switch ON and carry out troubleshooting. Hot short in wiring har3 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 Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 3 (since this is an internal defect, it cannot controller be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (R)
D475A, D475ASD-5E0
39
SEN01828-01
40 Troubleshooting
Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o "32") Blow-by pressure sensor system: Disconnection
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blow-by pressure sensor system: Disconnection failure (VHMS controller system) DHE5KB The signal voltage of the blow-by pressure sensor is below 0.1 V. None in particular. The blow-by pressure cannot be monitored with the monitoring function.
The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the error code can be checked.) The LED of the VHMS controller indicates "n3" o "32". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blow-by presENBP Voltage 1 sure sensor Between (B) and (A) 4.5 5.5 V Between (C) and (A) 0.3 0.7 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between V1 (female) (4) and Resis2 Max. 1 z in wiring harness or ENBP (female) (B) tance defective contact) Wiring harness between 2A (female) (18) and ResisMax. 1 z ENBP (female) (C) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 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) Causes
Circuit diagram related to blow-by pressure sensor
40
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o "31") Blow-by pressure sensor system: Hot short
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blow-by pressure sensor system: Hot short failure (VHMS controller system) DHE5KY The signal voltage of the blow-by pressure sensor is above 4.7 V. None in particular. The blow-by pressure cannot be monitored with the monitoring function.
The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the error code can be checked.) The LED of the VHMS controller indicates "n3" o "31". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blow-by presENBP Voltage 1 sure sensor Between (B) and (A) 4.5 5.5 V Between (C) and (A) 0.3 0.7 V a Prepare with starting switch OFF, then carry out troubleshooting Hot short in wiring harwithout turning starting switch ON. 2 ness (Contact with 24-V Between ground and wiring harness between circuit) Voltage Max. 1 V V2 (female) (18) and ENBP (female) (C) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 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) Causes
D475A, D475ASD-5E0
41
SEN01828-01
40 Troubleshooting
Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o "14") Transmission oil pressure sensor: Out of input signal range
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Transmission oil pressure sensor: Out of input signal range failure (VHMS controller system) DHT3KX Signal voltage of transmission oil pressure sensor is abnormal (below 0.3 V or about 4.9 V). None in particular. The system may not operate normally.
The machine monitor does not display the failure code. (If the data saved in the VHMS controller are downloaded to a personal computer, however, the failure code can be checked.) The LED of the VHMS controller indicates "n6" o "14". Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection Wiring harness between V1 (female) (2) and Resis1 Max. 1 z in wiring harness or TMMD (female) (B) tance defective contact) Wiring harness between V2A (female) (15) ResisMax. 1 z and TMMD (female) (C) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Between wiring harness between V1 (female) Resisground in wiring harness (2) and TMMD (female) (B) and chassis Min. 1 Mz 2 tance (Contact with ground cir- ground cuit) Between wiring harness between V2A ResisMin. 1 Mz (female) (15) and TMMD (female) (C) and tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring har3 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 a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective VHMS 4 controller V1 and V2A Voltage Between V1 (2) and V2A (12) Below 20 30 V Causes
Circuit diagram related to transmission oil pressure sensor
42
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [DK01KA] Left yoke angle sensor: Disconnection

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left yoke angle sensor: Disconnection failure (Transmission controller system) DK01KA The signal voltage of the left yoke angle sensor circuit is lower than the specified value. Flashes the caution lamp and turns on the caution buzzer. The tilt limiting system does not function.
The input state (voltage) from the left yoke angle sensor can be checked in the monitoring mode. (Code 90002: Left yoke angle sensor voltage) Method of reproducing failure code: Turn the starting switch ON. Causes Defective sensor 5-V 1 power supply system Defective left yoke angle sensor 2 (Internal disconnection or short circuit) Standard values when normal and remarks for troubleshooting If error code [DAQ7KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CSL (male) Resistance Between (A) and (C) 4.0 6.0 kz Between (A) and (B) 0.25 7.0 kz Between (B) and (C) 0.25 7.0 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisWiring harness between TMC3 (female) (34) Max. 1 z and CSL (female) (A) tance Wiring harness between TMC1 (female) (7) ResisMax. 1 z and CSL (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMC1 ResisMin. 1 Mz (female) (7) and CSL (female) (B) and chassis tance ground Transmission controller can be suspected to be defective if no problem is found in causes 1 4 (since this is an internal defect, it cannot be diagnosed).
Disconnection in wiring harness (Disconnection 3 in wiring harness or defective contact in connector) Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit) 5 Defective transmission controller
Circuit diagram related to left yoke angle sensor
D475A, D475ASD-5E0
43
SEN01828-01
40 Troubleshooting
Failure code [DK01KB] Left yoke angle sensor: Short circuit

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left yoke angle sensor: Short circuit failure (Transmission controller system) DK01KB The signal voltage of the left yoke angle sensor circuit is higher than the specified value. Flashes the caution lamp and turns on the caution buzzer. The tilt limiting system does not function.
The input state (voltage) from the left yoke angle sensor can be checked in the monitoring mode. (Code 90002: Left yoke angle sensor voltage) Method of reproducing failure code: Turn the starting switch ON. Standard values when normal and remarks for troubleshooting If error code [DAQ7KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left yoke angle CSL (male) Resistance sensor 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 a Prepare with starting switch OFF, then turn starting switch ON and Short circuit with power carry out troubleshooting. source in wiring harness 3 Between wiring harness between TMC1 (Contact with 24-V cir(female) (7) and CSL (female) (B) and chassis Voltage Max. 1 V cuit) ground Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 3 (since this is an internal defect, it cannot 4 controller be diagnosed). Causes Defective sensor 5-V 1 power supply system
Circuit diagram related to left yoke angle sensor
44
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [DK03KA] Right yoke angle sensor: Disconnection

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right yoke angle sensor: Disconnection failure (Transmission controller system) DK03KA The signal voltage of the right yoke angle sensor circuit is lower than the specified value. Flashes the caution lamp and turns on the caution buzzer. The tilt limiting system does not function.
The input state (voltage) from the right yoke angle sensor can be checked in the monitoring mode. (Code 90003: Right yoke angle sensor voltage) Method of reproducing failure code: Turn the starting switch ON. Causes Defective sensor 5-V 1 power supply system Defective right yoke angle sensor 2 (Internal disconnection or short circuit) Standard values when normal and remarks for troubleshooting If error code [DAQ7KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. CSR (male) Resistance Between (A) and (C) 4.0 6.0 kz Between (A) and (B) 0.25 7.0 kz Between (B) and (C) 0.25 7.0 kz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ResisWiring harness between TMC3 (female) (34) Max. 1 z and CSR (female) (A) tance Wiring harness between TMC1 (female) (13) ResisMax. 1 z and CSR (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMC1 ResisMin. 1 Mz (female) (13) and CSR (female) (B) and chastance sis ground Transmission controller can be suspected to be defective if no problem is found in causes 1 4 (since this is an internal defect, it cannot be diagnosed).
Disconnection in wiring harness (Disconnection 3 in wiring harness or defective contact in connector) Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit) 5 Defective transmission controller
Circuit diagram related to right yoke angle sensor
D475A, D475ASD-5E0
45
SEN01828-01
40 Troubleshooting
Failure code [DK03KB] Right yoke angle sensor: Short circuit

Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right yoke angle sensor: Short circuit failure (Transmission controller system) DK03KB The signal voltage of the right yoke angle sensor circuit is higher than the specified value. Flashes the caution lamp and turns on the caution buzzer. The tilt limiting system does not function.
The input state (voltage) from the right yoke angle sensor can be checked in the monitoring mode. (Code 90003: Right yoke angle sensor voltage) Method of reproducing failure code: Turn the starting switch ON. Standard values when normal and remarks for troubleshooting If error code [DAQ7KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right yoke CSR (male) Resistance angle sensor 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 a Prepare with starting switch OFF, then turn starting switch ON and Short circuit with power carry out troubleshooting. source in wiring harness 3 Between wiring harness between TMC1 (Contact with 24-V cir(female) (13) and CSR (female) (B) and chas- Voltage Max. 1 V cuit) sis ground Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 3 (since this is an internal defect, it cannot 4 controller be diagnosed). Causes Defective sensor 5-V 1 power supply system
Circuit diagram related to right yoke angle sensor
46
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [DK10KA] Fuel dial: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fuel dial: Disconnection failure (Steering controller system) DK10KA Signal voltage of fuel dial circuit is lower than the specified value. Flashes warning lamp and turns on alarm buzzer. Continues to control with decelerator pedal potentiometer signal. Operation of engine and transmission is limited.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input state (voltage) from fuel dial can be checked in monitoring mode. (Code 03000: Fuel dial voltage) Duplication of failure code: turn ON the starting switch. Causes Defective sensor 5V 1 power supply circuit Standard values when normal and remarks for troubleshooting Check if failure code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch still OFF. DIAL (male) Resistance Between (1) (3) 4.0 6.0 kz Between (1) (2) 0.5 4.5 kz Between (2) (3) 0.5 4.5 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between STCN1 (female) (22) ResisMax. 1 z DIAL (female) (1) tance Wiring harness between STCN1 (female) (8) ResisMax. 1 z DIAL (female) (2) tance Wiring harness between STCN1 (female) (21) ResisMax. 1 z DIAL (female) (3) tance a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between ResisMin. 1 Mz STCN1 (female) (22) DIAL (female) (1) tance Between ground and wiring harness between ResisMin. 1 Mz STCN1 (female) (8) DIAL (female) (2) tance a Prepare with starting switch OFF and diagnose with starting switch ON. STCN1 Voltage Between (22) (21) 4.6 5.4 V Between (8) (21) 0.5 4.5 V
Defective fuel dial 2 (internal disconnection and short circuit)
Defective steering and transmission controller
Circuit diagram related to fuel dial
D475A, D475ASD-5E0
47
SEN01828-01
40 Troubleshooting
Failure code [DK10KB] Fuel dial: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fuel dial: Short circuit failure (Steering controller system) DK10KB Signal voltage of fuel dial circuit is higher than the specified value. Flashes warning lamp and turns on alarm buzzer. Continues to control with decelerator pedal potentiometer signal. Operation of engine and transmission is limited.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input state (voltage) from fuel dial can be checked in monitoring mode. (Code 03000: Fuel dial voltage) Duplication of failure code: turn ON the starting switch. Causes Defective sensor 5 V 1 power supply circuit Standard values when normal and remarks for troubleshooting Check if failure code [DAQ7KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF and diagnose with starting switch still OFF. DIAL (male) Resistance Between (1) (3) 4.0 6.0 kz Between (1) (2) 0.5 4.5 kz Between (2) (3) 0.5 4.5 kz a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harness between STCN1 (female) (21) DIAL (female) (3) Resistance Max. 1 z
Defective fuel dial 2 (internal disconnection and short circuit)
a Prepare with starting switch OFF and diagnose with starting switch ON. Between ground and wiring harness between Voltage Max. 1V Hot short of wiring harSTCN1 (female) (22) DIAL (female) (1) 4 ness (contact with 24 V circuit) Between ground and wiring harness between Voltage Max. 1V STCN1 (female) (8) DIAL (female) (2) Between ground and wiring harness between Voltage Max. 1V STCN1 (female) (21) DIAL (female) (3) a Prepare with starting switch OFF and diagnose with starting switch ON. Defective steering and STCN1 Voltage 5 transmission controller 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
40 Troubleshooting
SEN01828-01
Failure code [DK30KA] Steering potentiometer (1): Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering potentiometer (1): Disconnection failure (Steering controller system) DK30KA Signal voltage of steering potentiometer (1) system (L) is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer (2) system (R). Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from steering potentiometer (1) (L) can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer (1)) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Defective 5 V sensor 1 power source system Defective steering potentiometer (1) 2 (Internal disconnection or short circuit) Standard values when normal and remarks for troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL2 (male) Resistance Between (5) (8) 3.2 kz 20% Between (7) (5) 1 6 kz (Right left steering) Between (7) (8) 6 1 kz (Right left steering) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN1 (female) (22) ResisMax. 1 z TL2 (female) (5) tance Wiring harness between STCN1 (female) (2) ResisMax. 1 z TL2 (female) (7) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisSTCN1 (female) (22) TL2 (female) (5) with Min. 1 Mz tance chassis ground Short circuit of wiring harness between ResisMin. 1 Mz STCN1 (female) (2) TL2 (female) (7) with tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN1 Voltage Between (2) (21) 0.5 4.5 V
Defective steering controller
Circuit diagram related to steering potentiometer
D475A, D475ASD-5E0
49
SEN01828-01
40 Troubleshooting
Failure code [DK30KB] Steering potentiometer (1): Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering potentiometer (1): Short circuit failure (Steering controller system) DK30KB Signal voltage of steering potentiometer (1) system (L) is higher than specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer (2) system (R). Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from steering potentiometer (1) (L) can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer (1)) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Defective 5 V sensor 1 power source system Defective steering potentiometer 1 2 (Internal disconnection or short circuit) Standard values when normal and remarks for troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL2 (male) Resistance Between (5) (8) 3.2 kz 20% Between (7) (5) 1 6 kz (Right left steering) Between (7) (8) 6 1 kz (Right left steering) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between STCN1 (female) (22) TL2 (female) (5) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between STCN1 (female) (2) TL2 (female) (7) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN1 Voltage Between (2) (21) 0.5 4.5 V
Short circuit with power 3 source in wiring harness (Contact with 24 V circuit)
50
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range 1
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering potentiometer (1): Input signal is out of normal range failure (Steering controller system) DK30KX Either of failure codes [DK30KA] and [DK30KB] of steering potentiometer systems (1) and (2) and failure codes [DK31KA] and [DK31KB] are displayed simultaneously. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Input (Voltage) from steering potentiometers can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer (1)) (Code 50301: Voltage of steering potentiometer (2)) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Standard values when normal and remarks for troubleshooting
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
D475A, D475ASD-5E0
51
SEN01828-01
40 Troubleshooting
Failure code [DK30KZ] Steering potentiometer (1): Disconnection or short circuit

Failure code Symptom of Steering potentiometer (1): Disconnection or short circuit failure (Steering controller system) DK30KZ When starting switch is turned ON, either of steering potentiometer systems (1) and (2) is abnormal, then either of failure codes [DK30KA] and [DK30KB] and failure codes [DK31KA] and [DK31KB] are displayed simultaneously. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Input (Voltage) from steering potentiometers can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer (1)) (Code 50301: Voltage of steering potentiometer (2)) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Standard values when normal and remarks for troubleshooting
52
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [DK30L8] Steering potentiometer (1): See table

Failure code Symptom of Steering potentiometer (1): See table failure (Steering controller system) DK30L8 Total signal voltage of each of steering potentiometer (1) system (ST1) and (2) system (ST2) is out of the specified range. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of normal one of steering potentiometer (1) system (ST1) and (2) (ST2). Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from steering potentiometers can be checked in monitoring mode. (Code 50300: Voltage of steering potentiometer (1)) (Code 50301: Voltage of steering potentiometer (2)) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Standard values when normal and remarks for troubleshooting
D475A, D475ASD-5E0
53
SEN01828-01
40 Troubleshooting
Failure code [DK31KA] Steering potentiometer (2): Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering potentiometer (2): Disconnection failure (Steering controller system) DK31KA Signal voltage of steering potentiometer (2) system (R) is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer (1) system (L). Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from steering potentiometer (2) (R) can be checked in monitoring mode. (Code 50301: Voltage of steering potentiometer (2)) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Defective sensor 5V 1 power source system Defective steering potentiometer (2) 2 (Internal disconnection or short circuit) Standard values when normal and remarks for troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL2 (male) Resistance Between (5) (8) 3.2 kz 20% Between (6) (5) 6 1 kz (Right left steering) Between (6) (8) 1 6 kz (Right left steering) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN1 (female) (22) ResisMax. 1 z TL2 (female) (5) tance Wiring harness between STCN1 (female) (19) ResisMax. 1 z TL2 (female) (6) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisSTCN1 (female) (22) TL2 (female) (5) with Min. 1 Mz tance chassis ground Short circuit of wiring harness between ResisMin. 1 Mz STCN1 (female) (19) TL2 (female) (6) with tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. STCN1 Voltage Between (19) (21) 0.5 4.5 V
54
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-01
Failure code [DK31KB] Steering potentiometer (2): Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Steering potentiometer (2): Short circuit failure (Steering controller system) DK31KB Signal voltage of steering potentiometer (2) system (R) is higher than the specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer (1) system (L). Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from steering potentiometer (2) (R) can be checked in monitoring mode. (Code 50301: Voltage of steering potentiometer (2)) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for steering). Causes Defective sensor power 1 source system Standard values when normal and remarks for troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering potenTL2 (male) Resistance tiometer (2) (Internal dis2 connection or short Between (5) (8) 3.2 kz 20% circuit) Between (6) (5) 1 6 kz (Right left steering) Between (6) (8) 6 1 kz (Right left steering) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between Hot short in wiring harSTCN1 (female) (22) TL2 (female) (5) with Voltage Max. 1 V 3 ness (Contact with 24 V chassis ground circuit) Short circuit of wiring harness between STCN1 (female) (19) TL2 (female) (6) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering con4 STCN1 Voltage troller Between (19) (21) 0.5 4.5 V
D475A, D475ASD-5E0
55
SEN01828-01
56
SEN01829-00
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
Troubleshooting by failure code (Display of code), Part 7
Troubleshooting by failure code (Display of code), Part 7 .............................................................................. 3 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
SEN01829-00
40 Troubleshooting
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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00

Failure code [DK40KA] Brake potentiometer: Disconnection
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Brake potentiometer: Disconnection failure (Steering controller system) DK40KA Signal voltage of brake potentiometer circuit is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Does not control with signal of brake potentiometer (Brake can be operated with pedal). Limits operation of engine and transmission. Brake control performance of brake pedal lowers. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from brake potentiometer can be checked in monitoring mode. (Code 50400: Voltage of brake potentiometer) Method of reproducing failure code: Turn starting switch ON and operate brake pedal. Cause Defective 5 V sensor 1 power source system
1
1
Standard values when normal and remarks for troubleshooting See if error code [DB35KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective brake potentiBRK (male) Resistance ometer (Internal disconBetween (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) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between STCN1 (female) Max. 1 z tance wiring or defective contact (22) BRK (female) (C) in connector) Wiring harness between STCN1 (female) (3) ResisMax. 1 z BRK (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness STCN1 (female) (22) BRK (female) (C) with Min. 1 Mz tance (Contact with ground circhassis ground cuit) Short circuit of wiring harness between ResisSTCN1 (female) (3) BRK (female) (B) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controller STCN1 Voltage Between (3) (21) 1.5 4.5 V
Circuit diagram related to brake potentiometer
D475A, D475ASD-5E0
SEN01829-00
40 Troubleshooting
Failure code [DK40KB] Brake potentiometer: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Brake potentiometer: Short circuit failure (Steering controller system) DK40KB Signal voltage of brake potentiometer circuit is higher than specification value. Blinks warning lamp and sounds alarm buzzer. Does not control brake with brake potentiometer signal (Brake can be controlled with pedal). Limits operations of engine and transmission. Brake cannot be controlled well with brake pedal. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1. Input state (Voltage) from brake potentiometer can be checked in monitoring mode (Code 50400: Brake potentiometer voltage). Method of reproducing failure code: Turn starting switch ON (+ Operate brake pedal). Cause Defective sensor 5V 1 power supply system
Standard values when normal and remarks for troubleshooting If failure code [DB35KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective brake potentiBRK (male) Resistance ometer (Internal disconBetween (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) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short (Contact with Wiring harness between STCN1 (female) Voltage Max. 1 V 24V circuit) in wiring har(22) BRK (female) (C) ness Wiring harness between STCN1 (female) (3) ResisMax. 1 V BRK (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact Wiring harness between STCN1 (female) ResisMax. 1 z in connector) (21) BRK (female) (A) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controlSTCN1 Voltage ler Between (3) (21) 1.5 4.5 V
Circuit diagram related to brake potentiometer
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range 1
Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Forward-reverse potentiometer: Input signal is out of normal range failure (Transmission controller system) DK55KX Either of failure codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and 2 and either of failure codes [DK57KA] and [DK57KB] are displayed simultaneously. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode. (Code 50200: Voltage of forward-reverse potentiometer 1) (Code 50201: Voltage of forward-reverse potentiometer 2) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/ reverse travel). Cause Standard values when normal and remarks for troubleshooting
D475A, D475ASD-5E0
SEN01829-00
40 Troubleshooting
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit 1

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Possible causes and the standard values when normal Failure code Symptom of Forward-reverse potentiometer: Disconnection or short circuit failure (Transmission controller system) DK55KZ When starting switch is turned ON, either of forward-reverse potentiometer systems 1 and 2 is abnormal, then either of failure codes [DK56KA] and [DK56KB] and either of failure codes [DK57KA] and [DK57KB] are displayed simultaneously. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode. (Code 50200: Voltage of forward-reverse potentiometer 1) (Code 50201: Voltage of forward-reverse potentiometer 2) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/ reverse travel). Cause Standard values when normal and remarks for troubleshooting
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DK55L8] Forward-reverse potentiometer: See table

Failure code Symptom of Forward-reverse potentiometer: See table failure (Transmission controller system) DK55L8 Total signal voltage of each of forward-reverse potentiometer 1 system (FR3) and 2 system (FR4) is out of the specified range. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of normal one of forward-reverse potentiometer 1 system (FR3) and 2 (FR4). Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode. (Code 50200: Voltage of forward-reverse potentiometer 1) (Code 50201: Voltage of forward-reverse potentiometer 2) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/ reverse travel). Cause Standard values when normal and remarks for troubleshooting
D475A, D475ASD-5E0
SEN01829-00
40 Troubleshooting
Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Forward-reverse potentiometer (1): Disconnection failure (Transmission controller system) DK56KA Signal voltage of forward-reverse potentiometer (1) system (R) is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of forward-reverse potentiometer (2) system (F). Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from forward-reverse potentiometer (1) (R) can be checked in monitoring mode. (Code 50200: Voltage of forward-reverse potentiometer (1)) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/ reverse travel). Cause Defective 5 V sensor 1 power source system Defective forward-reverse potentiometer (1) (Internal 2 disconnection or short circuit) Standard values when normal and remarks for troubleshooting See if error code [DAQ5KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL2 (male) Resistance Between (4) (1) 3.2 kz 20% Between (3) (4) 5.5 1.5 kz (Forward reverse) Between (3) (1) 1.5 5.5 kz (Forward reverse) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (22) ResisMax. 1 z TL2 (female) (4) tance Wiring harness between TMC1 (female) (2) ResisMax. 1 z TL2 (female) (3) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisMin. 1 Mz TMC1 (female) (2) TL2 (female) (3) with tance chassis ground Short circuit of wiring harness between ResisTMC1 (female) (22) TL2 (female) (4) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMC1 Voltage Between (2) (21) 0.5 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Circuit diagram related to forward-reverse potentiometer
D475A, D475ASD-5E0
SEN01829-00
40 Troubleshooting
Failure code [DK56KB] Forward-Reverse potentiometer (1): Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Forward-Reverse potentiometer (1): Short circuit failure (Transmission controller system) DK56KB Signal voltage of forward-reverse potentiometer (1) system (R) circuit is higher than specified value. Blinks warning lamp and sounds alarm buzzer. Continues control with signal of forward-reverse potentiometer (2) system (F). Limits operations of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1. Input state (Voltage) from forward-reverse potentiometer (1) (R) can be checked in monitoring mode (Code 50200: Forward-Reverse potentiometer (1) voltage). Method of reproducing failure code: Turn starting switch ON (+ Operate PCCS lever (Forward and reverse)). Cause Defective sensor 5V 1 power supply system Defective forward-reverse potentiometer (1) (Internal 2 disconnection or short circuit) Standard values when normal and remarks for troubleshooting If failure code [DAQ5KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL2 (male) Resistance Between (4) (1) 3.2 kz 20% Between (3) (4) 5.5 1.5 kz (Forward reverse) Between (3) (1) 1.5 5.5 kz (Forward reverse) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC1 (female) (2) Voltage Max. 1 V TL2 (female) (3) Wiring harness between TMC1 (female) (22) Voltage Max. 1 V TL2 (female) (4) Wiring harness between TMC1 (female) (21) Voltage Max. 1 V TL2 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (21) ResisMax. 1 z TL2 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMC1 Voltage Between (2) (21) 0.5 4.5 V
Disconnection in wiring harness (Disconnection in 4 wiring or defective contact in connector) 5 Defective transmission controller
10
D475A, D475ASD-5E0
40 Troubleshooting
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D475A, D475ASD-5E0
11
SEN01829-00
40 Troubleshooting
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Forward-reverse potentiometer (2): Disconnection failure (Transmission controller system) DK57KA Signal voltage of forward-reverse potentiometer (2) system (F) is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of forward-reverse potentiometer (1) system (R). Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from forward-reverse potentiometer (2) (F) can be checked in monitoring mode. (Code 50201: Voltage of forward-reverse potentiometer (2)) Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (for forward/ reverse travel). Cause Defective 5 V sensor 1 power source system Defective forward-reverse potentiometer (2) (Internal 2 disconnection or short circuit) Standard values when normal and remarks for troubleshooting See if error code [DAQ5KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL2 (male) Resistance Between (4) (1) 3.2 kz 20% Between (2) (4) 5.5 1.5 kz (Forward reverse) Between (2) (1) 1.5 5.5 kz (Forward reverse) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (22) ResisMax. 1 z TL2 (female) (4) tance Wiring harness between TMC1 (female) (19) ResisMax. 1 z TL2 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisMin. 1 Mz TMC1 (female) (19) TL2(female) (2) with tance chassis ground Short circuit of wiring harness between ResisTMC1 (female) (22) TL2 (female) (4) with Min. 1 Mz tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TMC1 Voltage Between (19) (21) 0.5 4.5 V
12
D475A, D475ASD-5E0
40 Troubleshooting
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D475A, D475ASD-5E0
13
SEN01829-00
40 Troubleshooting
Failure code [DK57KB] Forward-Reverse potentiometer (2): Short circuit1

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Forward-Reverse potentiometer (2): Short circuit failure (Transmission controller system) DK57KB Signal voltage of forward-reverse potentiometer (2) system (F) circuit is higher than specified value. Blinks warning lamp and sounds alarm buzzer. Continues control with signal of forward-reverse potentiometer (1) system (R). Limits operations of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, gear speed is limited to F1 and R1. Input state (Voltage) from forward-reverse potentiometer (2) (F) can be checked in monitoring mode (Code 50201: Forward-Reverse potentiometer (2) voltage). Method of reproducing failure code: Turn starting switch ON (+ Operate PCCS lever (Forward and reverse)). Cause Defective sensor 5V 1 power supply system Defective forward-reverse potentiometer (2) (Internal 2 disconnection or short circuit) Standard values when normal and remarks for troubleshooting If failure code [DAQ5KK] is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TL2 (male) Resistance Between (4) (1) 3.2 kz 20% Between (2) (4) 5.5 1.5 kz (Forward reverse) Between (2) (1) 1.5 5.5 kz (Forward reverse) a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC1 (female) (19) Voltage Max. 1 V TL2 (female) (2) Wiring harness between TMC1 (female) (22) Voltage Max. 1 V TL2 (female) (4) Wiring harness between TMC1 (female) (21) Voltage Max. 1 V TL2 (female) (1) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC1 (female) (21) ResisMax. 1 z TL2 (female) (1) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TCM1 Voltage Between (19) (21) 0.5 4.5 V
Disconnection in wiring harness (Disconnection in 4 wiring or defective contact in connector) 5 Defective transmission controller
14
D475A, D475ASD-5E0
40 Troubleshooting
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D475A, D475ASD-5E0
15
SEN01829-00
40 Troubleshooting
Failure code [DK60KA] Acceleration sensor: Disconnection

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Acceleration sensor: Disconnection failure (Steering controller system) DK60KA Signal voltage of acceleration sensor is below 0.5 V. Turns shoe slip control (SSC) function OFF. Even if shoe slips, engine speed does not change. Input (Voltage) from acceleration sensor can be checked in monitoring mode. (Code 60200: Voltage of acceleration sensor) Method of reproducing failure code: Turn starting switch ON. Cause Defective 5 V power 1 source system 2
Standard values when normal and remarks for troubleshooting See if failure code [DB37KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective acceleration sensor (Internal trouble) SSA Voltage Between (2) (3) 0.75 4.25 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) ResisMax. 1 z wiring or defective contact (34) SSA (female) (1) tance in connector) Wiring harness between STCN1 (female) (1) ResisMax. 1 z SSA (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Short circuit of wiring harness between Resisground in wiring harness STCN3 (female) (34) SSA (female) (1) with Min. 1 Mz tance (Contact with ground circhassis ground cuit) Short circuit of wiring harness between ResisMin. 1 Mz STCN1 (female) (1) SS3 (female) (2) with tance chassis ground a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering controlSTCN1 Voltage ler Between (1) (21) 0.75 4.25 V
16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Circuit diagram related to acceleration sensor
D475A, D475ASD-5E0
17
SEN01829-00
40 Troubleshooting
Failure code [DK60KB] Acceleration sensor: Short circuit

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Acceleration sensor: Short circuit failure (Steering controller system) DK60KB Acceleration sensor signal voltage is above 4.5 V. Stops shoe slip control (SSC) function. Engine speed does not change even if shoe slips.
Input state (Voltage) from acceleration sensor can be checked in monitoring mode (Code 60200: Acceleration sensor voltage). Method of reproducing failure code: Turn starting switch ON. Cause Standard values when normal and remarks for troubleshooting Defective 5V power supply If failure code [DB37KK] is displayed, carry out troubleshooting for it 1 system first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective acceleration 2 sensor (Internal defect) SSA Voltage Between (2) (3) 0.75 4.25 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between STCN1 (female) (1) Voltage Max. 1 V Hot short (Contact with SSA (female) (2) 3 24V circuit) in wiring harWiring harness between STCN3 (female) ness Voltage Max. 1 V (34) SSA (female) (1) Wiring harness between STCN1 (female) Voltage Max. 1 V (21) SSA (female) (3) a Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in 4 wiring or defective contact Wiring harness between STCN1 (female) ResisMax. 1 z in connector) (21) SSA (female) (3) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective steering control5 ler STCN1 Voltage Between (1) (21) 0.75 4.25 V
Circuit diagram related to acceleration sensor
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DKH1KA] Pitch angle sensor: disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Pitch angle sensor: Disconnection failure (Steering controller system) DKH1KA Signal voltage of pitch angle sensor is lower than the specified value. Flashes caution lamp and turns on caution buzzer. Cannot recognize pitch angle. Limits operation of engine and transmission. Gear shift shock is large. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from pitch angle sensor can be checked in monitoring mode. (Code 60100: Voltage of pitch angle sensor) Method of reproducing failure code: Turn starting switch ON. Cause Defective 24 V power 1 source system 2 Defective pitch angle sensor (Internal trouble)
Standard values when normal and remarks for troubleshooting See if failure code [DB36KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PT1 Voltage Between (B) (A) 0.15 4.85 V a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN1 (female) ResisMax. 1 z (16) PT1 (female) (C) tance Wiring harness between STCN1 (female) ResisMax. 1 z (13) PT1 (female) (B) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisMin. 1 Mz STCN1 (female) (16) PT1 (female) (C) with tance chassis ground Short circuit of wiring harness between ResisSTCN1 (female) (13) PT1 (female) (B) with Min. 1 Mz tance chassis ground Steering controller can be suspected to be defective if no problem is found in causes 1 4 (since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to pitch angle sensor
D475A, D475ASD-5E0
19
SEN01829-00
40 Troubleshooting
Failure code [DKH1KB] Pitch angle sensor: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Pitch angle sensor: Short circuit failure (Steering controller system) DKH1KB Signal voltage of pitch angle sensor is higher than the specified value. Flashes caution lamp and turns on caution buzzer. Cannot recognize pitch angle. Limits operation of engine and transmission. Gear shift shock is large. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Input (Voltage) from pitch angle sensor can be checked in monitoring mode. (Code 60100: Voltage of pitch angle sensor) Method of reproducing failure code: Turn starting switch ON. Cause Defective 24 V power 1 source system 2 Defective pitch angle sensor (Internal trouble)
Disconnection in wiring harness (Disconnection in 4 wiring or defective contact in connector) 5 Defective steering controller
Standard values when normal and remarks for troubleshooting See if failure code [DB36KK] is displayed. If it is displayed, carry out troubleshooting for it first. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PT1 Voltage Between (B) (A) 0.15 4.85 V a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between STCN1 (female) (13) PT1 (female) (B) with Voltage Max. 1 V chassis ground Short circuit of wiring harness between STCN1 (female) (21) PT1 (female) (A) with Voltage Max. 1 V chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN1 (female) ResisMax. 1 z (21) PT1 (female) (A) tance Steering controller can be suspected to be defective if no problem is found in causes 1 4 (since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to pitch angle sensor
20
D475A, D475ASD-5E0
40 Troubleshooting
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Failure code [DKH1KX] Pitch angle sensor: Out of input signal range 1
Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Pitch angle sensor: Out of input signal range failure (Steering controller system) DKH1KX Either of pitch angle sensor errors [DKH1KA] and [DKH1KB] occurred or steering controller CAN communication error [DB3RKR] occurred. Cannot recognize pitch angle. Gear speed is not changed automatically. Input state (Voltage) from pitch angle sensor can be checked in monitoring mode (Code 60100: Pitch angle sensor voltage). Method of reproducing failure code: Turn starting switch ON.
Possible Cause Standard values when normal and remarks for troubleshooting 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
SEN01829-00
40 Troubleshooting
Failure code [DLF1KA] Torque converter output speed sensor: Disconnection
Action code Failure code Symptom of Torque converter output speed sensor: Disconnection failure (Transmission controller system) CALL E03 DLF1KA 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 moniGeneral toring mode. (Code 31200: Torque converter speed) information Method of reproducing failure code: Start the engine + Drive the machine actually. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective torque conwithout turning starting switch ON. verter output speed sensor TC1 (male) Resistance (Internal disconnection or Between (1) and (2) 500 1,000 z short circuit) Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC2 (female) (20) ResisMax. 1 z wiring harness or defective and TC1 (female) (1) tance contact in connector) Wiring harness between TMC2 (female) (39) ResisMax. 1 z and TC1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Between wiring harness between TMC2 (Contact with ground cirResis(female) (20) and TC1 (female) (1) and chasMin. 1 Mz cuit) tance sis ground If causes 1 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.) Cause
Circuit diagram related to torque converter output speed sensor
22
D475A, D475ASD-5E0
40 Troubleshooting
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Failure code [DLT3KA] Transmission output speed sensor: Disconnection

Action code E01 Failure content Controller's action Symptoms that appear on machine General information
Failure code Symptom of Transmission output speed sensor: Disconnection failure (Transmission controller system) DLT3KA Transmission output speed sensor error [dLT3KA] occurred or transmission CAN communication error [DAQRKR] occurred. Assumes transmission output speed to be 0 rpm. Transmission speed cannot be monitored. Traction force cannot be calculated. Auto-shift down operation is defective. Gear shift shock is large. Input voltage from transmission output speed sensor can be checked in monitoring mode (Code 31400: Transmission output speed). Method of reproducing failure code: Turn starting switch ON + Drive machine actually.
Possible Cause Standard values when normal and remarks for troubleshooting causes and the Carry out troubleshooting for disconnection [dLT3KA] and transmission CAN communication error standard values when normal [DAQRKR].
D475A, D475ASD-5E0
23
SEN01829-00
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Failure code [dLT3KA] Transmission output speed sensor: Disconnection

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Transmission output speed sensor: Disconnection failure (Transmission controller system) dLT3KA Signal is not input from transmission output speed sensor. Assumes that transmission output speed is 0 rpm. Transmission speed cannot be monitored. Traction force cannot be calculated. Auto-shift down operation is defective. Gear shift shock is large. Input (rpm) from transmission output speed sensor can be checked in monitoring mode. (Code 31400: Transmission speed Method of reproducing failure code: Start engine and travel machine actually. Cause Defective transmission output speed sensor 1 (Internal disconnection or short circuit)
Hot short in wiring harness (Contact with 24-V circuit)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. TM1 (male) Resistance Between (1) (2) 500 1,000 z Between (1), (2) chassis Min. 1 Mz ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC2 (female) (30) ResisMax. 1 z TM1 (female) (1) tance Wiring harness between TMC2 (female) (29) ResisMax. 1 z TM1 (female) (2) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit of wiring harness between ResisTMC2 (female) (30) TM1 (female) (1) with Min. 1 Mz tance chassis ground Wiring harness between TMC2 (female) (29) ResisMin. 1 Mz and TM1 (female) (2) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC2 (female) (30) Voltage Max. 1 V and TM1 (female) (1) and chassis ground Wiring harness between TMC2 (female) (29) Voltage Max. 1 V and TM1 (female) (2) and chassis ground Transmission controller can be suspected to be defective if no problem is found in causes 1 4 (since this is an internal defect, it cannot be diagnosed).
24
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Circuit diagram related to transmission output speed sensor
D475A, D475ASD-5E0
25
SEN01829-00
40 Troubleshooting
Failure code [DLT3KB] Transmission output speed sensor: Short circuit

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Transmission output speed sensor: Short circuit failure (Transmission controller system) DLT3KB Signal from transmission output speed sensor does not change while machine is traveling. Assumes transmission output speed to be 0 rpm. Transmission speed cannot be monitored. Traction force cannot be calculated. Auto shift-down function does not work. Gearshift shocks are increased. Input voltage from transmission output speed sensor can be checked in monitoring mode (Code 31400: Transmission output speed). Method of reproducing failure code: Turn starting switch ON + Drive machine actually.
Cause Standard values when normal and remarks for troubleshooting Defective installation of Carry out adjustment according to Testing and adjusting, "Adjusting 1 transmission output speed transmission speed sensor". sensor a Prepare with starting switch OFF, then carry out troubleshooting Defective transmission without turning starting switch ON. output speed sensor TM1 (male) Resistance 2 (Internal disconnection or Between (1) (2) 500 1,000 z short circuit) Between (1) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harWiring harness between TMC2 (female) (30) ResisMin. 1 Mz 3 ness (Contact with GND TM1 (female) (1) tance circuit) Wiring harness between TMC2 (female) (29) ResisMin. 1 Mz and TM1 (female) (1) and chassis ground tance If causes 1 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be 4 controller carried out.)
Circuit diagram related to transmission output speed sensor
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DV00KB] Caution buzzer: Short circuit

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Caution buzzer: Short circuit failure (Machine monitor system) DV00KB Abnormal current flowed when caution buzzer circuit output ground signal. Flashes caution lamp. Stops caution buzzer circuit from outputting ground signal. Caution buzzer does not sound.
Method of reproducing failure code: Turn starting switch ON (When it is turned ON, buzzer sounds for 1 second). Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective caution buzzer 1 217 (male) Resistance (Internal short circuit) Between (1) (2) 200 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between 217 (Contact with 24 V circuit) (female) (1) S03 (female) (18) with chassis Voltage Max. 1 V ground a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 3 ness (Contact with GND ResisWiring harness between 217 (female) (1) and circuit) Min. 1 Mz S03 (female) (18) and chassis ground tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. S03 Caution buzzer Voltage 4 Defective monitor panel When turned OFF 20 30 V Between (18) When turned ON chassis ground Max. 3 V (sounding) Cause
Circuit diagram related to caution buzzer
D475A, D475ASD-5E0
27
SEN01829-00
40 Troubleshooting
Failure code [DW55KA] Blade pitch back solenoid: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch back solenoid: Disconnection failure (Transmission controller system) DW55KA Flashes warning lamp and turns on warning alarm. When the signal is output to the blade pitch back solenoid circuit, no current flows. Stops outputting the signal to the blade pitch back solenoid circuit. The blade is not pitched back. The output state (ON/OFF) to the blade pitch back solenoid can be checked in the monitoring mode. (Code 90000: Tilt pitch solenoid output 3) Method of reproducing failure code: Turn the starting switch ON. + Pitch back blade.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch back without turning starting switch ON. 1 solenoid PPB (male) Resistance (Internal disconnection) Between (1) and (2) 20 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (26) Resis2 Max. 1 z wiring harness or defective and PPB (female) (1) tance contact in connector) Wiring harness between TMC3 (female) (3) ResisMax. 1 z and PPB (female) (2) tance If causes 1 2 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be 3 controller carried out.)
Cause
Circuit diagram related to blade pitch back solenoid
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW55KB] Blade pitch back solenoid: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch back solenoid: Short circuit failure (Transmission controller system) DW55KB When signal was output to blade pitch back solenoid circuit, abnormal current flowed. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to blade pitch back solenoid. Blade does not pitch back.
Output state (ON/OFF) to blade pitch back solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). Method of reproducing failure code: Turn starting switch ON + Perform blade pitch back operation. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch back PPB (male) Resistance 1 solenoid (Internal short circuit) Between (1) (2) 20 60 z Between (1) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND Wiring harness between TMC3 (female) (26) Resiscircuit) Min. 1 Mz PPB (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 3 ness (with another wiring (female) (26) PPB (female) (1) and wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (3) PPB tance (female) (2) If causes 1 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be 4 controller carried out.) Cause
Circuit diagram related to blade pitch back solenoid
D475A, D475ASD-5E0
29
SEN01829-00
40 Troubleshooting
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch dump solenoid: Disconnection failure (Transmission controller system) DW56KA Flashes warning lamp and turns on warning alarm. When the signal is output to the blade pitch dump solenoid circuit, no current flows. Stops outputting the signal to the blade pitch dump solenoid circuit. The blade is not pitched forward. The output state (ON/OFF) to the blade pitch dump solenoid can be checked in the monitoring mode. (Code 90000: Tilt/pitch solenoid output 3) Method of reproducing failure code: Turn the starting switch ON. + Pitch the blade forward. Cause Defective blade pitch 1 dump solenoid (Internal disconnection)
Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector)
Hot short in wiring harness (Contact with 24-V circuit)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PPD (male) Resistance Between (1) and (2) 20 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between TMC3 (female) (16) ResisMax. 1 z and PPD (female) (1) tance Wiring harness between TMC3 (female) (3) ResisMax. 1 z and PPD (female) (2) tance a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between TMC3 (female) (16) and PPD (female) (1) and chas- Voltage Max. 1 V sis ground If causes 1 3 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to blade pitch dump solenoid
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch dump solenoid: Short circuit failure (Transmission controller system) DW56KB When signal was output to blade pitch dump solenoid circuit, abnormal current flowed. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to blade pitch dump solenoid circuit. Blade does not pitch dump. Output state (ON/OFF) to blade pitch dump solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). Method of reproducing failure code: Turn starting switch ON + Perform blade pitch dump operation.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch PPD (male) Resistance dump solenoid (Internal short circuit) Between (1) (2) 20 60 z Between (1) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between TMC3 (female) (16) Resiscircuit) Min. 1 Mz PPD (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 ness (with another wiring (female) (16) PPD (female) (1) and wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (3) PPD tance (female) (2) If causes 1 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Cause
D475A, D475ASD-5E0
31
SEN01829-00
40 Troubleshooting
Failure code [DW56KY] Blade pitch dump solenoid: Hot short

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch dump solenoid: Hot short failure (Transmission controller system) DW56KY Some current keeps flowing to blade pitch dump solenoid circuit. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to blade pitch dump solenoid circuit. Blade pitch dump solenoid keeps operating. Output state (ON/OFF) to blade pitch dump solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). Method of reproducing failure code: Turn starting switch ON + Perform blade pitch dump operation. Cause Defective blade pitch 1 dump solenoid (Internal short circuit) Hot short (Contact with 2 24V circuit) in wiring harness 3 Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PPD (male) Resistance Between (1) (2) 20 60 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC3 (female) (16) Voltage Max. 1 V PPD (female) (1). If causes 1 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
32
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW57KA] Left tilt limit solenoid: Disconnection

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left tilt limit solenoid: Disconnection failure (Transmission controller system) DW57KA When the signal is output to the left tilt limit solenoid circuit, no current flows. Flashes the caution lamp and turns on the caution buzzer. Stops outputting the signal to the left tilt limit solenoid circuit. The blade is not pitched forward. The left tilt limit function does not operate. The output state (ON/OFF) to the left tilt limit solenoid can be checked in the monitoring mode. (Code 90000: Tilt/pitch solenoid output 3) Method of reproducing failure code: Turn the starting switch ON. + Execute the left tilt mode.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left tilt limit without turning starting switch ON. 1 solenoid TLL (male) Resistance (Internal disconnection) Between (1) and (2) 20 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (27) Resis2 Max. 1 z wiring harness or defective and TLL (female) (1) tance contact in connector) Wiring harness between TMC3 (female) (3) ResisMax. 1 z and TLL (female) (2) tance If causes 1 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Cause
Circuit diagram related to left tilt limit solenoid
D475A, D475ASD-5E0
33
SEN01829-00
40 Troubleshooting
Failure code [DW57KB] Left tilt limit solenoid: Short circuit

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left tilt limit solenoid: Short circuit failure (Transmission controller system) DW57KB When signal was output to left tilt limit solenoid circuit, abnormal current flowed. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to left tilt limit solenoid circuit. Blade does not pitch dump. Left tilt limit function does not work. Output state (ON/OFF) to left tilt limit solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). Method of reproducing failure code: Turn starting switch ON + Perform left tilt limit mode.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left tilt limit soleTLL (male) Resistance noid (Internal short circuit) Between (1) (2) 20 60 z Between (1) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between TMC3 (female) (27) Resiscircuit) Min. 1 Mz TLL (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 ness (with another wiring (female) (27) TLL (female) (1) and wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (3) TLL tance (female) (2) If causes 1 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Cause
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW57KY] Left tilt limit solenoid: Hot short

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left tilt limit solenoid: Hot short failure (Transmission controller system) DW57KY Some current keeps flowing to left tilt limit solenoid circuit. Stops outputting signal to left tilt limit solenoid circuit. Left tilt limit solenoid keeps operating. Output state (ON/OFF) to left tilt limit solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). Method of reproducing failure code: Turn starting switch ON + Perform left tilt mode.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left tilt limit sole1 noid (Internal short circuit) TLL (male) Resistance Between (1) (2) 20 60 z a Prepare with starting switch OFF, then turn starting switch ON and Hot short (Contact with carry out troubleshooting. 2 24V circuit) in wiring harWiring harness between TMC3 (female) (27) ness Voltage Max. 1 V TLL (female) (1). If causes 1 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Cause
D475A, D475ASD-5E0
35
SEN01829-00
40 Troubleshooting
Failure code [DW58KA] Right tilt limit solenoid: Disconnection

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right tilt limit solenoid: Disconnection failure (Transmission controller system) DW58KA When the signal is output to the right tilt limit solenoid circuit, no current flows. Flashes the caution lamp and turns on the caution buzzer. Stops outputting the signal to the right tilt limit solenoid circuit. The blade is not pitched back. The right tilt limit function does not operate. The output state (ON/OFF) to the right tilt limit solenoid can be checked in the monitoring mode. (Code 90000: Tilt/pitch solenoid output 3) Method of reproducing failure code: Turn the starting switch ON. + Execute the right tilt mode.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective right tilt limit without turning starting switch ON. 1 solenoid TLR (male) Resistance (Internal disconnection) Between (1) and (2) 20 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (37) Resis2 Max. 1 z wiring harness or defective and TLR (female) (1) tance contact in connector) Wiring harness between TMC3 (female) (3) ResisMax. 1 z and TLR (female) (2) tance If causes 1 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Cause
Circuit diagram related to right tilt limit solenoid
36
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW58KB] Right tilt limit solenoid: Short circuit

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right tilt limit solenoid: Short circuit failure (Transmission controller system) DW58KB When signal was output to right tilt limit solenoid circuit, abnormal current flowed. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to right tilt limit solenoid circuit. Blade does not pitch back. Output state (ON/OFF) to right tilt limit solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). Method of reproducing failure code: Turn starting switch ON + Perform right tilt limit mode.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right tilt limit TLR (male) Resistance solenoid (Internal short circuit) Between (1) (2) 20 60 z Between (1) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between TMC3 (female) (37) Resiscircuit) Min. 1 Mz TLR (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 ness (with another wiring (female) (37) TLR (female) (1) and wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (3) TLR tance (female) (2) If causes 1 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Cause
D475A, D475ASD-5E0
37
SEN01829-00
40 Troubleshooting
Failure code [DW58KY] Right tilt limit solenoid: Hot short

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right tilt limit solenoid: Hot short failure (Transmission controller system) DW58KY Some current keeps flowing to right tilt limit solenoid circuit. Stops outputting signal to right tilt limit solenoid circuit. Right tilt limit solenoid keeps operating. Output state (ON/OFF) to right tilt limit solenoid can be checked in monitoring mode (Code 90000: Tilt/Pitch solenoid output 3). Method of reproducing failure code: Turn starting switch ON + Perform right tilt mode. Cause Defective right tilt limit 1 solenoid (Internal disconnection) Hot short (Contact with 2 24V circuit) in wiring harness 3 Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TLR (male) Resistance Between (1) (2) 20 60 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC3 (female) (37) Voltage Max. 1 V TLR (female) (1). If causes 1 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Dual tilt selector solenoid: Disconnection failure (Transmission controller system) DW59KA When signal is output to dual tilt selector solenoid circuit, any current does not flow. Stops outputting to dual tilt selector solenoid circuit. Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works).
Output (Current) to dual tilt selector solenoid can be checked in monitoring mode.] (Code 70600: Dual tilt solenoid drive current) Method of reproducing failure code: Turn starting switch ON and perform blade dual tilt operation. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective dual tilt selector without turning starting switch ON. 1 solenoid (Internal disconDUL (male) Resistance nection) Between (1) (2) 10 40 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (6) Resis2 Max. 1 z wiring or defective contact DUL (female) (1) tance in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z DUL (female) (2) tance If causes 1 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.) Cause
Circuit diagram related to dual tilt selector solenoid
D475A, D475ASD-5E0
39
SEN01829-00
40 Troubleshooting
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Dual tilt selector solenoid: Short circuit failure (Transmission controller system) DW59KB When signal was output to dual tilt selector solenoid circuit, abnormal current flowed. Stops outputting signal to dual tilt selector solenoid circuit. Dual tilt unit does not operate (When dual tilt operation is performed, single tilt unit operates). Output state (Current) to dual tilt selector solenoid can be checked in monitoring mode (Code 70600: Dual tilt solenoid drive current). Method of reproducing failure code: Turn starting switch ON + Perform dual tilt operation.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective dual tilt selector DUL (male) Resistance 1 solenoid (Internal short circuit) Between (1) (2) 10 40 z Between (1) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 ness (Contact with GND Wiring harness between TMC3 (female) (6) Resiscircuit) Min. 1 Mz DUL (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 3 ness (with another wiring (female) (6) DUL (female) (1) and wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (13) DUL tance (female) (2) If causes 1 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be 4 controller carried out.)
Cause
40
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW59KY] Dual tilt selector solenoid: Hot short

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Dual tilt selector solenoid: Hot short failure (Transmission controller system) DW59KY Some current keeps flowing to dual tilt selector solenoid circuit. Stops outputting signal to dual tilt selector solenoid circuit. Dual tilt selector solenoid keeps operating. Output state (Current) to dual tilt selector solenoid can be checked in monitoring mode (Code 70600: Dual tilt solenoid drive current). Method of reproducing failure code: Turn starting switch ON + Perform dual tilt operation.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective dual tilt selector without turning starting switch ON. 1 solenoid (Internal disconDUL (male) Resistance nection) Between (1) (2) 10 40 z a Prepare with starting switch OFF, then turn starting switch ON and Hot short (Contact with carry out troubleshooting. 2 24V circuit) in wiring harWiring harness between TMC3 (female) (6) ness Voltage Max. 1 V DUL (female) (1). If causes 1 2 are not detected, steering or transmission controller Defective steering or 3 may be defective. (Since trouble is in system, troubleshooting cantransmission controller not be carried out.)
Cause
D475A, D475ASD-5E0
41
SEN01829-00
40 Troubleshooting
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection 1

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch selector solenoid: Disconnection failure (Transmission controller system) DW5AKA When the signal is output to the blade pitch selector solenoid circuit, no current flows. Flashes the caution lamp and turns on the caution buzzer. Stops outputting the signal to the blade pitch selector solenoid circuit. The blade is not pitched back. (When the pitch back operation is performed, the blade may be tilted.) The output state (current) to the blade pitch selector solenoid can be checked in the monitoring mode. (Code 31625: Pitch solenoid current) Method of reproducing failure code: Turn the starting switch ON. + Pitch the blade back. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch without turning starting switch ON. 1 selector solenoid PTH (male) Resistance (Internal short circuit) Between (1) and (2) 10 40 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (28) Resis2 Max. 1 z wiring harness or defective and PTH (female) (1) tance contact in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z and PTH (female) (2) tance If causes 1 2 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be 3 controller carried out.) Cause
Circuit diagram related to blade pitch selector solenoid
42
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch selector solenoid: Short circuit failure (Transmission controller system) DW5AKB When signal was output to blade pitch selector solenoid circuit, abnormal current flowed. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to blade pitch selector solenoid circuit.
Blade pitch back unit does not operate (When pitch back operation is performed, tilt unit operates). Output state (Current) to blade pitch selector solenoid can be checked in monitoring mode (Code 31625: Pitch solenoid current). Method of reproducing failure code: Turn starting switch ON + Perform blade pitch back operation. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch PTH (male) Resistance selector solenoid (Internal short circuit) Between (1) (2) 10 40 z Between (1) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between TMC3 (female) (28) Resiscircuit) Min. 1 Mz PTH (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 ness (with another wiring (female) (28) PTH (female) (1) and wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (13) PTH tance (female) (2) If causes 1 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.) Cause
D475A, D475ASD-5E0
43
SEN01829-00
40 Troubleshooting
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch selector solenoid: Hot short failure (Transmission controller system) DW5AKY Some current keeps flowing to blade pitch selector solenoid circuit. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to blade pitch selector solenoid circuit. Blade pitch selector solenoid keeps operating.
Output state (Current) to blade pitch selector solenoid can be checked in monitoring mode (Code 31625: Pitch solenoid current). Method of reproducing failure code: Turn starting switch ON + Perform blade pitch back operation. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch without turning starting switch ON. 1 selector solenoid (Internal PTH (male) Resistance short circuit) Between (1) (2) 10 40 z a Prepare with starting switch OFF, then turn starting switch ON and Hot short (Contact with carry out troubleshooting. 2 24V circuit) in wiring harWiring harness between TMC3 (female) (28) ness Voltage Max. 1 V PTH (female) (1). If causes 1 2 are not detected, transmission controller may be Defective transmission 3 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.) Cause
44
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification): Disconnection
Failure code Symptom of Blade pitch selector solenoid (Superdozer specification): Disconnecfailure tion (Transmission controller system) DW5DKA When the signal is output to the blade pitch selector solenoid circuit, no current flows. Flashes the caution lamp and turns on the caution buzzer. Stops outputting the signal to the blade pitch selector solenoid circuit. The blade is not pitched back. (When the pitch back operation is performed, the blade may be tilted.) The output state (current) to the blade pitch selector solenoid can be checked in the monitoring mode. (Code 31625: Pitch solenoid current) Method of reproducing failure code: Turn the starting switch ON. + Pitch the blade back. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective blade pitch without turning starting switch ON. 1 dump solenoid PTH (male) Resistance (Internal disconnection) Between (1) and (2) 10 40 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between TMC3 (female) (28) Max. 1 z 2 tance wiring harness or defective and PTH (female) (1) contact in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z and PTH (female) (2) tance If causes 1 2 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be 3 controller carried out.) Cause
Circuit diagram related to blade pitch dump solenoid (Superdozer)
D475A, D475ASD-5E0
45
SEN01829-00
40 Troubleshooting
Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification): Short circuit
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch selector solenoid (Superdozer specification): Short cirfailure cuit (Transmission controller system) DW5DKB When signal was output to blade pitch selector solenoid circuit, abnormal current flowed. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to blade pitch selector solenoid circuit.
Blade pitch back unit does not operate (When pitch back operation is performed, tilt unit operates). Output state (Current) to blade pitch selector solenoid can be checked in monitoring mode (Code 31625: Pitch solenoid current). Method of reproducing failure code: Turn starting switch ON + Perform blade pitch back operation. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blade pitch PTH (male) Resistance dump solenoid (Internal short circuit) Between (1) (2) 10 40 z Between (1) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between TMC3 (female) (28) Resiscircuit) Min. 1 Mz PTH (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between TMC3 ness (with another wiring (female) (28) PTH (female) (1) and wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (13) PTH tance (female) (2) If causes 1 3 are not detected, transmission controller may be Defective transmission defective. (Since trouble is in system, troubleshooting cannot be controller carried out.) Cause
Circuit diagram related to blade pitch dump solenoid (Superdozer specification)
46
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification): Hot short
Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Blade pitch selector solenoid (Superdozer specification): Hot short failure (Transmission controller system) DW5DKY Some current keeps flowing to blade pitch dump solenoid circuit. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to blade pitch dump solenoid circuit. Blade pitch dump solenoid keeps operating. Output state (Current) to blade pitch dump solenoid can be checked in monitoring mode (Code 31625: Pitch solenoid current). Method of reproducing failure code: Turn starting switch ON + Perform blade pitch dump operation. Cause Defective blade pitch 1 dump solenoid (Internal short circuit) Hot short (Contact with 2 24V circuit) in wiring harness 3 Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PTH (male) Resistance Between (1) (2) 10 40 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between TMC3 (female) (28) Voltage Max. 1 V PTH (female) (1). If causes 1 2 are not detected, transmission controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to blade pitch dump solenoid (Superdozer specification)
D475A, D475ASD-5E0
47
SEN01829-00
40 Troubleshooting
Failure code [DW7BKA] Fan reverse solenoid: Disconnection

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fan reverse solenoid: Disconnection failure (Steering controller system) DW7BKA When the signal is output to the fan reverse solenoid circuit, no current flows. Stops outputting the signal to the fan reverse solenoid circuit. The fan reverse function cannot be used.
The output state (ON/OFF) to the fan reverse solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output 1) Method of reproducing failure code: Turn the starting switch ON. + Reverse the fan rotation direction. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective fan reverse without turning starting switch ON. 1 solenoid FAR (male) Resistance (Internal disconnection) Between (1) and (2) 34 44 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) Resis2 Max. 1 z wiring harness or defective (17) and FAR (female) (1) tance contact in connector) Wiring harness between STCN3 (female) (3) ResisMax. 1 z and FAR (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering found in causes 1 2 (Since this is an internal defect, it cannot be 3 controller diagnosed). Cause
Circuit diagram related to fan reverse solenoid
48
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DW7BKB] Fan reverse solenoid: Short circuit

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fan reverse solenoid: Short circuit failure (Steering controller system) DW7BKB When the signal is output to the fan reverse solenoid circuit, an abnormal current flows. Stops outputting the signal to the fan reverse solenoid. The fan reverse function cannot be used.
The output state (ON/OFF) to the fan reverse solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output 1) Method of reproducing error code: Turn the starting switch ON. + Reverse the fan rotation direction. Cause Defective fan reverse 1 solenoid (Internal short circuit) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FAR (male) Resistance Between (1) and (2) 34 44 z Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between STCN3 Resis(female) (17) and FAR (female) (1) and chasMin. 1 Mz tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between STCN3 (female) (17) and FAR (female) (1) and wirResisMin. 1 Mz ing harness between STCN3 (female) (13) tance and FAR (female) (2) Steering controller can be suspected to be defective if no problem is found in causes 1 3 (Since this is an internal defect, it cannot be diagnosed).
Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit) Short circuit in wiring harness 3 (Short circuit between wiring harnesses) Defective steering controller
D475A, D475ASD-5E0
49
SEN01829-00
40 Troubleshooting
Failure code [DW7BKY] Fan reverse solenoid: Hot short

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fan reverse solenoid: Hot short failure (Steering controller system) DW7BKY Some current keeps flowing to fan reverse solenoid circuit. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to fan reverse solenoid circuit. Fan keeps running in reverse. Output state (ON/OFF) to fan reverse solenoid can be checked in monitoring mode (Code 40914: Steering-related controller ON/OFF output 1). Method of reproducing failure code: Turn starting switch ON + Operate fan in reverse.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective fan reverse solewithout turning starting switch ON. 1 noid (Internal disconnecFAR (male) Resistance tion) Between (1) (2) 34 44 z a Prepare with starting switch OFF, then turn starting switch ON and Hot short (Contact with carry out troubleshooting. 2 24V circuit) in wiring harWiring harness between STCN3 (female) ness Voltage Max. 1 V (17) FAR (female) (1). If causes 1 2 are not detected, steering controller may be defecDefective steering control3 tive. (Since trouble is in system, troubleshooting cannot be carried ler out.)
Cause
50
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection 1

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Pump merge-divider solenoid: Disconnection failure (Steering controller system) DWJ0KA When the signal is output to the pump merge-divider solenoid circuit, no current flows. Flashes the caution lamp and turns on the caution buzzer. Stops outputting the signal to the pump merge-divider solenoid circuit. Blade tilt/pitch work may not be performed normally. The output state (ON/OFF) to the pump merge-divider solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output 1) Method of reproducing failure code: Turn the starting switch ON. + Execute the dual tilt mode. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective pump without turning starting switch ON. 1 merge-divider solenoid MFD (male) Resistance (Internal short circuit) Between (1) and (2) 20 60 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) Resis2 Max. 1 z wiring harness or defective (27) and MFD (female) (1) tance contact in connector) Wiring harness between STCN3 (female) (3) ResisMax. 1 z and MFD (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 2 (Since this is an internal defect, it cannot be 3 ler diagnosed). Cause
Circuit diagram related to pump merge-divider solenoid
D475A, D475ASD-5E0
51
SEN01829-00
40 Troubleshooting
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Pump merge-divider solenoid: Short circuit failure (Steering controller system) DWJ0KB When signal was output to pump merge-divider solenoid circuit, abnormal current flowed. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to pump merge-divider solenoid circuit. Blade may not be tilted or pitched normally. Output state (ON/OFF) to pump merge-divider solenoid can be checked in monitoring mode (Code 40914: Steering-related controller ON/OFF output 1). Method of reproducing failure code: Turn starting switch ON + Perform dual tilt mode.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective pump mergeMFD (male) Resistance divider solenoid (Internal short circuit) Between (1) (2) 20 60 z Between (1) ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. ness (Contact with GND Wiring harness between STCN3 (female) Resiscircuit) Min. 1 Mz (27) MFD (female) (1) tance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harBetween wiring harness between STCN3 ness (with another wiring (female) (27) MFD (female) (1) and wiring Resisharness) Min. 1 Mz harness between STCN3 (female) (3) MFD tance (female) (2) If causes 1 3 are not detected, steering controller may be defecDefective steering controltive. (Since trouble is in system, troubleshooting cannot be carried ler out.)
Cause
52
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Pump merge-divider solenoid: Hot short failure (Steering controller system) DWJ0KY Current keeps flowing to the pump merge-divider solenoid circuit. Flashes the caution lamp and turns on the caution buzzer. Stops outputting the signal to the pump merge-divider solenoid circuit. Blade tilt/pitch work may not be performed normally.
The output state (ON/OFF) to the pump merge-divider solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output 1) Method of reproducing failure code: Turn the starting switch ON. + Execute the dual tilt mode. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective pump without turning starting switch ON. 1 merge-divider solenoid MFD (male) Resistance (Internal short circuit) Between (1) and (2) 20 60 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Between wiring harness between STCN3 (Contact with 24-V circuit) (female) (27) and MFD (female) (1) and Voltage Max. 1 V chassis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 2 (Since this is an internal defect, it cannot be ler diagnosed). Cause
D475A, D475ASD-5E0
53
SEN01829-00
40 Troubleshooting
Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Sudden stop prevention solenoid: Disconnection failure (Steering controller system) DWN3KA When signal is output to sudden stop prevention solenoid circuit, any current does not flow. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode. (Code 31628: Sudden stop prevention solenoid drive current) Method of reproducing failure code: Turn starting switch ON. Cause Defective sudden stop 1 prevention solenoid (Internal disconnection) Possible causes and the standard values when normal
Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Defective steering controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ST8 (male) Resistance Between (1) (2) 5 25 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between STCN3 (female) (7) ResisMax. 1 z ST8 (female) (1) tance Wiring harness between STCN3 (female) ResisMax. 1 z (13) ST8 (female) (2) tance Steering controller can be suspected to be defective if no problem is found in causes 1 2 (Since this is an internal defect, it cannot be diagnosed).
Circuit diagram related to sudden stop prevention solenoid
54
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit1

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Sudden stop prevention solenoid: Short circuit failure (Steering controller system) DWN3KB When signal was output to sudden stop prevention solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode. (Code 31628: Sudden stop prevention solenoid drive current) Method of reproducing failure code: Turn starting switch ON. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective sudden stop ST8 (male) Resistance 1 prevention solenoid (Internal short circuit) Between (1) (2) 5 25 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between (Contact with ground cirResisSTCN3 (female) (7) ST8 (female) (1) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between 3 ness (with another wiring STCN3 (female) (7) ST8 (female) (1) with Resisharness) Min. 1 Mz wiring harness between STCN3 (female) (13) tance ST8 (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 3 (Since this is an internal defect, it cannot be 4 ler diagnosed). Cause
D475A, D475ASD-5E0
55
SEN01829-00
40 Troubleshooting
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Sudden stop prevention solenoid: Hot short failure (Steering controller system) DWN3KY Current keeps flowing to sudden stop prevention solenoid circuit. Flashes caution lamp and turns on caution buzzer. Limits operation of engine, transmission, and brake. Function of emergency sudden stop prevention does not operate. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode. (Code 31628: Sudden stop prevention solenoid drive current) Method of reproducing failure code: Turn starting switch ON. Cause Defective sudden stop 1 prevention solenoid (Internal disconnection) Possible causes and the standard values when normal
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ST8 (male) Resistance Between (1) (2) 5 25 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between STCN3 (female) (7) ST8 (female) (1) with Voltage Max. 1 V chassis ground Steering controller can be suspected to be defective if no problem is found in causes 1 2 (Since this is an internal defect, it cannot be diagnosed).
56
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fan pump solenoid 1: Disconnection failure (Transmission controller system) DWN5KA When signal is output to fan pump solenoid circuit, any current does not flow. Stops outputting to fan pump solenoid circuit. Output of the fan pump (LPV90) becomes maximum. Output (Current) to fan pump solenoid can be checked in monitoring mode. (Code 31623, 31624: Cooling fan solenoid output command current, output current) Method of reproducing failure code: Turn starting switch ON.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective fan pump solewithout turning starting switch ON. 1 noid (Internal disconnecFA1 (male) Resistance tion) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (17) Resis2 Max. 1 z wiring or defective contact FA1 (female) (1) tance in connector) Wiring harness between TMC3 (female) (23) ResisMax. 1 z FA1 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Cause
Circuit diagram related to fan pump solenoid
D475A, D475ASD-5E0
57
SEN01829-00
40 Troubleshooting
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fan pump solenoid 1: Short circuit failure (Transmission controller system) DWN5KB When signal was output to fan pump solenoid circuit, abnormal current flowed. Stops outputting to fan pump solenoid circuit. Output of the fan pump (LPV90) becomes maximum. Output (Current) to fan pump solenoid can be checked in monitoring mode. (Code 31623, 31624: Cooling fan solenoid output command current, output current) Method of reproducing failure code: Turn starting switch ON.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fan pump soleFA1 (male) Resistance 1 noid (Internal short circuit) Between (1) (2) 15 25 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between (Contact with ground cirResisTMC3 (female) (17) FA1 (female) (1) with Min. 1 Mz cuit) tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 3 ness (with another wiring (female) (17) FA1 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (23) FA1 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 3 (since this is an internal defect, it cannot 4 controller be diagnosed).
Cause
58
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DWN5KY] Fan pump solenoid 1: Hot short

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fan pump solenoid 1: Hot short failure (Transmission controller system) DWN5KY Current keeps flowing to fan pump solenoid circuit. Flashes warning lamp and turns on warning alarm. Stops outputting to fan pump solenoid circuit. Output of the fan pump (LPV90) becomes minimum. Fan speed does not increase. Output (Current) to fan pump solenoid can be checked in monitoring mode. (Code 31623, 31624: Cooling fan solenoid output command current, output current) Method of reproducing failure code: Turn starting switch ON.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective fan pump solewithout turning starting switch ON. 1 noid (Internal disconnecFA1 (male) Resistance tion) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) TMC3 (female) (17) FA1 (female) (1) with Voltage Max. 1 V chassis ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Cause
D475A, D475ASD-5E0
59
SEN01829-00
40 Troubleshooting
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection

Action code Failure code Symptom of Fan pump solenoid 2: Disconnection failure (Transmission controller system) E01 DWNCKA 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 appear on Output of the fan pump (LPV30) becomes maximum. machine The output state (current) to the fan pump solenoid can be checked in the monitoring mode. General (Code 31633, 31634: Cooling fan solenoid output command current, output current) information Method of reproducing failure code: Turn the starting switch ON.
Standard values when normal and remarks for troubleshooting Prepare with starting switch OFF, then carry out troubleshooting Defective fan pump without turning starting switch ON. 1 solenoid 2 FA2 (male) Resistance (Internal short circuit) Between (1) and (2) 5 15 z Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (7) Resis2 Max. 1 z wiring harness or defective and FA2 (female) (1) tance contact in connector) Wiring harness between TMC3 (female) (23) ResisMax. 1 z and FA2 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Cause
60
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-00
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fan pump solenoid 2: Short circuit failure (Transmission controller system) DWNCKB When the signal is output to the fan pump solenoid circuit, an abnormal current flows. Stops outputting the signal to the fan pump solenoid. Output of the fan pump (LPV30) becomes maximum. The output state (ON/OFF) to the fan pump solenoid can be checked in the monitoring mode. (Code 31633, 31634: Cooling fan solenoid output command current, output current) Method of reproducing failure code: Turn the starting switch ON. Cause Defective fan pump 1 solenoid 2 (Internal short circuit)
Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit) Short circuit in wiring harness 3 (Short circuit between wiring harnesses) Defective transmission controller
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FA2 (male) Resistance Between (1) and (2) 5 15 z Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMC3 Resis(female) (7) and FA2 (female) (1) and chasMin. 1 Mz tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMC3 (female) (7) and FA2 (female) (1) and wiring ResisMin. 1 Mz harness between TMC3 (female) (23) and tance FA2 (female) (2) Transmission controller can be suspected to be defective if no problem is found in causes 1 3 (since this is an internal defect, it cannot be diagnosed).
D475A, D475ASD-5E0
61
SEN01829-00
40 Troubleshooting
Failure code [DWNCKY] Fan pump solenoid 2: Hot short

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Fan pump solenoid 2: Hot short failure (Transmission controller system) DWNCKY Current keeps flowing to the fan pump solenoid circuit. Flashes warning lamp and turns on warning alarm. Stops outputting the signal to the fan pump solenoid circuit. Output of the fan pump (LPV30) becomes minimum. Fan speed does not increase. The output state (current) to the fan pump solenoid can be checked in the monitoring mode. (Code 31633, 31634: Cooling fan solenoid output command current, output current) Method of reproducing failure code: Turn the starting switch ON.
Standard values when normal and remarks for troubleshooting Prepare with starting switch OFF, then carry out troubleshooting Defective fan pump without turning starting switch ON. 1 solenoid 2 FA2 (male) Resistance (Internal short circuit) Between (1) and (2) 15 25 z Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Between wiring harness between TMC3 (Contact with 24-V circuit) (female) (7) and FA2 (female) (1) and chasVoltage Max. 1 V sis ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Cause
62
D475A, D475ASD-5E0
SEN01829-00
64
SEN01830-00
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
Troubleshooting by failure code (Display of code), Part 8 .............................................................................. 3 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
SEN01830-00
40 Troubleshooting
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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00

Failure code [DXE0KA] LS set solenoid: Disconnection
Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of LS set solenoid: Disconnection failure (Steering controller system) DXE0KA When the signal is output to the LS set solenoid circuit, no current flows. Stops outputting the signal to the LS set solenoid circuit. Flashes the caution lamp and turns on the caution buzzer. Pitching and tilting speed of the work equipment may become too high. The output state (ON/OFF) to the LS set solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output signal 1) Method of reproducing failure code: Turn the starting switch ON.
1
1
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective LS set solenoid 1 (Internal short circuit) LSV (male) Resistance Between (1) and (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) (37) Resis2 Max. 1 z wiring harness or defective and LSV (female) (1) tance contact in connector) Wiring harness between STCN3 (female) (3) ResisMax. 1 z and LSV (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 2 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
Circuit diagram related to LS set solenoid
D475A, D475ASD-5E0
SEN01830-00
40 Troubleshooting
Failure code [DXE0KB] LS set solenoid: Short circuit

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of LS set solenoid: Short circuit failure (Steering controller system) DXE0KB When the signal is output to the LS set solenoid circuit, an abnormal current flows. Stops outputting the signal to the LS set solenoid circuit. Flashes the caution lamp and turns on the caution buzzer. Pitching and tilting speed of the work equipment may become too high. The output state (ON/OFF) to the LS set solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output signal 1) Method of reproducing failure code: Turn the starting switch ON.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective LS set solenoid LSV (male) Resistance (Internal short circuit) Between (1) and (2) 15 25 z Between (1) and chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Between wiring harness between STCN3 (Contact with ground cirResis(female) (37) and LSV (female) (1) and chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness Between wiring harness between STCN3 (Short circuit between (female) (37) and LSV (female) (1) and wiring ResisMin. 1 Mz wiring harnesses) harness between STCN3 (female) (3) and tance LSV (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 3 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXE0KY] LS set solenoid: Hot short

Action code E02 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of LS set solenoid: Hot short failure (Steering controller system) DXE0KY Current keeps flowing to the LS set solenoid circuit. Stops outputting the signal to the LS set solenoid circuit. Flashes the caution lamp and turns on the caution buzzer. Pitching and tilting speed of the work equipment may become too high. The output state (ON/OFF) to the LS set solenoid can be checked in the monitoring mode. (Code 40914: Steering-related controller ON/OFF output signal 1) Method of reproducing failure code: Turn the starting switch ON.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective LS set solenoid 1 (Internal short circuit) LSV (male) Resistance Between (1) and (2) 15 25 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Between wiring harness between STCN3 (Contact with 24-V circuit) (female) (37) and LSV (female) (1) and chas- Voltage Max. 1 V sis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 2 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
D475A, D475ASD-5E0
SEN01830-00
40 Troubleshooting
Failure code [DXH1KA] Lock-up solenoid: Disconnection

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Lock-up solenoid: Disconnection failure (Transmission controller system) DXH1KA When signal is output to torque converter lock-up solenoid circuit, any current does not flow. Stops outputting to torque converter lock-up solenoid circuit. Torque converter is not locked-up. Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode. (Code 31627: Torque converter lock-up solenoid drive current) Method of reproducing failure code: Start engine and turn lock-up switch ON and drive machine.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective torque converter without turning starting switch ON. 1 lock-up solenoid (Internal 653 (male) Resistance short circuit) Between (1) (2) 30 80 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (38) Resis2 Max. 1 z wiring or defective contact 653 (female) (1) tance in connector) Wiring harness between TMC3 (female) (23) ResisMax. 1 z 653 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Cause
Circuit diagram related to torque converter lock-up solenoid
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXH1KB] Lock-up solenoid: Short circuit

Action code E01 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Lock-up solenoid: Short circuit failure (Transmission controller system) DXH1KB When signal was output to torque converter lock-up solenoid circuit, abnormal current flowed. Stops outputting to torque converter lock-up solenoid circuit. Torque converter is not locked-up. Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode. (Code 31627: Torque converter lock-up solenoid drive current) Method of reproducing failure code: Start engine and turn lock-up switch ON and drive machine.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective torque converter 653 (male) Resistance 1 lock-up solenoid (Internal short circuit) Between (1) (2) 30 80 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (38) 653 (female) (1) with chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 3 ness (with another wiring (female) (38) 653 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (23) 653 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 3 (since this is an internal defect, it cannot 4 controller be diagnosed).
Cause
Circuit diagram related to torque converter lock-up solenoid
D475A, D475ASD-5E0
SEN01830-00
40 Troubleshooting
Failure code [DXH1KY] Lockup solenoid: Hot short

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Lockup solenoid: Hot short failure (Transmission controller system) DXH1KY Some current keeps flowing to torque converter lockup solenoid circuit. Blinks warning lamp and sounds alarm buzzer. Stops outputting signal to torque converter lockup solenoid circuit. Torque converter lockup solenoid keeps operating. Once machine is stopped, engine speed is limited to medium (half). 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 (Code 31627: Torque converter lockup solenoid drive current). Method of reproducing failure code: Turn starting switch ON + Turn lockup switch ON + Drive machine.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective torque converter without turning starting switch ON. 1 lockup solenoid (Internal 653 (male) Resistance short circuit) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and Hot short (Contact with carry out troubleshooting. 2 24V circuit) in wiring harWiring harness between TMC3 (female) (38) ness Voltage Max. 1 V 653 (female) (1). If causes 1 2 are not detected, transmission controller may be Defective transmission 4 defective. (Since trouble is in system, troubleshooting cannot be controller carried out.)
Cause
Circuit diagram related to torque converter lockup solenoid
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXH4KA] 1st clutch ECMV: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 1st clutch ECMV: Disconnection failure (Transmission controller system) DXH4KA When signal is output to 1st clutch solenoid circuit, any current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 1st clutch solenoid circuit. Limits operation of engine and transmission. Automatic shift-down function does not work. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F2 and R2. Output (Current) to 1st clutch solenoid can be checked in monitoring mode. (Code 31602, 31612: Output command current, output current of 1st clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F1 or R1.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective 1st clutch solewithout turning starting switch ON. 1 noid (Internal disconnecS1T7 (male) Resistance tion) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (15) Resis2 Max. 1 z wiring or defective contact S1T7 (female) (1) tance in connector) Wiring harness between TMC3 (female) (3) ResisMax. 1 z S1T7 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 2 (Since this is an internal defect, it can3 controller not be diagnosed).
Cause
D475A, D475ASD-5E0
SEN01830-00
40 Troubleshooting
Failure code [DXH4KB] 1st clutch ECMV: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 1st clutch ECMV: Short circuit failure (Transmission controller system) DXH4KB When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 1st clutch solenoid circuit. Limits operation of engine and transmission. Automatic shift-down function does not work. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F2 and R2. Output (Current) to 1st clutch solenoid can be checked in monitoring mode. (Code 31602, 31612: Output command current, output current of 1st clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F1 or R1.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 1st clutch soleS1T7 (male) Resistance 1 noid (Internal short circuit) Between (1) (2) 5 15 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (15) S1T7 (female) (1) with chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 3 ness (with another wiring (female) (15) S1T7 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (3) S1T7 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 3 (since this is an internal defect, it cannot controller be diagnosed).
Cause
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXH4KY] 1st clutch ECMV: Hot short

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 1st clutch ECMV: Hot short failure (Transmission controller system) DXH4KY Current keeps flowing to 1st clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 1st clutch solenoid circuit. Limits operation of engine and transmission. Automatic shift-down function does not work. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Output (Current) to 1st clutch solenoid can be checked in monitoring mode. (Code 31602, 31612: Output command current, output current of 1st clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F2 or R2.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 1st clutch sole1 noid (Internal short circuit) S1T7 (male) Resistance Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with 24 V circuit) (female) (15) S1T7 (female) (1) with chassis Voltage Max. 1 V ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 2 (Since this is an internal defect, it cancontroller not be diagnosed).
Cause
D475A, D475ASD-5E0
11
SEN01830-00
40 Troubleshooting
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 2nd clutch ECMV: Disconnection failure (Transmission controller system) DXH5KA When signal is output to 2nd clutch solenoid circuit, any current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 2nd clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Output (Current) to 2nd clutch solenoid can be checked in monitoring mode. (Code 31603, 31613: Output command current, output current of 2nd clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F2 or R2. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective 2nd clutch solewithout turning starting switch ON. 1 noid (Internal disconnecS2T5 (male) Resistance tion) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (36) Resis2 Max. 1 z wiring or defective contact S2T5 (female) (1) tance in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z S2T5 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 2 (Since this is an internal defect, it can3 controller not be diagnosed). Cause
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 2nd clutch ECMV: Short circuit failure (Transmission controller system) DXH5KB When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 2nd clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Output (Current) to 2nd clutch solenoid can be checked in monitoring mode. (Code 31603, 31613: Output command current, output current of 2nd clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F2 or R2. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 2nd clutch soleS2T5 (male) Resistance 1 noid (Internal short circuit) Between (1) (2) 5 15 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (36) S2T5 (female) (1) with chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 3 ness (with another wiring (female) (36) S2T5 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (13) S2T5 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 3 (since this is an internal defect, it cannot controller be diagnosed). Cause
D475A, D475ASD-5E0
13
SEN01830-00
40 Troubleshooting
Failure code [DXH5KY] 2nd clutch ECMV: Hot short

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 2nd clutch ECMV: Hot short failure (Transmission controller system) DXH5KY Current keeps flowing to 2nd clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 2nd clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F2 and R2. Output (Current) to 2nd clutch solenoid can be checked in monitoring mode. (Code 31603, 31613: Output command current, output current of 2nd clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F1 or R1. Cause 1 Defective 2nd clutch solenoid (Internal short circuit) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S2T5 (male) Resistance Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Short circuit of wiring harness between TMC3 (female) (36) S2T5 (female) (1) with chassis Voltage Max. 1 V ground Transmission controller can be suspected to be defective if no problem is found in causes 1 2 (Since this is an internal defect, it cannot be diagnosed).
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 3rd clutch ECMV: Disconnection failure (Transmission controller system) DXH6KA When signal is output to 3rd clutch solenoid circuit, any current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 3rd clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Output (Current) to 3rd clutch solenoid can be checked in monitoring mode. (Code 31604, 31614: Output command current, output current of 3rd clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F3 or R3. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective 3rd clutch solewithout turning starting switch ON. 1 noid (Internal disconnecS3T3 (male) Resistance tion) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (5) Resis2 Max. 1 z wiring or defective contact S3T3 (female) (1) tance in connector) Wiring harness between TMC3 (female) (3) ResisMax. 1 z S3T3 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 2 (Since this is an internal defect, it can3 controller not be diagnosed). Cause
D475A, D475ASD-5E0
15
SEN01830-00
40 Troubleshooting
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 3rd clutch ECMV: Short circuit failure (Transmission controller system) DXH6KB When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 3rd clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Output (Current) to 3rd clutch solenoid can be checked in monitoring mode. (Code 31604, 31614: Output command current, output current of 3rd clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F3 or R3. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 3rd clutch soleS3T3 (male) Resistance 1 noid (Internal short circuit) Between (1) (2) 5 15 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (5) S3T3 (female) (1) with chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 3 ness (with another wiring (female) (5) S3T3 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (3) S3T3 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission 4 lem is found in causes 1 3 (since this is an internal defect, it cannot controller be diagnosed). Cause
16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXH6KY] 3rd clutch ECMV: Hot short

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of 3rd clutch ECMV: Hot short failure (Transmission controller system) DXH6KY Current keeps flowing to 3rd clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission 3rd clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F3 and R3. Output (Current) to 3rd clutch solenoid can be checked in monitoring mode. (Code 31604, 31614: Output command current, output current of 3rd clutch ECMV) Method of reproducing failure code: Start engine and drive machine in F1 or R1. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 3rd clutch sole1 noid (Internal short circuit) S3T3 (male) Resistance Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) TMCN3 (female) (5) S3T3 (female) (1) with Voltage Max. 1 V chassis ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 2 (Since this is an internal defect, it cancontroller not be diagnosed). Cause
D475A, D475ASD-5E0
17
SEN01830-00
40 Troubleshooting
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Reverse clutch ECMV: Disconnection failure (Transmission controller system) DXH7KA When signal is output to reverse clutch solenoid circuit, any current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission reverse clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1. Output (Current) to reverse clutch solenoid can be checked in monitoring mode. (Code 31606, 31616: Output command current, output current of reverse clutch ECMV) Method of reproducing failure code: Start engine and drive machine in reverse. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective reverse clutch without turning starting switch ON. 1 solenoid (Internal disconSRT1 (male) Resistance nection) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (25) Resis2 Max. 1 z wiring or defective contact SRT1 (female) (1) tance in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z SRT1 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 2 (Since this is an internal defect, it cannot 3 controller be diagnosed). Cause
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit

Failure code Symptom of Reverse clutch ECMV: Short circuit failure (Transmission controller system) DXH7KB When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission reverse clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1. Output (Current) to reverse clutch solenoid can be checked in monitoring mode. (Code 31606, 31616: Output command current, output current of reverse clutch ECMV) Method of reproducing failure code: Start engine and drive machine in reverse. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective reverse clutch SRT1 (male) Resistance solenoid (Internal short circuit) Between (1) (2) 5 15 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (25) SRT1 (female) (1) with chasMin. 1 Mz cuit) tance sis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 ness (with another wiring (female) (25) SRT1 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (13) SRT1 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 3 (since this is an internal defect, it cannot controller be diagnosed). Cause
D475A, D475ASD-5E0
19
SEN01830-00
40 Troubleshooting
Failure code [DXH7KY] Reverse clutch ECMV: Hot short

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Reverse clutch ECMV: Hot short failure (Transmission controller system) DXH7KY Current keeps flowing to reverse clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission reverse clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to R1. Output (Current) to reverse clutch solenoid can be checked in monitoring mode. (Code 31606, 31616: Output command current, output current of reverse clutch ECMV) Method of reproducing failure code: Start engine and drive machine in forward. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective reverse clutch without turning starting switch ON. 1 solenoid (Internal short cirSRT1 (male) Resistance cuit) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with 24 V circuit) (female) (25) SRT1 (female) (1) with chas- Voltage Max. 1 V sis ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 2 (Since this is an internal defect, it cannot controller be diagnosed). Cause
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXH8KA] Forward clutch ECMV: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Forward clutch ECMV: Disconnection failure (Transmission controller system) DXH8KA When signal is output to forward clutch solenoid circuit, any current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission forward clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to R1. Output (Current) to forward clutch solenoid can be checked in monitoring mode. (Code 31608, 31622: Output command current, output current of forward clutch ECMV) Method of reproducing failure code: Start engine and drive machine forward. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective forward clutch without turning starting switch ON. 1 solenoid (Internal disconSFT1 (male) Resistance nection) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (35) Resis2 Max. 1 z wiring or defective contact SFT1 (female) (1) tance in connector) Wiring harness between TMC3 (female) (13) ResisMax. 1 z SFT1 (female) (2) tance Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 2 (Since this is an internal defect, it can3 controller not be diagnosed). Cause
D475A, D475ASD-5E0
21
SEN01830-00
40 Troubleshooting
Failure code [DXH8KB] Forward clutch ECMV: Short circuit

Failure code Symptom of Forward clutch ECMV: Short circuit failure (Transmission controller system) DXH8KB When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission forward clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to R1. Output (Current) to forward clutch solenoid can be checked in monitoring mode. (Code 31608, 31622: Output command current, output current of forward clutch ECMV) Method of reproducing failure code: Start engine and drive machine forward. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward clutch SFT1 (male) Resistance solenoid (Internal short circuit) Between (1) (2) 5 15 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between TMC3 (Contact with ground cirResis(female) (35) SFT1 (female) (1) with chassis Min. 1 Mz cuit) tance ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between TMC3 ness (with another wiring (female) (35) SFT1 (female) (1) with wiring Resisharness) Min. 1 Mz harness between TMC3 (female) (13) SFT1 tance (female) (2) Transmission controller can be suspected to be defective if no probDefective transmission lem is found in causes 1 3 (since this is an internal defect, it cannot controller be diagnosed). Cause
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXH8KY] Forward clutch ECMV: Hot short

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Forward clutch ECMV: Hot short failure (Transmission controller system) DXH8KY Current keeps flowing to forward clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission forward clutch solenoid circuit. Limits operation of engine and transmission.
Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1. Output (Current) to forward clutch solenoid can be checked in monitoring mode. (Code 31608, 31622: Output command current, output current of forward clutch ECMV) Method of reproducing failure code: Start engine and drive machine reverse. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective forward clutch without turning starting switch ON. 1 solenoid (Internal short cirSFT1 (male) Resistance cuit) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between TMC3 (Contact with 24 V circuit) (female) (35) SFT1 (female) (1) with chassis Voltage Max. 1 V ground Transmission controller can be suspected to be defective if no probDefective transmission 3 lem is found in causes 1 2 (Since this is an internal defect, it cancontroller not be diagnosed). Cause
D475A, D475ASD-5E0
23
SEN01830-00
40 Troubleshooting
Failure code [DXH9KA] Right steering clutch ECMV: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right steering clutch ECMV: Disconnection failure (Steering controller system) DXH9KA When signal is output to right steering clutch solenoid circuit, current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to right. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90601, 90603: Right steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective right steering without turning starting switch ON. 1 clutch solenoid SRC7 (male) Resistance (Internal disconnection) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between STCN3 (female) (35) Max. 1 z 2 tance wiring or defective contact SRC7 (female) (1) in connector) Wiring harness between STCN3 (female) (23) ResisMax. 1 z SRC7 (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 2 (Since this is an internal defect, it cannot be 3 ler diagnosed).
Cause
24
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXH9KB] Right steering clutch ECMV: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right steering clutch ECMV: Short circuit failure (Steering controller system) DXH9KB When signal was output to right steering clutch solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to right. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90601, 90603: Right steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right steering SRC7 (male) Resistance clutch solenoid (Internal short circuit) Between (1) (2) 5 15 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisMin. 1 Mz STCN3 (female) (35) SRC7 (female) (1) cuit) tance with chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring Short circuit of wiring harness between harness (with another wirSTCN3 (female) (35) SRC7 (female) (1) Resising harness) Min. 1 Mz with wiring harness between STCN3 (female) tance (23) SRC7 (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 3 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
D475A, D475ASD-5E0
25
SEN01830-00
40 Troubleshooting
Failure code [DXH9KY] Right steering clutch ECMV: Hot short

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right steering clutch ECMV: Hot short failure (Steering controller system) DXH9KY Current keeps flowing to right steering clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to right. (Right clutch cannot be disconnected.) Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, machine cannot travel any more. Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90601, 90603: Right steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective right steering without turning starting switch ON. 1 clutch solenoid SRC7 (male) Resistance (Internal short circuit) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) STCN3 (female) (35) SRC7 (female) (1) Voltage Max. 1 V with chassis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 2 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXHAKA] Left steering clutch ECMV: Disconnection

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left steering clutch ECMV: Disconnection failure (Steering controller system) DXHAKA When signal is output to left steering clutch solenoid circuit, current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to left. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90600, 90602: Left steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left steering without turning starting switch ON. 1 clutch solenoid SLC5 (male) Resistance (Internal disconnection) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between STCN3 (female) (25) Max. 1 z 2 tance wiring or defective contact SLC5 (female) (1) in connector) Wiring harness between STCN3 (female) (23) ResisMax. 1 z SLC5 (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 2 (Since this is an internal defect, it cannot be 3 ler diagnosed).
Cause
Circuit diagram related to left steering clutch ECMV
D475A, D475ASD-5E0
27
SEN01830-00
40 Troubleshooting
Failure code [DXHAKB] Left steering clutch ECMV: Short circuit

Action code CALL E03 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left steering clutch ECMV: Short circuit failure (Steering controller system) DXHAKB When signal was output to left steering clutch solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to left. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90601, 90603: Left steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left steering SLC5 (male) Resistance clutch solenoid (Internal short circuit) Between (1) (2) 5 15 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisMin. 1 Mz STCN3 (female) (25) SLC5 (female) (1) with cuit) tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring Short circuit of wiring harness between harness (with another wirSTCN3 (female) (25) SLC5 (female) (1) with Resising harness) Min. 1 Mz wiring harness between STCN3 (female) (23) tance SLC5 (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 3 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXHAKY] Left steering clutch ECMV: Hot short

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left steering clutch ECMV: Hot short failure (Steering controller system) DXHAKY Current keeps flowing to left steering clutch solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering clutch solenoid circuit. Limits operation of engine and transmission. Machine cannot be steered to left. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, machine cannot travel any more. Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode. (Code 90600, 90602: Left steering clutch ECMV (E-POCV) output current, command current) Method of reproducing failure code: Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left steering without turning starting switch ON. 1 clutch solenoid SLC5 (male) Resistance (Internal short circuit) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24 V circuit) STCN3 (female) (25) SLC5 (female) (1) with Voltage Max. 1 V chassis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 2 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
D475A, D475ASD-5E0
29
SEN01830-00
40 Troubleshooting
Failure code [DXHBKA] Right brake ECMV: Disconnection

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right brake ECMV: Disconnection failure (Steering controller system) DXHBKA When signal is output to right steering brake solenoid circuit, any current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering brake solenoid circuit. Limits operation of engine, transmission and brake. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Right brake is kept applied. Output (Current) to right steering brake solenoid can be checked in monitoring mode. (Code 31620, 31618: Command current, output current of right steering brake ECMV) Method of reproducing failure code: Turn starting switch ON and release parking brake lever.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective right steering without turning starting switch ON. 1 brake solenoid (Internal SR83 (male) Resistance short circuit) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring Resisharness (Disconnection in Wiring harness between STCN3 (female) (15) Max. 1 z 2 tance wiring or defective contact SR83 (female) (1) in connector) Wiring harness between STCN3 (female) (13) ResisMax. 1 z SR83 (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 2 (Since this is an internal defect, it cannot be 3 ler diagnosed).
Cause
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXHBKB] Right brake ECMV: Short circuit

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right brake ECMV: Short circuit failure (Steering controller system) DXHBKB When signal was output to right steering brake solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering brake solenoid circuit. Limits operation of engine, transmission, and brake. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Right brake is kept applied. Output (Current) to right steering brake solenoid can be checked in monitoring mode. (Code 31620, 31618: Command current, output current of right steering brake ECMV) Method of reproducing failure code: Start engine and release parking brake lever.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective right steering SR83 (male) Resistance brake solenoid (Internal short circuit) Between (1) (2) 5 15 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisMin. 1 Mz STCN3 (female) (15) SR83 (female) (1) with cuit) tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between ness (with another wiring STCN3 (female) (15) SR83 (female) (1) with Resisharness) Min. 1 Mz wiring harness between STCN3 (female) (13) tance SR83 (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 3 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
D475A, D475ASD-5E0
31
SEN01830-00
40 Troubleshooting
Failure code [DXHBKY] Right brake ECMV: Hot short

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right brake ECMV: Hot short failure (Steering controller system) DXHBKY Current keeps flowing to right steering brake solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to right steering brake solenoid circuit. Limits operation of engine, transmission and brake. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Right brake is kept applied. Output (Current) to right steering brake solenoid can be checked in monitoring mode. (Code 31620, 31618: Command current, output current of right steering brake ECMV) Method of reproducing failure code: Turn starting switch ON and release parking brake lever.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective right steering without turning starting switch ON. 1 brake solenoid (Internal SR83 (male) Resistance short circuit) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24V circuit) STCN3 (female) (15) SR83 (female) (1) with Voltage Max. 1 V chassis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 2 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
32
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXHCKA] Left brake ECMV: Disconnection

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left brake ECMV: Disconnection failure (Steering controller system) DXHCKA When signal is output to left steering brake solenoid circuit, any current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering brake solenoid circuit. Limits operation of engine, transmission and brake. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Left brake is kept applied. Output (Current) to left steering brake solenoid can be checked in monitoring mode. (Code 31621, 31619: Command current, output current of left steering brake ECMV) Method of reproducing failure code: Turn starting switch ON and release parking brake lever.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left steering without turning starting switch ON. 1 brake solenoid (Internal SL81 (male) Resistance short circuit) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between STCN3 (female) (5) ResisMax. 1 z 2 tance wiring or defective contact SL81 (female) (1) in connector) Wiring harness between STCN3 (female) (13) ResisMax. 1 z SL81 (female) (2) tance Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 2 (Since this is an internal defect, it cannot be 3 ler diagnosed).
Cause
D475A, D475ASD-5E0
33
SEN01830-00
40 Troubleshooting
Failure code [DXHCKB] Left brake ECMV: Short circuit

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left brake ECMV: Short circuit failure (Steering controller system) DXHCKB When signal was output to left steering brake solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering brake solenoid circuit. Limits operation of engine, transmission, and brake. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Left brake is kept applied. Output (Current) to left steering brake solenoid can be checked in monitoring mode. (Code 31621, 31619: Command current, output current of left steering brake ECMV) Method of reproducing failure code: Start engine and release parking brake lever.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective left steering SL81 (male) Resistance brake solenoid (Internal short circuit) Between (1) (2) 5 15 z Between (1) chassis ground Min. 1 Mz a Prepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. ground in wiring harness Short circuit of wiring harness between (Contact with ground cirResisMin. 1 Mz STCN3 (female) (5) SL81 (female) (1) with cuit) tance chassis ground a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harShort circuit in wiring harness between ness (with another wiring STCN3 (female) (5) SL81 (female) (1) with Resisharness) Min. 1 Mz wiring harness between STCN3 (female) (13) tance SL81 (female) (2) Steering controller can be suspected to be defective if no problem is Defective steering controlfound in causes 1 3 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-00
Failure code [DXHCKY] Left brake ECMV: Hot short

Action code CALL E04 Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left brake ECMV: Hot short failure (Steering controller system) DXHCKY Current keeps flowing to left steering brake solenoid circuit. Flashes caution lamp and turns on caution buzzer. Stops outputting to left steering brake solenoid circuit. Limits operation of engine, transmission and brake. Sudden stop prevention valve is applied during travel. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it cannot travel any more. Output (Current) to left steering brake solenoid can be checked in monitoring mode. (Code 31621, 31619: Command current, output current of left steering brake ECMV) Method of reproducing failure code: Turn starting switch ON and release parking brake lever.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting Defective left steering without turning starting switch ON. 1 brake solenoid (Internal SL81 (male) Resistance short circuit) Between (1) (2) 5 15 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 Short circuit of wiring harness between (Contact with 24V circuit) STCN3 (female) (5) SL81 (female) (1) with Voltage Max. 1 V chassis ground Steering controller can be suspected to be defective if no problem is Defective steering control3 found in causes 1 2 (Since this is an internal defect, it cannot be ler diagnosed).
Cause
D475A, D475ASD-5E0
35
SEN01830-00
40 Troubleshooting
Failure code [F@BBZL] (or VHMS_LED display "n3" o "38") Engine blow-by pressure sensor: Abnormally high pressure occurrence
Action code Failure code Symptom of Engine blow-by pressure sensor: Abnormally high pressure occurfailure rence (VHMS controller system) F@BBZL Failure content Blow-by pressure sensor signal circuit detected pressure higher than 4.71 kPa {480 mmAq}. Controller's None in particular. action Symptoms that appear on If machine is used as it is, engine may be broken. 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 "n3" on VHMS controller LED changes to "38". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of blow-by 1 pressure (When system is Check engine and repair, if there is abnormality. normal) Defective blow-by presIf failure code [DHE5KB] or [DHE5KY] is displayed, carry out trou2 sure sensor system bleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller Between V2A (female) (18) V2A (female) 0.3 Voltage (12) 0.7 V
36
D475A, D475ASD-5E0
SEN01830-00
40 Troubleshooting
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 content Controller's action Symptoms that appear on machine General information Left front exhaust temperature sensor (1): Exhaust temperature Symptom of abnormal rise failure F@BYNS (VHMS controller system) Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700C in range above rated output speed and 750C in range below maximum torque speed) None in particular. If machine is used as it is, engine may be broken. Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). "n3" on VHMS controller LED changes to "61". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of left front 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective left front exhaust If failure code [DGT5KA] or [DGT5KB] is displayed, carry out trou2 temperature sensor bleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. V2A Exhaust temperature Voltage 3 Defective VHMS controller 20C Approx. 0.9 1.2 V (7) (13) 500C Approx. 2.6 3.5 V Failure code
38
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Circuit diagram related to exhaust temperature sensor (1)
D475A, D475ASD-5E0
39
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40 Troubleshooting
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left rear exhaust temperature sensor (1): Exhaust temperature failure abnormal rise (VHMS controller system) f@BYNS Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700C in range above rated output speed and 750C in range below maximum torque speed) None in particular. If machine is used as it is, engine may be broken. Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). "n3" on VHMS controller LED changes to "71". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of left rear 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective left rear exhaust If failure code [dGT5KA] or [dGT5KB] is displayed, carry out trouble2 temperature sensor shooting for it. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. V2A Exhaust temperature Voltage 3 Defective VHMS controller 20C Approx. 0.9 1.2 V (6) (13) 500C Approx. 2.6 3.5 V
40
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41
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40 Troubleshooting
Failure code [F@BZNS] (or VHMS_LED display "n3" o "38") Right front exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right front exhaust temperature sensor (1): Exhaust temperature failure abnormal rise (VHMS controller system) F@BZNS Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700C in range above rated output speed and 750C in range below maximum torque speed) None in particular. If machine is used as it is, engine may be broken. Failure code is not displayed on machine monitor (It can be checked, however, by downloading data saved in VHMS controller into personal computer). "n3" on VHMS controller LED changes to "38". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of right front 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective right front If failure code [DGT6KA] or [DGT6KB] is displayed, carry out trou2 exhaust temperature senbleshooting for it. sor a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller V2A (5) (13) Exhaust temperature 20C 500C Voltage Approx. 0.9 1.2 V Approx. 2.6 3.5 V
42
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43
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40 Troubleshooting
Failure code [f@BZNS] (or VHMS_LED display "n3" o "39") Right rear exhaust temperature sensor (1): Exhaust temperature abnormal rise 1
Action code Failure content Controller's action Symptoms that appear on machine General information Right rear exhaust temperature sensor (1): Exhaust temperature Symptom of abnormal rise failure f@BZNS (VHMS controller system) Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 1 for 20 seconds. (Exhaust temperature limit line 1: Straight line between 700C in range above rated output speed and 750C in range below maximum torque speed) None in particular. If machine is used as it is, engine may be broken. Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). "n3" on VHMS controller LED changes to "39". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of right rear 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective right rear If failure code [dGT6KA] or [dGT6KB] is displayed, carry out trouble2 exhaust temperature senshooting for it. sor a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller V2A (16) (13) Exhaust temperature 20C 500C Voltage Approx. 0.9 1.2 V Approx. 2.6 3.5 V Failure code
44
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45
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40 Troubleshooting
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left front exhaust temperature sensor (2): Exhaust temperature failure abnormal rise (VHMS controller system) F@BYNR Left front exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750C in range above rated output speed and 800C in range below maximum torque speed) None in particular. If machine is used as it is, engine may be broken. Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). "n3" on VHMS controller LED changes to "62". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of left front 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective left front exhaust If failure code [DGT5KA] or [DGT5KB] is displayed, carry out trou2 temperature sensor bleshooting for it. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller V2A (7) (13) Exhaust temperature 20C 500C Voltage Approx. 0.9 1.2 V Approx. 2.6 3.5 V
46
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47
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40 Troubleshooting
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Left rear exhaust temperature sensor (2): Exhaust temperature failure abnormal rise (VHMS controller system) f@BYNR Left rear exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750C in range above rated output speed and 800C in range below maximum torque speed) None in particular. If machine is used as it is, engine may be broken. Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). "n3" on VHMS controller LED changes to "72". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of left rear 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective left rear exhaust If failure code [dGT5KA] or [dGT5KB] is displayed, carry out trouble2 temperature sensor shooting for it. a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller V2A (6) (13) Exhaust temperature 20C 500C Voltage Approx. 0.9 1.2 V Approx. 2.6 3.5 V
48
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49
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Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right front exhaust temperature sensor (2): Exhaust temperature failure abnormal rise (VHMS controller system) F@BZNR Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750C in range above rated output speed and 800C in range below maximum torque speed) None in particular. If machine is used as it is, engine may be broken. Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). "n3" on VHMS controller LED changes to "82". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of right front 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective right front If failure code [DGT6KA] or [DGT6KB] is displayed, carry out trou2 exhaust temperature senbleshooting for it. sor a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller V2A (5) (13) Exhaust temperature 20C 500C Voltage Approx. 0.9 1.2 V Approx. 2.6 3.5 V
50
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51
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Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear exhaust temperature sensor (2): Exhaust temperature abnormal rise 1
Action code Failure content Controller's action Symptoms that appear on machine General information Failure code Symptom of Right rear exhaust temperature sensor (2): Exhaust temperature failure abnormal rise (VHMS controller system) f@BZNR Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust temperature limit line 2 for 10 seconds. (Exhaust temperature limit line 2: Straight line between 750C in range above rated output speed and 800C in range below maximum torque speed) None in particular. If machine is used as it is, engine may be broken. Failure code is not displayed on monitor panel (It can be checked, however, by downloading data saved in VHMS controller into personal computer). "n3" on VHMS controller LED changes to "92". Cause Standard values when normal and remarks for troubleshooting Abnormal rise of right rear 1 exhaust temperature Check engine and repair, if there is abnormality. (When system is normal) Defective right rear If failure code [dGT6KA] or [dGT6KB] is displayed, carry out trouble2 exhaust temperature senshooting for it. sor a Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 3 Defective VHMS controller V2A (16) (13) Exhaust temperature 20C 500C Voltage Approx. 0.9 1.2 V Approx. 2.6 3.5 V
52
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53
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Contents of troubleshooting table ................................................................................................................... 3 E-1 The engine does not start......................................................................................................................... 4 E-2 The preheater does not operate............................................................................................................... 8 E-3 The ripper pin puller cylinder does not operate ...................................................................................... 12 E-4 The monitor panel does not come on at all when the starting switch is turned on ................................. 14 E-5 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out..................................................................................................................................... 16 E-6 When the starting switch is turned on, the basic check items flash ....................................................... 17 E-7 While the engine is operating, any caution item flashes ........................................................................ 18 E-8 An emergency caution item flashes while the engine is running............................................................ 21 E-9 While the preheater is operating, the preheating pilot lamp does not come on ..................................... 24 E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine) ................................................................................................................. 26
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E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on ................................................................................................................................. 26 E-12 The engine coolant temperature gauge does not indicate normally..................................................... 27 E-13 Indication of the power train (torque converter) temperature gauge is abnormal................................. 28 E-14 The hydraulic oil temperature gauge does not indicate normally ......................................................... 29 E-15 Indication of the fuel gauge is abnormal............................................................................................... 30 E-16 Indications of gear speed and engine speed are abnormal.................................................................. 31 E-17 Indication of the shift mode service meter is abnormal ........................................................................ 31 E-18 The switch module cannot be operated................................................................................................ 32 E-19 The warning lamp does not flash or does not go out............................................................................ 33 E-20 The alarm buzzer does not sound or does not stop ............................................................................. 34 E-21 Auto shift down is not possible or is not released................................................................................. 35 E-22 The automatic pitch back system does not operate (only superdozer specification) ........................... 36 E-23 The alarm buzzer cannot be cancelled................................................................................................. 37 E-24 The operator mode cannot be operated ............................................................................................... 38 E-25 The service mode cannot be operated ................................................................................................. 40 E-26 The back-up alarm does not sound ...................................................................................................... 42 E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on ...... 44 E-28 Troubleshooting for air conditioner system........................................................................................... 50 E-29 Orbcomm terminal does not operate normally (Data are not transmitted) ........................................... 65 E-30 Fan does not reverse............................................................................................................................ 67 E-31 Gear cannot be shifted ......................................................................................................................... 69 E-32 Electric priming pump does not operate or does not stop automatically .............................................. 70
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Contents of troubleshooting table

a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Trouble Related information Problem that appears on machine Information related to detected trouble or troubleshooting
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 A harness not connected to the power (24 V) circuit comes 2 into contact with the power (24 V) circuit. Short circuit Causes by which a trouble A harness of an independent circuit abnormally comes into is assumed to be defected contact with one of another circuit. (The order number indicates a serial number, not <Notes on troubleshooting> (1) Method of indicating connector numbers and handling of Ta priority sequence.) 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 () leads as shown below unless especially specified. 4 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: indicate the ends of branch or source of merging within the parts of the same wiring harness Arrow (io): Roughly indicates mounting place on machine.
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E-1 The engine does not start

Symptom of failure (1) The engine does not start. 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 the starting switch is set to ON, the main electric power supply system is supposed to be out of order. So, inspect the main electric power supply system. 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 displayed, conduct troubleshooting for the displayed code first.) Cause 1 Insufficient battery capacity Standard values when normal and remarks for troubleshooting Battery voltage Min. 24 V Battery specific gravity Min. 1.26
General information
Defective starting switch (internal disconnection)
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. KEY (male) Between (5) and (3) Switch position OFF START Resistance Min. 1 Mz Max. 1 z
Defective neutral safety 3 relay (internal disconnection)
a Prepare with the starting switch OFF, then start the engine and carry out troubleshooting. If the engine starts in accordance with the engine starting arrangement 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 ON and carry out troubleshooting. Alternator Between Terminal R and ground Voltage Max. 1 V
Defective alternator (internal short-circuit)
a Prepare with the starting switch OFF, then start the engine and carry out troubleshooting. Starting motor A, B Electric power supply : between Terminal B and ground 5 Detective starting motor (internal defect) Charge : between Terminal R and ground Starting : between Terminal S and ground Voltage 20 30 V Max. 1 V 20 30 V
When the voltages of electric power supply, for charging and starting are normal but the starting motor does not rotate, the starting motor is defective. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection in wiring harness (disconnection in wir6 ing or defective contact in connector) Wiring harness between KEY (female) (3) and NFS (female) (3) Wiring harness between NSF (female) (5) and ST1 (female) (1) Wiring harness between NSF (female) (5) and ST2 (female) (1) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
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Cause
Standard values when normal and remarks for troubleshooting a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting.
Hot short in wiring harness (Contact with 24 V circuit) Hot short of wiring harness between STCN1 (female) (23) and pre-lubrication motor signal terminal with ground
Hot short of wiring harness between alternator R terminal and ST1 (female) (2) or ST2 (female) (2) with ground
Voltage
Max. 1 V
Voltage
Max. 1 V
Hot short of wiring harness between S03 (female) (9) and pre-heater relay HTRIC terminal with ground
Voltage
Max. 1 V
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40 Troubleshooting
Symptom of failure General information
(2) Trouble (1) is not detected but the engine does not start (When the machine is equipped with prelubricator). "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 side flashes, the engine oil pressure is not heightened. (In this case, the pre-lubrication motor and the engine oil pressure switch for pre-lubrication may be defective. Accordingly, carry out the following troubleshooting.) Cause Defective engine oil pressure switch for pre-lubrica1 tion (Internal disconnection or short circuit) Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then keep starting switch OFF or start engine and carry out troubleshooting. STCN2 Between (3) and chassis ground Starting switch OFF Start engine Resistance Max. 1 z Min. 1 Mz
Defective pre-lubrication 2 relay (PLUB)
When the relay is replaced with another one with the starting switch OFF, the engine starts or "PE" is displayed on the gear speed display 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. Pre-lubrication motor Between signal terminal and chassis ground Voltage 20 30 V
Defective pre-lubrication motor
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between engine oil pressure switch terminal POP and STCN2 (female) (3) Disconnection in wiring harness (Disconnection in 4 wiring harness or defective contact in connector) Wiring harness between KEY (female) (1) and pre-lubrication relay (PLUB) (female) (1) Wiring harness between pre-lubrication relay (PLUB) (female) (2) and STCN2 (female) (18) Wiring harness between pre-lubrication motor signal terminal and STCN1 (female) (23) Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis ground in wiring harness 5 (Contact with ground circuit) Between wiring harness between KEY (female) (1) and pre-lubrication relay (PLUB) (female) (1) and chassis ground Between wiring harness between pre-lubrication relay (PLUB) (female) (2) and STCN2 (female) (18) and chassis ground Between wiring harness between pre-lubrication motor signal terminal and STCN1 (female) (23) and chassis ground Resistance Resistance Resistance Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
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Circuit diagram related
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E-2 The preheater does not operate

Symptom of failure The preheater does not operate. a This troubleshooting describes the procedures to be followed when the automatic and manual preheating 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 available. When either function is performed, the preheating lamp comes on. 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.) Causes Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Starting switch Between 250 (B) 255 (R1) Switch position OFF HEAT (R1) Resistance Min. 1 Mz Max. 1 z
General information
Defective starting switch (internal disconnection)
Defective fuse 2 (FS22) 3 Defective circuit breaker (CB30, CB6) Defective preheater relay (internal disconnection)
If the fuse is burnt, it is highly possible that a defective grounding, etc. has occurred in the circuit. If the breaker is cutout, it is highly possible that a defective grounding, etc. has occurred in the circuit. a Prepare with starting switch OFF and diagnose with starting switch ON. If preheating starts normally at the intake air temperature below minus 5C after the preheater relay PHR is replaced with another one, the preheater relay PHR is defective. a Prepare with the starting switch OFF and diagnose with the starting switch HEAT. Heater relay Voltage 20 30V 20 30V Electric power supply: between terminal HTR1A, HTR2A and ground Signal: between terminal HTR1C, HTR2C and ground
Possible causes and the standard values when normal Defective heater relay 5 (internal defect)
When the both voltages of electric power supply and signal are normal and no operating noise is heard, the heater relay is defective. Defective diode (internal short circuit) a Prepare with starting switch OFF and diagnose with starting switch still OFF. Diagnose diode HTD1, HTD2 (male) See the Inspection procedure of diode in the Testing and adjusting section. a Prepare with starting switch OFF and diagnose with starting switch still OFF. Electrical intake air heater Between terminals Continuity Continue
Defective electrical intake air heater (internal defect)
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Causes
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF and diagnose with starting switch still OFF. Wiring harnesses between FS22 (2) PHR (female) (5) Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Wiring harness between PHR (female) (3) terminal HTR1C terminal HTR2C Wiring harness between starting switch 255 (R1) terminal HTR1C terminal HTR2C Wiring harness between terminal BRC of battery relay terminal HTR1A and terminal HTR1A Wiring harness between terminal REL1, REL2 of heater relay electrical intake air heater HT1
Max. 1 z
a Prepare with starting switch OFF and diagnose with starting switch still OFF. Between ground and wiring harness between FS22 (2) PHR (female) (5) Between ground and wiring harness between PHR (female) (3) terminal HTR1C terminal HTR2C Resistance Resistance Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz
Defective harness Between ground and wiring harness 9 grounding (contact with ground circuit) between starting switch 255 (R1) terminal HTR1C terminal HTR2C
Min. 1 Mz
Between ground and wiring harness between terminal BRC of battery relay terminal HTR1A and terminal HTR2A Between ground and wiring harness between terminal REL1, REL2 of heater relay electrical intake air heater HT1
Min. 1 Mz
Min. 1 Mz
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10
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11
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E-3 The ripper pin puller cylinder does not operate

Symptom of failure General information Cause 1 Defective fuse (FS22-2) Standard value in normal state/Remarks on troubleshooting When the fuse is blown, a ground fault may have possibly occurred to the circuit. The ripper pin puller cylinder does not operate.
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective pin puller switch 263 (male) Switch Resistance 2 (Internal disconnection or short circuit) Pull Max. 1 z Between (1) and (2) Press Min. 1 Mz Defective pin puller sole3 noid (Internal disconnection or short circuit) a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 224 (male) Between (1) and (2) Between (1) and ground Possible causes and the standard values when normal Resistance 10 80 z Min. 1 Mz
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection in wiring harness (Disconnection in 4 wiring or defective contact in connector) Wiring harness between FS22-2 outlet and 263 (female) (1) Wiring harness between 263 (female) (2) and 224 (female) (1) Wiring harness between 224 (female) (2) and ground Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
Ground fault of wiring harBetween wiring harness related to FS22-2 5 ness (Contact with ground (outlet side) and ground circuit) Between wiring harness (between 263 (female) (2) and 224 (female) (1)) and ground
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 6 Hot short in wiring harness Between wiring harness (between 263 (Contact with 24 V circuit) (female) (2) and 234 (female) (1)) and ground Wiring harness between 244 (female) (2) and ground Voltage Voltage Max. 1 V Max. 1 V
12
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E-4 The monitor panel does not come on at all when the starting switch is turned on
Symptom of failure General information The monitor panel does not come on at all when the starting switch is turned ON. When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge section and the lamp section come on for 2 sec. Cause 1 Defective circuit breaker (CB2) Standard value in normal state/Remarks on troubleshooting When the circuit breaker is cut off, the circuit may have possibly been short-circuited with ground. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between S03 (female) (1) (2) and CB2 outlet Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Wiring harness between S03 (female) (3) (4) and ground Wiring harness between S03 (female) (5), (6) and CB6 outlet Wiring harness between S01 (female) (1) and CB2 outlet Wiring harness between S01 (female) (2) and ground Possible causes and the standard values when normal Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness CB2 (outlet side) and S03 (female) (2) and S01 (female) (1) and ground Between wiring harness CB6 (outlet side) and S03 (female) (5) (6) and ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. S03 Between (1), (2) and (3), (4) 4 Defective monitor panel (Gauge/lamp module) S01 Between (1) and (2) Voltage 20 30 V Voltage 20 30 V
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON and OFF. S03 Between (5) (6) and (3) (4) 5 CAN communication error Voltage 20 30 V
If failure code [DAFRKR] of CAN communication error is displayed, carry out troubleshooting for it.
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E-5 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out
Symptom of failure General information Possible causes and the standard values when normal When the starting switch is turned ON, the monitor panel completely remains lighted and does not go out. When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge section and the lamp section come on for 2 sec. and go out. Cause 1 Defective monitor panel (Gauge/lamp module) Standard value in normal state/Remarks on troubleshooting This internal defect cannot be diagnosed.
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E-6 When the starting switch is turned on, the basic check items flash
Trouble Related information The radiator coolant level caution lamp flashes. When any basic check items are detected to be abnormal before the engine starts, they will flash. Cause 1 Radiator coolant level decrease Standard value in normal state/Remarks on troubleshooting Because the radiator coolant level decrease is detected, inspect the radiator coolant level (the lamp flashes below the specified level). a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. WLD (male) Between (1) and (2) Radiator coolant level Normal level Lower level Resistance Max. 1 z Min. 1 Mz
The main radiator coolant 2 level sensor is defective. (Internal disconnection) Possible causes and standard value in normal state
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between S03 (female) (11) Resis3 Max. 1 z wiring or defective contact and WLD (female) (1) tance in connector) Wiring harness between WLD (female) (2) ResisMax. 1 z and ground tance a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. S03 Between (11) and ground Radiator coolant level Normal level Lower level Voltage Max. 1 V 20 30 V
Defective monitor panel (Gauge/lamp module)
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E-7 While the engine is operating, any caution item flashes

Symptom of failure General information (1) The battery charge level caution lamp flashes. When any abnormality is detected during engine operation, the relevant caution item will flash. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with the starting switch OFF, then start the engine and carry out troubleshooting. Alternator Between Terminal R and ground Engine speed Min. medium speed (half) Voltage 20 30 V
Defective alternator (insufficient power generation)
a Prepare with the starting switch OFF, then carry out troubleshootDisconnection of wiring ing without turning the starting switch ON. harness (Disconnection in 2 wiring or defective contact Wiring harness between S04 (female) (9) and ResisMax. 1 z in connector) alternator R terminal tance Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit) a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness between S04 (female) (9), alternator terminal R, starting motor terminal R, STCN1 (female) (15), and TMCN1 (female) (15) and chassis ground Resistance Min. 1 Mz
Defective monitor panel (Gauge/lamp module)
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. S04 Between (9) and ground Engine speed Min. medium speed (half) Voltage 20 30 V
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(2) The air cleaner clogging caution lamp flashes. If abnormality is detected while the engine is running, the caution item lamp flashes. Cause 1 Clogged air cleaner Standard value in normal state/Remarks on troubleshooting Clean or replace the air cleaner. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector) Wiring harness between S03 (female) (13) and AF1 (female) (1) Wiring harness between AF1 (female) (2) and AF2 (female) (1) Wiring harness between AF1 (female) (2) chassis ground Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and the standard values when normal Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit) Between wiring harness between S03 (female) (13) and AF1 (female) (1) and chassis ground Between wiring harness between AF1 (female) (2) and AF2 (female) (1) and chassis ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective monitor panel (gauge, lamp module) S03 Between (13) and chassis ground Air cleaner When normal When clogged Voltage Max. 1 V 20 30 V
a Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective air cleaner clogAF1, AF2 (male) Air cleaner Resistance 5 ging sensor (Internal disconnection) When normal Max. 1 z Between (1) and (2) When clogged Min. 1 Mz
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E-8 An emergency caution item flashes while the engine is running

Symptom of failure General information (1) The engine oil pressure caution lamp flashes. If abnormality is detected while the engine is running, the emergency calculation item flashes and the caution buzzer sounds. The engine controller checks the engine oil pressure for abnormality. Failure code [B@BAZG] may be displayed, too. Cause 1 Standard value in normal state/Remarks on troubleshooting
Check the engine oil pressure, as the drop of engine oil pressure is Reduction of engine oil presdetected. sure Carry out the troubleshooting of "S-12 Oil pressure drops." If no problem is found in cause 1, the engine oil pressure sensor circuit can be suspected to be defective. So, carry out the troubleshooting of "Failure codes [CA135] and [CA141] Abnormal engine oil pressure sensor." Since this is an internal defect, it cannot be diagnosed.
Defective engine hydraulic 2 system 3 Defective monitor panel
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Symptom of failure
(2) The engine coolant temperature caution lamp flashes. When any abnormality is detected during engine operation, the relevant emergency warning item will sound the alarm buzzer. The engine coolant temperature caution lamp flashes or goes out as it links with indication on the engine coolant temperature gauge. The engine controller checks the engine coolant temperature for abnormality. Failure code [B@BCNS] may be displayed, too. Cause 1 Overheated engine coolant temperature Standard value in normal state/Remarks on troubleshooting As overheated engine coolant was detected, check the engine coolant temperature. (When the coolant temperature is over 102C, the lamp flashes. When the coolant temperature is over 105C, the lamp flashes and the buzzer sounds.)
General information
The engine coolant temCheck the indication on the engine coolant temperature gauge. If the perature sensor system is 2 indication is abnormal, carry out the troubleshooting of "E-12 Indicadefective. tion on the engine coolant temperature gauge is abnormal". (Engine controller system) 3 Defective monitor panel (Gauge/lamp module) When Causes 1 and 2 are not applicable, the monitor panel is supposed to be defective. (This is an internal defect, which cannot be troubleshot.)
(3) The power train oil temperature caution lamp flashes. When any abnormality is detected during engine operation, the relevant emergency warning item will sound the alarm buzzer. The power train oil temperature caution lamp flashes or goes out as it links with indication on the power train oil temperature gauge. Failure code [B@CENS] may be displayed, too. Cause 1 Overheated oil temperature of power train Standard value in normal state/Remarks on troubleshooting As an overheated power train oil temperature was detected, check the power train oil temperature. (Oil temperature above 120C: Lamp blinks, above 130C: Lamp blinks and buzzer sounds)
The power train oil temperCheck the indication on the power train oil temperature gauge. If the ature sensor system is indication is abnormal, carry out the troubleshooting of "E-13 Indica2 defective. tion on the power train oil temperature gauge is abnormal". (Machine monitor system) 3 Defective monitor panel (Gauge/lamp module) When Causes 1 and 2 are not applicable, the monitor panel is supposed to be defective. (This is an internal defect, which cannot be troubleshot.)
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(4) The hydraulic oil temperature caution lamp flashes. When any abnormality is detected during engine operation, the relevant emergency warning item will sound the alarm buzzer. The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the hydraulic oil temperature gauge. Failure code [B@HANS] may be displayed, too. Cause 1 Overheated hydraulic oil temperature Standard value in normal state/Remarks on troubleshooting As an overheated hydraulic oil temperature was detected, check the hydraulic oil temperature. (Above 100C: Lamp blinks, above 110C: Lamp blinks and buzzer sounds)
The hydraulic oil temperaCheck the indication on the engine coolant temperature gauge. If the ture sensor system is 2 indication is abnormal, carry out the troubleshooting of "E-14 Indicadefective. tion on the hydraulic oil temperature gauge is abnormal". (Machine monitor system) 3 Defective monitor panel (Gauge/lamp module) When Causes 1 and 2 are not applicable, the monitor panel is supposed to be defective. (This is an internal defect, which cannot be troubleshot.)
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E-9 While the preheater is operating, the preheating pilot lamp does not come on
Symptom of failure General information While the preheater is operating, the preheating pilot lamp does not come on. a This troubleshooting describes the procedures to be followed when the preheating lamp does not come on. (When the preheater mounting section is not heated, carry out the troubleshooting of "The preheater does not work.") For preheating, both the "Automatic Preheating Function" and the "Manual Preheating Function" are available. Even when either function is performed, the preheating lamp comes on. Cause Standard value in normal state/Remarks on troubleshooting
a Prepare with the starting switch OFF, then carry out troubleshootDisconnection of wiring ing without turning the starting switch ON. harness (Disconnection in 1 wiring or defective contact Wiring harness between S03 (female) (9) and ResisMax. 1 z in connector) heater relay HTR1C terminal tance Possible causes and the standard values when normal a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring har2 ness (Contact with ground Between wiring harness between S03 Resiscircuit) Min. 1 Mz (female) (9) and heater relay HTR1C terminal tance and ground a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 3 Defective monitor panel (Gauge/lamp module) S03 Between (9) and ground Starting switch ON HEAT Voltage Max. 1 V 20 30 V
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E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)
Symptom of failure General information Possible causes and the standard values when normal At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tiltmounted machine) Before troubleshooting the blade, make sure that the dual tilt can operate. (When the blade does not operate normally, the electrical system on the machine side or the hydraulic/mechanical system is supposed to be out of order. So, troubleshoot the relevant system.) Cause 1 Defective monitor panel (Gauge/lamp module) Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot.
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on
Symptom of failure General information Possible causes and the standard values when normal At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on. Before troubleshooting the torque converter, make sure that the lock-up is operating. (When the lock-up does not operate normally, the electrical system on the machine side or the hydraulic/ mechanical system is supposed to be out of order. So, troubleshoot the relevant system.) Cause 1 Defective monitor panel (Gauge/lamp module) Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot.
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E-12 The engine coolant temperature gauge does not indicate normally
Symptom of failure General information The engine coolant temperature gauge does not indicate normally. Information of the engine coolant temperature sensor is received from the engine controller by CAN communication. When any abnormality occurs in the engine coolant temperature sensor system, failure code [CA144] or [CA145] may be displayed. Cause Standard value in normal state/Remarks on troubleshooting If failure code [CA144] or [CA145] is displayed, carry out troubleshooting for it. 1 Defective engine coolant temperature sensor system a Diagnose with starting switch ON or with engine started. Caution lamp (d) OFF White range (a) Green range (b) 2 Engine controller CAN communication error Flashing Red range (c)
If failure code [DB2RKR] or [dB2RKR] is displayed, carry out troubleshooting for it. If causes 1 3 are not detected, monitor panel may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
3 Defective engine controller Since trouble is in system, troubleshooting cannot be carried out. 4 Defective monitor panel
Coolant temperature gauge and caution lamp
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E-13 Indication of the power train (torque converter) temperature gauge is abnormal
Symptom of failure General information Indication of the power train (torque converter) temperature gauge is abnormal. When any abnormality occurs in the power train oil pressure sensor system, failure code [DGT1KX] or [DGT1KA] may be displayed. Cause Standard value in normal state/Remarks on troubleshooting If failure code [DGT1KX] or [DGT1KA] is displayed, carry out troubleshooting for it. Defective power train oil 1 pressure sensor system Possible causes and the standard values when normal a Diagnose with starting switch ON or with engine started. Caution lamp (d) OFF White range (a) Green range (b) Flashing Red range (c)
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 2 Defective monitor panel (Gauge/lamp module) S04 (female) Between (12) and ground Torque converter oil temperature 10 130C Resistance About 3.8 kz about 80 kz
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E-14 The hydraulic oil temperature gauge does not indicate normally
Symptom of failure General information The hydraulic oil temperature gauge does not indicate normally. Signals of the hydraulic oil temperature sensor are received from the transmission controller through communication. When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code [DGS1KX] is displayed sometimes. Cause Standard value in normal state/Remarks on troubleshooting If failure code [DGS1KX] is displayed, carry out troubleshooting for it. a Diagnose with starting switch ON or with engine started. 1 Possible causes and the standard values when normal Defective hydraulic oil temperature sensor system Caution lamp (d) OFF White range (a) Green range (b) 2 3 4 Transmission controller CAN communication error Defective transmission controller Defective monitor panel (Gauge/lamp module) Flashing Red range (c)
If failure code [DAQRKR] is displayed, carry out troubleshooting for it. This is an internal defect, which cannot be troubleshot. This is an internal defect, which cannot be troubleshot.
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E-15 Indication of the fuel gauge is abnormal

Symptom of failure General information Cause Defective fuel level sensor. 1 (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 422 (male) Between (1) and (2) (ground) Remained fuel level Full Empty Resistance About 4 z About 85 z Indication of the fuel gauge is abnormal.
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between S04 (female) (10) and 422 (female) (1) Wiring harness between 422 (female) (2) and ground Resistance Resistance Max. 1 z Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between S04 (female) (10) and 422 (female) (1)) and ground Resistance Min. 1 Mz
Hot short in wiring harness (Contact with 24 V circuit) Between wiring harness (between S04 (female) (10) and 422 (female) (1)) and ground
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Voltage Max. 1 V
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 5 Defective monitor panel (Gauge/lamp module) S04 (female) Between (10) and ground Remained fuel level Full Empty Resistance About 4 z About 85 z
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E-16 Indications of gear speed and engine speed are abnormal

Symptom of failure General information (1) Indications of gear speed and engine speed are abnormal. Signals of gear speed and engine speed are received from the transmission controller and the engine controller through communication. Cause Possible causes and the standard values when normal Engine controller or trans1 mission controller CAN communication error 2 Defective monitor panel (Gauge/lamp module) Standard value in normal state/Remarks on troubleshooting If failure code [DB2RKR], [dB2RKR] or [DAQRKR] is displayed, carry out troubleshooting for it. This is an internal defect, which cannot be troubleshot.
E-17 Indication of the shift mode service meter is abnormal

Symptom of failure General information (1) During engine operation, the service meter does not advance. The service meter measures time according to engine drive signals (alternator voltage). Cause Possible causes and the standard values when normal Standard value in normal state/Remarks on troubleshooting
When the battery charge level caution lamp flashes during engine 1 Defective alternator system operation, carry out the troubleshooting of "While the engine is operating, caution items flash." 2 Defective monitor panel (Gauge/lamp module) This is an internal defect, which cannot be troubleshot.
Symptom of failure General information Possible causes and the standard values when normal
(2) Shift mode and service meter are not displayed at all.
Cause 1 Defective monitor panel (Gauge/lamp module)
Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot.
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E-18 The switch module cannot be operated

Symptom of failure General information Possible causes and the standard values when normal Cause 1 Defective monitor panel (Switch module) Standard value in normal state/Remarks on troubleshooting This is an internal defect, which cannot be troubleshot. (1) Though the switch is used, lamps do not change.
(2) Though the switch is used, the system setting does not change. Switch module signals are transmitted to each controller through communication. Cause Standard value in normal state/Remarks on troubleshooting
Disconnection in wiring har- a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. ness (Disconnection in wir1 ing or defective contact in Wiring harness between S01 (female) (8) ResisMax. 1 z connector) STCN2 (female) (21), TMC2 (female) (21) tance Defective monitor panel 2 (Switch module) a Prepare with the starting switch OFF, then start the engine and carry out the troubleshooting. S01 Between (8) and ground Voltage 69V
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E-19 The warning lamp does not flash or does not go out
Symptom of failure General information Possible causes and the standard values when normal Cause 1 Standard value in normal state/Remarks on troubleshooting The warning lamp does not flash or does not go out.
Defective machine monitor This is an internal defect, which cannot be troubleshot. (Gauge/lamp module)
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E-20 The alarm buzzer does not sound or does not stop
Symptom of failure General information The alarm buzzer does not sound or does not stop. When a short circuit occurs in the alarm buzzer system, the failure code is displayed but no other failure codes are displayed. Cause 1 Defective circuit breaker (CB2) Standard value in normal state/Remarks on troubleshooting When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 217 (male) Between (1) and (2) Between (2) and ground Resistance 200 z Min. 1 Mz
Defective alarm buzzer 2 (Internal disconnection or short circuit)
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection in wiring harness (Disconnection in wir- Wiring harness between S03 (female) (18) Resis3 Max. 1 z ing or defective contact in and 217 (female) (1) tance connector) Wiring harness between 217 (female) (2) and ResisMax. 1 z CB2 outlet tance a Prepare with the starting switch OFF, then carry out troubleshootShort circuit with chassis ing without turning the starting switch ON. 4 ground in wiring harness Resis(Contact with ground circuit) Between wiring harness related to CB2 (outMin. 1 Mz let side) and ground tance a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 5 Defective monitor panel (Gauge/lamp module) S03 Between (18) and ground Alarm buzzer At stop At operation (sounding) Voltage 20 30 V Max. 3 V
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E-21 Auto shift down is not possible or is not released

Symptom of failure General information Cause Defective auto shift down switch (Internal 1 disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. ASD (male) Between (2) and (3) Auto shift down switch OFF (0) ON (1) Resistance Min. 1 Mz Max. 1 z Auto shift down is not possible or is not released.
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between TMC3 (female) (39) and ADS (female) (3) Wiring harness between ADS (female) (2) and TMC1 (female) (10) Resistance Resistance Max. 1 z Max. 1 z
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit) 4 5 Defective transmission controller Defective transmission control system
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between TMC3 (female) (39) and ASD (female) (3)) and ground Resistance Min. 1 Mz
Since trouble is in system, troubleshooting cannot be carried out. If causes 1 4 are not detected, transmission controller may have defects related to this function.
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E-22 The automatic pitch back system does not operate (only superdozer specification)
Symptom of failure General information Cause Defective pivot turn switch 1 (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FTU (male) Between (2) and (3) Pivot turn switch OFF (0) ON (1) Resistance Min. 1 Mz Max. 1 z The machine cannot start or stop a pivot turn.
Disconnection in wiring harness (Disconnection in Wiring harness between TMC3 (female) (9) 2 wiring harness or defective and FTU (female) (3) contact in connector) Wiring harness between FTU (female) (2) and TMC1 (female) (10) Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between TMC3 (female) (9) and FTU (female) (3) Resistance Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective transmission controller TMC1, TMC3 Between TMC3 (9) and TMC1 (10) 5 Defective transmission control system Automatic pitch back switch OFF (0) ON (1) Voltage 20 30 V Max. 3 V
If none of causes 1 4 is the cause of the trouble, the transmission control system may be defective (Troubleshooting cannot be carried out since the defect is in the system).
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E-23 The alarm buzzer cannot be cancelled

Symptom of failure General information The alarm buzzer cannot be cancelled. The cancel signal is sent from the steering controller to the machine monitor by communication. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective buzzer cancel 1 switch (Internal disconnection or short circuit) BUZ (male) Between (1) and (2) Between (1) and (3) Buzzer cancel switch OFF (0) OFF (0) Resistance Min. 1 Mz Max. 1 z Min. 1 Mz Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Wiring harness between STCN2 (36) and BUZ (female) (2) Wiring harness between STCN2 (26) and BUZ (female) (3) Wiring harness between BUZ (female) (1) and STCN1 (female) (10) Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between STCN2 (36) and BUZ (female) (2)) and ground Between wiring harness (between STCN2 (26) and BUZ (female) (3)) and ground Resistance Resistance Min. 1 Mz Min. 1 Mz
4 5
Machine monitor CAN com- If failure code [DAFRKR] is displayed, carry out troubleshooting for munication error it. Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
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E-24 The operator mode cannot be operated

Symptom of failure General information Cause 1 Defective buzzer cancel switch system Standard value in normal state/Remarks on troubleshooting Since the buzzer cancel switch system is supposed to be out of order, carry out the troubleshooting of "The alarm buzzer cannot be cancelled." a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective information switch 2 (Internal short circuit or disconnection) CUR (male) Between (1) and (2) Between (1) and (3) Possible causes and the standard values when normal Information switch OFF (0) OFF (0) Resistance Min. 1 Mz Max. 1 z Min. 1 Mz Max. 1 z The operator mode cannot be operated.
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between STCN2 (16) and CUR (female) (2) Wiring harness between STCN2 (6) and CUR (female) (3) Wiring harness between CUR (female) (1) and STCN1 (female) (10) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
Short circuit with chassis Between wiring harness (between STCN2 4 ground in wiring harness (16) and CUR (female) (2)) and ground (Contact with ground circuit) Between wiring harness (between STCN2 (6) and CUR (female) (3)) and ground
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Resistance Resistance Min. 1 Mz Min. 1 Mz
5 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
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E-25 The service mode cannot be operated

Symptom of failure General information Cause 1 Defective buzzer cancel switch system Defective information switch system Defective circuit breaker (CB6) Standard value in normal state/Remarks on troubleshooting Since the buzzer cancel switch system is supposed to be out of order, carry out the troubleshooting of "E-23 The alarm buzzer cannot be cancelled". Since the information switch system is supposed to be out of order, carry out the troubleshooting of "E-24 The operator mode cannot be cancelled". When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Service switch OFF ON Resistance Min. 1 Mz Max. 1 z The service mode cannot be operated.
2 3
Defective service switch S24 4 (Internal short circuit or disconnection) Between (1) and (2), Between (4) and (5)
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between CB6 outlet and S24 Disconnection in wiring har- (1) ness (Disconnection in wir- Wiring harness between S24 (4) and STCN1 5 ing or defective contact in (female) (10) connector) Wiring harness between S03 (female) (16) and S24 (2) Wiring harness between STCN1 (female) (6) and S24 (5) Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Short circuit with chassis ground in wiring harness 6 (Contact with ground circuit) Between wiring harness (between CB6 (outlet) and S24 (1)) and ground Between wiring harness (between S24 (4) and STCN1 (female) (10)) and ground Between wiring harness (between S03 (female) (16) and S24 (2)) and ground Between wiring harness (between STCN1 (female) (6) and S24 (5)) and ground Resistance Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 7 Defective monitor panel (Gauge/lamp module) S03 Between (16) and ground Service switch OFF ON Voltage Max. 1 V 20 30 V
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 8 Defective steering controller STCN1 Between (6) and ground Service switch OFF ON Voltage About 8 V Max. 1 V
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E-26 The back-up alarm does not sound

Symptom of failure General information The back-up alarm does not sound. When a failure occurs on the primary side (coil side) of the back-up alarm relay, a relevant failure code is displayed, but in case of failure on the secondary side (contact side), no failure code is displayed. Cause 1 Defective fuse (FS22-1) Standard value in normal state/Remarks on troubleshooting When the fuse is blown, a ground fault may have probably occurred in the circuit. a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 2 Defective back-up relay (Internal disconnection) When the relay is replaced with another relay while the starting switch is set to OFF and the alarm sounds after the starting switch is turned on and the machine is operated in reverse, the back-up alarm relay (BKA) is defective. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between FS22-1 outlet and Disconnection in wiring har- BKA (female) (1), (3) ness (Disconnection in wir- Wiring harness between BKA (female) (5) 3 ing or defective contact in and BUA (female) (1) connector) Wiring harness between BUA (female) (2) and ground Wiring harness between TMC2 (female) (18) BKA (female) (2) Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit) Between wiring harness (between FS22-1 (outlet) and BKA (female) (1), (3)) and ground Between wiring harness (between BKA (female) (5) and BUA (female) (1)) and ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
Defective back-up alarm (Internal defect)
When Causes 1 to 4 are not applicable, the back-up alarm is supposed to be defective.
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E-27 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on 1
Symptom of failure General information (1) None of the night light, the headlamp and the working lamp on the panel comes on. Headlamp and working lamp are operated with 1 switch. If headlamp switch is operated, panel lighting is changed for night. Cause 1 Defective circuit breaker CB5 Standard value in normal state/Remarks on troubleshooting If circuit breaker is turned OFF, circuit probably has ground fault etc. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. FWL (male) Between (2) and (3) Switch OFF ON Resistance Min. 1 Mz Max. 1 z
Defective headlamp and 2 working lamp switch (International disconnection)
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Possible causes and the standard values when normal Wiring harness between FWL (female) (2) and CB5 outlet Wiring harness between FWL (female) (3) and LMFL (female) (1) and LMFR (female) (1) and LMW (female) (1) and S01 (female) (10) or S03 (female) (8) Wiring harness between LMFL (female) (2) and LMFR (female) (2) or LMW (female) (2) and ground Resistance Resistance Resistance Max. 1 z
Disconnection of wiring harness (Disconnection in 3 wiring or defective contact in connector)
Max. 1 z
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault of wiring har4 ness (Contact with ground circuit) Wiring harness between FWL (female) (2) CB5 outlet and ground Wiring harness between FWL (female) (3) LMFL (female) (1), LMFR (female) (1), LMW (female) (1), S01 (female) (10) or S03 (female) (8) and ground Resistance Resistance Min. 1 Mz
Min. 1 Mz
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(2) Only the night light on the panel does not comes on. (Whole or part) If headlamp switch is operated, panel lighting is changed for night. Cause 1 Standard value in normal state/Remarks on troubleshooting
Defective night lamp (S02) The night lamp is supposed to be defective. Check if the bulb is (Blown) blown. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between S01 (female) (10) and FWL (female) (3) Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Wiring harness between S01 (female) (2) and ground Wiring harness between S02 (female) (1) and CB2 (outlet) Wiring harness between S02 (female) (2) and ground Wiring harness between S03 (female) (8) and FWL (female) (3) Wiring harness between S03 (female) (3), (4) and ground
Possible causes and the standard values when normal Ground fault of wiring har3 ness (Contact with ground circuit)
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between S01 (female) (10) and FWL (female) (3)) and ground Between wiring harness (between S02 (female) (1) and CB2 (outlet)) and ground Between wiring harness (between S03 (female) (8) and FWL (female) (3)) and ground Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 4 Defective monitor panel (Switch module) Between S01 (10) and (2) Between S02 (1) and (2) Defective monitor panel 5 (Gauge/lamp module)
Light switch ON
20 30 V
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Between S03 (8) and (3), (4) Light switch ON 20 30 V
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(3) Only the headlamp does not comes on. (Both right and left, or one side only)
Cause 1 2 Defective headlamp (Blown) Defective circuit breaker (CB5)
Standard value in normal state/Remarks on troubleshooting The headlamp is supposed to be defective. Check if the bulb is blown. When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit. a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting.
Defective headlamp relay (Internal disconnection)
When the relay is replaced with another relay while the starting switch is set to OFF and the headlamp comes on after the starting switch is turned ON and the light switch is turned ON, the headlamp relay (LMFL, LMFR) are defective. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between CB5 (outlet) and LMFL (female) (3) and LMFR (female) (3) Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Wiring harness between LMFL (female) (5) and 204 (female) (1), 207 (female) (1) Wiring harness between LMFR (female) (5) and 203 (female) (1), 208 (female) (1) Wiring harness between LMFL (female) (2) ground Wiring harness between LMFR (female) (2) ground
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between CB5 (outlet) and LMFL (female) (3) and LMFR (female) (3)) and ground Between wiring harness (between LMFL (female) (5) and 204 (female) (1), 207 (female) (1)) and ground Between wiring harness (between LMFR (female) (5) and 203 (female) (1), 208 (female) (1)) and ground Resistance Resistance Resistance Min. 1 Mz
Ground fault of wiring har5 ness (Contact with ground circuit)
Min. 1 Mz
Min. 1 Mz
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. 6 Hot short (Contact with 24V Between wiring harness between LMFL circuit) in wiring harness (female) (2) and ground and ground Between wiring harness between LMFR (female) (3) and ground and ground Voltage Voltage Max. 1 V Max. 1 V
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(4) Only the working lamp does not comes on. (Both right and left, or one side only)
Cause 1 Defective working lamp (Blown)
Standard value in normal state/Remarks on troubleshooting The working lamp is supposed to be defective. Check if the bulb is blown. When the fuse is blown, a ground fault may have probably occurred in the circuit. a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. When the relay is replaced with another relay while the starting switch is set to OFF and the headlamp comes on after the starting switch is turned ON and the light switch is turned ON, the working lamp relay (LMW) is defective. a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
2 Defective fuse (FS22-4)
Defective working lamp 3 relay (Internal disconnection)
Wiring harness between FS22-4 (outlet) and LMW (female) (3) Wiring harness between LMW (female) (5) and 221 (female) (1) or 242 (female) (1) Wiring harness between LMW (female) (2) and ground
Resistance Resistance Resistance
Max. 1 z Max. 1 z Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring har5 ness (Contact with ground circuit) Between wiring harness (between FS22-4 (outlet) LMW (female) (3)) and ground Between wiring harness (between LMW (female) (5) and 221 (female) (1) or 242 (female) (1)) and ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Hot short (Contact with 24V 6 circuit) in wiring harness Between wiring harness between LMW Voltage Max. 1 V (female) (2) and ground
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(5) Only the rear lamp does not comes on. (Both right and left, or one side only)
Cause 1 Defective rear lamp (Blown)
Standard value in normal state/Remarks on troubleshooting The working lamp is supposed to be defective. Check if the bulb is blown. When the fuse is blown, a ground fault may have probably occurred in the circuit. a Prepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. RWL (male) Between (2) and (3) Switch OFF ON Resistance Min. 1 Mz Max. 1 z
2 Defective fuse (FS22-5)
Defective rear lamp switch 3 (International disconnection) Possible causes and the standard values when normal
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between RWL (female) (2) and FS22-5 (outlet) Wiring harness between RWL (female) (3) and 226 (female) (1) or 243 (female) (1) Resistance Resistance Max. 1 z Max. 1 z
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring har5 ness (Contact with ground circuit) Between wiring harness (between FS22-5 (outlet) RWL (female) (2)) and ground Between wiring harness (between RWL (female) (3) 226 (female) (1) and 243 (female) (1)) and ground Resistance Resistance Min. 1 Mz Min. 1 Mz
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E-28 Troubleshooting for air conditioner system

Troubleshooting procedure for air conditioner system a The control panel of the air conditioner constantly monitors the sensors and other devices in the system. When it detects any abnormality, "Self-diagnosis notice" is displayed by operating switches specially. a If you feel any abnormality in the air conditioner system, check the "Self-diagnosis notice" first according to the procedure for "Troubleshooting by self-diagnosis notice", and then; q If the "Self-diagnosis notice" is displayed, continue the "Troubleshooting by self-diagnosis notice". q If the "Self-diagnosis notice" is not displayed, carry out the "Troubleshooting by failure phenomenon". Troubleshooting by self-diagnosis notice a Check the "Self-diagnosis notice" on the control panel according to the following procedure.
q
How to display "Self-diagnosis notice" 1) Turn the starting switch ON. 2) Press OFF switch (1) and check that anything is not displayed on display monitor (2). 3) Hold the UP switch ( ) and DOWN switch ( ) of temperature setting switch (3) simultaneously for 3 seconds or more. 4) Check the "Self-diagnosis notice" displayed on display monitor (2). How to select "Self-diagnosis notice" If mu lt i pl e " S el f- d i ag no s i s n ot ic e s " a r e recorded, press the UP switch ( ) or DOWN switch ( ) of temperature setting switch (3) to select another notice. How to delete "Self-diagnosis notice" When reproducing the "Self-diagnosis notices" or after removing the cause of a failure, press the switches on both sides of recirc/fresh air selector switch (4) simultaneously for 3 seconds or more, and all the "Self-diagnosis notices" are deleted. Finishing display of "Self-diagnosis notice" To finish display of the "Self-diagnosis notice", press OFF switch (1) or turn the starting switch OFF.
Self-diagnosis notice E-E11 E12 E13 E14 E15 E16 E18 E21 E22 E43 E44 E45 E51 Failure mode No failures Disconnection in recirculated air sensor Short circuit in recirculated air sensor Disconnection in fresh air sensor Short circuit in fresh air sensor Disconnection in coolant temperature sensor Short circuit in coolant temperature sensor Short circuit in daylight sensor Disconnection in air blow sensor Short circuit in air blow sensor Abnormality in air outlet damper Abnormality in air mix damper Abnormality in recirculated and fresh air damper Abnormal refrigerant pressure
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Self-diagnosis notice E11 Contents of trouble
Symptom of failure
Disconnection in recirculated air sensor
Disconnection in the recirculated air sensor system is detected.
Fixes the recirculated air temperature for control. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information Cause Defective recirculated air 1 sensor (Internal disconnection) Possible causes and the standard values when normal Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male) Between (1) and (2) Resistance 300 z 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (13) and THI (female) (2) Wiring harness between AP2 (female) (20) and THI (female) (1) Resistance Resistance Max. 1 z Max. 1 z
Defective air conditioner system
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
Symptom of failure
Short circuit in recirculated air sensor
Disconnection in the recirculated air sensor system is detected.
Fixes the recirculated air temperature for control. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information Cause Defective recirculated air 1 sensor (Internal disconnection) Possible causes and the standard values when normal Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male) Between (1) and (2) Resistance 300 z 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (13) and THI (female) (2) Wiring harness between AP2 (female) (20) and THI (female) (1) Resistance Resistance Max. 1 z Max. 1 z
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Symptom of failure
Disconnection in fresh air sensor
Disconnection in the fresh air sensor system is detected.
Assumes that the fresh air sensor is not installed for control. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information Cause Defective fresh air sensor (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ACT (male) Between (1) and (2) Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Resistance 100 z 210 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (10) and ACT (female) (1) Wiring harness between AP2 (female) (20) and ACT (female) (2) Resistance Resistance Max. 1 z Max. 1 z
Symptom of failure
Short circuit in fresh air sensor
Short circuit in the fresh air sensor system is detected.
Assumes that the fresh air sensor is not installed for control. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information Cause Defective fresh air sensor (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. ACT (male) Between (1) and (2) Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Resistance 100 z 210 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (10) and ACT (female) (1) Wiring harness between AP2 (female) (20) and ACT (female) (2) Resistance Resistance Max. 1 z Max. 1 z
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Symptom of failure
Disconnection in coolant temperature sensor
Disconnection in the coolant temperature sensor system is detected.
Ignores the warm-up control and fixes the engine coolant temperature at 60C for control. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information Cause Defective coolant 1 temperature sensor (Internal disconnection) Possible causes and the standard values when normal Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THW (male) Between (1) and (2) Resistance 95 z 455 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (11) and THW (female) (2) Wiring harness between AP2 (female) (20) and THW (female) (1) Resistance Resistance Max. 1 z Max. 1 z
Symptom of failure
Short circuit in coolant temperature sensor
Short circuit in the coolant temperature sensor system is detected.
Ignores the warm-up control and fixes the engine coolant temperature at 60C for control. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information Cause Defective coolant 1 temperature sensor (Internal short circuit) Possible causes and the standard values when normal Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THW (male) Between (1) and (2) Resistance 95 z 455 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (11) and THW (female) (2) Wiring harness between AP2 (female) (20) and THW (female) (1) Resistance Resistance Max. 1 z Max. 1 z
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Symptom of failure
Short circuit in daylight sensor
Short circuit in the daylight sensor system is detected.
Assumes that the daylight sensor is not installed for control. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information Cause 1 Defective daylight sensor (Internal short circuit) Standard value in normal state/Remarks on troubleshooting The daylight sensor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (9) and SLS (female) (2) Wiring harness between AP1 (female) (6) and SLS (female) (1) Resistance Resistance Max. 1 z Max. 1 z
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Symptom of failure
Disconnection in air blow sensor
Disconnection in the air blow sensor (frost sensor) system is detected.
Fixes the evaporator temperature at 10C for control. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information Cause Defective air blow sensor 1 (frost sensor) (Internal disconnection) Possible causes and the standard values when normal Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THF (male) Between (1) and (2) Resistance 100 z 115 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (12) and THF (female) (2) Wiring harness between AP2 (female) (20) and THF (female) (1) Resistance Resistance Max. 1 z Max. 1 z
Symptom of failure
Short circuit in air blow sensor
Short circuit in the air blow sensor (frost sensor) system is detected.
Fixes the evaporator temperature at 10C for control. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information Cause Defective air blow sensor 1 (frost sensor) (Internal short circuit) Possible causes and the standard values when normal Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THF (male) Between (1) and (2) Resistance 100 z 115 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between AP1 (female) (12) and THF (female) (2) Wiring harness between AP2 (female) (20) and THF (female) (1) Resistance Resistance Max. 1 z Max. 1 z
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Symptom of failure
Abnormality in air outlet damper
Abnormality in air outlet servomotor system or front air outlet servomotor system is detected.
Stops the air outlet servomotor and front air outlet servomotor. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause 1 2 Standard value in normal state/Remarks on troubleshooting
Defective air outlet The air outlet servomotor may be defective. Check it directly. servomotor (Internal defect) Defective front air outlet The front air outlet servomotor may be defective. Check it directly. servomotor (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MV1 (female) (1) and AP2 (female) (20) Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Disconnection in wiring harness (Disconnection in 3 wiring harness or defective contact in connector) Possible causes and the standard values when normal
Wiring harness between MV1 (female) (3) and AP1 (female) (6) Wiring harness between MV1 (female) (5) and AP1 (female) (16) Wiring harness between MV1 (female) (6) and AP2 (female) (2) Wiring harness between MV1 (female) (7) and AP2 (female) (6)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MV2 (female) (1) and AP1 (female) (6) Disconnection in wiring harness (Disconnection in 4 wiring harness or defective contact in connector) Wiring harness between MV2 (female) (3) and AP2 (female) (20) Wiring harness between MV2 (female) (5) and AP1 (female) (15) Wiring harness between MV2 (female) (6) and AP2 (female) (1) Wiring harness between MV2 (female) (7) and AP2 (female) (11) 5 Defective air conditioner system Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
If none of causes 1 4 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, "Air conditioner".
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Symptom of failure
Abnormality in air mix damper
Abnormality in air mix servomotor system is detected.
Stops the air mix servomotor. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause 1 Standard value in normal state/Remarks on troubleshooting
Defective air mix servomoThe air mix servomotor may be defective. Check it directly. tor (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MAM (female) (1) and AP2 (female) (20) Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector)
Wiring harness between MAM (female) (3) and AP1 (female) (6) Wiring harness between MAM (female) (5) and AP1 (female) (7) Wiring harness between MAM (female) (6) and AP2 (female) (7) Wiring harness between MAM (female) (7) and AP2 (female) (6)
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Symptom of failure
Abnormality in recirculated and fresh air damper
Abnormality in recirculated and fresh air servomotor system is detected.
Stops the recirculated and fresh air servomotor. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause Defective recirculated and 1 fresh air servomotor (Internal defect) Standard value in normal state/Remarks on troubleshooting The recirculated and fresh air servomotor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MRF (female) (1) and AP2 (female) (20) Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector) Wiring harness between MRF (female) (3) and AP1 (female) (6) Wiring harness between MRF (female) (5) and AP1 (female) (8) Wiring harness between MRF (female) (6) and AP2 (female) (4) Wiring harness between MRF (female) (7) and AP2 (female) (5) 3 Defective air conditioner system Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
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Symptom of failure
Abnormality in refrigerant pressure
Abnormality in refrigerant pressure circuit is detected.
Turns the compressor clutch OFF. Action of control When the following condition is satisfied, the operation returns to normalcy. panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> General information Cause 1 Standard value in normal state/Remarks on troubleshooting
Defective high-low pressure The high-low pressure switch may be defective. Check it directly. switch (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Resistance Resistance Max. 1 z Max. 1 z
Disconnection in wiring harness (Disconnection in Wiring harness between AP1 (female) (5) 2 wiring harness or defective and SPHL (female) (2) contact in connector) Wiring harness between SPHL (female) (1) and chassis ground 3 Defective air conditioner system
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Troubleshooting by failure phenomenon

Symptom of failure General information Cause Defective circuit breaker 1 CB4 Standard value in normal state/Remarks on troubleshooting If the circuit breaker is turned OFF, the circuit probably has a grounding fault, etc. (Refer to cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between AP3 (male) (6) and 2 wiring harness or defective AP1 (female) (3) contact in connector) Wiring harness between AP2 (female) (19) and chassis ground Wiring harness between AP5 (male) (7) and chassis ground Possible causes and the standard values when normal Wiring harness between circuit breaker CB4 outlet and ACU (female) (4), (5) Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z The air conditioner does not operate. (1) The air conditioner does not operate at all.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between circuit breaker CB4 outlet and ACU (female) (4), (5) and chassis ground Between wiring harness between AP3 (male) (6) and AP1 (female) (3) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective air conditioner unit ACU Between (4) and (8) Voltage 20 30 V
If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective control panel AP1, AP2 Between AP1 (3) and AP2 (19) Voltage 20 30 V
If the above voltage is normal and the control panel does not operate, the control panel is defective.
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The air conditioner does not operate.
(2) Air does not come out (Air flow is insufficient).
Cause 1 Defective fuse (in unit)
Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective blower main relay 2 Resistance (on coil side) RLBM (male) Between (1) and (3) 300 440 z a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. RLBM Between (4) and chassis ground Fan switch ON (Operated) Voltage 20 30 V
Defective blower main relay (on contact side)
Defective blower linear controller (Internal defect)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Fan switch Operate in range of Low, Medium, and High If air flow can be changed with fan switch, blower linear controller is normal.
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Possible causes and the standard values when normal Defective blower motor (Internal defect) MB Between (1) and (2) Fan switch ON (Operated) Voltage 20 30 V
If the above voltage is normal and the blower motor does not rotate, the blower motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between circuit breaker CB4 outlet, ACU (4), AP3 (female) (6), and RLBM (female) (1) Wiring harness between circuit breaker CB4 outlet, ACU (5) and RLBM (female) (3) Wiring harness between AP2 (female) (8), AP4 (10) and RLBM (female) (2) Disconnection in wiring Wiring harness between AP2 (female) (19) harness (Disconnection in and chassis ground 6 wiring harness or defective Wiring harness between BLC (female) (3) contact in connector) and RLBM (female) (4) Wiring harness between MB (female) (1) and RLBM (female) (4) Wiring harness between MB (female) (2) and BLC (female) (4) Wiring harness between BLC (female) (1), ACU (8), and chassis ground Wiring harness between AP1 (female) (1), AP3 (8), and BLC (female) (2) 7 Defective air conditioner system Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
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The air conditioner does not operate.
(3) Air is not cooled (Cooling capacity is low).
Cause 1 Defective fuse (in unit)
Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. RLCC (male) Between (1) and (3) Resistance 140 340 z
Defective compressor clutch relay (on coil side)
Defective compressor 3 clutch relay (on contact side)
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position). RLCC Between (3) and chassis ground Fan switch ON (Operated) Voltage 20 30 V
Defective compressor clutch (Internal defect) Defective compressor (Internal defect)
The compressor clutch may be defective. Check it directly. The compressor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between circuit breaker CB4 outlet, ACU (4), AP3 (6), AP1 (female) (3) and RLCC (female) (1) Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Disconnection in wiring Wiring harness between circuit breaker CB4 harness (Disconnection in outlet, ACU (5) and RLCC (female) (4) 6 wiring harness or defective Wiring harness between AP2 (female) (9), contact in connector) AP4 (7) and RLCC (female) (2) Wiring harness between AP2 (19) and chassis ground Wiring harness between RLCC (female) (3), ACU (10) and A/C (female) (1) 7 Defective air conditioner system
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E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
Symptom of failure General information The ORBCOMM terminal does not operate normally (Data are not transmitted). Even if the ORBCOMM terminal is abnormal, it does not cause a trouble in the machine. Cause Standard value in normal state/Remarks on troubleshooting At least 3 minutes after starting the VHMS, check the decimal point at the right bottom of the LED of the VHMS controller or the decimal point at the right bottom of the central part of the lower line of the multi-information display unit. * To check the decimal point on the multi-information display unit, turn the starting switch ON and select the "Real-time monitoring mode" or "Dual display monitoring mode" and input the ID = 20300. Lamp is OFF Lamp is ON Power is not applied to ORBCOMM terminal or the communication with VHMS controller is abnormal. Power is applied to ORBCOMM terminal and the communication with VHMS controller is normal. But it does not capture satellite.
Terminal power supply is 1 abnormal or satellite is not captured
Possible causes and the standard values when normal Disconnection in wiring harness (Disconnection in wir2 ing harness or defective contact in connector)
Power is applied to ORBCOMM terminal, capturing satelFlashing lite and the communication with VHMS controller is normal. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between KOM1 (female) (36), (39), (40) and VF2 (male) (5) Between KOM1 (female) (37), (38) and chassis ground Between V4B (female) (3) and KOM1 (female) (11) Between V4B (female) (4) and KOM1 (female) (5) Between V4B (female) (10) and KOM1 (female) (4) Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z
Defective ORBCOMM tera Prepare with starting switch OFF, then carry out troubleshooting minal without turning starting switch ON. (When LED is turned OFF) 3 * Constant power supply is used. When disconnecting Between KOM1 (female) (36), (39), (40) and Voltage 20 30 V connector and carrying out KOM1 (female) (37), (38) troubleshooting, take care.
Decimal point position of VHMS controller
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Decimal point position of multi-function monitor
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E-30 Fan does not reverse

Symptom of failure General information When fan is set in fan cleaning mode or fan reverse mode (if equipped), fan does not reverse. If any switched is operated during reverse prohibition period, orange lamp blinks. Orange lamp lights up in cleaning mode and reverse mode. Cause Abnormality in fan reverse 1 solenoid Operation of fan cleaning 2 switch in reverse prohibition period Operation of fan reverse 3 switch (if equipped) in reverse prohibition period Defective fan cleaning switch (Internal disconnection) Standard value in normal state/Remarks on troubleshooting If failure code [DW7BKA], [DW7BKB] or [DW7BKY] is displayed, carry out troubleshooting for it first. If switch is operated after engine is started, fan does not reverse and orange lamp blinks. At this time, orange lamp indicated that switch operation is ineffective but does not indicate trouble. Turn key switch OFF to stop engine and turn battery relay OFF, and then set fan in fan cleaning or fan reverse mode again. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. FAN1 (male) Between (1) and (2) Switch OFF CLN position Resistance Min. 1 Mz Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective fan cleaning switch (if equipped) (Internal disconnection) FAN2 (male) Between (1) and (3) Switch OFF CLN position REV position OFF Between (3) and (4) CLN position REV position [When standard cleaning switch is employed] Disconnection in wiring harness (Internal disconnection) 5 [When optional reverse switch is employed] Disconnection in wiring harness (Internal disconnection) Resistance Min. 1 Mz Min. 1 Mz Max. 1 z Min. 1 Mz Max. 1 z Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between FAN1 (female) (1) and STCN1 (female) (10) Wiring harness between FAN1 (female) (2) and STCN2 (female) (38) Resistance Resistance Max. 1 z Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between FAN2 (female) (3) and STCN1 (female) (10) Wiring harness between FAN2 (female) (4) and STCN2 (female) (38) Wiring harness between FAN2 (female) (1) and STCN2 (female) (2) Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z
If causes 1 5 are not detected, steering controller may be defec6 Defective steering controller tive. (Since trouble is in system, troubleshooting cannot be carried out.)
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E-31 Gear cannot be shifted

Symptom of failure General information Cause Trouble in shift operation switch Shift-up switch 1 Shift-down switch Shift switch (Optional-type lever) 2 Gear speed limit 3 Defect in transmission clutch Standard value in normal state/Remarks on troubleshooting a When failure code related to shift operation switch is not displayed. Press shift operation switch for more than 10 seconds. If any of following failure code is displayed at this time, carry out troubleshooting for it. [DD12KA], [DD12KB], [DD13KA], [DD13KB], [DD5KA], [DD5KB] a When failure code related to shift operation switch is displayed. Carry out troubleshooting for displayed failure code. If failure code of action code E03 or E04 is displayed, gear speed limit is applied. In this case, carry out troubleshooting for that failure code first. Transmission clutch may have defect in it. Check it directly. Gear cannot be shifted (Shift switch does not work).
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E-32 Electric priming pump does not operate or does not stop automatically
Symptom of failure General information Cause 1 Low battery charge level 2 Defective circuit breaker CB8 Standard value in normal state/Remarks on troubleshooting Battery charge level may be low. Check battery directly. If circuit breaker CB8 is turned OFF, circuit probably has ground fault. (Check cause No. 5) Electric priming pump does not operate or does not stop automatically.
Disconnection in wiring a Prepare with battery ground cable disconnected, then connect it harness and carry out troubleshooting (since power supply is unswitched). (Power supply system) 3 (Disconnection in wiring or defective contact in Between EPP (1) (2) Voltage 20 30 V connector) a Prepare with battery ground cable disconnected, then connect battery and turn electric priming pump ON and carry out troubleshooting.
Disconnection in wiring Lamp blinks but stops in about 5 seconds. harness (Drive power supply system) Between EFPL (1) (2), EFPR (1) (2) Voltage 20 30 V 4 (Disconnection in wiring or a Prepare with battery ground cable disconnected, then carry out defective contact in troubleshooting without reconnecting (since power supply is connector) unswitched). Between EPP (female) (2) ground Resistance Max. 1 z
a Prepare with battery ground cable disconnected, then carry out troubleshooting without reconnecting (since power supply is unswitched). Wiring harness between EPP (female) (1) circuit breaker B8S and ground Ground fault in wiring harness 5 (Contact with ground circuit) Wiring harness between EPP (female) (3) EFPL (female) (1) and ground Wiring harness between EPP (female) (4) EFPL (female) (2) and ground Wiring harness between EPP (female) (5) EFPR (female) (1) and ground Wiring harness between EPP (female) (6) EFPR (female) (2) and ground Resistance Resistance Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz
a Prepare with battery ground cable disconnected, then connect battery and turn electric priming pump ON and carry out troubleshooting. Defective electric priming pump switch 6 (Malfunction or automatic stop failure) Between EPP (3) (4) and (5) (6) Voltage 20 30 V Lamp blinks but output voltage is improper. Results of troubleshooting steps 1 4 are normal and lamp does not blink. a When electric priming pump does not stop automatically, electric priming pump switch may be defective. (Turn toggle switch OFF to stop pump and then replace switch.) 7 Lamp blinks but stops in about 5 seconds. Overload on electric priming a If pump is overloaded, power supply is turned OFF automatically pump to protect circuit (Priming switch is reset automatically).
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Cause
Standard value in normal state/Remarks on troubleshooting a Prepare with battery ground cable disconnected, then carry out troubleshooting without reconnecting (since power supply is unswitched). Between EFPL (male) (1) (2) Resistance Resistance Resistance Resistance Resistance Resistance 13z Min. 1 Mz Min. 1 Mz 13z Min. 1 Mz Min. 1 Mz
Between EFPL (male) (1) pump body Trouble in electric priming 8 pump Between EFPL (male) (2) pump body Between EFPR (male) (1) (2) Between EFPR (male) (1) pump body Between EFPR (male) (2) pump body
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
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Serial number
40 Troubleshooting
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
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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
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Troubleshooting of hydraulic and mechanical system (H-mode)1

Information in troubleshooting table
a
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Trouble Related information Trouble in machine Information related to detected trouble or troubleshooting Cause 1 Standard value in normal state/Remarks on troubleshooting
Possible causes of trouble <Contents of description> (Given numbers are refer Standard value in normal state to judge possible causes ence numbers, which do not Remarks on judgment indicate priority)
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H-1 No force (no drawbar pull)

Symptom of failure General information No force (No drawbar pull) Before troubleshooting, check that the power train oil level is normal.
Causes Standard values when normal and remarks for troubleshooting 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 transmission main relief pressure is normal). Internal defect of torque Torque converter Torque converter 2 PCCS lever converter inlet pressure outlet pressure 0.39 0.64 MPa 0.8 1.0 MPa Full neutral {4.0 6.5 kg/cm2} {8.0 10.0 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high 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} a Prepare with starting switch OFF, then carry out troubleshooting Defective operation of without turning starting switch ON. 4 transmission main relief Check it directly that the spring free length (120.3 mm) is normal valve and that the spool moves smoothly. a Prepare with starting switch OFF, then drive the engine in low idle 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} 5 transmission valve (ECMV) REV 2.25 2.74 MPa {23.0 28.0 kg/cm2} 1ST 2ND 3RD 1.86 2.35 MPa {19.0 24.0 kg/cm2} 2.25 2.74 MPa {23.0 28.0 kg/cm2}
2.25 2.74 MPa {23.0 28.0 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Measuring conditions Engine speed Internal defect of transmis6 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 troubleshooting. Defective operation (drag7 Drive the engine in low idle mode and operate F2. Unless the ging) of brake machine moves, the brake is being dragged. (Execute the troubleshooting of Brake does not work.)
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Causes
8 Defective steering clutch
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting (after checking that the transmission main relief pressure is normal). PCCS lever Left stroke end Right stroke end 0 MPa Min. 2.45 MPa Left clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right clutch pressure {Min. 25 kg/cm2} {0 kg/cm2} 0 MPa Min. 2.45 MPa Left brake pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Right brake pressure {0 kg/cm2} {Min. 25 kg/cm2} When the oil pressure is abnormal, execute the troubleshooting of Steering is not possible.
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H-2 No travel (at 2nd or 3rd speed)

Symptom of failure General information No travel (at 2nd or 3rd speed) Before troubleshooting, check that the power train oil level is normal. Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes
Internal defect of torque converter
Defective operation of transmission valve (ECMV)
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Torque converter Torque converter PCCS lever inlet pressure outlet pressure 0.39 0.64 MPa 0.8 1.0 MPa Full neutral {4.0 6.5 kg/cm2} {8.0 10.0 kg/cm2} a Prepare with starting switch OFF, then drive the engine in low idle mode for troubleshooting. Transmission clutch Clutch pressure 2ND 3RD 2.25 2.74 MPa {23.0 28.0 kg/cm2}
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 supsion clutch posed to be defective. Check it directly. Defective operation (dragDefective operation (dragging) is supposed, check linkage valves. ging) of parking brake a Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (dragDrive the engine in low idle mode and operate F2. Unless the ging) of brake machine moves, the brake is being dragged. (Execute the troubleshooting of Brake does not work.) a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. PCCS lever Left stroke end Right stroke end 0 MPa Min. 2.45 MPa Left clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right clutch pressure Defective steering clutch, {Min. 25 kg/cm2} {0 kg/cm2} brake 0 MPa Min. 2.45 MPa Left brake pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Right brake pressure {0 kg/cm2} {Min. 25 kg/cm2} When the oil pressure is abnormal, execute the troubleshooting of Steering is not possible.
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H-3 No travel at all gear speeds

Symptom of failure General information No travel at all gear speeds Before troubleshooting, check that the power train oil level is normal.
Causes Standard values when normal and remarks for troubleshooting 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. Incorrect pressure set to Transmission main relief PCCS lever 2 transmission main relief pressure valve 2.55 3.04 MPa Full neutral {26.0 31.0 kg/cm2} a Prepare with starting switch OFF, then carry out troubleshooting Defective operation of without turning starting switch ON. 3 transmission main relief Check it directly that the spring free length (120.3 mm) is normal valve and that the spool moves smoothly. a Prepare with starting switch OFF, then drive the engine in low idle 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 2ND 3RD Possible causes and the standard values when normal 1.86 2.35 MPa {19.0 24.0 kg/cm2} 2.25 2.74 MPa {23.0 28.0 kg/cm2}
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 sup5 sion clutch posed 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 transmission main relief pressure is normal). Defective operation of 6 Brake pedal Brake oil pressure (right and left) brake Release Step on Min. 2.45 MPa {Min. 25 kg/cm2} 0 MPa {0 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting (after checking that the transmission main relief pressure is normal). PCCS lever Left stroke end Right stroke end Min. 2.45 MPa 0 MPa Left clutch pressure 2 {Min. 25 kg/cm } {0 kg/cm2} Defective seal of steering 7 0 MPa Min. 2.45 MPa clutch Right clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Left brake pressure {0 kg/cm2} {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right brake pressure {Min. 25 kg/cm2} {0 kg/cm2} 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.
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H-4 Machine travels only in one direction forward or in reverse

Symptom of failure General information Machine travels only in one direction Forward or in Reverse. Before troubleshooting, check that the power train oil level is normal.
Causes Standard values when normal and remarks for troubleshooting 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. Incorrect pressure set to PCCS lever Transmission main relief pressure 2 transmission main relief Full neutral 2.55 3.04 MPa {26.0 31.0 kg/cm2} valve When the oil pressure is abnormal, clean the valve and then check the oil pressure again. a Prepare with starting switch OFF, then carry out troubleshooting Defective operation of without turning starting switch ON. 3 transmission main relief Check it directly that the spring free length (120.3 mm) is normal valve and that the spool moves smoothly. a Prepare with starting switch OFF, then drive the engine in low idle 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 2ND 3RD 1.86 2.35 MPa {19.0 24.0 kg/cm2} 2.25 2.74 MPa {23.0 28.0 kg/cm2}
5 6
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 sion clutch be defective. Check it directly. Internal defect of transmis- The inside of the transmission clutch is supposed to be defective, sion clutch check it directly. a Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (dragDrive the engine in low idle mode and operate F2. Unless the ging) of brake machine moves, the brake is being dragged. (Execute the troubleshooting of Brake does not work.) Defective operation of forward-reverse potentiome- Perform troubleshooting related to forward-reverse potentiometer. ter of travel lever
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H-5 Large time lag at gear speed shifting or forward-reverse shifting

Symptom of failure General information Large time lag at gear speed shifting or forward-reverse shifting Before troubleshooting, check that the power train oil level is normal.
Causes Standard values when normal and remarks for troubleshooting 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. Defective operation of PCCS lever Transmission main relief pressure 2 transmission main relief Full neutral 2.55 3.04 MPa {26.0 31.0 kg/cm2} valve When the oil pressure is abnormal, clean the valve and then check the oil pressure again. a Prepare with starting switch OFF, then drive the engine in low idle 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} 3 transmission valve (ECMV) REV 2.25 2.74 MPa {23.0 28.0 kg/cm2} 1ST 2ND 3RD 1.86 2.35 MPa {19.0 24.0 kg/cm2} 2.25 2.74 MPa {23.0 28.0 kg/cm2}
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. a Move the machine to a flat ground and start the engine for troubleshooting. Defective operation (drag6 Drive the engine in low idle mode and operate F2. Unless the ging) of brake machine moves, the brake is being dragged. (Execute the troubleshooting of Brake does not work.)
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40 Troubleshooting
H-6 Steering is not possible

Symptom of failure General information Steering is not possible. Before troubleshooting, check that the power train oil level is normal. Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes Defective operation of brake
Defective operation of 2 steering clutch valve (ECMV)
Defective seal of steering clutch Internal defect of steering 4 clutch Defective operation of 5 steering potentiometer of travel lever 3
Standard values when normal and remarks for troubleshooting Prepare with starting switch OFF, then drive the engine in low idle mode for troubleshooting. Lift the machine with the blade and the ripper and steer the wheel for F3 travel (or R3 travel). If the track shoe stops, the brake is defective. (Execute the troubleshooting of Brake does not work.) a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. PCCS lever Left stroke end Right stroke end 0 MPa Min. 2.45 MPa Left clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right clutch pressure {Min. 25 kg/cm2} {0 kg/cm2} 0 MPa Min. 2.45 MPa Left brake pressure 2 {0 kg/cm } {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right brake pressure {Min. 25 kg/cm2} {0 kg/cm2} When the cause 2 is not applicable, the clutch seal is supposed to be defective. Check it directly. The inside of the steering clutch is supposed to be defective, check it directly. Perform the troubleshooting related to steering potentiometer.
10
D475A, D475ASD-5E0
40 Troubleshooting
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H-7 Steering is possible only on one side

Symptom of failure General information Steering is possible only on one side. Before troubleshooting, check that the power train oil level is normal. Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes
Defective operation of 1 steering clutch valve (ECMV)
Defective seal of steering clutch Internal defect of steering 3 clutch Defective operation of 4 steering potentiometer of travel lever 2
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. PCCS lever Left stroke end Right stroke end 0 MPa Min. 2.45 MPa Left clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right clutch pressure {Min. 25 kg/cm2} {0 kg/cm2} 0 MPa Min. 2.45 MPa Left brake pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Right brake pressure {0 kg/cm2} {Min. 25 kg/cm2} When the cause 1 is not applicable, the clutch seal is supposed to be defective. Check it directly. The inside of the steering clutch is supposed to be defective, check it directly. Perform the troubleshooting related to steering potentiometer.
D475A, D475ASD-5E0
11
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40 Troubleshooting
H-8 Steering overrun occurs

Symptom of failure General information Steering overrun occurs. Before troubleshooting, check that the power train oil level is normal. Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes Possible causes and the standard values when normal Defective operation of brake
Defective operation of steering clutch
Standard values when normal and remarks for troubleshooting a Prepare with starting the engine, then drive the engine in low idle mode for troubleshooting. Lift the machine with the blade and the ripper and steer the wheel for F3 travel (or R3 travel). If the track shoe stops, the brake is defective. (Execute the troubleshooting of Brake does not work.) When the track shoe does not stop in the troubleshooting of the cause 1, the steering clutch is defective. (Execute the troubleshooting of Steering is not possible.)
12
D475A, D475ASD-5E0
40 Troubleshooting
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H-9 Brake does not work

Symptom of failure General information Brake does not work. Before troubleshooting, check that the power train oil level is normal. Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.) Causes 1 Degradation of brake Defective operation of brake pedal
Defective operation of 3 steering brake valve (ECMV)
4 Defective brake seal 5 Internal defect of brake
Standard values when normal and remarks for troubleshooting a Start the engine for troubleshooting. Step on the brake pedal, shift the gear to F2 and drive the engine in high idle mode. When the machine moves, the brake performance is degraded. The brake pedal and the brake valve are supposed not to work normally. Check them directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. PCCS lever Left stroke end Right stroke end 0 MPa Min. 2.45 MPa Left clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Right clutch pressure {0 kg/cm2} {Min. 25 kg/cm2} 0 MPa Min. 2.45 MPa Left brake pressure {0 kg/cm2} {Min. 25 kg/cm2} Min. 2.45 MPa 0 MPa Right brake pressure {Min. 25 kg/cm2} {0 kg/cm2} When the brake seal is not normal in the troubleshooting of the 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 directly.
D475A, D475ASD-5E0
13
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40 Troubleshooting
H-10 Torque converter is not lock-up

Symptom of failure General information The torque converter is not lock-up. Before troubleshooting, check that the power train oil level is normal. Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
Causes Standard values when normal and remarks for troubleshooting 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. Defective operation of Torque converter Clutch pressure 2 torque converter lock-up valve Min. 1.13 1.42 MPa At lock-up time {Min. 11.5 14.5 kg/cm2} Defective seal of lock-up When the troubleshooting of the case 2 is not normal, the lock-up 3 clutch clutch seal is supposed to be defective. Check it directly. Internal defect of lock-up The inside of the lock-up clutch is supposed to be defective. Check 4 clutch it directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Measuring conditions Engine speed Internal defect of torque 5 converter F3 stall Min. 1,590 rpm F3 stall + Work equipment relief Min. 1,450 rpm (pitch back)
14
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40 Troubleshooting
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H-11 Power train oil is overheated

Symptom of failure The power train oil is overheated.
General information
Before troubleshooting, check that the power train oil level is normal. Before troubleshooting, check that the indication of the power train oil temperature gauge agrees with actual temperature of the power train oil. (When the indication does not agree with actual temperature, 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.) Standard values when normal and remarks for troubleshooting Engine output is supposed to have increased abnormally. TroubleRise 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 supor air entry in suction circuit posed to have entered from the suction circuit. Check them directly. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Torque converter Torque converter Internal defect of torque PCCS lever inlet pressure outlet pressure converter 0.39 0.64 MPa 0.8 1.0 MPa Full neutral {4.0 6.5 kg/cm2} {8.0 10.0 kg/cm2} Defective operation (slide) The inside of the transmission clutch is supposed to be defective 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 ging) of brake machine moves, the brake is being dragged. (Execute the troubleshooting of Brake does not work.) Defective operation (slide) The inside of the steering clutch is supposed to be defective (the of steering clutch clutch slides). Check it directly. Causes
1 2
D475A, D475ASD-5E0
15
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40 Troubleshooting
H-12 All work equipment speeds are slow

Symptom of failure General information All work equipment speeds are slow. Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. Causes Defective PTO (pump drive 1 unit of work equipment) Defective work equipment 2 pump Defective unload valve function
Defective set pressure or 4 defective function of main relief valve
Defective function of self5 pressure reducing valve (PPC original pressure) Internally defective PPC valve
Standard values when normal and remarks for troubleshooting The PTO pump drive unit of the work equipment is assumed to be defective; directly check it. The pump of the work equipment is assumed to be defective; directly check it. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Work equipment lever Unload pressure 2.94 4.9 MPa Full neutral {30 50 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Work equipment lever Main relief pressure 27.4 1.4 MPa Stroke end (Except blade cylinder) {280 14 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Original pressure of control cirWork equipment lever cuit Min. 3.72 MPa Full neutral {Min. 38 kg/cm2} When the troubleshooting in cause 5 is abnormal, the PPC valve is assumed to be defective internally; directly check it.
16
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H-13 Work equipment does not move

Symptom of failure General information Work equipment does not move. Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. Causes Defective PTO (Pump drive 1 unit of work equipment) Defective work equipment 2 pump Defective unload valve function
Defective set pressure or 4 defective function of main relief valve
Defective function of self5 pressure reducing valve (PPC original pressure) Defective function of work 6 equipment lock lever and PPC lock valve
Standard values when normal and remarks for troubleshooting The PTO pump drive unit of the work equipment is assumed to be defective; directly check it. The work equipment pump is assumed to be defective; directly check it. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Work equipment lever Unload pressure 2.94 4.9 MPa Full neutral {30 50 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Work equipment lever Main relief pressure 27.4 1.4 MPa Stroke end {280 14 kg/cm2} a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Original pressure of control cirWork equipment lever cuit Min. 3.72 MPa Full neutral {Min. 38 kg/cm2} Check that the PPC lock valve works properly when the work equipment lock lever is moved up and down.
D475A, D475ASD-5E0
17
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40 Troubleshooting
H-14 Blade lift speed is slow or lacks power

Symptom of failure General information Blade lift speed is slow or lacks power.
Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. Confirm whether the blade is remodeled. When the hydraulic drift rate of the blade lift is also high, carry out troubleshooting High Hydraulic Drift Rate of Blade Lift. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Defective PPC valve funcBlade lever PPC valve output pressure 1 tion Min. 3.72 MPa Lift stroke end {Min. 38 kg/cm2} 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. Causes
18
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40 Troubleshooting
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H-15 Blade tilt speed is slow or lacks power

Symptom of failure General information Blade tilt speed is slow or lacks power.
Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. Confirm whether the blade is remodeled. When the hydraulic drift rate of the blade tilt is also high, carry out troubleshooting High Hydraulic Drift Rate of Blade Tilt. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Defective PPC valve funcBlade lever PPC valve output pressure 1 tion Min. 3.72 MPa Lift stroke end {Min. 38 kg/cm2} 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 and observe how the phenomenon changes. Causes
D475A, D475ASD-5E0
19
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40 Troubleshooting
H-16 Ripper lift speed is slow or lacks power

Symptom of failure General information Ripper lift speed is slow or lacks power.
Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. Confirm whether the ripper is remodeled. When the hydraulic drift rate of the ripper lift is also high, carry out troubleshooting High Hydraulic Drift Rate of Ripper Lift. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Defective PPC valve funcRipper lever PPC valve output pressure tion Min. 3.72 MPa Lift stroke end {Min. 38 kg/cm2} Defective function of ripper The spool function of the ripper lift control valve is assumed to be 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 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 Aired ripper lift cylinder and observe how the phenomenon changes. Causes
2 3 4
20
D475A, D475ASD-5E0
40 Troubleshooting
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H-17 Ripper tilt speed is slow or lacks power

Symptom of failure General information Ripper tile speed is slow or lacks power. Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. Confirm whether the ripper is remodeled.
Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Defective PPC valve funcRipper lever PPC valve output pressure 1 tion Min. 3.72 MPa Tilt stroke end {Min. 38 kg/cm2} 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 and observe how the phenomenon changes.
Causes
D475A, D475ASD-5E0
21
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H-18 Excessive hydraulic drift of blade lift

Symptom of failure General information Excessive hydraulic drift of blade lift. Confirm whether the blade is remodeled. Confirm that no oil leaks the circuits in the work equipment before troubleshooting. Causes
Defective seal of blade lift control valve (Spool)
Defective seal of blade lift cylinder
Standard values when normal and remarks for troubleshooting Prepare with starting the engine, then stop the engine for troubleshooting. Follow the procedure below for troubleshooting. If the hydraulic drift speed becomes high, the spool seal of the blade lift control valve is assumed to be defective. 1) Prop up the machine using the blade lift, and lift the front of the 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. The seal of the blade lift cylinder is assumed to be defective; directly check it.
22
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H-19 Excessive hydraulic drift of blade tilt

Symptom of failure General information Excessive hydraulic drift of blade tilt. Confirm whether the blade is remodeled. Confirm that no oil leaks the circuits in the work equipment before troubleshooting. Causes
Defective seal of blade tilt control valve (Spool)
Defective seal of blade tilt cylinder
Standard values when normal and remarks for troubleshooting a Prepare with starting the engine, then stop the engine for troubleshooting. Follow the procedure below for troubleshooting. If the hydraulic drift speed becomes high, the spool seal of the blade tilt control valve is assumed to be defective. 1) Prop up the machine using the blade tilt, and lift the right of the machine. 2) Stop the engine, and release the lock lever. 3) Set the blade lever to the right tilt side, and confirm how the phenomenon changes. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Blade tilt cylinder Cylinder leak quantity Right tilt stroke end 20 cc/min
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23
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40 Troubleshooting
H-20 Excessive hydraulic drift of ripper lift

Symptom of failure General information Excessive hydraulic drift of ripper lift. Confirm whether the ripper is remodeled. Confirm that no oil leaks the circuits in the work equipment before troubleshooting. Causes
Defective seal of ripper lift control valve (Spool)
Defective seal of ripper lift cylinder
Standard values when normal and remarks for troubleshooting a Prepare with starting the engine, then stop the engine for troubleshooting. Follow the procedure below for troubleshooting. If the hydraulic drift speed becomes high, the spool seal of the ripper lift control valve (Hi) is assumed to be defective. 1) Prop up the machine using the blade tilt, and lift the rear of the 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. a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. 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 failure General information The ripper pin puller cylinder does not work. Confirm that the main relief pressure for transmission is normal before troubleshooting. Standard values when normal and remarks for troubleshooting a Prepare with starting switch OFF, then drive the engine in high idle mode for troubleshooting. Measurement Pin puller working Defective function of pin Pin puller switch 1 position pressure puller solenoid Push-in Cylinder bottom side Min. 2.55 MPa {Min. 26 kg/cm2} Pull-in Cylinder head side 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. Causes
24
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40 Troubleshooting
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H-22 Blade pitch does not work (dual tilt attachment machine)
Symptom of failure General information The blade pitch does not work.
Causes Defective function of blade 1 pitch selection solenoid valve Defective function of blade 2 pitch control valve (Spool) Defective function of blade 3 pitch cylinder
Standard values when normal and remarks for troubleshooting The spool of the blade pitch operation valve is assumed to be defective; directly check it.
The function of the blade pitch cylinder is assumed to be defective; directly check it. The function of the blade pitch selection solenoid valve is assumed to be defective; directly check it. Perform the troubleshooting related to the blade pitch. Defective function of blade Even if the failure code does not appear, confirm that the switch 4 pitch switch input is changed properly.
H-23 Abnormal sound comes out from around work equipment pump 1
Symptom of failure General information Abnormal noise from around work equipment pump. Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. Causes 1 Inappropriate oil Clogged hydraulic oil tank 2 strainer Standard values when normal and remarks for troubleshooting The oil used is assumed to be inappropriate; directly check it. The strainer of the hydraulic oil tank is assumed to be clogged; directly check it. Air is assumed to be inhaled in the suction circuit of the work 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
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
40 Troubleshooting
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
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40 Troubleshooting
S-15 Abnormal noise is made ............................................................................................................ 23 S-16 Vibration is excessive ................................................................................................................ 24
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40 Troubleshooting
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Troubleshooting of engine (S-mode)

Method of using troubleshooting chart
1
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 narrow 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 according 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.
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40 Troubleshooting
<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 symptoms 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].
D475A, D475ASD-5E0
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If we look for the linkage of these three phenomena to possible causes, we find that they have causal relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
D475A, D475ASD-5E0
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40 Troubleshooting
S-1 Starting performance is poor

Leaking or clogged fuel piping, entry of air Clogged air breather hole of fuel tank cap Defective contact of valve and valve seat Defective alternator (generator section)
1
Causes Defective alternator (regulator section)
Stuck or seized supply pump plunger
Defective intake air heater system
Confirm recent repair history Degree of Operated for long period machine operation Became worse gradually Starting performance Engine starts easily when warm Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently When engine is preheated or when temperature is low, preheating monitor does not indicate normally (if monitor is installed) During operation, charge level monitor indicates abnormal charge (if monitor is installed) Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Starting motor cranks engine slowly Fuel does not flow out if air bleeding plug of fuel filter is While engine is removed cranked with startIf spill hose from injector is disconnected, ing motor, little fuel spills When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive
E Q w w
E E Q Q w Q Q Q Q
Questions
w w
w w Q Q w w w
w w w E w Q Q w w w Q w w Q Q Q Q Q w Q Q Q w
Check items
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 Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting of the failure code for "No-pressure feed by supply pump (*1)" When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders When starting switch is turned to HEAT, intake air heater mount does not become warm Is voltage 20 30 V between alternator terminal B and terminal E with Yes engine at low idle? None When specific gravity of electrolyte and voltage of battery are measured, they are low Replace Correct Clean Clean Remedy
q q q q q q q q q
Replace Replace Replace Replace Replace Replace Correct Clean Clean
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
Troubleshooting
D475A, D475ASD-5E0
Defective or deteriorated battery
Clogged feed pump gauze filter
Worn piston ring and cylinder
Clogged air cleaner element
Clogged fuel filter element
Defective injector
General causes for poor starting performance are q Defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel (particularly during winter) q Coolant in exhaust pipe a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble, however.
40 Troubleshooting
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S-2 Engine does not start

Defective starting motor (safety relay section)
1
Causes
Defective connection of battery terminal
Defective starting motor (motor section)
Confirm recent repair history Degree of machine opera- Operated for long period tion Condition of horn when Horn does not sound starting switch is turned Horn volume is low ON Battery electrolyte is low Battery terminal is loose When starting switch is turned ON, there is no operating sound from battery relay When starting switch is turned to START, starting pinion does not move out Speed of rotation is low When starting switch is Makes grating noise turned to START, starting Soon disengages pinion moves out, but Makes rattling noise and does not turn Inspect flywheel ring gear directly
Questions
E E Q w w w Q Q w w Q w Q w w Q Q
Check items
Troubleshooting
When specific gravity of electrolyte and voltage of battery are measured, they are low There is not voltage (20 - 30 V) between battery relay terminal B and terminal E When terminal B and terminal C of starting switch are connected, engine starts When terminal B and terminal C at safety relay outlet are connected, engine starts When terminal B and terminal C at safety relay outlet are connected, engine does not start Replace
q q q q q
Replace Replace Replace Replace Replace Correct
Turn starting switch OFF, connect cord, turn the switch ON and carry out troubleshooting
D475A, D475ASD-5E0
Remedy
Carry out troubleshooting in E-mode
Defective steering circuit wiring
a) Engine does not turn General causes why engine does not turn q Engine seized inside o See "S-4 Engine stops during operations". q Water hammer caused by coolant which entered cylinder q Defective electrical system q Malfunction of hydraulic pump
Broken flywheel ring gear
Defective starting switch
Defective battery relay
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40 Troubleshooting
Defective operation of overflow valve (Does not close)
Leaking, clogging and entry of air to fuel piping
Clogged air breather hole of fuel tank cap
Wrong connection of supply pump PCV
b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out q Fuel is not being supplied q Supply of fuel is extremely small q Improper selection of fuel (particularly in winter)
Causes
Seized, abnormally worn feed pump
Defective operation of flow damper Replace
Broken supply pump shaft spline
Defective supply pump PCV
Clogged fuel filter element
Insufficient fuel in tank
Use of improper fuel
Confirm recent repair history Degree of Operated for long period E E machine operation Exhaust smoke suddenly stopped coming out (when starting again) Non-specified fuel is being used w Replacement of filters not carried out according to Operation and Maintenance w 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 When fuel filter is removed, there is no fuel in it w Q w Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q If air bleeding plug of fuel filter is removed, fuel does not flow While engine is Q Q Q out cranked with starting motor, If spill hose from injector is disconnected, little fuel spills Q When air is bled from fuel system, air comes out Inspect fuel filter directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" Carry out troubleshooting of failure code for "Abnormality in PCV1 (*2) or Abnormality in PCV2 (*3)" Inspect overflow valve directly Engine can be started in reduced cylinder mode Replace Correct Remedy
Questions
E w Q w w w w E E E E Q
Q Q
Q Q
Check items
Q w Q w w w w Q
q q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Correct Correct Clean Add
Troubleshooting
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] *2: Failure code [CA271], [CB271] and failure code [CA272], [CB272] *3: Failure code [CA273], [CB273] and failure code [CA274], [CB274]
D475A, D475ASD-5E0
Defective injector
40 Troubleshooting
SEN01833-00
Defective coolant temperature sensor and/or wiring harness
Worn dynamic valve system (Valve, rocker lever, etc.)
Leaking, clogging of fuel system, and entry of air
Stuck and/or seized supply pump plunger
Clogged injector and/or defective spray
Worn piston ring and/or cylinder liner
c) Exhaust smoke comes out but engine does not start (fuel is being injected) General causes why exhaust smoke comes out but engine does not start q Lack of rotating force due to defective electrical system q Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel
Causes
Confirm recent repair history Degree of machine Operated for long period E E E E operation Suddenly failed to start w w Q Non-specified fuel is being used Q Q Q Q Replacement of filters not carried out according to Operation and Maintenance w w w Manual Engine oil replenished more frequently w When engine is preheated or when temperature is low, preheating monitor does not w indicate normally (if monitor is installed) Dust indicator is red (if indicator 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 Fuel is leaking from fuel piping w When priming pump is operated, it makes no reaction or it is heavy w Q Q Starting motor cranks engine slowly w When engine is cranked, abnormal sound is generated around cylinder head w Fuel does not flow out if air bleeding plug of fuel filter is While engine is Q Q w w removed cranked with starting motor, If spill hose from injector is disconnected, little fuel spills Q Q w When exhaust manifold is touched immediately after starting engine, temperature of w some cylinders is low Inspect air cleaner directly q Inspect dynamic valve system directly q When compression pressure is measured, it is found to be low q When air is bled from fuel system, air comes out Inspect fuel filter, strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" When injector unit is tested, spray condition is bad When specific gravity of electrolyte and voltage of battery are measured, they are low Coolant temperature gauge does not indicate normally (if coolant temperature gauge is installed) When starting switch is turned to HEAT, intake air heater mount does not become warm Replace Replace Replace Clean Remedy Clean
Check items
Questions
q q q q q q q q
Replace Replace Replace Replace Correct Clean Clean Clean
Troubleshooting
D475A, D475ASD-5E0
Defective intake air heater system
Clogged fuel filter and/or strainer
Use of improper fuel
SEN01833-00
40 Troubleshooting
S-3 Engine does not pick up smoothly

Defective operation of flow damper (Maximum leakage from injector) Replace
1
Causes
Seized turbocharger or interference of turbocharger
Leaking, clogging of or entry of air to fuel piping
General causes why engine does not pick up smoothly Insufficient intake of air q Insufficient supply of fuel 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 electrical system)
q
Defective contact of valve and valve seat
Confirm recent repair history Degree of machine operation Operated for long period Engine pick-up suddenly became worse Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Blue under light load Color of exhaust gas is Black When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, interference sound is emitted from around turbocharger High idle speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive
Questions
E E w w
E Q Q
E E w w w w w Q w
w w w w w w w Q Q Q w w Q w w Q Q w w w Q w Q w w w
Check items
Inspect air cleaner directly q When compression pressure is measured, it is found to be low q q Inspect valve clearance directly q When turbocharger is rotated by hand, it is found to be heavy q When air is bled from fuel system, air comes out Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Adjusting Replace Replace Replace Clean Clean Remedy
Troubleshooting
q q q q q
Replace Correct Correct Clean Clean
10
D475A, D475ASD-5E0
Clogged injector and/or defective spray
Improper valve clearance
40 Troubleshooting
SEN01833-00
S-4 Engine stops during operations

Broken dynamic valve system (valve, rocker arm, etc.) Broken auxiliary equipment (pump, compressor, etc.)
1
Causes
Broken or seized piston and/or connecting rod
General causes why engine stops during operations q Seized parts inside engine q Insufficient supply of fuel q There is overheating q Malfunction of hydraulic pump
Broken or seized crankshaft bearing
Leaking and/or clogged fuel piping
Broken supply pump shaft spline
Confirm recent repair history Degree of machine operation Questions Operated for long period Abnormal noise was heard and engine stopped sudw w w w denly Condition when engine Engine overheated and stopped stopped Engine stopped slowly Engine stopped after hunting Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Fuel level monitor indicates low level (if monitor is installed) When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy Rust and water are found when fuel tank is drained Check items Metal particles are found when oil pan is drained Does not turn at all When engine is cranked by hand Turns in opposite direction Moves by amount of gear backlash Supply pump shaft does not turn Engine turns, but stops when load is applied to machine Inspect dynamic valve system directly Inspect piston and connecting rod directly Inspect crankshaft bearing directly Inspect gear train directly Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Inspect feed pump directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed Remedy
EE Q w Q w w Q w w Q Q Q Q Q Q Q Q Q w w w w w w w Q Q w w Q Q
w Q
w w w w w w
w w w
q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Replace Correct Clean Clean Clean Carry out troubleshooting in H-mode
Troubleshooting
Add
D475A, D475ASD-5E0
11
Malfunction of hydraulic pump
Broken or seized feed pump
Broken or seized gear train
SEN01833-00
40 Troubleshooting
S-5 Engine does not rotate smoothly

Defective operation of flow damper (Maximum leakage from injector)
1
Causes
General causes why engine does not rotate smoothly q Air in fuel system q Defective speed sensor (Error at degree that it is not indicated)
Clogged injector and/or defective spray (dirt in injector) Correct
Check items
Confirm recent repair history Degree of machine Operated for long period operation Occurs at a certain speed range Occurs at low idle Condition of hunting Occurs even when speed is raised Occurs on slopes Replacement of filters not carried out according to Operation and Maintenance Manual When fuel tank is inspected, it is found to be empty Air breather hole of fuel tank cap is clogged Rust and water are found when fuel tank is drained Fuel is leaking from fuel piping When priming pump is operated, it makes no reaction or it is heavy When air is bled from fuel system, air comes out Inspect feed pump gauze filter directly Inspect fuel filter and strainer directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Carry out troubleshooting of failure code for "Abnormality in engine Ne speed sensor (*1)" Carry out troubleshooting of failure code for "Abnormality in engine Bkup speed sensor (*2)"
E E Q w Q Q Q Q Q Q Q Q Q w Q w w w w Q Q w w Q Q q q q q q q q
Replace Replace Replace Replace Correct Correct Correct Clean Add
Questions
Troubleshooting
Remedy
*1: Failure code [CA689] and failure [CB689] *2: Failure code [CA778] and failure [CB778]
12
D475A, D475ASD-5E0
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
Q Q Q Q
40 Troubleshooting
SEN01833-00
S-6 Engine lacks output (or lacks power)

Defective installation of boost pressure sensor (air leakage)
1
Causes
Defective fuel temperature sensor and/or wiring harness Defective boost pressure sensor and/or wiring harness
Clogged injector or defective spray (dirt in injector)
Confirm recent repair history

Degree of machine Operated for long period operation
E Q Q w
E Q
E Q
E E Q Q Q Q Q Q Q Q Q Q
Questions
Suddenly Power was lost Gradually Non-specified fuel is being used Replacement of filters not carried out according to Operation and Maintenance Manual Engine oil replenished more frequently Dust indicator is red (if indicator is installed) Air breather hole of fuel tank cap is clogged Fuel is leaking from fuel piping Output becomes insufficient after short stop of operation Color of exhaust Black gas Blue under light load When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head
Q Q Q w w w w w w w w w w Q w w Q w w w Q Q Q Q Q Q w Q
Check items
High idle speed is too high High idle speed under no load is normal, but speed suddenly drops when load is applied Engine does not pick up smoothly and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive
Inspect air cleaner directly q Inspect air intake piping directly q When boost pressure is measured, it is found to be low q q q When compression pressure is measured, it is found to be low q q Inspect valve clearance directly q Inspect fuel filter and strainer directly Inspect feed pump gauze filter directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Inspect boost pressure sensor mount directly Carry out troubleshooting of failure code for "Abnormality in charge pressure sensor (*2)" Carry out troubleshooting of failure code for "Abnormality in fuel temperature sensor (*3)" Adjusting Replace Replace Replace Correct Correct Clean Clean Remedy
Troubleshooting
q q q q q q q q
Replace Replace Replace Replace Replace Replace Correct Clean
Defective drive of injector (signal and/or solenoid)
Air leakage from air intake piping
Leaking or clogged fuel piping
General causes why engine lacks output q Insufficient intake of air q Insufficient supply of fuel q Defective spray condition of fuel q Improper selection of fuel q Overheat o See "S-14 Coolant temperature becomes too high (Overheating)" q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
D475A, D475ASD-5E0
13
SEN01833-00
40 Troubleshooting
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] *2: Failure code [CA122] and failure code[CA123] *3: Failure code [CA263], [CB263] and failure code [CA265], [CB265]
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-00
S-7 Exhaust smoke is black (incomplete combustion)

Leakage of air between turbocharger and cylinder head
1
Causes Defective coolant temperature sensor or wiring harness
Clogged fuel spill piping (on cylinder head side)
Confirm recent repair history Degree of machine operation Operated for long period Suddenly became black Color of exhaust Gradually became black gas Blue under light load Non-specified fuel is being used Oil replenished more frequently Suddenly Power was lost Gradually Dust indicator is red (if indicator is installed) Muffler is crushed Air leaks between turbocharger and cylinder head, and clamp is loosened Engine is operated in low-temperature mode at normal temperature When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Exhaust noise is abnormal Engine does not pick up smoothly and combustion is irregular Blow-by gas is excessive If spill hose from injector is disconnected, abnormally much fuel spills
E w w
E Q
E Q Q Q Q
Questions
w Q Q w w Q w Q Q w w Q Q Q Q w w w Q Q Q Q w Q Q Q w w Q Q w Q Q Q Q
Check items
Inspect air cleaner directly q When turbocharger is rotated by hand, it is fount to be heavy q When compression pressure is measured, it is found to be low q Inspect valve clearance directly q When muffler is removed, exhaust sound improves Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinder Inspect fuel spill piping (on cylinder head side) directly Carry out troubleshooting of failure code for "Abnormality in coolant temperature sensor error (*2)" Adjusting Replace Replace Correct Clean Remedy
q q q q q q q
Troubleshooting
Adjusting
Adjusting
Replace
Replace
Replace
Replace
Replace
Improper fuel injection pressure
Crushed or clogged muffler
Clogged or seized injector
Abnormally worn injector
Improper injection timing
General causes why exhaust smoke is black q Insufficient intake of air q Excessive injection of fuel q Defective spray condition of fuel q Improper selection of fuel q Overheat o See "S-14 Coolant temperature becomes too high (Overheating)" q Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system)
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] *2: Failure code [CA144] and failure code[CA145] D475A, D475ASD-5E0
15
Replace
Correct
SEN01833-00
40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust smoke is blue)

Worn or damaged valve (stem, guide, seal)
1
Oil leakage from oil pan, cylinder head, etc. Correct
Clogged breather or breather hose
Dust sucked in from intake system
Worn seal at turbocharger end
Worn or damaged rear oil seal
Confirm recent repair history Degree of machine oper- Operated for long period ation Oil consumption suddenly increased Oil replenished more frequently Oil becomes contaminated quickly Outside of engine is contaminated with oil There are loose piping clamps in intake system Inside of turbocharger intake outlet pipe is contaminated with oil Inside of turbocharger exhaust outlet pipe is contaminated with oil There is oil in coolant Oil level in damper chamber is increasing Exhaust smoke is blue under light load Excessive Amount of blow-by gas None When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found contaminated abnormally Excessive play of turbocharger shaft Check breather and breather hose directly When compression pressure is measured, it is found to be low Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage There is external leakage of oil from engine Remedy
Questions
E E E w
E w Q Q w Q Q w w w w w
w w Q w w w Q Q w q q q q q q q q q q q q q q
Replace Replace Replace Replace Replace Replace Correct Correct Correct Correct Correct Correct Clean
Check items
w w w w
16
Troubleshooting
D475A, D475ASD-5E0
Oil leakage from oil drain plug
Oil leakage from oil cooler
General causes why oil consumption is excessive q Abnormal combustion of oil 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) q External leakage of oil q Wear of parts in lubrication system
Causes Turbocharger
Oil leakage from oil piping
Worn seal at blower end
Oil leakage from oil filter
Broken piston ring
Broken oil cooler
40 Troubleshooting
SEN01833-00
S-9 Oil becomes contaminated quickly

Clogged turbocharger lubrication drain tube Defective seal at turbocharger turbine end
1
Causes
Clogged breather and/or breather hose
Worn valve and/or valve guide
Defective oil filter safety valve
General causes why oil becomes contaminated q Entry of exhaust gas into oil due to internal wear q Clogging of lubrication passage q Use of improper fuel q Use of improper oil q Operation under excessive load
Check items
Confirm recent repair history Degree of machine operation Operated for long period E E E Non-specified fuel is being used Q Engine oil replenished more frequently w Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (if monitor is w Q installed) 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 w Blue under light load Color of exhaust gas Black w Excessive Q Q w Q Amount of blow-by gas None w Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low Inspect breather and breather hose directly Inspect oil cooler directly Inspect oil filter directly Spring of oil filter safety valve is hitched or broken Inspect turbocharger lubrication drain tube directly Remedy
Questions
q q q q q q q
Replace Replace Replace Replace Replace Clean Clean Clean See S-7
Troubleshooting
D475A, D475ASD-5E0
17
Exhaust smoke is bad
Clogged oil cooler
Clogged oil filter
SEN01833-00
40 Troubleshooting
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Leakage of fuel q Defective condition of fuel injection (fuel pressure, injection timing) q Excessive injection of fuel
q
1
Causes Defective coolant temperature sensor or wiring harness
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
Confirm recent repair history Degree of Operated for long period machine operation More than other machines of same model Condition of fuel Gradually increased consumption Suddenly increased There is external leakage of fuel from engine Combustion is irregular Engine oil level rises and oil smells of diesel fuel When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Low idle speed is high Torque converter stall speed or hydraulic pump relief speed is high Color of exhaust Black gas White Remove and inspect head cover directly Inspect feed pump oil seal directly Carry out troubleshooting of failure code for "No-pressure feed by supply pump error (*1)" When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change change on some cylinders If spill hose from injector is disconnected and measured, much fuel spills Carry out troubleshooting of failure code for "Abnormality in coolant temperature sensor (*2)" Confirm with monitoring function of machine monitor Remedy
Questions
E E Q Q Q Q w
E Q Q Q Q
w w w w Q Q Q Q Q q q q q q q q
Replace Replace Replace Replace Correct Correct Correct
Check items
Troubleshooting
Correct
Q Q
q
Correct
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249] *2: Failure code [CA144] and failure code[CA145]
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-00
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
Damaged cylinder liner O-ring and/or hole caused by pitting
General causes why oil is mixed in coolant q Internal leakage in lubrication system q Internal leakage in cooling system
Causes
Broken cylinder head and/or head gasket
Insufficient protrusion of cylinder liner
Confirm recent repair history Questions Degree of machine operation Oil level Operated for long period Suddenly increased Gradually increased
E Q Q Q Q Q Q
Hard water is being used as coolant Oil level has risen and oil is milky Check items
There are excessive air bubbles in radiator, coolant spurts back
Pressure-tightness test of cylinder head shows there is leakage Troubleshooting Inspect cylinder block and liner directly Inspect cylinder liner directly Pressure-tightness test of oil cooler shows there is leakage
q q q q q
Replace Replace Replace Replace Remedy Replace
Broken oil cooler core and/or O-ring
Cracks inside cylinder block
E Q Q w
D475A, D475ASD-5E0
19
SEN01833-00
40 Troubleshooting
S-12 Oil pressure drops
1
Causes Defective oil pressure sensor and/or defective wiring harness
General causes why oil pressure drops q Leakage, clogging, and/or wear of lubrication system q Defective oil pressure control q Improper selection of fuel (improper viscosity) q Deterioration of oil due to overheating
Check items
Confirm recent repair history Degree of machine operation Operated for long period Oil pressure monitor indicates low oil pressure (if monitor is installed) Non-specified oil is being used Replacement of filters not carried according to Operation and Maintenance Manual Indicates pressure drop at low idling time Oil pressure Indicates pressure drop at low and high idling times monitor Indicates pressure drop on slopes (if installed) Indicates pressure drop occasionally Oil level monitor indicates oil level drop (if monitor is installed) Oil level in oil pan is low External hydraulic piping is leaking or crushed Oil is milky or smells of diesel oil Metal particles are found when oil pan is drained Metal particles are found when oil filter is drained Metal particles are found in oil filter Inspect oil pan strainer and pipe directly Oil pump rotation is heavy, there is play in oil pump Valve and spring of oil pump relief valve are fatigued and damaged Inspect oil filter directly Carry out troubleshooting of failure code for "Abnormality in oil pressure sensor (*1)" If oil level sensor is replaced, oil level monitor indicates normally Remedy
Questions
E Q w Q w w w
Q w Q w Q w w w Q w Q Q w w w
w w q q q
Troubleshooting
See S-13
q q q q q
Adjusting Replace Replace Replace Correct Clean Clean Clean
Clean
*1: Failure code [CA135] and failure code[CA141]
20
Add
D475A, D475ASD-5E0
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
40 Troubleshooting
SEN01833-00
S-13 Oil level rises (Entry of coolant or fuel)

Clogged water pump drain hole (breather hole) and/or defective seal
1
Causes
Confirm recent repair history Degree of Operated for long period machine operation Fuel consumption increasing Coolant replenished more frequently There is oil mixed in coolant Oil smells of diesel fuel Oil is milky When engine is started, drops of water come from muffler When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, or coolant spurts back Exhaust smoke is white Water pump drain hole (breather hole) is clogged When water pump drain hole (breather hole) is cleaned, coolant comes out Oil level in damper chamber of machine is low Oil level in hydraulic tank is low When compression pressure is measured, it is found to be low Remove and inspect head cover directly Inspect cylinder block and/or liner directly Inspect rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage Remove and inspect water pump directly Remove and inspect thermostat cover directly Remove and inspect supply pump directly Inspect seal of auxiliary equipment directly Remedy
Questions
E E w Q Q w Q Q w Q Q
E w w
Q Q
w w w
Check items
Q w w w w
q q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Correct Correct Correct
Troubleshooting
D475A, D475ASD-5E0
21
Defective seal of auxiliary equipment (pump, compressor)
General causes why oil level rises q Coolant in oil (milky) q Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant".
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
SEN01833-00
40 Troubleshooting
S-14 Coolant temperature becomes too high (overheating)

1
Rise in power train oil temperature on applicable machine side
General causes why coolant temperature becomes too high q Lack of cooling air (deformation, and/or damages of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system q Oil temperature of power train is rising
Causes
Slipping fan belt and/or worn fan pulley
Defective radiator cap (pressure valve)
Confirm recent repair history Degree of machine operation Operated for long period Sudden overheated Condition for Persistent overheating Coolant tempera- Rises quickly ture gauge Does not go down from red range (if installed) Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Engine oil level has risen and oil is milky Fan belt tension is low Milky oil is floating on coolant There are excessive air bubbles in radiator and coolant spurts back When light bulb is held behind radiator core, no light passes through Radiator shroud, inside of underguard on applicable machine side are clogged with dirt or mud Coolant is leaking because of cracks in hose or loose clamps Coolant flows out from radiator overflow hose Fan belt whines under sudden acceleration Power train oil temperature gauge enters red range faster than engine coolant temperature gauge (if oil temperature gauge and coolant temperature gauge are installed) on the installed machine side When compression pressure is measured, it is found to be low Inspect cylinder liner directly Inspect oil cooler directly Temperature difference between upper and lower tanks of radiator is large When operation of thermostat is tested, it does not open at cracking temperature Temperature difference between upper and lower tanks of radiator is slight Inspect radiator core directly When operation of radiator cap is carried out, its cracking pressure is low Inspect fan belt and pulley directly When coolant temperature is measured, it is found to be normal Remedy
Questions
E E Q w Q w w Q
E E Q w w w Q Q w
w w w w w w w w w w
Check items
q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Correct Correct Correct Add Carry out troubleshooting in H-mode
22
Troubleshooting
D475A, D475ASD-5E0
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
40 Troubleshooting
SEN01833-00
S-15 Abnormal noise is made

General causes why abnormal noise is emitted q Abnormality due to defective parts q Abnormal combustion q Air leakage from air intake system 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 in the low-temperature mode. Accordingly, the engine sound rises slightly higher. This is no abnormality, however. a When the engine is accelerated, the engine sound rises slightly for approx. 3 seconds maximum. This is no abnormality, however.
Causes
1
Improper fuel injection timing (abnormality in coolant temperature sensor)
Deformed cooling fan and/or looseness or interference of fan belt
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
Excessive wear of piston ring and/or cylinder liner
Interference or seizure of turbocharger
Removed or seized gear train bushing
Improper gear train backlash
Clogged or seized injector
Confirm recent repair history Degree of machine operation Operated for long period Gradually increased Condition of abnormal noise Suddenly increased Non-specified fuel is being used Oil replenished more frequently Metal particles are found when oil filter is drained Air leaks between turbocharger and cylinder head When engine is cranked, interference sound is emitted from around turbocharger When engine is cranked, abnormal sound is generated around cylinder head When engine is cranked, beat noise is emitted around muffler When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust Blue under light load gas Black Engine does not pick up smoothly and combustion is irregular Abnormal noise is loud when engine is accelerated Blow-by gas is excessive When turbocharger is rotated by hand, it is fount to be heavy Inspect dynamic valve system directly When muffler is removed, abnormal noise disappears Inspect valve clearance directly When compression pressure is measured, it is found to be low Inspect gear train directly Inspect fan and fan belt directly When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change on some cylinders Abnormal noise is heard only when engine is started Confirm with monitoring function of machine monitor
Questions
E Q Q Q w w w w w w w Q w Q w Q Q w q q q q q q q q q q q q
Replace Replace Replace Replace Replace Replace Replace Replace Correct Correct Correct Correct
Q Q Q w
Check items
w Q Q
Troubleshooting
Remedy
D475A, D475ASD-5E0
Dirt caught in injector
23
SEN01833-00
40 Troubleshooting
S-16 Vibration is excessive

Misalignment between engine and devices on installed machine side
1
Causes Broken output shaft and/or parts in damper on installed machine side
Stuck dynamic valve system (valve, rocker lever, etc.)
General causes why vibration occurs q Defective parts (abnormal wear, breakage, etc.) 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.
Loose engine mounting bolts and/or broken cushions
Worn main bearing and/or connecting rod bearing
Check items
Confirm recent repair history Degree of machine operation Operated for long period Condition of vibra- Suddenly increased tion Gradually increased Non-specified oil is being used Metal particles are found when oil filter is drained Metal particles are found when oil pan is drained Oil pressure is low at low idle Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Inspect dynamic valve system directly Inspect main bearing and connecting rod bearing directly Inspect gear train directly Inspect camshaft bushing directly Confirm with monitoring function of machine monitor Inspect engine mounting bolts and cushions directly When alignment is checked, radial runout or facial runout is detected Inspect front support spigot joint portion directly Inspect output shaft or inside of damper directly Remedy
Questions
E Q Q Q w w Q Q w q q q
E Q Q w w Q
E Q
Worn front support spigot joint portion
Improper gear train backlash
Worn camshaft bushing
E Q
Q Q Q Q Q Q Q
Troubleshooting
q q q q q q
Adjusting Adjusting Replace Replace Replace Replace Replace Replace Replace
24
D475A, D475ASD-5E0
SEN01833-00
26
SEN02013-01
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
50 Disassembly and assembly1

General information on disassembly and assembly
How to read this manual ................................................................................................................................. 2 Coating materials list....................................................................................................................................... 4 Special tool list ................................................................................................................................................ 7 Sketches of special tools .............................................................................................................................. 14
D475A, D475ASD-5E0
SEN02013-01
50 Disassembly and assembly
How to read this manual

1. Removal and installation of assemblies
Special tools q As to the special tools needed for removal and installation, symbols such A1X1 are attached in the table along with respective part numbers, part names and quantity. q In addition to the above, the list of special tools contains the following information. 1) Necessity t: Special tools that cannot be substituted and should always be used (installed). q: Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They respectively have a new part number. R: Tools with upgraded part numbers. They are remodeled from already 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 interchangeable 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. k : Precautions related to safety in execution 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.
4 6
1
Installation q Except where otherwise instructed, installation of parts is done in the r evers e order of removal. q Instructions and precautions for installing parts are shown with [*1] mark in the Removal section, identifying which step the instructions are intended for. q As to the multi purpose tools used in installation, the numbers such [1], [2] are given. Their part numbers, part names and quantity are not described. q Marks shown in the Installation section stand for the following. k : Precautions related to safety in execution of work. a : This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque
5
: Quantity of oil or coolant to be added
Sketches of special tools q Various special tools are illustrated for the convenience of local manufacture.
This mark shows oil or coolant to be drained. : Weight of part or component
D475A, D475ASD-5E0
SEN02013-01
2. Disassembly and assembly of assemblies

Special tools q As to the special tools needed for disassembly and assembly, symbols such A1X1 are attached along with respective part numbers, part names and quantity. q In addition to the above, the list of special tools contains the following information. 1) Necessity t: Special tools that cannot be substituted and should always be used (installed). q: Special tools that will be useful if available and are substitutable with commercially available tools. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They respectively have a new part number. R: Tools with upgraded part numbers. They are remodeled from already 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 interchangeable 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 disassembly, 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. k : Precautions related to safety in execution of work. a : This mark gives guidance or precautions when doing the procedure.
6
Assembly q In Assembly section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of the oil and coolant added are described. q As to the multi purpose tools used in assembly, the numbers such [1], [2] are given. Their part numbers, part names and quantity are not described. q Various symbols used in Assembly section are explained and listed below. k : Precautions related to safety in execution of work a : This mark gives guidance or precautions when doing the procedure. 2 : Type of coating material 3 : Tightening torque
5
: Quantity of oil or coolant to be added
Sketches of special tools q Various special tools are illustrated for the convenience of local manufacture.
This mark shows oil or coolant to be drained.
D475A, D475ASD-5E0
SEN02013-01
Coating materials list

a a
(Rev. 2007.05) 1
The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this manual.
Komatsu code LT-1A Part number 790-129-9030 Q'ty 150 g Container Tube Main features and applications Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
Category
LT-1B
790-129-9050
20 g (2 pcs.)
Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion. Polyethylene Features: Resistance to heat and chemicals. container Used to fix and seal bolts and plugs. Can Used to stick and seal metal, glass, and plastics.
LT-2 LT-3 Adhesive LT-4 Holtz MH 705 ThreeBond 1735
09940-00030
50 g
790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener) 790-129-9040 790-129-9120 790-129-9140 250 g 75 g 50 g
Polyethylene Used to seal plugs. container Tube Heat-resistant seal used to repair engines. Quick-setting adhesive. Polyethylene Setting time: Within 5 sec. to 3 min. container Used mainly to stick metals, rubbers, plastics, and woods. Quick-setting adhesive. Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container Used mainly to stick rubbers, plastics, and metals. Features: Resistance to heat and chemicals. Polyethylene Used for fitted portions used at high temperacontainer tures. Tube Used to stick or seal gaskets and packings of power train case, etc.
Aron-alpha 201
790-129-9130
2g
Loctite 648-50 LG-1
79A-129-9110 790-129-9010
50 cc 200 g
LG-5
790-129-9080
1 kg
Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container Used to seal tapered plugs, elbows, and nipples of hydraulic piping. Features: Silicon-based heat and cold-resistant sealant. Used to seal flange surfaces and threaded portions. Used to seal oil pan, final drive case, etc. Features: Silicon-based quick-setting sealant. Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc. Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. Used to seal transfer case, etc.
Gasket sealant
LG-6
790-129-9020
200 g
Tube
LG-7 LG-8 ThreeBond 1207B
790-129-9070
1 kg
Tube
419-15-18131
100 g
Tube
D475A, D475ASD-5E0
SEN02013-01
CateKomatsu code gory LG-9 ThreeBond 1206D Gasket sealant LG-10 ThreeBond 1206E LG-11 ThreeBond 1121 ThreeBond 1211 Molybdenum disulfide lubricant
Part number
Q'ty
Container
Main features and applications Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. Can be coated with paint. Used as lubricant/sealant when the radiator hoses are inserted. Can be coated with paint. Feature: Can be used together with gaskets. Used for covers of the transmission case and steering case etc. Gasket sealant used to repair engine. Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. Used to lubricate linkages, bearings, etc. Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
790-129-9310
200 g
Tube
790-129-9320
200 g
Tube
790-129-9330 790-129-9090
200 g 100 g
Tube Tube
LM-P
09940-00040
200 g
Tube
Seizure prevention compound
LC-G NEVER-SEEZ
Can
SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)
Various
Various
Feature: Lithium grease with extreme pressure lubrication performance. General purpose type.
Used for parts under heavy load. Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM Grease Caution: 400 g x 10 Bellows-type Do not apply grease to rolling bearings like 400 g x 20 container swing circle bearings, etc. and spline. 16 kg Can The grease should be applied to work equipment pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg Bellows-type container Can Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.
Hyper White Grease G2-T, G0-T (*)
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*) SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*) G2-S ThreeBond 1855
400 g 16 kg
Bellows-type Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microCan organisms, animals, and plants. Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. Used for oil seals of the transmission, etc.
200 g
Tube
D475A, D475ASD-5E0
SEN02013-01
CateKomatsu code gory SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER Primer SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41 SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SEAL 580 SUPER S or W Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381
Part number
Q'ty 20 ml
Container Glass container Glass container
Main features and applications Used as primer for cab side. (Using limit: 4 months after date of manufacture) Used as primer for glass side. (Using limit: 4 months after date of manufacture) Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture) Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture) S is used for high-temperature season and W for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture) Used as adhesive for glass. (Using limit: 6 months after date of manufacture) Used as adhesive for glass. (Using limit: 6 months after date of manufacture) Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture) Used to seal front window. (Using limit: 6 months after date of manufacture) Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)
417-926-3910 20 ml Adhesive for cab glass Adhesive for cab glass
22M-54-27230
20 ml
Glass container
22M-54-27240
150 ml
Can
22M-54-27250
20 ml
Glass container
417-926-3910
320 ml
Polyethylene container
Adhesive
20Y-54-39850
310 ml
Polyethylene container Ecocart (Special container) Polyethylene container Polyethylene container
22M-54-27210
320 ml
417-926-3920
320 ml
Caulking material
20Y-54-55130
333 ml
22M-54-27220
333 ml
Cartridge
D475A, D475ASD-5E0
SEN02013-01
Special tool list

a
Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
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 New/ remodel Component Symbol Part No. 790-431-1120 791-520-4140 791-181-1020 Removal and installation of radiator guard assembly 791-765-1150 1 791-112-1180 790-101-2540 790-101-2102 790-101-1102 Removal, installation of cylinder head assembly 2 A 3 Removal, installation of engine front seal 795-931-1100 790-331-1110 Part Name Adapter Screw Sleeve Plate Nut Washer Puller (294 kN {30 ton}) Pump Wrench Seal puller assembly Sketch Q Q Press fitting of oil seal Q Press fitting of oil seal Q'ty Nature of work, remarks
a Necessity:
t t t t t t t t q t t t t t t t t t t t t t t t
1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 1 5 5 1 1 1 1 1 Disassembly, assembly of torque converter Disassembly, assembly of transmission Checking actuation of piston N Extraction of oil seal N N Tightening of cylinder head bolt Extraction of oil seal Pulling out pin or radiator guard
795T-621-1430 Plate 795T-621-1441 Push tool 4 01050-32240 01050-32225 01640-02232 3 Removal, installation of engine rear seal 795-931-1100 Bolt Bolt Washer Seal puller assembly Bolt Washer Bracket Repair stand Bracket Repair stand Oil leak tester
795T-621-1531 Push tool 5 01050-32050 01640-02032 790-413-1010 C 790-501-5000 790-413-1010 D 790-501-5000 799-301-1600
Disassembly and assembly of torque converter Disassembly and assembly of transmission
D475A, D475ASD-5E0
SEN02013-01
Necessity
New/ remodel
Sketch Q Q
Q'ty
Component
Symbol
Part No. 791-622-1110
Part Name Bracket Bolt Bolt
Nature of work, remarks
t t t t t t t t t t t t t t t t t t t t t
1 1 1 1 1 1 1 1 3 1 1 2 2 4 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 Disassembly and assembly of steering E
01016-51690 01011-81600
Removal, installation of clutch, brake assembly Press fitting of bearing Removal, installation of bearing round nut Removal, installation of final drive assembly
2 3
791T-822-1810 Push tool 791T-822-1820 Push tool 791-822-1830 790-337-1032 Wrench Lifting tool Plate Bolt Guide Block Leg Adapter Plate Nut Puller (294 kN {30 ton}) Pump Installer assembly Puller (294 kN {30 ton}) Pump Installer Puller (294 kN {30 ton}) Pump Installer assembly Puller (294 kN {30 ton}) Pump Puller (294 kN {30 ton}) Pump Guide
791-827-1910 01011-83015 790-431-1081 790-431-1031 790-101-2350 790-101-2430
790-101-2360 02215-11622 790-101-2102 790-101-1102 790-431-1101
Pulling out sprocket bearing
Disassembly and assembly of final drive assembly
3 J 4
790-101-2102 790-101-1102 791-585-1510 790-431-1220
Press fitting of sprocket bearing Installation of floating seal
Remover assembly t t t t t t
790-101-2102 790-101-1102 790-431-1210
Pulling out center hub
790-101-2102 790-101-1102 790-431-1230
Press fitting of center hub
Remover & installer t t t t
790-101-2102 790-101-1102
Pulling out, press fitting of carrier pin Assembly of No. 1 pinion
790-431-1240
D475A, D475ASD-5E0
SEN02013-01
Necessity
New/ remodel
Sketch Q
Q'ty
Component
Symbol
Part No. 791-830-1760 791-830-1320 790-101-2510 790-101-2570
Part Name Plate Rod Block Plate Nut Washer Puller (294 kN {30 ton}) Pump Installer Push tool Oil pump Installer Push tool Wrench Plate Installer Push tool Oil pump Lifting tool Adapter Shackle T-bolt Bolt Washer Plate Spacer Screw Nut Washer Puller (490 kN {50 ton}) Pump Plate Spacer Plate Screw Nut Washer Puller (490 kN {50 ton})
t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t
1 2 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 3 6 6 1 1 3 3 3 1 1 1 1 1 1 2 1 1
1 Assembly of Idler
01580-01613 01643-31645 790-101-2102 790-101-1102
Press fitting of idler bushing
2 3 4 5 Disassembly and assembly of carrier roller 6 7 8 9 10 Assembly of track roller L 12 11
791-560-1520 791-830-1480 791-601-1000 791-515-1520 790-830-1770 791-630-1270 791-830-1740 791-515-1520 791-830-1730 791-601-1000 790-401-1700 790-401-1761 790-401-1540 790-401-1770
Installation of floating seal Press fitting of seal guide Filling with oil Installation of floating seal N Press fitting of floating seal collar Removal, installation of round nut N N Press fitting of bushing Installation of floating seal Press fitting of seal ring Filling with oil Removal, installation of track roller assembly N
Disassembly and assembly of bogie and track roller
791T-830-1780 Plate 13 01011-62700 01673-32780 1 791-830-1620 2 791-830-1630 3 791-830-1640 14 4 01580-12722 5 01630-32780 6 790-101-4000
Fixture of bogie N N N Pulling out ring and shaft
Disassembly and assembly of bogie
7 790-101-1102 1 791-830-1650 2 791-830-1660 3 796-670-1120 15 4 790-434-1070 5 01580-13629 6 01643-33690 7 790-101-4000
N N N
Pulling out ring
D475A, D475ASD-5E0
SEN02013-01
Necessity
New/ remodel
Sketch Q Q Q Q Q Q
Q'ty
Component
Symbol
Part No.
Part Name
Nature of work, remarks Pulling out ring
15 8 790-101-1102 1 791-830-1620 2 791-830-1640 3 01580-12722 16 4 01643-32780 5 790-101-4000 6 790-101-1102 17 18 Disassembly and assembly of bogie 19 L 791-530-1510 791-601-1000 791-630-1860 791-630-1870 20 19M-09-12850 01643-33380
Pump Plate Screw Nut Washer Puller (490 kN {50 ton}) Pump Installer Oil pump Bracket Bracket Bolt Washer
t t t t t t t t t t t t t t t t
1 1 3 3 3 1 1 2 1 1 1 1 2 2 2 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 6 6 6 1 1 1 1 1 1 N N N N N N
Press fitting of pin assembly
791T-830-1670 Guide
Installation of floating seal Filling with oil
791T-830-1510 Spacer
Removal of No. 1 bogie assembly
791T-830-1700 Lifting tool 791T-830-1710 Bar 791T-830-1720 Plate 21 07283-31079 01582-01210 01643-31232 04530-11628 790-434-1401 1 790-101-2102 790-101-1102 791-685-8502 Disassembly and assembly of recoil spring 791-635-3160 M 2 790-201-2790 790-101-1300 790-101-1102 791-730-1120 3 01580-13326 01643-33380 792-900-1610 792-900-1530 Disassembly and assembly of equalizer bar N 1 791-775-1110 791T-850-1150 01582-53024 01643-33080 Grip Nut Washer Eye bolt
Removal of No. 1 bogie track roller
Remover assembly t Puller (294 kN {30 ton}) Pump Compressor Extension Spacer Cylinder (980 kN {100 ton}) Pump Bolt Nut Washer Adapter Screw Sleeve Plate Nut Washer t t t t t t t t t t t t t t t t
Pulling out idler cushion guide pin
Disassembly, assembly of recoil spring
Removal of recoil spring assembly
Pulling out center pin
10
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SEN02013-01
Necessity
New/ remodel
Sketch Q Q Q Q
Q'ty
Component
Symbol
Part No.
Part Name Puller (294 kN {30 ton}) Pump Bracket Bracket Screw Washer Nut Puller (294 kN {30 ton}) Pump Sleeve Plate Bolt Plate Washer Nut Jack assembly Pump Plug remover Pin brush Push tool Push tool Seal checker
790-101-2102 790-101-1102 791T-850-1160 791T-850-1170
t t t t t t t t t t t t t t t t t t t t t t
1 1 1 1 1 2 2 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 2 1 1 1 5 1 2 1
Pulling out center pin
Disassembly and assembly of equalizer bar
N 2
790-438-1110 790-101-2540 791-112-1180 790-101-2102 790-101-1102 791T-850-1180 791T-850-1190 791-730-1130
Pulling out side pin bushing
Disassembly and assembly of pivot shaft
791-101-3310 01643-32060 01580-02016 790-105-2300 790-101-1102 1 2 3 4 5 6 791-646-7531 791-660-7460 791-646-7900 791-932-1110 790-701-3000 and 791-601-1000 791-632-1010 1 791-832-1610 2 791-832-1270 3 01010-81495 4 791-832-1250
Press fitting of seal
Knocking out small plug Cleaning of pin Knocking in large plug Knocking in all plugs Filling with oil and checking air tightness Replacing of link seal
Oil pump Installer Plate Bracket Bolt Bracket Bolt Plate Shaft Frame Nut Eye bolt Adapter Adapter Guide Screw Pusher Extension Adapter t t t t t t t t t t t t t t t t t t
Disassembly and assembly of track shoe
5 01010-62050 6 791-832-1220 7 791-832-1230 8 791-832-1210 8 9 791-832-1240 10 04530-11628 11 791-832-1310 12 791-832-1280 13 791-832-1320 14 01320-41030 15 791-832-1640 16 791-832-1340 17 791-832-1650
Pulling out and press fitting of pin and bush
D475A, D475ASD-5E0
11
SEN02013-01
Necessity
New/ remodel
Sketch
Q'ty
Component
Symbol
Part No.
Part Name Adapter Guide Guide Adapter Guide Guide Extension Pusher Guide Eye bolt
18 791-832-1480 19 791-832-1670 20 791-832-1330 21 791-832-1660 22 791-832-1630 23 791-832-1470 24 791-832-1410 8 25 791-832-1350 26 791-832-1620 27 04530-11018 28 790-101-4500 29 790-101-1102 30 790-101-4200 31 790-685-9230 1 791-685-5600 2 791-685-5640 3 791-685-5660 4 791-685-5670 Disassembly and assembly of track shoe 5 791-685-5680 R 9 6 791-685-5690 7 791-685-5710 8 791-685-5720 9 791-685-5730 10 01252-30655 11 01580-01210 10 11 790-685-5740 1 791-832-1490 2 791-832-1510 1 791-685-5700 2 791-685-5650 3 791-685-5660 4 791-685-5670 5 791-685-5680 12 6 791-685-5690 7 791-685-5710 8 791-685-5720 9 791-685-5730 10 01252-30655 11 01580-01210 13 791-685-5750
t t t t t t t t t t
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Pulling out and press fitting of pin and bush N
Cylinder t (1960 kN {200 ton}) Pump Puller (294 kN {30 ton}) Spacer Adapter Ring Plate Ring Push tool Adapter Spring Bar Bolt Nut Push tool Push tool Push tool Push tool assembly Adapter Ring Plate Ring Push tool Adapter Spring Bar Bolt Nut Push tool t t t t t t t
Pulling out and press fitting of pin and bush
Push tool assembly t
N N N N N N N N N Press fitting ring (For large plug)
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
N N N N N N N N N N N N
Press fitting ring Press fitting ring
Press fitting ring (For small plug)
Press fitting ring (For small plug) Press fitting ring (For small plug)
Press fitting ring
12
D475A, D475ASD-5E0
SEN02013-01
Necessity
New/ remodel
Sketch
Q'ty
Component
Symbol
Part No.
Part Name Cylinder repair stand Push tool kit
Nature of work, remarks Disassembly, assembly of cylinder Press fitting of coil bushing Blade tilt (standard specification) Blade pitch (superdozer specification) Ripper tilt Ripper lift Ripper puller
790-502-1003 790-201-1702
q t
1 1
790-201-1881 2 790-201-1871 790-201-1721 790-101-5021 01010-50816 790-201-1500 790-201-1670 790-201-1680
Push tool
Push tool Push tool Grip Bolt Push tool kit Plate Plate t
1 1 1 1 1 1 1
Press fitting of dust seal Blade lift Ripper lift Blade tilt (standard specification) Blade pitch (superdozer specification) Ripper tilt Pin puller
3 Disassembly, assembly of hydraulic cylinder U
790-201-1690
Plate
790-201-1530 790-101-5021 01010-50816 4 790-720-1000 796-720-1690 07281-01919 796-720-1690 07281-02169 5 796-720-1710
Plate Grip Bolt Expander Ring Clamp Ring Clamp Ring t t t t t t
1 1 1 1 1 1 1 1 1
Installation of all cylinder piston rings Blade lift (standard specification) Blade lift (superdozer specification) Ripper tilt, lift Blade tilt (standard specification) Blade pitch (superdozer specification) Pin puller Removal and installation of pin puller cylinder head
07281-02709 796-720-1630 07281-00709 6 790-102-2303
Clamp Ring Clamp Wrench
t t t t
1 1 1 1
D475A, D475ASD-5E0
13
SEN02013-01
Sketches of special tools
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A4 Plate
A4 Push tool
14
D475A, D475ASD-5E0
SEN02013-01
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A5 Push tool
E2 Push tool
D475A, D475ASD-5E0
15
SEN02013-01
E2 Push tool
L13 Plate
16
D475A, D475ASD-5E0
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L17 Guide
L20 Spacer
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L21 Lifting tool
L21 Bar
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L-21 Plate
N1 Plate
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N2 Bracket
N2 Bracket
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P Sleeve
P Plate
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number
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
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Engine and cooling system (SAA12V140E-3)

Removal and installation of engine assembly
Special tools
New/remodel Necessity Symbol Sketch Q'ty
3.
Lift off radiator upper cover (2).

4
Radiator upper cover assembly: 85 kg
Part No.
Part Name
799-703-1200 799-703-1100 X 799-703-1111 799-703-1121 799-703-1401
Service tool kit Vacuum pump Vacuum pump Vacuum pump Gas leak detector
t 1 t 1 t 1 t 1 t 1
4.
Removal
k k k
Lower the work equipment to the ground and stop the engine. Set the parking brake lever and work equipment lock lever in the lock position. Disconnect the cable from the negative () terminal of the battery.
6
Remove engine hood assembly (3). For details, see "Removal and installation of engine hood assembly".
1. Drain the coolant.

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).
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6.
Remove undercovers (1st, 2nd and 3rd ones from the front) (33).
9.
Disconnect radiator outlet tube (11).
10. Disconnect torque converter oil cooler tubes (12) and (13). 11. Disconnect heater hose (14).
7.
Disconnect radiator inlet hoses (6) and aeration 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).
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13. Disconnect air conditioner hose (15) and remove the compressor assembly. 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).
16. Disconnect engine rear-side air conditioner hoses (23) and wiring connectors (24).
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.
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19. Sling universal joint (29), remove the mounting bolts, and lift off the universal joint.
4
Installation
q
Universal joint: 65 kg
q
Carry out installation in the reverse order to removal. Refilling with coolant Add coolant to the specified level, and run the engine to circulate the coolant through the system. 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
When removing the engine assembly, check that all the wirings and pipings are disconnected and the engine assembly does not interfere with other parts.
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Removal and installation of radiator assembly

Removal
1. Drain the coolant.
6
4.
1
5. 6.
Disconnect radiator inlet hoses (3) (right and left) and aeration hoses (4) (right and left). Disconnect sub-tank hose (5). Disconnect power line cooler aeration hose (6).
Coolant: 210 l
2.
Remove the fan motor assembly. For details, see "Removal and installation of fan motor assembly".
3.

4
7. 8. 9.
Remove isolator bolts (7) (2 each on the right and left sides). Remove wind breaker panels (8) (upper, lower, right and left). Disconnect headlamp connectors (9).
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10. Disconnect radiator upper wiring harness (10) and radiator coolant level sensor connector (11). 11. Sling radiator assembly (12) and remove upper mounting bolts (13) (2 each on the right and left sides).
13. Remove tube (15). 14. Lift off lower mounting bolts (16) (right and left). 15. Lift off radiator assembly (12). a When removing the radiator assembly, 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. Refilling with coolant 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
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Removal and installation of aftercooler assembly

Removal
1.
3.
1
4.
Disconnect radiator upper clamp (3) and aftercooler upper clamp (4). Remove mounting bolt (6) of aftercooler upper pipe (5).
5. 2. Lift off radiator upper cover (2).

4
Remove lower cover bolts (7) and open lower cover (8).
6.
Remove mounting bolt (10) of aftercooler lower pipe (9) and aftercooler lower mounting bolt (13).
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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
q
Carry out installation in the reverse order to removal.
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Removal and installation of radiator guard assembly

Special tools
New/remodel Necessity Symbol
3.
1
4.
Sketch
Sling blade lift cylinder assembly (4), then fit cylinder holder tool and secure to radiator guard. Drain coolant.
6
Coolant: 210 l
Part No.
Part Name
790-431-1120 791-520-4140 791-181-1020 791-765-1150 A 1 791-112-1180 790-101-2540 790-101-2102 790-101-1102
Adapter Screw Sleeve Plate Nut Washer
t 1 t 1 t 1 t 1 t 1 t 1
Puller t 1 (294 kN {30 ton}) Pump t 1
Q'ty
5.
Removal
1. Remove lock plate (1) of the lift cylinder rod pin, then remove pin (2). [*1] a Start the engine and retract the piston rod fully, then tie the piston rod with wire to prevent it from coming out. a Tie the piston rod on the opposite side in the same way. 6.
Disconnect radiator inlet and outlet hoses, aeration hose, and wiring harness clip. For details, see "Removal and installation of radiator assembly". Disconnect hydraulic cooler hose (5). Disconnect fan motor hose (6). k Release the remaining pressure from the hydraulic circuit. 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
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7.
Disconnect work equipment hoses (7) and (8).
Installation
q
[*1] a Standard shim thickness: 4 mm

q
Refilling with coolant Add coolant to the specified level, and run the engine to circulate the coolant through the system. Then check the coolant level again.
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. Remove lock plate, then using tool A1, pull front pin (12) to outside of radiator guard and remove.
9.
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
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Removal and installation of fuel tank assembly 1

Removal
1. Disconnect hose (1). a Before disconnecting the hose, close the fuel valve. Remove case (2).
6.
Remove fuel tank mounting bolt (9).
2.
7.
Lift off fuel tank assembly (10).

4
Fuel tank assembly (when full): 2,335kg
3. 4. 5.
Remove joint (3) and hose clamp (4). Disconnect fuel return hoses (5) and (6), and remove hose clamp (7). Disconnect fuel gauge wiring connector (8).
Installation
q
12
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Removal and installation of engine hood assembly

Removal
k
3.
1
4.
Disconnect wiring connectors (3) (201 and 209) and remove clamp (4). Disconnect hose (5) to the sub-tank and remove hose clamp (4).
Disconnect the cable from the negative () terminal of the battery. Remove right and left potentiometer wiring grommets (1) from the cover.
1.
5. 6.
Open right and left covers (6) and (7). Remove right and left side covers (8).
2.

4
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7. 8.
Loosen clamps (9) and disconnect air cleaner hoses (10). [*1] Remove sub-tank drain hose clamp (11).
11. Remove hood mounting bolts (16) and (17).
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
q
[*1] Hose inserted length: Min. 40 mm 3 Hose clamp: 8.83 0.5 Nm {0.9 0.05 kgm}
14
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Removal and installation of fan drive assembly 1

Removal
1. Drain the hydraulic oil.
6
5. 6.
Remove wiring harness clamp (5) and disconnect connector (6). Bracket (7).
Hydraulic tank: Approx. 340 l
2.
Remove 8 mounting bolts (2) of radiator mask (1) and open the radiator mask.
7. 8. 9. 3. 4. Remove net (3). Remove fan blade (4).
Disconnect fan motor hoses (8), (9) and (10). Sling fan drive assembly (11) and remove bracket mounting bolts (12). Lift off fan drive assembly (11).
4
Fan drive assembly: 250 kg
a a
Loosen mounting bolts (13) of the lower right and left shrouds. Move the fan to the position shown in the photo.
Installation
q
Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
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Removal and installation of fan motor assembly
Removal
1. Remove the fan drive assembly. For details, see "Removal and installation of fan drive assembly". Remove the mounting bolt and lock plate (1). [*1] 3. 4. 5. Remove nut (2). Remove fan (3). Remove the 4 mounting bolts and fan motor assembly (4). [*3]
4
[*2]
2.
Fan motor assembly: 65 kg
16
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Installation
q
[*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} After tightening the nut, check dimension (d) shown below. q MIN: 2.0 mm q MAX: 4.0 mm
[*3]
When fitting the fan motor and fan, clean and degrease them thoroughly.
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Engine (SAA12V140E-3)
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 ................................................................................................ 27
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Removal and installation of fuel supply pump assembly
4.
1
Remove fuel hose clamp (4) and bracket (5). Remove high-pressure pipe clamp (6) and high-pressure pipe (7). Remove clamp (8) and fuel tube (9). Remove lubrication tube (10). [*1]
5.
Removal of fuel supply pump on left bank side

k k k
6. 7.
a 1. 2.
Lower the work equipment to the ground and stop the engine. Set the parking brake lever and work equipment lock lever in the lock position. Disconnect the cable from the negative () terminal of the battery. Do not remove the undercover. Close the fuel valve under the fuel tank. 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 filters. 8. Remove common rail cover (11).
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9.
Disconnect wiring connectors (12). a Connectors: PCV1, PCV2 and G
Removal of fuel supply pump on right bank side

k k k
a 1. 2.
Lower the work equipment to the ground and stop the engine. Set the parking brake lever and work equipment lock lever in the lock position. Disconnect the cable from the negative () terminal of the battery. Do not remove the undercover. Close the fuel valve under the fuel tank. 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 supply 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 filters. Remove heat insulation plate (4).
4.
After the fuel supply pump is removed, the coupling on the drive case moves out of position. Accordingly, rotate the crankshaft to set the drive case in position when installing the fuel supply pump.
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5.
Disconnect wiring clamp (5) and fuel hose clamps (6).
7)
Disconnect 6 upper high-pressure pipes (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 following procedure. 1) Remove clamp (8). 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).
9)
Remove right and left mounting bolts (16) to remove common rail (17).
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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. 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 specified torque, tighten the sleeve nuts of the high-pressure pipe (between the supply pump and common rail).
1.
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 supply 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
2. 3.
Connect the wiring connector (12). Remove common rail cover (11).
Right fuel supply pump assembly: 17 kg
After the fuel supply pump is removed, the coupling on the drive case moves out of position. Accordingly, rotate the crankshaft to set the drive case in position when installing the fuel supply pump.
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3
High-pressure pipe
k
When handling the high-pressure pipe 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 tension is increased too much and the highpressure pipe may be broken when the sleeve nut is tightened. Before installing the high-pressure pipe, check it. If it has any defect, replace it since fuel may leak. q Check the taper seal of the connecting part (Part "a": Part of 2 mm from the end) for visible lengthwise slit "b" and dent "c". 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.
4)
5)
6)
Bracket mounting bolt (14): 19.6 29.4 Nm {2.0 3.0 kgm} Install lubrication tube (10). 3 Lubrication tube joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm} Install high-pressure pipe clamp (6) according to the following procedure. 1] Finger tighten all the mounting bolts of high-pressure pipe clamp (6) and bracket (16). 2] Tighten the high-pressure pipe clamp (6) mounting bolts permanently. a When tightening the high-pressure pipe clamp mounting bolts, tak e c ar e ex tr e me ly t hat a n excessive force will not be applied to the mounting area on the supply pump side. 3 Clamp bolt: 9.8 1 Nm {1 0.1 kgm} 3] Tighten bracket (16) mounting bolts permanently. Install 4 rubber covers (15) to the highpressure pipe sleeve nuts. a Install the rubber covers so that their slits will be directed as follows. q Supply pump side: Down q Common rail side: Inward (Facing each other)
4.
Install the high-pressure pipe according to the following procedure. 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 mounting bolts. 3) Tighten supply pump assembly bracket (14) mounting bolts. D475A, D475ASD-5E0
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Carry out the following installation in the reverse order to removal. Joint bolt on main fuel filter (upper) side: 24.5 34.3 Nm {2.5 3.5 kgm} Joint bolt on fuel supply pump side: 14.8 19.6 Nm {1.5 2.0 kgm}
[*1]
3 3
Check that each high-pressure pipe is at least 10 mm apart from the wiring harness around it.
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Removal and installation of cylinder head assembly

Special tools
4.
1
Remove mounting bands (3) and connector nuts and then wind a rope around muffler assembly (4) and lift it off.
4
Muffler assembly: 60 kg (1 piece)
Part No.
Part Name
A 2 790-331-1110
Wrench
q 1
Removal
k k k
Lower the work equipment to the ground and stop the engine. Set the parking brake lever and work equipment lock lever in the lock position. Disconnect the cable from the negative () terminal of the battery. Close the fuel valve under the fuel tank. Remove the engine hood. For details, see "Removal and installation of engine hood". Remove right and left engine side covers (1) and right and left covers (2).
Sketch
Q'ty
5.
1. 2. 3.
Remove the piping and then remove the corrosion resistor, air bleeding valve and mounting bracket (5) together.
4
Corrosion resistor, air bleeding valve and mounting bracket: Approx. 35 kg
6.
Remove muffler mounting bracket (6).

4
Muffler mounting bracket: 38 kg
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7. 8.
Remove aftercooler inlet pipe (7) and aftercooler outlet pipe (8). [*1] Remove bracket (9) and turbocharger intake connector (10) together. [*2] Remove turbocharger exhaust connector (11).
14. Remove the common rail cover. For details, see "Removal and installation of fuel supply pump assembly". 15. Remove right and left rubber covers (17) and (18). 16. Remove right and left high-pressure pipes (19).
9.
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).
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18. Remove each tube of the turbocharger. q Lubrication tube (21) q Lubricating oil drain tube (22) q Coolant tube (23) q Coolant drain tube (24)
19. Remove heat insulation cover (25). [*4] [*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
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21. Removal of injector external wiring 1) Remove cover plate (27). 2) Disconnect connector (28) from each cylinder head and disconnect wiring harness (29). 22. Remove air vent tubes (30) and (31). 23. Remove spill tube (32). 24. Remove head cover (33). [*6]
25. Removal of rocker arm assembly 1) Loosen locknuts (34) and then loosen adjustment screws (35) fully. a Check that the rocker arm is not affected by the valve tension but it is free. 2) Remove rocker arm assembly (36). a Put a location tag to each rocker arm assembly before storing.
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).
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5)
Insert small L-bar [B] under the fuel connector and pry out fuel injector (44) slowly. a Do not grip the solenoid valve at the top of the injector with pliers to pull out the injector.
Installation
Cylinder head assembly 1. 2. Install the cylinder head gasket. 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 a

2 3
If the cylinder head assembly is removed without removing the fuel injector, the injector tip projects from the bottom of the cylinder head. Accordingly, use a block, etc. to prevent the injector from interfering with the floor.
If there are 5 punch marks on the head of a bolt, do not reuse that bolt but replace it. Tighten the mounting bolts in the order shown in the figure. Cylinder head assembly mounting bolt: Molybdenum disulfide grease (LM-P) 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 Cylinder head assembly mounting bolt (7): 66.2 7.4 Nm {6.75 0.75 kgm}
30. Remove the cylinder head gasket.
12
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50 Disassembly and assembly a
SEN02338-01
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.
After tightening the bolts, make punch mark "a" on the main bolt head (Do not make it when new bolts are used, however).
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 after tightening the high-pressure pipe temporarily.
Fuel injector a Check that there is no dirt in the injector 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). Install gasket (48) to fuel injector (44). Insert fuel injector (44) and injector holder (49) together in the cylinder head.
Crosshead 7. Install crossheads (38). 2 Sliding parts of crosshead: Engine oil (EO30)
4. 5.
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8.
Adjust the crosshead according to the following procedure. 1) Loosen locknut (102) and then loosen adjustment screw (103) to a position where it will not touch valve stem (104). 2) Hold the contact face to the rocker arm with the finger to keep crosshead in contact 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}
10. Install push rods (37). a Check that each push rod end is fitted in the receiving area of the cam follower. 2 Both ends of push rod: Engine oil (EO30)
9.
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 mounting nuts, press the wiring harness against the injector body to take up the slack.
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} 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".
14
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Tightening torque for locknut: 52.9 64.7 Nm {5.4 6.6 kgm} After tightening the locknut, check the valve clearance again.
12. Install spill tube (32). 3 Joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm} 13. Place cylinder head cover (33). (Place it to prevent dirt from entering. It will need to be removed again.)
14. Fuel injector and high-pressure pipe (between common rail and fuel injector) k When handling the high-pressure pipe 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 s p ec i fi e d p os i t io n s e c ur e l y a n d tighten it to the specified torque. q Do not apply lubricant to the highpressure pipe sleeve nut and the threads of the mating part. a If lubricant is applied, the axial tension 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. q Check the taper seal of the connecting part (Part "a": Part of 2 mm from the end) for visible lengthwise slit "b" and dent "c". 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.
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1) 2)
3) 4) 5)
Fit O-ring (52) to the high-pressure pipe sleeve nut (51). 2 O-ring: Engine oil (EO30) Tighten sleeve nut (51) temporarily into fuel injector (44). a If sleeve nut (51) does not catch the threads, press its end with a small rod, etc. toward the injector and turn the spanner. Tighten sleeve nut (53) on the common rail side temporarily, too. Tighten injector holder (49) permanently. 3 Injector holder mounting bolt (43): 58.9 73.5 Nm {6.0 7.5 kgm} Tighten the sleeve nut to the specified torque. a Using a spanner-type torque wrench (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), check that O-rings (46) and (52) are not projected from the sleeve nut.
6) 7)
Install the cylinder head cover. 3 Cylinder head cover mounting bolt: 14.7 34.3 Nm {1.5 3.5 kgm} Install rubber covers (17) and (18) to the sleeve nuts of high-pressure pipes (19). a Install the rubber covers so that their slits will be directed as follows. q Injector side (17): Down q Common rail side (18): Cylinder block side
15. Air intake manifold assembly 1) Install the gasket. a Direct the side having the mark of "UP" up and direct it toward the air intake manifold. 2 Threaded part and seat of mounting bolt: Molybdenum disulfide grease (LM-P) a Tighten the mounting bolts according to the following procedure. 3 Air intake manifold mounting bolt: 58.8 73.5 Nm {6.0 7.5 kgm}
16
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16. Install the high-pressure pipe clamps (between the common rail and fuel injector). For details, see "Removal and installation of fuel supply pump assembly". 17. 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). a Using a spanner-type torque wrench (commercially available), control the tightening torque.
q
[*2]
Air intake connector mounting bolt: 49 68.6 Nm {5.0 7.0 kgm}
[*3]
3 3 3
Fuel tube joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm} Fuel hose joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm} Spill tube joint bolt Cylinder head side: 9.8 12.7 Nm {1.0 1.3 kgm} Air intake manifold side: 19.6 29.4 Nm {2.0 3.0 kgm} Turbocharger coolant tube joint bolt (upper side): 24.5 34.3 Nm {2.3 3.5 kgm} Turbocharger coolant tube sleeve nut (lower side): 24.5 59 Nm {2.3 6 kgm} Turbocharger coolant hose: 29.4 39.2 Nm {3.0 4.0 kgm}
[*4] Carry out the following installation in the reverse order to removal.
3 3 3
[*1]
q
Air hose Use a new MIKALOR clamp. 1) Set the hose to the original position (marked position). (Insertion depth of air 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) Do not use an impact wrench.
a
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} When using new hose 4) Tighten until dimension BDG becomes as follows. BDG: 17 20 mm
[*5] Exhaust manifold assembly 1) Install the gasket. a Direct the side having the mark of "OUT" toward the exhaust manifold. a Tighten the mounting bolts in the numeric order shown in the figure. a After tightening the mounting bolts, tighten them again to the same torque. 2 Threaded part and seat of mounting bolt: Molybdenum disulfide grease (LM-P) 3 Exhaust manifold mounting bolt: 44.1 53.9 Nm {4.5 5.5 kgm}
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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}
Refilling with coolant 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. Check that each high-pressure pipe is at least 10 mm apart from the wiring harness around it.
18
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Removal and installation of fuel injector assembly

Removal
k k k
Corrosion resistor, air bleeding valve and mounting bracket: Approx. 35 kg
1. 2. 3.
Lower the work equipment to the ground and stop the engine. Set the parking brake lever and work equipment lock lever in the lock position. Disconnect the cable from the negative () terminal of the battery. Close the fuel valve under the fuel tank. Remove the engine hood. For details, see "Removal and installation of engine hood". Remove right and left engine side covers (1) 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.
4
7. 8. 9.
Muffler assembly: 60 kg (1 piece)
Remove aftercooler inlet pipe (7) and aftercooler outlet pipe (8). [*1] Remove bracket (9) and turbocharger intake connector (10) together. [*2] Remove turbocharger exhaust connector (11).
5.
Remove the piping and then remove the corrosion resistor, air bleeding valve and mounting bracket (5) together.
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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).
14. Remove the common rail cover. For details, see "Removal and installation of fuel supply pump assembly". 15. Remove right and left rubber covers (17) and (18). 16. Remove right and left high-pressure pipes (19).
18. Removal of injector external wiring 1) Remove cover plate (27). 2) Disconnect connector (28) from each cylinder head and disconnect wiring harness (29). 19. Remove head cover (30).
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20. Removal of rocker arm assembly 1) Loosen locknuts (34) and then loosen adjustment screws (35) fully. a Check that the rocker arm is not affected by the valve tension but it is free. 2) Remove rocker arm assembly (36). a Put a location tag to each rocker arm assembly before storing.
5)
Insert small L-bar [B] under the fuel connector and pry out fuel injector (44) slowly. a Do not grip the solenoid valve at the top of the injector with pliers to pull out the injector.
Installation
Fuel injector a Check that there is no dirt in the injector sleeve. 2 O-ring: Engine oil (EO30) 1. Fit O-rings (46) and (47) to fuel injector (44). a Take care not to fit O-ring (47) to center groove (A). Install gasket (48) to fuel injector (44). Insert fuel injector (44) and injector holder (49) together in the cylinder head.
21. 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).
2. 3.
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4.
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 after tightening the high-pressure pipe temporarily.
6.
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} 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 mounting nuts, press the wiring harness against the injector body to take up the slack.
Tightening torque for locknut: 52.9 64.7 Nm {5.4 6.6 kgm} After tightening the locknut, check the valve clearance again.
22
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7.
Place the cylinder head cover. (Place it to prevent dirt from entering. It will need to be removed again.) Fuel injector and high-pressure pipe (between common rail and fuel injector) k When handling the high-pressure pipe 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 s p ec i f ie d p o s it i on s e c u r el y an d tighten it to the specified torque. q Do not apply lubricant to the highpressure pipe sleeve nut and the threads of the mating part. a If lubricant is applied, the axial tension 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. q Check the taper seal of the connecting part (Part "a": Part of 2 mm from the end) for visible lengthwise slit "b" and dent "c". 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.
1) 2)
8.
3) 4) 5)
Fit O-ring (52) to the high-pressure pipe sleeve nut (51). 2 O-ring: Engine oil (EO30) Tighten sleeve nut (51) temporarily into fuel injector (44). a If sleeve nut (51) does not catch the threads, press its end with a small rod, etc. toward the injector and turn the spanner. Tighten sleeve nut (53) on the common rail side temporarily, too. Tighten injector holder (49) permanently. 3 Injector holder mounting bolt (43): 58.9 73.5 Nm {6.0 7.5 kgm} Tighten the sleeve nut to the specified torque. a Using a spanner-type torque wrench (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), check that O-rings (46) and (52) are not projected from the sleeve nut.
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6) 7)
Install the cylinder head cover. 3 Cylinder head cover mounting bolt: 14.7 34.3 Nm {1.5 3.5 kgm} Install rubber covers (17) and (18) to the sleeve nuts of high-pressure pipes (19). a Install the rubber covers so that their slits will be directed as follows. q Injector side (17): Down q Common rail side (18): Cylinder block side
Removal
q
Carry out the following installation in the reverse order to removal.
[*1]
q
Air hose Use a new MIKALOR clamp. 1) Set the hose to the original position (marked position). (Insertion depth of air 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) Do not use an impact wrench. 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} When using new hose 4) Tighten until dimension BDG becomes as follows. BDG: 17 20 mm
a
q
9.
Install the high-pressure pipe clamps (between the common rail and fuel injector). For details, see "Removal and installation of fuel supply 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). a Using a spanner-type torque wrench (commercially available), control the tightening torque.
[*2]
Air intake connector mounting bolt: 49 68.6 Nm {5.0 7.0 kgm} Fuel tube joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm} Fuel hose joint bolt: 24.5 34.3 Nm {2.5 3.5 kgm}
[*3]
Check that each high-pressure pipe is at least 10 mm apart from the wiring harness around it.
24
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SEN02338-01
Removal and installation of engine front seal

Special tools
Part No.
Part Name
Sketch
Q'ty
Remove front seal (2) in the following procedure. 1) Replace the tip of tool A3 with the hook type one. 2) Hitch the hook to the hoop of front seal (2). 3) Remove front seal with impact of slide hammer (SH).
q
Tool A3
3 795-931-1100
Seal puller
t 1 t 1 t 1 t 3 t 3 t 3 N Q N Q
795T-621-1430 Plate A 795T-621-1441 Push tool 4 01050-32240 01050-32225 01640-02232 Bolt Bolt Washer
Removal
1. Remove radiator guard assembly. For details, see "Removal and installation of radiator guard assembly". Remove crankshaft pulley (1). [*1]
CS: Crankshaft
2.
3.
Remove front seal (2).
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Installation
1. Clean, degrease and then dry the contact surface between the front cover and front seal. Using a clean cloth, remove foreign matter deposited on the crankshaft flange. a Clean foreign matter deposited on the seal lip surface (surface around the crankshaft) and then degrease and dry the surface. a Check the crankshaft end face corner and lip siding surface for scratches due to the housing, burrs or rusts. When installing front oil seal (2), do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft.
2
3)
2.
Using the A4 (push tool), press oil seal (2) in the front case until it becomes the dimension (a) as shown in the figure. a Oil seal press fit dimensions (a): 17 mm (from shaft end surface) (b): 25.1 mm (from front cover end surface)
3.
Inner circumference of front oil seal: Gasket sealant (LG-7 or equivalent)

q
1)
The surface having the parts number (PN) marking must face to the outside of engine.
Carry out the following installation in the reverse order of removal.
[*1] a Align the dowel pin when installing the crankshaft pulley. a Tighten the mounting bolts in the order shown in the diagram below. 2 Threaded part and seat of bolt: Engine oil (EO30) 3 Crankshaft pulley mounting bolt: 1st time: 73.5 19.6 Nm {7.5 2.0 kgm} 2nd time: 245 19.6 Nm {25 2.0 kgm} 3rd time: 744.8 19.6 Nm {76 2.0 kgm} 2) Tighten bolts using the tool A4 (plate), and press oil seal (2) to the shaft end.
26
D475A, D475ASD-5E0

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Removal and installation of engine rear seal

Special tools
a
Sketch
Part No.
Part Name
3 795-931-1100 A 5 01050-32050 01640-02032
Seal puller Bolt Washer
t 1 t 1 t 5 t 5 N Q
q
795T-621-1531 Plate
Take care in the removal not to damage the seal installation position on the flywheel housing and the seal contact face on the crankshaft. Before removing, slightly drive the seal in once to free it from fixation. 1) Replace the tip of tool A3 with the hook type one. 2) Hitch the hook to the hoop of rear seal (3). 3) Remove rear seal with impact of slide hammer (SH). Tool A3
Removal
1. Remove damper assembly. For details, see "Removal and installation of damper assembly". 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
2.
Flywheel: 140 kg
Q'ty
CS: Crankshaft
3.
Remove rear seal (3).
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Installation
1. Clean, degrease and then dry the contact surface between the flywheel housing and rear seal. Using a clean cloth, remove foreign matter deposited on the crankshaft flange. a Clean foreign matter deposited on the seal lip surface (surface around the crankshaft) and then degrease and dry the surface. a Check the crankshaft end face corner and lip siding surface for scratches due to the housing, burrs or rusts. When installing rear oil seal (3), do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft.
2
4.
Using guide bolt, and install flywheel (2).
2.
3.
5.
Secure flywheel (2) and housing with plate [3].
Inner circumference of rear oil seal: Gasket sealant (LG-7 or equivalent)
1)
The surface having the parts number (PN) marking must face to the outside of engine.
2)
Using the A5 (push tool), press oil seal (3) in the flywheel housing until it becomes the dimension (a) as shown in the figure. a Oil seal press fit dimensions (a): 5 mm (from flywheel housing end surface)
Tighten the mounting bolts in the order shown in the diagram below. 2 Threaded part and seat of bolt: Engine oil (EO30) 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}
28
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6.
After installing flywheel, use dial gauge [4] to measure radial and face runout of flywheel. q Face runout: Max. 0.25 mm q Radial runout: Max. 0.25 mm
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

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
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Power train, Part 1

Removal and installation of damper assembly
Removal
1. Remove hood assembly. For details, see Removal and installation of hood assembly. Open underguard (3rd from front of machine). Remove drain plug (1) and drain damper oil.
6
6. 7. 8.
Remove holder (4) and coupling (5). Remove retainer (6).
[*2]
2. 3.
Sling damper cover (7), then use forcing screw [1] (12mm, P=1.75) to remove damper cover. k Install guide bolts (12 mm, P = 1.75, l = 100) in 2 mounting bolt holes in the top of the damper cover so that the damper cover does not come out suddenly.
4
Damper cover: 50 kg
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
5.
Sling universal joint (3), then remove mounting bolts, and lift off. [*1]
4
Damper assembly: 85 kg
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Installation
q

3
[*1]
Universal joint mounting bolt: 156.8 196 Nm {16 20 kgm} Holder mounting bolt thread: Thread tightener (LT-2) Holder mounting bolt: 490 607.6 Nm {50 62 kgm}
[*2]
2 3
Refilling with oil (damper case) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
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Disassembly and assembly of damper assembly

Disassembly
1. 2. 3. 4. 5. 6. 7. Remove bolt (1), then remove flange (2). Remove seal (3). Remove shaft (4). Remove rubber (5). Remove flange (6) from body (7). Remove seal (8). Remove bearing (9).
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).
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). 9. Remove oil seal (13) from retainer (14). 3. Align the bolt holes with body (7), then install flange (6). 2 Flange mating surface: Gasket sealant (LG-4) a Check that there are no dents, rust, oil or grease, or water on the mating surface, then coat both the flange and body surfaces with gasket sealant. a Coat with a thickness of about 0.1 0.2 mm, leave to dry for 2 3 minutes, then tighten.
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7.
Tighten bolt (1).
4. 5.
Set shaft (4) to flange and body assembly in position. Assemble rubber (5). a When assembling the rubber, coat the whole surface of the rubber, the outside circumference of the shaft, and the inside circumference of the body with grease (G2-LI). a After assembling the rubber, fill approx. 50% (approx. 400 g) of the space ((b) portion: 16 places) between the shaft and body with grease (G2-LI).
Assembly of damper cover assembly 8. Using push tool [1], press fit oil seal (13) to retainer (14). 2 Oil seal press-fitting surface: Gasket sealant (LG-1) a Coat the inside surface of the retainer thinly with gasket sealant and wipe off any sealant that is forced out. 2 Lip of oil seal: Grease (G2-LI)
9. 6. Install flange (2). 2 Flange mating surface: Gasket sealant (LG-4) a Check that there are no dents, rust, oil or grease, or water on the mating surface, then coat both the flange and body surfaces with gasket sealant. a Coat with a thickness of about 0.1 0.2 mm, leave to dry for 2 3 minutes, then tighten.
Using push tool [2], press fit bearing (10) to cover (12).
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10. Using push tool [1], press fit oil seal (11) to cover (12). 2 Oil seal press-fitting surface: Gasket sealant (LG-1) a Coat the inside surface of the cover thinly with gasket sealant and wipe off any sealant that is forced out. 2 Lip of oil seal: Grease (G2-LI)
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Removal and installation of power train unit assembly

Removal
1. Drain oil from hydraulic tank and power train case.
6 6
8.
Remove hydraulic pump inlet tube coupling (5) and hydraulic tank side coupling (6), and remove tube (7). Disconnect fan motor hose (8).
9.
10. Disconnect hoses (9) and (10).
Hydraulic tank: Approx. 120 l Power train case: Approx. 150 l
2.
Remove floor frame assembly. For details, see "Removal and installation of floor frame assembly". Remove fuel tank assembly. For details, see "Removal and installation of fuel tank assembly". Remove brake rod (1). Disconnect cable (2). 11. Disconnect steering hose (11). 12. Disconnect hoses (12) and (13).
3.
4. 5.
6. 7.
Disconnect lubrication hose (3). Disconnect fan motor pump tube coupling (4). 13. Remove hydraulic pump inlet tube (14). 14. Disconnect hydraulic pump PPC hoses (15) and (16).
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15. Disconnect hydraulic pump outlet hoses (17) and (18). 16. Disconnect hydraulic PPC hoses (19) and (20).
19. Remove universal joint (23).

4
[*1]
20. Remove front mount bolt (24). 17. Disconnect wiring connector (21) (PL1, PL2, PL3).
[*2]
21. Remove rear mount bolt (25), then remove mount cap (26). [*3]
4
Mount cap: 30 kg
18. Disconnect hose (22), then disconnect clamp (1 place) on top of steering case. 22. Remove housing clip (27), and move flange (28) towards final drive end. [*4] 23. Using forcing screws [1], remove cover (29).
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24. Remove shaft (30). a Pull out the shaft with forcing screws [2]. a If the shaft will not come out, set jack [3] 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 come out, and remove the shaft.
Installation
q

3
[*1]
Universal joint mounting bolt: 156.8 196 Nm {16 20 kgm} Front mount bolt: 1,519 1,911 Nm {155 195 kgm} Rear mount bolt: 823.2 1,029 Nm {84 105 kgm}
[*2]
[*3]
[*4]
Check that the housing clip is fitted securely in the flange. 3 Housing clip: 4.9 8.8 Nm {0.5 0.9 kgm} When installing the power train unit assembly, pay attention to the mating surface of the coupling, and be careful not to damage the seal of the rear mount coupling.
25. Lift off power train unit assembly (31).

4
[*5] [*5] a
Power train unit assembly: 5,500 kg
Refilling with oil Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
5 5
Power train case: Approx. 210 l Hydraulic tank: Approx. 140 l
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Removal and installation of PTO, torque converter assembly

Removal
1. Remove power train unit assembly. For details, see "Removal and installation of power train unit assembly". 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.
6.
Sling filter assembly (6), then remove.

4 4
Transmission filter assembly: 40 kg Torque converter, transmission lubrication filter assembly: Approx. 80 kg
2.
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 [*2]
3.
Remove brake rod (2).
[*1]
8.
Lift off mount bracket (9).

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. Remove oil filler tube (5).
5.
10
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10. Remove hose (12). 11. Remove gauge guide (13).
14. Remove PTO and torque converter assembly (19). [*3] 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
q

k
[*1] [*2]
Bend the cotter pin securely. PTO boss rotating portion: Grease (G2-LI)
[*3] 13. Remove oil pan (18). a Remove the block under the oil pan, sling the oil pan, then remove the mounting bolts and disconnect the oil pan.
4
Using a lever block, raise the PTO and torque converter assembly horizontally, align it with the spline of the shaft at the steering case end, then install.
Oil pan: 120 kg
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Disconnection and connection of PTO, torque converter assembly

Special tools
5. 6.
Remove oil seal (6).
[*2]
Remove spacer (7). a Remove snap ring (8), then remove the spacer.
Part No.
Part Name
790-413-1010 Bracket 790-501-5000 Repair stand
t 1 t 1
Disconnection
1. Set PTO and torque converter assembly (1) to tool C.
7.
Remove PTO assembly (9) and torque converter assembly (10). a Using eyebolts [1], raise the PTO assembly, then disconnect it from the torque converter assembly.
4
PTO, torque converter assembly: 830 kg
2. 3.
Remove coupling assembly (2). Remove cap (3). a Remove snap ring (4), then remove the cap. 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.
4.
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Connection
q
3)
Carry out connection in the reverse order to disconnection. 4) Adjust the clearance of the taper roller bearing as follows. 1) Assemble the oil seal to the retainer assembly, then install the cover, and tighten to 9.8 Nm {1 kgm}. 2) Using a clearance gauge, measure clearance (a) between the retainer and the housing. a Measure clearance (a) at four points ( A , B , C , D ) around the circumference, and take the average as clearance (a).
[*1]
Measure shim thickness. q (a) (0 to 0.05 mm) a Shim thickness: 0.15 mm, 0.20 mm, 0.50 mm Assemble the selected thickness of shim, and tighten the retainer assembly to the specified torque. 3 Retainer mounting bolt: 58.8 73.5 Nm {6 7.5 kgm} Assemble the shim as shown in the diagram below so that it does not come at position (b) of the retainer removal tap.
[*2]
Outer circumference of oil seal: Gasket sealant (LG-5)
D475A, D475ASD-5E0
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SEN02015-00
Disassembly and assembly of torque converter assembly

Special tools
2)
Using eyebolts [1], remove lockup clutch and drive case assembly (4). a Disassemble the lockup clutch and drive case assembly as follows. 1] Remove seal ring (5), and using forcing screws [2], remove input shaft (6).
Part No.
Part Name
790-413-1010 Bracket 790-501-5000 Repair stand
t 1 t 1
Disassembly
q
Set the torque converter assembly to tool C.
2] 3]
Remove snap ring (7), then remove plate (8). Set clutch housing side at bottom, and using forcing screws [3], remove turbine (9).
1. 2.
Torque converter valve assembly Remove torque converter valve assembly (1). Draining oil Remove 2 drain plugs (2), and drain oil from pump case. a After draining the oil, tighten the plugs. 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.
3.
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4]
5]
Set clutch housing at top, then using eyebolts [4], remove housing and piston assembly (10). a When the assembly is removed, the piston will fall out, so support it by hand when removing. Remove piston (11) from housing (12).
9]
Remove 3 discs (16) and 2 plates (17) from drive case (18). a After removing the discs and plates, keep them in a flat place to prevent them from becoming distorted.
4. 6] 7] Remove seal ring (13) from piston. Remove seal ring (14) from housing.
Stator assembly 1) Remove snap ring (19), then remove stator assembly (20). 2) Disassemble stator assembly as follows. 1] Remove snap ring (21), then remove race (22) from stator (23).
8]
Using push tool [5], remove bearing (15) from housing. 2] Remove snap ring (24) from stator (23).
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5.
Pump assembly 1) Remove snap ring (25). 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).
9.
Pin Remove pin (37).
10. Inner gear Remove snap ring (38), then remove inner gear (39). 3] 6. Remove bearing outer race (30) from guide (31). 11. Piston 1) Remove piston (40) from case (41).
Stator clutch housing Set stator clutch housing at top and remove stator clutch housing (32).
2) 3)
Remove seal ring (42) from piston. Remove seal ring (43) from case.
7. 8.
Spring Remove spring (33). 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.
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12. Stator shaft assembly 1) Tap stator shaft assembly (44) with a plastic hammer, and remove from case (45). 2) Disassemble stator shaft assembly as follows. 1] Using push tool [6], remove shaft as se mbly ( 46) from stato r s haft assembly.
5]
Using push tool [7], remove bearing (55), then remove plate (56).
2] 3] 4]
Remove snap ring (47), then remove bearing inner race (48), bushing (49), and seal ring (50) from shaft. Remove seal ring (51) from stator shaft (52). Remove snap ring (53), then remove plate (54).
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Assembly
a Wash all parts in clean flushing oil (in particular, oil holes, etc.), then dry them, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Set case (41) to tool C.
7)
Install snap ring (47), and secure inner race.
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 shaft securely.
8)
Tap stator shaft (52) with a plastic hammer 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)
5)
6)
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. Using push tool [9], press fit bushing (49) to shaft. a Be careful not to deform the bushing when press fitting. Using push tool [10], press fit inner race (48) to shaft.
2 3
Mounting bolt: Thread tightener (LT-2) Mounting bolt: 58.8 73.5 Nm {6 7.5 kgm}
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2.
Piston 1) Install seal ring (43) to case. 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.
6.
Spring Install spring (33).
7.
Stator clutch housing 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} Pump assembly 1) Assemble pump assembly as follows. 1] Using push tool, press fit bearing outer race (30) to guide (31). a Put drops (approx. 6 cc) of engine oil (SAE10W-CD or SAE30-CD) on the bearing and rotate about 10 times.
8. 3) Install piston (40) to case (41). 2 Contact surface of seal ring: Grease (G2-LI)
3.
Inner gear Install inner gear (39) and secure with snap ring (38).
2] 4. 5. Pin Install pin (37). Plate, discs, springs Install 1 plate (36), 2 discs (35), and springs (34). 3]
Set bearing and guide assembly (28) to pump (29), then tap with a plastic hammer and press fit bearing portion. Install retainer (27). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 58.8 74.5 Nm {6 7.5 kgm}
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2)
3)
Install pump assembly (26). a When installing the pump, be careful not to damage the seal ring assembled to the shaft. Install snap ring (25).
10. Lock-up clutch, drive case assembly 1) Assemble lock-up clutch and drive case assembly as follows. 1] Set turbine (9) to block [11], and set drive case (18) to turbine.
9.
Stator assembly 1) Assemble stator assembly as follows. 1] Install snap ring (24) to stator (23).
2]
Install 3 discs (16) and 2 plates (17).
3] Assemble race (22) to stator (23), and secure with snap ring (21). Install stator assembly (20) to stator shaft, and secure with snap ring (19). 2] 4]
2)
Install seal ring (14) to housing. 2 Outer circumference of seal ring: Grease (G2-LI) Install seal ring (13) to piston. 2 Outer circumference of seal ring: Grease (G2-LI)
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5]
6]
Install piston (11) to housing (12). 2 Contact surface of seal ring: Grease (G2-LI) a When installing, be careful not to damage the seal ring. 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: Thread tightener (LT-2) 3 Mounting bolt: 98 122.5 Nm {10 12.5 kgm}
2)
Using eyebolt [1], install lock-up clutch and drive case assembly (4). a Align the positions of the turbine oil groove ( mark) and drain plug (2) when installing.
3)
Tighten mounting bolts (3). 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}
7]
Using push tool, press fit bearing (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: Thread tightener (LT-2) 3 Mounting bolt: 156.8 196 Nm {16 20 kgm} 10] Install 2 seal rings (5).
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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}
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Disassembly and assembly of PTO assembly

Disassembly
1. PTO lubrication tube Sling PTO assembly and remove lubrication tube (1). a Remove the 3 lubrication tubes on the opposite side also, set the torque converter end at the bottom, then lower.
3)
Using puller [2], remove bearings (5) and (6) from gear (7).
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) 5)
Using push tool [3], remove boss (11) and bearing (12) from cover. Using forcing screw [4], remove bearing (12) from boss (11).
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4.
Scavenging drive gear Remove snap ring (13) from bottom of PTO case, then remove gear (14). Shaft assembly 1) Remove plate (15) of idler gear.
6.
Idler gear assembly 1) Remove idler gear assembly (19) and bearing (20) from bottom of PTO case. 2) Remove outer race (21).
5.
7. 2) Turn over PTO case, then using forcing screw [1], remove shaft assembly (16). a The bearing outer race and key assembly will come out from the bottom of the PTO case, so place a wooden block in position and be careful not to damage the assembly. Remove plug (17), then using forcing screw, push out bearing (18). a After removing the bearing, assemble the plug again in the correct position.
PTO case 1) Remove race assembly (24) together with bearing outer race (25).
3)
2)
Remove bearing inner races (26) and (27) from race (28).
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3) 4)
Remove bearing outer race (29). Remove sleeve (30).
Assembly
a a 1. Clean all parts, and check for dirt or damage. Check that the snap ring is fitted securely in the groove. Bearing 1) Using push tool, press fit bearing (23) to case. a Put drops (approx. 6 cc) of engine oil (SAE10W-CD or SAE30-CD) on the 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).
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3)
Using push tool, press fit bearing inner races (27) and (26) to race (28).
4.
Shaft assembly 1) Using push tool [6], press fit bearing inner race (18) to shaft. 2) Fit O-ring, align shaft assembly (16) with idler gear, then insert.
4) 5)
Install race assembly (24). 2 Internal surface of race: Anti-friction compound (LM-P) Using push tool, press fit bearing outer race (25). a Put drops (approx. 6 cc) of engine oil (SAE10W-CD or SAE30-CD) on the bearing and rotate about 10 turns.
5.
Bearing 1) Turn over PTO case, and press fit bearing spacer (31) and bearing inner race (20) to shaft, then tighten mounting bolts of shaft assembly. a Put drops (approx. 6 cc) of engine oil (SAE10W-CD or SAE30-CD) on the 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.
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2)
Install plate (15). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 98 123 Nm {10 12.5 kgm}
2)
3) 6. Scavenging drive gear 1) Install gear (14). 2 Spline portion: Grease (G2-LI)
Using push tool [8], press fit boss (11) and bearing (12) to cover. a Expand fit the bearing. 2 Boss spline portion: Grease (G2-LI) Install gear (10). 2 Gear spline portion: Grease (G2-LI) 2 Gear mounting bolt: Thread tightener (LT-2) 3 Gear mounting bolt: 98 122.6 Nm {10 12.5 kgm}
2) 7.
Install snap ring (13) from bottom of PTO case. 4) 5) Using push tool [7], press fit bearing (9) to gear (10). Raise cover assembly (8) and install. a If the cover assembly is stiff and does not enter the case, use a plastic hammer and tap evenly on the side face to install.
Power train, PPC pump gear assembly 1) Using push tool [7], press fit bearing (12) to boss (11).
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8.
Hydraulic pump gear assembly 1) Using push tool [7], press fit bearings (5) and (6) to gear (7).
9.
Lubrication tube Sling PTO assembly, then install lubrication tube (1). a Install 3 lubrication tubes also on the opposite side. 3 Mounting bolt: 19.6 29.4 Nm {2 3 kgm}
2)
3)
Using push tool [8], press fit gear assembly (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) Fit O-ring, then raise cover assembly (2) and install to case. a If the cover assembly is stiff and does not enter the case, use a plastic hammer and tap evenly on the side face to install.
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Removal and installation of TORQFLOW transmission assembly

Removal
q
Remove PTO and torque converter assembly. For details, see "Removal and installation of PTO, torque converter assembly". 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 steering.
4
1.
TORQFLOW transmission assembly: 1,330 kg
Installation
q
Carry out installation in the reverse order to removal. a Using a lever block, sling transmission assembly (1) horizontally, align with spline of shaft at steering case end, then install.
[*1]
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Disassembly and assembly of TORQFLOW transmission assembly

Special tools
3.
Transmission case 1) Turn over transmission assembly, and remove plate (10). 2) Using eyebolts, remove transmission case (11).
Part No.
Part Name
790-413-1010 Bracket D 790-501-5000 Repair stand 799-301-1600 Oil leak tester
t 1 t 1 t 1
Disassembly
q
Set the transmission assembly on the block. Control valve assembly 1) Remove cover (1). 2) Remove control valve together with seat. 4. assembly (2) Housing 1) Remove 17 tie bolts (12). 2) Using eyebolts, remove housing (13). 3) Remove seal ring (14) from housing.
1.
2.
Sleeve 1) Remove plug (8). 2) Using eyebolts [1], pull out sleeve (9).
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5. 6.
Spring Remove spring (15). 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. No. 1 ring gear Remove ring gear (19).
11. Sleeve, guide pin 1) Remove sleeve (27). 2) Remove guide pin (28).
7.
12. Shaft, No. 1, 2, 3 carrier assembly Using eyebolts, remove No. 1, 2, and 3 carrier assembly (29).
4
1) 8. No. 1 housing, piston 1) Using eyebolts, remove No. 1 housing and piston assembly (20). 2) Remove piston (22) from housing (21).
Shaft, No. 1, 2, 3 carrier assembly: 200 kg Disassemble the shaft and carrier assembly as follows. 1] Remove snap ring (130), then remove sun gear (30).
2] 9. Spring Remove spring (23).
Using eyebolts, remove shaft and No. 1 carrier assembly (31) from No. 2 and 3 carrier assembly (32).
10. Discs, plates, springs Remove discs (24), plates (25), and springs (26) in turn. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
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2)
Disassemble the shaft and No. 1 carrier assembly as follows. 1] Raise the assembly, then using forcing screw [2], remove shaft and cage assembly (33). 2] Using plastic hammer, remove cage assembly (34), spacer (35), and bearing (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)
Disassemble the No. 2, No.3 carrier assembly as follows. 1] Remove sun gear (48). 2] Using eyebolts, remove plate and gear assembly (49).
3] 4] 5]
Remove ring (50), and disassemble plate (51) and gear (52). Remove plate (54) from No. 2, 3 carrier assembly (53). Remove seal ring (55) from plate.
6] 7]
Remove shaft (42), ball (43), thrust washer (44), gear (45), and bearing (46) from No. 1 carrier assembly (41). Remove seal rings (47) and (131).
6]
Remove shaft (56), ball (57), thrust washer (58), gear (59), and bearing (60).
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7] 8]
Using push tool, remove collar and bearing assembly (61) from carrier. Using push tool, remove bearing (62).
15. No. 3 piston Remove No. 3 piston (71). 16. Spring Remove spring (72). 17. Discs, plates, springs Remove discs (73), plates (74), and springs (75) in turn. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
9]
Using puller and push tool, remove bearing (63) and spacer (64) from collar (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). 14. No. 2 housing, piston 1) Using eyebolts, remove No. 2 housing and piston assembly (68). 2)
4 No. 2 housing, piston: 80 kg Remove piston (70) from housing (69).
21. Spring Remove spring (79). 22. Discs, plates, springs Remove discs (80), plates (81), and springs (82) in turn. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
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23. Guide pin Remove guide pin (83). 24. Sun gear Remove snap ring (132), then remove sun gear (84).
26. No. 3 ring gear 1) Remove ring gear (91). 2) Remove ring (92) from ring gear.
25. Plate, bearing 1) Using eyebolts, remove plate and bearing assembly (85). 2) Using push tool [3], remove bearing (87) from plate (86). 3) Using puller [4] and push tool [3], remove bearing (88). 4) Using push tool, remove bearing (90) from collar (89).
27. Plate, ring gear 1) Using forcing screws, remove plate and ring gear assembly (93). 2) Remove ring gear (94). 28. No. 4 carrier, No. 5 clutch assembly Using eyebolts, remove No. 4 carrier and No. 5 clutch assembly (95).
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
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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).
3]
Remove shaft (98), ball (99), thrust washer (100), gear (101), and bearing (102).
30. Shaft assembly Set case so that shaft is at bottom, then using eyebolts, remove shaft assembly (117) from case (116).
4
1)
4] 5]
6] 7] 8]
Remove spring (103) and pin (104). Remove discs (105), plates (106), and springs (107). a Keep the discs and plates in a flat place to prevent them from becoming deformed. Remove guide pin (108). Remove inner gear (109). Remove seal ring (110) from inner gear.
Shaft assembly: 80 kg Disassemble the shaft assembly as follows. 1] Remove snap ring, then using eyebolts, sling shaft assembly, knock out bearing portion, and remove shaft assembly (118).
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2] 3]
Remove cage (119). Using stand [6], remove bearing (120).
9]
Remove snap ring (135), then remove boss and bearing (127). 10] Remove snap ring (136), then using push tool, remove bearing (129) from boss (128).
4] 5] 6]
Remove snap ring (134), then remove bearing (121) from cage (133). Remove seal ring (122). Remove cover (123).
Assembly
a Wash all parts in clean flushing oil (in particular, oil holes, etc.), then dry them, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 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 positioned correctly. Align the notches of the oil groove when installing the discs.
7] 8]
Remove bearing (124). Remove seal ring (126).
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1.
Shaft assembly 1) Assemble the shaft assembly as follows. 1] Install seal ring (126). 2] Using push tool, install baring (124). 2)
8]
Using eyebolts, sling shaft assembly (118), then press fit bearing, and secure with snap ring.
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] 4] 5]
Install cover (123). Install seal ring (122). 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).
6] 7]
Using push tool, press fit bearing (120). Fit seal ring and install cage (119).
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4] 5] 6] 7] 8]
Install seal ring (110) to inner gear. Install inner gear (109). Install guide pin (108). Install springs (107), plates (106), and discs (105) in turn. Install pin (104) and spring (103). a Free length of spring: 103.5 mm
11] Set No. 4 carrier assembly (96) to No. 5 clutch assembly (97), and using 2 guide bolts [5], compress spring, then tighten mounting bolts. a Check that the spring is fitted securely in the hole of the housing, then tighten the mounting bolts. 2 Mounting bolt: Thread tightener (LT-2) 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 carrier. 10] Assemble ball (99) to shaft (98), and push shaft into carrier. 3.
2)
Using eyebolts, install No. 4 carrier and No. 5 clutch assembly (95).
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 portion with a plastic hammer until there is no clearance at the mating surface. 2) Install ring gear (94).
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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). Guide pin Install guide pin (83). Discs, plates, springs Install springs (82), plates (81), and discs (80) in turn. Spring Install spring (79). a Free length of spring: 81.7 mm
7. 3) Using push tool, press fit bearing (87) in plate (86). a Set the large protrusion of the bearing assembly on top as shown in the diagram below, and install to the plate. Using eyebolts, install plate and bearing assembly (85). 8.
9.
4)
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10. No. 4 piston Fit seal ring and install No. 4 piston (78). 11. No. 3 housing Using eyebolts, fit seal ring and install No. 3 housing (77). 12. Seat Install seat (76).
17. No. 2 ring gear Install ring gear (67).
18. Shaft, No. 1, 2, 3 carrier assembly 1) Assemble the No. 2, No. 3 carrier as follows. 1] Install seal ring (66) to carrier. 2] Using push tool, press fit spacer (64) and bearing (63) in collar (65). 13. Discs, plates, springs 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).
3] 4]
Using push tool, press fit bearing (62). Using push tool, press fit collar and bearing (61) in carrier.
16. No. 2 housing, piston 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.
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5] 6]
Assemble bearing (60) in gear (59), then fit thrust washers (58) to both sides, and set in carrier. Assemble ball (57) to shaft (56), and push shaft into carrier.
2)
Assemble the shaft and No. 1 carrier assembly as follows. 1] Install seal rings (47), (131) to carrier. 2] Assemble bearing (46) in gear (45), 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] 8] 9]
Install seal ring (55) to plate. Install plate (54) to No. 2, 3 carrier assembly (53). Set plate (51) to gear (52), and install ring (50).
4] 5]
Install seal ring (40) to shaft (39). Install seal ring (38) to cage.
10] Using eyebolts, install plate and gear assembly (49). 11] Install sun gear (48), and secure with snap ring.
6] 7]
Using push tool, press fit bearing (37) in cage. Press fit bearing (36) in shaft.
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8]
Set spacer (35) to bearing and cage assembly (34), and press fit shaft (39).
2]
Set carrier assembly on its side, then install sun gear (30), and secure with snap ring (130). Using eyebolts, install shaft and No. 1, 2, 3 carrier assembly (29) to housing.
3)
Using eyebolts, install shaft and cage assembly (33). Assemble the shaft and carrier assembly as follows. 1] Using eyebolts, install shaft and No. 1 carrier assembly (31) to No. 2, 3 carrier assembly (32). a Align the sun gear with the tooth face of the planetary gear, and tap with a plastic hammer to install.
9]
19. Sleeve, guide pin 1) Install guide pin (28). 2) Install sleeve (27). 20. Discs, plates, springs Install springs (26), plates (25), and discs (24) in turn. 21. Spring Install spring (23). a Free length of spring: 112 mm
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22. No. 1 housing, piston 1) Fit seal ring and install piston (22) to housing (21). 2) Using eyebolts, install No. 1 housing and piston (20). a Check that the spring is fitted securely in the hole of the housing.
26. Housing 1) Install seal ring (14) to housing. 2) Using eyebolts, set housing (13) in position. 3) Tighten 17 tie bolts (12) in turn. 3 Tie bolts: 353 392 Nm {36 40 kgm}
23. No. 1 ring gear Install ring gear (19). 24. Discs, plates, springs. Install springs (18), plates (17), and discs (16) in turn. 25. Spring Install spring (15). a Free length of spring: 112 mm
27. Checking piston stroke Using tool D, check each piston stroke. a Air pressure: 0.5 0.6 MPa {5 6 kg/cm2} Unit: mm
Piston No. 1 (R) No. 2 (F) No. 3 (3) No. 4 (2) No. 5 (1) Standard stroke 7.4 8.4 4.8 5.0 7.1
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28. Transmission case 1) Using eyebolts, install transmission case (11). 2) Install plate (10).
2) 3)
Using push tool, install bearing (129) to boss (128), and secure with snap ring (136). Install boss and bearing assembly (127) to output shaft, and secure with snap ring (135). a Install the bearing slowly and be careful that shaft (115) is mated with the lock portion of boss (128).
29. Rotation detection shaft 1) Set case so that valve mounting surface is at top, then insert rotation detection shaft (115) from output end. a Check that the tip of the shaft is mated with the lock portion of its mating boss.
30. Sleeve 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).
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

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
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Power train, Part 2

Disassembly and assembly of steering case assembly
Special tools
2.
Part No.
Part Name
Clutch, brake assembly Using tool E1, sling clutch and brake assembly, then remove mounting bolts, and remove clutch and brake assembly (3). a Remove the clutch and brake assembly on the opposite side in the same way. When pulling out the clutch and brake assembly, be careful not to damage the discs and plates.
791-622-1110 1 01016-51690 E 2 01011-81600
Bracket Bolt Bolt
t 1 t 1 t 1 t 1 t 1 Q Q
791T-822-1810 Push tool 791T-822-1820 Push tool
Disassembly
1. Steering rod bracket 1) Remove cover (1). 2) Remove tube (2). 3) Remove brake rod bracket (20). 3. 4. Shafts Remove left and right shafts (4). Lubrication tube Remove lubrication tubes (5).
4)
Remove transmission output shaft speed sensor (75) and flange (76) together.
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5.
Pipes, steering valve 1) Remove left and right pipes (6). 2) Remove pipe (7).
7.
Transfer and gear housing assembly 1) Install a guide bolt and tighten forcing screws [1] to remove housing assembly (10).
3)
Remove steering valve assembly (21) with seat.
2)
Disassemble the transfer and gear housing 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.
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3] 4]
Reverse the transfer and gear housing assembly and remove lubrication tube (56). 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]
6]
Using forcing screws, remove cover (58). a Check the quantity and thickness of the inserted shims and then keep them. Remove holder (59).
12] Remove the bolts and remove housing (76) from case (78). 13] Remove drive gear and bearing assembly (77).
7] 8] 9]
Push pinion shaft (60) out of pinion housing assembly (57) with a press. Remove the holder. Using puller [12], remove bearing inner race (61) from pinion shaft (60). Remove cage and bearing assembly (62).
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14] Remove bearing outer race (79) from case (78).
8.
Cage 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) 9. Using eyebolts [2], remove cage (12).
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.
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10. Cage 1) Turn over steering case, and remove bearing cage (18). a Check the number and thickness of the shims, and keep in a safe place. 2) Remove outer race (19) from bearing cage.
2.
Bevel gear, shaft assembly 1) Assemble bevel gear and shaft as follows. 1] Using tool E2, press fit bearings (17) and (16). 2] Set bevel gear (14) to shaft (15), and tighten reamer bolt. 3 Reamer bolt: 490 607.6 Nm {50 62 kgm}
Assembly
a Wash all parts, then dry them, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Cage 1) Using push tool, press fit outer race (19). 2) Assemble shim, and install bearing cage (18). a Standard shim thickness: 2 mm 3 Mounting bolt: 245 308.7 Nm {25 31.5 kgm} 3.
2)
Using eyebolts, install bevel gear and shaft assembly (13).
1.
Cage 1) Using eyebolts [2], install cage (12). 3 Mounting bolt: 245 308.7 Nm {25 31.5 kgm}
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2)
Assemble shim, and install bearing cage (11). a Standard shim thickness: 2 mm 3 Mounting bolt: 245 308.7 Nm {25 31.5 kgm}
3]
Using the push tool, press fit bearing inner races (81) and (82).
4.
Adjusting preload Rotate bevel gear 10 20 turns, and fit pushpull scale [4] to tip of teeth, then measure rotating 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 assembly according to the following procedure. 1] Using the push tool, press fit bearing outer race (71) on the drive gear side and install snap ring (83). 2] Press fit bearing outer race (70) on the pinion side to housing (76).
5] 6]
Install drive gear and bearing assembly (77) to the case. Install housing (76), matching it to the dowel pin, and tighten the bolts. 3 Mounting bolt: 277 32 Nm {28.3 3.2 kgm}
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Using push tool [18], press fit inner race (61) to pinion shaft (60). 8] Install the holder. 2 Holder mounting bolt: Adhesive (LT-2) 3 Holder mounting bolt: 276.85 31.85 Nm {28.25 3.25 kgm} 9] Install pinion gear (64) and collar (63) to the pinion shaft.
7]
12] Tighten the mounting bolts of cover (58) temporarily in the following order. 3 Mounting bolt: 49 Nm {5 kgm}
10] Using push tool [19], press fit cage and bearing assembly (62). 11] Install holder (59). 2 Holder mounting bolt: Adhesive (LT-2) 3 Holder mounting bolt: 276.85 31.85 Nm {28.25 3.25 kgm}
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 following range with the shims. a Clearance (A): 0.05 0.15 mm a Check that the dispersion of the clearance is 0.05 mm or less through the periphery and the bearing is press fitted perfectly and is not leaning.
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15] Tighten the mounting bolts of cover (58) permanently in the following order. 3 Mounting bolt: 66.15 7.35 Nm {6.75 0.75 kgm}
2)
Install guide bolt [5] to the steering case and install housing assembly (10). 3 Mounting bolt: 245 308.7 Nm {25 31.5 kgm}
6. 16] Install the shim to pinion housing assembly (57). Using eyebolts [11], install pinion housing assembly (57). a Standard shim thickness: 2 mm 17] Install lubrication tube (56).
Adjusting tooth contact, backlash 1) Adjusting backlash Put the probe of dial gauge [6] in contact with the tip of the bevel gear teeth at right angles. Hold the bevel pinion in position, and read the measurement when the bevel gear is moved forward and backward. a Standard value for backlash: 0.3 0.4 mm a Measure at a minimum of 3 points on diagonally opposite sides.
18] Install lubrication tube (51) and block as a unit.
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Adjusting If correct backlash pattern is not obtained from the result of inspection, adjust as follows. 1] If backlash is too small: Adjust the shim thickness at the bevel pinion end to move the bevel pinion in direction (A), or adjust the shim thickness at the bearing cage of the bevel gear shaft to move the bevel gear in direction (B).
2)
Adjusting tooth contact Testing 1] Coat the tooth face of the bevel pinion lightly with red lead (minimum). Rotate the bevel gear in both the forward and reverse directions, and inspect the pattern left on the teeth. 2] The standard tooth contact should be as follows: (from small end of pinion) 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). 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.
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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 convex 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 direction (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 convex tooth face of the bevel gear and the small end of the concave tooth face. [Correct the tooth contact as follows.] Adjust the thickness of the shims at the bevel pinion to move the bevel pinion in direction (A) (the opposite direction from (A) above). Or adjust the thickness of the shims at the bearing cage of the bevel gear shaft to move the bevel gear in direction (B) (the opposite direction from (B) above), then check the tooth contact pattern and backlash again. a When adjusting the movement in or out of the bevel gear, 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.
7.
Transmission output shaft and input shaft 1) Install the speed sensor and flange according to the following procedure. 1] Install flange (76). a Remove the speed sensor. 2] Looking at transfer gear (85) through the hole of the flange, check that a tooth of the gear is at the center of the hole. a If a tooth is not seen, turn the transfer gear to bring a tooth to the center of the hole. 3] Remove locknut (84) from speed sensor (75). Apply gasket sealant to the 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)
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4]
5]
6]
Remove the speed sensor and flange as a unit and tighten locknut (84). a Take care that the speed sensor 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} Install speed sensor (75) and flange (76) as a unit. 2 Flange mounting bolt hole and flange mounting surface: Gasket sealant (LG-6) After installing the speed sensor, rotate the transfer gear slowly and check that the speed sensor does not interfere with the gear.
8.
Steering valve and pipe 1) Install steering valve assembly (21) and seat as unit.
2) 3) a
Install pipe (7). Install left and right pipes (6). Coat the O-rings thinly with grease (G2LI), and be careful not to damage them when installing.
2) 3)
Install input shaft (9) to the case and fix it with the snap ring. Install cage assembly (8). 9. Lubrication tube Install lubrication tubes (5).
10. Clutch, brake assembly Using tool E1, install clutch and brake assembly (3). 3 Mounting bolt: 279 30 Nm {28.5 3 kgm}
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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).
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Disassembly and assembly of steering clutch, brake assembly

Special tools
3.
Clutch, brake assembly Turn over clutch and brake assemblies, and using eyebolts [3], disconnect clutch assembly (6) and brake assembly (7).
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 1) Remove plate (3). Disassembly of clutch assembly 1. Stopper Remove stopper (8). 2. Discs, plates, springs Remove discs (9), springs (10), and plates (11) in turn. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
2) 3)
Using forcing screws [1], remove sleeve (4). Using puller [2], pull out bearing (5) from sleeve.
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3. 4.
Torque pin Remove torque pin (12). Clutch hub Using eyebolts, remove clutch hub (13). Plate 1) Using forcing screws [4], remove flange (14).
7. 8.
Spacer Remove spacer (22). Clutch cage, piston 1) Using eyebolts, remove clutch cage (23). 2) Remove piston (24).
5.
3) 9. 2) 6. Remove outer race (15) from flange. Bearing cage 1) Remove bearing cage assembly (16).
Remove outer race (25) from clutch cage.
Belleville springs Remove Belleville springs (26).
2)
Remove plate (18) and nut (19), then remove bearings (20) and (21) from cage (17).
10. Brake hub 1) Using eyebolts [5], remove brake hub (27). 2) Remove bearing (28) from brake hub.
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Disassembly of brake assembly 1. Stopper Remove stopper (29). 2. Discs, plates, springs Remove discs (30), springs (31), and plates (32) in turn. a Keep the discs and plates in a flat place to prevent them from becoming deformed.
4. 5.
Torque pin Remove torque pin (36). Piston Remove piston (37) and seal ring (38).
6.
Belleville springs 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.
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Assembly
Assembly of brake assembly 1. Belleville springs Install Belleville springs (39). a Fit the Belleville springs back to back when installing.
4.
Brake cage 1) Using push tool, install outer race (34) to brake cage. 2) Install seal ring (35). 3) Using eyebolts [6], install brake cage (33). 3 Mounting bolt: 245 308.7 Nm {25 31.5 kgm}
2. 3.
Piston Fit seal ring (38) and install piston (37). Torque pin Install torque pin (36).
5.
Discs, plates, springs Install plates (32), springs (31), and discs (30) in turn. a Check the mating surfaces of the discs and plates for dirt or damage, and coat them thinly with engine oil before assembling. Stopper Install stopper (29). 3 Mounting bolt: 245 308.7 Nm {35 31.5 kgm}
6.
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Assembly of clutch assembly 1. Brake hub 1) Using push tool, press fit bearing (28) in brake hub. 2) Using eyebolts [5], install brake hub (27) to clutch housing.
2) 3) 4.
Install piston (24). Using eyebolts, fit seal ring and install clutch cage (23) to housing.
Spacer Install spacer (22). 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}
5.
2.
Belleville springs Install Belleville springs (26). a Fit the Belleville springs back to back when installing. Clutch cage, piston 1) Install outer race (25) to clutch cage.
3.
2) 6.
Install bearing cage (16).
Plate 1) Using push tool, press fit outer race (15) to flange.
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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). Torque pin Install torque pin (12).
8.
2)
Set sleeve (4) to clutch and brake assemblies.
9.
Discs, plates, springs 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 assembling.
3)
10. Stopper Install stopper (8). 3 Mounting bolt: 245 308.7 Nm {25 31.5 kgm}
Install plate (3). 3 Mounting bolt: 112 9.8 Nm {11.5 1.0 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.
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Disassembly and assembly of transfer gear housing assembly

Disassembly
a 1. Set the transfer gear housing assembly on a block. Lubrication tube Remove lubrication tube (1) together with block. 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)
4.
Pinion housing 1) Remove lubrication tube (7). 2) Using eyebolts [2], remove pinion housing assembly (8). a Check the number and thickness of the slims, and keep in a safe place.
2.
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.
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5) 6)
Remove cage, bearing assembly (13). Remove collar (14) from transfer gear (15).
Assembly
1. Pinion assembly 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)
5)
Using push tool [5], press fit inner race (12) in pinion gear (11), and install holder. 3 Holder mounting bolt: 245 308.7 Nm {25 31.5 kgm} Install transfer gear (15) and collar (14) to pinion gear.
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6) 7)
Using push tool [6], press fit cage, bearing assembly (13). Install holder (10). 3 Holder mounting bolt: 245 308.7 Nm {25 31.5 kgm}
2.
Pinion housing 1) Assemble shim, and using eyebolts [2], install pinion housing assembly (8). a Standard shim thickness: 2 mm 2) Install lubrication tube (7).
8)
Install cover (9) as follows. q Tighten cover mounting bolts temporarily in the order shown in diagram below. (Approx. 49 Nm {5 kgm}) q Check clearance (A) between cover and cage, and check that it is as follows. Clearance (A): 0.53 0.47 mm a Check that the variation around the whole circumference is less than 0.05 mm. Check also that the bearing is 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}
3.
Transfer gear 1) Using push tool [7], press fit inner races (6) on both sides. 2) Set transfer gear (5) in case.
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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} Lubrication tube Install lubrication tube (1) together with block.
5.
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Removal and installation of power train pump assembly

Removal
1. 2. 3. Remove oil strainer inspection cover at front left of operators platform. Open undercover. (3rd from front of machine). Remove oil strainer (1). a Disconnect coupling (2) and remove strainer mounting bolts. Disconnect hose (3). Lift off power train pump assembly (4).
4
Removal and installation of scavenging pump assembly

Removal
1. 2. Open undercover. (3rd from front of machine). Disconnect inlet tube (1). a Oil will leak out from inside the piping, so prepare a container to catch the oil. Disconnect outlet tube (2). Remove scavenging pump assembly (3).
4
3. 4.
4. 5.
Scavenging pump assembly: 25 kg
Power train pump assembly: 64 kg
Installation
q
Installation
q
Carry out installation in the reverse order to removal. Refilling with oil (power train case) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
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Removal and installation of torque converter oil cooler

Removal
1. 2. 3. Remove engine undercover. Drain coolant. Open engine left side cover (1) and remove side cover (2).
7.
Sling torque converter oil cooler assembly (8), then lower assembly to remove.
4
Torque converter oil cooler assembly: 170 kg
Installation
q
Carry out installation in the reverse order to removal. Refilling with coolant Add coolant to the specified level, and run the engine to circulate the coolant through the system. Then check the coolant level again.
4.
Remove water tubes (3) and (4).
5. 6.
Remove oil inlet tube (5) and outlet tube (6). Disconnect aeration hose (7).
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Removal and installation of torque converter valve assembly

Removal
1. Remove operators cab assembly. For details, see "Removal and installation of operators cab assembly". Remove operators seat and floor frame cover. a Use turnbuckle (1) when disconnecting the brake rod. Check the mounting dimensions of the rod before disconnecting. [*1]
7. 8.
Remove hose clamp (6). Remove torque converter valve assembly (7). [*2]
4
Torque converter valve assembly: 33 kg
2.
Installation
q
Carry out installation in the reverse order to removal. a Adjust the brake pedal linkage. For details, see Testing and adjusting, Adjusting brake pedal and parking brake lever. 3 Turnbuckle locknut: 34.3 58.8 Nm {3.5 6 kgm}
3
[*1] 3. 4. 5. Disconnect connector of solenoid valve (2). Disconnect hose clamp (3). Disconnect central pressure detection hose (4). a Before removing the pressure detection hoses, mark them with tags to prevent any mistake in the mounting position when installing. Disconnect hose (5).
[*2]
Torque converter valve assembly mounting bolt: 43.1 53.9 Nm {4.4 5.5 kgm}
6.
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Disassembly and assembly of torque converter valve assembly
Disassembly of lock-up valve

1. 2. 3. 4. Remove solenoid valve (14), then remove ball (16), valve (15) and plug (19). Remove plug (3), then remove spring (5). Remove cover (7), then remove piston (10). Pull out spool (6).
Assembly of lock-up valve

1. 2. 3. 4. 5. Assemble spool (6). Assemble piston (10) to cover (7), then fit Oring and install cover. Assemble spring (5), then fit O-ring and install plug (3). Fit O-ring (17) to plug (19), then assemble. Assemble valve (15), then fit O-ring (18) to solenoid valve (14) and install.
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Disassembly of torque converter relief valve, main relief valve, stator clutch modulating valve, and lock-up clutch modulating valve
1. Disassembly of torque converter relief valve 1) Remove cover (10), then remove spring (9). 2) Remove cover (2), then remove valve (5), spring (6), and valve (7). 3) Pull out spool (8). 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) Pull out spool (20). Disassembly of stator clutch modulating valve 1) Remove cover (27), then remove piston (34) and spring (35). 2) Remove ring (30) from body. 3) Remove cover (41), then remove valve (40), spring (39), and valve (38). 4) Pull out spool (37), then remove shim (36) from spool. 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. 3) Remove cover (61), then remove valve (60), spring (59), and valve (58). 4) Pull out spool (57). 5) Remove shaft (56) and shim (54) from spool (57).
2.
3.
4.
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Assembly of lock-up modulating valve, stator clutch modulating valve, main relief valve and torque converter relief valve
a a Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 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. 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. Assembly of stator clutch modulating valve 1) Assemble spool (37). 2) Assemble valve (38), spring (39), and 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. Assembly of main relief valve 1) Assemble spool (20). 2) Assemble valve (23), spring (22), and valve (21) to spool, then fit O-ring and install cover (24). 3) Assemble spring (18), then fit O-ring and install cover (14). Assembly of torque converter relief valve 1) Assemble spool (8). 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).
1.
2.
3.
4.
30
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Removal and installation of transmission control valve assembly

Removal
1. Remove operators cab assembly. For details, see "Removal of operators cab assembly". Remove operators seat and floor frame cover. a Use turnbuckle (1) when disconnecting the brake rod. Check the mounting dimensions of the rod before disconnecting. [*1]
5. 6.
Disconnect wiring harness connector (4). (8 places) Disconnect central pressure detection hose (5). (4 places) a Before removing the pressure detection hoses, mark them with tags to prevent any mistake in the mounting position when installing. Remove transmission control valve assembly (6). (4 places)
2.
7.
Installation
3. 4. Disconnect hose clamp (2). Remove valve cover (3). [*1] a Adjust the brake pedal linkage. For details, see Testing and adjusting, Adjusting brake pedal and parking brake lever. 3 Turnbuckle locknut: 34.3 58.8 Nm {3.5 6 kgm}
q
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Disassembly and assembly of transmission control valve assembly (ECMV assembly)
Disassembly of ECMV assembly

q
2.
Before removing the ECMV assembly from the transmission assembly, clean around it so that dirt will not enter it and transmission assembly. Keep the removed parts so that they will not be damaged. Flow control valve 1) Remove bracket (20) and switch assembly (12) from valve body (1). 2) Remove spring (13), shim (14), and spring seat (15). 3) Remove sleeve (18), spring (17), and pin (16).
1.
Pressure control valve 1) Remove solenoid (2) from valve body (1). a Mask the solenoid to prevent dirt from entering it. 2) Remove valve (3) and ball (4). a Keep the ball so that it will not be lost. 3) Remove spool (7). a When removing the spool, check that it moves smoothly. 4) Remove spring (8) and shims (9) and (10) from spool (7). a Check the quantity of shims (9) and (10).
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50 Disassembly and assembly a a
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Assembly of ECMV assembly

a a If the pressure control valve was disassembled or any part of it was replaced, be sure to check the oil pressure. Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. Pressure control valve 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. 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). Testing ECMV oil pressure Check the ECMV oil pressure. For details, see Testing and adjusting, Testing ECMV oil pressure. 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 per shim (0.5 mm thick) 714-23-15580 Quantity of adjustment per shim (0.2 mm thick) 714-28-15590 0.06 MPa {Approx. 0.65 kg/cm2} 0.025 MPa {Approx. 0.26 kg/cm2}
Install the shim securely and do not drop it in the valve. After adjusting the shim, test the oil pressure again.
1.
2.
3.
4.
If the shim is increased, the oil pressure is heightened. If the former is decreased, the latter is lowered.
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Disassembly of priority valve

q
Assembly of priority valve

1. 2. Install valve (6), spring (7), and sleeve (5) to valve body (1). Fit the O-ring to plug (10) and install them to body (1). 3 Plug: 58.8 78.4 Nm {6 8 kgm} Install spool (2). a Check that the spool moves smoothly. Install spring (7) and shim (4). Fit O-ring (9) to plug (8) and install them to body (1). 3 Plug: 58.8 78.4 Nm {6 8 kgm}
Quantity of adjustment per shim (0.5 mm thick) 52 kPa {0.53 kg/cm2}
Remove the priority valve assembly from the transmission assembly. a Before removing the priority valve assembly, clean around it so that dirt will not enter the transmission assembly. Keep the removed parts so that they will not be damaged. Remove plug (8) from valve body (1). Remove shim (4) and spring (3). a Check the quantity of shim (4). Remove spool (2). a When removing the spool, check that it moves smoothly. Remove plug (10) from valve body (1). Remove sleeve (5), spring (7), and valve (6).
3. 1. 2. 3. 4.
4. 5.
a a
If the shim is increased, the oil pressure is heightened. If the former is decreased, the latter is lowered. After adjusting the shim, test the oil pressure again.
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Removal and installation of steering control valve assembly

Removal
1. Remove fuel tank assembly. For details, see Removal and installation of fuel tank assembly. Disconnect 3 wiring clamps (1). Remove valve cover (2).
2. 3.
4. 5.
Disconnect harness connector (3). Remove steering control valve assembly (4).
Installation
q
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Disassembly and assembly of steering control valve assembly
Disassembly of ECMV assembly

q
2.
Before removing the ECMV assembly from the steering assembly, clean around it so that dirt will not enter it and steering assembly. Keep the removed parts so that they will not be damaged. Flow control valve 1) Remove bracket (25), switch assembly (17), and cover (28) from valve body (1). 2) Remove springs (18) and (19) and spring seat (20). 3) Remove sleeve (23), spring (22), and pin (21).
1.
Pressure control valve 1) Remove solenoid (2) from valve body (1). a Mask the solenoid to prevent dirt from entering it. 2) Remove valve (3) and ball (4). a Keep the ball so that it will not be lost. 3) Remove spool (7). a When removing the spool, check that it moves smoothly. 4) Remove spring (13) and shims (14) and (15) from spool (7). Then, remove ring (12), sleeve (10), spring (9), and poppet (8). a Check the quantity of shims (14) and (15).
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50 Disassembly and assembly a a a
SEN02016-00
Assembly of ECMV assembly

a a If the pressure control valve was disassembled or any part of it was replaced, be sure to check the oil pressure. Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. Pressure control valve 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. 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 Orings (26) and (27) and install switch assembly (17) and bracket (25) with bolts (24). Testing ECMV oil pressure Check the ECMV oil pressure. For details, see Testing and adjusting, Testing ECMV oil pressure. 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).
Quantity of adjustment per shim (0.5 mm thick) 714-23-15580 Quantity of adjustment per shim (0.2 mm thick) 714-23-15590 0.06 MPa {Approx. 0.65 kg/cm2} 0.025 MPa {Approx. 0.26 kg/cm2}
If the shim is increased, the oil pressure is heightened. If the former is decreased, the latter is lowered. Install the shim securely and do not drop it in the valve. After adjusting the shim, test the oil pressure again.
1.
2.
3.
4.
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Removal and installation of final drive assembly

Special tools
4.
Part No.
Part Name
Remove cover (3), then using forcing screw, 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, then move the sprocket to the front or rear to a position where the shaft will come out, and remove the shaft. a Pull the shaft out to a position where it contacts the sprocket.
790-337-1032 J 1 791-827-1910 01011-83015
Lifting tool Plate Bolt
t 1 t 1 t 3
Removal
1. Remove track shoe assembly. For details, see "Expansion and installation of track shoe assembly". Raise chassis with jack or ripper and set stand [1] under frame. Remove covers (1) and (2). 5. 6. Remove 3 bolts of final drive and install tool J1. Sling final drive assembly (5), then remove mounting bolts, and lift off. [*2]
4
2. 3.
Final drive assembly: 3,600 kg
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Installation
q
Carry out installation in the reverse order to removal. a
[*1]
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. Final drive assembly mounting bolt: Thread tightener (LT-2) Final drive assembly mounting bolt: 1,960 2,450 Nm (200 250 kgm)
[*2]
2 3
Refilling with oil (final drive case) Add oil through the oil filler to the specified level.
5
Final drive case: 71 l (GO140)
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Disassembly and assembly of final drive assembly

Special tools
Disassembly
1. Draining oil Remove drain plug and drain oil from final drive case.
6
Final drive case: Approx. 71 l
Part No.
Part Name
2.
790-431-1081 Guide 790-431-1031 Block 790-101-2350 Leg 790-101-2430 Adapter 2 790-101-2360 Plate 02215-11622 Nut 790-101-2102 Puller (294 kN {30 ton})
t 1 t 1 t 2 t 2 t 4 t 2 t 1 t 1 t 1 t 1 t 1
Sprocket 1) Set final drive assembly to block (height: approx. 50 mm). 2) Remove sprocket (1).
790-101-1102 Pump 790-431-1101 Installer assembly 3 790-101-2102 Puller (294 kN {30 ton})
790-101-1102 Pump
3.
t 1 J 4 791-585-1510 Installer 790-431-1220 Remover assembly t 1 5 790-101-2102 Puller (294 kN {30 ton}) t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
Cover Using eyebolts [1], remove cover (2).
790-101-1102 Pump 790-431-1210 Installer assembly 6 790-101-2102 Puller (294 kN {30 ton}) Remover & installer Puller (294 kN {30 ton})
790-101-1102 Pump 790-431-1230 7 790-101-2102
790-101-1102 Pump 8 790-431-1240 Guide
4.
Hub 1) Remove plate (3). 2) Using eyebolts [2], lift off hub (4).
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5.
Sprocket hub assembly 1) Remove holder (5). a Check the number and thickness of the shims, and keep in a safe place.
4)
Remove bearing inner race (8) from sprocket hub assembly.
5) 2) 3) Using tool J2, disconnect sprocket hub assembly (6) and bearing (7) portion. Using eyebolts [3], remove sprocket hub assembly (6). 6)
Turn over sprocket hub assembly, then remove floating seal cover (9) and bearing outer races (10) and (11). Remove floating seal (12) from floating seal cover. a Keep the floating seal in a safe place to protect it from damage.
6. 7.
Wear guard Lift off wear guard (13). Cover assembly 1) Using eyebolts, lift off cover assembly (14).
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2)
Disassemble cover assembly as follows. 1] Remove floating seal cover (15). 2] Remove floating seal (16) from floating seal cover. a Keep the floating seal in a safe place to protect it from damage.
2)
Disassemble carrier assembly as follows. 1] Set carrier assembly on block (height: approx. 100mm). 2] Remove holder (21). 3] Using tool J7, remove planetary gear shaft (22).
3]
Remove spacer (17) and bearing inner race (18).
4]
Remove planet gear (23), bearing inner races (24A) and (24B), and spacer (24C).
4] 8.
Remove plate, then remove ring gear (19).
5]
Remove bearing outer race (24D).
Carrier assembly 1) Using eyebolts [5], remove carrier assembly (20).
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9.
Sun gear 1) Remove plate (25). 2) Remove holder (26). 3) Pull out sun gear shaft assembly (27).
2)
Using tool J5, pull out hub assembly (29) and bearing inner race (30) from shaft assembly (31).
3) 4) Remove holder (51) from sun gear shaft assembly, and pull out sun gear (52)
Disassemble hub assembly (29) as follows. 1] Remove gear (32) from hub (33). 2] Remove bearing outer races (34A) and (34B).
10. Hub, shaft assembly 1) Remove plate (28). 4) 5) Using eyebolts [6], pull out shaft assembly (31) from case. Disassemble shaft assembly as follows. 1] Remove collar (36). 2] Remove bearing inner race (37) and collar (38).
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11. Cage assembly 1) Using eyebolts [7], remove cage assembly (39). 2) Remove shims (40). a Check the number and thickness of the shims, and keep in a safe place.
13. Outer race, oil seals 1) Using puller [10], remove bearing outer race (48). 2) Remove oil seals (49) and (50) from cover.
3)
Disassemble cage assembly as follows. 1] Using puller [8], remove bearing outer race (41). 2] Remove oil seals (42) and (43).
Assembly
a Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 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).
1.
12. Gear assembly 1) Remove gear assembly (44). 2) Using puller [9], remove bearing inner races (45) and (46) from gear (47).
44
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2) 3)
Using eyebolts [6], install shaft assembly (31) to case. Assemble hub assembly as follows. 1] Using push tool, press fit bearing outer races (34A) and (34B) to hub (33).
5)
Install plate (28). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 490 608 Nm{50 62 kgm}
2. Set gear (32) to hub (33). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 823 1,029 Nm {84 105 kgm} Set shaft assembly (31) and hub assembly (29) in position, then using tool J6 , press fit bearing (30) portion. 2]
Carrier assembly 1) Assemble carrier assembly as follows. a The planetary gear bearing forms a set, so align the mating marks on the inner race, outer race, and spacer when assembling.
4)
1]
Install ring and spacer to planet gear, then using push tool [18], press fit top and bottom bear ing outer races (24D).
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2]
Assemble spacer (24C) and bearing inner races (24B) and (24A) to planet gear (23), then set to carrier. a Set so that the protruding part at the end face of the planet gear faces the outside of the machine.
3.
Sun gear 1) Press fit sun gear (52) to sun gear shaft, and install holder (51). 2 Holder mounting bolt: Thread tightener (LT-2) 2) Assemble sun gear shaft assembly (27) to carrier (53), then install holder (26) and spacer (25). 2 Holder mounting bolt: Thread tightener (LT-2)
3]
4]
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. Install holder (21). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 490 608 Nm {50 62 kgm} a After tightening the bolts, check that the gear rotates smoothly.
4.
Carrier, sun gear assembly Using eyebolts [5], install carrier and sun gear assembly (20).
46
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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. 2 Lip of oil seal: Grease (G2-LI) 2 Oil seal press-fitting surface: Gasket sealant (LG-5) 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.
2]
Using push tool [13], press fit bearing outer race (48) to cover.
7]
Install floating seal cover (15). a Fit a cork plug in the forcing tap.
3]
4] 5]
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. Install spacer (54), then using tool J3, press fit bearing inner race (18). Install spacer (17).
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Install so that the cut-out portion of the floating seal cover is facing the bottom as shown in the diagram below.
7.
Sprocket hub assembly 1) Using tool J4, install floating seal (12) 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.
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 surface of the case and cover. a Coat the whole circumference of the 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}
2) 3)
Using push tool, press fit bearing outer races (11) and (10). Install floating seal cover (9).
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
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5)
Using eyebolts [3], sling sprocket hub assembly (6) and set to cover. a Check that there is no dirt on the sliding surface of the floating seal, then coat thinly with engine oil.
8.
6)
Using tool J3, press fit bearing (7) portion. a Rotate the sprocket hub assembly when press fitting.
Hub 1) Using eyebolts [2], raise hub (4) and install. 2) Install plate (3). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 245 309 Nm {25 31.5 kgm}
7)
Install holder (5). a Tighten 6 mounting bolts temporarily at equal distances around the circumference, 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 tightening): Approx. 74 Nm {7.5 kgm} 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 490 608 Nm {50 62 kgm}
9.
Cover Using eyebolts [1], install cover (2).
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10. Sprocket Install sprocket (1). 3 Mounting bolt: 2,500 2,794 Nm {255 285 kgm}
12. Cage assembly 1) Assemble cage assembly as follows. 1] Using push tools [11] and [12], install oil seals (43) and (42). a Install the bottom oil seal with the part receiving the pressure at the bottom; install the top oil seal with the part receiving the pressure at the top. 2 Lip of oil seal: Grease (G2-LI) 2 Oil seal press-fitting surface: Gasket sealant (LG-5) 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.
2]
Using push tool [15], press fit bearing outer race (41).
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2)
Using eyebolt [7], set cage assembly (39) to case, and remove tool J8.
3)
4) 5) 6) 7)
Tighten mounting bolts (C), (D), (E), and (F) of cage (A) uniformly to a tightening torque of 69 Nm {7 kgm}, then loosen bolts. Tighten mounting bolts (C) and (D) of cage (A) uniformly to a tightening torque of 20 Nm {2 kgm}. In this condition, use feeler gauge [16] to measure clearances (a) and (b) between cage (A) and cage (B). Determine thickness (c) of shims to insert according to Table 1 on next page. Assemble shim set on the previous stage, then tighten mounting bolts of cage (A) uniformly. 3 Mounting bolts: 319 608 Nm {32.5 62 kgm}
13. Refilling with oil Tighten drain plug and add engine oil through the oil filler to the specified level.
5
Final drive case:
Approx. 71 l (GO140)
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Table 1
a + b (mm) More than 3.05 3.15 3.25 3.35 3.45 3.55 3.65 3.75 3.85 3.95 4.05 4.15 4.25 4.35 4.45 4.55 4.65 4.75 4.85 4.95 5.05 5.15 5.25 5.35 5.45 5.55 5.65 5.75 5.85 5.95 6.05 6.15 6.25 6.35 6.45 6.55 6.65 6.75 6.85 6.95 7.05 7.15 7.25 Less than 3.15 3.25 3.35 3.45 3.55 3.65 3.75 3.85 3.95 4.05 4.15 4.25 4.35 4.45 4.55 4.65 4.75 4.85 4.95 5.05 5.15 5.25 5.35 5.45 5.55 5.65 5.75 5.85 5.95 6.05 6.15 6.25 6.35 6.45 6.55 6.65 6.75 6.85 6.95 7.05 7.15 7.25 7.35 t = 0.15 9 6 3 7 4 1 8 5 2 9 6 3 7 4 1 8 5 2 9 6 3 7 4 1 8 5 2 9 6 3 7 4 1 8 5 2 9 6 3 Number of shim to use t = 0.5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 t = 1.0 1 1 2 1 1 2 1 1 2 1 1 2 2 1 2 2 1 2 2 1 2 2 3 2 2 3 2 2 3 3 2 3 3 2 3 3 2 3 3 2 3 3 Total shim thickness c (mm) 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.55 3.60 3.65 3.70 3.75 3.80 3.85 3.90 3.95
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53
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54
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

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
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Removal and installation of track frame assembly 1
Removal
1. Remove track shoe assembly. For details, see "Expansion and installation of track shoe assembly". Raise chassis with jack or ripper, then set support [1] under frame to keep rear of chassis off ground. Set hydraulic jack [2] to center of equalizer bar, and raise front of chassis. Sling track frame assembly. 7.
Using eyebolts [3], pull out pin (3). [*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 of the track frame before removing.
2.
3. 4.
8.
Remove mounting bolts, and disconnect cover (4) from track frame.
5. 6.
Remove cover (1). Remove cover (2). 9. Remove cover (5). 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).
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12. Lift off track frame assembly (10). [*3] a Oil will flow out from the pivot case, so catch it in an oil container.
6 4
Installation
q

2
Pivot case: 26 l Track frame assembly: 11,180 kg
[*1]
a [*2]
Inside surface of bushing: Grease (G2-LI) Before installing the pin, adjust the height of the track frame and align the center of the equalizer bar hole and track frame hole. Set the pin with the grease hole facing the outside of the machine.
a a
After removing the grease from the pressfitting surface of the seal, coat with gasket sealant (LG-6). Be careful not to install with the seal displaced in the direction of twisting. Be careful not to install the track frame with seal (11) displaced in the direction of twisting.
[*3]
Refilling with oil (pivot case) Add oil through oil filler to the specified level.
5
Pivot case: 26 l (SAE30)
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Disassembly and assembly of idler assembly

Special tools
6.
Using puller [4], remove seal guide (6) and retainer (7) and plate (8).
Part No.
Part Name
791-830-1760 791-830-1320 790-101-2510 790-101-2570 1 01580-01613 L 01643-31645 790-101-2102 790-101-1102 2 791-560-1520 3 791-830-1480 4 791-601-1000
Plate Rod Block Plate Nut Washer
t 1 t 2 t 1 t 2 t 2 t 2
7.
Remove seal guides (2) and (6) from retainers (3) and (7).
Puller t 2 (294 kN {30 ton}) Pump Installer Push tool Oil pump t 1 t 1 t 1 t 1
Disassembly
1. Remove oil filler plug and drain oil.
6
Idler: 2.0 2.2 l (GO140) 8. Remove floating seal (9) from seal guides (2) and (6). a Keep the floating seal in a safe place to protect it from damage. Remove floating seal (10) from seal guides (3) and (7). a Keep the floating seal in a safe place to protect it from damage.
2. 3.
Set idler assembly (1) on block [1]. Remove mounting bolts, then using forcing screws [2], remove seal guide (2) together with retainer (3) and plate (4).
9.
4. 5.
Turn over idler assembly. Remove mounting bolts, then using eyebolts [3], remove shaft (5) together with retainer.
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10. Remove bushings (11) from idler (12).
2. 3.
Using tool L2, install floating seal (10) to retainers (3) and (7). 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
a 1. Clean all parts, and check for dirt or damage. 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. a Press fit so that press-fitting dimension (a) from the end face of the idler to the top surface of the bushing is the dimension given below. q Press-fitting dimension (a): 17 0.5 mm
4.
Using eyebolts [3], set idler (12) to shaft (5). a Set block (height: approx. 200 mm) under the idler. Turn over idler assembly. a Tie with wire to prevent the shaft from falling out. Fit O-ring and install retainer (7) and plate (8) to idler.
5.
6.
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7.
Using tool L2, install floating seal (9) to seal guides (2) and (6).
9.
Using tool L4, fill with oil to specified level, then tighten oil filler plug.
3 5
Idler: 1.4 1.5 l (GO140) 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}
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 Turn over the idler assembly and repeat the same procedure to press fit the seal guide (6) on the opposite side.
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Removal and installation of recoil spring assembly

Special tools
5.
Lift off trunnion (3).

4
Trunnion: 140 kg
Part No.
Part Name
790-434-1401 Remover assembly t 1 M 1 790-101-2102 Puller (294 kN {30 ton}) t 1 t 1
790-101-1102 Pump
Removal
1. Remove track shoe assembly. For details, see "Expansion and installation of track shoe assembly". k To prevent danger, never stand in front of the idler yoke assembly. Drain oil from recoil cylinder chamber using oil pump.
6
6.
Remove covers (4). a Remove both the inside and outside covers.
2.
Recoil cylinder chamber: Approx. 75 l
3.
Using eyebolt [1], remove cover (1).

4
Cover: 70 kg
4.
Remove cover (2). 7. Using tool M1, remove pins (5). [*1] a Remove both the inside and outside pins.
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8.
Lift off idler and recoil spring assembly (6). [*2] a Using a lever block, keep the assembly horizontal, and be careful not to damage the oil seal at the track frame end.
4
2)
Loosen idler yoke mounting bolts (9) gradually in turn on diagonally opposite sides. [*4]
Idler, recoil spring assembly: 3,500 kg
9.
Disconnect recoil cylinder assembly (7) from idler yoke assembly (8) as follows. [*3] 1) Put idler yoke assembly (8) in contact with ground, then raise recoil cylinder assembly (7). a When doing this, check that there is no damage to the weld of recoil cylinder assembly (7). a Wrap cloth around the chrome plated bushing to protect it.
To prevent danger, never stand in front of the idler yoke assembly or behind the recoil cylinder assembly. The recoil spring inside the recoil cylinder is applying a pushing force of approx. 788 kN {approx. 81 tons} on the idler yoke, so be careful not to loosen the mounting bolts suddenly. Loosen the mounting bolts gradually until clearance (a) between the flange of the recoil cylinder and idler yoke is 8 12 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 mounting 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 disassemble as follows.
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If the torque does not drop during Steps 2) and 3) described above, and the torque when the bolts are loosened remains large, there is probably damage to recoil spring set bolt (10), or nut (11) at the tip of the shaft has fallen off, so there is danger that the idler yoke assembly may fly off to the front. For this reason, disassemble as follows.
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 confirmed 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 contact the bottom of the yoke (Y) thread. 3] Remove remaining 12 bolts (those not marked ). 4] Hold bolts [1] with a wrench to prevent them from turning, and loosen 2 nuts [2] simultaneously on diagonally opposite sides. a Be careful not to let the load bear on only one bolt. 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.
10. Remove ring (12).
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11. Pump in grease through lubricator (13), and remove cylinder (14) and piston assembly (15). [*5]
14. Remove holder (20) from recoil spring assembly.
12. Disassemble piston assembly (15) as follows. 1) Remove wear ring (16) from piston. 2) Remove snap ring (17), then remove packing (18).
Installation
q
Carry out installation in the reverse order to removal. 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. Using a lever block, keep horizontal and be careful not to damage the oil seal at the track frame end when installing. Adjust the clearance. For details, see Testing and adjusting, Adjusting clearance of idler. 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. Idler yoke assembly mounting bolt: Thread tightener (LT-2) Idler yoke assembly mounting bolt: 2,205 2,695 Nm {225 275 kgm}
[*1]
[*2]
a a
13. Remove recoil spring assembly (19).

4
[*3]
Recoil spring assembly: 780 kg
[*4]
2 3
[*5]
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.
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Disassembly and assembly of recoil spring assembly

Special tools
New/Remodel Necessity Symbol Sketch
2.
Apply hydraulic pressure slowly to compress spring, then remove lock plate (2) and remove nut (3). Release hydraulic pressure gradually and relieve tension of spring.
3.
Part No.
Part Name
791-685-8502 791-635-3160 M 2 790-201-2790 790-101-1300 790-101-1102
Compressor Extension Spacer
t 1 t 1 t 1
Cylinder (980 kN t 1 {100 ton}) Pump t 1
Disassembly
1. Remove recoil spring assembly (1) with tool M2. k The spring is under high installed load, so be careful to set it correctly. a Installed load of spring: Approx. 788 kN {approx. 81 ton} 4. Remove rear pilot (5), spacer (6), bolt (7), and front pilot (8) from spring (4).
Qty
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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. 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}
2.
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: Thread tightener (LT-2)
4.
Gradually release hydraulic pressure to completely release tension of spring, then remove recoil spring assembly (1) from tool M2.
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Removal and installation of track roller assembly

Special tools
Part No.
Part Name
790-401-1700 12 L 790-401-1761 790-401-1540 790-401-1770 13 01011-62700 01673-32780
Lifting tool Adapter Shackle T-bolt Bolt Washer
t 1 t 1 t 2 t 2 t 3 t 6 t 6 N Q
Qty
5. 6.
791T-830-1780 Plate
Remove the mounting bolts and place track roller assembly (2) on steel plate [1]. [*2] 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". Install tool L13 and secure bogie assembly (1). [*1]
2.
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. 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, running the engine at the low idling speed.
4.
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Installation
q
[*1] After removing tool L13, replace the mounting bolts of cover (3) with the regular parts. 3 Cover mounting bolt: 883 1,470 Nm {90 150 kgm}
Install the track roller assembly with the oil filler plug out. a After installing the track roller assembly, set the position of dowel pin (4). 2 Track roller assembly mounting bolt: Adhesive (LT-2) 3 Track roller assembly mounting bolt: 2,205 2,695 Nm {222 275 kgm}
[*3] [*2] Install S to the first and last track rollers and install D to the other track rollers. S: Single flange D: Double flange When using the assembling tool Set tool L12 under the track roller assembly (2) and lift up and set track roller assembly (2) to the track frame.
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Disassembly and assembly of track roller assembly

Special tools
6. 7.
Using press, remove seal guide (6) together with retainer (7) and plate (8) from shaft. Remove seal guides (2) and (6) from retainers (3) and (7).
Part No.
Part Name
8 791-830-1740 L 9 791-515-1520 10 791-830-1730 11 791-601-1000
Plate Installer Push tool Oil pump
t 1 t 1 t 1 t 1
Qty
N N
Disassembly
1. Remove oil filler plug and drain oil.
6
Track roller: 1.4 1.5 l
8.
2. 3.
Set track roller assembly (1) on block [1]. Remove mounting bolts, then using forcing screws [2], remove seal guide (2) together with retainer (3) and plate (4). Turn over track roller assembly. Remove mounting bolts, then using eyebolts [3], remove shaft (5) together with retainer. 9.
Remove floating seal (9) from seal guides (2) and (6). a Keep the floating seal in a safe place to protect it from damage. Remove floating seal (10) from retainers (3) and (7). a Keep the floating seal in a safe place to protect it from damage.
4. 5.
10. Remove bushing (11) from roller (12).
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Assembly
a 1. Clean all parts, and check for dirt or damage. 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 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 Turn over the track roller assembly and press fit seal guide (6) on the opposite side according to the above procedure.
2.
3. 4.
Using tool L9, install floating seal (10) to retainers (3) and (7). 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.
3 5
Track roller: 1.4 1.5 l (GO140) Oil filler plug: 156.8 254.8 Nm {16 26 kgm}
5. 6.
Using tool L9, install floating seal (9) to seal guides (2) and (6). Using tool L10, press fit seal guide (2) to shaft. a Seal guide press-fitting force: 49 83 kN {5 8.5 ton}
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Removal and installation of carrier roller assembly

Removal
1. 2. 3. Loosen the track shoe. For details, see Expanding track shoe assembly. Lift up the track shoe with hydraulic jack [1]. Lift off carrier roller assembly (1).
4
[*1]
Carrier roller assembly: 105 kg
Installation
q
Carry out installation in the reverse order to removal. 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}
[*1]
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Disassembly and assembly of carrier roller assembly

Special tools
5. 6.
Using tool L7, remove nut (4). Remove the fitted part of the seal guide with puller [2] and remove bearing (5) and roller (6) as one unit by using eyebolts.
Part No.
Part Name
4 791-601-1000 L 5 791-515-1520 6 790-830-1770 7 791-631-1270
Oil pump Installer Push tool Wrench
t 1 t 1 t 1 t 1 N
Disassembly
1. Remove the oil filler plug and drain the oil. a Drain the oil, turning the shaft.
6
Qty
Carrier roller: Approx. 13 l
7. 8.
Remove bearing outer race (7) from the roller. Remove seal guide (8) and bearing inner race (9) as one unit with puller [3].
2. 3. 4.
Set carrier roller assembly (1) to block [1]. Remove the mounting bolts and cover (2). Remove ring (3).
9.
Remove floating seal (10) from seal guide (8).
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10. Remove seal guide (11) with push tool [4]. 11. Remove floating seal (12) from seal guide (11).
Press fit the bearing inner race, turning the roller, until the roller becomes a little hard to turn.
5.
Assembly
a 1. 2. Clean the all parts and check them for dirt. Press fit bearing inner race (9) with push tool [5]. Press fit bearing outer race (7) with push tool [6].
Tighten nut (4) with tool L7. 3 Nut: 98 Nm {10 kgm} a After the nut is tightened, if its hole is not matched to the hole of the shaft, match its hole by loosening the nut. Install ring (3).
6.
7. 3. 4. Set roller (6) and bearing inner race (5) to the shaft. Press fit bearing inner race (5) to the shaft with push tool [7].
Fit the O-ring to cover (2) and install them.
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8. 9.
Install floating seal (10) to seal guide (8) with tool L5. Fit the O-ring to seal guide (8) and install them, matching them to the dowel pin.
12. Supply specified quantity of oil by using tool L4 and tighten the oil filler plug.
3 5
Carrier roller: 1.25 1.35 l (GO140) Oil filler plug: 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.
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Removal and installation of bogie assembly

Special tools
Necessity Qty New/Remodel Sketch Symbol
Removal
1. Loosen the track shoe. For details, see Expansion and installation of track shoe assembly. Install tool L13 and secure the bogie assembly.
2.
Part No.
Part Name
791T-830-1780 Plate 13 01011-62700 01673-32780 Bolt Washer
t 3 N Q t 6 t 6 t 1 N t 1 N t 3 N t 3 t 3
1 791-830-1620 Plate 2 791-830-1630 Spacer 3 791-830-1640 Screw 14 4 01580-12722 5 01630-32780 Nut Washer
Puller 6 790-101-4000 t 1 (490 kN {50 ton}) 7 790-101-1102 Pump 1 791-830-1650 Plate 2 791-830-1660 Spacer 3 796-670-1120 Plate L 4 790-434-1070 Screw 15 5 01580-13629 Nut 6 01643-33690 Washer t 1 t 1 N t 1 N t 1 t 1 N t 2 t 1
3.
Operate the blade and ripper to lift the machine body until the track roller assembly separates from the track link. k Set a block between the track roller and track link so that the machine body will not lower. Set block [1] out of the track shoe, matching it to the height of the track link. Set steel plate [2] on the track shoe and block [1]. Operate the blade and ripper to lower the machine body until the track roller of bogie assembly (1) comes in contact with steel plate [2]. a Operate the blade and ripper slowly, running the engine at the low idling speed.
4. 5. 6.
Puller 7 790-101-4000 t 1 (490 kN {50 ton}) 8 790-101-1102 Pump 1 791-830-1620 Plate 2 791-830-1640 Screw 3 01580-12722 16 4 01643-32780 5 790-101-4000 Nut Washer t 1 t 1 N t 3 N t 3 t 3
Puller t 1 (490 kN {50 ton}) t 1 t 2 N Q t 1 t 1
6 790-101-1102 Pump 17 18 19 791T-830-1670 Guide 791-530-1510 Installer 791-601-1000 Oil pump
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7.
Remove cover (2).
4) 5)
Set tool L15. 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 opposite side simultaneously. a Pushing out force: 225.5 460.9 kN {13 47 tons}
6) 7)
8)
Remove spacer (6). Remove spacer (9) and floating seals (10) between rings (7) and (8). a Store the floating seals so that they will not be damaged. Pull out the shaft and rings on the opposite side according to above steps 1) 7).
3)
Remove floating seals (5) from the end faces of rings (4) and (7). a Store the floating seals so that they will not be damaged. 9. Remove tool L13. 10. Place bogie assembly (1) on steel plate [2]. 11. Operate the blade and ripper to raise the machine body until the bogie assembly can be pulled out. k Set a block between the track roller and track link so that the machine body will not lower.
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12. Sling bogie assembly (1) and pull it out, sliding it on steel plate [2].
4
Bogie assembly: 1,200 kg
2) 3) 4) 5) 6)
Press fit shaft (3) to ring (8). Install spacer (9). Press fit ring (7) to shaft (3). Install spacer (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 rings (4) and (7) and install floating seals (10) to the opposite side of ring (7) and ring (8). 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. 2. Apply lever block [3] between the guard of bogie assembly (1) and the bogie assembly on the opposite side. Slide bogie assembly (1) on the steel plate to set it to the mounting position.
3.
Match the pin hole of the track frame to that of the bogie and set guide tool L17.
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4.
Press fitting of pin assembly 1) Set tool L16 and cover (2).
5.
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 (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 (2). a Push in the pin assembly to machined face (b) of the bogie. 2 Apply lubricant (LM-P) all over the side of the pin assembly. a Total press fitting force of pin assembly: 294.2 490.5 kN {30 50 tons}
6. 7.
Press fit the pin assembly on the opposite side of the bogie according to above steps 3 and 4. Tighten the mounting bolts of pin assembly cover (2) (2 places on inside and outside). 3 Cover mounting bolt: 883 1,470 Nm {90 150 kgm}
8.
Adjust the tension of the track shoe. For detail, see Testing and adjusting, "Testing and adjusting track shoe tension".
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Disassembly and assembly of bogie assembly

Special tools
Necessity Qty New/Remodel Sketch Symbol
3.
Disassemble the pin assembly according to Removal and installation of bogie assembly (Step 8). Disconnection of bogie Disconnect inner bogie (4) and outer bogie (5).
4.
Part No.
Part Name
1 791-830-1620 Plate 2 791-830-1640 Screw 3 01580-12722 Nut 16 4 01643-32780 Washer 5 790-101-4000
t 1 N t 3 N t 3 t 3
Puller t 1 (490 kN {50 ton}) t 1 t 1
6 790-101-1102 Pump 19 791-601-1000 Oil pump
Disassembly
1. Track roller assembly Turn over bogie assembly (1) and lift off 2 track roller assemblies (2).
Assembly
1. Assembly of pin assembly Assemble the pin assembly according to Removal and installation of bogie assembly (Steps 3 5 of Installation). Set inner bogie (4) to outer bogie (5). Press fitting of pin assembly 1) Set tool L16 and cover (3).
2. 3.
2.
Remove cover (3).
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2)
Press fit the pin assembly. 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 (3). a Push in the pin assembly to the machined face (b) of the bogie and secure the level difference of 5 mm between the bogie and pin assembly. 2 Apply lubricant (LM-P) all over the side of the pin assembly. a Total press fitting force of pin assembly: 294.2 490.5 kN {30 50 tons}
5.
Press fit the pin assembly on the opposite side of the bogie according to above steps 3 and 4. a After press fitting the pin assembly, rock the small bogie so that it can be moved with light force. Tighten the mounting bolts of pin assembly cover (3) (2 places on inside and outside). 3 Cover mounting bolt: 883 1,470 Nm {90 150 kgm} Track roller assembly Sling and install 2 track roller assemblies (2) to bogie assembly (1). 2 Track roller mounting bolt: Adhesive (LT-2) 3 Track roller mounting bolt: 2,205 2,695 Nm {225 275 kgm}
6.
7.
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)
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Removal and installation of No.1 bogie assembly

Special tools
Necessity Qty New/Remodel Sketch
Removal
1. Loosen track shoe tension. For details, see Expansion and installation of track shoe assembly. Operate blade and ripper, and raise chassis to a position where track roller of No. 2 bogie assembly is separated from track link. k Set a block between the track roller and the track link to prevent the chassis from coming down. Fit eyebolts to holes of pad mounting bolt (M12 x 2) portion at rear of No. 1 bogie assembly, and raise No. 1 bogie assembly (1).
2.
Symbol
Part No.
Part Name
1 791-830-1620 Plate 2 791-830-1630 Spacer 3 791-830-1640 Screw 14 4 01580-12722 5 01630-32780 6 790-101-4000 Nut Washer
t 1 N t 1 N t 3 N t 3 t 3
3.
Puller t 1 (490 kN {50 ton}) t 1 t 1 N t 1 N t 1 t 1 N t 2 t 1
7 790-101-1102 Pump 1 791-830-1650 Plate 2 791-830-1660 Spacer 3 796-670-1120 Plate 4 790-434-1070 Screw 15 5 01580-13629 6 01643-33960 7 790-101-4000 Nut Washer
Puller t 1 (490 kN {50 ton}) t 1 t 1 N t 3 N t 3 t 3
8 790-101-1102 Pump 1 791-830-1620 Plate 2 791-830-1640 Screw L 3 01580-12722 16 4 01643-32780 Nut Washer
4.
Put steel plate between track shoe and roller, then loosen roller cap bolts (2) approx. 20 mm. (Both inside and outside) Tap end face of shaft (3) with hammer and remove track roller assembly (4). q There is a dowel pin on the near side of the track roller assembly, so be careful not to break it. (Dowel pin insertion tolerance: 5 6 mm) Remove roller cap bolt (2), then put track roller assembly (4) on steel plate, and pull out.
4
5.
Puller 5 790-101-4000 t 1 (490 kN {50 ton}) 6 790-101-1102 Pump 17 18 19 791T-830-1670 Guide 791-530-1510 Installer 791-601-1000 Oil pump 791-630-1860 Bracket 791-630-1870 Bracket 20 791T-830-1510 Spacer 19M-09-12850 Bolt 01643-33380 Washer 791T-830-1700 Lifting tool 791T-830-1710 Bar 791T-830-1720 Plate 21 07283-31079 01582-01210 01643-31232 04530-11628 Grip Nut Washer Eye bolt t 1 t 2 N Q t 1 t 1 t 1 t 1 t 2 t 2 t 2 t 1 N Q 1 N Q 1 N Q 1 2 2 1 Q
6.
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7. 8.
Raise No. 1 bogie (5) with tool L20 and hold in position. Remove cover (6).
3)
Remove floating seals (9) from the end faces of rings (8) and (12). a Store the floating seals so that they will not be damaged.
9.
Pulling out shaft and ring 1) Set tool L14. 2) Push out shaft (7) and ring (8) to the opposite side simultaneously. a Pushing out force: 225.5 460.9 kN {13 47 tons} a When the ring is pushed out, it interferes with the idler. Accordingly, supply grease to the track tension adjustment parts in advance and move the idler cushion assembly to the front side of the machine body.
4)
Set tool L15.
5)
6) 7)
Pull out spacer (11) and rings (12) and (13). a Pulling out force: 225.5 460.9 kN {23 47 tons} Remove spacer (11). Remove spacer (14) and floating seals (10) between rings (12) and (13). a Store the floating seals so that they will not be damaged.
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10. Lower bogie (5) on the steel plate and pull it out.
4
Bogie assembly: 180 kg
2) 3) 4) 5) 6)
Press fit shaft (7) to ring (13). Install spacer (14). Press fit ring (12) to shaft (7). Install spacer (11). 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. Assembly of pin assembly 1) Using tool L18, install floating seals (9) to rings (8) and (12) and install floating seals (10) to the opposite side of ring (12) and ring (13). 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. 2. 3. Slide bogie (5) on steel plate [1] to the center. Set bogie (5) to the mounting position with tool L20.
4.
Match the pin hole of the track frame to that of the bogie and insert guide tool L17.
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5.
Press fitting of pin assembly 1) Set tool L16 and cover (6).
6.
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
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 (6). a Push in the pin assembly to machined face (b) of the bogie and secure the level difference of 5 mm between the bogie and pin assembly. 2 Apply lubricant (LM-P) all over the side of the pin assembly. a Total press fitting force of pin assembly: 294.2 490.5 kN {30 50 tons}
7. 8. 9.
Press fit the pin assembly on the opposite side of the bogie according to above steps 5 and 6. Install covers (6) (2 places on inside and outside). Install eyebolts instead of the pad mounting bolts (M12 x 2 pieces) of bogie (5) and lift and hold the bogie.
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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
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 adjusting track shoe tension.
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
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Serial number

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
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Expansion and installation of track shoe assembly
Expansion Checking before expansion of track shoe assembly
k
Expansion of track shoe assembly (Normal)

1
If Checking before expansion of track shoe assembly shows that there is no abnormality, do as follows. Set master link in position. a Bring the master link above the idler (just behind the center). a Set blocks [1] and [2] at the front end of the idler and between the carrier rollers so that the mating faces of the master link will not open until the master bolt is removed.
1.
k q
In some cases, it may be extremely dangerous to expand the track shoe assembly. To prevent danger, carry out the following checks before expansion of the track shoe assembly. Never loosen the lubricator more than one turn. Loosen lubricator (1) at the adjustment cylinder, release the grease, then move the machine backwards and forwards a short distance, and check that the track tension is relieved. If the shoe tension is relieved, go to "Expansion 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.
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). If the shoe tension is not relieved, go to "Expansion of track shoe assembly (when there is abnormality inside track frame)".
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3.
Remove track shoe (2). [*2] a Loosen each of the 4 bolts by 1 2 turns. Check that the 4 bolts can be turned lightly, then pull them out. Do not pull out only 1 bolt without loosening the other three. a If a bolt is turned forcibly while it cannot be turned lightly, the threads of it and master link (3) may be damaged.
1.
Remove work equipment assembly. For details, see "Removal and installation of work equipment assembly". Loosen lubricator (1), then move machine backwards and forwards to remove grease. k Never loosen lubricator (1) more than one turn. a Check that all the grease has been removed.
2.
4.
Raise tip of master link, move machine towards rear slowly, and lay out track shoe assembly (4). a Length of track: Approx. 12.5 m k To prevent danger, never stand in front of the idler yoke assembly.
3.
Drive slowly forward to put track shoe at idler end in contact with large block [3] or a wall (if another large bulldozer of the same capacity as the machine being repaired is available, put 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. Remove shoe (2), then disconnect master link (3). Move machine towards rear slowly and lay out track shoe assembly.
4. 5.
Expansion of track shoe assembly (when there is abnormality inside track frame)
a
k
When "Checking before expansion of track shoe assembly" shows any abnormality, do as follows. 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.
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Installation
q
Carry out installation in the reverse order to expansion (normal). a a a
[*1]
For details of the track shoe tension, see Testing and adjusting, Testing and adjusting of track shoe tension. Tighten all of the 4 bolts with the fingers until the master link contacting faces are fitted to each other. 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. 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
[*2]
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Overall disassembly and overall assembly of track shoe

Special tools
New/remodel Necessity Sketch Q'ty
Overall disassembly
a a When disassembling the track shoe, see shop manual Guidance for reusable parts Lubricated tracks (III) (Form No.: SEBG4092). Check that the track press has protective cover (1).
Symbol
Part No.
Part Name
1 2 3 4 5 6
791-646-7531 Plug remover 791-660-7460 Pin brush 791-646-7900 Push tool 791-932-1110 Push tool 790-701-3000 Seal checker and 791-601-1000 Oil pump 791-632-1010 Installer 1 791-685-5600 Push tool assembly
t 1 t 1 t 1 t 1 t 1 t 1 t 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 t 1 N N N N N N N N N N N N N N N N N N N
2 791-685-5640 Adapter 3 791-685-5660 Ring 4 791-685-5670 Plate 5 791-685-5680 Ring 9 6 791-685-5690 Push tool 7 791-685-5710 Adapter R 8 791-685-5720 Spring 9 791-685-5730 Bar 10 01252-30655 Bolt 11 01580-01210 Nut 1 791-685-5700 Push tool assembly
When removing the pin, totally cover pin end push tool (2) and link wedge with thick cloth (3) so that the broken pieces of wedge ring (4) will not be scattered.
2 791-685-5650 Adapter 3 791-685-5660 Ring 4 791-685-5670 Plate 5 791-685-5680 Ring 12 6 791-685-5690 Push tool 7 791-685-5710 Adapter 8 791-685-5720 Spring 9 791-685-5730 Bar 10 01252-30655 Bolt 11 01580-01210 Nut 13 791-685-5750 Push tool
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2.
The track press operator and other workers must put on helmets, safety glasses and earplugs. 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 80C and prevent the spatters from entering the clearance of the link so that the sealing parts will not be deteriorated by the heat.
Disassembly of link 1) Set the link assembly on the link press and hit it with a hammer so that the bushing will be fitted to the jaw. a If the link tread, outside of the bushing, etc. are worn, adjust the height of the jaw or guide plate to align the disassembly jig with the pin and bushing so that the link hole will not be damaged during disassembly. a If the above parts are not aligned perfectly, the link hole may be damaged and the pin and bushing may be broken during disassembly. a Drive the small plug of the pin inward with tool R1 after disassembly to avoid making the workshop dirty.
1.
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2)
Operate the left cylinder to pull out the fitted parts of the left link, pin, and bushing simultaneously. a Check the pulling out force of the pin and bushing to see if the necessary fitting force of the pin and bushing is obtained when they are turned over and assembled. a When the wedge link is cut, it bangs. This phenomenon is normal.
4)
Return the right cylinder and take out the links, pins, bushings, and spacers on both sides, then send the next link assembly to the jaw. a If the end faces of the bushings and sealing surfaces are damaged, oil will leak. Accordingly, handle them with care. a Take care not to scratch your hands with the sharp edges of a cut wedge link.
3)
Return the left cylinder and operate the right cylinder to pull out the right link, pin, and bushing simultaneously.
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3.
Inspection Inspect the following items to see if the parts can be reused for an oil lubricated track or a grease lubricated track, then generally examine whether the link assembly should be recycled as an oil lubricated track or as an grease lubricated track. a For judgment of recycling of the parts, see shop manual Guidance for reusable parts Lubricated tracks (III) (Form No.: SEBG4092). 1) Check the parts visually for damage, then apply a dye penetrant test or a magnetic flaw test to the parts which seem to be damaged. Discard a cracked part since it cannot be reused. 2) Measure the outside diameters of the fitting parts of the pin and bushing and those of the pin and bushing fitting parts of the link with a micrometer and a cylinder gauge to see if the allowable interference is obtained. When reusing the parts for an oil lubricated track, the pin and link must have the standard interference. a If the allowable interference is not obtained, replace the parts with new ones. a For the criteria, see Maintenance standard.
4) 5)
Precautions for storage Store the seal without removing it from the link to prevent rusting of the counterbore of the link, taking care not to damage the seal lip. Apply rust-preventive oil to the pin and bushing fitting parts and shoe and master link mating faces of the link. Apply rust-preventive oil all over the pin, bushing, and spacer. In particular, take care not to damage the end faces of the bushing.
Overall assembly
a When assembling the track shoe, see shop manual Guidance for reusable parts Lubricated tracks (III) (Form No.: SEBG4092).
When recycling for oil lubricated track 1. Preparation work 1) Cleaning of seal assembly Take the seal assembly out of the link and divide it into the seal ring and load ring, then clean them. a Since the seal ring and load ring are deteriorated easily by cleaning liquid (trichloroethylene, etc.), clean them quickly. After cleaning them, wipe off the cleaning liquid.
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2)
When reusing the pin, chamfer the corners of its end smoothly with a grinder. Remove the projections of the fitting parts with the grinder. a If the corners of the pin end are worn and sharpened, they may scuff the fitting parts to cause oil leakage.
1] 2] 3] 4]
Insert the plug in the hole of the guide through the plug inserting hole. Push the bar with the hand and insert the plug until it stops. Push the plug with the bar to press the guide against the pin. 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)
4)
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. If the large plug has been driven out, drive it with tool R3. Clean the pin hole with tool R2 in advance.
5)
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 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.
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6)
Adjust the dimensions of the fitting jig of the link press to keep the projection distance of the pin and bushing constant and keep the fitting dimensions of the seal within the limits when those parts are assembled. a For the standard dimensions, see Press-fitting jig dimension table for link press. a If the pin end (Part P) and link sides (Parts Q and R) are worn, count in the quantity of the wear when adjusting the dimensions of the fitting jig so that the pin and bushing will be projected by the same distance on both sides.
2.
Assembly of link 1) Apply oil (GO90) between the pin and bushing with a clean brush, then set them on this side of the link press jaw. a When reusing (turning) the bushing, set its worn side to the shoe fitting face of the link (which is directed up on the link press).
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 bushing: 1,274 kN {130 tons} Press cutting force C 1.8 x Average press fitting force (Set the press cutting force by adjusting the relief pressure of the link press.)
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.
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4)
Turn over the master links and check that they are press fitted in parallel.
7)
Apply gasket sealant (198-32-19890) to the pin fitting hole of the link to prevent oil from oozing through the scuffs of the pin fitting parts.
5)
Measure the projections of the bushing on both sides with a depth gauge. a Adjust the fitting jig of the link press so that the bushing will be projected by the same distance on both sides.
8)
Set the right link and install the spacer to the pin. 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 similarly 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.
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9)
Set the right jig on the receiving side and the left jig on the pushing side and press fit the pin and bushing simultaneously. 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}
11) Set the left link and install the spacer to the pin. a Apply oil similarly to the right link.
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.
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13) Press fit until the link, spacer, and bushing are fitted to each other. a Actually, you cannot see from outside if the above parts are fitted. Accordingly, 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.
15) Install the ring to jig R12.
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, disassemble and check for abnormality, then press fit again. a If the distance between the shoe bolt holes is shorter than the limit and the shoe cannot be installed, the spacer or bushing end may be worn more than the allowable limit. In this case, disassemble and replace the parts.
17) Similarly, insert the ring in the pin groove on the opposite side with jig R9.
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18) Push in the ring with jig R13. Pushing force of ring: 392 490 kN {40 50 tons}
20) Supply oil (GO90) with tool R5 until the oil supply pressure rises to 196 294 kPa {2 3 kg/cm2}. a In a cold or very cold district, supply Komatsu genuine oil (150-09-19270 or 195-32-61990) having better lowtemperature 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, disassemble and check the seal. If the seal is free from abnormality, assemble again.
Supply oil so that the depth L of the hollow of the pin hole will be in the following range when the link is left with the small plug side up (when the link assembly is placed on its side) for 30 minutes. Dimension L: 40 70 mm
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21) After supplying oil, drive in the small plug to the specified position with tool R4. a Apply GO90 around the small plug. a Drive in the plug to the following depth. Driving depth from end: 7.5 1 mm 22) Assemble the master link on the pin side at last. a Check that the master links on both sides are press fitted in parallel.
2)
When installing a double track, place the assembled double shoes on a level place in 1 line with the shoe side up. Pull pinside 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.
3.
Installation of shoe 1) 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} Retightening angle: 180 10
Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Master link) Initial torque: 980 98 Nm {100 10 kgm} Retightening angle: 180 10 a Tighten the bolts in the order of [1] [4].
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When recycling for grease 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, clean them quickly. After cleaning them, wipe off the cleaning liquid.
4) 5)
Clean the outside of the pin, surfaces of the spacer, and end faces and inside of the bushing, if they are dirty. Apply grease to the outside of the pin and surfaces of the spacer.
6)
2)
When reusing the pin, chamfer the corners of its end carefully with a grinder so that it will be press fitted smoothly.
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 counterbore of the link and seal assembly, the seal turns and its sealing performance 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.
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7)
Adjust the dimensions of the fitting jig of the link press to keep the projection distance of the pin and bushing constant and keep the fitting dimensions of the seal within the limits when those parts are assembled. a For the standard dimensions, see Press-fitting jig dimension table for link press. a If the pin end (Part P) and link sides (Parts Q and R) are worn, count in the quantity of the wear when adjusting the dimensions of the fitting jig so that the pin and bushing will be projected by the 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}
3)
4) 2. Assembly of link 1) Apply lithium grease (G2-LI) between the pin and bushing, then set them on this side of the link press jaw. a When reusing (turning) the bushing, set its worn side to the shoe fitting face of the link (which is directed up on the link press).
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. Turn over the master links and check that they are press fitted in parallel.
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5)
Measure the projections of the bushing on both sides with a depth gauge. a Adjust the fitting jig of the link press so that the bushing will be projected by the same distance on both sides.
7)
6)
Send out the master link and set the next pin and bushing. a When reusing the pin, install it with its side hole on the link tread side similarly 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. a If the outside of the pin is worn, set it with the un-worn part on the traction side. In this case, install it with its side hole on the link tread side, too.
8)
Set both links and operate both pushing jigs to press fit the pin and bushing simultaneously. 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 cutting force of pin and bushing: 1,274 kN {130 tons} Press cutting force C 1.8 x Average press fitting force (Set the press cutting force by adjusting the relief pressure of the link press.) 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.
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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} Retightening angle: 180 10
10) Match the jig to the pin hole and push it in until the ring is inserted in the pin groove. Similarly, insert the ring on the opposite side with jig R9. a A sound is made when the ring is inserted in the pin.
11) Push in the ring with jig R13. Pushing force of ring: 392 490 kN {40 50 tons}
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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} Retightening angle: 180 10 a Tighten the bolts in the order of [1] [4].
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Press-fitting jig dimension table for link press
Jig dimension (mm) a b c 4.6 2.0 59.1
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Field disassembly and assembly of one link

Special tools
Necessity Qty New/Remodel Sketch Necessity Qty New/Remodel Sketch t 1 N t 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 1 t 1 N Symbol Symbol
Part No.
Part Name
Part No.
Part Name
1 791-832-1610 Plate 2 791-832-1270 Bracket 3 01010-81495 5 01010-62050 Bolt Bolt 4 791-832-1250 Bracket 6 791-832-1220 Plate 7 791-832-1230 Shaft 8 791-832-1210 Frame 9 791-832-1240 Nut 10 04530-11628 Eye bolt 11 791-832-1310 Adapter 12 791-832-1280 Adapter 13 791-832-1320 Guide 14 01320-41030 Screw 8 15 791-832-1640 Pusher 16 791-832-1340 Extension 17 791-832-1650 Adapter 18 791-832-1480 Adapter 19 791-832-1670 Guide 20 791-832-1330 Guide R 21 791-832-1660 Adapter 22 791-832-1630 Guide 23 791-832-1470 Guide 24 791-832-1410 Extension 25 791-832-1350 Pusher 29 790-101-1102 Pump Puller (294 kN 30 790-101-4200 {30 ton}) 31 790-685-9230 Spacer Push tool 1 791-685-5600 assembly 2 791-685-5640 Adapter 3 791-685-5660 Ring 4 791-685-5670 Plate 9 5 791-685-5680 Ring 6 791-685-5690 Push tool 7 791-685-5710 Adapter 8 791-685-5720 Spring 9 791-685-5730 Bar 10 01252-30655 11 01580-01210 Bolt Nut
t 1 t 1 t 1 t 1 t 2 t 1 t 2 t 1 t 2 t 2 t 1 t 1 t 1 t 5 t 1 t 2 t 1 t 1 N t 1 t 1 t 1 t 1 t 1 N t 1 t 1 t 1 t 1 t 1 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 1 R
11
1 791-832-1490 Push tool 2 791-832-1510 Push tool Push tool 1 791-685-5700 assembly 2 791-685-5650 Adapter 3 791-685-5660 Ring 4 791-685-5670 Plate 5 791-685-5680 Ring 6 791-685-5690 Push tool 7 791-685-5710 Adapter 8 791-685-5720 Spring 9 791-685-5730 Bar 10 01252-30655 11 01580-01210 Bolt Nut
12
13
791-685-5750 Push tool
Disassembly
1. Install tools R8-4, R8-1, and R8-5 to link (1) with 2 bolts (2). a Use 2 track bolts as 2 bolts (2).
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2.
Install tool R8-12 to tool R8-4. a Check that the hole of R8-12 is aligned. If it is not aligned, retighten R8-5 and adjust the position of R8-12. Install tool R8-10 to tool R8-8. Install a rope to R8-10, then sling and install R8-10 to R8-12. Install tools R8-2 and R8-3 to tool R8-1. a Hitch and install R8-2 to the rib of R8-8 so that R8-8 will not lean.
5.
Pulling out of pin 1) Set tools R8-13, R8-14, and R8-15 to R811, then apply hydraulic pressure to push pin (3). 2) After the cylinder reaches the stroke end, connect tools R8-16 and R8-14 and repeat the work. 3) Repeat step 5.2). 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 R810, then sling them so that R8-7 will be horizontal. Insert R8-7 in the hole of R8-8 installed to the track, then clamp it with R8-9.
4.
6.
Set tools R8-30 and R8-31 to the roller tread side of the link to be disassembled, then connect tool R8-29 and apply hydraulic pressure to open the link by 5 6 mm and disconnect the link.
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7.
Repeat steps 1 5 to remove pin (4) on the opposite side.
Assembly
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 connected.
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3.
Set link (10) on the opposite side and support it with tool R8-19.
6.
Similarly to the disassembly procedure, push 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 link. 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 bushing. a Press fitting force of pin: 333 451 kN {34 46 tons} a Press fitting force of bushing: 245 382 kN {25 39 tons}
7.
Set link (12) to be connected to link (11) and connect them with tool R8-22 , then remove tools R8-30 and R8-31.
5.
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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, R814, 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) a Set the pin with its side hole on the link tread side. a Press fitting force of pin: 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".
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Disassembly and assembly of master link

Special tools
Necessity Qty New/Remodel Sketch Necessity Qty New/Remodel Sketch 1 N 1 N 1 1 t 1 N t 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 N 1 1 t 1 N Symbol Symbol
Part No.
Part Name
Part No.
Part Name
1 791-832-1610 Plate 2 791-832-1270 Bracket 3 01010-81495 Bolt 4 791-832-1250 Bracket 5 01010-62050 Bolt 6 791-832-1220 Plate 7 791-832-1230 Shaft 8 791-832-1210 Frame 9 791-832-1240 Nut 10 04530-11628 Eye bolt 11 791-832-1310 Adapter 12 791-832-1280 Adapter 13 791-832-1320 Guide 14 01320-41030 Screw 15 791-832-1640 Pusher 16 791-832-1340 Extension 8 17 791-832-1650 Adapter 18 791-832-1480 Adapter 19 791-832-1670 Guide R 20 791-832-1330 Guide 21 791-832-1660 Adapter 22 791-832-1630 Guide 23 791-832-1470 Guide 24 791-832-1410 Extension 25 791-832-1350 Pusher 26 791-832-1620 Guide 27 04530-11018 Eye bolt 28 791-101-4500
t 1 t 1 t 1 t 1 t 2 t 1 t 2 t 1 t 2 t 2 t 1 t 1 t 1 t 5 t 1 t 2 t 1 t 1 N t 1 t 1 t 1 t 1 t 1 N t 1 t 1 t 1 t 1 12 R 11 9
8 791-685-5720 Spring 9 791-685-5730 Bar 10 01252-30655 Bolt 11 01580-01210 Nut 1 791-832-1490 Push tool 2 791-832-1510 Push tool Push tool 1 791-685-5700 assembly 2 791-685-5650 Adapter 3 791-685-5660 Ring 4 791-685-5670 Plate 5 791-685-5680 Ring 6 791-685-5690 Push tool 7 791-685-5710 Adapter 8 791-685-5720 Spring 9 791-685-5730 Bar 10 01252-30655 Bolt 11 01580-01210 Nut 13 791-685-5750 Push tool
Disassembly
a 1. For the method of using tool R8, see Field disassembly of one link. Removal of track shoe assembly Remove the track shoe assembly from the track frame. For details, see Expanding track shoe assembly. Disassembly of shoe Disconnect the all master links and divide the shoes into 4 parts.
Cylinder t 1 (1960 kN {200 ton} t 1 t 1 t 1 1 N 1 N 1 N 1 N 1 N 1 N 1 N Puller (294 kN {30 ton})
29 790-101-1102 Pump 30 790-101-4200
2.
31 790-685-9230 Spacer Push tool 1 791-685-5600 assembly 2 791-685-5640 Adapter 9 3 791-685-5660 Ring 4 791-685-5670 Plate 5 791-685-5680 Ring 6 791-685-5690 Push tool 7 791-685-5710 Adapter
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3.
Removal of master link q Master pin type 1) Cutting of regular link with gas Cut the parts marked with gas and remove the parts marked . q Necessary special tool: Gas cutting machine
1)
Master link type Cutting and removal of master link on bushing side with gas Cut the parts marked with gas and remove the parts marked . Move master links (5) and (6) in the direction of 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
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Assembly
a 1. For the method of using tool R8, see "Field disassembly of one link". 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 L2 D1 D2 226 0.7 276 0.7 36 drill hole 33 x 2.0
2)
Set spacer (3) and seal assembly (4) to the counterbore of the link of the connecting part.
3)
Match the pin hole and bushing hole to each other and connect the pin and bushing with guide pin [2].
2.
Installation of bushing-side link 1) Expand the center of the link tread with tool R8 as shown in the figure. (Expand the link end by 10 mm.)
4)
Press fit pin (5) with tool R8 and install bushing-side master link (1). 2 Apply gasket sealant (198-3219890) to the pin hole of the link. a Set the pin with its side hole on the link tread side.
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5) 6) 7)
Install ring (6) with tools R8, R9, R11, R12, and R13. Install the shoe to the link of the connecting part. Drive large plug (7) with tool R3 and supply oil with tool R5, then drive small plug (8) with tool R4. a When press fitting both master links, take care that they will be in parallel with each other (Bushing side and pin side). a Do not damage the mating surfaces of the master links and end faces of the bushing. a Take care that dirt and sand will not stick to the seal, spacer, end of bushing, and tap-hole mating face of the master link.
2) 3) 4)
Pass pin (10) through bushing (9) and set and press fit pin-side master links (11) from both sides with tool R8. Install the ring with tools R8, R9, R11, R12, and R13. Drive large plug (13) with tool R3 and supply oil with tool R5, then drive small plug (14) with tool R4.
4.
3.
Assembly of link on pin side 1) Set spacer (3) and seal assembly (4) to the counterbore of the master link.
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. 2 Shoe bolt: Lubricant containing molybdenum disulfide (LM-P) 3 Shoe bolt (Master link) Initial torque: 980 98 Nm {100 10 kgm} Retightening angle: 180 10
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Removal and installation of pivot shaft assembly

Special tools
3.
Remove seal (2), then remove cover (3).
[*2]
Part No.
Part Name
791T-850-1180 Sleeve 791T-850-1190 Plate 791-730-1130 P 791-101-3310 01643-32060 01580-02016 790-105-2300 790-101-1102 Bolt Plate Washer Nut Jack assembly Pump
t 1 t 1 t 2 t 1 t 2 t 2 t 1 t 1
Q Q
Installation
q

2
[*1]
Removal
1. Remove track frame assembly. For details, see "Removal of track frame assembly". Sling pivot shaft assembly (1) and remove mounting bolts, then using forcing screw [1], pull out pivot shaft assembly. [*1]
4
Pivot shaft press-fitting surface: Anti-friction compound (LM-P)
[*2]
2.
Pivot shaft assembly: 390 kg
Using tool P, press fit seal (2) to the pivot shaft. 2 Seal press-fitting surface: Gasket sealant (LG-6) Check that press-fitting dimension (a) of the seal from the end face of the shaft is the specified dimension. Press-fitting dimension (a): 665 1.0 mm
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Removal and installation of equalizer bar

Special tools
5.
Set stand and hydraulic jack [1] (294 kN {30 ton}) under radiator guard.
Part No.
Part Name
792-900-1610 792-900-1530 791-775-1110
Adapter Screw Sleeve
t 1 t 1 t 1 t 1 t 1 t 1 Q
791T-850-1150 Plate N 1 01582-53024 Nut 01643-33080 790-101-2102 790-101-1102 Washer
6. 7. 8.
Remove cover (6). Remove cover (7). Remove main bolt (8) of side pin.
Puller t 1 (294 kN {30t on}) Pump t 1
Removal
1. Remove engine underguard and power train underguard (front).
4 4
Engine underguard: 330 kg Power train underguard (front): 340 kg
2.
Remove cover (1). 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. Remove seal (2) together with washer (3). [*1] Remove washer (4), then remove spacer (5). a Oil will flow out from the pivot case, so catch it in an oil container.
6
9.
3. 4.
Pivot case: 26 l
Using eyebolt [2], remove side pin (9). [*3] a It is difficult to remove the pin if the centers of the equalizer bar hole and track frame hole are not aligned, so use hydraulic jack [1] to adjust the height at the equalizer bar end before removing. a Repeat Steps 6 to 9 to remove the side pin on the opposite side.
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10. Operate hydraulic jack [1] slowly and lower chassis to point where equalizer bar contacts left and right track frames. 11. Disconnect lubrication tube (10). 12. Remove lock plate (11). [*4]
14. Operate blade and raise front of chassis, and set hydraulic jack under radiator guard. 15. Raise equalizer bar (13), move it past main frame and track frame, and remove. k After removing the equalizer bar, do 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 hole are not aligned, so use hydraulic jack [1] to adjust the height at the main frame end before removing.
Installation
q
Carry out installation in the reverse order to removal. a a After removing the grease from the pressfitting surface of the seal, coat with gasket sealant (LG-6). Be careful not to install with the seal displaced in the direction of twisting. Main mounting bolt of side pin: 2,450 2,695 Nm {250 275 kgm} After tightening main mounting bolts (8) of the side pin, tighten the mounting bolts of covers (6) and (7). Take care of the tightening order of main mounting bolts (8) of the side pin and the mounting bolts of covers (6) and (7).
[*1]
[*2]
a a
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[*3]
a [*4]
Inside surface of bushing: Grease (G2-LI) 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. Set the pin with the grease hole facing the outside of the machine. Lock plate mounting bolt: Tread tightener (LT-2) Lock plate mounting bolt: 1,519 1,911 Nm {155 195 kgm}
2 3
[*5]
Equalizer bar bushing and main frame bushing: Grease (G2-LI) Before installing the pin, operate the crane to align the center of the main frame hole and the equalizer bar hole.
Refilling with oil (pivot case) Add oil through oil filler to the specified level.
5
Pivot case: 26 l (SAE30)
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Disassembly and assembly of equalizer bar bushing

Special tools
3)
Set tool N2 in position and remove side bushing (4) from equalizer bar (5).
Part No.
Part Name
791T-850-1160 Bracket 791T-850-1170 Bracket 790-438-1110 N 2 790-101-2540 791-112-1180 790-101-2102 790-101-1102 Screw Washer Nut
t 1 t 1 t 1 t 2 t 2
Q Q
Puller t 1 (294 kN {30 ton}) Pump t 1
Assembly
1. Side bushing 1) Set side bushing (4) and tool N2 in position, then press fit side bushing (4) to equalizer bar (5). 2 Outer circumference of bushing: Anti-friction compound (LM-P)
Disassembly
1. Center bushing Remove center bushings (1).
2.
Side bushing 1) Remove seals (2). 2) Remove snap ring (3).
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Align the direction of installation of the side bushing as shown in the diagram below. 1] Make split surface (mating surface) (a) of outer bushing horizontal. 2] Set inner bushing and outer bushing grease hole (b) at an angle. Side bushing press-fitting force: 47 96 kN {4.8 9.8 ton}
2.
Center bushing Using press, press fit bushing (1). 2 Outer circumference of center bushing: Anti-friction compound (LM-P) a Center bushing press-fitting force: 68.6 233.2 kN {7 23.8 ton}
2)
3)
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 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. 2 Lip of oil seal: Grease (G2-LI)
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

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
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Hydraulic system
Removal and installation of hydraulic pump assembly
Removal
k
5.
1
Disconnect hoses (5).
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see Testing and adjusting, " 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. Disconnect the cable from the negative () terminal of the battery. Drain oil from hydraulic tank.
6
6.
Remove tube coupling (6).
1.
Hydraulic tank: 170 l
2.
Remove floor frame assembly. For details, see "Removal of floor frame assembly". Disconnect pump outlet hoses (1) and (2). Disconnect PPC hoses (3) and (4).
3. 4.
7. 8. 9.
Remove pump inlet tube (7). Disconnect PPC hoses (8) and (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.
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Installation
q
Carry out installation in the reverse order to removal. Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
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Removal and installation of hydraulic valve assembly

Removal
k
6.
Disconnect 5 PPC hoses (5) from bottom side. a PPC hoses are distinguished by color bands. Disconnect ripper hoses (6) and (7).
7.
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see Testing and adjusting, " 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. Disconnect the cable from the negative () terminal of the battery. Drain oil from hydraulic tank.
6
1.
Hydraulic tank: 170 l
8. 9.
Disconnect tubes (8) and (9). Disconnect hose (10).
2. 3. 4.
Remove right cover of operator cab. Remove hose (1). Disconnect 5 PPC hoses (2) from upper side.
10. Disconnect wiring connectors (11) and (12), and clamp (13). 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
q
Carry out installation in the reverse order to removal. Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air in the hydraulic piping For detail, see Testing and adjusting, Air bleeding from hydraulic cylinder. D475A, D475ASD-5E0
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Disassembly and assembly of control valve
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Disassembly
1. Ripper lift valve 1) Remove case (1), spring (12), and retainer (9). 2) Remove lower case (1), spring (12), and retainer (9). 3) Remove spool (2). a Do not disassemble spool assembly (2). Blade right tilt valve 1) Remove case (1), spring (15), and retainer (9). 2) Remove lower case (1), spring (15), and retainer (9). 3) Remove spool (3). a Do not disassemble spool assembly (3). Blade lift valve 1) Remove case (3), loosen bolt (8), and remove retainer (7) and spring (6). 2) Remove plate (2), spring (13), and retainer (10). 3) Remove lower case (1), plate (2), spring (14), and retainer (11). 4) Remove spool (4). a Do not disassemble spool assembly (4). Blade lift valve 1) Remove case (3), loosen bolt (8), and remove retainer (7) and spring (6). 2) Remove plate (2), spring (13), and retainer (10). 3) Remove lower case (1), plate (2), spring (14), and retainer (11). 4) Remove spool (4). a Do not disassemble spool assembly (4). Blade left tilt valve 1) Remove case (1), spring (15), and retainer (9). 2) Remove lower case (1), spring (15), and retainer (9). 3) Remove spool (3). a Do not disassemble spool assembly (3). Ripper tilt valve 1) Remove case (1), spring (12), and retainer (9). 2) Remove lower case (1), spring (12), and retainer (9). 3) Remove spool (2). a Do not disassemble spool assembly (2).
Assembly
q
Coat the sliding surface of each part with engine oil before installing. Ripper tilt 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 O-ring to case (1) and install them. 3 Case mounting bolt: 27.5 34.3 Nm {2.8 3.5 kgm} Blade left 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 O-ring to case (1) and install them. 3 Case mounting bolt: 27.5 34.3 Nm {2.8 3.5 kgm} Blade lift valve 1) Install spool (4) to the valve body. 2) Install lower retainer (11), spring (14), and plate (2). Fit the O-ring to case (1) and install them. 3) Install retainer (10), spring (13), and plate (2). 4) Install spring (6) and retainer (7) to case (3) and secure them with bolt (8). Fit the O-ring to case (3) and install them. 3 Retainer mounting bolt: 11.8 14.6 Nm {1.2 1.5 kgm} 3 Case mounting bolt: 27.5 34.3 Nm {2.8 3.5 kgm} Blade lift valve 1) Install spool (4) to the valve body. 2) Install lower retainer (11), spring (14), and plate (2). Fit the O-ring to case (1) and install them. 3) Install retainer (10), spring (13), and plate (2). 4) Install spring (6) and retainer (7) to case (3) and secure them with bolt (8). Fit the O-ring to case (3) and install them. 3 Retainer mounting bolt: 11.8 14.6 Nm {1.2 1.5 kgm} 3 Case mounting bolt: 27.5 34.3 Nm {2.8 3.5 kgm}
1.
2.
2.
3.
3.
4.
4.
5.
6.
D475A, D475ASD-5E0
SEN02019-00
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 O-ring to case (1) and install them. 3 Case mounting bolt: 27.5 34.3 Nm {2.8 3.5 kgm} 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 O-ring to case (1) and install them. 3 Case mounting bolt: 27.5 34.3 Nm {2.8 3.5 kgm}
6.
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SEN02019-00
Disassembly and assembly of merge divider valve and self pressure reducing valve assembly
D475A, D475ASD-5E0
SEN02019-00
Disassembly
1. Remove case (7) from valve body (1). Loosen bolt (6) and remove retainer (8), spring (5), retainer (4), plug (3), and spool (2). Remove plug (14), spring (12), and spool (11). Remove plug (18), spring (17), and spool (16).
Assembly
q
Coat the sliding surface of each part with engine oil before installing. Fit the O-ring and install ball (37), spring (36), and seat (35) to block (30). 3 Seat: 9.8 12.7 Nm {1.0 1.3 kgm} Fit the O-ring and install valve assembly (20) to block (30). 3 Valve assembly: 24.5 34.3 Nm {2.5 3.5 kgm} Install spool (31) and spring (32). Fit the O-ring and install plug (33). 3 Plug assembly: 19.6 24.5 Nm {2 2.5 kgm} Install spool (16) and spring (17). Fit the O-ring to plug (18) and install them to valve body (1). 3 Plug assembly: 147.1 186.3 Nm {15 19 kgm} 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} 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}
1. 2. 3. 4. 5. 6.
2. Remove plug (33), spring (32), and spool (31) from block (30). Remove valve assembly (20) from block (30). 3. Remove seat (35), spring (36), and ball (37) from block (30). a After disassembling, if any of body (1) and spools (2), (11), and (16) is defective, replace the whole merge divider valve assembly.
4.
5.
6.
10
D475A, D475ASD-5E0
SEN02019-00
Removal and installation of PPC relief valve assembly

Removal
k
Lower the work equipment to the ground and stop the engine. Release the remaining pressure in the hydraulic piping. For details, see Testing and adjusting, Releasing remaining pressure from hydraulic circuit. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove operators cab right cover. Remove hoses (1), (2), and (3).
1. 2.
3. 4.
Disconnect connector (4). Remove PPC relief valve assembly (5).
Installation
q
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SEN02019-00
Disassembly and assembly of hydraulic cylinder assembly

Special tools
Disassembly
1. Cylinder tube Remove cylinder tube. Quick drop valve assembly a Blade lift cylinder only. 1) Remove quick drop valve assembly (1).
2.
Part No.
Part Name
1 790-502-1003
Cylinder repair stand
q 1 t 1 1 1 1 1 1 t 1 1 1 1 1 1 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
790-201-1702 Push tool kit 790-201-1881 Push tool 2 790-201-1871 Push tool 790-201-1721 Push tool 790-101-5021 Grid 01010-50816 Bolt 790-201-1500 Push tool kit 790-201-1670 Plate 790-201-1680 Plate 3 790-201-1690 Plate U 790-201-1530 Plate 790-101-5021 Grip 01010-50816 Bolt 4 790-720-1000 Expander 796-720-1690 Ring 07281-01919 07281-02169 07281-02709 07281-00709 Clamp Clamp Clamp Clamp 796-720-1690 Ring 5 796-720-1710 Ring 796-720-1630 Ring 6 790-102-2303 Wrench
2)
Disassemble quick drop valve assembly as follows. 1] Remove elbow (2). 2] Remove spring (3), washer (4), and valves (5) and (6), and pull out collar (7).
12
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SEN02019-00
3.
Piston rod assembly 1) Set cylinder assembly (8) to tool U1. 2) Remove head assembly (9). 3) Pull out piston rod assembly (10). a Put an oil container under the cylinder to catch the oil.
6)
Disassemble piston assembly as follows. 1] Remove wear ring (17). 2] Remove piston ring (18).
5. 4. Piston assembly 1) Set piston rod assembly (10) to tool U1.
Head assembly 1) Remove head assembly (19) from piston rod.
2) 2) 3) 4) 5) Remove spacer (11). Remove piston assembly (12). Remove backup rings (13) and (14), and O-ring (15). Remove retainer (16).
Disassemble head assembly as follows. 1] Remove O-ring (20) and backup ring (21).
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SEN02019-00
2] 3]
Remove snap ring (22), then remove seal (23). 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. 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). 4] Install snap ring (22).
1.
2)
Install head assembly (19) to piston rod.
14
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SEN02019-00
2.
Piston assembly 1) Assemble piston assembly as follows. 1] Using tool U4, expand piston ring (18). a Set the piston ring on the expander and turn the handle 8 10 times to expand the ring. 2] Remove piston ring (18) from tool U4, then install to piston. 3] Set tool U5 in position and compress piston ring (18). 4] Install wear ring (17) to piston.
2) 3)
4) 5)
Install retainer (16). Install O-ring (15) and backup rings (14) and (13). a Coat the O-ring and backup ring portion with grease, and secure the backup ring to prevent it from opening. Install piston assembly (12). Assemble spacer (11) and tighten mounting bolts. 2 Mounting bolt: 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.
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SEN02019-00
2)
3)
Assemble piston rod (10) to cylinder (8). a Coat the seal portion of the piston with grease. a Push in the piston rod fully. 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}
2)
Install quick drop valve assembly (1).
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
SEN02019-00 a
Disassembly and assembly of ripper pin puller cylinder assembly

Special tools
Put an oil container under the cylinder to catch the oil.
Part No.
Part Name
1 790-502-1003 790-201-1702 790-201-1881 2 790-201-1871 790-201-1721 790-101-5021 01010-50816 790-201-1500 790-201-1670 790-201-1680 3 790-201-1690 U 790-201-1530 790-101-5021 01010-50816 4 790-720-1000 796-720-1690 07281-01919 796-720-1690 5 07281-02169 796-720-1710 07281-02709 796-720-1630 07281-00709 6 790-102-2303
Cylinder repair stand Push tool kit Push tool Push tool Push tool Grid Bolt Push tool kit Plate Plate Plate Plate Grip Bolt Expander Ring Clamp Ring Clamp Ring Clamp Ring Clamp Wrench
q 1 t 1 1 1 1 1 1 t 1 1 1 1 1 1 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
2.
Cylinder head assembly 1) Remove cylinder head assembly (2) from piston rod (3).
2) 3) 4) 5)
Remove O-ring (5) and backup ring (6). Remove O-ring (7). Remove snap ring (8), then remove dust seal (9). Remove rod packing (10), then remove bushing (11).
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 cylinder head assembly (2).
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SEN02019-00
3.
Piston rod assembly Remove piston ring (12) from piston rod (3).
2.
Cylinder head assembly 1) Using tool U2, press fit bushing (11) to cylinder 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. Piston rod assembly 1) Using tool U4, expand piston ring (12). a Set the piston ring on the expander and turn the handle 8 10 time to expand the ring. 2) Remove piston ring (12) from tool, then install to piston rod (3). 3) Using tool U5, compress piston ring (12). 2) Using tool U3, press fit dust seal (9) to cylinder head (4).
1.
18
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SEN02019-00
3) 4) 5)
Install snap ring (8) and rod packing (10). Install O-ring (7). Install backup ring (6) and O-ring (4).
3.
Cylinder assembly 1) Set cylinder to tool U1 and support with block [1]. 2) Install piston rod (3) together with cylinder head assembly (2). a Coat the seal portion of the piston with grease. a Coat the backup ring with grease. a Push in the piston fully. 3) Using tool U6, tighten cylinder head assembly (2). 3 Cylinder head assembly: 441 44.1 Nm {45 4.5 kgm}
6)
Install cylinder head assembly (2) to piston rod (3).
D475A, D475ASD-5E0
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SEN02019-00
20
SEN02020-00
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Work equipment
Work equipment .............................................................................................................................................. 2 Removal and installation of blade assembly ........................................................................................ 2 Disassembly and assembly of giant ripper assembly .......................................................................... 4
D475A, D475ASD-5E0
SEN02020-00
Work equipment
Removal and installation of blade 1 assembly
Removal
k k
Lower the work equipment to the ground in a horizontal place, and set blocks [1] securely under the left and right straight frames.
Release the remaining pressure from the hydraulic circuit. For details, see Testing and adjusting, " 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 hydraulic circuit". Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove left and right covers (4). Disconnect hoses (5). a Mark the hoses before disconnecting. a Fit blind plugs to prevent dirt or dust from entering the piping. Remove left and right trunnion caps (6).
3. 4.
5.
1. 2.
Remove lock plate (1) of lift cylinder rod pin and extract pin (2). [*1] 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 the cylinder from the blade on the opposite side.
6.
Remove blade assembly (7). a Start the engine, drive the machine slowly in reverse, and disconnect the blade assembly from the trunnions.
D475A, D475ASD-5E0
SEN02020-00
Installation
q
[*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
Refilling with oil (hydraulic tank) Add oil through 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
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Disassembly and assembly of giant ripper assembly

Disassembly
1. Mount machine on block [1] and lower blade to ground. k Lock the brake securely. Sling shank, then operate pin-puller switch and pull out shank pin. Raise ripper fully, and lower shank (1) to remove.
4
7.
Disconnect 4 lift cylinder hoses (4), 4 tilt cylinder hoses (5), and 2 pin-puller cylinder hoses (6).
2. 3.
Shank: 1,050 kg 8. Sling tilt cylinder assembly (7), then remove pin (8) and lift off tilt cylinder assembly (7).
4
4.
Set stand [2] under arm and beam.
Tilt cylinder assembly: 410 kg
5. 6.
Sling lift cylinder assembly and remove pin (2). a Start the engine, retract the piston rod fully, and lower on top of the arm. Sling lift cylinder assembly and remove pin (3). a Start the engine, retract the piston rod fully, and lower on top of the lift cylinder. k Release the remaining pressure from the hydraulic circuit. For details, see Testing and adjusting, "Releasing remaining pressure from hydraulic circuit".
9.
Sling lift cylinder assembly (9), then remove pin (10) and lift off lift cylinder assembly (9).
4
Lift cylinder assembly: 400 kg
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SEN02020-00
10. Sling beam (11), then remove left and right pins (12) and lift off beam (11).
4
2.
Beam: 2,450 kg
Sling beam (11) and set in mounting position, then fit left and right pins (12) and secure with lock plate.
4
Arm: 2,450 kg 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 lock plate.
4
4.
Arm: 1,800 kg Set a stand under the arm.
Sling tilt cylinder assembly (7) and set in mounting position, then fit pin (8) and secure with lock plate.
4
Tilt cylinder assembly: 410 kg
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SEN02020-00
5.
Connect 2 pin-puller cylinder hoses (6), 4 tilt cylinder hoses (5), and 4 lift cylinder hoses (4).
8.
Mount machine on block [1] and lower blade to ground. k Lock the brake securely. Operate ripper and raise slightly to remove stand [2].
9.
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. Sling lift cylinder assembly, start engine, extend piston rod and align with pin hole, then install pin (2) and secure with lock plate.
7.
12. Bleed air from cylinder. For details, see Testing and adjusting, "Bleed air from hydraulic cylinder".
D475A, D475ASD-5E0
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D475A, D475ASD-5E0
SEN02020-00
SEN02021-00
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Cab and its attachments ................................................................................................................................. 2 Removal and installation of ROPS guard............................................................................................. 2 Removal and installation of operators cab assembly .......................................................................... 3 Removal and installation of floor frame assembly................................................................................ 4
D475A, D475ASD-5E0
SEN02021-00

Removal and installation of ROPS 1 guard
Removal
1. 2. Sling ROPS guard (1) and remove 16 mounting bolts (2). [*1] Lift off ROPS guard (1).
4
ROPS guard: 918 kg
Installation
q

3
[*1]
ROPS guard mounting bolt: 1,960 2,450 Nm {200 250 kgm}
D475A, D475ASD-5E0
SEN02021-00
Removal and installation of operators cab assembly

Removal
k
6. 7.
Remove front covers (8), (9) and (10). Remove 3 mounting bolts (11), 6 bolts (12) and 15 bolts (13).
Disconnect the cable from the negative () terminal of the battery. Remove ROPS guard. For details, see Removal of ROPS guard. Remove left cover (1) of operators cab. Disconnect wiring connectors (12V, 21 and 20) (2). Disconnect 4 washer hoses (3) and 19 washer wires (4). Washer hose Red : Right door Black : Rear window Blue : Left door : Front window
1. 2. 3. 4.
8.
Sling operators cab assembly (14), then remove.

4
Operators assembly: 500 kg
5.
Remove garnishes (5), (6) and (7).
Installation
q
D475A, D475ASD-5E0
SEN02021-00
Removal and installation of floor frame assembly

Special tools
4.
Remove sidecover (5).
Part No.
Part Name
799-703-1200 Service tool kit 799-703-1100 Vacuum pump X 799-703-1110 Vacuum pump 799-703-1120 Vacuum pump
t 1 t 1 t 1 t 1
799-703-1401 Gas leak detector t 1
5.
Removal
1. Remove operators cab assembly. For details, see "Removal of operators cab assembly". Remove covers (1), (2) and (3).
Disconnect brake pedal linkage (6). [*4] a Check the mounting dimensions of brake rod before disconnection.
2.
6.
3.
Lift off operator's seat (4). a Remove the seat together with the undercover.
4
Disconnect wiring harness connectors (7) (VF1-CA1-VF2), (8) (PL1-PL2-PL3), (9) (FD5BWR1-PWR2-USB-12V-20-21), and (10) (TCIV12-BSW), and then disconnect the wiring clamp. Disconnect washer hose (11) and the clamp.
Operators seat: 64 kg
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7. 8.
Remove wiring connector (12) (CN2-SSA-PT1) and the clamp. Disconnect wiring connector (13) (995-111VFD) and remove the connector bracket.
11. Remove brake rod (17). 12. Disconnect parking brake cable (18). [*3]
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] 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.
10. Disconnect wiring connector and clamp (16).
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19. Remove 8 floor frame rear mounting bolts (26).
Installation
q
Carry out installation in the reverse order to removal. a a a
[*1]
Install the hoses without twisting or interference. Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Coat the O-rings thoroughly with compressor oil (Shell Suniso 4G or 5G).
20. Lift off floor frame assembly (27). a
4 Floor frame assembly: 500 kg Use a chain block to adjust the balance in all directions (front, rear, left, and right), and lift off slowly.
Tighten the air conditioner gas piping to the following tightening torques.
Tightening torque (Nm {kgm}) 13.23 1.47 {1.35 0.15} 22.05 2.45 {2.25 0.25} 31.85 2.45 {3.25 0.25} 5.39 1.47 {0.55 0.15} 9.8 1.96 {1.0 0.2}
Thread size 16 x 1.5 22 x 1.5 24 x 1.5 M6 bolt (receiver portion) M6 bolt (compressor portion)
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SEN02021-00
[*2]
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]
Adjust installed length of parking brake cable. For details, see Testing and adjusting, Adjusting brake pedal and parking brake lever.
[*4]
Adjust installed length of brake rod. For details, see Testing and adjusting, "Adjusting brake pedal and parking brake lever". 3 Brake pedal linkage turnbuckle: 34.3 58.8 Nm {3.5 6 kgm}
Charging with air conditioner gas Using tool X, charge the air conditioner circuit with air conditioner gas (R134a). Refilling with coolant Add coolant to the specified level, and run the engine to circulate the coolant through the system. Then check the coolant level again.
D475A, D475ASD-5E0
SEN02021-00
SEN02339-01
BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine model
D475A-5E0 D475ASD-5E0
Serial number

Electrical system
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
SEN02339-01
Removal and installation of controller assembly

Removal
k
5.
1
Disconnect wiring connectors of engine controller (6). (CN-LE1, CN-LE32, CN-LE31, CN-LE4, CNLE2, CN-LE52, CN-LE51) Remove engine controller (6). Remove engine controller mounting bracket (7). Disconnect wiring connectors of transmission controller (8). (CN-TMCN1, CN-TMCN2, CN-TMCN3) Remove transmission controller (8).
Disconnect the cable from the negative () terminal of the battery. Remove cover (1).
6. 7. 8.
1.
9.
10. Disconnect wiring connectors of steering controller (9). (CN-STCN1, CN-STCN2, CNSTCN3) 11. Remove steering controller (9).
2. 3. 4.
Remove services switch (2) and connector bracket (3). Remove 2 clips for wiring harness (5). Remove 3 brackets (4).
Installation
q
D475A, D475ASD-5E0
SEN02339-01
Removal and installation of engine controller assembly (left)

Removal
k
3.
1
Disconnect wirings (3), (4) and (5).
Disconnect the cable from the negative () terminal of the battery. Remove undercover (1).
1.
4.
Remove ground cable fixing bolt (6) and controller (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
q
D475A, D475ASD-5E0
SEN02339-01
Removal and installation of air conditioner condenser assembly

Removal
1. Open engine right side cover (1) and remove side covers (2) and (3).
3.
Remove air conditioner condenser assembly (5) from right side of chassis.
Installation
q
Carry out installation in the reverse order to removal. a a a a Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Check that there is no defect or deterioration on the O-ring. When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: NDOIL8, Zexcel: ZXL100PG (PAG 46 or equivalent)). 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]
[*1]
a a
k
Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.
Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). a Filling quantity: 1,100 g
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Removal and installation of air conditioner compressor assembly

Removal
k
4. 5.
Loosen 4 mount bolts (6). Loosen locknut, and remove adjustment bolt (7), then remove belt from pulley. [*2] Remove 4 mount bolts (6), then remove air conditioner compressor assembly (8).
6.
Disconnect the cable from the negative () terminal of the battery Open engine right side cover (1) and remove side covers (2) and (3).
1.
2. 3.
Disconnect air conditioner compressor clutch connector (CN-351) (4). Disconnect 2 compressor hoses (5). [*1] Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.
a a
k
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SEN02339-01
Installation
q
Carry out installation in the reverse order to removal. a a a a
[*1]
Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Check that there is no defect or deterioration on the O-ring. When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: NDOIL8, Zexcel: ZXL100PG (PAG 46 or equivalent)). 3 Air conditioner hose mounting bolt: 10 2 Nm {1.0 0.2 kgm} Adjust the belt tension. For details, see Testing and adjusting, "Testing and adjusting tension of air conditioner compressor belt".
[*2]
Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). a Filling quantity: 1,100 g
D475A, D475ASD-5E0
SEN02339-01
Removal and installation of air conditioner unit

Removal
k k
2. 3. 4. 5.
Remove fresh air filter (2). Remove cover (3). Remove duct (4). Remove garnishes (5) and (6).
a a
k
Disconnect the cable from the negative () terminal of the battery. Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person. Remove operator's seat (1).
6.
Disconnect air hose (7).
1.
7. 8. 9.
Remove fresh air filter bracket (8). Disconnect 2 air conditioner hoses (9). Disconnect heater hose (10).
10. Disconnect wire and wiring connector (11). 11. Remove air conditioner unit (12).
D475A, D475ASD-5E0
SEN02339-01
Installation
q
Carry out installation in the reverse order to removal. a a a a a
[*1]
Install the hoses without twisting or interference. Install the air conditioner circuit hoses carefully to prevent dirt, dust, or water from getting inside the hoses. Check that there are O-rings at the piping connection of the air conditioner hoses before installing. Check that there is no defect or deterioration on the O-ring. When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: NDOIL8, Zexcel: ZXL100PG (PAG 46 or equivalent)).
Tighten the air conditioner gas piping to the following tightening torques.
Tightening torque (Nm {kgm}) 13.231.47 {1.350.15} 22.052.45 {2.250.25} 31.852.45 {3.250.25} 5.391.47 {0.550.15} 9.81.96 {1.00.2}
Thread size 16 x 1.5 22 x 1.5 24 x 1.5 M6 bolt (receiver portion) M6 bolt (compressor portion)
q
Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). a Filling quantity: 1,100 g Refilling with coolant Add coolant to the specified level, and run the engine to circulate the coolant through the system. Then check the coolant level again. D475A, D475ASD-5E0
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BULLDOZER
1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine Model
D475A-5E0 D475ASD-5E0
Serial Number
90 Diagrams and drawings

Hydraulic diagrams and drawings
Hydraulic diagrams and drawings................................................................................................................... 3 Power train hydraulic circuit diagram ................................................................................................... 3 Hydraulic circuit diagram (1/3) ............................................................................................................. 5 Hydraulic circuit diagram (2/3) ............................................................................................................. 7 Hydraulic circuit diagram (3/3) ............................................................................................................. 9
D475A, D475ASD-5E0
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Hydraulic diagrams and drawings

Power train hydraulic circuit diagram
Power train hydraulic circuit diagram D475A, D475ASD-5E0
D475A, D475ASD-5E0
Hydraulic circuit diagram (1/3)
Hydraulic circuit diagram (1/3) D475A, D475ASD-5E0
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1SHOP MANUAL
D475A-5E0 D475ASD-5E0
Machine Model
D475A-5E0 D475ASD-5E0
Serial Number

Electrical diagrams and drawings
Electrical diagrams and drawings ................................................................................................................... 3 Electrical circuit diagram (1/13)............................................................................................................ 3 Electrical circuit diagram (2/13)............................................................................................................ 5 Electrical circuit diagram (3/13)............................................................................................................ 7 Electrical circuit diagram (4/13)............................................................................................................ 9 Electrical circuit diagram (5/13)...........................................................................................................11 Electrical circuit diagram (6/13).......................................................................................................... 13 Electrical circuit diagram (7/13).......................................................................................................... 15 Electrical circuit diagram (8/13).......................................................................................................... 17 Electrical circuit diagram (9/13).......................................................................................................... 19 Electrical circuit diagram (10/13)........................................................................................................ 21 Electrical circuit diagram (11/13) ........................................................................................................ 23 Electrical circuit diagram (12/13)........................................................................................................ 25 Electrical circuit diagram (13/13)........................................................................................................ 27 Electrical circuit diagram of inside cab ............................................................................................... 29 Connector arrangement diagram ....................................................................................................... 31
D475A, D475ASD-5E0
Electrical diagrams and drawings

Electrical circuit diagram (1/13)
Electrical circuit diagram (1/13) D475A, D475ASD-5E0
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Electrical circuit diagram of inside cab
Electrical circuit diagram of inside cab D475A, D475ASD-5E0
D475A, D475ASD-5E0
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Connector arrangement diagram

Connector No. 1 2 3 4 5 6 9 10 11 12 13 14 15 17 18 19 20 21 22 25 26 81 101 102 201 203 204 207 208 209 217 221 223 226 241 242 243 244 250 255 256 260 262 263 265 266 270 280 360 369 422 453 599 653 800 801 810 811 12S1 12S2 12V AC AC1 AC2 ACT ACT ACU ADH AF1 AF2 ANB ANR AP1 AP2 AP3 AP4 AP5 ASD ASUS B7L B7S B8L B8S B30S B105H1L B105H1S B105H2L B105H2S B105S BKA BLD BLMT BLSW BLU BRB BRB BRC BRC Model Giboshi Terninal Terninal Terninal Terninal KES1 KES1 KES1 KES1 M YAZAKI YAZAKI DT DTHD#8 DTHD#12 Terninal Giboshi M DT-B DT-A DT-B DT DT DT DT DT-A DT DT DT DT DT-A DT DT DT Terninal Terninal Terninal Terninal X X Terninal Terninal Terninal Terninal DT DT DT DT DT-A DT Giboshi Giboshi Giboshi Giboshi YAZAKI YAZAKI DT DT DT-A HD-24 DT Relay S KES1 DT DT Terninal Terninal AMP040 AMP040 SWP SWP SWP KES1 DT Relay DT YAZAKI KES1 DT Terninal Terninal Terninal Terninal Number of pins 1 1 1 4 1 1 6 9 6 6 6 6 2 4 4 4 1 1 1 1 2 2 12 12 12 2 2 2 2 12 2 2 2 2 12 2 2 2 1 1 1 1 2 2 1 1 1 1 6 6 2 2 12 2 1 1 1 1 2 2 3 2 12 31 2 5 12 4 2 2 1 1 16 20 12 16 8 4 2 1 1 1 1 1 1 1 1 1 1 5 2 2 4 2 1 1 1 1
D475A, D475ASD-5E0
Component name Address of stereogram J-9 J-9 J-9 I-9 I-9 I-9 G-9 K-9 J-1 J-2 K-2 K-2 K-2 G-9 L-4 K-3 Z-4 Z-3 L-9 K-9 K-2 H-9 P-3 P-3 D-7 C-7 C-7 D-7 C-7 E-1 AE-6 H-1 L-6 L-7 G-9, P-6 D-8 H-9 L-5 AI-9 AI-8 AI-8 AH-8 S-9 U-9 T-9 T-9 AH-9 AI-9 K-3 L-3 L-5 AZ-2 Z-4 AX-5 AN-2 AN-2 Z-5 Z-5 X-8 X-8 Z-3 AQ-7 W-8 Z-6 E-8 AK-2 Z-7 AI-6 G-1 H-1 AQ-7 AQ-7 U-2 U-2 Y-7 Z-7 Y-7 AH-8 U-9 C-9 C-8 C-8 C-8 B-9 C-9 C-9 B-9 B-9 B-9 AK-2 Q-8 X-8 AI-6 Q-8 F-9 J-2 F-8 H-1 Connector No. BRE BRE BRK BSW BUA BUZ CB1 CB2 CB3 CB4 CB5 CB6 CM29 CM30 CN1 CN1 CN2 CN2 CN3 CN3 CN4 CN4 CN5 CN5 CN6 CN6 CONV CSL CSR CT1 CTV CUR DEC DIAL DL1 DLT DPNL DUL EG1 EG2 EHL ENBP ENG ENG ENGL ESD EXA1 EXA2 EXA3 EXA4 EXTLF EXTLR EXTRF EXTRR EXT1 EXT2 EXT3 EXT4 F1T8 F2T6 F3T4 F30 F96 FA1 FA2 FAN1 FAN2 FAR FD5 FFT2 FL82 FLC6 FR84 FRC8 FRT2 FS11 FS12 FS21 FS22 FS31 FS32 FSB FTU FWL G G GND GND01 GND02 GND03 GND04 GND05 GND06 GND07 GND09 GND1 GND2 GND3 Model Terninal Terninal DT HD-18 DT KES-1 Terninal Terninal Terninal Terninal Terninal Terninal AMP070 AMP070 DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT KES-1 DT M BENDIX DT DT DT DTP HD-24 Relay DT DRC-60 DRC-60 HD-18 DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT DT KES1 KES1 DT DT-B DT DT DT DT DT DT HD-24 KES-1 KES-1 SUMITOMO SUMITOMO Terninal Terninal Terninal Terninal Terninal Terninal Terninal Terninal Terninal Terninal Terninal Terninal Number of pins 1 1 3 14 2 3 1 1 1 1 1 1 10 14 2 2 2 2 2 2 2 2 2 2 2 2 6 3 3 3 3 3 3 3 5 2 2 2 4 23 5 3 60 60 21 3 3 3 3 3 2 2 2 2 2 2 2 2 2 2 2 1 1 2 2 3 4 2 12 2 2 2 2 2 2 31 4 4 3 3 1 1 1 1 1 1 1 1 1 1 1 1 Component name Battery relay (Right) (Terminal E) Battery relay (Left) (Terminal E) Brake potentiometer Intermediate connector (BULGA specification) Backup alarm Buzzer switch Circuit breaker (20 A) (Steering controller) Circuit breaker (20 A) (Monitor panel) Circuit breaker (20 A) (Transmission controller) Circuit breaker (20 A) (Air conditioner) Circuit breaker (20 A) (Headlamp) Circuit breaker (20 A) (Starting switch terminal B) ORBCOMM terminal ORBCOMM terminal Injector #1 (Left bank) Injector #1 (Right bank) Injector #2 (Left bank) Injector #2 (Right bank) Injector #3 (Left bank) Injector #3 (Right bank) Injector #4 (Left bank) Injector #4 (Right bank) Injector #5 (Left bank) Injector #5 (Right bank) Injector #6 (Left bank) Injector #6 (Right bank) Converter Left yoke angle sensor Right yoke angle sensor CAN terminal resistor CAN terminal resistor Cursor switch Decelerator pedal Fuel control dial Download connector (ORBCOM specification) Download right (ORBCOM specification) Diode Dual tilt selector solenoid valve Intermediate connector (Engine) Intermediate connector (Engine) Engine hold relay Blow-by pressure Engine controller (Left bank) Engine controller (Right bank) Intermediate connector (Engine sensor) Intermediate connector (Fuse box) Exhaust temperature sensor amplifier (Left 1) Exhaust temperature sensor amplifier (Left 2) Exhaust temperature sensor amplifier (Right 1) Exhaust temperature sensor amplifier (Right 2) Exhaust temperature sensor (Left front) Exhaust temperature sensor (Left rear) Exhaust temperature sensor (Right front) Exhaust temperature sensor (Right rear) Exhaust temperature sensor amplifier (Left 1) Exhaust temperature sensor amplifier (Left 2) Exhaust temperature sensor amplifier (Right 1) Exhaust temperature sensor amplifier (Right 2) 1st clutch ECMV (Fill switch) 2nd clutch ECMV (Fill switch) 3rd clutch ECMV (Fill switch) Circuit breaker (30 A) Circuit breaker (105 A) Fun pump solenoid Fun pump solenoid Fan clean mode switch Fan reverse mode switch Fan reverse solenoid Fuse wiring harness Forward clutch ECMV (Fill switch) Left brake ECMV (Fill switch) Left clutch ECMV (Fill switch) Right brake ECMV (Fill switch) Right clutch ECMV (Fill switch) Reverse clutch ECMV (Fill switch) Fuse box Fuse box Fuse box Fuse box Fuse box Fuse box Intermediate connector (Fuse box) Auto pitch back switch Front working lamp switch G sensor (Left bank) G sensor (Right bank) Ground (Engine) Ground (Floor) Ground (Floor) Ground (Left fender) Ground (Right fender) Ground (Bulkhead) Ground (Heater relay) Ground (Floor) Ground (Left fender) Ground (Engine) Ground (Engine) Ground (Engine) Address of stereogram E-8 I-2 U-2 X-2 I-9 AH-7 AK-4 AK-4 AK-4 AK-3 AK-3 AK-3 AK-9 AJ-8 AS-9 AQ-7 AV-4 AR-8 AV-5 AR-8 AV-5 AS-8 AV-6 AS-9 AV-6 AU-9 X-8 E-1 B-3 AF-8 AN-6 AI-7 T-2 W-9 M-3 L-2 AX-8 R-8 AQ-1 AV-7 AK-1 AQ-3 AV-1 AU-2 AS-2 AN-1 AN-6 AL-5 AN-8 AJ-7 AU-9 AT-9 AT-9 AT-9 AM-5 AN-9 AJ-7 AN-9 AY-6 AY-6 AZ-6 B-9 B-9 AZ-2 BA-3 AI-7 AI-6 D-2 W-1 AZ-6 BB-6 BA-7 BA-6 BA-7 AY-6 AL-4 AL-4 AL-4 AL-4 AM-4 AM-4 W-1 AH-8 AI-6 AU-3 AQ-5 AT-3 X-1 X-1 J-2 E-8 P-3 AQ-2 AG-1 J-2 AS-2 AS-2 AT-3 Connector No. GND4 H01 H02 HLS HP1 HP2 HR1 HR2 HRN1 HRN2 HT1 HT2 HTR1A HTR1C HTR2A HTR2C J1939 KEY L.P. L.S. LMFL LMFR LMRP LMW LSV MFD MMS NE NSF NSW OEM OEM L OEM R OLLV OLV1 OLV2 P03 PAMB PCV1 PCV1 PCV2 PCV2 PFUEL PFUEL PHR PIM PL1 PL1F PL1M PL2 PL3 PLUB PM1 PNL POIL POP PPB PPD PPV PR1 PR2 PR3 PR4 PRE PRS PT1 PTH PW L PW R PWR1 PWR2 R.P. R.S. REL1 REL2 RES RES RES L RES R RPD RPNL RPU RSD RTB RTI RWL S01 S02 S03 S04 S1T7 S21 S24 S2T5 S3T3 SDS SFT1 SFTD Model Terninal Giboshi Giboshi DT DT DT DT-B DT-A Terninal Terninal Terninal Terninal Terninal Terninal Terninal Terninal DT-A DT HD-18 HD-18 Relay Relay Relay Relay DT DT DT-C SUMITOMO Relay DT HD-24 DRC-50 DRC-50 DT DT DT AMP SUMITOMO SUMITOMO SUMITOMO SUMITOMO AMP AMP Relay SUMITOMO HD-24 HD-24 HD-24 HD-24 HD-18 Relay Terninal HD-24 FRAMATOME Terninal DT DT DT Terninal Terninal Terninal Terninal DT DT DT DT DTP DTP DTHD#4 DTHD#4 HD-18 HD-18 Terninal Terninal DT DT DT DT DT X DT DT DT DT KES-1 AMP040 M AMP070 AMP070 DT DT DT DT DT DT Number of pins 1 1 1 2 3 3 12 12 1 1 1 1 1 1 1 1 8 6 14 14 5 5 5 5 2 2 12 3 5 3 21 50 50 2 2 2 6 3 2 2 2 2 3 3 5 3 23 23 23 31 14 5 1 31 3 1 2 2 2 1 1 1 1 2 2 3 2 4 4 1 1 14 14 1 1 2 2 3 3 2 2 2 2 2 2 4 12 2 20 12 2 3 2 2 2 2 3 Ground (Engine) Additional heater switch (If equipped) Additional heater switch (If equipped) Hydraulic oil level switch (If equipped) Work equipment pump oil pressure (F) Work equipment pump oil pressure (R) Intermediate connector (Hood) Intermediate connector (Hood) Horn (415 Hz) Horn (350 Hz) Electrical intake air heater (Left bank) Electrical intake air heater (Right bank) Preheater relay (Left) Preheater relay (Left) Preheater relay (Right) Preheater relay (Right) Intermediate connector Starting switch Intermediate connector (Injector left bank) Intermediate connector (Injector left bank) Front lamp relay (Left) Front lamp relay (Right) Ripper point lamp relay Working lamp relay Pump LS selector solenoid Merge-divider solenoid valve Intermediate connector Ne sensor Neutral safety relay Parking brake switch Intermediate connector Engine controller (Left bank) Engine controller (Right bank) Engine oil level switch Intermediate connector (Engine oil level) Intermediate connector (Engine oil level) Intermediate connector (Work equipment knob switch) Ambient pressure sensor Supply pump #1 (Left bank) Supply pump #1 (Right bank) Supply pump #2 (Left bank) Supply pump #2 (Right bank) Common rail pressure sensor (Left bank) Common rail pressure sensor (Right bank) Preheater relay Boost pressure sensor Intermediate connector (Power train) Intermediate connector (Emergency escape device) (If equipped) Intermediate connector (Emergency escape device) (If equipped) Intermediate connector (Power train) Intermediate connector (Power train) Pre-lubricator relay Pre-lubricator motor (If equipped) Intermediate connector (Emergency escape device) (If equipped) Engine oil pressure sensor Pre-lubricator pressure switch (If equipped) Pitch back solenoid valve Pitch dump solenoid valve Pitch priority solenoid valve Pre-lubricator relay (If equipped) Pre-lubricator relay (If equipped) Pre-lubricator relay (If equipped) Pre-lubricator relay (If equipped) Pre-lubricator Pre-lubricator Pitch angle sensor Pitch selector solenoid valve Engine controller (Left bank) Engine controller (Right bank) Intermediate connector (fuse) Intermediate connector (fuse) Intermediate connector Intermediate connector (Injector right bank) Preheater relay (Left) Preheater relay (Right) Left bank resistor (Pull-up) Right bank resistor (Pull-up) CAN terminal resistor (Left bank) CAN terminal resistor (Right bank) Ripper lower oil pressure switch Resistor Ripper raise oil pressure switch Diode Ripper tilt back oil pressure switch Ripper tilt in oil pressure switch Rear working lamp switch Monitor panel Monitor panel Monitor panel Monitor panel 1st clutch ECMV (Solenoid) Intermediate connector (Monitor) Service switch 2nd clutch ECMV (Solenoid) 3rd clutch ECMV (Solenoid) Hydraulic oil temperature sensor Forward clutch ECMV (Solenoid) PCCS lever shift-down switch Component name Address of stereogram AT-3 Y-2 Y-2 H-9 F-9 F-9 P-4 P-4 D-1 C-7 AV-6 AR-8 AR-1 AR-1 AQ-1 AQ-2 AU-2 AH-8 AS-2 AS-2 AK-1 AL-1 AL-1 AL-1 AW-5 R-7 AO-6 AV-8 AM-1 AM-4 AR-3 AV-1 AU-2 AR-3 AU-9 AS-8 Q-9 AV-6 AU-3 AQ-5 AU-4 AQ-5 AU-4 AU-9 AM-1 AR-3 BB-4 AY-8 AY-8 AY-8, BB-4 BB-4 AK-3 F-1 AW-9 AV-4 AV-5 R-8 R-8 S-8 E-8 E-8 F-1 G-1 AN-3 AN-4 R-1 R-8 AV-1 AT-2 Z-5 Z-5 AQ-5 AQ-5 AR-2 AQ-2 AT-3 AQ-4 AU-1 AQ-3 P-9 AY-9 Q-9 P-6 Q-8 P-9 AI-7 AG-8 AF-8 AG-8 AG-8 AY-6 AG-8 AD-6 AY-6 AZ-6 AZ-2 AZ-6 V-9 Connector No. SFTU SL81 SLC5 SLS SR83 SRC7 SRT1 SRV SSA ST/B2 ST1 ST2 ST8 STB STCN1 STCN2 STCN3 STF SW SW SX8 TAM1 TC1 TFUEL TFUEL TIM TL1 TL2 TL3 TLL TLR TLS TM1 TMC1 TMC2 TMC3 TMF TMMD TOIL TRS TS1 TS1F TS2 TS2F TTM TTMF TWTR USB V1 V2A V2B V3A V3B V4A V4B VDA VDB VDW VEG VF1 VF2 WLD Model DT DT DT DT DT DT-A DT Terninal DT DT DT Terninal DRC26 DRC26 DRC26 X Terninal Terninal Terninal PACKARD DT PACKARD PACKARD PACKARD HD-24 DT-B DT DT DT DT DT DRC26 DRC26 DRC26 X DT PACKARD DT DT-C DT-C DT-D DT-D DT-B DT-B PACKARD DTHD#8 AMP070 AMP070 AMP070 AMP070 AMP070 AMP070 AMP070 HD-18 DT-A BENDIX HD-24 HD-24 HD-24 DT Number of pins 3 2 2 2 2 2 2 12 4 1 3 2 2 1 24 40 40 4 1 1 1 2 2 2 2 2 23 8 6 2 2 2 2 24 40 40 4 3 2 2 12 12 12 12 12 12 2 1 20 18 12 18 12 14 10 14 8 5 21 21 23 2 Component name PCCS lever shift-up switch Left brake ECMV (Solenoid) Left clutch ECMV (Solenoid) Daylight sensor Right brake ECMV (Solenoid) Right clutch ECMV (Solenoid) Reverse clutch ECMV (Solenoid) Service connector Acceleration sensor (SSC model) Safety relay (Terminal B) Intermediate connector (Starting motor A) Intermediate connector (Starting motor B) Emergency stop valve Safety relay (Terminal B) Steering controller Steering controller Steering controller Steering controller write connector Battery relay (Right) (Terminal BR) Battery relay (Left) (Terminal BR) Ground Intake air temperature sensor Torque converter outlet speed sensor Fuel temperature sensor (Left bank) Fuel temperature sensor (Right bank) Intake air temperature sensor Intermediate connector (PCCS lever) PCCS lever potentiometer Intermediate connector (Console) Left tilt limit solenoid valve Right tilt limit solenoid valve Blade tilt left oil pressure switch Transmission outlet speed sensor Transmission controller Transmission controller Transmission controller Transmission write connector Transmission main oil pressure Engine oil temperature sensor Blade tilt right oil pressure switch Intermediate connector (Monitor panel) Intermediate connector (Steering controller) Intermediate connector (Monitor panel) Intermediate connector (Steering controller) Intermediate connector (Monitor panel) Intermediate connector (Transmission controller) Coolant temperature sensor Intermediate connector (Fuse) VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller VHMS controller Intermediate connector (Download) Intermediate connector (Left fender) VHMS download (ORBCOM specification) Intermediate connector (Engine) Intermediate connector (Floor) Intermediate connector (Floor) Coolant level sensor Address of stereogram V-9 BB-6 BA-6 AF-8 BB-6 BA-7 AX-5 AH-2 R-1 AV-4 AV-5 AV-5 BB-6 AV-5 AD-2 AE-2 AE-1 AD-4 F-9 I-1 L-4 AV-8 BB-5 AU-4 AQ-6 AQ-4 Y-2 W-8 W-9 Q-7 Q-7 Q-8 BB-5 AI-5 AI-5 AI-4 AD-4 AW-5 AV-4 P-8 AI-3 AI-3 AD-3 AD-3 AD-5 AD-5 AR-3 Z-4 AK-6 AL-9 AM-9 AM-5 AL-5 AO-8 AO-7 M-3 Z-4 Y-8 AV-7 AJ-6 AK-5 C-2
Connector arrangement diagram D475A, D475ASD-5E0
Lamp outlet connector (Cab) Rear left speaker (Cab) Rear left speaker (Cab) Rear wiper motor (Cab) Rear right speaker (Cab) Rear right speaker (Cab) Front wiper motor (Cab) Radio (Cab) Left wiper switch (Cab) Front wiper switch (Cab) Right wiper switch (Cab) Rear wiper switch (Cab) Lamp switch (Cab) Right door wiper motor (Cab) Left door wiper motor (Cab) Intermediate connector (Window washer) Cab power supply Cab unswitched power supply Cigarette lighter (Cab) Rotary lamp outlet connector (Cab) Rotary lamp switch (Cab) Room lamp (Cab) Intermediate connector (Bulkhead wiring harness) Intermediate connector (Bulkhead wiring harness) Intermediate connector (Yoke angle sensor) Right headlamp Left headlamp Left headlamp Right headlamp Intermediate connector (Small hood) Caution buzzer Left working lamp Ripper point lamp (If equipped) Left rear working lamp Intermediate connector (Right fender) Right working lamp Right rear working lamp Pin puller solenoid Starting switch (Terminal B) Starting switch (Terminal R1) Starting switch (Terminal R2) Starting switch (Terminal BR) Intermediate connector (Horn switch) Pin puller switch Horn switch Horn switch Starting switch (Terminal ACC) Starting switch (Terminal C) Washing tank motor Washing tank motor Fuel level gauge Torque converter oil temperature sensor Intermediate connector (Left fender) Lockup solenoid Intermediate connector (Spare power supply 1) Intermediate connector (Spare power supply 2) Spare power supply 1 Spare power supply 2 Accessory socket Accessory socket Intermediate connector (Cab) Air conditioner compressor Intermediate connector (Air conditioner) Intermediate connector (Air conditioner) Air conditioner external air sensor ACC cut relay Air conditioner unit Additional heater switch Air cleaner clogging sensor Air cleaner clogging sensor Alternator (Terminal B) Alternator (Terminal R) Air conditioner control panel Air conditioner control panel Air conditioner unit Air conditioner unit Air conditioner unit Auto shift-down switch Intermediate connector (Air suspension seat) Circuit breaker (30 A) Circuit breaker (30 A) Circuit breaker (30 A) Circuit breaker (30 A) Circuit breaker (30 A) Circuit breaker (105 A) Circuit breaker (105 A) Circuit breaker (105 A) Circuit breaker (105 A) Circuit breaker (105 A) Backup alarm relay Blade lower oil pressure switch Air conditioner additional blower Additional blower motor switch Blade raise oil pressure switch Battery relay (Right) (Terminal B) Battery relay (Left) (Terminal B) Battery relay (Right) (Terminal M) Battery relay (Left) (Terminal M)
The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles, 12 poles) are as follows. DT-A = Gray, DT-B = Black, DT-C = Green, DT-D = Brown
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D475a Bulldozer

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SEN00203-04

-5E0 D475A D475ASD -5E0

D475A30001 and up D475ASD- 30001

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Composition of shop manual

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D475A, D475ASD-5E0 Bulldozer Form No. SEN00205-04

2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)

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6 Safety check before starting work 7 8

9 Good physical condition and preparation 10

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13) 14) 15)

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Example of O-ring (Fitted to every joint of hoses and tubes)

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How to read the shop manual

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Explanation of terms for maintenance standard

Example: Standard size 120 a

Tolerance 0.022 0.126

Example: Standard size 60 Tolerance Shaft Hole 0.030 +0.046 0.076 +0

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Handling of electric equipment and hydraulic component

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Connection (Example of incomplete setting of (a))

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Handling of connectors newly used for engines

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How to read electric wire code

Heat-resistant low-voltAEX age wire for automobile