D475A 5E0 Workshop

SEN00203-16
BULLDOZER
-5E0
D475A
D475ASD -5E0
SERIAL NUMBERS
D475A30001
and up
D475ASD- 30001
SEN00205-16
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
00 Index and foreword
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
D475A, D475ASD-5E0
SEN00205-16
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
Form Number
Shop Manual, contents binder, binder label and tabs ............................................................ SEN00203-16
00 Index and foreword ......................................................................................................... SEN00204-16
Index ............................................................................................................................... SEN00205-16 q
Foreword and general information .................................................................................. SEN00206-05
01 Specification.................................................................................................................... SEN00207-01
Specification and technical data...................................................................................... SEN00208-01
10 Structure, function and maintenance standard ............................................................... SEN00209-03
Engine and cooling system ............................................................................................. SEN00210-00
Power train, Part 1 ...........................................................................................................SEN00211-01
Power train, Part 2 .......................................................................................................... SEN00212-02
Undercarriage and frame ................................................................................................ SEN00213-01
Hydraulic system, Part 1 ................................................................................................. SEN00214-00
Work equipment.............................................................................................................. SEN00217-00
Cab and its attachments ................................................................................................. SEN00218-00
Electrical system ............................................................................................................. SEN00219-02
20 Standard value table ....................................................................................................... SEN00220-01
Standard service value table........................................................................................... SEN01816-01
30 Testing and adjusting ...................................................................................................... SEN00221-06
Testing and adjusting, Part 1........................................................................................... SEN01817-03
40 Troubleshooting .............................................................................................................. SEN00222-05
Failure code table and fuse locations ............................................................................. SEN01821-04
General information on troubleshooting.......................................................................... SEN01822-03
Troubleshooting by failure code, Part 1 .......................................................................... SEN01823-02
D475A, D475ASD-5E0
SEN00205-16

Troubleshooting by failure code (Display of code), Part 7 .............................................. SEN01829-02
Troubleshooting of electrical system (E-mode)............................................................... SEN01831-02
Troubleshooting of hydraulic and mechanical system (H-mode) .................................... SEN01832-02
Troubleshooting of engine (S-mode) .............................................................................. SEN01833-01
50 Disassembly and assembly ............................................................................................ SEN00223-08
General information on disassembly and assembly ....................................................... SEN02013-06 q
Engine and cooling system (SAA12V140E-3) ................................................................ SEN02014-01
Engine (SAA12V140E-3) ................................................................................................ SEN02338-03
Power train, Part 1 .......................................................................................................... SEN02015-01 q
Power train, Part 2 .......................................................................................................... SEN02016-03 q
Undercarriage and frame, Part 1 .................................................................................... SEN02017-03
Hydraulic system ............................................................................................................ SEN02019-01
Electrical system............................................................................................................. SEN02339-02
90 Diagrams and drawings .................................................................................................. SEN00224-03
Hydraulic diagrams and drawings................................................................................... SEN00225-00
Electrical diagrams and drawings ................................................................................... SEN00226-03
D475A, D475ASD-5E0
SEN00205-16
Table of contents

Index ............................................................................................................................... SEN00205-16
Composition of shop manual ...................................................................................................
2
Table of contents......................................................................................................................
4
Foreword and general information .................................................................................. SEN00206-05
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
Radiator and oil cooler.............................................................................................................
2
Engine mount...........................................................................................................................
3
Cooling fan pump.....................................................................................................................
4
Cooling fan motor .................................................................................................................... 26
Power train, Part 1 ...........................................................................................................SEN00211-01
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
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
SEN00205-16
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
Work equipment hydraulic equipment arrangement diagram ..................................................
2
PPC control piping diagram.....................................................................................................
6
Work equipment control...........................................................................................................
8
Work equipment pump ............................................................................................................ 10
PPC valve................................................................................................................................ 27
PCCS lever.............................................................................................................................. 38
Control valve............................................................................................................................
2
CLSS ....................................................................................................................................... 17
Unload valve............................................................................................................................ 20
Introduction of LS pressure ..................................................................................................... 21
LS bypass plug ........................................................................................................................ 22
Pressure compensation valve ................................................................................................. 23
Blade lift valve ......................................................................................................................... 26
Merge-divider valve ................................................................................................................. 34
Self pressure reducing valve ................................................................................................... 36
Pilot solenoid valve.................................................................................................................. 40
Hydraulic tank, hydraulic filter..................................................................................................
2
Accumulator.............................................................................................................................
4
Work equipment cylinder .........................................................................................................
6
Piston valve .............................................................................................................................
8
Quick drop valve...................................................................................................................... 10
Blade control knob (Dual tilt specification)............................................................................... 12
Blade control knob (Superdozer specification) ........................................................................ 13
Pitch and dual solenoid valve .................................................................................................. 14
Pin puller hydraulic circuit diagram .......................................................................................... 15
Pin puller solenoid valve.......................................................................................................... 16
Cylinder stay ............................................................................................................................
2
Blade .......................................................................................................................................
4
Ripper equipment ....................................................................................................................
8
Cab mount ...............................................................................................................................
2
Cab ..........................................................................................................................................
3
Air conditioner..........................................................................................................................
6
Electrical system............................................................................................................. SEN00219-02
Engine control system .............................................................................................................
2
CRI engine control system ......................................................................................................
6
Monitor system ........................................................................................................................ 10
Machine monitor ...................................................................................................................... 12
Mode selection system ............................................................................................................ 30
Electrical equipment ................................................................................................................ 34
Palm command control system (PCCS) .................................................................................. 36
Sensors ................................................................................................................................... 38
Vehicle health monitoring system (VHMS) .............................................................................. 45
D475A, D475ASD-5E0
SEN00205-16
ORBCOMM terminal................................................................................................................ 51
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
Tools for testing, adjusting, and troubleshooting......................................................................
3
Measuring engine speed ......................................................................................................... 6
Measuring intake air pressure (boost pressure) ...................................................................... 10
Measuring exhaust temperature .............................................................................................. 12
Measuring exhaust gas color................................................................................................... 14
Adjusting valve clearance ........................................................................................................ 16
Testing compression pressure ................................................................................................. 18
Measuring blow-by pressure.................................................................................................... 20
Measuring engine oil pressure................................................................................................. 22
Handling of fuel system devices .............................................................................................. 23
Releasing residual pressure from fuel system......................................................................... 23
Testing fuel pressure................................................................................................................ 24
Handling of reduced cylinder mode operation ......................................................................... 25
Handling of no injection cranking operation............................................................................. 25
Testing fuel return and leak amount......................................................................................... 26
Bleeding air from fuel circuit .................................................................................................... 29
Bleeding air from fuel circuit (Low-grade fuel specification) .................................................... 31
Testing fuel circuit for leakage ................................................................................................. 33
Testing and adjusting alternator belt tension ........................................................................... 34
Testing and adjusting belt tension for air conditioner compressor ........................................... 35
Adjusting fuel control dial and decelerator pedal ..................................................................... 36
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
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
D475A, D475ASD-5E0
SEN00205-16
Testing and adjusting operator's seat isolator.......................................................................... 61

Testing and adjusting, Part 3 .......................................................................................... SEN01819-04
Special functions of monitor panel (EMMS).............................................................................
2
Testing and adjusting, Part 4 .......................................................................................... SEN01820-03
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 ............................................................................. SEN01821-04
Failure code table ....................................................................................................................
2
Fuse locations ......................................................................................................................... 12
General information on troubleshooting.......................................................................... SEN01822-03
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 ............................................................................. 46
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
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
D475A, D475ASD-5E0
SEN00205-16
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
Failure code [CA111] Engine controller (Left bank): Internal abnormality................................
4
Failure code [CB111] Engine controller (Right bank): Internal abnormality .............................
6
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank):
Abnormal speed sensor signal.............................................................................................
8
Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank):
Abnormal speed sensor signal.............................................................................................
9
Failure code [CA122] Charge pressure sensor too high (At left bank only):
Excessively high voltage detected ....................................................................................... 10
Failure code [CA123] Charge pressure sensor too low (At left bank only):
Excessively low voltage detected......................................................................................... 12
Failure code [CA131] Decelerator pedal sensor abnormally high level (Only left bank):
High voltage detection.......................................................................................................... 13
Failure code [CA132] Decelerator pedal sensor too low (At left bank only):
Failure code [CA135] Oil pressure sensor too high (At left bank only):
Failure code [CA141] Oil pressure sensor too low (At left bank only):
Failure code [CA144] Coolant temperature sensor too high:
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Failure code [CA154] Charge temperature sensor too low (At left bank only):
Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank):
Low voltage detection .......................................................................................................... 28
Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank):
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank):
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank):
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Failure code [CA227] Sensor power source (2) too high (At left bank):
Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank):
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed............ 40
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
D475A, D475ASD-5E0
SEN00205-16
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):
Failure code [CB263] Fuel temperature sensor too high (At right bank):
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit .......................................... 50
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ....................................... 51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection................................... 52
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection ................................ 53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit .......................................... 54
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ....................................... 55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection................................... 56
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection ................................ 57
Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit
(At left bank): Disconnection, short circuit............................................................................
4
6
8
(At left bank): Disconnection, short circuit............................................................................ 10
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 [CA386] Sensor power supply (1) abnormally high level (Left bank):
High voltage detection ......................................................................................................... 24
Failure code [CA441] Power supply voltage abnormally low level (Left bank):
Failure code [CB441] Power supply voltage abnormally low level (Right bank):
Failure code [CA442] Power supply voltage abnormally high level (Left bank):
Failure code [CB442] Power supply voltage abnormally high level (Right bank):
Failure code [CA449] Common rail abnormally high pressure (2) (Left bank):
Abnormally high pressure occurrence ................................................................................. 30
Failure code [CB449] Common rail abnormally high pressure (2) (Right bank):
Abnormally high pressure occurrence ................................................................................. 30
Failure code [CA451] Common rail pressure sensor too high (At left bank):
D475A, D475ASD-5E0
SEN00205-16
Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank):
Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank):
Abnormally low voltage detection......................................................................................... 36
Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank):
Abnormally low voltage detection......................................................................................... 36
Failure code [CA553] Common rail pressure too high (1) (At left bank):
Excessively high pressure detected..................................................................................... 37
Failure code [CB553] Common rail pressure too high (1) (At right bank):
Excessively high pressure detected..................................................................................... 38
Failure code [CA554] In-range error in common rail pressure sensor (At left bank):
In-range error ....................................................................................................................... 39
Failure code [CB554] In-range error in common rail pressure sensor (At right bank):
In-range error ....................................................................................................................... 39
Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank):
Loss of pressure feed detected............................................................................................ 40
Loss of pressure feed detected (Low-grade fuel specification)............................................ 44
Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank):
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal ..... 52
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal ... 54
Failure code [CA691] Intake air temperature sensor abnormally high level
(Only left bank): High voltage detection ............................................................................... 56
Failure code [CA692] Intake air temperature sensor abnormally low level
(Only left bank): Low voltage detection ................................................................................ 58
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank):
Abnormal phase ................................................................................................................... 59
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank):
Abnormal phase ................................................................................................................... 59
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 [CA1633] KOMNET abnormality (Left bank): Communication error ................... 26
10
D475A, D475ASD-5E0
SEN00205-16
Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level
(Only left bank): High voltage detection ............................................................................... 28
Failure code [CA2186] Decelerator pedal sensor power source too low
(At left bank only): Excessively low voltage detected........................................................... 30
Failure code [D110KA] Battery relay: Disconnection ............................................................... 32
Failure code [D110KB] Battery relay: Short circuit .................................................................. 34
Failure code [D130KA] Neutral safety relay: Disconnection.................................................... 36
Failure code [D130KB] Neutral safety relay: Short circuit ....................................................... 38
Failure code [D161KA] Back-up alarm relay: Disconnection ................................................... 40
Failure code [D161KB] Back-up alarm relay: Short circuit ...................................................... 42
Failure code [D182KZ] Preheater relay: Disconnection or short circuit ................................... 44
Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection ................. 46
Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit ..................... 48
Failure code [D5ZRKA] Snap shot switch: Disconnection....................................................... 50
Failure code [D5ZRKB] Snap shot switch: Short circuit .......................................................... 51
Failure code [DAFRKR] Monitor panel CAN communication: Communication error ............... 52
Failure code [dAFRKR] Monitor panel CAN communication: Communication error................ 54
Failure code [daFRKR] Monitor panel CAN communication: Communication error ................ 56
Failure code [DAQ0KT] Transmission controller: Abnormality in controller............................. 58
Failure code [DAQ1KK] Transmission controller main power supply:
Power supply voltage reduction (Input)................................................................................ 60
Failure code [DAQ2KK] Transmission controller load power supply:
Failure code [DAQ5KK] Transmission controller potentiometer power supply:
Source voltage reduction (input) .......................................................................................... 64
Failure code [DAQ6KK] Transmission controller sensor power supply:
Failure code [DAQ9KQ] Transmission controller type collation:
Type select signal inconsistency.......................................................................................... 67
Failure code [DAQRKR] Transmission controller sensor CAN communication:
Communication error (Objective component system abnormality) ...................................... 68
Failure code [DAQSKR] Transmission controller S-NET communication:
Defective communication (Abnormality in objective component system) ............................ 70
Failure code [DB2RKR] Engine controller (Left bank) CAN communication:
Communication error ...........................................................................................................
4
Failure code [dB2RKR] Engine controller (Left bank) CAN communication:
6
Failure code [db2RKR] Engine controller (Right bank) CAN communication:
8
Failure code [DB30KT] Steering controller: Abnormality in controller...................................... 10
Failure code [DB31KK] Steering controller main power supply:
Failure code [DB32KK] Steering controller load power supply:
Failure code [DB35KK] Steering controller potentiometer power supply:
Failure code [DB36KK] Steering controller sensor power supply:
D475A, D475ASD-5E0
11
SEN00205-16
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
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
VHMS sensor power supply (24 V): Lowering of output voltage.......................................... 30
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
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 ....................................................................................... 17
12
D475A, D475ASD-5E0
SEN00205-16
Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front):
Disconnection (or LED of VHMS controller indicates "n3" o "12") ...................................... 18
Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear):
Disconnection (or LED of VHMS controller indicates "n3" o "22") ...................................... 20
Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front):
Short circuit (or LED of VHMS controller indicates "n3" o "11") .......................................... 22
Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" o "21")
Left bank exhaust temperature sensor system (Rear): Short circuit .................................... 24
Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o "24")
Right bank exhaust temperature sensor system (Front): Disconnection ............................. 26
Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o "26")
Right bank exhaust temperature sensor system (Rear): Disconnection.............................. 28
Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o "23")
Right bank exhaust temperature sensor system (Front): Short circuit................................. 30
Right bank exhaust temperature sensor system (Rear): Short circuit ................................. 32
Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection ......... 34
Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit............. 35
Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection......... 36
Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit ............ 37
Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o "32")
Blow-by pressure sensor system: Disconnection ................................................................ 38
Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o "31")
Blow-by pressure sensor system: Hot short ........................................................................ 39
Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o "14")
Transmission oil pressure sensor: Out of input signal range ............................................... 40
Failure code [DK01KA] Left yoke angle sensor: Disconnection .............................................. 41
Failure code [DK01KB] Left yoke angle sensor: Short circuit .................................................. 42
Failure code [DK03KA] Right yoke angle sensor: Disconnection ............................................ 43
Failure code [DK03KB] Right yoke angle sensor: Short circuit ............................................... 44
Failure code [DK10KA] Fuel dial: Disconnection ..................................................................... 45
Failure code [DK10KB] Fuel dial: Short circuit ........................................................................ 46
Failure code [DK30KA] Steering potentiometer (1): Disconnection......................................... 48
Failure code [DK30KB] Steering potentiometer (1): Short circuit ............................................ 50
Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range ......... 52
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 ............................................ 56
3
Failure code [DK40KA] Brake potentiometer: Disconnection ..................................................
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
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
D475A, D475ASD-5E0
13
SEN00205-16
Failure code [DV00KB] Caution buzzer: Short circuit .............................................................. 27

Failure code [DW55KA] Blade pitch back solenoid: Disconnection......................................... 28
Failure code [DW55KB] Blade pitch back solenoid: Short circuit ............................................ 29
Failure code [DW56KA] Blade pitch dump solenoid: Disconnection ....................................... 30
Failure code [DW56KB] Blade pitch dump solenoid: Short circuit ........................................... 31
Failure code [DW56KY] Blade pitch dump solenoid: Hot short ............................................... 32
Failure code [DW57KA] Left tilt limit solenoid: Disconnection ................................................. 33
Failure code [DW57KB] Left tilt limit solenoid: Short circuit ..................................................... 34
Failure code [DW57KY] Left tilt limit solenoid: Hot short ......................................................... 35
Failure code [DW58KA] Right tilt limit solenoid: Disconnection............................................... 36
Failure code [DW58KB] Right tilt limit solenoid: Short circuit .................................................. 37
Failure code [DW58KY] Right tilt limit solenoid: Hot short....................................................... 38
Failure code [DW59KA] Dual tilt selector solenoid: Disconnection.......................................... 39
Failure code [DW59KB] Dual tilt selector solenoid: Short circuit ............................................. 40
Failure code [DW59KY] Dual tilt selector solenoid: Hot short.................................................. 41
Failure code [DW5AKA] Blade pitch selector solenoid: Disconnection ................................... 42
Failure code [DW5AKB] Blade pitch selector solenoid: Short circuit ....................................... 43
Failure code [DW5AKY] Blade pitch selector solenoid: Hot short ........................................... 44
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer specification):
Disconnection....................................................................................................................... 45
Failure code [DW5DKB] Blade pitch selector solenoid (Superdozer specification):
Short circuit .......................................................................................................................... 46
Failure code [DW5DKY] Blade pitch selector solenoid (Superdozer specification):
Hot short............................................................................................................................... 47
Failure code [DW7BKA] Fan reverse solenoid: Disconnection................................................ 48
Failure code [DW7BKB] Fan reverse solenoid: Short circuit ................................................... 49
Failure code [DW7BKY] Fan reverse solenoid: Hot short........................................................ 50
Failure code [DWJ0KA] Pump merge-divider solenoid: Disconnection ................................... 51
Failure code [DWJ0KB] Pump merge-divider solenoid: Short circuit....................................... 52
Failure code [DWJ0KY] Pump merge-divider solenoid: Hot short ........................................... 53
Failure code [DWN3KA] Sudden stop prevention solenoid: Disconnection............................. 54
Failure code [DWN3KB] Sudden stop prevention solenoid: Short circuit ................................ 55
Failure code [DWN3KY] Sudden stop prevention solenoid: Hot short..................................... 56
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection ............................................... 57
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit ................................................... 58
Failure code [DWN5KY] Fan pump solenoid 1: Hot short ....................................................... 59
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection............................................... 60
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit .................................................. 61
Failure code [DWNCKY] Fan pump solenoid 2: Hot short....................................................... 62
Failure code [DXE0KA] LS set solenoid: Disconnection..........................................................
3
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
7
Failure code [DXH1KB] Lock-up solenoid: Short circuit ..........................................................
Failure code [DXH1KY] Lockup solenoid: Hot short ................................................................
8
Failure code [DXH4KA] 1st clutch ECMV: Disconnection........................................................
9
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ........................................................... 10
Failure code [DXH4KY] 1st clutch ECMV: Hot short................................................................ 11
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ...................................................... 12
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit .......................................................... 13
Failure code [DXH5KY] 2nd clutch ECMV: Hot short .............................................................. 14
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ....................................................... 15
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit........................................................... 16
Failure code [DXH6KY] 3rd clutch ECMV: Hot short ............................................................... 17
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection ............................................... 18
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit................................................... 19
Failure code [DXH7KY] Reverse clutch ECMV: Hot short ....................................................... 20
14
D475A, D475ASD-5E0
SEN00205-16
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)............................................................... SEN01831-02
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
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.................................... 30
E-15 Indication of the fuel gauge is abnormal ......................................................................... 31
E-16 Indications of gear speed and engine speed are abnormal ............................................ 32
E-17 Indication of the shift mode service meter is abnormal ................................................... 32
E-18 The switch module cannot be operated .......................................................................... 33
E-19 The warning lamp does not flash or does not go out ...................................................... 34
E-20 The alarm buzzer does not sound or does not stop........................................................ 35
D475A, D475ASD-5E0
15
SEN00205-16
E-21 Auto shift down is not possible or is not released ........................................................... 36

E-22 The automatic pitch back system does not operate (only superdozer specification) ...... 37
E-23 The alarm buzzer cannot be cancelled ........................................................................... 38
E-24 The operator mode cannot be operated.......................................................................... 39
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) .................................... SEN01832-02
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
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or
engine overheats) ........................................................................................................... 26
H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with
operator's seat isolator)................................................................................................... 27
Troubleshooting of engine (S-mode)............................................................................... SEN01833-01
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
16
D475A, D475ASD-5E0
SEN00205-16
S-15 Abnormal noise is made ................................................................................................. 23

S-16 Vibration is excessive ..................................................................................................... 24
50 Disassembly and assembly
General information on disassembly and assembly ....................................................... SEN02013-06
How to read this manual..........................................................................................................
2
Coating materials list ...............................................................................................................
4
Special tools list .......................................................................................................................
7
Sketches of special tools ......................................................................................................... 14
Engine and cooling system (SAA12V140E-3) ................................................................ SEN02014-01
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) ................................................................................................ SEN02338-03
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
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......................................................................... 24
Removal and installation of TORQFLOW transmission assembly .......................................... 31
Disassembly and assembly of TORQFLOW transmission assembly ...................................... 32
Disassembly and assembly of steering case assembly ..........................................................
2
Disassembly and assembly of steering clutch, brake assembly.............................................. 15
Disassembly and assembly of transfer gear housing assembly.............................................. 23
Removal and installation of power train pump assembly ........................................................ 27
Removal and installation of scavenging pump assembly ........................................................ 27
Removal and installation of torque converter oil cooler ........................................................... 28
Removal and installation of torque converter valve assembly................................................. 29
Disassembly and assembly of torque converter valve assembly ............................................ 30
Removal and installation of transmission control valve assembly ........................................... 34
Disassembly and assembly of transmission control valve assembly (ECMV assembly) ........ 35
Removal and installation of steering control valve assembly .................................................. 38
Disassembly and assembly of steering control valve assembly .............................................. 39
Removal and installation of final drive assembly ..................................................................... 41
Disassembly and assembly of final drive assembly ................................................................ 43
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
D475A, D475ASD-5E0
17
SEN00205-16
Removal and installation of bogie assembly............................................................................ 21

Disassembly and assembly of bogie assembly ....................................................................... 25
Removal and installation of No.1 bogie assembly ................................................................... 27
Removal and installation of operator's seat isolator ................................................................ 32
Disassembly and assembly of operator's seat isolator ............................................................ 33
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............................................................................................................. SEN02019-01
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
Removal and installation of blade assembly............................................................................
2
Disassembly and assembly of giant ripper assembly ..............................................................
4
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 ............................................................................................................. SEN02339-02
Removal and installation of controller assembly......................................................................
2
Removal and installation of engine controller assembly (left)..................................................
3
Removal and installation of air conditioner condenser assembly ............................................
4
Removal and installation of air conditioner compressor assembly ..........................................
5
Removal and installation of air conditioner unit .......................................................................
7
90 Diagrams and drawings
Hydraulic diagrams and drawings................................................................................... SEN00225-00
Power train hydraulic circuit diagram.......................................................................................
3
Hydraulic circuit diagram (1/3) .................................................................................................
5
7
9
Electrical diagrams and drawings ................................................................................... SEN00226-03
Electrical circuit diagram (1/13) ...............................................................................................
3
5
7
9
Electrical circuit diagram (5/13) ............................................................................................... 11
Electrical circuit diagram (10/13) ............................................................................................. 21
Electrical circuit diagram (11/13).............................................................................................. 23
Electrical circuit diagram of inside cab..................................................................................... 29
Connector arrangement diagram............................................................................................. 31
18
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00205-16
19
SEN00205-16
D475A, D475ASD-5E0 Bulldozer

Form No. SEN00205-16
2013 KOMATSU
All Rights Reserved
Printed in Japan 01-13(02)
20
SEN00206-05
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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, D475ASD-5E0
SEN00206-05
Safety notice
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. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels 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)
8)
9)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
w elding work, alw ays wear welding
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.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.
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
6 Safety check before starting work

7
Wearing protective goggles

(for cleaning or grinding work)
Wearing shielding goggles and protectors

(for welding work)
9 Good physical condition and preparation

10
Precautions against work which you are

not used to or you are used to too much
D475A, D475ASD-5E0
2.
3.
Preparations for work

1) Before adding oil or making any repairs,
park the machine on a 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.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) 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.
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) For the machine equipped with a battery disconnct switch, turn the battery
disconnect switch to the OFF (O) position and pull the switch key out, before
starting the work. For machines without
a battery disconnct switch, remove the
cable from the battery , before starting the
work. Always remove the cable from the
negative (-) terminal first.
D475A, D475ASD-5E0
SEN00206-05
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.
8) 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.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
10) 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.
11) 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.
SEN00206-05
12) 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 ar l y c a r e f u l t o c h e c k t h a t t h e y a r e
installed correctly.
13) When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
14) When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
15) 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.
16) 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.
4.
Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
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}.
8)
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.
D475A, D475ASD-5E0
SEN00206-05
6.
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.
q
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.
5.
Precautions for using mobile crane

a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
D475A, D475ASD-5E0
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.
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.
SEN00206-05
7.
Selecting wire ropes

1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
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
8.
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,
VA L E O T H E R M A L S Y S T E M S :
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".
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.
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 gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
D475A, D475ASD-5E0
How to read the shop manual

q
q
q
1.
SEN00206-05
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.
2.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
D475A, D475ASD-5E0
SEN00206-05
3.
4.
Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q
Revised edition mark

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

selecting hoisting wire, or when working posture is important, etc.
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
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.
5.
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 { }.
D475A, D475ASD-5E0
SEN00206-05
Explanation of terms for maintenance standard
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1.
Standard size and tolerance

q
To be accurate, the finishing size of parts
is a little different from one to another.
q
To specify a finishing size of a part, a 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.
Example:
Standard size
120
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
D475A, D475ASD-5E0
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN00206-05
2.
Standard clearance and standard value

q
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.
3.
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.
4.
Repair limit and allowable value or allowable dimension

q
The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q
If a part is worn to the repair limit, it must
be replaced or repaired.
q
The performance and function of a product lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
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.
10
5.
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.
q
6.
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.
q
D475A, D475ASD-5E0
Handling of electric equipment and hydraulic component
SEN00206-05
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.
D475A, D475ASD-5E0
11
SEN00206-05
12
3)
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.
4)
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.
5)
Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating 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.
D475A, D475ASD-5E0
3.
SEN00206-05
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]
q
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.
3]
Action to take after removing connectors

After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
D475A, D475ASD-5E0
13
SEN00206-05
2)
14
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.
D475A, D475ASD-5E0
3)
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
D475A, D475ASD-5E0
SEN00206-05
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN00206-05
4)
16
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
oil and water from the compressed 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.
D475A, D475ASD-5E0
4.
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.
5.
Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
D475A, D475ASD-5E0
SEN00206-05
17
SEN00206-05
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1.
Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2.
Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.
3.
Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4.
Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil 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.
18
D475A, D475ASD-5E0
5.
Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6.
Flushing operations
After disassembling and assembling the 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.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil 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.
D475A, D475ASD-5E0
SEN00206-05
19
SEN00206-05
Handling of connectors newly used for engines

a
1.
Mainly, following engines are object for following connectors.

q
95E-5
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
95 170, 12V140 engines
q
Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE
(95 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
2.
Pull lock type (PACKARD-2)

95 170, 12V140 engines
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.
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.
20
D475A, D475ASD-5E0
3.
SEN00206-05
Push lock type

q
95, 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 engines

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

(4) in the direction of the arrow.
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.
D475A, D475ASD-5E0
21
SEN00206-05
4)
95, 125 170, 12V140 engines

While pressing lock (E) of the connector,
pull out connector (5) in the direction of
the arrow.
Example)
Fuel pressure sensor 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.
1)
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.
2)
Connect the connector according to the

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)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22
D475A, D475ASD-5E0
SEN00206-05
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
AVS
Heat-resistant low-voltAEX
age wire for
automobile
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
D475A, D475ASD-5E0
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
23
SEN00206-05
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
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
24
D475A, D475ASD-5E0
3.
SEN00206-05
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
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
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 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
D475A, D475ASD-5E0
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
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
25
SEN00206-05
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)
26
Sleeve nut (elbow end)
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
Split flange type hoses and tubes

Nominal
number
04
05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
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
07049-02734
27
22.5
34
D475A, D475ASD-5E0
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN00206-05
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.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
D475A, D475ASD-5E0
27
SEN00206-05
4)
5)
28
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.
D475A, D475ASD-5E0
SEN00206-05
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.
D475A, D475ASD-5E0
29
SEN00206-05
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
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
D475A, D475ASD-5E0
SEN00206-05
Type 3
1.
Disconnection
1) Hold the tightening portion and push body
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)
D475A, D475ASD-5E0
31
SEN00206-05
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.
a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt

mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a
Tightening torque
Nm
11.8 14.7
27 34
59 74
98 123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,520 1,910
1,960 2,450
2,450 3,040
2,890 3,630
kgm
1.2 1.5
2.8 3.5
6.0 7.5
10.0 12.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155 195
200 250
250 310
295 370
The following table applies to the bolts in Fig. B.

mm
6
8
10
12
a Fig. A
Width across flats

mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
Width across flats

mm
10
12
14
17
Tightening torque
Nm
kgm
5.9 9.8
0.6 1.0
13.7 23.5
1.4 2.4
34.3 46.1
3.5 4.7
74.5 90.2
7.6 9.2
a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32
D475A, D475ASD-5E0
2.
Table of tightening torques for split flange bolts

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

mm
10
12
16
3.
Width across flats

mm
14
17
22
Tightening torque
Nm
59 74
98 123
235 285
kgm
6.0 7.5
10.0 12.5
23.5 29.5
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.
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN00206-05
Thread diameter
mm
14
20
24
33
42
Width across flats

mm
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
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
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
D475A, D475ASD-5E0
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

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}
33
SEN00206-05
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.
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
6.
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}
Taper seal
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
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
Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer
diameter
of pipe
(mm)
Width
across
flats
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36

Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
1-3/16-12UN
30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
34
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
D475A, D475ASD-5E0
8.
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
9.
SEN00206-05
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
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.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
D475A, D475ASD-5E0
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
35
SEN00206-05
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.
2.
Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
36
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
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
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
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
D475A, D475ASD-5E0
SEN00206-05
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
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
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
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
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
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
Liters to U.S. Gallons
0
10
20
30
40
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
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
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
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
13.473
16.115
18.756
21.398
24.040
D475A, D475ASD-5E0
13.737
16.379
19.020
21.662
24.304
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
37
SEN00206-05
Liters to U.K. Gallons
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
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
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
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
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
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
100
110
120
130
140
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
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
38
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
D475A, D475ASD-5E0
SEN00206-05
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
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
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
D475A, D475ASD-5E0
39
SEN00206-05
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
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
40
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00206-05
41
SEN00206-05

2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
42
SEN00208-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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
Item
Unit
Semi-U tiltdozer
+ giant ripper
Full-U tiltdozer
+ giant ripper
Superdozer +
counterweight
Overall length
mm
11,565
12,065
10,525
Overall height (including ROPS)
mm
4,646
4,646
4,646
Overall width
mm
5,265
6,205
6,465
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Specifications
Semi-U tiltdozer and full-U tiltdozer specifications

Machine model
D475A-5E0
Serial Number
30001 and up
Weight
Machine weight
Tractor
83,510
Above + Semi-U tiltdozer
100,010
Above + Variable giant ripper
107,370
Above + ROPS cab + Air conditioner
108,310
m
4.6
Gradeability
deg.
30
Stability (Front, Rear, Left, Right)
deg.
35
Forward
1st
3rd
0 10.9
Reverse
Gear
speeds
Min. turning radius
Performance
kg
1st
0 4.7
2nd
2nd
0 3.5
km/h
0 6.3
km/h
0 8.4
3rd
0 14.3
127.5 {1.30}
Ground
pressure
Tractor
152.7 {1.56}
Semi-U dozer
Semi-U dozer + Variable giant ripper
kPa {kg/cm }
163.9 {1.67}
165.3 {1.69}
Above + ROPS cab + Air conditioner

+ Perforated side cover
6,680
Overall
width
Overall
height
Dimensions
Overall
length
Tractor
Semi-U dozer
Semi-U dozer + Variable giant ripper
mm
8,705
11,565
Full-U dozer + Variable giant ripper
12,065
Tractor
3,620
Semi-U dozer
mm
5,265
Full-U dozer
6,205
Up to ROPS top
4,646
Up to exhaust pipe end
mm
Up to exhaust duct top
3,861
2,770
Track gauge
Length of track on ground
Track shoe width
Minimum ground clearance
D475A, D475ASD-5E0
4,546
mm
4,524
710
711
SEN00208-01
01 Specification
Machine model
D475A-5E0
Serial Number
30001 and up
mm
l {cc}
Komatsu SAA12V140E-3
4-cycle, water-cooled, V-type, direct-injection
engine with turbocharger and aftercooler
12140 x 165
30.48 {30,480}
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
rpm
rpm
g/kWh {g/HPh}
664/2,000 {890/2,000}
3,825/1,400 {390/1,400}
2,150
600
215 {160}
Model name
Type
Performance
Engine
Number of cylinderBore x Stroke

Total displacement
Rated output
Max. torque
High idle
Low idle
Min. fuel consumption ratio
(at rated output)
Starting motor
Alternator
Battery
Type of radiator core
Torque converter
Power train
Transmission
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
Steering clutch
Wet, multiple disc clutch, spring-actuated,

hydraulic (hand-operated) type
interlocked with brake
Steering brake

hydraulic (foot/hand-operated) type
Type of suspension
Undercarriage
D-type
Bevel gear shaft
Final drive
1-stage spur gear and 1-stage planetary

gear, splash lubrication type
Hard, equalizing beam type
Carrier roller
2 pieces on each side
Track roller
Track shoe
Assembly type single grouser shoe,

41 pieces on each side,
Pitch: 317.5 mm, Width: 710 mm
Power train + Lubricating oil pump (Tandem)

Scavenging pump (Tandem)
24 V, 7.5 kW x 2
24 V, 100 A
12V, 220 Ah x 4
Gear type (BAL 160 + 160 + 112)

Gear (BAR 63 + 320)
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Machine model
D475A-5E0
Serial Number
30001 and up
Work equipment
pump
Max. pressure
MPa {kg/cm2}
Type
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 }
Max. discharge pressure: 17.5 {178}
l/min/rpm
Theoretical discharge pressure: 178/1,934
Work equipment
valve
MPa {kg/cm }
Max. using pressure: 17.5 {178}
Type
For blade lift
6-spool type: 1 pc.
For blade tilt
Hydraulic
For ripper lift
For ripper tilt
Dimensions of
blade tilt cylinder
Dimensions of
blade lift cylinder
Type
Hydraulic
cylinders
Work equipment hydraulic system
Fixed swash plate type (LMF 180)

Cooling fan motor
Double acting piston

Bore of cylinder
180
Outside diameter of piston rod
110
Stroke of piston
mm
1,925
Max. distance between pins
3,155
Min. distance between pins
1,230
Bore of cylinder
250
140
Stroke of piston
mm
293
1,988
1,695
D475A, D475ASD-5E0
Machine model
D475A-5E0
Serial Number
30001 and up
Bore of cylinder
(Both of right and left)
Stroke of piston
250
mm
293
1,988
1,695
225
120
Bore of cylinder
Bore of cylinder
225
140
Stroke of piston
mm
645
2,175
1,530
Stroke of piston
mm
540
2,020
1,480
Hydraulic tank
140
Dimensions of
ripper lift cylinder
Dimensions of blade
dual tilt cylinder
01 Specification
Dimensions of
ripper tilt cylinder
Hydraulic cylinders
SEN00208-01
Box type (External control valve type)
D475A, D475ASD-5E0
01 Specification
Machine model
D475A-5E0
Serial Number
30001 and up
Performance
Dimensions
Performance
Dimensions
Width of blade
Height of blade
Angle of blade cutting edge
Performance
Max. tilting distance

Max. pitch angle
Max. pitch back angle

Max. pitch angle
Max. digging depth

Max. lift
Digging angle (Standard)
Performance
Dimensions
Full-U dozer
Giant ripper
Dimensions
Max. lift above ground

Max. drop below ground
Changing range of blade
cutting edge angle
Capacity of blade
Semi-U dozer
Width of blade
Height of blade
Performance
Brace type (Right tilt cylinder)
Performance
Blade supporting method
Semi-U dozer
+ Pitch
Hydraulic semi-U tiltdozer

Hydraulic full-U tiltdozer
Full-U dozer
+ Pitch
Type

Changing range of blade
cutting edge angle
Capacity of blade
Multi-ripper
Work equipment
SEN00208-01
mm
mm
mm
deg.
1,676
954
770
6
m3
38.1 <SAE 27.2>
mm
mm
deg.
5,265
2,690
52
mm
mm
mm
deg.
1,676
954
905
6
m3
42.3 <SAE 34.4>
mm
mm
deg.
3,640
1,580
52
mm
deg.
deg.
1,145
6
6
mm
deg.
deg.
1,350
6
6
mm
mm
deg.
1,124
1,196
45 (Adjustable steplessly to 32.5 54)
Length of beam
mm
3,085
Number of shanks
pcs.
Max. digging depth

Max. lift
Digging angle (Standard)
mm
mm
deg.
1,744
1,196
45 (Adjustable steplessly to 34 56)
Length of beam
mm
1,477
Number of shanks
pcs.
D475A, D475ASD-5E0
SEN00208-01
01 Specification
Superdozer specification
Machine model
D475ASD-5E0
Serial Number
30001 and up
Weight
Machine weight
Tractor
Superdozer + ROPS cab + Air conditioner
84,430
kg
113,120
+ Counterweight
m
4.6
Gradeability
deg.
30
Stability (Front, Rear, Left, Right)
deg.
35
Forward
Reverse
Gear speeds
1st
0 4.7
Ground
pressure
0 10.9
Overall
length
3rd
Tractor
Overall
width
1st
Tractor
Tractor
Overall
height
Dimensions
Performance
Min. turning radius
2nd
2nd
0 3.5
km/h
km/h
0 8.4
3rd
Superdozer + ROPS cab +
0 14.3
113.0 {1.15}
2
kPa {kg/cm }
151.4 {1.54}
Air conditioner + Counterweight
Superdozer + Counterweight
Superdozer
mm
mm
Up to ROPS top
Up to exhaust pipe end
mm
Up to exhaust duct top
Length of track on ground

Track shoe width
Minimum ground clearance
6,680
10,525
3,620
6,465
4,646
4,546
3,861
2,770
Track gauge
0 6.3
mm
4,524
810
711
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Machine model
D475ASD-5E0
Serial Number
30001 and up
Komatsu SAA12V140E-3
Model name
4-stroke, water-cooled, V-type, direct-injection
Type
engine with turbocharger and aftercooler

mm
12140 x 165
l {cc}
30.48 {30,480}
Rated output
kW/rpm {HP/rpm}
677/2,000 {908/2,000}
Max. torque
Nm/rpm {kgm/rpm}
3,825/1,400 {390/1,400}
High idle
rpm
2,150
Low idle
rpm
600
g/kWh {g/HPh}
215 {160}
Number of cylinderBore x Stroke
Performance
Engine
Total displacement
Min. fuel consumption ratio

(at rated output)
Starting motor
Alternator
Battery
Type of radiator core
Torque converter
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,
Power train
3 forward/reverse gear speeds type

Bevel gear shaft
Spiral bevel gear, splash lubrication type

Steering clutch
hydraulic (hand-operated) type

Steering brake
hydraulic (foot/hand-operated) type

Final drive
Undercarriage
Type of suspension
1-stage spur gear and 1-stage planetary gear,

splash lubrication type
Hard, equalizing beam type
Carrier roller
Track roller

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)
D475A, D475ASD-5E0
Gear type (BAL 160 + 160 + 112)

Gear (BAR 63 + 320)
SEN00208-01
01 Specification
Machine model
D475ASD-5E0
Serial Number
30001 and up
Work equipment
pump
Max. pressure
MPa {kg/cm2}
Type
27.5 {280}
Variable swash plate type:
2 pcs. (HPV 125 + 125)
Capacity
l/min
542
(at engine speed of 2,000 rpm)

Variable swash plate type: 2 pcs. (LPV 90 + 30)
Work equipment
valve
Cooling fan motor
Max. discharge pressure: 17.5 {178}
l/min/rpm
Theoretical discharge pressure: 178/1,934

Fixed swash plate type (LMF 180)
MPa {kg/cm2}
Max. using pressure: 17.5 {178}
Type
For blade lift
6-spool type: 1 pc.
For blade tilt
Hydraulic
For ripper lift

For ripper tilt
Dimensions of
blade lift cylinder
Dimensions of
blade pitch cylinder
Double acting piston

Bore of cylinder
180
110
Stroke of piston
mm
1,925
3,155
1,230
Bore of cylinder
250
140
Stroke of piston
mm
660
2,154
1,494
Hydraulic tank
10
MPa {kg/cm }
Type
Hydraulic
cylinders
Cooling fan pump
Box type (External control valve type)
D475A, D475ASD-5E0
Performance
Dimensions
Superdozer
Work equipment
01 Specification
SEN00208-01
Machine model
D475ASD-5E0
Serial Number
30001 and up
Type
Hydraulic superdozer (Pitchdozer)
Blade supporting method
Cylinder type

Max. pitch dump angle
Capacity of blade
mm
mm
mm
deg.
deg.
m3
2,016
804
900 (at cutting edge angle of 52)
15
15
45.0 <SAE 36.6>
Width of blade
mm
6,465
Height of blade
mm
2,690
deg.
42 67
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
D475A-5E0
Serial Number
30001 and up
Engine and damper assembly

Engine assembly
Damper assembly
4,115
3,900
215
Main radiator assembly

Aftercooler assembly
Oil cooler assembly
Fuel tank assembly [When full]
485
30
129
863 [2,335]
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.)
5,350
830
1,335
40
2,290
75
180
72
64
25
100
Final drive assembly (Each side)

Main frame assembly
3,575
9,120
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.)
13,190
2,976
708
248
237
106
Track shoe assembly (710 mm)

Pivot shaft assembly (each side)
Equalizer bar
13,530
370
733
Hydraulic tank assembly

Control valve
290
195
Blade lift cylinder assembly (Each side)

Blade tilt cylinder assembly
509
504
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
12
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.
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Unit: kg
Machine model
D475A-5E0
Serial Number
30001 and up
Radiator guard assembly

Radiator guard
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, D475ASD-5E0
4,550
2,530
509
65
100
267
324
340
448
197
474
570
527
520
934
600
455
64
13
SEN00208-01
01 Specification
Superdozer specification
Unit: kg
Machine model
D475ASD-5E0
Serial Number
30001 and up
Engine and damper assembly

Engine assembly
Damper assembly
4,115
3,900
215
Main radiator assembly

Aftercooler assembly
Oil cooler assembly
Fuel tank assembly [When full]
485
30
129
863 [2,335]
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.)
5,350
830
1,335
40
2,290
75
180
72
64
25
100
Final drive assembly (Each side)

Main frame assembly
3,575
9,120
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.)
13,190
2,976
708
248
237
106
Track shoe assembly (810 mm)

Pivot shaft assembly (each side)
Equalizer bar
14,450
370
733
Hydraulic tank assembly

Control valve
290
195

Blade pitch cylinder assembly (Each side)
509
508
Superdozer assembly
Blade
Straight frame (Left)
Straight frame (Right)
Pitch cylinder assembly (Each side)
21,200
11,950
1,770
1,770
508
Counterweight
6,400
Radiator guard assembly

Radiator guard
Cooling fan motor
4,640
2,530
509
65
14
D475A, D475ASD-5E0
01 Specification
SEN00208-01
Unit: kg
Machine model
D475ASD-5E0
Serial Number
30001 and up
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, D475ASD-5E0
100
267
324
340
448
197
474
570
527
520
934
600
455
64
15
SEN00208-01
01 Specification
Fuel, coolant and lubricants

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

2007 KOMATSU
All Rights Reserved
Printed in Japan 08-07 (01)
18
SEN00210-00
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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. Main radiator
2. Sub radiator
3. Turbocharger
4. Engine
5. Power train oil cooler
6. Water pump
D475A, D475ASD-5E0
SEN00210-00
Engine mount
Unit: mm
No.
Check item
Clearance between bracket

and cushion
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
78
0.030
0.060
+0.006
0.048
0.018
0.066
0.1
200
0.043
0.083
+0.072
+0.072
0.043
0.155
Standard
size
Replace
2

and bushing
Free height of rubber mount
D475A, D475ASD-5E0
Standard size
Repair limit
118
116
0.1
SEN00210-00
Cooling fan pump
Type: LPV90 + 30
DC: Discharge port

SC: Suction port
1.
2.
LPV90 Hydraulic pump

D475A, D475ASD-5E0
SEN00210-00
1.
DC: Discharge port

SC: Suction port
D475A, D475ASD-5E0
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
D475A, D475ASD-5E0
SEN00210-00
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Shaft
Cradle
Case
Rocker cam
Shoe
Piston
Cylinder block
Valve plate
Spring
Servo piston
SEN00210-00
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).
D475A, D475ASD-5E0
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.
SEN00210-00
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.]
D475A, D475ASD-5E0
SEN00210-00
2)
q
10
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.
D475A, D475ASD-5E0
3)
SEN00210-00
PC valve, EPC valve, and servo piston
IM:
PA:
PEPC:
Control current input connector

Pump discharge port
EPC basic pressure input port
Servo piston
1. Servo piston
2. Lever
3. Spring
D475A, D475ASD-5E0
PC valve
4. Piston
5. Seat
6. Spring
7. Spool
8. Sleeve
9. Plug
EPC valve
10. EPC valve
11
SEN00210-00
Function
q
The PC valve works so the relationship
between the current input to the EPC valve
and pump swash plate angle (a) will be as
shown in the figure below.
12
D475A, D475ASD-5E0
SEN00210-00
(1) When EPC output pressure is high [When EPC current (i) is large]
14
D475A, D475ASD-5E0
SEN00210-00
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.
D475A, D475ASD-5E0
15
SEN00210-00
(2) When EPC output pressure is low [When EPC current (i) is small]
16
D475A, D475ASD-5E0
SEN00210-00
Operation
q
If EPC current (i) reduces and the EPC output
pressure lowers, spool (7) is pushed to the
right by the force of spring (6).
q
Accordingly, port (g) is disconnected from port
(f) and port (f) is connected to the drain circuit.
q
At this time, the oil in chamber (X) on the large
diameter side of servo piston (1) flows through
port (f) of the PC valve to the drain circuit.
q
As a result, servo piston (1) is moved toward
the maximum swash plate angle side (lower
side) by the pressure of chamber (Y) on the
small diameter side.
D475A, D475ASD-5E0
17
SEN00210-00
2.
P1:
PAEPC:
PDA2:
PEPC:
PS:
TO:
18
Pump discharge port

EPC output pressure pickup port
Breather
EPC valve basic pressure input port
Pump suction port
Drain port
D475A, D475ASD-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SEN00210-00
Shaft
Oil seal
Case
Rocker cam
Shoe
Piston
Cylinder block
Valve plate
Spring
Servo piston
Ball
D475A, D475ASD-5E0
19
SEN00210-00
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)
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
20
D475A, D475ASD-5E0
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
(7) changes. Angle (a) is called the swash
plate angle.
q
If angle (a) is made between center line (X) of
(7), plane (A) works as a cam for shoe (5).
q
Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
result, each piston (6) sucks and discharges oil
by (F) (E).
q
In other words, if cylinder block (7) rotates and
the volume of chamber (E) is decreased, the
oil is discharged from chamber (E). On the
other hand, the volume of chamber (F) is
increased and the oil is sucked in chamber (F).
[In the figure, chamber (F) is at the end of the
suction stroke and chamber (E) is at the end of
the discharge stroke.]
D475A, D475ASD-5E0
SEN00210-00
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.
21
SEN00210-00
2)
q
22
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).
D475A, D475ASD-5E0
3)
Servo valve
P:
PE:
PH:
T:
EPC valve basic pressure input port

Control piston pressure output port
Pump discharge pressure input port
Drain port
1.
2.
3.
4.
5.
6.
7.
Plug
Lever
Retainer
Seat
Spool
Piston
Sleeve
D475A, D475ASD-5E0
SEN00210-00
23
SEN00210-00
A: Drain side
B: Pump discharge pressure input side
C: EPC output pressure receiving pressure
D: EPC output pressure side

P: EPC basic pressure input side
Function
q
The servo valve works so the relationship
between the current input to the EPC valve
and pump swash plate angle (a) will be as
shown in the figure below.
24
D475A, D475ASD-5E0
SEN00210-00
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
D475A, D475ASD-5E0
25
SEN00210-00
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}
26
D475A, D475ASD-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SEN00210-00
Output shaft
Case
Thrust plate
Shoe
Piston
Cylinder block
Valve plate
End cover
Center spring
Safety-suction valve
D475A, D475ASD-5E0
27
SEN00210-00
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.
28
D475A, D475ASD-5E0
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
SEN00210-00
Function
q
When the pressure in port (P) of the motor
rises at the starting time of the engine, this
valve protects the fan system circuit. (Safety
valve)
q
When the fan pump stops, the hydraulic oil
does not flow into the motor. Since the motor
continues revolution because of the force of
inertia, however, the pressure on the outlet
side of the motor rises.
q
When the oil stops flowing in from inlet port (P),
the safety-suction valve sucks in the oil on the
outlet side and supplies it to port (MA) where
there is not sufficient oil to prevent cavitation.
(Suction valve)
D475A, D475ASD-5E0
29
SEN00210-00
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).
30
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).
If poppet (5) opens, the pressure in port (C)

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

in port (A), main valve (2) moves to the right
and the hydraulic oil flows through port (A) to
port (B), thus generation of abnormal pressure
is prevented.
Even if abnormal pressure is generated, suction valve (7) having a large section diameter
does not operate since (d1) < (d4).
D475A, D475ASD-5E0
2)
q
SEN00210-00
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).
D475A, D475ASD-5E0
31
SEN00210-00
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).
32
D475A, D475ASD-5E0
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).
D475A, D475ASD-5E0
SEN00210-00
33
SEN00211-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

Power train, Part 1

Power train...................................................................................................................................................... 2
Power train hydraulic equipment arrangement diagram ................................................................................. 4
Damper and universal joint ............................................................................................................................. 6
General view of power train unit ..................................................................................................................... 8
Torque converter, PTO .................................................................................................................................. 10
Torque converter valve.................................................................................................................................. 18
Torque converter lockup control system ....................................................................................................... 28
Scavenging pump ......................................................................................................................................... 29
Transmission control ..................................................................................................................................... 31
Transmission................................................................................................................................................. 32
D475A, D475ASD-5E0
SEN00211-01
Power train
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 respec-
tive 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.
D475A, D475ASD-5E0
1.
2.
3.
4.
5.
Engine (SAA12V140E-3)
Damper
Universal joint
Power train, lubrication pump
(BAL160+160+112)
Work equipment pump
(HPV125+125)
D475A, D475ASD-5E0
6.
7.
8.
9.
10.
11.
12.
Fan pump (LPV90+30)

Torque converter
Transmission
Steering clutch
Steering brake
Final drive
Sproket
SEN00211-01
13.
14.
15.
16.
17.
18.
19.
Track shoe
Transfer
Transfer drive gear
Bevel pinion
Bevel gear
PTO
Scavenging pump
SEN00211-01
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)
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00211-01
SEN00211-01
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
q
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.
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.
D475A, D475ASD-5E0
SEN00211-01
Unit: mm
No.
12
Check item
Clearance between flywheel

housing and cover
13
Clearance between flywheel

housing and damper
14
Outer diameter of oil seal

contact face on coupling
15
Outer diameter of bearing

contact face on output shaft
D475A, D475ASD-5E0
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
647.7
0.024
0.104
+0.080
+0.080
0.024
0.184
0.2
571.5
0.022
0.092
+0.070
+0.070
0.022
0.162
0.2
Standard size
Repair limit
120
119.9
55
54.9
Replace
SEN00211-01
Power train system

1
General view of power train unit
D475A, D475ASD-5E0
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
SEN00211-01
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
Transmission
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
Outline
q
The power train unit broadly consists of torque
converter and PTO (4), transmission (7), and
steering unit (9). Therefore, after the power
train unit is removed, it can be divided into
torque converter and PTO (4), transmission
(7), and steering unit (9).
q
Steering unit (9) consists of the transfer, bevel
gear shaft, steering clutch, and the steering
brake.
D475A, D475ASD-5E0
SEN00211-01
Torque converter, PTO

a
10
PTO: Abbreviation for Power Take Off
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00211-01
11
SEN00211-01
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.
12
Cooling fan pump mounting port

Hydraulic pump mounting port
Power train, torque converter, and lubricating
oil pump mounting port
Scavenging pump mounting port
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
D475A, D475ASD-5E0
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.
SEN00211-01
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).
Conditions for the direct (lockup) range

Torque converter output shaft speed:
Min. 1,360 rpm
Set transmission pressure:
Min. 1.91 MPa {19.5 kg/cm2}
Both conditions must be satisfied.
Conditions for the torque converter (unlock)
range
Torque converter output shaft speed:
Max. 1,330 rpm
Set transmission pressure:
Max. 1.47 MPa {15.0 kg/cm2}
Either condition must be satisfied.
D475A, D475ASD-5E0
13
SEN00211-01
14
D475A, D475ASD-5E0
SEN00211-01
Unit: mm
No.
Check item
Criteria
Outside diameter of oil seal contact

surface of input coupling
Remedy
Standard size
Tolerance
Repair limit
125
0
0.063
124.8
Inside diameter of seal ring contact surface of sleeve
115
+0.035
0
115.1
Inside diameter of seal ring contact

surface of retainer
190
+0.046
0
190.5
Inside diameter of seal ring contact

surface of pump shaft
120
+0.035
0
120.5
Backlash between input shaft and

PTO idler gear
0.198 0.484
Backlash between PTO idler gear

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

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

scavenging pump drive gear
0.198 0.484
Wear of input shaft

seal ring
10
11
Width
0.01
0.03
3.6
Thickness
4.05
4.5
0.12
Thickness of lockup clutch disc
5.4
0.1
4.9
Thickness of lockup clutch plate
5.0
0.1
4.5
Overall thickness of lockup clutch

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

assembly
15.8
0.15
14.7
Tolerance
Standard size
12
13
14
15
Fitting tolerance of
PTO idler gear bearing
power train, torque
converter, lubricating oil pump, and
cooling fan pump
drive gear bearing
hydraulic pump
drive gear bearing
scavenging pump
drive gear bearing
Shaft
Hole
140
0
0.018
0.008
0.033
Inside
diameter
80
0
0.019
0
0.015
Outside
diameter
(cover side)
140
0
0.018
+0.012
0.028
Outside
diameter
(case side)
140
0
0.018
+0.015
0.010
Inside
diameter
65
+0.030
+0.011
0
0.015
Outside
diameter
(cover side)
160
0
0.025
+0.012
0.028
Outside
diameter
(case side)
140
0
0.018
+0.015
0.010
Inside
diameter
(cover side)
75
+0.030
+0.011
0
0.015
Inside
diameter
(case side)
65
+0.030
+0.011
0
0.015
Outside
diameter
72
0
0.013
+0.009
0.021
Inside
diameter
35
+0.025
+0.009
0
0.010
Outside
diameter
Standard size
16
Stator clutch return spring
D475A, D475ASD-5E0
37.0
Replace
Repair limit
Free length Installed length Installed load

54.1
Repair by hard
chrome plating
or replace
125.4 N
{12.8 kg}
Free length
Installed load
50.9
106.9 N
{10.9 kg}
15
SEN00211-01
Power transmitting route

When lockup clutch is disengaged and stator
clutch is engaged
16
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.
When lockup clutch is engaged and stator

clutch is disengaged
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.
D475A, D475ASD-5E0
SEN00211-01
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.
D475A, D475ASD-5E0
17
SEN00211-01
PTF:
TCF:
TC :
SC :
LC :
drT:
dr:
P3 :
P8 :
PSC:
PPL:
18

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
D475A, D475ASD-5E0
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
D475A, D475ASD-5E0
SEN00211-01
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
19
SEN00211-01
20
D475A, D475ASD-5E0
SEN00211-01
Unit: mm
No.
Check item
Clearance between main relief

valve and valve body
Criteria
Standard
size
Tolerance
Shaft
Hole
Remedy
Standard
clearance
Clearance
limit
40
0.035
0.045
+0.016
0
0.035
0.061
0.081
Clearance between torque converter relief valve and valve body
40
0.035
0.045
+0.016
0
0.035
0.061
0.081
Clearance between stator clutch

modulating valve and valve body
25
0.035
0.045
+0.013
0
0.035
0.058
0.078
Clearance between lockup clutch

modulating valve and valve body
25
0.035
0.045
+0.013
0
0.035
0.058
0.078
Clearance between lockup selector valve and valve body
25
0.035
0.045
+0.013
0
0.035
0.058
0.078
Standard size
Main relief valve spring
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
120.3
101.5
1,455 N
{148.5 kg}
116.7
1,383 N
{141.1 kg}

spring
116.92
86.3
645.6 N
{65.83 kg}
113.4
613 N
{62.5 kg}

spring
103.5
95.2
151.9 N
{15.5 kg}
100.4
144 N
{14.7 kg}

spring (outside)
141.4
88.7
158.6 N
{16.18 kg}
137.2
151 N
{15.4 kg}
10

spring (inside)
80.5
80.5
78.1
66
54
55.9 N
{5.7 kg}
64.0
53.0 N
{5.4 kg}
11 Lockup selector valve spring
D475A, D475ASD-5E0
Replace
21
SEN00211-01
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}

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
q
The lockup solenoid valve controls the lockup
selector valve by changing the pilot pressure
for it in response to electrical signals received
from the controller.
Lockup selector valve
q
The lockup selector valve turns the lockup
clutch and stator clutch engaged and disengaged.
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}

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.
22
D475A, D475ASD-5E0
Operation of main relief valve
The oil from the hydraulic pump flows through

the filter, port (A) of the torque converter valve,
and orifice (a) of torque converter relief valve
(1) to chamber (B).
SEN00211-01
Operation of torque converter relief valve
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.
D475A, D475ASD-5E0
23
SEN00211-01
Operation of lockup solenoid valve and lockup selector valve

When traveling in torque converter range
24
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).
D475A, D475ASD-5E0
SEN00211-01
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.
D475A, D475ASD-5E0
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).
25
SEN00211-01
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.
26
D475A, D475ASD-5E0
SEN00211-01
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.
D475A, D475ASD-5E0
27
SEN00211-01
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 machine monitor 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.
28
D475A, D475ASD-5E0
Scavenging pump
SEN00211-01
Type: BAR(3)63+320
A:
B:
C:
Suction port from torque converter

Suction port from steering unit
Discharge port
1.
2.
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)
D475A, D475ASD-5E0
Tandem gear pump

Front
63.3
Rear
319.4
Maximum discharge pressure

(MPa {kg/cm2})
0.98 {10}
Maximum speed (rpm)
1,997
29
SEN00211-01
30
D475A, D475ASD-5E0
Transmission control
SEN00211-01
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.
Brake pedal
Lock lever
PCCS lever
(Forward-Reverse, Gear shift)
Transmission neutral switch
Cable
UP switch
(Gear is shifted up each time this switch is
pressed.)
DOWN switch
(Gear is shifted down each time this switch is
pressed.)
4.
5.
6.
7.
8.
D475A, D475ASD-5E0
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).
31
SEN00211-01
Transmission
32
D475A, D475ASD-5E0
A:
B:
C:
D:
E:
F:
G:
H:
J:
K:
L:
M:
N:
P:
dr:
To transmission lubrication circuit

To priority valve
To scavenging pump (from steering case)
From scavenging pump (to transmission oil pan)
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
1.
2.
3.
4.
Transmission input shaft

Front case
Rear case
D475A, D475ASD-5E0
SEN00211-01
33
SEN00211-01
34
D475A, D475ASD-5E0
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
SEN00211-01
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.
Number of
plates
Number of discs
R clutch
F clutch
3rd clutch
2nd clutch
1st clutch
Combinations of clutches at respective gear

speeds and reduction ratio
Gear speed
Clutch used
Reduction ratio
Forward 1st
speed
F 1st
3.282
Forward 2nd
speed
F 2nd
1.789
Forward 3rd
speed
F 3rd
1.000
Neutral
1st (*)
Reverse 1st
speed
R 1st
2.563
Reverse 2nd
speed
R 2nd
1.397
Reverse 3rd
speed
R 3rd
0.781
*: Filled with oil at low pressure.

(Except for low temperature and abnormal conditions.)
D475A, D475ASD-5E0
35
SEN00211-01
36
D475A, D475ASD-5E0
SEN00211-01
Unit: mm
No.
Check item
Criteria
Standard size
R clutch spring (12 pcs.)
Remedy
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
100.0
90.0
140.5 N
{14.3 kg}
94.0
119.6 N
{12.2 kg}
F clutch spring (12 pcs.)
100.0
94.0
84.3 N
{8.5 kg}
94.0
70.6 N
{7.2 kg}
3rd clutch spring (12 pcs.)
84.0
72.0
150.5 N
{15.4 kg}
79.0
128.5 N
{13.1 kg}
2nd clutch spring (12 pcs.)
81.7
63.0
119.1 N
{12.2 kg}
76.8
102.0 N
{10.4 kg}
1st clutch spring (12 pcs.)
103.5
76.0
238.7 N
{24.4 kg}
97.3
203.0 N
{20.7 kg}
Total assembled thickness of

7 discs and 6 plates of R clutch
Standard size
Tolerance
Repair limit
72.6
0.36
68.9

7 discs and 6 plates of F clutch
72.6
0.36
68.9

5 discs and 4 plates of 3rd clutch
50.2
0.30
47.5

4 discs and 3 plates of 2nd clutch
39.0
0.26
36.9
10

6 discs and 5 plates of 1st clutch
61.4
0.43
58.2
5.4
0.1
4.9
5.4
0.15
4.9
5.8
0.1
5.2
Width
3.0
0.01
0.03
2.70
Thickness
4.0
0.12
3.85
Width
4.0
0.01
0.03
3.60
Thickness
5.0
0.15
4.85
Width
4.0
0.01
0.03
3.60
Thickness
5.0
0.15
4.85
Width
6.0
0.01
0.03
5.50
Thickness
6.8
0.15
6.65
Width
4.0
0.01
0.04
3.60
Thickness
5.0
0.15
4.85
Width
4.0
0.01
0.04
3.60
Thickness
4.0
0.15
3.85
F, R,
11 Thickness of clutch disc 2nd, 3rd

1st
12 Thickness of clutch plate

13
14
15
16
17
18
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)
Replace
Backlash between
19
sun gear and planetary pinion
0.16 0.35
Backlash between
planetary pinion and ring gear
0.18 0.38
20
D475A, D475ASD-5E0
37
SEN00211-01
Disc clutch
Structure
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).
Operation
When clutch is engaged (fixed)
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
38
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.
D475A, D475ASD-5E0
SEN00211-01
Power transmitting route

Forward 1st speed
When the transmission is set to the forward 1st

speed, the F clutch and 1st 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 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).
D475A, D475ASD-5E0
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).
39
SEN00211-01
Forward 2nd speed
40
When the transmission is set to the forward

2nd speed, the F clutch and 2nd clutch are
engaged.The power transmitted from the
gear (4). The 2nd clutch is actuated by the oil
pressure applied to the 2nd clutch piston, and
fixes 2nd ring gear (17).
F ring gear (4).
ring gear (12).
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).
D475A, D475ASD-5E0
SEN00211-01
Forward 3rd speed
When the transmission is set to the forward 3rd

s p e ed , t h e F c l u t c h a n d 3 r d c lu t c h ar e
gear (4). The 3rd clutch is actuated by the oil
pressure applied to the 3rd clutch piston, and
fixes 3rd ring gear (12).
F ring gear (4).
D475A, D475ASD-5E0
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).
41
SEN00211-01
Reverse 1st speed
42
When the transmission is set to the reverse 1st

s p e e d , t h e R c l u t c h a n d 1 s t c lu t c h a r e
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).
ring gear (12).
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).
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00211-01
43
SEN00211-01

2009 KOMATSU
All Rights Reserved
44
SEN00212-02
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

Power train, Part 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
SEN00212-02
D475A, D475ASD-5E0
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.
SEN00212-02
Operation table of ECMV

ECMV
Gear speed
Forward 1st
Forward 2nd
Forward 3rd
2nd
3rd
Q
Q
Q
Reverse 1st
Reverse 2nd
Reverse 3rd
* Neutral
1st
Q
Q
Q
Q
*: Filled with oil at low pressure.

(Except for low temperature and abnormal conditions.)
Filter
Priority valve
Lubricating oil relief valve
1st clutch ECMV
2nd clutch ECMV
3rd clutch ECMV
F clutch ECMV
R clutch ECMV
Valve seat
D475A, D475ASD-5E0
SEN00212-02
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:
To clutch
From pump
Drain
Drain
Clutch oil pressure pickup port
1.
2.
3.
4.
5.
6.
7.
Fill switch connector

Proportional solenoid connector
Flow rate pickup valve
Fill switch
Proportional solenoid
Pressure control valve
Nameplate (*1)
*1:
Clutch used
Stamp of the
nameplate
F, R, 1st, 2nd, 3rd
A*******
D475A, D475ASD-5E0
Outline of ECMV
q
The ECMV consists of 1 pressure control valve
and 1 fill switch.
q
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.
SEN00212-02
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
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.
The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned ON during triggering (Range
D).
D475A, D475ASD-5E0
SEN00212-02
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
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).
The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned ON during triggering (Range
D).
D475A, D475ASD-5E0
During filling (Range B 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).
D475A, D475ASD-5E0
SEN00212-02
Pressure regulation (Range C in chart)
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.
SEN00212-02
Priority valve
Unit: mm
No.
Check item
Clearance between spool and

valve body
Criteria
Standard
size
22
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.035
0.045
+0.013
0
0.035
0.058
0.078
Standard size
3.
4.
5.
Return spring
Valve body
Spool
Piston
Remedy
Replace
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
38.8
28.5
84.7 kN
{8.6 kg}
37.6
80.4 kN
{8.2 kg}
Outline
q
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.
D475A, D475ASD-5E0
Operation from start to finish 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.
D475A, D475ASD-5E0
SEN00212-02
Operation right after finishing of gear shifting
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.
SEN00212-02
Lubricating oil relief valve
Unit: mm
No.
Check item

valve body
Criteria
Standard
size
22
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.035
0.045
+0.013
0
0.035
0.058
0.078
Standard size
3.
4.
5.
10
Return spring
Remedy
Replace
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
68.5
37
91.9 N
{9.37 kg}
66.5
87.3 N
{8.9 kg}
Lubricating oil pressure pickup port

Spool
Valve body
Outline
q
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}
D475A, D475ASD-5E0
SEN00212-02
Torque converter, power train, lubricating oil pump
Type: BAL(4)160+(4)160+(4)112
Unit: mm
No.
Check item
Criteria
Type
Side clearance
BAL(4)160
BAL(4)112
Clearance between plain bearing

inner diameter and gear shaft
BAL(4)160
Depth to knock in pin
BAL(4)160
BAL(4)112
Type
BAL(4)112
Clearance limit
0.04 0.10
0.13
0.060 0.145
0.20
Tolerance
Repair limit
14
0
0.5
5.9 Nm {0.6 kgm}
Type
Speed
(rpm)
Discharge
pressure
(MPa{kg/
cm2})
Standard
delivery
amount
(l/min)
Delivery
amount limit
(l/min)
BAL(4)160
2,000
2.94 {30}
288
266
BAL(4)112
2,000
2.94 {30}
205
188
5.
6.
7.
Lubricating oil pump

Power train pump
Torque converter pump
A:
B:
C:
D:
Suction port
Lubricating oil pump discharge port
Power train pump discharge port
Torque converter pump discharge port
D475A, D475ASD-5E0
Replace
Standard size
Rotating torque of spline shaft
Delivery amount
Oil: SAE10WCD
Oil temperature: 45 55 C
Remedy
Standard clearance
Outline
q
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.
11
SEN00212-02
Steering, brake control

a
a
12
PCCS: Abbreviation for Palm Command Control System

Regarding the transmission related description of operation of the PCCS lever, refer to Transmission
control.
D475A, D475ASD-5E0
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
D475A, D475ASD-5E0
SEN00212-02
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 a proportional current to steering controller (11) through potentiometer (10) 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 emergency
brake activation. (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.
13
SEN00212-02
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.
14
D475A, D475ASD-5E0
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
D475A, D475ASD-5E0
SEN00212-02
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
15
SEN00212-02
Unit: mm
No.
20
Check item
Backlash between No.1
pinion and No.1 gear
Criteria
Remedy
Standard clearance
Clearance limit
0.26 0.96
0.96
21
Backlash between sun gear

and planet pinion
0.25 0.70
0.70
22
Backlash between planetary

pinion and ring gear
0.26 0.83
0.83
Outside diameter of No.1

pinion oil seal contact surface
Standard size
Repair limit
23
120.0
119.9
24
Thickness of thrust collar of

inner body roller bearing
24.8
24.75
25
Thickness of thrust coller of

No.1 gear boss roller bearing
14.0
13.95
26
Dimensions from cover

mounting face to button head
72
70.5
27
Clearance between planetary pinion shaft and carrier

(small end)
Replace
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
110
0.035
0.054
0.024
0.059
0.024
0.030
0.030
135
0.035
0.054
0.067
0.107
0.072
0.013
0.013
Standard
size
28
Clearance between planetary pinion shaft and carrier

(large end)
29
Standard shim thickness for

No.1 pinion bearing cage
30
Dimension of end face of

final drive cover and end face
of bearing
7.3 8.3
31
Clearance of floating seal

guard
3.1 4.7
32
Wear of wear guard
16
Adjust
Standard size
Repair limit
47.5
17
Rebuild or
replace
D475A, D475ASD-5E0
SEN00212-02
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.
D475A, D475ASD-5E0
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).
17
SEN00212-02
Sprocket
Unit: mm
No.
1
2
18
Check item
Criteria
Remedy
Standard size
Repair limit
486
470
32.5
26.5
Wear of tooth tip

Thickness of tooth root
Replace or
overlaying
welding
D475A, D475ASD-5E0
SEN00212-02
Full-scale drawing of sprocket tooth profile
D475A, D475ASD-5E0
19
SEN00212-02
20
D475A, D475ASD-5E0
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
SEN00212-02
1.
2.
3.
4.
5.
Transmission
Steering unit
Breather
Drain plug
21
SEN00212-02
22
D475A, D475ASD-5E0
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
D475A, D475ASD-5E0
SEN00212-02
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)
23
SEN00212-02
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
24
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.
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00212-02
25
SEN00212-02
26
D475A, D475ASD-5E0
SEN00212-02
Unit: mm
No.
Check item
Brake plate
Criteria
Standard size
Tolerance
Repair limit
Thickness
4.2
0.1
3.8
Strain
Max. 0.3
0.4
Thickness
5.4
0.1
4.3
Replace
Strain
Max. 0.3
0.4
Repair or replace
82.2
0.41
72.6
4.2
0.1
3.8
Brake disc

8 brake plates and 9 discs
Remedy
Thickness
Clutch plate
Repair or replace
Strain
Max. 0.3
0.4
Repair or replace
5.4
0.1
4.5
Replace
Strain
Repair or replace
Clutch disc
Max. 0.4
0.5

8 clutch plates and 8 discs
76.8
0.40
69.3
Inside diameter of seal ring

contact surface of sleeve
190
+0.046
0
190.5
Large
diameter
parts
350
+0.089
0
350.1
Small
diameter
parts
300
+0.052
0
300.1
Large
diameter
parts
350
+0.089
0
350.1
Small
diameter
parts
300
+0.052
0
300.1
Inside diameter
of seal ring contact
face of clutch piston
Replace
Thickness
Inside diameter
of seal ring contact
surface of brake piston
Standard size
10 Brake spring
11 Clutch spring
Clearance between bevel gear

12
and reamer bolt
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
19.7
12.9
46.97 kN
{4,790 kg}
19.1
44.62 kN
{4,550 kg}
20.4
12.9
55.7 kN
{5,680 kg}
20.0
52.96 kN
{5,400 kg}
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
+0.023
+0.002
+0.033
0
0.023
0.031
Max. 0.031
20
Tolerance
Standard clearance
Clearance limit
0.4 0.7
1.0
Backlash between clutch hub and

disc
0.4 0.7
1.0
15
Backlash between bevel pinion and

bevel gear
0.30 0.40
0.75
16
Preload of bevel gear shaft taper

roller bearing
17
Standard shim thickness of bearing

cage
13
Backlash between brake hub and

disc
14
D475A, D475ASD-5E0
Replace
Replace
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
27
SEN00212-02
Unit: mm
No.
Check item
18 Backlash between transfer gears

19
Thickness of collar between

transfer gear and bearing
20
Standard shim thickness of

bearing cage
28
Criteria
Remedy
Standard clearance
Clearance limit
0.26 0.67
0.75
Standard size
Tolerance
Repair limit
19.3
0.1
18.9
2.0
Adjust or replace
Replace
Adjust shim
D475A, D475ASD-5E0
SEN00212-02
Operation of steering clutch

When steering clutch is turned engaged
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.
When steering clutch is turned disengaged
D475A, D475ASD-5E0
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.
29
SEN00212-02
Operation of steering brake

When steering brake is released
When the PCCS lever is in the neutral position and the brake pedal is released, the steering 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.
When steering brake is applied

(When PCCS lever is operated)
q
q
30
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.
D475A, D475ASD-5E0
SEN00212-02
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
31
SEN00212-02
32
D475A, D475ASD-5E0
P:
L:
PS:
LC:
LL:
LB:
LBL:

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
D475A, D475ASD-5E0
SEN00212-02
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.
33
SEN00212-02
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:
To clutch or brake
From pump
Drain
Drain
To clutch or brake pressure pickup port
1.
2.
3.
4.
5.
6.
7.
Fill switch connector

Proportional solenoid connector
Pressure detection valve
Fill switch
Proportional solenoid
Nameplate (*1)
34
*1:
Clutch used
Stamp of the nameplate
Steering clutch,
Steering brake
R*******
Outline
q
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.
D475A, D475ASD-5E0
SEN00212-02
Outline of ECMV
q
The ECMV consists of 1 pressure control valve
and 1 fill switch.
q
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
SEN00212-02
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.)
36
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.
D475A, D475ASD-5E0
SEN00212-02
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.
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.
D475A, D475ASD-5E0
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.
37
SEN00212-02
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.)
38
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.
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).
D475A, D475ASD-5E0
SEN00212-02
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.
D475A, D475ASD-5E0
If the brake pedal is depressed, the parking

brake valve connected by the linkage operates
to open the brake circuit and drain the oil.
39
SEN00212-02
Parking brake valve
Unit: mm
No.
Check item

valve body
Criteria
Tolerance
Standard
size
14
Outside diameter of dust seal

contact surface of spool
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
0.020
0.030
+0.011
0
0.020
0.041
0.05
Standard size
Tolerance
Repair limit
14
0.020
0.030
13.9
Standard size
4.
5.
40
Return spring
Spool
Valve body
Replace
Repair by hard
chrome plating
or replace
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
65
47.7
38.2 N
{3.9 kg}
63
36.3 N
{3.7 kg}
Replace
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.
D475A, D475ASD-5E0
SEN00212-02
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
SEN00212-02
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
D475A, D475ASD-5E0
SEN00212-02
43
SEN00212-02

2009 KOMATSU
All Rights Reserved
44
SEN00213-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

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
2nd
3rd
4th
5th
6th
7th
8th
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.
13
Check item
Criteria
Item
Repair limit
Curvature
7 (for length of 3,000)
Twisting
3 (for level length of 3,000)
Dents (cylinder portion)
12
Deformation of track frame

outer cylinder
Clearance between inner

cylinder and guide
Standard
size
70
14
15
Clearance between idler

bogie and guide
Press-fitting force for cartridge
D475A, D475ASD-5E0
Remedy
Tolerance
Shaft
Hole
0.15
0.35
+0.3
+0.3
Standard
clearance
Repair or
Replace
Clearance
limit
Replace
0.15 0.65
Standard clearance
Clearance limit
0 0.5
3.0
2.0
Adjust
294.20 490.33 kN {30 50 ton}
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
Criteria
Standard size
10
11
Recoil spring
Clearance between inner

cylinder and outer cylinder of
outer cylinder bushing
12
Press-fitting force for outer

cylinder bushing
(inner cylinder side)
13
Clearance between recoil

spring mount nut and lock
plate
Free length
Installation
length
1,713
1,425
Standard
size
445
Remedy
Repair limit
Installation
Installation
Free length
load
load
725.7 kN
{74,000 kg}
Tolerance
1,696
683.1 kN
{69,700 kg} Replace
Shaft
Hole
Standard
clearance
Clearance
limit
0.068
0.165
+0.323
+0.600
0.128
0.488
0.8
129.4 389.1 kN {13.2 39.7 ton}

Adjust
D475A, D475ASD-5E0
0 1.0
SEN00213-01
Idler
D475A, D475ASD-5E0
SEN00213-01
Unit: mm
No.
Check item
Criteria
Outside diameter of
protruding part
Remedy
Standard size
Repair limit
1,043
Outside diameter of tread

surface
990
959
Depth of tread
26.5
42
Thickness of tread
36
20.5
Overall width
347
Width of tread
96
105
Clearance between shaft

and bushing
Standard
size
180
Shaft
Hole
Standard
clearance
0.350
0.413
+0.168
+0.003
0.353
0.581
Clearance
limit
Standard size
Repair limit
335.0
Interference between ring

and shaft
Standard
size
Tolerance
Shaft
Hole
+0.046
+0.046
0.15
0.20
Replace
bushing
Rebuild or
replace
Width of shaft flange
115
10
Tolerance
Rebuild or
replace
Standard Interference
interference
limit
0.15 0.246
Standard size
Repair limit
0.52 0.98
Replace ring
End play
D475A, D475ASD-5E0
SEN00213-01
Track roller
D475A, D475ASD-5E0
SEN00213-01
2nd 7th track rollers (double flanged roller)

Unit: mm
No.
Check item
Outside diameter of flange

(outside)
Criteria
Remedy
Standard size
Repair limit
344

(inside)
332
300
246
Thickness of tread
71.5
44.5
Overall width
423
Width of tread
99.5
Width of flange
(Outside of flange)
34.5
19.5
Width of flange
(Inside of flange)
27.5
12.5
379
10

and bushing
Standard
size
147
11
Interference between shaft

and seal ring
Standard
size
84
12
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.350
0.413
+0.170
+0.170
0.350
0.583
Tolerance
Shaft
Hole
+0.046
+0.046
0.15
0.20
Replace
bushing
interference
limit
Replace
0.150
0.246
Standard size
Clearance limit
0.44 0.91
End play
D475A, D475ASD-5E0
Rebuild or
replace
Adjust or
replace
SEN00213-01
1st and 8th track rollers (single flanged roller)

Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
349
315
240
Thickness of tread
74
36.5
Overall width
423
Width of tread
99.5
Width of flange
34.5
19.5
379
10
Clearance between shaft and

bushing
Standard
size
157
11

and seal guide
Standard
size
95
12
10
End play
Tolerance
Shaft
Hole
Standard
clearance
0.350
0.413
+0.171
+0.007
0.350
0.583
Tolerance
Shaft
Hole
Standard
interference
+0.046
0
0.15
0.20
0.15
0.246
0.44 0.91
Rebuild or
replace
Clearance
limit
Replace
bushing
Interference
limit
Replace
Adjust or
replace
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00213-01
11
SEN00213-01
Carrier roller
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
275
Outside diameter of carrier

roller tread
240
215
Width of carrier roller tread
96
Thickness of tread
49.5
37
Width of flange
25
14

and ring
Tolerance
Rebuild or
replace
Shaft
Hole
Standard
interference
Standard
clearance
95
+0.046
+0.046
0.15
0.20
0.150
0.246
90
0.2
0.2
+0.35
+0.35
0 0.55
Standard
size
Replace
7

and support
Play in axial direction of

roller
12
Standard size
Clearance limit
0 0.22
D475A, D475ASD-5E0
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).
D475A, D475ASD-5E0
SEN00213-01
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
13
SEN00213-01
Track shoe
14
Portion P shows the link on the side where the bushing is pressed fitted.
D475A, D475ASD-5E0
SEN00213-01
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
317.8
320.8
Link pitch
Turn or
replace
Turning
Standard size
2
Load
Heavy load
116
107.5
110
22.5
14
16.5
Outside diameter of bushing
Thickness of bushing
Height of link
Standard size
Repair limit
199
181 (*1)
53.5
35.5 (*2)
One side
1.6
Both sides
3.2
Thickness of link
(bushing press-fitting portion)
Clearance
between links
Tolerance
Standard size
7
Interference between regular

pin and link
a. Regular
link
Shoe bolt
b. Master
link
Standard
interference
Shaft
Hole
113
+0.652
+0.552
+0.087
+0.087
0.465 0.652
70
+0.496
+0.436
+0.124
+0.050
0.312 0.446
Interference between bushing

and link
Tightening torque (Nm {kgm})
Tightening angle (deg)
785 78 {80 8}
180 10
980 98 {100 10}
180 10
Turn or
replace
Rebuild or
replace
Adjust or
replace
Retighten
*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
16
Check item
Criteria
Remedy
Standard size
Repair limit
105
35
133
63
Height of grouser
Overall height of shoe
Repair by
build-up
welding or
replace
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00213-01
17
SEN00213-01
Main frame
18
D475A, D475ASD-5E0
SEN00213-01
Unit: mm
No.
Check item
Criteria
Standard size
Interference between steering case and bushing
Repair limit
Tolerance
Standard
size
Remedy
Standard
clearance
Clearance
limit
+0.052
+0.052
(Std.interference)
0.004
0.108
Min. 0
Shaft
Hole
315
0.108
+0.056
Clearance between steering

frame and final drive cage
390
0.018
0.075
+0.057
+0.057
0.018
0.132
0.2

and cushion
78
0.030
0.060
+0.006
0.048
0.018
0.066
0.1
Clearance between ripper

arm mounting pin and
bushing
140
0.043
0.106
+0.210
+0.050
0.093
0.316
1.5
Clearance between ripper

cylinder mounting pin and
bushing
110
0.036
0.090
+0.301
+0.118
0.154
0.371
1.5
Clearance between radiator

guard mounting pin and
bushing
Hole 100.2
Shaft 100
0.036
0.090
+0.164
+0.062
0.298
0.454
1.5
Clearance between radiator

guard mounting pin and
bushing
Hole 115.2
Shaft 115
0.043
0.106
+0.140
+0.031
0.274
0.446
1.5
Clearance between equalizer

bar shaft and bushing
140
0.043
0.083
+0.208
+0.131
0.174
0.291
1.5
Protrusion of rubber at end

face of seal
Standard size
Repair limit
0.5
10
Free height of front mount

rubber
118
116
11
Free height of rear mount

rubber
58
56
12
Press-fitting force for ripper

arm mounting bushing
126.5 253 kN {12.9 25.8 ton}
13
Press-fitting force for ripper

cylinder mounting bushing
111.8 267.7 kN {11.4 27.3 ton}
14
Press-fitting force for radiator

guard mounting bushing
62.8 142.2 kN {6.4 14.5 ton}
15
Press-fitting force for radiator

guard mounting bushing
53.9 106.9 kN {5.5 10.9 ton}
16
Press-fitting force for

equalizer bar shaft mounting
bushing
65.7 153 kN {6.7 15.6 ton}
D475A, D475ASD-5E0
Replace
Adjust
19
SEN00213-01
Suspension
20
D475A, D475ASD-5E0
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
D475A, D475ASD-5E0
SEN00213-01
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).
21
SEN00213-01
Unit: mm
No.
Check item
Criteria
12
Press-fitting force for side

pin bushing
47.0 96.0 kN {4.8 9.8 ton}
13
Press-fitting force for side

pin bushing
121.5 294 kN {12.4 30 ton}
14
Press-fitting force for center pin bushing
68.6 232.2 kN {7 23.8 ton}
15
Clearance between center pin and bushing
Tolerance
Remedy
Shaft
Hole
Standard
clearance
140
0.043
0.083
+0.225
+0.143
0.186
0.308
1.0
Standard
size
Clearance
limit
16
Clearance between side

pin and bushing
115
0.048
0.078
+0.015
0.015
0.033
0.093
1.0
17
Clearance between pivot

shaft and bushing
260
0.190
0.271
+0.138
+0.026
0.216
0.409
1.0
18
Clearance between pivot

shaft and bushing
220
0.145
0.208
+0.114
+0.038
0.204
0.340
1.0
19
Interference between side

pin boss and bushing
Standard
size
Tolerance
interference
limit
Shaft
Hole
200
+0.051
+0.031
0.033
0.079
0.064
0.130
20
Interference between
thrust washer and seal
270
+0.216
+0.086
0.234
0.286
0.320
0.502
21
Interference between
thrust washer and seal
194
+0.096
+0.050
0.075
0.147
0.125
0.243
22
Interference between pivot

shaft and seal
263
+0.108
+0.056
0.122
0.203
0.178
0.311
22
Replace
bushing
Replace
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00213-01
23
SEN00213-01

2007 KOMATSU
All Rights Reserved
24
SEN00214-00
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

Hydraulic system, Part 1

Hydraulic system, Part 1 ................................................................................................................................. 2
Work equipment hydraulic equipment arrangement diagram............................................................... 2
PPC control piping diagram ................................................................................................................. 6
Work equipment control ....................................................................................................................... 8
Work equipment pump ....................................................................................................................... 10
PPC valve .......................................................................................................................................... 27
PCCS lever ........................................................................................................................................ 38
D475A, D475ASD-5E0
SEN00214-00
Work equipment hydraulic equipment arrangement diagram
Semi U-dozer (single 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.
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
D475A, D475ASD-5E0
7.
8.
9.
10.
11.
12.
Fan pump
Work equipment pump
L.H. blade lift cylinder
Blade pitch cylinder
Fan motor
Oil cooler
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
D475A, D475ASD-5E0
6.
7.
8.
9.
Ripper lift cylinder (left)

Ripper tilt cylinder (left)
Pin puller solenoid valve
Brake valve
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
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)
DC: Discharge
SC: Suction
10
Outline
q
This pump consists of two variable-capacity
swash plate-type piston pumps, CO valve, LS
valve, and EPC valve.
D475A, D475ASD-5E0
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
Front main pump

Rear main pump
LS valve
CO valve
LS-EPC valve
Front shaft
Cradle
Front case
Rocker cam
D475A, D475ASD-5E0
SEN00214-00
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
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.
12
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)
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
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.)
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
SEN00214-00
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.)
13
SEN00214-00
2. Control of delivery amount

q
q
q
14
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).
D475A, D475ASD-5E0
SEN00214-00
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
3.
4.
5.
6.
7.
8.
Ball
Spool
Spring
Retainer
Cover
Spring
4. CO valve
A. PPL : CO control pressure output port

B. PA : Pump port
A. PDP : Drain port
1.
2.
Plug
Servo piston assembly
D475A, D475ASD-5E0
15
SEN00214-00
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}.
16
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.
D475A, D475ASD-5E0
SEN00214-00
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.)
D475A, D475ASD-5E0
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).
17
SEN00214-00
(2) Operation in direction of maximum pump delivery amount
q
q
18
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 (dPLS) [the difference between oil
pressures (PLS) and (PP)] changes when
ports (D) and (E) of spool (6) are connected.
D475A, D475ASD-5E0
SEN00214-00
(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 (dPLS) 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
19
SEN00214-00
(4) When servo piston is balanced
20
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}.
D475A, D475ASD-5E0
SEN00214-00
The operation of the LS valve is shown in the following table.
Solenoid drive table

Single specification
Dual specification
Superdozer
specification
Raise
Lift
Lower
Left tilt
Left tilt limit

Single tilt
Right tilt
Right tilt limit

Blade
Left tilt
Left tilt limit
Right tilt
Right tilt limit
Rear pitch
Forward pitch
Dual tilt
Pitch
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
D475A, D475ASD-5E0
21
SEN00214-00
2) CO valve
(1) When actuator load is small and pump pressure (PP) is low
q
q
22
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.
D475A, D475ASD-5E0
SEN00214-00
(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
23
SEN00214-00
5. LS-EPC valve
A. PSIG : To LS valve
B. PT
: To tank
C. PEPC: From self pressure reducing valve
24
1.
2.
3.
4.
5.
6.
7.
Coil
Body
Spring
Spool
Rod
Plunger
Connector
D475A, D475ASD-5E0
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.
SEN00214-00
Operation
1)
q
q
q
D475A, D475ASD-5E0
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.
25
SEN00214-00
2)
q
q
q
26
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.
D475A, D475ASD-5E0
SEN00214-00
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
D475A, D475ASD-5E0
P3 : To blade tilt valve (LEFT TILT) PPC port

P4 : To blade tilt valve (RIGHT TILT) PPC port
T : To hydraulic tank
27
SEN00214-00
1.
2.
3.
4.
5.
6.
28
Spool
Metering spring
Centering spring
Piston
Disc
Nut (For connecting lever)
7.
8.
9.
10.
11.
Joint
Plate
Retainer
Body
Filter
D475A, D475ASD-5E0
SEN00214-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
12
Centering spring
(For port P1)
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
34.0 x 15.5
31.9
94 N
{9.6 kg}
75.2 N
{7.68 kg}
13
Centering spring
(For port P2)
43.2 x 15.5
34.0
78.5 N
{8 kg}
62.8 N
{6.4 kg}
14
Centering spring
(For ports P3 and P4)
48.57 x 15.5
32.5
107.9 N
{11 kg}
86.3 N
{8.8 kg}
15
Metering spring
(For port P1)
29.27 x 8.15
25.4
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
16
Metering spring
(For port P2)
26.3 x 8.15
24.1
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
17
Metering spring
26.53 x 8.15
24.9
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
D475A, D475ASD-5E0
If spring is
damaged or
deformed,
replace it
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).
30
(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).
D475A, D475ASD-5E0
SEN00214-00
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
SEN00214-00

(When control lever is returned)
q
32
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).
4) When lever is operated to stroke end

q
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).
D475A, D475ASD-5E0
5) When blade is floated

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.
D475A, D475ASD-5E0
SEN00214-00
6) When FLOAT state of blade is reset

q
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.
33
SEN00214-00
2. Ripper PPC valve
P
P1
P2
P3
P4
T
34
: 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
D475A, D475ASD-5E0
SEN00214-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
12
Centering spring
Free length
x Outside
diameter
Repair limit
Installed
length
Installed
load
50.4 x 15.5
Free length
Installed
load
34.0
55.9 N
{5.7 kg}
44.7 N
{4.56 kg}
13
Centering spring
50.1 x 15.5
34.0
71.4 N
{7.28 kg}
56.9 N
{5.8 kg}
14
Metering spring
26.5 x 8.20
24.9
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
D475A, D475ASD-5E0
If spring is
damaged or
deformed,
replace it
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.

(Neutral o Fine control)
q
36
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

(When control lever is returned)
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).
D475A, D475ASD-5E0
SEN00214-00
4) When lever is operated to stroke end

q
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).
37
SEN00214-00
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
38
5.
6.
7.
Screw
Lever
Connector
D475A, D475ASD-5E0
SEN00214-00
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.
D475A, D475ASD-5E0
2)
q
Operation for steering

Free return.
39
SEN00214-00
2. Output voltage characteristics

q
40
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.
D475A, D475ASD-5E0
SEN00214-00

2006 KOMATSU
All Rights Reserved
42
SEN00215-00
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up


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
D475A, D475ASD-5E0
SEN00215-00
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 lift PPC valve
: From blade lift PPC valve
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
6-spool valve
Cover 1
Cover 2
Merge-divider valve
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)
(on blade left tilt head side)
(on blade lift head side)
(on blade lift head side)
(on blade right tilt head side)
(on ripper lift head side)
D475A, D475ASD-5E0
8.
9.
10.
11.
12.
13.
14.

(on ripper lift bottom side)
(on blade right tilt bottom side)
(on blade lift bottom side)
(on blade lift bottom side)
(on blade left tilt bottom side)
(on ripper tilt bottom side)
Main relief valve
SEN00215-00
(4/8)
D475A, D475ASD-5E0
1.
2.
3.
4.
5.
6.
7.
8.
SEN00215-00
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
No.
Check item
Criteria
Remedy
Standard size
Spool return spring
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
54.5 x 34.8
51.2
393 N
{40.1 kg}
315 N
{32.1 kg}
301 N
{30.7 kg}
10
Spool return spring
54 x 34.8
50.5
377 N
{38.4 kg}
11
Spool return spring
69.9 x 34.8
65
390 N
{39.8 kg}
312 N
{31.8 kg}
12
Spool return spring
72.3 x 37.0
65.5
354 N
{36.1 kg}
283 N
{28.9 kg}
13
Spool return spring
52.9 x 22.3
33
274 N
{27.9 kg}
219 N
{22.3 kg}
D475A, D475ASD-5E0
If spring is
damaged or
deformed,
replace it.
SEN00215-00
(5/8)
D475A, D475ASD-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
SEN00215-00
Safety-suction valve (Blade left tilt head)

Safety-suction valve (Blade lift head)
Plug (Superdozer Spec.)
Safety-suction valve (Blade lift head)
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
Criteria
Remedy
Standard size
15
Check valve spring
D475A, D475ASD-5E0
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
11.5 x 4.6
8.5
1.5 N
{0.15 kg}
1.2 N
{0.12 kg}
If spring is
damaged or
deformed,
replace it.
SEN00215-00
(6/8)
10
D475A, D475ASD-5E0
1.
2.
SEN00215-00
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)
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
13
Piston return spring
D475A, D475ASD-5E0
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
36.9 x 11.1
28
29.4 N
{3 kg}
23.5 N
{2.4 kg}
If spring is
damaged or
deformed,
replace it.
11
SEN00215-00
(7/8)
12
D475A, D475ASD-5E0
SEN00215-00
Blade lift valve

2. Spool
3. Pressure compensation valve (Right)
4. Pressure compensation valve (Left)
5. Suction valve
Blade lift valve
7. Spool
8. Pressure compensation valve (Raise)
9. LS shuttle valve
10. Pressure compensation valve (Lower)
11. Suction valve
12. Check valve for regeneration circuit
Blade right tilt valve
13. Suction valve
14. Spool
15. Pressure compensation valve (Reverse)
17. Pressure compensation valve (Forward)
18. Suction valve
Ripper lift valve
19. Suction valve
20. Spool
21. Pressure compensation valve (Curl)
23. Pressure compensation valve (Dump)
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
25
26
Regeneration valve spring
Piston return spring
D475A, D475ASD-5E0
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
31.5 x 10.3
19.5
6.2 N
{0.6 kg}
4.9 N
{0.5 kg}
36.9 x 11.1
28
29.4 N
{3 kg}
23.5 N
{2.4 kg}
If spring is
damaged or
deformed,
replace it.
13
SEN00215-00
(8/8)
14
D475A, D475ASD-5E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
SEN00215-00
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
Criteria
Remedy
Standard size
19
Check valve spring
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
11.5 x 4.6
8.5
1.5 N
{0.15 kg}
1.2 N
{0.12 kg}
20
Spool return spring
46.6 x 21.8
33
156.8 N
{16.0 kg}
125.5 N
{12.8 kg}
21
Spool return spring
64.5 x 32.3
63
177.5 N
{18.1 kg}
142.0 N
{14.5 kg}
22
Sequence valve spring
70.9 x 18
59
199.8 N
{20.4 kg}
160.0 N
{16.3 kg}
D475A, D475ASD-5E0
If spring is
damaged or
deformed,
replace it.
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
CLSS
SEN00215-00
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
D475A, D475ASD-5E0
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.
17
SEN00215-00
2. Basic principle
1)
q
18
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.
D475A, D475ASD-5E0
2)
q
SEN00215-00
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
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.
D475A, D475ASD-5E0
4.
5.
Check valve
LS shuttle valve
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).
21
SEN00215-00
LS bypass plug
1.
2.
3.
4.
5.
22
Main pump
Main spool
LS shuttle valve
LS bypass plug
Function
q
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.
D475A, D475ASD-5E0
SEN00215-00
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.
24
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.
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.
34
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.
D475A, D475ASD-5E0
2.
q
SEN00215-00
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
36
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
2.
SEN00215-00
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
D475A, D475ASD-5E0
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.
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).
38
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
4.
SEN00215-00
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:
40
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
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
PPD
TLL
TLR
PTH
DUL
PPV
MFD
Raise
Lift
Lower
Left tilt
Single tilt
Right tilt
Left tilt
Blade
Left tilt limit

Dual tilt
Right tilt
Right tilt limit
Rear pitch
Forward pitch
Pitch
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
Solenoid drive table (Superdozer specification)

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

Blade
Single tilt
Right tilt
Right tilt limit

Rear pitch
Pitch
Forward pitch
q
q
Raise
Lift
Lower
Ripper
Raise
Tilt
Lower
D475A, D475ASD-5E0
41
SEN00215-00

2006 KOMATSU
All Rights Reserved
42
SEN00216-01
BULLDOZER
1SHOP MANUAL
2SHOP
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up


Hydraulic tank, hydraulic filter ......................................................................................................................... 2
Accumulator .................................................................................................................................................... 4
Work equipment cylinder ................................................................................................................................ 6
Piston valve..................................................................................................................................................... 8
Quick drop valve ........................................................................................................................................... 10
Blade control knob (Dual tilt specification) .................................................................................................... 12
Blade control knob (Superdozer specification) ............................................................................................. 13
Pitch and dual solenoid valve ....................................................................................................................... 14
Pin puller hydraulic circuit diagram ............................................................................................................... 15
Pin puller solenoid valve ............................................................................................................................... 16
D475A, D475ASD-5E0
SEN00216-01
Hydraulic tank, hydraulic filter
1.
2.
3.
4.
5.
6.
Cover
Sight gauge
Cover
Hydraulic tank
Oil filler cap
Hydraulic filter element
7.
8.
9.
10.
11.
12.
Spring
Suction valve
Strainer
Drain plug
Drain valve
Breather, with valve function
D475A, D475ASD-5E0
SEN00216-01
Specified value
Tank capacity
Hydraulic
tank
Breather
(l)
310
High
(l)
Level inside
Middle (l)
tank
Low
(l)
210
140
Cracking pressure
(kPa {kg/cm2})
17.0 2.5
{0.17 0.025}
Vacuum valve
actuating pressure
(kPa {kg/cm2})
2.0 0.3
{0.02 0.003 }
170
Specified value
150 30
{1.53 0.3}
Cracking pressure
(kPa {kg/cm2})
Hydraulic Mesh size
filter
Filtering area
Filtering oil flow
Strainer
Mesh size
Filtering area
D475A, D475ASD-5E0
(m)
2
(cm )
30/8
17,600
(l/min)
703
(m)
105
(cm )
3,600
SEN00216-01
Accumulator
For PPC valve
1.
2.
3.
4.
5.
6.
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.
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
D475A, D475ASD-5E0
SEN00216-01
SEN00216-01
Work equipment cylinder

q
Blade lift cylinder
Blade tilt cylinder, superdozer pitch cylinder
Ripper lift cylinder, ripper tilt cylinder
D475A, D475ASD-5E0
SEN00216-01
Pin puller cylinder
Unit: mm
No.
Check item
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
Blade lift
110
0.036
0.090
+0.261
+0.047
0.083
0.351
0.65
Blade tilt
140
0.043
0.106
+0.263
+0.047
0.090
0.369
0.67
Ripper lift
120
0.036
0.090
+0.263
+0.048
0.084
0.353
0.65
Ripper tilt
140
0.043
0.106
+0.263
+0.047
0.090
0.369
0.67
Pin puller
30
0.065
0.117
+0.133
+0.007
0.072
0.250
0.55
Blade lift
65
+0.5
+0.2
1.0
Blade tilt
90
0.300
0.200
+0.100
+0.013
0.200
0.400
1.0
Ripper lift
110
+0.207
+0.120
1.0
Ripper tilt
110
+0.207
+0.120
1.0
Pin puller
Ball
29
0.100
0.200
Blade lift
145
0.145
0.245
Blade tilt
90
Ripper lift
110
+0.207
+0.120
1.0
Ripper tilt
110
+0.195
+0.122
1.0
Clearance between cylinder

bottom support shaft and boss
26
+0.1
Clearance
between piston
rod and bushing
Clearance
between piston
rod support shaft
and bushing
Clearance
between cylinder
support shaft
bushing and yoke
Clearance
between cylinder
bottom support
shaft and bushing
D475A, D475ASD-5E0
+0.457
+0.370
Replace
1.0
SEN00216-01
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.
2.
When piston valve is open

The end of valve (6) touches the cylinder bottom before piston rod (1) reaches the stroke
end, and then valve (6) and piston valve (3) do
not move any more and only piston (2) continues moving.
At this time, the oil on the cylinder head side
which has been stopped by piston valve (3) is
relieved through piston valve seats (4) and (5),
thus the oil pressure in the cylinder does not
rise any more.
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.
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00216-01
SEN00216-01
Quick drop valve
For blade lift cylinder
2.
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.
1.
2.
Valve body
Spool
3.
4.
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.
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
SEN00216-01
Unit: mm
No.
Check item
Clearance between spool

and valve body
Criteria
Standard
size
38.0
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.011
0.016
+0.010
+0.016
0.011
0.026
0.03
Standard size
2
Valve spring
D475A, D475ASD-5E0
Remedy
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
75.2
55.9
136.3 N
{13.9 kg}
67.7
122.6 N
{12.5 kg}
Replace
11
SEN00216-01
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.
12
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.
D475A, D475ASD-5E0
SEN00216-01
Blade control knob (Superdozer specification)
1.
2.
3.
4.
5.
Forward pitch switch

Rear pitch switch
Cover
Connector (male)
Connector (female)
D475A, D475ASD-5E0
Outline
q
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.
13
SEN00216-01
Pitch and dual solenoid valve
1.
2.
3.
4.
5.
Connector
Solenoid (a)
Valve
Solenoid (b)
Manual push pin
A:
B:
P:
T:
Port A
Port B
Port P
Port T
14
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.
D475A, D475ASD-5E0
SEN00216-01
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})
Pin-puller solenoid valve
D475A, D475ASD-5E0
8. Pin-puller cylinder
9. Steering case
10. Scavenging pump
A: To transmission lubrication circuit
B: To torque converter circuit
C: To transmission valve circuit and torque
converter lockup circuit
15
SEN00216-01
Pin puller solenoid valve
1.
2.
3.
4.
5.
6.
7.
8.
9.
16
Plug
Spring
Spring retainer
Valve body
Spool
Spring retainer
Spring
Push pin
Solenoid assembly
A.
B.
C.
D.
To pin puller cylinder head

To pin puller cylinder bottom
To steering case
D475A, D475ASD-5E0
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).
D475A, D475ASD-5E0
SEN00216-01
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).
17
SEN00216-01

2008 KOMATSU
All Rights Reserved
18
SEN00217-00
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Cylinder stay ........................................................................................................................................ 2
Blade .................................................................................................................................................... 4
Ripper equipment................................................................................................................................. 8
D475A, D475ASD-5E0
SEN00217-00
Work equipment
Cylinder stay
Unit: mm
No.
Criteria
Tolerance
Hole
Standard
clearance
Clearance
limit
210
0.050
0.122
+0.167
+0.005
0.145
0.289
0.5

yoke and bushing
160
0.043
0.106
+0.192
+0.129
0.172
0.298
0.5
Clearance between lift cylinder

supporting shaft and bushing
145
0.145
0.245
+0.040
+0.016
0.145
0.285
0.5

yoke and bushing
Standard
size
Remedy
Shaft
Check item
Replace
D475A, D475ASD-5E0
SEN00217-00
Blade
Full U-dozer, Semi U-dozer, Superdozer
Unit: mm
D475A, D475ASD-5E0
No.
SEN00217-00
Check item
Clearance between brace pin

and brace
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
Shaft
Hole
90
0.2
0.3
+0.3
+0.1
0.3 0.6

and bracket
90
0.2
0.3
+0.3
+0.1
0.3 0.6

and bracket
90
0.3
0.4
+0.1
+0.6
0.3 0.5

and bushing
90
0.3
0.4
+0.1
+0.6
0.3 0.5
Clearance between center

brace and cap spherical
surface
200
0.2
0.3
+0.3
+0.6
0.2 0.6
Clearance between joint and

bracket
240
0.2
0.4
+1.5
+1.0
1.2 1.9
Clearance between frame pin

and joint
120
0.3
0.5
+0.3
+0.6
0.3 0.8
Clearance between frame pin

and bracket
120
0.3
0.5
+0.207
+0.120
0.420
0.707
Clearance between straight

frame joint bushings
185
+0.206
+0.166
0.014
0.060
0.152
0.266
10
Clearance between trunnion

and cap spherical surface
250
0.5
1.0
+1.0
+0.6
0.5 2.0
11
Clearance between joint and

bracket
240
0.2
0.4
+0.3
+0.1
0.3 0.7
12
Clearance between blade pin

and joint
120
0.3
0.5
+0.3
+0.6
0.3 0.8
13
Clearance between blade pin

and bracket
120
0.3
0.5
+0.208
+0.118
0.418
0.708
14

link pin and blade bracket
145
0.043
0.108
+0.225
+0.106
0.149
0.333
15

link pin and center link
145
0.043
0.108
+0.225
+0.106
0.149
0.333
16

link and blade bracket
550
0.2
0.8
+0.3
+0.6
0.2 1.1
17

brace spherical surface and cap
200
0.2
0.3
+0.3
+0.6
0.2 0.6
18
Clearance between lift

cylinder head pin and cylinder
65
0.3
0.5
+0.5
+0.2
0.5 1.0
19
Clearance between lift cylinder

head pin and cross joint
65
0.3
0.5
+0.3
+0.6
0.3 0.8
20

and lateral pin
65
0.3
0.5
+0.3
+0.6
0.3 0.8
21
Clearance between cross

joint and lateral pin
65
0.3
0.5
+0.5
+0.2
0.5 1.0
D475A, D475ASD-5E0
Replace
Adjust shim
or replace
Replace
Adjust shim
or replace
Replace
SEN00217-00
Cutting edge, end bit
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
510
383
Width of end bit
720
635
Height of end bit inside
393
330
Height of cutting edge
405
351 (240 after turned)
Height of end bit outside
Replace
Replace or
turn
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
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
140
0.043
0.106
+0.193
+0.050
0.093
0.299
1.5
Clearance between bushing

and beam and arm mount pin
140
0.043
0.106
+0.500
+0.300
0.343
0.606
1.5

mount pin and bushing
110
0.036
0.090
+0.289
+0.123
0.159
0.379
1.5
Outside diameter of shank

mount pin
Wear of point
Wear of protector
D475A, D475ASD-5E0
Standard size
Tolerance
Repair limit
100
0.3
Standard size
Repair limit
460
300
224
184
Replace
SEN00217-00
D475A, D475ASD-5 Bulldozer

2006 KOMATSU
All Rights Reserved
10
SEN00218-00
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

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.
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
Cab
SEN00218-00
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
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
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
A.
B.
C.
Fresh air
Recirculated air
Hot air/cold air
D475A, D475ASD-5E0
SEN00218-00
SEN00218-00

2006 KOMATSU
All Rights Reserved
SEN00219-02
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

Electrical system
Engine control system..................................................................................................................................... 2
CRI engine control system.............................................................................................................................. 6
Monitor system.............................................................................................................................................. 10
Machine monitor ........................................................................................................................................... 12
Mode selection system ................................................................................................................................. 30
Electrical equipment...................................................................................................................................... 34
Palm command control system (PCCS) ....................................................................................................... 36
Sensors......................................................................................................................................................... 38
Vehicle health monitoring system (VHMS).................................................................................................... 45
ORBCOMM terminal ..................................................................................................................................... 51
D475A, D475ASD-5E0
SEN00219-02
Engine control system
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Battery relay (Right)

Steering controller
Battery (Right)
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
SEN00219-02
System diagram
Note
The design of the machine monitor differs by a
machine. For details, see section Machine monitor.
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)
D475A, D475ASD-5E0
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).
SEN00219-02
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
D475A, D475ASD-5E0
SEN00219-02
SEN00219-02
CRI engine control system

a
CRI: Abbreviation for Common Rail Injection.
System diagram
1.
STD specification
D475A, D475ASD-5E0
1. NE speed sensor
2. Engine throttle controller
3. Injector assembly
3A. Orifice
3B. Control chamber
3C. Hydraulic piston
3D. Injector
3E. Nozzle
4. Fuel tank
5. Strainer
6. Pre fuel filter (with water separator)
7. Priming pump (main)
8. Fuel filter
9. Engine throttle controller cooler
10. Pressure limiter
11. Flow damper
12. High pressure injection pipe
13. Common rail
14. Fuel supply pump assembly
14A. PCV
14B. High pressure pump
14C. Feed pump
14D. Bypass valve
14E. Bkup speed sensor (G sensor)
15. Overflow valve
D475A, D475ASD-5E0
SEN00219-02
Outline
q
The signals detected by various sensors are
input to the engine 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.
System configuration
q
The CRI system consists of fuel supply pump
(14), common rail (13), injector (3), engine
throttle controller (2) 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)
(14A) 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 (3E) side of the injector and control
chamber (3B) 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 (3A). 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.
SEN00219-02
2.
Machine of poor fuel arrangement specification
D475A, D475ASD-5E0
1. NE speed sensor
2. Engine throttle controller
3. Injector assembly
3A. Orifice
3B. Control chamber
3C. Hydraulic piston
3D. Injector
3E. Nozzle
4. Orifice (For bleeding air)
5. Fuel tank
6. Strainer
7. Pre fuel filter (with water separator)
8. Priming pump
9. Fuel filter
10. Engine throttle controller cooler
11. Pressure limiter
12. Flow damper
13. High pressure injection pipe
14. Common rail
15. Fuel supply pump assembly
15A. PCV
15B. High pressure pump
15C. Feed pump
15D. Bypass valve
15E. Bkup speed sensor (G sensor)
16. Overflow valve
17. Air bleeding valve
18. Water separator
D475A, D475ASD-5E0
SEN00219-02
Outline
q
The signals detected by various sensors are
input to the engine 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.
System configuration
q
The CRI system consists of fuel supply pump
(15), common rail (14), injector (3), engine
throttle controller (2) 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)
(15A) 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 (3E) side of the injector and control
chamber (3B) 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 (3A). 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.
SEN00219-02
Monitor system
Note
Outline
q
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,
10
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
SEN00219-02
Processing in machine monitor (Common to all specifications)

Display of machine monitor
Contents and conditions of processing
Method
Flow of signals
1) Display of travel direction and gear speed.

F1, R3, etc. are notified by CAN signals according
to information of transmission controller.
CAN
Transmission controller o Steering

controller o Machine monitor
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 signals.
CAN
3) Display of failure
When the machine has a failure, the corresponding CAN
failure code is notified to the monitor panel by CAN
signals.
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 machine monitor displays code on the multiinformation section.
Engine speed sensor o Steering

Engine sensor/solenoid o Steering

controller or transmission controller
o Machine monitor
Sensors and solenoids o Engine

throttle controller o Steering
Display of monitoring condition

Method
Flow of signals
1) The communication conditions of each sensor,

each solenoid, and CAN signals are displayed.
The item Nos. and device conditions are notified to
the machine monitor by CAN signals.
The machine monitor displays the items and each
value on its multi-information section.
CAN
Each sensor o Steering controller

or transmission controller o
Machine monitor
Sensors o Engine throttle controller
o Steering controller o Machine
monitor
2) Each items is selected by using the cursor

switches, selector switches, buzzer cancel switch,
and shift UP/DOWN switches.
Machine monitor o Controller o

Machine monitor
Other items
Method
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
Steering controller o Machine

monitor
D475A, D475ASD-5E0
Note
CAN is abbreviation for Controller
Area Network, which is a
communication standard name
provided by ISO etc.
11
SEN00219-02
Machine monitor
Monitor portion
Serial No.: 30001 30070
1.
2.
3.
4.
5.
6.
Engine speedometer
Engine coolant temperature gauge
Power train oil temperature gauge
Hydraulic oil temperature gauge
Fuel level gauge
Display section A
(Travel direction and gear speed and others)
7. Torque converter lock-up indicator lamp
8. Charging condition caution lamp
9. Engine oil pressure caution lamp
10. Engine coolant temperature caution lamp
11. Power train oil temperature caution lamp
12. Hydraulic oil temperature caution lamp
12
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Air cleaner clogging caution lamp

Radiator coolant level caution lamp
Hydraulic oil level caution lamp
Engine oil level caution lamp
Engine pre-heating indicator lamp
Maintenance caution lamp
Dual tilt selector indicator lamp
Warning red lamp
Radiator fan operation indicator orange lamp
Display section B (Multi-information)
Mode selection switches portion
No.15 and No.16 are optional.
D475A, D475ASD-5E0
SEN00219-02
Serial No.: 30071 and up
1.
2.
3.
4.
5.
6.
Engine speedometer
Engine coolant temperature gauge
Power train oil temperature gauge
Hydraulic oil temperature gauge
Fuel level gauge
Display section A
(Travel direction and gear speed and others)
7. Torque converter lock-up indicator lamp
8. Charging condition caution lamp
9. Engine oil pressure caution lamp
10. Engine coolant temperature caution lamp
11. Power train oil temperature caution lamp
12. Hydraulic oil temperature caution lamp
D475A, D475ASD-5E0
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Air cleaner clogging caution lamp

Radiator coolant level caution lamp
Hydraulic oil level caution lamp
Engine oil level caution lamp
Engine pre-heating indicator lamp
Maintenance caution lamp
Dual tilt selector indicator lamp
Warning red lamp
Radiator fan operation indicator orange lamp
Radiator fan operation indicator lamp/symbol
(The indicator which admits change operation)
No.15 and No.16 are optional.
13
SEN00219-02
Outline
q
The monitor section is an LCD screen which
consists of the gauges that constantly indicate
the machine condition, character screen that
displays the current travel condition of the
machine (travel direction and gear speed),
caution lamps that indicate abnormalities of the
machine, indicator lamps that show the operation guide, and multi-information unit that displays the service meter and maintenance
information.
The CPU in the machine monitor processes
the signals from the sensors at various places
of the machine and indicates the results on the
screen.
3.
Indicators
The necessary timings of the operations of the
machine are indicated by the indicator lamps in
the monitor section.
Indication items (type of the indicator lamps),
their operations, and their indication methods
are shown in the List of display of cautions
and indicators which will appear later.
The blinking intervals of the indicator lamps
are the same with the caution lamps.
Operation
1. Operation check (Check before starting)
While the engine is stopped (five or more seconds after the engine is stopped), if the power
is turned ON (the starting switch is turned to
the ON position), all items of the gauges, indicator lamps and caution lamps of the monitor
section operate as follows to indicate that each
of them operates normally.
1) All items of the gauges, indicator lamps
and caution lamps light for about 3 seconds and then go off.
2) The alarm buzzer sounds for about 1 second, synchronizing with 1) above.
2.
14
Cautions
If the machine has any trouble, the caution
lamp corresponding to the trouble part in the
monitor section blinks or lights and the alarm
buzzer sounds as required.
The caution items (types of the caution lamps),
caution lamps corresponding to the caution
items, and operation of the alarm buzzer are
shown in the List of display of cautions and
indicators which will appear later.
All the items, except the items of indication category Check before starting in List of display
of cautions and indicators shown later, are
monitored while the engine is running, from the
start to the stop of the engine.
The items of display category Check before
starting are monitored from when the starting
switch is turned ON while the engine is
stopped.
The blinking intervals of the caution lamps and
the sounding intervals of the alarm buzzer are
set to about 0.8 seconds, which fluctuates
more or less when the ambient temperature is
low (below about 10C), but that does not
indicate trouble.
D475A, D475ASD-5E0
4.
Gauges
The gauges display the typical drawing of the
items that the operator monitors constantly
before and during operation among the information items (signals) from the sensors at various parts of the machine.
The gauges display constantly from when the
starting switch is turned ON to when the starting switch is turned OFF and operates constantly while the engine is running.
Each scale does not read values but indicates
colored ranges. The pointer is indicated by
changing (turning ON and OFF) the color of a
narrow LCD segment.
The operator checks in which range of each
gauge the coloring segment is (or the position
of the first segment when multiple coloring
segments are displayed in the gauge).
The types, designs and displayed color bands
of the gauges are shown in the List of display
of gauges which will appear later.
The thermometer among the gauges, if the
above segment indicates the red range, the
caution lamp and the alarm buzzer described
before operate, too.
For the relationship between the gauge (thermometer), caution lamp and alarm buzzer, see
the List of display of cautions and indicators
which will appear later.
D475A, D475ASD-5E0
SEN00219-02
5.
Display section A
Display section A displays the following.
(1) Normal display (Operation mode display)
T h e c u r r e n t tr av el o p e r a t i o n of t h e
machine is indicated by alphanumerics.
That is, travel in forward 1st gear is indicated by F1, travel at reverse 2nd gear is
indicated by R2, and setting of the gear in
neutral is indicated by N. If the parking
brake is set in the parking position, P is
displayed.
The CPU of this monitor system processes and indicates the set information
items (signals) of the PCCS lever and
parking brake lever and those from the
transmission controller.
Note: PCCS: Abbreviation for Palm command control system. For details, see
the Operation and Maintenance Manual.
(2) Special display (Service mode choice display)
T h is i s sp ec ia l d is pl ay wh ic h i s no t
described in the Operation and Maintenance Manual. It is used by the servicemen
for testing, adjusting, troubleshooting, etc.
In this case, the display of display section
B described later is changed to various
service mode displays, and display section A is also changed to indicate which
service mode is selected by display section B.
The selected service mode is indicated by
the service mode type code of 2 alphanumeric letters such as 1C, EE, bE, etc. For
details, see 30 Testing and adjusting of
this manual.
15
SEN00219-02
6.
16

Display section B is called the multi-information unit, which is set in the operation mode
when the starting switch is turned ON and
which has the following 4 types of indicating
function.
(1) Default (Operation mode display)
While the machine is in operation, display
section B displays the service meter (integrated operating time of the machine) and
the preset forward and reverse gear
speeds.
The service meter advances and the hourglass symbol at the service meter head
blinks while the engine is running.
This machine has the function of driving in
the preset forward or reverse gear speed.
The preset gear speed is indicated by F*
for forward and R* for reverse on the left
of the service meter to indicate that the
transmission is preset and the preset gear
speed.
(2) Maintenance display
The display can be changed with a specified switch to indicate the information
related to the maintenance of the
machine.
The following modes can be selected by
this function. For details of them and the
operating procedure, see the Operation
and Maintenance Manual or 30 Testing
and adjusting of this manual.
q
Maintenance mode
q
PM clinic auxiliary mode
q
Error code display mode
q
Adjustment mode
(3) Action code display
If a serious trouble occurs which should
be notified to the operator while the
machine is operating in the normal display
mode, the action code is displayed instead
of the normal display.
Action codes are alphanumerics such as
E01, E02, etc. The types and meanings of
them and remedies for them are described
in the Operation and Maintenance Manual
or 30 Testing and adjusting of this manual.
If an action code other than E01 is displayed, the warning lamp (red) blinks and
the alarm buzzer sounds, too.
(4) Special display (Service mode display)

This is the special display described in
Display section A, (2). The modes corresponding to the various service modes
displayed in Display section A are displayed.
For the types and meanings of the various
service modes and remedies for them,
see 30 Testing and adjusting of this manual.
As explained in Display section A, (2), this
display is not described either in the Operation and Maintenance Manual.
D475A, D475ASD-5E0
SEN00219-02
List of display of cautions and indicators

Serial No.: 30001 30070
Display
category
Symbol
Indicated item
Indication range
Indication method
Check before starting
Radiator coolant level
Engine oil level

(If equipped)
Below low level
Displayed when starting switch is

turned ON while engine is
stopped or when abnormality
occurs.
When normal: OFF
When abnormal: Blinking.
Warning lamp blinks and
alarm buzzer sounds, too.
Hydraulic oil level

(If equipped)
Charging condition
When charging is defective
Engine oil press.
Below 49.0 kPa {0.5 kg/cm2}
Below low level
Air cleaner clogging
When clogged
Reference: Below 650 mmH2O
Hydraulic oil level

(If equipped)
Below low level
Cautions
SAP00522
Engine coolant temp.
D475A, D475ASD-5E0
When coolant temp. gauge is in

red range (above 102C)
Displayed when abnormality

occurs while engine is running.
When normal: OFF
Displayed when abnormality occurs while engine is running.

102C 105C (1st red segment):
Blinking
Above 105C (2nd red segment):
Blinking. Warning lamp blinks and
17
SEN00219-02
Display
category
Symbol
Indicated item
When power train oil temp.

gauge is in red range (above
120C)
Hydraulic oil temp.
When hydraulic oil temperature

100C)

Blinking
Maintenance
After replacement period of filter

or oil

When normal: OFF
When abnormal: ON
Engine oil level

(If equipped)
Alarm
Auxiliary caution
Red
Non-symbol
The whole engine drive does not

work.
Blinking: Blinks if caution having *

in indicated item column blinks.
Blinks if action code other than
E01 is displayed in Display
section A (Multi-information)
OFF: Same as cautions having *
in indicated item column.
When engine is preheated
During preheating period: ON

Other than preheating period:
OFF
If engine controller judges from
coolant temperature that
preheating is necessary,
automatic preheating starts.
When starting switch is turned to
preheating position (turned left),
preheating starts, too.
When possible
When possible: ON
When impossible: OFF
Turned ON when tilt switch of
blade (work equipment) control
lever is turned to dual tilt
operation position (dual tilt
operation is possible) and turned
OFF when returned.
Indicators
Engine preheater
(Electric heater ONOFF)
Indication that dual tilt

operation is possible
18
Indication method
Blinking
Power train oil temp.
Cautions
Indication range
D475A, D475ASD-5E0
Display
category
Symbol
Indicators
Orange
Non-symbol
Indicated item
Indication that engine

can be started with
cooling fan in reserve
direction for cleaning
cooling device such as
radiator and that
cooling fan rotation
direction cannot be
changed while engine
is running regardless of
current cooling fan
rotation direction
SEN00219-02
Indication range
Indication method
ON: Turned ON when fan rotation
selector switch is turned to CLN
position.
ON: When cooling fan rotation

direction is in reverse rotation
mode
Blinking: When cooling fan
rotation direction cannot be
changed
Blinking: Blinks for 3 seconds to

notify that cooling fan rotation
direction cannot be changed
when fan rotation selector switch
is operated while engine is
running.
OFF: Turned OFF when fan
rotation selector switch is
operated again while this lamp is
ON (At this time, cooling fan
rotation direction is set in forward
rotation mode).
Lamp position
Lock-up mode ONOFF
In lock-up mode
ON: In lock-up mode

OFF: In torque converter drive
mode
D475A, D475ASD-5E0
19
SEN00219-02
List of display of cautions and indicators

Display
category
Symbol
Indicated item
Indication range
Indication method
Check before starting
Engine oil level

(If equipped)
Below low level
Displayed when starting switch is

turned ON while engine is
stopped or when abnormality
occurs.
When normal: OFF
Hydraulic oil level

(If equipped)
Charging condition
When charging is defective
Engine oil press.
Below 49.0 kPa {0.5 kg/cm2}
Below low level
When clogged
Reference: Below 650 mmH2O
Hydraulic oil level

(If equipped)
Below low level
Engine coolant temp.

102C 105C (1st red segment
and all segments under it): BlinkWhen coolant temperature gauge
ing
is in red range (above 102C)
Above 105C (2nd red segment
and all segments under it): Blinking. Warning lamp blinks and
Cautions
SAP00522
20
Displayed when abnormality

occurs while engine is running.
When normal: OFF
D475A, D475ASD-5E0
Display
category
Symbol
Indicated item
Power train oil temp.
SEN00219-02
Indication range

When power train oil temperature and all segments under it): Blinkgauge is in red range (above
ing
120C)
When hydraulic oil temperature

100C)
Maintenance
After replacement period of filter

or oil

When normal: OFF
When abnormal: ON
Cautions
Hydraulic oil temp.

and all segments under it): Blinking
Engine oil level

(If equipped)
Alarm
Auxiliary caution
Red
Non-symbol
The whole engine drive does not

work.
Blinking: Blinks if caution having *

in indicated item column blinks.
Blinks if action code other than
E01 is displayed in Display
section A (Multi-information)
OFF: Same as cautions having *
in indicated item column.
When engine is preheated
During preheating period: ON

Other than preheating period:
OFF
If engine controller judges from
coolant temperature that
preheating is necessary,
automatic preheating starts.
When starting switch is turned to
preheating position (turned left),
preheating starts, too.
When possible
When possible: ON
When impossible: OFF
Turned ON when tilt switch of
blade (work equipment) control
lever is turned to dual tilt
operation position (dual tilt
operation is possible) and turned
OFF when returned.
Indicators
Engine preheater
(Electric heater ONOFF)
Indication that dual tilt

operation is possible
D475A, D475ASD-5E0
Indication method
21
SEN00219-02
Display
category
Symbol
Indicated item
Indication range
Indicators
Indication that cooling

fan rotation direction is
When cooling fan rotation
in reserve rotation
direction is in reserve rotation
mode when cooling
mode
device such as radiator
is being cleaned
Orange
Non-symbol
Indication that cooling

fan rotation direction
cannot be changed
When cooling fan rotation
while engine is running
regardless of current
cooling fan rotation
direction
Indication method
ON: Turned ON when fan rotation
selector switch is turned to CLN
position.
OFF: Turned OFF when fan
rotation selector switch is
operated again while this lamp is
ON (At this time, cooling fan
rotation direction is set in forward
rotation mode).
Blinking: Blinks for 3 seconds to
notify that cooling fan rotation
when fan rotation selector switch
is operated while engine is
running.
Lamp position
Lock-up mode ONOFF
In lock-up mode
ON: In lock-up mode
OFF: In torque converter drive
mode
22
D475A, D475ASD-5E0
SEN00219-02
List of display of gauges

Serial No.: 30001 30070
Display
category
Symbol
Indicated item
Indication range
Indication method
Engine coolant
temperature
Corresponding segment (1 place)
is turned ON.
Power train oil
temperature
Gauges
Hydraulic oil
temperature
Corresponding segment and all

segments under it are turned ON.
Fuel level
Engine speed
D475A, D475ASD-5E0

23
SEN00219-02

Display
category
Symbol
Indicated item
Indication range
Indication method
Engine coolant
temperature
Gauges
Power train oil

temperature
Hydraulic oil
temperature

Fuel level
Engine speed
24
D475A, D475ASD-5E0
SEN00219-02
Outline of display section A and display section B

Display
section
Form and position
Display section A
Serial No.: 30001 30070

Fig. reference of 12 page.
Fig. reference of 13 page.
Indicated item
1) Normal display (Operation mode
display)
Current travel direction and
gear speed
Forward 1st: F1
Reverse 2nd: R2, etc.
Neutral: N, Parking: P
Indication method
Display unit consist of 18 segments
and indicates various alphanumerics
by turning on corresponding segments.
Example of forward 1st gear
2) Special display
(Service mode display)
Selected service mode symbol
when display section B is changed
For details of selection of normal disto special display
play and special display, see 30 Testing and adjusting of this manual.
1) Normal display
Display unit displays 2 16-alphanu(Operation mode display)
meric lines.
Preset forward gear speed and
Preset gear speed is displayed by verreverse gear speed.
tically enlarged letters, however.
Service meter (Integrated oper- For details of selection of this display
ating hours of machine)
and normal display, see 30 Testing
and adjusting of this manual.
D475A, D475ASD-5E0
2) Indication of maintenance
1) Example of normal display
Following modes related to maintenance and indicated by selecting
operation
Maintenance mode
PM clinic auxiliary mode
Failure indication mode
2) Example of maintenance display
Adjustment mode
3 Indication of action code
If serious trouble occurs while
machine is operating, action code
is displayed automatically instead
3 Example of action code
of normal display
25
SEN00219-02
Display
section
26
Form and position
Indicated item
4) Special display (Service mode display)
Machine information necessary to
service is displayed by special
selecting operation.
Information is displayed in following modes.
1C: Maintenance interval
change mode
EE: Electric system error code
display mode
bE: Mechanical system error
code display mode
Cb: Adjustment mode
Ld: Load memory display mode
5R: Real-time monitoring mode
dR: Dual display monitoring
mode
Indication method
4) Example of special display
Note: Service mode symbols (1C, EE,

etc.) shown in indicated item column are
selected service mode symbols described
in Display section A, which are displayed
in Display section A.
D475A, D475ASD-5E0
SEN00219-02

The machine monitor has the Mode selector
switch section to operate the Mode selection system described later.
Serial No.: 30001 30070
Note: The switch operations of the 2 serial No.

group machines are the same.
D475A, D475ASD-5E0
27
SEN00219-02
1.
Switch functions
a)
b)
c)
q
ON-OFF switching in lock-up mode

Economy mode setting OFF, mode 1,
mode 2
ON-OFF switching in reverse slow mode
Option
The machine with SSC (Shoe slip control)
fu nc t io n pu t on o pt io na l ly ha s t he n ex t
switches.
a)
b)
c)
d)
e)
ON-OFF switching in lock-up mode

Economy mode setting OFF, mode 1,
mode 2
ON-OFF switching in reverse slow mode
ON-OFF switching in SSC mode
SSC mode level setting Mode 1 to 5
2.
Operation
For the operation, see Mode selection system.
3.
Initial setting when key is turned ON

When a new machine is shipped from the factory, all the functions are turned OFF as a rule
so that the operator can select only the necessary functions depending on the job site condition.
28
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00219-02
29
SEN00219-02
Mode selection system
System diagram
Note
30
D475A, D475ASD-5E0
Outline
q
In this section, SSC (Shoe slip control) which is
an optional device, is also explained for reasons of compilation.
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 following engine control modes are available; Economy mode control used for dozing,
SSC used for ripping, reverse slow mode control for both dozing and ripping, and lock-up
control to select the direct drive or torque converter drive.
SEN00219-02
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.
Function of mode selection system

T he sy stem c onsists of the mode selec tion
switches installed to machine monitor (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 lock-up system of the torque
converter according to the signals from the transmission output speed sensor, and various sensors.
The function of each controller is explained below.
Functions of steering controller and 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 mode selection
switches, and speed information from the
transmission controller, then sends it as the
SSC command to the engine controller.
4. The transmission controller sends lock-up signal to the lock-up solenoid valve, judging from
input gear speed information from the transmission controller.
a See Operation of torque converter Lockup control system.
D475A, D475ASD-5E0
31
SEN00219-02
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.
a
a
32
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.
Note 1: When the lock-up mode is not selected, the other Economy, Reverse slow, SSC, and Rock-bed
selection modes can be selected simultaneously.
Note 2: When the lock-up mode is selected, Reverse slow mode can be selected simultaneously, but
Economy, SSC, and Rock-bed selection modes cannot be selected simultaneously.
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00219-02
33
SEN00219-02
Electrical equipment
Operation of lamp system
Lamp system circuit diagram
34
D475A, D475ASD-5E0
SEN00219-02
Engine preheating (Electrical intake air heater) control
Preheating circuit
D475A, D475ASD-5E0
35
SEN00219-02
Palm command control system (PCCS)
1.
2.
3.
4.
5.
6.
7.
8.
9.
36
Machine monitor
Auto shift down switch
Engine controller
Steering controller
Transmission output shaft speed sensor
Engine speed sensor
Note
D475A, D475ASD-5E0
Shift mode function

Function
If you shift the PCCS lever to the forward or
reverse, the gear speed selected from the shift
mode is turned on.
PCCS lever is control lever of steering, directional
and gear shift in joystick lever of left hand.
PCCS is abbreviation of Palm command control
system.
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.
SEN00219-02
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
Display
The selected shift mode is displayed on the Multiinformation.
For the Multi-information, see Machine monitor.
D475A, D475ASD-5E0
37
SEN00219-02
Sensors
1
Type of sensor
Sensor method
When normal
When abnormal
Engine oil pressure
Contact
OFF
ON
Engine coolant temperature
Resistance
Torque converter oil temperature
Resistance
Hydraulic oil temperature
Resistance
Contact
ON
OFF
Fuel level
Resistance
Engine oil level
Contact
ON
OFF
Contact
ON
OFF
Resistance
Torque converter speed sensor
Resistance
Acceleration sensor
Resistance
Pitch angle sensor
Resistance
Engine oil pressure sensor
1.
2.
3.
38
Plug
Contact ring
Contact
4.
5.
6.
Diaphragm
Spring
Terminal
D475A, D475ASD-5E0
SEN00219-02
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
4.
5.
Wire
Connector
Radiator coolant level sensor
1.
2.
3.
Float
Sensor
Tube
D475A, D475ASD-5E0
39
SEN00219-02
Fuel level sensor
1.
2.
3.
4.
5.
6.
7.
40
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
SEN00219-02
Engine oil level sensor
1.
2.
3.
Float
Sensor
Tube
4.
5.
Wire
Connector
4.
5.
Wire
Connector
Air cleaner clogging sensor
1.
2.
3.
Boss
Switch
Conduit
D475A, D475ASD-5E0
41
SEN00219-02
1.
2.
3.
Magnet
Terminal
Case
4.
5.
Boots
Connector
Torque converter speed sensor
1.
2.
3.
42
Connector
Flange
Sensor
D475A, D475ASD-5E0
SEN00219-02
Acceleration sensor
1.
2.
3.
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.
D475A, D475ASD-5E0
43
SEN00219-02
Pitch angle sensor
1.
2.
3.
4.
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.
44
D475A, D475ASD-5E0
SEN00219-02
Vehicle health monitoring system (VHMS)

Outline
q
The VHMS consists of the VHMS controller
and various sensors (some of which are used
by others systems, too) and records the operating condition of the machine. It collects and
records the position information and operation
information of the machine, data of measuring
instruments, etc. for later maintenance and
service. The data to be checked are downloaded to a personal computer.
If the ORBCOMM terminal system is installed

to the machine, it can transmit the data
recorded in the VHMS by satellite communication for the wireless management by the
administrator or the service department.
For the use of the VHMS, see 30 Testing and
adjusting, Part 4 of this manual.
VHMS controller
D475A, D475ASD-5E0
45
SEN00219-02
Input and output signals

CN1 [CN 1]
Pin No.
CN2 [CN2 A, B]
Signal name
CN1-1 NC
Input/
Output
Pin No.
Signal name
Input/
Output
CN2-A1 NC
CN1-2 Sensor power supply (24V)
Output
CN2-A2 NC
Output
CN2-A3 NC
Output
CN2-A4 NC
Output
CN2-A5 Exhaust temperature (Right 1)
Input
CN2-A6 Exhaust temperature (Left 2)
Input
CN2-A7 Exhaust temperature (Left 1)
Input
Power supply (Constant power supply)

(24V)
Input
Power supply (Constant power supply)

CN1-7
(24V)
Input
CN1-8 BR power supply (24V)
Input
CN1-9 BR power supply (24V)
Input
CN1-6
CN1-10 NC
CN1-11 GND
Input
CN1-12 GND
Input
CN1-13 NC
CN1-14 NC
CN1-15 NC
CN1-16 NC
CN1-17 Start signal

CN1-18 NC
Input
CN1-19 GND
Input
CN1-20 GND
Input
CN2-A8 NC
CN2-A9 DIS_SELO (OPEN)
Input
CN2-A10 NC
CN2-A11 NC
CN2-A12 Sensor GND
Input
CN2-A13 Sensor GND
Input
CN2-A14 NC
CN2-A15 Transmission, main oil pressure
Input
CN2-A16 Exhaust temperature (Right 2)
Input
CN2-A17 WAKE UP (Low)
Input
CN2-A18 Blow-by pressure
Input
CN2-B1 NC
CN2-B2 NC
CN2-B3 NC
CN2-B4 NC
CN2-B5 NC
CN2-B6 Wake up HI
Input
CN2-B7 NC
CN2-B8 NC
CN2-B9 GND
Input
CN2-B10 NC
CN2-B11 NC
CN2-B12 CONNECTOR Selection 1 (GND)
46
Input
D475A, D475ASD-5E0
CN3 [CN 3 A, B]
Pin No.
SEN00219-02
CN4 [CN 4 A, B]
Signal name
CN3-A1 NC
CN3-A2 CAB out D/L Sw
Input/
Output
Pin No.
Signal name
CN4-A1 NC
Input
CN4-A2 NC
CN3-A3 NC
CN4-A3 GND
CN3-A4 NC
CN4-A4 CAN (1) H (KOM-NET/c)
CN3-A5
Model selection
(See ORB connection)
Input
CN3-A6 NC
CN3-A7 NC
CN3-A8 NC
CN3-A9
CONNECTOR SELECTION 2
(OPEN)
Input/
Output
Input
CN4-A5 CAN (0) shield CGC

CN4-A6 CAN (0) H CGC
Input/
Output
Input
Input/
Output
CN4-A7 NC
CN4-A8 NC
CN4-A9 GND
Input
CN3-A10 NC
CN4-A10 RS232C RX0 (PC Tool)
Input
CN3-A11 NC
CN4-A11 RS232C TX0 (PC Tool)
Output
CN3-A12 NC
CN4-A12 CAN (1) L (KOM-NET/c)
Input/
Output
CN3-A13 GND
Input
CN4-A13 CAN (1) SH (KOM-NET/c)
Input
CN3-A14 NC
CN3-A15 NC
CN4-A14 CAN (0) L CGC
CN3-A16 NC
CN4-B1 NC
CN3-A17 NC
Input
CN4-B2 NC
CN3-A18 NC
CN4-B3 RS232C GND
CN3-B1 NC
CN4-B4 RS232C TX1 (Orbcomm)
CN3-B2 NC
CN4-B5 NC
CN3-B3 NC
CN4-B6 NC
CN3-B4 NC
CN4-B7 NC
CN3-B5 NC
CN4-B8 NC
CN3-B6 Snap shot Sw
Input
CN3-B7 NC
CN3-B8 NC
CN3-B9 GND
Input
CN3-B10 NC
CN3-B11 NC
CONNECTOR SELECTION 3
CN3-B12
(OPEN)
D475A, D475ASD-5E0
Input
Input/
Output
Input
Output
CN4-B9 GND
Input
CN4-B10 RS232C RX1 (Orbcomm)
Input
CN5
Pin No.
Signal name
Input/
Output
TX +
Output
TX
Output
RX +
Input
RT 3
Input
RT 4
Input
RX
Input
RT 1
Input
RT 2
Input
NC
10
GND
11
5 V POWER SUPPLY
12
GND
Output
Input
47
SEN00219-02
Sensors
Engine oil temperature sensor
Exhaust temperature sensor/amplifier
Specifications
Specifications
Type of sensor:
Thermistor
Rated voltage:
Measurement range:
40 130C
80 130C
(Assured accuracy: 2C)
Sensed temperature range: 100 1,000C

300 800C
(Assured accuracy: 10C)
Max. power consumption: 0.5 mW

Pressure resistance:
4.9 MPa {50 kg/cm}
Using temperature:
30C to +140C
Performance table
Temper- Resis- Temper- Resis- Temper- Resisature
tance
ature
tance
ature
tance
(C)
(kz)
(C)
(kz)
(C)
(kz)
30
35.27
80
6.571
110
2.887
40
24.28
85
5.682
115
2.544
50
17.05
90
4.931
120
2.248
60
12.20
95
4.293
125
1.992
70
8.884
100
3.750
130
1.769
a:
Heat sensing part of sensor Outside diameter of mounting part: R1/4
Function
The engine oil temperature sensor is installed to
the engine oil filter. It inputs the change of the temperature as the change of the thermistor resistance
to the VHMS controller.
48
DC 24 V
Output voltage characteristics

(Ambient temperature: 20C)
Reference values
Sensed
temperature
(C)
50
Output voltage
1.191
(V)
100
400
700
800
1.397
2.626
3.899
4.316
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)
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.
D475A, D475ASD-5E0
SEN00219-02
Atmospheric temperature sensor

Specifications
Power consumption:
Max. 0.5 mW
Pressure resistance:
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)
a.
20
10
10
20
50
30.32 18.58 11.74 7.623 5.077 1.712
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.
D475A, D475ASD-5E0
49
SEN00219-02
Engine blow-by pressure sensor
1.
2.
3.
Sensor
Connector
Atmospheric pressure intake tube
A.
B.
C.
GND (Black)
Power supply (Red)
Output (White)
Specifications and function

Pressure range:
0 20 kPa
{0 2,040 mmH2O}
Allowable pressure:
20 to 100 kPa
{2,040 to 10,200 mmH2O}
Source voltage:
5 0.25 V
Output characteristics:See graph.

q
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.
50
Sensor
Connector
D475A, D475ASD-5E0
SEN00219-02
ORBCOMM terminal
1.
2.
Communication antenna connection

DRC connector (40-pole) connection
Outline
q
The ORBCOMM terminal obtains various kinds of machine information recorded in the VHMS controller
and transmits them via the wireless communication antenna. It has a CPU (Central Processing Unit)
and wireless communication function.
q
This terminal has an LED lamp and a 7-segment display lamp used for inspection and troubleshooting.
Input/Output signals
q
DRC connector
Pin No.
Input/Output
Pin No.
NC
Signal name
16
NC
Signal name
Input/Output
NC
17
NC
NC
18
NC
COMM 232C RXD
Input
19
PWR_CTR_EXT
COMM 232C TXD
Output
20
NC
NC
21
NC
NC
22
NC
NC
23
NC
NC
24
NC
10
NC
25
NC
Output
11
GND_RS232C
26
NC
12
NC
27
NC
13
NC
28
NC
14
NC
29
DOUT (GND)
15
NC
30
GND
31
NC
32
NC
33
NC
34
NC
35
NC
36
PWR_CTR_KEY
37
GND_PWR
38
GND_PWR
39
PWR_IN_BATT
Input
40
PWR_IN_BATT
Input
D475A, D475ASD-5E0
Output
Input
51
SEN00219-02
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.
52
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN00219-02
53
SEN00219-02

2009 KOMATSU
All Rights Reserved
54
SEN01816-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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
Item
Machine model
D475A, D475ASD-5E0
Engine
SAA12V140E-3
Measurement conditions
Speed
High idle (*1)

Low idle
Rated speed
Intake air pressure

(Boost pressure)
At rated output
Exhaust temperature
Whole speed range

(Outside air temperature: 20C)
Exhaust gas color
At sudden acceleration
At high idle (*1)
Valve clearance
(At normal temperature)
Intake valve
Exhaust valve
Compression pressure
(Engine oil: SAE15W-40
or SAE30)
Oil temperature: 40 60 C
(Engine speed)
Blow-by pressure
(Engine oil: SAE15W-40
or SAE30)
Coolant temperature:
Within operating range
At rated output
Oil pressure
(oil temperature: 90
110C)
At high idle
SAE0W30EOS
SAE5W40EOS
SAE10W30DH
SAE15W40DH
SAE30DH
At low idle
SAE0W30EOS
SAE5W40EOS
SAE10W30DH
SAE15W40DH
SAF30DH
Unit
Standard value for

new machine
Service limit value
rpm
2,150 (+25/50)
650 50
2,000
2,150 (+25/50)
650 50
kPa {mmHg}
Min. 132.30 {1000}
Max. 650
Max. 700
Bosch index
Max. 4.5
Max. 1.0
Max. 5.5
Max. 2.0
mm
0.35 0.02
0.57 0.02
MPa {kg/cm2}
(rpm)
Min. 4.1 {42}

(200 250)
Min. 2.0 {20}

(200 250)
kPa
{mmH2O}
Max. 2.94 {300}
Max. 5.88 {600}
0.29 0.44
{3.0 4.5}
Min. 0.20 {2.0}
Min. 0.08 {0.8}
Min. 0.07 {0.7}
MPa
{kg/cm2}
Oil temperature
Whole speed range (In oil pan)
80 110
Max. 120
Tension of alternator belt
Deflection under finger pressure of 58.8 N {6 kg}
mm
20 2
Tension of air conditioner compressor belt
Deflection under finger pressure of 58.8 N {6 kg}
mm
20 2
(*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
Category
Machine model
Measurement item
Engine speed
Deceleration low idle

speed
Deceleration high idle
speed
Torque converter stall
speed
D475A, D475ASD-5E0
Standard value
for new
machine
Service limit
value
900 50
900 50
2,000 50
2,000 50
1,690 50
Min. 1,590
1,615 75
Min. 1,450
45 15
45 15
Neutral o Forward
30 5
30 5
Neutral o Reverse
30 5
30 5
40 5
(Play: Max. 3)
40 5
(Play: Max. 3)
40 5
(Play: Max. 3)
40 5
(Play: Max. 3)
78 10
78 10
58 10
58 10
90 10
90 10
60 10
60 10
60 10
60 10
78 10
78 10
81 10
81 10
59 9.8
{6.0 1.0}
59 9.8
{6.0 1.0}
Neutral o
Forward, Reverse
56.9 6.9
{5.8 0.7}
56.9 6.9
{5.8 0.7}
Forward, Reverse
o Neutral
51 6.9
{5.2 0.7}
51 6.9
{5.2 0.7}
Neutral o Left
25.5 4.9
{2.6 0.5}
25.5 4.9
{2.6 0.5}
Neutral o Right
28.4 4.9
{2.9 0.5}
28.4 4.9
{2.9 0.5}
Unit
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
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
Stop engine
Press pedal to center
Forward,
reverse
Control lever and pedal stroke
PCCS
lever
Stop engine
Set lever to center
Neutral o Left
mm
Steering
Neutral o Right
Full stroke
Brake pedal
Run engine at low idle

Blade control lever

Hydraulic oil temperature:
Set lever to center
Neutral o
Raise/Lower

Set lever to center
Neutral o
Raise/Lower
Stroke to oil pressure of 0
mm
Neutral o Float
Control lever and pedal operating effort
mm
Decelerator pedal
PCCS
lever
Neutral o
Left/Right tilt
Neutral o
Tilt in/out
Stop engine
Forward,
reverse
Stop engine
Set lever to center
mm
mm
N{kg}
N{kg}
Steering
D475A, D475ASD-5E0
SEN01816-01
Control lever and pedal operating effort
Category
Machine model
Unit
Standard value
for new
machine
Service limit
value
N{kg}
490.3 49.0
{50.0 5.0}
490.3 49.0
{50.0 5.0}
Neutral o Raise
39.2 9.8
{4.0 1.0}
39.2 9.8
{4.0 1.0}

Hydraulic oil tempera- Neutral o Lower
ture:
Neutral o Float
Set lever to center
39.2 9.8
{4.0 1.0}
39.2 9.8
{4.0 1.0}
82.4 13.7
{8.4 1.4}
82.4 13.7
{8.4 1.4}
Neutral o
Left/Right tilt
28.4 9.8
{2.9 1.0}
28.4 9.8
{2.9 1.0}
Neutral o
Raise/Lower
21.6 4.9
{2.2 0.5}
21.6 4.9
{2.2 0.5}
20.6 4.9
{2.1 0.5}
20.6 4.9
{2.1 0.5}
400 30
Min. 350
980 50
Min. 880
15.2 2.5
{155 25}
15.2 2.5
{155 25}
High idle
0.78 0.98
{8 10}
0.78 0.98
{8 10}
Low idle
0.03 0.20
{0.3 2}
0.03 0.20
{0.3 2}
High idle
0.39 0.64
{4 6.5}
0.39 0.64
{4 6.5}
Low idle
0.03 0.15
{0.3 0.15}
0.03 0.15
{0.3 0.15}
High idle
1.3 1.42
{11.5 14.5}
1.3 1.42
{11.5 14.5}
High idle
2.55 2.74
{26.0 28.0}
Min. 2.55
{Min. 26.0}
2.55 2.74
{26.0 28.0}
Min. 2.45
{Min. 25.0}
High idle
2.65 2.98
{27.0 30.4}
2.55 3.04
{26.0 31.0}
Low idle
2.35 2.89
{24.0 29.5}
2.45 3.04
{25.0 31.0}
Transmission F clutch pressure
Low idle
2.35 2.74
{24.0 28.0}
2.25 2.74
{23.0 28.0}
Transmission R clutch
pressure
Low idle
2.35 2.74
{24.0 28.0}
2.25 2.74
{23.0 28.0}
Transmission 1st clutch

pressure
Low idle
1.96 2.35
{20.0 24.0}
1.86 2.35
{19.0 24.0}
Transmission 2nd clutch

pressure
Low idle
2.35 2.74
{24.0 28.0}
2.25 2.74
{23.0 28.0}
Measurement item
Brake pedal
Blade control lever
Fan
Min. speed
Max. speed
Circuit oil pressure
Torque converter inlet pressure
Power train oil pressure
Torque converter outlet

pressure
D475A, D475ASD-5E0
Torque converter lock-up

clutch pressure
Torque converter stator
clutch pressure
Transmission main relief

pressure

Set lever to center
Neutral o
Tilt in/out
Engine at low
idle
Hydraulic oil temperature: Within operating Engine at high

range
idle
Fan 100% mode
Engine at high
idle
Power train oil temperature: Within operating Low idle

range
N{kg}
N{kg}
rpm
MPa
{kg/cm2}
MPa
{kg/cm2}
D475A, D475ASD-5E0
SEN01816-01
Category
Machine model
Measurement item
D475A, D475ASD-5E0
Unit
Low idle
2.35 2.74
{24.0 28.0}
2.25 2.74
{23.0 28.0}
Transmission lubricating
pressure
High idle
0.15 0.29
{1.5 3.0}
0.15 0.29
{1.5 3.0}
High idle
2.65 2.98
{27.0 30.4}
Min. 2.45
Min. {25}
Low idle
2.35 2.89
{24.0 29.5}
2.26 2.89
{23.0 29.5}
High idle
2.65 2.98
{27.0 30.4}
Min. 2.45
{Min. 25}
2.35 2.89
{24.0 29.5}
2.26 2.89
{23.0 29.5}
High idle
2.65 2.98
{27.0 30.4}
Min. 2.45
{Min. 25}
Low idle
2.35 2.89
{24.0 29.5}
2.26 2.89
{23.0 29.5}
High idle
2.65 2.98
{27.0 30.4}
Min. 2.45
{Min. 25}
Low idle
2.35 2.89
{24.0 29.5}
2.26 2.89
{23.0 29.5}
Low idle
2.65 3.03
{27.0 30.9}
Min. 2.55
{Min. 26}
Forward 1st
3.3 0.3
3.3 0.3
Forward 2nd
6.2 0.3
6.2 0.3
Forward 3rd
11.2 0.6
11.2 0.6
Reverse 1st
4.2 0.3
4.2 0.3
Reverse 2nd
8.0 0.4
8.0 0.4
14.0 0.7
14.0 0.7
3.4 0.3
3.4 0.3
Forward 2nd
6.3 0.3
6.3 0.3
Forward 3rd
11.6 0.6
11.6 0.6
Reverse 1st
4.4 0.3
4.4 0.3
Reverse 2nd
8.4 0.4
8.4 0.4
Reverse 3rd
14.3 0.7
14.3 0.7
Power train oil temperature: Within

Low idle
operating range
Steering right clutch pressure
Steering right brake pressure
Ripper pin puller pressure
Travel speed
D475A, D475ASD-5E0
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
When lockup switch

is OFF
Steering left brake pressure
When lockup switch

is ON
Power train oil pressure
Service limit
value
Transmission 3rd clutch

pressure
Steering left clutch pressure
Power train
Standard value
for new
machine
Reverse 3rd
Forward 1st
MPa
{kg/cm2}
km/h
SEN01816-01
Machine model
Work
equipment
Pump
merge
Measurement
/divide
conditions
(ReferRelieving ence)
method
Raise
relief
Standard
value for
new
machine
Engine speed
Specification
Measurement
Category
Item
D475A, D475ASD-5E0
Right
steering
tilt
Blade
dual tilt
Pitch
back
Raise
relief
Low
22.1 1.4 22.1 1.4 22.1 1.4 22.1 1.4

{225 14} {225 14} {225 14} {225 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
24.5 1.4 24.5 1.4 24.5 1.4 24.5 1.4

{250 14} {250 14} {250 14} {250 14}
Low
23.0 1.4 23.0 1.4 23.0 1.4 23.0 1.4

{235 14} {235 14} {235 14} {235 14}
High
24.0 1.4 24.0 1.4 27.4 1.4 27.4 1.4

{245 14} {245 14} {280 14} {280 14}
Merge
Merge
Merge
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}
High
24.5 1.4 24.5 1.4 24.5 1.4 24.5 1.4

{250 14} {250 14} {250 14} {250 14}
Low
21.1 1.4 21.1 1.4 21.1 1.4 21.1 1.4

{215 14} {215 14} {215 14} {215 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Divide
Divide
Merge
Ripper
Lower
relief
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}
Divide Hydraulic
oil temperature:
Low
MPa
45 55C
Relieve
{kg/cm2}
only circuit High
Right dual
to be meaDivide
sured
tilt
Low
Pitch
dump
Service
limit value
High
Merge
Left dual
tilt
Dual tilt
Relief pressure
Work equipment oil pressure
Blade
single
tilt
Left
steering
tilt
Standard
value for
new
machine
Unit
Blade
Lower
relief
Service
limit value
Merge
D475A, D475ASD-5E0
SEN01816-01
Machine model
Work
equipment
Pump
merge
Measurement
/divide
conditions
method
Dual tilt
Tilt in
Standard
value for
new
machine
Engine speed
Specification
Measurement
Category
Item
D475A, D475ASD-5E0
Raise
relief
Relief pressure
Single tilt
Blade
single
tilt
Left
steering
tilt
Right
steering
tilt
Raise
relief
Lower
relief
Tilt back
D475A, D475ASD-5E0

outlet pressure (F)
outlet pressure (R)
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
26.5 1.4 26.5 1.4 26.5 1.4 26.5 1.4

{270 14} {270 14} {270 14} {270 14}
Low
22.1 1.4 22.1 1.4 22.1 1.4 22.1 1.4

{225 14} {225 14} {225 14} {225 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Merge
Merge
Merge
Merge
High
Hydraulic
Merge
oil temperature:
Low
MPa
45 55C
Relieve
{kg/cm2}
only circuit High
to be meaMerge
sured
Low
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}
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}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Merge
Merge
Ripper
Tilt in
Service
limit value
High
Blade
Lower
relief
Standard
value for
new
machine
Unit
Ripper
Tilt back
Service
limit value
Merge
Merge
SEN01816-01
Machine model
Work
equipment
Pump
merge
Measurement
/divide
conditions
method
Raise
relief
Standard
value for
new
machine
Engine speed
Specification
Measurement
Category
Item
D475A, D475ASD-5E0
Right
steering
tilt
Pitch
dump
Super
Relief pressure
Blade
single
tilt
Blade
dual tilt
Pitch
back
Raise
relief
Lower
relief
Tilt back

outlet pressure (F)
outlet pressure (R)
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
24.5 1.4 24.5 1.4 24.5 1.4 24.5 1.4

{250 14} {250 14} {250 14} {250 14}
Low
23.0 1.4 23.0 1.4 23.0 1.4 23.0 1.4

{235 14} {235 14} {235 14} {235 14}
High
25.0 1.4 25.0 1.4 25.0 1.4 25.0 1.4

{255 14} {255 14} {255 14} {255 14}
Merge
Merge
Divide Hydraulic
oil temperature:
Low
MPa
45 55C
Relieve
{kg/cm2}
only circuit High
to be meaDivide
sured
Low
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}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
High
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Low
27.4 1.4 27.4 1.4 27.4 1.4 27.4 1.4

{280 14} {280 14} {280 14} {280 14}
Merge
Merge
Ripper
Tilt in
Service
limit value
High
Merge
Left steerMerge
ing tilt
Standard
value for
new
machine
Unit
Blade
Lower
relief
Service
limit value
Merge
Merge
D475A, D475ASD-5E0
SEN01816-01
Machine model
D475A, D475ASD-5E0
Specification
Measurement
Category
Item
Work
equipment
Blade
LS differential pressure
Dual tilt
Blade
single tilt
Blade
dual tilt
Ripper
Standard value for

new machine
Service limit value
Raise relief
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Lower
relief
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Left
steering tilt
1.76 0.2
{18 2}
1.76 0.2
{18 2}
Right
steering tilt
1.76 0.2
{18 2}
1.76 0.2
{18 2}
Left dual
tilt
1.76 0.2
{18 2}
1.76 0.2
{18 2}
Right dual
tilt
1.76 0.2
{18 2}
1.76 0.2
{18 2}
Pitch dump
1.76 0.2
{18 2}
1.76 0.2
{18 2}
Pitch back
1.76 0.2
{18 2}
1.76 0.2
{18 2}
Raise relief
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}
Tilt back
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Raise relief
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Lower
relief
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Left steering tilt
1.76 0.2
{18 2}
1.76 0.2
{18 2}
Right
steering tilt
1.76 0.2
{18 2}
1.76 0.2
{18 2}
Raise relief
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Lower
relief
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Tilt in
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Tilt back
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Relieving
method
Lower
relief
Tilt in
Single tilt
Blade
Blade
single tilt
Ripper
D475A, D475ASD-5E0

Run engine at high idle
Unit
MPa
{kg/cm2}
SEN01816-01
Machine model
D475A, D475ASD-5E0
Specification
Measurement
Category
Item
Work
equipment
Work equipment
10
Blade
single tilt
Super
LS differential pressure
Blade
Blade
dual tilt
Standard value for

new machine
Service limit value
Raise relief
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Lower
relief
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Left
steering tilt
1.76 0.2
{18 2}
1.76 0.2
{18 2}
Right
steering tilt
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}
Tilt in
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Tilt back
2.45 0.2
{25 2}
2.45 0.2
{25 2}
Relieving
method
Pitch dump
Pitch back
Unit

Raise relief
Ripper
Lower
relief
MPa
{kg/cm2}
Unload pressure

45 55 C
Set all work equipment
control levers in neutral
2.94 4.9
{30 50}
2.94 4.9
{30 50}
Work equipment control oil

pressure

Set all work equipment
control levers in neutral
Engine at high idle
3.92 4.51
{40 46}
Min. 3.72
{Min. 38}
PPC valve output pressure

Set lever at stroke end
Engine at high idle
3.92 4.51
{40 46}
Min. 3.72
{Min. 38}
Blade tilt cylinder

Leakage Blade pitch cylinder
from Ripper shift cylinder
cylinder
Ripper tilt cylinder

Measure leakage for 1
minute while relieving cylinder
20
20
20
20
cc/min
D475A, D475ASD-5E0
SEN01816-01
Category
Machine model
Measurement item
D475A, D475ASD-5E0
Standard
Service limit
Unit value for new
value
machine
Measuring posture
Low
idle
14 3.5
Max. 20.0
High
idle
5.0 0.5
Max. 6.0
Low
idle
1.8 0.3
Max. 2.5
High
idle
1.8 0.3
Max. 2.5
Low
idle
15.8 3.5
Max. 22.0
High
idle
5.1 0.5
Max. 7.0
Low
idle
1.7 0.3
Max. 3.0
High
idle
1.7 0.3
Max. 2.2
Low
idle
4.0 1.5
Max. 6.5
High
idle
3.3 0.5
Max. 6.0
Low
idle
4.4 1.5
Max. 6.0
High
idle
3.6 0.5
Max. 6.0
Low
idle
5.5 1.5
Max. 8.0
High
idle
3.1 0.5
Max. 5.0
Low
idle
5.5 1.5
Max. 8.0
High
idle
3.1 0.5
Max. 5.0
Raise
Blade lift
(Single tiltdozer
specification)
(Dual tiltdozer
specification)
sec
Apply no load on blade.
Between blade on ground and raising stroke end
Lower
Measuring posture
Raise
sec
Between blade on ground and raising stroke end
Blade speed
Work equipment
Blade lift
(Superdozer
specification)
Lower
Measuring posture
Left tilt
Blade tilt
(Single tiltdozer
specification)
sec
Between left tilt end and right tilt
end
Right tilt
Measuring posture
Left tilt
Blade tilt
(Dual tiltdozer
specification)
sec
end
D475A, D475ASD-5E0
Right tilt
11
SEN01816-01
Category
Machine model
Measurement item
D475A, D475ASD-5E0
Standard
Service limit
Unit value for new
value
machine
Measuring posture
Low
idle
4.0 1.5
High
idle
3.3
Max. 6.0
Left tilt
Blade tilt
(Superdozer
specification)
Low
idle
4.4 1.5
High
idle
3.6
Low
idle
9.6 1.5
13.0
High
idle
4.4 0.5
6.0
Low
idle
6.6 1.6
Max. 10.0
High
idle
4.1 0.5
Max. 6.0
Low
idle
23.0 3.0
Max. 30
High
idle
7.8 1.0
Max. 10
Low
idle
16.0 2.0
Max. 23.0
High
idle
7.2 1.0
Max. 9.5
Low
idle
7.7 1.0
Max. 12.0
High
idle
3.0 0.5
Max. 4.0
Low
idle
3.0 0.5
Max. 5.0
High
idle
3.0 0.5
Max. 4.0
Max. 6.5
Right tilt
Measuring posture
Pitch
dump
Blade speed
Max. 6.0
sec
end
Blade pitch
(Dual tiltdozer
specification)
+0.5
-0.8
Max. 6.0
sec
Between pitch back end and pitch
dump end
Work equipment
+0.5
-0.8
Pitch
back
Measuring posture
Pitch
dump
Blade pitch
(Superdozer
specification)
sec
Hydraulic oil temperature: Within
operating range
Between pitch back end and pitch
dump end
Pitch
back
Measuring posture
Ripper speed
Raise
12
sec
Ripper lift
Lower
Select lowest shank hole.
Between ripper on ground and raising stroke end
D475A, D475ASD-5E0
SEN01816-01
Category
Machine model
Measurement item
D475A, D475ASD-5E0
Standard
Service limit
Unit value for new
value
machine
Measuring posture
Low
idle
15.6 1.5
Max. 22.0
High
idle
5.2 0.5
Max. 7.0
Low
idle
9.1 1.5
Max. 14.0
High
idle
3.3 0.5
Max. 4.5
Low
idle
Max. 2.5
3.2
Low
idle
High
idle
Max. 2.7
3.5
Max. 1.0
1.5
Work equipment
Time lag
Ripper speed
Tilt in
Ripper tilt
sec
Select lowest shank hole.
Between forward tilt end and rear
tilt end
Tilt out
Blade
(Single tiltdozer
specification)
(Dual tiltdozer
specification)

range
Lower blade from max. rising position and
measure time after blade comes in contact
with ground until idler is lifted.
Blade
(Superdozer
specification)

range
Lower blade from max. rising position and
measure time after blade comes in contact
with ground until idler is lifted.
Ripper

range
Lower ripper from max. rising position and
measure time after ripper comes in contact
with ground until sprocket is lifted.
High
idle
sec
High
idle
sec
Measuring posture
Hydraulic drift of
lifted blade
mm/
Max. 150/15 Max. 300/15
min
Hydraulic drift
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
Hydraulic drift of
machine tilted by
blade
mm/
min
Max. 50/5
Max. 100/5

Stop engine.
Tilt blade to maximum to push up shoe on either side
and then measure reduction of shoe height (h) in 5
minutes.
D475A, D475ASD-5E0
13
SEN01816-01
Category
Machine model
Measurement item
D475A, D475ASD-5E0
Standard
Service limit
Unit value for new
value
machine
Measuring posture
Hydraulic drift of
machine lifted by
blade
mm/
min
Max. 50/5
Max. 100/5
mm/
Max. 80/15
min
Max. 160/15

Stop engine.
Push up front part of machine with blade and then
measure reduction of idler center height (h) in 5 minutes.
Hydraulic drift
Work equipment
Measuring posture
Hydraulic drift of
lifted ripper
Stop engine.
Raise ripper to max. rising position and then measure
reduction of shank bottom height (h) in 15 minutes.
Measuring posture
Hydraulic drift of
machine lifted by
ripper
mm/
min
Max. 30/5
Max. 60/5

Stop engine.
Push up rear part of machine with ripper and then
measure reduction of sprocket center height (h) in 5
minutes.
14
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN01816-01
15
SEN01816-01

2007 KOMATSU
All Rights Reserved
16
SEN01817-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
Testing and adjusting, Part 1

Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Measuring engine speed................................................................................................................................. 6
Measuring intake air pressure (boost pressure) ........................................................................................... 10
Measuring exhaust temperature ................................................................................................................... 12
Measuring exhaust gas color ........................................................................................................................ 14
Adjusting valve clearance ............................................................................................................................. 16
Testing compression pressure ...................................................................................................................... 18
Measuring blow-by pressure......................................................................................................................... 20
Measuring engine oil pressure...................................................................................................................... 22
Handling of fuel system devices ................................................................................................................... 23
Releasing residual pressure from fuel system .............................................................................................. 23
Testing fuel pressure..................................................................................................................................... 24
Handling of reduced cylinder mode operation .............................................................................................. 25
Handling of no injection cranking operation .................................................................................................. 25
Testing fuel return and leak amount.............................................................................................................. 26
Bleeding air from fuel circuit.......................................................................................................................... 29
D475A, D475ASD-5E0
SEN01817-03
Bleeding air from fuel circuit (Low-grade fuel specification).......................................................................... 31

Testing fuel circuit for leakage....................................................................................................................... 33
Testing and adjusting alternator belt tension................................................................................................. 34
Testing and adjusting belt tension for air conditioner compressor ................................................................ 35
Adjusting fuel control dial and decelerator pedal .......................................................................................... 36
D475A, D475ASD-5E0
SEN01817-03
Testing or adjusting
item
Air boost pressure
(boost pressure)
Coolant temperature,
oil temperature and
exhaust temperature
Part No.
1
Exhaust gas color
Valve clearance
Compression pressure
Blow-by pressure
Engine oil pressure
799-401-2220 Hose
799-101-1502 Digital temperature gauge
1 99.9 1,299C
799-201-9001 Handy smoke checker
Commercial
item
Smoke meter
Commercial
item
Thickness gauge
Bosch index: 0 9
0 7 MPa {0 70 kg/cm2}
KIT Part No.: 795-502-1205
795-471-1310 Adapter
6217-71-6150 Gasket
799-201-1504 Blow-by checker
1 0 5 kPa {0 500 mmH2O}
799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester
1 Pressure gauge: 60 MPa {600 kg/cm2}
1 Pressure gauge: 1.0 MPa {10 kg/cm2}
1 *As common as G2
795-471-1450 Adapter
07005-00812 Gasket
6151-51-8490 Spacer
6141-71-1710 Joint
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
*As common as G1
Commercial
item
Hose
Commercial
item
Hose
Commercial
item
Measuring cylinder
Commercial
item
Stopwatch
07376-70315 Plug
1 *As common as G2
799-101-5220 Nipple (10 x 1.25 mm)
07002-11023
1
Power train oil pressure K 2
3
D475A, D475ASD-5E0
1 101 200 kPa {760 1,500 mmHg}
H 2
799-201-2202 Boost gauge kit
Testing fuel return and

leak amount
Remarks
795-502-1590 Compression gauge
Testing fuel pressure
Part name
Quantity
Symbol
Tools for testing, adjusting, and troubleshooting
O-ring
*As common as G1
item
Emergency escape
method when power
train has trouble
Part No.
2
1
Testing and adjusting

work equipment and
HSS oil pressure
2
M
Measuring ripper pin

puller solenoid valve
output pressure
566-35-43561 Nipple (18 x 1.5 mm)
07002-11823
O-ring
799-101-5220 Nipple (10 x 1.25 mm)

07002-11023
O-ring
1
1
1
1
799-401-3100 Adapter (size 02)
799-401-3200 Adapter (size 03)
799-401-3200 Adapter (size 03)
1 *As common as P3
Measuring fan pump

circuit pressure
T 1
Commercial
item
Measuring cylinder
799-205-1100 Tachometer KIT
799-402-3800 Angle gauge
79A-264-0021 0 294 N {0 30 kg}
79A-264-0091 0 490 N {0 50 kg}
Scale
Work equipment speed
Commercial
item
Stopwatch
Voltage and resistance
Commercial
item
Tester
799-608-3211 Diskette
799-608-3220 Harness
Commercial
item
Notebook type personal

computer
*As common as G1
*As common as G1
*As common as G1
Commercial
item
Initializing VHMS controller
*As common as G1
Stroke and hydraulic

drift
Measuring fan motor

speed
790-190-1601 Pump assembly
Operating effort
Measuring internal
leakage of work
equipment cylinder
195-06-71220 Wiring harness
Remarks
Adjusting blade tilt

angle control
799-401-2701 Differential pressure gauge 1
7824-66-6430 Resistor
N 1
799-101-5160 Nipple (R1/8)
1
Measuring PPC valve
output pressure
19M-06-32820 Switch assembly
5
Testing control circuit
basic pressure
Part name
Quantity
Symbol
SEN01817-03
*As common as G1
OS: Windows 98/2000/Me/XP

Terminal "RS232C" is with it
D475A, D475ASD-5E0
Diagnosis of sensor
and harness
D475A, D475ASD-5E0
SEN01817-03
Part No.
Part name
Quantity
item
Symbol
Remarks
799-601-7400 T-adapter assembly
1 For AMP040
1 For AMP070
1 For HD30
1 For DT connector
1 For DRC26-24 (40 pins)
799-601-7310 Adapter
1 For SWP 12 pins
799-601-7320 Adapter
1 For SWP 16 pins
799-601-7360 Adapter
1 For relay (5 pins)
799-601-3450 Adapter
1 For VHMS download harness
1 Connector for engine
799-601-4130 T-adapter
1 Ne sensor
799-601-4150 T-adapter
1 Oil pressure sensor
799-601-4211 T-adapter
1 Controller (50-pole)
799-601-4220 T-adapter
799-601-4240 Socket
1 Ambient pressure sensor
799-601-4250 Socket
1 Boost pressure sensor
799-601-4260 T-adapter
799-601-4330 Socket
1 G (Bkup) sensor
799-601-4350 T-adapter box
1 60-pole
799-601-9020 T-adapter
1 Injector
799-601-9420 T-adapter
1 Common rail pressure
799-601-9430 Socket
1 Supply pump PCV
795-799-5530 Socket
795-799-5540 Socket
1 Boost and intake temperature sensor
799-601-9310 Plate
1 For 24-pole
799-601-9320 T-adapter box
1 For 24-pole
Coolant, fuel and oil temperature

sensor
SEN01817-03
Measuring engine speed

a
Measure the engine speed under the following

condition.
q
q
q
Power train oil temperature:
1.
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.
Serial numbers: 30001 30070
3.
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)
Serial numbers: 30071 and up
4.
2.
Measuring decelerator pedal speed

dial in the high idle position.
control lever in neutral, and measure the
engine speed with the decelerator pedal
depressed.
Measuring low idle speed

dial in the low idle position.
control lever in neutral and measure the
engine speed.
D475A, D475ASD-5E0
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.
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.
D475A, D475ASD-5E0
SEN01817-03
6)
7)
Repeat above steps 2) 5) 3 times.

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.
SEN01817-03
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)
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.
D475A, D475ASD-5E0
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
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
SEN01817-03
SEN01817-03
Measuring intake air pressure

(boost pressure)
a
2.
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
3.
Install nipple [1] of boost gauge kit A and connect gauge [2].
q
Left bank
Measuring instruments for intake air pressure

(boost pressure)
Symbol
A
k
1.
10
Part No.
Part name
799-201-2202
Boost gauge kit
799-401-2220
Hose
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
q
q
Open the left and right side covers of the
engine.
D475A, D475ASD-5E0
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.
5.
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.
D475A, D475ASD-5E0
SEN01817-03
6.
After finishing test, remove the testing instrument and return the removed parts.
q
Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before installing.
2 Plug: LT2 or LG-5
a The boost pressure can be tested in the
Pm Clinic auxiliary mode: 05 of the
machine monitor.
a The boost pressure displayed in the Pm
clinic auxiliary mode is absolute pressure.
11
SEN01817-03
Measuring exhaust temperature 1

a
Measuring instrument for exhaust temperature

Symbol
Part No.
799-101-1502
Name
Digital thermometer
Measure the exhaust temperature under the

following condition.
q
Engine coolant temperature:
q
q
1.
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
functions of monitor panel.
2.
12
2)
3.
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
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
If the monitor panel is not used, measure the

exhaust temperature according to the following
procedure.
k Remove and install the measuring
instruments after the exhaust manifold
is cooled down.
a Measure the exhaust temperatures of the
right and left banks separately.
1) Open the right and left side covers (1) of
the engine.
D475A, D475ASD-5E0
4.
5.
SEN01817-03
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)
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.
D475A, D475ASD-5E0
2)
3)
k
6.
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
temperature.
After finishing measurement, remove the measuring instrument and return the removed
parts.
q
Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before installing.
2 Plug: LC-G
13
SEN01817-03
Measuring exhaust gas color

a
Measuring instrument for exhaust gas color
Symbol
C
k
1.
Part No.
799-201-9001
Commercial
item
Part name
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.
Handy smoke checker

Smoke meter
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
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)
3)
4)
5)
5)
6)
14
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)
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.
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
8)
9)
SEN01817-03
Place the contaminated filter paper on the

clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
measuring instrument and reinstall the
removed parts.
D475A, D475ASD-5E0
15
SEN01817-03
Adjusting valve clearance

a
Adjusting tool for valve clearance
Symbol
Part No.
Commercially
available
Part name
Thickness gauge
1.
Remove cylinder head cover.

a For details, see Removal and installation
of cylinder head assembly in Disassembly and assembly.
2.
Rotate the crankshaft forward and match

stamped line of R1.6 TOP on vibration damper
(1) to pointer (2), by setting RH No. 1 cylinder
to the compression top dead center while
watching the movement of the intake valve of
RH No. 6 cylinder.
16
At near the compression top dead center

of the RH No. 1 cylinder, the intake valve
of RH No. 6 cylinder moves.(opens).
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.
D475A, D475ASD-5E0
4.
Tighten locknut (6) to secure adjustment

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

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

parts.
3 Cylinder head cover mounting bolt:
14.7 34.3 Nm {1.5 3.5 kgm}
D475A, D475ASD-5E0
SEN01817-03
17
SEN01817-03
Testing compression pressure

a
4.
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.
5.
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.
6.
Disconnect engine controller connectors (1)

(PW R) and (2) (PW L).
Testing tools for compression pressure
Symbol
E
Part No.
Part name
795-502-1590
Compression gauge
795-471-1310
Adapter
6261-71-6150
Gasket
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).
1.
Remove cylinder head cover of the cylinder to

be tested for compression pressure.
a For details, see Removal and installation
of cylinder head assembly in Disassembly and assembly.
2.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a See Adjusting valve clearance.
3.
Disconnect fuel high-pressure tube (3) and

injector wiring harness and remove injector (4).
a Disconnect the terminal of the injector wiring harness on the injector side and the
bracket on the rocker housing side and
r e m o v e t h e i n j e c t o r w ir i n g h a r n e s 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).
18
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.
D475A, D475ASD-5E0
7.
Rotate the engine with the starting motor and

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

and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Push in injector (11) with the hand to
assemble holder (12) temporarily.
2) Tighten bolt (13) and washer (14) 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}
SEN01817-03
4)
Tighten the clamp and spacer with the

bolt.
5) Install rocker arm assembly.
93 103 Nm {9.5 10.5 kgm}
a Adjust the valve clearance. For details,
see Adjusting valve clearance.
6) Install head cover.
29.4 34.3 Nm {3.0 3.5 kgm}
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}
D475A, D475ASD-5E0
19
SEN01817-03
Measuring blow-by pressure

a
Measuring instrument for blow-by pressure

Symbol
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
1.
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 The monitor indicates the absolute value.
2.
If the VHMS is not installed, measure by the

following method.
1) Remove right and left covers (2) of engine
undercover (1).
2)
20
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.
3)
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.
4)
Run the engine at high idle and measure

the blow-by pressure when the torque
converter is stalled.
a For details of the procedure for torque
c o n v e r t e r s ta l l , s e e M e a s u r i 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.
D475A, D475ASD-5E0

a
5)
SEN01817-03
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.

measuring instrument and return the
removed parts.
D475A, D475ASD-5E0
21
SEN01817-03
Measuring engine oil pressure

a
Measuring instruments for engine oil pressure

Symbol
G
1
2
Part No.
4)
Name
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
1.
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
2.
3)
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.
5)

measuring instruments and return the
removed parts.
a The boost pressure can be tested in
the Pm Clinic auxiliary mode: 03 of
the machine monitor.
22
D475A, D475ASD-5E0
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.
D475A, D475ASD-5E0
SEN01817-03
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.)
23
SEN01817-03
Testing fuel pressure

a
1.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
795-471-1450
Adapter
07005-00812
Gasket
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
Fuel pressure
At high idle or
at the equivalent of rated
output speed
0.15 0.3 MPa

{1.5 3 kg/cm2}
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.
2.
Install adapter H3 and gasket H4 to the plug

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

connect to hydraulic tester H2.
24
4.
Measuring tools for fuel pressure
Symbol
5.
Since the fuel circuits of the right and left banks

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

and return the removed parts.
D475A, D475ASD-5E0
Handling of reduced cylinder

mode operation
a
1.
2.
3.
SEN01817-03
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.
D475A, D475ASD-5E0
Handling of no injection cranking

operation
1
a
a
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).
25
SEN01817-03
Testing fuel return and leak amount
Testing tools for fuel return and leak amount
Symbol
26
Part No.
Part name
6151-51-8490
Spacer
6141-71-1710
Joint
Commercially
available
Hose
Commercially
available
Hose
Commercially
available
Measuring cylinder
Commercially
available
Stopwatch
07376-70315
Plug
1.
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.
of the spacer.
Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
D475A, D475ASD-5E0
4)
5)
SEN01817-03
Insert joint J2 to common rail (1) side and

retighten it with the currently removed joint
bolt.
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.
2.
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.
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)
Leaking amount
(cc/min)
Equivalent to rated
operation
Max. 10
D475A, D475ASD-5E0
27
SEN01817-03
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).
7)
4)
5)
6)
28
Rated output speed

(rpm)
Return (Spill) limit

(cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
After finishing testing, stop the engine.
4.
Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
5.
Check the right bank similarly.
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.
D475A, D475ASD-5E0
Bleeding air from fuel circuit
SEN01817-03
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.
1.
Remove fuel pre-filter (1) and fill it with fuel.

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

filter (2).
29
SEN01817-03
2.
Install fuel pre-filter (1) to the filter head.

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

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

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

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

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 2.
30
D475A, D475ASD-5E0
Bleeding air from fuel circuit

(Low-grade fuel specification)
a
SEN01817-03
1.
Bleed air according to this procedure in the following cases.

q
When the fuel filter was replaced
q
When fuel ran out
q
When starting the engine for the first time
after replacing the fuel piping or supply
pump
When replacing the fuel filter, do not add
fuel to the main filter. It is not necessary
either to add fuel to the pre-filter.
Set the starting switch to OFF position.
2.
Open the right and left side covers.
3.
Open air bleeding valves (4) (right and left).

a Set the valve levers in parallel with the
piping.
a See the operating procedure sticker stuck
near the valves of the air bleeding piping.
4.
Right bank
Set switch (2) of electric priming pump switch

(1) installed in the engine compartment to the
ON position.
a Lamp (3) will start flashing and operation
of the electric priming pump will be
started.
q
Release switch (2), and it automatically
returns to its original position.
Left bank
D475A, D475ASD-5E0
31
SEN01817-03
a
a
a
k
The buit-in timer of this switch automatically starts or stops operation of the electric priming pump. (See the figure below)
Operation of the electric priming pump is
stopped as long as flashing of the lamp is
continued. It is not an error.
Shifting the switch to OFF while the lamp
is flashing turns off the lamp and stops the
electric priming pump, too.
Pressure is constantly applied to the
fuel circuit as long as operation of the
electric priming pump is continued.
Loosening the air bleeding plug from
this state might allow fuel to burst out.
Thus, dont try to loosen the plug while
the pump is in operation.
5.
As the specified duration (about 6.5 minutes) is

expired, lamp (3) automatically goes off, stopping the electric priming pump.
a When the fuel filter alone was replaced,
above completes bleeding air.
6.
When fuel is not provided in the fuel circuit

such as when run out of fuel occurred or when
replacement of the fuel pipe or supply pump
was done, set switch (2) to ON again after
the electric priming pump is automatically
stopped.
7.
Bleeding air, in this case, completes as lamp

(3) went off.
8.
Close air bleeding valve (4).

a Set the valve levers at right angles to the
piping.
32
9.
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, the air in the
low-pressure circuit may have not been
bled. In this case, start the engine according to the following procedure.
1) Turn electric priming pump switch (2) to
the ON position.
2) While the electric priming pump is operating, crank the engine to start with the starting motor. If the engine still does not start,
wait for about 2 minutes and repeat steps
1) and 2).
3) After the engine starts, keep it running for
at least 5 minutes to bleed all air from the
fuel circuit.
a Do not operate the starting motor continuously for more than 20 seconds.
a For the filter replacement procedure, see
the standard specification.
D475A, D475ASD-5E0
Testing fuel circuit for leakage

k
SEN01817-03
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.
1.
Spray color checker (developer) over the fuel

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

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

leakage.
a Inspect the high-pressure circuit parts
concentration on the areas coated with the
color checker, for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4.
Run the engine at low idle.
5.

leakage.
6.
Run the engine at high idle.
7.

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

engine.
a Relieve by tilting the blade or raising the
ripper.
D475A, D475ASD-5E0
9.

leakage.
a If any fuel leakage is not detected, inspection is completed.
33
SEN01817-03
Testing and adjusting alternator

belt tension
1
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
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
1.
Loosen nut (B) and bolt (2) alternately.
2.
Adjust belt tension using nut (A).
3.
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}
4.
Tighten nut (B) to fix plate (3).

a After adjusting, test the belt tension again.
34
D475A, D475ASD-5E0
SEN01817-03
Testing and adjusting belt tension

for air conditioner compressor 1
Testing
q
Measure deflection (a) of the belt when it is
p ushed with a finge r a t a p oint midway
between the compressor pulley and the engine
drive pulley.
q
Pushing force: Approx. 59 N {approx. 6 kg}
q
Deflection (a) of belt: 20 2 mm
Adjusting
a If the belt deflection is outside the standard
value, adjust as follows.
1.
Loosen 3 mounting bolts and nuts (1) and locknuts (2) and (3).
2.
Turn locknut (3) and move air conditioner compressor (4) together with the bracket to adjust
the tension of the belt.
3.
Tighten locknuts (2), (3) and 3 mounting bolts

and nuts (1).
D475A, D475ASD-5E0
35
SEN01817-03
Adjusting fuel control dial and decelerator pedal
1.
36
Outline of fuel control system

q
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.
[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
D475A, D475ASD-5E0
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.
SEN01817-03
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).
5.
Check of decelerator position (decelerator

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

a Measure the final accelerator position in
the monitoring mode.
q
Monitoring mode: 31706
(Final 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.
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
D475A, D475ASD-5E0
37
SEN01817-03

2009 KOMATSU
All Rights Reserved
38
SEN01818-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

Measuring power train oil pressure................................................................................................................. 3
Adjusting transmission speed sensor ........................................................................................................... 12
Simple method to test brake performance .................................................................................................... 13
Adjusting brake pedal and parking brake lever ............................................................................................. 14
Adjusting PCCS lever console position......................................................................................................... 17
Emergency escape method when power train has trouble ........................................................................... 18
Inspecting wear of sprocket .......................................................................................................................... 20
Testing and adjusting track shoe tension ...................................................................................................... 21
Testing and adjusting work equipment oil pressure ...................................................................................... 22
Testing and adjusting control circuit basic pressure...................................................................................... 33
Measuring PPC valve output pressure and solenoid valve output pressure................................................. 34
Adjusting play of PPC valve.......................................................................................................................... 40
Measuring outlet pressure of ripper pin puller solenoid valve ....................................................................... 41
Checking parts which caused hydraulic drift of blade and ripper .................................................................. 42
Measuring internal leakage of work equipment cylinder ............................................................................... 43
Releasing residual pressure from work equipment cylinder ......................................................................... 44
D475A, D475ASD-5E0
SEN01818-03
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
Testing and adjusting operator's seat isolator ............................................................................................... 61
D475A, D475ASD-5E0
SEN01818-03
Measuring power train oil

pressure
a
Measuring instruments for power train oil pressure

Symbol
1
K
2
3
2
3
Part No.
Name

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
q
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
No. Stamp
1
IN
Measured oil pressure

T/C inlet pressure
OUT T/C outlet pressure

SC
Gauge
(MPa {kg/cm2})
2.5 {25}
1.0 {10}
T/C stator clutch pressure
6 {60}
2.5 {25}
LU
T/C lockup clutch pressure
TM
T/M main relief pressure
6 {60}
FWD T/M F clutch pressure
6 {60}
REV T/M R clutch pressure
6 {60}
1ST T/M 1st clutch pressure
6 {60}
2ND T/M 2nd clutch pressure
6 {60}
10
3RD T/M 3rd clutch pressure
6 {60}
11
LB
S/T left brake pressure
6 {60}
12
RB
S/T right brake pressure
6 {60}
13
LC
Left clutch pressure
6 {60}
14
RC
Right clutch pressure
6 {60}
15
T/M lubricating pressure
D475A, D475ASD-5E0
1.0 {10}
SEN01818-03
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).
{10 kg/cm2}.
2)
2)
3)
4)
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.

removed parts.
3)
4)
Start the engine and set the PCCS lever in


removed parts.
D475A, D475ASD-5E0
3.
Measuring torque converter stator clutch

pressure (SC)
(3).
a Use an oil pressure gauge of 6 MPa
{60 kg/cm2}.
2)
3)
4)
Run the engine and set the PCCS lever in

SEN01818-03
4.
Measuring torque converter lock-up clutch

pressure (LU)
(4).
{25 kg/cm2}.
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).
3)
4)
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.
removed parts.

removed parts.
5)
6)
D475A, D475ASD-5E0
SEN01818-03
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
(EMMS).
a If the machine is not equipped with the
VHMS, measure the transmission main
relief pressure according to the following
procedure.
(5).
{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).
{60 kg/cm2}.
2)
3)
4)
2)
3)
4)
Run the engine and set the PCCS lever in


removed parts.
5)
6)
Run the engine, set the monitor panel in

the Adjustment mode, and disengage
(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.
is running at low idle.

removed parts.
D475A, D475ASD-5E0
7.
Measuring transmission R clutch pressure

(R)
(7).
{60 kg/cm2}.
2)
3)
4)
5)
6)
SEN01818-03
8.
Measuring transmission 1st clutch pressure (1ST)

(8).
{60 kg/cm2}.

(EMMS).
the transmission speed (in rpm).
position.
Set the PCCS lever in the REVERSE 3rd
2)

removed parts.
6)
D475A, D475ASD-5E0
3)
4)
5)

(EMMS).
the transmission speed (Unit: 1 rpm).
position.
Set the PCCS lever in the FORWARD 1st

removed parts.
SEN01818-03
9.
Measuring transmission 2nd clutch pressure (2ND)

(9).
{60 kg/cm2}.
2)
3)
4)
5)
6)
10. Measuring transmission 3rd clutch pressure (3RD)

(10).
{60 kg/cm2}.

(EMMS).
the transmission speed (in rpm).
position.
Set the PCCS lever in the FORWARD 2nd
2)

removed parts.
6)
3)
4)
5)

(EMMS).
a The message display displays the
transmission speed (in rpm).
position.
Set the PCCS lever in the FORWARD 3rd

removed parts.
D475A, D475ASD-5E0
11. Measuring steering left brake pressure (LB)

(11).
{60 kg/cm2}.
2)
3)
4)
Run the engine and set the parking brake

lever in the FREE position.
a Check that the oil pressure becomes
0 when the PCCS lever is set to the
steering left stroke end.
0 when the brake pedal is pressed
fully or when the parking brake lever
is set in the LOCK position.

removed parts.
D475A, D475ASD-5E0
SEN01818-03
12. Measuring steering right brake pressure

(RB)
(12).
{60 kg/cm2}.
2)
3)
4)

0 when the PCCS lever is set to the
steering right stroke end.
0 when the brake pedal is pressed
fully or when the parking brake lever
is set in the LOCK position.

removed parts.
SEN01818-03
13. Measuring steering left clutch pressure

(LC)
(13).
{60 kg/cm2}.
2)
3)
4)
5)
10
14. Measuring steering right clutch pressure

(RC)
(14).
{60 kg/cm2}.

Set the PCCS lever to the steering left
stroke end.
a Set the direction of the PCCS lever in
neutral.
0 when the steering of the PCCS
lever is returned to the neutral position.
2)

removed parts.
5)
3)
4)

Set the PCCS lever to the steering right
stroke end.
a Set the direction of the PCCS lever in
neutral.
0 when the steering of the PCCS
lever is returned to the neutral position.

removed parts.
D475A, D475ASD-5E0
SEN01818-03
15. Measuring transmission lubricating oil

pressure
1) Connect hydraulic tester K2 to oil pressure pickup nipple (15).
{10 kg/cm2}.
2)
Run the engine at high idle and measure

the oil pressure.
3)

removed parts.
D475A, D475ASD-5E0
11
SEN01818-03
Adjusting transmission speed

sensor
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}
7.
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.
After finishing adjustment, set the monitor

panel in the Monitoring display mode and
check that the transmission speed is displayed
normally.
a Monitoring code: 31400 (Transmission
speed)
The torque converter output speed sensor for

the VHMS is not adjustable.
1.
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).
2.
Install flange (2) to the steering case temporarily.
3.
Looking at bevel gear (4) through the hole of

flange (2), check that the tooth tip is at the center of the hole.
a If the tooth tip is not at the center, run the
engine and move the machine forward or
in reverse a little to set the tooth tip to the
center.
4.
Tighten sensor (1) until its tip touches the tooth

tip of gear (4).
2 Threads of sensor:
5.
Return sensor (1) from the above position by

the specified angle.
a Returning angle of sensor: 1/2 1 turn
a Adjust clearance (b) between the sensor
tip and gear tooth tip to 0.75 1.50 mm.
12
6.
D475A, D475ASD-5E0
Simple method to test brake

performance
SEN01818-03
Implement simple method to test brake performance under the following condition.
q
1.
Set the blade and ripper in the travel posture

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

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

brake pedal is depressed securely, set PCCS
lever in the forward and 2nd gear speed 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.
4.
Press the decelerator pedal and set the fuel

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

that the machine does not start when the
engine speed reaches the high idle level.
k Since the torque converter is stalled,
press the brake pedal securely and
keep your right foot on the decelerator
pedal for safety until the work is finished.
D475A, D475ASD-5E0
13
SEN01818-03
Adjusting brake pedal and parking brake lever
Brake pedal side
14
D475A, D475ASD-5E0
SEN01818-03
Parking brake lever side
Adjusting brake pedal side

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
2.
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}
D475A, D475ASD-5E0
3.
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
4.
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.
15
SEN01818-03
5.
16
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).
7.
Adjusting installed length of parking brake

cable
1) Connect parking brake cable (9) to the
lever side, and then adjust installed
dimensions (h) and (j).
q
Installed dimension (h) of cable: 22.5
mm
q
Installed dimension (j) of cable: 14.5
mm
2) Connect parking brake cable (9) to the
valve side.
q
Installed dimension (m) of cable: 15
mm
q
Installed dimension (k) of cable: 20.5
mm
3) Operate parking brake lever (10) between
the FREE position and LOCK position and
adjust the position of rod end (11) so that
spool stroke (n) of brake valve (4) will be
normal.
q
Spool stroke (n): 23.0 mm
8.
Checking brake oil pressure

Run the engine and set the parking brake lever
in the FREE position and LOCK position and
check that the brake oil pressure will be as 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
9.
Checking limit switch

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

position.
2.
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
(Machine with operators seat isolator:
178.5 mm)
a The locknut on the rear side of the turnbuckle is a left-handed (reversing) screw.
D475A, D475ASD-5E0
SEN01818-03
17
SEN01818-03

a
Emergency escape method when

power train has trouble
1
a
Devices used for emergency escape

Symbol
Part No.
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.
Part name
19M-06-32820 Switch assembly

L
195-06-71220 Wiring harness

2
1.
790-190-1601 Pump assembly
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.
2)
18
7824-66-6430 Register
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.
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
4)
5)
SEN01818-03
Start the engine and set the parking brake

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)
2.
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
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.
D475A, D475ASD-5E0
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.
19
SEN01818-03
7)
20
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.
D475A, D475ASD-5E0
Testing and adjusting track shoe

tension
1
Testing
1. Move the machine slowly on a level place, then
stop it.
a Do not apply the brake when stopping.
2.
Place straight steel bar (1) between the idler

and front carrier roller and measure clearance
(a) between the bottom of the steel bar and
shoe grouser.
q
Standard clearance (a): 20 30 mm
D475A, D475ASD-5E0
SEN01818-03
Adjusting
a If the track shoe tension is abnormal, adjust it
1.
Remove cover (2).
2.
When the tension is too high

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

Add grease through grease fitting (4).
a If the track shoe is not tensed well, move
the machine forward and in reverse slowly.
a After the adjustment is finished, check the
track tension again.
21
SEN01818-03
Testing and adjusting work

equipment oil pressure
a
1
2
M
4)
Run the engine at high idle and set the

blade lever and ripper lever in neutral, and
measure the oil pressure.
5)

removed parts.
Part No.
Name

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
22
Install nipples M2, M3, and connect them

to oil pressure gauge [1] of hydraulic
tester M1.
{60 kg/cm2}.
Testing and adjusting instruments for work

equipment oil pressure
Symbol
1.
3)
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
D475A, D475ASD-5E0
2.
Measuring main relief pressure (Single tilt

specification)
a Measure the main relief pressure at the
same point as the unload pressure.
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.
SEN01818-03
3)
a

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.
D475A, D475ASD-5E0
23
SEN01818-03
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.
kg/cm2}.
a The oil pressure of the divided oil can be
measured by measuring while pitching
back the ripper.
2) Run the engine at high idle, raise or pitch
back the ripper to relieve the cylinder at a
stroke end, and measure the oil pressure.
3)
24

removed parts.

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

tilt specification)
a Measure the blade tilt relief pressure at
the same point as the unload pressure.
kg/cm2}.
a Since all of the oils from the 2 pumps are
merged in the work equipment circuit of
the single tilt specification, the oil pressure
of the divided oil cannot be measured.
2) Run the engine at high idle, tilt the blade
to the left to relieve the cylinder at a stroke
3)
SEN01818-03

removed parts.

mode.
D475A, D475ASD-5E0
25
SEN01818-03
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.
kg/cm2}.
a Measure the pressure of the divided oil
from the 2 pumps during pitch dump operation.
2) Run the engine at high idle, pitch dump
the blade to relieve the cylinder at a stroke
3)
26

removed parts.

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

a Measure the blade raise relief pressure at
the same point as the unload pressure.
kg/cm2}.
1) Block the return side hose of the blade lift
cylinder.
SEN01818-03
3)
4)
Run the engine at high idle, raise the

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

mode.
D475A, D475ASD-5E0
27
SEN01818-03
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.
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)
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)
4)
28

a
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.
D475A, D475ASD-5E0

a
5)
a
6)
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.
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
measuring instruments and return the
removed parts.
D475A, D475ASD-5E0
SEN01818-03
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}.
4)
Start the engine and set the work equipment lock lever in the FREE position.
29
SEN01818-03
5)
Run the engine at high idle, perform the

operations shown in the following table,
and measure the LS valve output pressure.
Specification
Operation
Common to all
Raise blade
specifications
Dual tilt and
superdozer
Raise ripper or
pitch back to
relieve
Single tilt
Raise ripper or tilt

to right to relieve
6)
LS valve output
pressure
(MPa {kg/cm2})
0 {0}
1.4
27.4 + 2.74
+ 14
{280 28}
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
pump circuit, adjust the ma in re lief
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

removed parts.
1)
30
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}
D475A, D475ASD-5E0
SEN01818-03
a
a
2)
2.
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}
After finishing adjustment, check again

that the oil pressure is normal according to
the procedure for measurement described
above.
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)
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)
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
D475A, D475ASD-5E0
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.
31
SEN01818-03
a
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
q
(11): LS valve for front pump circuit
q
(12): LS valve for rear pump circuit
1)
32
After finishing adjustment, check again

that the oil pressure is normal according to
the procedure for measurement described
above.
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}
D475A, D475ASD-5E0
SEN01818-03
Testing and adjusting control

circuit basic pressure
a
Run the engine at high idle, set the blade lever

and ripper lever in neutral, and measure the oil
pressure.
4.
parts.
Measuring instruments for control circuit basic

pressure
Symbol
N
3.
Part No.
Part name

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.
Measuring
k Stop the machine on a level place, lower
a Measure the control circuit basic pressure
under the following condition.
q
1.
Remove the right ROPS front cover.
2.
Connect oil pressure gauge [1] of hydraulic

tester N1 to oil pressure pickup nipple (1).
a Use the oil pressure gauge of 6 MPa {60
kg/cm2}.
D475A, D475ASD-5E0
Adjusting
a The self-pressure reducing valve cannot be
adjusted.
33
SEN01818-03
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.
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
Part name

2 799-401-3100 Adapter (02)

3 799-401-3200 Adapter (03)
1.
34
Stop the machine on a level place, lower

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
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].
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.
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
D475A, D475ASD-5E0
1)
2)
3)
4)
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
SEN01818-03
Measure the following solenoid valve output pressures on the work equipment control side.
q
Blade left tilt circuit (Left tilt/pitch
dump circuit) (6) after passing
q
Blade lower circuit (7) after passing
q
Blade right tilt circuit (Right tilt/pitch
dump circuit) (8) after passing
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 When measuring the output pressure
of the pitch dump solenoid valve or
pitch back solenoid valve of the
superdozer specification, set the
blade lever in neutral and operate the
knob switch.
a Measure the output pressure of the tilt
limit solenoid valve while checking
the tilting direction of the blade lever.
When the blade is set at the tilt limit
angle, the output pressure from the
PPC valve is stopped.
D475A, D475ASD-5E0
35
SEN01818-03
1)
2)
3)
4)
36
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
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 When measuring the output pressure
of the pitch dump solenoid valve or
pitch back solenoid valve of the
superdozer specification, set the
blade lever in neutral and operate the
knob switch.
a Measure the output pressure of the tilt
limit solenoid valve while checking
the tilting direction of the blade lever.
When the blade is set at the tilt limit
angle, the output pressure from the
PPC valve is stopped.
D475A, D475ASD-5E0
SEN01818-03
Single tilt specification
D475A, D475ASD-5E0
37
SEN01818-03
Dual tilt specification and superdozer specification
38
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN01818-03
39
SEN01818-03
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)
1.
Remove boot (1).
2.
Loosen locknut (2) and turn disc (3) to adjust

the play.
a Do not move the piston at this time.
3.
Fix disc (3) and tighten locknut (2).

3 Locknut: 98 127 Nm {10 13 kgm}
4.
Install boot (1).
40
D475A, D475ASD-5E0
SEN01818-03
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
Part No.
2 799-401-3200
k
Name

Oil pressure pickup adapter
(Size 03)

Measure the outlet pressure of the ripper pin
puller solenoid valve under the following condition.
q
1.
Disconnect pin puller cylinder hose (1) or (2).
2.
Install oil pressure pickup adapter Q2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester Q1 and connect oil pressure gauge [2].
kg/cm2}.
D475A, D475ASD-5E0
4.
Run the engine at high idle and operate the ripper pin puller switch and measure the oil pressure.
5.
parts.
41
SEN01818-03
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.
1.
Stop the engine with the cylinder at the following positions.

1) Blade lift cylinder
Tense blade to push up the front of
machine.
a Do not extend the blade lift cylinder to
the stroke end since it is equipped
with the piston valve.
3)
2.
2)
42
Blade tilt cylinder

Retract the tilt cylinder to the stroke end
and tense blade further to push up the
right side of the machine.
Ripper lift cylinder

Te nse rippe r to push u p the rea r of
machine.
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.
[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 o r e , t h e d r i ft i 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.
D475A, D475ASD-5E0
SEN01818-03
Measuring internal leakage of

work equipment cylinder
a
a
a
3.
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.
4.
After 30 seconds, measure leakage for 1

minute.
5.
After finishing
removed parts.
Measuring instruments for internal leakage of

Symbol
Part No.
Purchased
Name
Measuring cylinder
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.
1.
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.
2.
Disconnect hose on the cylinder head side and

block the hose side with a plug.
a Remove the hose cover of the blade tilt
cylinder.
k Take care not to disconnect the hose
on the bottom side.
D475A, D475ASD-5E0
measurement,
return
the
43
SEN01818-03
Releasing residual pressure from

1
Bleeding air from work equipment

cylinder
1
When disconnecting the piping between the

control valve and work equipment cylinder,
release the residual pressure from the circuit
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.
1.
Loosen the hydraulic tank oil filler cap gradually to release the residual pressure from the
tank.
1.
Run the engine at low idle for about 5 minutes.
2.
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.
3.
Running the engine at high idle and carry out

the operation in 2.
4.
Running the engine at low idle, move the cylinder to the stroke end to relieve the oil.
2.
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.
3.
Run the engine at low idle for about 5 seconds,

then stop it.
4.
Repeat steps 2 3 above 2 3 times.
44
D475A, D475ASD-5E0
Adjusting ripper lever position
a
a
SEN01818-03
Adjust the ripper lever to the best position

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

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

from neutral position
1) Remove lock bolt (1).
2) Remove lever (2) and reverse it.
3) Install lever (2) to lever (5) and set it to the
best position.
4) Tighten lock bolt (1) to secure lever (2).
5) Loosen nut (3).
6) Reverse knob (4).
7) Tighten nut (3) to secure knob (4).
D475A, D475ASD-5E0
45
SEN01818-03
Adjusting work equipment lock lever
1.
Adjust dimension (a) between pins of rod (1).

Dimension (a) between pins: 442.6 mm
2.
46
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.
D475A, D475ASD-5E0
SEN01818-03
Measuring fan motor speed

a
1.
2.
3.
4.
Insert probe [2] of tachometer kit S through the

radiator mask and set it out of the fan net with
stand [3] and connect it to multi-tachometer [4].
a 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.
Start the engine and set the monitor panel in

the adjustment mode.
a Adjustment code: 1005 (Fan 100% speed
mode)
6.
Run the engine at low idle and high idle and

measure the fan motor speed.
7.
parts.
Measuring instruments for fan motor speed

Symbol
Part No.
799-205-1100
Name
Tachometer kit
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.
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).
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.
D475A, D475ASD-5E0
47
SEN01818-03
Measuring fan circuit oil

pressure
a
Measuring instruments for fan circuit oil pressure

Symbol
T
Part No.
Name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester

Measure the fan circuit oil pressure under the
q
1.
Open the radiator mask.
2.
Connect oil pressure gauge [1] of hydraulic

tester T1 to the oil pressure pickup nipple
installed to the underside of fan motor (1).
a Use the oil pressure gauge of 40 MPa
{400 kg/cm2}.
3.
Start the engine and set the monitor panel in

the adjustment mode.
a Adjustment code: 1005 (Fan 100% speed
mode)
4.
Run the engine at high idle and measure the

fan circuit oil pressure.
48
5.
parts.
D475A, D475ASD-5E0
Bleeding air from fan pump

a
SEN01818-03
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.
1.
Remove the floor inspection cover.
2.
Loosen air bleeders (1) and (2), and leave it for

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

bleeders (1) and (2).
D475A, D475ASD-5E0
49
SEN01818-03
Measurement procedure for blade

tilt control angle
(Dual tiltdozer specification)
1
a
a
1.
50
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.
3.
Hold the buzzer cancel switch in the select

position [U] for 2.5 seconds to display the
maintenance mode.
4.
Set the information switch in the [>] position to

select the adjustment mode.
5.
Set the buzzer cancel switch in the select position [U] to select the adjustment selection
screen.
Measuring instrument for blade tilt control

angle
Symbol
Part No.
799-402-3800
Name
Angle gauge
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
D475A, D475ASD-5E0
6.
Operate information switches [<] and [>] to

select the tilt limit setting screen.
7.
Set the buzzer cancel switch in the select position [U] to select the tilt limit adjustment mode.
8.
Press the pitch switch of the blade lever, and

the buzzer sounds and the work equipment
position in the standard posture is saved.
9.
Raise the blade tip to about 1 m above the

ground.
SEN01818-03
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.
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).
D475A, D475ASD-5E0
51
SEN01818-03
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.
angle too much.
angle gauge U.
16. Set the toggle switch of the blade lever in the

signal tilt position and then set it in the dual tilt
position again to save the right tilt limit value in
the system.
a When saving is finished, the buzzer
sounds.
position [t] to cancel the tilt limit adjustment
mode.
18. Lower the work equipment to the ground and
stop the engine.
19. Start the engine again, tilt the blade to the right
and left, and check that the blade does not
interfere with the track shoe at any height.
52
D475A, D475ASD-5E0
SEN01818-03
Measurement procedure for blade

tilt control angle
(Superdozer specification)
1
a
a
1.
2.
Measuring instrument for blade tilt control

angle
Symbol
Part No.
799-402-3800
Name
Angle gauge
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.
3.
Hold the buzzer cancel switch in the select

position [U] for 2.5 seconds to display the
maintenance mode.
4.
Set the information switch in the [>] position to

select the adjustment mode.
5.
Set the buzzer cancel switch in the select position [U] to select the adjustment selection
screen.
6.
Operate information switches [<] and [>] to

select the tilt limit setting screen.
Adjust installed length (a) of rod (1) and connect it to potentiometer lever (2) and yoke (3).
q
Installed length (a): 425 mm
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.
D475A, D475ASD-5E0
53
SEN01818-03
7.
Set the buzzer cancel switch in the select position [U] to select the tilt limit adjustment mode.
8.
Press the pitch back button (lower button) of

the work equipment lever, and the buzzer
sounds and the work equipment position in the
standard posture is saved.
9.
Set the buzzer cancel switch in the cancel

position [t] once to cancel the tilt limit adjustment mode temporarily.
13. Press the pitch dump button (upper button),

and the buzzer sounds and the left limit position is saved.
angle too much.
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.
angle too much.
angle gauge U.
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
54
D475A, D475ASD-5E0
SEN01818-03
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]
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)
7]
Secure the end of hose [1] to the

operator's seat with tape.
D475A, D475ASD-5E0
55
SEN01818-03
2.
56
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.
D475A, D475ASD-5E0
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).
SEN01818-03
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]
D475A, D475ASD-5E0
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
greased, the knob becomes
heavy.
57
SEN01818-03
4.
ii)
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)
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]
58
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.
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
SEN01818-03
Adjusting blade
If the blade is removed and installed or disassembled and reassemble, adjust it according
1.
Adjusting shims for assembly

1) Adjust the shim of center (1).
2)
Adjust the shim of trunnion (2) (shim

adjustment type).
Adjusted
point
Adjusted
point
Adjusted
clearance
Standard
clearance
Standard shim
thickness
See note
4.5 mm
Adjusted
Standard clearclearance
ance
c
1.56 0.65 mm
(Total thickness
clearance)
Standard
shim thickness
12 mm
Note: Adjust the shim so that the play of the

ball in the axial direction will be less
than 1 mm and the ball can rotate
smoothly.
D475A, D475ASD-5E0
59
SEN01818-03
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
Semi-U
Right tilt distance

(e1)
Approx. 900
mm
Approx. 750
mm
Left tilt distance

(e2)
Approx. 900
mm
Approx. 750
mm
3)
60
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.
D475A, D475ASD-5E0
SEN01818-03
Testing and adjusting operator's seat isolator

a
Machine with operator's seat isolator
1.
Breakage of rubber
q
Criterion: When the operator's seat is
pressed with the hand, it must not touch
the stopper of operator's seat isolator.
a When the criterion is not satisfied.
q
Remove and disassemble the operator's
seat isolator and check the rubber for
breakage.
q
If the rubber is broken, replace the operator's seat isolator assembly.
1) Pull slide (1) and move the operator's seat
to the forward end.
2)
Pull turning lever (2) and rotate turntable

(3) by 13 degrees.
D475A, D475ASD-5E0
3)
Stand backrest (4) of the operator's seat

upright.
4)
Open window (5) on the left side of the

operator's cab.
61
SEN01818-03
5)
2.
62
Press the seat surface through the window.
Oil leakage from damper

q
Criterion: No oil leakage from damper.
q
Replace the operator's seat isolator
assembly.
1)
Remove bolts (7) of front cover (6) of the

operator's seat and remove the front
cover.
2)
Check damper (8) for oil leakage.
D475A, D475ASD-5E0
3.
SEN01818-03
Breakage of stopper rubber

q
Criterion: The stopper must not come off.
q
Replace the operator's seat isolator
assembly.
1) Put your feet on foot rest (9) and brace
your legs.
2)
Check that stopper (10) touches stopper

rubber (11) and does not the steel portion.
D475A, D475ASD-5E0
63
SEN01818-03

2011 KOMATSU
All Rights Reserved
64
SEN01819-04
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

Special functions of monitor panel (EMMS) .................................................................................................... 2
D475A, D475ASD-5E0
SEN01819-04
Special functions of monitor panel (EMMS)
Display section of special

functions
Operation section 1 of special

functions (Basic operation)
1.
3.
2.
Upper panel
(Gear speed display section)
Lower panel
(Multi-information section)
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
D475A, D475ASD-5E0
SEN01819-04
Normal function and special functions of monitor panel (EMMS)

The monitor panel (EMMS) has the normal and special functions, and displays information of various types
at the gear speed display section and the multi-information section of the center of the monitor panel.
Some items are displayed automatically according to the internal setting of the monitor panel and the others
are displayed according to the operation of the switches.
1. Normal function: Operator mode
With this function, an operator can view and change the items displayed normally or displayed by the
operation of the switches.
2. Special function 1: Service mode
With this function, a serviceman can display and change the displayed items by the specified switching
operation for testing, adjusting and troubleshooting.
Flow of each mode and function
D475A, D475ASD-5E0
SEN01819-04
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.
Normal display mode (Default)

The monitor panel displays the following information normally.
Gear speed display section (1):
q
Left side: Travel direction (PNFR)
q
Right side: Gear speed (123)
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-R1F1-R2F2-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.
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.
D475A, D475ASD-5E0
SEN01819-04
Maintenance item list

Replacement interval (h)
No.
Display
Maintenance item
1st time (fixed)
2nd time and more

(changeable)
ENG OIL
Engine oil
500
500
ENG FILT
Engine oil filter
500
500
FUEL FILT
Fuel main filter
1000
1000
HYD FILT
Hydraulic oil filter
250
2000
CORR RES
Corrosion resistor
1000
1000
DAMP OIL
Damper oil
2000
2000
FNL OIL
Final drive oil
250
2000
HYD OIL
Hydraulic oil
250
2000
HSS FILT
Charge filter (*1)
10
POWL OIL
Power train oil
250
1000
11
POWL FLT
Power train oil filter
250
500
12
F. PRE FLT
Fuel pre-filter
500
500
(*1): Displayed on D475A-5 but not set.
2.
Pm clinic auxiliary mode

(2-PM CLINIC MODE)
In this mode, the condition of the machine is
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.
Order
Display
Item
01
01-ENG. SPEED
02
02-COOLANT TEMP Coolant temperature
03
03-ENG OIL PRESS Engine oil pressure
04
04-AMB PRESS
Ambient pressure
05
05-BOOST PRESS
Engine boost pressure
06
06-BOOST TEMP
Engine boost temperature
07
07-T/C TEMP
Power train oil temperature
08
08-HYD TEMP
09
09-HYD. PRESS F
Hydraulic oil pressure

(F pump)
10
10-HYD. PRESS R
Hydraulic oil pressure

(R pump)
13
13-BATTERY VOLT
Battery voltage
Engine speed
The ambient pressure and boost pressure is

displayed in absolute value.
D475A, D475ASD-5E0
SEN01819-04
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.
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.
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.)
No.
Display
Item
01:LCD BRIGHTNESS
Adjustment of LCD
brightness
02:DSP BRIGHTNESS
Adjustment of display brightness
03:DSP CONTRAST
Adjustment of display contrast
04:FAN 100% SPEED
Fan 100% speed

mode (For cleaning
radiator)
05:NO INJECTION
No injection cranking mode
06:TILT LIMIT
Tilt limit adjustment

mode
07:PRE_LUB ON
Pre-lubrication reset
mode against prelubrication trouble
D475A, D475ASD-5E0
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.)
2)
Brightness of display
This mode is to adjust brightness of the
backup lamp at the multi-information section. (See Operation and maintenance
manual.)
3)
Contrast of display
This mode is to adjust contrast of the liquid
crystal at the multi-information section.
(See Operation and maintenance manual.)
4)
Fan 100% mode

This function is to control rotation speed of
the cooling fan forcedly at approximately
100% of the maximum speed.
1] This mode is selected by operating the
information switch.
2] The mode is selected by turning the
buzzer cancel switch to the [U] position.
3] 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.
SEN01819-04
5)
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]
In above 3 seconds, WAIT displayed

on the lower line changes to ACTIVE
and the mode becomes effective.
4]
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.
5]
D475A, D475ASD-5E0
SEN01819-04
a
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.
D475A, D475ASD-5E0
SEN01819-04
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 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
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.
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.
repair.
Engine boost pressure is defective.

Move machine to safe place.
Action code is displayed. Usable gear speeds are limited.
Engine speed does not rise fully.
CALL E03 Caution lamp flashes.
repair.
Caution buzzer sounds. Gear shifting shocks become large.
Steering performance lowers.
Action code is displayed. Engine cannot be controlled.
CALL E04 Caution lamp flashes.
Machine cannot travel.
Caution buzzer sounds. Machine stops.
D475A, D475ASD-5E0
Stop machine immediately.

repair.
SEN01819-04
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
1C
Display and item

5-EXCHG. INTVAL. INTERVAL MODE
Maintenance interval change mode
6-ELEC. FAULT CODE MODE
EE
Electrical system failure code display

mode
7-MACHINE CHECK CODE MODE
bE
Cb
Ld
5R
dR
55
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 *
* VHMS specification only
2) Selecting and executing mode to be used

Select the mode to be used with information
switch (5) and execute it with buzzer cancel
switch (4).
q
[ > ]: Next mode No.
q
[ < ]: Previous mode No.
q
[U]: Execute mode.
a For the details of operation in each mode,
see the following pages.
3) Finishing mode and function
The current mode and function can be finished
by either of the following method, regardless of
the current mode and hierarchy.
(1) When continuing the operation in another
mode or function or in the operator mode:
Return to the mode screen or function
screen to be used next by operating
buzzer cancel switch (4).
q
[t]: Screen returns.
(2) When finishing the all operation:
Turn off the starting switch.
10
D475A, D475ASD-5E0
5.
Maintenance interval change mode

(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.
SEN01819-04
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).
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.
D475A, D475ASD-5E0
11
SEN01819-04
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.
12
If you do not use the maintenance function, set the all times
to 0.
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 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.)
D475A, D475ASD-5E0
SEN01819-04
Maintenance item list

Replacement interval (h)
No.
Display
Maintenance item
1st time (fixed)
2nd time and more

(changeable)
01: ENG OIL
Engine oil
500
500
02: ENG FILT
Engine oil filter
500
500
03: FUEL FILT
Fuel main filter
1000
1000
04: HYD FILT
Hydraulic oil filter
250
2000
06: CORR RES Corrosion resistor
1000
1000
07: DAMP OIL
Damper oil
2000
2000
08: FNL OIL
Final drive oil
250
2000
10: HYD OIL
Hydraulic oil
250
2000
12: HSS FILT
Charge filter (*1)
10
19: POWL OIL
Power train oil
250
1000
11
20: POWL FILT Power train oil filter
250
500
12
41: F. PRE-FLT Fuel pre-filter
500
500
(*1): Displayed on D475A-5 but not set.
The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that
the first maintenance has been finished in the maintenance mode of the operator mode, then change
the 2nd and after interval times.
D475A, D475ASD-5E0
13
SEN01819-04
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.
(EE) is displayed on gear speed
section (2).
2] Display the failure code display
screen by operating buzzer cancel
switch (4).
q
[U]: Execute mode.
6.
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.
2)
14
Flashing and lighting of failure code

Flashing: Code is being output currently.
Lighting: Code is not being output
currently.
Display in the case where no codes are

recorded
If no failure codes have been output up to
shown below.
D475A, D475ASD-5E0

a
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.
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
a The failure codes are displayed from
the oldest one in order of length of
time after they were output.
5)
Method of deleting failure code

While displaying a failure code to be
deleted, operate shift-up switch (6) or
shift-down switch (7).
q
[UP] or [DOWN]: Delete failure code.
a A failure code which is being output
currently (which is flashing) cannot be
deleted.
SEN01819-04
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)

1] Select Mechanical system failure
code display mode on the mode
selection screen.
(bE) is displayed on gear speed
section (2).
2] Display the failure code display
switch (4).
q
[U]: Execute mode.
D475A, D475ASD-5E0
15
SEN01819-04
2)
3)
16

a
Display in the case where no codes are

recorded
If no failure codes have been output up to
shown below.
Display in the case where 1 or more codes

are recorded
If any failure code has been output up to
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.
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)
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
a All the failure codes, including ones
which have not been displayed, are
displayed in numeric order.
5)
Method of deleting failure code

The mechanical system failure codes cannot be deleted.
D475A, D475ASD-5E0
8.
Adjustment mode
(8-SERVICE ADJUST MODE)
In this mode, you can adjust the control system
and various devices of the machine.
1)

i) Select Adjustment mode on the
mode selection screen.
(Cb) is displayed on gear speed
section (2).
ii) Display the adjustment code input
switch (4).
q
[U]: Execute mode.
SEN01819-04
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.
a
D475A, D475ASD-5E0
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.
17
SEN01819-04
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)
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.
18
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.
D475A, D475ASD-5E0
SEN01819-04
Adjustment modes list and adjustment procedure

No. Code
Adjustment item
Related information
Disassembly Sending
and assembly in order
[1] 0001 INP TEL NO.
Phone No. input mode
Numerals and symbols
[2] 0002 S/T S. CODE
Steering controller specification set
Code
[3] 0003 T/M S. CODE
Transmission controller specification

set
Code
[4] 0004 BODY TYPE
Machine specification set
Code
[5] 0005 BRAKE BASE
Brake potentiometer zero point adjustVoltage

ment
[6] 0007 ENG. FULL CH
Engine deceleration cut mode
Engine speed
[7] 0008 INT-> 123456
Common rail reduced cylinder mode
Speed/Fuel injection
rate
[8] 0009 PITCH SENS.
Pitch angle sensor initialization set
Voltage
[9] 0010 FAN 70%MODE
Fan speed 70% speed mode
(Adjustment amount)
8
7
[10] 0022 VHMS INST
VHMS specification set
Set state
[11] 0530 STALL CHECK
Stall speed check mode
Engine speed
[12] 1005 FAN 100%MODE Fan speed 100% mode
(Date of adjustment in
factory)
[13] 1012 S/T N-SET
Steering lever neutral set
Voltage
[14] 1013 S/T M. L-SET
Steering lever left set
Voltage
[15] 1014 S/T M. R-SET
Steering lever right set
Voltage
[16] 1015 BRKLH. OFST
Left brake oil pressure offset (set)
Oil pressure
[17] 1016 BRKRH. OFST
Right brake oil pressure offset (set)
Oil pressure
[18] 1112 PRE LUB SEL
Pre-lubrication set
Set state
[19] 2223 R SLOW CUT
Reverse slow stop set
Set state
[20] 5535 CLUTCH OPEN
Clutch disengagement mode
Transmission speed
[21] 5537 CLT LH. OFST
Left clutch oil pressure offset (set)
Oil pressure
[22] 5538 CLT RH. OFST
Right clutch oil pressure offset (set)
Oil pressure
[23] 9801 ENG. LEVEL
Engine oil level display mode

(if equipped)
Set state
[24] 9993 HYD. LEVEL
Hydraulic oil level display mode

(if equipped)
Set state
[25] 9995 LOCK BRAKE
Electrical brake constantly ON mode
Voltage
[26] 9996 MECHA BRAKE Electrical brake release mode
Voltage
[27] 9997 HI IDLE SET
High idle limit mode
Revolving speed
[28] 9998 SFT INHIBIT
3rd speed cut set
Permit
a
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.
D475A, D475ASD-5E0
19
SEN01819-04
[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.
20
[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
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.
D475A, D475ASD-5E0
[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:
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.
SEN01819-04
2)
3)
[4] 0004: Machine specification code setting

q
This code is used to have the machine specification recognized by the controllers which
compose the system.
q
The specification of the work equipment, SSC
and travel lever are set with this code.
q
Adjustment method
a Since setting of this code is reset when Transmission controller specification setting is executed, adjust it after that.
1) Select code 0004 in the adjustment mode.
(a): Indicates specification of travel lever
(1st place)
(b): Indicates specification of work equipment (2nd place)
(c): Indicates specification of SSC (3rd
place)
No.
Type of work equipment
800
Single tilt
801
Single tilt
SSC power set 1
802
Single tilt
SSC power set 2
810
Dual tilt
Specification
811
Dual tilt
SSC power set 1
812
Dual tilt
SSC power set 2
820
Superdozer
a
a
4)
D475A, D475ASD-5E0
Each time shift-down switch (7) is

pressed, display of the 1st place changes.
Select a proper specification (standard
specification or optional specification) of
the travel lever.
Each time shift-up switch (6) is pressed,
display of the 2nd place and 3rd place
changes. Select proper specifications of
the work equipment and SSC.
a If the SSC is installed to the machine,
be sure to select Power setting 1.
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.
Set buzzer cancel switch (4) in the [U]
position to save the machine specification.
a When the buzzer cancel switch is
operated, the alarm buzzer sounds.
k If the actual machine specification
is different from the setting in the
controller, the machine may move
unexpectedly or an error may be
made. Accordingly, be sure to set
the machine specification correctly.
Even if this code is turned OFF, the setting
is effective.
21
SEN01819-04
[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).
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.
is effective.
22
[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.
D475A, D475ASD-5E0
[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.
SEN01819-04
[8] 0009: Pitch angle sensor initial set

q
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.
is effective.
[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
When the cursor is at cylinder 6, if information switch (5) is operated to the right
[>], the rig ht ban k cylin ders can be
reduced.
(L 1,2,3,4,5,6 o R 1,2,3,4,5,6)
D475A, D475ASD-5E0
23
SEN01819-04
[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.
24
[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.
D475A, D475ASD-5E0
[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.
SEN01819-04
[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.
sounds.
a Even if adjustment is carried out, the display on the lower line does not change.
is effective.
a This code is not for adjusting the steering
performance.
[14] 1013: Steering lever left set

This code is used to adjust the maximum left
steering position of the PCCS lever.
q
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.
sounds.
is effective.
performance.
q
D475A, D475ASD-5E0
25
SEN01819-04
[15] 1014: Steering lever right set

q
This code is used to adjust the maximum right
steering position of the PCCS lever.
q
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.
sounds.
is effective.
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).
sounds.
is effective.
[17] 1016: Right brake oil pressure offset

q
This code is used to adjust the right brake oil
pressure manually.
q
q
Adjustment method:
pressure.
q
q
pressure
26
D475A, D475ASD-5E0
2)
a
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.
SEN01819-04
[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.
is effective.
[18] 1112: Pre-lubrication set (if equipped)

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:
setting.
q
q
[Pre-Lub ON]: Machine is equipped with
pre-lubrication system
q
[Pre-Lub OFF]: Machine is not equipped
with pre-lubrication system
a If setting of installation and non-installation
of the pre-lubrication system is wrong, an
error may be detected.
is effective.
q
D475A, D475ASD-5E0
27
SEN01819-04
[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.
28
[21] 5537: Left steering clutch oil pressure offset

q
This code is used to adjust the left clutch oil
pressure manually.
q
q
Adjustment method:
pressure.
q
q
pressure
sounds.
is effective.
D475A, D475ASD-5E0
[22] 5538: Right steering clutch oil pressure offset

q
This code is used to adjust the right clutch oil
pressure manually.
q
q
Adjustment method:
pressure.
q
q
pressure
sounds.
is effective.
D475A, D475ASD-5E0
SEN01819-04
[23] 9801: Engine oil level set (if equipped)

q
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:
setting.
q
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.
29
SEN01819-04
[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:
setting.
q
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:
effective and the electric brake is constantly
turned on.
[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:
effective and the electric brake is constantly
turned off.
q
30
D475A, D475ASD-5E0
[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.
sounds.
a Once the high idle speed is limited, the
engine speed does not reach the original
high idle speed, even if the fuel control dial
is operated.
is effective.
D475A, D475ASD-5E0
SEN01819-04
[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.
is effective.
31
SEN01819-04
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)

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
section (2).
2] Display the information screen by
operating buzzer cancel switch (4).
q
[U]: Execute mode.
2)
No.
Changing information screen

Change the information screen by operating information switch (5).
q
[ > ]: Next screen.
q
[ < ]: Previous screen.
Display
Item
01-1000 rpm SMR
1000 rpm service

data
02-FOWARD ODO M
Forward travel
distance
03-REVERSE ODO M
Reverse travel
distance
04-F1 ODO Meter
F1 travel distance
05-F2 ODO Meter
F2 travel distance
06-F3 ODO Meter
F3 travel distance
07-R1 ODO Meter
R1 travel distance
08-R2 ODO Meter
R2 travel distance
09-R3 ODO Meter
R3 travel distance
3)
Display of 1,000rpm service meter (01)

This code is used to display the service
meter which integrates the operation
hours only while the engine speed is
higher than 1,000rpm.
a The data cannot be reset.
32
D475A, D475ASD-5E0
SEN01819-04
4)
Display of forward odometer (02)

On this screen, the integrated forward
travel distance is displayed.
7)
Display of F2 odometer (05)

On this screen, the integrated F2 (Forward
2nd gear) travel distance is displayed.
5)
Display of reverse odometer (03)

On this screen, the integrated reverse
travel distance is displayed.
8)

3rd gear) travel distance is displayed.
6)

1st gear) travel distance is displayed.
9)
Display of R1 odometer (07)

On this screen, the integrated R1
(Reverse 1st gear) travel distance is displayed.
D475A, D475ASD-5E0
33
SEN01819-04
10) Display of R2 odometer (08)

(Reverse 2nd gear) travel distance is displayed.
11) Display of R3 odometer (09)

(Reverse 3rd gear) travel distance is displayed.
12) Moving machine with saved load displayed

FREE position, gear speed display unit (1)
is set in the normal display mode again
and the machine can operate normally.
load saving display mode.)
traveling.
parking brake lever to the LOCK position temporarily, and then start the
operation.
34
D475A, D475ASD-5E0
SEN01819-04
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] Select Real-time monitoring mode
on the mode selection screen.
(5R) is displayed on gear speed
section (2).
2] Display the monitoring code input
switch (4).
q
[U]: Execute mode.
q
q
q
q

1)
2]
After inputting the code, display the

m on ito ring scree n by op erating
q
[ ]: Enter input code.
a If the input code is normal, the
monitoring screen shown at right
appears.
2)
If the input code is abnormal, the

code input screen appears again
after the screen shown at right.
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).
D475A, D475ASD-5E0
35
SEN01819-04
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.
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.
When operating machine in monitoring

mode
displays normally and the machine can be
operated normally.
monitoring mode.)
traveling.
5)
36
D475A, D475ASD-5E0
6)
SEN01819-04
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.
D475A, D475ASD-5E0
37
SEN01819-04
Monitoring mode table

No. Code
Monitoring item
Unit
Remarks
Automatic
selection
00201 ENG M ID L
Engine controller model selection name, left bank
Letter
00203 ENG M ID R
Engine controller model selection name, right bank
Letter
01002 ENG REV L
Engine speed, left bank
rpm
01004 ENG REV R
Engine speed, right bank
rpm
01603 Remote Th
2nd throttle position
03000 FUEL DIAL
Fuel control dial voltage
mV
25
03200 BATTERY
Battery voltage
mV
39
03201 S/T ACC
Steering controller ACC input voltage
mV
03202 S/T PWR2
Steering controller load power supply voltage
mV
10 03203 E-ECM PW L
Engine controller power supply voltage, left bank
mV
11 03206 E-ECM PW R
Engine controller power supply voltage, right bank
mV
12 03207 S/T PWR1
Steering controller unswitched power supply voltage
mV
13 03208 T/M PWR1
Transmission controller unswitched power supply voltage
mV
14 03212 T/M ACC
Transmission controller ACC input voltage
mV
15 03216 T/M PWR2
Transmission controller load power supply voltage
mV
16 04104 COOLANT TP
Engine coolant temperature
17 04105 COOLANT TP
Engine coolant temperature sensor voltage
mV
18 04200 FUEL SENS
Fuel level sensor voltage
mV
37
19 04401 HYD.TEMP
20 08100 HSI BREAK
HSI line break point
rpm
21 08200 TQ Sel
Torque curve selection
Letter
22 08300 Droop Type
Droop type selection
Letter
23 08400 Droop SW
Droop switch selection
Letter
24 08500 Droop Trim
Droop trim selection
Letter
25 10500 S/T 5V PW1
Steering controller sensor 5V power supply voltage 1
mV
26 10501 T/M 5V PW1
Transmission controller sensor 5V power supply voltage

1
mV
27 10505 S/T 5V PW2
Steering controller sensor 5V power supply voltage 2
mV
28 10506 T/M 5V PW2

2
mV
29 10700 S/T 24V PW
Steering controller sensor 24V power supply voltage
mV
30 10701 T/M 24V PW
mV
31 14200 FUEL TMP L
Fuel temperature, left bank
32 14201 FUEL TMP L
Fuel temperature sensor voltage, left bank
mV
33 14202 FUEL TMP R
Fuel temperature, right bank
34 14203 FUEL TMP R
Fuel temperature sensor voltage, right bank
mV
35 17201 PCV TMG L
PCV closing timing, left bank
CA
36 17202 PCV TMG R
PCV closing timing, right bank
CA
37 17500 ENG MODE
Engine controller mode selection
Letter
38 18300 ENG IVSW 1
Engine controller idle validation switch 1
bit
(See detailed
information)
39 18301 ENG IVSW 1
Engine controller idle validation switch 2
bit
(See detailed
information)
38
D475A, D475ASD-5E0
No. Code
SEN01819-04
Monitoring item
Unit
Remarks
Automatic
selection
40 18400 INTAKE TEMP Intake air temperature
41 18401 INTAKE TEMP Intake air temperature sensor voltage
mV
42 18500 BOOST TEMP Boost temperature
43 18501 BOOST TEMP Boost temperature sensor voltage
mV
mg/st
45 18700 ENG TRUQUE Engine output torque
Nm
46 18900 E-ECM TP L
Engine controller ECM inside temperature, left bank
47 18902 E-ECM TP R
Engine controller ECM inside temperature, right bank
48 20201 T/M. PROGRM
Transmission controller program version
Letter
44 18600 INJECT CMD
Final injection rate command
49 20202 S/T. PROGRM
Steering controller program version
Letter
50 20216 ENG BLD L
Engine controller build version, left bank
Letter
51 20217 ENG CAL L
Engine controller calibration data version, left bank
Letter
52 20218 ENG CAL R
Engine controller calibration data version, right bank
Letter
53 20219 ENG BLD R
Engine controller build version, right bank
Letter
54 20301 VHMS
VHMS LED monitor
LED
40
55 20400 E-ECM SN L
Engine controller ECM serial No., left bank
Letter
56 20401 E-ECM SN R
Engine controller ECM serial No., right bank
Letter
57 30100 T/C TEMP.
Torque converter oil temperature
58 31200 T/M IN
Transmission input speed
rpm
59 31400 T/M OUT
Transmission output speed
rpm
60 31520 T/M-FILL
Transmission-related fill switch input state
bit
(See detailed
information)
61 31521 S/T FILL
Steering-related fill switch input state
bit
(See detailed
information)
62 31602 1st CLUTCH
1st clutch ECMV current command value
mA
63 31603 2nd CLUTCH
2nd clutch ECMV current command value
mA
64 31604 3rd CLUTCH
3rd clutch ECMV current command value
mA
65 31606 Rev CLUTCH
Reverse clutch ECMV current command value
mA
66 31608 Frd CLUTCH
Forward clutch ECMV current command value
mA
67 31612 1 CLUTCH F
1st clutch ECMV output feedback current
mA
33
68 31613 2 CLUTCH F
2nd clutch ECMV output feedback current
mA
34
69 31614 3 CLUTCH F
3rd clutch ECMV output feedback current
mA
35
70 31616 R CLUTCH F
Reverse clutch ECMV output feedback current
mA
32
71 31618 BRAKE R.H.
Right brake ECMV output feedback current
mA
27
72 31619 BRAKE L.H.
Left brake ECMV output feedback current
mA
26
73 31620 BRAKE R.H.
Right brake ECMV current command value
mA
74 31621 BRAKE L.H.
Left brake ECMV current command value
mA
75 31622 F CLUTCH F
Forward clutch ECMV output feedback current
mA
76 31623 FAN PUMP. O
Cooling fan pump solenoid output command current
mA
77 31624 FAN PUMP. F
Cooling fan pump solenoid output feedback current
mA
78 31625 PITCH SOL.
Blade pitch solenoid output feedback current
mA
79 31627 L/U SOL
Torque converter lockup solenoid output feedback current
mA
36
80 31628 E. BRAKE SL
Sudden stop prevention solenoid output feedback current
mA
28
81 31633 FAN PMP2. O
Cooling fan pump 2 solenoid output command current
mA
D475A, D475ASD-5E0
31
39
SEN01819-04
No. Code
Monitoring item
Unit
Remarks
Automatic
selection
mA
mV
24
82 31634 FAN PMP2. F
Cooling fan pump 2 solenoid output feedback current
83 31701 DECEL
Decelerator position
84 31703 DECEL
Decelerator pedal potentiometer voltage
85 31706 F THROTTLE
Final accelerator position
10
86 32900 BODY ANGLE Machine pitch angle
18
87 36001 Accel Adj
Throttle correction value data
88 36200 PRESS CMD
Final common rail pressure command
MPa
89 36300 INJECT CMD
Final injection timing command
CA
90 36400 RAIL PR L
Common rail pressure, left bank
MPa
12
91 36401 RAIL PR L
Common rail pressure sensor voltage, left bank
mV
92 36403 RAIL PR R
Common rail pressure, right bank
MPa
13
93 36404 RAIL PR R
Common rail pressure sensor voltage, right bank
mV
94 36500 BOOST PRS
Boost pressure
kPa
(Absolute
pressure)
14
95 36501 BOOST PRS
Boost pressure sensor voltage
mV
96 36700 ENG TORQUE Engine converted torque
15
97 37200 ENG OIL PRS
Engine oil pressure
kPa
11
98 37201 ENG OIL PRS
Engine oil pressure sensor voltage
mV
99 37301 FUEL RATE
Fuel injection rate
L/h
(Absolute
pressure)
100 37400 ABM PRESS
Ambient pressure
kPa
101 37401 ABM PRESS
Ambient pressure sensor voltage
mV
102 37500 ATM TEMP
Ambient temperature
103 40001 VEHICLE SP
Travel speed (Theoretical value)
km/h
104 40905 T/M-SW1
Transmission-related controller input signal 1
bit
(See detailed
information)
105 40906 T/M-SW2
Transmission-related controller input signal 2
bit
(See detailed
information)
106 40907 T/M OP SIG
Transmission-related controller operation input signal
bit
(See detailed
information)
107 40908 T/M HYD SW
Blade lever oil pressure switch input signal
bit
(See detailed
information)
108 40909 T/M SOL. 2
Transmission-related controller ON/OFF output 2
bit
(See detailed
information)
109 40910 S/T-SW1
Steering-related controller switch input signal 1
bit
(See detailed
information)
110 40911 S/T-SW2
bit
(See detailed
information)
111 40913 S/T-SW5
bit
(See detailed
information)
112 40914 S/T SOL. 1
Transmission-related controller ON/OFF output 1
bit
(See detailed
information)
113 40915 S/T SOL. 2
Steering-related controller output signal 2
bit
(See detailed
information)
114 42600 EXH TEMP LF
Exhaust temperature, left front
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
mV
40
D475A, D475ASD-5E0
SEN01819-04
No. Code
Monitoring item
118 42604 EXH TEMP LF
Exhaust temperature sensor voltage, left front
Unit
Remarks
Automatic
selection
mV
119 42605 EXH TEMP RR Exhaust temperature sensor voltage, right rear
mV
120 42606 EXH TEMP LR Exhaust temperature, left rear
121 42607 EXH TEMP LR Exhaust temperature sensor voltage, left rear
mV
122 42700 ENG OIL TMP
Engine oil temperature
123 42701 ENG OIL TMP
Engine oil pressure sensor voltage
mV
124 42800 BLOWBY PRS
Blow-by pressure
kPa
125 43000 T/M PRESS
Transmission main relief pressure
MPa
126 43502 IdleCancel
Warm-up operation cancel flag
bit
(See detailed
information)
127 44202 Accel Up
Throttle upper limit value data
128 44203 Accel low
Throttle lower limit value data
129 50200 T/M LEVR 1
Directional lever potentiometer 1 voltage
mV
19
130 50201 T/M LEVR 2
Directional lever potentiometer 2 voltage
mV
20
131 50300 S/T LEVR 1
Steering potentiometer 1 voltage
mV
21
132 50301 S/T LEVR 2
Steering potentiometer 2 voltage
mV
22
133 50400 BRAKE PEDL
Brake pedal potentiometer voltage
mV
23
134 50900 N-SAFTY
Neutral safety relay drive voltage
mV
38
135 51000 ENG REG
Regulation command speed
rpm
136 51100 FUEL DIAL
Fuel control dial command speed
rpm
137 60000 TRACTION
Traction force (Theoretical value)
138 60100 BODY ANGLE
Machine pitch angle sensor voltage
mV
139 60200 ACCELERATN
Acceleration sensor voltage
mV
140 60300 SSC ORDER
SSC command speed
rpm
141 60400 S/T-SW6
Steering-related controller input signal 6
bit
(See detailed
information)
142 60500 ENG.CON. PW
Engine controller drive voltage
mV
143 60600 BR HOLD
Battery relay drive voltage
mV
144 60700 S/T MODE
Steering state code
Letter
145 60800 FILL MODE
Fill condition setting variable
Letter
146 60909 MOD MODE
Modulation condition setting variable
Letter
147 70000 CHG.P. MODE
Gearshift point condition setting variable
Letter
148 70200 T/M OUT
Transmission speed sensor voltage
mV
149 70300 B. KNOB SW
Blade lever knob switch input signal
bit
(See detailed
information)
150 70305 T/M RIPER2
Ripper lever oil pressure switch input signal
bit
(See detailed
information)
151 70400 BACK ALARM
Backup alarm relay drive voltage
mV
152 70600 DUAL SOL.
Dual tilt solenoid drive current
mA
153 70700 HYD. PUMP 1
Work equipment pump oil pressure 1
MPa
16
154 70701 HYD. PUMP 1
Work equipment oil pressure sensor 1 voltage
mV
155 70702 HYD. PUMP 2
Work equipment pump oil pressure 2
MPa
17
156 70703 HYD. PUMP 2
Work equipment oil pressure sensor 2 voltage
mV
157 90000 T/M SOL. 3
Tilt and pitch solenoid output 3 bit output signal
bit
(See detailed
information)
158 90001 T/M SOL. 4
Dual tilt and pitch solenoid output 4 bit output signal
bit
(See detailed
information)
D475A, D475ASD-5E0
41
SEN01819-04
No. Code
Monitoring item
Unit
Remarks
Automatic
selection
159 90002 BL YOKE L
Left yoke angle sensor voltage
mV
160 90003 BL YOKE R
Right yoke angle sensor voltage
mV
161 90600 S/T CLT LH
Left clutch ECMV output feedback current
mA
29
162 90601 S/T CLT RH
Right clutch ECMV output feedback current
mA
30
163 90602 S/T CLT LH
Left clutch ECMV output current
mA
164 90603 S/T CLT RH
Right clutch ECMV output current
mA
165 92100 F1 SMR
F1 integrated travel hours
166 92101 F2 SMR
167 92102 F3 SMR
168 92200 R1 SMR
R1 integrated travel hours
169 92201 R2 SMR
170 92202 R3 SMR
171 99901 TRIG T F
Trigger time F
msec
172 99902 TRIG T R
Trigger time R
msec
173 99903 TRIG T 1
Trigger time 1
msec
174 99904 TRIG T 2
Trigger time 2
msec
175 99905 TRIG T 3
Trigger time 3
msec
176 99906 TM SFT
Transmission shift
Letter
177 99907 LU
Lockup state
bit
(See detailed
information)
178 99908 TM IN TRQ
Transmission input torque
Nm
179 99909 DOZING h
Dozing hours
180 99910 RIPPING h
Ripping hours
181 99911 PATH NUM
Number of path
path
182 99913 TC IN TRQ
Torque converter input torque
Nm
183 99914 H. P 1 TRQ
Work equipment pump 1 input torque
Nm
184 99915 H. P 2 TRQ
Work equipment pump 2 input torque
Nm
185 99917 BR L PRESS
Left brake oil pressure
MPa
186 99918 BR R PRESS
Right brake oil pressure
MPa
187 99919 CL L PRESS
Left clutch oil pressure
MPa
188 99920 CL R PRESS
Right clutch oil pressure
MPa
42
The numbers in the Automatic selection column can be displayed in numeric order by setting the information switch in the > or < position.
D475A, D475ASD-5E0
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.
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)
D475A, D475ASD-5E0
SEN01819-04
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)
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)
43
SEN01819-04
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)
44
D475A, D475ASD-5E0
SEN01819-04
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)

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)
D475A, D475ASD-5E0
45
SEN01819-04

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)
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)
46
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)
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)
D475A, D475ASD-5E0

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)
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)
D475A, D475ASD-5E0
SEN01819-04
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)
90000: Tilt/Pitch solenoid output 3 bit output signal

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)
47
SEN01819-04
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)
48
D475A, D475ASD-5E0
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)

1] Select Dual display monitoring
mode on the mode selection screen.
(dR) is displayed on gear speed
section (2).
2] Display the monitoring code input
switch (4).
q
[U]: Execute mode.
SEN01819-04
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
q
q
q
2] After inputting the codes, display the
m on ito ring scree n by op erating
q
[U]: Enter input code.
If the input codes are normal, the

monitoring screen shown below
appears.
D475A, D475ASD-5E0
49
SEN01819-04
a
3)
If the input codes are incorrect,

the code input screen appears
again after the screen shown
below.
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.
4)
When operating machine in monitoring

mode
(1) displays normally and the machine can
be operated normally.
monitoring mode.)
traveling.
50
D475A, D475ASD-5E0
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.
D475A, D475ASD-5E0
SEN01819-04
51
SEN01819-04

2009 KOMATSU
All Rights Reserved
52
SEN01820-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

Adjustment method when controller has been replaced ................................................................................. 2
Preparation work for troubleshooting for electrical equipment system ........................................................... 4
Inspection procedure of diode......................................................................................................................... 8
Handling of optional devices ........................................................................................................................... 9
Initialization procedures for VHMS controller................................................................................................ 10
Precautions for replacing VHMS controller ................................................................................................... 31
Pm Clinic service .......................................................................................................................................... 36
D475A, D475ASD-5E0
SEN01820-03
Adjustment method when

controller has been replaced
a
a
a
1.
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.
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.
6.
Adjusting machine specification

Select Machine specification set (0004) and
adjust the machine specification.
After the machine is assembled or transmission controller or steering controller is

replaced, adjust the system according to the
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.
2.
Setting system in service mode

After step 1, turn the starting switch ON again
and set the monitor panel in the Adjustment
mode of the service mode.
3.
Adjusting steering controller

Select Steering controller specification set
(0002) and adjust the steering controller.
a Execute this code only when the transmission controller is also replaced.
4.
D475A, D475ASD-5E0
7.
Adjusting brake potentiometer

Select Brake potentiometer initial set (0005)
and adjust the brake potentiometer.
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.)
D475A, D475ASD-5E0
SEN01820-03
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.
SEN01820-03
Preparation work for

troubleshooting for electrical
equipment system
a
3)
Insert or connect T-adapters in or to connectors S01, S02, S03, and S04 of monitor panel (2).
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.
1.
Monitor panel
1) Remove cover (1).
2) Remove the 2 mounting bolts and pull out
monitor panel (2) toward the operators
seat.
2.
Engine controller
1) Open left and right side covers (1) and
remove side covers (2) and (3).
2)
Remove cover (4) of engine controller.
D475A, D475ASD-5E0
3)
SEN01820-03
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}
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.
D475A, D475ASD-5E0
3.
1) Remove dashboard cover (1).
SEN01820-03
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}
4.
Steering controller
1) Remove dashboard undercover (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}
D475A, D475ASD-5E0
5.
VHMS controller
1) Open the floor left side cover and remove
cover (1).
2)
Remove amplifier mounting cover (2).
SEN01820-03
6.
ORBCOMM terminal
1) Open the floor left side cover and remove
cover (1).
2)
3)
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.
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.
D475A, D475ASD-5E0
SEN01820-03
Inspection procedure of diode
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)
2.
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)
D475A, D475ASD-5E0
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.
1.
Connecting the ACC signal of starting

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

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

If the C signal (starting signal) of the starting
switch is necessary for a optional device such
as the pre-lubricator, connect it through the 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.
4.
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.
D475A, D475ASD-5E0
SEN01820-03
SEN01820-03
Initialization procedures for VHMS

controller
1
a
Initialization tools for VHMS controller
Symbol
Part No.
799-608-3211
Diskette
799-608-3220
Wiring harness
Commercially
available
Notebook type personal computer (OS: Windows98/2000/

NT/Me/XP Terminal
"RS232C" is with it)
10
Part name
1.
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 ORBCOMM-less
Specification. In case of ORBCOMM-less
Specification, omit the procedures necessary
for ORBCOMM Specification only.
During the initialization work, confirm each
work according to the VHMS Initialization
Work Checklist.
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
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]
2.
Information to be checked
The VHMS controller and ORBCOMM terminal are in the VHMS controller box
under the left side cover of the floor.
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.
D475A, D475ASD-5E0
SEN01820-03
2)
3)
4)
a
a
Execute initialization of VHMS from

the connector in the cab.
Use the ground download connector
for only downloading.
5)
6)
3.
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.
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.
D475A, D475ASD-5E0
7)
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.
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.
11
SEN01820-03
9)
Right decimal
point
12
Display
OFF
Power is not supplied to ORBCOMM controller.

Communication line to VHMS
controller is abnormal.
ON
Satellite is not captured.

Power is supplied to ORBCOMM controller.
controller is normal.
Blinking
Power is supplied to ORBCOMM controller.

controller is normal.
Satellite is captured.
8)
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.
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.
4.
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: 7826146000
4) Select [Data clear and Set up] in the
[Select Function] column.
5) Press the [OK] button to go to the setup
screen.
D475A, D475ASD-5E0
5.
SEN01820-03
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)
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.
Initialization of VHMS controller (Tool

before Ver. 3.5.2.1)
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.
D475A, D475ASD-5E0
13
SEN01820-03
[Communication Setting] [For ORBCOMM specification only]

a Execute this setting after requesting for opening of the ORBCOMM terminal and finishing
the opening procedure.
6) Open the [Communication Setting] tab.
7) Check all the data.
8)
14
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].
D475A, D475ASD-5E0
9)
SEN01820-03
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].
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.
GCC Code
1
120
130
Area
N.America (*1)
C.S.Americas
Faroe lslands
Europe (*2)
Middle East
Asia (*3)
Africa
Oceania
CLS
Japan
D475A, D475ASD-5E0
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 o r c h e c k in g t h e s e t t i n g
appears. Check the setting again and
press the [OK] button if the setting is
correct.
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].
Remarks
*1: Except U.S. Territories
in Micronesia and Midway lsland
*2: Except Faroe lslands

*3: Except Japan
15
SEN01820-03
6.
Initialization of VHMS controller (Ver. 3.5.2.1

or after)
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.
2)
16
If the VHMS was installed additionally, the information of [Serial No.] etc.
must be input.
Select [Set up & All clear] and press the

Next button.
D475A, D475ASD-5E0
4)
5)
6)
7)
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.
120
130
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.
Set the GCC Code to the applicable area

and then press the Next button.
GCC Code
1
SEN01820-03
Area
N.America (*1)
C.S.Americas
Faroe lslands
Europe (*2)
Middle East
Asia (*3)
Africa
Oceania
CLS
Japan
Remarks
*1: Except U.S. Territories
in Micronesia and Midway lsland
*2: Except Faroe lslands

*3: Except Japan
10) After finishing the work of changing the

contents of initialization, press the OK
button to finish the program.
D475A, D475ASD-5E0
17
SEN01820-03
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.
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.
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.
3) Selection and execution of mode.
1] Select Snap shot mode on the mode
selection screen.
a If the mode is selected, code (55)
is displayed in gear speed display unit (1) and the title is displayed in multi-information unit
(2).
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.
18
D475A, D475ASD-5E0
5]
SEN01820-03
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.
D475A, D475ASD-5E0
19
SEN01820-03
Time (sec)
Finish
Start
No.
Table 1 Operations of machine to be executed while snap shot is operated

Operation of machine
State of machine
0:00 0:25 25
0:25 0:50 25
0:50 1:40 50
1:40 2:30 50 Deceleration slow
2:30 3:00 30
Transmission
Fuel
SteerWork equipment control
ing
dial
Decelerator pedal
Brake
pedal
Parking
brake
LH
LOW
HI
Released Released
RH
LOW
HI
Released Released
HI
HI
Released Released
HI
LOW
Released Released
High-pressure
relief & high idle
HI
HI
Released Released
3:00 3:30 30
High-pressure
relief & low idle
Right tilt (or

pitch back in
case of dual tilt
model)
LOW
HI
Released Released
3:30 4:00 30
Port relief &

high idle
4:00 4:30 30
Port relief &

low idle
4:30 5:10 40
Torque converter
stall & low idle
Torque converter
10 5:10 6:00 50 stall (F3) & high
idle (Note 1)
11 6:00 6:30 30
Low idle
High idle
High idle
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
HI
Released Released
Left tilt (or pitch

dump in case of
dual tilt model)
LOW
HI
Released Released
NoF1oF2oF
3oNoR1oR2
oR3oN
LOW
HI
ON
Released
NoF3 (Shift to
F3, then run
engine at full
throttle)
HI
LOWo
Shift to F3,
then HI
ON
Released
HI
HI
NoF3 (Shift to
F3, then run
engine at high
idle)
Left tilt (or pitch

dump in case of
dual tilt model)
HI
LOWo
Shift to F3,
then HI
ON
Released
HIo
LOW
HI
Released
ON
Released Released
(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.
(Note 2): Keep running the engine at low idle until the oil temperature is lowered to the normal level.
a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine
speed to high idle.
a After stalling the torque converter, watch the power train oil temperature gauge and take care not to
overheat the power train oil.
(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature
gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the
engine at high idle to lower the oil temperature.)
20
D475A, D475ASD-5E0
6]
The screen shown below appears 7

minutes 30 seconds after the snap
shot is started, and then the initial
screen appears 5 seconds after. (End
of snap shot)
SEN01820-03
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
D475A, D475ASD-5E0
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)
21
SEN01820-03
9]
22
Check Click position graphic value

display.
D475A, D475ASD-5E0
SEN01820-03
10] Click a point in the graph, and the

value of each measurement item at
that point on the X-axis is displayed
under the graph.
(Example of displayed graph: This is
different from the actual graph.)
D475A, D475ASD-5E0
23
SEN01820-03
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.
Engine at high idle
Deceleration slow
High-pressure relief & engine at full throttle
Q
Q
High-pressure relief & engine at slow

Port relief & engine at full throttle
Q
Q
Port relief & engine at slow

Q
Torque converter stall & engine at slow

Torque converter stall (F3) & engine at full
throttle
Work equipment pump (FR)
3rd clutch fill switch
2nd clutch fill switch
1st clutch fill switch
Rear clutch fill switch
Steering right brake fill switch
Steering left brake fill switch
Steering right clutch fill switch
Steering left clutch fill switch
Engine at low idle
Front clutch fill switch
Exhaust temperature
Blow-by pressure
Engine speed
State of machine
Engine oil pressure
Measurement items
Engine at full throttle

Torque converter stall & high-pressure relief
Engine at high idle o Engine at low idle
24
D475A, D475ASD-5E0
8.
SEN01820-03
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.
D475A, D475ASD-5E0
Input [User Name] and [Password].

For the operation procedures, see the
Operation and Maintenance Manual
for VHMS Technical Analysis Tool.
25
SEN01820-03
5)
9.
Check of downloaded data

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.
2)
26
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.
After checking the set data, terminate

[VHMS Technical Analysis Tool].
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.
3)
If the data was downloaded in the cab,

disconnect wiring harness Z2 from download connector VDW.
4)
If the data was downloaded on the

ground, turn switch (2) OFF and disconnect wiring harness Z2 from download
connector DL1.
D475A, D475ASD-5E0
SEN01820-03
11. Communication to Komatsu

After completing steps 1 to 9 successfully,
send the VHMS/WebCARE setting notification
form to VHMS/WebCARE Support Center of
Komatsu, Tokyo.
a Since Komatsu has to set the receiving
side of the satellite communication, be
sure to inform Komatsu of the completion
of the setting.
a Send the VHMS data by Notes (LAN) or
E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)
FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
D475A, D475ASD-5E0
27
SEN01820-03
(Objective model: D475A-5E0 Bulldozer)
28
D475A, D475ASD-5E0
SEN01820-03
(Objective model: D475A-5E0 Bulldozer)
D475A, D475ASD-5E0
29
SEN01820-03
30
D475A, D475ASD-5E0
SEN01820-03
Precautions for replacing VHMS

controller
1
a
Part No.
799-608-3211
Diskette
799-608-3220
Wiring harness
Commercially
available
Notebook type personal computer (OS:

Windows98/2000/NT/
Me/XP Terminal
"RS232C" is with it)
a
a
3)
Check all the information before replacing

the VHMS controller.
Select [Save] from [File] in the menu.
Name
Select Save/Load and press the OK

button.
Tools for replacing VHMS controller

Symbol
2)
When the VHMS controller needs to be

replaced, set it before removing it and the
installed new VHMS controller according to the
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.
4)
[Work before replacing VHMS controller]

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

set in VHMS controller (Before Ver. 3.5.2.1)
a Transfer the set data of the VHMS controller to be replaced to the personal computer and then write it in the newly
installed VHMS controller.
2-1. Check and saving of information set in VHMS
controller to be replaced
1) Connect the personal computer and start
the VHMS technical analysis tool.
a See Initialization procedures for
VHMS controller.
D475A, D475ASD-5E0
31
SEN01820-03
5)
6)
7)
8)
9)
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.
5)
The saved information is displayed on

another screen.
Press the [Edit] button to set the time.
Select [Exit] from [File] in the menu to finish the VHMS technical analysis tool.
Disconnect the personal computer.
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
VHMS controller.
2) Select Save/Load and press the OK
button.
32
6)
D475A, D475ASD-5E0
7)
After setting the time, press the OK button.
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.
SEN01820-03
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.
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 Transfer the set data of the VHMS controller to be replaced to the personal computer and then write it in the newly
installed VHMS controller.
3-1. Check and saving of information set in VHMS

controller to be replaced
1) Connect the personal computer and start
the VHMS technical analysis tool.
VHMS controller.
2) Select [When VHMS needs to be
replaced] and press the Next button.
D475A, D475ASD-5E0
33
SEN01820-03
3)
Select [Save Current Setting before

replacement of VHMS controller] and
press the Next button.
4)
Check all the information before replacing

the VHMS controller and press the Save
button.
3-2. Writing of set information in new VHMS controller

1) Connect the personal computer again and
VHMS controller.
2) Select [When VHMS needs to be
replaced] and press the Next button.
3)
5)
6)
7)
8)
34
Select [Use Previous setting after replacement of VHMS controller] and press the
Next button.
Select [Exit] from [File] in the menu to finish the VHMS setting tool.
Disconnect the personal computer.
VHMS controller, 9. Disconnection of
Personal Computer.
Turn the personal computer OFF.
Replace the VHMS controller.
D475A, D475ASD-5E0
4)
5)
The saved information is displayed. Press

the Next button.
Set the time and press the Apply button.
SEN01820-03
7)
The above completes modification of the

setting. Press [OK] button to end the
VHMS initial setting tool.
[Work after replacing VHMS controller]

a After replacing the VHMS controller, carry out
initialization according to the Initialization 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.
D475A, D475ASD-5E0
35
SEN01820-03
Pm Clinic service
Model
Serial No.
Service meter
T D475A-5E0
T D475ASD-5E0
User name
Date of clinic
/
Serviceman
Specifications
Blade
Attachment
T Semi U blade
T U blade
T Super blade
T
Shoe width
T Variable Multi-shank ripper

T Variable giant ripper
T Counterweight (
kg)
T
T 710 mm
T 810 mm
T 910 mm
T
%
%
%
%
Operating conditions
Quarry, mine
Construction
Type of soil (specific gravity)
Type of work
T Coal
T Construction, civil engineering
T Rock
T Dozing
T Gold
T Roads
T Gravel
T Side cutting
T Limestone
T Tunnels
T Sand
T Ripping
T Clay
T Travel
Existence of abnormalities
Oil, coolant level check
T Engine coolant level
When necessary
T Engine oil level
T Power train
T Damper case
T Hydraulic oil level
T Final drive
T(
Ambient temperature
Max.
Min.
Height above sea level

C
Operator's opinion
Visual check results
Failure code history
[
Content:
[
Content:
Content:
Engine coolant temperature: Max. range
36
[
Content:
Power train oil temperature: Max. range
D475A, D475ASD-5E0
SEN01820-03
Measuring points for Pm clinic (1/3)
Reference pages for measurement procedures

1. Engine speed: Testing and adjusting, Part 1, Pages 6 9
2. Blow-by pressure: Testing and adjusting, Part 1, Pages 20, 21
3. Engine oil pressure: Testing and adjusting, Part 1, Page 22
4. Boost pressure: Testing and adjusting, Part 1, Pages 10, 11
5. Exhaust temperature: Testing and adjusting, Part 1, Pages 12, 13
D475A, D475ASD-5E0
37
SEN01820-03

6. Torque converter parts: Testing and adjusting, Part 2, Pages 4 5
7. Transmission parts: Testing and adjusting, Part 2, Pages 6 8
8. Steering brake parts: Testing and adjusting, Part 2, Pages 9 10
38
D475A, D475ASD-5E0
SEN01820-03

9. Work equipment and HSS parts: Testing and adjusting, Part 2, Pages 22 32
10. Control circuits: Testing and adjusting, Part 2, Pages 33 39
11. Fan parts: Testing and adjusting, Part 2, Pages 48 49
D475A, D475ASD-5E0
39
SEN01820-03
Decelerator low idle

Decelerator high idle
Low idle
High idle
Low idle
Transmission: Neutral
Oil temperature:
High idle
Low idle
High idle
High idle
40
Transmission: F3
(Adjustment code: 5535)
Low idle
Transmission: R3
Low idle
Transmission: F1
Low idle
Transmission: F2
Low idle
Transmission: F3
Low idle
D475A, D475ASD-5E0
SEN01820-03
Low idle
High idle
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
D475A, D475ASD-5E0
41
SEN01820-03
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
D475A, D475ASD-5E0
SEN01820-03
Pm clinic
Undercarriage check sheet
Serial number
Work order
Date
/
T D475A-5E0 #
T D475ASD-5E0 #
Service meter
/
Serviceman
h
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
D475A, D475ASD-5E0
Left
track
A: Clearance between
links
Right
track
A: Clearance between
links
Pin No.
1.6
Pin No.
1.6
43
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)

(Program form No.: SELA195001)
44
D475A, D475ASD-5E0
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)

(Program form No.: SELA195001)
IMPACT
D475A, D475ASD-5E0
45
SEN01820-03

2010 KOMATSU
All Rights Reserved
46
SEN01821-04
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
40 Troubleshooting
Failure code table and fuse locations

Failure code table ........................................................................................................................................... 2
Fuse locations............................................................................................................................................... 12
D475A, D475ASD-5E0
SEN01821-04
40 Troubleshooting
Failure code table

Failure
code
Transmission clutch
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
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
Component in
charge
Action
code
Category of record
Clutch slip
T/M
Electrical system
Double engagement
T/M
Clutch slip
T/M
Troubled part
1380MW Lockup clutch

1500L0
Left brake oil pressure
2302LH Left brake oil pressure

2302NR Left steering brake thermal load
Trouble
Command current is OFF and

fill signal is ON
Command current is ON and
fill signal is OFF
fill signal is ON
fill signal is OFF
fill signal is ON
fill signal is OFF
fill signal is ON
fill signal is OFF
fill signal is ON
fill signal is OFF
Clutch slip
fill signal is ON
fill signal is OFF
fill signal is ON
fill signal is OFF
Abnormal heating
fill signal is ON
fill signal is OFF
Abnormal heating
fill signal is ON
fill signal is OFF
Abnormal heating
6001ZK Failure code for design
CALL E03 Electrical system
Electrical system
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
T/M
S/T
Electrical system
S/T
S/T
S/T
TroubleshootCALL E04 Electrical system ing by failure

code, Part 1
SEN01823-02
Electrical system
S/T
S/T
S/T
S/T
S/T
S/T
S/T
S/T
A000NS Engine
Overheat
MON
Mechanical system
AA10NX Air cleaner
Clogging
MON
Mechanical system
AB00MA Battery charge abnormality
Malfunction
MON
Mechanical system
B@BAZG Engine oil
Oil pressure reduction
ENG
Mechanical system
B@BAZK Engine oil
Oil level reduction
MON
Mechanical system
B@BCNS Engine coolant
Overheat
ENG
Mechanical system
B@BCZK Engine coolant
Coolant level reduction
MON
Mechanical system
B@BEBF Fuel
Water in fuel
MON
Mechanical system
Reference
manual
D475A, D475ASD-5E0
40 Troubleshooting
Failure
code
SEN01821-04
Troubled part
Trouble
Component in
charge
Action
code
Category of record
Reference
manual
B@BFZK Fuel level
Reduction
MON
Mechanical system
B@CENS Power train oil
Overheat
MON
Mechanical system
B@CHZG HSS charge oil pressure
Low oil pressure
MON
B@CHZK Power train
Oil level reduction
MON
Mechanical system Troubleshooting by failure

Mechanical system code, Part 1
B@GAZK Battery electrolyte level
Electrolyte level reduction
MON
Mechanical system SEN01823-02
B@HANS Hydraulic oil
Overheat
MON
Mechanical system
B@HAZK Hydraulic oil
Oil level reduction
S/T
Mechanical system
CA111
Engine controller (Left bank)
Internal abnormality
ENG CALL E04 Electrical system
CB111
Engine controller (Right bank)
Internal abnormality
Speed sensor signal error
Speed sensor signal error
High voltage detection
Low voltage detection
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 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)
low level (Right bank)
abnormally high level (Only left bank)
abnormally low level (Only left bank)
Ambient temperature sensor abnormally high level (Only left bank)
Ambient temperature sensor abnormally low level (Only left bank)
high level (Left bank)
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
D475A, D475ASD-5E0
TroubleshootENG CALL E01 Electrical system ing by failure

code, Part 2
SEN01824-01
Abnormally high speed
ENG

Mechanical system
SEN01821-04
Failure
code
40 Troubleshooting
Troubled part
Trouble
Component in
charge
Action
code
Category of record
Reference
manual
CB265

CA271
PCV1 short circuit (Left bank)
Short circuit
CB271
PCV1 short circuit (Right bank)
Short circuit
CA272
PCV1 disconnection (Left bank)
Disconnection
CB272
PCV1 disconnection (Right bank)
Disconnection
ENG CALL E03 Electrical system Troubleshooting by failure

ENG CALL E03 Electrical system code, Part 2
CA273
PCV2 short circuit (Left bank)
Short circuit
ENG CALL E03 Electrical system SEN01824-01
CB273
PCV2 short circuit (Right bank)
Short circuit
CA274
PCV2 disconnection (Left bank)
Disconnection
CB274
PCV2 disconnection (Right bank)
Disconnection
Disconnection/Short circuit
Mismatch
Mismatch
Circuit abnormality
Circuit abnormality
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
Injector #1 (L/B#1) 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)
Power supply voltage abnormally low
level (Left bank)
Power supply voltage abnormally low
level (Right bank)
Power supply voltage abnormally
Power supply voltage abnormally
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)

code, Part 3
SEN01825-03

Abnormally high pressure

occurrence
occurrence


occurrence
occurrence
ENG
E02
Electrical system
ENG
E02
Electrical system
D475A, D475ASD-5E0
40 Troubleshooting
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)
(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)
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)
CA2249
(Left bank)
CB2249
(Right bank)
SEN01821-04
Trouble
Component in
charge
Action
code
Category of record
In-range error occurrence
In-range error occurrence
Low pressure occurrence
ENG
E02
Electrical system
ENG
E02
Electrical system

code, Part 3
SEN01825-03
ENG
E01
Electrical system
ENG
Phase error
Phase error
All data loss
All data loss
Bkup signal error
Bkup signal error
Communication error
Communication error
Distinction error
Distinction error
ENG CALL E03 Electrical system Troubleshooting by failure

ENG CALL E03 Electrical system code, Part 4
ENG CALL E03 Electrical system SEN01826-01
Communication error
Signal error
Signal error
E01
Electrical system
D110KA Battery relay
Disconnection
S/T
Electrical system
D110KB Battery relay
Short circuit
S/T
Electrical system
D130KA Neutral safety relay
Disconnection
T/M
E02
Electrical system
D130KB Neutral safety relay
Short circuit
T/M
E02
Electrical system
D161KA Backup alarm relay
Disconnection
T/M
E01
Electrical system
D475A, D475ASD-5E0
Reference
manual
SEN01821-04
Failure
code
40 Troubleshooting
Troubled part
Trouble
Component in
charge
Action
code
Category of record
D161KB Backup alarm relay
Short circuit
T/M
E01
Electrical system
D182KZ Preheater relay
Disconnection/short circuit
S/T
E01
Electrical system
Disconnection
S/T
Electrical system
Short circuit
S/T
Electrical system
D5ZRKA Snap shot switch
Disconnection
S/T
Electrical system
D5ZRKB Snap shot switch
Short circuit
S/T
Electrical system
Engine controller ACC signal cut

relay
Engine controller ACC signal cut
D190KB
relay
D190KA
Monitor panel CAN communication

(MON)
dAFRKR
(T/M)
daFRKR
(S/T)
DAFRKR
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
DB30KT Steering controller

DB31KK
DB32KK
DB35KK
DB36KK
DB37KK
DB39KQ
dB3RKR
DB3SKR
MON CALL E03 Electrical system
Communication error
T/M
Communication error
S/T
Controller internal abnormality
T/M
Power supply voltage reduction (Input)

Model selection signal disagreement
T/M

code, Part 4
E01
Electrical system
SEN01826-01
T/M
T/M
T/M
E01
Electrical system
T/M
T/M
Communication error
T/M
Communication error
T/M
Communication error
S/T
Communication error
T/M
Communication error
S/T
Controller internal abnormality
S/T
Steering controller main power sup- Power supply voltage reduction (Input)
ply
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
DBB0KK
[n9 o 01]
DBB0KQ
[nF o 11]
DBB3KK
[n9 o 05]
DBB5KP
VHMS sensor power supply (5 V)
[n9 o 04]
DBB6KP
[n9 o 02]
Communication error
Reference
manual
E01
E01
Electrical system
Electrical system
S/T
S/T
S/T
S/T
S/T
CALL E03 Electrical system Troubleshooting by failure

CALL E03 Electrical system code, Part 5
S/T
CALL E04 Electrical system SEN01827-02
S/T
S/T
E01
Electrical system
VHMS
VHMS
VHMS
Output voltage reduction
VHMS
VHMS
D475A, D475ASD-5E0
40 Troubleshooting
Failure
code
Troubled part
SEN01821-04
Trouble
Component in
charge
Action
code
Category of record
Reference
manual
DBB7KP
[n9 o 03]
DBBQKR
VHMS KOM-NET
[n8 o 02]
VHMS controller CAN communicadbBRKR
tion
VHMS
Communication error
VHMS
Communication error
S/T
Electrical system
DD12KA Shift-up switch
Disconnection
T/M
E02
Electrical system
DD12KB Shift-up switch
Short circuit
T/M
E02
Electrical system
DD13KA Shift-down switch
Disconnection
T/M
E02
Electrical system
DD13KB Shift-down switch
Short circuit
T/M
E02
Electrical system
DD14KA Parking brake lever switch
Disconnection
T/M
DD14KB Parking brake lever switch
Short circuit
T/M
DDB9L4 Reverse switch
Signal disagreement
T/M
E02
Electrical system
DDK3L4 Forward switch
Signal disagreement
T/M
E02
Electrical system
DDK5KA Shift switch
Disconnection
T/M
E02
DDK5KB Shift switch
Short circuit
T/M
E02
Electrical system Troubleshooting by failure

Electrical system code, Part 5
T/M
E02
Electrical system SEN01827-02
T/M
E02
Electrical system
Blade tilt right oil pressure switch

Switch ON for long time
system
Blade tilt left oil pressure switch sysDDN3LD
tem
DDN2LD
DDN7KA Blade pitch switch
Disconnection
T/M
E02
Electrical system
DDN7KB Blade pitch switch
Short circuit
T/M
E02
Electrical system
DDN9KA Blade tilt switch
Disconnection
T/M
E01
Electrical system
DDN9KB Blade tilt switch
Short circuit
T/M
E01
Electrical system
DDNALD Blade lift raise full oil pressure switch Switch ON for long time
T/M
Electrical system
DDNBLD Ripper lift raise oil pressure switch
T/M
Electrical system
DDNCLD Ripper lift lower oil pressure switch
T/M
Electrical system
DDNDLD Ripper tilt in oil pressure switch
T/M
Electrical system
DDNELD Ripper tilt back oil pressure switch
T/M
Electrical system
T/M
Electrical system
DDQ2KA Parking brake lever switch
Disconnection
S/T
DDQ2KB Parking brake lever switch
Short circuit
S/T
DDQ2L4 Parking brake lever switch (S/T)
Signal disagreement
S/T
dDQ2L4 Parking brake lever switch (T/M)
Signal disagreement
T/M
DDT5KA Neutral switch
Disconnection
T/M
DDT5KB Neutral switch
Short circuit
T/M
DDT5KQ Lever specification selection error
Model selection signal disagreement
T/M
DGS1KX Hydraulic oil temperature sensor
Out of input signal range
T/M
Electrical system
DGT1KA Power train oil temperature sensor
Disconnection
MON
E01
Electrical system
DGT1KX Power train oil temperature sensor
MON
E01
Electrical system
DDNFLD
Ripper lift lower full oil pressure

switch
D475A, D475ASD-5E0

code, Part 6
SEN01828-03
SEN01821-04
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
40 Troubleshooting
Component in
charge
Action
code
Category of record
Disconnection
VHMS
Disconnection
VHMS
Short circuit
VHMS
Short circuit
VHMS
Disconnection
VHMS
Disconnection
VHMS
Short circuit
VHMS
Short circuit
VHMS
Disconnection
T/M
Electrical system
Short circuit
T/M
Electrical system
Disconnection
T/M
Electrical system
Short circuit
T/M
Electrical system
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)
sensor (F)
sensor (R)
sensor (R)
Trouble
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]
Disconnection
VHMS
Hot short
VHMS
VHMS
DK01KA Left yoke angle sensor
Disconnection
T/M
E02
Electrical system
DK01KB Left yoke angle sensor
Short circuit
T/M
E02
Electrical system
DK03KA Right yoke angle sensor
Disconnection
T/M
E02
Electrical system
DK03KB Right yoke angle sensor
Short circuit
T/M
E02
Electrical system
DK10KA Fuel control dial
Disconnection
S/T
DK10KB Fuel control dial
Short circuit
S/T
DK30KA Steering potentiometer (1)
Disconnection
S/T
DK30KB Steering potentiometer (1)
Short circuit
S/T
DK30KX Steering potentiometer (1)
S/T
DK30KZ Steering potentiometer (1)
Disconnection or short circuit
S/T
DK30L8 Steering potentiometer (1)
Analog signal disagreement
S/T
DK31KA Steering potentiometer (2)
Disconnection
S/T
DK31KB Steering potentiometer (2)
Short circuit
S/T
DK40KA Brake potentiometer
Disconnection
S/T
DK40KB Brake potentiometer
Short circuit
S/T
DK55KX Forward-reverse potentiometer
T/M
DK55KZ Forward-reverse potentiometer
Disconnection or short circuit
T/M

code (Display
of code), Part 7
DK55L8 Forward-reverse potentiometer
Analog signal disagreement
T/M
DK56KA Forward-reverse potentiometer (1)
Disconnection
T/M
DK56KB Forward-reverse potentiometer (1)
Short circuit
T/M
Troubleshooting by failure
code, Part 6
SEN01828-03
D475A, D475ASD-5E0
40 Troubleshooting
Failure
code
SEN01821-04
Troubled part
Trouble
Component in
charge
Action
code
Category of record
DK57KA Forward-reverse potentiometer (2)
Disconnection
T/M
DK57KB Forward-reverse potentiometer (2)
Short circuit
T/M
DK60KA Acceleration sensor
Disconnection
S/T
E01
Electrical system
DK60KB Acceleration sensor
Short circuit
S/T
E01
Electrical system
DKH1KA Pitch angle sensor
Disconnection
S/T
DKH1KB Pitch angle sensor
Short circuit
S/T
DKH1KX Pitch angle sensor
Reference
manual
S/T
E01
Electrical system
Torque converter output speed senDLF1KA

Disconnection
sor
T/M
Electrical system
DLT3KA Transmission output speed sensor
Disconnection
T/M
E01
Electrical system
dLT3KA Transmission output speed sensor
Disconnection
T/M
E01
Electrical system
DLT3KB Transmission output speed sensor
Short circuit
T/M
E01
Electrical system
DV00KB Alarm buzzer
Short circuit
MON
E02
Electrical system
DW55KA Blade pitch back solenoid
Disconnection
T/M
DW55KB Blade pitch back solenoid
Short circuit
T/M
DW56KA Blade pitch dump solenoid
Disconnection
T/M
DW56KB Blade pitch dump solenoid
Short circuit
T/M
DW56KY Blade pitch dump solenoid
Hot short
T/M
DW57KA Left tilt limit solenoid
Disconnection
T/M

code (Display
E02
Electrical system
of code), Part 7
DW57KB Left tilt limit solenoid
Short circuit
T/M
E02
Electrical system SEN01829-02
DW57KY Left tilt limit solenoid
Hot short
T/M
E02
Electrical system
DW58KA Right tilt limit solenoid
Disconnection
T/M
E02
Electrical system
DW58KB Right tilt limit solenoid
Short circuit
T/M
E02
Electrical system
DW58KY Right tilt limit solenoid
Hot short
T/M
E02
Electrical system
DW59KA Dual tilt selector solenoid
Disconnection
T/M
E01
Electrical system
DW59KB Dual tilt selector solenoid
Short circuit
T/M
E01
Electrical system
DW59KY Dual tilt selector solenoid
Hot short
T/M
E01
Electrical system
DW5AKA Blade pitch selector solenoid
Disconnection
T/M
E02
Electrical system
DW5AKB Blade pitch selector solenoid
Short circuit
T/M
E02
Electrical system
DW5AKY Blade pitch selector solenoid
Hot short
T/M
E02
Electrical system
Disconnection
T/M
Short circuit
T/M
Hot short
T/M
DW7BKA Fan reverse solenoid
Disconnection
T/M
E01
Electrical system
DW7BKB Fan reverse solenoid
Short circuit
T/M
E01
Electrical system
DW7BKY Fan reverse solenoid
Hot short
T/M
E01
Electrical system
Blade pitch dump solenoid

DW5DKB
DW5DKY
DW5DKA
D475A, D475ASD-5E0
SEN01821-04
Failure
code
40 Troubleshooting
Troubled part
Trouble
Component in
charge
Action
code
Category of record
Reference
manual
DWJ0KA Pump merge-divider solenoid
Disconnection
S/T
E02
Electrical system
DWJ0KB Pump merge-divider solenoid
Short circuit
S/T
E02
Electrical system
DWJ0KY Pump merge-divider solenoid
Hot short
S/T
E02
Electrical system
DWN3KA Sudden stop prevention solenoid
Disconnection
S/T
DWN3KB Sudden stop prevention solenoid
Short circuit
S/T
DWN3KY Sudden stop prevention solenoid
Hot short
S/T
DWN5KA Fan pump solenoid (1)
Disconnection
T/M
DWN5KB Fan pump solenoid (1)
Short circuit
T/M
DWN5KY Fan pump solenoid (1)
Hot short
T/M
E02
Electrical system
DWNCKA Fan pump solenoid (2)
Disconnection
T/M
E01
Electrical system
DWNCKB Fan pump solenoid (2)
Short circuit
T/M
E01
Electrical system
DWNCKY Fan pump solenoid (2)
Hot short
T/M
E02
Electrical system
DXE0KA LS set solenoid
Disconnection
T/M
E02
Electrical system
DXE0KB LS set solenoid
Short circuit
T/M
E02
Electrical system
DXE0KY LS set solenoid
Hot short
T/M
E02
Electrical system
DXH1KA Lockup solenoid
Disconnection
T/M
E01
Electrical system
DXH1KB Lockup solenoid
Short circuit
T/M
E01
Electrical system
DXH1KY Lockup solenoid
Hot short
T/M
DXH4KA 1st clutch ECMV
Disconnection
T/M
DXH4KB 1st clutch ECMV
Short circuit
T/M
DXH4KY 1st clutch ECMV
Hot short
T/M
DXH5KA 2nd clutch ECMV
Disconnection
T/M
DXH5KB 2nd clutch ECMV
Short circuit
T/M
DXH5KY 2nd clutch ECMV
Hot short
T/M

code (Display
of code), Part 8
DXH6KA 3rd clutch ECMV
Disconnection
T/M
DXH6KB 3rd clutch ECMV
Short circuit
T/M
DXH6KY 3rd clutch ECMV
Hot short
T/M
DXH7KA Reverse clutch ECMV
Disconnection
T/M
DXH7KB Reverse clutch ECMV
Short circuit
T/M
DXH7KY Reverse clutch ECMV
Hot short
T/M
DXH8KA Forward clutch ECMV
Disconnection
T/M
DXH8KB Forward clutch ECMV
Short circuit
T/M
DXH8KY Forward clutch ECMV
Hot short
T/M
DXH9KA Right steering clutch ECMV
Disconnection
S/T
DXH9KB Right steering clutch ECMV
Short circuit
S/T
10

code (Display
of code), Part 7
E01
Electrical system
SEN01829-02
E01
Electrical system
D475A, D475ASD-5E0
40 Troubleshooting
Failure
code
SEN01821-04
Troubled part
Trouble
Component in
charge
Action
code
Category of record
Reference
manual
DXH9KY Right steering clutch ECMV
Hot short
S/T
DXHAKA Left steering clutch ECMV
Disconnection
S/T
DXHAKB Left steering clutch ECMV
Short circuit
S/T
DXHAKY Left steering clutch ECMV
Hot short
S/T
DXHBKA Right brake ECMV
Disconnection
S/T
DXHBKB Right brake ECMV
Short circuit
S/T
DXHBKY Right brake ECMV
Hot short
S/T
DXHCKA Left brake ECMV
Disconnection
S/T
DXHCKB Left brake ECMV
Short circuit
S/T
DXHCKY Left brake ECMV
Hot short
S/T

code (Display
of code), Part 8
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]
Abnormality high pressure

occurrence
Exhaust temperature abnormal rise
a
a
a
a
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)
VHMS
VHMS
VHMS
VHMS
VHMS
VHMS
VHMS
VHMS
VHMS
SEN01830-01
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
SEN01821-04
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.
Type of power supply
Fuse capacity (A)
Accessory power supply
20
2
3
20
VHMS controller
Unswitched power supply
20
Cab power supply
10
Converter operation support center
20
Converter operation support center
4
5
Destination of power
VHMS controller
Fuse box B [FS22]

Fuse No.
Fuse capacity (A)
Backup alarm
20
Preheater power supply, pin puller, air suspension seat
20
Additional heater power supply
20
Working lamp
20
Rear lamp
Fuse box C [FS32]

Fuse No.
Fuse capacity (A)
ACC signal
20
Horn
20
Spare power supply (1)
20
Spare power supply (2)
20
Spare ACC signal
Cab fuse box D

Fuse No.
Fuse capacity (A)
10
10
Rear wiper
10
Right wiper
10
Front wiper
10
Left wiper
12
Radio, cigarette lighter, room lamp
20
Additional headlamp
20
Additional rear lamp, rotary lamp
Spare
Spare
10
10
Radio memory
D475A, D475ASD-5E0
40 Troubleshooting
SEN01821-04
Fuse locations and fuse Nos.

Inside of left console box in cab
Lower right part of cab overhead
D475A, D475ASD-5E0
13
SEN01821-04
40 Troubleshooting
Circuit breaker
No
Connector No.
F30
30
Cab unswitched power supply
F96
105
Main power supply
B105H2L
105
B105H1L
105
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
B7L
30
Engine controller unswitched power supply
B8L
30
Engine controller unswitched power supply
CB1
20
Steering controller
CB2
20
Monitor panel
10
CB3
20
11
CB4
20
Air conditioner
12
CB5
20
Headlamp
13
CB6
20
Starting switch unswitched power supply
14
Capacity (A)
Circuit
Remarks
Installed in console box at

left of operator's seat
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.
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01821-04
15
SEN01821-04

2011 KOMATSU
All Rights Reserved
16
SEN01822-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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 ................................................................................................... 46
D475A, D475ASD-5E0
SEN01822-03
Points to remember when troubleshooting

k
k
k
k
k
k
40 Troubleshooting
Stop the machine in a level place, and check that the lock 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, an important point is of course to understand the structure and function. However, a shortcut 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.
2.
3.
4.
5.
6.
When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately after 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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01822-03
Sequence of events in troubleshooting
D475A, D475ASD-5E0
SEN01822-03
40 Troubleshooting
Checks before troubleshooting 1

Judgement
Value
Action
1. Check fuel level
Add fuel
2. Check for impurities in fuel
Clean, drain
3. Check fuel filter
Replace
4. Check hydraulic oil level
Add oil
5. Check oil level in damper case
Add oil
6. Check power train oil level
Add oil
7. Check engine oil level (engine oil pan level)
Add oil
8. Check coolant level
Add water
9. Check dust indicator for clogging
Clean or replace
10.Check travel of brake pedal
Adjust
1. Check for abnormal noise, smell
Repair
2. Check for oil leakage
Repair
3. Carry out air bleeding
Bleed air
1. Check for looseness, corrosion of battery terminal, wiring
20 30 V
Tighten or replace
2. Check for looseness, corrosion of alternator terminal, wiring
Tighten or replace
3. Check for looseness, corrosion of starting motor terminal,

wiring
Tighten or replace
4. Check battery voltage (engine stopped)
Replace
5. Check battery electrolyte level
Add or replace
6. Check for discolored, burnt, exposed wiring
Replace
7. Check for missing wiring clamps, hanging wire
Repair
8. Check for water leaking on wiring (pay particularly careful

attention to water leaking on connectors or terminals)
Disconnect connector and dry
9. Check for blown, corroded fuses
Replace
10.Check alternator voltage (engine running at 1/2 throttle or

above)
After running
for several
minutes:
27.5 29.5 V
Replace
11. Check operating sound of battery relay (starting switch

ON, OFF)
Replace
Lubricating oil, coolant

Electrical equipment
Other check items
Hydraulic,
mechanical
equipment
Checks before starting
Item
D475A, D475ASD-5E0
40 Troubleshooting
SEN01822-03
Classification and procedures of troubleshooting
Classification of troubleshooting
Mode
Display of
code
Contents
Troubleshooting by failure code (Display of code)
E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical system
S-mode
Troubleshooting of engine
Procedure for troubleshooting

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

If an action code is not displayed on the machine monitor, check for a failure code in the failure code 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]).
3.
Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of Phenomena looking like troubles and troubleshooting Nos., and then carry out troubleshooting related to that phenomenon in the E-mode, H-mode, or S-mode.
D475A, D475ASD-5E0
SEN01822-03
40 Troubleshooting
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
Check the error code

q
Phenomena related to engine

3 The engine does not start easily (It always takes time to start)
4
The engine does not crank
S-1
E-1
S-2a)
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
S-2b)
S-2c)
The engine speed does not rise sharply (Follow-up performance is

low)
S-3
8 The engine stops during operation
S-4
9 Engine rotation is abnormal (The engine hunts)
S-5
10 Output is insufficient or power is low
S-6
11 Exhaust gas color is bad (Incomplete combustion)
S-7
12 Oil is consumed much or exhaust gas color is bad
S-8
13 Oil becomes dirty quickly
S-9
14 Fuel is consumed much
S-10
15 Coolant contains oil (or it blows back or reduces)
S-11
16 The engine oil pressure caution lamp lights up (Oil pressure lowers)
S-12
17 Oil level rises
S-13
18 Coolant temperature rises too high (Overheating)
S-14
19 Abnormal sound comes out
S-15
20 Vibration is excessive
S-16
21 The preheater does not operate
E-2
Phenomena related to power train
22 Power is low (Drawbar pull is low)
H-1
23 The machine does not travel (in the 2nd or 3rd gear speed)
H-2
24 The machine does not travel start in any gear speed
H-3
25 The machine can travel in only forward or reverse direction
H-4
Time lag is large in shifting the gear speed or changing the travel
26
direction
H-5
27 The machine cannot be steered
H-6
28 The machine can be steered in only 1 direction
H-7
29 The machine overruns when steered
H-8
30 The brake does not operate
H-9
31 The torque converter is not locked up
H-10
32 The torque converter oil is overheated
H-11
S-6
Phenomena related to work equipment

33 Speed of the whole work equipment is low
H-12
34 Any part of the equipment does not move
H-13
35 Blade lifting speed or power is low
H-14
36 Blade tilting speed or power is low
H-15
37 Ripper lifting speed or power is low
H-16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01822-03
Troubleshooting
No.
Phenomena looking like trouble
Code
display
E-mode
H-mode
38 Ripper tilting speed or power is low
H-17
39 Hydraulic drift of blade lifting is large
H-18
40 Hydraulic drift of blade tilting is large
H-19
41 Hydraulic drift of ripper lifting is large
H-20
The ripper pin puller cylinder does not operate (if the giant ripper is
42
installed)
H-21
43 The blade does not pitch (if the dual tilt system installed)
H-22
44 Abnormal sound comes out from around hydraulic pump
H-23
S-mode
Phenomena related to monitor panel (Operator mode: Ordinary screen)

45
When the starting switch is turned ON, no items are displayed on

monitor panel
E-4
46
When the starting switch is turned ON, all items are kept displayed on
monitor panel
E-5
47 When the starting switch is turned ON, the basic check items flash
E-6
48 Caution items flash while the engine is running
E-7
49 Emergency warning items flash while the engine is started
E-8
50
When the preheater is operated, the preheater pilot lamp does not
light up
E-9
51
When the dual tilt is selected, the dual/single tilt selector lamp does
not light up (if the dual tilt system is equipped)
E-10
52
When the torque converter is locked up, the torque converter lockup
pilot lamp does not light up
E-11
53 Display of the engine coolant temperature gauge is abnormal
E-12
54 Display of the power train oil temperature gauge is abnormal
E-13
55 Display of the hydraulic oil temperature gauge is abnormal
E-14
56 Display of the fuel level gauge is abnormal
E-15
57 Display of the gear speed and engine speed is abnormal
E-16
58 Display of the shift mode and service meter is abnormal
E-17
59 The switch module cannot be operated
E-18
60 The caution lamp does not flash or go off
E-19
61 The caution buzzer does not sound or go off
E-20
62 The auto shift-down system does not operate or reset
E-21
63 The auto pitch-back system does not operate or reset
E-22
64 The caution buzzer cannot be canceled
E-23
65 The operator mode does not operate
E-24
Phenomena related to monitor panel (Service mode: Special function screen)

66 The service mode does not operate
E-25
Other phenomena
67 The backup alarm does not sound
E-26
The night lamp of the panel, headlamp, working lamp, and rear lamp
68
do not light up
E-27
69 The air conditioner does not operate
E-28
70 The ORBCOMM terminal does not operate normally
E-29
71 Fan does not reverse
E-30
72 Gear cannot be shifted
E-31
73 Electric priming pump does not operate or does not stop
E-32
D475A, D475ASD-5E0
SEN01822-03
40 Troubleshooting
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
Failure code
Display of
panel
Display of panel
Failure
Trouble that appears in the machine
symptom
Failure content State where the monitor panel or controller detects the trouble
Controller's
action
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
Possible causes
and standard
value in normal
state
<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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01822-03
Related circuit diagram
This is the excerpted circuit diagram related to troubleshooting.

Connector No.: Indicates (model number of pins) (color)
Arrow (io): Indicates the approximate mounting place on machine
D475A, D475ASD-5E0
SEN01822-03
Connection table for connector pin numbers

a
10
40 Troubleshooting
(Rev. 2009.04)
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.
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01822-03
11
SEN01822-03
12
40 Troubleshooting
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40 Troubleshooting
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13
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14
40 Troubleshooting
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40 Troubleshooting
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15
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16
40 Troubleshooting
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40 Troubleshooting
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17
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18
40 Troubleshooting
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40 Troubleshooting
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19
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20
40 Troubleshooting
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40 Troubleshooting
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21
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22
40 Troubleshooting
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40 Troubleshooting
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23
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24
40 Troubleshooting
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40 Troubleshooting
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25
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26
40 Troubleshooting
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40 Troubleshooting
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27
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40 Troubleshooting
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40 Troubleshooting
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29
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30
40 Troubleshooting
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40 Troubleshooting
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31
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32
40 Troubleshooting
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40 Troubleshooting
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33
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34
40 Troubleshooting
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40 Troubleshooting
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35
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40 Troubleshooting
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40 Troubleshooting
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37
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40 Troubleshooting
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40 Troubleshooting
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40
40 Troubleshooting
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40 Troubleshooting
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41
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40 Troubleshooting
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40 Troubleshooting
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43
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44
40 Troubleshooting
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01822-03
45
SEN01822-03
40 Troubleshooting
T- branch box and T- branch adapter table

a
(Rev. 2009.03)
1
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
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.
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
799-601-3200 T-box (for MS)
37
q
q
799-601-3380 Plate for MS (14-pin)

799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
24
MS-24P
17
MS-17P
17
MS-17P
MS-5P
10
MS-10P
MS-5P
17
MS-17P
19
MS-19P
14
MS-14P
q
q
799-601-3470 Case
799-601-2710 Adapter for MIC
MIC-5P
q q
13
MIC-13P
q q
17
MIC-17P
q q q
21
MIC-21P
q q q
MIC-9P
799-601-2750 Adapter for ECONO
ECONO2P
q q
ECONO3P
q q
ECONO4P
q q
ECONO8P
q q
12 ECONO12P q q
799-601-2810 Adapter for DLI
DLI-8P
q q
12
DLI-12P
q q
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
q
q q
q q
q q q
799-601-2850 Case
799-601-4350 T-box (for DRC 60, ECONO)
60
799-601-4360 Case
799-601-7010 Adapter for X (T-adapter)
799-601-7020 Adapter for X
X2P
q q q
X3P
q q q
q
q
X4P
q q q
799-601-7050 Adapter for SWP
SW6P
q q q
q q q
SW8P
12
SW12P
q
M2P
q q q
M3P
q q q
14
SW14P
16
SW16P
799-601-7080 Adapter for M (T-adapter)
799-601-7090 Adapter for M
46
q
q
D475A, D475ASD-5E0
40 Troubleshooting
SEN01822-03
Out of kit
799-601-4201
q q q
799-601-4101
S8P
799-601-9300
799-601-9200
799-601-7140 Adapter for S
799-601-9100
M8P
799-601-9000
799-601-8000
q
799-601-7500
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
799-601-7000
799-601-2800
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
799-601-7150 Adapter for S (White)
10
S10P
q q q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q
799-601-7170 Adapter for S (Blue)
16
S16P
q q q
16
S16PW
12
S12PW
799-601-7180 Adapter for AMP040
A8P
12
A12P
q
q
q
q
16
A16P
q q q
20
A20P
q q q
799-601-7230 Short connector for X
q q q
q q
799-601-7240 Case
799-601-7270 Case
799-601-7510 Adapter for 070
10
07-10
799-601-7520 Adapter for 070
12
07-12
799-601-7530 Adapter for 070
14
07-14
799-601-7540 Adapter for 070
18
07-18
799-601-7550 Adapter for 070
20
07-20
799-601-7360 Adapter for relay
REL-5P
799-601-7370 Adapter for relay
REL-6P
799-601-7380 Adapter for JFC
799-601-9010 Adapter for DTM
DTM2
799-601-9020 Adapter for DT
DT2
DT3
DT4
DT6
799-601-9060 Adapter for DT (Gray)
DT8GR
799-601-9070 Adapter for DT (Black)
DT8B
799-601-9080 Adapter for DT (Green)
DT8G
799-601-9090 Adapter for DT (Brown)
DT8BR
799-601-9110 Adapter for DT (Gray)
12
DT12GR
799-601-9120 Adapter for DT (Black)
12
DT12B
799-601-9130 Adapter for DT (Green)
12
DT12G
799-601-9140 Adapter for DT (Brown)
12
DT12BR
799-601-9210 Adapter for HD30-18
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin)

799-601-9320 T-box (for ECONO)
D475A, D475ASD-5E0
24
q q
q q
q q
q q
47
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
40 Troubleshooting
Number of pins
SEN01822-03
799-601-9330 Case
799-601-9340 Case
799-601-9350 Adapter for DRC
40
DRC-40
799-601-9360 Adapter for DRC
24
DRC-24
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
A3
q q
q q
1,2,3
795-799-5520* Socket for engine (HPI-T2)
Socket for engine (HPI-T2)

Temperature sensor
q q
q q
795-799-5460 Cable for engine (HPI-T2)
799-601-4110 Adapter for engine (140-T3) PIM
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
FCIN
q q
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
FCIB
q q

799-601-4160
Oil pressure switch
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
4180
q q
Socket for engine (CRI-T3)

799-601-4190*
Commonrail pressure
1,2,3L
q q
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
1,2,3A
q q
799-601-9430*
795-799-5540*
799-601-4140
799-601-4230*

Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2)

Socket for engine (CRI-T3) TIM

Atomosphere pressure

Air intake pressure/temperature
799-601-4250* Socket for engine (CRI-T3) PIM
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
1,2,3,G
q q

799-601-4340*
Pump actuator
2,PA
q q
1,2,3,4T
799-601-4260 Adapter for controller (ENG)
DTP4
799-601-4380*
Socket for engine (CRI-T3)(95)

Air intake pressure/temperature
q
q q
50
DRC50
60
DRC60
799-601-4390* Socket for controller (95 ENG)
60
799-601-4280* Box for controller (PUMP)
121
799-601-9720 Adapter for controller (HST)
16
HST16A
16
HST16B
26
HST26A
2,
3,
4,
799-601-9890
Multi-adapter for
DT2 4 and DTM2
* Shows not T-adapter but socket.
48
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01822-03
49
SEN01822-03

2009 KOMATSU
All Rights Reserved
50
SEN01823-02
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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
SEN01823-02
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
SEN01823-02
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.
1
Possible
causes and the
standard values
when normal
2
3
4
Cause
Lockup clutch slip
(When system is normal)
Defective engine speed
sensor system
Defective torque converter speed sensor
Defective transmission
controller
D475A, D475ASD-5E0
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.
SEN01823-02
40 Troubleshooting
Failure code [1500L0] Transmission clutch: Dual engagement

Action code
Failure code
CALL E03
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
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
SEN01823-02
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
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.
1
Possible
causes and the
standard values
when normal
2
3
4
Cause
Transmission clutch slip
Defective torque converter
speed sensor system
speed sensor
controller
D475A, D475ASD-5E0

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.
SEN01823-02
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.
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
Cause
Possible
causes and the
standard values
when normal

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
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 pres4
sure system is assumed to be abnormal. Carry out the related trousure system
bleshooting (H mode).
Circuit diagram related to transmission forward clutch ECMV
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
15SALH
The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit.
Becomes neutral (N) at forward operation.

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.
Method of reproducing failure code: Engine start + Forward running
Cause
Possible
causes and the
standard values
when normal

Defective forward clutch fill
FFT2 (male)
PCCS lever
Resistance
N
Min. 1 Mz
Between (1)
chassis ground
F (Forward)
Max. 1 z
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
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
D475A, D475ASD-5E0
SEN01823-02
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
15SBL1
The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.
Becomes neutral (N) at forward operation.

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.
Method of reproducing failure code: Engine start + Neutral running
Cause
Possible
causes and the
standard values
when normal

Defective reverse clutch fill
FRT2 (male)
PCCS lever
Resistance
1
N
Min. 1 Mz
Between (1)
chassis ground
R (Reverse)
Max. 1 z
2 ing (Contact with ground
Wiring
Resiscircuit)
Min. 1 Mz
FRT2 (female) (1) with chassis ground
tance
TMC1
PCCS lever
Voltage
3
controller
N
5
11 V
Between (24)
chassis ground
R (Reverse)
Max. 1 V
Circuit diagram related to transmission reverse clutch ECMV
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
15SBLH
The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit.
Becomes neutral (N) at reverse operation.

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.
Method of reproducing failure code: Engine start + Reverse running
Cause
Possible
causes and the
standard values
when normal

Defective reverse clutch fill
FRT2 (male)
PCCS lever
Resistance
N
Min. 1 Mz
Between (1)
chassis ground
R (Reverse)
Max. 1 z
ResisMax. 1 z
in connector)
FRT2 (female) (1)
tance
TMC1
PCCS lever
Voltage
controller
N
5
11 V
Between (24)
chassis ground
R (Reverse)
Max. 1 V
D475A, D475ASD-5E0
SEN01823-02
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
15SEL1
The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit.
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.
Method of reproducing failure code: Engine start + F1 or R1 o Neutral running
Cause
Possible
causes and the
standard values
when normal

Defective 1st clutch fill
F1T8 (male)
PCCS lever
Resistance
Other than F1/R1
Min. 1 Mz
Between (1)
chassis ground
F1R1
Max. 1 z
ing (Contact with ground
Wiring harness between TMC1 (female) (23)
Resiscircuit)
Min. 1 Mz
F1T8 (female) (1) with chassis ground
tance
TMC1
PCCS lever
Voltage
controller
Other than F1/R1
5 11 V
Between (23)
chassis ground
F1R1
Max. 1 V
Circuit diagram related to transmission level 1 clutch ECMV
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
15SELH
The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit.
The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Method of reproducing failure code: Engine start + F1 or R1 running
Cause
Possible
causes and the
standard values
when normal

Defective 1st clutch fill
F1T8 (male)
PCCS lever
Resistance
1
Other than F1/R1
Min. 1 Mz
Between (1)
chassis ground
F1R1
Max. 1 z
a
Prepare
with
starting
switch
OFF,
then
carry
out
troubleshooting
2
ResisMax. 1 z
in connector)
F1T8 (female) (1)
tance
TMC1
PCCS lever
Voltage
3
controller
Other than F1/R1
5 11 V
Between (23)
chassis ground
F1R1
Max. 1 V
Circuit diagram related to transmission 1st clutch ECMV
D475A, D475ASD-5E0
11
SEN01823-02
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
15SFL1
The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit.
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Method of reproducing failure code: Engine start + F2 or R2 running o Neutral running
Cause
Possible
causes and the
standard values
when normal

Defective 2nd clutch fill
F2T6 (male)
PCCS lever
Resistance
Other than F2/R2
Min. 1 Mz
Between (1)
chassis ground
F2R2
Max. 1 z
Resiscircuit)
Min. 1 Mz
tance
TMC1
PCCS lever
Voltage
controller
Other than F2/R2
5 11 V
Between (17)
chassis ground
F2R2
Max. 1 V
Circuit diagram related to transmission 2nd clutch ECMV
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
15SFLH
The fill switch signal is not set on at output to the transmission level 2 clutch solenoid circuit.
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Cause
Possible
causes and the
standard values
when normal

Defective 2nd clutch fill
F2T6 (male)
PCCS lever
Resistance
1
Other than F2/R2
Min. 1 Mz
Between (1)
chassis ground
F2R2
Max. 1 z
a
Prepare
with
starting
switch
OFF,
then
carry
out
troubleshooting
2
ResisMax. 1 z
in connector)
F2T6 (female) (1)
tance
TMC1
PCCS lever
Voltage
3
controller
Other than F2/R2
5 11 V
Between (17)
chassis ground
F2R2
Max. 1 V
D475A, D475ASD-5E0
13
SEN01823-02
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
15SGL1
The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit.
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Method of reproducing failure code: Engine start + F3 or R3 running o Neutral running
Cause
Possible
causes and the
standard values
when normal

Defective 3rd clutch fill
F3T4 (male)
PCCS lever
Resistance
Other than F3/R3
Min. 1 Mz
Between (1)
chassis ground
F3R3
Max. 1 z
Resiscircuit)
Min. 1 Mz
tance
TMC1
PCCS lever
Voltage
controller
Other than F3/R3
5 11 V
Between (11)
chassis ground
F3R3
Max. 1 V
Circuit diagram related to transmission 3rd clutch ECMV
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
15SGLH
The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit.
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Cause
Possible
causes and the
standard values
when normal

Defective 3rd clutch fill
F3T4 (male)
PCCS lever
Resistance
1
Other than F3/R3
Min. 1 Mz
Between (1)
chassis ground
F3R3
Max. 1 z
a
Prepare
with
starting
switch
OFF,
then
carry
out
troubleshooting
2
ResisMax. 1 z
in connector)
F3T4 (female) (1)
tance
TMC1
PCCS lever
Voltage
3
controller
Other than F3/R3
5 11 V
Between (11)
chassis ground
F3R3
Max. 1 V
D475A, D475ASD-5E0
15
SEN01823-02
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
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
1
Possible
causes and the
standard values
when normal
2
3
4
16
Cause
Power train clutch slip
(When the system is normal)
Defective engine rotation
sensor
rotation sensor system
controller

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 codes [DLT3KA], [DLT3KB] are displayed. If
they are displayed, carry out the troubleshooting.
Since this is an internal defect, it cannot be diagnosed.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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.
Limits operation of engine, transmission, and brake.
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
Cause
Possible
causes and the
standard values
when normal

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
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
Circuit diagram related to right steering clutch ECMV
D475A, D475ASD-5E0
17
SEN01823-02
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
2201LH
The fill switch signal is not set off at output to the right steering clutch solenoid circuit.
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)
Cause
Possible
causes and the
standard values
when normal

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
wiring or defective contact Wiring harness between STCN3 (female)
ResisMax. 1 z
in connector)
(39) FRC8 (female) (1)
tance
STCN3
PCCS lever
Voltage
Defective steering controller
N (Neutral)
5 11 V
Between (39)
chassis ground
Right steering
Max. 1 V
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
2202L1
The fill switch signal is not set off at output stop of the left steering clutch solenoid circuit.
The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring
Cause
Possible
causes and the
standard values
when normal

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
Resiscircuit)
Min. 1 Mz
FLC6 (female) (1) with chassis ground
tance
STCN3
PCCS lever
Voltage
N (Neutral)
5 11 V
Between (29)
chassis ground
Left steering
Max. 1 V
Circuit diagram related to left clutch ECMV
D475A, D475ASD-5E0
19
SEN01823-02
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
2202LH
The fill switch signal is not set off at output to the left steering clutch solenoid circuit.
The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring
Method of reproducing failure code: Engine start + Parking brake lever release + PCCS lever
operated (left steering)
Cause
Possible
causes and the
standard values
when normal

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
wiring or defective contact Wiring harness between STCN3 (female) (29)
ResisMax. 1 z
in connector)
FLC6 (female) (1)
tance
STCN3
PCCS lever
Voltage
N (Neutral)
5 11 V
Between (29)
chassis ground
Left steering
Max. 1 V
Circuit diagram related to left clutch ECMV
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
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
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
SEN01823-02
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
2301L1
The fill switch signal is not set off at output stop of the right steering brake solenoid circuit.
The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring
mode.
Cause
Possible
causes and the
standard values
when normal

FR84 (male)
PCCS lever
Resistance
brake fill switch
(Internal short)
N (Neutral)
Max. 1 z
Between (1)
chassis ground
Right steering
Min. 1 Mz
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.
PCCS lever
Voltage
ler
N
(Neutral)
Max.
1V
Between (25)
chassis ground
Right steering
5 11 V
Circuit diagram related to right steering brake ECMV
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
2301LH
The fill switch signal is not set off at output to the right steering brake solenoid circuit.
The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring
mode.
Method of reproducing failure code: Engine start + Parking bake lever release
Cause
Possible
causes and the
standard values
when normal

FR84 (male)
PCCS lever
Resistance
clutch fill switch
(Internal short)
N (Neutral)
Max. 1 z
Between (1)
chassis ground
Right steering
Min. 1 Mz
ResisMax. 1
in connector)
FR84 (female) (1)
tance
Mz
PCCS lever
Voltage
ler
N
(Neutral)
Max.
1V
Between (25)
chassis ground
Right steering
5 11 V
D475A, D475ASD-5E0
23
SEN01823-02
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
24
Failure code
Symptom of Right steering brake thermal load: Abnormal heating
failure
2301NR
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
Improper steering during downslope travel (Machine traveled down and was steered to right con1
tinuously)
ler
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
2302L1
The fill switch signal is not set off at output stop of the left steering brake solenoid circuit.
The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring
Cause
Possible
causes and the
standard values
when normal

FL82 (male)
PCCS lever
Resistance
brake fill switch
(Internal short)
N (Neutral)
Max. 1 z
Between (1)
chassis ground
Right steering
Min. 1 Mz
Resiscircuit)
Min. 1 Mz
FL82 (female) (1) with chassis ground
tance
PCCS lever
Voltage
ler
N (Neutral)
Max. 1 V
Between (35)
chassis ground
Left steering
5 11 V
Circuit diagram related to left steering brake ECMV
D475A, D475ASD-5E0
25
SEN01823-02
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
2302LH
The fill switch signal is not set on at output stop of the left steering brake solenoid circuit.
The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring
Method of reproducing failure code: Engine start + Parking brake lever release
Cause
Possible
causes and the
standard values
when normal

FL82 (male)
PCCS lever
Resistance
brake fill switch
(Internal short)
N (Neutral)
Max. 1 z
Between (1)
chassis ground
Left steering
Min. 1 Mz
ResisMax. 1 z
in connector)
FL82 (female) (1)
tance
PCCS lever
Voltage
ler
N (Neutral)
Max. 1 V
Between (35)
chassis ground
Left steering
5 11 V
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
2302NR
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
Improper steering during downslope travel (Machine traveled down and was steered to left con1
tinuously)
ler
D475A, D475ASD-5E0
27
SEN01823-02
40 Troubleshooting
Failure code [6001ZK] Failure code for design

Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
28
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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
SEN01823-02
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
Defective air cleaner clog2 ging sensor (Internal disconnection)
Possible
causes and the
standard values
when normal
3
wiring or defective contact
in connector)
4 Defective machine monitor

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
Wiring harness between S03 (female) (13)
ResisMax. 1z
AF1 (female) (1)
tance
Wiring harness between AF1 (female) (2)
ResisMax. 1z
AF2 (female) (1)
tance
ResisMax. 1z
chassis ground
tance
troubleshooting.
S03
Air cleaner
Voltage
When
normal
Max.
1V
Between (13)
chassis ground
When clogged
Min. 7 V
Electric circuit diagram related to air cleaner clogging
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
Defective charge level
2
caution lamp system
D475A, D475ASD-5E0

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.
31
SEN01823-02
40 Troubleshooting
Failure code [B@BAZG] Engine oil: Oil pressure too low

Action code
Failure code
B@BAZG
Failure content
Controller's
action
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.
Symptoms that
appear on
machine
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).
General
information
The engine oil pressure caution symbol on the machine monitor flashes and this failure code is
recorded.
Duplication of failure code: Start the engine.
Possible
causes and the
standard values
when normal
Cause
Reduction of engine oil

1 pressure
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.
Defective engine oil pressure caution lamp circuit
If cause 1 is not detected, engine oil sensor system may be detective.

Carry out troubleshooting for the failure codes [CA135] and [CA141].
32
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
Failure code [B@BAZK] Engine oil: Oil level reduction

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 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
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
SEN01823-02
40 Troubleshooting
Failure code [B@BCNS] Engine coolant: Overheat

Action code
Failure code
B@BCNS
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
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
Possible
causes and the
standard values
when normal
34
1 Engine coolant overheat

Engine coolant may be overheating. Check it directly and remove
cause if it is overheating.
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].
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
Failure code [B@BCZK] Engine coolant: Level too low

Action code
Failure code
B@BCZK
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Symptom of Engine coolant: Level too low

failure
(Mechanical system)
Engine coolant level decreases when starting switch is turned ON.

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
Possible
causes and the
standard values
when normal
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
D475A, D475ASD-5E0
Carry out troubleshooting in accordance with When starting switch

is turned ON, engine coolant level caution flashes in E mode.
35
SEN01823-02
40 Troubleshooting
Failure code [B@BEBF] Fuel: Water in fuel

Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
36
Failure code
Symptom of Fuel: Water in fuel
failure
(Mechanical system)
B@BEBF
There was water in fuel and water separator 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
40 Troubleshooting
SEN01823-02
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.
D475A, D475ASD-5E0
37
SEN01823-02
40 Troubleshooting
Failure code [B@CENS] Power train oil: Overheat

Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
38
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.
Cause
Power train oil temperature
1 overheat (When system is
in normal state)
Defective power train oil
2 temperature overheat caution lamp system

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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
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
HSS charge oil pressure is reduced and HSS charge oil pressure caution lamp lights up.
None in particular.
None in particular.
Since above caution lamp is not set on this machine, above failure code not occur. Above failure
code is listed up in mechanical system failure code table, however.
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.
D475A, D475ASD-5E0
39
SEN01823-02
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.
Failure code [B@HANS] Hydraulic oil: Overheat

Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
40
Failure code
Symptom of Hydraulic oil: Overheat
failure
(Mechanical system)
B@HANS
During rotation of engine, hydraulic oil caution lamp flashes.
Flashes warning lamp and turns on caution buzzer. (Function of machine monitor))
If machine is operated as it is, work equipment circuit units may be damaged.
The hydraulic oil temperature caution symbol of the machine monitor flashes and this failure code
is recorded.
Cause
1 overheat (When system is
in normal state)
Defective hydraulic oil tem2 perature caution lamp system

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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01823-02
Failure code [B@HAZK] Hydraulic oil: Level reduction

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 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: During rotation of engine, hydraulic oil temperature caution
lamp on machine monitor blinks and this failure code is recorded.
Cause
Hydraulic oil level reduc1 tion (When system is in
normal state)

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
SEN01823-02

2009 KOMATSU
All Rights Reserved
42
SEN01824-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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):
D475A, D475ASD-5E0
SEN01824-01
40 Troubleshooting
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ................. 20
Failure code [CA145] Coolant temperature sensor too low (At left bank only):
Failure code [CA153] Charge temperature sensor too high (At left bank only):
Failure code [CA154] Charge temperature sensor too low (At left bank only):
Low voltage detection ............................................................................................................................ 28
Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank):
Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank):
Failure code [CA221] Atmospheric pressure sensor too high (At left bank only):
Failure code [CA222] Atmospheric pressure sensor too low (At left bank only):
Failure code [CA227] Sensor power source 2 too high (At left bank):
Failure code [CA234] Engine over speed (At left bank only): Excessively high speed ................................. 40
Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only):
Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only):
Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank):
Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank):
Failure code [CA271] PCV1 short circuit (Left bank): Short circuit ............................................................... 50
Failure code [CB271] PCV1 short circuit (Right bank): Short circuit ............................................................. 51
Failure code [CA272] PCV1 disconnection (Left bank): Disconnection ........................................................ 52
Failure code [CB272] PCV1 disconnection (Right bank): Disconnection...................................................... 53
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit ............................................................... 54
Failure code [CB273] PCV2 short circuit (Right bank): Short circuit ............................................................. 55
Failure code [CA274] PCV2 disconnection (Left bank): Disconnection ........................................................ 56
Failure code [CB274] PCV2 disconnection (Right bank): Disconnection...................................................... 57
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01824-01
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.
Machine continues operation normally but may stop suddenly or may not able to start again once it
stops.
Cause
1 Defective circuit breaker
Possible
causes and the
standard values
when normal
harness (Disconnection
2
in wiring or defective
contact in connector)
Ground fault in wiring

3 harness (Contact with
GND circuit)
Defective engine
controller

Circuit breaker may be defective. Check it directly. (If fuse is broken
or circuit breaker is turned OFF, circuit probably has ground fault.)
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
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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to engine controller power supply
D475A, D475ASD-5E0
SEN01824-01
40 Troubleshooting
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
CB111
Controller has abnormality in it.
Machine continues operation normally but may stop suddenly or may not able to start again once it
stops.
Cause
1 Defective circuit breaker
Possible
causes and the
standard values
when normal
2

GND circuit)
Defective engine
controller

Circuit breaker may be defective. Check it directly. (If fuse is broken
or circuit breaker is turned OFF, circuit probably has ground fault.)
Wiring harness between PW R (female) (3),
ResisMax. 1 z
(4) battery (+)
tance
ResisMax. 1 z
(2) ground
tance
ResisMin. 1 Mz
PW R (female) (3), (4) battery (+) and
tance
ground
PW R
Voltage
Between (3), (4) (1), (2)
20 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
D475A, D475ASD-5E0
SEN01824-01
40 Troubleshooting
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.
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

Carry out troubleshooting of [CA689].
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).
3
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
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.
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

Carry out troubleshooting of [CB689].
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)
Defective engine
6
controller
diagnosed).
3
D475A, D475ASD-5E0
SEN01824-01
40 Troubleshooting
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}).
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)
Cause
Defective sensor power
1
source circuit
Defective charge pres2 sure (boost pressure)

sensor (internal defect)
harness
3 (disconnection or defective contact of connectors)
Possible
causes and the
standard values
when normal
10
Defective harness
grounding
4
(contact with ground
circuit)
Harness short
(Harness internal short)
Defective engine
controller

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
ResisMax. 1 z
PIM (female) (3)
tance
ResisMax. 1 z
PIM (female) (2)
tance
still OFF.
ResisMin. 1 Mz
ENG (female) (37) PIM (female) (1)
tance
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
still OFF.
Between wiring harness from ENG (female)
Resis(37) to PIM (female) (1) and wiring harness
Min. 1 Mz
tance
from ENG (female) (44) to PIM (female) (3)
Min. 1 Mz
tance
Min. 1 Mz
tance
ENG
Voltage
Between (37) (47)
Power source
4.75 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to charge pressure sensor
D475A, D475ASD-5E0
11
SEN01824-01
40 Troubleshooting
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
12
Failure code Symptom of Charge pressure sensor too low (At left bank only): Excessively low
failure
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}).
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)
Cause
1

source circuit

D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
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.
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
Possible
causes and the
standard values
when normal

If failure code [CA2185] is also displayed, carry out troubleshooting
for it first.

DEC (male)
Resistance
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
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
ResisMax. 1z
DEC (female) (C)
tance
ResisMin. 1 Mz
OEM L (female) (22) DEC (female) (A)
tance
harness (Contact with
ResisGND circuit)
Min. 1 Mz
OEM L (female) (9) DEC (female) (B)
tance
ResisMin. 1 Mz
OEM L (female) (23) DEC (female) (C)
tance
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
D475A, D475ASD-5E0
13
SEN01824-01
40 Troubleshooting
Circuit diagram related to decelerator pedal sensor
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Failure code [CA132] Decelerator pedal sensor too low (At left bank
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.
Engine speed cannot be controlled by decelerator pedal.

The signal voltage of decelerator pedal can be checked in monitoring mode.
(Code: 31703 Decelerator voltage)
Cause
If failure code [CA2186] is displayed at the same time, carry out trou1 pedal sensor power supbleshooting for it first.
ply circuit
D475A, D475ASD-5E0
15
SEN01824-01
40 Troubleshooting
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})
The signal voltage of engine oil pressure sensor can be checked in monitoring function.
(Code: 37201 Engine oil pressure sensor voltage)
Cause
1
source circuit
Possible
causes and the
standard values
when normal
4
16

If failure code [CA187] or [CA227] is displayed at the same time, carry
out troubleshooting for it first.
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
still OFF.
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)
ResisMax. 1 z
POIL (female) (3)
tance
still OFF.
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)
tance
ResisMin. 1 Mz
tance
still OFF.
Resis(37) to POIL (female) (1) and wiring harness
Min. 1 Mz
tance
from ENG (female) (47) to POIL (female) (2)
Harness short
(Harness internal short) Between wiring harness from ENG (female)
Min. 1 Mz
tance
Min. 1 Mz
tance
Defective engine controller
ENG
Voltage
Between (37) (47)
Power source
4.75 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to oil pressure sensor
D475A, D475ASD-5E0
17
SEN01824-01
40 Troubleshooting
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
18
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})
The signal voltage of engine oil pressure sensor can be checked in monitoring function.
(Code: 37201 Engine oil pressure sensor voltage)
Cause
1

source circuit

D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01824-01
19
SEN01824-01
40 Troubleshooting
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).
Exhaust gas color becomes white.
The signal voltage of coolant temperature sensor can be checked in monitoring function.
(Code: 04105 Coolant temperature sensor voltage)
Cause
Possible
causes and the
standard values
when normal
20

Defective coolant
still OFF.
1 temperature sensor
TWTR (male)
Coolant temperature
Resistance
(Internal defect)
Between (A) (B)
10 100C
0.6 20 kz
still OFF.
harness
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
still OFF.
Harness short
3
Between
ENG (female) (15) all pins of ENG
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
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.)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to coolant temperature sensor
D475A, D475ASD-5E0
21
SEN01824-01
40 Troubleshooting
Failure code [CA145] Coolant temperature sensor too low (At left bank
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).
The signal voltage of coolant temperature sensor can be checked in monitoring function.
(Code: 04105 Coolant temperature sensor voltage)
Cause
Possible
causes and the
standard values
when normal
22

Defective coolant
still OFF.
TWTR (male)
Coolant temperature
Resistance
(Internal defect)
Between (A) (B)
10 100C
0.6 20 kz
Defective harness
still OFF.
2 grounding (contact with
Resisground circuit)
Min. 1 Mz
ENG (female) (15) TWTR (female) (A)
tance
still OFF.
Harness short
3
Between ENG (female) (15) all pins of ENG
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.
4
connector
insulation
still OFF.
5
ENG (female)
Coolant temperature
Resistance
Between (15) (38)
10 100C
0.6 20 kz
Defective engine
6
controller
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to coolant temperature sensor
D475A, D475ASD-5E0
23
SEN01824-01
40 Troubleshooting
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).
The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
monitoring function. (Code: 18501 Boost temperature sensor voltage)
Cause
Possible
causes and the
standard values
when normal
24

still OFF.
Defective charge temperTIM (male)
Air boost temperature
Resistance
1 ature (boost temperature)
Between (A) (B)
10 100C
0.5 20 kz
Between (A) ground
In all range
Min. 1 Mz
still OFF.
harness (disconnection Wiring harness between ENG (female) (23)
Resis2
Max. 1 z
or defective contact of
TIM (female) (A)
tance
connectors)
ResisMax. 1 z
JB TIM (female) (B)
tance
still OFF.
Harness short
3
Between
ResisMin. 1 Mz
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.
4
connector
insulation
still OFF.
5
ENG (female)
Resistance
Between (23) (47)
10 100C
0.5 20 kz
Defective engine
6
controller
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to charge temperature sensor
D475A, D475ASD-5E0
25
SEN01824-01
40 Troubleshooting
Failure code [CA154] Charge temperature sensor too low (At left bank
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
CA154
Excessively low voltage is detected at signal circuit of charge temperature (boost temperature)
sensor.
Operates with a fixed charge temperature (boost temperature) (70C).
The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
monitoring function. (Code: 18501 Boost temperature sensor voltage)
Cause
Possible
causes and the
standard values
when normal
26

still OFF.
Defective charge temperTIM (male)
Resistance
1 ature (boost temperature)
Between (A) (B)
10 100C
0.5 20 kz
Between (A) ground
In all range
Min. 1 Mz
Defective harness
still OFF.
Between
ground and wiring harness between
Min. 1 Mz
ENG (female) (23) TIM (female) (A)
tance
still OFF.
Harness short
3
Between
ResisMin. 1 Mz
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.
4
connector
insulation
still OFF.
ENG (female)
Resistance
5
Between (23) (47)
10 100C
0.5 20 kz
Between (23) ground
In all range
Min. 1 Mz
Defective engine
6
controller
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to charge temperature sensor
D475A, D475ASD-5E0
27
SEN01824-01
40 Troubleshooting
Failure code [CA187] Sensor power supply (2) abnormally low level
(Left 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
28
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
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.
Output lowers.
Cause

Carry out troubleshooting for failure code [CA227].
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
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
Failure code Symptom of Sensor power supply (2) abnormally low level (Right bank): Low voltfailure
age detection (Engine controller system)
CA187
Bkup sensor operates with Ne speed sensor signal.
Output lowers.
Possible
causes and the
standard values
when normal
D475A, D475ASD-5E0
Cause

Carry out troubleshooting for failure code [CB227].
29
SEN01824-01
40 Troubleshooting
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.
Cause
Possible
causes and the
standard values
when normal

Defective oil temperature
1
TOIL (male)
Oil temperature
Resistance
Between (A) (B)
0 100C
0.5 36 kz
harness (Disconnection Wiring harness between ENG (female) (17)
Resis2
Max. 1 z
in wiring or defective con- TOIL (female) (A)
tance
tact in connector)
ResisMax. 1 z
TOIL (female) (B)
tance
ResisGND circuit)
Min. 1 Mz
ENG (female) (17) TOIL (female) (A)
tance
Defective engine control4
ENG
Oil temperature
Resistance
ler
(17) (47)
0 100C
0.5 36 kz
Circuit diagram related to engine oil temperature sensor
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
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
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.
Possible
causes and the
standard values
when normal
D475A, D475ASD-5E0
Cause

31
SEN01824-01
40 Troubleshooting
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}).
Output decreases.
The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
(Code: 37401 Atmospheric pressure sensor voltage)
Cause
1
source circuit
Defective atmospheric
2 pressure sensor
(internal defect)
Possible
causes and the
standard values
when normal
harness (disconnection
3
or defective contact of
connectors)
Defective harness
ground circuit)
32
Harness short

If failure code [CA352] or [CA386] is displayed at the same time, carry
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
still OFF.
ResisMax. 1 z
PAMB (female) (1)
tance
ResisMax. 1 z
PAMB (female) (2)
tance
ResisMax. 1 z
PAMB (female) (3)
tance
still OFF.
ResisMin. 1 Mz
ENG (female) (37) PAMB (female) (1)
tance
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
still OFF.
Resis(37) to PAMB (female) (1) and wiring harness
Min. 1 Mz
tance
from ENG (female) (3) to PAMB (female) (2)
Min. 1 Mz
tance
Min. 1 Mz
tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Cause
Possible
causes and the
standard values
when normal
Defective engine
controller

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
Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
34
Failure code Symptom of Atmospheric pressure sensor too low (At left bank only): Excessively
failure
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}).
Output decreases.
The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
(Code: 37401 Atmospheric pressure sensor voltage)
Cause

Carry out troubleshooting of failure code [CA221].
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01824-01
35
SEN01824-01
40 Troubleshooting
Failure code [CA227] Sensor power source (2) too high (At left bank):
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
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}).
Output decreases.
Cause
Possible
causes and the
standard values
when normal
36

Check the codes that are displayed at the same time. If any other
1 Defective related circuits
codes are displayed, carry out troubleshooting for those codes.
ON.
Bkup speed sensor
G connector
Disconnect the
Engine oil pressure
Defective sensor
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
still OFF.
harness
Resis3 (disconnection or defecMax. 1 z
each sensor (female)
tance
tive contact of connecWiring harness between ENG (female) (47)
Resistors)
Max. 1 z
tance
still OFF.
Defective harness
grounding
Resis4
Min. 1 Mz
tance
(contact with ground cir- ENG (female) (37) each sensor (female)
cuit)
ResisMin. 1 Mz
ENG (female) (47) each sensor (female)
tance
still OFF.
Harness short
5
(Harness internal short) (37) to each sensor (female) and wiring harResisMin. 1 Mz
ness from ENG (female) (47) to each sensor
tance
(female)
ON.
ENG
Voltage
ler
Between (37) (47)
4.75 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
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
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
Possible
causes and the
standard values
when normal
38
Cause
1 Related defective system If another code is also displayed, carry out troubleshooting for it.
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.
harness (Disconnection Wiring harness between ENG (female) (37)
Resis3
Max. 1 z
in wiring or defective con- each sensor (female)
tance
tact in connector)
ResisMax. 1 z
tance
Resis4 harness (Contact with
Min. 1 Mz
tance
GND circuit)
ResisMin. 1 Mz
tance
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)
ENG
Voltage
ler
Between (37) (47)
4.75 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to sensor power source (2) (At right bank)
D475A, D475ASD-5E0
39
SEN01824-01
40 Troubleshooting
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
CA234
The engine speed exceeds upper control limit speed.
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.
Cause
Possible
causes and the
standard values
when normal
40

The improper usage of equipped machine can be suspected. Instruct
2 Improper usage
the proper usage.
Defective engine
3
controller
diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01824-01
41
SEN01824-01
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.
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).
Cause
Possible
causes and the
standard values
when normal
42

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.
still OFF.
harness
Wiring harness between left bank ENG
(female) (16) Ne (female) (1)
tance
tive contact of connecWiring harness between left bank ENG
Resistors)
Max. 1 z
tance
still OFF.
Defective harness
Resisgrounding
Min. 1 Mz
3
tance
(contact with ground cir- left bank ENG (female) (16) Ne (female) (1)
cuit)
ResisMin. 1 Mz
left bank ENG (female) (48) Ne (female) (2)
tance
still OFF.
Harness short
Between
wiring harness from left bank ENG
4
(Harness internal short) (female) (16) to Ne (female) (1) and wiring
ResisMin. 1 Mz
harness from left bank ENG (female) (48) to
tance
Ne (female) (2)
ON.
ler
Left bank ENG
Voltage
Between (16) (48)
4.75 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to Ne speed sensor power source
D475A, D475ASD-5E0
43
SEN01824-01
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
CB238
Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controls using Bkup speed sensor signal.
Cause
Possible
causes and the
standard values
when normal
44

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.
still OFF.
harness
Wiring harness between left bank ENG
tance
tive contact of connecWiring harness between right bank ENG
Resistors)
Max. 1 z
tance
still OFF.
Defective harness
Resisgrounding
Min. 1 Mz
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)
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)
ON.
ler
Voltage
Between left bank ENG (16)
right bank ENG (48)
4.75 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to Ne speed sensor power source
D475A, D475ASD-5E0
45
SEN01824-01
40 Troubleshooting
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
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)
Cause
Possible
causes and the
standard values
when normal
46

Defective fuel temperastill OFF.
ture sensor (internal
TFUEL (male)
Fuel temperature
Resistance
defect)
Between (A) (B)
10 100C
0.6 20 kz
still OFF.
harness
Resis(disconnection or defecMax. 1 z
TFUEL (female) (A)
tance
Resistors)
Max. 1 z
TFUEL (female) (B)
tance
still OFF.
Defective harness
grounding
ResisMin. 1 Mz
(contact with ground cir- ENG (female) (30) TFUEL (female) (A)
tance
cuit)
still OFF.
ENG (female)
Fuel temperature
Resistance
Between (30) (47)
10 100C
0.6 20 kz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Circuit diagram related to fuel temperature sensor
D475A, D475ASD-5E0
47
SEN01824-01
40 Troubleshooting
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
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)
Cause
Possible
causes and the
standard values
when normal

Defective fuel temperastill OFF.
ture sensor (internal
TFUEL (male)
Fuel temperature
Resistance
defect)
Between (A) (B)
10 100C
0.6 20 kz
still OFF.
harness
Resis(disconnection or defecMax. 1 z
TFUEL (female) (A)
tance
Resistors)
Max. 1 z
TFUEL (female) (B)
tance
still OFF.
Defective harness
grounding
ResisMin. 1 Mz
(contact with ground cir- ENG (female) (30) TFUEL (female) (A)
tance
cuit)
still OFF.
ENG (female)
Fuel temperature
Resistance
Between (30) (47)
10 100C
0.6 20 kz
Circuit diagram related to fuel temperature sensor
48
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
Failure code [CA265] Fuel temperature sensor abnormally low level

Action code
E01
Failure content
Controller's
action
Failure code Symptom of Fuel temperature sensor abnormally low level (Left bank): Low voltfailure
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
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
Cause

Failure code [CB265] Fuel temperature sensor abnormally low level

Action code
E01
Failure content
Controller's
action
Failure code Symptom of Fuel temperature sensor abnormally low level (Right bank): Low voltfailure
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
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
D475A, D475ASD-5E0
Cause

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
CALL E03
CA271
Failure content Short circuit occurred in supply pump PCV1 circuit.
Controller's
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)
Possible
causes and the
standard values
when normal

GND circuit)
Hot short (Contact with

3 24V circuit) in wiring
harness
Defective engine
controller

PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2) ground
Min. 1 Mz
ResisMin. 1 Mz
ENG (female) (4) PCV1 (female) (1)
tance
ResisMin. 1 Mz
tance
Voltage
Max. 1 V
Voltage
Max. 1 V
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z
Min. 1 Mz
Circuit diagram related to supply pump PCV1
50
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
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
CB271
Short circuit occurred in supply pump PCV1 circuit.
Cause
1 PCV1
Possible
causes and the
standard values
when normal

GND circuit)

harness
Defective engine
controller

PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Min. 1 Mz
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
Voltage
Max. 1 V
Voltage
Max. 1 V
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z
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
CA272
Disconnection occurred in supply pump PCV1 circuit.
Cause
1 PCV1
(Internal disconnection)
Possible
causes and the
standard values
when normal
2

GND circuit)
Defective engine
controller

PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Min. 1 Mz
ResisMax. 1 z
PCV1 (female) (1)
tance
ResisMax. 1 z
PCV1 (female) (2)
tance
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z
Min. 1 Mz
52
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
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
CB272
Cause
1 PCV1
Possible
causes and the
standard values
when normal
2

GND circuit)
Defective engine
controller

PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Min. 1 Mz
ResisMax. 1 z
PCV1 (female) (1)
tance
ResisMax. 1 z
PCV1 (female) (2)
tance
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z
Min. 1 Mz
D475A, D475ASD-5E0
53
SEN01824-01
40 Troubleshooting
Failure code [CA273] PCV2 short circuit (Left bank): Short circuit
Action code
Failure code Symptom of PCV2 short circuit (Left bank): Short circuit
failure
CALL E03
CA273
Failure content Short circuit occurred in supply pump PCV2 circuit.
Controller's
action
Symptoms that
appear on
machine
General
information
Cause
1 PCV2
Possible
causes and the
standard values
when normal

GND circuit)

harness
Defective engine
controller

PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Min. 1 Mz
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
Voltage
Max. 1 V
Voltage
Max. 1 V
ENG (female)
Resistance
Between (9) (10)
2.3 5.3 z
Min. 1 Mz
54
D475A, D475ASD-5E0
40 Troubleshooting
SEN01824-01
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
CB273
Short circuit occurred in supply pump PCV2 circuit.
Cause
1 PCV2
Possible
causes and the
standard values
when normal

GND circuit)

harness
Defective engine
controller

PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Min. 1 Mz
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
Voltage
Max. 1 V
Voltage
Max. 1 V
ENG (female)
Resistance
Between (9) (10)
2.3 5.3 z
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
CA274
Cause
2
Possible
causes and the
standard values
when normal
3

PCV2 (Internal disconPCV2 (male)
Resistance
nection)
Between (1) (2)
2.3 5.3 z
Resisharness (Disconnection Wiring harness between ENG (female) (9)
Max. 1 z
tance
in wiring or defective con- PCV2 (female) (1)
tact in connector)
ResisMax. 1 z
PCV2 (female) (2)
tance
Resisharness (Contact with
Min. 1 Mz
tance
GND circuit)
ResisMin. 1 Mz
tance
Defective engine controlENG (female)
Resistance
ler
Between (9) (10)
2.3 5.3 z
Min. 1 Mz
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
CB274
Cause
2
Possible
causes and the
standard values
when normal
3

PCV2 (Internal disconPCV2 (male)
Resistance
nection)
Between (1) (2)
2.3 5.3 z
Resisharness (Disconnection Wiring harness between ENG (female) (9)
Max. 1 z
tance
in wiring or defective con- PCV2 (female) (1)
tact in connector)
ResisMax. 1 z
PCV2 (female) (2)
tance
Min. 1 Mz
tance
GND circuit)
ResisMin. 1 Mz
tance
Defective engine controlENG (female)
Resistance
ler
Between (9) (10)
2.3 5.3 z
Min. 1 Mz
D475A, D475ASD-5E0
57
SEN01824-01

2007 KOMATSU
All Rights Reserved
58
SEN01825-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
40 Troubleshooting

Failure code [CA322] Injector #1 (L/B #1) system disconnection or short circuit (At left bank):
Disconnection, short circuit ......................................................................................................................... 4
Disconnection, short circuit ....................................................................................................................... 10
Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch ............................................... 16
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
SEN01825-03
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
Excessively high pressure detected..........................................................................................................37
Excessively high pressure detected..........................................................................................................38
Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error................39
Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error .............39
Loss of pressure feed detected.................................................................................................................40
Loss of pressure feed detected (Low-grade fuel specification) ................................................................44
Loss of pressure feed detected.................................................................................................................48
Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal..............................52
Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal ...........................54
Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank):
High voltage detection...............................................................................................................................56
Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank):
Low voltage detection................................................................................................................................58
Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase...............59
Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase ............59
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01825-03
SEN01825-03
40 Troubleshooting
Failure code [CA322] Injector #1 (L/B #1) system disconnection or short

circuit (At left bank): Disconnection, short circuit
Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Injector #1 (L/B #1) system disconnection or short circuit (At left
failure
bank): Disconnection, short circuit (Engine controller system)
CA322
A disconnection or short circuit has occurred in injector #1 circuit.
Output decreases.
Speed is not stable.
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.
Cause
2
Possible
causes and the
standard values
when normal
3

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
switch still OFF.
harness
ResisMax. 1 z
(disconnection or defective CN1 (female) (1)
tance
contact of connectors)
ResisMax. 1 z
CN1 (female) (2)
tance
switch still OFF.
Defective harness
Resisgrounding (contact with
Min. 1 Mz
ENG (female) (45) CN1 (female) (1)
tance
ground circuit)
ResisMin. 1 Mz
tance
Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry
injector or wiring harness out troubleshooting for them, too.
switch still OFF.
ENG (female)
Resistance
Between (45) (53)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to injector #1
D475A, D475ASD-5E0
SEN01825-03
40 Troubleshooting

Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
failure
CA323
Output decreases.
Cause
2
Possible
causes and the
standard values
when normal
3

switch still OFF.
CN5 (male)
Resistance
(internal defect)
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
switch still OFF.
harness
ResisMax. 1 z
(disconnection or defective CN5 (female) (1)
tance
ResisMax. 1 z
CN5 (female) (2)
tance
switch still OFF.
Defective harness
Resisgrounding (contact with
Min. 1 Mz
tance
ground circuit)
ResisMin. 1 Mz
tance
Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry
injector or wiring harness out troubleshooting for them, too.
switch still OFF.
ENG (female)
Resistance
Between (46) (60)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
D475A, D475ASD-5E0
SEN01825-03
40 Troubleshooting

Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
failure
CA324
Output decreases.
Cause
(internal defect)
harness
2
(disconnection or defective
Possible
causes and the
standard values
when normal
Defective harness ground3 ing (contact with ground

circuit)
Defective another cylinder

injector or wiring harness
5 Defective engine controller

switch still OFF.
CN3 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
switch still OFF.
ResisMax. 1 z
CN3 (female) (1)
tance
ResisMax. 1 z
CN3 (female) (2)
tance
switch still OFF.
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
If multiple failure codes are displayed for injector malfunction, carry
out troubleshooting for them, too.
switch still OFF.
ENG (female)
Resistance
Between (55) (52)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
D475A, D475ASD-5E0
SEN01825-03
40 Troubleshooting

Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
failure
CA325
Output decreases.
Cause
(internal defect)
harness
2
Possible
causes and the
standard values
when normal

circuit)

10

switch still OFF.
CN6 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
switch still OFF.
ResisMax. 1 z
CN6 (female) (1)
tance
ResisMax. 1 z
CN6 (female) (2)
tance
switch still OFF.
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
switch still OFF.
ENG (female)
Resistance
Between (57) (59)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
D475A, D475ASD-5E0
11
SEN01825-03
40 Troubleshooting

Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
failure
CA331
Output decreases.
Cause
(internal defect)
harness
2
Possible
causes and the
standard values
when normal

circuit)

12

switch still OFF.
CN2 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
switch still OFF.
ResisMax. 1 z
CN2 (female) (1)
tance
ResisMax. 1 z
CN2 (female) (2)
tance
switch still OFF.
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
switch still OFF.
ENG (female)
Resistance
Between (54) (51)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
D475A, D475ASD-5E0
13
SEN01825-03
40 Troubleshooting

Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
failure
CA332
Output decreases.
Cause
(internal defect)
harness
2
Possible
causes and the
standard values
when normal

circuit)

14

switch still OFF.
CN4 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
switch still OFF.
ResisMax. 1 z
CN4 (female) (1)
tance
ResisMax. 1 z
CN4 (female) (2)
tance
switch still OFF.
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
switch still OFF.
ENG (female)
Resistance
Between (56) (58)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
D475A, D475ASD-5E0
15
SEN01825-03
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
16
Failure code
Symptom of Engine controller data mismatch (Left bank): Mismatch
failure
CA342
Data mismatch occurred in engine controller.
Engine cannot be started or operated.
Cause

D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
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
Failure code
Symptom of Engine controller data mismatch (Right bank): Mismatch
failure
CB342
Data mismatch occurred in engine controller.
Engine cannot be started or operated.
Possible
causes and the
standard values
when normal
D475A, D475ASD-5E0
Cause

17
SEN01825-03
40 Troubleshooting
Failure code [CA351] Abnormal injector drive circuit (At left bank):
Abnormal circuit
Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Abnormal injector drive circuit (At left bank): Abnormal circuit
failure
CA351
Abnormality has occurred in injector drive circuit.
Operates with limited output. (Limits common rail pressure.)
Output decreases.
Cause
Possible
causes and the
standard values
when normal
18

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.)
switch still OFF.
harness
Wiring harness between PW L (female) (3)
ResisMax. 1 z
(disconnection or defective (4) battery (+)
tance
Wiring harness between PW L (female) (1)
ResisMax. 1 z
(2) and ground
tance
Defective harness
switch still OFF.
grounding (contact with
Between
Min. 1 Mz
PW L (female) (3) (4) battery (+)Resistance
tance
switch ON.
PW L
Voltage
Between (3), (4) (1), (2)
20 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to controller power source
D475A, D475ASD-5E0
19
SEN01825-03
40 Troubleshooting
Failure code [CB351] Injector drive circuit abnormality (Right bank):

Circuit abnormality
Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Injector drive circuit abnormality (Right bank): Circuit abnormality
failure
CB351
Abnormality occurred in injector drive circuit.
Limits output and continues operation (Limits common rail pressure).
Output lowers.
Cause
1
2
Possible
causes and the
standard values
when normal
20

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.)
harness (Disconnection in Wiring harness between PW R (female) (3),
ResisMax. 1 z
wiring or defective contact (4) battery (+)
tance
in connector)
ResisMax. 1 z
(2) ground
tance
ResisGND circuit)
Min. 1 Mz
PW R (female) (3), (4) battery (+)
tance
PW R
Voltage
Between (3), (4) (1), (2)
20 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
D475A, D475ASD-5E0
21
SEN01825-03
40 Troubleshooting
Failure code [CA352] Sensor power supply (1) abnormally low level
Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
22
Failure code
Symptom of Sensor power supply (1) abnormally low level (Left bank): Low voltfailure
CA352
Common rail pressure sensor limits output and continues operation (Limits common rail pressure).
Output lowers.
Cause

D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Failure code [CB352] Sensor power supply (1) abnormally low level
Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Sensor power supply (1) abnormally low level (Right bank): Low voltSymptom of
age detection
failure
CB352
Output lowers.
Possible
causes and the
standard values
when normal
D475A, D475ASD-5E0
Cause

23
SEN01825-03
40 Troubleshooting
Failure code [CA386] Sensor power supply (1) abnormally high level
(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 Sensor power supply (1) abnormally high level (Left bank): High voltfailure
CA386
High voltage was detected in sensor power supply (1) (5 V) circuit.
Output lowers.
Cause
1 Related defective system
Possible
causes and the
standard values
when normal
24

If another code is also displayed, carry out troubleshooting for it.
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.
Wiring
harness between ENG (female) (33)
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
ResisMax. 1 z
PFUEL (female) (3)
tance
ResisMin. 1 Mz
ENG (female) (33) PFUEL (female) (1)
tance
ResisGND circuit)
Min. 1 Mz
tance
ResisMin. 1 Mz
tance
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
harness (with another
Resis(female) (33) PFUEL (female) (1) and wirwiring harness)
Min. 1 Mz
tance
PFUEL (female) (3)
tance
PFUEL (female) (3)
ENG
Voltage
Between (33) (47)
4.75 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to sensor power supply 1 (5V)
D475A, D475ASD-5E0
25
SEN01825-03
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
Failure code
Sensor power supply (1) abnormally high level (Right bank): High
Symptom of
voltage detection
failure
CB386
High voltage was detected in sensor power supply (1) (5 V) circuit.
Output lowers.
Cause
1 Related defective system
Defective sensor
(Internal defect)
3
in connector)
Possible
causes and the
standard values
when normal
Ground fault in wiring har4 ness (Contact with GND

circuit)
Short circuit in wiring har5 ness (with another wiring

harness)
26

If another code is also displayed, carry out troubleshooting for it.
When device at right
is disconnected, if
Right common rail
error code disapPFUEL connector
pressure sensor
pears, that device has
defect in it.
ResisMax. 1 z
PFUEL (female) (1)
tance
ResisMax. 1 z
PFUEL (female) (2)
tance
ResisMax. 1 z
PFUEL (female) (3)
tance
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
tance
PFUEL (female) (2)
tance
PFUEL (female) (3)
tance
PFUEL (female) (3)
ENG
Voltage
Between (33) (47)
4.75 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to sensor power supply (1) (5V)
D475A, D475ASD-5E0
27
SEN01825-03
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
CA441
Low voltage was detected in power supply voltage circuit.
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
28
Failure code
Symptom of Power supply voltage abnormally low level (Right bank): Low voltage
failure
CB441
Low voltage was detected in power supply voltage circuit.
it stops.
Cause

D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
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
Failure code
Symptom of Power supply voltage abnormally high level (Left bank): High voltage
failure
CA442
High voltage was detected in power supply voltage circuit.
it stops.
Possible
causes and the
standard values
when normal
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
Failure code
Symptom of Power supply voltage abnormally high level (Right bank): High voltfailure
CB442
High voltage was detected in power supply voltage circuit.
it stops.
Possible
causes and the
standard values
when normal
D475A, D475ASD-5E0
Cause

29
SEN01825-03
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).
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
30
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).
Output lowers.
Cause

D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01825-03
31
SEN01825-03
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.)
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
1
source circuit
Possible
causes and the
standard values
when normal
4
32

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.
switch still OFF.
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
ResisMax. 1 z
PFUEL (female) (3)
tance
switch still OFF.
ResisMin. 1 Mz
Defective harness groundENG (female) (33) PFUEL (female) (1)
tance
ing (contact with ground
Resiscircuit)
Min. 1 Mz
tance
ResisMin. 1 Mz
tance
switch still OFF.
(33) to PFUEL (female) (1) and wiring harResisMin. 1 Mz
ness from ENG (female) (25) to PFUEL
tance
(female) (2)
Harness short
tance
(female) (3)
tance
(female) (3)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Cause
Possible
causes and the
standard values
when normal

a Prepare with starting switch OFF, and diagnose with starting
switch ON or with engine started.
ENG
Voltage
Between (33) (47)
4.75 5.25 V
Between (25) (47)
0.25 4.6 V
Circuit diagram related to common rail pressure sensor
D475A, D475ASD-5E0
33
SEN01825-03
40 Troubleshooting
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
CB451
High voltage was detected in common rail pressure sensor circuit.
Output lowers.
Signal voltage of common rail pressure sensor can be checked with monitoring function
(Code: 36404: Common rail pressure sensor voltage).
Cause
1
supply system
Possible
causes and the
standard values
when normal
4
34

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
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.
Wiring
harness between ENG (female) (33)
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
ResisMax. 1 z
PFUEL (female) (3)
tance
ResisMin. 1 Mz
Ground fault in wiring harENG (female) (33) PFUEL (female) (1)
tance
ness (Contact with GND
Resiscircuit)
Min. 1 Mz
tance
ResisMin. 1 Mz
tance
tance
PFUEL (female) (2)
Short circuit in wiring harness (with another wiring Between wiring harness between ENG
(female) (33) PFUEL (female) (1) and wirResisharness)
Min. 1 Mz
tance
PFUEL (female) (3)
tance
PFUEL (female) (3)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Cause
Possible
causes and the
standard values
when normal

ENG
Voltage
Between (33) (47)
4.75 5.25 V
Between (25) (47)
0.25 4.6 V
Circuit diagram related to common rail pressure sensor
D475A, D475ASD-5E0
35
SEN01825-03
40 Troubleshooting
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.
Output lowers.
Cause

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
36
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.
Output lowers.
Cause

D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
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.
Output decreases.
Common rail pressure can be checked with the monitoring function.
(Code: 36400 Common rail pressure)
Cause
1
2
Possible
causes and the
standard values
when normal
4
5
6
7

Defective related circuits
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.
[CA451]
sensor
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.
D475A, D475ASD-5E0
37
SEN01825-03
40 Troubleshooting
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.
Output decreases.
Cause
1
2
Possible
causes and the
standard values
when normal
4
5
6
7
38

Defective related circuits
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.
[CB451]
sensor
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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
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
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.
Output decreases.
Possible
causes and the
standard values
when normal
Cause

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
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.
Output decreases.
Possible
causes and the
standard values
when normal
D475A, D475ASD-5E0
Cause

39
SEN01825-03
40 Troubleshooting
Failure code [CA559] Loss of pressure feed from supply pump (1) (At
left bank): Loss of pressure feed detected
Action code
E02
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Loss of pressure feed from supply pump (1) (At left bank): Loss of
failure
pressure feed detected (Engine controller system)
CA559
Loss of pressure feed (level 1) from supply pump has occurred.
Limits common rail pressure.
Output decreases.
Cause
2
Possible
causes and the
standard values
when normal

used.

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
0.15 0.3 MPa
circuit
(At high idle or under the load
{1.5 3.0 kg/cm2}
equivalent to rating (stalling))
4 Clogged filter or strainer
a See Note 2 for the contents of diagnosis.
Since an electrical defect of supply pump PCV is suspected, carry
5
out troubleshooting for the following codes.
of supply pump PCV
[CA271], [CA272], [CA273], and [CA274]
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.
40
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Note 1: When low-pressure circuit equipment is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q
Overflow valve (1): Spring is seen through both holes.
q
Bypass valve (2): Spring is seen through hole on nut side.
q
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D475A, D475ASD-5E0
41
SEN01825-03
40 Troubleshooting
Check sheet for no-pressure feed

Model
Model and serial No.
Operation No.
#
Date inspected
Engine
Engine serial No.
Worker's name
A. Visual inspections
1
Fuel leakage to outside
Clogged fuel tank breather
Pass Fail
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation)
3
Service meter
Checking failure codes
Pass Fail
/
Checking monitoring information

Code
*1
Display item
Engine speed
Condition for inspection
Unit
Standard value
(reference value)
Low idle
rpm
600 700
High idle
rpm
2,100 2,200
Equivalent to rating
rpm
2,000
Measured value
Pass Fail
Low idle
High idle
100
mm3
Command for common

rail pressure
MPa
*5
Fuel pressure in
common rail
MPa
Low idle
CA
*6
Command for
fuel injection timing
High idle
CA
CA
kPa
*2
Throttle speed
*3
Command for fuel injection rate
*4
*7
Boost pressure
*8
Coolant temperature
(high temperature)
Low idle
*9
Coolant temperature
(low temperature)
Low idle
*10
Fuel temperature
Low idle
Unit
Standard value
(reference value)
Checking reduced cylinder mode operation (engine speed)

Function
5
*11
Cut-out cylinder
42
Measured value
Pass Fail
Cylinder No. 1
Low idle
rpm
Cylinder No. 2
Low idle
rpm
Cylinder No. 3
Low idle
rpm
Cylinder No. 4
Low idle
rpm
Cylinder No. 5
Low idle
rpm
Cylinder No. 6
Low idle
rpm
Unit
Standard value
(reference value)
At high idle or under the load equivalent to rating (stalling)
MPa
{kg/cm2}
0.15 0.3
{1.5 3.0}
C. Inspection of pressure in fuel circuit

6
Pressure in fuel low pressure circuit
Measured value
Pass Fail
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
D. Inspection of strainer and filter

7
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
12 Injector return amount
Unit
Standard value
(reference value)
Under the load equivalent to rating

(stalling)
cc/min
Max 10
Equivalent to rating: 1,600 rpm
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
Measured value
Pass Fail
Rotation speed:
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
D475A, D475ASD-5E0
43
SEN01825-03
40 Troubleshooting
left bank): Loss of pressure feed detected (Low-grade fuel specification)
Action code
E02
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Loss of pressure feed from supply pump (1) (At left bank): Loss of
Symptom of
pressure feed detected (Low-grade fuel specification)
failure
CA559
Output decreases.
Cause
2
Possible
causes and the
standard values
when normal

used.


3
circuit device
0.15 0.3 MPa
circuit
{1.5 3.0 kg/cm2}
5
of supply pump PCV
[CA271], [CA272], [CA273], and [CA274]
6
pressure sensor
Max. 10 cc/min.
(stalling)]
(stalling)
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

44
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03

1) Fuel level
3) Water separator and pre-filter filled with water
8) Clogged screen in water separator
q
q
q
Note 2: Check, clean, and replace the filters and

strainers according to the following procedure.
1) Water separator: Disassemble, check, and
clean screen (4) if clogged.
2) Gauze filter: Disassemble and check. If
clogged, clean.
3) Upstream strainer of gauze filter: If the
gauze filter is clogged, clean the upstream
filter, too.
D475A, D475ASD-5E0
45
SEN01825-03
40 Troubleshooting

Model
Operation No.
#
Date inspected
Engine
Engine serial No.
Worker's name
1
Pass Fail
3
Service meter
Pass Fail
/

Code
*1
Display item
Engine speed
Unit
Standard value
(reference value)
Low idle
rpm
600 700
High idle
rpm
2,100 2,200
rpm
2,000
Measured value
Pass Fail
Low idle
High idle
100
mm3
Command for common

rail pressure
MPa
*5
Fuel pressure in
common rail
MPa
Low idle
CA
*6
Command for
High idle
CA
CA
kPa
*2
Throttle speed
*3
*4
*7
Boost pressure
*8
Coolant temperature
(high temperature)
Low idle
*9
Coolant temperature
(low temperature)
Low idle
*10
Fuel temperature
Low idle
Unit
Standard value
(reference value)

Function
5
*11
Cut-out cylinder
46
Measured value
Pass Fail
Cylinder No. 1
Low idle
rpm
Cylinder No. 2
Low idle
rpm
Cylinder No. 3
Low idle
rpm
Cylinder No. 4
Low idle
rpm
Cylinder No. 5
Low idle
rpm
Cylinder No. 6
Low idle
rpm
Unit
Standard value
(reference value)
MPa
{kg/cm2}
0.15 0.3
{1.5 3.0}

6
Measured value
Pass Fail
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03

7
Pass Fail

amount
11
Pressure limiter
leak amount
Unit
Standard value
(reference value)

(stalling)
cc/min
Max 10
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
Measured value
Pass Fail
Rotation speed:
Return amount:

D475A, D475ASD-5E0
47
SEN01825-03
40 Troubleshooting
Failure code [CB559] Loss of pressure feed from supply pump (1) (At
right bank): Loss of pressure feed detected
Action code
E02
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Loss of pressure feed from supply pump (1) (At right bank): Loss of
failure
CB559
Output decreases.
Cause
2
Possible
causes and the
standard values
when normal

used.


3
circuit device
0.15 0.3 MPa
circuit
{1.5 3.0 kg/cm2}
5
of supply pump PCV
[CB271], [CB272], [CB273], and [CB274]
6
pressure sensor
Max. 10 cc/min.
(stalling)]
(stalling)
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

48
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03

1) Fuel level
q
q
q
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.
D475A, D475ASD-5E0
49
SEN01825-03
40 Troubleshooting

Model
Operation No.
#
Date inspected
Engine
Engine serial No.
Worker's name
1
Pass Fail
3
Service meter
Pass Fail
/

Code
*1
Display item
Engine speed
Unit
Standard value
(reference value)
Low idle
rpm
600 700
High idle
rpm
2,100 2,200
rpm
2,000
Measured value
Pass Fail
Low idle
High idle
100
mm3
Command for common

rail pressure
MPa
*5
Fuel pressure in
common rail
MPa
Low idle
CA
*6
Command for
High idle
CA
CA
kPa
*2
Throttle speed
*3
*4
*7
Boost pressure
*8
Coolant temperature
(high temperature)
Low idle
*9
Coolant temperature
(low temperature)
Low idle
*10
Fuel temperature
Low idle
Unit
Standard value
(reference value)

Function
5
*11
Cut-out cylinder
50
Measured value
Pass Fail
Cylinder No. 1
Low idle
rpm
Cylinder No. 2
Low idle
rpm
Cylinder No. 3
Low idle
rpm
Cylinder No. 4
Low idle
rpm
Cylinder No. 5
Low idle
rpm
Cylinder No. 6
Low idle
rpm
Unit
Standard value
(reference value)
MPa
{kg/cm2}
0.15 0.3
{1.5 3.0}

6
Measured value
Pass Fail
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03

7
Pass Fail

amount
11
Pressure limiter
leak amount
Unit
Standard value
(reference value)

(stalling)
cc/min
Max 10
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
Measured value
Pass Fail
Rotation speed:
Return amount:

D475A, D475ASD-5E0
51
SEN01825-03
40 Troubleshooting
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
CA689
Abnormal signal of the engine Ne speed sensor has been detected.
Operates using Bkup speed sensor signal.
Causes
1
source circuit
harness
2
Defective harness grounding

3
(contact with ground circuit)
Possible
causes and the
standard values
when normal
Harness short
Defective mounting of sen5 sor or defective parts for

speed detection
6
Defective engine Ne
speed sensor
52

switch still OFF.
Wiring harness between left ENG (female)
ResisMax. 1 z
(16) NE (female) (1)
tance
ResisMax. 1 z
tance
ResisMax. 1 z
tance
switch still OFF.
ResisMin. 1 Mz
left ENG (female) (16) NE (female) (1)
tance
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
switch still OFF.
Between wiring harness from left ENG
Resis(female) (16) to NE (female) (1) and wiring
Min. 1 Mz
tance
harness from left ENG (female) (48) to NE
(female) (2)
(female) (16) to NE (female) (1) and wiring
ResisMin. 1 Mz
tance
(female) (3)
ResisMin. 1 Mz
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).
diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to engine Ne speed sensor
D475A, D475ASD-5E0
53
SEN01825-03
40 Troubleshooting
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
CB689
Abnormal signal of the engine Ne speed sensor has been detected.
Operates using Bkup speed sensor signal.
Causes
1
source circuit
harness
2
Defective harness grounding

3
Possible
causes and the
standard values
when normal
Harness short
Defective mounting of sen5 sor or defective parts for

speed detection
6
Defective engine Ne
speed sensor
54

If failure code [CB238] is displayed at the same time, carry out troubleshooting for it first.
switch still OFF.
ResisMax. 1 z
tance
Wiring harness between right ENG (female)
ResisMax. 1 z
tance
ResisMax. 1 z
tance
switch still OFF.
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
right ENG (female) (48) NE (female) (2)
tance
ResisMin. 1 Mz
right ENG (female) (27) NE (female) (3)
tance
switch still OFF.
Resis(female) (16) to NE (female) (1) and wiring
Min. 1 Mz
tance
harness from right ENG (female) (48) to NE
(female) (2)
ResisMin. 1 Mz
tance
(female) (3)
Between wiring harness from right ENG
ResisMin. 1 Mz
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
diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to engine Ne speed sensor
D475A, D475ASD-5E0
55
SEN01825-03
40 Troubleshooting
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
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)
Possible
causes and the
standard values
when normal
2
in connector)

circuit)
56

TAM1
Intake air temperature
Resistance
Between (A) (B)
10 100C
0.5 20 kz
Between (A) ground
All range
Min. 1 Mz
ResisMax. 1z
TAM1 (female) (A)
tance
ResisMax. 1z
TAM1 (female) (B)
tance
ResisMin. 1 Mz
ENG (female) (43) TAM1 (female) (A)
tance
ENG (female)
Intake air temperature
Resistance
Between (43) (47)
10 100C
0.5 20 kz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
Circuit diagram related to intake air temperature sensor
D475A, D475ASD-5E0
57
SEN01825-03
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
58
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

D475A, D475ASD-5E0
40 Troubleshooting
SEN01825-03
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.
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
Defective engine Ne
speed sensor circuit
Defective engine Bkup

speed sensor system

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
[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.
Cause
Possible
causes and the
standard values
when normal
Defective engine Ne
speed sensor circuit

speed sensor system
D475A, D475ASD-5E0

Since a defect of engine Ne speed sensor can be suspected, carry
[CB689]
Since a defect of engine Bkup speed sensor can be suspected, carry
[CB778]
59
SEN01825-03

2009 KOMATSU
All Rights Reserved
60
SEN01826-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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
D475A, D475ASD-5E0
SEN01826-01
40 Troubleshooting
Failure code [CA1633] KOMNET abnormality (Left bank): Communication error......................................... 26
Failure code [CA2185] Decelerator pedal sensor power supply abnormally high level (Only left bank):
Failure code [CA2186] Decelerator pedal sensor power source too low (At left bank only):
Loss of pressure feed detected.............................................................................................................. 31
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
Power supply voltage reduction (Input).................................................................................................. 60
Failure code [DAQ5KK] Transmission controller potentiometer power supply:
Source voltage reduction (input) ............................................................................................................ 64
Source voltage reduction (input) ............................................................................................................ 65
Failure code [DAQ9KQ] Transmission controller type collation: Type select signal inconsistency ............... 67
Failure code [DAQRKR] Transmission controller sensor CAN communication:
Communication error (Objective component system abnormality) ........................................................ 68
Defective communication (Abnormality in objective component system) .............................................. 70
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
Failure code
Symptom of Loss of all engine controller data (At left bank): Loss of all data
failure
CA757
Loss of all data in engine controller has been detected.
The engine cannot be started, or cannot be operated.
Possible
causes and the
standard values
when normal
Cause

Failure code [CB757] Loss of all engine controller data (At right bank):
1
Loss of all data
Action code
CALL E04
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Loss of all engine controller data (At right bank): Loss of all data
failure
CB757
Loss of all data in engine controller has been detected.
The engine cannot be started, or cannot be operated.
Possible
causes and the
standard values
when normal
D475A, D475ASD-5E0
Cause

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.
Cause
1
source circuit
Possible
causes and the
standard values
when normal

If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first.
switch still OFF.
Max. 1 z
(37) left G (female) (1)
tance
harness
2
(disconnection or defective Wiring harness between left ENG (female)
ResisMax. 1 z
tance
ResisMax. 1 z
tance
switch still OFF.
ResisMin. 1 Mz
Defective harness
left ENG (female) (37) left G (female) (1)
tance
Min. 1 Mz
tance
ResisMin. 1 Mz
tance
switch still OFF.
(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
4
ResisMin. 1 Mz
tance
(female) (3)
ResisMin. 1 Mz
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
6
speed sensor
7 Defective engine controller found in causes 1 6 (since this is an internal defect, it cannot be
diagnosed).
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
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
1
supply system
2
in connector)

circuit)
Possible
causes and the
standard values
when normal

harness)
Defective sensor installa5 tion or defective speed

sensing part
6

speed sensor

If failure code [CB187] or [CB227] is displayed, carry out troubleshooting for it first.
ResisMax. 1 z
(37) right G (female) (1)
tance
ResisMax. 1 z
tance
ResisMax. 1 z
tance
ResisMin. 1 Mz
right ENG (female) (37) right G (female) (1)
tance
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
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)
ResisMin. 1 Mz
tance
ResisMin. 1 Mz
tance
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
action
Symptoms that
During operation: Engine continues operation with 1 bank.
appear on
When key is ON: Engine cannot be started.
machine
General
information
Cause
Possible
causes and the
standard values
when normal

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)
ResisMax. 1 z
(6) right ENG (female) (6)
tance
Resis2 harness (Contact with
Min. 1 Mz
left ENG (female) (8) right ENG (female) (8)
tance
GND circuit)
ResisMin. 1 Mz
left ENG (female) (6) right ENG (female) (6)
tance
Left ENG (female)
Resistance
Between (8) (6)
108 132 z
Min. 1 Mz
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
action
Symptoms that
During operation: Engine continues operation with 1 bank.
appear on
machine
General
information
Possible
causes and the
standard values
when normal
10
Cause

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
Possible
causes and the
standard values
when normal
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.
Cause
1
wiring or defective contact Wiring harness between OEM L (female) (7)
ResisMax. 1 z
in connector)
OEM L (female) (34)
tance
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
ResisMin. 1 Mz
3 Defective engine controller Between OEM L (female) (7) ground
tance
ResisBetween OEM L (female) (8) ground
Min. 1 Mz
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
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 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.
Cause
1
wiring or defective contact Wiring harness between OEM R (female) (7)
ResisMin. 1 Mz
in connector)
OEM R (female) (34)
tance
Resiscircuit)
Between OEM R (female) (8) ground
Min. 1 Mz
tance
ResisMin. 1 Mz
3 Defective engine controller Between OEM R (female) (7) ground
tance
ResisBetween OEM R (female) (8) ground
Min. 1 Mz
tance
Circuit diagram related to multicontroller distinction wiring harness key
12
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01826-01
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
action
Symptoms that
Output lowers.
appear on
Engine speed is unstable.
machine
General
information
Cause
2
Possible
causes and the
standard values
when normal
3
14

CN1 (male)
Resistance
(Internal defect)
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
Resisharness (Disconnection in Wiring harness between ENG (female) (45)
Max. 1 z
tance
wiring or defective contact CN1 (female) (1)
in connector)
ResisMax. 1 z
CN1 (female) (2)
tance
Ground fault in wiring harBetween ground and wiring harness between
Resisness (Contact with GND
Min. 1 Mz
tance
circuit)
ResisMin. 1 Mz
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
ENG (female)
Resistance
Between (45) (53)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to injector #7 (R/B #1)
D475A, D475ASD-5E0
15
SEN01826-01
40 Troubleshooting

1
Action code
Failure code
failure
CALL E03
CB1549
Controller's
action
Symptoms that
Output lowers.
appear on
machine
General
information
Cause
2
Possible
causes and the
standard values
when normal
3
16

CN2 (male)
Resistance
(Internal defect)
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
Max. 1 z
tance
in connector)
ResisMax. 1 z
CN2 (female) (2)
tance
Min. 1 Mz
tance
circuit)
ResisMin. 1 Mz
tance
tive wiring harness
ENG (female)
Resistance
Between (54) (51)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
17
SEN01826-01
40 Troubleshooting

1
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.
Output lowers.
Cause
2
Possible
causes and the
standard values
when normal
3
18

CN4 (male)
Resistance
(Internal defect)
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
Max. 1 z
tance
in connector)
ResisMax. 1 z
CN4 (female) (2)
tance
Min. 1 Mz
tance
circuit)
ResisMin. 1 Mz
tance
tive wiring harness
ENG (female)
Resistance
Between (56) (58)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
19
SEN01826-01
40 Troubleshooting

1
Action code
Failure code
failure
CALL E03
CB1552
Controller's
action
Symptoms that
Output lowers.
appear on
machine
General
information
Cause
2
Possible
causes and the
standard values
when normal
3
20

CN5 (male)
Resistance
(Internal defect)
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
Max. 1 z
tance
in connector)
ResisMax. 1 z
CN5 (female) (2)
tance
Min. 1 Mz
tance
circuit)
ResisMin. 1 Mz
tance
tive wiring harness
ENG (female)
Resistance
Between (46) (60)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
21
SEN01826-01
40 Troubleshooting

1
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.
Output lowers.
Cause
2
Possible
causes and the
standard values
when normal
3
22

CN6 (male)
Resistance
(Internal defect)
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
Max. 1 z
tance
in connector)
ResisMax. 1 z
CN6 (female) (2)
tance
Min. 1 Mz
tance
circuit)
ResisMin. 1 Mz
tance
tive wiring harness
ENG (female)
Resistance
Between (57) (59)
0.4 1.1 z
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
D475A, D475ASD-5E0
23
SEN01826-01
40 Troubleshooting

1
Action code
Failure code
failure
CALL E03
CB1622
Controller's
action
Symptoms that
Output lowers.
appear on
machine
General
information
Cause
2
Possible
causes and the
standard values
when normal
3
24

CN3 (male)
Resistance
(Internal defect)
Between (1) (2)
0.4 1.1 z
Min. 1 Mz
Max. 1 z
tance
in connector)
ResisMax. 1 z
CN3 (female) (2)
tance
Min. 1 Mz
tance
circuit)
ResisMin. 1 Mz
tance
tive wiring harness
ENG (female)
Resistance
Between (55) (52)
0.4 1.1 z
Min. 1 Mz
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
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
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
1
in connector)
Possible
causes and the
standard values
when normal

circuit)
26

ResisMax. 1 z
OEM R (female) (46)
tance
ResisMax. 1 z
OEM R (female) (47)
tance
Resis108
OEM L (female) (47)
tance
132 z
ResisMin. 1 Mz
OEM L (female) (46) OEM R (female) (46)
tance
ResisMin. 1 Mz
OEM L (female) (47) OEM R (female) (47)
tance
Resis108
OEM L (female) (47)
tance
132 z
Wiring harness between OEM R (female)
Resis108
(46) OEM R (female) (47)
tance
132 z
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to KOMNET
D475A, D475ASD-5E0
27
SEN01826-01
40 Troubleshooting
Failure code [CA2185] Decelerator pedal sensor power supply

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 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.
Engine speed cannot be controlled with decelerator pedal.
Cause
Defective decelerator sensor (Internal defect)
2
in connector)
Possible
causes and the
standard values
when normal

circuit)

harness)
28

When device at right
is disconnected, if
code disappears, that Decelerator sensor
DEC connector
device has trouble in
it.
ResisMax. 1 z
DEC (female) (A)
tance
ResisMax. 1 z
DEC (female) (C)
tance
ResisMin. 1 Mz
OEM L (female) (22) DEC (female) (A)
tance
ResisMin. 1 Mz
OEM L (female) (23) DEC (female) (C)
tance
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)
OEM L
Voltage
Between (22) (23)
4.75 5.25 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to decelerator pedal sensor power supply
D475A, D475ASD-5E0
29
SEN01826-01
40 Troubleshooting
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
Failure code
Symptom of Decelerator pedal sensor power source too low (At left bank only):
failure
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.
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
30
Engine speed cannot be controlled by decelerator pedal.
Cause
1

D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
left bank): Loss of pressure feed detected
1
Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Loss of pressure feed from supply pump (2) (At left bank): Loss of
failure
CA2249
Loss of pressure feed (level 2) occurred in the common rail circuit.
Operates with limited output.
Engine is hard to start.
Exhaust gas color becomes black.
Output decreases.
Possible
causes and the
standard values
when normal
Cause
1

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
CB2249
Loss of pressure feed (level 2) occurred in the common rail circuit.
Operates with limited output.
Engine is hard to start.
Exhaust gas color becomes black.
Output decreases.
Cause
1
D475A, D475ASD-5E0

31
SEN01826-01
40 Troubleshooting
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
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.
Cause
Possible
causes and the
standard values
when normal
32

Defective battery relay
Battery relay
Continuity
Between terminals BR
Continue
ground terminal (E)
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
Short circuit with chassis
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
Defective steering controlSTCN3 (female)
Continuity
ler
Between (4) chassis ground
Continue
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to battery relay
D475A, D475ASD-5E0
33
SEN01826-01
40 Troubleshooting
Failure code [D110KB] Battery relay: Short circuit
Action code
Failure code
Symptom of Battery relay: Short circuit
failure
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.
Cause
Possible
causes and the
standard values
when normal
34

Battery relay
Continuity/resistance
1
Between
terminals
BR

Continue
ground terminal (E)
Between terminal BR
Min. 1 Mz
chassis ground
Hot short in wiring harness
2
Short
(Contact with 24V circuit)
STCN3 (female) (4) battery relay SW
Voltage Max. 1 V
KEY (female) (4) with chassis ground
Starting switch
Voltage
3
ler
Between (4)
ON
20 30 V
chassis ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to battery relay
D475A, D475ASD-5E0
35
SEN01826-01
40 Troubleshooting
Failure code [D130KA] Neutral safety relay: Disconnection
Action code
Failure code
Symptom of Neutral safety relay: Disconnection
failure
E02
D130KA
Failure content 24 V is not generated when ground of neutral safety relay circuit is interrupted.
Controller's
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)
Cause
Possible
causes and the
standard values
when normal
36

Defective neutral safety
1 relay (Internal disconnecNSF (male)
Resistance
tion)
Between (1) (2)
200 400 z
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
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
TMC2
Parking brake lever
Voltage
4
controller
Lock position
Max. 1 V
Between (8)
chassis ground
Free position
20 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to neutral safety relay
D475A, D475ASD-5E0
37
SEN01826-01
40 Troubleshooting
Failure code [D130KB] Neutral safety relay: Short circuit
Action code
Failure code
Symptom of Neutral safety relay: Short circuit
failure
E02
D130KB
Failure content Abnormal current flowed in neutral safety relay circuit at the time of ground output.
Controller's
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
Cause
Possible
causes and the
standard values
when normal
38

1
relay (Internal short circuit)
NSF (male)
Resistance
Between (1) (2)
200 400 z
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
TMC2
Parking brake lever
Voltage
3
controller
Lock position
Max. 1 V
Between (8)
chassis ground
Free position
20 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to neutral safety relay
D475A, D475ASD-5E0
39
SEN01826-01
40 Troubleshooting
Failure code [D161KA] Back-up alarm relay: Disconnection
Action code
Failure code
Symptom of Back-up alarm relay: Disconnection
failure
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
Cause
Possible
causes and the
standard values
when normal
40

If fuse is burnout, circuit probably has short circuit with chassis
1 Defective fuse FS22-1
ground.
Defective back-up alarm
2 relay (Internal disconnecBKA (male)
Resistance
tion)
Between (1) (2)
200 400 z
Defective disconnection in
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
Resisground in wiring harness TMC2 (female) (18) BKA (female) (2) with
Min. 1 Mz
tance
4
cuit)
Short circuit of wiring harness between BKA
Resis(female) (1) FS22-1 outlet port with chassis
Min. 1 Mz
tance
ground
TMC2
PCCS lever
Voltage
5
controller
Neutral position
20 30 V
Between (18)
chassis ground
Reverse position
Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to back-up alarm relay
D475A, D475ASD-5E0
41
SEN01826-01
40 Troubleshooting
Failure code [D161KB] Back-up alarm relay: Short circuit
Action code
Failure code
Symptom of Back-up alarm relay: Short circuit
failure
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
Cause
Possible
causes and the
standard values
when normal
42

1
relay (Internal short circuit)
BKA (male)
Resistance
Between (1) (2)
200 400 z
2
TMC2 (female) (18) BKA (female) (2) with
Voltage Max. 1 V
chassis ground
TMC2
PCCS lever
Voltage
3
controller
Neutral position
20 30 V
Between (18)
chassis ground
Reverse position
Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to back-up alarm relay
D475A, D475ASD-5E0
43
SEN01826-01
40 Troubleshooting
Failure code [D182KZ] Preheater relay: Disconnection or short circuit 1

Action code
Failure code
Symptom of Preheater relay: Disconnection or short circuit
failure
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.
Cause
2
Possible
causes and the
standard values
when normal
3
44

Defective preheater relay
PHR (male)
Resistance
Between (1) and (2)
200 400 z
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
Short circuit with chassis Between wiring harness between STCN2
Resisground in wiring harness (female) (19) and RHR (female) (2) and
Min. 1 Mz
tance
cuit)
Between wiring harness between PHR
Resis(female) (1) and starting switch ACC (270)
Min. 1 Mz
tance
and chassis ground
Starting switch
Voltage
ler
ON
20 30 V
Between (19) chassis
ground
OFF
Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to preheater relay
D475A, D475ASD-5E0
45
SEN01826-01
40 Troubleshooting
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
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).
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)
3
Possible
causes and the
standard values
when normal
4
46

If fuse is broken, circuit probably has ground fault etc.
ACC cut relay
ACT (male)
Resistance
Between (1) (2)
200 400 z
harness
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
Resisground in wiring harness Between ground and wiring harness between
Min. 1 Mz
STCN2 (female) (8) ACT (female) (2)
tance
(Contact with ground
circuit)
ResisMin. 1 Mz
ACT (female) (1) starting switch ACC (270)
tance
Defective steering
STCN2
Starting switch
Voltage
controller
Between (8)
ON
Max. 1 V
chassis ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to engine controller ACC signal cut relay
D475A, D475ASD-5E0
47
SEN01826-01
40 Troubleshooting
Failure code [D190KB] Engine controller ACC signal cutout relay: Short
circuit
1
Action code
Failure code
Symptom of Engine controller ACC signal cutout relay: Short circuit
failure
D190KA
Failure content When signal was output to engine controller ACC cut relay, abnormal current flowed.
Controller's
Stops outputting signal to engine controller ACC cut relay.
action
Symptoms that
appear on
Engine stop function of steering controller does not work.
machine
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).
General
information
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
Possible
causes and the
standard values
when normal
48

1 ACC cut relay
ACT (male)
Resistance
Between (1) (2)
200 400 z
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
Defective steering
3
STCN2
Starting switch
Voltage
controller
Between (8)
ON
Max. 1 V
chassis ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to engine controller ACC signal cut relay
D475A, D475ASD-5E0
49
SEN01826-01
40 Troubleshooting
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
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.

Cause
2
Possible
causes and the
standard values
when normal
3

a
Prepare
with starting switch OFF, then carry out troubleshooting
wiring harness or defective Wiring harness between STCN2 (female) (9)
Voltage Max. 1 V
and V3B (female) (6)
Between
wiring harness between STCN2
(Contact with ground cirResisMin. 1 Mz
(female)
(9)
and V3B (female) (6) and chascuit)
tance
sis ground
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
Defective VHMS controller
V3B
Voltage
Between (6) and chassis ground
20 30 V
Circuit diagram related to snap shot switch
50
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
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
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.

Cause
Possible
causes and the
standard values
when normal

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
STCN2
Snap shot switch
Voltage
ler
Trigger
Max. 1 V
Between (9) and
Out of period
chassis ground
20 30 V
just after trigger
3 Defective VHMS controller
V3B
Voltage
20 30 V
Circuit diagram related to snap shot switch
D475A, D475ASD-5E0
51
SEN01826-01
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
(Machine monitor system)
DAFRKR
Monitor panel cannot recognize steering controller in CAN communication circuit.
Limits operations of engine and transmission.
System may not operate normally.
Once machine is stopped, gear speed is limited to F1 and R1.

Cause
Possible
causes and the
standard values
when normal
52

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
(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)
ResisMax. 1 z
(female) (47) or CT1 (female) (B) or V4A
tance
(female) (12) or RES (female) (B) or SRV
(male) (10)
Resis(32) or OEM L (female) (46) or OEM R
Min. 1 Mz
tance
Ground fault in wiring har(female) (4) or RES (female) (A) or SRV
(male) (3) and ground
circuit)
Min. 1 Mz
tance
Voltage Max. 1 V
(female) (4) or RES (female) (A) or SRV
3 24V circuit) in wiring har(male) (3) and ground
ness
Voltage Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Cause
Possible
causes and the
standard values
when normal

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.)
Circuit diagram related to CAN communication
D475A, D475ASD-5E0
53
SEN01826-01
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
failure
dAFRKR
Transmission cannot recognize monitor panel in CAN communication circuit.
Limits operations of engine, transmission and brake.

Cause
Possible
causes and the
standard values
when normal
54

ResisMax. 1 z
tance
1
in connector)
ResisMax. 1 z
tance
(male) (10)
Min. 1 Mz
tance
circuit)
Min. 1 Mz
tance
Voltage Max. 1 V
ness
Voltage Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Cause
Possible
causes and the
standard values
when normal

4
resistor
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.)
D475A, D475ASD-5E0
55
SEN01826-01
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
failure
daFRKR
Steering controller cannot recognize monitor panel in CAN communication circuit.

Cause
Possible
causes and the
standard values
when normal
56

ResisMax. 1 z
tance
1
in connector)
ResisMax. 1 z
tance
(male) (10)
Min. 1 Mz
tance
circuit)
Min. 1 Mz
tance
Voltage Max. 1 V
ness
Voltage Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Cause
Possible
causes and the
standard values
when normal

4
resistor
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
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
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
58
Cause
1
controller

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.)
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01826-01
59
SEN01826-01
40 Troubleshooting

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.
Monitor panel may not display normally.
Relays and solenoids may not be driven and system may not operate normally.
Once machine is stopped, it cannot travel at all.
Charge level (Voltage) of battery can be checked in monitoring mode
(Code 03200: Battery voltage).
Cause
1
CB6 (20 A)
2
CB30 (30 A)
Possible
causes and the
standard values
when normal
60

If circuit breaker CB6 is turned OFF, circuit probably has ground
fault.
fault.
Wiring harness between TMC3 (female) (1),
ResisMax. 1 z
(11)
CB6
(2)
tance
Resis3
Wiring harness between CB6 (1) F30
Max. 1 z
tance
in connector)
ResisWiring harness between B30S battery relay
Max. 1 z
BRB terminal
tance
ResisMax. 1 z
(31), (32), (33) ground
tance
ResisMin. 1 Mz
Ground fault in wiring harTMC3 (female) (1), (11) CB6 (2)
tance
Resiscircuit)
Min. 1 Mz
CB6 (1) F30
tance
ResisMin. 1 Mz
B30S battery relay BRB terminal
tance
5
TMC3
Voltage
controller
Between (1), (11) (21), (31),
20 30 V
(32), (33)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to transmission controller power supply
D475A, D475ASD-5E0
61
SEN01826-01
40 Troubleshooting

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
DAQ2KK
Power supply voltage of transmission controller load (relays, solenoids, etc.) is below 17 V.
Charge level (Voltage) of battery can be checked in monitoring mode
(Code 03200: Battery voltage).
Cause
1
CB3 (20 A)
2
CB105 (105 A)
Possible
causes and the
standard values
when normal
62

fault.
fault.
ResisMax. 1 z
(12), (22) CB3 (2)
tance
Resis3
Max. 1 z
tance
in connector)
Wiring harness between B105S battery
ResisMax. 1 z
relay BRC terminal
tance
ResisMax. 1 z
(31), (32), (33) ground
tance
ResisMin. 1 Mz
Ground fault in wiring harTMC3 (female) (2), (12), (22) CB3 (2)
tance
Resiscircuit)
Min. 1 Mz
CB3 (1) F96
tance
ResisMin. 1 Mz
B105S battery relay BRC terminal
tance
5
TMC3
Voltage
controller
Between (2), (12), (22) (21),
20 30 V
(31), (32), (33)
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.
Stops output to 5 V power supply circuit if abnormal voltage flows.
Once machine is stopped, travel is limited to F1 an R1.

Cause
Possible
causes and the
standard values
when normal

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
Short
(Contact with ground cirResisTMC1 (female) (22) TL2 (female) (4) with
Min. 1 Mz
cuit)
tance
chassis ground
TMC1 (female) (22) TL2 (female) (4) with
Voltage Max. 1 V
chassis ground
TMC1
Voltage
controller
Between (22) (21)
4.5 5.5 V
Circuit diagram related to transmission controller potentiometer power supply
64
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01

Source voltage reduction (input)
1
Action code
E01
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
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
Possible
causes and the
standard values
when normal
controller
D475A, D475ASD-5E0

TMC1
Voltage
(16) (21)
20 30 V
65
SEN01826-01
40 Troubleshooting

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
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.
Cause
Defective work equipment pump oil pressure
1
sensor (Internal short circuit)
Possible
causes and the
standard values
when normal

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.
Resiscircuit)
TMC3 (female) (34) HP1 or HP2 (female)
Min. 1 Mz
tance
(B)
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)
Defective steering or
4
TMC3, TMC1
Voltage
Between TMC3 (34) TMC1 (21)
4.5 5.5 V
Circuit diagram related to transmission controller sensor power supply
66
D475A, D475ASD-5E0
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.
Machine does not operate at all.
Once machine is stopped, it cannot travel any more.

Cause
Possible
causes and the
standard values
when normal

It is normal if error code lights on (reset display) after carrying out
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.
2
wiring or defective contact Short circuit of wiring harness between
ResisMax. 1 z
in connector)
TMC3 (female) (10) with chassis ground
tance
3
controller
TMC3
Voltage
Max. 1 V
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
Failure code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Transmission controller CAN communication: Communication error

Symptom of
(Objective component system abnormality)
failure
DAQRKR
Transmission controller cannot recognize monitor panel, steering controller, engine controller or
VHMS controller in CAN communication circuit.

Cause
Possible
causes and the
standard values
when normal
68

ResisMax. 1 z
tance
1
in connector)
ResisMax. 1 z
tance
(male) (10)
Min. 1 Mz
tance
circuit)
ResisMin. 1 Mz
tance
Voltage Max. 1 V
ness
Voltage Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Cause
Possible
causes and the
standard values
when normal

resistor
Defective monitor panel,

engine controller, trans5 mission controller, steering
controller or VHMS controller

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.)
D475A, D475ASD-5E0
69
SEN01826-01
40 Troubleshooting

Defective communication (Abnormality in objective component
system)
1
Action code
E01
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Transmission controller S-NET communication: Defective communiSymptom of

cation (Abnormality in objective component system)
failure
DAQSKR
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.
Cause
1
in connector)
2
(Contact with ground circuit)
Possible
causes and the
standard values
when normal
70

Defective monitor panel

(Switch module)
controller

ResisMax. 1 z
S01 (female) (8)
tance
ResisTMC2 (female) (21) S01 (female) (8) with
Min. 1 Mz
tance
chassis ground
TMC2 (female) (21) S01 (female) (8) with
Voltage
Max. 1 V
chassis ground
S01
Voltage
69V
TMC2
Voltage
Between (21) (31)
69V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01826-01
Circuit diagram related to S-NET communication
D475A, D475ASD-5E0
71
SEN01826-01

2007 KOMATSU
All Rights Reserved
72
SEN01827-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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
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
Defective communication (Abnormality in objective component system) .............................................. 24
VHMS controller: Lowering of source voltage........................................................................................ 26
D475A, D475ASD-5E0
SEN01827-03
40 Troubleshooting
Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o "11")
Check of VHMS controller model: Disagreement of model selection .................................................... 27
VHMS controller: Lowering of direct source voltage .............................................................................. 28
VHMS sensor power supply (5 V): Lowering of output voltage.............................................................. 29
VHMS sensor power supply (24 V): Lowering of output voltage............................................................ 30
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
D475A, D475ASD-5E0
SEN01827-03
SEN01827-03
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
DB2RKR
Steering controller cannot recognize engine controller (Left bank) in CAN communication circuit.

Cause
Possible
causes and the
standard values
when normal

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
harness (Disconnection in SRV (male) (3)
1
in connector)
CT1 (female) (B) STCN2 (female) (22) or
ResisTMC2 (female) (22) or RES (female) (B) or
Max. 1 z
tance
SRV (male) (10)
ResisMax. 1 z
ACT (female) (6)
tance
Min. 1 Mz
tance
SRV (male) (3) and ground
2 harness
(Contact with GND circuit) Wiring harness between OEM L (female) (47)
Min. 1 Mz
tance
ResisMin. 1 Mz
ACT (female) (6) and ground
tance
Voltage Max. 1 V
TMC2 (female) (32) or RES (female) (A) or
harness
Voltage Max. 1 V
TMC2 (female) (22) or RES (female) (B) or
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause
Possible
causes and the
standard values
when normal

4
resistor
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
or steering controller
D475A, D475ASD-5E0
SEN01827-03
40 Troubleshooting
Failure code [dB2RKR] Engine controller (Left bank) CAN

Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
failure
dB2RKR
Transmission controller cannot recognize engine controller (Left bank) in CAN communication circuit.

Cause
Possible
causes and the
standard values
when normal

Max. 1 z
tance
harness (Disconnection in SRV (male) (3)
1
in connector)
Max. 1 z
tance
SRV (male) (10)
ResisMax. 1 z
ACT (female) (6)
tance
Min. 1 Mz
tance
2 harness
Wiring
harness between OEM L (female) (47)
(Contact with GND circuit)
Min. 1 Mz
tance
ResisMin. 1 Mz
ACT (female) (6) and ground
tance
Voltage Max. 1 V
TMC2 (female) (32) or RES (female) (A) or
harness
TMC2 (female) (22) or RES (female) (B) or
Voltage Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause
Possible
causes and the
standard values
when normal

4
resistor
Resistance
Between (A) (B)
100 140 z
5
power supply
defective. Carry out troubleshooting for failure code [CA111].
If causes 1 5 are not detected, engine controller or transmission
6
controller may be defective. (Since trouble is in system, troubleor transmission controller
shooting cannot be carried out.)
D475A, D475ASD-5E0
SEN01827-03
40 Troubleshooting
Failure code [db2RKR] Engine controller (Right bank) CAN

Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
failure
db2RKR
Steering controller cannot recognize engine controller (Right bank) in CAN communication circuit.
Cause
Possible
causes and the
standard values
when normal

(46) CT1 (female) (A) STCN2 (female)
(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)
(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)
Min. 1 Mz
tance
(A) or S04 (female) (1), (2) or V4A (female)
2 harness
(4) or SRV (male) (3) and ground
Min. 1 Mz
tance
Voltage Max. 1 V
(A) or S04 (female) (1), (2) or V4A (female)
harness
Voltage Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause
Possible
causes and the
standard values
when normal

4
resistor
Resistance
Between (A) (B)
100 140 z
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
or steering controller
D475A, D475ASD-5E0
SEN01827-03
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
10
Failure code
Symptom of
Steering controller: Abnormality in controller
failure
DB30KT
Information of ROM (nonvolatile storage) of steering controller is not normal.
Take no particular action.
Steering performance may be reduced.
Brake performance may be reduced.
Cause
1
Defective steering
controller

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.)
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01827-03
11
SEN01827-03
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.
Monitor panel may not display normally.
Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage).
Cause
1
CB6 (20 A)
2
CB30 (30 A)
Possible
causes and the
standard values
when normal
12

fault.
fault.
Wiring harness between STCN3 (female) (1),
ResisMax. 1 z
(11) CB6 (2)
tance
Resis3
Max. 1 z
tance
in connector)
Wiring harness between B30S battery relay
ResisMax. 1 z
BRB terminal
tance
ResisMax. 1 z
(21), (31), (32), (33) ground
tance
Prepare with starting switch OFF, then carry out troubleshooting
ResisMin. 1 Mz
STCN3 (female) (1), (11) CB6 (2)
tance
4 harness
Resis(Contact with GND circuit) Between ground and wiring harness between
Min. 1 Mz
CB6 (1) F30
tance
ResisMin. 1 Mz
B30S battery relay BRB terminal
tance
Prepare with starting switch OFF, then turn starting switch ON and
Defective steering
5
STCN3
Voltage
controller
Between (1), (11) (21), (31),
20 30 V
(32), (33)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to steering controller power supply
D475A, D475ASD-5E0
13
SEN01827-03
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.
Charge level (Voltage) of battery can be checked in monitoring mode (Code 03200: Battery voltage).
Cause
1
CB1 (20 A)
2
CB105 (105 A)
Possible
causes and the
standard values
when normal
14

fault.
fault.
Wiring harness between STCN3 (female) (2),
ResisMax. 1 z
(12), (22) CB1 (2)
tance
Resis3
Max. 1 z
tance
in connector)
Wiring harness between B105S battery
ResisMax. 1 z
relay BRC terminal
tance
ResisMax. 1 z
(21), (31), (32), (33) ground
tance
ResisMin. 1 Mz
STCN3 (female) (2), (12), (22) CB1 (2)
tance
4 harness
Resis(Contact with GND circuit) Between ground and wiring harness between
Min. 1 Mz
CB1 (1) F96
tance
ResisMin. 1 Mz
B105S battery relay BRC terminal
tance
Defective steering
STCN3
Voltage
5
controller
Between (2), (12), (22) (21),
20 30 V
(31), (32), (33)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to steering controller power supply
D475A, D475ASD-5E0
15
SEN01827-03
40 Troubleshooting

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.
If abnormal current flows, controller stops output of 5V power supply circuit.

Cause
Possible
causes and the
standard values
when normal
16

Defective brake
BRK (male)
Resistance
1 potentiometer
Between (C) (A)
5 kz 20%
Sensor
Between (C) ground
Min. 1 Mz
Defective fuel control dial
DIAL (male)
Resistance
2 potentiometer
Between (1) (3)
5 kz 15%
Sensor
Between (1) ground
Min. 1 Mz
Defective steering
TL2 (male)
Resistance
3 potentiometer
Between (5) (8)
3.2 kz 20%
Between (8) ground
Min. 1 Mz
4 harness
Resis(Contact with GND circuit) STCN1 (female) (22) TL2 (female) (5) or
Min. 1 Mz
tance
BRK (female) (C) or DIAL (female) (1)
harness
STCN1 (female) (22) TL2 (female) (5) or
Voltage Max. 1 V
BRK (female) (C) or DIAL (female) (1)
Defective steering
6
controller
STCN1
Voltage
Between (22) (21)
4.5 5.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to steering controller potentiometer power supply
D475A, D475ASD-5E0
17
SEN01827-03
40 Troubleshooting

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.
Once machine is stopped, travel is limited to F1 and R1.

Cause
Possible
causes and the
standard values
when normal

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.
2
Short
(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
STCN1
Voltage
ler
Between (16) (21)
20 30 V
Circuit diagram related to steering controller sensor power supply
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03

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.
Stops output of 5 V power supply circuit if abnormal voltage flows.

Cause
2
Possible
causes and the
standard values
when normal
3

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
turn starting switch ON and carry out troubleshooting.
Short
(female) (34) SSA (female) (C) with
Min. 1 Mz
cuit)
tance
chassis ground
STCN3 (female) (34) SSA (female) (1) with Voltage Max. 1 V
chassis ground
Defective steering
STCN1, STCN3
Voltage
controller
Between STCN3 (34)
20 30 V
STCN1 (21)
Circuit diagram related to steering controller sensor power supply
D475A, D475ASD-5E0
19
SEN01827-03
40 Troubleshooting
Failure code [DB39KQ] Steering controller type selection: Type select

signal inconsistency
1
Action code
CALL E04
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Steering controller type selection: Type select signal inconsistency
failure
DB39KQ
Internal spec. setting of steering controller is inconsistent with spec. set signal.
(Steering controller may not recognize normally)
Stops all outputs of steering controller.
Problem that appears on machineMachine does not operate at all.

Cause
Possible
causes and the
standard values
when normal

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)
2
ResisMax. 1 z
in connector)
(20) chassis ground
tance
Defective steering
3
controller
STCN3
Voltage
Max. 1 V
Circuit diagram related to steering controller type select
20
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01827-03
21
SEN01827-03
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
dB3RKR
Transmission controller cannot recognize steering controller in CAN communication circuit.

Cause
Possible
causes and the
standard values
when normal
22

ResisMax. 1 z
tance
1
in connector)
Max. 1 z
tance
(male) (10)
Min. 1 Mz
tance
2 harness
Min. 1 Mz
tance
Voltage Max. 1 V
harness
Voltage Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause
Possible
causes and the
standard values
when normal

resistor
Defective steering
5 controller or transmission
controller

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
SEN01827-03
40 Troubleshooting

Defective communication (Abnormality in objective component
system)
Action code
E01
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Steering controller S-NET communication: Defective communication

Symptom of
(Abnormality in objective component system)
failure
DB3SKR
Transmission controller cannot recognize S-NET.
Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
Cause
1
in connector)
2
circuit)
Possible
causes and the
standard values
when normal
24


(Switch module)
Defective steering
controller

ResisMax. 1 z
(21) S01 (female) (8)
tance
ResisSTCN2 (female) (21) S01 (female) (8) with
Min. 1 Mz
tance
chassis ground
STCN2 (female) (21) S01 (female) (8) with Voltage Max. 1 V
chassis ground
S01
Voltage
69V
STCN2
Voltage
Between (21) (31)
69V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to S-NET communication
D475A, D475ASD-5E0
25
SEN01827-03
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".
Cause
Possible
causes and the
standard values
when normal

harness (Disconnection in Wiring harness between V1 (female) (8), (9)
Resis1
Max. 1 z
wiring harness or defective and FS12 (fuse) (1)
tance
Wiring harness between V1 (female) (11) and
ResisMax. 1 z
GND 01
tance
2
Between wiring harness between V1
Resis(female) (8), (9) and FS12 (fuse) (1) and
Min. 1 Mz
circuit)
tance
chassis ground
Between V1 (female) (8), (9) and V1 (female)
Voltage 20 30 V
(11), (12) or chassis ground
Circuit diagram related to VHMS controller power supply
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Failure code [DBB0KQ] (or LED of VHMS controller indicates "nF" o

"11") Check of VHMS controller model: Disagreement of model
selection
1
Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
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 LED of the VHMS controller indicates "nF" o "11".
Cause
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)
harness (Disconnection in Between wiring harness V1 (female) (11),
Resis2
Max. 1 z
wiring harness or defective (12) and chassis ground
tance
Between wiring harness V3A (female) (9)
ResisMax. 1 z
and chassis ground
tance
Between V1 (female) (11), (12) and chassis
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
SEN01827-03
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
DBB3KK
The direct source voltage is below 19.5 V.
None in particular.
Cause
Possible
causes and the
standard values
when normal

harness (Disconnection in Wiring harness between V1 (female) (6), (7)
Resis1
Max. 1 z
wiring harness or defective and FS12 (fuse) (2)
tance
ResisMax. 1 z
GND 01
tance
2
Between wiring harness between V1
Resis(female) (6), (7) and FS12 (fuse) (2) and
Min. 1 Mz
circuit)
tance
chassis ground
Between V1 (female) (6), (7) and V1 (female)
Voltage 20 30 V
(11), (12) or chassis ground
Circuit diagram related to VHMS controller power supply
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
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.
Cause
Possible
causes and the
standard values
when normal

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
2
wiring harness or defective Between wiring harness V1 (female) (4) and
ResisMax. 1 z
ENBP (female) (B)
tance
Between V1 (female) (4) and V2A (female)
4.5
Voltage
(12)
5.5 V
Circuit diagram related to sensor power supply 5 V
D475A, D475ASD-5E0
29
SEN01827-03
40 Troubleshooting

Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of VHMS sensor power supply (24 V): Lowering of output voltage
failure
(Disconnection or short circuit) (VHMS controller system)
DBB6KP
The sensor source voltage (24 V) is out of the normal range (20 30 V).
None in particular.
Cause
Possible
causes and the
standard values
when normal
30

harness (Disconnection in Wiring harness between V1 (female) (2)
1
wiring harness or defective EXA1 (female) (A), V1 (female) (2) EXA2
Resis(female) (A), V1 (female) (2) EXA3 (female)
Max. 1 z
tance
(A), V1 (female) (2) EXA4 (female) (A) V1
(female) (2) TMMD (female) (B)
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)
tance
EXA3 (female) (A), V1 (female) (2) EXA4
(female) (A) V1 (female) (2) TMMD
(female) (B) with chassis ground
Between V1 (2) and V2A (13)
Voltage 20 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
D475A, D475ASD-5E0
31
SEN01827-03
40 Troubleshooting

Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of VHMS sensor power supply (12 V): Lowering of output voltage
failure
(Disconnection or short circuit) (VHMS controller system)
DBB7KP
The sensor source voltage (12 V) is out of the normal range (11.5 12.5 V).
None in particular.
Cause
Possible
causes and the
standard values
when normal

1
wiring harness or defecBetween wiring harness V1 (female) (3) and
ResisMax. 1 z
tive contact in connector) DLT (female) (1)
tance
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
V1
Voltage
Between (3) and (11), (12)
11.5 12.5 V
32
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01827-03
33
SEN01827-03
40 Troubleshooting
Failure code [DBBQKR] (or VHMS_LED display "n8" o "02") VHMS

KOM-NET: Communication error
Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of VHMS KOM-NET: Communication error
failure
DBBQKR
Communication (CAN) information cannot be received from each controller.
None in particular.
Failure code is not displayed on monitor panel (It can be checked, however, by downloading data
saved in VHMS controller into personal computer).
"n8" on VHMS controller LED changes from "n8" to "02".
Cause
Possible
causes and the
standard values
when normal
34

ResisMax. 1 z
tance
1
in connector)
Max. 1 z
tance
(male) (10)
Min. 1 Mz
tance
circuit)
ResisMin. 1 Mz
tance
Voltage Max. 1 V
ness
Voltage Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause
Possible
causes and the
standard values
when normal

resistor

CT1 (male), RES (male),
RES L (male), RES R (male),
Resistance
CTV (male)
Between (A) (B)
100 140 z
D475A, D475ASD-5E0
35
SEN01827-03
40 Troubleshooting
Failure code [dbBRKR] VHMS controller CAN communication:

Communication error
Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of VHMS controller CAN communication: Communication error
failure
dbBRKR
Steering controller cannot recognize VHMS controller in CAN communication circuit.
None in particular.
Data related to VHMS cannot be monitored.
Data related to VHMS may not be obtained normally.
Cause
Possible
causes and the
standard values
when normal
36

ResisMax. 1 z
tance
1
in connector)
Max. 1 z
tance
(male) (10)
Min. 1 Mz
tance
GND circuit)
Min. 1 Mz
tance
Voltage Max. 1 V
harness
Voltage Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Cause
Possible
causes and the
standard values
when normal

4
resistor
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
D475A, D475ASD-5E0
37
SEN01827-03
40 Troubleshooting
Failure code [DD12KA] Shift up switch: Disconnection

Action code
E02
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of
Shift up switch: Disconnection (Transmission controller system)
failure
DD12KA
Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time.
Recognizes that switch is not pressed.
Shift up is not possible.
Auto shift down does not function.
Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
Input state (ON/OFF) from shift up 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 shift up switch.
Cause
Defective shift up switch

2
in connector)
Possible
causes and the
standard values
when normal
38

controller

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)
ResisMax. 1 z
TL3 (female) (3)
tance
ResisMax. 1 z
TL3 (female) (1)
tance
ResisMax. 1 z
TL3 (female) (2)
tance
Voltage Max. 1 V
chassis ground
Voltage Max. 1 V
chassis ground
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to shift up switch and shift down switch
D475A, D475ASD-5E0
39
SEN01827-03
40 Troubleshooting
Failure code [DD12KB] Shift up switch: Short circuit

Action code
E02
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of
Shift up switch: Short circuit (Transmission controller system)
failure
DD12KB
Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time.
Shift up is not possible.
Input state (ON/OFF) from shift up switch can be checked in monitoring mode.
Cause
Possible
causes and the
standard values
when normal


2
40
controller

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)
ResisTMC1 (female) (6) TL3 (female) (3) with
Min. 1 Mz
tance
chassis ground
Min. 1 Mz
tance
chassis ground
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
D475A, D475ASD-5E0
41
SEN01827-03
40 Troubleshooting
Failure code [DD13KA] Shift down switch: Disconnection

Action code
E02
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Shift down switch: Disconnection
failure
DD13KA
Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time.
Shift down is not possible.
Input state (ON/OFF) from shift down 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 shift down switch.
Cause
Defective shift down

1 switch
2
in connector)
Possible
causes and the
standard values
when normal
42

controller

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)
ResisMax. 1 z
TL3 (male) (6)
tance
ResisMax. 1 z
TL3 (male) (4)
tance
ResisMax. 1 z
TL3 (male) (5)
tance
TMC3 (female) (19) TL3 (male) (6) with
Voltage Max. 1 V
chassis ground
TMC3 (female) (29) TL3 (male) (4) with
Voltage Max. 1 V
chassis ground
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
D475A, D475ASD-5E0
43
SEN01827-03
40 Troubleshooting
Failure code [DD13KB] Shift down switch: Short circuit

Action code
E02
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Shift down switch: Short circuit
failure
DD13KB
Signals of two systems of shift down switch circuit were turned ON (CLOSE)
Shift down is not possible.
Input state (ON/OFF) from shift down switch can be checked in monitoring mode.
Cause
Possible
causes and the
standard values
when normal
44

Shift down switch
TL3 (male)
Defective shift down switch
OFF (Release)
ON (Press)
1
Resistance between
Max. 1 z
Min. 1 Mz
(5) (6)
Resistance between
Min. 1 Mz
Max. 1 z
(5) (4)
Resisground in wiring harness TMC3 (female) (19) TL3 (male) (6) with
Min. 1 Mz
2
tance
cuit)
ResisTMC3 (female) (29) TL3 (male) (4) with
Min. 1 Mz
tance
chassis ground
Shift down switch
TMC1, TMC3
OFF (Release)
ON (Press)
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
D475A, D475ASD-5E0
45
SEN01827-03
40 Troubleshooting
Failure code [DD14KA] Parking brake lever switch: Disconnection

Action code
E02
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
Possible
causes and the
standard values
when normal
46
Failure code
Symptom of Parking brake lever switch: Disconnection
failure
DD14KA
Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same
time.
Recognizes parking brake lever is in Free position.

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.
Method of reproducing failure code: Turn starting switch ON and operate parking brake lever.
When failure code [DD14KA] occurred alone
Cause
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)
ResisMax. 1 z
branched point of circuit JF1
tance
Parking brake lever
TMC1
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
Parking brake lever
Parking brake lever switch
NSW (male)
1
Free position
Lock position
Between (A) (B)
Max. 1 z
Min. 1 Mz
Between (A) (B)
Min. 1 Mz
Max. 1 z
Wiring harness between NSW (female) (B)
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
D475A, D475ASD-5E0
40 Troubleshooting
Possible
causes and the
standard values
when normal
SEN01827-03
When failure codes [DD14KA] and [DDQ2KA] occurred at the same time
Cause
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
(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
SEN01827-03
40 Troubleshooting
Failure code [DD14KB] Parking brake lever switch: Short circuit

Action code
E02
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Parking brake lever switch: Short circuit
failure
DD14KB
Signals of two systems of parking brake lever switch circuit were turned ON (CLOSE) at the same
time.

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).
Method of reproducing failure code: Turn starting switch ON and operate parking brake lever.
Cause
Possible
causes and the
standard values
when normal
48

Parking brake lever
Parking brake lever switch
NSW (male)
1
Free position
Lock position
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.
Resisground in wiring harness
TMC1 (female) (18), STCN2 (female) (5) with
Min. 1 Mz
2
tance
(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
Parking brake lever
TMC1
Defective transmission conFree position
Lock position
3
troller
Between (18)
Max. 1 V
5 11 V
chassis ground
Between (12)
5 11 V
Max. 1 V
chassis ground
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
D475A, D475ASD-5E0
49
SEN01827-03
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
DDB9L4
Signals of 2 reverse switch circuit systems disagree with each other.
Assumes that switch is not pressed.

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).
Cause
Possible
causes and the
standard values
when normal
50

Reverse switch
TL3 (male)
Defective reverse switch
OFF (Released)
ON (Pressed)
Resistance between
Min. 1 Mz
Max. 1 z
(6) (5)
Resistance between
Min. 1 Mz
Max. 1 z
(4) (2)
Wiring
Max. 1 z
tance
harness (Disconnection in TL3 (female) (6)
ResisMax. 1 z
in connector)
TL3 (female) (4)
tance
ResisMax. 1 z
TL3 (female) (5)
tance
Min. 1 Mz
TMC3 (female) (19) TL3 (female) (6)
tance
GND circuit)
ResisMin. 1 Mz
tance
Voltage Max. 1 V
24V circuit) in wiring
harness
Voltage Max. 1 V
Reverse switch
Reverse switch
OFF (Released)
ON (Pushed)
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to forward-reverse switch
D475A, D475ASD-5E0
51
SEN01827-03
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
DDK3L4
Signals of 2 forward switch circuit systems disagree with each other.

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.
Cause
Possible
causes and the
standard values
when normal
52

Forward switch
TL3 (male)
Defective forward switch
OFF (Released)
ON (Pressed)
1
Resistance between
Min. 1 Mz
Max. 1 z
(3) (5)
Resistance between
Min. 1 Mz
Max. 1 z
(1) (2)
TL3 (female) (3)
Max. 1 z
tance
191. Resistance
2
Resisin connector)
Max. 1 z
TL3 (female) (1)
tance
ResisMax. 1 z
TL3 (female) (2)
tance
Resis3 ness (Contact with GND
Min. 1 Mz
tance
circuit)
ResisMin. 1 Mz
tance
Voltage Max. 1 V
4 24V circuit) in wiring harTMC1 (female) (6) TL3 (female) (3)
ness
Voltage Max. 1 V
Forward switch
TMC1, TMC2
OFF (Released)
ON (Pushed)
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to forward-reverse switch
D475A, D475ASD-5E0
53
SEN01827-03
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
DDK5KA
Signals of 2 gearshift switch circuit systems are turned OFF (opened) simultaneously.
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

2
in connector)
Possible
causes and the
standard values
when normal
54

controller

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)
ResisMax. 1 z
SNL (male) (2)
tance
ResisMax. 1 z
SNC (male) (3)
tance
ResisMax. 1 z
SNC (male) (1)
tance
TMC2 (female) (7) SNC (male) (2) with
Voltage Max. 1 V
chassis ground
TMC2 (female) (10) SNC (male) (3) with
Voltage Max. 1 V
chassis ground
Shift switch
TMC1,TMC2
OFF (Release)
ON (Press)
Voltage between
Max. 1 V
5 11 V
TMC2 (7) TMC1
(10)
Voltage between
TMC2 (10) TMC1
Max. 1 V
5 11 V
(10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to shift switch
D475A, D475ASD-5E0
55
SEN01827-03
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
DDK5KB
Signals of 2 gearshift switch circuit systems are turned ON (closed) simultaneously.
Gear cannot be shifted up or down (1st o 2nd).
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
Possible
causes and the
standard values
when normal


2
56
controller

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)
ResisTMC2 (female) (7) SNC (male) (2) with
Min. 1 Mz
tance
chassis ground
ResisTMC2 (female) (10) SNC (male) (3) with
Min. 1 Mz
tance
chassis ground
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to shift switch
D475A, D475ASD-5E0
57
SEN01827-03
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
Possible
causes and the
standard values
when normal
Failure code
Symptom of Blade tilt right oil pressure switch system: Switch is ON for long time
failure
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
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.
troubleshooting.
Defective blade tilt right oil
TRS (male)
Blade lever
Resistance
2 pressure switch
Neutral
Min. 1 Mz
Between (1) and (2)
Right tilt
Max. 1 z
3
Between
wiring harness between TMC2
(Contact with ground cirResis(female)
(6)
and TRS (female) (1) and chasMin. 1 Mz
cuit)
tance
sis ground
troubleshooting.
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
SEN01827-03
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
Possible
causes and the
standard values
when normal
Failure code
Symptom of Blade tilt left oil pressure switch system: Switch is ON for long time
failure
DDN3LD
The signal of the blade tilt left oil pressure switch circuit is kept turned ON for 60 seconds.
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)
Cause
1 (When electrical system is reproductive operation is performed, it is suspected that the lever
normal)
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
3
Between
(16)
and TLS (female) (1) and chasMin. 1 Mz
cuit)
tance
sis ground
troubleshooting.
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
SEN01827-03
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
DDN7KA
The signals of the 2 blade pitch switch circuit systems are turned OFF (opened) simultaneously.
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).
Cause
Possible
causes and the
standard values
when normal
60

Blade pitch switch
P03 (male)
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)
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
ResisMax. 1 z
and P03 (female) (1)
tance
Between wiring harness between TMC2
(female) (15) and P03 (female) (5) and chas- Voltage Max. 1 V
sis ground
(Contact with 24-V circuit)
(female) (5) and P03 (female) (2) and chasVoltage Max. 1 V
sis ground
Blade pitch switch
TMC1, TMC2
OFF (Released)
ON (Pressed)
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to blade pitch switch and blade tilt switch
D475A, D475ASD-5E0
61
SEN01827-03
40 Troubleshooting
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
DDN7KB
Signals of two systems of blade pitch switch circuit were turned ON (CLOSE) at the same time.
Blade pitch does not function (Operating blade pitch causes tilt operation.)
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.
Cause
Possible
causes and the
standard values
when normal
62

Blade pitch switch
P03 (male)
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)
TMC2 (female) (15) P03 (female) (5) with
Voltage Max. 1 V
2
(Contact with ground circhassis ground
cuit)
Voltage Max. 1 V
chassis ground
Blade pitch switch
TMC1, TMC2
OFF (Release)
ON (Press)
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
Circuit diagram related to blade pitch switch & blade tilt switch
D475A, D475ASD-5E0
63
SEN01827-03
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
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.)
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).
Cause
Possible
causes and the
standard values
when normal
3
64

Blade tilt switch
P03 (male)
Defective blade tilt switch
SINGLE
DUAL
Resistance between
Max. 1 z
Min. 1 Mz
(3) (6)
Resistance between
Min. 1 Mz
Max. 1 z
(3) (4)
Wiring
Max. 1 z
tance
harness (Disconnection in P03 (female) (6)
ResisMax. 1 z
in connector)
P03 (female) (4)
tance
ResisMax. 1 z
P03 (female) (3)
tance
Hot short in wiring harness TMC2 (female) (35) P03 (female) (6) with
Voltage Max. 1 V
(Contact with 24 V circuit) chassis ground
Voltage Max. 1 V
chassis ground
Blade tilt switch
TMC1, TMC2
SINGLE
DUAL
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
D475A, D475ASD-5E0
65
SEN01827-03
40 Troubleshooting
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.)
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
Possible
causes and the
standard values
when normal
Defective blade tilt switch


2
66
controller

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)
Voltage Max. 1 V
chassis ground
Voltage Max. 1 V
chassis ground
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
D475A, D475ASD-5E0
67
SEN01827-03
40 Troubleshooting
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
Possible
causes and the
standard values
when normal
Failure code
Symptom of Blade lift raise full oil pressure switch: Switch is ON for long time
failure
DDNALD
The signal of the blade lift raise full oil pressure switch circuit is kept turned ON for 60 seconds.
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)
Cause
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)
troubleshooting.
Defective blade lift raise
BLU (male)
Blade lever
Resistance
2 full oil pressure switch
Neutral
Min. 1 Mz
Between (1) and (2)
Raise
Max. 1 z
3
Between
(36)
and BLU (female) (1) and chasMin. 1 Mz
cuit)
tance
sis ground
troubleshooting.
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
68
D475A, D475ASD-5E0
40 Troubleshooting
SEN01827-03
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
Possible
causes and the
standard values
when normal
Failure code
Symptom of Ripper lift raise oil pressure switch: Switch is ON for long time
failure
DDNBLD
The signal of the ripper lift raise oil pressure switch circuit is kept turned ON for 60 seconds.
The shoe slip control (SSC) function does not operate normally.
Ripper lift raise operation becomes slow.
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)
Cause
1 (When electrical system is resetting operation is performed, it is suspected that the lever was
normal)
operated to cause an error.
troubleshooting.
Defective ripper lift raise oil
RPU (male)
Ripper lever
Resistance
2 pressure switch
Neutral
Min. 1 Mz
Between (1) and (2)
Raise
Max. 1 z
3
Between
(13)
and RPU (female) (1) and
Min. 1 Mz
cuit)
tance
chassis ground
troubleshooting.
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
SEN01827-03
40 Troubleshooting
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
Possible
causes and the
standard values
when normal
Failure code
Symptom of Ripper lift lower oil pressure switch: Switch is ON for long time
failure
DDNCLD
The signal of the ripper lift lower oil pressure switch circuit is kept turned ON for 60 seconds.
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)
Cause
normal)
troubleshooting.
Defective ripper lift lower
RPD (male)
Ripper lever
Resistance
2 oil pressure switch
Neutral
Min. 1 Mz
Between (1) and (2)
Lower
Max. 1 z
3
Between
(3)
and RPD (female) (1) and chasMin. 1 Mz
cuit)
tance
sis ground
troubleshooting.
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
40 Troubleshooting
SEN01827-03
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
Possible
causes and the
standard values
when normal
Failure code
Symptom of Ripper tilt in oil pressure switch: Switch is ON for long time
failure
DDNDLD
The signal of the ripper tilt in oil pressure switch circuit is kept turned ON for 60 seconds.
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)
Cause
normal)
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
3
Between
(2)
and RT1 (female) (1) and chasMin. 1 Mz
cuit)
tance
sis ground
troubleshooting.
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
SEN01827-03
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
Possible
causes and the
standard values
when normal
Failure code
Symptom of Ripper tilt back oil pressure switch: Switch is ON for long time
failure
DDNELD
The signal of the ripper tilt back oil pressure switch circuit is kept turned ON for 60 seconds.
The tilt back speed of the ripper lowers.
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)
Cause
Wrong operation of lever If the service code lamp still lights up (resetting is still urged) after
normal)
troubleshooting.
Defective ripper tilt back oil
RT8 (male)
Ripper lever
Resistance
2 pressure switch
Neutral
Min. 1 Mz
Between (1) and (2)
Tilt back
Max. 1 z
3
Between
(38)
and RT8 (female) (1) and chasMin. 1 Mz
cuit)
tance
sis ground
troubleshooting.
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
40 Troubleshooting
SEN01827-03
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
Failure code
Symptom of Blade lift lower full pressure switch: Switch is ON for long time
failure
DDNFLD
The signal of the blade lift lower full oil pressure switch circuit is kept turned ON for 60 seconds.
The lift lower speed of the blade lowers.
General
information
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)
Possible
causes and the
standard values
when normal
Cause
normal)
troubleshooting.
Defective blade lift lower
BLD (male)
Blade lever
Resistance
2 full oil pressure switch
Neutral
Min. 1 Mz
Between (1) and (2)
Lower full
Max. 1 z
3
Between
(26)
and BLD (female) (1) and chasMin. 1 Mz
cuit)
tance
sis ground
troubleshooting.
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
SEN01827-03

2009 KOMATSU
All Rights Reserved
74
SEN01828-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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 ................. 17
Failure code [DGT5KA] Left bank exhaust temperature sensor system (Front):
Disconnection (or LED of VHMS controller indicates "n3" o "12")........................................................ 18
Failure code [dGT5KA] Left bank exhaust temperature sensor system (Rear):
Disconnection (or LED of VHMS controller indicates "n3" o "22")........................................................ 20
Failure code [DGT5KB] Left bank exhaust temperature sensor system (Front):
Short circuit (or LED of VHMS controller indicates "n3" o "11")............................................................ 22
D475A, D475ASD-5E0
SEN01828-03
40 Troubleshooting
Left bank exhaust temperature sensor system (Rear): Short circuit...................................................... 24
Failure code [DGT6KA] (or LED of VHMS controller indicates "n3" o "24")
Right bank exhaust temperature sensor system (Front): Disconnection ............................................... 26
Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o "26")
Right bank exhaust temperature sensor system (Rear): Disconnection................................................ 28
Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o "23")
Right bank exhaust temperature sensor system (Front): Short circuit................................................... 30
Right bank exhaust temperature sensor system (Rear): Short circuit ................................................... 32
Failure code [DH22KA] Work equipment pump oil pressure sensor (F): Disconnection............................... 34
Failure code [DH22KB] Work equipment pump oil pressure sensor (F): Short circuit .................................. 35
Failure code [DH23KA] Work equipment pump oil pressure sensor (R): Disconnection .............................. 36
Failure code [DH23KB] Work equipment pump oil pressure sensor (R): Short circuit .................................. 37
Failure code [DHE5KB] (or LED of VHMS controller indicates "n3" o "32")
Blow-by pressure sensor system: Disconnection .................................................................................. 38
Failure code [DHE5KY] (or LED of VHMS controller indicates "n3" o "31")
Blow-by pressure sensor system: Hot short .......................................................................................... 39
Failure code [DHT3KX] (or LED of VHMS controller indicates "n6" o "14")
Transmission oil pressure sensor: Out of input signal range ................................................................. 40
Failure code [DK01KA] Left yoke angle sensor: Disconnection .................................................................... 41
Failure code [DK01KB] Left yoke angle sensor: Short circuit ....................................................................... 42
Failure code [DK03KA] Right yoke angle sensor: Disconnection ................................................................. 43
Failure code [DK03KB] Right yoke angle sensor: Short circuit ..................................................................... 44
Failure code [DK10KA] Fuel dial: Disconnection .......................................................................................... 45
Failure code [DK10KB] Fuel dial: Short circuit .............................................................................................. 46
Failure code [DK30KA] Steering potentiometer (1): Disconnection .............................................................. 48
Failure code [DK30KB] Steering potentiometer (1): Short circuit .................................................................. 50
Failure code [DK30KX] Steering potentiometer (1): Input signal is out of normal range............................... 52
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 .................................................................. 56
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01828-03
SEN01828-03
40 Troubleshooting
Failure code [DDQ2KA] Parking brake lever switch: Disconnection

Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
Possible
causes and the
standard values
when normal
Failure code Symptom of Parking brake lever switch: Disconnection

failure
DDQ2KA
Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same
time.

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).
(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
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)
ResisMax. 1 z
branched point of circuit JF1
tance
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
Parking brake lever
Parking brake lever
NSW
1 switch
Free position
Lock position
Between (A) (B)
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Max. 1 z
Between (A) (B)
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
D475A, D475ASD-5E0
40 Troubleshooting
Possible
causes and the
standard values
when normal
SEN01828-03
When failure codes [DDQ2KA] and [DD14KA] occurred at the same time
Cause
Hot short in wiring har(female) (B) TMC1 (female) (18) STCN2
Voltage
Max. 1 V
3 ness (Contact with 24 V
circuit)
(female) (C) TMC1 (female) (12) STCN2
Voltage
Max. 1 V
D475A, D475ASD-5E0
SEN01828-03
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
General
information
Possible
causes and the
standard values
when normal
Failure code Symptom of Parking brake lever switch: Short circuit

failure
DDQ2KB
Signals of both parking brake lever switch circuit systems are turned ON (closed) simultaneously.
Recognizes that parking brake lever is at FREE position.

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.
When failure codes [DDQ2KA] and [DD14KA] are displayed simultaneously
Cause
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
Short circuit with chassis Short circuit of wiring harness between NSW
Resisground in wiring harness (female) (B) TMC1 (female) (18) STCN2
Min. 1 Mz
2
tance
(Contact with ground cir- (female) (5) with chassis ground
cuit)
Resis(female) (C) TMC1 (female) (12) STCN2
Min. 1 Mz
tance
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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
D475A, D475ASD-5E0
SEN01828-03
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
General
information
Failure code Symptom of Parking brake lever switch: Disagreement of signals

failure
DDQ2L4
Switch input signal of steering controller disagrees with communication signal from transmission
controller.
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.
Cause
Possible
causes and the
standard values
when normal

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
Defective steering con3
troller
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Failure code [dDQ2L4] Parking brake lever switch: Disagreement of

signals
Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code Symptom of Parking brake lever switch: Disagreement of signals

failure
dDQ2L4
Switch input signal of steering controller disagrees with communication signal from transmission
controller.
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.
Cause
Possible
causes and the
standard values
when normal

See if failure codes [DAFRKR], [DBBQKR], [DB3RKR], and
Defective CAN communi1
[DAQRKR] are displayed. If they are displayed, carry out troublecation signal system
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
troller
D475A, D475ASD-5E0
SEN01828-03
40 Troubleshooting
Failure code [DDT5KA] Neutral switch: Disconnection

Action code
CALL E04
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code Symptom of

Neutral switch: Disconnection (Transmission controller system)
failure
DDT5KA
Signals of two systems of neutral switch circuit were turned OFF (OPEN) at the same time.
Recognizes that switch is pressed.
Input state (ON/OFF) from neutral switch can be checked in monitoring mode.
Method of reproducing failure code: Turn starting switch ON (and operate neutral switch).
Cause
Possible
causes and the
standard values
when normal
3
10

Neutral switch
SNC (male)
Defective neutral switch
OFF (Release)
ON (Press)
Resistance between
Max. 1 z
Min. 1 Mz
(4) (6)
Resistance between
Min. 1 Mz
Max. 1 z
(4) (5)
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
ResisMax. 1 z
SNC (female) (4)
tance
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)
(female) (17) SNC (female) (5) with chassis Voltage
Max. 1 V
ground
Shift up switch
TMC1,TMC2
OFF (Release)
ON (Press)
Voltage between
controller
Max. 1 V
5 11 V
TMC2 (27)
TMC1 (10)
Voltage between
TMC2 (17)
5 11 V
Max. 1 V
TMC1 (10)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Circuit diagram related to neutral switch
D475A, D475ASD-5E0
11
SEN01828-03
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.
Recognizes that switch is pressed.
Input state (ON/OFF) from neutral switch can be checked in monitoring mode.
Method of reproducing failure code: Turn starting switch ON (and operate neutral switch).
Cause
Possible
causes and the
standard values
when normal
12

Neutral switch
SNC (male)
Defective neutral switch
OFF (Release)
ON (Press)
1
Resistance between
Max. 1 z
Min. 1 Mz
(4) (6)
Resistance between
Min. 1 Mz
Max. 1 z
(4) (5)
Short circuit with chassis Short circuit of wiring harness between TMC2
Resisground in wiring harness (female) (27) SNC (female) (6) with chassis
Min. 1 Mz
2
tance
(Contact with ground cir- ground
cuit)
Resis(female) (17) SNC (female) (5) with chassis
Min. 1 Mz
tance
ground
Shift up switch
TMC1, TMC2
OFF (Release)
ON (Press)
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)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Circuit diagram related to neutral switch
D475A, D475ASD-5E0
13
SEN01828-03
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
Possible
causes and the
standard values
when normal
Failure code Symptom of Lever specification selection: Model selection signal disagreement
failure
DDT5KQ
Travel lever cannot select PCCS standard specification.
Input state (ON/OFF) from neutral switch can be checked in monitoring mode
Cause
Worng selection of travel a Check type of travel lever in adjustment
Select optional travel
1
lever
mode: 0004
lever
ResisMin. 1 Mz
TMC2 (female) (17) SNC (female) (5)
tance
GND circuit)
ResisMin. 1 Mz
TMC2 (female) (27) SNC (female) (6)
tance
If causes 1 and 2 are not detected, transmission controller may be
3
controller
carried out.)
Circuit diagram related to lever specification selection
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
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
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)
2
in wiring or defective contact in connector)
Possible
causes and the
standard values
when normal

3

controller

SDS (male)
Resistance
Between (1) (2)
3.5 k 90 kz (10 100C)
Between (1), (2) chassis ground
Min. 1 Mz
ResisMax. 1 z
SDS (female) (1)
tance
ResisMax. 1 z
SDS (female) (2)
tance
Resis(female) (14) SDS (female) (1) with chassis
Min. 1 Mz
tance
ground
(female) (14) SDS (female) (1) with chassis
Voltage
Max. 1 V
ground
TMC1 (female)
Resistance
Between (14) (21)
3.5 k 90 kz (10 100C)
Min. 1 Mz
Circuit diagram related to hydraulic oil temperature sensor
D475A, D475ASD-5E0
15
SEN01828-03
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
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.
Causes
(Short circuit)
Possible
causes and the
standard values
when normal
harness
2 (Disconnection in wiring
or defective contact in
connector)
Defective harness
ground circuit)

still OFF.
453 (male)
Resistance
Between (1) (2)
3.5 kz 90 kz (10 100C)
Min. 1 Mz
still OFF.
ResisMax. 1 z
453 (female) (1)
tance
ResisMax. 1 z
453 (female) (2)
tance
453 (female) (2)
Resistance
Max. 1 z
Hot short of wiring
still OFF.
4 harness
Resis(contact with 24 V circuit)
Min. 1 Mz
S04 (female) (12) 453 (female) (1)
tance
Machine monitor can be suspected to defective if no problem is found
Defective machine
5
in causes 1 4 (since this is an internal defect, it cannot be diagmonitor
nosed).
Circuit diagram related to power train oil temperature sensor
16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Failure code [DGT1KX] Power train oil temperature sensor: Input signal
is out of normal range
1
Action code
E01
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code Symptom of Power train oil temperature sensor: Input signal out of range
failure
DGT1KX
Power train temperature sensor signal is out of normal range.
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.
Causes
(Short circuit)
Possible
causes and the
standard values
when normal
harness
2 (Disconnection in wiring
or defective contact in
connector)
Defective harness
ground circuit)

still OFF.
453 (male)
Resistance
Between (1) (2)
3.5 kz 90 kz (10 100C)
Min. 1 Mz
still OFF.
ResisMax. 1 z
453 (female) (1)
tance
ResisMax. 1 z
453 (female) (2)
tance
453 (female) (2)
Resistance
Max. 1 z
Hot short of wiring
still OFF.
4 harness
Resis(contact with 24 V circuit)
Min. 1 Mz
S04 (female) (12) 453 (female) (1)
tance
Machine monitor can be suspected to defective if no problem is found
Defective machine
5
in causes 1 4 (since this is an internal defect, it cannot be diagmonitor
nosed).
Circuit diagram related to power train oil temperature sensor
D475A, D475ASD-5E0
17
SEN01828-03
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
Possible
causes and the
standard values
when normal
18
Failure code Symptom of Left bank exhaust temperature sensor system (Front): Disconnection
failure
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.
Causes
Abnormal rise of left bank
1 exhaust temperature
Check the engine, then repair it if it has any abnormality.
When the left bank exhaust temperature senDefective left bank
Exhaust temperature
sor (Front) is replaced, the condition does not
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.
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.
500C
Voltage
started
2.6 3.5 V
(with no
load)
ResisMax. 1 z
EXA2 (female) (A)
tance
Wiring harness between V2A (female) (7) and
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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible
causes and the
standard values
when normal
Defective VHMS
controller

troubleshooting.
Voltage 20 30 V
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
19
SEN01828-03
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
Possible
causes and the
standard values
when normal
20
Failure code Symptom of Left bank exhaust temperature sensor system (Rear): Disconnection
failure
dGT5KA
The signal voltage of the left bank exhaust temperature sensor is below 0.5 V.
None in particular.
Causes
Abnormal rise of left bank
When the left bank exhaust temperature senDefective left bank
Exhaust temperature
sor (Rear) is replaced, the condition does not
sensor is normal
become normal.
sensor
sor (Rear) is replaced, the condition becomes
sensor is defective
normal.
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.
500C
Voltage
started
2.6 3.5 V
(with no
load)
ResisMax. 1 z
EXA4 (female) (A)
tance
Max. 1 z
tance
4
ResisWiring harness between V2A (female) (13)
Max. 1 z
defective contact)
tance
Wiring harness between EXT4 (male) (1) and
ResisMax. 1 z
EXTLR (female) (1)
tance
ResisMax. 1 z
EXTLR (female) (2)
tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible
causes and the
standard values
when normal
Defective VHMS
controller

troubleshooting.
Voltage 20 30 V
troubleshooting.
V2A
Exhaust temperature
Voltage
Before engine is
20C
Approx. 0.9 1.2 V
Between
started
(6) and
(13)
500C
Approx. 2.6 3.5 V
(with no load)
Circuit diagram related to left bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
21
SEN01828-03
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
DGT5KB
The signal voltage of the left bank exhaust temperature sensor is above 4.9 V.
None in particular.
Causes
Defective left bank

sensor
Defective left bank

exhaust temperature
2
sensor
amplifier
Possible
causes and the
standard values
when normal

3

source in wiring harness
4
22

sor is replaced, the condition does not
sensor is normal
become normal.
sor is replaced, the condition becomes norsensor is defective
mal.
troubleshooting.
Between (A) and (C)
Voltage 20 30 V
Before
Approx.
engine is
20C
Voltage
0.9 1.2 V
EXA2
started
V1, V2A Between
After
(B) and
line
engine
is
(C)
Approx.
500C
Voltage
started
2.6 3.5 V
(with no
load)
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
ResisMin. 1 Mz
(male) (2) and EXTLF (female) (2) and chastance
sis ground
ResisMin. 1 Mz
(2) and EXA2 (female) (B), (C)
tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible
causes and the
standard values
when normal

troubleshooting.
Voltage 20 30 V
troubleshooting.
Defective VHMS control5
ler
V2A
Exhaust temperature
Voltage
Before engine is
20C
Approx. 0.9 1.2 V
Between
started
(7) and
(13)
500C
Approx. 2.6 3.5 V
(with no load)
Circuit diagram related to left bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
23
SEN01828-03
40 Troubleshooting
Failure code [dGT5KB] (or LED of VHMS controller indicates "n3" o

"21") Left bank exhaust temperature sensor system (Rear): Short circuit1
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
dGT5KB
The signal voltage of the left bank exhaust temperature sensor is above 4.9 V.
None in particular.
Causes
Defective left bank

sensor
Defective left bank

exhaust temperature
2
sensor
amplifier
Possible
causes and the
standard values
when normal

3

4
24

sor is replaced, the condition does not
sensor is normal
become normal.
sor is replaced, the condition becomes norsensor is defective
mal.
troubleshooting.
Between (A) and (C)
Voltage 20 30 V
Before
Approx.
engine is
20C
Voltage
0.9 1.2 V
EXA4
started
V1, V2A Between
After
(B) and
line
engine
is
(C)
Approx.
500C
Voltage
started
2.6 3.5 V
(with no
load)
ResisMin. 1 Mz
tance
tance
sis ground
Resis(male) (1) and EXTLR (female) (1) and chasMin. 1 Mz
tance
sis ground
Resis(male) (2) and EXTLR (female) (2) and chasMin. 1 Mz
tance
sis ground
ResisMin. 1 Mz
tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible
causes and the
standard values
when normal

troubleshooting.
Voltage 20 30 V
troubleshooting.
Defective VHMS control5
ler
V2A
Exhaust temperature
Voltage
Before engine is
20C
Approx. 0.9 1.2 V
Between
started
(6) and
(13)
500C
Approx. 2.6 3.5 V
(with no load)
Circuit diagram related to left bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
25
SEN01828-03
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
Possible
causes and the
standard values
when normal
26
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.
Causes
Abnormal rise of right
bank exhaust tempera1
ture
When the right bank exhaust temperature
Defective right bank
Exhaust temperature
sensor (Front) is replaced, the condition does
sensor is normal
not become normal.
sensor
Exhaust temperature
sensor (Front) is replaced, the condition
sensor is defective
becomes normal.
troubleshooting.
Between (A) and (C)
Voltage 20 30 V
Before
Approx.
engine is
20C
Voltage
0.9
1.2 V
EXA1
started
Between
sensor amplifier
V1, V2A
After
(B) and
line
engine
is
(C)
Approx.
500C
Voltage
started
2.6 3.5 V
(with no
load)
ResisMax. 1 z
EXA1 (female) (A)
tance
Max. 1 z
tance
4
Max. 1 z
defective contact)
tance
ResisMax. 1 z
EXTRF (female) (1)
tance
ResisMax. 1 z
EXTRF (female) (2)
tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible
causes and the
standard values
when normal
Defective VHMS
controller

troubleshooting.
Voltage 20 30 V
troubleshooting.
V2A
Exhaust temperature
Voltage
Before engine is
20C
Approx. 0.9 1.2 V
Between
started
(5) and
(13)
500C
Approx. 2.6 3.5 V
(with no load)
Circuit diagram related to right bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
27
SEN01828-03
40 Troubleshooting
Failure code [dGT6KA] (or LED of VHMS controller indicates "n3" o

"26") Right bank exhaust temperature sensor system (Rear):
Disconnection
Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
28
Failure code Symptom of Right bank exhaust temperature sensor system (Rear): Disconnection
failure
dGT6KA
The signal voltage of the right bank exhaust temperature sensor is below 0.5 V.
None in particular.
Causes
Abnormal rise of right
bank exhaust tempera1
ture
Exhaust temperature
sensor (Rear) is replaced, the condition does
sensor is normal
not become normal.
sensor
Exhaust temperature
sensor (Rear) is replaced, the condition
sensor is defective
becomes normal.
troubleshooting.
Between (A) and (C)
Voltage 20 30 V
Before
Approx.
engine is
20C
Voltage
0.9
1.2 V
EXA3
started
Between
sensor amplifier
V1, V2A
After
(B) and
line
engine
is
(C)
Approx.
500C
Voltage
started
2.6 3.5 V
(with no
load)
ResisMax. 1 z
EXA3 (female) (A)
tance
Max. 1 z
tance
harness (Disconnection and EXA3 (female) (B)
4
Max. 1 z
defective contact)
tance
ResisMax. 1 z
EXTRR (female) (1)
tance
ResisMax. 1 z
EXTRR (female) (2)
tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible
causes and the
standard values
when normal
Defective VHMS
controller

troubleshooting.
Voltage 20 30 V
troubleshooting.
V2A
Exhaust temperature
Voltage
Before engine is
20C
Approx. 0.9 1.2 V
Between
started
(16) and
(13)
500C
Approx. 2.6 3.5 V
(with no load)
Circuit diagram related to right bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
29
SEN01828-03
40 Troubleshooting
Failure code [DGT6KB] (or LED of VHMS controller indicates "n3" o

"23") Right bank exhaust temperature sensor system (Front): 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 (Front): Short circuit
failure
DGT6KB
The signal voltage of the right bank exhaust temperature sensor is above 4.9 V.
None in particular.
Causes
Possible
causes and the
standard values
when normal
30

Exhaust temperature
sensor (Front) is replaced, the condition does
sensor is normal
not become normal.
sensor
Exhaust temperature
sensor (Front) is replaced, the condition
sensor is defective
becomes normal.
troubleshooting.
Between (A) and (C)
Voltage 20 30 V
Before
Approx.
engine is
20C
Voltage
0.9 1.2 V
started
EXA1
sensor amplifier
V1, V2A Between
After
(B) and
line
engine is
(C)
Approx.
started
500C
Voltage
2.6 3.5 V
(with no
load)
ResisMin. 1 Mz
tance
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
Resis(male) (2) and EXTRF (female) (2) and chasMin. 1 Mz
tance
sis ground
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
tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible
causes and the
standard values
when normal
Defective VHMS
controller

troubleshooting.
Between V1 (2) and chassis ground
Voltage 20 30 V
troubleshooting.
V2A
Exhaust temperature
Voltage
Before engine is
20C
Approx. 0.9 1.2 V
Between
started
(5) and
(13)
500C
Approx. 2.6 3.5 V
(with no load)
Circuit diagram related to right bank exhaust temperature sensor (Front)
D475A, D475ASD-5E0
31
SEN01828-03
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
dGT6KB
The signal voltage of the right bank exhaust temperature sensor is above 4.9 V.
None in particular.
Causes
Possible
causes and the
standard values
when normal
32

Exhaust temperature
sensor (Rear) is replaced, the condition does
sensor is normal
not become normal.
sensor
Exhaust temperature
sensor (Rear) is replaced, the condition
sensor is defective
becomes normal.
troubleshooting.
Between (A) and (C)
Voltage 20 30 V
Before
Approx.
engine is
20C
Voltage
0.9 1.2 V
started
EXA3
sensor amplifier
V1, V2A Between
After
(B) and
line
engine is
(C)
Approx.
started
500C
Voltage
2.6 3.5 V
(with no
load)
ResisMin. 1 Mz
tance
Resis(female) (16) and EXA3 (female) (B) and
Min. 1 Mz
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
Resis(male) (2) and EXTRR (female) (2) and chasMin. 1 Mz
tance
sis ground
Between
wiring harness between V1 (female)
Resiscircuit)
Min. 1 Mz
tance
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Causes
Possible
causes and the
standard values
when normal
Defective VHMS
controller

troubleshooting.
Between V1 (2) and chassis ground
Voltage 20 30 V
troubleshooting.
V2A
Exhaust temperature
Voltage
Before engine is
20C
Approx. 0.9 1.2 V
Between
started
(16) and
(13)
500C
Approx. 2.6 3.5 V
(with no load)
Circuit diagram related to right bank exhaust temperature sensor (Rear)
D475A, D475ASD-5E0
33
SEN01828-03
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
DH22KA
Signal voltage of work equipment pump oil pressure sensor (F) circuit is below 0.2 V.
Recognizes hydraulic pump (F) oil pressure to be 0.
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))
Causes
Defective 5 V power
1
source system
2
sensor (F) (Internal trouble)
Possible
causes and the
standard values
when normal
3

4
5
controller

See if error code [DAQ7KK] is displayed. If it is displayed, carry out
troubleshooting for it first.
HP1
Voltage
Between (C) (A)
0.5 6.0 V
ResisMax. 1 z
HP1 (female) (B)
tance
ResisMax. 1 z
HP1 (female) (C)
tance
ResisMax. 1 z
HP1 (female) (A)
tance
Resis(female) (9) HP1 (female) (C) with chassis
Min. 1 Mz
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).
Circuit diagram related to work equipment pump oil pressure sensor (F)
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
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
DH22KB
Signal voltage of work equipment pump oil pressure sensor (F) circuit is above 4.8 V
Recognizes hydraulic pump (F) oil pressure to be 0.
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))
Causes
Defective 5 V power
1
source system
Possible
causes and the
standard values
when normal

Defective work equipout troubleshooting.
ment pump oil pressure
2
sensor (F) (Internal trouHP1
Voltage
ble)
Between (C) (A)
0.5 6.0 V
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
35
SEN01828-03
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
DH23KA
Signal voltage of work equipment pump oil pressure sensor (R) circuit is below 0.2 V.
Recognizes hydraulic pump (R) oil pressure to be 0.
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))
Causes
Defective 5 V power
1
source system
2
sensor (R) (Internal trouble)
Possible
causes and the
standard values
when normal
3

4
5
controller

HP2
Voltage
Between (C) (A)
0.5 6.0 V
ResisMax. 1 z
HP2 (female) (B)
tance
ResisMax. 1 z
HP2 (female) (C)
tance
ResisMax. 1 z
HP2 (female) (A)
tance
Resis(female) (3) HP2 (female) (C) with chassis
Min. 1 Mz
tance
ground
be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (R)
36
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
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
DH23KB
Signal voltage of work equipment pump oil pressure sensor (R) circuit is above 4.8 V
Recognizes hydraulic pump (R) oil pressure to be 0.
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))
Causes
Defective 5 V power
1
source system
Possible
causes and the
standard values
when normal

Defective work equipout troubleshooting.
ment pump oil pressure
2
sensor (R) (Internal trouHP2
Voltage
ble)
Between (C) (A)
0.5 6.0 V
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
4
controller
be diagnosed).
Circuit diagram related to work equipment pump oil pressure sensor (R)
D475A, D475ASD-5E0
37
SEN01828-03
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
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.
are downloaded to a personal computer, however, the error code can be checked.)
Causes
Possible
causes and the
standard values
when normal

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
harness (Disconnection Wiring harness between V1 (female) (4) and
Resis2
Max. 1 z
ENBP (female) (B)
tance
defective contact)
Wiring harness between 2A (female) (18) and
ResisMax. 1 z
ENBP (female) (C)
tance
Defective VHMS control- Between V1 (female) (4) and V2A (female)
3
Voltage 4.5 5.5 V
ler
(12)
Between V2A (female) (18) and V2A (female)
Voltage 0.3 0.7 V
(12)
Circuit diagram related to blow-by pressure sensor
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
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
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.
are downloaded to a personal computer, however, the error code can be checked.)
Causes
Possible
causes and the
standard values
when normal

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
Between
circuit)
Voltage
Max. 1 V
V2 (female) (18) and ENBP (female) (C)
Defective VHMS control- Between V1 (female) (4) and V2A (female)
3
Voltage 4.5 5.5 V
ler
(12)
Between V2A (female) (18) and V2A (female)
Voltage 0.3 0.7 V
(12)
D475A, D475ASD-5E0
39
SEN01828-03
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
DHT3KX
Transmission oil pressure signals cannot be obtained.
None in particular.
Causes
Possible
causes and the
standard values
when normal

harness (Disconnection Wiring harness between V1 (female) (2) and
Resis1
Max. 1 z
TMMD (female) (B)
tance
defective contact)
ResisMax. 1 z
and TMMD (female) (C)
tance
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)
Resis(female) (15) and TMMD (female) (C) and
Min. 1 Mz
tance
chassis ground
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
Defective VHMS
4
controller
V1 and V2A
Voltage
Below 20 30 V
Circuit diagram related to transmission oil pressure sensor
40
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
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
DK01KA
The signal voltage of the left yoke angle sensor circuit is lower than the specified value.
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)
Causes
Defective sensor 5-V
1
power supply system
Defective left yoke angle
sensor
2
short circuit)
Possible
causes and the
standard values
when normal
3 in wiring harness or
defective contact in connector)
4
5
controller

If error code [DAQ7KK] is displayed, carry out troubleshooting for it
first.
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
ResisMax. 1 z
and CSL (female) (A)
tance
ResisMax. 1 z
and CSL (female) (B)
tance
Resis(female) (7) and CSL (female) (B) and chassis
Min. 1 Mz
tance
ground
be diagnosed).
Circuit diagram related to left yoke angle sensor
D475A, D475ASD-5E0
41
SEN01828-03
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
DK01KB
The signal voltage of the left yoke angle sensor circuit is higher than the specified value.
The input state (voltage) from the left yoke angle sensor can be checked in the monitoring mode.
(Code 90002: Left yoke angle sensor voltage)
Causes
1
power supply system
Possible
causes and the
standard values
when normal

first.
Defective left yoke angle
CSL (male)
Resistance
sensor
2
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
3
Between
(Contact with 24-V cir(female)
(7)
and CSL (female) (B) and chassis Voltage
Max. 1 V
cuit)
ground
4
controller
be diagnosed).
Circuit diagram related to left yoke angle sensor
42
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
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
DK03KA
The signal voltage of the right yoke angle sensor circuit is lower than the specified value.
The input state (voltage) from the right yoke angle sensor can be checked in the monitoring mode.
(Code 90003: Right yoke angle sensor voltage)
Causes
1
power supply system
Defective right yoke
angle sensor
2
short circuit)
Possible
causes and the
standard values
when normal
3 in wiring harness or
defective contact in connector)
4
5
controller

first.
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
ResisMax. 1 z
and CSR (female) (A)
tance
ResisMax. 1 z
and CSR (female) (B)
tance
Resis(female) (13) and CSR (female) (B) and chasMin. 1 Mz
tance
sis ground
be diagnosed).
Circuit diagram related to right yoke angle sensor
D475A, D475ASD-5E0
43
SEN01828-03
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
DK03KB
The signal voltage of the right yoke angle sensor circuit is higher than the specified value.
The input state (voltage) from the right yoke angle sensor can be checked in the monitoring mode.
(Code 90003: Right yoke angle sensor voltage)
Causes
1
power supply system
Possible
causes and the
standard values
when normal

first.
Defective right yoke
CSR (male)
Resistance
angle sensor
2
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
3
Between
(Contact with 24-V cir(female)
(13)
and CSR (female) (B) and chas- Voltage
Max. 1 V
cuit)
sis ground
4
controller
be diagnosed).
Circuit diagram related to right yoke angle sensor
44
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
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
DK10KA
Signal voltage of fuel dial circuit is lower than the specified value.
Continues to control with decelerator pedal potentiometer signal.
Operation of engine and transmission is limited.

Input state (voltage) from fuel dial can be checked in monitoring mode.
(Code 03000: Fuel dial voltage)
Causes
Defective sensor 5V
1
power supply circuit
Defective fuel dial

2 (internal disconnection
and short circuit)
Possible
causes and the
standard values
when normal
harness
Defective harness
grounding
4
Defective steering and


Check if failure code [DAQ7KK] is displayed. If it is displayed, carry
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
still OFF.
ResisMax. 1 z
DIAL (female) (1)
tance
ResisMax. 1 z
DIAL (female) (2)
tance
ResisMax. 1 z
DIAL (female) (3)
tance
still OFF.
ResisMin. 1 Mz
STCN1 (female) (22) DIAL (female) (1)
tance
ResisMin. 1 Mz
tance
ON.
Voltage
STCN1
Between (22) (21)
4.6 5.4 V
Between (8) (21)
0.5 4.5 V
Circuit diagram related to fuel dial
D475A, D475ASD-5E0
45
SEN01828-03
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
DK10KB
Signal voltage of fuel dial circuit is higher than the specified value.
Continues to control with decelerator pedal potentiometer signal.
Operation of engine and transmission is limited.

Input state (voltage) from fuel dial can be checked in monitoring mode.
(Code 03000: Fuel dial voltage)
Causes
Defective sensor 5 V
1
power supply circuit
Defective fuel dial

2 (internal disconnection
and short circuit)
Possible
causes and the
standard values
when normal
harness

Check if failure code [DAQ7KK] is displayed. If it is displayed, carry
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
still OFF.
DIAL (female) (3)
Resistance
Max. 1 z
ON.
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
Voltage
Max. 1V
ON.
Defective steering and
STCN1
Voltage
5
Between (22) (21)
4.6 5.4 V
Between (8) (21)
0.5 4.5 V
Circuit diagram related to fuel dial
46
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01828-03
47
SEN01828-03
40 Troubleshooting
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
DK30KA
Signal voltage of steering potentiometer (1) system (L) is lower than the specified value.
Continues controlling with signal of steering potentiometer (2) system (R).

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
Possible
causes and the
standard values
when normal
48

See if error code [DB35KK] is displayed. If it is displayed, carry out
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector TL2.
3. Turn starting switch to ON position.
4. Operate PCCS lever (steering) and perform troubleshooting.
Defective PCCS lever
a If power supply voltage is normal and sensor output voltage is
steering potentiometer 2
abnormal (0.5 V or lower), internal open circuit and ground fault
2
(internal open circuit) or
cannot be identified. In this case, go to cause 4.
ground fault
If check result of cause 4 is normal, PCCS lever steering potentiometer 2 is defective.
Sensor
0.96 to
Between TL2 (female) (6) and (8)
Voltage
output
4.04 V
Resis3
Max. 1 z
TL2 (female) (5)
tance
ResisMax. 1 z
TL2 (female) (7)
tance
Resisground in wiring harness STCN1 (female) (22) TL2 (female) (5) with
Min. 1 Mz
4
tance
chassis ground
circuit)
ResisSTCN1 (female) (2) TL2 (female) (7) with
Min. 1 Mz
tance
chassis ground
Defective steering
5
STCN1
Voltage
controller
Between (2) (21)
0.5 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Circuit diagram related to steering potentiometer
D475A, D475ASD-5E0
49
SEN01828-03
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
DK30KB
Signal voltage of steering potentiometer (1) system (L) is higher than specified value.
Continues controlling with signal of steering potentiometer (2) system (R).

Input (Voltage) from steering potentiometer (1) (L) can be checked in monitoring mode.
Causes
1
power source system
Possible
causes and the
standard values
when normal
50

2
ground fault
Sensor
0.96 to
Voltage
output
4.04 V
STCN1 (female) (22) TL2 (female) (5) with
Voltage
Max. 1 V
chassis ground
Voltage
Max. 1 V
chassis ground
Defective steering
4
controller
STCN1
Voltage
Between (2) (21)
0.5 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
D475A, D475ASD-5E0
51
SEN01828-03
40 Troubleshooting
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
Possible
causes and the
standard values
when normal
Failure code Symptom of Steering potentiometer (1): Input signal is out of normal range
failure
DK30KX
Either of failure codes [DK30KA] and [DK30KB] of steering potentiometer systems (1) and (2) and
failure codes [DK31KA] and [DK31KB] are displayed simultaneously.
Input (Voltage) from steering potentiometers can be checked in monitoring mode.
Method of reproducing failure code: Turn starting switch ON and operate PCCS lever
(for steering).
Causes
Carry out troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Failure code [DK30KZ] Steering potentiometer (1): Disconnection or

short circuit
Action code
CALL E04
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
52
Failure code Symptom of Steering potentiometer (1): Disconnection or short circuit

failure
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.
Method of reproducing failure code: Turn starting switch ON and operate PCCS lever
(for steering).
Causes
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
Failure code [DK30L8] Steering potentiometer (1): See table

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 Steering potentiometer (1): See table

failure
DK30L8
Total signal voltage of each of steering potentiometer (1) system (ST1) and (2) system (ST2) is out
of the specified range.
Continues controlling with signal of normal one of steering potentiometer (1) system (ST1) and (2)
(ST2).

Causes
D475A, D475ASD-5E0
53
SEN01828-03
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
DK31KA
Signal voltage of steering potentiometer (2) system (R) is lower than the specified value.
Continues controlling with signal of steering potentiometer (1) system (L).

Input (Voltage) from steering potentiometer (2) (R) can be checked in monitoring mode.
Causes
Defective sensor 5V
1
power source system
Possible
causes and the
standard values
when normal
54

2
ground fault
Sensor
0.96 to
Voltage
output
4.04 V
Resis3
Max. 1 z
TL2 (female) (5)
tance
ResisMax. 1 z
TL2 (female) (6)
tance
Resisground in wiring harness STCN1 (female) (22) TL2 (female) (5) with
Min. 1 Mz
4
tance
chassis ground
circuit)
ResisSTCN1 (female) (19) TL2 (female) (6) with
Min. 1 Mz
tance
chassis ground
Defective steering
5
STCN1
Voltage
controller
Between (19) (21)
0.5 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
D475A, D475ASD-5E0
55
SEN01828-03
40 Troubleshooting
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
DK31KB
Signal voltage of steering potentiometer (2) system (R) is higher than the specified value.
Continues controlling with signal of steering potentiometer (1) system (L).

Input (Voltage) from steering potentiometer (2) (R) can be checked in monitoring mode.
Causes
1
source system
Possible
causes and the
standard values
when normal
56

2
ground fault
Sensor
0.96 to
Voltage
output
4.04 V
Hot short in wiring harSTCN1 (female) (22) TL2 (female) (5) with
Voltage
Max. 1 V
3 ness (Contact with 24 V
chassis ground
circuit)
Voltage
Max. 1 V
chassis ground
troller
STCN1
Voltage
Between (19) (21)
0.5 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01828-03
D475A, D475ASD-5E0
57
SEN01828-03

2011 KOMATSU
All Rights Reserved
58
SEN01829-02
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
40 Troubleshooting
Troubleshooting by failure code

(Display of code), Part 7
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
Failure code [DKH1KX] Pitch angle sensor: Out of input signal range ......................................................... 21
D475A, D475ASD-5E0
SEN01829-02
40 Troubleshooting
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
SEN01829-02
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
DK40KA
Signal voltage of brake potentiometer circuit is lower than the specified value.
Does not control with signal of brake potentiometer (Brake can be operated with pedal).
Brake control performance of brake pedal lowers.
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
1
power source system
Possible
causes and the
standard values
when normal

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)
harness (Disconnection in Wiring harness between STCN1 (female)
ResisMax. 1 z
wiring or defective contact (22) BRK (female) (C)
tance
in connector)
ResisMax. 1 z
BRK (female) (B)
tance
Resisground in wiring harness STCN1 (female) (22) BRK (female) (C) with
Min. 1 Mz
tance
cuit)
ResisSTCN1 (female) (3) BRK (female) (B) with
Min. 1 Mz
tance
chassis ground
Defective steering controlVoltage
STCN1
ler
Between (3) (21)
1.5 4.5 V
Circuit diagram related to brake potentiometer
D475A, D475ASD-5E0
SEN01829-02
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
DK40KB
Signal voltage of brake potentiometer circuit is higher than specification value.
Does not control brake with brake potentiometer signal (Brake can be controlled with pedal).
Brake cannot be controlled well with brake pedal.
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
Possible
causes and the
standard values
when normal

If failure code [DB35KK] is displayed, carry out troubleshooting for it
first.
Defective brake potentiBRK (male)
Resistance
ometer (Internal disconBetween (A) (C)
4.0 6.0 kz
nection or short circuit)
Between (A) (B)
Between (B) (C)
24V circuit) in wiring harVoltage Max. 1 V
(22) BRK (female) (C)
ness
ResisMax. 1 V
BRK (female) (B)
tance
ResisMax. 1 z
in connector)
(21) BRK (female) (A)
tance
STCN1
Voltage
Between (3) (21)
1.5 4.5 V
Circuit diagram related to brake potentiometer
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
Possible
causes and the
standard values
when normal
Failure code
Symptom of Forward-reverse potentiometer: Input signal is out of normal range
failure
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.
Input (Voltage) from forward-reverse potentiometers 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
D475A, D475ASD-5E0
SEN01829-02
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
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.
reverse travel).
Cause
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DK55L8] Forward-reverse potentiometer: See table

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 Forward-reverse potentiometer: See table
failure
DK55L8
Total signal voltage of each of forward-reverse potentiometer 1 system (FR3) and 2 system (FR4)
is out of the specified range.
Continues controlling with signal of normal one of forward-reverse potentiometer 1 system (FR3)
and 2 (FR4).

reverse travel).
Cause
D475A, D475ASD-5E0
SEN01829-02
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
DK56KA
Signal voltage of forward-reverse potentiometer (1) system (R) is lower than the specified value.
Continues controlling with signal of forward-reverse potentiometer (2) system (F).

Input (Voltage) from forward-reverse potentiometer (1) (R) can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer (1))
reverse travel).
Cause
1
power source system
Defective PCCS lever Forward-reverse potentiome2

ter 1 (internal open circuit)
or ground fault
Possible
causes and the
standard values
when normal
3
in connector)

4
controller

4. Operate PCCS lever (Forward-reverse) and perform troubleshooting.
If check result of cause 4 is normal, PCCS lever Forward-reverse
potentiometer 1 is defective.
Sensor
0.96 to
Voltage
output
4.04 V
ResisMax. 1 z
TL2 (female) (4)
tance
ResisMax. 1 z
TL2 (female) (3)
tance
Min. 1 Mz
tance
chassis ground
ResisMin. 1 Mz
tance
chassis ground
TMC1
Voltage
Between (2) (21)
0.5 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Circuit diagram related to forward-reverse potentiometer
D475A, D475ASD-5E0
SEN01829-02
40 Troubleshooting
Failure code [DK56KB] Forward-Reverse potentiometer (1): 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 (1): Short circuit
failure
DK56KB
Signal voltage of forward-reverse potentiometer (1) system (R) circuit is higher than specified
value.
Continues control with signal of forward-reverse potentiometer (2) system (F).

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

or ground fault
Possible
causes and the
standard values
when normal
3 24V circuit) in wiring harness
4
in connector)
10
controller

If failure code [DAQ5KK] is displayed, carry out troubleshooting for it
first.
Sensor
0.96 to
Voltage
output
4.04 V
Voltage Max. 1 V
TL2 (female) (3)
Voltage Max. 1 V
TL2 (female) (4)
Voltage Max. 1 V
TL2 (female) (1)
ResisMax. 1 z
TL2 (female) (1)
tance
Voltage
TMC1
Between (2) (21)
0.5 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
D475A, D475ASD-5E0
11
SEN01829-02
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
DK57KA
Signal voltage of forward-reverse potentiometer (2) system (F) is lower than the specified value.
Continues controlling with signal of forward-reverse potentiometer (1) system (R).

Input (Voltage) from forward-reverse potentiometer (2) (F) can be checked in monitoring mode.
(Code 50201: Voltage of forward-reverse potentiometer (2))
reverse travel).
Cause
1
power source system

or ground fault
Possible
causes and the
standard values
when normal
3
in connector)

4
12
controller

Sensor
0.96 to
Voltage
output
4.04 V
ResisMax. 1 z
TL2 (female) (4)
tance
ResisMax. 1 z
TL2 (female) (2)
tance
ResisTMC1 (female) (19) TL2(female) (2) with
Min. 1 Mz
tance
chassis ground
Min. 1 Mz
tance
chassis ground
TMC1
Voltage
Between (19) (21)
0.5 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
D475A, D475ASD-5E0
13
SEN01829-02
40 Troubleshooting
Failure code [DK57KB] Forward-Reverse potentiometer (2): 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 (2): Short circuit
failure
DK57KB
Signal voltage of forward-reverse potentiometer (2) system (F) circuit is higher than specified
value.
Continues control with signal of forward-reverse potentiometer (1) system (R).

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

or ground fault
Possible
causes and the
standard values
when normal
4
in connector)
14
controller

If failure code [DAQ5KK] is displayed, carry out troubleshooting for it
first.
Sensor
0.96 to
Voltage
output
4.04 V
Voltage Max. 1 V
TL2 (female) (2)
Voltage Max. 1 V
TL2 (female) (4)
Voltage Max. 1 V
TL2 (female) (1)
ResisMax. 1 z
TL2 (female) (1)
tance
Voltage
TCM1
Between (19) (21)
0.5 4.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
D475A, D475ASD-5E0
15
SEN01829-02
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
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)
Cause
Defective 5 V power
1
source system
Possible
causes and the
standard values
when normal
16

See if failure code [DB37KK] is displayed. If it is displayed, carry out
sensor (Internal trouble)
SSA
Voltage
Between (2) (3)
0.75 4.25 V
ResisMax. 1 z
wiring or defective contact (34) SSA (female) (1)
tance
in connector)
ResisMax. 1 z
SSA (female) (2)
tance
Resisground in wiring harness STCN3 (female) (34) SSA (female) (1) with
Min. 1 Mz
tance
cuit)
ResisSTCN1 (female) (1) SS3 (female) (2) with
Min. 1 Mz
tance
chassis ground
Steering controller can be suspected to be defective if no problem is
Defective steering controlfound in causes 1 4 (since this is an internal defect, it cannot be
ler
diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Circuit diagram related to acceleration sensor
D475A, D475ASD-5E0
17
SEN01829-02
40 Troubleshooting
Failure code [DK60KB] Acceleration sensor: Short circuit

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 Acceleration sensor: Short circuit
failure
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).
Cause
Defective 5V power supply If failure code [DB37KK] is displayed, carry out troubleshooting for it
1
system
first.
2
SSA
Voltage
Between (2) (3)
0.75 4.25 V
Voltage Max. 1 V
SSA (female) (2)
3 24V circuit) in wiring harWiring harness between STCN3 (female)
ness
Voltage Max. 1 V
(34) SSA (female) (1)
Voltage Max. 1 V
4
ResisMax. 1 z
in connector)
tance
ler
diagnosed).
Circuit diagram related to acceleration sensor
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DKH1KA
Signal voltage of pitch angle sensor is lower than the specified value.
Cannot recognize pitch angle.
Gear shift shock is large.
Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
(Code 60100: Voltage of pitch angle sensor)
Cause
Defective 24 V power
1
source system
Possible
causes and the
standard values
when normal
Defective pitch angle sensor (Internal trouble)
3
in connector)

4

PT1
Voltage
Between (B) (A)
0.15 4.85 V
ResisMax. 1 z
(16) PT1 (female) (C)
tance
ResisMax. 1 z
(13) PT1 (female) (B)
tance
ResisSTCN1 (female) (16) PT1 (female) (C) with
Min. 1 Mz
tance
chassis ground
ResisSTCN1 (female) (13) PT1 (female) (B) with
Min. 1 Mz
tance
chassis ground
diagnosed).
Circuit diagram related to pitch angle sensor
D475A, D475ASD-5E0
19
SEN01829-02
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
DKH1KB
Signal voltage of pitch angle sensor is higher than the specified value.
Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
(Code 60100: Voltage of pitch angle sensor)
Cause
Defective 24 V power
1
source system
Possible
causes and the
standard values
when normal
Defective pitch angle sensor (Internal trouble)

4
in connector)
5

PT1
Voltage
Between (B) (A)
0.15 4.85 V
STCN1 (female) (13) PT1 (female) (B) with Voltage Max. 1 V
chassis ground
STCN1 (female) (21) PT1 (female) (A) with Voltage Max. 1 V
chassis ground
ResisMax. 1 z
(21) PT1 (female) (A)
tance
diagnosed).
Circuit diagram related to pitch angle sensor
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DKH1KX
Either of pitch angle sensor errors [DKH1KA] and [DKH1KB] occurred or steering controller CAN
communication error [DB3RKR] occurred.
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).
Possible
Cause
causes and the
Carry out troubleshooting for disconnection [DKH1KA] and short circuit [DKH1KB] in pitch angle
standard values
sensor
and steering controller CAN communication [DB3RKR].
when normal
D475A, D475ASD-5E0
21
SEN01829-02
40 Troubleshooting
Failure code [DLF1KA] Torque converter output speed sensor:

Disconnection
Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Torque converter output speed sensor: Disconnection
failure
DLF1KA
Signals from the torque converter output speed sensor are not input.
Recognizes torque converter output speed is 0 rpm.
The torque converter speed cannot be monitored.
The input state (rpm) from the torque converter output speed sensor can be checked in the monitoring mode. (Code 31200: Torque converter speed)
Method of reproducing failure code: Start the engine + Drive the machine actually.
Cause
Possible
causes and the
standard values
when normal

Defective torque conwithout turning starting switch ON.
verter output speed sensor
TC1 (male)
Resistance
Between
(1)
and
(2)
500
1,000 z
short circuit)
Min. 1 Mz
ResisMax. 1 z
wiring harness or defective and TC1 (female) (1)
tance
ResisMax. 1 z
and TC1 (female) (2)
tance
Between
(20)
and TC1 (female) (1) and chasMin. 1 Mz
cuit)
tance
sis ground
If causes 1 3 are not detected, transmission controller may be
controller
carried out.)
Circuit diagram related to torque converter output speed sensor
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
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.
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
causes and the
standard values Carry out troubleshooting for disconnection [dLT3KA] and transmission CAN communication error
when normal [DAQRKR].
D475A, D475ASD-5E0
23
SEN01829-02
40 Troubleshooting
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
dLT3KA
Signal is not input from transmission output speed sensor.
Assumes that transmission output speed is 0 rpm.

Auto-shift down operation is defective.
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
output speed sensor
1
short circuit)
2
in connector)
Possible
causes and the
standard values
when normal
24

3

controller

TM1 (male)
Resistance
Between (1) (2)
500 1,000 z
Between (1), (2) chassis
Min. 1 Mz
ground
ResisMax. 1 z
TM1 (female) (1)
tance
ResisMax. 1 z
TM1 (female) (2)
tance
ResisTMC2 (female) (30) TM1 (female) (1) with
Min. 1 Mz
tance
chassis ground
ResisMin. 1 Mz
and TM1 (female) (2) and chassis ground
tance
Voltage Max. 1 V
Voltage Max. 1 V
be diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Circuit diagram related to transmission output speed sensor
D475A, D475ASD-5E0
25
SEN01829-02
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
Possible
causes and the
standard values
when normal
Failure code
Symptom of Transmission output speed sensor: Short circuit
failure
DLT3KB
Signal from transmission output speed sensor does not change while machine is traveling.
Assumes transmission output speed to be 0 rpm.

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
Defective installation of
Carry out adjustment according to Testing and adjusting, "Adjusting
1 transmission output speed
transmission speed sensor".
sensor
output speed sensor
TM1 (male)
Resistance
2
Between
(1)
(2)
500
1,000 z
short circuit)
Between (1) ground
Min. 1 Mz
Ground fault in wiring harWiring harness between TMC2 (female) (30)
Resis3 ness (Contact with GND
Min. 1 Mz
TM1 (female) (1)
tance
circuit)
ResisMin. 1 Mz
tance
4
controller
carried out.)
Circuit diagram related to transmission output speed sensor
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
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).
Cause
Possible
causes and the
standard values
when normal

Defective caution buzzer
1
217 (male)
Resistance
Between (1) (2)
200 z
2
Short
circuit of wiring harness between 217
(female) (1) S03 (female) (18) with chassis Voltage Max. 1 V
ground
Wiring harness between 217 (female) (1) and
Resiscircuit)
Min. 1 Mz
S03 (female) (18) and chassis ground
tance
S03
Caution buzzer
Voltage
4 Defective monitor panel
When turned OFF
20 30 V
Between (18)
When turned ON
chassis ground
Max. 3 V
(sounding)
Circuit diagram related to caution buzzer
D475A, D475ASD-5E0
27
SEN01829-02
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
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.
Cause
Possible
causes and the
standard values
when normal

Defective blade pitch back
1 solenoid
PPB (male)
Resistance
Between (1) and (2)
20 60 z
Resis2
Max. 1 z
wiring harness or defective and PPB (female) (1)
tance
ResisMax. 1 z
and PPB (female) (2)
tance
3
controller
carried out.)
Circuit diagram related to blade pitch back solenoid
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DW55KB
When signal was output to blade pitch back solenoid circuit, abnormal current flowed.
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.
Cause
Possible
causes and the
standard values
when normal

Defective blade pitch back
PPB (male)
Resistance
1 solenoid (Internal short circuit)
Between (1) (2)
20 60 z
Between (1) ground
Min. 1 Mz
Resiscircuit)
Min. 1 Mz
PPB (female) (1)
tance
Resis(female)
(26)
PPB (female) (1) and wiring
harness)
Min. 1 Mz
tance
harness between TMC3 (female) (3) PPB
(female) (2)
4
controller
carried out.)
Circuit diagram related to blade pitch back solenoid
D475A, D475ASD-5E0
29
SEN01829-02
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
DW56KA
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
Possible
causes and the
standard values
when normal

1 dump solenoid
PPD (male)
Resistance
Between (1) and (2)
20 60 z
Resisharness (Disconnection in Wiring harness between TMC3 (female) (16)
2
Max. 1 z
tance
wiring harness or defective and PPD (female) (1)
ResisMax. 1 z
and PPD (female) (2)
tance
3
controller
carried out.)
Circuit diagram related to blade pitch dump solenoid
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DW56KB
When signal was output to blade pitch dump solenoid circuit, abnormal current flowed.
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
Method of reproducing failure code: Turn starting switch ON + Perform blade pitch dump operation.
Cause
Possible
causes and the
standard values
when normal

PPD (male)
Resistance
dump solenoid (Internal
short circuit)
Between (1) (2)
20 60 z
Between (1) ground
Min. 1 Mz
Resiscircuit)
Min. 1 Mz
PPD (female) (1)
tance
Short circuit in wiring harness (with another wiring Between wiring harness between TMC3
Resis(female) (16) PPD (female) (1) and wiring
harness)
Min. 1 Mz
tance
harness between TMC3 (female) (3) PPD
(female) (2)
controller
carried out.)
D475A, D475ASD-5E0
31
SEN01829-02
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
DW56KY
Some current keeps flowing 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
Cause
Possible
causes and the
standard values
when normal

1 dump solenoid (Internal
short circuit)
3
controller

PPD (male)
Resistance
Between (1) (2)
20 60 z
Voltage Max. 1 V
PPD (female) (1).
carried out.)
32
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DW57KA
When the signal is output to the left tilt limit solenoid circuit, no current flows.
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.
Method of reproducing failure code: Turn the starting switch ON. + Execute the left tilt mode.
Cause
Possible
causes and the
standard values
when normal

Defective left tilt limit
1 solenoid
TLL (male)
Resistance
Between (1) and (2)
20 60 z
Resis2
Max. 1 z
wiring harness or defective and TLL (female) (1)
tance
ResisMax. 1 z
and TLL (female) (2)
tance
3
controller
carried out.)
Circuit diagram related to left tilt limit solenoid
D475A, D475ASD-5E0
33
SEN01829-02
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
DW57KB
When signal was output to left tilt limit solenoid circuit, abnormal current flowed.
Stops outputting signal to left tilt limit solenoid circuit.
Left tilt limit function does not work.
Output state (ON/OFF) to left tilt limit solenoid can be checked in monitoring mode
Method of reproducing failure code: Turn starting switch ON + Perform left tilt limit mode.
Cause
Possible
causes and the
standard values
when normal

Defective left tilt limit soleTLL (male)
Resistance
noid (Internal short circuit)
Between (1) (2)
20 60 z
Between (1) ground
Min. 1 Mz
Wiring
Resiscircuit)
Min. 1 Mz
TLL (female) (1)
tance
ness (with another wiring
Resis(female)
(27)
TLL (female) (1) and wiring
harness)
Min. 1 Mz
tance
harness between TMC3 (female) (3) TLL
(female) (2)
controller
carried out.)
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DW57KY
Some current keeps flowing to left tilt limit solenoid circuit.
Blinks waring lamp and sounds alarm buzzer.
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
Method of reproducing failure code: Turn starting switch ON + Perform left tilt mode.
Cause
Possible
causes and the
standard values
when normal

Defective left tilt limit sole1
TLL (male)
Resistance
Between (1) (2)
20 60 z
2 24V circuit) in wiring harWiring harness between TMC3 (female) (27)
ness
Voltage Max. 1 V
TLL (female) (1).
3
controller
carried out.)
D475A, D475ASD-5E0
35
SEN01829-02
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
DW58KA
When the signal is output to the right tilt limit solenoid circuit, no current flows.
Stops outputting the signal to the right tilt limit solenoid circuit.
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.
Method of reproducing failure code: Turn the starting switch ON. + Execute the right tilt mode.
Cause
Possible
causes and the
standard values
when normal

Defective right tilt limit
1 solenoid
TLR (male)
Resistance
Between (1) and (2)
20 60 z
Resis2
Max. 1 z
wiring harness or defective and TLR (female) (1)
tance
ResisMax. 1 z
and TLR (female) (2)
tance
3
controller
carried out.)
Circuit diagram related to right tilt limit solenoid
36
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DW58KB
When signal was output to right tilt limit solenoid circuit, abnormal current flowed.
Stops outputting signal to right tilt limit solenoid circuit.
The right tilt limit function does not operate.
Output state (ON/OFF) to right tilt limit solenoid can be checked in monitoring mode
Method of reproducing failure code: Turn starting switch ON + Perform right tilt limit mode.
Cause
Possible
causes and the
standard values
when normal

TLR (male)
Resistance
Between (1) (2)
20 60 z
Between (1) ground
Min. 1 Mz
Resiscircuit)
Min. 1 Mz
TLR (female) (1)
tance
Resis(female)
(37)
TLR (female) (1) and wiring
harness)
Min. 1 Mz
tance
harness between TMC3 (female) (3) TLR
(female) (2)
4
controller
carried out.)
D475A, D475ASD-5E0
37
SEN01829-02
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
DW58KY
Some current keeps flowing to right tilt limit solenoid circuit.
Blinks waring lamp and sounds alarm buzzer.
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
Method of reproducing failure code: Turn starting switch ON + Perform right tilt mode.
Cause
Possible
causes and the
standard values
when normal

1 solenoid (Internal disconnection)
3
controller

TLR (male)
Resistance
Between (1) (2)
20 60 z
Voltage Max. 1 V
TLR (female) (1).
carried out.)
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
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.
Cause
Possible
causes and the
standard values
when normal

Defective dual tilt selector
1 solenoid (Internal disconDUL (male)
Resistance
nection)
Between (1) (2)
10 40 z
Resis2
Max. 1 z
wiring or defective contact DUL (female) (1)
tance
in connector)
ResisMax. 1 z
DUL (female) (2)
tance
3
controller
carried out.)
Circuit diagram related to dual tilt selector solenoid
D475A, D475ASD-5E0
39
SEN01829-02
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
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.
Cause
Possible
causes and the
standard values
when normal

DUL (male)
Resistance
Between (1) (2)
10 40 z
Between (1) ground
Min. 1 Mz
Resiscircuit)
Min. 1 Mz
DUL (female) (1)
tance
Resis(female)
(6)
DUL (female) (1) and wiring
harness)
Min. 1 Mz
tance
harness between TMC3 (female) (13) DUL
(female) (2)
4
controller
carried out.)
40
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
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.
Cause
Possible
causes and the
standard values
when normal

1 solenoid (Internal disconDUL (male)
Resistance
nection)
Between (1) (2)
10 40 z
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
D475A, D475ASD-5E0
41
SEN01829-02
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
DW5AKA
When the signal is output to the blade pitch selector solenoid circuit, no current flows.
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.
Cause
Possible
causes and the
standard values
when normal

1 selector solenoid
PTH (male)
Resistance
Between (1) and (2)
10 40 z
Resis2
Max. 1 z
wiring harness or defective and PTH (female) (1)
tance
ResisMax. 1 z
and PTH (female) (2)
tance
3
controller
carried out.)
Circuit diagram related to blade pitch selector solenoid
42
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DW5AKB
When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.
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).
Cause
Possible
causes and the
standard values
when normal

PTH (male)
Resistance
selector solenoid (Internal
short circuit)
Between (1) (2)
10 40 z
Between (1) ground
Min. 1 Mz
Resiscircuit)
Min. 1 Mz
PTH (female) (1)
tance
Resis(female)
(28)
PTH (female) (1) and wiring
harness)
Min. 1 Mz
tance
harness between TMC3 (female) (13) PTH
(female) (2)
controller
carried out.)
D475A, D475ASD-5E0
43
SEN01829-02
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
DW5AKY
Some current keeps flowing to blade pitch selector solenoid circuit.
Blade pitch selector solenoid keeps operating.
Cause
Possible
causes and the
standard values
when normal

1 selector solenoid (Internal
PTH (male)
Resistance
short circuit)
Between (1) (2)
10 40 z
ness
Voltage Max. 1 V
PTH (female) (1).
3
controller
carried out.)
44
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
Failure code [DW5DKA] Blade pitch selector solenoid (superdozer

specification): Disconnection
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): Disconnecfailure
tion (Transmission controller system)
DW5DKA
When the signal is output to the blade pitch selector solenoid circuit, no current flows.
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.
Cause
Possible
causes and the
standard values
when normal

1 dump solenoid
PTH (male)
Resistance
Between (1) and (2)
10 40 z
Resisharness (Disconnection in Wiring harness between TMC3 (female) (28)
2
Max. 1 z
tance
wiring harness or defective and PTH (female) (1)
ResisMax. 1 z
and PTH (female) (2)
tance
3
controller
carried out.)
Circuit diagram related to blade pitch dump solenoid (Superdozer)
D475A, D475ASD-5E0
45
SEN01829-02
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.
Blade pitch back unit does not operate (When pitch back operation is performed, tilt unit operates).
Cause
Possible
causes and the
standard values
when normal

PTH (male)
Resistance
dump solenoid (Internal
short circuit)
Between (1) (2)
10 40 z
Between (1) ground
Min. 1 Mz
Wiring
Resiscircuit)
Min. 1 Mz
PTH (female) (1)
tance
Resis(female)
(28)
PTH (female) (1) and wiring
harness)
Min. 1 Mz
tance
harness between TMC3 (female) (13) PTH
(female) (2)
controller
carried out.)
Circuit diagram related to blade pitch dump solenoid (Superdozer specification)
46
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DW5DKY
Some current keeps flowing 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
Cause
Possible
causes and the
standard values
when normal

1 dump solenoid (Internal
short circuit)
3
controller

PTH (male)
Resistance
Between (1) (2)
10 40 z
Voltage Max. 1 V
PTH (female) (1).
carried out.)
Circuit diagram related to blade pitch dump solenoid (Superdozer specification)
D475A, D475ASD-5E0
47
SEN01829-02
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
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.
Cause
Possible
causes and the
standard values
when normal

Defective fan reverse
1 solenoid
FAR (male)
Resistance
Between (1) and (2)
34 44 z
Resis2
Max. 1 z
wiring harness or defective (17) and FAR (female) (1)
tance
ResisMax. 1 z
and FAR (female) (2)
tance
Defective steering
3
found in causes 1 2 (Since this is an internal defect, it cannot be
controller
diagnosed).
Circuit diagram related to fan reverse solenoid
48
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
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.
Method of reproducing error code: Turn the starting switch ON. + Reverse the fan rotation direction.
Cause
Defective fan reverse
1 solenoid
Possible
causes and the
standard values
when normal

2

harness
3
(Short circuit between
wiring harnesses)
Defective steering
controller

FAR (male)
Resistance
Between (1) and (2)
34 44 z
Min. 1 Mz
Resis(female) (17) and FAR (female) (1) and chasMin. 1 Mz
tance
sis ground
Resis(female) (17) and FAR (female) (1) and wirMin. 1 Mz
tance
ing harness between STCN3 (female) (13)
and FAR (female) (2)
diagnosed).
D475A, D475ASD-5E0
49
SEN01829-02
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
DW7BKY
Some current keeps flowing to fan reverse solenoid circuit.
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.
Cause
Possible
causes and the
standard values
when normal

Defective fan reverse solewithout turning starting switch ON.
1 noid (Internal disconnecFAR (male)
Resistance
tion)
Between (1) (2)
34 44 z
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.)
50
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DWJ0KA
When the signal is output to the pump merge-divider solenoid circuit, no current flows.
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.
Method of reproducing failure code: Turn the starting switch ON. + Execute the dual tilt mode.
Cause
Possible
causes and the
standard values
when normal

Defective pump
1 merge-divider solenoid
MFD (male)
Resistance
Between (1) and (2)
20 60 z
Resis2
Max. 1 z
wiring harness or defective (27) and MFD (female) (1)
tance
ResisMax. 1 z
and MFD (female) (2)
tance
ler
diagnosed).
Circuit diagram related to pump merge-divider solenoid
D475A, D475ASD-5E0
51
SEN01829-02
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
DWJ0KB
When signal was output to pump merge-divider solenoid circuit, abnormal current flowed.
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.
Cause
Possible
causes and the
standard values
when normal

Defective pump mergeMFD (male)
Resistance
divider solenoid (Internal
short circuit)
Between (1) (2)
20 60 z
Between (1) ground
Min. 1 Mz
Resiscircuit)
Min. 1 Mz
(27) MFD (female) (1)
tance
Resis(female)
(27)
MFD (female) (1) and wiring
harness)
Min. 1 Mz
tance
harness between STCN3 (female) (3) MFD
(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.)
52
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DWJ0KY
Current keeps flowing to the pump merge-divider solenoid circuit.
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.
Cause
Possible
causes and the
standard values
when normal

Defective pump
1 merge-divider solenoid
MFD (male)
Resistance
Between (1) and (2)
20 60 z
2
(female) (27) and MFD (female) (1) and
Voltage Max. 1 V
chassis ground
ler
diagnosed).
D475A, D475ASD-5E0
53
SEN01829-02
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
DWN3KA
When signal is output to sudden stop prevention solenoid circuit, any current does not flow.
Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode.
(Code 31628: Sudden stop prevention solenoid drive current)
Cause
Defective sudden stop
1 prevention solenoid (Internal disconnection)
Possible
causes and the
standard values
when normal
2
in connector)

ST8 (male)
Resistance
Between (1) (2)
5 25 z
ResisMax. 1 z
ST8 (female) (1)
tance
ResisMax. 1 z
(13) ST8 (female) (2)
tance
diagnosed).
Circuit diagram related to sudden stop prevention solenoid
54
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DWN3KB
When signal was output to sudden stop prevention solenoid circuit, abnormal current flowed.
Cause
Possible
causes and the
standard values
when normal

ST8 (male)
Resistance
1 prevention solenoid (Internal short circuit)
Between (1) (2)
5 25 z
Min. 1 Mz
2
Short
(female) (7) ST8 (female) (1) with
Min. 1 Mz
cuit)
tance
chassis ground
Short circuit in wiring har3 ness (with another wiring Short circuit in wiring harness between
ResisSTCN3 (female) (7) ST8 (female) (1) with
harness)
Min. 1 Mz
tance
wiring harness between STCN3 (female) (13)
ST8 (female) (2)
ler
diagnosed).
D475A, D475ASD-5E0
55
SEN01829-02
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
DWN3KY
Current keeps flowing to sudden stop prevention solenoid circuit.
Function of emergency sudden stop prevention does not operate.
Cause
1 prevention solenoid (Internal disconnection)
Possible
causes and the
standard values
when normal


ST8 (male)
Resistance
Between (1) (2)
5 25 z
STCN3 (female) (7) ST8 (female) (1) with
Voltage Max. 1 V
chassis ground
diagnosed).
56
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
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)
Cause
Possible
causes and the
standard values
when normal

Defective fan pump solewithout turning starting switch ON.
1 noid (Internal disconnecFA1 (male)
Resistance
tion)
Between (1) (2)
5 15 z
Resis2
Max. 1 z
wiring or defective contact FA1 (female) (1)
tance
in connector)
ResisMax. 1 z
FA1 (female) (2)
tance
3
lem is found in causes 1 2 (Since this is an internal defect, it cancontroller
not be diagnosed).
Circuit diagram related to fan pump solenoid
D475A, D475ASD-5E0
57
SEN01829-02
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
DWN5KB
When signal was output to fan pump solenoid circuit, abnormal current flowed.
Cause
Possible
causes and the
standard values
when normal

Defective fan pump soleFA1 (male)
Resistance
1
Between (1) (2)
15 25 z
Min. 1 Mz
2
Short
(Contact with ground cirResisTMC3 (female) (17) FA1 (female) (1) with
Min. 1 Mz
cuit)
tance
chassis ground
Short circuit in wiring har3 ness (with another wiring Short circuit in wiring harness between TMC3
Resis(female) (17) FA1 (female) (1) with wiring
harness)
Min. 1 Mz
tance
harness between TMC3 (female) (23) FA1
(female) (2)
4
controller
be diagnosed).
58
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
DWN5KY
Current keeps flowing to fan pump solenoid circuit.
Output of the fan pump (LPV90) becomes minimum.
Fan speed does not increase.
Cause
Possible
causes and the
standard values
when normal

Defective fan pump solewithout turning starting switch ON.
1 noid (Internal disconnecFA1 (male)
Resistance
tion)
Between (1) (2)
5 15 z
2
(Contact with 24 V circuit) Short circuit of wiring harness between
TMC3 (female) (17) FA1 (female) (1) with
Voltage Max. 1 V
chassis ground
3
not be diagnosed).
D475A, D475ASD-5E0
59
SEN01829-02
40 Troubleshooting
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection

Action code
E01
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Fan pump solenoid 2: Disconnection
failure
DWNCKA
When the signal is output to the fan pump solenoid circuit, no current flows.
Stops outputting the signal to the fan pump solenoid circuit.
The output state (current) to the fan pump solenoid can be checked in the monitoring mode.
Cause
Possible
causes and the
standard values
when normal

Defective fan pump
1 solenoid 2
FA2 (male)
Resistance
Between (1) and (2)
5 15 z
Resis2
Max. 1 z
wiring harness or defective and FA2 (female) (1)
tance
ResisMax. 1 z
and FA2 (female) (2)
tance
3
not be diagnosed).
60
D475A, D475ASD-5E0
40 Troubleshooting
SEN01829-02
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
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.
The output state (ON/OFF) to the fan pump solenoid can be checked in the monitoring mode.
Cause
Defective fan pump
1 solenoid 2
Possible
causes and the
standard values
when normal

2

harness
3
wiring harnesses)
controller

FA2 (male)
Resistance
Between (1) and (2)
5 15 z
Min. 1 Mz
Resis(female) (7) and FA2 (female) (1) and chasMin. 1 Mz
tance
sis ground
Resis(female) (7) and FA2 (female) (1) and wiring
Min. 1 Mz
tance
harness between TMC3 (female) (23) and
FA2 (female) (2)
be diagnosed).
D475A, D475ASD-5E0
61
SEN01829-02
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
DWNCKY
Current keeps flowing to the fan pump solenoid circuit.
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.
Cause
Possible
causes and the
standard values
when normal

Defective fan pump
1 solenoid 2
FA2 (male)
Resistance
Between (1) and (2)
15 25 z
2
(Contact with 24-V circuit) Between wiring harness between TMC3
(female) (7) and FA2 (female) (1) and chasVoltage Max. 1 V
sis ground
3
not be diagnosed).
62
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01829-02
63
SEN01829-02

2011 KOMATSU
All Rights Reserved
64
SEN01830-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
40 Troubleshooting
Troubleshooting by failure code

(Display of code), Part 8
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
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ................................................................................ 16
D475A, D475ASD-5E0
SEN01830-01
40 Troubleshooting
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
SEN01830-01
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
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.
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)
Cause
Possible
causes and the
standard values
when normal

Defective LS set solenoid
1
LSV (male)
Resistance
Between (1) and (2)
5 15 z
harness (Disconnection in Wiring harness between STCN3 (female) (37)
Resis2
Max. 1 z
wiring harness or defective and LSV (female) (1)
tance
ResisMax. 1 z
and LSV (female) (2)
tance
ler
diagnosed).
Circuit diagram related to LS set solenoid
D475A, D475ASD-5E0
SEN01830-01
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
DXE0KB
When the signal is output to the LS set solenoid circuit, an abnormal current flows.
Cause
Possible
causes and the
standard values
when normal

LSV (male)
Resistance
Between (1) and (2)
5 15 z
Min. 1 Mz
Between
(Contact with ground cirResis(female) (37) and LSV (female) (1) and chasMin. 1 Mz
cuit)
tance
sis ground
harness
Resis(female) (37) and LSV (female) (1) and wiring
Min. 1 Mz
wiring harnesses)
tance
harness between STCN3 (female) (3) and
LSV (female) (2)
Defective steering controlfound in causes 1 3 (Since this is an internal defect, it cannot be
ler
diagnosed).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXE0KY
Current keeps flowing to the LS set solenoid circuit.
Cause
Possible
causes and the
standard values
when normal

1
LSV (male)
Resistance
Between (1) and (2)
5 15 z
2
(female) (37) and LSV (female) (1) and chas- Voltage Max. 1 V
sis ground
ler
diagnosed).
D475A, D475ASD-5E0
SEN01830-01
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
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.
Cause
Possible
causes and the
standard values
when normal

1 lock-up solenoid (Internal
653 (male)
Resistance
short circuit)
Between (1) (2)
5 15 z
Resis2
Max. 1 z
wiring or defective contact 653 (female) (1)
tance
in connector)
ResisMax. 1 z
653 (female) (2)
tance
3
not be diagnosed).
Circuit diagram related to torque converter lock-up solenoid
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
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.
Cause
Possible
causes and the
standard values
when normal

653 (male)
Resistance
1 lock-up solenoid (Internal
short circuit)
Between (1) (2)
30 80 z
Min. 1 Mz
2
(Contact with ground cirResis(female) (38) 653 (female) (1) with chassis
Min. 1 Mz
cuit)
tance
ground
Short circuit in wiring har3 ness (with another wiring Short circuit in wiring harness between TMC3
Resis(female) (38) 653 (female) (1) with wiring
harness)
Min. 1 Mz
tance
harness between TMC3 (female) (23) 653
(female) (2)
4
controller
be diagnosed).
Circuit diagram related to torque converter lock-up solenoid
D475A, D475ASD-5E0
SEN01830-01
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
DXH1KY
Some current keeps flowing to torque converter lockup solenoid circuit.
Stops outputting signal to torque converter lockup solenoid circuit.
Torque converter lockup solenoid keeps operating.
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.
Cause
Possible
causes and the
standard values
when normal

1 lockup solenoid (Internal
653 (male)
Resistance
short circuit)
Between (1) (2)
5 15 z
2 24V circuit) in wiring harWiring
ness
Voltage Max. 1 V
653 (female) (1).
4
controller
carried out.)
Circuit diagram related to torque converter lockup solenoid
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXH4KA
When signal is output to 1st clutch solenoid circuit, any current does not flow.
Stops outputting to transmission 1st clutch solenoid circuit.
Automatic shift-down function does not work.
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.
Cause
Possible
causes and the
standard values
when normal

Defective 1st clutch solewithout turning starting switch ON.
1 noid (Internal disconnecS1T7 (male)
Resistance
tion)
Between (1) (2)
5 15 z
Resis2
Max. 1 z
wiring or defective contact S1T7 (female) (1)
tance
in connector)
ResisMax. 1 z
S1T7 (female) (2)
tance
3
not be diagnosed).
D475A, D475ASD-5E0
SEN01830-01
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
DXH4KB
When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.
Cause
Possible
causes and the
standard values
when normal

Defective 1st clutch soleS1T7 (male)
Resistance
1
Between (1) (2)
5 15 z
Min. 1 Mz
2
(Contact with ground cirResis(female) (15) S1T7 (female) (1) with chassis
Min. 1 Mz
cuit)
tance
ground
Short circuit in wiring harShort
circuit in wiring harness between TMC3
(female)
(15) S1T7 (female) (1) with wiring
Resisharness)
Min. 1 Mz
harness between TMC3 (female) (3) S1T7
tance
(female) (2)
4
controller
be diagnosed).
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXH4KY
Current keeps flowing to 1st clutch solenoid circuit.
Cause
Possible
causes and the
standard values
when normal

Defective 1st clutch sole1
S1T7 (male)
Resistance
Between (1) (2)
5 15 z
2
Short
circuit of wiring harness between TMC3
(female) (15) S1T7 (female) (1) with chassis Voltage Max. 1 V
ground
3
not be diagnosed).
D475A, D475ASD-5E0
11
SEN01830-01
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
DXH5KA
When signal is output to 2nd clutch solenoid circuit, any current does not flow.
Stops outputting to transmission 2nd clutch solenoid circuit.

Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
(Code 31603, 31613: Output command current, output current of 2nd clutch ECMV)
Cause
Possible
causes and the
standard values
when normal

Defective 2nd clutch solewithout turning starting switch ON.
Resistance
tion)
Between (1) (2)
5 15 z
Resis2
Max. 1 z
tance
in connector)
ResisMax. 1 z
S2T5 (female) (2)
tance
3
not be diagnosed).
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXH5KB
When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.

Cause
Possible
causes and the
standard values
when normal

Defective 2nd clutch soleS2T5 (male)
Resistance
1
Between (1) (2)
5 15 z
Min. 1 Mz
2
Min. 1 Mz
cuit)
tance
ground
(female)
Resisharness)
Min. 1 Mz
tance
(female) (2)
4
controller
be diagnosed).
D475A, D475ASD-5E0
13
SEN01830-01
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
DXH5KY
Current keeps flowing to 2nd clutch solenoid circuit.

Cause
Possible
causes and the
standard values
when normal
Defective 2nd clutch solenoid (Internal short circuit)

controller

S2T5 (male)
Resistance
Between (1) (2)
5 15 z
(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
SEN01830-01
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
DXH6KA
When signal is output to 3rd clutch solenoid circuit, any current does not flow.
Stops outputting to transmission 3rd clutch solenoid circuit.

Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
(Code 31604, 31614: Output command current, output current of 3rd clutch ECMV)
Cause
Possible
causes and the
standard values
when normal

Defective 3rd clutch solewithout turning starting switch ON.
Resistance
tion)
Between (1) (2)
5 15 z
Resis2
Max. 1 z
tance
in connector)
ResisMax. 1 z
S3T3 (female) (2)
tance
3
not be diagnosed).
D475A, D475ASD-5E0
15
SEN01830-01
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
DXH6KB
When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.

Cause
Possible
causes and the
standard values
when normal

Defective 3rd clutch soleS3T3 (male)
Resistance
1
Between (1) (2)
5 15 z
Min. 1 Mz
2
Min. 1 Mz
cuit)
tance
ground
(female)
Resisharness)
Min. 1 Mz
tance
(female) (2)
4
controller
be diagnosed).
16
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXH6KY
Current keeps flowing to 3rd clutch solenoid circuit.

Cause
Possible
causes and the
standard values
when normal

Defective 3rd clutch sole1
S3T3 (male)
Resistance
Between (1) (2)
5 15 z
2
Short
TMCN3 (female) (5) S3T3 (female) (1) with Voltage Max. 1 V
chassis ground
3
not be diagnosed).
D475A, D475ASD-5E0
17
SEN01830-01
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
DXH7KA
When signal is output to reverse clutch solenoid circuit, any current does not flow.
Stops outputting to transmission reverse clutch solenoid circuit.

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.
Cause
Possible
causes and the
standard values
when normal

Defective reverse clutch
1 solenoid (Internal disconSRT1 (male)
Resistance
nection)
Between (1) (2)
5 15 z
Resis2
Max. 1 z
wiring or defective contact SRT1 (female) (1)
tance
in connector)
ResisMax. 1 z
SRT1 (female) (2)
tance
3
lem is found in causes 1 2 (Since this is an internal defect, it cannot
controller
be diagnosed).
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit

Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Reverse clutch ECMV: Short circuit
failure
DXH7KB
When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.

Method of reproducing failure code: Start engine and drive machine in reverse.
Cause
Possible
causes and the
standard values
when normal

SRT1 (male)
Resistance
solenoid (Internal short circuit)
Between (1) (2)
5 15 z
Min. 1 Mz
(Contact with ground cirResis(female) (25) SRT1 (female) (1) with chasMin. 1 Mz
cuit)
tance
sis ground
(female)
(25) SRT1 (female) (1) with wiring
Resisharness)
Min. 1 Mz
harness between TMC3 (female) (13) SRT1
tance
(female) (2)
controller
be diagnosed).
D475A, D475ASD-5E0
19
SEN01830-01
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
DXH7KY
Current keeps flowing to reverse clutch solenoid circuit.

Once machine is stopped, travel is limited to R1.
Method of reproducing failure code: Start engine and drive machine in forward.
Cause
Possible
causes and the
standard values
when normal

1 solenoid (Internal short cirSRT1 (male)
Resistance
cuit)
Between (1) (2)
5 15 z
2
Short
(female) (25) SRT1 (female) (1) with chas- Voltage
Max. 1 V
sis ground
3
lem is found in causes 1 2 (Since this is an internal defect, it cannot
controller
be diagnosed).
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXH8KA
When signal is output to forward clutch solenoid circuit, any current does not flow.
Stops outputting to transmission forward clutch solenoid circuit.

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.
Cause
Possible
causes and the
standard values
when normal

Defective forward clutch
1 solenoid (Internal disconSFT1 (male)
Resistance
nection)
Between (1) (2)
5 15 z
Resis2
Max. 1 z
wiring or defective contact SFT1 (female) (1)
tance
in connector)
ResisMax. 1 z
SFT1 (female) (2)
tance
3
not be diagnosed).
D475A, D475ASD-5E0
21
SEN01830-01
40 Troubleshooting
Failure code [DXH8KB] Forward clutch ECMV: Short circuit

Action code
CALL E03
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Failure code
Symptom of Forward clutch ECMV: Short circuit
failure
DXH8KB
When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.

Method of reproducing failure code: Start engine and drive machine forward.
Cause
Possible
causes and the
standard values
when normal

SFT1 (male)
Resistance
solenoid (Internal short circuit)
Between (1) (2)
5 15 z
Min. 1 Mz
(Contact with ground cirResis(female) (35) SFT1 (female) (1) with chassis
Min. 1 Mz
cuit)
tance
ground
(female)
(35) SFT1 (female) (1) with wiring
Resisharness)
Min. 1 Mz
harness between TMC3 (female) (13) SFT1
tance
(female) (2)
controller
be diagnosed).
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXH8KY
Current keeps flowing to forward clutch solenoid circuit.

Method of reproducing failure code: Start engine and drive machine reverse.
Cause
Possible
causes and the
standard values
when normal

1 solenoid (Internal short cirSFT1 (male)
Resistance
cuit)
Between (1) (2)
5 15 z
2
Short
(female) (35) SFT1 (female) (1) with chassis Voltage Max. 1 V
ground
3
not be diagnosed).
D475A, D475ASD-5E0
23
SEN01830-01
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
DXH9KA
When signal is output to right steering clutch solenoid circuit, current does not flow.
Stops outputting to right steering clutch solenoid circuit.
Machine cannot be steered to right.
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).
Cause
Possible
causes and the
standard values
when normal

1 clutch solenoid
SRC7 (male)
Resistance
Between (1) (2)
5 15 z
Resisharness (Disconnection in Wiring harness between STCN3 (female) (35)
2
Max. 1 z
tance
wiring or defective contact SRC7 (female) (1)
in connector)
ResisMax. 1 z
SRC7 (female) (2)
tance
ler
diagnosed).
24
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXH9KB
When signal was output to right steering clutch solenoid circuit, abnormal current flowed.
Machine cannot be steered to right.
Cause
Possible
causes and the
standard values
when normal

SRC7 (male)
Resistance
clutch solenoid
Between (1) (2)
5 15 z
Min. 1 Mz
Short
(female) (35) SRC7 (female) (1)
Min. 1 Mz
cuit)
tance
with chassis ground
Short
harness (with another wirResisSTCN3
(female) (35) SRC7 (female) (1)
ing harness)
Min. 1 Mz
tance
with wiring harness between STCN3 (female)
(23) SRC7 (female) (2)
ler
diagnosed).
D475A, D475ASD-5E0
25
SEN01830-01
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
DXH9KY
Current keeps flowing to right steering clutch solenoid circuit.
Machine cannot be steered to right. (Right clutch cannot be disconnected.)
Once machine is stopped, machine cannot travel any more.
Cause
Possible
causes and the
standard values
when normal

1 clutch solenoid
SRC7 (male)
Resistance
Between (1) (2)
5 15 z
2
STCN3 (female) (35) SRC7 (female) (1)
Voltage Max. 1 V
with chassis ground
ler
diagnosed).
26
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXHAKA
When signal is output to left steering clutch solenoid circuit, current does not flow.
Stops outputting to left steering clutch solenoid circuit.
Machine cannot be steered to left.
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)
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).
Cause
Possible
causes and the
standard values
when normal

1 clutch solenoid
SLC5 (male)
Resistance
Between (1) (2)
5 15 z
2
Max. 1 z
tance
wiring or defective contact SLC5 (female) (1)
in connector)
ResisMax. 1 z
SLC5 (female) (2)
tance
ler
diagnosed).
Circuit diagram related to left steering clutch ECMV
D475A, D475ASD-5E0
27
SEN01830-01
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
DXHAKB
When signal was output to left steering clutch solenoid circuit, abnormal current flowed.
Cause
Possible
causes and the
standard values
when normal

SLC5 (male)
Resistance
clutch solenoid
Between (1) (2)
5 15 z
Min. 1 Mz
Short
(female) (25) SLC5 (female) (1) with
Min. 1 Mz
cuit)
tance
chassis ground
Short
harness (with another wirResisSTCN3
(female) (25) SLC5 (female) (1) with
ing harness)
Min. 1 Mz
tance
wiring harness between STCN3 (female) (23)
SLC5 (female) (2)
ler
diagnosed).
28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXHAKY
Current keeps flowing to left steering clutch solenoid circuit.
Once machine is stopped, machine cannot travel any more.
Cause
Possible
causes and the
standard values
when normal

1 clutch solenoid
SLC5 (male)
Resistance
Between (1) (2)
5 15 z
2
STCN3 (female) (25) SLC5 (female) (1) with Voltage Max. 1 V
chassis ground
ler
diagnosed).
D475A, D475ASD-5E0
29
SEN01830-01
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
DXHBKA
When signal is output to right steering brake solenoid circuit, any current does not flow.
Stops outputting to right steering brake solenoid circuit.
Limits operation of engine, transmission and brake.
Sudden stop prevention valve is applied during travel.
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.
Cause
Possible
causes and the
standard values
when normal

1 brake solenoid (Internal
SR83 (male)
Resistance
short circuit)
Between (1) (2)
5 15 z
2
Max. 1 z
tance
wiring or defective contact SR83 (female) (1)
in connector)
ResisMax. 1 z
SR83 (female) (2)
tance
ler
diagnosed).
30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXHBKB
When signal was output to right steering brake solenoid circuit, abnormal current flowed.
Method of reproducing failure code: Start engine and release parking brake lever.
Cause
Possible
causes and the
standard values
when normal

SR83 (male)
Resistance
brake solenoid (Internal
short circuit)
Between (1) (2)
5 15 z
Min. 1 Mz
Short
(female) (15) SR83 (female) (1) with
Min. 1 Mz
cuit)
tance
chassis ground
circuit in wiring harness between
STCN3
(female) (15) SR83 (female) (1) with Resisharness)
Min. 1 Mz
wiring harness between STCN3 (female) (13) tance
SR83 (female) (2)
ler
diagnosed).
D475A, D475ASD-5E0
31
SEN01830-01
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
DXHBKY
Current keeps flowing to right steering brake solenoid circuit.
Cause
Possible
causes and the
standard values
when normal

SR83 (male)
Resistance
short circuit)
Between (1) (2)
5 15 z
2
STCN3 (female) (15) SR83 (female) (1) with Voltage Max. 1 V
chassis ground
ler
diagnosed).
32
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXHCKA
When signal is output to left steering brake solenoid circuit, any current does not flow.
Stops outputting to left steering brake solenoid circuit.
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)
Cause
Possible
causes and the
standard values
when normal

SL81 (male)
Resistance
short circuit)
Between (1) (2)
5 15 z
harness (Disconnection in Wiring harness between STCN3 (female) (5) Resis2
Max. 1 z
tance
wiring or defective contact SL81 (female) (1)
in connector)
Wiring harness between STCN3 (female) (13) ResisMax. 1 z
SL81 (female) (2)
tance
ler
diagnosed).
D475A, D475ASD-5E0
33
SEN01830-01
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
DXHCKB
When signal was output to left steering brake solenoid circuit, abnormal current flowed.
Left brake is kept applied.
Method of reproducing failure code: Start engine and release parking brake lever.
Cause
Possible
causes and the
standard values
when normal

SL81 (male)
Resistance
brake solenoid (Internal
short circuit)
Between (1) (2)
5 15 z
Min. 1 Mz
Short
(female) (5) SL81 (female) (1) with
Min. 1 Mz
cuit)
tance
chassis ground
circuit in wiring harness between
STCN3
(female) (5) SL81 (female) (1) with Resisharness)
Min. 1 Mz
wiring harness between STCN3 (female) (13) tance
SL81 (female) (2)
ler
diagnosed).
34
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
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
DXHCKY
Current keeps flowing to left steering brake solenoid circuit.
Cause
Possible
causes and the
standard values
when normal

SL81 (male)
Resistance
short circuit)
Between (1) (2)
5 15 z
2
Short
STCN3 (female) (5) SL81 (female) (1) with Voltage Max. 1 V
chassis ground
ler
diagnosed).
D475A, D475ASD-5E0
35
SEN01830-01
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 content
Controller's
action
Symptoms that
appear on
machine
Failure code
Symptom of Engine blow-by pressure sensor: Abnormally high pressure occurfailure
rence (VHMS controller system)
F@BBZL
Blow-by pressure sensor signal circuit detected pressure higher than 4.71 kPa {480 mmAq}.
None in particular.
If machine is used as it is, engine may be broken.
General
information
"n3" on VHMS controller LED changes to "38".
Possible
causes and the
standard values
when normal
Cause
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.
Between V2A (female) (18) V2A (female)
0.3
Voltage
(12)
0.7 V
36
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01830-01
37
SEN01830-01
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
Failure code
Left front exhaust temperature sensor (1): Exhaust temperature

Symptom of
abnormal rise
failure
F@BYNS
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.
General
information
Possible
causes and the
standard values
when normal
Cause
Abnormal rise of left front
Check engine and repair, if there is abnormality.
Defective left front exhaust If failure code [DGT5KA] or [DGT5KB] is displayed, carry out trou2
temperature sensor
bleshooting for it.
V2A
Exhaust temperature
Voltage
20C
Approx. 0.9 1.2 V
(7) (13)
500C
Approx. 2.6 3.5 V
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
Circuit diagram related to exhaust temperature sensor (1)
D475A, D475ASD-5E0
39
SEN01830-01
40 Troubleshooting
Failure code [f@BYNS] (or VHMS_LED display "n3" o "71") Left rear
Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
40
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
None in particular.
Cause
Abnormal rise of left rear
Defective left rear exhaust If failure code [dGT5KA] or [dGT5KB] is displayed, carry out trouble2
temperature sensor
shooting for it.
V2A
Exhaust temperature
Voltage
20C
Approx. 0.9 1.2 V
(6) (13)
500C
Approx. 2.6 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
D475A, D475ASD-5E0
41
SEN01830-01
40 Troubleshooting
Failure code [F@BZNS] (or VHMS_LED display "n3" o "38") Right front
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 front exhaust temperature sensor (1): Exhaust temperature
failure
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.
Failure code is not displayed on machine monitor (It can be checked, however, by downloading
data saved in VHMS controller into personal computer).
Cause
Abnormal rise of right front
Defective right front
If failure code [DGT6KA] or [DGT6KB] is displayed, carry out trou2 exhaust temperature senbleshooting for it.
sor
42
V2A
Exhaust temperature
Voltage
(5) (13)
20C
500C
Approx. 0.9 1.2 V

Approx. 2.6 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
D475A, D475ASD-5E0
43
SEN01830-01
40 Troubleshooting
Failure code [f@BZNS] (or VHMS_LED display "n3" o "39") Right rear
Action code
Failure content
Controller's
action
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
Failure code
Right rear exhaust temperature sensor (1): Exhaust temperature

Symptom of
abnormal rise
failure
f@BZNS
Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust
None in particular.
Cause
Abnormal rise of right rear
Defective right rear
If failure code [dGT6KA] or [dGT6KB] is displayed, carry out trouble2 exhaust temperature senshooting for it.
sor
44
V2A
Exhaust temperature
Voltage
(16) (13)
20C
500C
Approx. 0.9 1.2 V

Approx. 2.6 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
D475A, D475ASD-5E0
45
SEN01830-01
40 Troubleshooting
Failure code [F@BYNR] (or VHMS_LED display "n3" o "62") Left front
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 front exhaust temperature sensor (2): Exhaust temperature
failure
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
None in particular.
Cause
Abnormal rise of left front
Defective left front exhaust If failure code [DGT5KA] or [DGT5KB] is displayed, carry out trou2
temperature sensor
bleshooting for it.
46
V2A
Exhaust temperature
Voltage
(7) (13)
20C
500C
Approx. 0.9 1.2 V

Approx. 2.6 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
D475A, D475ASD-5E0
47
SEN01830-01
40 Troubleshooting
Failure code [f@BYNR] (or VHMS_LED display "n3" o "72") Left rear
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 rear exhaust temperature sensor (2): Exhaust temperature
failure
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
None in particular.
Cause
Abnormal rise of left rear
Defective left rear exhaust If failure code [dGT5KA] or [dGT5KB] is displayed, carry out trouble2
temperature sensor
shooting for it.
48
V2A
Exhaust temperature
Voltage
(6) (13)
20C
500C
Approx. 0.9 1.2 V

Approx. 2.6 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
D475A, D475ASD-5E0
49
SEN01830-01
40 Troubleshooting
Failure code [F@BZNR] (or VHMS_LED display "n3" o "82") Right front
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 front exhaust temperature sensor (2): Exhaust temperature
failure
F@BZNR
Right front exhaust temperature sensor signal circuit detected temperature higher than exhaust
None in particular.
Cause
Abnormal rise of right front
Defective right front
If failure code [DGT6KA] or [DGT6KB] is displayed, carry out trou2 exhaust temperature senbleshooting for it.
sor
50
V2A
Exhaust temperature
Voltage
(5) (13)
20C
500C
Approx. 0.9 1.2 V

Approx. 2.6 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
D475A, D475ASD-5E0
51
SEN01830-01
40 Troubleshooting
Failure code [f@BZNR] (or VHMS_LED display "n3" o "92") Right rear
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 rear exhaust temperature sensor (2): Exhaust temperature
failure
f@BZNR
Right rear exhaust temperature sensor signal circuit detected temperature higher than exhaust
None in particular.
Cause
Abnormal rise of right rear
Defective right rear
If failure code [dGT6KA] or [dGT6KB] is displayed, carry out trouble2 exhaust temperature senshooting for it.
sor
52
V2A
Exhaust temperature
Voltage
(16) (13)
20C
500C
Approx. 0.9 1.2 V

Approx. 2.6 3.5 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01830-01
D475A, D475ASD-5E0
53
SEN01830-01

2009 KOMATSU
All Rights Reserved
54
SEN01831-02
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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
D475A, D475ASD-5E0
SEN01831-02
40 Troubleshooting
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 ......................................................... 30
E-15 Indication of the fuel gauge is abnormal............................................................................................... 31
E-16 Indications of gear speed and engine speed are abnormal.................................................................. 32
E-17 Indication of the shift mode service meter is abnormal ........................................................................ 32
E-18 The switch module cannot be operated................................................................................................ 33
E-19 The warning lamp does not flash or does not go out............................................................................ 34
E-20 The alarm buzzer does not sound or does not stop ............................................................................. 35
E-21 Auto shift down is not possible or is not released................................................................................. 36
E-22 The automatic pitch back system does not operate (only superdozer specification) ........................... 37
E-23 The alarm buzzer cannot be cancelled................................................................................................. 38
E-24 The operator mode cannot be operated ............................................................................................... 39
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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Contents of troubleshooting table

a
Trouble
Related
information
Problem that appears on machine

Information related to detected trouble or troubleshooting
Cause

<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
Possible causes
and standard
value in normal
state
<Phenomenon of defective harness>

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.
D475A, D475ASD-5E0
SEN01831-02
40 Troubleshooting
E-1 The engine does not start

Symptom of
failure
(1) The engine does not start.
General
information
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

Battery voltage
Battery specific gravity
Min. 24 V
Min. 1.26
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.
2
Defective starting switch

(internal disconnection)
KEY (male)
Between (5) and (3)

3 relay (internal disconnection)
Defective alternator (internal short-circuit)
Possible
causes and the
standard values
when normal
Switch position
Resistance
OFF
Min. 1 Mz
START
Max. 1 z
a Prepare with the starting switch OFF, then start the engine and
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
Voltage
Between Terminal R and ground
Max. 1 V
Detective starting motor

(internal defect)
Starting motor A, B
Voltage
Electric power supply : between

Terminal B and ground
20 30 V
Charge : between Terminal R

and ground
Max. 1 V
Starting : between Terminal S

and ground
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.
Disconnection in wiring harness (disconnection in wir6
ing or defective contact in
connector)
Wiring harness between KEY (female) (3)

and NFS (female) (3)
Resistance
Max. 1 z
Wiring harness between NSF (female) (5)

and ST1 (female) (1)
Resistance
Max. 1 z
Wiring harness between NSF (female) (5)

and ST2 (female) (1)
Resistance
Max. 1 z
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Cause

Possible
causes and the
standard values
when normal
Hot short of wiring harness between alternator R terminal and ST1 (female) (2) or ST2
(female) (2) with ground
Voltage
Max. 1 V

(Contact with 24 V circuit) Hot short of wiring harness between STCN1
(female) (23) and pre-lubrication motor signal terminal with ground
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
D475A, D475ASD-5E0
SEN01831-02
40 Troubleshooting
Symptom of
failure
(2) Trouble (1) is not detected but the engine does not start (When the machine is equipped with prelubricator).
General
information
"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)
Defective pre-lubrication
2
relay (PLUB)

a Prepare with starting switch OFF, then keep starting switch OFF
or start engine and carry out troubleshooting.
STCN2
Starting switch
Resistance
Between (3) and

chassis ground
OFF
Max. 1 z
Start engine
Min. 1 Mz
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.
Defective pre-lubrication
motor
Pre-lubrication motor
Voltage
Between signal terminal

and chassis ground
20 30 V

Possible
causes and the
standard values
when normal
4
wiring harness or defective
Wiring harness between engine oil pressure

switch terminal POP and STCN2 (female) (3)
Resistance
Max. 1 z
Wiring harness between KEY (female) (1)

and pre-lubrication relay (PLUB) (female) (1)
Resistance
Max. 1 z
Wiring harness between pre-lubrication relay

(PLUB) (female) (2) and STCN2 (female)
(18)
Resistance
Max. 1 z
Wiring harness between pre-lubrication

motor signal terminal and STCN1 (female)
(23)
Resistance
Max. 1 z


5
Between wiring harness between KEY

(female) (1) and pre-lubrication relay (PLUB)
(female) (1) and chassis ground
Resistance
Min. 1 Mz
Between wiring harness between pre-lubrication relay (PLUB) (female) (2) and STCN2
Resistance
Min. 1 Mz
Between wiring harness between pre-lubrication motor signal terminal and STCN1
Resistance
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Circuit diagram related
D475A, D475ASD-5E0
SEN01831-02
40 Troubleshooting
E-2 The preheater does not operate

Symptom of
failure
The preheater does not operate.
General
information
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

switch still OFF.

Defective fuse
2
(FS22)
3

(CB30, CB6)
Defective preheater relay

Starting switch
Switch position
Resistance
Between 250 (B)

255 (R1)
OFF
Min. 1 Mz
HEAT (R1)
Max. 1 z
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.
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.
Possible
causes and the
standard values
when normal
Defective heater relay
5
(internal defect)
Heater relay
Voltage
Electric power supply: between

terminal HTR1A, HTR2A and
ground
20 30V
Signal: between terminal

HTR1C, HTR2C and ground
20 30V
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)
Defective electrical intake

air heater (internal defect)

switch still OFF.
Diagnose diode HTD1, HTD2 (male)
See the Inspection procedure of diode in the Testing and
adjusting section.
switch still OFF.
Electrical intake air heater
Continuity
Between terminals
Continue
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Causes

switch still OFF.
Wiring harnesses between FS22 (2) PHR
(female) (5)
Wiring harness between PHR (female) (3)

terminal HTR1C terminal HTR2C
harness
Wiring harness between starting switch 255
8
(disconnection or defective (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
Possible
causes and the
standard values
when normal
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

switch still OFF.
Between ground and wiring harness
between FS22 (2) PHR (female) (5)
Resistance
Min. 1 Mz

between PHR (female) (3) terminal HTR1C
terminal HTR2C
Resistance
Min. 1 Mz
Defective harness
9 grounding
(contact with ground circuit) between starting switch 255 (R1) terminal
HTR1C terminal HTR2C
Resistance
Min. 1 Mz

between terminal BRC of battery relay terminal HTR1A and terminal HTR2A
Resistance
Min. 1 Mz

between terminal REL1, REL2 of heater
relay electrical intake air heater HT1
Resistance
Min. 1 Mz
D475A, D475ASD-5E0
SEN01831-02
40 Troubleshooting
10
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01831-02
11
SEN01831-02
40 Troubleshooting
E-3 The ripper pin puller cylinder does not operate

Symptom of
failure
The ripper pin puller cylinder does not operate.
General
information
Cause
1 Defective fuse (FS22-2)

When the fuse is blown, a ground fault may have possibly occurred
to the circuit.
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)
Possible
causes and the
standard values
when normal
224 (male)
Resistance
Between (1) and (2)
10 80 z
Between (1) and ground
Min. 1 Mz
4
in connector)
Wiring harness between FS22-2 outlet and

263 (female) (1)
Resistance
Max. 1 z

224 (female) (1)
Resistance
Max. 1 z

ground
Resistance
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
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
6
12
Hot short in wiring harness Between wiring harness (between 263

(Contact with 24 V circuit) (female) (2) and 234 (female) (1)) and ground
Voltage
Max. 1 V

ground
Voltage
Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
D475A, D475ASD-5E0
13
SEN01831-02
40 Troubleshooting
E-4 The monitor panel does not come on at all when the starting switch
is turned on
Symptom of
failure
The monitor panel does not come on at all when the starting switch is turned ON.
General
information
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

(CB2)

When the circuit breaker is cut off, the circuit may have possibly
been short-circuited with ground.
2
in connector)
Possible
causes and the
standard values
when normal
Wiring harness between S03 (female) (1) (2)

and CB2 outlet
Resistance
Max. 1 z
Wiring harness between S03 (female) (3) (4)

and ground
Resistance
Max. 1 z

and CB6 outlet
Resistance
Max. 1 z
Wiring harness between S01 (female) (1) and

CB2 outlet
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
3
Between wiring harness CB2 (outlet side)

and S03 (female) (2) and S01 (female) (1)
and ground
Resistance
Min. 1 Mz
Between wiring harness CB6 (outlet side)

and S03 (female) (5) (6) and ground
Resistance
Min. 1 Mz

(Gauge/lamp module)
S03
Voltage
Between (1), (2) and (3), (4)
20 30 V
S01
Voltage
Between (1) and (2)
20 30 V
a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON and OFF.
5 CAN communication error
14
S03
Voltage
Between (5) (6) and (3) (4)
20 30 V
If failure code [DAFRKR] of CAN communication error is displayed,

D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
D475A, D475ASD-5E0
15
SEN01831-02
40 Troubleshooting
E-5 When the starting switch is turned on, the monitor panel completely
remains lighted and does not go out
Symptom of
failure
When the starting switch is turned ON, the monitor panel completely remains lighted and does not
go out.
General
information
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.
Possible
causes and the
standard values
when normal
16
Cause
1

(Gauge/lamp module)

This internal defect cannot be diagnosed.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
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

decrease
Because the radiator coolant level decrease is detected, inspect the

radiator coolant level (the lamp flashes below the specified level).
The main radiator coolant

2 level sensor is defective.
WLD (male)
Between (1) and (2)
Possible causes
and standard
value in normal
state
Resistance
Normal level
Max. 1 z
Lower level
Min. 1 Mz
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
4

(Gauge/lamp module)
S03
Voltage
Between (11) and

ground
Normal level
Max. 1 V
Lower level
20 30 V
D475A, D475ASD-5E0
17
SEN01831-02
40 Troubleshooting
E-7 While the engine is operating, any caution item flashes

Symptom of
failure
(1) The battery charge level caution lamp flashes.
General
information
When any abnormality is detected during engine operation, the relevant caution item will flash.
Cause

Possible
causes and the
standard values
when normal
Defective alternator (insufficient power generation)
Alternator
Engine speed
Voltage
Between Terminal R
and ground
Min. medium speed

(half)
20 30 V
a Prepare with the starting switch OFF, then carry out troubleshootDisconnection of wiring
ing without turning the starting switch ON.
2
wiring or defective contact Wiring harness between S04 (female) (9) and
ResisMax. 1 z
in connector)
alternator R terminal
tance
3
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
4
18

(Gauge/lamp module)
S04
Engine speed
Voltage
Between (9) and

ground
Min. medium speed

(half)
20 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
D475A, D475ASD-5E0
19
SEN01831-02
40 Troubleshooting
Symptom of
failure
(2) The air cleaner clogging caution lamp flashes.
General
information
If abnormality is detected while the engine is running, the caution item lamp flashes.
Cause
1 Clogged air cleaner

Clean or replace the air cleaner.
2

and AF1 (female) (1)
Resistance
Max. 1 z

and AF2 (female) (1)
Resistance
Max. 1 z

chassis ground
Resistance
Max. 1 z

Possible
causes and the
standard values
when normal

3
Between wiring harness between S03

(female) (13) and AF1 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Between wiring harness between AF1

(female) (2) and AF2 (female) (1) and chassis ground
Resistance
Min. 1 Mz
4

(gauge, lamp module)
Defective air cleaner clog5 ging sensor (Internal disconnection)
S03
Air cleaner
Voltage
Between (13) and

chassis ground
When normal
Max. 1 V
When clogged
20 30 V
troubleshooting.
AF1, AF2 (male)
Between (1) and (2)
Air cleaner
Resistance
When normal
Max. 1 z
When clogged
Min. 1 Mz
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-8 An emergency caution item flashes while the engine is running

Symptom of
failure
(1) The engine oil pressure caution lamp flashes.
General
information
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
Possible
causes and the
standard values
when normal
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."
Defective engine hydraulic

2
system
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.
D475A, D475ASD-5E0
21
SEN01831-02
40 Troubleshooting
Symptom of
failure
(2) The engine coolant temperature caution lamp flashes.
General
information
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
Possible
causes and the
standard values
when normal
Overheated engine coolant temperature

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.)
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".
3

(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.)
Symptom of
failure
(3) The power train oil temperature caution lamp flashes.
General
information
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
Possible
causes and the
standard values
when normal
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
2
tion on the power train oil temperature gauge is abnormal".
3
22
Overheated oil temperature of power train

(Gauge/lamp module)
troubleshot.)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Symptom of
failure
(4) The hydraulic oil temperature caution lamp flashes.
General
information
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
Possible
causes and the
standard values
when normal
Overheated hydraulic oil

temperature

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
tion on the hydraulic oil temperature gauge is abnormal".
3

(Gauge/lamp module)
D475A, D475ASD-5E0
troubleshot.)
23
SEN01831-02
40 Troubleshooting
E-9 While the preheater is operating, the preheating pilot lamp does not
come on
Symptom of
failure
While the preheater is operating, the preheating pilot lamp does not come on.
General
information
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
a Prepare with the starting switch OFF, then carry out troubleshootDisconnection of wiring
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
Ground fault of wiring har2 ness (Contact with ground Between wiring harness between S03
Resiscircuit)
(female) (9) and heater relay HTR1C terminal
Min. 1 Mz
tance
and ground
3
24

(Gauge/lamp module)
S03
Starting switch
Voltage
Between (9) and

ground
ON
Max. 1 V
HEAT
20 30 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
D475A, D475ASD-5E0
25
SEN01831-02
40 Troubleshooting
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
At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tiltmounted machine)
General
information
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.)
Possible
causes and the
standard values
when normal
Cause
1

(Gauge/lamp module)

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
At the locking-up of the torque converter, the torque converter lock-up display lamp does not come
on.
General
information
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.)
Possible
causes and the
standard values
when normal
26
Cause
1

(Gauge/lamp module)

D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-12 The engine coolant temperature gauge does not indicate normally
Symptom of
failure
The engine coolant temperature gauge does not indicate normally.
General
information
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

If failure code [CA144] or [CA145] 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
2
Defective engine coolant

temperature sensor system
Engine controller CAN

communication error
Caution lamp (d)

OFF
Flashing
White range (a)

Green range (b)
Red range (c)
If failure code [DB2RKR] or [dB2RKR] is displayed, carry out troubleshooting for it.
3 Defective engine controller Since trouble is in system, troubleshooting cannot be carried out.
If causes 1 3 are not detected, monitor panel may be defective.

(Since trouble is in system, troubleshooting cannot be carried out.)
Coolant temperature gauge and caution lamp

D475A, D475ASD-5E0
27
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40 Troubleshooting
E-13 Indication of the power train (torque converter) temperature gauge

is abnormal
Symptom of
failure
Indication of the power train (torque converter) temperature gauge is abnormal.
General
information
When any abnormality occurs in the power train oil pressure sensor system, failure code [DGT1KX]
or [DGT1KA] may be displayed.
Cause

If failure code [DGT1KX] or [DGT1KA] is displayed, carry out troubleshooting for it.

1
pressure sensor system
Possible
causes and the
standard values
when normal
Caution lamp (d)

OFF
Flashing
White range (a)

Green range (b)
Red range (c)
2

(Gauge/lamp module)
S04 (female)
Torque converter oil

temperature
Resistance
Between (12) and

ground
10 130C
About 3.8 kz
about 80 kz

28
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
D475A, D475ASD-5E0
29
SEN01831-02
40 Troubleshooting
E-14 The hydraulic oil temperature gauge does not indicate normally
Symptom of
failure
The hydraulic oil temperature gauge does not indicate normally.
General
information
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

If failure code [DGS1KX] is displayed, carry out troubleshooting for it.
1
Possible
causes and the
standard values
when normal
Defective hydraulic oil temperature sensor system
Caution lamp (d)

OFF
Flashing
White range (a)

Green range (b)
Red range (c)
CAN communication error
If failure code [DAQRKR] is displayed, carry out troubleshooting for

it.
controller

(Gauge/lamp module)

30
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-15 Indication of the fuel gauge is abnormal

Symptom of
failure
Indication of the fuel gauge is abnormal.
General
information
Cause
Defective fuel level sensor.

short circuit)
2
in connector)
Possible
causes and the
standard values
when normal

3
circuit)

422 (male)
Remained fuel level
Resistance
Between (1) and (2)

(ground)
Full
About 4 z
Empty
About 85 z
and 422 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
Between wiring harness (between S04
(female) (10) and 422 (female) (1)) and
ground
Resistance
Min. 1 Mz

(Contact with 24 V circuit) Between wiring harness (between S04
(female) (10) and 422 (female) (1)) and
ground
Voltage
Max. 1 V
5

(Gauge/lamp module)
S04 (female)
Remained fuel level
Resistance
Between (10) and

ground
Full
About 4 z
Empty
About 85 z
D475A, D475ASD-5E0
31
SEN01831-02
40 Troubleshooting
E-16 Indications of gear speed and engine speed are abnormal

Symptom of
failure
(1) Indications of gear speed and engine speed are abnormal.
General
information
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

(Gauge/lamp module)

If failure code [DB2RKR], [dB2RKR] or [DAQRKR] is displayed,
E-17 Indication of the shift mode service meter is abnormal

Symptom of
failure
(1) During engine operation, the service meter does not advance.
General
information
The service meter measures time according to engine drive signals (alternator voltage).
Cause
Possible
causes and the
standard values
when normal
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
Symptom of
failure

(Gauge/lamp module)
(2) Shift mode and service meter are not displayed at all.
General
information
Possible
causes and the
standard values
when normal
32
Cause
1

(Gauge/lamp module)

D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-18 The switch module cannot be operated

Symptom of
failure
(1) Though the switch is used, lamps do not change.
General
information
Possible
causes and the
standard values
when normal
Cause
1

(Switch module)

Symptom of
failure
(2) Though the switch is used, the system setting does not change.
General
information
Switch module signals are transmitted to each controller through communication.

Cause
Possible
causes and the
standard values
when normal
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
2
(Switch module)
carry out the troubleshooting.
S01
Voltage
69V
D475A, D475ASD-5E0
33
SEN01831-02
40 Troubleshooting
E-19 The warning lamp does not flash or does not go out
Symptom of
failure
The warning lamp does not flash or does not go out.
General
information
Possible
causes and the
standard values
when normal
34
Cause
1
Defective machine monitor

(Gauge/lamp module)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-20 The alarm buzzer does not sound or does not stop
Symptom of
failure
The alarm buzzer does not sound or does not stop.
General
information
When a short circuit occurs in the alarm buzzer system, the failure code is displayed but no other
failure codes are displayed.
Cause

(CB2)
When the circuit breaker is cut off, a ground fault may have possibly
occurred in the circuit.
Defective alarm buzzer

short circuit)
Possible
causes and the
standard values
when normal
217 (male)
Resistance
Between (1) and (2)
200 z
Min. 1 Mz
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)
ResisMax. 1 z
CB2 outlet
tance
a Prepare with the starting switch OFF, then carry out troubleshootShort circuit with chassis
4 ground in wiring harness
Resis(Contact with ground circuit) Between wiring harness related to CB2 (outMin. 1 Mz
let side) and ground
tance
5

(Gauge/lamp module)
S03
Between (18) and
ground
Alarm buzzer
Voltage
At stop
20 30 V
At operation
(sounding)
Max. 3 V
D475A, D475ASD-5E0
35
SEN01831-02
40 Troubleshooting
E-21 Auto shift down is not possible or is not released

Symptom of
failure
Auto shift down is not possible or is not released.
General
information
Cause
Defective auto shift down

switch (Internal
1
disconnection or short
circuit)

ASD (male)
Between (2) and (3)
Possible
causes and the
standard values
when normal
2
in connector)

3
circuit)
Auto shift down

switch
Resistance
OFF (0)
Min. 1 Mz
ON (1)
Max. 1 z
and ADS (female) (3)
Resistance
Max. 1 z
Wiring harness between ADS (female) (2)

and TMC1 (female) (10)
Resistance
Max. 1 z
Between wiring harness (between TMC3
(female) (39) and ASD (female) (3)) and
ground
Resistance
Min. 1 Mz
controller
control system
If causes 1 4 are not detected, transmission controller may have

defects related to this function.
36
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-22 The automatic pitch back system does not operate (only superdozer
specification)
Symptom of
failure
The machine cannot start or stop a pivot turn.
General
information
Cause
Defective pivot turn switch

short circuit)

FTU (male)
Between (2) and (3)
Pivot turn switch
Resistance
OFF (0)
Min. 1 Mz
ON (1)
Max. 1 z

Possible
causes and the
standard values
when normal
2
wiring harness or defective and FTU (female) (3)
Wiring harness between FTU (female) (2)
and TMC1 (female) (10)
3
circuit)
Resistance
Max. 1 z
Resistance
Max. 1 z

(female) (9) and FTU (female) (3)
Resistance
Min. 1 Mz
4
controller
TMC1, TMC3
Between TMC3 (9)
and TMC1 (10)
control system
Automatic pitch
back switch
Voltage
OFF (0)
20 30 V
ON (1)
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).
D475A, D475ASD-5E0
37
SEN01831-02
40 Troubleshooting
E-23 The alarm buzzer cannot be cancelled

Symptom of
failure
The alarm buzzer cannot be cancelled.
General
information
The cancel signal is sent from the steering controller to the machine monitor by communication.
Cause

Defective buzzer cancel

1 switch (Internal disconnection or short circuit)
BUZ (male)
Between (1) and (2)
Between (1) and (3)
Buzzer cancel switch
Resistance
OFF (0)
Min. 1 Mz
OFF (0)
Min. 1 Mz
Max. 1 z
Max. 1 z
Possible
causes and the
standard values
when normal
Disconnection in wiring harness (Disconnection in

2
in connector)

3
Wiring harness between STCN2 (36) and

BUZ (female) (2)
Resistance
Max. 1 z

BUZ (female) (3)
Resistance
Max. 1 z
Wiring harness between BUZ (female) (1)

and STCN1 (female) (10)
Resistance
Max. 1 z
Between wiring harness (between STCN2
(36) and BUZ (female) (2)) and ground
Resistance
Min. 1 Mz

(26) and BUZ (female) (3)) and ground
Resistance
Min. 1 Mz
Machine monitor CAN com- If failure code [DAFRKR] is displayed, carry out troubleshooting for
munication error
it.
38
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-24 The operator mode cannot be operated

Symptom of
failure
The operator mode cannot be operated.
General
information
Cause

switch system
Since the buzzer cancel switch system is supposed to be out of

order, carry out the troubleshooting of "The alarm buzzer cannot be
cancelled."
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
Resistance
OFF (0)
Min. 1 Mz
Max. 1 z
OFF (0)
Min. 1 Mz
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring
3
or defective contact in connector)

CUR (female) (2)
Resistance
Max. 1 z

CUR (female) (3)
Resistance
Max. 1 z
Wiring harness between CUR (female) (1)

Resistance
Max. 1 z
4 ground in wiring harness
(16) and CUR (female) (2)) and ground
(6) and CUR (female) (3)) and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
5 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
D475A, D475ASD-5E0
39
SEN01831-02
40 Troubleshooting
E-25 The service mode cannot be operated

Symptom of
failure
The service mode cannot be operated.
General
information
Cause

switch system
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".
Defective information
switch system
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".

(CB6)
Defective service switch

S24
4 (Internal short circuit or disconnection)
Between (1) and (2),
Between (4) and (5)
Service switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
Possible
causes and the
standard values
when normal
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)
Resistance
Max. 1 z
Resistance
Max. 1 z
and S24 (2)
Resistance
Max. 1 z

and S24 (5)
Resistance
Max. 1 z
6
Between wiring harness (between CB6 (outlet) and S24 (1)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between S24 (4)

and STCN1 (female) (10)) and ground
Resistance
Min. 1 Mz

(female) (16) and S24 (2)) and ground
Resistance
Min. 1 Mz

(female) (6) and S24 (5)) and ground
Resistance
Min. 1 Mz
7

(Gauge/lamp module)
S03
Service switch
Voltage
Between (16) and

ground
OFF
Max. 1 V
ON
20 30 V
8
40
STCN1
Service switch
Voltage
Between (6) and

ground
OFF
About 8 V
ON
Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
D475A, D475ASD-5E0
41
SEN01831-02
40 Troubleshooting
E-26 The back-up alarm does not sound

Symptom of
failure
The back-up alarm does not sound.
General
information
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

When the fuse is blown, a ground fault may have probably occurred
in the circuit.
Defective back-up relay

When the relay is replaced with another relay while the starting
switch is set to OFF and the alarm sounds after the starting switch is
turned on and the machine is operated in reverse, the back-up alarm
relay (BKA) is defective.
Possible
causes and the
standard values
when normal
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)
Resistance
Max. 1 z
Resistance
Max. 1 z
and ground
Resistance
Max. 1 z

BKA (female) (2)
Resistance
Max. 1 z
4
circuit)
42

(Internal defect)
Between wiring harness (between FS22-1

(outlet) and BKA (female) (1), (3)) and
ground
Resistance
Min. 1 Mz
Between wiring harness (between BKA

(female) (5) and BUA (female) (1)) and
ground
Resistance
Min. 1 Mz
When Causes 1 to 4 are not applicable, the back-up alarm is supposed to be defective.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
D475A, D475ASD-5E0
43
SEN01831-02
40 Troubleshooting
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
(1) None of the night light, the headlamp and the working lamp on the panel comes on.
General
information
Headlamp and working lamp are operated with 1 switch.

If headlamp switch is operated, panel lighting is changed for night.
Cause

CB5
If circuit breaker is turned OFF, circuit probably has ground fault etc.
Defective headlamp and

2 working lamp switch (International disconnection)
FWL (male)
Between (2) and (3)
Switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
Possible
causes and the
standard values
when normal
Disconnection of wiring
3
in connector)
Wiring harness between FWL (female) (2)

and CB5 outlet
Resistance
Max. 1 z

and LMFL (female) (1) and LMFR (female)
(1) and LMW (female) (1) and S01 (female)
(10) or S03 (female) (8)
Resistance
Max. 1 z
Wiring harness between LMFL (female) (2)

and LMFR (female) (2) or LMW (female) (2)
and ground
Resistance
Max. 1 z

Ground fault of wiring har4 ness (Contact with ground
circuit)
44

CB5 outlet and ground
Resistance
Min. 1 Mz

LMFL (female) (1), LMFR (female) (1), LMW
(female) (1), S01 (female) (10) or S03
(female) (8) and ground
Resistance
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Symptom of
failure
(2) Only the night light on the panel does not comes on. (Whole or part)
General
information
If headlamp switch is operated, panel lighting is changed for night.

Cause
1
Defective night lamp (S02) The night lamp is supposed to be defective. Check if the bulb is
(Blown)
blown.
2
in connector)
Possible
causes and the
standard values
when normal

and FWL (female) (3)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

CB2 (outlet)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

FWL (female) (3)
Resistance
Max. 1 z

and ground
Resistance
Max. 1 z

circuit)

(female) (10) and FWL (female) (3)) and
ground
Resistance
Min. 1 Mz

(female) (1) and CB2 (outlet)) and ground
Resistance
Min. 1 Mz

(female) (8) and FWL (female) (3)) and
ground
Resistance
Min. 1 Mz
4

(Switch module)
Between S01 (10)

and (2)
Between S02 (1) and
(2)

5
(Gauge/lamp module)
D475A, D475ASD-5E0
Light switch ON
20 30 V
Between S03 (8) and
(3), (4)
Light switch ON
20 30 V
45
SEN01831-02
Symptom of
failure
40 Troubleshooting
(3) Only the headlamp does not comes on. (Both right and left, or one side only)
General
information
Cause
Defective headlamp
(Blown)
The headlamp is supposed to be defective. Check if the bulb is

blown.

(CB5)
Defective headlamp relay

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.
Possible
causes and the
standard values
when normal
4
in connector)
Wiring harness between CB5 (outlet) and

LMFL (female) (3) and LMFR (female) (3)
Resistance
Max. 1 z

and 204 (female) (1), 207 (female) (1)
Resistance
Max. 1 z
Wiring harness between LMFR (female) (5)

and 203 (female) (1), 208 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
Wiring harness between LMFR (female) (2)

ground
Resistance
Max. 1 z

circuit)
Between wiring harness (between CB5 (outlet) and LMFL (female) (3) and LMFR
(female) (3)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between LMFL

(female) (5) and 204 (female) (1), 207
Resistance
Min. 1 Mz
Between wiring harness (between LMFR

(female) (5) and 203 (female) (1), 208
Resistance
Min. 1 Mz
6
46
Hot short (Contact with 24V Between wiring harness between LMFL
(female) (2) and ground and ground
circuit) in wiring harness
Voltage
Max. 1 V
Between wiring harness between LMFR

(female) (3) and ground and ground
Voltage
Max. 1 V
D475A, D475ASD-5E0
40 Troubleshooting
Symptom of
failure
SEN01831-02
(4) Only the working lamp does not comes on. (Both right and left, or one side only)
General
information
Cause
1
Defective working lamp

(Blown)
Defective working lamp

3 relay (Internal disconnection)

The working lamp is supposed to be defective. Check if the bulb is
blown.
in the circuit.
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.
Possible
causes and the
standard values
when normal
4
in connector)
Wiring harness between FS22-4 (outlet) and

LMW (female) (3)
Resistance
Max. 1 z
Wiring harness between LMW (female) (5)

and 221 (female) (1) or 242 (female) (1)
Resistance
Max. 1 z
Wiring harness between LMW (female) (2)

and ground
Resistance
Max. 1 z
circuit)

(outlet) LMW (female) (3)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between LMW

(female) (5) and 221 (female) (1) or 242
Resistance
Min. 1 Mz
Hot short (Contact with 24V
6
circuit) in wiring harness
Between wiring harness between LMW
Voltage Max. 1 V
(female) (2) and ground
D475A, D475ASD-5E0
47
SEN01831-02
Symptom of
failure
40 Troubleshooting
(5) Only the rear lamp does not comes on. (Both right and left, or one side only)
General
information
Cause
Defective rear lamp

(Blown)
The working lamp is supposed to be defective. Check if the bulb is

blown.
in the circuit.
Defective rear lamp switch

3 (International disconnection)
RWL (male)
Between (2) and (3)
Possible
causes and the
standard values
when normal
4
in connector)
Switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
Wiring harness between RWL (female) (2)
and FS22-5 (outlet)
Resistance
Max. 1 z
Wiring harness between RWL (female) (3)

and 226 (female) (1) or 243 (female) (1)
Resistance
Max. 1 z
circuit)
48

(outlet) RWL (female) (2)) and ground
Resistance
Min. 1 Mz
Between wiring harness (between RWL

(female) (3) 226 (female) (1) and 243
Resistance
Min. 1 Mz
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
D475A, D475ASD-5E0
49
SEN01831-02
40 Troubleshooting
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 m u ltip le "Self-di a g n o s i s n o t i c 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
50
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
D475A, D475ASD-5E0
40 Troubleshooting
Self-diagnosis
notice
Symptom of
failure
E11
Contents of
trouble
SEN01831-02
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
Possible
causes and the
standard values
when normal
2
in connector)
Self-diagnosis
notice
Symptom of
failure
E12
Contents of
trouble
Defective air conditioner

system

THI (male)
Resistance
Between (1) and (2)
300 z 430 kz

Wiring harness between AP1 (female) (13)
and THI (female) (2)
Resistance
Max. 1 z

Resistance
Max. 1 z
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".
Short circuit in recirculated air sensor
Disconnection in the recirculated air sensor system is detected.
Fixes the recirculated air temperature for control.

panel
General
information
Cause
Defective recirculated air
1 sensor
Possible
causes and the
standard values
when normal
2
in connector)

system
D475A, D475ASD-5E0

THI (male)
Resistance
Between (1) and (2)
300 z 430 kz

Resistance
Max. 1 z

Resistance
Max. 1 z
51
SEN01831-02
40 Troubleshooting
Self-diagnosis
notice
Symptom of
failure
E13
Contents of
trouble
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.
panel
General
information
Cause
Possible
causes and the
standard values
when normal
2
in connector)
Self-diagnosis
notice

system
Symptom of
failure
E14
Contents of
trouble
Defective fresh air sensor


ACT (male)
Resistance
Between (1) and (2)
100 z 210 kz

and ACT (female) (1)
Resistance
Max. 1 z

Resistance
Max. 1 z
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.
panel
General
information
Cause
Possible
causes and the
standard values
when normal
2
in connector)
52
Defective fresh air sensor


system

ACT (male)
Resistance
Between (1) and (2)
100 z 210 kz

Resistance
Max. 1 z

Resistance
Max. 1 z
D475A, D475ASD-5E0
40 Troubleshooting
Self-diagnosis
notice
Symptom of
failure
E15
Contents of
trouble
SEN01831-02
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.
panel
General
information
Cause
Defective coolant
Possible
causes and the
standard values
when normal
2
in connector)
Self-diagnosis
notice
Symptom of
failure
E16
Contents of
trouble

system

THW (male)
Resistance
Between (1) and (2)
95 z 455 kz

and THW (female) (2)
Resistance
Max. 1 z

Resistance
Max. 1 z
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.
panel
General
information
Cause
Defective coolant
Possible
causes and the
standard values
when normal
2
in connector)

system
D475A, D475ASD-5E0

THW (male)
Resistance
Between (1) and (2)
95 z 455 kz

Resistance
Max. 1 z

Resistance
Max. 1 z
53
SEN01831-02
40 Troubleshooting
Self-diagnosis
notice
Symptom of
failure
E18
Contents of
trouble
Short circuit in daylight sensor
Short circuit in the daylight sensor system is detected.
Assumes that the daylight sensor is not installed for control.

panel
General
information
Cause
1
Possible
causes and the
standard values
when normal
2
in connector)
54
Defective daylight sensor


system

The daylight sensor may be defective. Check it directly.
and SLS (female) (2)
Resistance
Max. 1 z

and SLS (female) (1)
Resistance
Max. 1 z
D475A, D475ASD-5E0
40 Troubleshooting
Self-diagnosis
notice
Symptom of
failure
E21
Contents of
trouble
SEN01831-02
Disconnection in air blow sensor
Disconnection in the air blow sensor (frost sensor) system is detected.
Fixes the evaporator temperature at 10C for control.

panel
General
information
Cause
Defective air blow sensor
1 (frost sensor)
Possible
causes and the
standard values
when normal
2
in connector)
Self-diagnosis
notice
Symptom of
failure
E22
Contents of
trouble

system

THF (male)
Resistance
Between (1) and (2)
100 z 115 kz

and THF (female) (2)
Resistance
Max. 1 z

Resistance
Max. 1 z
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.

panel
General
information
Cause
Defective air blow sensor
1 (frost sensor)
Possible
causes and the
standard values
when normal
2
in connector)

system
D475A, D475ASD-5E0

THF (male)
Resistance
Between (1) and (2)
100 z 115 kz

Resistance
Max. 1 z

Resistance
Max. 1 z
55
SEN01831-02
40 Troubleshooting
Self-diagnosis
notice
Symptom of
failure
E43
Contents of
trouble
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.
panel
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 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)
3
Possible
causes and the
standard values
when normal
Resistance
Max. 1 z
Wiring harness between MV1 (female) (3) and

AP1 (female) (6)
Resistance
Max. 1 z

AP1 (female) (16)
Resistance
Max. 1 z

AP2 (female) (2)
Resistance
Max. 1 z

AP2 (female) (6)
Resistance
Max. 1 z

4
56

AP2 (female) (20)

system

AP1 (female) (6)
Resistance
Max. 1 z

AP2 (female) (20)
Resistance
Max. 1 z

AP1 (female) (15)
Resistance
Max. 1 z

AP2 (female) (1)
Resistance
Max. 1 z

AP2 (female) (11)
Resistance
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".
D475A, D475ASD-5E0
40 Troubleshooting
Self-diagnosis
notice
Symptom of
failure
E44
Contents of
trouble
SEN01831-02
Abnormality in air mix damper
Abnormality in air mix servomotor system is detected.
Stops the air mix servomotor.

panel
General
information
Cause
1
Defective air mix servomoThe air mix servomotor may be defective. Check it directly.
tor (Internal defect)
Possible
causes and the
standard values
when normal
2

system
D475A, D475ASD-5E0
Wiring harness between MAM (female) (1)

and AP2 (female) (20)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
57
SEN01831-02
40 Troubleshooting
Self-diagnosis
notice
Symptom of
failure
E45
Contents of
trouble
Abnormality in recirculated and fresh air damper
Abnormality in recirculated and fresh air servomotor system is detected.
Stops the recirculated and fresh air servomotor.

panel
General
information
Cause
Defective recirculated and

1 fresh air servomotor
(Internal defect)
The recirculated and fresh air servomotor may be defective. Check it

directly.
Possible
causes and the
standard values
when normal
2
58

system
Wiring harness between MRF (female) (1) and

AP2 (female) (20)
Resistance
Max. 1 z

AP1 (female) (6)
Resistance
Max. 1 z

AP1 (female) (8)
Resistance
Max. 1 z

AP2 (female) (4)
Resistance
Max. 1 z

AP2 (female) (5)
Resistance
Max. 1 z
D475A, D475ASD-5E0
40 Troubleshooting
Self-diagnosis
notice
Symptom of
failure
E51
Contents of
trouble
SEN01831-02
Abnormality in refrigerant pressure
Abnormality in refrigerant pressure circuit is detected.
Turns the compressor clutch OFF.

panel
General
information
Cause
1
Possible
causes and the
standard values
when normal
Defective high-low pressure

The high-low pressure switch may be defective. Check it directly.
switch (Internal defect)
harness (Disconnection in Wiring harness between AP1 (female) (5)
2
wiring harness or defective and SPHL (female) (2)
Wiring harness between SPHL (female) (1)
and chassis ground
3

system
D475A, D475ASD-5E0
Resistance
Max. 1 z
Resistance
Max. 1 z
59
SEN01831-02
40 Troubleshooting
60
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Troubleshooting by failure phenomenon

Symptom of
failure
The air conditioner does not operate.
(1) The air conditioner does not operate at all.
General
information
Cause
1
CB4

If the circuit breaker is turned OFF, the circuit probably has a grounding fault, etc. (Refer to cause 3.)
Wiring harness between circuit breaker CB4
outlet and ACU (female) (4), (5)
harness (Disconnection in Wiring harness between AP3 (male) (6) and
2
wiring harness or defective AP1 (female) (3)
and chassis ground
Wiring harness between AP5 (male) (7) and

chassis ground
Possible
causes and the
standard values
when normal
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Between wiring harness between circuit

breaker CB4 outlet and ACU (female) (4), (5)
and chassis ground
Resistance
Min. 1 Mz
Between wiring harness between AP3 (male)

(6) and AP1 (female) (3) and chassis ground
Resistance
Min. 1 Mz
4

unit
ACU
Voltage
Between (4) and (8)
20 30 V
If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective.
5 Defective control panel
AP1, AP2
Voltage
Between AP1 (3) and AP2 (19)
20 30 V
If the above voltage is normal and the control panel does not operate, the control panel is defective.
D475A, D475ASD-5E0
61
SEN01831-02
Symptom of
failure
40 Troubleshooting
(2) Air does not come out (Air flow is insufficient).
General
information
Cause
1 Defective fuse (in unit)

If the fuse (in the unit) is broken, the circuit probably has a grounding
fault, etc. Check the related circuits.

Defective blower main relay
2
Resistance
(on coil side)
RLBM (male)
300 440 z
Between (1) and (3)
3
Defective blower main relay

(on contact side)
RLBM
Fan switch
Voltage
Between (4) and

chassis ground
ON (Operated)
20 30 V
4
Defective blower linear

controller (Internal defect)
Fan switch
Operate in range of Low,
Medium, and High
If air flow can be changed with fan

switch, blower linear controller is
normal.
5
Defective blower motor

(Internal defect)
Possible
causes and the
standard values
when normal
Fan switch
Voltage
Between (1) and (2)
ON (Operated)
20 30 V
If the above voltage is normal and the blower motor does not rotate,
the blower motor is defective.
outlet, ACU (4), AP3 (female) (6), and RLBM
(female) (1)
Resistance
Max. 1 z

outlet, ACU (5) and RLBM (female) (3)
Resistance
Max. 1 z
Wiring harness between AP2 (female) (8),

AP4 (10) and RLBM (female) (2)
Resistance
Max. 1 z
harness (Disconnection in and chassis ground
6
Wiring harness between BLC (female) (3)
and RLBM (female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between MB (female) (1) and

RLBM (female) (4)
Resistance
Max. 1 z
Wiring harness between MB (female) (2) and

BLC (female) (4)
Resistance
Max. 1 z
Wiring harness between BLC (female) (1),

ACU (8), and chassis ground
Resistance
Max. 1 z

AP3 (8), and BLC (female) (2)
Resistance
Max. 1 z
62
MB

system

D475A, D475ASD-5E0
40 Troubleshooting
Symptom of
failure
SEN01831-02
(3) Air is not cooled (Cooling capacity is low).
General
information
Cause
1 Defective fuse (in unit)
Defective compressor
clutch relay (on coil side)
3 clutch relay
(on contact side)
Possible
causes and the
standard values
when normal

If the fuse (in the unit) is broken, the circuit probably has a grounding
fault, etc. Check the related circuits.
RLCC (male)
Resistance
Between (1) and (3)
140 340 z
carry out troubleshooting (Setting of temperature: Highest cooling
position).
RLCC
Fan switch
Voltage
Between (3) and

chassis ground
ON (Operated)
20 30 V
clutch (Internal defect)
The compressor clutch may be defective. Check it directly.
(Internal defect)
The compressor may be defective. Check it directly.

outlet, ACU (4), AP3 (6), AP1 (female) (3)
and RLCC (female) (1)
Resistance
Max. 1 z
harness (Disconnection in outlet, ACU (5) and RLCC (female) (4)
6
AP4 (7) and RLCC (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between AP2 (19) and chassis ground
Resistance
Max. 1 z
Wiring harness between RLCC (female) (3),

ACU (10) and A/C (female) (1)
Resistance
Max. 1 z

system
D475A, D475ASD-5E0

63
SEN01831-02
40 Troubleshooting
64
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-29 Orbcomm terminal does not operate normally (Data are not
transmitted)
Symptom of
failure
The ORBCOMM terminal does not operate normally (Data are not transmitted).
General
information
Even if the ORBCOMM terminal is abnormal, it does not cause a trouble in the machine.
Cause
Terminal power supply is

1 abnormal or satellite is not
captured

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
Power is not applied to ORBCOMM terminal or the communication with VHMS controller is abnormal.
Lamp is
ON
Power is applied to ORBCOMM terminal and the communication with VHMS controller is normal. But it does
not capture satellite.
Power is applied to ORBCOMM terminal, capturing satelFlashing lite and the communication with VHMS controller is normal.
Possible
causes and the
standard values
when normal

Disconnection in wiring harness (Disconnection in wir2

ing harness or defective
Between KOM1 (female) (36), (39), (40) and

VF2 (male) (5)
Resistance
Max. 1 z
Between KOM1 (female) (37), (38) and chassis ground
Resistance
Max. 1 z
Between V4B (female) (3) and KOM1

(female) (11)
Resistance
Max. 1 z

(female) (5)
Resistance
Max. 1 z

(female) (4)
Resistance
Max. 1 z
Defective ORBCOMM tera Prepare with starting switch OFF, then carry out troubleshooting
minal
(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
D475A, D475ASD-5E0
65
SEN01831-02
40 Troubleshooting
Decimal point position of multi-function monitor
66
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-30 Fan does not reverse

Symptom of
failure
When fan is set in fan cleaning mode or fan reverse mode (if equipped), fan does not reverse.
General
information
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

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.
FAN1 (male)
Between (1) and (2)
Switch
Resistance
OFF
Min. 1 Mz
CLN position
Max. 1 z

4
Defective fan cleaning
switch
(if equipped)
Possible
causes and the
standard values
when normal
FAN2 (male)
Switch
Resistance
OFF
Min. 1 Mz
Between (1) and (3)
CLN position
Min. 1 Mz
REV position
Max. 1 z
OFF
Min. 1 Mz
Between (3) and (4)
[When standard cleaning

switch is employed]
harness
CLN position
Max. 1 z
REV position
Min. 1 Mz

Wiring harness between FAN1 (female) (1)
Resistance
Max. 1 z

Resistance
Max. 1 z

5
[When optional reverse
switch is employed]
harness

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
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.)
D475A, D475ASD-5E0
67
SEN01831-02
40 Troubleshooting
68
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
E-31 Gear cannot be shifted

Symptom of
failure
Gear cannot be shifted (Shift switch does not work).
General
information
Cause
Possible
causes and the
standard values
when normal
Trouble in shift operation

switch
Shift-up switch
1
Shift-down switch
Shift switch
(Optional-type lever)
2 Gear speed limit
Defect in transmission
clutch
D475A, D475ASD-5E0

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.
69
SEN01831-02
40 Troubleshooting
E-32 Electric priming pump does not operate or does not stop
automatically
Symptom of
failure
Electric priming pump does not operate or does not stop automatically.
General
information
Cause
1 Low battery charge level
2

CB8

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)
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.
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).
Resistance
Between EPP (female) (2) ground
Max. 1 z
a Prepare with battery ground cable disconnected, then carry out

unswitched).
Possible
causes and the
standard values
when normal
harness
5
circuit)
Wiring harness between EPP (female) (1)

circuit breaker B8S and ground
Resistance
Min. 1 Mz

EFPL (female) (1) and ground
Resistance
Min. 1 Mz

EFPL (female) (2) and ground
Resistance
Min. 1 Mz

EFPR (female) (1) and ground
Resistance
Min. 1 Mz

EFPR (female) (2) and ground
Resistance
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.)
70
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).
D475A, D475ASD-5E0
40 Troubleshooting
SEN01831-02
Cause

a Prepare with battery ground cable disconnected, then carry out
unswitched).
Possible
causes and the
standard values
when normal
Trouble in electric priming

8
pump
Between EFPL (male) (1) (2)
Resistance
13z
Between EFPL (male) (1) pump body
Resistance
Min. 1 Mz
Between EFPL (male) (2) pump body
Resistance
Min. 1 Mz
Between EFPR (male) (1) (2)
Resistance
13z
Between EFPR (male) (1) pump body
Resistance
Min. 1 Mz
Between EFPR (male) (2) pump body
Resistance
Min. 1 Mz
D475A, D475ASD-5E0
71
SEN01831-02

2008 KOMATSU
All Rights Reserved
72
SEN01832-02
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
40 Troubleshooting
Troubleshooting of hydraulic and

mechanical system (H-mode)
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
D475A, D475ASD-5E0
SEN01832-02
40 Troubleshooting
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
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats) . 26
H-25 Operator's seat isolator quakes abnormally or makes shocks (Machine with operator's seat isolator) 27
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
Information in troubleshooting table

a
Trouble
Related
information
Trouble in machine
Information related to detected trouble or troubleshooting
Cause
Possible causes
and standard
value in normal
state
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)
D475A, D475ASD-5E0
SEN01832-02
40 Troubleshooting
H-1 No force (no drawbar pull)

Symptom of
failure
General
information
Possible
causes and the
standard values
when normal
No force (No drawbar pull)

Before troubleshooting, check that the power train oil level is normal.
Causes
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
0.8 1.0 MPa
0.39 0.64 MPa
Full neutral
{8.0 10.0 kg/cm2}
{4.0 6.5 kg/cm2}
Incorrect pressure set to
idle mode for troubleshooting.
3 transmission main relief
PCCS lever
valve
Full neutral
2.55 3.04 MPa {26.0 31.0 kg/cm2}
Defective operation of
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
FWD
2.25
2.74
MPa {23.0 28.0 kg/cm2}
5
transmission valve (ECMV)
REV
2.25 2.74 MPa {23.0 28.0 kg/cm2}
1ST
1.86 2.35 MPa {19.0 24.0 kg/cm2}
2ND
2.25 2.74 MPa {23.0 28.0 kg/cm2}
3RD
2.25 2.74 MPa {23.0 28.0 kg/cm2}

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.)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
Causes
Possible
causes and the
standard values
when normal
8 Defective steering clutch
D475A, D475ASD-5E0

PCCS lever
Left stroke end
Right stroke end
0 MPa
Min. 2.45 MPa
{0 kg/cm2}
{Min. 25 kg/cm2}
Min. 2.45 MPa
0 MPa
{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.
SEN01832-02
40 Troubleshooting
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 transmission main relief pressure is normal. (See H-1.)
Causes

converter

Torque converter
Torque converter
PCCS lever
inlet pressure
outlet pressure
0.8 1.0 MPa
0.39 0.64 MPa
Full neutral
{8.0 10.0 kg/cm2}
{4.0 6.5 kg/cm2}
mode for troubleshooting.
Transmission clutch
Clutch pressure
2ND
2.25 2.74 MPa {23.0 28.0 kg/cm2}
3RD
3
Possible
causes and the
standard values
when normal
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
Defective operation (dragDrive the engine in low idle mode and operate F2. Unless the
ging) of brake
PCCS lever
Left stroke end
Right stroke end
Min. 2.45 MPa
0 MPa
{Min. 25 kg/cm2}
{0 kg/cm2}
Min. 2.45 MPa
0 MPa
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
{0 kg/cm2}
{Min. 25 kg/cm2}
When the oil pressure is abnormal, execute the troubleshooting of
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-3 No travel at all gear speeds

Symptom of
failure
General
information
No travel at all gear speeds

Causes
Transmission main relief
PCCS lever
pressure
valve
2.55 3.04 MPa
Full neutral
{26.0 31.0 kg/cm2}
Check
valve
Transmission clutch
Clutch pressure
FWD
2.25 2.74 MPa {23.0 28.0 kg/cm2}
4
REV
2.25 2.74 MPa {23.0 28.0 kg/cm2}
1ST
1.86 2.35 MPa {19.0 24.0 kg/cm2}
2ND
2.25 2.74 MPa {23.0 28.0 kg/cm2}
3RD
Possible
causes and the
standard values
when normal
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.
6
Brake pedal
Brake oil pressure (right and left)
brake
Release
Min. 2.45 MPa {Min. 25 kg/cm2}
Step on
0 MPa {0 kg/cm2}
PCCS lever
Left stroke end
Right stroke end
0 MPa
Min. 2.45 MPa
2
}
{0
kg/cm2}
{Min.
25
kg/cm
Defective seal of steering
7
0 MPa
Min. 2.45 MPa
clutch
{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
{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.
D475A, D475ASD-5E0
SEN01832-02
40 Troubleshooting
H-4 Machine travels only in one direction forward or in reverse

Symptom of
failure
General
information
Possible
causes and the
standard values
when normal
Machine travels only in one direction Forward or in Reverse.

Causes
PCCS lever
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.
Check
valve
Transmission clutch
Clutch pressure
FWD
2.25
2.74
MPa {23.0 28.0 kg/cm2}
4
REV
2.25 2.74 MPa {23.0 28.0 kg/cm2}
1ST
1.86 2.35 MPa {19.0 24.0 kg/cm2}
2ND
2.25 2.74 MPa {23.0 28.0 kg/cm2}
3RD
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.
Defective operation (dragDrive the engine in low idle mode and operate F2. Unless the
ging) of brake
Defective operation of forward-reverse potentiome- Perform troubleshooting related to forward-reverse potentiometer.
ter of travel lever
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-5 Large time lag at gear speed shifting or forward-reverse shifting

Symptom of
failure
General
information
Possible
causes and the
standard values
when normal
Large time lag at gear speed shifting or forward-reverse shifting

Causes
PCCS lever
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.
Transmission clutch
Clutch pressure
FWD
2.25
2.74
MPa {23.0 28.0 kg/cm2}
3
REV
2.25 2.74 MPa {23.0 28.0 kg/cm2}
1ST
1.86 2.35 MPa {19.0 24.0 kg/cm2}
2ND
2.25 2.74 MPa {23.0 28.0 kg/cm2}
3RD
2.25 2.74 MPa {23.0 28.0 kg/cm2}

Defective seal of transmis- When the cause 3 is not applicable, the clutch seal is supposed to
4
sion clutch
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective,
5
sion clutch
check it directly.
Defective operation (drag6
Drive the engine in low idle mode and operate F2. Unless the
ging) of brake
D475A, D475ASD-5E0
SEN01832-02
40 Troubleshooting
H-6 Steering is not possible

Symptom of
failure
General
information

Causes
Possible
causes and the
standard values
when normal
brake
2 steering clutch valve
(ECMV)

clutch
Internal defect of steering
4
clutch
5 steering potentiometer of
travel lever
10

Prepare with starting switch OFF, then drive the engine in low idle
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.)
PCCS lever
Left stroke end
Right stroke end
0 MPa
Min. 2.45 MPa
{0 kg/cm2}
{Min. 25 kg/cm2}
Min. 2.45 MPa
0 MPa
{Min. 25 kg/cm2}
{0 kg/cm2}
0 MPa
Min. 2.45 MPa
Left brake pressure
2
{0 kg/cm }
{Min. 25 kg/cm2}
0 MPa
Min. 2.45 MPa
{Min. 25 kg/cm2}
{0 kg/cm2}
When the cause 2 is not applicable, the clutch seal is supposed to
The inside of the steering clutch is supposed to be defective, check
it directly.
Perform the troubleshooting related to steering potentiometer.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-7 Steering is possible only on one side

Symptom of
failure
General
information
Steering is possible only on one side.

Causes
Possible
causes and the
standard values
when normal
1 steering clutch valve
(ECMV)

clutch
Internal defect of steering
3
clutch
4 steering potentiometer of
travel lever
D475A, D475ASD-5E0

PCCS lever
Left stroke end
Right stroke end
0 MPa
Min. 2.45 MPa
{0 kg/cm2}
{Min. 25 kg/cm2}
0 MPa
Min. 2.45 MPa
{0 kg/cm2}
{Min. 25 kg/cm2}
0 MPa
Min. 2.45 MPa
Left brake pressure
{0 kg/cm2}
{Min. 25 kg/cm2}
0 MPa
Min. 2.45 MPa
{0 kg/cm2}
{Min. 25 kg/cm2}
When the cause 1 is not applicable, the clutch seal is supposed to
The inside of the steering clutch is supposed to be defective, check
it directly.
Perform the troubleshooting related to steering potentiometer.
11
SEN01832-02
40 Troubleshooting
H-8 Steering overrun occurs

Symptom of
failure
General
information
Steering overrun occurs.

Causes
Possible
causes and the
standard values
when normal
12
brake
steering clutch

a Prepare with starting the engine, then drive the engine in low idle
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.)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-9 Brake does not work

Symptom of
failure
General
information
Brake does not work.

Causes
1 Degradation of brake
Possible
causes and the
standard values
when normal
brake pedal
3 steering brake valve
(ECMV)
4 Defective brake seal

5 Internal defect of brake
D475A, D475ASD-5E0

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.
PCCS lever
Left stroke end
Right stroke end
Min. 2.45 MPa
0 MPa
{Min. 25 kg/cm2}
{0 kg/cm2}
0 MPa
Min. 2.45 MPa
{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
{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.
13
SEN01832-02
40 Troubleshooting
H-10 Torque converter is not lock-up

Symptom of
failure
General
information
Possible
causes and the
standard values
when normal
14
The torque converter is not lock-up.

Causes
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.
Measuring conditions
Engine speed
5
converter
F3 stall
Min. 1,590 rpm
F3 stall + Work equipment relief
Min. 1,450 rpm
(pitch back)
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-11 Power train oil is overheated
Symptom of
failure
The power train oil is overheated.
General
information
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.)
Causes
1
2
Possible
causes and the
standard values
when normal

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.
Torque converter
Torque converter
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
Defective operation (slide) The inside of the steering clutch is supposed to be defective (the
of steering clutch
clutch slides). Check it directly.
D475A, D475ASD-5E0
15
SEN01832-02
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
Possible
causes and the
standard values
when normal
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)
16
Internally defective PPC

valve

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.
Work equipment lever
Unload pressure
2.94 4.9 MPa
Full neutral
{30 50 kg/cm2}
Main relief pressure
27.4 1.4 MPa
Stroke end
(Except blade cylinder)
{280 14 kg/cm2}
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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-13 Work equipment does not move

Symptom of
failure
General
information
Work equipment does not move.

Causes
Defective PTO (Pump drive
1
unit of work equipment)
Defective work equipment
2
pump
Possible
causes and the
standard values
when normal
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
D475A, D475ASD-5E0

The PTO pump drive unit of the work equipment is assumed to be
The work equipment pump is assumed to be defective; directly
check it.
Unload pressure
2.94 4.9 MPa
Full neutral
{30 50 kg/cm2}
Main relief pressure
27.4 1.4 MPa
Stroke end
{280 14 kg/cm2}
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.
17
SEN01832-02
40 Troubleshooting
H-14 Blade lift speed is slow or lacks power
Symptom of
failure
Blade lift speed is slow or lacks power.
General
information
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.
Causes
Possible
causes and the
standard values
when normal
18

Defective PPC valve funcBlade lever
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)
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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-15 Blade tilt speed is slow or lacks power
Symptom of
failure
Blade tilt speed is slow or lacks power.
General
information
When the hydraulic drift rate of the blade tilt is also high, carry out troubleshooting High Hydraulic
Drift Rate of Blade Tilt.
Causes
Possible
causes and the
standard values
when normal

Defective PPC valve funcBlade lever
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)
The blade tilt cylinder is assumed to be aired; carry out the air bleed
3 Aired blade tilt cylinder
D475A, D475ASD-5E0
19
SEN01832-02
40 Troubleshooting
H-16 Ripper lift speed is slow or lacks power
Symptom of
failure
Ripper lift speed is slow or lacks power.
General
information
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.
Causes
1
Possible
causes and the
standard values
when normal
2
3
4
20

Defective PPC valve funcRipper lever
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 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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-17 Ripper tilt speed is slow or lacks power

Symptom of
failure
General
information
Ripper tile speed is slow or lacks power.

Causes
Possible
causes and the
standard values
when normal

Defective PPC valve funcRipper lever
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)
The ripper tilt cylinder is assumed to be aired; carry out the air bleed
3 Aired ripper tilt cylinder
D475A, D475ASD-5E0
21
SEN01832-02
40 Troubleshooting
H-18 Excessive hydraulic drift of blade lift

Symptom of
failure
General
information
Excessive hydraulic drift of blade lift.

Confirm that no oil leaks the circuits in the work equipment before troubleshooting.
Causes
Possible
causes and the
standard values
when normal
22
Defective seal of blade lift

control valve (Spool)
Defective seal of blade lift

cylinder

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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-19 Excessive hydraulic drift of blade tilt

Symptom of
failure
General
information
Excessive hydraulic drift of blade tilt.

Causes
Possible
causes and the
standard values
when normal
Defective seal of blade tilt

Defective seal of blade tilt

cylinder
D475A, D475ASD-5E0

a Prepare with starting the engine, then stop the engine for troubleshooting.
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.
3) Set the blade lever to the right tilt side, and confirm how the phenomenon changes.
Blade tilt cylinder
Cylinder leak quantity
Right tilt stroke end
20 cc/min
23
SEN01832-02
40 Troubleshooting
H-20 Excessive hydraulic drift of ripper lift

Symptom of
failure
General
information
Excessive hydraulic drift of ripper lift.

Causes
Possible
causes and the
standard values
when normal
Defective seal of ripper lift

Defective seal of ripper lift

cylinder

a Prepare with starting the engine, then stop the engine for troubleshooting.
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.
3) Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
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.
Causes
Possible
causes and the
standard values
when normal
24

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.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-22 Blade pitch does not work (dual tilt attachment machine)
Symptom of
failure
General
information
Possible
causes and the
standard values
when normal
The blade pitch does not work.
Causes
Defective function of blade
1 pitch selection solenoid
valve
2
pitch control valve (Spool)
3
pitch cylinder

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.
4
Even if the failure code does not appear, confirm that the switch
pitch switch
input is changed properly.
H-23 Abnormal sound comes out from around work equipment pump 1
Symptom of
failure
General
information
Possible
causes and the
standard values
when normal
Abnormal noise from around work equipment pump.

Causes
1 Inappropriate oil
Clogged hydraulic oil tank
2
strainer

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
25
SEN01832-02
40 Troubleshooting
H-24 Fan speed is abnormal (Sound and/or vibration of fan are/is

abnormally large or engine overheats)
Symptom of
failure
General
information
Fan rotation is normal (Sound/Vibration of fan is abnormally large or engine overheats).

Before carring out troubleshooting, check that oil level in hydraulic tank is normal.
Causes
1 Defective engine rotation
Defective PTO (fan pump

drive)
Possible
causes and the
standard values
when normal
Defect in fan pump or fan

motor
4 Defective fan
26

a Start engine and carry out troubleshooting.
Engine speed
Engine low idle
650 rpm
Engine high idle
2,150 rpm
If engine speed is low, carry out troubleshooting for the engine troubleshooting S-5 Rotation is irregular.
Fan pump drive of PTO may be defective. Check it directly.
a Prepare with starting switch OFF, then run engine at high idle and
Fan pump EPC circuit basic
pressure
3.72 MPa
{38 kg/cm2}
Fan drive circuit pressure
15.2 2.5 MPa
Fan 100% mode
{155 25 kg/cm2}
Defective fan
Fan 100% mode
880 rpm
Fan may be broken or installed defectively. Check it directly.
D475A, D475ASD-5E0
40 Troubleshooting
SEN01832-02
H-25 Operator's seat isolator quakes abnormally or makes shocks

(Machine with operator's seat isolator)
Symptom of
failure
General
information
Possible
causes and the
standard values
when normal
Operator's seat isolator quakes abnormally.

When operator's seat isolator quakes largely, it makes shocks.
Causes
Breakage of laminated rub- The laminated rubber may be broken. Perform Testing and adjust1
ber
ing, "Breakage of rubber".
The damper may malfunction. Perform Testing and adjusting, "Oil
2 Malfunction of damper
leakage from damper".
The stopper rubber may be broken. Perform Testing and adjusting,
3 Breakage of stopper rubber
"Breakage of stopper rubber".
D475A, D475ASD-5E0
27
SEN01832-02

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All Rights Reserved
28
SEN01833-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
40 Troubleshooting
Troubleshooting of engine (S-mode)

Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16
S-9 Oil becomes contaminated quickly ......................................................................................................... 17
S-10 Fuel consumption is excessive............................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 19
S-12 Oil pressure drops ................................................................................................................................ 20
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 21
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 22
S-15 Abnormal noise is made....................................................................................................................... 23
D475A, D475ASD-5E0
SEN01833-01
40 Troubleshooting
S-16 Vibration is excessive ........................................................................................................................... 24
D475A, D475ASD-5E0
40 Troubleshooting
Method of using troubleshooting chart
SEN01833-01
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.
D475A, D475ASD-5E0
SEN01833-01
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
40 Troubleshooting
SEN01833-01
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
SEN01833-01
40 Troubleshooting
S-1 Starting performance is poor
Q Q
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Stuck or seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter element
E E
Q w w
E
w
Q Q Q Q
w
w w Q Q
w
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
q
q
q
q
q
q
q
q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
q
Clean
Replace
Correct
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
Remedy
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Worn piston ring and cylinder
Correct
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
Defective contact of valve and valve seat
Clogged air cleaner element
Causes
Clean
Troubleshooting
Check items
Questions
General causes for poor starting performance are

q
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.
*1: Failure code [CA559], [CB559] and failure code [CA2249], [CB2249]
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-2 Engine does not start
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
q
Malfunction of hydraulic pump
Defective starting motor (motor section)
Defective steering circuit wiring
Defective starting motor (safety relay section)
Defective connection of battery terminal
w
w
w
Q
Q
w
w
Q
w
w
Q
q
q
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
Replace
Replace
Replace
Correct
Remedy
Replace
Troubleshooting
Inspect flywheel ring gear directly
D475A, D475ASD-5E0
E E
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
Turn starting switch OFF,

connect cord, turn the
switch ON and carry out
troubleshooting
Carry out troubleshooting

in E-mode

Degree of machine operaOperated for long period
tion
Condition of horn when
Horn does not sound
starting switch is turned
Horn volume is low
ON
Replace
Check items
Questions
Broken flywheel ring gear
Causes
SEN01833-01
40 Troubleshooting
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)
Defective injector
Defective operation of flow damper
Defective operation of overflow valve (Does not close)
Wrong connection of supply pump PCV
Defective supply pump PCV
Broken supply pump shaft spline
Seized, abnormally worn feed pump
E
w Q w w w
w E
Q Q
Q Q
E E
Q
Q
w Q
w w w w

Inspect fuel 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
q
q
q
q q
q
q
q
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Clean
Replace
Correct
Correct
q q
Add
Remedy
Clogged fuel filter element
Leaking, clogging and entry of air to fuel piping
Insufficient fuel in tank

Degree of
E E
machine operation
Exhaust smoke suddenly stopped coming out (when starting again)
w
w
Manual
When fuel tank is inspected, it is found to be empty
w
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
w
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
Replace
Troubleshooting
Check items
Questions
Use of improper fuel
Causes
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
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
q
q
Improper selection of fuel
Defective intake air heater system
Defective coolant temperature sensor and/or wiring harness
Clogged injector and/or defective spray
Stuck and/or seized supply pump plunger
Clogged fuel filter and/or strainer
Leaking, clogging of fuel system, and entry of air
Worn piston ring and/or cylinder liner
Worn dynamic valve system (Valve, rocker lever, etc.)

Degree of machine
E
E E
E
operation
Suddenly failed to start
w
w
Q
Q
Q
Q Q
w
w w
Manual
w
When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally (if monitor is installed)
w
Q
w w
When fuel filter is removed, there is no fuel in it
w
w
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
w
q
q
q
q
q
q
q
Replace
Replace
Replace
Clean
Replace
Clean
Clean
Correct
Clean
q
Replace
Replace
Remedy
Replace

q
Inspect dynamic valve system directly
q
q
Inspect fuel filter, strainer 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
Clean
Troubleshooting
Check items
Questions
Causes
D475A, D475ASD-5E0
SEN01833-01
40 Troubleshooting
S-3 Engine does not pick up smoothly
General causes why engine does not pick up smoothly

q
q
q
Defective spray condition of fuel
q
q
Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electrical system)
E
w
Clogged injector and/or defective spray
Defective operation of flow damper (Maximum leakage from injector)
E E
Q Q
Q
w
w w w
w w
w
w
w
w
w w
w
w Q Q
Q
w
w Q
w
w
Q
Q
w w
Q w
q
q
q
Correct
Replace
Replace
Clean
Clean
q q
Clean
Replace
Replace
Adjusting
Replace

q
q
q
Inspect valve clearance directly
q
When turbocharger is rotated by hand, it is found to be heavy
q
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
Remedy
Leaking, clogging of or entry of air to fuel piping
Seized turbocharger or interference of turbocharger
Improper valve clearance
E E
Correct

Degree of
machine operation Operated for long period
Engine pick-up suddenly became worse
Replacement of filters not carried out according to Operation and Maintenance Manual
Blue under light load
Color of exhaust
gas is
Black
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
Clean
Troubleshooting
Check items
Questions
Causes
10
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-4 Engine stops during operations
General causes why engine stops during operations

q
Seized parts inside engine
q
q
There is overheating
q
Broken auxiliary equipment (pump, compressor, etc.)
Broken supply pump shaft spline
Broken or seized feed pump
Leaking and/or clogged fuel piping
Broken or seized gear train
Broken or seized crankshaft bearing
Broken or seized piston and/or connecting rod
Broken dynamic valve system (valve, rocker arm, etc.)
Causes
EE
Q w Q w w
w Q
Condition when engine Engine overheated and stopped

stopped
Engine stopped slowly
Q
w
w Q
Q Q
Q Q Q
Q Q Q

Manual
w w
Engine stopped after hunting
w
w
Fuel level monitor indicates low level (if monitor is installed)

w
w Q Q
w w
Q Q

Check items
w w
w w
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
w
w
Supply pump shaft does not turn
q
q
q
q
q
q
q q
Replace
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Add
Replace
q
Replace
Remedy
Replace

Inspect piston and connecting rod directly
Inspect crankshaft bearing directly
Inspect gear train 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
Replace
Troubleshooting
Engine turns, but stops when load is applied to machine
Questions
Abnormal noise was heard and engine stopped sudw w w w

denly

in H-mode
Degree of machine
operation
D475A, D475ASD-5E0
11
SEN01833-01
40 Troubleshooting
S-5 Engine does not rotate smoothly
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)
Q
w
Defective G (Bkup) speed sensor or wiring harness
Defective Ne speed sensor and/or wiring harness
Clogged injector and/or defective spray (dirt in injector)
Defective operation of flow damper (Maximum leakage from injector)
Clogged fuel filter or strainer
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

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)"
q
q
q q
q
Correct
Correct
Correct
Replace
Replace
Replace
Clean
q
Add
Remedy
Leaking or clogging or entry of air to fuel piping
E E
Replace

Degree of machine
operation
Occurs at a certain speed range
Occurs at low idle
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Correct
Troubleshooting
Check items
Questions
Low setting of low idle speed
Causes
*1: Failure code [CA689] and failure [CB689]

*2: Failure code [CA778] and failure [CB778]
12
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output
q
q
q
q
q
Overheat
o See "S-14 Coolant temperature becomes too
high (Overheating)"
q
(limiting injection rate (output) because of an
error in electrical system)
1
Defective fuel temperature sensor and/or wiring harness
Defective boost pressure sensor and/or wiring harness
Defective drive of injector (signal and/or solenoid)
Defective installation of boost pressure sensor (air leakage)
Clogged injector or defective spray (dirt in injector)
Leaking or clogged fuel piping
Air leakage from air intake piping
Causes
Q Q Q
Q
E E
Q Q
Q Q
Q
Q
w
Q
Q Q Q
w
w
w
w
w w
w
w
w

w
Q
High idle speed is too high

High idle speed under no load is normal, but speed suddenly drops when
load is applied
w w Q
w
Q Q
Q Q Q Q
D475A, D475ASD-5E0
q
q
q
q q
q
q
Replace
Replace
Correct
Replace
Replace
Replace
Correct
q
Clean
Replace
Adjusting
Replace
Replace
Correct

q
Inspect air intake piping directly
q
When boost pressure is measured, it is found to be low
q q q
q
q
q
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)"
Remedy
w Q
Clean
Replace
Suddenly
Power was lost
Gradually
Output becomes insufficient after short stop of operation
Color of exhaust Black
gas
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Clean
Troubleshooting
Check items
Questions
Degree of machine
operation
13
SEN01833-01
40 Troubleshooting
*2: Failure code [CA122] and failure code[CA123]
14
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-7 Exhaust smoke is black (incomplete combustion)
E
w
w
Defective coolant temperature sensor or wiring harness
Improper fuel injection pressure
Improper injection timing
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Clogged or seized injector
E
Q Q Q
Q
Q
w
Q Q
w
w
Q
w
Q
Q
Q Q
Q
w
w
Q Q Q
Q w
w
w
Q Q
Q
Q
w
Q Q Q
Q
Q w
w
w
q
q
q
q
q
Replace
Adjusting
Adjusting
Correct
Replace
Replace
Replace
Replace
Correct
Adjusting
Replace
Replace

q
When turbocharger is rotated by hand, it is fount to be heavy
q
q
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)"
Remedy
Crushed or clogged muffler
Leakage of air between turbocharger and cylinder head
Replace

Degree of
machine operation
Suddenly became black
Color of exhaust Gradually became black
gas
Oil replenished more frequently
Suddenly
Power was lost
Gradually
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
Torque converter stall speed or pump relief speed is high
(Fuel is injected excessively)
Exhaust noise is abnormal
If spill hose from injector is disconnected, abnormally much fuel spills
Causes
Clean
Troubleshooting
Check items
Questions
General causes why exhaust smoke is black

q
q
Excessive injection of fuel
q
q
q
Overheat
o See "S-14 Coolant temperature becomes too high
(Overheating)"
q
(limiting injection rate (output) because of an error in
electrical system)
D475A, D475ASD-5E0
15
SEN01833-01
40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust smoke is blue)

Degree of machine oper- Operated for long period
ation
Oil consumption suddenly increased
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
Oil leakage from oil pan, cylinder head, etc.
Oil leakage from oil drain plug
Oil leakage from oil piping
Oil leakage from oil filter
Oil leakage from oil cooler
Broken oil cooler
Worn or damaged rear oil seal
Broken piston ring
Clogged breather or breather hose
Turbocharger
Worn seal at blower end
Worn seal at turbocharger end
E E E
E
w
Q
Q
w
Q Q w
w w w w w
w
w
Q w
w
w
Q
w w
w w
Q
w
q
q
q q
q
q q
q
q q
Correct
Correct
Correct
Correct
Replace
Replace
Correct
Replace
Replace
Clean
Replace
Replace
q q q q
Correct
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
Inspect rear oil seal directly
Pressure-tightness test of oil cooler shows there is leakage
There is external leakage of oil from engine
Remedy
16
Worn or damaged valve (stem, guide, seal)
Dust sucked in from intake system
Causes
Correct
Troubleshooting
Check items
Questions
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
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-9 Oil becomes contaminated quickly
Exhaust smoke is bad
Clogged turbocharger lubrication drain tube
Defective oil filter safety valve
Clogged oil filter
Clogged oil cooler
Clogged breather and/or breather hose
Worn valve and/or valve guide
Defective seal at turbocharger turbine end
Causes

Degree of machine operation
E E E
Q
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
Color of exhaust gas
Black
w
Excessive
Q Q w
Q
Amount of blow-by gas
None
w
Excessive play of turbocharger shaft

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
q q
q
q
q
Clean
Replace
Replace
Clean
Clean
Replace
Replace
q
Remedy
D475A, D475ASD-5E0
See S-7
Replace
Troubleshooting
Check items
Questions
General causes why oil becomes contaminated

q
Entry of exhaust gas into oil due to internal wear
q
Clogging of lubrication passage
q
q
Use of improper oil
q
Operation under excessive load
17
SEN01833-01
40 Troubleshooting
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

q
Leakage of fuel
q
Defective condition of fuel injection (fuel pressure, injection timing)
q
Excessive injection of fuel
Defective coolant temperature sensor or wiring harness
Defective operation of injector
Defective spray by injector
Defective common rail fuel pressure
Defective supply pump plunger
Defective feed pump oil seal
Fuel leakage from fuel filter, piping, etc.
Q Q Q
Q
Q Q
w
w
w
w
w
Q
Q
Q Q
Q Q
Q
q
q
q
q
q
q
Correct
Correct
Replace
q
Replace
Correct
q
Replace
Remedy
Replace
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
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
E E
Correct

Degree of
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
Correct
Troubleshooting
Check items
Questions
Fuel leakage inside head cover
Causes
18
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is mixed in coolant
q
Internal leakage in lubrication system
q
Internal leakage in cooling system
Broken oil cooler core and/or O-ring
Insufficient protrusion of cylinder liner
Damaged cylinder liner O-ring and/or hole caused by pitting
Cracks inside cylinder block
Broken cylinder head and/or head gasket
Causes
Degree of machine
operation
Oil level
Suddenly increased
Q
Q Q
Gradually increased
Q Q
Hard water is being used as coolant
Check items
Oil level has risen and oil is milky
Troubleshooting
There are excessive air bubbles in radiator, coolant spurts back
Pressure-tightness test of cylinder head shows there is leakage
q q
Inspect cylinder block and liner directly
Inspect cylinder liner directly
D475A, D475ASD-5E0
Replace
Replace
Replace
Remedy
Replace
Replace
Questions
19
SEN01833-01
General causes why oil pressure drops

q
Leakage, clogging, and/or wear of lubrication system
q
Defective oil pressure control
q
Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed.
q
Deterioration of oil due to overheating
Defective oil level sensor and/or wiring harness
Defective oil pressure sensor and/or defective wiring harness
Leaking, crushed, clogged hydraulic piping
Clogged oil filter
Defective oil pump relief valve
Defective oil pump
Clogged and/or broken pipe in oil pan
Clogged strainer in oil pan
Coolant and fuel mixing in oil
Lack of oil in oil pan
w
Q
w
Q Q
w
w
w
w
w
w
w
q
q q
q
q
q
q
Replace
Replace
Correct
Clean
Adjusting
Replace
q
Clean
Remedy
Q w
Q
w
Q
w w w Q
See S-13
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
Add

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
Clean
Troubleshooting
Check items
Questions
Worn journal of bearing
Causes
Clean
S-12 Oil pressure drops
40 Troubleshooting
20
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-13 Oil level rises (Entry of coolant or fuel)
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".

Degree of
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
Defective seal of auxiliary equipment (pump, compressor)
w
Q
Q
Defects in supply pump
Defective thermostat seat
Clogged water pump drain hole (breather hole) and/or defective seal
Worn or damaged rear oil seal
Cracks inside cylinder block
Fuel leakage inside head cover
Broken oil cooler core and/or O-ring
E
w
w
Q Q
Q
Q
Q
Q
Q
w
w
w
w

Remove and inspect head cover directly
Inspect cylinder block and/or liner directly
Inspect rear oil seal directly
Remove and inspect water pump directly
Remove and inspect thermostat cover directly
Remove and inspect supply pump directly
Inspect seal of auxiliary equipment directly
q
q q
q
q
q
q
q
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Correct
q
Remedy
D475A, D475ASD-5E0
E E
Replace
Troubleshooting
Check items
Questions
Causes
21
SEN01833-01
40 Troubleshooting
S-14 Coolant temperature becomes too high (overheating)

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
Rise in power train oil temperature on applicable machine side
Defective coolant temperature gauge
Slipping fan belt and/or worn fan pulley
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged or crushed radiator fins
Defective operation of thermostat
Broken water pump
Lack of coolant
Clogged or broken oil cooler
E E
Q w
Q
Q
Q w w
w
w
w
w Q
w
w
w
w
w
w
w
w
w
q
q
q
q
q
q
Replace
Correct
Replace
Correct
Correct
Replace
Replace
Add

in H-mode
Replace

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
E E
Replace

Degree of
machine operation
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
Replace
Troubleshooting
Check items
Questions
Causes
Remedy
22
D475A, D475ASD-5E0
40 Troubleshooting
SEN01833-01
S-15 Abnormal noise is made
D475A, D475ASD-5E0
Improper fuel injection timing (abnormality in coolant temperature sensor)
Dirt caught in injector
Clogged or seized injector
Deformed cooling fan and/or looseness or interference of fan belt
Removed or seized gear train bushing
Improper gear train backlash
Excessive wear of piston ring and/or cylinder liner
Defective inside of muffler (dividing board out of position)
Q Q
Q
Q
w
w
w
w
w
w
w
w Q
w
Q w
Q
Q
w
Q Q
Q
w
When turbocharger is rotated by hand, it is fount to be heavy

When muffler is removed, abnormal noise disappears
Inspect fan and fan belt directly
Abnormal noise is heard only when engine is started
q
q
q
q
q q
q
q q
q
Correct
Correct
Replace
Correct
Replace
Replace
Replace
Replace
Replace
q
Correct
Remedy
Broken dynamic valve system (valve and/or rocker lever)
Replace

Degree of
machine operation
Gradually increased
Condition of
abnormal noise
Suddenly increased
Air leaks between turbocharger and cylinder head
When engine is cranked, beat noise is emitted around muffler
Color of exhaust Blue under light load
gas
Black
Abnormal noise is loud when engine is accelerated
Interference or seizure of turbocharger
Leakage of air between turbocharger and cylinder head
Causes
Replace
Troubleshooting
Check items
Questions
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.
23
SEN01833-01
40 Troubleshooting
S-16 Vibration is excessive

Degree of
machine operation
Condition of vibra- Suddenly increased
tion
Gradually increased
Non-specified oil is being used
Oil pressure is low at low idle
Vibration occurs at mid-range speed
Vibration follows engine speed
Q
Q
w
w
Q
Q
Q
w
w
Q
E
Q
Q
Q
Q Q Q Q
Exhaust smoke is black

Inspect main bearing and connecting rod bearing directly
Inspect camshaft bushing directly
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
Broken output shaft and/or parts in damper on installed machine side
Worn front support spigot joint portion
Misalignment between engine and devices on installed machine side
Loose engine mounting bolts and/or broken cushions
Worn camshaft bushing
Improper gear train backlash
E
Q
q
q
q
q
q
q
q
Replace
Replace
Adjusting
Replace
Adjusting
Replace
Replace
Replace
q
Remedy
24
Worn main bearing and/or connecting rod bearing
Stuck dynamic valve system (valve, rocker lever, etc.)
Causes
Replace
Troubleshooting
Check items
Questions
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.
D475A, D475ASD-5E0
40 Troubleshooting
D475A, D475ASD-5E0
SEN01833-01
25
SEN01833-01

2008 KOMATSU
All Rights Reserved
26
SEN02013-06
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools .............................................................................................................................. 14
D475A, D475ASD-5E0
SEN02013-06
How to read this manual

1.
(Rev. 2009.01)
1
Removal and installation of assemblies

Special tools
q
Special tools which are necessary for
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
q : Special tools that will be useful if available and are substitutable with tools
available on the market
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The 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 not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Removal
q
In Removal section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety
a : Guidance or precautions for the work
[*1] : This mark shows that instructions or precautions for parts installation work are given in
Installation section.
6 : Amount of oil or coolant to be drained
4:
Weight of part or component
Installation
q
Unless otherwise instructed, installation of
parts is to be done in the reverse order to
removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in Removal section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
Marks shown in the Installation section stand
for the following.
k
: Precautions related to work safety

: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished
Sketches of special tools

q
Various special tools are illustrated for the local
manufacture.
D475A, D475ASD-5E0
2.
SEN02013-06
Disassembly and assembly of assemblies

Special tools
q
Special tools which are necessary for disassembly and assembly of parts are
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used.
q : Special tools that will be useful if available and are substitutable with tools
available on the market.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The 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 not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Disassembly
q
In Disassembly section, the work procedures,
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in Disassembly section are as follows.
k

6 : Amount of oil or coolant drained
Assembly
q
In Assembly section, the work procedures,
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in Assembly section are as follows.
k

2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished

Various special tools are illustrated for the local
manufacture.
D475A, D475ASD-5E0
SEN02013-06
Coating materials list

a
a
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.
Category
Komatsu
code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloPolyethylene
ride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene Features: Resistance to heat and chemicals.

container Used to fix and seal bolts and plugs.
Adhesive
LT-3
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
790-129-9140
Can
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
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.
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
Features: Resistance to heat and chemicals.

Polyethylene
Used for fitted portions used at high temperacontainer
tures.
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.
LG-5
Gasket sealant
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
LT-4
ThreeBond
1735
790-129-9080
LG-6
790-129-9160
200 g
Tube
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.
LG-7
790-129-9170
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
LG-8
ThreeBond
1207B
(Rev. 2009.02)
1
419-15-18131
100 g
D475A, D475ASD-5E0
Gasket sealant
CateKomatsu code
gory
Molybdenum
disulfide
lubricant
Container
790-129-9310
200 g
Tube
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.
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
Used as lubricant/sealant when the radiator

hoses are inserted.
Can be coated with paint.
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
Feature: Can be used together with gaskets.

Used for covers of the transmission case and
steering case etc.
ThreeBond
1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
Can
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.
Various
Various
Feature: Lithium grease with extreme pressure

lubrication performance.
General purpose type.
LC-G
NEVER-SEEZ
09940-00040
09995-00250
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Grease
Q'ty
LG-9
ThreeBond
1206D
LM-P
Seizure
prevention
compound
Part number
SEN02013-06
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
D475A, D475ASD-5E0
200 g
190 g
Used for parts under heavy load.

Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
swing circle bearings, etc. and spline.
400 g x 20 container
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg
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.
Bellows-type Since this grease is decomposed by natural baccontainer

teria in short period, it has less effects on microCan
organisms, animals, and plants.
SEN02013-06
G2-U-S
ENS grease
427-12-11871
SUNSTAR
PAINT PRIMER
580 SUPER
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
SUNSTAR
PAINT PRIMER
435-95
Q'ty
Container
Tube
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.
2 kg
Can
Feature: Urea (organic system) grease with heat

resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
20 ml
Glass
container
Used as primer for cab side.

(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
Used as primer for glass side.

20 ml
Glass
container
200 g
417-926-3910
22M-54-27230
Adhesive for cab glass
G2-S
ThreeBond
1855
Part number
Used as primer for painted surface on cab

side.
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
Used as primer for sash (Almite).

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
S is used for high-temperature season

and W for low-temperature season as
adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Used as adhesive for glass.

SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window.

Cartridge
Used to seal joint of glasses.

Translucent white seal.
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Grease
CateKomatsu code
gory
Used as adhesive for glass.

Used to seal joints of glass parts.
D475A, D475ASD-5E0
SEN02013-06
Special tools list
Component
Removal and installation of radiator

guard assembly
Removal, installation
of cylinder head
assembly
790-431-1120
Adapter
791-520-4140
Screw
791-181-1020
Sleeve
791-765-1150
Plate
791-112-1180
Nut
790-101-2540
Washer
790-101-2102
Puller
(294 kN {30 ton})
790-101-1102
Pump
790-331-1110
Wrench
Tightening of cylinder
head bolt
795-931-1100
Seal puller assembly
Extraction of oil seal
795T-621-1430 Plate
795T-621-1441 Push tool
01050-32280
Bolt
01582-02218
Nut
01640-22232
Washer
795-931-1100
Seal puller assembly
795T-621-1531 Push tool
01050-32050
Bolt
Symbol
of engine front seal
3
of engine rear seal
Disassembly and
assembly of torque
converter
Disassembly and
assembly of PTO
assembly
Part No.
D475A, D475ASD-5E0
Part Name
01640-02032
Washer
790-413-1010
Bracket
790-501-5000
Repair stand
791T-813-1110
Push tool
Sketch
New/
remodel
Q'ty
* *** ****
Tools with part number 79 Tmeans that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
Necessity:
t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any modification.
Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
Sketches of special tools).
Necessity
Nature of work, remarks
Pulling out pin or radiator

guard
Press fitting of oil seal
Extraction of oil seal

N
Q
Press fitting of oil seal
Disassembly, assembly of
torque converter
791T-813-1120 Plate
04020-01228
Pin
01017-52030
Bolt
01643-32000
Washer
PTO assembly
Disassembly and
assembly of transmission
1
Disassembly and
assembly of steering
2
3
Disassembly and
assembly of final
drive assembly
3
J
4
Part Name
790-413-1010
Bracket
790-501-5000
Repair stand
799-301-1600
Oil leak tester
Sketch
Part No.
New/
remodel
Symbol
Q'ty
Component
Necessity
SEN02013-06

transmission
Checking actuation of piston
791-622-1110
Bracket
01016-51690
Bolt
01011-81600
Bolt
791T-822-1810 Push tool
791T-822-1820 Push tool
791-822-1830
Wrench
790-337-1032
Lifting tool
791-827-1910
Plate
01011-83015
Bolt
790-431-1081
Guide
790-431-1031
Block
790-101-2350
Leg
790-101-2430
Adapter
790-101-2360
Plate
02215-11622
Nut
790-101-2102
Puller
(294 kN {30 ton})
790-101-1102
Pump
790-431-1101
Installer assembly
790-101-2102
Puller
(294 kN {30 ton})
790-101-1102
Pump
791-585-1510
Installer
790-431-1220
Remover assembly t
790-101-2102
Puller
(294 kN {30 ton})
790-101-1102
Pump
790-431-1210
Installer assembly
790-101-2102
Puller
(294 kN {30 ton})
790-101-1102
Pump
790-431-1230
Remover & installer t
790-101-2102
Puller
(294 kN {30 ton})
790-101-1102
Pump
790-431-1240
Guide
Removal, installation of
clutch, brake assembly
Press fitting of bearing
bearing round nut
final drive assembly
Pulling out sprocket bearing
Press fitting of sprocket

bearing
Installation of floating seal
Pulling out center hub
Press fitting of center hub
Pulling out, press fitting of

carrier pin
Assembly of No. 1 pinion
D475A, D475ASD-5E0
1
Assembly of Idler
790-101-2510
Block
790-101-2570
Plate
01580-01613
Nut
01643-31645
Washer
790-101-2102
Puller
(294 kN {30 ton})
Sketch
Rod
Press fitting of idler bushing
790-101-1102
Pump
Installer
791-830-1480
Push tool
Press fitting of seal guide
791-601-1000
Oil pump
Filling with oil
791-515-1520
Installer
791-830-1770
Push tool
791-630-1270
Wrench
791-830-1740
Plate
791-515-1520
Installer
10
791-830-1730
Push tool
11
791-601-1000
Oil pump
790-401-1700
Lifting tool
790-401-1761
Adapter
790-401-1540
Shackle
790-401-1770
12
13
14
Disassembly and
assembly of bogie
15
D475A, D475ASD-5E0
Plate
Part Name
791-560-1520
Disassembly and
assembly of bogie
and track roller
791-830-1760
791-830-1320
Part No.
Disassembly and
assembly of carrier
roller
Assembly of track
roller
New/
remodel
Symbol
Q'ty
Component
SEN02013-06
Necessity
T-bolt
791T-830-1780 Plate
01011-62700
Bolt
01673-32780
Washer
Press fitting of floating seal

collar
round nut
N
Press fitting of bushing

Press fitting of seal ring

Filling with oil
track roller assembly
Q
Fixture of bogie
1 791-830-1620
Plate
2 791-830-1630
Spacer
3 791-830-1640
Screw
4 01580-12722
Nut
5 01630-32780
Washer
6 790-101-4000
Puller
(490 kN {50 ton})
7 790-101-1102
Pump
Pulling out ring and shaft
1 791-830-1650
Plate
2 791-830-1660
Spacer
3 796-670-1120
Plate
4 790-434-1070
Screw
5 01580-13629
Nut
6 01643-33690
Washer
7 790-101-4000
Puller
(490 kN {50 ton})
Pulling out ring
1 791-830-1620
Plate
2 791-830-1640
Screw
Part No.
15 8 790-101-1102
Nut
Washer
5 790-101-4000
Puller
(490 kN {50 ton})
6 790-101-1102
3 01580-12722
16 4 01643-32780
Disassembly and
assembly of bogie
Part Name
18
791-530-1510
Installer
19
791-601-1000
Oil pump
Filling with oil
21
10
Press fitting of pin assembly
Pump
791-630-1860
Bracket
791-630-1870
Bracket
791T-830-1510 Spacer
19M-09-12850
Bolt
01643-33380
Washer
791T-830-1710 Bar
791T-830-1720 Plate
07283-31079
Grip
01582-01210
Nut
01643-31232
Washer
04530-11628
Eye bolt
790-434-1401
Remover assembly t
790-101-2102
Puller
(294 kN {30 ton})
790-101-1102
Pump
791T-830-1700 Lifting tool
Disassembly and
assembly of
equalizer bar
Pulling out ring
791T-830-1670 Guide
17
20
Disassembly and
assembly of recoil
spring
Sketch
Pump
Symbol
New/
remodel
Q'ty
Component
Necessity
SEN02013-06
791-685-8502
Compressor
791-635-3160
Extension
790-201-2790
Spacer
790-101-1300
Cylinder
(980 kN {100 ton})
790-101-1102
Pump
791-730-1120
Bolt
01580-13326
Nut
01643-33380
Washer
792-900-1610
Adapter
792-900-1530
Screw
791-775-1110
Sleeve
791T-850-1150 Plate
01582-53024
Nut
01643-33080
Washer
Removal of No. 1 bogie

assembly
Removal of No. 1 bogie

track roller
Pulling out idler cushion

guide pin
recoil spring
Removal of recoil spring

assembly
Pulling out center pin
D475A, D475ASD-5E0
Puller
(294 kN {30 ton})
790-101-1102
Pump
791T-850-1160 Bracket
791T-850-1170 Bracket
790-438-1110
Screw
790-101-2540
Washer
791-112-1180
Nut
790-101-2102
Puller
(294 kN {30 ton})
790-101-1102
Pump
791T-850-1180 Sleeve
791T-850-1190 Plate
791-730-1130
Bolt
791-101-3310
Plate
01643-32060
Washer
01580-02016
Nut
790-105-2300
Jack assembly
790-101-1102
Pump
791-646-7531
Plug remover
791-660-7460
Pin brush
Cleaning of pin
791-646-7900
Push tool
Knocking in large plug
791-932-1110
Push tool
Knocking in all plugs
790-701-3000
and
791-601-1000
Seal checker
Filling with oil and checking air tightness
791-632-1010
Installer
Replacing of link seal
1 791-832-1610
Plate
Disassembly and
assembly of
equalizer bar
N
2
Disassembly and
assembly of pivot
shaft
Disassembly and
assembly of track
shoe
D475A, D475ASD-5E0
Part No.
Part Name
2 791-832-1270
Bracket
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 01310-21032
Screw
15 791-832-1640
Pusher
16 791-832-1340
Extension
17 791-832-1650
Adapter
Pulling out center pin
Pulling out side pin bushing
Press fitting of seal
Knocking out small plug
Oil pump
3 01010-81495
Sketch
790-101-2102
Symbol
New/
remodel
Q'ty
Component
SEN02013-06
Necessity
Pulling out and press fitting of pin and bush
11
18 791-832-1480
Adapter
19 791-832-1670
Guide
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
Pusher
8 25 791-832-1350
26 791-832-1620
Disassembly and
assembly of track
shoe
Guide
27 04530-11018
Eye bolt
28 790-101-4500
Cylinder
t
(1960 kN {200 ton})
29 790-101-1102
Pump
30 790-101-4200
Puller
(294 kN {30 ton})
31 791-685-9230
Spacer
1 791-685-5600
Push tool assembly t
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
N
N
9 791-685-5730
Bar
Bolt
11 01580-01210
Nut
791-685-5740
Push tool
1 791-832-1490
Push tool
2 791-832-1510
Push tool
1 791-685-5700
Push tool 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
11
12
13
791-685-5750
Push tool
2 791-685-5640
10 01252-30655
10
12
Part Name
Sketch
Part No.
New/
remodel
Symbol
Q'ty
Component
Necessity
SEN02013-06
Press fitting ring

(For large plug)
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
D475A, D475ASD-5E0
790-502-1003
Cylinder repair
stand
cylinder
790-201-1702
Push tool kit
Press fitting of coil bushing
790-201-1881
Push tool
790-201-1871
Push tool
Ripper lift
Ripper puller
790-201-1721
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
Push tool kit
790-201-1670
790-201-1680
Press fitting of dust seal
Plate
Blade lift
Plate
Ripper lift
790-201-1690
Plate
Blade tilt
(standard specification)
Blade pitch
(superdozer specification)
Ripper tilt
790-201-1530
Plate
Pin puller
790-101-5021
Grip
01010-50816
Bolt
790-720-1000
Expander
796-720-1690
Ring
07281-01919
Clamp
796-720-1690
Ring
07281-02169
Clamp
796-720-1710
Ring
07281-02709
Clamp
796-720-1630
Ring
07281-00709
Clamp
790-102-2304
Wrench
D475A, D475ASD-5E0
Blade tilt
Blade pitch
Ripper tilt
Disassembly, assembly of hydraulic cylinder
Sketch
Part Name
Part No.
New/
remodel
Symbol
Q'ty
Component
SEN02013-06
Necessity
Installation of all cylinder

piston rings
Blade lift (standard specification)
Blade lift (superdozer
specification)
Ripper tilt, lift
Blade tilt
Blade pitch
Pin puller
Removal and installation
of pin puller cylinder head
13
SEN02013-06
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A4 Plate
A4 Push tool
14
D475A, D475ASD-5E0
SEN02013-06
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A5 Push tool
C2 Push tool
D475A, D475ASD-5E0
15
SEN02013-06
C2 Plate
E2 Push tool
16
D475A, D475ASD-5E0
SEN02013-06
E2 Push tool
L13 Plate
D475A, D475ASD-5E0
17
SEN02013-06
L17 Guide
L20 Spacer
18
D475A, D475ASD-5E0
SEN02013-06
L21 Lifting tool
L21 Bar
D475A, D475ASD-5E0
19
SEN02013-06
L-21 Plate
N1 Plate
20
D475A, D475ASD-5E0
SEN02013-06
N2 Bracket
N2 Bracket
D475A, D475ASD-5E0
21
SEN02013-06
P Sleeve
P Plate
22
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN02013-06
23
SEN02013-06

2013 KOMATSU
All Rights Reserved
Printed in Japan 01-13(02)
24
SEN02014-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

Engine and cooling system (SAA12V140E-3)
Engine and cooling system (SAA12V140E-3) ................................................................................................ 2
Removal and installation of engine assembly ...................................................................................... 2
Removal and installation of radiator assembly..................................................................................... 6
Removal and installation of aftercooler assembly ................................................................................ 8
Removal and installation of radiator guard assembly ........................................................................ 10
Removal and installation of fuel tank assembly ................................................................................. 12
Removal and installation of engine hood assembly ........................................................................... 13
Removal and installation of fan drive assembly ................................................................................. 15
Removal and installation of fan motor assembly................................................................................ 16
D475A, D475ASD-5E0
SEN02014-01
Engine and cooling system (SAA12V140E-3)

Removal and installation of
engine assembly
4.
Lift off radiator upper cover (2).

4
Radiator upper cover assembly: 85 kg
Removal
k
k
k
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.
Collect the air conditioner refrigerant (R134a)
from air conditioner circuit in advance.
[*1]
a Ask professional traders for collecting and
filling operation of refrigerant.
a Never release the refrigerant to the atmosphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or filling the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified person.
Remove engine hood assembly (3).

For
details, see "Removal and installation of
engine hood assembly".
6.
Remove right and left engine side covers (4)

and right and left covers (5).
Drain the coolant.

6
3.
5.
Coolant: 210 l
Remove right and left potentiometer wiring

grommets (1) from the cover.
D475A, D475ASD-5E0
7.
Remove undercovers (1st, 2nd and 3rd ones

from the front) (33).
SEN02014-01
10. Disconnect radiator outlet tube (11).

11. Disconnect torque converter oil cooler tubes
(12) and (13).
12. Disconnect heater hose (14).
8.
Disconnect radiator inlet hoses (6) and aeration hoses (7).
13. 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).
9.
Lift off the right and left aftercooler inlet piping

assemblies.
a Loosen hose clamps (8).
a Remove pipe mounting bolt (9).
a Remove piping fixing bracket (10).
D475A, D475ASD-5E0
SEN02014-01
14. Disconnect air conditioner hose (15) and

remove the compressor assembly.
a Cover the hoses so that dirt, water, etc.
will not enter them.
a Disconnect all the clamps of hose (11).
17. Disconnect engine rear-side air conditioner

hoses (23) and wiring connectors (24).
18. Disconnect fuel filter hose (25), 4 hoses (26)

and heater hose (27) between the valve and
engine.
15. Remove engine lubricating oil pump hose (18),
pump mounting bracket mounting bolts (19),
and pump and bracket assembly (20).
a Remove cables (21).
19. Remove damper rubber shield (28).
16. Remove cables (22) from the starting motor.
D475A, D475ASD-5E0
20. Sling universal joint (29), remove the mounting

bolts, and lift off the universal joint.
4
SEN02014-01
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.
Universal joint: 65 kg
Coolant: 210 l
21. Remove front mounting bolt (30) and rear

mounting bolt (31).
22. 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.
D475A, D475ASD-5E0
SEN02014-01

radiator assembly
4.
Disconnect radiator inlet hoses (3) (right and

left) and aeration hoses (4) (right and left).
5.
Disconnect sub-tank hose (5).
6.
Disconnect power line cooler aeration hose

(6).
Removal
1.
Drain the coolant.

6
2.
Coolant: 210 l

3.

4
Remove the fan motor assembly. For

details, see "Removal and installation of
fan motor assembly".
7.
Remove isolator bolts (7) (2 each on the right

and left sides).
8.
Remove wind breaker panels (8) (upper, lower,

right and left).
9.
Disconnect headlamp connectors (9).
D475A, D475ASD-5E0
SEN02014-01
10. Disconnect radiator upper wiring harness (10)

and radiator coolant level sensor connector
(11).
13. Remove tube (15).
11. Sling radiator assembly (12) and remove upper

mounting bolts (13) (2 each on the right and
left sides).
15. Lift off radiator assembly (12).

a When removing the radiator assembly,
take care not to damage its core.
14. Lift off lower mounting bolts (16) (right and left).
Radiator assembly: 485 kg
12. Remove undercover (14).
Installation
q

removal.

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5
D475A, D475ASD-5E0
Coolant: 210 l
SEN02014-01

aftercooler assembly
3.
Disconnect radiator upper clamp (3) and aftercooler upper clamp (4).
4.
Remove mounting bolt (6) of aftercooler upper

pipe (5).
5.
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).
Removal
1.
2.


4
D475A, D475ASD-5E0
7.
Sling aftercooler (11) and remove upper

mounting bolts (12).
8.
Move aftercooler upper pipe (5) and lower pipe

(9) toward the engine and lift off aftercooler
(11), taking care that the aftercooler will not
interfere with the pipes.
SEN02014-01
Installation
q

removal.
D475A, D475ASD-5E0
SEN02014-01

radiator guard assembly
Adapter
t 1
791-520-4140
Screw
t 1
791-181-1020
Sleeve
t 1
791-765-1150
Plate
t 1
Nut
t 1
790-101-2540
Washer
t 1
790-101-2102
Puller
t 1
(294 kN {30 ton})
790-101-1102
Pump
A 1 791-112-1180
4.
Drain coolant.
6
t 1
5.
Disconnect radiator inlet and outlet hoses, aeration hose, and wiring harness clip.
For details, see "Removal and installation of
radiator assembly".
6.
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.
Removal
1.
2.
10
Coolant: 210 l
Sketch
Q'ty
790-431-1120
New/remodel
Necessity
Symbol
Part Name
Sling blade lift cylinder assembly (4), then fit

cylinder holder tool and secure to radiator
guard.
Special tools
Part No.
3.
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.
Remove hood assembly.

hood assembly".
Remove engine side covers (left and right).
D475A, D475ASD-5E0
7.
Disconnect work equipment hoses (7) and (8).
SEN02014-01
Installation
q

removal.
[*1]
a Standard shim thickness: 4 mm
q

5
8.
Sling radiator guard assembly and remove lock

bolt, then using tool A1, push rear pin (11) to
inside of radiator guard and remove.
9.
Remove lock plate, then using tool A1, pull

front pin (12) to outside of radiator guard and
remove.
Coolant: 210 l
10. Lift off radiator guard assembly (13).

a Be extremely careful not to damage the
wiring and piping when removing.
4
Radiator guard assembly: 4,700 kg
D475A, D475ASD-5E0
11
SEN02014-01
Removal and installation of fuel

tank assembly
1
6.
Remove fuel tank mounting bolt (9).
7.
Lift off fuel tank assembly (10).
Removal
1.
Disconnect hose (1).

a Before disconnecting the hose, close the
fuel valve.
2.
Remove case (2).
3.
Remove joint (3) and hose clamp (4).
4.
Disconnect fuel return hoses (5) and (6), and

remove hose clamp (7).
5.
Disconnect fuel gauge wiring connector (8).
Fuel tank assembly (when full): 2,335kg
Installation
q
12

removal.
D475A, D475ASD-5E0

engine hood assembly
SEN02014-01
3.
Disconnect wiring connectors (3) (201 and

209) and remove clamp (4).
4.
Disconnect hose (5) to the sub-tank and

remove hose clamp (4).
5.
Open right and left covers (6) and (7).
6.
Remove right and left side covers (8).
Removal
k
1.
2.


4
D475A, D475ASD-5E0
13
SEN02014-01
7.
Loosen clamps (9) and disconnect air cleaner

hoses (10).
[*1]
8.
Remove sub-tank drain hose clamp (11).
9.
Disconnect wiring connectors (12) (HR1 and

HR2 at the right rear of the hood).
11. Remove hood mounting bolts (16) and (17).
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

removal.
[*1]
Hose inserted length: Min. 40 mm
3 Hose clamp:
8.83 0.5 Nm {0.9 0.05 kgm}
14
D475A, D475ASD-5E0
Removal and installation of fan

drive assembly
1
SEN02014-01
5.
Remove wiring harness clamp (5) and disconnect connector (6).
6.
Bracket (7).
7.
Disconnect fan motor hoses (8), (9) and (10).
8.
Sling fan drive assembly (11) and remove

bracket mounting bolts (12).
9.
Lift off fan drive assembly (11).
Removal
1.
Drain the hydraulic oil.

6
2.
Hydraulic tank: Approx. 340 l
Remove 8 mounting bolts (2) of radiator mask

(1) and open the radiator mask.
3.
Remove net (3).
4.
Remove fan blade (4).
a
a
Fan drive assembly: 250 kg
Loosen mounting bolts (13) of the lower

right and left shrouds.
Move the fan to the position shown in the
photo.
Installation
D475A, D475ASD-5E0

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.
15
SEN02014-01
Removal and installation of fan motor assembly
Removal
1.
2.
Remove the fan drive assembly. For details,

see "Removal and installation of fan drive
assembly".
3.
Remove nut (2).
4.
Remove fan (3).
Remove the mounting bolt and lock plate (1).

[*1]
5.
Remove the 4 mounting bolts and fan motor

assembly (4).
[*3]
4
16
[*2]
Fan motor assembly: 65 kg
D475A, D475ASD-5E0
SEN02014-01
Installation
q

removal.
[*1]
Be sure to adjust the hole of lock plate (1) by
turning nut (2) in the tightening direction.
[*2]
[*3]
Mounting nut (2):

1,080 1,275 Nm {110 130 kgm}
After tightening the nut, check dimension
(d) shown below.
q
MIN: 2.0 mm
q
MAX: 4.0 mm
When fitting the fan motor and fan, clean

and degrease them thoroughly.
D475A, D475ASD-5E0
17
SEN02014-01

2009 KOMATSU
All Rights Reserved
18
SEN02338-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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
D475A, D475ASD-5E0
SEN02338-03

supply pump assembly
Removal of fuel supply pump on left bank

side
k

Do not remove the undercover.
1.
Close the fuel valve under the fuel tank.
2.
Remove left side cover (1) and left cover (2).
3.
Remove 2 main fuel filters (3).

a Use a filter wrench etc. to remove the filters.
k
k
4.
Remove fuel hose clamp (4) and bracket (5).
5.
Remove high-pressure pipe clamp (6) and

high-pressure pipe (7).
6.
Remove clamp (8) and fuel tube (9).
7.
Remove lubrication tube (10).
8.
Remove common rail cover (11).
[*1]
D475A, D475ASD-5E0
9.
Disconnect wiring connectors (12).

a Connectors: PCV1, PCV2 and G
SEN02338-03
Removal of fuel supply pump on right bank

side
k

Do not remove the undercover.
1.
2.
Remove right side cover (1) and right cover

(2).
3.
Remove 4 engine oil filters (3).

a Use a filter wrench etc. to remove the filters.
4.
Remove heat insulation plate (4).
k
k
10. Remove the mounting bolts of fuel supply

pump assembly (13) and pull out the fuel supply pump assembly and mounting bracket (14)
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
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.
11. If necessaty, remove nut (15), coupling (16)

and key (17) from supply pump assembly (13).
D475A, D475ASD-5E0
SEN02338-03
5.
Disconnect wiring clamp (5) and fuel hose

clamps (6).
6.
Remove hose clamp (7) of the fuel air bleeding

valve.
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).
7)
Disconnect 6 upper high-pressure pipes

(13) of the common rail and high-pressure
pipes (14) on this side.
8)
Disconnect common rail wiring connector

(15).
9)
Remove right and left mounting bolts (16)

to remove common rail (17).
D475A, D475ASD-5E0
8.
Remove brackets (18) and (19).
9.
Remove clamp (20) and fuel tube (21).
SEN02338-03
13. If necessary, remove nut (25), coupling (26)

and key (27) from supply pump assembly (24).
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
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.
D475A, D475ASD-5E0
SEN02338-03
Installation
a
The following is the installation procedure for

the left bank fuel supply pump assembly. The
basic installation procedure for the right fuel
supply pump assembly is the same.
1.
Install key (17), coupling (16) to supply pump

assembly (13), then tighten with nut (15).
a Be careful not to forget the key (17) when
installing the coupling (16).
3 Nut:
176 196 Nm {18 20 kgm}
High-pressure pipe
k
2.
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).
5.
3.
Connect the wiring connector (12).
4.
Remove common rail cover (11).
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.
Install the high-pressure pipe according to the

1) Install high-pressure pipe assembly (7)
and then tighten the sleeve nuts to the
specified torque.
a Using a spanner-type torque wrench
(commercially available), control the
tightening torque.
3 High-pressure
pipe sleeve nut
(Supply pump side):
39.2 49 Nm {4 5 kgm}
High-pressure pipe sleeve nut
(Common rail side):
39.2 58.8 Nm {4 6 kgm}
2) Tighten the supply pump assembly mounting bolts.
3) Tighten supply pump assembly bracket
(14) mounting bolts.
D475A, D475ASD-5E0

3
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)
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,
ta ke care ex tremely that an
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)
D475A, D475ASD-5E0
SEN02338-03
Carry out the following installation in the

reverse order to removal.
[*1]
3
3
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}
Check that each high-pressure pipe is at

least 10 mm apart from the wiring harness
around it.
SEN02338-03

cylinder head assembly
4.
1
A 2 790-331-1110
Wrench
Muffler assembly: 60 kg (1 piece)
Sketch
New/remodel
Q'ty
Part Name
Necessity
Symbol
Special tools
Part No.
Remove mounting bands (3) and connector

nuts and then wind a rope around muffler
assembly (4) and lift it off.
q 1
Removal
k
k
k

1.
2.
Remove the engine hood. For details, see

"Removal and installation of engine hood".
3.

5.
Remove the piping and then remove the corrosion resistor, air bleeding valve and mounting
bracket (5) together.
4
6.
Remove muffler mounting bracket (6).

4
Corrosion resistor, air bleeding valve

and mounting bracket: Approx. 35 kg
Muffler mounting bracket: 38 kg
D475A, D475ASD-5E0
7.
SEN02338-03
Remove aftercooler inlet pipe (7) and aftercooler outlet pipe (8).
[*1]
8.
Remove bracket (9) and turbocharger intake

connector (10) together.
[*2]
9.
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).
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
12. Disconnect fuel hose and piping (14).
Air intake manifold: 35 kg
[*3]
13. Remove main fuel filter assembly (15) and fuel

prefilter assembly (16).
D475A, D475ASD-5E0
SEN02338-03
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
10
Turbocharger and exhaust manifold

assembly: 60 kg
D475A, D475ASD-5E0
SEN02338-03
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).
[*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.
24. Remove head cover (33).
26. Remove push rods (37).

27. Remove crossheads (38).
28. Removal of fuel injector
1) Remove injector terminal mounting nuts
(39).
2) Remove clamp mounting bolt (40).
3) Push connector (41) into the cylinder head
and remove injector wiring harness (42).
4) Remove holder mounting bolt (43).
D475A, D475ASD-5E0
11
SEN02338-03
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.
Install the cylinder head gasket.
2.
Sling and install cylinder head assembly (45).

4
Cylinder head assembly: 30 kg
29. Lift off cylinder head assembly (45).

4
Cylinder head assembly: 30 kg
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.
a
a
2
3
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
D475A, D475ASD-5E0

a
SEN02338-03
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).
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).
4.
Install gasket (48) to fuel injector (44).
5.
Insert fuel injector (44) and injector holder (49)

together in the cylinder head.
D475A, D475ASD-5E0
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.
Crosshead
7. Install crossheads (38).
2 Sliding parts of crosshead:
Engine oil (EO30)
13
SEN02338-03
8.
9.
14
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}
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.
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)
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.
93 103 Nm {9.5 10.5 kgm}
a Tighten locknut (34) after adjusting the
valve clearance.
see Testing and adjusting, "Testing and
adjusting valve clearance".
D475A, D475ASD-5E0

3
Tightening torque for locknut:

52.9 64.7 Nm {5.4 6.6 kgm}
After tightening the locknut, check the
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.)
D475A, D475ASD-5E0
SEN02338-03
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
specified position securely and
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.
15
SEN02338-03
1)
2)
3)
4)
5)
16
Fit O-ring (52) to the high-pressure pipe

sleeve nut (51).
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.
tightening torque.
3 High-pressure pipe (19) sleeve nut
(Injector side):
39.2 49 Nm {4 5 kgm}
(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.

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).
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:
a Tighten the mounting bolts according
3 Air intake manifold mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
D475A, D475ASD-5E0
16. Install the high-pressure pipe clamps (between

the common rail and fuel injector). For details,
pump assembly".
SEN02338-03
[*2]
Air intake connector mounting bolt:

49 68.6 Nm {5.0 7.0 kgm}
[*3]
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).
(commercially available), control the tightening torque.
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}
[*4]
q

[*1]
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}
3
3
3
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}
[*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:
3 Exhaust manifold mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
When using new hose

4) Tighten until dimension BDG becomes as
follows.
BDG: 17 20 mm
D475A, D475ASD-5E0
17
SEN02338-03
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]
18
Air vent tube mounting bolt:

9.8 12.7 Nm {1.0 1.3 kgm}

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.

around it.
D475A, D475ASD-5E0

injector assembly
SEN02338-03
4
Corrosion resistor, air bleeding valve

and mounting bracket: Approx. 35 kg
Removal
k
k
k
1.

2.
Remove the engine hood. For details, see

"Removal and installation of engine hood".
3.

6.
Remove muffler mounting bracket (6).

4
4.
Remove mounting bands (3) and connector

nuts and then wind a rope around muffler
assembly (4) and lift it off.
4
5.
Muffler mounting bracket: 38 kg
7.
Remove aftercooler inlet pipe (7) and aftercooler outlet pipe (8).
[*1]
8.
Remove bracket (9) and turbocharger intake

connector (10) together.
[*2]
9.
Remove turbocharger exhaust connector (11).
Muffler assembly: 60 kg (1 piece)
Remove the piping and then remove the corrosion resistor, air bleeding valve and mounting
bracket (5) together.
D475A, D475ASD-5E0
19
SEN02338-03
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
12. Disconnect fuel hose and piping (14).
Air intake manifold: 35 kg
[*3]
13. Remove main fuel filter assembly (15) and fuel

prefilter assembly (16).
14. Remove the common rail cover. For details,

pump assembly".
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).
15. Remove right and left rubber covers (17) and

(18).
16. Remove right and left high-pressure pipes
(19).
20
D475A, D475ASD-5E0
SEN02338-03
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
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).
D475A, D475ASD-5E0
Fuel injector
a Check that there is no dirt in the injector
sleeve.
1.
Fit O-rings (46) and (47) to fuel injector (44).

a Take care not to fit O-ring (47) to center
groove (A).
2.
Install gasket (48) to fuel injector (44).
3.
Insert fuel injector (44) and injector holder (49)

together in the cylinder head.
21
SEN02338-03
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.
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.
22
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.
93 103 Nm {9.5 10.5 kgm}
a Tighten locknut (34) after adjusting the
valve clearance.
see Testing and adjusting, "Testing and
adjusting valve clearance".
Tightening torque for locknut:

52.9 64.7 Nm {5.4 6.6 kgm}
After tightening the locknut, check the
D475A, D475ASD-5E0
7.
Place the cylinder head cover. (Place it to prevent dirt from entering. It will need to be
removed again.)
8.
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
specified position securely and
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.
SEN02338-03
1)
2)
D475A, D475ASD-5E0
3)
4)
5)
Fit O-ring (52) to the high-pressure pipe

sleeve nut (51).
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.
tightening torque.
(Injector side):
39.2 49 Nm {4 5 kgm}
(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.
23
SEN02338-03
6)
7)
9.
Install the cylinder head cover.

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).
q
Injector side (17): Down
q
Common rail side (18):
Cylinder block side
Removal
q

[*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
Install the high-pressure pipe clamps (between

the common rail and fuel injector). For details,
pump assembly".
10. Install the high-pressure pipes (between the

common rail and fuel supply pump). For
details, see "Removal and installation of fuel
supply pump assembly".
a For precautions, see the section of the
high-pressure pipe (between the common
rail and fuel injector).
(commercially available), control the tightening torque.
[*2]
Air intake connector mounting bolt:

49 68.6 Nm {5.0 7.0 kgm}
[*3]
24
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}

around it.
D475A, D475ASD-5E0
SEN02338-03
a

engine front seal
3 795-931-1100
Seal puller
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
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
CS: Crankshaft
t 1
795T-621-1430 Plate
t 1 N Q
795T-621-1441 Push tool
t 1 N Q
4 01050-32280
Bolt
t 3
01582-02218
Nut
t 3
01640-22232
Washer
t 3
Removal
1.
Remove radiator guard assembly.

radiator guard assembly".
2.
Remove crankshaft pulley (1).
3.
Remove front seal (2).
D475A, D475ASD-5E0
[*1]
25
SEN02338-03
Installation
1.
Clean, degrease and then dry the contact surface between the front cover and front seal.
2.
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.
3.
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
1)
3)
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)
Inner circumference of front oil seal:

Gasket sealant (LG-7 or equivalent)
The surface having the parts number (PN)

marking must face to the outside of
engine.

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)
26
Tighten bolts using the tool A4 (plate),

and press oil seal (2) to the shaft end.
D475A, D475ASD-5E0
SEN02338-03
a

engine rear seal
Seal puller
795T-621-1531 Plate
01640-02032
CS: Crankshaft
Sketch
New/remodel
Part Name
Q'ty
Part No.
5 01050-32050
a
Necessity
Symbol
A
Special tools
3 795-931-1100
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
t 1
t 1 N Q
Bolt
t 5
Washer
t 5
Removal
1.
Remove damper assembly.

damper assembly".
2.
Sling with eyebolts [1] (M16, P=2), remove

mounting bolts (1), screw in forcing screws [2]
(M12, P=1.75), then remove flywheel (2).
4
3.
Flywheel: 140 kg
Remove rear seal (3).
D475A, D475ASD-5E0
27
SEN02338-03
Installation
1.
Clean, degrease and then dry the contact surface between the flywheel housing and rear
seal.
2.
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.
3.
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
1)
2)
28
4.
Using guide bolt, and install flywheel (2).
5.
Secure flywheel (2) and housing with plate [3].
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}
Inner circumference of rear oil seal:

Gasket sealant (LG-7 or equivalent)
The surface having the parts number (PN)

marking must face to the outside of
engine.
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)
D475A, D475ASD-5E0
6.
SEN02338-03
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
D475A, D475ASD-5E0
29
SEN02338-03

2011 KOMATSU
All Rights Reserved
30
SEN02015-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
Power train, Part 1

Power train, Part 1 .......................................................................................................................................... 2
Removal and installation of damper assembly..................................................................................... 2
Disassembly and assembly of damper assembly ................................................................................ 4
Removal and installation of power train unit assembly ........................................................................ 7
Removal and installation of PTO, torque converter assembly ........................................................... 10
Disconnection and connection of PTO, torque converter assembly .................................................. 12
Disassembly and assembly of torque converter assembly ................................................................ 14
Disassembly and assembly of PTO assembly ................................................................................... 24
Removal and installation of TORQFLOW transmission assembly ..................................................... 31
Disassembly and assembly of TORQFLOW transmission assembly................................................. 32
D475A, D475ASD-5E0
SEN02015-01
Power train, Part 1

damper assembly
6.
Remove holder (4) and coupling (5).
7.
Remove retainer (6).
Removal
8.
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.
1.
Remove hood assembly.

For details, see Removal and installation of
hood assembly.
2.
Open underguard (3rd from front of machine).
3.
Remove drain plug (1) and drain damper oil.

6
4.
Remove dipstick and dipstick guide (2).
Sling universal joint (3), then remove mounting

bolts, and lift off.
[*1]
4
Damper cover: 50 kg
Damper case: Approx. 2.2 l
9.
5.
[*2]
Sling damper assembly (8), then using guide

bolt [2] (16 mm, P = 2.0) and nut [3], loosen nut
slowly so that damper assembly does not
come out suddenly, then remove.
4
Damper assembly: 85 kg
D475A, D475ASD-5E0
SEN02015-01
Installation
q
[*1]
[*2]

removal.
3
2
3
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}
Refilling with oil (damper case)

level, and run the engine to circulate the oil
through the system. Then check the oil level
again.
D475A, D475ASD-5E0
SEN02015-01
Disassembly and assembly of

damper assembly
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.
3.
Align the bolt holes with body (7), then install

flange (6).
2 Flange mating surface:
a Check that there are no dents, rust, oil or
grease, or water on the mating surface,
then coat both the flange and body 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.
Disassembly
1.
Remove bolt (1), then remove flange (2).
2.
Remove seal (3).
3.
Remove shaft (4).
4.
Remove rubber (5).
5.
Remove flange (6) from body (7).
6.
Remove seal (8).
7.
Remove bearing (9).
Disassembly of damper cover assembly

8. Remove bearing (10) and seal (11) from cover
(12).
9.
Remove oil seal (13) from retainer (14).
D475A, D475ASD-5E0
SEN02015-01
7.
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:
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.
Tighten bolt (1).
Using push tool [2], press fit bearing (10) to

cover (12).
Install flange (2).

2 Flange mating surface:
a Check that there are no dents, rust, oil or
grease, or water on the mating surface,
then coat both the flange and body 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.
D475A, D475ASD-5E0
SEN02015-01
10. Using push tool [1], press fit oil seal (11) to
cover (12).
a Coat the inside surface of the cover thinly
with gasket sealant and wipe off any sealant that is forced out.
D475A, D475ASD-5E0
SEN02015-01
Removal and installation of power

train unit assembly
8.
Remove hydraulic pump inlet tube coupling (5)

and hydraulic tank side coupling (6), and
remove tube (7).
Removal
9.
Disconnect fan motor hose (8).
1.
Drain oil from hydraulic tank and power train

case.
6
6
10. Disconnect hoses (9) and (10).

Power train case: Approx. 150 l
2.
Remove floor frame assembly.

floor frame assembly".
3.
Remove fuel tank assembly.

fuel tank assembly".
4.
Remove brake rod (1).
5.
Disconnect cable (2).
11. Disconnect steering hose (11).

12. Disconnect hoses (12) and (13).
6.
Disconnect lubrication hose (3).
7.
Disconnect fan motor pump tube coupling (4).
13. Remove hydraulic pump inlet tube (14).

14. Disconnect hydraulic pump PPC hoses (15)
and (16).
D475A, D475ASD-5E0
SEN02015-01
15. Disconnect hydraulic pump outlet hoses (17)

and (18).
19. Remove universal joint (23).

4
[*1]
16. Disconnect hydraulic PPC hoses (19) and (20).
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).
D475A, D475ASD-5E0
SEN02015-01
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
[*1]
[*2]
[*3]
[*4]

removal.
3
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}
Check that the housing clip is fitted

securely in the flange.
3 Housing clip:
4.9 8.8 Nm {0.5 0.9 kgm}
25. Lift off power train unit assembly (31).

4
Power train unit assembly: 5,500 kg
[*5]
[*5]
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.
Refilling with oil

again.
5
5
D475A, D475ASD-5E0
Power train case: Approx. 210 l

SEN02015-01
Removal and installation of PTO,

torque converter assembly
6.
Sling filter assembly (6), then remove.

4
4
Removal
1.
Remove power train unit assembly.

power train unit assembly".
2.
Raise power train unit assembly (1) and set on

block.
a Set blocks under the front of the oil pan,
transmission rear case, and steering case.
7.
Remove brake rod (2).
[*1]
8.
Disconnect central pressure detection hose

(3), then remove together with central pressure
detection bracket (4).
a Before removing the pressure detection
hoses, mark them with tags to prevent any
mistake in the mounting position when
installing.
5.
Remove oil filler tube (5).
10
[*2]
Mount bracket: 70 kg
Remove tube (10) and scavenging pump (11).

k Sling the scavenging pump, then
remove the mounting bolts.
4
4.
Power train pump, strainer assembly:

100 kg
Lift off mount bracket (9).

4
9.
Torque converter, transmission lubrication filter assembly: Approx. 80 kg
Remove power train pump (7) and strainer

assembly (8).
k Sling the power train pump, then
remove together with the strainer.
4
3.
Transmission filter assembly: 40 kg
Scavenging pump: 24 kg
D475A, D475ASD-5E0
10. Remove hose (12).

11. Remove gauge guide (13).
SEN02015-01
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: 72 kg
Installation
q
[*1]
[*2]
[*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

removal.
k
Bend the cotter pin securely.
PTO boss rotating portion:

Grease (G2-LI)
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
D475A, D475ASD-5E0
11
SEN02015-01
Disconnection and connection of

PTO, torque converter assembly
5.
Remove oil seal (6).
6.
Remove spacer (7).

a Remove snap ring (8), then remove the
spacer.
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.
790-413-1010 Bracket
t 1
790-501-5000 Repair stand
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Disconnection
1.
Set PTO and torque converter assembly (1) to

tool C1.
2.
Remove coupling assembly (2).
3.
Remove cap (3).

a Remove snap ring (4), then remove the
cap.
4.
Remove retainer assembly (5).

[*1]
a Using forcing screws, remove the cover,
retainer assembly, and shims.
a Check the number and thickness of the
shims, and keep in a safe place.
12
PTO, torque converter assembly:

830 kg
D475A, D475ASD-5E0
Connection
q
SEN02015-01
3)
Carry out connection in the reverse order to

disconnection.
4)
[*1]
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}.
a Apply liquid gasket (LG-5) to the oil
seal press-fitting face.
a Apply liquid gasket (LG-5) thinly to
the inside of the retainer hole and
wipe off any part forced out.
a Install the oil seal without slanting it.
a Apply grease (G2-LI) to the oil seal lip
part
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).
D475A, D475ASD-5E0
Measure shim thickness.

(a) (0 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.
2 Mounting bolt:
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.
q
13
SEN02015-01

torque converter assembly
2)
790-413-1010 Bracket
t 1
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
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).
Disassembly
q
Set the torque converter assembly to tool C1.
2]
3]
1.
Torque converter valve assembly

Remove torque converter valve assembly (1).
2.
Draining oil
Remove 2 drain plugs (2), and drain oil from
pump case.
a After draining the oil, tighten the plugs.
3.
Lockup clutch, drive case assembly

1) Leaving 2 mounting bolts (3) in position,
remove mounting bolts, then place input
shaft side on top and remove remaining
mounting bolts.
14
Remove snap ring (7), then remove

plate (8).
Set clutch housing side at bottom,
and using forcing screws [3], remove
turbine (9).
D475A, D475ASD-5E0
4]
5]
SEN02015-01
9]
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).
4.
6]
7]
Remove seal ring (13) from piston.

Remove seal ring (14) from housing.
8]
Using push tool [5], remove bearing

(15) 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).
2]
D475A, D475ASD-5E0
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.
Remove snap ring (24) from stator

(23).
15
SEN02015-01
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).

Set stator clutch housing at top and remove
stator clutch housing (32).
2)
3)
7.
Spring
Remove spring (33).
8.
Springs, discs, plate

Remove springs (34), 2 discs (35), and 1 plate
(36).
a After removing the discs and plates, keep
them in a flat place to prevent them from
becoming distorted.
16
Remove seal ring (42) from piston.

Remove seal ring (43) from case.
D475A, D475ASD-5E0
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
assem bly (4 6) from stator sha ft
assembly.
2]
3]
4]
SEN02015-01
5]
Using push tool [7], remove bearing

(55), then remove plate (56).

bearing inner race (48), bushing (49),
and seal ring (50) from shaft.
Remove seal ring (51) from stator
shaft (52).
plate (54).
D475A, D475ASD-5E0
17
SEN02015-01
Assembly
a
1.
7)
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 C1.
Stator shaft assembly

1) Assemble plate (56) to stator shaft (52),
and using push tool, press fit bearing (55).
a Drop power train oil TO30 or TO10 to
the bearing by at least 6 cc and rotate
it 10 turns.
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.
4)
5)
6)
18
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.
Install snap ring (47), and secure inner

race.
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.
2
3
Mounting bolt:
Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
D475A, D475ASD-5E0
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 Install the seal rings in the correct
directions with their grooves (a) in the
directions shown in the figure.
D475A, D475ASD-5E0
SEN02015-01
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).
4.
Pin
Install pin (37).
5.
Plate, discs, springs

Install 1 plate (36), 2 discs (35), and springs
(34).
6.
Dowel pins
Install dowel pins (34A).
7.
Spring
Install spring (33).
19
SEN02015-01
8.

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}
9.
Pump assembly
1) Assemble pump assembly as follows.
1] Using push tool, press fit bearing
outer race (30) to guide (31).
a Drop power train oil TO30 or
TO10 to the bearing by at least 6
cc and rotate it 10 turns.
20
2]
2)
3)
4)
Set bearing and guide assembly (28)

to pump (29), then tap with a plastic
hammer and press fit bearing portion.
3] Install retainer (27).
2 Mounting bolt:
3 Mounting bolt:
58.8 74.5 Nm {6 7.5 kgm}
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).
Install drain plug.
3 Drain plug:
9.8 12.7 Nm {1 1.3 kgm}
D475A, D475ASD-5E0
10. Stator assembly

1) Assemble stator assembly as follows.
1] Install snap ring (21) to stator (23).
When assembling, take care of the
direction of the stator vanes (See
view Y below).
SEN02015-01
11. 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.
2]
2]
2)
Assemble race (22) to stator (23), and

secure with snap ring (24).
Install stator assembly (20) to stator shaft,
and secure with snap ring (19).
D475A, D475ASD-5E0
Install discs (16) (3 pieces) and plates

(17) (2 pieces). At this time, place
block (12) to adjust the height so that
the disc and plate are not caught in.
21
SEN02015-01
3]
4]
Install seal ring (14) to housing.

Be careful to assemble the seal ring
facing in the direction shown in the
diagram below.
2 Outer circumference of seal
ring: Grease (G2-LI)
Install seal ring (13) to piston.
Install the seal rings in the correct
directions with their grooves (b) in the
2 Outer circumference of seal
ring: Grease (G2-LI)
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:
3 Mounting bolt:
98 122.5 Nm {10 12.5 kgm}
7]
Using push tool, press fit bearing

(15).
a Drop power train oil TO30 or
TO10 to the bearing by at least 6
cc and rotate it 10 turns.
8] Install plate (8), and secure with snap
ring (7).
9] Install input shaft (6).
2 Mounting bolt:
3 Mounting bolt:
156.8 196 Nm {16 20 kgm}
10] Install 2 seal rings (5).
22
D475A, D475ASD-5E0
2)
Using eyebolt [1], install lock-up clutch

and drive case assembly (4).
a Align the positions of the turbine oil
groove ( mark) and drain plug (2)
when installing.
3)
Tighten mounting bolts (3).

3 Mounting bolt:
49 58.8 Nm {5 6 kgm}
D475A, D475ASD-5E0
SEN02015-01
12. 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}
23
SEN02015-01

PTO assembly
3)
Using puller [2], remove bearings (5) and

(6) from gear (7).
791T-813-1110 Push tool
t 1
791T-813-1120 Plate
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Disassembly
1.
2.
24
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.
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).
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).
4)
5)
Using push tool [3], remove boss (11) and

bearing (12) from cover.
Using forcing screw [4], remove bearing
(12) from boss (11).
D475A, D475ASD-5E0
4.
Scavenging drive gear

Remove snap ring (13) from bottom of PTO
case, then remove gear (14).
5.
Shaft assembly
1) Remove plate (15) of idler gear.
2)
3)
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.
SEN02015-01
6.
Idler gear assembly

1) Remove idler gear assembly (19) and
bearing (20) from bottom of PTO case.
2) Remove outer race (21).
7.
PTO case
1) Remove race assembly (24) together with
bearing outer race (25).
2)
D475A, D475ASD-5E0
Remove bearing inner races (26) and (27)

from race (28).
25
SEN02015-01
3)
4)
8.
26
Remove bearing outer race (29).

Remove sleeve (30).
Bearing
2) Remove bearing (23).
D475A, D475ASD-5E0
Assembly
a
a
Clean all parts, and check for dirt or damage.

Check that the snap ring is fitted securely in
the groove.
1.
Idler gear
1) Using push tool [5], press fit bearing outer
race (21) to gear (19).
2) Position idler gear to PTO case.
2.
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.
3) Tighten shaft assembly (16) mounting
bolts lightly (to prevent the shaft assembly
from moving when the PTO case is turned
over).
D475A, D475ASD-5E0
SEN02015-01
3.
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.
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
it 10 turns.
2)
4.
Install plate (15).

2 Mounting bolt:
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
Scavenging drive gear

1) Press-fit bearing (23) to the case up to 1/2
of the width.
2) Turn over the PTO case and put in gear
(14).
3) By using push tool C2 press-fit the gear to
the inner race of bearing (23).
4) Press-fit bearing (23) to the case up to the
full width.
5) Install snap ring (23A) and snap ring
(23B).
it 10 turns
2 Spline portion: Grease (G2-LI)
27
SEN02015-01
5.
Power train, PPC pump gear assembly

1) Using push tool [7], press fit bearing (12)
to boss (11).
it 10 turns.
2)
3)
28
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:
3 Gear mounting bolt:
98 122.6 Nm {10 12.5 kgm}
D475A, D475ASD-5E0
4)
5)
6.
SEN02015-01
2)
Using push tool [7], press fit bearing (9) to

gear (10).
it 10 turns.
Raise cover assembly (8) and install.
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
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.
Hydraulic pump gear assembly

1) Using push tool [7], press fit bearings (5)
and (6) to gear (7).
it 10 turns.
D475A, D475ASD-5E0
3)
7.
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.
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
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.
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}
29
SEN02015-01
8.
Install sleeve (30) to the PTO case.

a Install the sleeve with the chamfered
inside circumference facing down.
a Expand-fit the sleeve.
9.
Install the PTO case to the T/C case.
2)
Using push tool, press fit bearing inner

races (27) and (26) to race (28).
3)
Install race assembly (24).

2 Internal surface of race:
Anti-friction compound (LM-P)
Using push tool, press fit bearing outer
race (25).
it 10 turns.
10. Install the input shaft parts.

1) Using push tool, press fit bearing outer
race (29).
4)
30
D475A, D475ASD-5E0

TORQFLOW transmission
assembly
SEN02015-01
4.
Removal
1.
2.
3.
Remove gauge assembly (2) at the rear face of

steering assembly (3).
Remove shaft (3).
Remove snap ring (4) then remove shaft (5)
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
TORQFLOW transmission assembly:

1,330 kg
Installation
q
[*1]
D475A, D475ASD-5E0

removal.
a
Using a lever block, sling transmission

assembly (1) horizontally, align with spline
of shaft at steering case end, then install.
31
SEN02015-01

TORQFLOW transmission
assembly
3.
Transmission case
Using eyebolts, remove transmission case
(11).
4.
Housing
1) Remove 17 tie bolts (12).
2) Using eyebolts, remove housing (13).
3) Remove seal ring (14) from housing.
790-413-1010 Bracket
t 1
t 1
799-301-1600 Oil leak tester
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Disassembly
q
Set the transmission assembly on the block.
1.
Control valve assembly

2) Remove control valve
together with seat.
2.
32
assembly
(2)
Sleeve
1) Remove plug (8).
2) Using eyebolts [1], pull out sleeve (9).
D475A, D475ASD-5E0
5.
Spring
Remove spring (15).
6.
Discs, plates, springs

Remove discs (16), plates (17), and springs
(18) in turn.
a Keep the discs and plates in a flat place to
prevent them from becoming deformed.
7.
No. 1 ring gear

Remove ring gear (19).
SEN02015-01
11. Sleeve, guide pin

1) Remove sleeve (27).
2) Remove guide pin (28).
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
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

(26) in turn.
D475A, D475ASD-5E0
33
SEN02015-01
2)
Disassemble the shaft and No. 1 carrier

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

1] Remove sun gear (48).
2] Using eyebolts, remove plate and
gear assembly (49).
3]
4]
5]
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]
34
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.

washer (58), gear (59), and bearing
(60).
D475A, D475ASD-5E0
7]
8]
Using push tool, remove collar and

bearing assembly (61) from carrier.
Using push tool, remove bearing (62).
SEN02015-01
15. No. 3 piston

Remove No. 3 piston (71).
16. Spring
Remove spring (72).
(75) in turn.
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
2)
4 No. 2 housing, piston: 80 kg

Remove piston (70) from housing (69).
21. Spring
Remove spring (79).
(82) in turn.
D475A, D475ASD-5E0
35
SEN02015-01
23. Guide pin

Remove guide pin (83).
26. No. 3 ring gear

1) Remove ring gear (91).
2) Remove ring (92) from ring gear.
24. Sun gear

Remove snap ring (132), then remove sun
gear (84).
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
36
No. 4 carrier assembly, No. 5

clutch assembly: 160 kg
D475A, D475ASD-5E0
SEN02015-01
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]

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.
D475A, D475ASD-5E0
Shaft assembly: 80 kg
Disassemble the shaft assembly as follows.
1] Remove the snap ring. By using eyebolts, sling shaft assembly (117) and
drive out the bearing to remove cage
assembly (118).
37
SEN02015-01
2]
3]
Remove cage (119).

Using stand [6], remove bearing
(120).
4]
Remove snap ring (134), then

remove bearing (121) from cage
(133).
Remove seal ring (122).
Remove cover (123).
5]
6]
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).
Assembly
a
a
a
7]
8]
38
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.
Align the notches of the oil groove when installing the discs.
After installing the bearing, drop power train oil
TO30 or TO10 to it by at least 6 cc and rotate it
10 turns.
Remove bearing (124).

Remove seal ring (126).
D475A, D475ASD-5E0
1.
SEN02015-01
Shaft and cage assembly

1) Install seal ring (126).
2) By using the push tool, install bearing
(124).
3)
4)
5)
Install cover(123).
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
Install seal ring (122) to cage (133).
2 Periphery of seal ring:
Grease (G2-LI)
Install the outer race of bearing (121) to
cage (133) and fix it with snap ring (134).
8)
6)
7)
a
By using the push tool, press-fit bearing

(120) to cage(133).
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
Install the seal ring to cage (119).
Install the seal rings in the correct directions with their grooves (c) in the directions shown in the figure.
Grease (G2-LI)
D475A, D475ASD-5E0
Install cage (133) to cage (119).

3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
9)
Install cage assembly (118) to case (116).

3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
10) Install shaft assembly (117) to cage
assembly(118).
11) Install the snap ring.
12) Turn over the assembly and press-fit the
inner race of bearing (121) to shaft
assembly (117).
39
SEN02015-01
2.
No. 4 carrier and No. 5 clutch assembly

1) Install the dowel pin (1piece) for
spacer(113) to No. 5 housing (111).
2) By using the push tool, install spacer (113)
to No. 5 housing (111).
Grease (G2-LI)
4) Install the seal rings to piston (112)and
housing (111).
Grease (G2-LI)
directions with their grooves (d) in the
5)
6)
7)
8)
9)
Install seal ring (110)to inner gear (109).

Grease (G2-LI)
Install inner gear (109).
Install guide pin (108).
Install springs (107) (6 pieces), plates
(106) (5 pieces), and discs (105) (6
pieces) alternately.
Install pins (104) and springs (103).
a Free length of spring: 103.5 mm
10) Install bearing (102) to gear (101), fit

thrust washers (100) to both sides, and
set them to the carrier.
11) Install ball (99) to shaft (98) and push the
shaft into the carrier.
40
D475A, D475ASD-5E0
12) Install dowel pins (2 pieces) to No. 5

clutch assembly (97), set No.4 carrier
assembly (96) and compress the springs
by using guide bolts [5] (2 pieces), and
then tighten the mounting bolts.
a Check that the springs are fitted
securely into the holes of the housing,
and then tighten the mounting bolts.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
157 196 Nm {16 20 kgm}
SEN02015-01
4.
No.3 ring gear

1) Install snap ring (92) to the ring gear.
2) Install No. 3 ring gear (91).
5.
Cover, bearing, and collar assembly

1) By using the push tool, press-fit bearing
(90) to collar (89).
(88).
13) By using eyebolts, insert No. 4 carrier and

No. 5 clutch assembly (95) into shaft
assembly (117).
3.
Plate and ring gear

1) By using eyebolts, install plate (93),
matching it to the dowel pins.
a Since the plate must be installed in
the correct direction, check the bolt
holes and drive in the dowel pin portions with a plastic hammer until play
between the mating faces is eliminated.
2) Install No. 4 ring gear (94).
3) Install No. 4 sun gear.
D475A, D475ASD-5E0
41
SEN02015-01
3)
4)
By using the push tool, press-fit bearing

and cover assembly (87) to cover (86).
a When installing the collar to the cover,
direct its large protrusion end up.
By using eyebolts, install "cover, bearing,
and collar assembly"(85).
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
10. No. 4 piston and No. 3 housing

1) Install the seal rings to piston (78) and
housing (77).
directions with their grooves (g) in the
Grease (G2-LI)
2) Install No. 4 piston (78) to No. 3 housing
(77).
6.
No. 3 sun gear

Install No. 3 sun gear (84) and secure it with
snap ring (132).
7.
Guide pin
Install guide pin (83).
a Guide pin length: 207 mm
8.
Discs, plates, and springs

Install springs (82) (4 pieces each), plates (81)
(3 pieces), and discs (80) (4 pieces) alternately.
9.
Springs
Install springs (79).
a Free length of spring: 81.7 mm
42
3)
4)
By using eyebolts, install No. 3 housing

(77).
Install seats (76).
D475A, D475ASD-5E0
SEN02015-01
11. Discs, plates, and springs

Install springs (75) (5pieces each), plates (74)
12. Springs
a Free length of spring: 84 mm
3)
By using eyebolts, install No.2 housing

and piston assembly (68).
a Check that the springs are fitted
securely into the holes of the housing.
13. No. 3 piston and No. 2 housing

1) Install the seal rings to No. 3 piston (71)
and No. 2 housing (69).
directions with their grooves (e) in the
Grease (G2-LI)
(69).
15. No. 2 and No. 3 carriers
1) Install plate (54) to the carrier.
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
2) Install seal ring (66) to the carrier and
install seal ring (55) to plate (54 .
2 After centering the seal ring, fix it
by applying grease (G2-LI).
14. No. 2 housing and No. 2 piston

directions with their grooves (f) in the
Grease (G2-LI)
(69).
D475A, D475ASD-5E0
43
SEN02015-01
3)
4)
5)
Install bearing (60) to gear (59), fit thrust

washers (58) to both sides, and set them
to the carrier.
Install ball (57) to shaft (56) and push the
shaft into the carrier.
By using eyebolts, install carrier assembly
(53).
20. Ring gear

1) Install cover and snap ring (50) to ring
gear (52).
2) Engage the internal teeth of the ring gear
assembly with the external teeth of carrier
assembly (53).
3) Install the cover to carrier assembly (53)
and fix the ring gear assembly.
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
16. No. 2 ring gear

Install No. 2 ring gear.
17. Guide pin and sleeve
1) Install guide pin (28).
a Guide pin length: 270 mm
2) Install sleeve (27).
Install springs (26) (7 pieces each), plate (25)
(6 pieces), discs (24) (7 pieces) alternately.
19. Springs
44
21. No. 1 housing and No. 1piston

a Install the seal rings in the correct directions with their grooves (h) in the directions shown in the figure.
Grease (G2-LI)
(21).
D475A, D475ASD-5E0
3)
a
By using eyebolts, install No. 1 housing

and piston (20).
Check that the springs are fitted securely
into the holes of the housing.
22. No. 1 carrier assembly

1) Install bearing (46) to gear (45), fit thrust
washer (44) to both sides, and set carrier
(41).
2) Install ball (43) to shaft (42) and push the
shaft into carrier (41).
3) Install seal rings (47) and (131) to carrier
(41).
4) Install snap ring (41) to the carrier.
5) Install ring gear (19) to the carrier.
D475A, D475ASD-5E0
SEN02015-01
23. Input shaft assembly

(36) to shaft (39).
(37) to the cage.
3)
4)
5)
Set spacer (35) to bearing and cage

assembly (34) and press-fit shaft (39).
Install seal ring (40) to shaft (39).
Grease (G2-LI)
Install seal ring (38) to bearing and cage
assembly (34).
Grease (G2-LI)
45
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24. Shaft and carrier assembly

1) Install No. 1 carrier assembly to bearing
and cage assembly (34).
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
2) Turn over the shaft and insert No. 1 sun
gear into shaft (39).
3) By using the push tool, press-fit the bearings (2 pieces) to the collar.
4) Press-fit the spacer to the collar according
1] As shown below, press-fit the spacer
so that the lubrication groove A of the
spacer matches with lubrication
groove B of collar.
2] Apply adhesive (LT-2) to the inside
wall of the spacer and wipe off the
part of it forced out after press-fitting
the spacer. Take care that (LT-2) does
not stick to the bearing.
5)
6)
7)
8)
9)
46

Install springs (18) (7 pieces each), plates (17)
26. Springs
Insert the bearing and collar assembly into

shaft (39).
Insert No. 2 sun gear (30) into shaft (39).
Install bushing (39A).
By using eyebolts, install shaft and carrier
assembly (29).
D475A, D475ASD-5E0
27. Housing
1) Install seal ring (14) to the housing.
2) By using eyebolts, set housing (13).
3) Tighten tie bolts (12) (17 pieces) alternately.
3 Tie bolt:
353 392 Nm {36 40 kgm}
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29. Transmission case

Fit the O- ring to the mating face of transmission case (11), and then install the transmission case by using eyebolts.
3 Mounting bolt:
245 309 Nm {25 31.5 kgm}

Check of stroke of each piston
By using tool D, check the stroke of each piston.
a Air pressure:
0.5 0.6 MPa {5 6 kg/cm2}
Unit: mm
Piston
Standard stroke
No. 1 (R)
7.4
No. 2 (F)
8.4
No. 3 (3)
4.8
No. 4 (2)
5.0
No. 5 (1)
7.1
D475A, D475ASD-5E0
47
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30. 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.
2)
3)
4)
48
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).
Install boss (129A).
31. Sleeve
1) Install sleeve (9).
2) Install plug (8).
32. Control valve assembly

1) Install control valve assembly (2) together
with seat.
3 Mounting bolt:
44 54 Nm {4.5 5.5 kgm}
2 Mounting bolt: Gasket sealant (LG-5)
2) Install cover (1).
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN02015-01
49
SEN02015-01

2013 KOMATSU
All Rights Reserved
50
SEN02016-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
Power train, Part 2

Disassembly and assembly of steering case assembly.................................................................................. 2
Disassembly and assembly of steering clutch, brake assembly ................................................................... 15
Disassembly and assembly of transfer gear housing assembly ................................................................... 23
Removal and installation of power train pump assembly .............................................................................. 27
Removal and installation of scavenging pump assembly ............................................................................. 27
Removal and installation of torque converter oil cooler ................................................................................ 28
Removal and installation of torque converter valve assembly ...................................................................... 29
Disassembly and assembly of torque converter valve assembly.................................................................. 30
Removal and installation of transmission control valve assembly ................................................................ 34
Disassembly and assembly of transmission control valve assembly (ECMV assembly) .............................. 35
Removal and installation of steering control valve assembly........................................................................ 38
Disassembly and assembly of steering control valve assembly ................................................................... 39
Removal and installation of final drive assembly .......................................................................................... 41
Disassembly and assembly of final drive assembly...................................................................................... 43
D475A, D475ASD-5E0
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steering case assembly
2.
Clutch, brake assembly

Using tool E1, sling clutch and brake assembly,
then remove mounting bolts, and remove
clutch and brake assembly (3).
a Remove the clutch and brake assembly
on the opposite side in the same way.
When pulling out the clutch and brake
assembly, be careful not to damage the
discs and plates.
3.
Shafts
Remove left and right shafts (4).
4.
Lubrication tube
Remove lubrication tubes (5).
Bracket
t 1
1 01016-51690
Bolt
t 1
01011-81600
Bolt
t 1
791-622-1110
E
2
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
791T-822-1810 Push tool
t 1
791T-822-1820 Push tool
t 1
Disassembly
1.
Steering rod bracket

2) Remove tube (2).
3) Remove brake rod bracket (20).
4)
Remove transmission output shaft speed

sensor (75) and flange (76) together.
D475A, D475ASD-5E0
5.
Pipes, steering valve

1) Remove left and right pipes (6).
2) Remove pipe (7).
3)
Remove steering valve assembly (21) with

seat.
D475A, D475ASD-5E0
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6.
Transfer and gear housing assembly

1) Install a guide bolt and tighten forcing
screws [1] to remove housing assembly
(10).
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).
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3]
4]
5]
6]
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.
Using forcing screws, remove cover

(58).
a Check the quantity and thickness
of the inserted shims and then
keep them.
Remove holder (59).
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).
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).
D475A, D475ASD-5E0
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12] Remove the bolts and remove housing (76) from case (78).
13] Remove drive gear and bearing
assembly (77).
14] Remove bearing outer race (79) from

case (78).
16] Remove bearing outer race (70) from

housing (76).
17] Remove snap ring (83), and then
remove bearing outer race (71) from
housing (76).
7.
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.
D475A, D475ASD-5E0
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2)
8.
Using eyebolts [2], remove cage (12).
9.
Bevel gear, shaft assembly

1) Using eyebolts, remove bevel gear and
shaft assembly (13).
2)
Disassemble the bevel gear and shaft

1] Pull out reamer bolt, and remove
bevel gear (14) from shaft (15).
2] Using puller [3], remove bearings (16)
and (17) from shaft.
Assembly
a
a
1.
Cage
1) Turn over steering case, and remove
bearing cage (18).
2) Remove outer race (19) from bearing
cage.
Wash all parts, then dry them, and check for

dirt or damage. Coat the sliding surfaces of all
parts with engine oil before installing.
After installing the bearing, drip power train oil
10 turns.
Cage
1) Using push tool, press fit outer race (19).
2) Assemble shim, and install bearing cage
(18).
q
Standard shim thickness: 2 mm
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
D475A, D475ASD-5E0
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}
2)
3.
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2)
Assemble shim, and install bearing cage

(11).
q
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
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}
5.
Transfer and gear housing assembly

1) Assemble the transfer and gear housing
assembly according to the following procedure.
1] Press fit bearing outer race (70) on
the pinion side to housing (76).
2] Using the push tool, press fit bearing
outer race (71) on the drive gear side
and install snap ring (83).
Using eyebolts, install bevel gear and

shaft assembly (13).
Cage
1) Using eyebolts [2], install cage (12).
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
D475A, D475ASD-5E0
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3]
Using the push tool, press fit bearing

inner races (81) and (82).
7]
8]
9]
4]
Using push tool [18], press fit inner

race (61) to pinion shaft (60).
Install the holder.
Adhesive (LT-2)
276.85 31.85 Nm
{28.25 3.25 kgm}
Install pinion gear (64) and collar (63)
to the pinion shaft.
Using the push tool, press fit bearing

outer race (79) to case (78).
10] Using push tool [19], press fit cage

and bearing assembly (62).
11] Install holder (59).
Adhesive (LT-2)
276.85 31.85 Nm
{28.25 3.25 kgm}
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}
D475A, D475ASD-5E0
12] Tighten the mounting bolts of cover

(58) temporarily in the following order.
3 Mounting bolt: 49 Nm {5 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.
15] Clearance (A): 0.05 0.15 mm
16] 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.
D475A, D475ASD-5E0
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17] 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}
18] Install the shim to pinion housing

assembly (57). Using eyebolts [11],
install pinion housing assembly (57).
q
19] Install lubrication tube (56).
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20] Install lubrication tube (51) and block

as a unit.
2)
10
6.
Adjusting tooth contact, backlash

1) Adjusting backlash
Put the probe of dial gauge [6] in contact
with the tip of the bevel gear teeth at right
angles. Hold the bevel pinion in position,
and read the measurement when the
bevel gear is moved forward and backward.
a Standard value for backlash:
0.3 0.4 mm
a Measure at a minimum of 3 points on
diagonally opposite sides.
Install guide bolt [5] to the steering case

and install housing assembly (10).
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
D475A, D475ASD-5E0
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]
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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
same position when the gear is
rotated in forward or reverse.
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.
D475A, D475ASD-5E0
11
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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.
12
7.
Transmission output shaft and input shaft

1) Install the speed sensor and flange
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)
D475A, D475ASD-5E0
4]
5]
6]
2)
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:
After installing the speed sensor,
rotate the transfer gear slowly and
check that the speed sensor does not
interfere with the gear.
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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.
Install input shaft (9) to the case and fix it

with the snap ring.
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}
D475A, D475ASD-5E0
13
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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) When removing plugs (20) and using bolts
(21), set 5 washers under each bolt head
to shorten the bolt stem length to 64 mm.
If these washers are not used, the bolts
break the plate when they are tightened.
Remove bolts (21) and tighten them into
the plug holes to compress the clutch
springs and set the brake free.
12. Steering rod, bracket

1) Install brake rod bracket (20).
2) Install tube (2).
3) Install cover (1).
14
D475A, D475ASD-5E0
SEN02016-03

steering clutch, brake assembly
3.
E 3 791-822-1830
Wrench
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Clutch, brake assembly

Turn over clutch and brake assemblies, and
using eyebolts [3], disconnect clutch assembly
(6) and brake assembly (7).
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.
2)
3)

Remove discs (9), springs (10), and plates (11)
in turn.
Using forcing screws [1], remove sleeve

(4).
Using puller [2], pull out bearing (5) from
sleeve.
D475A, D475ASD-5E0
15
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3.
Torque pin
Remove torque pin (12).
7.
Spacer
Remove spacer (22).
4.
Clutch hub
Using eyebolts, remove clutch hub (13).
8.
Clutch cage, piston

1) Using eyebolts, remove clutch cage (23).
2) Remove piston (24).
5.
Plate
1) Using forcing screws [4], remove flange
(14).
3)
9.
2)
6.
Belleville springs
Remove Belleville springs (26).
Bearing cage
1) Remove bearing cage assembly (16).
2)
16
Remove outer race (15) from flange.
Remove outer race (25) from clutch cage.
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.
D475A, D475ASD-5E0
Disassembly of brake assembly

1. Stopper
Remove stopper (29).
2.
3.
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4.
Torque pin
Remove torque pin (36).
5.
Piston
Remove piston (37) and seal ring (38).
6.
Belleville springs
Remove Belleville springs (39).

Remove discs (30), springs (31), and plates
(32) in turn.
Brake cage
1) Using eyebolts [6], remove brake cage
(33).
2) Remove outer race (34) and seal ring (35)
from brake cage.
D475A, D475ASD-5E0
17
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Assembly
Assembly of brake assembly
a
a
Clean each part, and check for dirt or damage.

After installing the bearing, drip power train oil
10 turns.
1.
Disc springs
Install disc springs (39).
a Install the disc springs back to back by the
set (of the same number).
18
Install the seal rings to the piston and

brake cage.
Install the seal rings in the correct directions with their grooves (j) in the directions
shown in the figure.
Grease(G2-LI)
Install and fit the piston to the housing
(Remove after fitting).
2.
Piston
Install piston (37).
3.
Torque pin
Install torque pin (36).
4.
Brake cage
1) Using push tool, install outer race (34) to
brake cage.
3) Using eyebolts [6], install brake cage (33).
2 Mounting bolt:
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
D475A, D475ASD-5E0
5.

q
Set the brake hub. (Use it as a jig temporarily to mesh the internal teeth of the
brake disc.)
q
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.
6.
Stopper
Install stopper (29).
q
Remove brake hub.
3 Mounting bolt:
245 308.7 Nm {35 31.5 kgm}
q
After Installing the stopper, remove
the brake hub.
D475A, D475ASD-5E0
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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.
3) Install snap ring (27A).
19
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2.
3.
Belleville springs
Install Belleville springs (26).
a Fit the Belleville springs back to back
when installing.
q
Install the seal rings to the piston and
brake cage.
Install the seal rings in the correct directions with their grooves (k) in the directions shown in the figure.
Grease(G2-LI)
q
Install and fit the piston to the housing.
2)
3)
4.
Spacer
Install spacer (22).
5.
Bearing cage
1) Using push tool, press fit bearings (21)
and (20) to cage (17), then tighten nut
(19), and install plate (18).
a Hold the cage with press, and using a
hook wrench (tool E3), tighten the
nut.
3 Nut:
490 607.6 Nm {50 62 kgm}
Clutch cage, piston

1) Install outer race (25) to clutch cage.
2)
6.
20
Install piston (24).

Using eyebolts, fit seal ring and install
clutch cage (23) to housing.
Install bearing cage (16).
Plate
1) Using push tool, press fit outer race (15) to
flange.
D475A, D475ASD-5E0
2)
7.
8.
Install flange (14).

2 Mounting bolt:
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
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10. Stopper
Install stopper (8).
2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
Clutch hub
Set guide bolts to housing, and using eyebolts,
install clutch hub (13).
2 Mounting bolt:
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
Torque pin
Install torque pin (12).
Connection of clutch, brake assembly

1. Clutch, brake assembly
Using eyebolts [3], install brake assembly (7)
to clutch assembly (6).
2.
9.
Sleeve
1) Install O-ring (6A)and seal ring (6B)to the
sleeve. Apply grease (G2-LI) to each part.

Install plates (11), springs (10), and discs (9) in
turn.
a Assemble the discs and plates in the order
shown in the figure. (A plate must be
inserted between the piton and each disc.)
2)
Using push tool [7], press fit bearing (5) in

sleeve.
Check the mating surfaces of the discs

and plates for dirt or damage, and coat
them thinly with engine oil before assembling.
D475A, D475ASD-5E0
21
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3.
22
3)
Set sleeve (4) to clutch and brake assemblies.
4)
Install plate (3).

2 Mounting bolt:
3 Mounting bolt:
112 9.8 Nm {11.5 1.0 kgm}
Collar
Fit collar (2) and install plate (1).
D475A, D475ASD-5E0

transfer gear housing assembly
SEN02016-03
4.
Pinion housing
1) Remove lubrication tube (7).
2) Using eyebolts [2], remove pinion housing
assembly (8).
the slims, and keep in a safe place.
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).
Disassembly
a
Set the transfer gear housing assembly on a

block.
1.
Lubrication tube
Remove lubrication tube (1) together with
block.
2.
Bearing cage
1) Remove bearing cage (2).
2) Using push tool, remove bearing (3).
3) Remove snap ring, and using push tool,
remove bearing (4)
3.
Transfer gear
1) Remove transfer gear (5).
2) Using puller [1], remove inner races (6) on
both sides.
D475A, D475ASD-5E0
23
SEN02016-03
5)
6)
Remove cage, bearing assembly (13).

Remove collar (14) from transfer gear
(15).
7)
Using push tool [4], remove outer race

(16), bearings (17) and (18), collar (19),
and outer race (20).
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).
4)
5)
24
Using push tool [5], press fit inner race

(12) in pinion gear (11), and install holder.
245 308.7 Nm {25 31.5 kgm}
Install transfer gear (15) and collar (14) to
pinion gear.
D475A, D475ASD-5E0
6)
7)
8)
SEN02016-03
Using push tool [6], press fit cage, bearing

assembly (13).
Install holder (10).
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).
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.
D475A, D475ASD-5E0
25
SEN02016-03
4.
Bearing cage
1) Using push tool, press fit bearing (4), and
secure with snap ring.
2) Using push tool, press fit bearing (3).
3) Install bearing cage assembly (2) to case.
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
5.
Lubrication tube
Install lubrication tube (1) together with block.
26
D475A, D475ASD-5E0
SEN02016-03
Removal and installation of power

train pump assembly

scavenging pump assembly
Removal
Removal
1.
Remove oil strainer inspection cover at front

left of operators platform.
1.
Open undercover. (3rd from front of machine).
2.
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.
3.
Remove oil strainer (1).

a Disconnect coupling (2) and remove
strainer mounting bolts.
3.
Disconnect outlet tube (2).
4.
Remove scavenging pump assembly (3).
4.
5.
Lift off power train pump assembly (4).

4
Scavenging pump assembly: 25 kg
Power train pump assembly: 64 kg
Installation
q

removal.
Refilling with oil (power train case)

again.
Installation
q

removal.
D475A, D475ASD-5E0
27
SEN02016-03

torque converter oil cooler
7.
Removal
1.
Remove engine undercover.
2.
Drain coolant.
3.
Open engine left side cover (1) and remove

side cover (2).
Sling torque converter oil cooler assembly (8),

then lower assembly to remove.
Torque converter oil cooler assembly:
170 kg
Installation
4.
Remove water tubes (3) and (4).
5.
Remove oil inlet tube (5) and outlet tube (6).
6.
Disconnect aeration hose (7).
28

removal.

D475A, D475ASD-5E0

torque converter valve assembly
SEN02016-03
7.
Remove hose clamp (6).
8.
Remove torque converter valve assembly (7).

[*2]
4
Removal
1.
Remove operators cab assembly.

operators cab assembly".
2.
Remove operators seat and floor frame cover.

a Use turnbuckle (1) when disconnecting
the brake rod. Check the mounting dimensions of the rod before disconnecting. [*1]
Torque converter valve assembly:

33 kg
Installation
q
[*1]
3.
Disconnect connector of solenoid valve (2).
4.
Disconnect hose clamp (3).
5.

(4).
installing.
6.
[*2]

removal.
a
Adjust the brake pedal linkage.

Adjusting brake pedal and parking brake
lever.
3 Turnbuckle locknut:
34.3 58.8 Nm {3.5 6 kgm}
3
Torque converter valve assembly

mounting bolt:
43.1 53.9 Nm {4.4 5.5 kgm}
D475A, D475ASD-5E0
29
SEN02016-03
Disassembly and assembly of torque converter valve assembly
Disassembly of lock-up valve
Assembly of lock-up valve
1.
Remove solenoid valve (14), then remove ball

(16), valve (15) and plug (19).
1.
Assemble spool (6).
2.
2.
Remove plug (3), then remove spring (5).
Assemble piston (10) to cover (7), then fit Oring and install cover.
3.
Remove cover (7), then remove piston (10).
3.
Assemble spring (5), then fit O-ring and install

plug (3).
4.
Pull out spool (6).

4.
Fit O-ring (17) to plug (19), then assemble.
5.
Assemble valve (15), then fit O-ring (18) to

solenoid valve (14) and install.
30
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN02016-03
31
SEN02016-03
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).
2.
Disassembly of main relief valve

1) Remove cover (14), then remove spring
(18).
2) Remove cover (24), then remove valve
(21), spring (22), and valve (23).
3.
Disassembly of stator clutch modulating

valve
1) Remove cover (27), then remove piston
(34) and spring (35).
2) Remove ring (30) from body.
4) Pull out spool (37), then remove shim (36)
from spool.
4.
Disassembly of lock-up clutch modulating

valve
1) Remove cover (45), then remove piston
(52), springs (53) and (55).
2) Remove ring (47) from body.
5) Remove shaft (56) and shim (54) from
spool (57).
32
D475A, D475ASD-5E0
SEN02016-03
Assembly of lock-up modulating valve, stator clutch modulating valve, main relief
valve and torque converter relief valve
a
a

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.
1.
Assembly of lock-up clutch modulating

valve
1) Set shim to shaft (56) and assemble to
spool (57).
a Standard shim thickness: 2.0 mm
2) Assemble spool (57).
3) Assemble valve (58), spring (59), and
valve (60) to spool, then fit O-ring and
install cover (61).
4) Assemble ring (47) to body.
5) Assemble springs (53) and (55).
6) Assemble piston (52) to cover (45), then fit
O-ring and install cover.
2.
Assembly of stator clutch modulating valve

valve (40) to spool (37), then fit O-ring and
install cover (41).
3) Set shim (36) to spool (37) and assemble
ring (30) to body.
a Standard shim thickness: 0.5 mm
4) Assemble spring (35).
5) Assemble piston (34) to cover (27), then fit
O-ring and install cover.
3.
Assembly of main relief valve

valve (21) to spool, then fit O-ring and
install cover (24).
3) Assemble spring (18), then fit O-ring and
install cover (14).
4.
Assembly of torque converter relief valve

2) Assemble valve (7), spring (6), and valve
(5) to spool, then fit O-ring and install
cover (2).
3) Assemble spring (9), then fit O-ring and
install cover (10).
D475A, D475ASD-5E0
33
SEN02016-03

transmission control valve
assembly
5.
Disconnect wiring harness connector (4). (8

places)
6.

(5). (4 places)
installing.
7.
Remove transmission control valve assembly

(6). (4 places)
Removal
1.

For details, see "Removal of operators cab
assembly".
2.
Remove operators seat and floor frame cover.

a Use turnbuckle (1) when disconnecting
the brake rod. Check the mounting dimensions of the rod before disconnecting. [*1]
3.
Disconnect hose clamp (2).
4.
Remove valve cover (3).
Installation
q
[*1]
34

removal.
a
Adjust the brake pedal linkage.

Adjusting brake pedal and parking brake
lever.
3 Turnbuckle locknut:
34.3 58.8 Nm {3.5 6 kgm}
D475A, D475ASD-5E0
SEN02016-03
Disassembly and assembly of transmission control valve assembly

(ECMV assembly)
Disassembly of ECMV assembly

q
1.
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).
D475A, D475ASD-5E0
2.

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).
35
SEN02016-03
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
1.

1) Install shims (9) and (10) and spring (8) to
spool (7), and then install the spool to
body (1).
q
Standard number of shims: 3
q
Standard shim thickness: 1.5 mm
(Thickness of 1 shim: 0.2 mm, 0.5
mm)
a Check that the spool moves smoothly.
2) Put ball (4) in valve (3), fit O-ring (5), and
install them.
3) Fit O-ring (6) to the solenoid and install
them to body (1).
a When reusing all of valve body (1),
spring (8), spool (7), solenoid (2), and
valve (3), install the standard number
of the shims.
a When replacing solenoid valve (2),
check that spring (8) is installed
securely.
2.
Flow control valve

1) Install sleeve (18), spring (17), and pin
(16) to body (1).
2) Install shim (14) and spring (13) to spring
seat (15), fit O-ring (21) to body (1), and
install switch assembly (12) and bracket
(20) with bolts (19).
3.
Testing ECMV oil pressure

Check the ECMV oil pressure. For details, see
Testing and adjusting, Testing ECMV oil pressure.
4.
Adjusting ECMV oil pressure

As a result of testing, if the oil pressure is out
of the standard range, adjust it with shims (9)
and (10).
Quantity of adjustment
per shim (0.5 mm thick)
714-23-15580
0.06 MPa
{Approx. 0.65 kg/cm2}
714-28-15590
0.025 MPa
36
a
a
Install the shim securely and do not drop it

in the valve.
After adjusting the shim, test the oil pressure again.
If the shim is increased, the oil pressure is

heightened. If the former is decreased, the
latter is lowered.
D475A, D475ASD-5E0
Disassembly of priority valve

q
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.
damaged.
SEN02016-03
Assembly of priority valve

1.
Install valve (6), spring (7), and sleeve (5) to

valve body (1).
2.
Fit the O-ring to plug (10) and install them to

body (1).
3 Plug: 58.8 78.4 Nm {6 8 kgm}
3.
Install spool (2).

4.
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}
1.
Remove plug (8) from valve body (1).
2.
Remove shim (4) and spring (3).

a Check the quantity of shim (4).
3.
Remove spool (2).

a When removing the spool, check that it
moves smoothly.
4.
Remove plug (10) from valve body (1).
5.
Remove sleeve (5), spring (7), and valve (6).
D475A, D475ASD-5E0
52 kPa {0.53 kg/cm2}

latter is lowered.
37
SEN02016-03

steering control valve assembly
Removal
1.
Remove fuel tank assembly.

For details, see Removal and installation of
fuel tank assembly.
2.
Disconnect 3 wiring clamps (1).
3.
Remove valve cover (2).
4.
Disconnect harness connector (3).
5.
Remove steering control valve assembly (4).
Installation
q
38

removal.
D475A, D475ASD-5E0
SEN02016-03
Disassembly and assembly of steering control valve assembly
Disassembly of ECMV assembly

q
1.
Before removing the ECMV assembly from the

steering assembly, clean around it so that dirt
will not enter it and steering assembly.
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).
D475A, D475ASD-5E0
2.

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.
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).
39
SEN02016-03
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
1.

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)
3) Fit the O-ring to valve (3), install the ball,
fit the O-ring to the solenoid (2), and install
them to body (1).
a When reusing all of valve body (1),
spring (13), spool (7), solenoid (2),
and valve (3), install the standard
number of the shims.
a When replacing solenoid valve (2),
check that spring (13) is installed
securely.
2.
Flow control valve

1) Install sleeve (23), spring (22), and pin
(21) to body (1).
2) Install springs (19) and (18) to spring seat
(20) and put them in cover (28). Fit Orings (26) and (27) and install switch
assembly (17) and bracket (25) with bolts
(24).
3.
Testing ECMV oil pressure

Check the ECMV oil pressure. For details, see
Testing and adjusting, Testing ECMV oil pressure.
4.
Adjusting ECMV oil pressure

As a result of testing, if the oil pressure is out
of the standard range, adjust it with shims (14)
and (15).
40
714-23-15580
0.06 MPa
714-23-15590
0.025 MPa
a
a
a

latter is lowered.
Install the shim securely and do not drop it
in the valve.
D475A, D475ASD-5E0
SEN02016-03
Removal and installation of final

drive assembly
4.
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.
5.
Remove 3 bolts of final drive and install tool J1.
6.
Sling final drive assembly (5), then remove

mounting bolts, and lift off.
[*2]
790-337-1032
J
1 791-827-1910
01011-83015
Lifting tool
t 1
Plate
t 1
Bolt
t 3
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Removal
1.
Remove track shoe assembly.

For details, see "Expansion and installation of
track shoe assembly".
2.
Raise chassis with jack or ripper and set stand

[1] under frame.
3.
Remove covers (1) and (2).
D475A, D475ASD-5E0
Final drive assembly: 3,600 kg
41
SEN02016-03
Installation
q

removal.
[*1]
q
[*2]
Installed position of gear hole cover button

(6): 72 0.8 mm
If the installed position is higher than the
specified position, the button may be
driven defectively. In this case, pull out the
button, check for foreign matter and scuffing, and then driving it again.
.
2
3
42
Final drive assembly mounting bolt:

Final drive assembly mounting bolt:
1,960 2,450 Nm (200 250 kgm)
D475A, D475ASD-5E0
SEN02016-03

final drive assembly
Disassembly
1.
790-431-1081 Guide
t 1
790-431-1031 Block
t 1
790-101-2350 Leg
t 2
790-101-2430 Adapter
2 790-101-2360 Plate
t 2
02215-11622 Nut
790-101-2102
Puller
(294 kN {30 ton})
Sprocket
1) Set final drive assembly to block (height:
approx. 50 mm).
2) Remove sprocket (1).
3.
Cover
Using eyebolts [1], remove cover (2).
4.
Hub
2) Using eyebolts [2], lift off hub (4).
t 1
790-431-1101 Installer assembly
t 1
790-101-1102 Pump
2.
t 2
t 1
Puller
(294 kN {30 ton})
t 1
t 1
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
790-431-1210 Installer assembly
t 1
Puller
(294 kN {30 ton})
790-101-1102 Pump
t 1
790-101-1102 Pump
6 790-101-2102
t 1
t 1
790-431-1230
Remover &
installer
t 1
790-101-2102
Puller
(294 kN {30 ton})
t 1
790-101-1102 Pump
t 1
8 790-431-1240 Guide
t 1
D475A, D475ASD-5E0
Final drive case: Approx. 71 l
t 4
790-101-1102 Pump
3 790-101-2102
Sketch
Q'ty
Part Name
New/remodel
Part No.
Necessity
Symbol
Special tools
Draining oil
Remove drain plug and drain oil from final
drive case.
43
SEN02016-03
5.
Sprocket hub assembly

2)
3)
44
Using tool J2, disconnect sprocket hub

assembly (6) and bearing (7) portion.
Using eyebolts [3], remove sprocket hub
assembly (6).
4)
Remove bearing inner race (8) from

sprocket hub assembly.
5)
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)
6.
Wear guard
Lift off wear guard (13).
7.
Cover assembly
1) Using eyebolts, lift off cover assembly
(14).
D475A, D475ASD-5E0
2)
8.
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.
3]
Remove spacer (17) and bearing

inner race (18).
4]
Remove plate, then remove ring gear

(19).
SEN02016-03
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).
4]
Remove planet gear (23), bearing

inner races (24A) and (24B), and
spacer (24C).
5]
Remove bearing outer race (24D).
Carrier assembly
1) Using eyebolts [5], remove carrier assembly (20).
D475A, D475ASD-5E0
45
SEN02016-03
9.
Sun gear
3) Pull out sun gear shaft assembly (27).
4)
2)
Using tool J5, pull out hub assembly (29)

and bearing inner race (30) from shaft
assembly (31).
3)
Disassemble hub assembly (29) as follows.

1] Remove gear (32) from hub (33).
2] Remove bearing outer races (34A)
and (34B).
4)
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).
Remove holder (51) from sun gear shaft

assembly, and pull out sun gear (52)
10. Hub, shaft assembly

5)
46
D475A, D475ASD-5E0
11. Cage assembly

1) Using eyebolts [7], remove cage assembly
(39).
2) Remove shims (40).
3)
Disassemble cage assembly as follows.

1] Using puller [8], remove bearing outer
race (41).
2] Remove oil seals (42) and (43).
SEN02016-03
13. Outer race, oil seals

1) Using puller [10], remove bearing outer
race (48).
2) Remove oil seals (49) and (50) from
cover.
Assembly
a

1.
Hub, shaft assembly

1) Assemble shaft assembly as follows.
1] Install collar (38).
2] Using push tool [17], press fit bearing
inner race (37).
3] Install collar (36).
12. Gear assembly

1) Remove gear assembly (44).
2) Using puller [9], remove bearing inner
races (45) and (46) from gear (47).
D475A, D475ASD-5E0
47
SEN02016-03
2)
3)
5)
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).
2.
2]
4)
Set gear (32) to hub (33).

2 Mounting bolt:
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.
Install plate (28).

2 Mounting bolt:
3 Mounting bolt:
490 608 Nm{50 62 kgm}
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.
1]
48
Install ring and spacer to planet gear,

then using push tool [18], press fit top
and bottom bearing outer races
(24D).
D475A, D475ASD-5E0
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]
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:
3 Mounting bolt:
490 608 Nm {50 62 kgm}
a After tightening the bolts, check
that the gear rotates smoothly.
4]
D475A, D475ASD-5E0
SEN02016-03
3.
Sun gear
1) Press fit sun gear (52) to sun gear shaft,
and install holder (51).
2) Assemble sun gear shaft assembly (27) to
carrier (53), then install holder (26) and
spacer (25).
4.
Carrier, sun gear assembly

Using eyebolts [5], install carrier and sun gear
assembly (20).
49
SEN02016-03
5.
Cover assembly
1) Assemble cover assembly as follows.
1] Using push tools [11] and [12], install
oil seals (50) and (49).
a Install the bottom oil seal with the part
receiving the pressure at the bottom;
install the top oil seal with the part
receiving the pressure at the top.
a Coat the inside surface of the case
thinly with gasket sealant and wipe off
any sealant that is forced out.
2]
3]
4]
5]
50
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.
7]
Install floating seal cover (15).

a Fit a cork plug in the forcing tap.
Using push tool [13], press fit bearing

outer race (48) to cover.
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).
D475A, D475ASD-5E0

a
2)
6.
Install so that the cut-out portion

of the floating seal cover is facing
the bottom as shown in the diagram below.
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}
SEN02016-03
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)
3)
Using push tool, press fit bearing outer

races (11) and (10).
Install floating seal cover (9).
4)
Set bearing (8) to sprocket hub assembly.
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}
D475A, D475ASD-5E0
51
SEN02016-03
5)
52
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.
6)
Using tool J3, press fit bearing (7) portion.

a Rotate the sprocket hub assembly
when press fitting.
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:
3 Mounting bolt:
490 608 Nm {50 62 kgm}
8.
Hub
1) Using eyebolts [2], raise hub (4) and
install.
2) Install plate (3).
2 Mounting bolt:
3 Mounting bolt:
245 309 Nm {25 31.5 kgm}
9.
Cover
Using eyebolts [1], install cover (2).
D475A, D475ASD-5E0
10. Sprocket
Install sprocket (1).
3 Mounting bolt:
2,500 2,794 Nm {255 285 kgm}
SEN02016-03
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.
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]
D475A, D475ASD-5E0
Using push tool [15], press fit bearing

outer race (41).
53
SEN02016-03
2)
Using eyebolt [7], set cage assembly (39)

to case, and remove tool J8.
3)
Tighten mounting bolts (C), (D), (E), and

(F) of cage (A) uniformly to a tightening
torque of 69 Nm {7 kgm}, then loosen
bolts.
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}
4)
5)
6)
7)
54
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 (GO85W140)
D475A, D475ASD-5E0
SEN02016-03
Table 1
a + b (mm)
Number of shim to use
More than
Less than
t = 0.15
3.05
3.15
3.15
3.25
3.25
3.35
3.35
3.45
3.45
3.55
3.55
3.65
3.65
3.75
Total shim
thickness c (mm)
t = 0.5
t = 1.0
1.85
1.90
1.95
2.00
2.05
2.10
3.75
2.15
3.85
2.20
3.85
3.95
2.25
3.95
4.05
2.30
4.05
4.15
2.35
4.15
4.25
2.40
4.25
4.35
2.45
4.35
4.45
2.50
4.45
4.55
2.55
4.55
4.65
2.60
4.65
4.75
2.65
4.75
4.85
2.70
4.85
4.95
2.75
4.95
5.05
2.80
5.05
5.15
2.85
5.15
5.25
2.90
5.25
5.35
2.95
5.35
5.45
3.00
5.45
5.55
3.05
5.55
5.65
3.10
5.65
5.75
3.15
5.75
5.85
3.20
5.85
5.95
3.25
5.95
6.05
3.30
6.05
6.15
3.35
6.15
6.25
3.40
6.25
6.35
3.45
6.35
6.45
3.50
6.45
6.55
3.55
6.55
6.65
3.60
6.65
6.75
3.65
6.75
6.85
3.70
6.85
6.95
3.75
6.95
7.05
3.80
7.05
7.15
3.85
7.15
7.25
3.90
7.25
7.35
3.95
D475A, D475ASD-5E0
55
SEN02016-03

2013 KOMATSU
All Rights Reserved
56
SEN02017-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
Undercarriage and frame, Part 1

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
Removal and installation of operator's seat isolator...................................................................................... 32
Disassembly and assembly of operator's seat isolator ................................................................................. 33
D475A, D475ASD-5E0
SEN02017-03
Removal and installation of track

1
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.
8.
Remove mounting bolts, and disconnect cover

(4) from track frame.
9.
Remove cover (5).

a With the right track frame, disconnect 4
blade tilt cylinder hoses from the cover.
Removal
1.

2.
Raise chassis with jack or ripper, then set support [1] under frame to keep rear of chassis off
ground.
3.
Set hydraulic jack [2] to center of equalizer bar,

and raise front of chassis.
4.
Sling track frame assembly.
5.
Remove cover (1).
6.
Remove cover (2).
10. Remove seal (6) together with washer (7). [*2]

11. Remove washer (8), then remove spacer (9).
D475A, D475ASD-5E0
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
Pivot case: 26 l
Track frame assembly: 13,500 kg
SEN02017-03
Installation
q
[*1]

removal.
2
[*2]
a
a
[*3]
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.
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.
Refilling with oil (pivot case)

Add oil through oil filler to the specified level.
5
D475A, D475ASD-5E0
Pivot case: 26 l (SAE30)
SEN02017-03

idler assembly
6.
Using puller [4], remove seal guide (6) and

retainer (7) and plate (8).
7.
Remove seal guides (2) and (6) from retainers

(3) and (7).
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.
9.

and (7).
791-830-1760
Plate
t 1
791-830-1320
Rod
t 2
790-101-2510
Block
t 1
790-101-2570
1 01580-01613
Plate
t 2
Nut
t 2
01643-31645
Washer
t 2
790-101-2102
Puller
t 2
(294 kN {30 ton})
790-101-1102
Pump
t 1
2 791-560-1520
Installer
t 1
3 791-830-1480
Push tool
t 1
4 791-601-1000
Oil pump
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
Disassembly
1.
Remove oil filler plug and drain oil.

6
Idler: 1.4 1.5 l (GO140)
2.
Set idler assembly (1) on block [1].
3.
Remove mounting bolts, then using forcing

screws [2], remove seal guide (2) together with
4.
Turn over idler assembly.
5.
Remove mounting bolts, then using eyebolts

[3], remove shaft (5) together with retainer.
D475A, D475ASD-5E0
10. Remove bushings (11) from idler (12).
SEN02017-03
2.
Using tool L2, install floating seal (10) to retainers (3) and (7).
3.
Fit O-ring and install retainer (3) and plate (4)

to idler.
a Check that the plate can be turned
smoothly with the hand.
4.
Using eyebolts [3], set idler (12) to shaft (5).

a Set block (height: approx. 200 mm) under
the idler.
5.
Turn over idler assembly.

a Tie with wire to prevent the shaft from falling out.
6.
Fit O-ring and install retainer (7) and plate (8)

to idler.
Assembly
a
1.

Set bushing (11) and tool L1 to idler (12), and
press fit bushing (11).
a First, center the bushing with a plastic
hammer, then press fit with a puller.
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
D475A, D475ASD-5E0
SEN02017-03
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.
5
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}
Idler: 1.4 1.5 l (GO140)

Oil filler plug:
156.8 254.8 Nm {16 26 kgm}
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.
D475A, D475ASD-5E0
SEN02017-03
Removal and installation of recoil

spring assembly
5.
Lift off trunnion (3).

4
Trunnion: 140 kg
Sketch
Q'ty
Part Name
New/remodel
Part No.
Necessity
Symbol
Special tools
790-434-1401 Remover assembly t 1

M 1 790-101-2102
Puller
(294 kN {30 ton})
790-101-1102 Pump
t 1
t 1
Removal
1.

k To prevent danger, never stand in front
of the idler yoke assembly.
2.
Drain oil from recoil cylinder chamber using oil

pump.
6
3.
4.
6.
Remove covers (4).

a Remove both the inside and outside covers.
7.
Using tool M1, remove pins (5).

[*1]
a Remove both the inside and outside pins.
Recoil cylinder chamber: Approx. 75 l
Using eyebolt [1], remove cover (1).

4
Cover: 70 kg
Remove cover (2).
D475A, D475ASD-5E0
SEN02017-03
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)
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.
3)
Loosen idler yoke mounting bolts (9) gradually in turn on diagonally opposite sides.
[*4]
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.
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.
D475A, D475ASD-5E0

k
SEN02017-03
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.
D475A, D475ASD-5E0
10. Remove ring (12).
SEN02017-03
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
[*1]
[*2]

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.
Adjusting clearance of idler.
13. Remove recoil spring assembly (19).

4
[*3]
Recoil spring assembly: 780 kg
[*4]
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.
2
3
[*5]
10
Idler yoke assembly mounting bolt:

Idler yoke assembly mounting bolt:
2,205 2,695 Nm {225 275 kgm}
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.
D475A, D475ASD-5E0
SEN02017-03
Release hydraulic pressure gradually and

relieve tension of spring.
4.
Remove rear pilot (5), spacer (6), bolt (7), and

front pilot (8) from spring (4).
Part No.
M 2
Part Name
791-685-8502
Compressor
t 1
791-635-3160
Extension
t 1
790-201-2790
Spacer
t 1
790-101-1300
Cylinder (980 kN
t 1
{100 ton})
790-101-1102
Pump
Sketch
3.
New/Remodel
Special tools
Qty
Apply hydraulic pressure slowly to compress

spring, then remove lock plate (2) and remove
nut (3).
Necessity
2.
Symbol

recoil spring assembly
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}
D475A, D475ASD-5E0
11
SEN02017-03
Assembly
1.
Assemble front pilot (8), bolt (7), spacer (6),

and rear pilot (5) to spring (4), then set in tool
M2.
k The spring is under high installed load,
so be careful to set all parts correctly.
2.
Apply hydraulic pressure slowly to compress

spring, and set so that installed length of spring
is specified value.
a Installed length (a) of spring: 1,461 mm
a Installed load of spring:
Approx. 788 kN {approx. 81 ton}
3.
Fit nut (3), then install lock plate (2).

a When securing the recoil spring mounting
nut, make a clearance (b) of 0 1 mm
between lock plate (2) and nut (3), then
bring lock plate (2) and bolt (7) into tight
contact, and secure in position.
2 Lock plate mounting bolt:
4.
Gradually release hydraulic pressure to completely release tension of spring, then remove
recoil spring assembly (1) from tool M2.
12
D475A, D475ASD-5E0
SEN02017-03
Removal and installation of track

roller assembly
12
L
790-401-1700
Lifting tool
t 1
790-401-1761
Adapter
t 1
790-401-1540
Shackle
t 2
790-401-1770
T-bolt
t 2
791T-830-1780 Plate
t 3
13 01011-62700
01673-32780
Bolt
t 6
Washer
t 6
Sketch
New/Remodel
Part Name
Qty
Part No.
Necessity
Symbol
Special tools
5.
Remove the mounting bolts and place track

roller assembly (2) on steel plate [1].
[*2]
6.
Operate the blade and ripper to lift the machine

body until track roller assembly (2) separates
from the bogie.
7.
Pull track roller assembly (2) out of the

machine body from the top of the steel plate
with a bar, etc.
[*3]
N Q
Removal
1.
Loosen the track shoe. For details, see

"Expansion and installation of track shoe
assembly".
2.
Install tool L13 and secure bogie assembly (1).

[*1]
3.

body until track roller assembly (2) separates
from the track shoe.
4.
Place steel plate [1] on the track shoe and

operate the blade and ripper to lower the
machine body until the track roller assembly
comes in contact with the steel plate.
a Operate the blade and ripper slowly, running the engine at the low idling speed.
D475A, D475ASD-5E0
Track roller assembly: 240 kg
13
SEN02017-03

a
Installation
q
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}

removal.
[*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}
[*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
14
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.
D475A, D475ASD-5E0
SEN02017-03

track roller assembly
6.
Using press, remove seal guide (6) together

with retainer (7) and plate (8) from shaft.
7.
Remove seal guides (2) and (6) from retainers

(3) and (7).
8.

and (6).
9.
Remove floating seal (10) from retainers (3)

and (7).
t 1
Installer
t 1
10 791-830-1730
Push tool
t 1
11 791-601-1000
Oil pump
t 1
Part Name
Sketch
New/Remodel
Plate
9 791-515-1520
Part No.
Necessity
8 791-830-1740
Symbol
Qty
Special tools
Disassembly
1.
Remove oil filler plug and drain oil.

6
Track roller: 1.4 1.5 l
2.
Set track roller assembly (1) on block [1].
3.
Remove mounting bolts, then using forcing

screws [2], remove seal guide (2) together with
4.
Turn over track roller assembly.
5.
Remove mounting bolts, then using eyebolts

[3], remove shaft (5) together with retainer.
10. Remove bushing (11) from roller (12).
D475A, D475ASD-5E0
15
SEN02017-03
Assembly
a
1.

Set roller (12) to press, then using tool L8,
press fit bushing (11).
a First, center the bushing with a plastic
hammer, then press fit with a press.
a Press fit so that press-fitting dimension (a)
from the end face of the roller to the top
surface of the bushing is the dimension
given below.
q
Press-fitting dimension (a):
17 0.5 mm
2.
Set shaft (5) to roller.
3.
Using tool L9, install floating seal (10) to retainers (3) and (7).
4.
Fit O-ring and install retainers (3), (7) and plate

(8) to roller.
a Check that the plate can be turned
smoothly with the hand.
7.
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):
141.5 0.2 mm
Turn over the track roller assembly and
press fit seal guide (6) on the opposite
side according to the above procedure.
Using tool L11, fill with oil to specified level,

then tighten oil filler plug.
5
5.
Using tool L9, install floating seal (9) to seal

guides (2) and (6).
6.
Using tool L10, press fit seal guide (2) to shaft.

a Seal guide press-fitting force:
49 83 kN {5 8.5 ton}
16
Track roller: 1.4 1.5 l (GO140)

Oil filler plug:
156.8 254.8 Nm {16 26 kgm}
D475A, D475ASD-5E0
SEN02017-03

carrier roller assembly
Removal
1.
Loosen the track shoe. For details, see

Expanding track shoe assembly.
2.
Lift up the track shoe with hydraulic jack [1].
3.
Lift off carrier roller assembly (1).

4
[*1]
Carrier roller assembly: 105 kg
Installation
q
[*1]

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}
D475A, D475ASD-5E0
17
SEN02017-03

carrier roller assembly
5.
Using tool L7, remove nut (4).
6.
Remove the fitted part of the seal guide with

puller [2] and remove bearing (5) and roller (6)
as one unit by using eyebolts.
7.
Remove bearing outer race (7) from the roller.
8.
Remove seal guide (8) and bearing inner race

(9) as one unit with puller [3].
9.
Remove floating seal (10) from seal guide (8).
4 791-601-1000
Oil pump
t 1
5 791-515-1520
Installer
t 1
6 790-830-1770
Push tool
t 1
7 791-631-1270
Wrench
t 1
Sketch
Qty
Part Name
New/Remodel
Part No.
Necessity
Symbol
Special tools
Disassembly
1.
Remove the oil filler plug and drain the oil.

a Drain the oil, turning the shaft.
6
Carrier roller: Approx. 13 l
2.
Set carrier roller assembly (1) to block [1].
3.
Remove the mounting bolts and cover (2).
4.
Remove ring (3).
18
D475A, D475ASD-5E0
SEN02017-03
a
10. Remove seal guide (11) with push tool [4].

11. Remove floating seal (12) from seal guide (11).
5.
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.
6.
Install ring (3).
7.
Fit the O-ring to cover (2) and install them.
Assembly
a
Clean the all parts and check them for dirt.
1.
Press fit bearing inner race (9) with push tool

[5].
2.
Press fit bearing outer race (7) with push tool

[6].
3.
Set roller (6) and bearing inner race (5) to the

shaft.
4.
Press fit bearing inner race (5) to the shaft with

push tool [7].
D475A, D475ASD-5E0
Press fit the bearing inner race, turning

the roller, until the roller becomes a little
hard to turn.
19
SEN02017-03
8.
Install floating seal (10) to seal guide (8) with

tool L5.
9.
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.
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.
20
D475A, D475ASD-5E0
SEN02017-03
Removal and installation of bogie

assembly
Part No.
13
14
Part Name
791T-8301780
Plate
t 3 N Q
01011-62700
Bolt
t 6
01673-32780
Washer
t 6
1 791-830-1620 Plate
t 1 N
2 791-830-1630 Spacer
t 1 N
3 791-830-1640 Screw
t 3 N
4 01580-12722
Nut
t 3
5 01630-32780
Washer
t 3
6 790-101-4000
Puller
t 1
(490 kN {50 ton})
7 790-101-1102 Pump
t 1
1 791-830-1650 Plate
t 1 N
2 791-830-1660 Spacer
t 1 N
3 796-670-1120 Plate
t 1
4 790-434-1070 Screw
t 1 N
Nut
t 2
6 01643-33690
Washer
t 1
7 790-101-4000
Puller
t 1
(490 kN {50 ton})
15 5 01580-13629
8 790-101-1102 Pump
t 1
1 791-830-1620 Plate
t 1 N
2 791-830-1640 Screw
t 3 N
3 01580-12722
16 4 01643-32780
5 790-101-4000
Nut
t 3
Washer
t 3
17
2.
Install tool L13 and secure the bogie assembly.
3.

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.
4.
Set block [1] out of the track shoe, matching it

to the height of the track link.
5.
Set steel plate [2] on the track shoe and block

[1].
6.
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.
Guide
t 1
t 2 N Q
18
791-530-1510 Installer
t 1
19
791-601-1000 Oil pump
t 1
D475A, D475ASD-5E0
Loosen the track shoe. For details, see Expansion and installation of track shoe assembly.
Puller
t 1
(490 kN {50 ton})
6 790-101-1102 Pump
791T-8301670
1.
Necessity
Qty
New/Remodel
Sketch
Symbol
Special tools
Removal
21
SEN02017-03
7.
Remove cover (2).
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}
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}
6)
7)
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).
8)
3)
Remove floating seals (5) from the end

faces of rings (4) and (7).
9.
Remove tool L13.
10. Place bogie assembly (1) on steel plate [2].

11. Operate the blade and ripper to raise the
machine body until the bogie assembly can be
pulled out.
track link so that the machine body will
not lower.
22
D475A, D475ASD-5E0
SEN02017-03
12. Sling bogie assembly (1) and pull it out, sliding

it on steel plate [2].
4
2)
3)
4)
5)
6)
Bogie assembly: 1,200 kg
Press fit shaft (3) to ring (8).

Install spacer (9).
Press fit ring (7) to shaft (3).
Install spacer (6).
2 Apply lubricant (LM-P) to parts (a)
(about 10 mm) of rings (8) and (4).
Installation
1.
Assembly of pin assembly

1) Using tool L18, install floating seals (5) to
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.
D475A, D475ASD-5E0
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.
23
SEN02017-03
4.

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
2)
24
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}
Pin assembly: 180 200 cc (GO-140)
6.
Press fit the pin assembly on the opposite side

of the bogie according to above steps 3 and 4.
7.
Tighten the mounting bolts of pin assembly

cover (2) (2 places on inside and outside).
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".
D475A, D475ASD-5E0
SEN02017-03
Disassemble the pin assembly according to

Removal and installation of bogie assembly
(Step 8).
Special tools
4.
Disconnection of bogie
Disconnect inner bogie (4) and outer bogie (5).
Part No.
Part Name
Necessity
Qty
New/Remodel
Sketch
3.
Symbol

bogie assembly
1 791-830-1620 Plate
t 1 N
2 791-830-1640 Screw
t 3 N
3 01580-12722 Nut
16 4 01643-32780 Washer
5 790-101-4000
t 3
Puller
t 1
(490 kN {50 ton})
6 790-101-1102 Pump
19
t 3
791-601-1000 Oil pump
t 1
t 1
Disassembly
1.
2.
Track roller assembly

Turn over bogie assembly (1) and lift off 2 track
roller assemblies (2).
Assembly
1.

Assemble the pin assembly according to
Removal and installation of bogie assembly
(Steps 3 5 of Installation).
2.
Set inner bogie (4) to outer bogie (5).
3.

Remove cover (3).
D475A, D475ASD-5E0
25
SEN02017-03
2)
4.
Press fit the pin assembly.

pin assembly up (when the pin
assembly is installed to the machine).
(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.

a After press fitting the pin assembly, rock
the small bogie so that it can be moved
with light force.
6.
Tighten the mounting bolts of pin assembly

cover (3) (2 places on inside and outside).
883 1,470 Nm {90 150 kgm}
7.
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}
Refilling with oil

tool L19.
a Oil supplying pressure: 0.49 MPa {5 kg/
cm2}
5
26
Pin assembly: 180 200 cc (GO140)
D475A, D475ASD-5E0
SEN02017-03
Removal and installation of No.1

bogie assembly
Removal
1.
Loosen track shoe tension.

For details, see Expansion and installation of
track shoe assembly.
2.
Operate blade and ripper, and raise chassis to

a position where track roller of No. 2 bogie
assembly is separated from track link.
the track link to prevent the chassis
from coming down.
3.
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).
4.
Put steel plate between track shoe and roller,

then loosen roller cap bolts (2) approx. 20 mm.
(Both inside and outside)
5.
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)
6.
Remove roller cap bolt (2), then put track roller

assembly (4) on steel plate, and pull out.
14
Part No.
1 791-830-1620 Plate
t 1 N
2 791-830-1630 Spacer
t 1 N
3 791-830-1640 Screw
t 3 N
4 01580-12722
Nut
t 3
5 01630-32780
Washer
t 3
6 790-101-4000
Puller
t 1
(490 kN {50 ton})
7 790-101-1102 Pump
t 1
1 791-830-1650 Plate
t 1 N
2 791-830-1660 Spacer
t 1 N
3 796-670-1120 Plate
t 1
4 790-434-1070 Screw
t 1 N
Nut
t 2
6 01643-33960
Washer
t 1
7 790-101-4000
Puller
t 1
(490 kN {50 ton})
15 5 01580-13629
Part Name
Necessity
Qty
New/Remodel
Sketch
Symbol
Special tools
8 790-101-1102 Pump
t 1
1 791-830-1620 Plate
t 1 N
2 791-830-1640 Screw
t 3 N
3 01580-12722
Nut
t 3
Washer
t 3
16 4 01643-32780
Puller
5 790-101-4000
t 1
(490 kN {50 ton})
6 790-101-1102 Pump
t 1
791T-830-1670 Guide
t 2 N Q
18
t 1
19
791-601-1000 Oil pump
t 1
791-630-1860 Bracket
t 1
791-630-1870 Bracket
t 1
791T-830-1510 Spacer
t 2
19M-09-12850 Bolt
t 2
17
20
01643-33380
Washer
791T-830-1700 Lifting tool
21
t 2
t 1 N Q
791T-830-1710 Bar
1 N Q
791T-830-1720 Plate
1 N Q
07283-31079
Grip
01582-01210
Nut
01643-31232
Washer
04530-11628
Eye bolt
D475A, D475ASD-5E0
27
SEN02017-03
7.
Raise No. 1 bogie (5) with tool L20 and hold in

position.
8.
Remove cover (6).
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.
3)
Remove floating seals (9) from the end

faces of rings (8) and (12).
4)
Set tool L15.
5)
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).
6)
7)
28
D475A, D475ASD-5E0
SEN02017-03
10. Lower bogie (5) on the steel plate and pull it

out.
4
2)
3)
4)
5)
6)
Bogie assembly: 180 kg
Press fit shaft (7) to ring (13).

2 Apply lubricant (LM-P) to parts (a)
(about 10 mm) of rings (13) and (8).
Installation
1.

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.
D475A, D475ASD-5E0
2.
Slide bogie (5) on steel plate [1] to the center.
3.
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.
29
SEN02017-03
5.

6.
Refilling with oil

tool L19.
a Oil supplying pressure: 0.49 MPa {5 kg/
cm2}
5
2)
30
Press fit the pin assembly (11).

pin assembly up in the mounting state
on the machine body.
(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}
Pin assembly: 180 200 cc
7.

8.
Install covers (6) (2 places on inside and outside).
9.
Install eyebolts instead of the pad mounting

bolts (M12 x 2 pieces) of bogie (5) and lift and
hold the bogie.
D475A, D475ASD-5E0
SEN02017-03
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.
D475A, D475ASD-5E0
31
SEN02017-03

operator's seat isolator
3.
1
Remove operator's seat (1).

4
Operator's seat:
50 kg
Removal
1.
Disconnect power connector (2) of operator's

seat (1).
2.
Remove four M8 nuts (4) securing operator's

seat (1) and bracket (3).
4.
Remove four M12 nuts (6) securing operator's

seat isolator (5) and turntable.
Installation
q
32
Perform installation in the reverse order to

removal.
D475A, D475ASD-5E0

operator's seat isolator
a
SEN02017-03
Disassembly
q
Perform disassembly in the reverse order to

assembly.
Assembly
1.
Install stopper rubbers (3) to two stopper

bosses (2) of base plate (1).
a Hitch one side of stopper rubber (3) to the
groove of the boss and press it with a
round bar to install it to the boss.
D475A, D475ASD-5E0
2.
Install four laminated rubbers (4) to base plate

(1) with eight M10 bolts (5).
3 Laminated rubber mounting bolt:
40 Nm {4.08 kgm}
3.
Install collar (7) to damper mounting pin (6) of

the base plate with the tapered side down.
33
SEN02017-03
4.
Install protection tube (9) side of damper (8) to

the mounting pin of the base plate.
5.
Install slotted head nut (10) and pass cotter pin

(11) and bend it to secure. (2 places)
6.
7.
Insert the top plate mounting pin into free side

(15) of the damper installed to the top plate
and remove the tape.
8.
Match the holes of the top plate with the

mounting screws of the laminated rubbers and
secure them with eight M10 bolts (5).
3 Laminated rubber mounting bolt:
40 Nm {4.08 kgm}
9.
Place plate (16) on the stopper pin and secure

it with two M10 bolts (17).
Put collar (13) to the damper mounting pin of

top plate (12) with the tapered side down and
secure it with tape (14) to prevent it from falling.
10. Turn over the top plate, install slotted head nut
(10) to the mounting pin, and pass cotter pin
(11) and bend it to secure. (Two places)
34
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN02017-03
35
SEN02017-03

2011 KOMATSU
All Rights Reserved
36
SEN02018-02
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
Undercarriage and frame, Part 2

Expansion and installation of track shoe assembly......................................................................................... 2
Overall disassembly and overall assembly of track shoe ............................................................................... 5
Press-fitting jig dimension table for link press ............................................................................................... 21
Field disassembly and assembly of one link................................................................................................. 22
Disassembly and assembly of master link .................................................................................................... 27
Removal and installation of pivot shaft assembly ......................................................................................... 31
Removal and installation of equalizer bar ..................................................................................................... 32
Disassembly and assembly of equalizer bar bushing ................................................................................... 35
D475A, D475ASD-5E0
SEN02018-02
Expansion and installation of

track shoe assembly
Expansion of track shoe assembly (Normal)

1
If Checking before expansion of track shoe

assembly shows that there is no abnormality,
do as follows.
1.
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.
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.
Expansion
Checking before expansion of track shoe
assembly
k
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)".
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)".
D475A, D475ASD-5E0
3.
4.
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.
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.
SEN02018-02
1.
Remove work equipment assembly.

work equipment assembly".
2.
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.
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.
4.
Remove shoe (2), then disconnect master link

(3).
5.
Move machine towards rear slowly and lay out

track shoe assembly.
Expansion of track shoe assembly (when

there is abnormality inside track frame)
a
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.
D475A, D475ASD-5E0
SEN02018-02
Installation
q
[*1]

expansion (normal).
a
a
a
[*2]
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
D475A, D475ASD-5E0
SEN02018-02
Part No.
Part Name
791-646-7531 Plug remover
t 1
791-660-7460 Pin brush
t 1
791-646-7900 Push tool
t 1
791-932-1110 Push tool
t 1
790-701-3000 Seal checker

and
791-601-1000 Oil pump
t 1
t 1
Push tool
assembly
t 1
2 791-685-5640 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
1 791-685-5600
Push tool
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
1 791-685-5700
12
13
791-685-5750 Push tool
D475A, D475ASD-5E0
t 1
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).
Sketch
Symbol
New/remodel
Special tools
Q'ty
Overall disassembly
Necessity
Overall disassembly and overall

assembly of track shoe
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.
SEN02018-02
2.
The track press operator and other workers

must put on helmets, safety glasses and earplugs.
1.
Removal of shoe
Sling the shoe assembly and set it on a floor
with the shoe up. Remove the shoe with a
shoe bolt impact wrench.
a If a shoe bolt is still hard (If its torque is not
lowered to 0) after it is unscrewed by 1
turn, loosen the other bolts, and it can be
removed easily.
a If a bolt is unscrewed forcibly while its
torque is not 0, it will stick to the link and
will need to be repaired.
a When moving the shoe assembly, take
care not to damage the master link.
a If it is obliged to cut a shoe nut with gas,
keep the temperature of the sealing parts
below 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.
D475A, D475ASD-5E0
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.
3)
Return the left cylinder and operate the

right cylinder to pull out the right link, pin,
and bushing simultaneously.
D475A, D475ASD-5E0
SEN02018-02
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.
SEN02018-02
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.

a
3)
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.
D475A, D475ASD-5E0
2)
3)
4)
SEN02018-02
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.
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.
D475A, D475ASD-5E0
1]
2]
3]
4]
5)
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.
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.
SEN02018-02
6)
7)
10
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.
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.)
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}
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.
D475A, D475ASD-5E0
4)
Turn over the master links and check that

they are press fitted in parallel.
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
6)
SEN02018-02
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.
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.
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.
D475A, D475ASD-5E0
11
SEN02018-02
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.
12
D475A, D475ASD-5E0
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.
SEN02018-02
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.
D475A, D475ASD-5E0
17) Similarly, insert the ring in the pin groove

on the opposite side with jig R9.
13
SEN02018-02
18) Push in the ring with jig R13.

Pushing force of ring:
392 490 kN {40 50 tons}
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.
14
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.
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
D475A, D475ASD-5E0
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.
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
D475A, D475ASD-5E0
SEN02018-02
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.
Shoe bolt:
Lubricant containing molybdenum disulfide (LM-P)
3 Shoe bolt (Master link)
Initial torque:
980 98 Nm {100 10 kgm}
a Tighten the bolts in the order of [1]
[4].
15
SEN02018-02
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)
6)
16
2)
When reusing the pin, chamfer the corners of its end carefully with a grinder so
that it will be press fitted smoothly.
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.
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.
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.
D475A, D475ASD-5E0
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
SEN02018-02
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)

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.
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).
D475A, D475ASD-5E0
17
SEN02018-02
5)
Measure the projections of the bushing on

both sides with a depth gauge.
a Adjust the fitting jig of the link press
so that the bushing will be projected
7)
6)
18
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.)
bolt holes with a shoe bolt hole pitch
gauge. If the result is within the limits, stop
press fitting.
D475A, D475ASD-5E0
9)
SEN02018-02
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.
Install the ring to jig R12.
3.
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.
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}
11) Push in the ring with jig R13.

Pushing force of ring:
392 490 kN {40 50 tons}
D475A, D475ASD-5E0
19
SEN02018-02
4.
20
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:
disulfide (LM-P)
Initial torque:
980 98 Nm {100 10 kgm}
a Tighten the bolts in the order of [1] [4].
D475A, D475ASD-5E0
SEN02018-02
Press-fitting jig dimension table for link press
Jig dimension (mm)

a
4.6
2.0
59.1
D475A, D475ASD-5E0
21
SEN02018-02
Field disassembly and assembly

of one link
1 791-832-1610 Plate
t 1
2 791-832-1270 Bracket
t 1
3 01010-81495
t 1
Bolt
t 1 N
2 791-832-1510 Push tool
t 1 N
1 N
t 1
5 01010-62050
t 2
2 791-685-5650 Adapter
1 N
6 791-832-1220 Plate
t 1
3 791-685-5660 Ring
1 N
7 791-832-1230 Shaft
t 2
8 791-832-1210 Frame
t 1
9 791-832-1240 Nut
t 2
Bolt
12
4 791-685-5670 Plate
1 N
5 791-685-5680 Ring
1 N
6 791-685-5690 Push tool
1 N
1 N
Eye bolt
t 2
7 791-685-5710 Adapter
11 791-832-1310 Adapter
t 1
8 791-685-5720 Spring
1 N
12 791-832-1280 Adapter
t 1
9 791-685-5730 Bar
1 N
13 791-832-1320 Guide
t 1
10 01252-30655
Bolt
t 5
11 01580-01210
Nut
Screw
8 15 791-832-1640 Pusher
22
1 791-832-1490 Push tool
4 791-832-1250 Bracket
14 01310-21032
Part Name
Push tool
1 791-685-5700
assembly
10 04530-11628
11
Part No.
Necessity
Qty
New/Remodel
Sketch
Part Name
Symbol
Part No.
Necessity
Qty
New/Remodel
Sketch
Symbol
Special tools
13
t 1
16 791-832-1340 Extension
t 2
17 791-832-1650 Adapter
t 1
18 791-832-1480 Adapter
t 1 N
19 791-832-1670 Guide
t 1
20 791-832-1330 Guide
t 1
21 791-832-1660 Adapter
t 1
22 791-832-1630 Guide
t 1
23 791-832-1470 Guide
t 1 N
24 791-832-1410 Extension
t 1
25 791-832-1350 Pusher
t 1
29 790-101-1102 Pump
t 1
Puller (294 kN
30 790-101-4200
{30 ton})
t 1
31 791-685-9230 Spacer
t 1
Push tool
1 791-685-5600
assembly
1 N
2 791-685-5640 Adapter
1 N
3 791-685-5660 Ring
1 N
4 791-685-5670 Plate
1 N
5 791-685-5680 Ring
1 N
6 791-685-5690 Push tool
1 N
7 791-685-5710 Adapter
1 N
8 791-685-5720 Spring
1 N
9 791-685-5730 Bar
1 N
10 01252-30655
Bolt
11 01580-01210
Nut
791-685-5750 Push tool
t 1 N
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).
D475A, D475ASD-5E0
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.
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.
4.
Insert R8-7 in the hole of R8-8 installed to the

track, then clamp it with R8-9.
D475A, D475ASD-5E0
SEN02018-02
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).
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.
23
SEN02018-02
7.
8.
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}
Repeat step 6 to remove link (5).
2)
2.
24
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}
Set link sub-assembly (9) to the link to be connected.
D475A, D475ASD-5E0
3.
Set link (10) on the opposite side and support it

with tool R8-19.
4.
Similarly to the disassembly procedure, set

tools R8-29, R8-6 R8-11, and R8-24 to the
link.
5.
SEN02018-02
6.
Similarly to the disassembly procedure, push

open link (11) to be connected by using tools
R8-30 and R8-31.
7.
Set link (12) to be connected to link (11) and

connect them with tool R8-22, then remove
tools R8-30 and R8-31.
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.
333 451 kN {34 46 tons}
a Press fitting force of bushing:
245 382 kN {25 39 tons}
D475A, D475ASD-5E0
25
SEN02018-02
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)
link tread side.
666 902 kN {68 92 tons}
9.
Install the ring with tools R9, R11, R12, and

R13.
a For the method of using the tools, see
"Overall assembly of track shoe".
26
D475A, D475ASD-5E0
SEN02018-02

master link
t 1
2 791-832-1270 Bracket
t 1
3 01010-81495 Bolt
t 1
4 791-832-1250 Bracket
t 1
11 01580-01210 Nut
5 01010-62050 Bolt
t 2
1 791-832-1490 Push tool
t 1 N
6 791-832-1220 Plate
t 1
2 791-832-1510 Push tool
t 1 N
7 791-832-1230 Shaft
t 2
t 1
1 N
8 791-832-1210 Frame
Push tool
1 791-685-5700
assembly
9 791-832-1240 Nut
t 2
2 791-685-5650 Adapter
1 N
10 04530-11628 Eye bolt
t 2
3 791-685-5660 Ring
1 N
11 791-832-1310 Adapter
t 1
4 791-685-5670 Plate
1 N
12 791-832-1280 Adapter
t 1
5 791-685-5680 Ring
1 N
13 791-832-1320 Guide
t 1
6 791-685-5690 Push tool
1 N
1 N
11
12
8 791-685-5720 Spring
1 N
9 791-685-5730 Bar
1 N
10 01252-30655 Bolt
1
1
14 01320-41030 Screw
t 5
7 791-685-5710 Adapter
15 791-832-1640 Pusher
t 1
8 791-685-5720 Spring
1 N
t 2
9 791-685-5730 Bar
1 N
t 1
10 01252-30655 Bolt
18 791-832-1480 Adapter
t 1 N
11 01580-01210 Nut
19 791-832-1670 Guide
t 1
20 791-832-1330 Guide
t 1
21 791-832-1660 Adapter
t 1
22 791-832-1630 Guide
t 1
23 791-832-1470 Guide
t 1 N
24 791-832-1410 Extension
t 1
25 791-832-1350 Pusher
t 1
26 791-832-1620 Guide
t 1
27 04530-11018 Eye bolt
t 1
8 17 791-832-1650 Adapter
28 791-101-4500
30 790-101-4200
Puller (294 kN
{30 ton})
31 790-685-9230 Spacer
t 1
t 1
791-685-5750 Push tool
t 1 N
Disassembly
a
For the method of using tool R8, see Field disassembly of one link.
1.
Removal of track shoe assembly

Remove the track shoe assembly from the
track frame. For details, see Expanding track
shoe assembly.
2.
Disassembly of shoe
Disconnect the all master links and divide the
shoes into 4 parts.
t 1
Push tool
1 791-685-5600
assembly
1 N
2 791-685-5640 Adapter
1 N
3 791-685-5660 Ring
1 N
4 791-685-5670 Plate
1 N
5 791-685-5680 Ring
1 N
6 791-685-5690 Push tool
1 N
7 791-685-5710 Adapter
1 N
D475A, D475ASD-5E0
13
Cylinder
t 1
(1960 kN {200 ton}
29 790-101-1102 Pump
Part Name
1 791-832-1610 Plate
16 791-832-1340 Extension
Part No.
Necessity
Qty
New/Remodel
Sketch
Part Name
Symbol
Part No.
Necessity
Qty
New/Remodel
Sketch
Symbol
Special tools
27
SEN02018-02
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
2)
1)
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)
28
Master link type

Cutting and removal of master link on
bushing side with gas
with gas and
. 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
Removal of master link on pin side

with gas and
. 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
D475A, D475ASD-5E0
Assembly
a
For the method of using tool R8, see "Field disassembly of one link".
1.
Assembly of bushing-side link

1) Press fit bushing-side master link (1) to
bushing (2) with a press.
a When press fitting both master links,
take care that they will be in parallel
with each other.
a Do not damage the mating surfaces
of the master links and end faces of
the bushing.
Unit: mm
2.
L1
226 0.7
L2
276 0.7
D1
36 drill hole
D2
33 x 2.0
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.)
D475A, D475ASD-5E0
SEN02018-02
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].
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.
link tread side.
29
SEN02018-02
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)
4.
3.
30
Assembly of link on pin side

1) Set spacer (3) and seal assembly (4) to
the counterbore of the master link.
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.
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:
disulfide (LM-P)
Initial torque:
980 98 Nm {100 10 kgm}
D475A, D475ASD-5E0
SEN02018-02
Removal and installation of pivot

shaft assembly
3.
Remove seal (2), then remove cover (3).
[*2]
Sketch
Q'ty
Part Name
New/remodel
Part No.
Necessity
Symbol
Special tools
791T-850-1180 Sleeve
t 1
791T-850-1190 Plate
t 1
791-730-1130
Bolt
t 2
791-101-3310
Plate
t 1
01643-32060
Washer
t 2
01580-02016
Nut
t 2
790-105-2300
Jack assembly
t 1
790-101-1102
Pump
t 1
Installation
q
[*1]
Removal
1.
2.
2
2
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]

removal.
[*2]
Pivot shaft assembly: 390 kg

a
q
q
D475A, D475ASD-5E0
Pivot shaft press-fitting surface:

Pivot shaft mounting bolt:
Adhesive (LT-2)
Pivot shaft mounting bolt:
1,519 1,911 Nm {155 195 kgm2}
Using tool P, press fit seal (2) to the pivot

shaft.
2 Seal press-fitting surface:
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
Press-fitting surface:
20.6 32.4 kN {2.1 3.3 ton}
31
SEN02018-02

equalizer bar
5.
Set stand and hydraulic jack [1] (294 kN {30

ton}) under radiator guard.
6.
Remove cover (6).
792-900-1610
Adapter
t 1
792-900-1530
Screw
t 1
791-775-1110
Sleeve
t 1
791T-850-1150 Plate
N 1 01582-53024 Nut
t 1
Sketch
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
t 1
t 1
01643-33080
Washer
790-101-2102
Puller
t 1
(294 kN {30t on})
7.
Remove cover (7).
790-101-1102
Pump
t 1
8.
Remove main bolt (8) of side pin.
9.
Using eyebolt [2], remove side pin (9).

[*3]
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.
Removal
1.
Remove engine underguard and power train

underguard (front).
4
4
2.
Engine underguard: 330 kg

Power train underguard (front): 340 kg
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.
3.
Remove seal (2) together with washer (3). [*1]
4.
Remove washer (4), then remove spacer (5).

a Oil will flow out from the pivot case, so
catch it in an oil container.
6
32
Pivot case: 26 l
D475A, D475ASD-5E0
SEN02018-02
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]
13. Using tool N1, remove center pin (12).

[*5]
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.
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
Installation
q
[*1]

removal.
a
a
[*2]
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.
a
a
D475A, D475ASD-5E0
Equalizer bar assembly: 600 kg
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).
33
SEN02018-02
[*3]
[*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.
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)

5
34
Lock plate mounting bolt:

Tread tightener (LT-2)
Lock plate mounting bolt:
1,519 1,911 Nm {155 195 kgm}
Pivot case: 26 l (SAE30)
D475A, D475ASD-5E0
SEN02018-02

equalizer bar bushing
3)
Set tool N2 in position and remove side

bushing (4) from equalizer bar (5).
N 2
Sketch
Q'ty
Part Name
New/remodel
Part No.
Necessity
Symbol
Special tools
791T-850-1160 Bracket
t 1
791T-850-1170 Bracket
t 1
790-438-1110
Screw
t 1
790-101-2540
Washer
t 2
791-112-1180
Nut
t 2
790-101-2102
Puller
t 1
(294 kN {30 ton})
790-101-1102
Pump
Disassembly
1.
Center bushing
Remove center bushings (1).
2.
Side bushing
1) Remove seals (2).
D475A, D475ASD-5E0
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:
35
SEN02018-02
a
2)
3)
36
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:
a Center bushing press-fitting force:
68.6 233.2 kN {7 23.8 ton}

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.
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN02018-02
37
SEN02018-02

2010 KOMATSU
All Rights Reserved
38
SEN02019-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
Hydraulic system
Removal and installation of hydraulic pump assembly ................................................................................... 2
Removal and installation of hydraulic valve assembly .................................................................................... 4
Disassembly and assembly of control valve ................................................................................................... 5
Disassembly and assembly of merge divider valve and self pressure reducing valve assembly ................... 9
Removal and installation of PPC relief valve assembly .................................................................................11
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 12
Disassembly and assembly of ripper pin puller cylinder assembly ............................................................... 17
D475A, D475ASD-5E0
SEN02019-01

hydraulic pump assembly
5.
Disconnect hoses (5).
6.
Remove tube coupling (6).
7.
Remove pump inlet tube (7).
8.
Disconnect PPC hoses (8) and (9).
9.
Disconnect wiring clamp at the top of pump

(10) and wiring harness connector (11).
Removal
k
1.

and stop the engine. Release the remaining
pressure in the hydraulic piping.
" R e l e a s i n g 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.
Drain oil from hydraulic tank.
6
Hydraulic tank: 170 l
2.
Remove floor frame assembly.

For details, see "Removal of floor frame
assembly".
3.
Disconnect pump outlet hoses (1) and (2).
4.
Disconnect PPC hoses (3) and (4).
10. Sling hydraulic assembly (12), then remove

mounting bolts, and remove.
D475A, D475ASD-5E0
SEN02019-01
Installation
q

removal.
Refilling with oil (hydraulic tank)

again.
D475A, D475ASD-5E0
SEN02019-01

hydraulic valve assembly
6.
Disconnect 5 PPC hoses (5) from bottom side.

a PPC hoses are distinguished by color
bands.
Removal
7.
Disconnect ripper hoses (6) and (7).
8.
Disconnect tubes (8) and (9).

1.

" R e l e a s i n g r e m a i n i n g p re s s u re f r o m
hydraulic circuit".
tank.
Drain oil from hydraulic tank.
6
Hydraulic tank: 170 l
2.
Remove right cover of operator cab.
9.
3.
Remove hose (1).
10. Disconnect wiring connectors (11) and (12),

and clamp (13).
4.
Disconnect 5 PPC hoses (2) from upper side.

11. Sling control valve assembly (14), and then
remove.
4
5.
Main control valve assembly: 195 kg
Disconnect blade lift hoses (3) and blade tilt

hoses (4).
Installation

removal.

again.
Bleeding air in the hydraulic piping

For detail, see Testing and adjusting, Air bleeding from hydraulic cylinder.
D475A, D475ASD-5E0
SEN02019-01
Disassembly and assembly of control valve
D475A, D475ASD-5E0
SEN02019-01
D475A, D475ASD-5E0
SEN02019-01
Disassembly
Assembly
1.
Coat the sliding surface of each part with

1.
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}
2.

27.5 34.3 Nm {2.8 3.5 kgm}
3.
Blade lift valve

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
11.8 14.6 Nm {1.2 1.5 kgm}
27.5 34.3 Nm {2.8 3.5 kgm}
4.
Blade lift valve

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
11.8 14.6 Nm {1.2 1.5 kgm}
27.5 34.3 Nm {2.8 3.5 kgm}
2.
3.
4.
Ripper lift valve

1) Remove case (1), spring (12), and retainer
(9).
2) Remove lower case (1), spring (12), and
retainer (9).
a Do not disassemble spool assembly
(2).
(9).
retainer (9).
(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).
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).
5.

(9).
retainer (9).
(3).
6.
Ripper tilt valve

(9).
retainer (9).
(2).
D475A, D475ASD-5E0
SEN02019-01
5.

27.5 34.3 Nm {2.8 3.5 kgm}
6.
Ripper lift valve

27.5 34.3 Nm {2.8 3.5 kgm}
D475A, D475ASD-5E0
SEN02019-01
Disassembly and assembly of merge divider valve and self pressure

reducing valve assembly
D475A, D475ASD-5E0
SEN02019-01
Disassembly
Assembly
1.
Remove case (7) from valve body (1). Loosen

bolt (6) and remove retainer (8), spring (5),
retainer (4), plug (3), and spool (2).
Coat the sliding surface of each part with

1.
2.
Remove plug (14), spring (12), and spool (11).
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}
3.
Remove plug (18), spring (17), and spool (16).

2.
4.
Remove plug (33), spring (32), and spool (31)

from block (30).
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}
5.
Remove valve assembly (20) from block (30).

3.
6.
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.
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}
4.
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}
5.
Install spring (12) to spool (11). Fit the O-ring to

plug (14) and install them.
3 Plug assembly:
147.1 186.3 Nm {15 19 kgm}
6.
Install retainer (4), spring (5), retainer (8), and

plug (3) to spool (2) and install them to body
(1). Fit the O-ring and install case (7).
3 Mounting bolt of case (7):
27.5 34.3 Nm {2.8 3.5 kgm}
10
D475A, D475ASD-5E0
SEN02019-01
Removal and installation of PPC

relief valve assembly
Removal
k

Releasing remaining pressure from hydraulic circuit.
tank.
1.
Remove operators cab right cover.
2.
Remove hoses (1), (2), and (3).
3.
Disconnect connector (4).
4.
Remove PPC relief valve assembly (5).
Installation
q

removal.
D475A, D475ASD-5E0
11
SEN02019-01

hydraulic cylinder assembly
Disassembly
1 790-502-1003
Cylinder repair
stand
t 1
790-201-1881 Push tool
790-201-1871 Push tool
790-201-1721 Push tool
790-101-5021 Grid
01010-50816
790-201-1500 Push tool kit
790-201-1680 Plate
3 790-201-1690 Plate
790-201-1530 Plate
790-101-5021 Grip
01010-50816
Bolt
4 790-720-1000 Expander
t 1
07281-01919
t 1
796-720-1690 Ring
t 1
07281-02169
t 1
Clamp
796-720-1710 Ring
t 1
07281-02709
t 1
Clamp
796-720-1630 Ring
t 1
07281-00709
t 1
Clamp
6 790-102-2304 Wrench
12
Sketch
Quick drop valve assembly

a Blade lift cylinder only.
1) Remove quick drop valve assembly (1).
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).
t 1
796-720-1690 Ring
Clamp
2.
t 1
790-201-1670 Plate
Cylinder tube
Remove cylinder tube.
q 1
790-201-1702 Push tool kit
Bolt
New/remodel
Part Name
Q'ty
Part No.
Necessity
Symbol
Special tools
1.
t 1
D475A, D475ASD-5E0
3.
SEN02019-01
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)
5.
4.
Disassemble piston assembly as follows.

1] Remove wear ring (17).
2] Remove piston ring (18).
Head assembly
1) Remove head assembly (19) from piston
rod.
Piston assembly
1) Set piston rod assembly (10) to tool U1.
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).
D475A, D475ASD-5E0
Disassemble head assembly as follows.

1] Remove O-ring (20) and backup ring
(21).
13
SEN02019-01
2]
3]

seal (23).
Remove packing (24), then remove
bushing (25).
5]
Install backup ring (21) and O-ring

(20).
Assembly
a

engine oil before installing. Be careful not to
damage the packings, dust seals, and O-rings
when installing.
1.
Head assembly
1) Assemble head assembly as follows.
1] Using tool U2, press fit bushing (25)
to head.
2] Install packing (24).
3] Using tool U3, press fit seal (23).
4] Install snap ring (22).
14
2)
Install head assembly (19) to piston rod.
D475A, D475ASD-5E0
2.
SEN02019-01
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)
3.
D475A, D475ASD-5E0
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:
3 Mounting bolt:
Blade lift:
98 123 Nm {10 12.5 kgm}
Blade lift, ripper lift, ripper tilt:
157 196 Nm {16 20 kgm}
Piston rod assembly

1) Set cylinder (8) to tool U1.
15
SEN02019-01
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)
5.
4.
16
Install quick drop valve assembly (1).
Cylinder tube
Install cylinder tube.
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).
D475A, D475ASD-5E0
SEN02019-01
a

ripper pin puller cylinder
assembly
Put an oil container under the cylinder

to catch the oil.
Cylinder repair
stand
q 1
790-201-1702
Push tool kit
t 1
790-201-1881
Push tool
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
790-201-1530
Plate
790-101-5021
Grip
01010-50816
Bolt
1 790-502-1003
t 1
796-720-1690
Ring
t 1
07281-01919
Clamp
t 1
796-720-1690
Ring
t 1
07281-02169
Clamp
t 1
796-720-1710
Ring
t 1
07281-02709
Clamp
t 1
796-720-1630
Ring
t 1
07281-00709
Clamp
t 1
Wrench
t 1
6 790-102-2304
2.

1) Remove cylinder head assembly (2) from
piston rod (3).
t 1
Expander
4 790-720-1000
Sketch
Q'ty
Part Name
New/remodel
Part No.
Necessity
Symbol
Special tools
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).
D475A, D475ASD-5E0
17
SEN02019-01
3.
Piston rod assembly

Remove piston ring (12) from piston rod (3).
2.

1) Using tool U2, press fit bushing (11) to cylinder head (4).
Assembly
a

engine oil before installing. Be careful not to
damage the packings, dust seals, and O-rings
when installing.
1.
Piston rod assembly

1) Using tool U4, expand piston ring (12).
a Set the piston ring on the expander
and turn the handle 8 10 time to
expand the ring.
2) Remove piston ring (12) from tool, then
install to piston rod (3).
3) Using tool U5, compress piston ring (12).
2)
18
Using tool U3, press fit dust seal (9) to cylinder head (4).
D475A, D475ASD-5E0
3)
4)
5)
Install snap ring (8) and rod packing (10).

Install O-ring (7).
Install backup ring (6) and O-ring (4).
6)
Install cylinder head assembly (2) to piston rod (3).
D475A, D475ASD-5E0
SEN02019-01
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}
19
SEN02019-01

2008 KOMATSU
All Rights Reserved
20
SEN02020-00
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
Work equipment
Work equipment .............................................................................................................................................. 2
Removal and installation of blade assembly ........................................................................................ 2
Disassembly and assembly of giant ripper assembly .......................................................................... 4
D475A, D475ASD-5E0
SEN02020-00
Work equipment
Removal and installation of blade
1
assembly
1
k
Removal
k
Lower the work equipment to the ground in

a horizontal place, and set blocks [1]
securely under the left and right straight
frames.
1.
Remove lock plate (1) of lift cylinder rod pin

and extract pin (2).
[*1]
2.
Sling lift cylinder assembly (3), then start

engine and retract piston rod fully, fit cylinder
lock tool and secure to radiator guard.
a Tie the piston rod with wire to prevent it
from coming out.
q
Repeat the same procedure to disconnect
the cylinder from the blade on the opposite side.
Release the remaining pressure from the

hydraulic circuit.
" R e l e a s i n g re m a i ni n g pr e s s ur e f ro m
hydraulic circuit".
tank.
3.
Remove left and right covers (4).
4.

a Mark the hoses before disconnecting.
a Fit blind plugs to prevent dirt or dust from
entering the piping.
5.
Remove left and right trunnion caps (6).
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

removal.
[*1]
a Adjust with block [1] so that height (b) and
width (c) of the left and right straight frames are
the dimensions given below.
q
Height (b) of trunnion portion:
Approx. 981 mm
q
Brace width (c): Approx. 3,840 mm

Run the engine to circulate the oil through the
system. Then check the oil level again.
D475A, D475ASD-5E0
SEN02020-00

giant ripper assembly
7.
Disconnect 4 lift cylinder hoses (4), 4 tilt cylinder hoses (5), and 2 pin-puller cylinder hoses
(6).
8.
Sling tilt cylinder assembly (7), then remove

pin (8) and lift off tilt cylinder assembly (7).
Disassembly
1.
Mount machine on block [1] and lower blade to

ground.
k Lock the brake securely.
2.
Sling shank, then operate pin-puller switch and

pull out shank pin.
3.
Raise ripper fully, and lower shank (1) to

remove.
4
4.
Shank: 1,050 kg
Set stand [2] under arm and beam.

4
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.
"Releasing remaining pressure from
hydraulic circuit".
9.
Tilt cylinder assembly: 410 kg
Sling lift cylinder assembly (9), then remove

pin (10) and lift off lift cylinder assembly (9).
4
Lift cylinder assembly: 400 kg
D475A, D475ASD-5E0
10. Sling beam (11), then remove left and right

pins (12) and lift off beam (11).
4
SEN02020-00
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
Arm: 1,800 kg
Set a stand under the arm.
D475A, D475ASD-5E0
4.
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
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.
9.
Operate ripper and raise slightly to remove

stand [2].
10. Raise ripper fully, pass wire through shank

holder, then raise shank (1) slowly, align with
pin hole, and operate pin-puller switch to insert
shank pin.
11. Raise blade and lower machine from block [1].
6.
Sling tilt cylinder assembly, start engine,

extend piston rod and align with pin hole, then
install pin (3) and secure with lock plate.
7.
Sling lift cylinder assembly, start engine,

extend piston rod and align with pin hole, then
install pin (2) and secure with lock plate.
12. Bleed air from cylinder.

For details, see Testing and adjusting, "Bleed
air from hydraulic cylinder".
D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN02020-00
SEN02020-00

2007 KOMATSU
All Rights Reserved
SEN02021-01
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up

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
SEN02021-01
Removal and installation of ROPS

1
guard
Removal
1.
Sling ROPS guard (1) and remove 16 mounting bolts (2).

[*1]
2.
Lift off ROPS guard (1).

4
ROPS guard: 918 kg
Installation
q
[*1]

removal.
3
ROPS guard mounting bolt:

1,960 2,450 Nm {200 250 kgm}
D475A, D475ASD-5E0

operators cab assembly
SEN02021-01
6.
Remove front covers (8), (9) and (10).
7.
Remove 3 mounting bolts (11), 6 bolts (12) and

15 bolts (13).
8.
Sling operators cab assembly (14), then

remove.
Removal
k

1.
Remove ROPS guard.

For details, see Removal of ROPS guard.
2.
Remove left cover (1) of operators cab.
3.
Disconnect wiring connectors (12V, 21 and 20)

(2).
4.
Disconnect 4 washer hoses (3) and 19 washer

wires (4).
Washer hose
Red : Right door Black : Rear window
Blue : Left door
: Front window
5.
Operators assembly: 500 kg
Remove garnishes (5), (6) and (7).
Installation
q
D475A, D475ASD-5E0

removal.
SEN02021-01
Removal and installation of floor

frame assembly
3.
Removal
k
a
a
k
Operators seat: 64 kg
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.
In the case that you do not drain the coolant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
1.

For details, see "Removal of operators cab
assembly".
2.
Remove covers (1), (2) and (3).
Lift off operator's seat (4).

a Remove the seat together with the undercover.
4.
Remove sidecover (5).
5.
Disconnect brake pedal linkage (6).

[*4]
a Check the mounting dimensions of brake
rod before disconnection.
D475A, D475ASD-5E0
6.
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.
SEN02021-01
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.
7.
Remove wiring connector (12) (CN2-SSA-PT1)

and the clamp.
8.
Disconnect wiring connector (13) (995-111VFD) and remove the connector bracket.
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.
9.
Disconnect blade PPC hose (14A), hose (14B)

and ripper PPC hose (15).
[*2]
10. Disconnect wiring connector and clamp (16).
D475A, D475ASD-5E0
SEN02021-01
19. Remove 8 floor frame rear mounting bolts (26).
Installation
q
[*1]

removal.
a
a
a
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.
Thread size
16 x 1.5
13.23 1.47 {1.35 0.15}
22 x 1.5
22.05 2.45 {2.25 0.25}
24 x 1.5
31.85 2.45 {3.25 0.25}
M6 bolt
(receiver portion)
5.39 1.47 {0.55 0.15}
M6 bolt
(compressor portion)
9.8 1.96 {1.0 0.2}
D475A, D475ASD-5E0
[*2]
[*3]
[*4]
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.
Adjust installed length of parking brake

cable. For details, see Testing and adjusting, Adjusting brake pedal and parking
brake lever.
Adjust installed length of brake rod.

"Adjusting brake pedal and parking brake
lever".
3 Brake pedal linkage turnbuckle:
34.3 58.8 Nm {3.5 6 kgm}
Charging with air conditioner gas

Charge the air conditioner circuit with air conditioner gas (R134a).

D475A, D475ASD-5E0
SEN02021-01
SEN02021-01

2009 KOMATSU
All Rights Reserved
SEN02339-02
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine model
Serial number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
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
SEN02339-02

controller assembly
5.
Disconnect wiring connectors of engine controller (6).

(CN-LE1, CN-LE32, CN-LE31, CN-LE4, CNLE2, CN-LE52, CN-LE51)
6.
Remove engine controller (6).
7.
Remove engine controller mounting bracket

(7).
8.
Disconnect wiring connectors of transmission

controller (8).
(CN-TMCN1, CN-TMCN2, CN-TMCN3)
9.
Remove transmission controller (8).
Removal
k
1.

Remove cover (1).
10. Disconnect wiring connectors of steering controller (9). (CN-STCN1, CN-STCN2, CNSTCN3)
11. Remove steering controller (9).
2.
Remove services switch (2) and connector

bracket (3).
3.
Remove 2 clips for wiring harness (5).
4.
Remove 3 brackets (4).
Installation
q

removal.
D475A, D475ASD-5E0

engine controller assembly (left)
SEN02339-02
3.
Disconnect wirings (3), (4) and (5).
4.
Remove ground cable fixing bolt (6) and controller (7).
5.
Remove the right controller similarly to the left

one.
Removal
k
1.
2.

Remove undercover (1).
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.
Installation
q
D475A, D475ASD-5E0

removal.
SEN02339-02
Removal and installation of air

conditioner condenser assembly
3.
Remove air conditioner condenser assembly

(5) from right side of chassis.
Removal
1.
Open engine right side cover (1) and remove

side covers (2) and (3).
Installation
q
2.
[*1]
[*1]

removal.
a
a
a
a
a
a
k

advance.
atmosphere.

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: NDO I L 8 , Va l e o t h e r m a l s y s t e m s :
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}
Filling air conditioner circuit with refrigerant (R134a)

Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 1,100 g
D475A, D475ASD-5E0
SEN02339-02

conditioner compressor
assembly
4.
Loosen 4 mount bolts (6).
5.
Loosen locknut, and remove adjustment bolt

(7), then remove belt from pulley.
[*2]
Removal
6.
Remove 4 mount bolts (6), then remove air

conditioner compressor assembly (8).

terminal of the battery
1.
Open engine right side cover (1) and remove

side covers (2) and (3).
2.
Disconnect air conditioner compressor clutch

connector (CN-351) (4).
3.
Disconnect 2 compressor hoses (5).

[*1]
advance.
atmosphere.
a
a
k

D475A, D475ASD-5E0
SEN02339-02
Installation
q
[*1]

removal.
a
a
a
a
[*2]

before installing.
3 Air conditioner hose mounting bolt:
10 2 Nm {1.0 0.2 kgm}
Adjust the belt tension.

"Testing and adjusting tension of air conditioner compressor belt".

(R134a).
D475A, D475ASD-5E0
SEN02339-02

conditioner unit
3.
Remove fresh air filter (2).
4.
Remove cover (3).
Removal
5.
Remove duct (4).
6.
Remove garnishes (5) and (6).
7.
Disconnect air hose (7).
8.
Remove fresh air filter bracket (8).
9.
Disconnect 2 air conditioner hoses (9).
1.
2.

Collect the air conditioner refrigerant (R134a)
from air conditioner circuit in advance.
[*1]
a Ask professional traders for collecting and
filling operation of refrigerant.
a Never release the refrigerant to the atmosphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or filling the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified person.
Remove operator's seat (1).

11. Disconnect wire and wiring connector (11).
12. Remove air conditioner unit (12).
D475A, D475ASD-5E0
SEN02339-02
Installation
q
[*1]

removal.
a
a
a
a
a
Install the hoses without twisting or interference.

before installing.
Tighten the air conditioner gas piping to the following tightening

torques.
Thread size
16 x 1.5
13.231.47 {1.350.15}
22 x 1.5
22.052.45 {2.250.25}
24 x 1.5
31.852.45 {3.250.25}
M6 bolt
(receiver portion)
5.391.47 {0.550.15}
M6 bolt (compressor portion)
9.81.96 {1.00.2}

(R134a).

D475A, D475ASD-5E0
D475A, D475ASD-5E0
SEN02339-02
SEN02339-02

2009 KOMATSU
All Rights Reserved
10
SEN00225-00
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine Model
Serial Number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
Hydraulic diagrams and drawings

Hydraulic diagrams and drawings................................................................................................................... 3
Power train hydraulic circuit diagram ................................................................................................... 3
Hydraulic circuit diagram (1/3) ............................................................................................................. 5
D475A, D475ASD-5E0
Hydraulic diagrams and drawings
SEN00225-00
Power train hydraulic circuit diagram

D475A, D475ASD-5E0
Power train hydraulic circuit diagram
D475A, D475ASD-5E0
Hydraulic circuit diagram (1/3)

D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0

D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0

D475A, D475ASD-5E0
SEN00225-00
D475A, D475ASD-5E0
SEN00225-00

2006 KOMATSU
All Rights Reserved
12
SEN00226-03
BULLDOZER
1SHOP MANUAL
D475A-5E0
D475ASD-5E0
Machine Model
Serial Number
D475A-5E0
D475ASD-5E0
30001 and up
30001 and up
Electrical diagrams and drawings

Electrical circuit diagram (1/13)....................................................................................................................... 3
Electrical circuit diagram (5/13)......................................................................................................................11
Electrical circuit diagram (6/13)..................................................................................................................... 13
Electrical circuit diagram (10/13)................................................................................................................... 21
Electrical circuit diagram (11/13) ................................................................................................................... 23
Electrical circuit diagram of inside cab.......................................................................................................... 29
Connector arrangement diagram .................................................................................................................. 31
D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0
Electrical circuit diagram (1/13)

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0
11

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0
13

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0
15

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0
17

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0
19

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0
21

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0
23

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0
25

D475A, D475ASD-5E0
SEN00226-03
D475A, D475ASD-5E0
27
Electrical circuit diagram of inside cab
D475A, D475ASD-5E0
SEN00226-03
Electrical circuit diagram of inside cab

D475A, D475ASD-5E0
29
Connector arrangement diagram
Connector arrangement diagram

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

Battery relay (Left) (Terminal M)
F-8
GND2
Terninal
Ground (Engine)
AS-2
SFT1
H-1
GND3
Terninal
Ground (Engine)
AT-3
SFTD
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
V-9
SEN00226-03
D475A, D475ASD-5E0
31
D475A, D475ASD-5E0
SEN00226-03
33
SEN00226-03

2009 KOMATSU
All Rights Reserved
34

D475A 5E0 Workshop

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D475A 5E0 Workshop

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SEN00203-16

00 Index and foreword

00 Index and foreword

Composition of shop manual

00 Index and foreword

Troubleshooting by failure code, Part 4 .......................................................................... SEN01826-01

00 Index and foreword

00 Index and foreword

00 Index and foreword

Undercarriage and frame................................................................................................ SEN00213-01

00 Index and foreword

00 Index and foreword

Testing and adjusting operator's seat isolator.......................................................................... 61

00 Index and foreword

Failure code [B@BAZG] Engine oil: Oil pressure too low........................................................ 32

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

Failure code [DB39KQ] Steering controller type selection:

00 Index and foreword

00 Index and foreword

Failure code [DV00KB] Caution buzzer: Short circuit .............................................................. 27

00 Index and foreword

Failure code [DXH8KA] Forward clutch ECMV: Disconnection ............................................... 21

00 Index and foreword

E-21 Auto shift down is not possible or is not released ........................................................... 36

00 Index and foreword

S-15 Abnormal noise is made ................................................................................................. 23

00 Index and foreword

Removal and installation of bogie assembly............................................................................ 21

00 Index and foreword

D475A, D475ASD-5E0 Bulldozer

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Foreword and general information

00 Index and foreword

Important safety notice

If welding repairs are needed, always

Prohibition of operation and handling by

6 Safety check before starting work

Wearing protective goggles

Wearing shielding goggles and protectors

9 Good physical condition and preparation

Precautions against work which you are

00 Index and foreword

Preparations for work

When raising a heavy component (heavier

12) When assembling or installing parts,

Precautions for sling work and making

00 Index and foreword

Limit the hanging angle to 60, as a rule.

When installing wire ropes to an angular

00 Index and foreword

11) Do not use twisted or kinked wire ropes.

Precautions for using mobile crane

Precautions for using overhead hoist crane

Selecting wire ropes

00 Index and foreword

Example of O-ring (Fitted to every joint of

For tightening torque, see the precautions for

The allowable load is one-sixth of the

00 Index and foreword

How to read the shop manual

Composition of shop manual