Komatsu D275a PDF

SEBM026308
Machine model Serial number
D275A-5 25001 and up
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• D275A-5 mounts the SDA6D140E-3 engine.

For details of the engine, see the 140-3 Series Engine Shop Manual.
© 2016
All Rights Reserved 00-1
Printed in Japan 10-16 (01) (8)
00
CONTENTS
No. of page
01 GENERAL ......................................................................................... 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1
20 TESTING AND ADJUSTING ............................................................. 20-1
30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1
90 OTHERS ............................................................................................ 90-1
00-2 D275A-5
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The affected pages are indicated by using the
Mark Indication Action required
following marks. It is requested that necessary
actions must be taken to these pages according to Q Page to be newly added Add
the table below.
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LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

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q 10-201 (8) 20- 116 (4) 20-172 (5) 20-309 (7) 20-418 (1)
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20-483 (1) 20-542 (1) 20-615 (1) 20-817 (7) 30- 42 (2)
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20-485 (4) 20-544 (1) 20-617 (1) 20-819 (7) 30- 44 (2)
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20-487 (4) 20-546 (1) 20-619 (1) 20-821 (7) 30- 46 (2)
20-488 (1) 20-547 (1) 20-620 (1) 20-822 (7) 30- 47 (7)
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20-490 (1) 20-549 (1) 20-622 (1) 30- 1 (3) 30- 49 (2)
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30- 90 (2) 30-149 (2) 30-208 (2) 90-11
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30- 117 (2) 30-176 (2) 30-235 (2)
30- 118 (2) 30-177 (2) 30-236 (2)
30- 119 (2) 30-178 (2) 30-237 (2)
30-120 (2) 30-179 (2) 30-238 (2)
30-121 (2) 30-180 (2) 30-239 (2)
30-122 (2) 30-181 (2) 30-240 (2)
30-123 (2) 30-182 (2) 30-241 (2)
30-124 (2) 30-183 (2) 30-242 (2)
30-125 (2) 30-184 (2) 30-243 (2)
30-126 (2) 30-185 (2) 30-244 (2)
30-127 (2) 30-186 (2) 30-245 (2)
30-128 (2) 30-187 (2) 30-246 (2)
30-129 (2) 30-188 (2) 30-247 (7)
30-130 (2) 30-189 (2) 30-248 (2)
30-131 (2) 30-190 (2) 30-249 (7)
30-132 (2) 30-191 (2) 30-250 (2)
30-133 (2) 30-192 (2) 30-251 (2)
30-134 (2) 30-193 (2) 30-252 (2)
30-135 (2) 30-194 (2) 30-253 (2)
30-136 (2) 30-195 (2) 30-254 (2)
30-137 (2) 30-196 (4) 30-255 (2)
30-138 (2) 30-197 (4) 30-256 (2)
30-139 (2) 30-198 (2) 30-257 (2)
30-140 (2) 30-199 (2) 30-258 (2)
30-141 (2) 30-200 (2)
30-142 (2) 30-201 (2) 90- 1 (4)
30-143 (2) 30-202 (2) 90- 2 (7)
30-144 (2) 30-203 (2) 90- 3 (7)
30-145 (2) 30-204 (2) 90- 5 (4)
30-146 (2) 30-205 (2) 90- 5-1 (4)
30-147 (2) 30-206 (2) 90- 7 (6)
00-2-4 D275A-5
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

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

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

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

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

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the

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

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

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

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from 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.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

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

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

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

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

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
GENERAL
01 GENERAL
SPECEFICATION DRAWING .................................................................................................................. 01- 2

SPECIFICATIONS ................................................................................................................................... 01- 3
WEIGHT TABLE ...................................................................................................................................... 01- 9
TABLE OF FUEL, COOLANT AND LUBRICANT .................................................................................... 01- 11
D275A-5 01-1
GENERAL SPECEFICATION DRAWING
SPECEFICATION DRAWING
Semi U-tilt dozer + U-tilt dozer + Semi U-tilt dozer + U-tilt dozer+
Item Unit
Giant ripper Giant ripper Multi-shank ripper Multi-shank ripper
Overall 9,290 9,625 8,905 9,245

A mm
length
Overall
3,965 3,965 3,965 3,965
B height mm
(3,985) (3,985) (3,985) (3,985)
(with ROPS)
Overall 4,300 4,615 4,300 4,615

C mm
width
01-2 D275A-5
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D275A-5
Serial number 25001 and up
Machine weight
• Bare tractor 38,430
Weight
kg
• Above with semi U-dozer + variable multi- 50,800
shank ripper + ROPS + cab + air condi-
tioner + side cover
Min. turning radius m 3,9 (Pivot turn)
Gradeability deg. 30
Stability (front, rear, left, right) deg. 35
Forward
Transmission speed ranges
1st speed 3.8

2nd speed km/h 6.7
3rd speed 11.2
Performance
Reverse
1st speed 4.9

2nd speed km/h 8.7
3rd speed 14.9
Bare tractor
Ground pressure
With semi U-dozer + variable multi- 88.26 {0.90}

shank ripper
With ROPS + cab + air conditioner + 117.67 {1.20}
kPa {kg/cm2}
side cover
With U-dozer + variable multi-shank 119.63 {1.22}
ripper + ROPS + cab + air conditioner
+ side cover
Overall height Overall width Overall length
Bare tractor (To top of lift cylinder) 5,570

With Semi U-dozer + variable multi- 8,930
shank ripper mm
With U-dozer + variable multi-shank 9,270
ripper
Bare tractor (To top of lift cylinder) 2,925
Dimensions
With Semi U-dozer + variable multi- 4,300

shank ripper mm
With U-dozer + variable multi-shank 4,620
ripper
To top of exhaust pipe 3,965

To top of air intake duct mm 3,110
(To top of control lever)
D275A-5 01-3
(4)

Overall height
With cab 3,775

With ROPS canopy mm 3,975
With canopy 3,975
Dimensions
Track gauge 2,260

Length of track on ground 3,480
Track shoe width (Standard) mm 610
Minimum ground clearance 510
(To the bottom of under cover)
Name SDA6D140E-3
Type of engine 4-cycle, water-cooled, in-line vertical type,

direct injection type with turbocharger and aftercooler
Number of cylinders = Bore × Stroke mm 6—140×165

Piston displacement ¬ {cc} 15.24 {15,240}
Performance
Flywheel horsepower kw{HP}/rpm 306{410}/2,000

Engine
Max. torque Nm{kgm}/rpm 1,989{203}/1,400

Max. speed at no load rpm 2,150
Min. speed at no load rpm 700
Min. fuel consumption ratio g/kw•h {g/HP•h} 215 {160}
Starting motor 24V, 11kW

Alternator 24V, 75A
Battery 12V, 170Ah × 2
Radiator core type D-7

Power train system
Torque converter 3-element, 1-stage, 1-phase (TCS46-4Z)
Planetary gear type, multiple disc clutch type,

hydraulically actuated type (electric),
Transmission force-feed lubrication gear pump type,
forward 3-speed, reverse 3-speed,
electrically operated type
01-4 D275A-5
Bevel gear shaft Spiral bevel gear type, splash type lubrication
Wet, multiple disc clutch type, hydraulic drive type,

Power train system
Steering clutch hand operated type, interconnected with steering

brake
Wet multi-disc type, spring boosted type, hydraulic

Steering brake drive type, foot and hand operation type, clutch linkage
type
Spur gear 1-stage, planetary gear 1-stage type, spiral

Final drive
bevel gear type, splash type lubrication
Suspension Rigid, balancing beam type

Undercarriage
Carrier roller 2 on each side
Track roller 7 on each side
Assembly type, single grouser, 39 each side Pitch:

Track shoe (610 mm)
260.6 mm
Power train + lubrication pump (tandem) Gear type (BAR(3)100+50)
Scavenging pump Gear type (BAR(3)140)

hydraulic system
Work equipment
MPa Variable swash plate type (HPV95)

{kg/cm2} Max. discharge pressure: 27.4 {280}
Work equipment pump
¬/min/rpm Logical discharge pressure: 256/2,286
Variable in-line pump type
MPa Variable swash plate type: (LPV45)

{kg/cm2} Max. discharge pressure: 15.7 {160}
Fan pump
¬/min/rpm Logical discharge pressure: 103/2,286
MPa
{kg/cm2} Fixed swash plate type (LMF75)
Fan motor
¬/min/rpm Max. allowable working pressure: 15.7 {160}
D275A-5 01-5
(4)
Type
Main control
• For blade lift Double + single + single type, spool type,

valve
• For blade tilt hydraulic assisted type Ripper tilt + ripper lift +
• For ripper lift blade lift + blade tilt
• For ripper tilt
Type Double acting piston type

Dimension of riper Dimension of ripper Dimension of blade Dimension of blade Dimension of blade
Cylinder bore mm 120

lift cylinder
Piston rod outside diameter mm 80

Piston stroke (Max.) mm 1,495
Max. distance between pins mm 2,470
Min. distance between pins mm 985

tilt cylinder
Work equipment hydraulic system

Piston stroke (Max.) mm 190
Min. distance between pins mm 1,365
Hydraulic cylinder
tilt + pitch cylinder


lift cylinder


tilt cylinder

Hydraulic tank Box type(Control valve externally installed type)
01-6 D275A-5
Type Hydraulic semi U-tilt dozer,Hydraulic U-tilt dozer
Blade support method Brace type (Right-side tilt cylinder)
Max. lifting blade height mm 1,450

Performance
(from ground level)

Max. lowering blade depth mm 640
(from ground level)
Semi U-dozer
Max. tilt mm 1,000

Blade cutting angle variation deg. ±6
Blade capacity (SAE) m3 13.7
Dimensions
Blade width mm 4,300

Blade height mm 1,960
Blade cutting angle deg. 52
Work equipment
Max. lifting blade height mm 1,450

Performance
(from ground level)

Max. lowering blade depth mm 640
(from ground level)
Max. tilt mm 1,070
U-dozer
Blade cutting angle variation deg. ±6

Blade capacity (SAE) m3 16.6
Dimensions Performance Dimensions
Blade width mm 4,620

Blade height mm 1,975
Blade cutting angle deg. 52
Semi U-dozer
Max. tilt mm 1,140

Max. pitch angle deg. 6
Max. pitch-back angle deg. 6
U-dozer
Max. tilt mm 1,220

Max. pitch angle deg. 6
Max. pitch-back angle deg. 6
D275A-5 01-7
Type Variable cutting angle type,parallelogram type

Variable multi-shank ripper
Weight kg 4,490
Beam length mm 2,495
Number of shanks unit 3
Cutting angle (Standard) deg. 51.7 (Stepless adjustment is possible between 38.9
Performance
and 61.2 deg.)

Cutting depth Two Switch-Selectable
Work equipment
Max. digging depth mm 900

Max. lifting height mm 955
Type Variable cutting angle type, parallelogram type
Variable giant ripper
Weight kg 4,600
Beam length mm 1,252
Number of shanks unit 1
Cutting angle (Standard) deg. 52.7 (Stepless adjustment is possible between 38.7
Performance
and 62.2°)
Cutting depth – 4
Max. digging depth mm 1,420
Max. lifting height mm 1,195
01-8 D275A-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
¤ This weight table is for reference in handling or
transporting components.
Unit: kg
Engine and dumper assembly 1,930

• Engine assembly 1,765
• Dumper assembly 135
• Universal joint 25
• Engine mounting parts (Wiring) 5
Main radiator assembly 306

(Including built-in oil cooler)
Sub radiator assembly 73
Hydraulic cooler 78
Fuel tank assembly (When empty) 385
Fuel tank assembly (When full) 1,090
Power train unit assembly 2,615

• Torque converter, PTO assembly 534
• Transmission assembly 645
• Steering clutch, brake assembly 910
• Brake valve assembly 14
• Cooler bypass valve assembly 5
• Power train filter assembly 23 × 2
• Scavenging pump 19
• Power train, lubricating pump 27
• Work equipment pump 63
• Fan pump 45
• Fan motor 25
Final drive assembly 1,720 × 2

Sprocket teeth (25×5) × 2
Hull frame assembly 4,054
Track group assembly (each side) 5,021

• Track frame 1,396
• Idler assembly 333
• Recoil spring assembly 352
• First bogie and track roller assembly 231
• Second-fourth bogies and track roller assembly 527 × 3
• Track roller assembly (Single flange x 1) 149 × 2
• Track roller assembly (Double flange x 1) 161 × 5
• Carrier roller assembly 58 × 2
D275A-5 01-9
GENERAL WEIGHT TABLE
Unit: kg
Track shoe assembly (610mm width, wet type) 3,405 × 2

Pivot shaft assembly 142 × 2
Equalizer bar 273
Hydraulic tank assembly 166

Main control valve
(Blade lift + blade tilt + ripper lift + ripper tilt) 99
Engine underguard 250

Transmission underguard 312
Operator seat 41
Semi U-tilt dozer assembly 6,750

• Blade 4,150
• Straight frame 967 × 2
• Tilt brace 153 × 1
• Center brace 141 × 2
• Tilt cylinder assembly 230
Semi U-tilt + pitch dozer assembly 6,827

• Blade 4,150
• Straight frame 967 × 2
• Center brace 141 × 2
• Pitch cylinder assembly 230 × 2
Radiator guard assembly (Including cylinder yoke + lattice mask) 1,336

Blade lift cylinder assembly 235 × 2
Multi-shank ripper assembly 4,462

• Shank 350 × 3
• Lift cylinder assembly 184 × 2
• Tilt cylinder assembly 155 × 2
Giant ripper assembly 3,600

• Shank 600 × 1
• Lift cylinder assembly 184 × 2
• Tilt cylinder assembly 155 × 2
• Pin puller cylinder assembly 7
ROPS assembly 650

Cab assembly 415
ROPS canopy 650
Dash board 83
Floor frame assembly 591
Air conditioner assembly (Including air conditioner unit assembly) 87
Operator seat assembly 64
01-10 D275A-5
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANT
TABLE OF FUEL, COOLANT AND LUBRICANT
Ambient temperature Specified Refilled

Refilling position Kind of oil oil amount oil amount
–30 –20 –10 0 10 20 30 40°C (¬) (¬)
SAE 30CD
SAE 10WCD
Engine oil pan 55 52
SAE 10W-30CD
SAE 15W-40CD
SAE 30CD 150 90

Power train oil pan
Engine oil
Final drive case (each side)
SAE 10WCD 40 40
Damper case 1.5 1.5

SAE 30CD
Pivot shaft case (each side) 10 10
153 130
SAE 10WCD (Bare
tractor)
Hydraulic oil SAE 10W-30CD

270 130
(With
SAE 15W-40CD blade and
ripper)
Idler (each) 0.85 0.85
Track roller (each) 0.80 0.80

Gear oil GO 140
Carrier roller (each) 0.65 0.65
Bogie cartridge pin (each) 0.67 0.67
ASTM D975 No. 2

Fuel tank Diesel fuel 840 —
ASTM D975
No. 1
Cooling system
Coolant Komatsu genuine super coolant (AF-NAC added) 130 —
(Including reservoir tank)
D275A-5 01-11
(5)
STRUCTURE, FUNCTION AND
10 STRUCTURE, FUNCTION AND

POWER TRAIN ................................................................................................................................... 10- 4

OVERALL DRAWING OF POWER TRAIN UNIT ................................................................................ 10- 7
DAMPER, UNIVERSAL JOINT ........................................................................................................... 10- 10
TORQUE CONVERTER, PTO ............................................................................................................ 10- 13
TORQUE CONVERTER ...................................................................................................................... 10- 16
SCAVENGING PUMP ......................................................................................................................... 10- 19
TRANSMISSION CONTROL ............................................................................................................... 10- 21
TRANSMISSION ................................................................................................................................. 10- 22
TRANMISSION ECMV ........................................................................................................................ 10- 36
MAIN RELIEF VALVE AND TORQUE CONVERTER VALVE ............................................................. 10- 42
POWER TRAIN PUMP, STEERING LUBRICATION PUMP ................................................................ 10- 45
LUBRICATION RELIEF VALVE ........................................................................................................... 10- 46
STEERING, BRAKE CONTROL ......................................................................................................... 10- 49
BEVEL GEAR SHAFT, STEERING CLUTCH AND BRAKE ................................................................ 10- 51
STEERING CONTROL VALVE ............................................................................................................ 10- 61
STEERING CLUTCH ECMV ................................................................................................................ 10- 63
STEERING BRAKE ECMV .................................................................................................................. 10- 64
PARKING BRAKE VALVE ................................................................................................................... 10- 71
SUDDEN BRAKE PREVENTION VALVE ........................................................................................... 10- 72
FINAL DRIVE ...................................................................................................................................... 10- 73
SPROCKET ......................................................................................................................................... 10- 78
TRACK FRAME ................................................................................................................................... 10- 80
RECOIL SPRING ................................................................................................................................ 10- 82
IDLER .................................................................................................................................................. 10- 84
TRACK ROLLER ................................................................................................................................. 10- 86
CARRIER ROLLER ............................................................................................................................. 10- 88
TRACK ROLLER BOGIE ..................................................................................................................... 10- 90
TRACK SHOE ..................................................................................................................................... 10- 92
MAIN FRAME ...................................................................................................................................... 10- 94
SUSPENSION ..................................................................................................................................... 10- 96
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM ...................................................................... 10- 99
PPC CONTROL PIPING DIAGRAM .................................................................................................... 10- 102
WORK EQUIPMENT CONTROL ........................................................................................................ 10- 104
WORK EQUIPMENT PUMP ................................................................................................................ 10- 106
COOLING FAN PUMP ........................................................................................................................ 10- 122
COOLING FAN MOTOR ..................................................................................................................... 10- 130
HYDRAULIC TANK ............................................................................................................................. 10- 136
ACCUMULATOR ................................................................................................................................. 10- 138
PPC LOCK VALVE .............................................................................................................................. 10- 139
PPC VALVE (For blade lift, blade tilt).................................................................................................... 10- 141
PPC VALVE (For ripper) ....................................................................................................................... 10- 148
HYDRAULIC CYLINDER ..................................................................................................................... 10- 154
PISTON VALVE ................................................................................................................................... 10- 157
D275A-5 10-1
QUICK DROP VALVE ......................................................................................................................... 10- 158

PIN PULLER SWITCH ........................................................................................................................ 10- 159
PIN PULLER SOLENOID VALVE ....................................................................................................... 10- 160
BLADE CONTROL KNOB .................................................................................................................. 10- 162
PITCH, DUAL TILT SOLENOID VALVE .............................................................................................. 10- 163
CONTROL VALVE .............................................................................................................................. 10- 166
OPERATION OF CONTROL VALVE ................................................................................................... 10- 174
SELF-REDUCING PRESSURE VALVE .............................................................................................. 10- 191
CYLINDER STAY ................................................................................................................................ 10- 198
BLADE ................................................................................................................................................ 10- 200
RIPPER EQUIPMENT ........................................................................................................................ 10- 206
CAB MOUNT ...................................................................................................................................... 10- 208
CAB ..................................................................................................................................................... 10- 209
AIR CONDITIONER ............................................................................................................................ 10- 211
ENGINE CONTROL ............................................................................................................................ 10- 212
ENGINE CONTROL SYSTEM ............................................................................................................ 10- 213
DECELERATION POTENTIOMETER ................................................................................................ 10- 214
CRI ENGINE CONTROL SYSTEM ..................................................................................................... 10- 216
MONITOR SYSTEM ........................................................................................................................... 10- 218
MONITOR PANEL ............................................................................................................................... 10- 220
SENSORS .......................................................................................................................................... 10- 223
ELECTRICAL EQUIPMENT ................................................................................................................ 10- 227
PALM COMMAND CONTROL SYSTEM ............................................................................................ 10- 230
10-2 D275A-5
MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
Outline
• The power generated by engine (1) has its tor- • Steering brake (13) is disc type similar to the
sional vibration dampened by damper (2), and steering clutch. The power output from the
then passes through universal joint (3), and is steering clutch is slowed down in the final drive
transmitted to torque converter (9). (14) and rotates sprocket (15).
• The power from the engine is transmitted • The final drive consists of a single-stage spur
through the oil by torque converter (9) to the gear system and a single-stage planetary gear
transmission input shaft (turbine shaft) in accor- system. The sprocket drives track shoe (16) to
dance with the change in load. move the machine. The power output from
• Transmission (10) uses a combination of a plan- steering brake (13) is transmitted to final drive
etary gear system and hydraulic clutches to re- (14).
duce the speed and shift the gears (3 forward • Final drive (14) reduces the speed with the sin-
gears and 3 reverse gears). It connects 2 sets of gle-stage spur gear system and single-stage
clutches selected according to the change in planetary gear system to rotate sprocket (15)
load, and transmits the power to bevel gear (11) and drive track shoe (16) and move the machine.
from the bevel pinion at the rear end of the trans- The oil from fan pump (17) driven with PTO (6)
mission. rotates fan motor (18).
• The power divided into right and left portions by
the bevel gear is transmitted to the respective
steering clutches (12). Steering clutches (12)
turn on and off the power transmitted from the
bevel gear shaft to the final drive to control the
travel direction of the machine.
• The travel direction is changed by operating the
steering lever to turn off the power of the steering
clutch on the turning side. The turning radius is
controlled with steering brake (13) installed to
the outside of the steering clutch.
10-4 D275A-5
MAINTENANCE STANDARD POWER TRAIN
1. Engine (SDA6D140E-3) 7. Power train pump 14. Final drive

2. Damper (SAL(3)-100) 15. Sprocket
3. Universal joint 8. Steering lubricating oil pump 16. Track shoe
4. Scavenging pump (SAR(3)-50) 17. Fan pump (LPV45)
(BAR(3)-140) 9. Torque converter 18. Fan motor (LMF75)
5. Work equipment pump 10. Transmission
(HPV95) 11. Bevel gear
6. PTO 12. Steering clutch
13. Steering brake
D275A-5 10-5
(4)
MAINTENANCE STANDARD OVERALL DRAWING OF POWER TRAIN UNIT
OVERALL DRAWING OF POWER TRAIN UNIT
D275A-5 10-7
10-8 D275A-5
1. Work equipment pump Outline

2. Torque converter, PTO • The power train unit consists of the main compo-
3. Power train pump nents of torque converter (2), transmission (5),
4. Steering lubricating oil pump and steering unit (13). Accordingly, after the
5. Transmission power train unit is removed, it can be divided into
6. Parking brake valve the torque converter, transmission unit, and
7. Right clutch ECMV steering unit.
8. Left clutch ECMV • The steering unit consists of the bevel pinion
9. Sudden brake prevention valve unit, bevel gear shaft, steering clutch, and steer-
10. Right brake ECMV ing brake.
11. Left brake ECMV
12. Fan pump A. Left clutch oil pressure pick-up port (LC)
13. Steering unit B. Left brake oil pressure pick-up port (LB)
14. Main relief valve, torque converter relief valve C. Rightt clutch oil pressure pick-up port (RC)
15. Power train oil strainer D. Right brake oil pressure pick-up port (RB)
16. Scavenging pump E. Transmission 1st clutch oil pressure pick-up port
(F1)
F. Transmission 2nd clutch oil pressure pick-up
port (2ND)
G. Transmission 3rd clutch oil pressure pick-up port
(3RD)
H. Transmission R clutch oil pressure pick-up port
(R)
J. Transmission F clutch oil pressure pick-up port
(FWD)
K. Torque converter requlator pressure pick-up port
(OUT)
L. Torque converter relief pressure pick-up port (IN)
D275A-5 10-9
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
10-10 D275A-5
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
1. Breather Outline
2. Oil level gauge • The damper dampens the torsional vibration
3. Drain plug caused by the change in engine torque and the
4. Output shaft impact torque generated when accelerating sud-
5. Flywheel denly or when carrying out heavy-duty digging.
6. Outer body In this way it acts to protect the torque converter,
7. Coupling transmission, and other parts of the power train.
8. Universal joint • This damper has few component parts: it uses a
9. Cover rubber coupling, so the vibration is absorbed by
10. Rubber coupling the damping effect of the rubber material.
11. Inner body
Operation
• This motive force from the engine passes
through flywheel (5) and it transmitted to outer
body (6).
• The torsional vibration of the engine is absorbed
by rubber coupling (10), and the power is trans-
mitted to inner body (11). It passes through uni-
versal joint (8), and is then transmitted to the
torque converter and transmission.
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
size clearance limit
12 Clearance between flywheel Shaft Hole
housing and cover
– 0.022 + 0.070 0.022–
511.18 0.2
– 0.092 0 0.162
– 0.020 + 0.063 0.020– Replace

13 Clearance between flywheel and 466.72 0.2
damper – 0.083 0 0.146
Standard size Tolerance Repair limit

14 Outer circumference of coupling
oil seal contact surface 0
90 89.8
– 0.087
D275A-5 10-11
(4)
MAINTENANCE STANDARD TORQUE CONVERTER, PTO
TORQUE CONVERTER, PTO
D275A-5 10-13
10-14 D275A-5
1. Work equipment pump mounting port

2. Scavenging pump mounting port
Outline
3. Fan pump mounting port
• The torque converter is the 3-element, 1-stage,
4. PTO lubrication tube
and 1-phase type, which is combined with the
5. Power train, Steering lubricating oil pump
transmission into 1 unit.
mounting port
6. Coupling
7. Input shaft [PTO drive gear (56 teeth)]
Structure
8. Idler gear (77 teeth)
• Pump (15) is combined with coupling (6), input
9. Idler gear shaft
shaft (7), and drive case (11) into 1 unit and ro-
10. Torque converter case
tated by the engine power.
11. Drive case
• Turbine (12) is combined with turbine boss (21)
12. Turbine
and transmission input shaft (20) into 1 unit and
13. Stator
rotated by the engine power.
14. Stator boss
• Stator (13) is combined with stator boss (14) and
15. Pump
stator shaft (17) into 1 unit and fixed to front
16. Retainer
housing (19) and rear housing (18).
17. Stator shaft
• The front hosing and rear housing of the stator
18. Stator rear housing
clutch are bolted to the front housing of the trans-
19. Stator front housing
mission R clutch.
20. Transmission input shaft
• The PTO unit consists of input shaft (7), idler
21. Turbine boss (90 teeth)
gear (8), scavenging pump drive gear (24), work
22. Pump drive gear (49 teeth)
equipment pump and power train pump drive
(Work equipment, power train, and steering lu-
gear (22), and fan pump drive gear (23).
bricating oil pump)
23. Fan pump drive gear (49 teeth)
24. Scavenging pump drive gear (57 teeth)
25. Power train oil strainer
A. To oil cooler
B. Torque converter oil inlet
C. To steering case (From scavenging pump)
D. To transmission case (From torque converter
case)
E. From steering case and transmission case
(Oil pan pass)
D275A-5 10-15
(4)
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
10-16 D275A-5
Unit: mm

1 Outside diameter of coupling oil
seal contact surface 0 Repair hard
120 119.8
– 0.054 chrome plating or
replace
2 Inside diameter of retainer seal + 0.040
150 150.5
ring contact surface 0
Backlash between PTO drive Standard clearance Clearance limit

3 gear and scavenging pump drive
gear 0.204–0.512 –
4 Backlash between PTO drive

0.204–0.512 –
gear and driven gear
Standard size Repair limit

5 Wear of stator shaft seal ring
Width: 4.4 Width: 4.0
Height: 5.5 Height: 5.1
D275A-5 10-17
(4)
Power train route
Flow of power
• The engine power is transmitted through the
damper and universal joint to coupling (1) and
rotates input shaft (2), drive case (3), and pump
(4) as 1 unit. The power of the pump rotates
turbine (5) through oil. Then, the power of the
turbine is transmitted through turbine boss (6)
to transmission input shaft (7).
The power of input shaft (2) is used to drive
gear pumps through idler gear (8).
Flow of oil
• The oil is sent through the main relief valve and
its pressure is reduced below the set pressure
by the torque converter relief valve. Then, it
flows in inlet port A and through the oil path of
stator front housing (1) to pump (2).
The oil is given centrifugal force by pump (2)
and flows in turbine (3) and gives its energy to
turbine (3).
The oil from turbine (3) is sent to stator (4) and
then returned to pump (2). A part of the oil is
sent from stator (4) through outlet port B to the
oil cooler, however.
10-18 D275A-5
(4)
MAINTENANCE STANDARD SCAVENGING PUMP
SCAVENGING PUMP
BAR (3) 140
A. Discharge port
B. Suction port
Unit: mm
1 Spline shaft rotation torque –
Discharge Standard Permissible

Rotating
pressure discharge discharge
Delivery Type speed
_
(Oil: E010-CD
(rpm) ( MPa
{kg/cm2} ) amount
(¬/min)
amount
(¬/min)
–
Oil temperature: 45 - 55°C) 2.94

BAR140 2,500 – –
{30}
D275A-5 10-19
(4)
MAINTENANCE STANDARD TRANSMISSION CONTROL
TRANSMISSION CONTROL
a For steering operation concerned to operation of a PCCS: Abbreviation for Palm Command Control
PCCS lever, see STEERING AND BRAKE System
CONTROL.
SWD05824
1. Brake pedal Lever positions Outline

2. Safety lever 1 : Neutral • The transmission is controlled with PCCS le-
3. PCCS lever (Forward-Reverse, 2 : Forward ver (3).
Gear shift) 3 : Reverse The PCCS lever is used to select the travel
3A. UP switch 4 : OFF direction and shift the gear.
(Gear is shifted up each 5 : Shift UP • Since the safety mechanism is employed,
time this switch is pressed.) 6 : Shift DOWN transmission neutral safety switch (4) does
3B. DOWN switch 7 : Free not work and the engine does not start un-
(Gear is shifted down each 8 : Lock less safety lever (2) is in the LOCK position.
time this switch is pressed.)
4. Transmission neutral safety
switch
5. Cable
6. Transmission control valve
D275A-5 10-21
(7)
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
10-22 D275A-5
A. To forward clutch L. From power train pump

B. To reverse clutch M. To steering valve
C. To 3rd clutch N. To steering case
D. To 2nd clutch P. From steering case
E. To 1st clutch Q. Transmission lubrication oil inlet
F. To torque converter case R. Transmission 1st clutch pressure pick-up port
G. From torque converter case S. Transmission 3rd clutch pressure pick-up port
H. To scavenging pump T. Transmission R clutch pressure pick-up port
J. To torque converter case U. Transmission 2nd clutch pressure pick-up port
K. From scavenging pump V. Transmission F clutch pressure pick-up port
D275A-5 10-23
(4)
10-24 D275A-5
(4)
1. Main relief valve Outline

2. Transmission case
• The transmission consists of planetary gear sys-
3. Transmission control valve and valve cover as-
tems and disc clutches and has "3 forward gear
sembly
speeds and 3 reverse gear speeds".
4. Lubricating oil relief valve
• Among the 5 sets of planetary gear system and
5. Input shaft
disc clutch of the transmission, 2 clutches are
6. Reverse clutch sungear (34 teeth)
fixed hydraulically with control valves to select 1
7. Pinion shaft
rotating direction and rotating speed.
8. Ring gear of reverse travel (86 teeth)
• Clutches No. 1, No. 2, No. 3, No. 4, and No. 5 are
9. Planetary pinion for reverse travel (26 teeth)
fixed respectively when the reverse, forward,
10. Disc
3rd, 2nd, and 1st gears are selected.
11. Plate
12. Piston
13. Planetary pinion for forward travel (27 teeth) Number of plates and discs
14. Planetary pinion for 3rd gear speed (36 teeth)
Clutch No. Number of discs Number of plates
15. Ring gear for 3rd gear speed (Number of internal
teeth: 91, Number of external teeth: 105)
No.1 6 6
16. Sun gear for 2nd gear speed (39 teeth) No.2 8 7
17. Planetary pinion for 1st gear speed (21 teeth) No.3 4 5
18. Sun gear for 1st gear speed (49 teeth) No.4 4 5
19. Output shaft (Number of teeth of sun gear for 3rd No.5 3 4
gear speed: 20)
20. Ring gear for 1st gear speed (Number of internal
teeth: 91, Number of external teeth: 105) Gear speeds and operated clutches
21. 1st clutch carrier (90 teeth)
22. Clutch housing for 1st gear speed Gear speed Operated clutches (Turned ON)
23. Clutch housing for 2nd gear speed
Forward 1st No.2·No.5
24. Planetary pinion for 2nd gear speed (26 teeth)
Forward 2nd No.2·No.4
25. Ring gear for 2nd gear speed (Number of inter- Forward 3rd No.2·No.3
nal teeth: 90, Number of external teeth: 105) Neutral ª 1. No.5
26. Clutch housing for 3rd gear speed Reverse 1st No.1·No.5
27. Carrier for 2nd and 3rd gear speeds Reverse 2nd No.1·No.4
28. Clutch housing for forward travel Reverse 3rd No.1·No.3
29. Sun gear for forward travel (37 teeth)
30. Ring gear for forward travel (Number of internal ª1: While the transmission is in neutral, the 1st
teeth: 91, Number of external teeth: 105) clutch is filled with low-pressure oil and en-
31. Carrier for forward travel (86 teeth) gaged so that the machine can start without a
32. Clutch housing for reverse travel time lag.
33. Return spring
34. Ring gear for reverse travel (Number of internal
teeth: 90, Number of external teeth: 105)
35. Pin
36. Carrier for reverse travel (90 teeth)
D275A-5 10-25
(4)
10-26 D275A-5
Unit: mm

Installed Installed Installed
1 No. 1 clutch spring (12 pcs.) Free length Free length
length load load
174.6N 165.7N
91 71.2 88.3
{17.8 kg} {16.9 kg}
52.7N 50.0N
2 No. 2 clutch spring (12 pcs.) 84 79.8 81.5
{5.4 kg} {5.1 kg}
95N 90.2N
3 No. 3 clutch spring (12 pcs.) 68 59.5 66.0
{9.7 kg} {9.2 kg}
93.1N 88.3N
4 No. 4 clutch spring (12 pcs.) 70 51 67.9
{9.5 kg} {9.0 kg}
83.3N 79.4N
5 No. 5 clutch spring (12 pcs.) 70 53 67.9
{8.5 kg} {8.1 kg}
Thickness of clutch disc Standard size Tolerance Repair limit

6
(No. 1, 2 clutches)
5.4 ± 0.1 4.9
7 Thickness of clutch disc 5.4 ± 0.1 4.6

(No. 3 - 5 clutches)
8 Thickness of clutch plate 3.2 ± 0.1 2.9

(No. 1 - 5 clutches)
9 Total thickness of No. 1 clutch 51.6 ± 0.3 48.8
10 Total thickness of No. 2 clutch 65.6 ± 0.4 62.3 Replace
Backlash between each sun gear Standard clearance Clearance limit

14 and planetary pinion (Forward, re-
verse, 1st - 3rd gear speeds) 0.14–0.35 –
Backlash between each planetary

15 gear and internal teeth of ring 0.15–0.38 –
gear (Forward, reverse, 1st and
2nd gear speeds)
Backlash between planetary pin-

16 ion and internal teeth of ring gear 0.16–0.41 –
(3rd gear speed)
17 Backlash between carrier and in- 0.18–0.54 –

ternal teeth of ring gear (Reverse)
Backlash between each carrier

18 and internal teeth of ring gear 0.18–0.48 –
(Forward, 1st gear speed)
D275A-5 10-27
(4)
Unit: mm

Inside diameter of seal ring con-
tact face +0.052
φ 255 φ 255.1
0
+0.15
19 Width of seal ring groove 4.0 4.4
+0.10
-0.01
Width of seal ring 4.0 3.6
-0.04
Thickness of seal ring 5.0 ±0.15 4.5
Inside diameter of seal ring con- +0.052

φ 270 φ 270.1
tact face 0
+0.15 Replace
Width of seal ring groove 4.0 4.4
20 +0.10
-0.01
-0.04
Inside diameter of seal ring con- +0.046

φ 220 φ 220.1
tact face 0
+0.15
Width of seal ring groove 4.0 4.4
21 +0.10
-0.01
-0.04
10-28 D275A-5
(4)
Operation
1. Operation of disc clutch
• To lock ring gear (8) a disc clutch is used. The
clutch consists of piston (12), plates (11), discs
(10), pin (35) and piston return springs (33).
The internal teeth of the disc engage with the ex-
ternal teeth of the ring gear.
The teeth on the outside diameter of the plate
engage with pins (35) secured by housing (32).
Clutch engaged (locked)

• Oil from the control valve flows under pressure
through the port in housing (32) to the back of
piston (12).
The piston presses plates (11) and discs (10) to-
gether, and the resulting frictional force stops the
rotation of discs so ring gear (8) meshing with
the internal teeth of the disc is locked.
Clutch disengaged (free)

• When the supply of pressure oil from the control
valve is shut off, piston (12) is returned to its orig-
inal position by the force of piston return spring
(33). This relieves the frictional force between
plates (11) and discs (10), making the ring (8)
free.
D275A-5 10-29
Oil circuit of 1st clutch

Since the 1st clutch is the farthest from the control
valve and has the longest circuit to the cylinder, it
takes the longest time to fill the circuit.
To solve this problem, the oil is supplied to the 1st
clutch even if the gear shift lever is in the NEUTRAL
position,
Accordingly, when the gear shift lever is shifted from
the NEUTRAL position to the F1 position, the pump
is required to supply oil of only quantity to fill the for-
ward clutch.
When the gear shift switch is changed from the F1 to
F2, the pump is required to supply fill of only quantity
to fill the 2nd clutch since the forward clutch has
been filled with the oil.
The time lag in the gear shifting operation is reduced
by using the oil as explained above.
10-30 D275A-5
2. Forward 1st
• When the transmission is set to FORWARD 1st, • Carrier (21) is meshed with ring gear (25), and
the No. 2 clutch and No. 5 clutch are engaged. rotates as one unit, so the rotation is transmitted
The motive force from the torque converter to planet pinion (17).
transmitted to input shaft (5) is then transmitted • Ring gear (20) is being held in position by No. 5
to output shaft (19). clutch, so the rotation of planet pinion (17) ro-
• No. 2 clutch is actuated by the hydraulic pres- tates sun gear (18), and this rotates output shaft
sure applied to the clutch piston, and holds ring (19).
gear (30) in position. No. 5 clutch is actuated by
the hydraulic pressure applied to the clutch pis-
ton, and engages ring gear (20).
• The motive force from the torque converter is
transmitted to input shaft (5), and the rotation of
the input shaft passes through sun gear (29) and
is transmitted to planet pinion (13).
• Ring gear (30) is held in position by No. 2 clutch,
so the rotation of planet pinion (13) rotates carri-
er (31), which is on the inside of ring gear (30).
• Carrier (31) and carrier (27) are joined by a
spline, and rotate as one unit, so the rotation of
carrier (31) passes through planet pinion (24)
and is transmitted to ring gear (25).
D275A-5 10-31
3. Forward 2nd
• When the transmission is set to FORWARD 2nd • Carrier (31) and carrier (27) are joined by a
the No. 2 clutch and No. 4 clutch are engaged. spline, and rotate as one unit, so the rotation is
The motive force from the torque converter transmitted to planet pinion (24).
• No. 2 clutch is actuated by the hydraulic pres- tates sun gear (16), and this rotates output shaft
sure applied to the clutch piston, and holds ring (19).
10-32 D275A-5
4. Forward 3rd
• When the transmission is set to FORWARD 3rd • Carrier (31) and carrier (27) are joined by a
the No. 2 clutch and No. 3 clutch are engaged. spline, and rotate as one unit, so the rotation is
The motive force from the torque converter transmitted to planet pinion (14).
• No. 2 clutch is actuated by the hydraulic pres- tates output shaft (19).
sure applied to the clutch piston, and holds ring
D275A-5 10-33
5. Reverse 1st
• When the transmission is set to REVERSE 1st, carrier (31) passes through planet pinion (24)
the No. 1 clutch and No. 5 clutch are engaged. and is transmitted to ring gear (25).
The motive force from the torque converter • Carrier (21) is meshed with ring gear (25), and
transmitted to input shaft (5) is then transmitted rotates as one unit, so the rotation is transmitted
to output shaft (19). to planet pinion (17).
• No. 1 clutch is actuated by the hydraulic pres- • Ring gear (20) is being held in position by No. 5
sure applied to the clutch piston, and holds car- clutch, so the rotation of planet pinion (17) ro-
rier (36) in position. No. 5 clutch is actuated by tates sun gear (18), and this rotates output shaft
the hydraulic pressure applied to the clutch pis- (19).
• Carrier (36) is held in position by No. 1 clutch, so
the rotation of planet pinion (9) rotates ring gear
(8).
Ring gear (8) rotates in the opposite direction
from the input shaft, and rotates carrier (31).
• Carrier (31) and carrier (27) are joined by a
spline, and rotate as one unit, so the rotation of
10-34 D275A-5
(4)
MAINTENANCE STANDARD TRANMISSION ECMV
TRANMISSION ECMV
(Electronic Control Modulation Valve)
10-36 D275A-5
1. Proportional solenoid valve for 3rd clutch ECMV

2. Proportional solenoid valve for 1st clutch ECMV
3. Proportional solenoid valve for R clutch ECMV
4. Proportional solenoid valve for 2nd clutch ECMV
5. Proportional solenoid valve for F clutch ECMV
6. Fill switch for 3rd clutch
7. Fill switch for 2nd clutch
8. Fill switch for 1st clutch
9. Fill switch for R clutch
10. Fill switch for F clutch
11. Connector for 1st proportional solenoid valve
12. Connector for 3rd proportional solenoid valve
13. Connector for R proportional solenoid valve
14. Connector for 2nd proportional solenoid valve
15. Connector for F proportional solenoid valve
16. Connector for 3rd fill switch
17. Connector for 2nd fill switch
18. Connector for 1st fill switch
19. Connector for R fill switch
20. Connector for F fill switch
21. Filter
22. Pressure control valve
23. Oil pressure detection valve
24. Pressure control valve spring
A. 1st clutch operating pressure pick-up port

B. 3rd clutch operating pressure pick-up port
C. R clutch operating pressure pick-up port
D. 2nd clutch operating pressure pick-up port
E. F clutch operating pressure pick-up port
F. To clutch
P. From pump
T. Drain
D275A-5 10-37
(4)
Outline of ECMV
• The ECMV (Electronic Control Modulation
Valve) consists of the following two units, a pres-
sure control valve and fill switch.
• Pressure control valve
Converts a current sent from the transmission
controller to the proportional solenoid valve, to
an oil pressure.
• Fill switch
Detects that the clutch is filled with oil. It has the
functions below.
1) It outputs a signal (fill signal) to the controller
as soon as the clutch is filled with oil to report
the completion of filling.
2) It outputs a signal (fill signal) to the controller
while an oil pressure is applied to the clutch
to report the presence/absence of oil pres-
sure.
A region: Before gear shift (When draining)
B region: Filling starts (During trigger)
C region: Filling finishes
D region: Voltage regulation
E region: During filling
ECMV and proportional solenoid

• One proportional solenoid is attached to one EC-
MV. After receiving the command current from
the controller, it produces thrust in the right fig-
ure.
By making the proportional solenoid-produced

thrust act on the pressure control valve spool, it
produces an oil pressure shown in the right fig-
ure. By controlling the amount of command cur-
rent, the thrust is changed to operate the
pressure control valve, controlling the oil flow
and oil pressure.
ECMV and fill switch

• One fill switch is attached to one ECMV. When
the clutch completes filling, the pressure of the
clutch turns "ON" the fill switch. By this signal,
the oil pressure starts build-up.
10-38 D275A-5
(4)
Operation of ECMV
• The ECMV is controlled by the command current
sent from the controller to the proportional sole-
noid and the fill switch output signal.
The relation among the proportional solenoid
command current of the ECMV, the clutch input
pressure, and fill switch output signal is as
shown in the figure to the right.
A region: Before gear shift (When draining)

B region: Filling starts (During trigger)
C region: Filling finishes
D region: Voltage regulation
E region: During filling
• The clutch is crimped by the piston when shifting

the gear with the gear shift switch. If a high oil
pressure is applied suddenly, however, the pis-
ton connects to the clutch suddenly, causing the
machine to make a sudden start and give an ex-
cessive shock to the machine.
To prevent them, it is designed so that if you con-
nect the ECMV to shift gears with the gear shift
switch, the oil pressure to the clutch may be
gradually increased up to the specified level. By
this design, the clutch is excited smoothly to
eliminate the shock at the start, improve the du-
rability of the power transfer system, and also
provide operator comfort.
1. Before gear shift (Region A in the diagram)

When a current is not carried to the proportional
solenoid (1), the pressure control valve (2) is
draining the oil at the clutch port A through the
drain port dr.
Since, at that time, no oil pressure acts on the oil
pressure detection valve (3), the fill switch (4) is
OFF.
D275A-5 10-39
2. When filling (When inputting the trigger com-

mand to the pressure control valve)
(B and C regions in the diagram)
If you supply a current to the proportional sole-
noid (1) with no oil in the clutch, an oil pressure
proportional to the solenoid force acts on the
chamber B, pushing the pressure control valve
(2) rightward. This operation opens the pump
port P and clutch port A to start filling the clutch
with oil. When the clutch is filled with oil, the fill
switch (4) is turned ON.
3. Pressure regulation (D region in the diagram)

If you flow a current to the proportional solenoid
(1), the solenoid produces thrust proportional to
the current. Pressure is regulated by striking a
balance among the thrust of the solenoid, the
thrust of the oil pressure of the clutch port, and
reaction force of the pressure control spring (5).
10-40 D275A-5
MAINTENANCE STANDARD MAIN RELIEF VALVE AND TORQUE CONVERTER VALVE
MAIN RELIEF VALVE AND TORQUE CONVERTER VALVE
1. Body Outline
2. Torque converter relief valve
1. Main relief valve
3. Valve spring
Main relief valve (6) sets the set pressure of the
4. Piston
oil pressure for the transmission, steering clutch,
5. Piston spring
and brake.
6. Main relief valve
7. Valve spring 2. Torque converter relief valve
8. Piston spring Torque converter relief valve (2) acts to protect
9. Piston the torque converter from abnormal high pres-
sure by relieving the circuit if the torque convert-
A. Drain port (for torque converter relief) er inlet port pressure rises above the set
B. Drain port pressure.
C. From pump Unit: MPa {kg/cm2}
D. Drain port Set pressure
E. To torque converter
P1. Main relief oil pressure detection port Main relief pressure 3.2 ± 0.1{32.7 ± 1.0}
P8. Torque converter relief oil pressure detection
Torque converter relief
port 0.98 ± 0.05{10.2 ± 0.5}
pressure
10-42 D275A-5
(4)
Unit: mm
Tolerance
Clearance between size clearance limit
10 Shaft Hole
main relief valve and valve body
– 0.035 + 0.013 0.035–
28 0.08
– 0.045 0 0.058
Clearance between main relief – 0.020 + 0.021 0.020–

11 19 0.07
valve and piston – 0.030 0 0.051
Clearance between torque
– 0.035 + 0.013 0.035–
12 converter relief valve and valve 22 0.08
– 0.045 0 0.068
body
Clearance between torque – 0.020 + 0.018 0.020–
13 15 0.07
converter relief valve and piston – 0.030 0 0.048

Replace
Main relief valve spring Free length Free length
14 length load load
(outside)
481N 457N
122 78 118.3
{49kg} {46.6kg}
Main relief valve spring 368N 349N

15 108 78 104.8
(inside) {37.5kg} {35.6kg}
7.32N 6.96N
16 Main relief valve piston spring 30 25 29.1
{0.746kg} {0.71kg}
Torque converter relief valve 182N 174N

17 50 40.5 48.5
spring {18.6kg} {17.7kg}
Torque converter relief valve 4.87N 4.61N

18 26 20 25.2
piston spring {0.497kg} {0.47kg}
D275A-5 10-43
(4)
Operation of main relief valve

• The oil from power train pump passes through
the filter, enters port A of the main relief valve,
then passes through orifice a and enters port B.
When the oil from the pump fills the circuit, the oil
pressure starts to rise.
• As the oil pressure in the circuit rises, the oil en-
tering port B pushes piston (4). The reaction
compresses spring (7), moves main relief valve
(6) to the left in the arrow direction, and opens
ports A and C.
Then, the oil from the pump is relieved from port
A to port C, then flows from port C to the torque
converter.
The oil pressure at port A at this point is 3.2 ± 0.1
MPa {32.7 ± 1.0 kg/cm2}.
Operation of torque converter relief valve

• The oil relieved by the main relief valve flows
from port C to the torque converter, and at the
same time, passes through orifice b and enters
port D.
When the passage to the torque converter is
filled with oil, the oil pressure starts to rise.
• As the oil pressure to the torque converter rises,
the oil entering port D pushes piston (9). The re-
action compresses spring (3), moves relief valve
(2) to the right in the arrow direction, and opens
ports C and E.
Then, the oil from port C is relieved to port E and
is drained to the oil tank.
The oil pressure at port C at this point is
0.98±0.05MPa {10.2±0.5 kg/cm2}.
10-44 D275A-5
(4)
MAINTENANCE STANDARD POWER TRAIN PUMP, STEERING LUBRICATION PUMP
POWER TRAIN PUMP, STEERING LUBRICATION PUMP

SAR (3) 100 + 50
Unit: mm
Standard
Type Clearance limit
clearance
1 Side clearance
SAR (3) 100 0.13–0.18 0.22
SAR (3) 50 0.10–0.15 0.19
Clearance between plain SAR (3) 100

2 bearing inner diameter and gear 0.060–0.149 0.20 Replace
shaft outer diameter SAR (3) 50
Type Standard size Tolerance
3 Pin driving depth SAR (3) 100 0

14
SAR (3) 50 – 0.5
4 Spline shaft rotation torque 13.7–73.5Nm{1.4–2.4kgm}
Delivery
Standard Delivery
Speed pressure
Type delivery limit
Delivery (rpm) MPa
(¬/min) (¬/min)
{kg/cm2}
– –
(Oil: EO10-CD
Oil temperature: 45 – 50°C) SAR (3) 100 32.7 ± 1 188 174
2,300rpm
SAR (3) 50 3 ± 0.3 94 86
D275A-5 10-45
(4)
MAINTENANCE STANDARD LUBRICATION RELIEF VALVE
LUBRICATION RELIEF VALVE
1. Forward clutch housing • The lubrication relief valve is installed to the right
2. Spring side face of the forward clutch housing. And pre-
3. Piston vents any abnormal pressure in the lubrication
oil.
A. From oil cooler
B. Drain Unit: MPa {kg/cm2}
C. Drain
Set pressure
Outline Pressure when normal 0.14 ± 0.05 {1.4 ± 0.5}

• The oil leaving the torque converter passes
through the oil cooler built in the radiator lower Cracking pressure 0.30 ± 0.03 {3.0 ± 0.3}
tank. It then goes through the lubrication relief
valve and lubricates the transmission and PTO.
Unit: mm

Free length Free length
4 Lubrication relief valve spring length load load Replace
12.5N 11.9N
26 23.6 25.2
{1.27kg} {1.21kg}
10-46 D275A-5
MAINTENANCE STANDARD STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL

• Regarding the transmission-related description
of the operation of the PCCS lever, refer to the
TRANSMISSION CONTROL.
• PCCS: Palm Command Control System
SJD05823
10-48 D275A-5
(7)
MAINTENANCE STANDARD STEERING, BRAKE CONTROL
1. Brake pedal Positions of levers and pedals

2. Safety lever 1 : Neutral
3. PCCS lever (Steering) 2 : Forward straight
4. Steering controller 3 : Reverse straight
5. Limit switch 4 : Left clutch OFF
6. Steering ECMV 5 : Left clutch OFF
7. Brake valve Left brake ON
8. Parking brake lever (From safety lever) 6 : Right clutch OFF
9. Cable 7 : Right clutch OFF
10. Rod (From brake pedal) Right brake ON
11. Potentiometer 8 : Brake OFF
9 : Brake ON
10: Free
K : Lock
Outline
• PCCS lever (3) sends electric signals to steering • If PCCS lever (3) is tilted fully to the left, the left
controller (4). Receiving those signals, steering steering clutch is “disengaged“ completely. if the
controller (4) sends proportional currents to left steering brake is turned ON at this time, the
steering ECMV (6) to control the steering clutch- machine turns sharply to the left.
es and brakes. • Safety lever (2) is connected to parking brake le-
• Brake pedal (1) sends electric signals through ver (8) and used to apply the parking brake, too.
potentiometer (11) to steering controller (4). Re-
ceiving this signal, streering controller (4) sends
proportional current to steering ECMV (6) to op-
erate the brakes. In this case, both brakes are
applied simultaneously to stop the machine.
Rod (10) works as a redundant device to operate
the brake through brake valve (7) (only in the
complete braking mode).
• If PCCS lever (3) is tilted a little to the left, the left
streering clutch is “half disengaged“ and the ma-
chine turns gradually to the left.
D275A-5 10-49
(4)
MAINTENANCE STANDARD BEVEL GEAR SHAFT, STEERING CLUTCH AND BRAKE
BEVEL GEAR SHAFT, STEERING CLUTCH AND BRAKE
10-50 D275A-5
D275A-5 10-51
10-52 D275A-5
1. Cover A. To transmission case (power train pump)

2. Output shaft B. From transmission case (scavenging pump)
3. Cylinder C. To pin puller solenoid valve
4. Spring D. From pin puller solenoid valve
5. Brake piston E. Drain plug
6. Return spring F. Left brake oil pressure pick-up port
7. Brake plate (6 pcs. on each side) G. Right brake oil pressure pick-up port
8. Brake disc (7 pcs. on each side) H. Left clutch oil Pressure pick-up port
9. Brake outer drum (140 teeth) J. Right clutch oil Pressure pick-up port
10. Hub (106 teeth)
11. Bearing cage
12. Shim (For adjustment of bevel gear)
13. Bearing A
14. Bevel gear shaft
15. Bevel gear (46 teeth)
16. Bearing B
17. Hub (84 teeth)
18. Clutch outer drum (115 teeth)
19. Clutch plate (6 pcs. on each side)
20. Clutch disc (7 pcs. on each side)
21. Clutch Piston
22. Hub
23. Shim (For adjustment of bevel pinion)
24. Bearing cage
25. Bearing
26. Nut (For adjustment of preload on bearing)
27. Bevel pinion (19 teeth)
D275A-5 10-53
(4)
Unit: mm

Replace
28 Brake plate Thickness 2.9 ±0.1 2.6
Distortion – 0.3 0.4 Repair or replace
Thickness 4.5 ±0.1 4.0 Replace

29 Brake disc
Total assembly thickness of brake

30 48.9 – 45.3
plate and disc
Replace
Thickness 2.6 ±0.1 2.3
31 Clutch plate
Thickness 4.7 ±0.15 4.2 Replace

32 Clutch disc
Total assembly thickness of clutch
33 48.5 – 44.8
plate and disc
Standard clearance Clearance limit
Backlash between brake disc and
34
hub 1.00
0.42–0.72
Backlash between clutch disc and
35 0.33–0.69 0.96
hub
Backlash between bevel gear and
36 0.25–0.33 0.50
pinion
Tolerance
Standard Standard Clear-
size Shaft Hole clearance ance limit
Inside diameter of Large di-
37 seal ring contact face ameter -0.5 +0.081 0.500–
270 –
of brake piston -0.7 0 0.781
portion
Small di-
– 0.100 + 0.072 0.100–
ameter 220 – Replace
– 0.172 0 0.244
portion
Large di-
-0.5 +0.081 0.500–
ameter 260 –
Inside diameter of -0.7 0 0.781
portion
38 seal ring contact face
of clutch piston Small di-
-0.085 + 0.063 0.085–
ameter 180 –
-0.148 0 0.211
portion

Inside diameter of seal ring con-
tact face + 0.040
φ 125 φ 125.1
0
+ 0.070
39 Width of seal ring groove 4.1 4.6
+ 0.020
0
-0.080
10-54 D275A-5
(4)
Outline
Bevel gear shaft Steering brakes
• The bevel gear shaft device changes the output • The steering brakes are connected to the steer-
power of the transmission by a right angle to the ing clutches on both sides respectively. They
lateral directions and reduce the output speed by control the power transmitted from the steering
using a bevel pinion and a bevel gear. clutches to the final drives to change the turning
• The bevel gear shaft device has a spiral bevel direction of the machine and brake the machine.
pinion and spiral bevel gear and is lubricated • The steering brakes are wet-type, multiple disc
forcibly with pressurized oil. clutch-type, spring force brakes. They are driven
• The bevel gear shaft device consists of bevel hydraulically together with the clutches by the
pinion (27) meshed with bevel gear (15), bevel steering ECMV valve operated with the PCCS
gear shaft (14), and bearings (13) and (16) to lever.
support the bevel gear shaft. The steering brakes are lubricated forcedly with
oil supplied by the power train lubricating oil
Steering clutches pump and lubricating circuit of the scavenging
pump. The lubricating oil flows through the
• The steering clutches are connected to both bev-
paths in the steering case, cover, cylinder, disc,
el gear shafts respectively through the splines.
and plate.
They transmit and cut out the power of the bevel
While the engine is stopped, even if the brake
gear shafts to the final drives to change the turn-
pedal is not pressed, the back pressure of the
ing direction of the machine.
steering brake piston lowers and the brake is
• The steering clutches are wet-type multiple-disc
"applied". After the engine is started again, how-
hydraulic clutches. They are driven hydraulically
ever, as the hydraulic pressure in the circuit ris-
together with the brakes by the steering ECMV
es, the brake is "released". Accordingly, the
valve operated with the PCCS lever.
parking brake must be kept locked.
The steering clutches are lubricated forcedly
• Each steering brake consists of hub (10) con-
with oil supplied by the power train lubricating oil
nected to clutch outer drum (18), disc (8) en-
pump. The lubricating oil from the pump flows
gaged with the hub, plate (7), the periphery of
through the paths in the steering case, cover,
which is connected to the brake outer drum (9)
cylinder, hub, disc, and plate.
by spline, brake outer drum (9), brake piston (5)
• Each steering clutch consists of hub (17) con-
to press the disc and plate against each other,
nected to the bevel gear shaft by spline, disc (20)
spring (4), and cylinder (3), hub (22), cover (1),
engaged with the hub, plate (19), the periphery
and output shaft (2) to support these parts.
of which is connected to the clutch outer drum by
Brake outer drum (9) and cover (1) are fixed to
spline, clutch outer drum (18), clutch piston (21)
the steering case.
to press the disc and plate against each other,
Output shaft (2) is connected to hub (22) by
and hub (10) and bearing to support these parts.
spline and fixed by the stopper in the axial direc-
Clutch outer drum (18) and hub (10) are con-
tion.
nected to steering brake and transmit the power
from the bevel gear shaft through hub (22) to
output shaft (2).
D275A-5 10-55
Operation of steering clutch

1. When steering clutch is turned "ON"
When the PCCS lever is in the "neutral" position,
the steering ECMV applies the maximum hy-
draulic pressure clutch to piston (1).
Under this condition, the clutch piston is pushed
to the right by the hydraulic force to press disc
(2) and plate (3) against the stopper of clutch
outer drum (4).
Accordingly, the power from bevel gear shaft (5)
is transmitted through hub (6) and the pressed
disc and plate to clutch outer drum (4), then fur-
ther transmitted through hubs (7) and (8), which
are fixed to the clutch outer drum, and output
shaft (9) to the final drive.
2. When steering clutch is turned "OFF"

If the PCCS lever is operated to right or left, the
steering ECMV opens the drain circuit, then the
hydraulic pressure on the back of clutch piston
(1) starts lowering to 0.
As the hydraulic pressure lowers, the pressure
on disc (2) and plate (3) lowers to 0. The power
from bevel gear shaft (5) rotates only hub (6) and
disc and is not transmitted to clutch outer drum
(4) and after parts, that is, it is not transmitted to
the final drive.
If the PCCS lever is released, the steering
ECMV applies the maximum hydraulic pressure
to clutch piston (1) to turn "ON" the clutch as ex-
plained in 1 above.
If the left steering clutch is turned "OFF", the
power is transmitted to only the right steering
clutch and the machine turns to the left conse-
quently.
10-56 D275A-5
Operation of steering brake

1. When steering brake is "released"
When the PCCS lever is in the "neutral" position
and the brake pedal is at the "release" position,
the steering ECMV sets both steering clutch
pressure and steering brake pressure to the
maximum. Accordingly, the steering clutch is
turned "ON" and the oil flows in the back pres-
sure port of piston (1) of the brake.
As the hydraulic pressure rises, the oil pushes
the brake piston to the left to compress spring (2)
to reduce the pressure on disc (3) and plate (4)
to 0. Then, the power transmitted from bevel
gear shaft (5) through the steering clutch to hub
(6) is further transmitted through hub (7) and out-
put shaft (8) to the final drive.
2. When steering brake is turned "ON" (When

PCCS lever is "operated")
If the PCCS lever is operated to the right or left,
the steering ECMV so changes that the steering
clutch is turned "OFF" and the hydraulic pres-
sure on the back side of brake piston (1) is re-
leased into the drain circuit.
Under this condition, the brake piston is pushed
out to the right by the tension of spring (2), then
disc (3) and plate (4) are pressed against the
stopper of brake outer drum (9).
The brake outer drum is connected to the steer-
ing case and fixed.
Accordingly, even if the steering clutch is turned
"OFF", hub (6), or output shaft (8), which is re-
volving inertially stops as the disc and plate are
fixed to each other.
Since the braking force can be adjusted by con-
trolling the hydraulic pressure on brake piston (1)
with the PCCS lever, the turning radius and turn-
ing time can be controlled.
D275A-5 10-57
3. When brake is turned "ON" (When PCCS le-

ver is in "neutral" position and brake pedal is
"pressed")
If the brake pedal is pressed, the brake ECMV so
changes that the hydraulic pressure on the back
side of brake piston (1) is released into the drain
circuit, then only the brake operates with the
steering clutch kept turned "ON" and output shaft
(8) stops.
The braking force can be adjusted by controlling
the hydraulic pressure applied to brake piston (1)
with the brake pedal.
10-58 D275A-5
MAINTENANCE STANDARD STEERING CONTROL VALVE
STEERING CONTROL VALVE
10-60 D275A-5
(4)
MAINTENANCE STANDARD STEERING CONTROL VALVE
1. Parking brake valve Outline

2. ECMV (For right clutch) • This machine employs four ECMV (electronic-
3. ECMV (For left clutch) controlled modulation valve) on the steering con-
4. Sudden braking prevention valve trol valve.
5. ECMV (For right brake) • The steering control valve is provided on respec-
6. ECMV (For left brake) tive valve sheets as the assembly.
7. Filter • The steering control valve is situated in the cir-
8. Valve seat cuit between the power train pump via the main
relief valve and the piston of the steering clutch
and the brake. It is consisted with two pairs of the
A. Left clutch operating pressure pick-up port steering clutch Brake ECMV (right and left) and
B. Right clutch operating pressure pick-up port the brake ECMV (right and left).
C. Left brake operating pressure pick-up port • Shifting the PCCS lever (steering and forward/
D. Right brake operating pressure pick-up port reverse) right or left disconnects the steering
E. To left clutch clutch. Shifting it further turns “ON“ the brake.
F. To left lubrication The controller sends the instruction to respective
G. To left brake ECMV to cause the gradual or sudden turn
H. To right clutch whichever is designated by the operating posi-
J. To right lubrication tion of the PCCS lever (steering lever).
K. To right brake Depending on depth of the pedal depression, the
L. From steering lubrication pump controller instructs ECMV to apply the right and
M. From pump left brakes to stop the machine.
N. To pin puller solenoid valve The controller that is electrically connected to the
PCCS lever and pedal performs above opera-
tions by switching the steering control valves
(each ECMV).
The steering control valves feed the oil from the
power train pump to the steering clutch and
brake to operate their disk clutches.
• The sudden stop prevention valve disables sud-
den braking that can result when a failure is de-
tected in the electric systems.
• Shifting the parking brake lever to the “Lock“ po-
sition switches the port of the parking brake
valve, thereby draining the oil between the
ECMV for left-and-right brakes. As the result, the
machine brake is turned on.
The parking brake is also connected to the brake
pedal via the linkage.
D275A-5 10-61
(4)
MAINTENANCE STANDARD STEERING CLUTCH ECMV
STEERING CLUTCH ECMV

(Electronic control modulation valve)
A: To clutch 1. Connector for fill switch

T: Drain 2. Connector for proportional solenoid
Dr: Drain 3. Oil pressure pick-up valve
P: From pump 4. Fill switch
P1: Clutch oil pressure pick-up port 5. Proportional solenoid
P2. Pilot oil pressure pick-up port 6. Pressure control valve
D275A-5 10-63
MAINTENANCE STANDARD STEERING BRAKE ECMV
STEERING BRAKE ECMV

(Electronic control modulation valve)
A: To brake 1. Connector for fill switch

T: Drain 2. Connector for proportional solenoid
Dr: Drain 3. Oil pressure pick-up valve
P: From pump 4. Fill switch
P1: Brake oil pressure pick-up port 5. Proportional solenoid
P2. Pilot oil pressure pick-up port 6. Pressure control valve
10-64 D275A-5
Outline of ECMV
• The ECMV (Electronic Control Modulating valve)
consists of a pressure control valve and a fill
switch.
• Pressure control valve
This valve allows a proportional solenoid to re-
ceive a current sent from a steering controller
and converts it to oil pressure.
• Fill switch
This component detects that a clutch is filled with
oil and has the following functions.
1) When the clutch is filled with the oil, at the
same time, a signal (fill signal) is output to
the controller and transmits filling termina-
tion.
2) While oil pressure is applied to the clutch,
the signal (fill signal) is output to the control-
ler and transmits the presence of oil pres-
sure.
ECMV and Proportional Solenoid

• One proportional solenoid is mounted for each
ECMV. A thrust is generated according to the
command current of the controller.
The thrust generated by the proportional sole-
noid is actuated on a pressure control valve
spool and generates oil pressure. Accordingly,
by controlling an amount of the command cur-
rent, the thrust changes and the pressure control
valve is actuated, then a flow of oil and the oil
pressure is controlled.
Operation of ECMV
• The ECMV is controlled using the command cur-
rent from the controller to the proportional sole-
noid and a fill switch output signal.
Outline
• This valve sets the steering clutch oil pressure or
the steering brake oil pressure to a set pressure
and switches a circuit to the clutch chamber and
the brake chamber.
D275A-5 10-65
Operation
1. When PCCS lever is in "neutral" and brake pedal is "released": Straight travel
(Both clutches are turned "ON", both brakes are "released", and parking brake is turned "OFF".)
• When the PCCS lever is in "neutral" and the the brake piston moves to the left and compress-
brake pedal is "released", solenoid (1) of the es the brake spring to "release" the brake.
clutch ECMV is turned ON and ball (2) is pressed • When the parking brake is turned "OFF", the
to the left to close the sealing part. parking brake valve is closed and the oil in the
The oil from the power train pump flows through brake circuit is not drained.
the main relief valve to port Pc of the clutch EC-
MV. Then, it flows through orifice "a" to port F
and pushes valve (3) to the left to open the path
between port Pc and port C and close the path
between port C and port Dr.
The oil in port C flows to the back pressure port
of the clutch piston to turn "ON" the clutch.
• Solenoid (5) of the brake ECMV is also turned
ON and ball (6) is pressed to the left to close the
sealing part. The oil in port Pb flows to port E
and pushes valve (7) to the left to open the path
between port Pb and port B and close the path
between port B and port Dr.
The oil in port B flows to the back pressure port
of the brake piston. As the back pressure rises,
10-66 D275A-5
(4)
2. When PCCS lever is operated to left halfway: Gradual turn

(Left clutch is turned "OFF", left brake is "half released", right clutch is turned "ON", right brake is
"released", and parking brake is turned "OFF")
• When the PCCS lever is operated to the left half- pressure is stabilized at a point where this thrust
way, solenoid (1) of the left clutch ECMV is is balanced with the sum of the thrust caused by
turned OFF and the sealing part of ball (2) is the oil pressure in the brake port and the reaction
opened. The oil from the power train pump is force of pressure control valve spring (8).
drained through port Pc, orifice "a", and sealing • Accordingly, if the stroke of the PCCS lever is
part of ball (2). Accordingly, the path between short, the oil pressure in port B and the circuit is
port Pc and port C is closed and the path be- controlled high and the brake is "half released".
tween port C and port Dr is opened. As the oil in If the stroke is long, the oil pressure is controlled
port C is drained through port Dr, the clutch is low and the brake is turned "ON".
turned "OFF". • When the parking brake is turned "OFF", the
The oil pressure in the charge circuit, etc. is se- parking brake valve is closed and the oil in the
cured by orifice "a". brake circuit is not drained.
• Solenoid (5) of the left brake ECMV is turned ON
and ball (6) is pressed to the left to close the
sealing part. The oil in port Pb flows to port E
and pushes valve (7) to the left. The oil pressure
in port B and the circuit is controlled by the com-
mand current sent from the controller to solenoid
(5) according to the operation stroke of the
PCCS lever.
If a current flows into solenoid (5), the solenoid
generates thrust proportional to the current. The
D275A-5 10-67
(4)
3. When PCCS lever is operated to left fully: Sharp turn

(Left clutch is turned "OFF", left brake is turned "ON", right clutch is turned "ON", right brake is "re-
leased", and parking brake is turned "OFF")
• If the PCCS lever under the condition in 2 above

is operated to the left fully, solenoid (5) of the left
brake ECMV is turned OFF and the sealing part
of ball (6) is opened.
Since the oil in port E is drained through the seal-
ing part, valve (7) is moved to the right by the
tension of spring (8). At this time, the path be-
tween port Pb and port B is closed and the path
between port B and port Dr is opened.
• The oil from the power train pump is drained
through port Pb, orifice "b", and sealing part of
ball (6).
The oil pressure in the charge circuit, etc. is se-
cured by orifice "b".
The oil flowing in the back pressure port of the
brake piston is drained through port B into port
Dr and the brake is turned "ON" by the tension of
the brake spring.
• When the parking brake is turned "OFF", the
parking brake valve is closed and the oil in the
brake circuit is not drained.
10-68 D275A-5
4. When brake pedal is "pressed"

(Both clutches are turned "ON", both brakes are turned "ON", and parking brake is turned "OFF")
• If the brake pedal is pressed fully, solenoids (5)

of both brake ECMV’s are turned OFF.
• The controller outputs a command current to so-
lenoids (5) according to the pressing stroke of
the brake pedal.
If a current flows into solenoids (5), the solenoids
generate thrust proportional to the current. The
pressure is stabilized at a point where this thrust
is balanced with the sum of the thrust caused by
the oil pressure in the brake port and the reaction
force of pressure control valve spring (8), thus
the braking force can be adjusted.
Since the PCCS lever is not operated, solenoids
(1) of both clutch ECMV’s are turned ON, thus
both clutches are turned ON.
• If the brake pedal is pressed, the parking brake
valve linked with it operates to drain the oil from
the brake circuit.
D275A-5 10-69
5. When parking brake is turned "ON"

(Clutch is turned "ON", brake is turned "ON", joystick is in "neutral", and brake pedal is "released")
• If the safety lever for the PCCS lever is set in the

"LOCK" position, parking brake valve (1) moves
to the left and the path between port A, port B,
and port C is opened. As a result, the oil in the
brake piston port under the back pressure is
drained through port A, port B, and port C. Then,
the back pressure in the brake piston port lowers
continuously and the brake is turned "ON" com-
pletely and kept under that condition.
• When the engine is started again, the path be-
tween port A, port B, and drain port C is kept
open. Accordingly, the brake is kept turned
"ON".
• If the parking brake is turned "OFF", parking
brake valve (1) moves to the right and the path
between port A, port B, and drain port C is
closed. Accordingly, the brake is "released" by
the oil pressure.
10-70 D275A-5
MAINTENANCE STANDARD PARKING BRAKE VALVE
PARKING BRAKE VALVE
Unit: mm
Tolerance
Clearance between parking brake size Shaft Hole clearance limit
1 Replace
valve spool and valve body
– 0.020 + 0.011 0.020–
14 0.05
– 0.030 0 0.041
Outside diameter of sliding parts Tolerance Clearance limit Repair by hard

2 fitting to dust seal and V-packing 14 chromium plating
– 0.020
(Spool) 13.9 or replace
– 0.030

Using
3 Parking brake valve spool spring Free length length
Using load Free length Using load Replace
38.2N 36.3N
65 47.7 63.1
{3.9kg} {3.71kg}
D275A-5 10-71
MAINTENANCE STANDARD SUDDEN BRAKE PREVENTION VALVE
SUDDEN BRAKE PREVENTION VALVE
Outline
• The sudden brake prevention valve is installed to
prevent the brake from stopping the machine
suddenly because of a trouble in the electric sys-
tem.
• Sudden brake prevention valve (1) is installed in
the brake ECMV pilot pressure drain circuit. If
brake ECMV solenoid valve (2) is deactivated,
the oil is drained from the brake circuit and the
brake is applied suddenly. To prevent this, if so-
lenoid valve (3) of sudden brake prevention
valve (1) is deactivated, the circuit of throttle a is
formed. As a result, pilot pressure drain circuit D
is choked and the brake is SEMI-RELEASED.
10-72 D275A-5
10 STRUCTURE, FUNCTION AND MAINTENANCE
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
Outline
• The final drive is a single stage spur gear, single
stage planetary gear reduction type. The lubrica-
tion is of splash type using the rotation of the
gears. The final drive can be removed and in-
stalled as a single unit.
• Floating seal (1) is installed to the rotating sliding
portion of the sprocket to prevent the entry of dirt
or sand and to prevent leakage of lubricating oil.
D275A-5 10-73
10-74 D275A-5
1. Floating seal 12. Cover

2. Sun gear 13. No.1 pinion
3. Carrier 14. Final drive case
4. Hub 15. Bearing cage
5. Cover 16. No.1 gear
6. Sprocket hub 17. No.1 gear hub
7. Sprocket teeth 18. Boss
8. Floating seal guard 19. Shaft
9. Cover 20. Wear guard
10. Planetary gear 21. Pivot shaft
11. Ring gear
Unit: mm

22 Backlash between No.1 pinion
and No.1 gear
0.28–0.93 0.93
Backlash between sun gear and Replace

23 0.22–0.81 0.81
planet pinion
Backlash between planet pinion
24 0.25–0.90 0.90
and ring gear

25 Outside diameter of No.1 pinion Repair or replace
oil seal contact surface 0 94.913
95
– 0.087
Thickness of thrust collar of roller Standard size Repair limit

26
bearing 30 –
Tolerance
Clearance between planetary size clearance limit
27 gear shaft and carrier Shaft Hole Replace
(Short diameter)
– 0.036 – 0.024 – 0.023-
85 0.1
– 0.058 – 0.059 0.034
Clearance between planetary
28 gear shaft and carrier – 0.036 – 0.072 – 0.071-
105 – 0.14
(Long diameter) – 0.058 – 0.107 – 0.014
Standard shim thickness for No.1

29 2 Adjust
pinion bearing cage
Standardclearance Repair limit

30 Wear of wear guard Repair or replace
72 18
D275A-5 10-75
(4)
Path of power transmission
10-76 D275A-5
• The power from the bevel gear shaft and steer-

ing clutch is transmitted to 1st pinion (13) to ro-
tate 1st gear (16) meshed with the 1st pinion and
sun gear (2) meshed with the 1st gear.
The rotation of sun gear (2) is transmitted to
planetary pinion (10). Since ring gear (11)
meshed with the planetary pinion is fixed to cov-
er (9), the planetary pinion rotates along the ring
gear and revolves around the sun gear.
At this time, the rotational force of sun gear (2) is
transmitted as the rotational force of carrier (3) to
support the planetary pinion through hub (4) to
sprocket hub (6).
The rotating direction of carrier (3) is the same
with sun gear (2).
The rotational force transmitted to sprocket hub
(6) is further transmitted to sprocket teeth (7).
D275A-5 10-77
MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm

1 Wear of tooth tip
402.4 386 Replace or repair
2 Thickness of tooth tip 23.2 17
10-78 D275A-5
(4)
MAINTENANCE STANDARD SPROCKET
SPROCKET TOOTH PROFILE
ª The above drawing is reduced to approx. 34%. Enlarge it to approx. 291% to return it to the full scale and
make a copy on an OHP sheet.
D275A-5 10-79
MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
1. Idler Outline
2. Recoil spring assembly • The track roller uses an K-shape bogie mount to increase the
3. Carrier roller ground contact area between the track shoe and ground surface
4. Track frame on rough surfaces, thereby increasing the drawbar pull.
5. Sprocket • The K-shape bogie is fitted with rubber pads to absorb the shock
6. Sprocket cover guard from the ground surface.
7. Track roller bogie
8. Track roller
9. Track roller support guard Track roller, bogie
10. Pivot shaft
11. Cylinder
12. Guide Track roller flange type and bogie arrangement
1st 2nd 3rd 4th 5th 6th 7th
S D D D D D S
10-80 D275A-5
MAINTENANCE STANDARD TRACK FRAME
Unit: mm
Item Repair limit
Deformation of track frame outer Curvature 7 (for length of 3,000)

4 Repair or replace
pipe Twisting 3 (for level length of 300)
Dents (pipe portion) 12
Standard Tolerance Standard Clearance

Clearance between inner pipe size clearance limit
11 and adjustment cylinder protru- Shaft Hole Replace
sion – 0.15 + 0.1
50 0.15–0.45 2.0
– 0.35 0
Clearance between idler bogie Standard clearance Clearance limit

12 Adjust
and guide 0–0.5 3.0
13 Press-fitting force for cartridge 2.75–530 kN {28–54 ton} –
D275A-5 10-81
MAINTENANCE STANDARD RECOIL SPRING
RECOIL SPRING
Outline
1. Yoke • Recoil spring (4) is used to adjust the track ten-
2. Nut sion by pumping in or releasing grease from lu-
3. Retainer bricator (10) to move rod (5) forward or
4. Recoil spring backward. The recoil spring (4) also acts to
5. Rod dampen any sudden shock brought to bear on
6. Spring cylinder the idler.
7. Retainer
8. Holder
9. Piston
10. Lubricator (for pumping in and releasing grease)
11. Grease chamber cylinder
10-82 D275A-5
MAINTENANCE STANDARD RECOIL SPRING
Unit: mm

12 Recoil spring length load load
372.7 kN 345.1 kN
1,231 1,045 1.415
{38,000kg} {35,185kg}
Standard Tolerance Standard Clearance Replace

Clearance between inner cylinder size clearance limit
Shaft Hole
13 and outer cylinder of outer cylin-
der bushing – 0.055 + 0.317 0.115–
340 0.8
– 0.228 + 0.060 0.545
Clearance between adjustment – 0.100 + 0.054 0.100–

14 110 –
cylinder and bushing – 1.350 0 0.404
Press-fitting force for outer cylin-

15 42.1–96.1 kN{4.3–9.8ton}
der bushing (outer cylinder side)
Press-fitting force for outer cylin-

16 44.1–228.6 kN{4.5–23.3ton} Adjust
der bushing (inner cylinder side)
Clearance between recoil spring

17 0–1.0
mount nut and lock plate
D275A-5 10-83
(4)
MAINTENANCE STANDARD IDLER
IDLER
10-84 D275A-5
MAINTENANCE STANDARD IDLER
Unit: mm

Outside diameter of protruding
1
part
822 –
2 Outside diameter of tread surface 780 755
3 Width of protruding part 121 –

Rebuild or
4 replace
Width of tread 77 85.5
5 Overall tread 275 –
6 Thickness of tread 25.5 13
7 Width of shaft flange 242 –

Clearance between shaft and size Shaft Hole clearance limit
8 Replace bushing
bushing
– 0.350 + 0.170 0.340–
147 –
– 0.413 – 0.010 0.583
Tolerance Standard
Standard Interfer-
interfer-
Interference between shaft and size Shaft Hole ence limit
9 ence
seal guard
+ 0.046 – 0.150 0.150–
84 – Replace
0 – 0.200 0.246
10 Play in axial direction of shaft
0.5–1.0 –
D275A-5 10-85
(4)
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
10-86 D275A-5
(4)
MAINTENANCE STANDARD TRACK ROLLER
Unit: mm

Outside diameter of flange
1
(outside of single flange)
291 –
Outside diameter of flange
2 277 –
(inside of double flange)
single
flange 255 185
3 Outside diameter
double
flange 255 195
single
flange 65 30
4 Thickness of tread Rebuild or
double replace
flange 65 35
5 Overall width 336 –
6 Width of tread (single flange) 80 –
7 Width of tread (double flange) 80 –

Width of flange (outside of double
8 27.5 12.5
flange)
Width of flange (ibside of double
9 24 9
flange)
10 Width of shaft flange 28.5 – Replace

11 Replace bushing
bushing
– 0.350 + 0.225 0.343–
115 –
– 0.413 – 0.007 0.038
Tolerance Standard
Standard Interfer-
interfer-
12 ence
seal guard
+ 0.046 – 0.150 0.150–
65 – Replace
0 – 0.200 0.246
0.44–0.91 –
D275A-5 10-87
(4)
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
10-88 D275A-5
MAINTENANCE STANDARD CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
232 –
Outside diameter of carrier roller
2 200 175
tread Rebuild or
3 Thickness of tread replace
40 27.5
4 Width of carrier roller tread 76.5 –
5 Width of flange 23 12

6 Replace bushing
support
0 + 0.35 0–
76 –
– 0.2 0 0.550
Tolerance Standard
Standard Interfer-
interfer-
7 ence
seal guard
+ 0.210 + 0.030 0.120–
77 – Replace
+ 0.150 0 0.210

0–0.22 –
D275A-5 10-89
(4)
MAINTENANCE STANDARD TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
1. Guide 6. Small bogie Outline

2. Cap 7. Track roller assembly • The track roller are installed to
3. Track roller assembly (double) 8. Cover small bogie (6). The track rollers
4. Large bogie 9. Cartridge pin and track shoes are always in
5. Rubber mount contact.
• The vibration of the machine
from the ground surface is ab-
sorbed by rubber mount (5).
10-90 D275A-5
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
★ Portion P shows the link on the side where the

bushing is pressed fitted.
10-92 D275A-5
MAINTENANCE STANDARD TRACK SHOE
Unit: mm

Reverse or
1 Link pitch
replace
260.6 263.6
2 Height of grouser 88 30 Lug welding

rebuild or replace
3 Thickness of plate 20 –
4 Link height 166 148 Rebuild or

replace
5 Thickness of link metal 51.7 33.7
6 Bushing outside diameter 82(Standard areas)

90.5
84.5(Heavy-duty areas)
7 8.6(Standard areas)
Thickness of bushing metal 17.1
11.1(Heavy-duty areas)
Tolerance Standard
Standard Interfer- Reverse or
interfer-
Interference between bushing size Shaft Hole ence limit replace
8 ence
and link
+ 0.602 + 0.087 0.285–
90 0.10
+ 0.372 0 0.602
Interference between pin and link + 0.296 – 0.206 0.442–
55.5 –
(without wedge ring) + 0.236 – 0.280 0.576
9
Interference between pin and link + 0.296 – 0.034 0.270–
55.5 –
(with wedge ring) + 0.236 – 0.096 0.392
10 Clearance between link and link Each side Both sides Both sides
1.4 2.8 –
Replace
Tightening torque Additional tightening
11 Tightening torque for regular bolt
784±78 Nm {80 ± 8kgm} 120° ± 10°
12 Tightening torque for master bolt 490±49 Nm {50 ± 5kgm} 180° ± 10°
D275A-5 10-93
(4)
MAINTENANCE STANDARD MAIN FRAME
MAIN FRAME
10-94 D275A-5
MAINTENANCE STANDARD MAIN FRAME
1. Main frame
2. Cage
3. Clamp
4. Cover
5. Seal
6. Clamp
7. Cap
8. Plate
Unit: mm

Clearance between radiator size Shaft Hole clearance limit
9
guard mounting pin and bushing
– 0.030 + 0.257 0.410–
80 0 more than
– 0.076 + 0.170 0.555
Clearance between radiator – 0.030 + 0.257 0.343–
10 80 1.0
guard mounting pin and bushing – 0.076 + 0.170 0.405 Replace
Clearance between ripper beam – 0.036 + 0.267 0.098–
11 110 1.5
mount pin and bushing – 0.090 + 0.180 0.254
Clearance between ripper cylin- – 0.036 + 0.257 0.064–
12 90 1.5
der mounting pin and bushing – 0.090 + 0.170 0.256
Clearance between equalizer bar – 0.036 – 0.109–
13 120 1.5
shaft and bushing – 0.090 – 0.260
Press-fitting force for radiator
14 6.08–138.3kN {6.2–14.1ton}
guard mount bushing
Press-fitting force for radiator
15 68.7–155.0kN {7.0–15.8ton}
guard mount bushing
Press-fitting force for ripper beam
16 69.7–37.3kN {7.1–14.0ton} Adjust
mount bushing
Press-fitting force for ripper cylin-
17 57.9–114.8kN {5.9–11.7ton}
der mount bushing
Press-fitting force for equalizer
18 31.4–105.9kN {2–13ton}
bar shaft bushing
D275A-5 10-95
MAINTENANCE STANDARD SUSPENSION
SUSPENSION
1. Equalizer bar 8. Seal Outline

2. Pivot shaft assembly 9. Bushing • The front of the track frame rocks up and down us-
3. Cover 10. Side pin ing the rear pivot shafts (6) as a fulcrum.
4. Thrust plate 11. Center pin Equalizer bar (1) rocks using center pin (11) as a
5. Thrust plate 12. Bushing fulcrum. The left and right track frames are con-
6. Pivot shaft nected by side pin (10).
7. Seal cage
10-96 D275A-5
Unit: mm

Clearance between center pin size Shaft Hole clearance limit
13
and bushing
– 0.030 + 0.247 0.196–
105 1.0
– 0.060 – 0.166 0.307
Clearance between side pin and – 0.030 + 0.046 0.030–

14 75 1.0 Replace bushing
bushing – 0.060 0 0.106
Tolerance Standard Interfer-

Standard
interference
Interference between side pin size Shaft Hole
15 ence limit
boss and bushing
0 – 0.088 0.098–
140 –
– 0.018 – 0.098 0.106
Press-fitting force for center pin
16 32.4–225.6kN {3.3–23ton}
bushing
–
Press-fitting force for side pin
17 34.3–68.7kN {3.5–7.0ton}
bushing
D275A-5 10-97
q1. Indicates the left of the blade single tilt specifications.

q2. Indicates the right of the blade single tilt specifications.
Unit: mm
Standard Tolerance Standard Interference

Interference between size Shaft Hole interference limit
18
thrust washer and seal
+ 0.213 – 0.180 0.278–
210 –
+ 0.098 – 0.226 0.439 Replace
Interference between thrust + 0.140 – 0.061 0.161–
19 140 –
washer and seal + 0.100 – 0.124 0.264
Interference between pivot + 0.096 – 0.075 0.125–
20 194 –
shaft and seal + 0.050 – 0.147 0.243

Clearance between pivot size Shaft Hole clearance limit
21
shaft and bushing Replacing
– 0.145 + 0.132 0.204– bushing
155 1.0
– 0.208 + 0.059 0.340
Clearance between pivot – 0.170 + 0.144 0.229–
22 190 1.0
shaft and bushing – 0.242 + 0.059 0.386
10-98 D275A-5
MAINTENANCE STANDARD WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

SEMI U-DOZER
SJD05821
1. Blade tilt cylinder

2. R.H. blade lift cylinder
3. Main control valve
4. Accumulator
5. Hydraulic tank
6. Work equipment pump
7. L.H. blade lift cylinder
8. Oil cooler
D275A-5 10-99
(7)
MULTI-SHANK RIPPER
1. Main control valve

2. Divider block
3. Ripper tilt cylinder
4. Ripper lift cylinder
10-100 D275A-5
GIANT RIPPER
• The diagram shows a machine equipped with a
pin puller cylinder
1. Main control valve 6. Ripper lift cylinder (left)

2. Divider block 7. Ripper tilt cylinder (left)
3. Ripper tilt cylinder (right) 8. Pin puller solenoid valve
4. Ripper lift cylinder (right) 9. Brake valve
5. Pin puller cylinder a. To steering case
D275A-5 10-101
MAINTENANCE STANDARD PPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM

PPC CONTROL PIPING DIAGRAM
SJD05822
1. Blade control PPC valve 5. PPC lock valve

2. Main control valve 6. Work equipment safety lever
3. Accumulator 7. Work equipment pump
4. Ripper control PPC valve
10-102 D275A-5
(7)
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL

• The diagram shows a machine equipped with
pin puller cylinder.
10-104 D275A-5
(4)
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL
1. Work equipment safety lever

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

1 : Blade HOLD
2 : Blade LOWER
3 : Blade FLOAT
4 : Blade RAISE
5 : Blade LEFT TILT/PITCH
6 : Blade RIGHT TILT/PITCH
7 : Ripper HOLD
8 : Ripper RAISE
9 : Ripper LOWER
0 : Ripper TILT IN
A : Ripper TILT BACK
B : FREE
C : LOCK
D : Single tilt
E : Dual tilt
F : Pitch OFF
G : Pitch ON
H : Pin puller switch PUSH IN
I : Pin puller switch PUSH OUT
Outline
• The work equipment control employs a PPC
method which uses a PPC valve to move each
control valve spool.
• Work equipment safety lever (1) is interconnect-
ed with PPC lock valve (6), and at the LOCK po-
sition, the oil in the PPC circuit is stopped.
D275A-5 10-105
(4)
MAINTENANCE STANDARD WORK EQUIPMENT PUMP
WORK EQUIPMENT PUMP

HPV95 (112-cm3/rev specification)
Outline
This pump consists of a swash plate-type variable-capacity piston pump and an LS valve.
10-106 D275A-5
1. Piston pump
2. Control assembly
PA1 : Pump discharge

PD1 : Pump drain
PD2 : Pump drain
PP1 : Pump pressure signal
PP2 : 2nd pump pressure signal
PS1 : Pump suction
PLS1 : Load pressure input
PLS2 : Load pressure pick-up
PNC1 : Control pressure
PNC2 : Control pressure pick-up
Specifications
Model: HPV95 (112 cm3/rev)
Theoretical displacement: 112 ±1 cm3/rev
Rated speed: 2,302 rpm
Max. cut-off pressure: 31.9 MPa {325 kg/cm2}
D275A-5 10-107
PA : Pump discharge PD2 : Pump drain

PA1 : Pump pressure signal PS1 : Pump suction
PD1 : Pump drain PNC1 : Control pressure
10-108 D275A-5
1. Shaft 8. Piston
2. Case 9. Cylinder block
3. Cradle 10. Valve plate
4. Rocker cam 11. End cap
5. Shoe 12. Impeller
6. Servo piston 13. Spline
7. Lod
D275A-5 10-109
Outline
• The engine rotation and torque transmitted to • Piston (8) carries out motion relative to the axial
the pump shaft is converted to hydraulic energy direction inside each cylinder chamber of cylin-
and pressurized oil is discharged according to der block (9).
the load. • The cylinder block (9) carries out rotation relative
• It is possible to change the discharge amount by to valve plate (10) while sealing the pressurized
changing the swash plate angle. oil, and this surface ensures that the hydraulic
balance is maintained correctly.
Structure
• The oil inside each cylinder chamber of cylinder
• Cylinder block (9) is supported to shaft (1) by a block (9) is sucked in and discharged through
spline (13), and shaft (1) is supported by the valve plate (10).
front and rear bearings. • Impeller (12) is fixed to shaft (1), and rotates to-
• The end of piston (8) has a concave ball shape gether with the shaft, it makes it easier for the oil
and shoe (5) is caulked to it to form one unit. Pis- sucked in from the suction port to be sucked in
ton (8) and shoe (5) form a spherical bearing. and sends it into the cylinder chamber by centrif-
• Rocker cam (4) holds plane A, and shoe (5) is al- ugal force.
ways pressed against this surface as it slides in
a circle.
• Rocker cam (4) forms a static bearing sending
high pressure oil at cylindrical surface B of cra-
dle (3), which is fixed to the case, and carries out
a sliding movement.
10-110 D275A-5
OPERATION
1. Operation of pump
• Cylinder block (9) rotates together with shaft (1),
and shoe (5) slides on plane A. When this hap-
pens, rocker cam (4) moves along cylindrical
surface B, so angle α of center line X of rocker
cam (4) to the axial direction of cylinder block (9)
changes. This angle α is called the swash plate
angle.
• With swash plate angle α formed by the angle

between center line X of rocker cam (4) to the
axial direction of cylinder block (9), plane A acts
as a cam for shoe (5).
In this way, piston (8) slides inside cylinder block
(9), and as a result, a difference is generated be-
tween volumes E and F inside the cylinder block.
The amount of suction and discharge is equal to
difference F - E.
• In other words, cylinder block (9) rotates, and the
volume pf chamber E becomes smaller, so oil is
discharged during this process. At the same
time, the volume of chamber F becomes larger
and oil is sucked in this process.
• When center line X of rocker cam (4) is the same

as the axial direction of cylinder block (9) (swash
plate angle = 0), the difference between volumes
E' and F' inside cylinder block (9) is 0, so pump
does not suction and discharge, and no pump-
ing's carried out. Actually swash plate angle
does not become 0.)
• The swash plate angle α is proportional to pump
discharge volume.
D275A-5 10-111
2. Control of discharge amount

• If swash plate angle α becomes larger, the differ-
ence between volumes E and F becomes larger,
and oil discharge Q is increased. Swash plate
angle α is changed by servo piston (6).
• Servo Piston (6) carries out reciprocal move-
ment in a straight line according to the command
from the LS valve single pressure. This straight
line movement is transmitted to rocker cam (4)
through rod (7), and rocker cam (4), which is
supported on the cylindrical surface by cradle (3)
rotates on the cylindrical surface.
• The area receiving the pressure is different at
the left and right sides of servo piston (6), and
the receiving pressure at the small diameter pis-
ton end is always connected with main pump dis-
charge pressure (self pressure) PP.
• Output pressure PNC of the LS valve is applied
to the chamber receiving the pressure at the
large diameter piston end (which receives pres-
sure of the pump).
• The movement of servo piston (6) is controlled
by the relationship of the size of pump pressure
PP and the pressure at the large diameter piston
end, and the comparative size of the ratio of area
receiving the pressure at the large diameter pis-
ton end and small diameter piston end.
• The movement of the servo piston is controlled
by a valve called the LS valve. Main pump pres-
sure PP and pressure PLS (the LS pressure)
from the control valve outlet port enter this valve.
• The relationship between discharge volume Q
and the difference in pressure (∆ P = PP - PLS)
(called the LS differential pressure) between
main pump pressure PP and LS pressure PLS
and is as shown in the diagram on the right.
10-112 D275A-5
Control assembly
PP: Pump pressure signal

PT: Drain
PLS1: Load pressure signal
PLS2: Load pressure pick-up
PNV1: Control pressure
PNV2: Control pressure pick-up
D275A-5 10-113
1. Valve body 8. Locknut

2. LS valve 9. Locknut
3. Variable throttle valve 10. Plug
4. Plug 11. Spring
5. Spool 12. Spool
6. Spring 13. Plug
7. Plug
10-114 D275A-5
1. Operation of LS valve
1) When the control valve is at HOLD position
Operation
• The LS valve is a 3-way selector valve, and main
pump pressure PP and pressure PLS (LS pres-
sure) from the outlet port of the control valve are
applied to d port and a port.
• Spool (4) of this LS valve is pushed by the force
of spring (3) from the end receiving the LS pres-
sure, and the position of the spool (4) is deter-
mined by the LS pressure PLS + spring force F
and the size of main pump pressure PP.
• Main pump pressure PP always effects to ports
d and e. LS pressure PLS enters chamber g
from port a.
• Before the engine is started, servo piston (1) is
pushed to the right by spring (5) of rod (2). (See
the diagram on the right)
• After the engine is started, lf the control lever is
at HOLD position, the LS pressure PLS is 0 MPa
{0kg/cm2}. (The circuit is connected to the drain
circuit through the passage inside the control
valve spool.)
• When this happens, spool (4) is pushed to the
left, and port d and port c are connected. Pump
pressure PP enters the large diameter piston
end from port f, and the difference in area of pis-
ton (1) to the left so that the swash plate angle
becomes minimum.
D275A-5 10-115
(4)
2) Movement in direction to increase pump discharge ( to the right)
Operation
• When LS differential pressure ∆ PLS, which is • Circuits c - f, which are the pressure of f port at
the difference in pressure between main pump the large diameter piston end of servo piston (1),
pressure PP and LS pressure PLS, becomes become the drain pressure, so servo piston (1) is
smaller (for example, the area of opening of the pushed from the small diameter piston end to the
control valve becomes larger and pump pres- large diameter piston end.
sure PP is reduced), spool (4) is pushed to the Rod (2) also moves to the right because of this
right under the combined force of the LS pres- movement, and changes the swash plate angle.
sure PLS and the force of spring (3). Main pump
pressure PP enters chamber h. The combined
force of spring (3) and the force of LS pressure
PLS is greater than the force of main pump pres-
sure PP, so spool (4) is pushed to the right.
• Because of the movement of spool (4), port c
and port b are connected, and circuit c - f be-
come drain pressure PT.
10-116 D275A-5
3) Movement in direction to reduce pump dis-

charge (to the left)
Operation
• The following explains the situation when servo • Main pump pressure PP also enters the small di-
piston (1) moves to the left (the direction to make ameter piston end, but servo piston (1) is pushed
the discharge amount smaller). If LS differential from the large diameter piston end to the small
pressure ∆ PLS becomes larger (for example, diameter piston end because of the difference in
the area of opening of the control valve becomes area between the large diameter piston end and
smaller and pump pressure PP increases), spool the small diameter piston end.
(4) is pushed to the left by pump pressure PP. • As a result, rod (2) moves in the direction to
• Because of the movement of spool (4), main make the swash plate angle smaller (to the left).
pump pressure PP flows into port c, and main
pump pressure PP enters the large diameter pis-
ton end from port f.
D275A-5 10-117
4) When servo piston is balanced
Operation
• In the LS valve, lf main pump pressure PP is bal- • When this happens, the force pushing the small
anced with the combined force of LS pressure diameter piston and the force pushing the large
PLS at chamber g and force F of spring (3), ser- diameter piston are balanced, so servo piston (1)
vo piston (1) stops at the intermediate position stops. In other words, the following condition is
for the swash plate angle. (Force F of spring (3) reached.
converted to the hydraulic power: Approx. 1.96 • Pump pressure PP x area receiving pressure at
MPa {20kg/cm2}. small diameter piston end = hydraulic pressure
• If an LS pressure (main pump pressure - force of PNC at the large diameter piston end x area re-
spring) that fulfills the above conditions for bal- ceiving pressure at large diameter piston end.
ancing enters ports a, main pump pressure PP The difference I area between the large diameter
entering from port d and combined force F of piston and small diameter piston is normally ap-
spring (3) and the force from LS pressure PLS prox. 2:1, so the pressure at the large diameter
are balanced, and pressure of a certain size en- piston end is approx. 1/2 of pump pressure PP.
ters port f from port c.
10-118 D275A-5
2. Operation of variable throttle valve

1) Properties of variable throttle valve
• Because the main pump controls its own pres-
sure, there is a tendency for the response speed
of the swash plate to be quick at high pressure
and slow at low pressure.
The variable throttle valve has been installed be-
tween the LS valve and the port at the large di-
ameter end of the servo piston for the following
reasons.
1 To reduce the swash plate speed between
MIN and MAX at high pressure; to reduce
the impact force on the rod and other parts of
the main pump; and to prevent excessive re-
sponse.
2 To prevent cavitation at the suction port
caused by the sudden increase in the suc-
tion volume when changing from MIN to
MAX.
• The characteristics of the variable throttle valve

are as shown in the diagram below.
It has the function and property of maintaining
the response during operations at low pressure
by making the area of the opening smaller at
high pressure and the area of the opening larger
at low pressure, and by preventing the above
problems 1 and 2 at high pressure.
D275A-5 10-119
2) Pump discharge pressure at high pressure
Operation
• In the variable throttle valve (6), main pump
pressure PP from LS valve (5) passes through
port b and enters port f.
• When main pump pressure PP is high, if it is
greater than the force of spring (3) because of
the difference in area of the land portion diame-
ters at both ends of chamber f, spool (4) is
moved to the left.
• If spool (4) moves to the left, the area of the
opening from port a to port c is throttled, so the
flow of oil entering the large diameter end of ser-
vo piston (1) from port d is reduced and the
speed of movement of servo piston (1) becomes
slower.
10-120 D275A-5
3) Pump discharge pressure at low pressure
Operation
• When main pressure PP is low, even if it enters
chamber f from port b, the pressure is low, so it
does not become greater than the force of spring
(3), and spool (4) remains pushed to the right.
• The area of the opening from port a to port c be-
comes larger, so output pressure PNC from the
LS valve (5) is transmitted as it is.
D275A-5 10-121
MAINTENANCE STANDARD COOLING FAN PUMP
COOLING FAN PUMP

LPV45
P: EPC valve main pressure TO: Drain

PE: Pump charge pressure PHO: Pump discharge pressure
10-122 D275A-5
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
D275A-5 10-123
Function
• The rotation and torque of the engine are trans- • Piston (6) in each cylinder of cylinder block (7)
mitted to the shaft of this pump and converted moves relatively in the axial direction.
into hydraulic energy in this pump. This pump • Cylinder block (7) rotates relatively against valve
discharges the pressurized oil according to the plate (8), sealing the pressurized oil, and the hy-
load. draulic balance is maintained properly.
• The discharge of this pump can be changed by • The oil in each cylinder of cylinder block (7) can
changing the swash plate angle in it. be sucked and discharged through valve plate
(8).
Structure
• Cylinder block (7) is supported on shaft (1)
through spline a. Shaft (1) is supported by the
front and rear bearings.
• The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6) and
shoe (5) form a spherical bearing.
• Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slid circularly.
Rocker cam (4) slides around ball (11).
10-124 D275A-5
Operation
1. Operation of pump
• Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane A. At this time,
rocker cam (4) tilts around ball (11). As a result,
angle α between center line X of rocker cam (4)
and the axis of cylinder block (7) changes. Angle
α is called the swash plate angle.
• If angle α is made between center line X of rock-
er cam (7) and the axis of cylinder block (7),
plane A works as a cam for shoe (5).
• Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between vol-
umes E and F in cylinder block (7). As a result,
each piston (6) sucks and discharges oil by F - E.
• In other words, if cylinder block (7) rotates and
the volume of chamber E is decreased, the oil is
discharged from chamber E. On the other hand,
the volume of chamber F is increased and the oil
is sucked in chamber F. (In the figure, chamber
F is at the end of the suction stroke and chamber
E is at the end of the discharge stroke.)
• If center line X of rocker cam (4) is equal to the
axial of cylinder block (7) (the swash plate angle
is 0), there is not a difference between volumes
E and F in cylinder block (7) and oil is not sucked
or discharged. (The swash plate angle is not set
to 0 actually, however.)
• In short, swash plate angle α is in proportion to
the pump discharge.
D275A-5 10-125
2. Control of discharge
• If swash plate angle α is increased, the differ-
ence between volumes E and F is increased, or
discharge Q is increased. Swash plate angle α
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)
slides around ball (11).
10-126 D275A-5
Servo valve
P: EPC valve main pressure

T: Drain
PE: Control piston pressure
PH: Pump discharge pressure
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
D275A-5 10-127
(4)
Function
• The servo valve controls the current input to the • The servo piston is raised by the rocker cam.
EPC valve and the swash plate angle of the The position feedback is applied and the lever
pump so that they will be related as shown in the moves to compress the spring.
figure. • If spool (5) is pushed back, the pump discharge
circuit and the servo piston circuit are shut off.
The pressure in the servo piston chamber lowers
and the rocker cam returns toward the maximum
swash plate angle.
• These processes are repeated until the swash
plate is fixed to a position where the EPC output
is balanced with the spring force.
• Accordingly, as the EPC output pressure is
heightened, the swash plate angle is decreased.
As the EPC output pressure is lowered, the
swash plate angle is increased.
• The output pressure of the EPC valve is applied

to the piston chamber to push the piston. Piston
(6) pushes spool (5) until it is balanced with the
spring.
• Then, the land of the servo piston pressure pas-
sage is connected to the pump discharge pas-
sages by the cut of spool (5) and the discharge
pressure is led to the servo piston.
10-128 D275A-5
Safety valve
Function
• The fan pump discharge pressure is heightened
when the engine is started or the fan is stopped
and rotated in reverse.
• The safety valve is installed to protect the fan
system circuit.
• If the discharge pressure exceeds the cracking
pressure of the safety valve, the seat of the safe-
ty valve opens to relieve the oil into the drain
passage and prevent generation of abnormally
high pressure in the discharge port.
D275A-5 10-129
MAINTENANCE STANDARD COOLING FAN MOTOR
COOLING FAN MOTOR

LMF75
P : From fan pump

T : From oil cooler to tank
TC : To tank
Specifications
Model: LMF75
Capacity: 75 cc/rev
Rated speed: 1,050 rpm
Rated flow rate: 78.8 ¬/min
Cracking pressure of check valve:
76.5 kPa {0.78 kg/cm2}
10-130 D275A-5
1. Output shaft 11. Check valve

2. Case 12. Changeover screw
3. Thrust plate 13. Changeover spool
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Center spring
10. Check valve spring
Unit: mm

Free length
Installed Installed Installed If damaged or
x Outside Free length
10 Check valve spring length load load deformed,
diameter
replace spring
13.72N 10.29N
16.4 × 8.9 11.5 –
{1.4kg} {1.05kg}
D275A-5 10-131
1. Hydraulic motor unit

Function
• This hydraulic motor is called a swash plate-type
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into
rotary motion.
Principle of operation
• The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only 1 side of the Y-Y line
connecting the top dead center and bottom dead
center of the stroke of piston (4).
• The oil sent to 1 side of cylinder block (5) press-
es pistons (4) (4 or 5 pieces) and generates
force F1 (F1 kg = P kg/cm2 x π/4D2 cm2).
• This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of α degrees
to the output shaft (1), the force is divided into
components F2 and F3.
• The radial component F3 generates torque
against the Y-Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
• The resultant of this torque [T = Σ(F3 x ri)] ro-
tates the cylinder block (5) through the piston.
• Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output shaft
revolves to transmit the torque.
10-132 D275A-5
2. Suction valve
Function
• If the fan pump stops, the hydraulic oil does not
flow into the motor. Since the motor continues
revolution because of the force of inertia, howev-
er, the pressure on the outlet side of the motor
rises.
• When the oil stops flowing in from inlet port P, the
suction valve sucks in the oil on the outlet side
and supplies it to the port MA where there is not
sufficient oil to prevent cavitation.
Operation
(1) When pump is started
• If the hydraulic oil from the pump is supplied to
port P and the pressure on the MA side rises and
starting torque is generated in the motor, the mo-
tor starts revolution. The oil on the outlet MB
side of the motor returns through port T to the
tank.
(2) When pump is stopped

• If the engine is stopped and the input revolution
of the fan pump lowers to 0 rpm, the hydraulic oil
from the pump is not supplied to port P any
more. As the hydraulic oil is not supplied to the
MA side of the motor, the motor speed lowers
gradually to stop.
• If the motor shaft is revolved by the force of iner-
tia while the oil flow in the port P is reducing, the
oil in port T on the outlet side is sent by the suc-
tion valve to the MA side to prevent cavitation.
D275A-5 10-133
3. Operation of revolution direction changeover valve

(1) Forward rotation of motor (Clockwise rota- (2) Reverse rotation of motor (Counterclockwise
tion) rotation)
• To rotate the motor forward (clockwise), adjust • To rotate the motor in reverse (counterclock-
changeover screw (12) to position A (until the wise), adjust changeover screw (12) to position
screw stops). B (until the screw stops).
• Then, changeover spool (13) moves to the right Then, changeover spool (13) moves to the left to
to set the motor in the forward rotation mode. set the motor in the reverse rotation mode.
10-134 D275A-5
MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Oil filler cap 7. Hydraulic tank

2. Hydraulic filter element 8. Strainer
3. Spring 9. Sight gauge
4. Suction valve 10. Pressure valve
5. Cover 11. Drain valve
6. Cover 12. Drain plug
10-136 D275A-5
MAINTENANCE STANDARD HYDRAULIC TANK
Specified value Specified value
Tank capacity (¬) 200 Cracking pressure 102.9 ± 19.6

(KPa {kg/cm2}) {1.05 ± 0.2}
Hydraulic Hi (¬) 149
Level inside Hydraulic Mesh size (µm) 30/8
tank Center (¬) 135
tank filter
Filtering area (cm2) 13,600
Low (¬) 117
Filtering oil flow (¬/min) 245
Cracking pressure 16.7 ± 6.9
(KPa {kg/cm2}) {0.17 ± 0.07} Mesh size (µm) 105
Breather Strainer
cap Vacuum valve actuating Filtering area (cm2) 1,850
0– 0.49
pressure
{0– 0.005 }
(KPa {kg/cm2})
D275A-5 10-137
MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
For PPC valve
1. Glass plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3.1MPa {32kg/cm2}
Max. actuation pressure: 1.2MPa {12kg/cm2}
Function
• The accumulator is installed between the PPC
charge pump and the PPC valve. Even if the en-
gine is stopped with the work equipment still
raised, the pressure of the nitrogen gas com-
pressed inside the accumulator sends the pilot
pressure to the main control valve to actuate it
and enable the work equipment to move down
under its own weight.
Operation
• After the engine is stopped, when the PPC valve
is at neutral, chamber A inside the bladder is
compressed by the oil pressure in chamber B.
• When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa {30 kg/
cm2}, and the pressure of the nitrogen gas in
chamber A expands the bladder, so the oil in
chamber B acts as the pilot pressure and actu-
ates the main control valve.
10-138 D275A-5
(4)
MAINTENANCE STANDARD PPC LOCK VALVE
PPC LOCK VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The PPC lock valve is installed in the PPC circuit
between the PPC, charge valve and PPC valve.
If the work equipment safety lever is placed at
the LOCK position, the PPC lock valve is actuat-
ed together with the work equipment safety le-
ver. This stops the oil in the PPC circuit and
makes it impossible to operate the work equip-
ment.
D275A-5 10-139
(4)
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
For blade lift, blade tilt
P. From PPC charge valve port P P1. To blade tilt valve port PA2
T. To hydraulic tank P2. To blade tilt valve port PB2
P3. To blade lift valve port PB3
P4. To blade lift valve port PA3
D275A-5 10-141
1. Spool 6. Nut (for lever joint)

2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disc 10. Body
10-142 D275A-5
Unit: mm

11 Centering spring (for P1) length load load
108.8N 87.0N
34.0 × 15.5 31.6 –
{11.09kg} {8.87kg}
16.7N 13.7N
12 Metering spring (for P3, P4) 27.23 × 8.14 24.9 –
{1.7kg} {1.4kg}
99.0N 79.2N Replace spring

13 Centering spring (for P2) 43.2 × 15.5 31.6 –
{10.09kg} {8.07kg} if damaged or
deformed
113.2N 90.5N
14 Centering spring (for P3, P4) 48.57 × 15.5 31.6 –
{11.54kg} {9.23kg}
16.7N 13.7N
15 Metering spring (for P1, P2) 26.53 × 8.15 24.9 –
{1.7kg} {1.4kg}
159.36N 127.5N
16 Detent spring (for P4) 20.39 × 19.5 13.1 –
{16.25kg} {13kg}
38.44N 30.79N
17 Detent spring (for P3) 45.36 × 7.5 26 –
{3.92kg} {3.14kg}
D275A-5 10-143
Operation
1. At neutral
1) PPC valve for blade lift
Ports PA3 and PB3 of the blade lift control valve,
and ports P3 and P4 of the PPC valve are con-
nected to drain chamber D through fine control
hole f in spool (1).
2) PPC valve for blade tilt

Ports PA2 and PB2 of the blade tilt control valve,
and ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine control
hole f in spool (1).
10-144 D275A-5
2. During fine control (neutral-fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
passes through fine control hole f and goes from
port P4 to port PA3.
When the pressure at port P4 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port P4.
When this happens, spool (1) moves up or down
so that force of metering spring (2) is balanced
with pressure at port P4.
The relationship in the position of the spool (1)
and body (10) (fine control hole f is at a point
midway between drain hole D and pump pres-
sure chamber PP) does not change until retainer
(9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control level, so the pressure at port P4 also ris-
es in proportion to the travel in the control lever.
In this way the control valve spool moves to a po-
sition where the pressure in chamber PA3 (the
same as the pressure at port P4) and the force
of the control valve spool return spring are bal-
anced.
D275A-5 10-145
3. During fine control

(When control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up to the force of centering spring (3)
and the pressure at port P4.
When this happens, fine control hole f is con-
nected to drain chamber D, and the pressure oil
at port P4 is released.
If the pressure at port P4 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P4 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P3 and enters cham-
ber PB3 to fill the chamber with oil.
4. At full stroke
When disc (5) pushes down piston (4), and re-
tainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f and
flows to chamber PA3 from port P4, and pushes
the control valve spool.
The oil returning from chamber PB3 from port P3
through fine control hole f' and flows to drain
chamber D.
10-146 D275A-5
5. Blade operated to FLOAT

When piston (4) at port P4 (LOWER side) is
pushed by disc (5) and moves down, protrusion
a of the piston contacts ball (11) during the
downward stroke. (The detent starts to be actu-
ated.)
If piston (4) is pushed further, ball (11) pushes up
collar (12), which is being held by detent spring
(13), and moves to the outside, so the ball pass-
es over protrusion a of the piston. At this point,
piston (4') at the opposite side is pushed up by
the spring (14).
As a result, the oil inside chamber F flows
through b and c and enters chamber E, and pis-
ton (4') follows disc (5). Passage d is intercon-
nected with port P4, so it is under more or less
the same pressure as port P4.
Chamber E is normally interconnected with drain
chamber D, but when ball (11) passes over pro-
trusion a of the piston, passage d and chamber
E (which were shut off) are interconnected and
pressurized oil flows. At the same time, the con-
trol valve also moves to the FLOAT position, so
the blade circuit is set to the FLOAT condition.
The pressurized oil inside chamber E pushes up
piston (4'), so even of the lever is released, it is
held at the FLOAT position.
6. Blade released from FLOAT

When disc (5) is returned from the FLOAT posi-
tion, it is pushed down by a force greater than
the pressure of the oil in chamber E.
For this reason, chamber E is shut off from pas-
sage d and is connected to the drain chamber.
Therefore, the oil pressure inside chamber E is
lost, and the FLOAT, position is released.
D275A-5 10-147
PPC VALVE
For ripper
P. From charge pump

T. To hydraulic tank
P1. To ripper tilt (BACK)
P2. To ripper tilt (IN)
P3. To ripper lift (LOWER)
P4. To ripper lift (RAISE)
10-148 D275A-5
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for lever joint)
Unit: mm

12 Centering spring (for P3, P4) Free length Free length
length load load
71.39N 56.9 Replace spring

50.05×15.5 34 – if damaged or
{7.28kg} {5.8kg}
deformed
55.9N 45.1N
13 Centering spring (for P1, P2) 50.35×15.5 34 –
{5.7kg} {4.6kg}
16.7N 17.7N
14 Metering spring 26.53×8.15 24.9 –
{1.7kg} {1.4kg}
D275A-5 10-149
Operation
1. At neutral
Ports A and B of the control valve and ports P1,
P2, P3 and P4 of the PPC valve are connected
to drain chamber D through fine control hole f of
spool (1).
10-150 D275A-5
2. During fine control (neutral → fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the charging pump
pressure through fine control hole f and goes
from port P1 to port A.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port P1. The relation-
ship in the position of the spool (1) and body (10)
(fine control hole f is at a point midway between
drain hole D and pump pressure chamber PP)
does not change until retainer (9) contacts spool
(1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port P1 also ris-
es in proportion to the travel in the control lever.
In this way the control valve spool moves to a po-
sition where the pressure in chamber A (the
same as the pressure at port P1) and the force
of the control valve spool return spring are bal-
anced.
D275A-5 10-151
3. During fine control

(When control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil
at port P1 is released.
If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f'
in the valve on the side that is not working.
The oil passes through port P2 and enters cham-
ber B to fill the chamber with oil.
4. At full stroke
When disc (5) pushes down piston (4), and re-
tainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the charg-
ing pump passes through fine control hole f and
flows to chamber A from port P1, and pushes the
control valve spool.
The oil returning from chamber B passes form
port P2 through fine control hole f' and flows to
drain chamber D.
10-152 D275A-5
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
Blade lift cylinder
Blade tilt cylinder
Ripper lift cylinder
10-154 D275A-5
Ripper tilt cylinder
Unit: mm

size Shaft Hole clearance limit
– 0.030 + 0.258 0.078–

Blade lift 80 0.745
– 0.076 + 0.048 0.334
Clearance between
1 piston rod and bush- – 0.036 + 0.257 0.084–
Blade tilt 100 0.693
ing – 0.090 + 0.047 0.347
– 0.036 + 0.257 0.084–

Ripper lift 100 0.693
– 0.090 + 0.047 0.347
– 0.036 + 0.257 0.084–

Ripper tilt 90 0.693
– 0.090 + 0.047 0.347
Clearance between
piston rod spherical 100 + 0.300
2 – – 1.0
surface and blade Blade lift (Ball) 0
ball portion
+ 0.207 Replace
Blade lift 90 – – 1.0
+ 0.120
Clearance between
+ 0.200
3 piston rod spherical Blade tilt 70 – – 1.0
0
shaft and bushing
+ 0.207
Ripper lift 90 – – 1.0
+ 0.120
Clearance between
cylinder support – 0.120 + 0.035 0.120–
4 Blade lift 95 1.0
shaft bushing and – 0.207 0 0.242
yoke
+ 0.174
Blade tilt 70 – – 2.0
+ 0.100
Clearance between
cylinder bottom sup- + 0.207
5 90 – – 1.0
port shaft and bush- Ripper lift + 0.120
ing
+ 0.207
Ripper tilt 90 – – 1.0
+ 0.120
Thickness of stan-
dard shim between
6 Blade lift 4.0 Adjust
tip of piston rod and
cap
D275A-5 10-155
Dual tilt cylinder (Opt)
Pin puller cylinder (Opt)
Unit: mm

Clearance between
1 piston rod and bush- Dual tilt – 0.036 + 0.257 0.084–
100 0.693
ing – 0.090 + 0.047 0.347
Pin puller – 0.065 + 0.133 0.072–

30 0.55
– 0.117 + 0.007 0.250
Clearance between piston rod + 0.200 Replace

2 70 – – 1.0
support shaft and bushing 0
Clearance between piston rod – 0.100

3 29 – – –
spherical surface and bushing – 0.200
Clearance between cylinder bot- + 0.174

4 70 – – 2.0
tom support shaft and bushing + 0.100
Clearance between cylinder bot- + 0.100

5 26 – – –
tom support shaft and bushing – 0.100
10-156 D275A-5
MAINTENANCE STANDARD PISTON VALVE
PISTON VALVE
For blade lift cylinder
Outline
• The piston valve is installed on the piston in the
blade lift cylinder. When the piston reaches its
stroke end, the valve releases the oil from the
hydraulic pump to reduce the oil pressure being
exerted on the piston.
When the blade is tilted, the blade is subject to a
tortional force owing to the uneven position of
the pistons in the two cylinders; that is the piston
one side is still moving while the piston on the
other side has reached its stroke end.
The piston valves are installed to prevent the tor-
tional force from occurring. When one of the pis-
tons reaches its stroke end, its piston valve
opens to relieve the oil pressure.
In addition the piston valve relieves the shock
which occurs when the piston comes into contact
with the cylinder head or the bottom and serves
to redure the subsequent surge pressure in the
cylinder by letting the oil escape from the cylin-
der before the piston reaches its stroke end.
Operation
1. Piston valve CLOSED

Pressurized oil from the hydraulic pump acts on
piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction of
the arrow until piston valve seat (4) comes into
snug contact with the tapered section, thereby,
this causing the pressure in the cylinder to rise
and moving piston (2) in the direction of the ar-
row.
2. Piston valve OPEN

Just before piston rod (1) reaches the end of its
stroke, the tip of valve (6) contacts the cylinder
bottom, so valve (6) and piston valve (3) stop at
that position and do not move further. Only pis-
ton (2) moves further.
When this happens, the oil at the cylinder head,
which was sealed by piston valve (3), escapes
from piston valve seats (4) and (5), and the pres-
sure inside the cylinder stops rising.
D275A-5 10-157
MAINTENANCE STANDARD QUICK DROP VALVE
QUICK DROP VALVE

For blade lift cylinder
Unit: mm

Clearance between spool and size Shaft Hole clearance limit
1
valve body
– 0.011 + 0.010 0.011–
38.0 0.03
– 0.016 0 0.026
Replace

2 Valve spring Free length Free length
length load load
136.3N 122.6N
75.2 55.9 67.7
{13.9kg} {12.5kg}
10-158 D275A-5
MAINTENANCE STANDARD PIN PULLER SWITCH
PIN PULLER SWITCH
1. Connector
2. Wire
3. Switch
4. Knob
Function
• The pin puller solenoid valve is controlled by
turning the pin puller switch ON/OFF. This
changes the oil circuit to the pin puller cylinder
and sets the shank mounting pin to the PUSH IN
or PULL OUT position.
D275A-5 10-159
MAINTENANCE STANDARD PIN PULLER SOLENOID VALVE
PIN PULLER SOLENOID VALVE
1. Plug A. To pin puller cylinder bottom

2. Spring B. To pin puller cylinder head
3. Spring retainer P. From power train pump
4. Valve body T. To HSS case
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
10-160 D275A-5
MAINTENANCE STANDARD PIN PULLER SOLENOID VALVE
Operation
1. Pin puller switch at PUSH IN position

When the pin puller switch is set to the PUSH IN
position, no electric current flows to solenoid (9)
and it is deenergized.
Then, ports P and A and ports B and P of spool
(5) open, and the oil from the power train pump
flows from port P to port A, and enters the bot-
tom end of pin puller cylinder (10).
When the oil enters the bottom end of the cylin-
der and the pressure in the circuit starts to rise,
the cylinder extends and pushes shank mount-
ing pin (11) into shank (12).
2. Pin puller switch at PULL OUT position

When the pin puller switch is set to the PULL
OUT position, electricity flows to solenoid (9) and
it is excited. Then, the solenoid pushes out push
pin (8) and spool (5) moves to the left in the ar-
row direction.
At this point, ports P and A and ports B and T
close, and ports P and B and ports A and T
open, so the oil from the power train pump flows
from port P to port B and enters the head end of
pin puller cylinder (10).
When the oil enters the cylinder head end and
the pressure in the circuit rises, the cylinder re-
tracts and pulls shank mounting pin (11) out of
shank (12).
D275A-5 10-161
MAINTENANCE STANDARD BLADE CONTROL KNOB
BLADE CONTROL KNOB
1. Switch (dual-single selector switch) • If switch (1) is set to the DUAL position and the
2. Switch (pitch) lever is operated, blade carries out dual tilt oper-
3. Cover ation. If the lever is tilted to the left, the blade
4. Connector (male) carries out left dual tilt operation. If the lever is
5. Connector (female) tilted to the right, the blade carries out right dual
tilt operation.
Outline
• If switch (1) is set in either DUAL or SINGLE po-
• If the blade control knob is tilted forward, back- sition and the lever is tilted to the right or left
ward, to the right, or to the left, the blade is while switch (2) is pressed and held, the blade is
raised, lowered, tilted to the right, or tilted to the pitched.
left. If switch (1) is set to the DUAL position and
the lever is tilted to the right or left, dual tilt oper-
ation is carried out. If the lever is tilted to the
right or left while (2) is pressed and held, pitching
operation is carried out.
• If switch (2) is pressed and the lever is operated,
the blade is pitched. If the lever is tilted to the
left, the blade is pitched back. If the former is tilt-
ed to the right, the latter is pitched forward.
10-162 D275A-5
MAINTENANCE STANDARD PITCH SELECTOR SOLENOID VALVE
PITCH SELECTOR SOLENOID VALVE
1. Connector OUTLINE
2. Solenoid (b) • The pitch switch solenoid valve is located be-
3. Valve tween the PPC valve and the blade valve, and at
4. Solenoid (a) thedownstream of the pitch tilt switch solenoid
5. Manual push pin valve, and its function is to switch the PPC pilot
A. A port pressure.
B. B port • By operating the pitch back switch or the pitch
P. P port dump switch of the blade control lever, the pilot
T. T port pressure can be delivered to the left pitch cylin-
der and the right pitch cylinder, and it enables to
switch from the tilt to the pitch.
• In addition, the pitch solenoid valve is operated
by the controller.
D275A-5 10-163
(4)
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Standard specification
Cautions for tightening bolts marked with ª
Tighten the 3 bolts in the following 3 steps so
that they will be tightened equally.
1st time: 58.8 ±9.8 Nm {6 ± 1 kgm}
2nd time: 137.3 ± 9.8 Nm {14 ± 1 kgm}
3rd time: 186.3 ± 9.8 Nm {19 ±1 kgm}
A: Pump pressure pick-up port LS: To work equipment pump LS valve

B: LS pressure pick-up port P1: From pump
C: PPC main pressure PR: PPC output
T: Drain TS: Seal drain
A1: To blade tilt right cylinder head PA1: From blade PPC valve port P3
A2: To blade lift cylinder head PA2: From blade PPC valve port P1
A3: To ripper lift cylinder head PA3: From ripper PPC valve port P3
A4: To ripper tilt cylinder bottom PA4: From ripper PPC valve port P1
B1: To blade tilt right cylinder bottom PB1: From blade PPC valve port P4
B2: To blade lift cylinder bottom PB2: From blade PPC valve port P2
B3: To ripper lift cylinder bottom PB3: From ripper PPC valve port P4
B4: To ripper tilt cylinder head PB4: From ripper PPC valve port P2
10-166 D275A-5
(4)
1. Valve block 5. Blade tilt spool

2. Ripper tilt spool 6. Valve body
3. Ripper lift spool 7. Load check valve
4. Blade lift spool 8. Pressure compensation valve
Unit: mm
Standard size Repair limit Replace

Free length
Spool return spring x Outside Free length
9 length load load
(only for blade lift) diameter
223.4N 178.4N
76.3 × 30 68.5 –
{22.8kg} {18.2kg}
140.1N 111.7N
10 Spool return spring 51.7 × 31.3 50 –
{14.3kg} {11.4kg}
If damaged or
Spool return spring 216.6N 173.5N deformed,
11 54.7 × 36.5 32.5 –
(for blade lift FLOAT) {22.1kg} {17.7kg} replace spring
12.7N 9.8N
12 Load check valve spring 20.8 × 10.2 13.5 –
{1.3kg} {1.0kg}
Pressure compensation valve 562N 449N
13 108.3 × 29.5 81 –
192.4N 154N
14 Unload spring 86.7 × 30 66 –
{19.63kg} {15.7kg}
D275A-5 10-167
1. LS check valve 5. Unload valve

2. Main relief valve 6. Suction valve
3. LS relief valve 7. Check valve (built in spool)
4. Self-pressure reducing valve
Unit: mm

Free length
x Outside Free length
8 Suction valve spring length load load
diameter
6.37N 5.1N
64.9 × 12.5 56 – If damaged or
{0.65kg} {0.52kg}
deformed,
14.7N 11.8N replace spring
9 Check valve spring in spool 27.9 × 6.5 22.5 –
{1.5kg} {1.2kg}
0.29N 0.20N
{0.03kg} {0.02kg}
10-168 D275A-5
1. Suction valve 3. LS bypass valve

2. Preset check valve
Unit: mm
Free length
× Outside Free length
4 Suction valve spring length load load deformed,
diameter
replace spring
5.49N 4.4N
46.8 × 7.5 40.6 –
{0.56kg} {0.45kg}
D275A-5 10-169
Dual tilt specification

Cautions for tightening bolts marked with ª
Tighten the 3 bolts in the following 3 steps
so that they will be tightened equally.
1st time: 58.8 ±9.8 Nm {6 ± 1 kgm}
2nd time: 137.3 ± 9.8 Nm {14 ± 1 kgm}
3rd time: 186.3 ± 9.8 Nm {19 ±1 kgm}
A: Pump pressure pick-up port LS: To work equipment pump LS valve

B: LS pressure pick-up port P1: From pump
C: PPC main pressure PR: PPC output
T: Drain TS: Seal drain
A1: To blade tilt right cylinder head PA1: From dual tilt and pitch changeover valve
A2: To blade lift cylinder head PA2: From blade PPC valve port P1
A3: To blade tilt left cylinder head PA3: From dual tilt and pitch changeover valve
A4: To ripper lift cylinder head PA4: From ripper PPC valve port P3
A5: To ripper tilt cylinder bottom PA5: From ripper PPC valve port P1
B1: To blade tilt right cylinder bottom PB1: From dual tilt and pitch changeover valve
B2: To blade lift cylinder bottom PB2: From blade PPC valve port P2
B3: To blade tilt left cylinder bottom PB3: From dual tilt and pitch changeover valve
B4: To ripper lift cylinder bottom PB4: From ripper PPC valve port P4
B5: To ripper tilt cylinder head PB5: From ripper PPC valve port P2
10-170 D275A-5
(4)
1. Valve block 6. Blade tilt right spool

2. Ripper tilt spool 7. Valve body
3. Ripper lift spool 8. Load check valve
4. Blade tilt left spool 9. Pressure compensation valve
5. Blade lift spool
Unit: mm

Free length
Spool return spring Installed Installed Installed
10 × Outside Free length
(only for blade lift) length load load
diameter
223.4N 178.4N
76.3 × 30 68.5 –
{22.8kg} {18.2kg}
140.1N 111.7N
11 Spool return spring 51.7 × 31.3 50 –
{14.3kg} {11.4kg} If damaged or
Spool return spring 216.6N 173.5N deformed,
12 54.7 × 36.5 33.5 –
(for blade lift FLOAT) {22.1kg} {17.7kg} replace spring
12.7N 9.8N
13 Load check valve spring 20.8 × 10.2 13.5 –
{1.3kg} {1.0kg}
Pressure compensation valve 562N 449N
14 108.3 × 29.5 81 –
192.4N 154N
15 Unload spring 86.7 × 30 66 –
{19.63kg} {15.7kg}
D275A-5 10-171
1. LS check valve 5. Unload valve

2. Main relief valve 6. Suction valve
3. LS relief valve 7. Check valve (built in spool)
4. Self-pressure reducing valve
Unit: mm

Free length
8 Suction valve spring × Outside Free length
length load load
diameter
6.37N 5.1N If damaged or
64.9 × 12.5 56 –
{0.65kg} {0.52kg} deformed,
14.7N 11.8N replace spring
{1.5kg} {1.2kg}
0.29N 0.20N
{0.03kg} {0.02kg}
10-172 D275A-5
1. Suction valve 3. LS bypass valve

2. Preset check valve
Unit: mm

Free length
× Outside Free length
4 Suction valve spring length load load deformed,
diameter
replace spring
5.49N 4.4N
46.8 × 7.5 40.6 –
{0.56kg} {0.45kg}
D275A-5 10-173
MAINTENANCE STANDARD OPERATION OF CONTROL VALVE
OPERATION OF CONTROL VALVE
FUNCTION
• When the main spool is at the HOLD position, it
drains the excess oil discharged by the pump,
and prevents the pressure from being formed in
the circuit from rising.
OPERATION
1 At hold (operation of unload valve)
(1) When the main spool is at the HOLD posi- (3) When FO becomes larger than set load FS of
tion, the pump pressure passes from cham- spring (2), the spool moves to the right and con-
ber A through Oriffice (4) to chamber D. nects the passage between chamber A and
Chambers C and C' are connected to the chamber B, so the oil from the pump is drained.
drain circuit. Therefore, spool (1) is balanced at a position that
(2) When oil is supplied from the pump, the matches the supply of oil from the pump.
pressure in chamber D rises, and spool (1) is Actually, the amount of oil supplied from the
pushed to the right by pressure FO which is pump is small, so the pressure in the circuit is al-
determined by the cross-sectional area of most the same as the set load of spring (2).
piston (3) receiving the pressure.
10-174 D275A-5
(4)
2 Control of oil flow

(1) Work equipment valve (Following explanation is
for blade right tilt cylinder circuit)
• Use of the CLSS circuit (Closed Center Load
Sensing System) makes it possible to control the
oil flow by adjusting the area of opening of the
spool driven by the PPC valve, regardless of the
load.
1) At HOLD
When the spool is at the HOLD position, the spool (3) of the pressure compensation valve, so
pump pressure is sent from chamber A through it pushes against the load of spring (4) and
the notch in spool (3) of the pressure compensa- moves to the right to the maximum stroke posi-
tion valve, and passes through chamber B to tion. In this condition, the area of the opening to
chamber C. Chamber G is drained through spool (1) of the blade tilt valve is at its minimum.
chamber H to chamber F. When this happens,
the pump pressure is acting on the left end of
D275A-5 10-175
(4)
2) At blade right tilt
1 When the tilt lever is operated to right tilt, pilot • ∆PLS = differential pressure between ports
pressure PB1 acts on the right end of spool (1) K and J = 1.96 MPa {20kg/cm2}
through the PPC valve, and when the pressure • ∆PLS' = differential pressure between ports
becomes greater than the set load of spring (2), I and D
the spool starts to move to the left. It is balanced • ∆PLS ≈ ∆PLS'
at a position corresponding to PPC output pres-
sure PB1.
10-176 D275A-5
(4)
2 Chamber C and chamber D are connected, and

the oil from the pump flows through ports A, B,
C, and D to tilt cylinder (6). At the same time, the
load pressure in chamber D passes through LS
orifice (5) and chamber H, and is sent to cham-
ber G. It is also sent from the LS circuit O to
pump servo valve (7).
3 The condition of the pressure of spool (3) is
chamber B pressure ≈ chamber C pressure, and
chamber G pressure ≈ chamber D pressure, so
spool (3) is controlled by the differential pressure
of spool (1) (chamber C pressure - Chamber D
pressure), and balances with spring (4).
In other words, if the oil flow is too large, the dif-
ferential pressure of spool (1) becomes larger,
so spool (3) moves in the direction to throttle the
oil flow; on the other hand, if the oil flow is too
small, spool (3) moves in the direction to in-
crease the oil flow.
4 In addition, pump servo valve (7) is controlled so

that the differential pressure between pump
pressure P and LS pressure LS (LS differential
pressure: ∆PLS) remains constant, so a suitable
amount of oil flows to ensure that the loss of
pressure at the control valve (∆PLS') is equal to
∆PLS. The loss of pressure in the control valve
is determined by the area of the opening of the
main spool, so the oil flow matches the opening
of the spool.
5 The return oil flow from the tilt cylinder passes
through chamber E and chamber F, and is
drained.
D275A-5 10-177
(4)
3) Meter-out control when blade moves down under its own weight (work equipment lever at LOWER)
10-178 D275A-5
• In the case where the blade falls owing to the

weight of the blade, the return flow from a cylin-
der is controlled according to the opening area of
main spool (1).
• Oil flows from the suction valve (2) to a cylinder

so that it prevents the circuit from being evacuat-
ed.
1) When a spool port opens with PPC output

pressure at PA2, oil on the cylinder head
side passes through ports A, B and D and
then drains into the tank owing to the weight
of the blade. At this time, the opening area
between ports A and B squeezes the return
flow from a lift cylinder in order to control the
drop speed.
2) In the case where the blade falls owing to the
weight of the blade, oil on the cylinder head
side passes through a drain circuit and the
suction valve (2) and then it is supplied to the
cylinder bottom side. At the same time, the
output flow from the pump passes through
ports A1, B1, C1, D1 and E1 and then it is
supplied to the cylinder bottom side.
D275A-5 10-179
(4)
4) Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT)
10-180 D275A-5
(4)
• When the lift valve is at FLOAT, the cylinder port

and drain port are connected to put the circuit in
a no-load condition.
• When the lift valve is in the FLOAT condition, the
pump passage and cylinder ports A3 and B3 are
separated so that the other control valves can be
operated.
1) When the work equipment control lever is at
the FLOAT position, if pressure PA3 be-
comes 3.4 MPa (35 kg/cm 2 ) or more, lift
spool (1) is moved to the maximum stroke
position.
2) In this condition, ports A3 and B3 and the LS
passage O are all connected to the drain cir-
cuit, so there is no load on the lift cylinder.
3) If the cylinder is driven by the weight of the
blade, the oil entering from A3 flows to ports
A, B, B1 and A1, while the rest of the oil
flows through port D, and is drained. The oil
from suction valve (9) flows to port B3. When
this happens, the oil flow is throttled by the
area of opening between ports A and B of
spool (1), and the cylinder speed is con-
trolled.
4) The pump circuit chamber E and ports A3
and B3 are separated, and pump pressure P
is formed, so it is possible to carry out com-
pound operations with other control valves.
D275A-5 10-181
(4)
3. At relief
(1) Blade lift, blade tilt, ripper lift, ripper tilt
★ The diagram shows the condition at relief for work equipment LS relief valve (5) with blade tilt stroke end.
• ∆P1 = ∆P3 + ∆P4 = Differential pressure be- • ∆P4 = Differential pressure between ports B and
tween ports M and P P
• ∆P2 = Differential pressure between ports P and • ∆LS = ∆P1 + ∆P2 = Differential pressure
N between ports M and N = 1.96 MPa (20 kg/cm2)
• ∆P3 = Differential pressure between ports M and
B
10-182 D275A-5
(4)
1) If blade tilt valve (1) is moved, and the pres-

sure of tilt cylinder (8) becomes higher, work
equipment LS relief valve (5) will crack and
oil will be drained from LS circuit O. (Ports P,
F, G, J, and K). As a result, there will be a
drop in pressure in LS passage O starting
from LS sensing hole F, and ∆P2 will become
larger.
2) For the same reason, if the pressure in
chamber I and H drops, spool (2) will push
against spring (3) and move to the right, and
will make the opening between chambers B
and C smaller, so the flow between cham-
bers B and C will be throttled and ∆P4 will
become larger.
3) Because of the pump swash plate control,
the system circuit is balanced at a circuit
pressure which makes the pressure loss
generated by the flow at work equipment LS
relief valve (5) ∆P1 + ∆P2 equal to LS differ-
ential pressure (∆LS). When this happens,
pump LS valve (6) detects the differential
pressure generated by LS relief valve (5),
and moves the pump swash plate from the
maximum to the minimum position where the
LS differential pressure is 1.96 MPa (20 kg/
cm2).
4) When the pump is at the minimum swash
plate angle (minimum oil flow), if the mini-
mum oil flow is greater than the LS relief oil
flow + leakage at any part, the pressure is
confined in the pump circuit (between the
pump and chambers A and chamber B
through pressure compensation valve (7)),
so the LS differential pressure rises. If this
differential pressure goes above the set
pressure for unload valve (4), the unload
valve is actuated to relieve the excess oil
flow and balance the circuit.
D275A-5 10-183
(2) Compound operation of work equipment valve

★ The diagram shows the condition when the blade lift and tilt valves are operated at the same time.
10-184 D275A-5
• It consists of a parallel circuit, so when com-

pound operations are carried out, the oil flow is
divided according to the size of each spool open-
ing.
1) Tilt spool (1) and lift spool (2) are actuated by

PPC valve output pressure PA1 and PB2,
and each is balanced at a position that
matches its own pilot pressure.
2) When pressure P2≤ ≤ P3

Lift valve load pressure P3 is sent to pump
LS valve (4) through LS passage O.
1 When pump swash plate does not reach

maximum angle
When the maximum flow of oil from the
pump is greater than the total of the oil flow
demanded by the tilt valve and lift valve, an
oil flow that matches the opening of the spool
flows to both the tilt valve and lift valve.
2 When pump swash plate is at maximum an-

gle
When the maximum flow of oil from the
pump is smaller than the total of the oil flow
demanded by the tilt valve and lift valve, the
flow of oil to the tilt valve and lift valve is di-
vided according to differential pressure PO -
P2 and differential pressure PO - P3. In other
words, more oil flows to P2 where the load is
small.
★ In cases where the blade is raised in the air

and the tilt valve and lift valve (for raise) are
operated at the same time, the tilt valve load
pressure is smaller than the lift valve load
pressure, so the flow of oil to the tilt valve is
given priority. In addition, the oil flow de-
manded by the tilt valve is smaller, so the
condition is just as if priority was given to the
oil flow for the tilt valve.
3) When pressure P2 = pressure P3

P - P2 ≈ P - P3, so an oil flow proportional to
the size of the spool opening is distributed to
each spool.
D275A-5 10-185
(3) Unload valve preset system

★ The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is op-
erated.
10-186 D275A-5
(4)
• This improves the response of the system in-

cluding the pump swash plate and pressure
compensation valve by sending the pilot pres-
sure (basic pressure of PPC valve) to the LS cir-
cuit, and compensating the rise of the LS circuit
pressure.
(1) When lift spool (1) is at the HOLD position, pilot

pressure P1 (basic pressure of PPC valve) is
sent through preset check valve (3) to the cham-
ber F of the pressure compensation valve. This
pressure is called preset pressure P2. At the
same time, unload pressure P is being sent to
chamber B, but P1 + FO > P (FO: load of spring
(4)), so pressure compensation spool (2) moves
to the left and the size of the opening between A
and B becomes the maximum.
(2) When spool (1) is switched, unload pressure P

flows immediately through chamber A, B, C, D,
and E to lift cylinder (8), so the pressure at the
port starts to rise and the time lag becomes
smaller.
(3) At the same time, preset pressure P2 is supplied

to LS circuit O by the timing of the spool, and the
pressure in the LS circuit rises. Because of this,
unload valve (7) closes, and oil is sent further to
pump LS valve (6) to improve the response of
the pump swash plate angle. This makes it pos-
sible to reduce the response time for giving the
necessary oil flow. Check valve (5) is built into
the spool to prevent preset pressure P2 from
venting in force from the cylinder port.
(4) When cylinder port pressure P3 rises and be-

comes greater than preset pressure P2, it
pushed up check valve (5), and oil is sent to
chamber F of the pressure compensation valve
and pump LS valve (6) to give the basic ∆PLS
control.
When this happens, pressure P3 at the cylinder
port is prevented from entering the PPC pump
circuit by preset check valve (3).
D275A-5 10-187
(4)
(4) Dual tilt and pitch system

★ A machine with the dual tilt specification has the dual tilt and pitch system circuit.
1) When single tilt operation is carried out
• In the single tilt mode, solenoid valve (1) is in the

neutral position and connected to PA3 and PB3
of the control valve as shown in the figure. PPC
circuits (2) and (3) are separated from output cir-
cuits (4) and (5) of the PPC valve.
Accordingly, the right tilt cylinder does not move
and only the left tilt cylinder moves to carry out
the single tilt operation.
10-188 D275A-5
(4)
2) When dual tilt operation is carried out
• In the dual tilt mode, solenoid changeover valve

(1) is changed as shown in the figure.
At this time, PPC circuit (2) connected to PB1 of
the control valve is connected to output circuit (4)
of the PPC valve.
PPC circuit (3) connected to PA1 of the control
valve is connected to output circuit (5) of the
PPC valve.
Accordingly, both tilt cylinders move in the oppo-
site directions to carry out the dual tilt operation.
D275A-5 10-189
3) When pitch operation is carried out
• In the pitch mode, solenoid changeover valve (1)

is changed as shown in the figure.
At this time, PPC circuit (2) connected to PB1 of
the control valve is connected to output circuit (5)
of the PPC valve.
PPC circuit (3) connected to PA1 of the control
valve is connected to output circuit (4) of the
PPC valve.
Accordingly, both tilt cylinders move in the same
direction to carry out the pitch operation.
10-190 D275A-5
MAINTENANCE STANDARD SELF-REDUCING PRESSURE VALVE
SELF-REDUCING PRESSURE VALVE
P1 : From pump
P2 : To control valve
PC : To front pump LS valve
PR : Supply to PPC valve etc.
TS : To hydraulic tank
D275A-5 10-191
1. Valve (sequence valve) 6. Spring (reducing valve main)

2. Spring 7. Valve (reducing valve)
3. Screw 8. Spring (safety valve)
4. Poppet 9. Ball
5. Spring (reducing valve pilot)
10-192 D275A-5
Unit: mm

Free length
Spring × Outside Free length
10 length load load
(reducing pressure valve, main) diameter
19.6N 17.7N
19.2 × 7.2 16.1 –
{2kg} {1.8kg} Replace spring if
Spring 28.0N 22.4N any damages or
11 17.8 × 7.2 12.7 – deformations are
(reducing pressure valve, pilot) {2.86kg} {2.29kg}
found.
199.8N 186.2
12 Spring 71 × 18 59 –
{20.4kg} {19kg}
61.7N 58.8N
13 Spring (safety valve) 16.1 × 7.8 13.4 –
{6.3kg} {6kg}
D275A-5 10-193
Function
• The self-pressure reducing valve lowers the dis-
charge pressure of the main pump and supplies
control pressure to the solenoid valves, PPC
valves, etc.
Operation
1. When engine is stopped

• Poppet (5) is pressed against the seat by
spring (6) and the passage between ports
PR and T is closed.
• Valve (8) is pressed downward by spring (7)

and the passage between ports P1 and PR
is opened.
• Valve (2) is pressed to the left by spring (3)
and the passage between ports P1 and P2 is
closed. (See Fig. 1.)
10-194 D275A-5
(4)
2. When in neutral or load pressure P2 is low

(When blade is moving under its own weight)
Note:When load pressure P2 is lower than output • If the PR pressure rises above the set level, pop-
pressure PR of the self-pressure reducing pet (5) opens and the hydraulic oil flows from the
valve. PR port through hole a in spool (8) and opening
• Valve (2) receives the force of spring (3) and PR of poppet (5) to tank port T.
pressure (which is 0 MPa {0 kg/cm2} when the Accordingly, differential pressure is generated
engine is stopped) in the direction to close the between before and after hole a in spool (8) and
circuit between ports P1 and P2. If the hydraulic then spool (8) moves to close the passage be-
oil flows in from port P1, the P1 pressure between port P1 and PR. The P2 pressure is con-
comes almost equal to the total of the force of trolled constant (at the set pressure) by the area
spring (7) and the value of area of φd x PR pres- of the oil passage at this time and supplied as
sure, then the area of the passage between the PR pressure. (See Fig. 2.)
ports P1 and P2 is so adjusted that the P1 pres-
sure will be kept constant above the PR pres-
sure.
D275A-5 10-195
(4)
3. When load pressure P2 is high
• If load pressure P2 rises and the pump dis- • If the PR pressure rises above the set pressure,
charge increases because of digging operation poppet (5) opens and the hydraulic oil flows from
of the work equipment, etc., the P1 pressure ris- the PR port through hole a in spool (8) and open-
es higher than the total of the force of spring (7) ing of poppet (5) to tank port T.
and the value of φ d x PR pressure, and then Accordingly, differential pressure is generated
valve (2) moves to the right stroke end. between before and after hole a in spool (8) and
As a result, the area of the passage between then spool (8) moves to close the passage be-
ports P1 and P2 increases and the passage re- tween port P1 and PR. The P1 pressure is low-
sistance lowers and the loss of the engine power ered and controlled constant (at the set
is reduced. pressure) by the area of the oil passage at this
time and supplied as the PR pressure. (See Fig.
3.)
10-196 D275A-5
(4)
4. When abnormally high pressure is generated
• If the PR pressure on the self-pressure reducing

valve rises high abnormally, ball (10) separates
from the seat against the force of spring (9) and
the hydraulic oil flows from output port PR to T.
Accordingly, the PR pressure lowers. By this op-
eration, the hydraulic devices (PPC valves, sole-
noid valves, etc.) are protected from abnormally
high pressure. (See Fig. 4.)
D275A-5 10-197
MAINTENANCE STANDARD CYLINDER STAY
CYLINDER STAY
1. Yoke 4. Bushing
2. Oil seal 5. Air Breather plug
3. Bushing
Unit: mm

Clearance between cylinder yoke
6
and bushing
– 0.172 + 0.088 0.218–
140 –
– 0.235 + 0.046 0.323
Replace
Clearance between cylinder yoke – 0.160 + 0.075 0.199–
7 105 –
and bushing – 0.214 + 0.039 0.289
Clearance between lift cylinder – 0.120 + 0.035 0.120–

8 95 0.5
support shaft and bushing – 0.207 0 `0.242
10-198 D275A-5
10 STRUCTURE, FUNCTION AND MAINTENANCE
MAINTENANCE STANDARD BLADE
BLADE
Semi U-dozer
10-200 D275A-5
Unit: mm

Clearance between brace and size Shaft Hole clearance limit
1
brace
– 0.3 + 0.5 Replace
70 0.6–1.0 2
– 0.5 + 0.3
Clearance between brace pin and – 0.3 + 0.5

2 70 0.6–1.0 2
bracket – 0.5 + 0.3
Clearance between brace spheri- – 0.2 + 0.3

3 115 0.2–0.6 1
cal surface and cap – 0.3 0 Adjust shim or
Clearance between center brace – 0.2 + 0.3 replace
4 130 0.2–0.6 1
spherical surface and cap – 0.3 0
Clearance between joint and – 0.2 + 0.5

5 170 0.5–1.2 2
blade bracket – 0.7 + 0.3

6 170 0.5–1.2 2
frame – 0.7 + 0.3
Clearance between frame pin – 0.3 + 0.3

7 60 0.3–0.8 3
and joint – 0.5 0
Replace
8 60 0.3–0.8 3
and frame – 0.5 0
Clearance between blade bracket – 0.3 + 0.3

9 60 0.3–0.8 3
pin and joint – 0.5 0

10 60 0.3–0.8 3
pin and blade – 0.5 0
Clearance between center brace – 0.2 + 0.3 Adjust shim or

11 130 0.2–0.6 1
spherical surface and cap – 0.3 0 replace
Clearance between center link – 0.04 + 0.3

12 115 0.14–0.40 2
pin and center link – 0.10 + 1.0

13 115 0.14–0.40 2
pin and blade bracket – 0.10 + 1.0
Replace
14 400 0.2–0.9 2
and blade bracket – 0.4 0
Clearance between trunnion and – 0.5 + 1.0

15 195 0.5–2.0 8
cap spherical surface – 1.0 0
D275A-5 10-201
(8)
U-dozer
10-202 D275A-5
Unit: mm

Clearance between brace and size Shaft Hole clearance limit
1
brace
– 0.3 + 0.5 Replace
70 0.6–1.0 2
– 0.5 + 0.3
Clearance between brace pin and – 0.3 + 0.5

2 70 0.6–1.0 2
bracket – 0.5 + 0.3
Clearance between brace spheri- – 0.2 + 0.3

3 115 0.2–0.6 1
cal surface and cap – 0.3 0 Adjust shim or
Clearance between center brace – 0.2 + 0.3 replace
4 130 0.2–0.6 1
spherical surface and cap – 0.3 0

5 170 0.5–1.2 2
blade bracket – 0.7 + 0.3

6 170 0.5–1.2 2
frame – 0.7 + 0.3

7 60 0.3–0.8 3
and joint – 0.5 0
Replace
8 60 0.3–0.8 3
and frame – 0.5 0

9 60 0.3–0.8 3
pin and joint – 0.5 0

10 60 0.3–0.8 3
pin and blade – 0.5 0
Clearance between center brace – 0.2 + 0.3 Adjust shim or

11 130 0.2–0.6 1
spherical surface and cap – 0.3 0 replace

12 115 0.14–0.40 2
pin and center link – 0.10 + 1.0

13 115 0.14–0.40 2
pin and blade bracket – 0.10 + 0.1
Replace
14 400 0.2–0.9 2
and blade bracket – 0.4 0
Clearance between trunnion and – 0.5 + 1.0

15 195 0.5–2.0 8
cap spherical surface – 1.0 0
D275A-5 10-203
(8)
Cutting edge, end bit
Unit: mm

1 Height of outside of end bit
415 300
Replace
2 Width of end bit 662 500
3 Height of inside of end bit 330 260
4 Height of cutting edge 330 260 (215 to turning) Turn or replace
10-204 D275A-5
MAINTENANCE STANDARD RIPPER EQUIPMENT
RIPPER EQUIPMENT
Variable multiple shank ripper
10-206 D275A-5
MAINTENANCE STANDARD RIPPER EQUIPMENT
Giant ripper
Unit: mm

Clearance between bushing and
1
bracket and arm mount pin
– 0.036 + 0.207 0.156–
110 1.5
– 0.090 + 0.120 0.297
Clearance between bushing and – 0.036 + 0.207 0.156–

2 120 1.5
beam and arm mount pin – 0.090 + 0.120 0.297
Clearance between cylinder – 0.036 + 0.207 0.156–

3 90 1.5 Replace
mount pin and bushing – 0.090 + 0.120 0.297
Clearance between shank and Standard size Tolerance Repair limit

4
mount pin
82 ± 0.3 –

5 Wear of point
420 255
6 Wear of protector 155 115
D275A-5 10-207
MAINTENANCE STANDARD CAB MOUNT
CAB MOUNT
1. Support Outline
2. Damper mount (front) • Viscous mounts are installed at two places at the
3. Damper mount (rear) front and two places at the rear to secure the
floor frame and cab.
• An oil-filled damper mount is used to absorb the
vibration.
10-208 D275A-5
MAINTENANCE STANDARD CAB
CAB
Cab assembly
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
D275A-5 10-209
MAINTENANCE STANDARD CAB
ROPS guard
1. ROPS guard
10-210 D275A-5
MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
Air conditioner piping
1. Air conditioner compressor 9. Valve (hot water outlet)

2. Condenser 10. Receiver tank
3. Window defroster 11. Hot water return piping
4. Side defroster 12. Valve (hot water inlet)
5. Air conditioner unit 13. Refrigerant piping
6. Vent A. Fresh air
7. Blower motor B. Recirculated air
8. Hot water pick-up piping C. Hot air/cold air
D275A-5 10-211
MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Decelerator pedal Outline

2. Starter switch • The throttle signal and throttle dial are input to
3. Decelerator potentiometer the steering controller and transmission control-
4. Steering controller ler and processed together with the other infor-
5. Transmission controller mation, then the result is sent as the throttle
6. Fuel throttle dial command to the engine controller. The engine
7. Engine controller controller controls the fuel supply pump accord-
8. Battery ing to the command.
9. Battery relay
10. Starter
11. Fuel supply pump
10-212 D275A-5
MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
Outline
• The engine controller receives the manual sig- • The information of the engine controller is used
nals of the 2nd throttle and the 3rd throttle sig- commonly by the all controllers through the net-
nals which is the control signals from the work for the optimum control of the engine and
machine body, then selects the lower engine machine body.
speed and controls the fuel supply pump. • The automatic deceleration function sets the en-
The 3rd throttle control signals contain the fol- gine speed to 1,000 rpm temporarily when the
lowing. travel direction is changed from F3, R3, or R2 (to
1 1st throttle signal protect the transmission clutch).
2 Automatic deceleration (F3, R3, R2)
• The steering controller selects the lowest engine

speed from information 1 and 2 and transmits
it as the 3rd throttle to the engine controller.
D275A-5 10-213
MAINTENANCE STANDARD DECELERATION POTENTIOMETER
DECELERATION POTENTIOMETER
1. Connector Outline
2. Lever • The deceleration potentiometer is installed to the
3. Body front lower part of the operator's cab and con-
4. Potentiometer nected to the decelerator pedal by linkage.
5. Coupling
6. Shaft • If the decelerator pedal is pressed, the throttle
7. Stopper potentiometer shaft rotates by the linkage and
the potentiometer resistance changes.
Constant voltage is applied between pins A and
C of the potentiometer and an electric signal is
sent through pin B to the engine controller ac-
cording to the position of the decelerator pedal.
10-214 D275A-5
MAINTENANCE STANDARD CRI ENGINE CONTROL SYSTEM
CRI ENGINE CONTROL SYSTEM

★ "CRI" is an abbreviation for Common Rail Injection.
System diagram
Outline
• The signals detected by various sensors are in-
put to the engine controller.
• The input signals are processed by the controller
and output to each actuator to control the fuel in-
jection rate and fuel injection timing.
10-216 D275A-5
MAINTENANCE STANDARD CRI ENGINE CONTROL SYSTEM
1. Fuel tank System configuration

2. Fuel supply pump assembly • The CRI system consists of fuel supply pump
2A. PCV (2), common rail (5), injector (8), ECU (10) to
2B. High pressure pump control them, and sensors.
2C. Priming pump • The fuel supply pump generates fuel pressure in
2D. Feed pump the common rail. The fuel pressure is controlled
2E. Bypass valve by the fuel discharge rate of the supply pump.
2F. G speed sensor The discharge rate is controlled by turning on
3. Fuel filter and off PCV (discharge control valve) (2A) of the
4. Overflow valve fuel supply pump according to the electric sig-
5. Common rail nals from the ECU.
6. Pressure limiter The common rail receives the pressurized fuel
7. Flow damper from the fuel supply pump and distributes it to
8. Injector assembly the cylinders.
8A. Orifice The fuel pressure is sensed by the common rail
8B. Control chamber fuel pressure sensor installed to the common rail
8C. Hydraulic piston and controlled by the feedback method so that
8D. Injector the actual fuel pressure will match to the com-
8E. Nozzle mand pressure set according to the engine
9. Fuel cooler speed and the load on the engine.
10. ECU (Engine Control Unit) The fuel pressure in the common rail is applied
11. NE speed sensor to the nozzle (8E) side of the injector and control
chamber (8B) through the fuel injection pipe of
each cylinder.
• The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve). If the TWV is
turned on, the fuel circuit is so changed that the
high-pressure fuel in the control chamber will
flow through orifice (8A). The needle valve is
raised to start fuel injection by the nozzle crack-
ing pressure applied as the high-pressure fuel on
the nozzle side. If the TWV is turned off, the fuel
circuit is so change that the high-pressure fuel
will be applied to the control chamber through
the orifice. As a result, the needle valve lowers
and finishes fuel injection. Accordingly, the fuel
injection timing and fuel injection rate are con-
trolled respectively by the timing to turn on the
TWV and the length of the turn-on time of the
TWV.
D275A-5 10-217
MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
• The monitor system monitors the machine con- • The CPU (Central Processing Unit) in it process-
dition with the sensors installed to various parts es, displays, and outputs the information. The
of the machine and processes and displays the display unit is LCD (Liquid Crystal Display) and
obtained information on the panel quickly to no- the switches are seat switches.
tify the operator of the machine condition.
The main display sections and functions of the
panel are as follows.
1) Monitor unit which turns on the alarm when
the machine has a trouble.
2) Gauge unit which constantly displays the
machine condition (coolant temperature,
torque converter oil temperature, fuel level,
etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and volt-
age of the sensors and solenoids.
10-218 D275A-5
MAINTENANCE STANDARD MONITOR SYSTEM
Processing in monitor panel (Common to all specifications)

Display of monitor panel
1 Contents and conditions of processing 2 Method 3 Flow of signals
1) Display of travel direction and gear speed.
F1, R3, etc. are notified by CAN according to information Transmission controller–Steering
of transmission controller. controller–Monitor panel
2) Display of engine speed in gauge number. CAN Engine speed sensor–Engine

The number of pulses the engine rotation is converted (Controller Area Network) controller– Steering controller–
into a gauge number and notified to the monitor panel by Monitor panel
CAN.
3) Display of troubleshooting CAN

When the machine has a trouble, the corresponding fail- Each sensor/solenoid–Control-
ure code is notified to the monitor panel by CAN. ler–Monitor panel
Which one should be turned on, the buzzer or the cau-
tion lamp, is notified, too.
1 In normal state
User code
2 In trouble 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 occurrences
The monitor panel displays the code on the hour meter
section.
Display of monitoring condition

1) The communication conditions of each sensor, each so- CAN
lenoid, and CAN are displayed.
The item Nos. and device conditions are notified to the Each sensor–Controller–Monitor
monitor panel by CAN. panel
The monitor panel displays the items and each value on
its multi-information section.
2) Each items is selected by using the cursor switches, se- Monitor panel–Controller–Monitor
lector switches, buzzer cancel switch, and shift UP/ panel
DOWN switches.
Other items
1) Function selection mode (Displayed each time cancel
switch is turned to left)
1 Replacement periods of oil filter and oil are dis-
played.
2 Engine speed, oil pressure in work equipment cir-
cuit, etc. are displayed.
3 Failure codes related to electronic control are dis-
played. — —
4 Brightness of display, etc. are adjusted.
2) Mode to change replacement periods of maintenance
mode
3) Mode to display failure codes related to machine body
such as overheating, abnormal water temperature, etc.
4) Mode to display service meter and information related to
load on machine
D275A-5 10-219
(4)
MAINTENANCE STANDARD MONITOR PANEL
MONITOR PANEL
Monitor portion
1. Display plate (Speed range display) 9. Engine water temperature caution lamp
2. Charge lamp 10. Dual tilt display lamp
3. Power train oil temperature gauge 11. Engine oil pressure caution lamp
4. Engine water temperature gauge 12. Maintenance caution lamp
5. Fuel gauge 13. Preheat pilot lamp
6. Hydraulic oil temperature gauge 14. Radiator water level check lamp
7. Hydraulic oil temperature caution lamp 15. Display plate (Multi information)
8. Power train oil temperature caution lamp
Outline 3. Cautions
• The monitor portion consists of a monitor that is- Caution items are checked until the engine stops
sues an alarm when an error occurred in a vehi- after the engine starts.
cle, a gauge that always displays the state of the If an error occurs, the error is displayed by flash-
vehicle, and the service meter. ing and the alarm lamp synchronously flashes.
The monitor portion installs a microcomputer Further, if an emergency item flashes, the alarm
and processes and displays signals from each buzzer also sounds synchronously.
sensor. ★ Flashing of the monitor and alarm lamp is re-
Besides, the items displayed on the monitor por- peated. They come on and off for about 0.8 sec-
tion and gauge portion are listed in the table on ond.
the next page. ★ The flashing period of the monitor slightly chang-
es when atmospheric temperature is low (below
Operation
about - 10°C), but this case in not abnormal.
1. When the power turns on (When the starter
switch is ON)
1) All items of the gauge and monitor portions
come on for three seconds.
2) The alarm lamp comes on for two seconds.
2. Star-up inspection
1) After all lighting of Section 1 is terminated, if
there is an error in a start-up inspection item,
the item flashes.
2) If the engine is started, the check items be-
fore starting go off. (If the engine is running
is judged by the signal (CAN) from the en-
gine controller.)
10-220 D275A-5
Monitor panel display

Display
Symbol Display item Display range Display method
category
Displays when engine is stopped and

starting switch is ON
Radiator water level Below low level
Display when normal: OFF
Display when abnormal: Flashes
Check
When sensor is abnormal

Engine oil pressure or when wiring harness is
Display when abnormal: ON
disconnected
Displays when starting switch is ON and

Caution 1
engine is running
Battery charge When charge is defective Display when normal: OFF
SAP00522 Display when abnormal: Flashes
CAUTION lamp flashes
Below 49.0kPa
Engine oil pressure
{0.5kg/cm2}
Radiator water level Below low level
When at highest level

(108°C or above) on Displays when starting switch is ON and
Engine water temperature
engine water engine is running
Caution 2
temperature gauge
Display when abnormal: Flashes
When at highest level
CAUTION lamp flashes
Torque converter oil tem- (130°C or above) on
perature engine water Alarm buzzer sounds
temperature gauge
Hydraulic oil temperature 105±3°C or above
When replacement time

Maintenance of filter or oil has been
passed
Lights according to required time

determined by engine controller based.
Preheating When preheating It also lights at the time of manual pre-
heat by setting starting switch at preheat
position (turning it counterclockwise).
Pilot
Display lights at the time of operation.

Dual tilt At the time of operation
It goes off at the time of non-operation.
D275A-5 10-221
Display
Symbol Display item Display range Display method
category
Engine water temperature
Torque converter oil One place lights up to show

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

Fuel level
plicable level
Multi information
Service meter Actuated when the engine is

From 0 to 99999
(Hours meter) rotating
10-222 D275A-5
Switch portion (For SSC specification)

1. Switch functions
a) Economy mode setting - OFF, mode 1, mode 2
b) ON-OFF switching in reverse slow mode
c) ON-OFF switching in SSC mode
d) SSC mode level setting - Mode 1 to 5
Economy mode function

In a field, such as a rock-bed place where many shoe 2. Initial Setup at key ON
slips are generated, the following power is output in The function the operator desires according to
each mode so that the frequency of decelerator oper- the situation of an operating place is selected and
ation can decrease. all functions shall be set to the OFF state.
• Economy mode 1 → Set to about 90% of the full
power.
• Economy mode 2 → Set to about 70% of the full
power.
• Reverse slow mode → Set to about 80% of the
full travel speed at reverse time.
D275A-5 10-223
(6)
MAINTENANCE STANDARD SENSORS
SENSORS
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine water temperature Resistance – –

Torque converter
Resistance – –
oil temperature
Hydraulic oil temperature Resistance – –
Radiator water level Contact ON OFF
Fuel level Resistance – –
Charge pressure Contact ON OFF
Engine oil pressure sensor
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
10-224 D275A-5
(6)
Engine cooling water temperature sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
Radiator water level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
D275A-5 10-225
(6)
Transmission output shaft speed sensor
1. Magnet
2. Terminal
3. Case
4. Boots
5. Connector
Pitch angle sensor
1. Body
2. Tube
3. Wire
4. Connector
10-226 D275A-5
(6)
Fuel level sensor
1. Connector Function
2. Float • The fuel sensor is installed to the side face of the
3. Arm fuel tank. The float moves up and down accord-
4. Body ing go to the fuel level. This movement of the
5. Spring float is transmitted by the arm and actuates a
6. Contact variable resistance. This sends a signal to the
7. Spacer monitor panel to indicate the remaining fuel lev-
el. When the display on the monitor panel reach-
es a certain level, a warning lamp flashes.
D275A-5 10-227
(6)
MAINTENANCE STANDARD MODE SELECTION SYSTEM (FOR SSC SPECIFICATION)
MODE SELECTION SYSTEM (For SSC specification)

(SSC (Shoe Slip Control) System)
System diagram
Outline
• The mode selection system automatically car-
ries out engine control to match the operating
mode selected by the operator, and acts to re-
duce fuel consumption, extend the life of the
track shoes, and reduce the frequency of opera-
tion of the deceleration.
• The engine control modes consist of the econo-
my mode control used when dozing, the SSC
(shoe ship control) used when ripping, and the
reverse slow mode control, which can be used
for either operation.
10-228 D275A-5
(6)
Function of model selection system Function of engine controller

• This system consists of the mode selection pan- 1. The engine controller controls the fuel supply
el (containing a microcomputer) to select work- pump according to the lowest engine speed
ing condition, steering controller (containing a (highest voltage) in the 3 signals of the manual
microcomputer) to control the engine, engine command input from the deceleration potentiom-
controller to receive the commands from the eter, manual signal of the throttle dial, and the
steering controller and controls the fuel supply SSC command signal.
pump, transmission controller to judge the gear
speed according to the signals from the trans-
mission output speed sensor, and various sen-
sors.
The function of each controller is explained be-
low.
Functions of steering controller and

transmission controller
1. The steering controller calculates the travel
speed to the ground from the signals of the ac-
celeration sensor and inputs the transmission
output speed sensor signal to it to calculate the
shoe speed, then obtains the shoe slip rate.
2. If the engine speed sensor signal and transmis-
sion output speed sensor signal are input, the
steering controller calculates the traction force.
3. The steering controller calculates the optimum
engine speed from the results of 1 and 2 above,
mode set signal of the monitor panel, and speed
information from the transmission controller,
then sends it as the SSC command to the engine
controller.
D275A-5 10-229
(6)
Operation of mode selection system

• Work can be performed under the optimum conditions by simply or simultaneously selecting four modes in
accordance with the contents of work
Simulta-
Mode Single
Work neous Mode work condition Mode operation, characteristic
switch selection selection
1. When F1 is shifted with the economy 1. When the economy mode (1 or 2) and SSC
mode switch 1 or 2 ON are set simultaneously, the F1 shift economy
control is performed. When the ripper lever is
actuated and the switch is turned on, the slip
control is performed.
Economy
Dozing
2. The engine output can be suppressed in two

! ! stages without performing the decelerator op-
eration of the engine.
Mode 1: 90% (at 1.5 km/h)
Mode 2: 65% (at 1.5 km/h)
3. At neutral time, the engine speed can be sup-
pressed partially
1. When R1, R2, and R3 are shifted 1. The engine speed can be suppressed without
Reverse slow
performing the decelerator operation of the en-

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

force characteristic (refer to the rock-bed se-
lection shown below) selected by the operator
Ripping
among the index force characteristics set in

five stages and suppresses the generation of a
slip.
3. The steering controller regards the index force
! ! immediately before the slip (exceeding the
shoe ripping ratio of 30% is generated, as the
maximum, and performs the engine output
control. At this time, the steering controller per-
forms index characteristic down of about 30 to
80% and performs the engine outpuut control
if a ripper tilt or ripper up signal is input.
4. At neutral time, the engine speed is sup-
pressed partially.
Set to ON in connection with SSC 1. When the SSC is set to ON, the selection
Rock-bed
selection
mode 3 comes on.

2. 1 ⇔ 3 ⇔ 5 is selected in accordance with the
state and load of the rock-bed
★ 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.
10-230 D275A-5
(6)
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
Outline
• The acceleration sensor is installed under the
front of the operator's cab.
• With the acceleration sensor, the position of the
ball inside the sensor changes according to the
acceleration.
Inside the sensor, there is a coil that detects the
position of the ball. This is amplified by the amp
and is sent as a voltage change to the SSC con-
troller.
• The input and output characteristics of the sensor
are shown in the diagram on the right.
D275A-5 10-231
(6)
MAINTENANCE STANDARD ELECTRICAL EQUIPMENT
ELECTRICAL EQUIPMENT
Relay box
10-232 D275A-5
(6)
Operation of lamp system
Lamp system circuit diagram
D275A-5 10-233
(6)
Preheat (Electrical intake air heater) control
Preheat circuit
10-234 D275A-5
(6)
MAINTENANCE STANDARD PALM COMMAND CONTROL SYSTEM
PALM COMMAND CONTROL SYSTEM
1. Monitor panel (Multi-information) 6. Steering control valve

2. Auto shift-down switch 7. Transmission output speed sensor
3. Engine controller 8. Transmission control valve
4. Transmission controller 9. Engine speed sensor
5. Steering controller
D275A-5 10-235
(6)
MAINTENANCE STANDARD PALM COMMAND CONTROL SYSTEM
• Shift Mode Function

1. Function
If you shift the lever to the forward or reverse, the
gear speed selected from the shift mode is
turned on.
• Shift mode 1
• Shift mode 2
2. Type of Modes
1 F1-R2
2 F2-R2
3 F1-R1 (Manual mode)
3. Selecting method
Shift the steering or forward-reverse lever to “N”.
Shift up switch ON Shit up switch ON
Manual mode Shift mode 1 Shift mode 2
Shift down switch ON Shift down switch ON
4. Displaying method
Monitor panel
• Auto Shift-down Function

1. Operating condition
This function automatically shifts the gear speed
down if load is increased while the machine is
travelling at 2nd or 3rd speed or while the ma-
chine is in operation.
2. Selecting method
Turn the auto shift-down switch (1) “ON”.
3. Operation and features of the mode
1) This function turns on the shift-down auto-
matically by calculating the drawbar pull
(load to the machine body) based the engine
speed, transmission speed and throttle infor-
mation from the steering controller.
2) Once the machine is automatically shifted
down, shit-up won’t be turned on automati-
cally (shift up from the manual switch is
available, though).
3) This function is available for both the forward
and reverse travel.
10-236 D275A-5
(6)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLES

Standard value table for engine ............................................................................................................... 20- 2
Standard value table for chassis ............................................................................................................. 20- 3
TESTING AND ADJUSTING ................................................................................................................... 20-101
TROUBLESHOOTING ............................................................................................................................ 20-301
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the ma-
chine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the re-
sults of various tests. It is used for reference together with the state of repair and the history of operation to
judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
D275A-5 20-1
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Engine SDA6D140E-3
Item Measurement conditions Unit Standard value for Service limit value
new machine
High idling 2,150 ± 50 2,150 ± 50
Speed Low idling rpm 700 ± 50 700 ± 50
Rated speed 2,000 2,000
Intake air pressure
At rated output kPa {mmHg} Min. 116.0 {870} Min. 97.3 {730}
(Boost pressure)
Whole speed range
Exhaust temperature °C Max. 650 Max. 700
(Outside air temperature: 20°C)
At sudden acceleration Max. 6.0 Max. 8.0
Exhaust gas color Bosch index
At high idling Max. 1.0 Max. 2.0
Valve clearance Air intake valve 0.35 —
mm
(At normal temperature) Exhaust valve 0.57 —
2
Oil temperature: 40 – 60°C MPa {kg/cm } Min. 2.4 {24.6} Min. 2.84 {29}
Compression pressure
(Engine speed: 200 – 250rpm) (rpm) (200 – 250) (200 – 250)
Cooling water temperature:
Blow-by pressure Within operating range kPa {mmH2O} Max. 1.96 {200} Max. 3.92 {400}
At rated output
Cooling water temperature:
Within operating range
At high idling
SAE30 or SAE15W-40 oil 0.34 – 0.54 {3.5 – 5.5} Min. 0.21 {2.1}
Oil pressure
SAE10W oil MPa {kg/cm2} 0.29 – 0.49 {3.0 – 5.0} Min. 0.18 {1.8}
(SAE15W-40 oil)
At low idling
SAE30 or SAE15W-40 oil 0.12 {1.2} Min. 0.08 {0.8}
SAE10W oil 0.10 {1.0} Min. 0.07 {0.7}
Oil temperature Whole speed range (In oil pan) °C 90 – 110 Max. 120
Deflection under finger pressure
Tension of alternator belt mm 13 – 16 13 – 16
of 98N {10kg}
Tension of air conditioner Deflection under finger pressure
mm 10 10
compressor belt of 58.8N {6kg}
20-2 D275A-5
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Standard value for Service
Category Item Measurement conditions Unit new machine limit value
Decelerator pedal • Engine water temperature:
900 ± 50 900 ± 50
speed Within operating range
Auto deceleration • Torque converter oil temperature:
Within operating range 2,000 ± 25 2,000 ± 25
speed
Engine speed
Torque converter stall • Hydraulic oil temperature:

Within operating range 1,620 ± 50 1,510
speed rpm
• Decelerator pedal speed: Press pedal.
• Auto deceleration speed:
Torque converter stall Set all equipment in neutral.
+ Work equipment re- • Torque converter stall speed: F3 1,580 ± 50 1,450
lief speed • Torque converter stall + Work equip-
ment relief speed: F3 + Ripper RAISE
Neutral → 30 ± 10 30 ± 10
Forward and Forward
PCCS lever
reverse Neutral → 30 ± 10 30 ± 10
• Stop engine. Reverse
mm
• Set lever knob to center. Neutral → 40 ± 10 40 ± 10
Left (Play: Max. 3) (Play: Max. 3)
Steering
Neutral → 40 ± 10 40 ± 10
Stroke of control lever/pedal
Right (Play: Max. 3) (Play: Max. 3)

• Stop engine.
Decelerator pedal mm 47 ± 5 47 ± 5
• Set pedal to center.
All stroke 75 ± 8 75 ± 8
• Engine: Low idling
Brake pedal Stroke to 0 of mm
• Set pedal to center. 61 ± 10 61 ± 10
oil pressure
• Engine: Low idling Neutral –
72 ± 10 72 ± 10
• Hydraulic oil temperature: Raise/Float
Blade lever mm
Within operating range Neutral –
53 ± 10 53 ± 10
• Set lever knob to center. Right/Left tilt
Neutral –
• Engine: Low idling 85 ± 10 85 ± 10
Raise/Lower
• Hydraulic oil temperature:
Ripper lever Neutral – mm
Forward/ 85 ± 10 85 ± 10
• Set lever knob to center. Reverse tilt
Neutral → 46.1 ± 4.9 46.1 ± 4.9
Forward and Forward {4.7 ± 0.5} {4.7 ± 0.5}
PCCS lever
reverse Neutral → 46.1 ± 4.9 46.1 ± 4.9

• Stop engine. Reverse {4.7 ± 0.5} {4.7 ± 0.5}
N {kg}
• Set lever knob to center. Neutral → 26.5 ± 4.9 26.5 ± 4.9
Operating effort of control lever/pedal
Left {2.7 ± 0.5} {2.7 ± 0.5}

Steering
Neutral → 26.5 ± 4.9 26.5 ± 4.9
Right {2.7 ± 0.5} {2.7 ± 0.5}
• Stop engine. 49.0 ± 9.8 49.0 ± 9.8
Decelerator pedal N {kg} {5.0 ± 1.0} {5.0 ± 1.0}
• Engine: Low idling 490.0 ± 49.0 490.0 ± 49.0
Brake pedal N {kg} {50.0 ± 5.0} {50.0 ± 5.0}
Neutral → 82.3 ± 9.8 27.4 ± 9.8
• Engine: Low idling Raise {8.4 ± 1.0} {8.4 ± 1.0}
• Hydraulic oil temperature: Neutral → 82.3 ± 9.8 82.3 ± 9.8
Blade lever N {kg}
Within operating range Float {8.4 ± 1.0} {8.4 ± 1.0}
• Set lever knob to center. Neutral – 27.4 ± 9.8 27.4 ± 9.8
Right/Left tilt {2.8 ± 1.0} {2.8 ± 1.0}
• Engine: Low idling Neutral – 24.5 ± 9.8 24.5 ± 9.8
• Hydraulic oil temperature: Raise/Lower {2.5 ± 1.0} {2.5 ± 1.0}
Ripper lever N {kg}
Within operating range Neutral – 24.5 ± 9.8 24.5 ± 9.8
• Set lever knob to center. Tilt in/out {2.5 ± 1.0} {2.5 ± 1.0}
D275A-5 20-3
1
(7)

Standard value for Service
Category Item Measurement conditions Unit new machine limit value
Engine: Max. 0.2 Max. 0.2
Torque converter in- Low idling {Max. 2} {Max. 2}
let pressure Engine: 0.49 – 1.0 0.49 – 1.0
High idling {5 – 10} {5 – 10}
Engine: Max. 0.2 Max. 0.2
• Torque converter oil
Torque converter Low idling MPa {Max. 2} {Max. 2}
temperature:
outlet pressure
Within operating range Engine: {kg/cm2} 0.49 ± 0.1 0.49 ± 0.1
High idling {5 ± 1} {5 ± 1}
Engine: 2.65 ± 0.2 2.65 ± 0.2
Torque converter
Low idling {27 ± 2} {27 ± 2}
stator clutch pres-
Engine: 2.65 ± 0.2 2.65 ± 0.2
sure
High idling {27 ± 2} {27 ± 2}
Engine: 2.84 – 3.14 Min. 2.65
Transmission main Low idling {29 – 32} {Min. 27}
relief pressure Engine: 3.14 – 3.43 Min. 2.94
High idling {32 – 35} {Min. 30}
Engine: 2.84 – 3.14 Min. 2.65
Transmission F Low idling {29 – 32} {Min. 27}
clutch pressure Engine: 3.14 – 3.43 Min. 2.94
Engine: 2.84 – 3.14 Min. 2.65
Transmission R Low idling {29 – 32} {Min. 27}
Power train oil pressure
Engine: 2.84 – 3.14 Min. 2.65

Transmission 1st Low idling {29 – 32} {Min. 27}
Engine: 2.84 – 3.14 Min. 2.65
Transmission 2nd Low idling {29 – 32} {Min. 27}
• Torque converter oil Engine: 2.84 – 3.14 Min. 2.65
MPa
Transmission 3rd temperature: Low idling {kg/cm2} {29 – 32} {Min. 27}
clutch pressure Within operating range Engine: 3.14 – 3.43 Min. 2.94
Transmission lubri- Engine: 0.05 – 0.29 0.05 – 0.29
cating oil pressure
(For reference) High idling {0.5 – 3.0} {0.5 – 3.0}
Engine: 1.77 ± 0.20 1.77 ± 0.29
Steering left clutch Low idling {18 ± 2} {18 ± 3}
pressure Engine: 1.77 ± 0.20 1.77 ± 0.29
High idling {18 ± 2} {18 ± 3}
Engine: 2.84 – 3.14 Min. 2.26
Steering left brake Low idling {29 – 32} {Min. 23}
pressure Engine: 3.14 – 3.43 Min. 2.45
Engine: 1.77 ± 0.20 1.77 ± 0.29
Steering right clutch Low idling {18 ± 2} {18 ± 3}
pressure Engine: 1.77 ± 0.20 1.77 ± 0.29
High idling {18 ± 2} {18 ± 3}
Engine: 2.84 – 3.14 Min. 2.26
Steering right brake Low idling {29 – 32} {Min. 23}
pressure Engine: 3.14 – 3.43 Min. 2.45
20-4 D275A-5
1

Category Item Measurement conditions Unit Standard value for Service
new machine limit value
pressure
train oil
• Torque converter oil

Power
Ripper pin puller op- Engine: MPa 3.14 – 3.43 Min. 2.45
temperature:
erating pressure High idling {kg/cm2} {32 – 35} {Min. 25}
• Flat road F1 3.7 ± 0.2 3.7 ± 0.2

Performance of power train
• Engine water
temperature: F2 6.6 ± 0.3 6.6 ± 0.3
• Torque converter oil F3 10.6 ± 0.6 10.6 ± 0.6
temperature:
Travel speed km/h
• Engine: High idling R1 4.8 ± 0.2 4.8 ± 0.2
• Run up distance:
10 – 30m R2 8.5 ± 0.4 8.5 ± 0.4
• Measuring distance:
20m R3 14.3 ± 0.7 14.3 ± 0.7
Engine:
— —
Low idling
Unload pressure 2.45
+ 1.37
2.45
+ 1.37
Engine: 0 0
High idling {25
+ 14 + 14
0 } {25 0 }
Engine: 27.44 ± 1.37 27.44 ± 1.37

Blade lift relief pres- Low idling {280 ± 14} {280 ± 14}
sure • Hydraulic oil Engine: 27.44 ± 1.37 27.44 ± 1.37
temperature: High idling {280 ± 14} {280 ± 14}
Within operating range Engine: 27.44 ± 1.37 27.44 ± 1.37
• Unload pressure: Low idling {280 ± 14} {280 ± 14}
Work equipment oil pressure
Blade tilt relief pres-

Set all equipment in
sure Engine: 27.44 ± 1.37 27.44 ± 1.37
neutral. MPa
High idling {280 ± 14} {280 ± 14}
• Relief pressure: {kg/cm2}
Set cylinder to stroke Engine: 27.44 ± 1.37 27.44 ± 1.37
Ripper lift relief pres- end. Low idling {280 ± 14} {280 ± 14}
sure • LS pressure: Engine: 27.44 ± 1.37 27.44 ± 1.37
Set cylinder to stroke High idling {280 ± 14} {280 ± 14}
end. Engine: 27.44 ± 1.37 27.44 ± 1.37
Ripper tilt relief pres- Low idling {280 ± 14} {280 ± 14}
sure Engine: 27.44 ± 1.37 27.44 ± 1.37
High idling {280 ± 14} {280 ± 14}
Engine: 25.48 ± 1.27 25.48 ± 1.27
LS pressure
Low idling {260 ± 13} {260 ± 13}
(Load sensing pres-
Engine: 25.48 ± 1.27 25.48 ± 1.27
sure)
High idling {260 ± 13} {260 ± 13}
Control circuit main + 0.49 + 0.49
• Hydraulic oil temperature: 3.43 0 3.43 – 0.20
pressure
Within operating MPa +5 +5
(PPC, fan) {35 0 } {35 – 2 }
range {kg/cm2}
PPC valve output • Engine: High idling 3.14 – 3.92 3.14 – 3.92
pressure {32 – 40} {32 – 40}
D275A-5 20-5
(1)
(4)

Low idling 8 – 15 20
Raise
High idling 3–5 6
Blade lift sec
Low idling 1 – 1.5 2
Lower
45 – 55°C
• Apply no load to blade.
• Between ground level and ris- High idling 1 – 1.5 2
ing end of blade
Low idling 3–5 7

Left tilt
High idling 2.8 ± 0.5 3.5

Blade tilt sec
• Hydraulic oil temperature: Low idling 3–5 7

Right tilt
45 – 55°C
• Between left tilt end and right High idling 2.8 ± 0.5 3.5
tilt end
Work equipment speed
Low idling 5–8 10

Work equipment
Left tilt

Blade
sec
dual tilt
• Hydraulic oil temperature: Low idling 5–8 10
Right tilt
45 – 55°C
• Between left tilt end and right High idling 2.8 ± 0.5 3.5
tilt end
Low idling 6–9 12

Forward

Blade
sec
pitch • Hydraulic oil temperature:
Backward
45 – 55°C Low idling 5–8 10

• Between forward end and
backward end High idling 2.8 ± 0.5 3.5
Raise

Ripper lift sec
45 – 55°C Low idling 3.3 – 4.3 6
Lower
• Apply no load to ripper.

• Between ground level and ris-
ing end of blade High idling 3.5 ± 0.5 4.5
20-6 D275A-5
1

Tilt in
Ripper tilt sec
• Hydraulic oil temperature: Low idling 8 – 14 17
Tilt out
45 – 55°C
• Apply no load to ripper.
• Between tilt-in end and tilt-out High idling 3.5 ± 0.5 4.5
end
45 – 55°C Low idling Max. 8 11
• Move lever to stroke end.
Blade • Lower ripper from max. rising posi-
tion and measure time after ripper
comes in contact with ground until High idling Max. 1.8 2.5
Time lag
sproket is lifted.
sec
45 – 55°C Low idling Max. 6 8
• Move lever to stroke end.
Ripper • Lower ripper from max. rising posi-
tion and measure time after ripper
comes in contact with ground until High idling Max. 1.5 2.5
sprocket is lifted.
Work equipment
Hydraulic
drift of lift- Max. 200/15 minutes 300/15 minutes
ed blade
• Hydraulic oil temperature: 45 – 55°C
• Engine: Stopped
• Measure reduction of blade bottom height h
(for 15 minutes).
Hydraulic
Hydraulic drift
drift of
machine Max. 50/5 minutes 100/15 minutes
lifted by mm
blade
• Engine: Stopped
• Measure reduction of idler center height h
(for 5 minutes).
Hydraulic
drift of
tilted by
blade
• Engine: Stopped
• Measure reduction of idler center height h
(for 5 minutes).
D275A-5 20-7
1

Hydraulic
drift of lift- Max. 80/15 minutes 160/15 minutes
ed ripper
• Engine: Stopped
Hydraulic drift
• Measure reduction of shank bottom height h

(for 15 minutes).
mm
Work equipment
Hydraulic
drift of
lifted by
ripper • Hydraulic oil temperature: 45 – 55°C
• Engine: Stopped
• Measure reduction of sprocket center height h
(for 5 minutes).
Leakage from cylinder
Blade tilt
4 16
cylinder
• Engine: High idling
Ripper lift • Hydraulic oil temperature: 45 – 55°C
cc/min 4 16
cylinder • Relieve cylinder and measure leakage for 1
minute.
Ripper tilt
4 16
cylinder
• Fan: 100% speed mode
Min. speed 450 ± 30 400
Cooling fan
• Engine: Low idling

Fan speed rpm
• Fan: 100% speed mode
Max. speed 1,050 ± 50 950
• Engine: High idling
Fan pump oil • Fan: 100% speed mode MPa 16.17 - 19.11 16.17 - 19.11
pressure • Engine: High idling (kg/cm2) {165 - 195} {165 - 195}
20-8 D275A-5
(1)
(4)
TESTING AND ADJUSTING 20
Tools for testing, adjusting, and troubleshooting .................................................................................. 20-102-1

Measuring engine speed ......................................................................................................................... 20-103
Measuring intake air pressure (Boost pressure) ...................................................................................... 20-106
Measuring exhaust temperature .............................................................................................................. 20-108
Measuring exhaust gas color ................................................................................................................... 20- 110
Adjusting valve clearance ........................................................................................................................ 20- 111
Measuring compression pressure ........................................................................................................... 20- 112
Measuring blow-by pressure ................................................................................................................... 20- 113
Measuring engine oil pressure ................................................................................................................ 20- 114
Handling of fuel system devices .............................................................................................................. 20- 115
Releasing residual pressure from fuel system ......................................................................................... 20- 115
Measuring fuel pressure .......................................................................................................................... 20- 116
Bleeding air from fuel circuit .................................................................................................................... 20- 117
Inspection of fuel circuit for leakage ........................................................................................................ 20- 119
Testing and adjusting alternator belt tension ........................................................................................... 20-120
Testing and adjusting air conditioner compressor belt tension ................................................................ 20-120
Adjusting fuel control dial and decelerator pedal ..................................................................................... 20-121
Measuring power train oil pressure ......................................................................................................... 20-123
Adjusting transmission speed sensor ...................................................................................................... 20-130
Simple method of testing brake performance .......................................................................................... 20-131
Adjusting brake pedal and parking brake lever ....................................................................................... 20-132
Adjusting PCCS lever console position ................................................................................................... 20-134
Emergency escape method when power train has trouble ...................................................................... 20-135
Adjusting clearance of idler ..................................................................................................................... 20-138
Inspecting wear of sprocket ..................................................................................................................... 20-138
Testing and adjusting track shoe tension ................................................................................................. 20-139
Testing and adjusting work equipment oil pressure ................................................................................. 20-140
Testing and adjusting control circuit main pressure ................................................................................. 20-144
Measuring PPC valve output pressure .................................................................................................... 20-145
Adjusting play of PPC valve .................................................................................................................... 20-147
Measuring outlet pressure of ripper pin puller solenoid valve ................................................................. 20-148
Testing parts which cause hydraulic drift of blade and ripper .................................................................. 20-149
Measuring internal leakage of work equipment cylinder .......................................................................... 20-150
Releasing residual pressure from work equipment cylinder .................................................................... 20-151
Bleeding air from work equipment cylinder .............................................................................................. 20-151
Adjusting ripper lever position ................................................................................................................. 20-152
Adjusting safety lock lever ....................................................................................................................... 20-153
Measuring fan motor speed ..................................................................................................................... 20-154
Measuring fan circuit oil pressure ............................................................................................................ 20-154
Changing rotation direction of fan motor .............................................................................................. 20-154-1
D275A-5 20-101
(4)
(1)
Bleeding air from fan pump ...................................................................................................................... 20-155

Adjusting blade ........................................................................................................................................ 20-156
Special functions of monitor panel (EMMS) ............................................................................................. 20-158
Handling of high-voltage circuit of engine controller ................................................................................ 20-204
Adjustment method of replaced controller ............................................................................................... 20-204
Preparation work for troubleshooting for electric system ......................................................................... 20-206
Handling of optional devices .................................................................................................................... 20-208
Pm clinic service ...................................................................................................................................... 20-209
Undercarriage troubleshooting report ...................................................................................................... 20-215
¤ When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safe-
ty pins and blocks to prevent the machine from moving.
¤ When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
¤ When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
¤ Be careful not to get caught in the fan, fan belt, or other rotating parts.
20-102 D275A-5
(1)
(4)
TOOLS FOR TESTING, ADJUSTING, AND
TESTING AND ADJUSTING TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
Measuring intake air pres- -101 – 200kPa {-760 –
A 799-201-2202 Boost gauge kit 1
sure (boost pressure) 1,500mmHg}
Measuring exhaust temper- B 799-101-1502 Digital thermometer 1 -99.9 – 1,299fC
ature – 799-201-1150 Adapter connector 1 For Pm clinic specification
1 799-201-9000 Handy smoke checker 1 Pollution level: 0 - 70% (With
Measuring exhaust gas col- standard color)
C
or 2 Purchased Smoke meter 1 (Pollution level x 1/10
Bosch index)
Air intake side: 0.35 mm,
Adjusting valve clearance D Purchased Thickness gauge 1
Exhaust side: 0.57 mm
0 – 6.9MPa {0 – 70kg/cm2}
795-502-1590 Compression gauge 1
Measuring compression Kit No. : 795-502-1205
–
pressure 795-471-1310 Adapter 1
6217-71-6110 Gasket 1
Measuring blow-by pres-
E 799-201-1504 Blow-by checker 1
sure
Pressure gauge :
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600kg/cm2}
Measuring engine oil pres-
F Pressure gauge :
sure 790-261-1203 Digital hydraulic tester 1
58.8MPa {600kg/cm2}
Pressure gauge :
2 799-401-2320 Hydraulic tester 1
0.98MPa {10kg/cm2}
Measuring fuel pressure F – – – ★ Same as above F
Pressure gauge :
1 {25, 60, 400, 600kg/cm2}
Pressure gauge :
Measuring power train oil 790-261-1203 Digital hydraulic tester 1
N 58.8MPa {600kg/cm2}
pressure
Pressure gauge :
2 799-401-2320 Hydraulic tester 1
0.98MPa {10kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
3
07002-11023 O-ring 1
19M-06-32820 Switch assembly 1
Emergency escape when 1 7824-66-6430 Resistor 1
H
power train has trouble 17M-06-41530 Wiring harness 1
2 790-190-1600 Pump assembly 1
Pressure gauge :
1 {25, 60, 400, 600kg/cm2}
Testing and adjusting work Pressure gauge :
G 790-261-1203 Digital hydraulic tester 1
equipment oil pressure 58.8MPa {600kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
Pressure gauge :
Testing and adjusting con- 1 {25, 60, 400, 600kg/cm2}
J
trol circuit basic pressure Pressure gauge :
790-261-1203 Digital hydraulic tester 1
58.8MPa {600kg/cm2}
2 799-401-3200 Oil pressure pickup adapter 1 Size: 03
D275A-5 20-102-1
(4)
TOOLS FOR TESTING, ADJUSTING, AND
TESTING AND ADJUSTING TROUBLESHOOTING
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
Pressure gauge :
1 {25, 60, 400, 600kg/cm2}
Measuring PPC valve out- Pressure gauge :
K 790-261-1203 Digital hydraulic tester 1
put pressure 58.8MPa {600kg/cm2}
Pressure gauge :
Measuring ripper pin puller 1 {25, 60, 400, 600kg/cm2}
solenoid valve outlet pres- P
Pressure gauge :
sure 790-261-1203 Digital hydraulic tester 1
58.8MPa {600kg/cm2}
Measuring leakage in work
L Purchased Measuring cylinder 1
equipment cylinder
Digital indication
Measuring fan motor speed M 799-203-8001 Multitachometer 1 60 – 2,000rpm
60 – 19,999rpm
Pressure gauge :
1 {25, 60, 400, 600kg/cm2}
Measuring fan circuit oil Pressure gauge :
Q 790-261-1203 Digital hydraulic tester 1
pressure 58.8MPa {600kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
3
07002-11023 O-ring 1
Measuring water tempera-
– – – – ★ Same as above B
ture and oil temperature
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294N {0 – 30kg}
–
and pressing force 79A-264-0091 Push-pull scale 1 0 – 490N {0 – 50kg}
Measuring stroke and hy-
– Purchased Scale 1
draulic drift
Measuring work equipment
– Purchased Stopwatch 1
speed
Measuring voltage and re-
– Purchased Tester 1
sistance
799-601-7400 T-adapter assembly
799-601-7360 Adapter For relay (5-pin)
799-601-9000 T-adapter assembly For heavy-duty wire connector
For heavy-duty wire connector
Troubleshooting for sen- 799-601-9300 T-adapter assembly
– (For 24-pin and 40-pin types)
sors and wiring harnesses
799-601-9410 Socket For NE sensor and G sensor
For boost pressure sensor and
799-601-9420 Adapter
fuel sensor
799-601-9430 Socket For PCV solenoid
20-102-2 D275A-5
(4)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED
★ Measure the engine speed under the following 3. Measuring high idling speed
condition. 1) Start the engine and set the fuel control dial
• Engine water temperature: in the high idling position.
Within operating range 2) Set the PCCS lever and work equipment
• Torque converter oil temperature: control lever in neutral and measure the en-
Within operating range gine speed.
• Power train oil temperature: ★ The high idling speed measured in the “Mon-
Within operating range itoring mode” or in the “Pm Clinic auxiliary
mode” is the auto-deceleration speed.
1. Preparation work ★ When measuring the high idling speed of the
Turn the starting switch ON and set the monitor engine, use the “Adjustment mode”.
panel in the “Monitoring mode” to prepare for Adjustment code:
measurement of the engine speed. 0007 (Engine decelerator cut mode)
★ For the operating method, see “SPECIAL
FUNCTIONS OF MONITOR PANEL
(EMMS)”.
• Monitoring code: 01000 (Engine speed)
4. Measuring decelerator pedal speed

1) Start the engine and set the fuel control dial
in the high idling position.
2) Set the PCCS lever and work equipment
2. Measuring low idling speed control lever in neutral and press the decel-
1) Start the engine and set the fuel control dial erator pedal and measure the engine speed.
in the low idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the en-
gine speed.
D275A-5 20-103
1
5. Measuring torque converter stall speed 6. Torque converter stall + Work equipment re-
1) Start the engine and set the fuel control dial lief speed (Full stall speed)
in the low idling position. 1) Start the engine and set the fuel control dial
2) Press the brake pedal securely and set the in the low idling position and raise the ripper
parking brake lever in the FREE position and to the stroke end.
set the PCCS lever in the FORWARD and 2) Keep pressing the brake pedal securely and
3rd gear speed position. set the parking brake lever in the FREE po-
★ Before going to the next step, check that sition and set the PCCS lever in the FOR-
the upper display unit of the monitor pan- WARD and 3rd gear speed position.
el is set in the normal display state and it ★ Before going to the next step, check that
displays [F3]. the upper display unit of the monitor pan-
★ Keep the steering unit in neutral. el is set in the normal display state and it
3) Press the decelerator pedal and set the fuel displays [F3].
control dial in the high idling position. ★ Set the steering unit in neutral.
4) Return the decelerator pedal slowly to stall 3) Press the decelerator pedal and set the fuel
the torque converter with the engine at high control dial in the high idling position.
idling. 4) Return the decelerator pedal slowly to stall
¤ Keep pressing the brake pedal securely the torque converter with the engine at high
and keep your right foot on the decelera- idling.
tor pedal for safety until the work is fin- ¤ Keep pressing the brake pedal securely
ished. and keep your right foot on the decelera-
5) Just after the power train oil temperature tor pedal for safety until the work is fin-
gauge reads the top line of the green range, ished.
return the direction of the PCCS lever into 5) Just after the torque converter oil tempera-
neutral. ture gauge reads the top line of the green
range, return the direction of the PCCS lever
into neutral.
6) Repeat above steps 2) – 5) 3 times.

7) Perform steps 2) – 4) again and measure the
engine speed about 5 seconds after the 6) Repeat above steps 2) – 5) 3 times.
power train oil temperature gauge reads the
top line of the green range.
★ After finishing measurement, return the
direction of the PCCS lever into neutral
and lower the power train oil temperature
with the engine at high idling.
20-104 D275A-5
1
7) Perform steps 2) – 4) again and relieve the ★ The engine speed can be measured in the “Pm
ripper in the raising direction and measure Clinic auxiliary mode” of the monitor panel (Mea-
the engine speed about 5 seconds after the sure the high idling speed of the engine in the
power train oil temperature gauge reads the “Adjustment mode”, however).
top line of the green range.
★ After finishing measurement, return the
direction of the PCCS lever into neutral
and lower the power train oil temperature
with the engine at high idling.
D275A-5 20-105
1
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
★ Measuring instruments for intake air pressure ★ Insert the joint of the gauge and hose half-
(boost pressure) way and open the self-seal on the hose side
repeatedly, and the oil is drained.
Symbol Part No. Name ★ If Pm kit (A) is available, the air bleeding cou-
A 799-201-2202 Boost gauge kit pling (790-261-1130) in it may be used.
★ If any oil is left in the hose, the gauge does
★ A nipple (quick coupler) is installed to the intake not move. Accordingly, be sure to drain the
air pressure (boost pressure) pickup port of the oil.
Pm clinic specification machine.
¤ When installing and removing the measuring in- 5. Run the engine at high idling and stall the torque
strument, take care not to touch a hot part. converter and measure the intake air pressure
(boost pressure) at this time.
★ Measure the intake air pressure (boost pres-
★ For the procedure for stalling the torque con-
sure) under the following condition.
verter, see MEASURING ENGINE SPEED.
• Engine water temperature:
★ Normally, the intake air pressure (boost
pressure) should be measured while the en-
• Torque converter oil temperature:
gine is operated at the rated output. In the
field, however, an approximate value can be
obtained by stalling the torque converter.
1. Open the right side cover of the engine.
2. Remove boost pressure pick-up plug (1).
6. After finishing measurement, remove the mea-

suring instrument and return the removed parts.
3. Install nipple 1 of boost gauge kit A and connect

gauge 2.
4. Run the engine at medium or higher speed and

drain the oil from the hose.
20-106 D275A-5
(1)
(4)
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
★ The boost pressure can be measured in the “Pm

Clinic auxiliary mode” of the monitor panel.
D275A-5 20-107
1
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE
★ Measuring instrument for exhaust temperature
Symbol Part No. Name

B 799-101-1502 Digital thermometer
★ Measuring instruments for exhaust temperature

(Pm clinic specification)
An exhaust temperature sensor is installed to the
Pm clinic specification machine. Accordingly,
prepare an adapter connector to connect the ex-
haust temperature sensor to a digital thermome-
ter.

4. Procedure for measuring maximum exhaust
B 799-101-1502 Digital thermometer temperature for troubleshooting
- 799-201-1150 Adapter connector Operate the machine actually and measure the
maximum exhaust temperature.
¤ Install and remove the measuring instrument af- ★ Use the PEAK mode of the digital thermom-
ter the exhaust manifold is cooled. eter.
★ Measure the exhaust temperature under the fol- ★ The exhaust temperature largely depends
lowing condition. on the outside air temperature (intake air
• Engine water temperature: temperature of the engine). Accordingly, if
Within operating range any abnormal value is obtained, correct it by
• Torque converter oil temperature: the following calculation.
Within operating range • Corrected value [°C] = Measured value +
• Hydraulic oil temperature: 2 × (20 – Outside air temperature)
1. Open the right side cover of the engine and re-

move turbocharger heat insulation cover (1).
5. Procedure for measuring exhaust temperature

periodically for preventive maintenance
★ If the torque converter is stalled simply, the
torque converter oil temperature is overheat-
2. Remove exhaust temperature pick-up plug (2). ed before the exhaust temperature is stabi-
lized. Accordingly, measure according to the
3. Install sensor 1 of digital thermometer B and following procedure.
connect them to meter 2. 1) Stall the torque converter fully to raise the
★ Clamp the wiring harness of the digital ther- exhaust temperature to about 650°C accord-
mometer so that it will not touch a hot part ing to the following procedure (Condition a in
during measurement. the figure).
i) Start the engine and set the fuel control
dial to the low idling position. Raise the
20-108 D275A-5
(1)
(4)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
ripper lift cylinder to the stroke end with MEASURING EXHAUST GAS
the ripper lever.
ii) Press the brake pedal securely and set COLOR
the PCCS lever in the FORWARD 3rd
gear speed position.
★ Measuring instrument for exhaust gas color
iii) Press the decelerator pedal and set the
fuel control dial to the high idling posi- Symbol Part No. Name
tion.
1 799-201-9000 Handy smoke checker
iv) Return the decelerator pedal slowly to C
stall the torque converter and relieve the 2 Purchased Smoke meter
ripper in raising direction with the engine
at high idling. ¤ When installing and removing the measuring in-
strument, take care not to touch a hot part.
¤ Press the brake pedal securely and keep ★ If an air source and a electric power source are
your right foot on the decelerator pedal not available in the field, use handy smoke
for safety until the work is finished. checker C1. When recording official data, use
2) Stop only relieving the ripper and lower the smoke meter C2.
exhaust temperature by only stalling the ★ Measure the exhaust gas color under the follow-
torque converter (Condition b in the figure). ing condition.
★ If the temperature does not lower but ris- • Engine water temperature:
es, set the temperature in step 1). Within operating range
3) After the temperature lowers and is stabi-
lized, measure it (Condition c in the figure). 1. Measuring with handy smoke checker C1
1) Stock a sheet of filter paper to C1.
¤ Just after the torque converter oil tempera-
2) Insert the exhaust gas intake pipe in the ex-
ture gauge reads the red range, return the di-
haust pipe.
rection of the PCCS lever into neutral and
3) Start the engine.
lower the torque converter oil temperature.
4) Accelerate the engine suddenly or run it at
high idling and operate the handle of smoke
checker C1 so that the filter paper will absorb
the exhaust gas.
5) Remove the filter paper and compare it with

the attached scale.
6) After finishing measurement, remove the
measuring instrument and return the re-
moved parts.

D275A-5 20-109
1
(4)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
2. Measuring with smoke meter C2 6) Start the engine.

1) Insert probe 1 of smoke meter C2 in the out- 7) Accelerate the engine suddenly or run it at
let of the exhaust pipe and fix it to the ex- high idling and press the accelerator pedal of
haust pipe with a clip. smoke meter C2 and collect the exhaust gas
into the filter paper.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated val-
ue.
moved parts.
2) Connect the probe hose, receptacle of the

accelerator switch, and air hose to smoke
meter C2.
★ Limit the supplied air pressure to 1.5MPa
{15kg/cm2}.
3) Connect the power cable to a receptacle of
AC power supply.
★ Before connecting the cable, check that
the power switch of the smoke meter is
turned off.
4) Before connecting the cable, check that the
power switch of the smoke meter is turned
off.
★ Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter
C2.
20-110 D275A-5
1
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE
★ Adjusting instrument for valve clearance

D Purchased Filler gauge
1. Open the inspection cover under the universal

joint (1) and disconnect universal joint (1) from
the engine.
4. Insert filler gauge D in clearance b between

rocker arm (4) and cross head (5) and adjust the
valve clearance with adjustment screw (6).
★ Adjust the adjustment screw with the filler
gauge inserted so that the filler gauge can be
moved lightly.
5. Fix adjustment screw (6) and tighten locknut (7).

2. Open the right side cover of the engine and re- 3 Locknut:
move all cylinder head covers (2). 53.0 – 64.7Nm {5.4 – 6.6kgm}
★ After tightening the locknut, check the valve
clearance again.
3. Rotate the crankshaft forward and set line a of

“1.6TOP” of the damper to pointer (3) to set the
No. 1 cylinder piston to the compression top 6. Rotate the crankshaft forward by 120 degrees
dead center. and repeat steps 3 – 5 for each cylinder in the fir-
★ Rotate the hexagonal part of the water pump ing order.
drive shaft end to crank the engine. • Firing order: 1 – 5 – 3 – 6 – 2 – 4
★ When the No. 1 cylinder piston is at the com-
pression top dead center, the No. 1 cylinder
rocker arm can be moved with the hand by
the valve clearance. If the rocker arm does
not move, the piston is not at the compres-
sion top dead center. In this case, revolve
the crankshaft 1 more turn.
D275A-5 20-111
1
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
7. After finishing adjustment, return the removed ★ For the method of measuring compression pres-
parts. sure, see the Engine Shop Manual for “140-3
3 Cylinder head cover mounting bolt: Series”.
29.4 – 34.3Nm {3.0 – 3.5kgm}
3 Universal joint mounting bolt:
98.0 – 122.5Nm {10.0 – 12.5kgm}
20-112 D275A-5
1
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE
★ Measuring instrument for blow-by pressure ★ The blow-by pressure may vary largely with
the engine condition. If the measured value
Symbol Part No. Name is judged abnormal, check for increase of oil
E 799-201-1504 Blow-by kit consumption, bad exhaust gas color, deteri-
oration of oil, high deterioration speed of oil,
★ Measure the blow-by pressure under the follow- etc. which are related to the abnormal blow-
ing condition. by pressure.
1. Open the left side cover of the engine and pull

out blow-by hose (1).
2. Install nozzle 1 of blow-by checker E to blow-by

hose (1) and connect them to gauge 2.

3. Run the engine at high idling, stall the torque

converter, and measure the blow-by pressure.
★ For the procedure for stalling the torque con-
verter, see MEASURING ENGINE SPEED.
★ Normally, the blow-by pressure should be
measured while the engine is operated at the
rated output. In the field, however, an ap-
proximate value can be obtained by stalling
the torque converter.
★ If it is impossible to run the engine at the rat-
ed output or stall the torque converter, mea-
sure while the engine is running at high
idling.
The value obtained in this case is about 80%
of the blow-by pressure at the rated output.
D275A-5 20-113
1
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE
★ Measuring instruments for engine oil pressure 3. Run the engine at low idling and high idling and
measure the engine oil pressure in each speed.
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
F
Hydraulic tester
2 799-401-2320
(0.98MPa {10kg/cm2})
★ A nipple (quick coupler) is installed to the engine

oil pressure switch mounting part of the Pm clinic
specification machine.
★ Measure the engine oil pressure under the fol-
lowing condition.
1. Open the left side cover of the engine and re- suring instruments and return the removed
move engine oil pressure switch (1). parts.
2. Install nipple 1 of hydraulic tester F1 and con-

nect them to hydraulic tester F2.
20-114 D275A-5
(1)
(4)
HANDLING OF FUEL SYSTEM DEVICES
TESTING AND ADJUSTING RELEASING RESIDUAL
HANDLING
PRESSURE
OF FUEL
FROM
SYSTEM
FUELDEVICES
SYSTEM
HANDLING OF FUEL SYS- RELEASING RESIDUAL

TEM DEVICES PRESSURE FROM FUEL SYS-
TEM
★ Precautions for testing and adjusting fuel system ★ Pressure is generated in the low-pressure circuit
The common rail fuel injection system (CRI) con- and high-pressure circuit of the fuel system while
sists of more precise parts than the conventional the engine is running.
fuel injection pump and nozzle. If foreign matter Low-pressure circuit:
enters this system, it can cause a trouble. Feed pump – Fuel filter – Fuel supply pump
When testing and adjusting the fuel system, take High-pressure circuit:
care more than the past. If dust, etc. sticks to any Fuel supply pump – Common rail – Fuel in-
part, wash that part thoroughly with clean fuel. jector
★ Precautions for replacing fuel filter capacitor ★ The pressure in both low-pressure circuit and
Be sure to use Komatsu genuine fuel filter car- high-pressure circuit lowers to a safety level au-
tridge. tomatically 30 seconds after the engine is
Since the common rail fuel injection system stopped.
(CRI) consists of more precise parts than the ★ Before the fuel circuit is tested and its parts are
conventional fuel injection pump and nozzle, it removed, the residual pressure in the fuel circuit
employs a high-efficiency special filter to prevent must be released completely. Accordingly, ob-
foreign matter from entering it. serve the following.
If a filter other than the genuine one is used, the ¤ Before testing the fuel system or removing its
fuel system may have a trouble. Accordingly, parts, wait at least 30 seconds after stopping the
never use such a filter. engine until the residual pressure in the fuel cir-
cuit is released. (Do not start the work just after
stopping the engine since there is residual pres-
sure.)
D275A-5 20-115
1
TESTING AND ADJUSTING MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE
★ Measuring instrument for fuel pressure 3. Run the engine at high idling and measure the
fuel pressure.
Symbol Part No. Name ★ If the fuel pressure is in the following range,
799-101-5002 Hydraulic tester it is normal.
1
790-261-1203 Digital hydraulic tester 0.15 - 0.3MPa {1.5 - 3kg/cm2}
F
Hydraulic tester
2 799-401-2320
(0.98MPa {10kg/cm2})
★ Measure only the fuel pressure in the low-pres-

sure circuit from the feed pump to the fuel filter
and fuel supply pump.
¤ Since the pressure in the high-pressure circuit
from the fuel supply pump to the common rail
and fuel injector is very high, it cannot be mea-
sured.
1. Open the left side cover of the engine and re-

move fuel pressure pick-up plug (1).
suring instruments and return the removed
parts.
2. Install nipple 1 of hydraulic tester F1 and con-

nect them to hydraulic tester F2.
20-116 D275A-5
4
(4)
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
★ If fuel is used up or if a fuel circuit device is re-

moved and installed, bleed air from the fuel cir-
cuit according to the following procedure.
1. Remove fuel filter (1) and fill it with fuel and in-
stall it again.
★ Fill the fuel filter with clean fuel and take care
that dirt will not enter it.
★ Add fuel through inlet ports a (8 places) of
the filter. Since hole b is the outlet port (clean
side), do not add fuel through it.
★ If clean fuel is not available, do not remove
the filter but fill it with the fuel from the fuel
tank by operating the priming pump. 2. Remove air bleed plug (2a) of the fuel filter and
operate priming pump (3).
★ Operate the priming pump until the fuel flows
out of the plug hole and install the plug.
3 Air bleed plug:
7.8 – 9.8kgm {0.8 – 1.0Nm}
D275A-5 20-117
1
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
3. Remove plug (2b) of the fuel filter and operate

priming pump (3).
out of the plug hole, then install the plug.
3 Plug: 3.9 – 6.9kgm {0.4 – 0.7Nm}
4. Loosen air bleeder (4) of the fuel supply pump

and operate priming pump (3) 90 – 100 times.
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 – 6.9kgm {0.5 – 0.7Nm}
5. Start the engine with the starting motor.

★ The air in the high-pressure circuit is bled au-
tomatically if the engine is cranked.
★ If the engine does not start, there may be still
air in the low-pressure circuit. In this case,
repeat the above steps from 2.
20-118 D275A-5
1
TESTING AND ADJUSTING INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
¤ Very high pressure is generated in the high-pres- 8. Run the engine at high idling and apply a load to
sure circuit of the fuel system. If fuel leaks while it.
the engine is running, it is dangerous since it can ★ Relief the oil by blade raising operation.
catch fire.
After testing the fuel system or removing its 9. Inspect the fuel piping and devices for fuel leak-
parts, inspect it for fuel leakage according to the age.
following procedure. ★ Inspect around the high-pressure circuit
★ Clean and degrease the engine and the parts parts coated with the color checker for fuel
around it in advance so that you can inspect it leakage.
easily for fuel leakage. ★ If any fuel leakage is detected, repair it and
inspect again from step 2.
1. Spray color checker (developer) over the fuel ★ If any fuel leakage is not detected, inspection
supply pump, common rail, fuel injector, and is completed.
joints of the high-pressure piping.
2. Run the engine at speed below 1,000rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel leak-

age.
★ Inspect around the high-pressure circuit
parts coated with the color checker for fuel
leakage.
★ If any fuel leakage is detected, repair it and
4. Run the engine at low idling.

age.
leakage.
6. Run the engine at high idling.

age.
leakage.
D275A-5 20-119
(1)
(4)
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING

ALTERNATOR BELT TEN- AIR CONDITIONER COM-
SION PRESSOR BELT TENSION
Testing Testing
• Press the intermediate point between alternator • Press the intermediate point between air condi-
pulley and drive pulley with a finger and measure tioner compressor pulley and drive pulley with a
deflection “a” of the belt. finger and measure deflection “a” of the belt.
★ Pressing force: Approx. 98N {Approx. 10kg} ★ Pressing force: Approx. 58.8N {Approx. 6kg}
Adjusting Adjusting
★ If the deflection is abnormal, adjust it according ★ If the deflection is abnormal, adjust it according
to the following procedure. to the following procedure.
1. Loosen the 2 alternator mounting bolts and the 1 1. Loosen the 2 compressor bracket mounting
adjustment rod set bolt. bolts.
2. Loosen locknut (1) and turn adjustment nut (2) to 2. Loosen locknut (1) and turn adjustment nut (2) to
move alternator (3) and adjust the belt tension. move compressor (3) and adjust the belt tension.
3. Tighten the 2 alternator mounting bolts and the 1 3. Tighten the 2 compressor bracket mounting
adjustment rod set bolt. bolts.
20-120 D275A-5
1
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
1. Outline of fuel control system

The following 3 signals are input as speed
signals to the engine controller.
1) Fuel control dial potentiometer signal
2) Decelerator pedal potentiometer signal
3) 3rd throttle signal
• The engine controller controls the fuel con-
trol device (CRI system) of the engine ac-
cording to the lowest one of these speed
signals.
• Adjust the decelerator pedal speed with the
decelerator pedal linkage.
D275A-5 20-121
(1)
(4)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
2. Preparation work 3. Adjusting decelerator pedal speed

1) Start the engine and set the monitor panel in Keeping the fuel control dial in the high idling po-
the “Adjustment mode” to prepare for mea- sition, press decelerator pedal (2) to the stopper
surement of the engine speed. and check that the decelerator pedal speed is
★ For the operating method, see “SPE- normal.
CIAL FUNCTIONS OF MONITOR PAN- • Decelerator pedal speed: 900 ± 50rpm
EL (EMMS)”. ★ If the decelerator pedal speed is abnormal,
• Adjustment code: adjust dimension a of rod (1).
0007 (Engine decelerator cut mode) • Standard dimension a of rod:
★ The unit of displayed engine speed is 124mm (For reference)
1rpm.
4. High idling speed
Set the fuel control dial in the high idling position
and check that the high idling speed is normal.
★ If the high idling speed is abnormal, adjust it
according to the following procedure.
• High idling speed: 2,150 ± 50rpm
When engine speed is above 1,950rpm:
Lower the engine speed below 1,900rpm
temporarily with stopper bolt (3) to eliminate
the play of the decelerator pedal, then
heighten it to the high idling speed.
When engine speed is below 1,950rpm:
Heighten the engine speed to the high idling
speed with stopper bolt (3).
2) Set the fuel control dial in the high idling po-

sition and check that the engine speed is
above 1,000rpm.
★ If the engine speed is below 1,000rpm,
heighten it above 1,000rpm by increas-
ing dimension a of rod (1).
20-122 D275A-5
(1)
(4)
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE
★ Measuring instruments for power train oil pres- Steering left brake oil pres-
sure 10 LB 5.9 {60}
sure
Steering right clutch oil pres-
Symbol Part No. Name 11 RC 5.9 {60}
sure
1 Steering right brake oil pres-
790-261-1203 Digital hydraulic tester 12 RB 5.9 {60}
sure
Hydraulic tester Transmission lubricating oil
N 2 799-401-2320 13 - 0.98 {10}
(0.98MPa {10kg/cm2}) pressure
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
★ A nipple (quick coupler) is installed to the trans-

mission lubricating oil pressure pickup port of the
Pm clinic specification machine.
¤ Stop the machine on level ground and lower the
work equipment to the ground, then set the park-
ing brake lever and safety lock lever in the lock
position.
★ Measure the power train oil pressure under the
following condition.
★ Centralized pressure pickup ports (1) - (12) are
installed inside the inspection cover on the right
outside of the operator's cab and transmission
lubricating oil pressure pickup port (13) is in-
stalled to the top of the power train filter.
★ Table of locations of centralized pressure pickup

points for measuring oil pressure and gauges to
use
Stam Gauge
No. Oil pressure to be measured
p (MPa {kg/cm2})
Torque converter inlet oil
1 IN 2.5 {25}
pressure
Torque converter outlet oil
2 OUT 0.98 {10}
pressure
Transmission main relief
3 TM 5.9 {60}
pressure
Transmission forward clutch
4 FWD 5.9 {60}
oil pressure
Transmission reverse clutch
5 R 5.9 {60}
oil pressure
Transmission 1st clutch oil
6 1ST 5.9 {60}
pressure
Transmission 2nd clutch oil
7 2ND 5.9 {60}
pressure
Transmission 3rd clutch oil
8 3RD 5.9 {60}
pressure
Steering left clutch oil pres-
9 LC 5.9 {60}
sure
D275A-5 20-123
(1)
(4)
1. Measuring torque converter inlet pressure 2. Measuring torque converter outlet pressure
(IN) (OUT)
1) Connect oil pressure gauge 1 of hydraulic 1) Connect hydraulic tester N1 to oil pressure
tester N1 to oil pressure pick-up nipple (1). pick-up nipple (2).
★ Use an oil pressure gauge of 2.5MPa ★ Use an oil pressure gauge of 0.98MPa
{25kg/cm2}. {10kg/cm2}.
2) Start the engine and set the PCCS lever in 2) Start the engine and set the PCCS lever in
the full neutral position. the full neutral position.
3) Measure the oil pressure while the engine is 3) Measure the oil pressure while the engine is
running at low idling and high idling. running at low idling and high idling.
4) After finishing measurement, remove the 4) After finishing measurement, remove the
measuring instrument and return the re- measuring instrument and return the re-
moved parts. moved parts.
20-124 D275A-5
(1)
(4)
3. Measuring transmission main relief pressure 4. Measuring transmission forward clutch pres-
(TM) sure (FWD)
1) Connect oil pressure gauge 1 of hydraulic 1) Connect oil pressure gauge 1 of hydraulic
tester N1 to oil pressure pick-up nipple (3). tester N1 to oil pressure pick-up nipple (4).
{60kg/cm2}. {60kg/cm2}.
2) Run the engine and set the PCCS lever in 2) Run the engine and set the parking brake le-
the full neutral position. ver in the FREE position.
3) Measure the oil pressure while the engine is 3) Press the brake pedal and set the PCCS le-
running at low idling and high idling. ver in the FORWARD and 3rd gear speed
position.
4) Measure the oil pressure while the engine is
running at low idling.
¤ Since the torque converter will be
stalled, press the brake pedal securely
and keep your right foot on the decelera-
tor pedal for safety until the work is fin-
ished.

moved parts.

moved parts.
D275A-5 20-125
(1)
(4)
5. Measuring transmission reverse clutch pres- 6. Measuring transmission 1st clutch pressure
sure (R) (1ST)
{60kg/cm2}. {60kg/cm2}.
2) Run the engine and set the parking brake le- 2) Run the engine and set the parking brake le-
ver in the FREE position. ver in the FREE position.
3) Press the brake pedal and set the PCCS le- 3) Press the brake pedal and set the PCCS le-
ver in the REVERSE 3rd gear speed position ver in the FORWARD and 1rd gear speed
4) Measure the oil pressure while the engine is position.
running at low idling 4) Measure the oil pressure while the engine is
¤ Since the torque converter will be running at low idling.
stalled, press the brake pedal securely ¤ Since the torque converter will be
and keep your right foot on the decelera- stalled, press pressing the brake pedal
tor pedal for safety until the work is fin- securely.
ished. ¤ Do not raise the engine speed to hight
idling during measurement.

measuring instrument and return the re- 5) After finishing measurement, remove the
moved parts. measuring instrument and return the re-
moved parts.
20-126 D275A-5
(1)
(4)
7. Measuring transmission 2nd clutch pressure 8. Measuring transmission 3rd clutch pressure
(2ND) (3RD)
{60kg/cm2}. {60kg/cm2}.
3) Press the brake pedal and set the PCCS le- 3) Press the brake pedal and set the PCCS le-
ver in the FORWARD and 2nd gear speed ver in the FORWARD and 3rd gear speed
position. position.
running at low idling running at low idling.
¤ Since the torque converter will be ¤ Since the torque converter will be
stalled, keep pressing the brake pedal stalled, keep pressing the brake pedal
securely. securely.
¤ Do not raise the engine speed to high ¤ Do not raise the engine speed to hight
idling during measurement. idling during measurement.
5) After finishing measurement, remove the 5) After finishing measurement, remove the
measuring instrument and return the re- measuring instrument and return the re-
moved parts. moved parts.
D275A-5 20-127
(1)
(4)
9. Measuring steering left clutch pressure (LC) 10. Measuring steering left brake pressure (LB)
{60kg/cm2}. {60kg/cm2}.
3) Set the PCCS lever in the steering neutral 3) Set the PCCS lever in the steering neutral
position. position.
★ Check that the oil pressure lowers to 0 ★ Check that the oil pressure lowers to 0
when the PCCS lever is moved to the left when the PCCS lever is moved to the left
steering stroke end. steering stroke end.
★ Check that the oil pressure lowers to 0
when the brake pedal is pressed or the
parking brake lever is set in the LOCK
position.

moved parts.

moved parts.
20-128 D275A-5
(1)
(4)
11. Measuring steering right clutch pressure (RC) 12. Measuring steering right brake pressure (RB)
{60kg/cm2}. {60kg/cm2}.
3) Set the PCCS lever in the steering neutral 3) Set the PCCS lever in the steering neutral
position. position.
★ Check that the oil pressure lowers to 0 ★ Check that the oil pressure lowers to 0
when the PCCS lever is moved to the when the PCCS lever is moved to the
right steering stroke end. right steering stroke end.
★ Check that the oil pressure lowers to 0
when the brake pedal is pressed or the
parking brake lever is set in the LOCK
position.

moved parts.

moved parts.
D275A-5 20-129
(1)
(4)
13. Measuring transmission lubricating oil pres- 14. Measuring output pressure of sudden stop
sure prevention valve
1) Remove oil pressure pickup plug (13). 1) Connect oil pressure gauge (1) of hydraulic
tester N1 to oil pressure pickup nipples (10)
and (12).
★ Use an oil pressure gauge of 5.9MPa
{60kg/cm2}.
• (10): For steering left brake oil pressure
2) Install nipple N3 and connect hydraulic tester

N2.
{10kg/cm2}.
• (12): For steering right brake oil pressure
3) Run the engine at high idling and measure

the oil pressure
.
2) Run the engine and set the monitor panel in
the adjustment mode.
★ For the method of operating the adjust-
ment mode, see SPECIAL FUNCTIONS
OF MONITOR PANEL (EMMS).
★ Adjustment code: 9995 (Electric brake
constant ON mode)
3) Set the parking brake lever in the FREE po-
sition and set the all PCCS levers in the
NEUTRAL position.
4) Measure the oil pressure while the engine is
running at low idling.
★ If the output pressure of the sudden stop
prevention valve is in the following
4) After finishing measurement, remove the range, it is normal.
measuring instruments and return the re- • 1.13 - 1.57 MPa {11.5 - 16.0 kg/cm2}
moved parts.
20-129-1 D275A-5
(4)

measuring instruments and return the re-
moved parts.
D275A-5 20-129-2
(4)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR
1. Remove the undercover of the fuel tank and then 6. Remove sensor (1) and flange (2) together and
remove transmission speed sensor (1) and secure them with nut (3).
flange together. ★ Take care not to change the adjustment an-
★ Before adjusting transmission speed sensor gle of the sensor.
(1), remove it and check that its tip is free 3 Nut: 49.0 – 68.6Nm {5 – 7kgm}
from steel chips and flaws, then install it
again.
7. Install flange (2) and sensor to the steering case
★ Before installing, separate sensor (1), flange
with the mark of “CB UP” directed to the upper
(2), and nut (3).
side of the steering case.
2. Install flange (2) to the steering case temporarily

8. After finishing adjustment, set the monitor panel
with the mark of “CB UP” directed to the upper
in the “Monitoring display mode” and check that
side of the steering case.
it displays the transmission speed normally.
★ For the operating method, see “SPECIAL
3. Look at bevel gear (4) through the hole of flange
FUNCTIONS OF MONITOR PANEL
(2) and check that a tooth tip is at the center of
(EMMS)”.
the hole.
★ Monitoring code: 31400 (Transmission speed)
★ If the tooth tip is not at the center of the hole,
run the engine and move the machine for-
ward or in reverse to adjust the position of
the tooth tip.
4. Tighten sensor (1) until its tip comes in contact

with the tooth tip of gear (4).
2 Threads of sensor a:
Gasket sealant (LG-5)
5. Return sensor (1) by the specified angle.

★ Returning angle of sensor: 1/2 – 1 turn
★ Adjust clearance b between the sensor tip
and gear tooth tip to 0.75 – 1.50mm.
20-130 D275A-5
1
TESTING AND ADJUSTING SIMPLE METHOD OF TESTING BRAKE PERFORMANCE
SIMPLE METHOD OF TEST-

ING BRAKE PERFORMANCE
★ Carry out the simple test of brake performance

under the following condition.
1. Set the blade and ripper in the travel position on

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

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

pedal and set the PCCS lever in the FORWARD
and 2nd gear speed position.
¤ If this test is carried out in the 1st gear posi-
tion, the brake will be overloaded. Accord-
ingly, be sure to carry out in the 2nd gear
speed.
★ Set the steering unit in neutral.
4. Press the decelerator pedal and set the fuel con-

trol dial in the high idling position.
5. Return the decelerator pedal slowly and check

that the machine does not start when the engine
speed reaches the high idling level.
¤ Since the torque converter will be stalled,
press the brake pedal securely and keep
your right foot on the decelerator pedal for
safety until the work is finished.
D275A-5 20-131
1
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER

Brake pedal side
Parking brake lever side
20-132 D275A-5
(1)
(4)
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
Adjusting brake pedal side ★ For the method of operating the adjustment
1. Adjusting brake pedal stroke mode, see SPECIAL FUNCTIONS OF
Adjust stroke "a" of brake pedal (1) by adjusting MONITOR PANEL (EMMS).
installed dimension "b" of stopper bolt (2). ★ Adjustment code:
★ Adjust the brake pedal stroke with the brake 0005 (Brake potentiometer initial setting)
rod disconnected from the pedal.
• Pedal stroke "a": 74 mm
• Installed dimension "b" of stopper bolt: 42 Adjusting parking brake lever side
mm 6. Assembly and installation of lever assembly
1) Assemble lever assembly (7) and adjust the
2. Adjusting installed length of brake rod operation of limit switch (8).
1) Install brake rod (3) and leave brake pedal ★ Assemble the lever assembly with the
(1) free [Do not press brake pedal (1)]. parking cable disconnected from the le-
2) Adjust installed dimensions "c" and "d" of ver.
brake rod (3) with turnbuckle (5) so that the • When lever is at upper position: OFF, at
spool of brake valve (4) will be at the OFF lower position: ON
position. • • Operating stroke of limit switch: 3 mm
★ The locknut screw of the turnbuckle on 2) Install lever assembly (7).
the brake pedal side is left-handed.
• Installed dimension "c": 32 mm 7. Adjusting installed length of parking cable
• Installed dimension "d": 14 mm 1) Connect parking cable (9) to the lever side
13 Locknut: and valve side, and then adjust installed di-
34.3 – 58.8Nm {3.5 – 6.0kgm} mensions "f" and "g".
• Installed dimension "f" of cable:
112.8 mm
3. Checking brake pedal stroke
• Installed dimension "g" of cable:
1) Press brake pedal (1) and check that its
114.0 mm
stroke is as adjusted in step 1 above.
2) Operate parking lever (10) between the
2) Press brake pedal (1) and check that it is
FREE position and LOCK position and ad-
stopped at stopper (6).
just the position of rod end (11) so that spool
3) Press brake pedal (1) and check that spool
stroke "h" of brake valve (4) will be normal.
stroke "e" of brake valve (4) is in the normal
• Spool stroke "h": 23.0 mm
range at this time.
• Spool stroke "e": 19 – 23 mm
8. Checking brake oil pressure
Run the engine and set the parking brake lever
4. Checking brake oil pressure
in the FREE position and LOCK position and
1) Run the engine and set the monitor panel in
check that the brake oil pressure will be as fol-
the adjustment mode.
lows.
★ For the method of operating the adjust-
★ For the measuring point of the brake oil pres-
ment mode, see SPECIAL FUNCTIONS
sure, see MEASURING POWER TRAIN OIL
OF MONITOR PANEL (EMMS).
PRESSURE.
★ Adjustment code:
• LOCK position: 0, FREE position: Specified
9996 (Electric brake OFF mode)
pressure
sition and press the brake pedal and check
9. Checking limit switch
that brake oil pressures on both sides be-
1) Turn the starting switch ON and set the mon-
come 0 at this time.
itor panel in the display mode.
★ For the point to measure the brake oil
★ For the method of operating the display
pressure, see MEASURING POWER
mode, see SPECIAL FUNCTIONS OF
TRAIN OIL PRESSURE.
MONITOR PANEL (EMMS).
• Monitoring code:
5. Setting brake potentiometer to initial posi-
40910 (Steering controller input signal 1)
tion
Turn the starting switch ON and set the monitor
sition and LOCK position and check that the
panel in the adjustment mode and set the brake
limit switch signals are input normally.
potentiometer to the initial position.
D275A-5 20-133
(1)
(4)
TESTING AND ADJUSTING ADJUSTING PCCS LEVER CONSOLE POSITION
ADJUSTING PCCS LEVER CONSOLE POSITION
1. Set operator’s seat (1) in the forward (dozing)

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

parallel with operator’s seat (1).
★ If the console is not parallel with the opera-
tor’s seat, adjust dimension a of rod (3).
• Standard dimensions a: 179mm
★ The locknut on the rear side of the turnbuck-
le is a left-handed (reversing) screw.
20-134 D275A-5
1
TESTING AND ADJUSTING EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS

TROUBLE
★ Devices used for emergency escape ★ Since the female side of connector PL2
is kept disconnected, mask it with a vinyl
Symbol Part No. Part name sheet, etc.
19M-06-32820 Switch assembly ★ Put switch assembly 1 in the cab
1 7824-66-6430 Register through the cab window.
H
17M-06-41560 Wiring harness
2 790-190-1600 Pump assembly
1. Escape with switch box (Use H1)

★ 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.
★ The engine must be startable for the follow-
ing procedure. If the engine cannot be start-
ed, see EMERGENCY ESCAPE WITH
BRAKE RELEASING DEVICE.
1) Connect switch assembly 1 and register 2 3) Disconnect neutral safety relay (NSF) in the
to wiring harness 3 of emergency escape fuse room and connect pins 3 and 5 of the
device H1. connector on the wiring harness side.
★ Perform this operation only when the en-
¤ Since register 2 controls the drive volt-
gine does not start electrically because
age of the solenoid, connect it to the wir-
of a trouble in the transmission control-
ing harness before connecting to the
ler.
machine.
¤ If the engine is started by this method,
¤ Set the all gear speed switches of switch
the neutral safety function does not
assembly 1 in the OFF position and the
work. Accordingly, before starting the en-
direction switch in the P position to pre-
gine, set the parking brake lever in the
vent the machine from starting suddenly.
LOCK position and set the PCCS lever in
the full neutral position.
¤ Start the engine by this method only in
an emergency. If the engine does not
start in another case, be sure to carry out
troubleshooting and repair the trouble.
2) Open the left fender inspection cover and

connect wiring harness 3 to connectors PL1
(1) and PL2 (2).
• Connector PL1 (1):
Connect to male side and female side.
• Connector PL2 (2):
Connect to male side.
D275A-5 20-135
(1)
(4)
4) Start the engine and set the parking brake le- 2. Escape with brake releasing device (Use H2)
ver in the FREE position. ★ If the engine cannot be started and the park-
5) Operate switch assembly 1 and move the ing brake cannot be released, escape ac-
machine to a safe place. cording to the following procedure.
★ The gear speed switch is so made that 1) Assemble pump assembly H2.
the switch on the lower gear speed will
be operated first.
2) Install volume pump 4 of pump assembly

H2 to the outside of the operator’s cab.
3) Remove the fuel tank undercover and dis-

connect supply hose (3) of the pin puller so-
lenoid valve.
20-136 D275A-5
1
4) Connect end hose 5 of pump assembly H2

to the supply hose.
★ Block the solenoid valve side with plug
6.
5) Turn the starting switch ON and set the park-

ing brake lever in the FREE position.
6) Operate the vacuum pump to raise the brake
releasing oil pressure to the initial pressure.
• Initial pressure:
Approx. 2.74MPa {28kg/cm2}
★ Since an accumulator is installed in the
circuit, the handle must be operated 30 –
50 times to raise the oil pressure.
★ 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.
7) Tow the machine to a safe place.
★ The brake releasing oil pressure lowers
gradually because of internal leakage
and the brake is applied again about 1
minutes after. Accordingly, work quickly.
★ If the brake releasing pressure lowers to
about 1.5MPa {16kg/cm2}, the brake is
applied. In this case, operate the volume
pump again to raise the brake releasing
pressure to the initial pressure.
D275A-5 20-137
1
ADJUSTING CLEARANCE OF IDLER
TESTING AND ADJUSTING INSPECTINGCLEARANCE
ADJUSTING WEAR OF SPROCKET
OF IDLER
ADJUSTING CLEARANCE OF INSPECTING WEAR OF

IDLER SPROCKET
★ If the idler runs out or tilts because of wear of the ★ Make a copy of the “Full-scale drawing of
side guide, upper and lower guides, and guide sprocket tooth profile” on a transparent sheet
plate, adjust according to the following proce- and apply it to the sprocket directly to see if the
dure. sprocket is serviceable.
1. Drive the machine for 1 – 2m on a level place,

then measure clearance a (on the inside and
outside).
2. If clearance a is more than 3mm, remove bolt (1)

and reduce shims (2).
• Standard clearance a on each side:
0 – 0.5mm
• Thicknesses of shim:
0.5mm, 1.0mm
★ When the machine is new, the total thickness
of the shims on each side is 7mm.
★ Reduce the shims on the inside and outside
equally.
3 Mounting bolt:
490 – 608Nm {50 – 62kgm}
20-138 D275A-5
1
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION
Testing
1. Drive the machine slowly on a level place, then
stop it.
★ Do not apply the brake when stopping.
2. Place straight steel bar (1) between the idler and

front carrier roller and measure clearance a be-
tween the bottom of the steel bar and shoe
grouser.
• Standard clearance a: 20 – 30mm
Adjusting
★ If the track shoe tension is abnormal, adjust it ac-
cording to the following procedure.
1. Remove cover (2).
2. When the tension is too high

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

Add grease through grease fitting (4).
★ If the track shoe is not tensed well, drive the
machine forward and in reverse slowly.
D275A-5 20-139
1
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
★ Testing and adjusting instruments for work

equipment oil pressure

1
G
799-101-5220 Nipple (10 × 1.25mm)
2
07002-11023 O-ring
Measuring
¤ Stop the machine on a level place, lower the
work equipment to the ground, and set the park-
ing brake lever and safety lock lever in the LOCK 4) Run the engine at high idling and set the
position. blade lever and ripper lever in neutral and
★ Measure the work equipment oil pressure under measure the oil pressure.
the following condition.
1. Measuring unload pressure

1) Open the right fender inspection cover.
2) Remove work equipment oil pressure sensor
(1).

moved parts.
3) Install nipple G2 and connect oil pressure

gauge 1 of hydraulic tester G1.
{400kg/cm2}.
20-140 D275A-5
1
2. Measuring main relief pressure ★ The unload pressure and main relief pressure
★ Measure the main relief pressure at the can be measured in the “Pm Clinic auxiliary
same point with the unload pressure. mode” of the monitor panel.
{400kg/cm2}.
1) Start the engine and set the safety lock lever

2) Run the engine at high idling and operate the
blade lever and ripper lever to relieve each
cylinder at a stroke end and measure the oil
pressure.

moved parts.
D275A-5 20-141
1
3. Measuring LS pressure (Load Sensing pres-

sure)
1) Open the right fender inspection cover.
2) Remove oil pressure pick-up port (2).

moved parts.
3) Install nipple G2 and connect oil pressure

gauge 1 of hydraulic tester G1.
{400kg/cm2}.
4) Start the engine and set the safety lock lever

5) Run the engine at high idling and operate the
blade lever and ripper lever to relieve each
cylinder at a stroke end and measure the oil
pressure.
20-142 D275A-5
1
Adjusting 4) After finishing adjustment, check both main

★ The unload pressure cannot be adjusted. relief pressure and LS pressure (load sens-
ing pressure) again according to the proce-
1. Adjusting main relief pressure dure for measurement described above.
★ If the main relief pressure is abnormal, adjust
LS relief valve (3) of the control valve ac- 2. Adjusting LS pressure (load sensing pres-
cording to the following procedure. sure)
★ If the LS relief valve is adjusted, the LS pres- ★ If the LS pressure (load sensing pressure) is
sure (load sensing pressure) is changed, abnormal, adjust LS relief valve (3) of the
too. control valve.
★ If the LS relief valve is adjusted, the main re-
lief pressure is changed, too.
★ Adjust the LS pressure similarly to the main
relief pressure.
★ After finishing adjustment, check both LS
pressure (load sensing pressure) and main
relief pressure again according to the proce-
dure for measurement described above.
1) Fixing adjustment nut (4), loosen locknut (5).

2) Turn the adjustment nut (4) to adjust the
pressure.
¤ Do not remove the adjustment nut. If it is
removed, the internal parts may come
off.
★ If the adjustment nut is
• turned to the right, the pressure ris-
es.
• turned to the left, the pressure low-
ers.
★ Quantity of adjustment per turn of adjust-
ment nut:
Approx. 19.6MPa {200kg/cm2}
3) Fixing adjustment nut (4), tighten locknut (5).
3 Locknut:
39 – 49Nm {4 – 5kgm}
D275A-5 20-143
(1)
(4)
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRES-

SURE
★ Testing and adjusting instruments for control cir-

cuit main pressure

1
J 790-261-1203 Digital hydraulic tester
2 799-401-3100 Oil pressure pickup adapter (Size 02)
★ A nipple (quick coupler) is installed to the control

valve outlet hose of the Pm clinic specification
machine.
★ The control circuit main pressure is the pressure
lowered by the self-pressure reducing valve of
the control valve. It is used commonly for work 5. Run the engine at high idling and set the blade
equipment PPC, and fan pump control. lever and ripper lever in neutral and measure the
oil pressure.
Measuring
ing brake lever and safety lock lever in the LOCK
position.
★ Measure the control circuit main pressure under
1. Open the right fender inspection cover.
2. Disconnect hose (1).

Adjusting
★ The self-pressure reducing valve cannot be ad-
justed.
3. Install oil pressure pickup adapter J2 and con-

nect the disconnected hose again.
4. Install nipple 1 of hydraulic tester J1 and con-

nect oil pressure gauge 2.
{400kg/cm2}.
20-144 D275A-5
(4
(1)
4)
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
★ Measuring instruments for PPC valve output 3. Install nipple 1 of hydraulic tester K1 and con-
pressure nect oil pressure gauge 2.

1
K

position.
★ Before measuring the PPC valve output pres-
sure, check that the control circuit main pressure
4. Start the engine and set the safety lock lever in
is normal.
the FREE position.
★ Measure the PPC valve output pressure under
5. Run the engine at high idling and operate the
control lever of the circuit to be measured and
measure the oil pressure.
★ Measure the oil pressure with the lever at a
1. Open the right side cover.
stroke end.
★ When measuring the blade circuit, operate
2. Remove the pressure switch or pressure pick-up
the lever until the blade floats.
lug (1) of the circuit to be measured.
★ For the circuit to be measured, see the draw-
ing on the next page.
★ If a circuit does not have a pressure switch or
a pressure pick-up plug, install oil pressure
pickup adapter K2 or K3.

D275A-5 20-145
(1)
(4)
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
20-146 D275A-5
1
TESTING AND ADJUSTING ADJUSTING PLAY OF PPC VALVE
ADJUSTING PLAY OF PPC VALVE
★ If the end play of the blade lever and ripper lever

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

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

3 Locknut: 98 – 127Nm {10 – 13kgm}
4. Install boot (1).
D275A-5 20-147
1
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID
TESTING AND ADJUSTING VALVE
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER

SOLENOID VALVE
★ Measuring instruments for outlet pressure of rip-

per pin puller solenoid valve

1
P 790-261-1203 Digital hydraulic tester

position.
★ Measure the outlet pressure of the ripper pin
4. Run the engine at high idling and operate the rip-
puller solenoid valve under the following condi-
per pin puller switch and measure the oil pres-
tion.
sure.
1. Disconnect pin puller cylinder hose (1) or (2).

2. Install oil pressure pickup adapter P2 and con-

3. Install nipple 1 of hydraulic tester P1 and con-

nect oil pressure gauge 2.
★ Use an oil pressure gauge of 5.9MPa {60kg/
cm2}.
20-148 D275A-5
(1)
(4)
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND
TESTING AND ADJUSTING RIPPER
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE

AND RIPPER
★ If the blade or ripper drifts hydraulically, check to

see if the cause is on the cylinder packing side
or control valve side according to the following
procedure.
1. Set the cylinders to be tested in the following po-

sitions and stop the engine.
1) Blade lift cylinder
Brace the blade to raise the front side of the
machine body.
★ Since the blade lift cylinder is equipped
with a piston valve, do not extend it to the
stroke end.
2. Extend the cylinder to be tested with the corre-
sponding lever and check its movement.
• If the lowering speed is increased, the cylin-
der packing is defective.
• If the lowering speed does not change, the
control valve is defective.
★ If the pressure in the accumulator is lost, run
the engine for about 10 seconds to heighten
the pressure in the accumulator.
[Reference]
Reason why the lowering speed is increased
when the cylinder packing is the cause of the
2) Blade tilt cylinder hydraulic drift:
Extract the tilt cylinder to the stroke end and 1) If the machine is set in the above position
brace the blade to push up the right side of (where the holding pressure is applied to the
the machine body. bottom side), the oil leaks from the bottom
side to the head side. Since the volume on
the head side is less than that on the bottom
side by the volume of the rod, the pressure in
the head side is increased by the oil flowing
in from the bottom side.
2) As the pressure in the head side is in-
creased, it is balanced at a certain level
(which depends on the leakage), then the
lowering speed is lowered.
3) If the circuit on the head side is opened to the
drain circuit by the above operation of the le-
ver (the bottom side is closed by the check
valve at this time), the oil on the head side
flows in the drain circuit. As a result, the
3) Ripper lift cylinder pressure is unbalanced and the lowering
Brace the ripper to push up the rear side of speed is increased.
the machine body.
D275A-5 20-149
1
TESTING AND ADJUSTING MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYL-

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

block the hose side with a plug.
★ Remove the hose cover of the blade tilt cyl-
inder.
¤ Take care not to disconnect the hose on the
bottom side.
20-150 D275A-5
(1)
(4)
RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDER
TESTING AND ADJUSTING RELEASING RESIDUAL
BLEEDING
PRESSURE
AIR FROM
FROM WORK
WORK EQUIPMENT CYLINDER
RELEASING RESIDUAL BLEEDING AIR FROM WORK

PRESSURE FROM WORK EQUIPMENT CYLINDER
EQUIPMENT CYLINDER
★ When disconnecting the piping between the con- ★ If the work equipment cylinder is removed and
trol valve and work equipment cylinder, release installed or its piping is disconnected and con-
the residual pressure from the circuit according nected, bleed air from its circuit according to the
to the following procedure. following procedure.
1. Loosen the oil filler cap of the hydraulic tank 1. Run the engine at low idling for about 5 minutes.
gradually to release the residual pressure from
the tank. 2. Running the engine at low idling, extend and re-
tract the cylinder to be bled 4 – 5 times.
2. Set the safety lock lever in the FREE position ★ Move the piston rod to about 100mm before
and operate the work equipment control lever to the stroke end and never relieve the oil.
each direction.
★ If the work equipment control lever is operat- 3. Running the engine at high idling and carry out
ed 2 – 3 times, the residual pressure in the the operation in 2.
accumulator is released.
4. Running the engine at low idling, move the cylin-
3. Run the engine at low idling for about 5 seconds, der to the stroke end to relieve the oil.
then stop it.
4. Repeat steps 2 – 3 above 2 – 3 times.
D275A-5 20-151
1
TESTING AND ADJUSTING ADJUSTING RIPPER LEVER POSITION
ADJUSTING RIPPER LEVER POSITION
★ Adjust the ripper lever to the best position ac- 5) Loosen nut (3).
cording to the following procedure. 6) Reverse knob (4).
★ The ripper lever can be adjusted forward and in 7) Tighten nut (3) to secure knob (4).
reverse within the range of ±40mm from the cen-
ter 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).
20-152 D275A-5
1
TESTING AND ADJUSTING ADJUSTING SAFETY LOCK LEVER
ADJUSTING SAFETY LOCK LEVER
1. Adjust dimension a between pins of rod (1).

• Dimension a between pins: 444mm
2. Connect rod (1) to safety lock lever (2) and PPC

lock valve (3).
★ Install connecting pin (4) on the safety lock
lever side with the cotter pin on the outside
of the machine.
D275A-5 20-153
1
MEASURING FAN MOTOR SPEED
TESTING AND ADJUSTING MEASURING FAN CIRCUIT
MEASURING FAN OIL PRESSURE
MOTOR SPEED
MEASURING FAN MOTOR MEASURING FAN CIRCUIT

SPEED OIL PRESSURE
★ Measuring instruments for fan motor speed ★ Measuring instruments for fan circuit oil pressure
Symbol Part No. Name Symbol Part No. Name

M 799-203-8001 Multitachometer 799-101-5002 Hydraulic tester
1
1. Open the radiator mask and stick 1 sheet of re- Oil pressure pickup adapter
flecting tape 1 to the fan. Q 2 799-401-3400
(Size: 05)
2. Set stand 3 of probe 2 of multitachometer M, 799-101-5220 Nipple (10 x 1.25 mm)
matching it to reflecting tape 1, then connect it 3
07002-11023 O-ring
to multitachometer M
¤ Take care that the probe will not interfere
with the fan. ★ A nipple (quick coupler) is installed to the fan
pump outlet hose of the Pm clinic specification
machine.
¤ Stop the machine on level ground and lower the
work equipment to the ground, then set the park-
ing brake lever and safety lock lever in the lock
position.
★ Measure the fan circuit oil pressure under the fol-
lowing condition.
• Hydraulic oil temperature: Within operating
range
1. Remove the floor inspection cover and discon-

nect hose (1).
3. Close the radiator.

¤ Be sure to close the radiator mask before
starting the engine. Do not start the engine
with the radiator mask open.
4. Run the engine and set the monitor panel in the
adjustment mode.
★ For the method of operating the adjustment
★ Adjustment code: 1005 (Fan 100% speed
mode)
5. Measure the fan motor speed while the engine is
running at high idling and low idling.
2. Install oil pressure pickup adapter Q2 and con-
3. Install nipple Q3 and connect oil pressure gauge

(1) of hydraulic tester Q1.
★ Use an oil pressure gauge of 39.2 MPa {400
kg/cm2}.

20-154 D275A-5
(4)
MEASURING FAN CIRCUIT OIL PRESSURE
TESTINGAND
TESTING ANDADJUSTING
ADJUSTING CHANGING ROTATION DIRECTION OF FAN MOTOR
CHANGING ROTATION
DIRECTION OF FAN MOTOR
★ When reversing the current of the cooling air in

the cold season or reversing it for cleaning the
radiator fins, change the rotation direction of the
fan motor according to the following procedure.
¤ When changing the rotation direction of the fan
motor, be sure to stop the engine.
¤ When starting the engine, be sure to close the
radiator mask.
1. Open the radiator mask and loosen locknut (1).
2. Turn screw (2) to change the position of spool

(3).
4. Run the engine and set the monitor panel in the
★ Turn or return the screw until the spool end
adjustment mode.
is stopped by the motor case.
★ For the method of operating the adjustment
• NORMAL: Normal direction (to pull air)
• REVERSE: Reverse direction (to push air)
★ Adjustment code:
3. Secure screw (2) with locknut (1) and close the
1005 (Fan 100% speed mode)
radiator mask.
5. Measure the fan circuit oil pressure while the en- 3 Locknut: 59 – 74Nm {6.0 – 7.5kgm}
gine is running at high idling and low idling.

suring instruments and return the removed
parts.
D275A-5 20-154-1
(4)
TESTING AND ADJUSTING BLEEDING AIR FROM FAN PUMP
BLEEDING AIR FROM FAN PUMP
★ 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 bleeder (1) and leave it for 15 min-

utes.
3. After 15 minutes, run the engine at low idling.
4. After oil flows out of air bleeder (1), tighten air

bleeder (1).
D275A-5 20-155
1
TESTING AND ADJUSTING ADJUSTING BLADE
ADJUSTING BLADE
★ If the blade is removed and installed or disas- 2) Adjust the shim of lift (2).
sembled and reassemble, adjust it according to
the following procedure. Adjusted Adjusted Standard Standard
shim
point clearance clearance thickness
1. Adjusting shims for assembly
2 b Max. 1mm 4.0mm
1) Adjust the shim of center (1).
Adjusted Adjusted Standard Standard

shim
1 a See note. 4.5mm
Note: Adjust the shim so that the play of the

ball in the axial direction will be less
than 1mm and the ball can rotate
smoothly.
20-156 D275A-5
1
TESTING AND ADJUSTING ADJUSTING BLADE
3) Adjust the shim of trunnion (3).
Adjusted Adjusted Standard Standard

shim
1.56 ± 0.65mm
3 c (Total 12mm
thickness)
2. Adjusting blade tilt distance

1) Adjust dimension d of brace (4) with the han-
dle.
• Dimension d of brace: 1,460mm
2) Measure right and left tilt distances e1 and
e2.
• Right tilt distance e1: Approx. 700mm
• Left tilt distance e2: Approx. 700mm
3) If both tilt distances are not the same, adjust
dimension d of brace (4) according to the fol-
lowing procedure.
• e1 > e2: Increase dimension d finely.
• e1 < e2: Decrease dimension d finely.
D275A-5 20-157
1
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Display section of special func- Operation section 1 of special Operation section 2 of special
tions functions functions
(Basic operation) (Changeover operation)
1. Gear speed display section 3. Service switch 4. Buzzer cancel switch
2. Multi-information section 5. Information switch
6. Shift-up switch
7. Shift-down switch
★ EMMS: Equipment Management Monitoring System

★ The monitor panel with the SSC specification is partly different from the above figure but it is operated sim-
ilarly.
20-158 D275A-5
(6)
1
Normal function and special functions of monitor panel (EMMS)

The monitor panel (EMMS) has the normal function and special functions and displays information of various
types at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed according to the operation of the switches.
1. Normal function: Operation mode
With this function, the operator can display and change the items displayed normally.
2. Special function: Service mode
With this function, a serviceman can display and change the displayed items with special switches for test-
ing, adjusting, and troubleshooting.
Flow of modes and functions
Operator mode
Normal display (Default) 1 Maintenance mode Maintenance item: 11 items
➨
➨
[>] [<]
2 Pm clinic auxiliary mode Auxiliary menu: 4 items
Travel direction/Gear speed ➨
➨
➨
[ ] [>] [<]
+
(q) 3 Error code display mode
Shift mode/Service meter
➨ ➨
➨
[>] [<]
[ ] 4 Adjustment mode Adjustment menu: 4 items
➨
➨
[>] [<]
➨
(Automatic) 1 Maintenance mode
Action code display function

➨
➨
[ON] & [ ](q) [ ]
Service mode
Maintenance interval change

5 Maintenance item: 12 items
mode
➨
➨
[>] [<]
Electric system error code
6
display mode
➨
➨
[>] [<]
Mechanical system error code
7
display mode
➨
➨
[>] [<]
8 Adjustment mode Adjustment menu: 21 items
➨
➨
[>] [<]
9 Load memory display mode Display menu: 3 items
➨
➨
[>] [<]
10 Real-time monitoring mode
➨
➨
[>] [<]
11 Dual display monitoring mode [ON]: Service switch
[ ]: Buzzer cancel switch (Left)
➨
➨
[>] [<]
[ ]: Buzzer cancel switch (Right)
Maintenance interval change [ > ]: Information switch (Right)
5
mode [ < ]: Information switch (Left)
(q): Min. 2.5 sec
D275A-5 20-159
(1)
(4)
Operation and display in operator mode (Outline)

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

The monitor panel displays the following information
normally.
Gear speed display section (1):
• Left side: Travel direction (P·N·F·R)
• Right side: Gear speed (1·2·3)
• Graphics: Engine speed
Multi-information section (2):
★ Information is displayed in 2 lines of 16 charac-
ters each.
• Left side:
Gear shift mode (F1-R1·F1-R2·F2-R2)
• Right side:
Service meter (Unit: 0.1h)
★ To change the normal display mode to the oper-
ator mode, hold buzzer cancel switch (4) in the
[ ] 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-infor-
mation section (2) and reset after the replace-
ment.
★ Gear speed display section (1) keeps dis-
playing normally.
Order Display Item

1 01:ENG OIL Engine oil
2 02:ENG FLT Engine oil filter
3 03:BYPS FLT Bypass filter
4 04:FUEL FLT Fuel filter
5 05:CORR FLT Corrosion resistor
6 06:P/L OIL Power train oil
7 07:P/L FLT Power train oil filter
8 08:HYD OIL Hydraulic oil
9 09:HYD FLT Hydraulic oil filter
10 10:DAMP OIL Damper oil
11 11:F/D OIL Final drive oil
20-160 D275A-5
(1)
(4)
2. Pm clinic auxiliary mode

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

1 01:ENG. SPEED Engine speed
2 02:BOOST PRESSURE Boost pressure
03:HYD. PUMP PRES Work equipment oil
3
pressure
4 04:BATTERY VOLT Battery voltage
3. Error code display mode

(3-FAULT CODE DISPLAY MODE)
In this mode, the contents of each fault in the
machine are displayed by a 6-character error
code on the multi-information section (2).
When the user or the operator needs to be noti-
fied of the error code of each fault, this mode is
applied.
playing normally.
★ When a serviceman needs to check the error
codes for troubleshooting, the Electric sys-
tem error code display mode and the Me-
chanical system error code display mode
should be used for more detailed informa-
tion.
★ Method of checking error code:
Turn buzzer cancel switch (4) to the [ ] po-
sition on the screen shown at right, and the
all error codes detected currently are dis-
played at the interval of about 2 seconds. (To
finish displaying, turn the buzzer cancel
switch to the [ ] position.)
D275A-5 20-161
1
(5)
Error codes table
Error Action Caution Caution

Fault part Fault Controller
code code lamp buzzer
1500L0 Transmission clutch q See separate table (L0) Transmission CALL E03 ● ●
15SAL1 Forward clutch q See separate table (L1) Transmission CALL E03 ● ●
15SALH Forward clutch q See separate table (LH) Transmission CALL E03 ● ●
15SBL1 Reverse clutch q See separate table (L1) Transmission CALL E03 ● ●
15SBLH Reverse clutch q See separate table (LH) Transmission CALL E03 ● ●
15SEL1 1st clutch q See separate table (L1) Transmission CALL E03 ● ●
15SELH 1st clutch q See separate table (LH) Transmission CALL E03 ● ●
15SFL1 2nd clutch q See separate table (L1) Transmission CALL E03 ● ●
15SFLH 2nd clutch q See separate table (LH) Transmission CALL E03 ● ●
15SGL1 3rd clutch q See separate table (L1) Transmission CALL E03 ● ●
15SGLH 3rd clutch q See separate table (LH) Transmission CALL E03 ● ●
2201L1 Right clutch q See separate table (L1) Steering CALL E04 ● ●
2201LH Right clutch q See separate table (LH) Steering CALL E04 ● ●
2202L1 Left clutch q See separate table (L1) Steering CALL E04 ● ●
2202LH Left clutch q See separate table (LH) Steering CALL E04 ● ●
2301L1 Right brake q See separate table (L1) Steering CALL E04 ● ●
2301LH Right brake q See separate table (LH) Steering CALL E04 ● ●
2302L1 Left brake q See separate table (L1) Steering CALL E04 ● ●
2302LH Left brake q See separate table (LH) Steering CALL E04 ● ●
AB00MA Alternator Malfunction (MA) Machine
AD00L2 Common rail q See separate table (L2) Engine E02 ● ●
AD00MA Common rail Malfunction (MA) Engine E02 ● ●
AD10L3 Fuel supply pump q See separate table (L3) Engine CALL E03 ● ●
AD10MA Fuel supply pump Malfunction (MA) Engine CALL E03 ● ●
AD10MB Fuel supply pump Defective function (MB) Engine E02 ● ●
AD11KA Fuel supply pump solenoid 1 Disconnection (KA) Engine CALL E03 ● ●
AD11KB Fuel supply pump solenoid 1 Short circuit (KB) Engine CALL E03 ● ●
AD51KA Fuel supply pump solenoid 2 Disconnection (KA) Engine CALL E03 ● ●
AD51KB Fuel supply pump solenoid 2 Short circuit (KB) Engine CALL E03 ● ●
ADA1KA No. 1 injector solenoid Disconnection (KA) Engine E02 ● ●
ADAZKB No. 1, 2, 3 injector solenoid Short circuit (KB) Engine CALL E03 ● ●
ADB1KA No. 2 injector solenoid Disconnection (KA) Engine E02 ● ●
ADC1KA No. 3 injector solenoid Disconnection (KA) Engine E02 ● ●
ADD1KA No. 4 injector solenoid Disconnection (KA) Engine E02 ● ●
ADDZKB No. 4, 5, 6 injector solenoid Short circuit (KB) Engine CALL E03 ● ●
ADE1KA No. 5 injector solenoid Disconnection (KA) Engine E02 ● ●
ADF1KA No. 6 injector solenoid Disconnection (KA) Engine E02 ● ●
B@BAZG Engine oil Oil pressure reduction (ZG) Machine
B@BCNS Radiator coolant Overheat (NS) Machine
B@BCZK Radiator coolant Level reduction (ZK) Machine
B@CENS Power train oil Overheat (NS) Machine
20-162 D275A-5
1

B@HANS Hydraulic oil Overheat (NS) Machine ●
D110KA Battery relay Disconnection (KA) Steering
D110KB Battery relay Short circuit (KB) Steering
D130KA Neutral safety relay Disconnection (KA) Transmission E02 ● ●
D130KB Neutral safety relay Short circuit (KB) Transmission E02 ● ●
D161KA Back-up alarm relay Disconnection (KA) Transmission E01
D161KB Back-up alarm relay Short circuit (KB) Transmission E01
D1D0KB Engine controller load power relay Short circuit (KB) Engine CALL E04 ● ●
DAFRKR Monitor panel CAN communication Defective communication (KR) Monitor CALL E03 ● ●
DAQ0KK Transmission controller Lowering of source voltage(Input) (KK) Transmission CALL E04 ● ●
DAQ0KT Transmission controller Fault in controller (KT) Transmission E02 ● ●
DAQ5KK Transmission controller potentiometer power Lowering of source voltage(Input) (KK) Transmission CALL E03 ● ●
DAQ6KK Transmission controller sensor power Lowering of source voltage(Input) (KK) Transmission E01
DAQ9KQ Transmission controller model checking Nonconformance of model selection signal (KQ) Transmission CALL E04 ● ●
Defective communication(Abnormality in objec-
DAQRKR Transmission controller CAN communication Transmission CALL E03 ● ●
tive component) (KR)
DAQSKR Transmission controller SNET communication Transmission E01
DB20KT Engine controller Fault in controller (KT) Engine CALL E03 ● ●
DB22KK Engine controller load power Lowering of source voltage(Input) (KK) Engine CALL E04 ● ●
DB29KQ Engine controller model selection Nonconformance of model selection signal (KQ) Engine CALL E03 ● ●
DB2AMA Fuel injection amount adjustment switch signal Malfunction (MA) Engine CALL E03 ● ●
DB2RKR Engine controller CAN communication Engine CALL E03 ● ●
DB30KK Steering controller Lowering of source voltage(Input) (KK) Steering CALL E04 ● ●
DB30KT Steering controller Fault in controller (KT) Steering E01
DB35KK Steering controller potentiometer power Lowering of source voltage(Input) (KK) Steering CALL E03 ● ●
DB36KK Steering controller sensor power Lowering of source voltage(Input) (KK) Steering CALL E03 ● ●
DB39KQ Steering controller model checking Nonconformance of model selection signal (KQ) Steering CALL E04 ● ●
DB3RKR Steering controller CAN communication Steering CALL E03 ● ●
DB3SKR Steering controller SNET communication Steering E01
DD11KB Starting switch Short circuit (KB) Engine CALL E04 ● ●
DD12KA Shift-up switch Disconnection (KA) Transmission E02 ● ●
DD12KB Shift-up switch Short circuit (KB) Transmission E02 ● ●
DD13KA Shift-down switch Disconnection (KA) Transmission E02 ● ●
DD13KB Shift-down switch Short circuit (KB) Transmission E02 ● ●
DD14KA Parking brake lever switch Disconnection (KA) Transmission CALL E03 ● ●
DD14KB Parking brake lever switch Short circuit (KB) Transmission CALL E03 ● ●
DDE2L6 Engine oil pressure switch q See separate table (L6) Engine CALL E03 ● ●
q See separate table (LD)

Ripper lift raise oil pressure switch
DDN4LD Steering
[SSC specification]

Ripper lift lower oil pressure switch
DDN5LD Steering
[SSC specification]

Ripper tilt oil pressure switch
DDN6LD Steering
[SSC specification]
DDN7KA Blade pitch switch Disconnection (KA) Transmission E02 ● ●
DDN7KB Blade pitch switch Short circuit (KB) Transmission E02 ● ●
DDN9KA Blade tilt switch Disconnection (KA) Transmission E01
DDN9KB Blade tilt switch Short circuit (KB) Transmission E01
DDQ2KA Parking brake lever switch Disconnection (KA) Steering CALL E03 ● ●
D275A-5 20-163
(1)
(4)

DDQ2KB Parking brake lever switch Short circuit (KB) Steering CALL E03 ● ●
DDQ2L4 Parking brake lever switch q See separate table (L4) Steering CALL E03 ● ●
Engine water temperature sensor
DGE2KX Out of input signal range (KX) Engine CALL E03 ● ●
(for high temperature)
q See separate table (L6)

Engine water temperature sensor
DGE3L6 Engine E02 ● ●
(for low temperature)
DGE4KX Fuel temperature sensor Out of input signal range (KX) Engine E01
DGS1KX Hydraulic oil temperature sensor Out of input signal range (KX) Transmission
DH21KA Work equipment pump oil pressure sensor Disconnection (KA) Transmission E01
DH21KB Work equipment pump oil pressure sensor Short circuit (KB) Transmission E01
DH30KX Boost pressure sensor Out of input signal range (KX) Engine E02 ● ●
DH40KX Common rail pressure sensor Out of input signal range (KX) Engine CALL E03 ● ●
DK10KX Fuel control dial Out of input signal range (KX) Engine CALL E03 ● ●
DK12KX Deceleration potentiometer Out of input signal range (KX) Engine CALL E03 ● ●
DK30KA Steering potentiometer 1 Disconnection (KA) Steering CALL E03 ● ●
DK30KB Steering potentiometer 1 Short circuit (KB) Steering CALL E03 ● ●
DK30KX Steering potentiometer 1 Out of input signal range (KX) Steering CALL E04 ● ●
DK30KZ Steering potentiometer 1 Disconnection or short circuit (KZ) Steering CALL E04 ● ●
DK30L8 Steering potentiometer 1 q See separate table (L8) Steering CALL E03 ● ●
DK31KA Steering potentiometer 2 Disconnection (KA) Steering CALL E03 ● ●
DK31KB Steering potentiometer 2 Short circuit (KB) Steering CALL E03 ● ●
DK40KA Brake potentiometer Disconnection (KA) Steering CALL E03 ● ●
DK40KB Brake potentiometer Short circuit (KB) Steering CALL E03 ● ●
DK55KX Forward/Reverse potentiometer Out of input signal range (KX) Transmission CALL E04 ● ●
DK55KZ Forward/Reverse potentiometer Disconnection or short circuit (KZ) Transmission CALL E04 ● ●
DK55L8 Forward/Reverse potentiometer q See separate table (L8) Transmission CALL E03 ● ●
DK56KA Forward/Reverse potentiometer 1 Disconnection (KA) Transmission CALL E03 ● ●
DK56KB Forward/Reverse potentiometer 1 Short circuit (KB) Transmission CALL E03 ● ●
DK57KA Forward/Reverse potentiometer 2 Disconnection (KA) Transmission CALL E03 ● ●
DK57KB Forward/Reverse potentiometer 2 Short circuit (KB) Transmission CALL E03 ● ●
DK60KA Acceleration sensor (SSC specification) Disconnection (KA) Steering E01
DK60KB Acceleration sensor (SSC specification) Short circuit (KB) Steering E01
DKH1KA Pitch angle sensor Disconnection (KA) Steering CALL E03 ● ●
DKH1KB Pitch angle sensor Short circuit (KB) Steering CALL E03 ● ●
DLE3LC Engine Ne speed sensor q See separate table (LC) Engine CALL E03 ● ●
DLF1KA Transmission output speed sensor Disconnection (KA) Transmission E01 ● ●
DLH1LC Engine G speed sensor q See separate table (LC) Engine CALL E03 ● ●
DV00KB Caution buzzer Short circuit (KB) Monitor E02 ●
DW59KA Blade dual selection solenoid Disconnection (KA) Transmission E01
DW59KB Blade dual selection solenoid Short circuit (KB) Transmission E01
DW5AKA Blade pitch selection solenoid Disconnection (KA) Transmission E02 ● ●
DW5AKB Blade pitch selection solenoid Short circuit (KB) Transmission E02 ● ●
DWN3KA Emergency stop prevention solenoid Disconnection (KA) Steering CALL E04 ● ●
DWN3KB Emergency stop prevention solenoid Short circuit (KB) Steering CALL E04 ● ●
DWN5KA Fan pump solenoid Disconnection (KA) Transmission E01
DWN5KB Fan pump solenoid Short circuit (KB) Transmission E01
DXH4KA 1st clutch ECMV Disconnection (KA) Transmission CALL E03 ● ●
DXH4KB 1st clutch ECMV Short circuit (KB) Transmission CALL E03 ● ●
DXH5KA 2nd clutch ECMV Disconnection (KA) Transmission CALL E03 ● ●
DXH5KB 2nd clutch ECMV Short circuit (KB) Transmission CALL E03 ● ●
20-164 D275A-5
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(4)

DXH6KA 3rd clutch ECMV Disconnection (KA) Transmission CALL E03 ● ●
DXH6KB 3rd clutch ECMV Short circuit (KB) Transmission CALL E03 ● ●
DXH7KA Reverse clutch ECMV Disconnection (KA) Transmission CALL E03 ● ●
DXH7KB Reverse clutch ECMV Short circuit (KB) Transmission CALL E03 ● ●
DXH8KA Forward clutch ECMV Disconnection (KA) Transmission CALL E03 ● ●
DXH8KB Forward clutch ECMV Short circuit (KB) Transmission CALL E03 ● ●
DXH9KA Right clutch ECMV Disconnection (KA) Steering CALL E03 ● ●
DXH9KB Right clutch ECMV Short circuit (KB) Steering CALL E03 ● ●
DXHAKA Left clutch ECMV Disconnection (KA) Steering CALL E03 ● ●
DXHAKB Left clutch ECMV Short circuit (KB) Steering CALL E03 ● ●
DXHBKA Right brake ECMV Disconnection (KA) Steering CALL E04 ● ●
DXHBKB Right brake ECMV Short circuit (KB) Steering CALL E04 ● ●
DXHCKA Left brake ECMV Disconnection (KA) Steering CALL E04 ● ●
DXHCKB Left brake ECMV Short circuit (KB) Steering CALL E04 ● ●
Separate table: Trouble codes list
Trouble code Detail of trouble Trouble code Detail of trouble
KA Disconnection L4 ON/OFF signals do not agree with each other
Operation state and stop state do not agree with sig-

KB Short circuit L6
nals
KK Lowering of source voltage (Input) L8 Analog signals do not agree with each other
KQ Disagreement of model selection signals LC Speed signals do not agree with each other
Communication defective (Abnormality in objective

KR LD Switch is pressed for long time
component)
When command current is turned ON, fill signal is

KT Internal defect of controller LH
turned OFF
KX Out of input signal range MA Malfunction
KZ Disconnection or short circuit MB Lowering of function
L0 Double engagement MW Slip
When command current is turned OFF, fill signal is

L1 NS Overheating
turned ON
L2 Fuel pressure is too high ZG Lowering of oil pressure
L3 Objective part cannot be controlled ZK Lowering of level
★ "Controller" in the table indicates classification of the controller in charge of system check, monitor panel,
and code.
MON: Fault code of electric system checked by monitor panel
ENG: Fault code of electric system checked by engine controller
T/M: Fault code of electric system checked by transmission controller
S/T: Fault code of electric system checked by steering controller
Machine: Fault code of mechanical system
D275A-5 20-165
(1)
(4)
4. Adjustment mode (4-USER ADJUST MODE)

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

Adjustment of LCD
1 01:LCD BRIGHTNES
brightness
Adjustment of display
2 02:DSP BRIGHTNES
brightness
Adjustment of display
3 03:DSP CONTRAST
contrast
Fan 100% speed
4 04:FAN 100% SPEED mode (For cleaning
radiator)
20-166 D275A-5
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(4)
Action code display function

If a fault to be notified to the operator occurs during
work, an action code and a phone No. are displayed
on the multi-information section (2).
★ Gear speed display section (1) keeps displaying
normally.
★ 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.)
★ If an important action code is displayed, the cau-
tion lamp flashes and the caution buzzer sounds.
<Reference>
An action code is displayed only when a serious fault
occurs.
Even if an action code is not displayed, a fault may
have occurred. If you feel any abnormality, be sure
to check for a error code in the “Electric system error
code display mode” and “Mechanical system error
code display mode” of the service mode.
Action codes table
Action
Indication method of fault Contents of fault Remedy
code
• Automatic function stops or nor-
mal function stops partially but
• Blade dual tilt mechanism does
E01 • Only action code is displayed. machine can work.
not work.
• Call your Komatsu distributor for
repair.
• Stop engine and start it again,
• Gear is not shifted up or down. and you can operate machine
• Action code is displayed.
• Blade tilt is not limited. without limiting function. You
E02 • Caution lamp flashes.
• Blade pitch mechanism does not must take care, however.
• Caution buzzer sounds.
work. • Call your Komatsu distributor for
repair.
• Engine water temperature is de-
fective.
• Usable gear speeds are limited.
• Action code is displayed. • Move machine to safe place.
• Engine speed does not rise fully.
CALL E03 • Caution lamp flashes. • Call your Komatsu distributor for
• Gear shifting shocks become
• Caution buzzer sounds. repair.
large.
• Steering performance lowers.
• Brake shocks become large.
• Action code is displayed. • Engine cannot be controlled. • Stop machine immediately.
CALL E04 • Caution lamp flashes. • Machine cannot travel. • Call your Komatsu distributor for
• Caution buzzer sounds. • Machine stops. repair.
D275A-5 20-167
1
Operation and display in service mode

Method of changing to service mode
★ 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 op-
erating service switch (3) and buzzer cancel
switch (4).
• Keeping the service switch in the ON posi-
tion, hold the buzzer cancel switch in the [ ]
position for 2.5 seconds.
★ If the monitor panel (1) is set in the service
mode, [1C] is displayed on the gear speed
display section.
★ Each time the monitor panel is set in the ser-
vice mode, the “Maintenance interval
change mode” is displayed first.
2) Selecting and executing mode to be used

Select the mode to be used with information
switch (5) and execute it with buzzer cancel
switch (4).
• [ > ]: Next mode No.
• [ < ]: Previous mode No.
• [ ]: Execute mode.
★ For the details of operation in each mode,
see the following pages.
Or- Gear speed
Display and item
der display
3) Finishing mode and function
The current mode and function can be finished 5-EXCHG. INTVAL. SET MODE
1 1C
by either of the following method, regardless of Maintenance interval change mode
the current mode and hierarchy. 6-ELEC. FAULT CODE MODE
1 When continuing the operation in another 2 EE Electric system fault code display
mode or function or in the operator mode: mode
Return to the mode screen or function
7-MACHINE FAULT CODE MODE
screen to be used next by operating buzzer
cancel switch (4). 3 bE Mechanical system fault code dis-
• [ ]: Screen returns. play mode
2 When finishing the all operation: 8-SERVICE ADJUST MODE
4 Cb
Turn off the starting switch. Adjustment mode
9-LOAD MEMORY DISPLAY
5 Ld MODE
Load memory display mode
10-REAL TIME MONITORING
6 5R MODE
Real time monitoring mode
11-DUAL DISPLAY MONITORING
7 dR MODE
Dual display monitoring mode
20-168 D275A-5
(1)
(4)
5. Maintenance interval change mode

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

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

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

The following items are displayed on the in-
formation section.
1: Code
2: Maintenance item
3: Replacement interval time (Set time)
★ The items shown at right are examples.
★ If the replacement interval does not need
to be changed, finish the operation on
this screen.
★ If the replacement interval needs to be
changed, go to step 4).
D275A-5 20-169
1
4) Changing replacement interval time

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

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

change of setting by operating buzzer
cancel switch (4).
• [ ]: Enter change.
★ If the change is finished normally, the
information display screen appears
after the screen shown at right.
★ If the change is not finished normally,

the information display screen be-
fore the change appears after the
screen shown at right. In this case,
execute the above operation again.
20-170 D275A-5
1
Maintenance items table
Replacement interval time

Order Display Item 1st time 2nd time and after
(Cannot be changed) (Can be changed)
1 01:ENG OIL Engine oil 0500h 0500h
2 02:ENG FLT Engine oil filter 0500h 0500h
3 03:BYPS FLT Bypass filter — —
4 04:FUEL FLT Fuel filter 0250h 0500h
5 05:CORR FLT Corrosion resistor 1000h 1000h
6 06:P/L OIL Power train oil 0250h 1000h
7 07:P/L FLT Power train oil filter 0250h 0500h
8 08:HYD OIL Hydraulic oil 0250h 2000h
9 09:HYD FLT Hydraulic oil filter 0250h 2000h
10 10:DAMP OIL Damper oil 2000h 2000h
11 11:F/D OIL Final drive oil 0250h 000h
★ 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.
D275A-5 20-171
1
(4)
6. Electric system error code display mode

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

i) Select “Electric system error code display
mode” on the mode selection screen.
★ If the mode is selected, code (EE) is
ii) Display the error code display screen by
operating buzzer cancel switch (4).
2) Display in the case where no codes are re-

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

are recorded
If any error code has been output up to now,
the information section displays as shown at
right.
1: Record No. (Up to 20)
2: Error code (Code being output currently
is flashing)
3: Number of past occurrences
4: Time measured by service meter after
first occurrence
last occurrence
★ For the details of displayed error codes,
see the “ERROR CODES TABLE” in the
operator mode.
20-172 D275A-5
1
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★ Flashing and lighting of error code

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

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

While a error code to be deleted, operate
shift-up switch (6) or shift-down switch (7).
• [UP] or [DOWN]: Delete error code.
★ A error code which is being output cur-
rently (which is flashing) cannot be delet-
ed.
D275A-5 20-173
1
7. Mechanical system error code display mode

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

i) Select “Mechanical system error code
display mode” on the mode selection
screen.
★ If the mode is selected, code (bE) is
ii) Display the error code display screen by
operating buzzer cancel switch (4).
2) Display in the case where no codes are re-

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

are recorded
If any error code has been output up to now,
the information section displays as shown at
right.
1: Record No. (Up to 20)
2: Error code (Code being output currently
is flashing)
3: Number of past occurrences
first occurrence
last occurrence
★ For the details of displayed error codes,
see the “ERROR CODES TABLE” in the
operator mode.
20-174 D275A-5
1
(5)
★ Flashing and lighting of error code

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

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

The mechanical system error codes cannot
be deleted.
D275A-5 20-175
1
8. Adjustment mode
(8-SERVICE ADJUST MODE)
In this mode, you can adjust the control system
and various devices of the machine.

i) Select “Adjustment mode” on the mode
selection screen.
★ If the mode is selected, code (Cb) is
ii) Display the adjustment code input
switch (4).
2) Selecting adjustment items

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

1: Code
2: Adjustment item
3: Related information
★ For the detailed information and adjust-
ment procedure, see “ADJUSTMENT
MODE TABLE AND ADJUSTMENT
PROCEDURE”.
20-176 D275A-5
1
★ If an incorrect code is input, the adjust-

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

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

ited function)
After one of some adjustment items is select-
ed, if the information switch is operated, the
next adjustment item is selected automati-
cally, even if the code of the next adjustment
item is not input.
• [>]: Code is increased
• [<]: Code is decreased
★ This function is applied to only the items
having numbers in the Automatic selec-
tion column of the Adjustment mode ta-
ble. Those items are selected in the
order of their numbers.
★ Note that this operation is not effective
while the parking brake lever is in the
RESET position.
★ You may return to the screen for input-
ting codes and enter a code without us-
ing this function.
D275A-5 20-177
1
(4)
Adjustment mode table and adjustment procedure
Disas- Auto-
Related sembly/ matic
No. Code Adjustment item
information Assem- selec-
bly tion
1 0001 INP TEL NO. Phone No. input mode Figure/Symbol
2 0002 S/T S.CODE Steering controller specification set Code q 1
3 0003 T/M S.CODE Transmission controller specification set Code q 2
4 0004 BODY TYPE Machine specification set Code q 3
5 0005 BRAKE BASE Brake potentiometer Zero-point adjustment Voltage q 4
6 0007 ENG.FULL CH Engine deceleration-cut mode Speed 5
7 0008 INJ->123456 Common rail reduced cylinder mode Speed
8 0009 PITCH SENS. Pitch angle sensor initial set Voltage 6
9 0010 FAN 70%MODE Fan 70% speed mode Speed 7
A 1005 FAN100%MODE Fan 100% speed mode Speed 8
B 1012 S/T N-SET Steering lever neutral set Voltage
C 1013 S/T M.L-SET Steering lever left set Voltage
D 1014 S/T M.R-SET Steering lever right set Voltage
E 1015 BRK LH. OFST Left brake oil pressure adjustment mode Pressur
F 1016 BRK RH. OFST Right brake oil pressure adjustment mode Pressur
G 2233 R SLOW CUT Reverse slow stop set Letter
H 5535 CLUTCH OPEN Clutch disengagement mode Revolving speed
I 5537 CLT LH. OFST Left clutch oil pressure offset (set) Oil pressure
J 5538 CLT RH. OFST Right clutch oil pressure offset (set) Oil pressure
K 9995 LOCK BRAKE Electric brake normally ON mode Voltage
L 9996 MECHA BRAKE Electric brake release mode Voltage
M 9997 HI LIMIT High idling limit mode Speed
N 9998 SFT LIMITER Gear speed limit mode Permit
k Items marked with q in the Disassembly/Assembly column of the above table must be adjusted after the
machine is assembled or any controller is replaced. (For the adjustment procedure, see “ADJUSTMENT AF-
TER REPLACEMENT OF CONTROLLER”.)
20-178 D275A-5
1
(7)
1 0001: Phone number input mode

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

• This code is used to initialize the specification
codes recognized by the steering controller and
the set values of the memory in the controller.
• The specification code is displayed on the lower
line.
• Adjustment method:
1) Set buzzer cancel switch (4) in the [ ] posi-
tion and check that the caution buzzer
sounds.
2) Check that the displayed specification code
has changed from [A*A] to [AAA].
★ If specification code [AAA] is not displayed,
the controller wiring harness or the controller
unit may be defective.
★ Even if this code is turned off, the setting is
effective.
D275A-5 20-179
1
(4)
3 0003: Transmission controller specification set

• This code is used to initialize the specification
codes recognized by the transmission controller
and the set values of the memory in the control-
ler.
• The specification code is displayed on the lower
line.
• Adjustment method (HSS specification):
sounds.
2) Check that the displayed specification code
has changed from [1*1] to [111].
a If specification code [111] is not displayed,
the controller wiring harness or the controller
unit may be defective.
a Even if this code is turned off, the setting is
effective.
4 0004: Machine specification set

• This code is used to have the machine specifica-
tion recognized by the controllers which com-
pose the system.
• The machine specification code is displayed on
the lower line.
a Since this code is reset when “Transmission
controller specification set” is executed, ad-
just it after that.
1) Select the code of the machine specification
by setting shift switch.
sounds. No. Work equipment type SSC type
¤ If the machine specification is different from 00 Single tilt SSC function OFF
the setting in the controller, the machine may 10 Dual tilt SSC function OFF
move abnormally or an error may be made.
Accordingly, be sure to match the setting to
the machine specification.
effective.
20-180 D275A-5
1
(7)
5 0005: Brake potentiometer zero-point adjust-

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

• This code is used to stop the auto-deceleration
function of the engine and check the high idling
speed of the engine singly.
• The engine speed is displayed on the lower line
(Display range: 0 – 3000).
• Using method:
While this code is displayed, its function is turned
on and the auto-deceleration function is turned
off.
★ If this code is turned off, its function is turned
off.
D275A-5 20-181
(1)
(4)
7 0008: Common rail reduced cylinder mode

★ When the engine common rail system seems to
be faulty, 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 faulty cylinder from the change of
the engine speed.
★ Since a fault is detected by the difference of the
engine speed in the reduced cylinder mode op-
eration from that in the normal mode operation,
use this function while the engine is running.
• The engine speed is displayed on the lower line
(Display range: 0 – 3000).
• Using method:
Select the cylinders to be turned off for the re-
duced cylinder mode operation by operating in-
formation switch (5) and buzzer cancel switch
(4).
Use this method to turn on the selected cylinders
again, too.
• [ ]: Execute or stop reduced cylinder mode
operation.
★ The figure at right is an example that No. 2
cylinder is turned off for reduced cylinder
mode operation and turned on again (The
cylinder No. lamp is turned off in the reduced
cylinder mode operation and on in the nor-
mal mode operation).
★ Only one or more cylinders can be turned off
for the reduced cylinder mode operation.
★ If this code is turned off, its function is turned
off.
8 0009: Pitch angle sensor initial set

• This code is used to adjust the zero point and in-
stallation error of the pitch angle sensor.
• The deviation from the standard neutral position
is displayed by voltage on the lower line (Display
range: 0 – 5000).
Set buzzer cancel switch (4) in the [ ] position
and check that the caution buzzer sounds.
effective.
20-182 D275A-5
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(4)
9 0010: Fan 70% speed mode

• This code forcedly sets the rpm of cooling fan at
70%.
• The lower part displays data for factory adjust-
ment.
The function is enabled with this code displayed
to control the rpm of cooling fan to approximately
70%.
a Ending this code disables the function.
0
A 1005: Fan 100% speed mode

• This code forcedly sets the rpm of cooling fan at
approximately 100%.
• The lower part displays data for factory adjust-
ment.
The function is enabled with this code displayed
to control the rpm of cooling fan to approximately
100%.
a Ending this code disables the function.
D275A-5 20-183
1
(7)
B 1012: Steering lever neutral set

• This code is used to adjust the steering neutral
position of the PCCS lever.
• The deviation of the steering potentiometer from
the standard neutral position is displayed by volt-
age on the lower line (Display range: 0 – 5000).
Set buzzer cancel switch (4) in the [ ] position
and check that the caution buzzer sounds.
effective.
C 1013: Steering lever left set

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

• This code is used to adjust the maximum right
steering position of the PCCS lever.
the standard maximum right position is displayed
by voltage on the lower line (Display range: 0 –
5000).
1) Set the PCCS lever to the right steering
stroke end.
sounds.
effective.
20-184 D275A-5
1
(4)
E 1015: Left brake oil pressure adjustment mode

• This code is the function of adjusting the brake
oil pressure.
• The brake pressure is indicated on the lower
line.
(Indication range: -0.3 - 0.3 MPa {-3.1 - 3.1 kg/
cm2})
1) Adjust the pressure with shift-up switch (6)
and shift-down switch (7).
• [UP] Value is increased. (Braking force
is decreased.).
• [DOWN] Value is decreased. (Braking
force is increased.).
★ In the figure, the pressure is set to 0.3
MPa {3.1 kg/cm2}.
2) Set buzzer cancel switch (4) to the [ ]
position and check that the buzzer sounds.
★ The above setting is effective even after this
code is finished.
F 1016: Right brake oil pressure adjustment mode

• This code is the function of adjusting the brake
oil pressure.
• The brake pressure is indicated on the lower
line.
(Indication range: -0.3 - 0.3 MPa {-3.1 - 3.1 kg/
cm2})
• Adjustment method
1) Adjust the pressure with shift-up switch (6)
and shift-down switch (7).
• [UP] Value is increased. (Braking force
is decreased.)
• [DOWN] Value is decreased. (Braking
force is increased.)
★ In the figure, the pressure is set to -0.3
MPa {-3.1 kg/cm2}.
2) Set buzzer cancel switch (4) to the [ ] posi-
tion and check that the buzzer sounds.
★ The above setting is effective even after this
code is finished.
D275A-5 20-185
1
(4)
G 2233: Reverse slow stop set

• This code is used to stop the reverse slow func-
tion forcibly, regardless of operation of the
switches on the monitor panel.
• Whether the reverse slow function is turned on is
displayed by letters on the lower line.
Change the setting by operating information
switch (5).
• [<],[>]: Change setting.
• [DEACTIVE]: Turn off reverse slow function.
• [ACTIVE]: Turn on reverse slow function.
a If the reverse slow function is turned off,the
reverse travel speed is not lowered even if
the reverse slow mode switch on the monitor
panel is turned on.
effective.
H 5535: Both steering clutches disengagement

• This code is used to engage the transmission
clutch without driving the machine for testing, ad-
justing, troubleshooting, Pm Clinic, etc.
• The transmission speed (Unit: rpm) is displayed
on the lower line.
• Using method:
While this code is displayed, the function is
effective and steering clutches on both sides are
disengaged. Accordingly, the machine does not
travel even if the PCCS lever is operated.
a If this code is turned off, the function be-
comes ineffective.
I 5537: Left steering clutch oil pressure offset

• This code is used to adjust the left clutch oil pres-
sure manually.
• The offset oil pressure (Unit: 0.01 MPa) is dis-
played on the lower line (If it has been adjusted,
its value is displayed. It can be adjusted further
within the allowable range).
a The allowable adjustment range is ± 0.3
MPa {3 kg/cm2} (Displayed value: 300)
1) Operate the shift switch to set the offset oil
pressure.
• Shiftup switch (6): Increase oil pressure
• Shiftdown switch (7): Decrease oil pres-
sure
a The offset pressure is increased or de-
creased by 0.05 MPa {0.5 kg/cm2} (Dis-
played value: 50).
2) Set buzzer cancel switch (4) in the [U] posi-
sounds.
effective.
20-186 D275A-5
1
(7)
J 5538: Right steering clutch oil pressure offset

• This code is used to adjust the right clutch oil
pressure manually.
• The offset oil pressure (Unit: 0.01 MPa) is dis-
played on the lower line (If it has been adjusted,
its value is displayed. It can be adjusted further
within the allowable range).
a The allowable adjustment range is ± 0.3
MPa {3 kg/cm2} (Displayed value: 300)
1) Operate the shift switch to set the offset oil
pressure.
• Shiftup switch (6): Increase oil pressure
• Shiftdown switch (7): Decrease oil pres-
sure
a The offset pressure is increased or de-
creased by 0.05 MPa {0.5 kg/cm2} (Dis-
played value: 50).
2) Set buzzer cancel switch (4) in the [U] posi-
sounds.
effective.
K 9995: Electric brake normally ON mode

• This code is used to check that sudden stop pre-
vention valve works normally.
• The voltage of the brake potentiometer is dis-
played on the lower line.
• Using method:
on and the electric brake is normally turned on.
a If this code is turned off, its function is turned
off.
L 9996: Electric brake release mode

• This code is used to check the operation of the
mechanical brake.
• The voltage of the brake potentiometer is dis-
played on the lower line.
• Using method:
on and the electric brake is normally released.
a If this code is turned off, its function is turned
off.
D275A-5 20-187
1
(7)
M 9997: High idling limit mode

• This code is used to limit the use high idling
speed.
• The engine speed (set value) is displayed on the
lower line.
• Limit range: High idling speed – –400rpm
• Using method:
1) Select a limit speed by setting information
switch (5) in the [ > ] position or [ < ] position.
sounds.
a If the high idling speed is limited, the engine
speed is not raised to the normal high idling
level even if the fuel control dial is controlled
so.
effective.
N 9998: Gear speed limit mode

• This code is used to limit the use of the 3 gear
speeds.
• The usable gear speeds are displayed by bits on
the lower line (in the order of the 3rd, 2nd, and
1st from the left).
• Using method:
Limit or allow the use of the maximum gear
speed by operating information switch (5) and
buzzer cancel switch (4).
• [ ]: Change setting.
• Display on lower line [o]:
Gear speed is effective.
• Display on lower line [ ]:
Gear speed is not effective.
a If the use of a gear speed is limited, the
transmission is not shifted to that gear speed
even if the gear shift-up switch is operated.
effective.
20-188 D275A-5
1
(7)
9. Load memory display mode

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

i) Select “Load memory display mode” on
the mode selection screen.
★ If the mode is selected, code (Ld) is
ii) Display the adjustment code input
switch (4).
2) Changing information screen No. Displayed information

Change the information screen by operating
01 1,000rpm service meter
information switch (5).
• [ > ]: Next screen. 02 Forward odometer
• [ < ]: Previous screen. 03 Reverse odometer
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.
★ The data cannot be reset.
D275A-5 20-189
1
4) Display of forward odometer (02)

On this screen, the integrated forward travel
distance is displayed.
5) Display of reverse odometer (02)

On this screen, the integrated reverse travel
distance is displayed.
6) When operating machine in load memory

display mode
position, gear speed display (1) section dis-
erated normally.
parking brake lever to the LOCK position
20-190 D275A-5
1
10. Real-time monitoring mode

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

i) Select “Real-time monitoring mode” on
the mode selection screen.
★ If the mode is selected, code (5R) is
ii) Display the monitoring code input screen
by operating buzzer cancel switch (4).
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit code of the item to be monitored by
operating information switch (5), shift-up
switch (6), and shift-down switch (7).
ii) After inputting the code, display the mon-

itoring screen by operating buzzer can-
cel switch (4).
• [ ]: Enter input code.
★ If the input code is normal, the moni-
toring screen shown at right ap-
pears.
D275A-5 20-191
1
★ If the input code is abnormal, the

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

(Right figure shows examples)
1: Code
2: Monitoring item
3: Information
4: Unit (Not displayed for some items)
★ 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).
• [ ]: Hold and release.
★ While the monitored item is held, the let-
ter “H” is displayed at the left end of the
lower line.
5) When operating machine in monitoring mode

position, gear speed display section displays
normally and the machine can be operated
normally.
parking brake lever to the FREE position
20-192 D275A-5
1
6) Automatic selection of monitoring item (Lim-

ited function)
After one of some monitoring items is select-
ed, if the information switch is operated, the
next monitoring item is selected automatical-
ly, even if the code of the next monitoring
item is not input.
• [ > ]: Code is increased
• [ < ]: Code is decreased
★ This function is applied to only the items
having numbers in the Automatic selec-
tion column of the Monitoring mode ta-
ble. Those items are selected in the
order of their numbers.
★ Note that this operation is not effective
while the parking brake lever is in the
RESET position.
★ You may return to the screen for input-
ting codes and enter a code without us-
ing this function.
D275A-5 20-193
(1)
(4)
Monitoring mode table
Auto-
matic
No. Code Monitored item Unit Display range
selec-
tion
1 01000 ENG. SPEED Engine speed rpm 0 – 3000 1
2 03000 FUEL DIAL Voltage of fuel control dial mV 0 – 5000
3 03001 FUEL DIAL Acceleration ratio % 0 – 100 2
4 03200 BATTERY Battery voltage mV 0 – 30000 31
5 04102 WATER HIGH Engine water temperature (High temperature side) °C 0 – 150 21
6 04104 WATER LOW Engine water temperature (Low temperature side) °C –30 – 100 22
7 04200 FUEL LEVEL Fuel level sensor voltage mV 0 – 5000 24
8 04204 FUEL TEMP. Fuel temperature °C 0 – 150
9 04401 HYD. TEMP. Hydraulic oil temperature °C 0 – 150
10 10000 FAN rpm Command speed of cooling fan pump rpm 0 – 1500
11 20000 ENG-MACHIN Engine controller program No. Character
MON. PRO-
12 20200 Monitor panel (Tachometer module) program No. Character
GRM
13 20201 T/M. PROGRM Transmission controller program No. Character
14 20202 S/T. PROGRM Steering controller program No. Character
ENG-PRO-
15 20203 Engine controller program No. Character
GRM
16 30100 T/C TEMP. Torque converter oil temperature °C 0 – 150 23
17 31400 T/M OUT Transmission speed rpm 0 – 5000 25
18 31520 T/M-FILL Input state of transmission fill switch Bit (See detailed information)
19 31521 S/T FILL Input state of steering fill switch Bit (See detailed information)
20 31602 1st CLUTCH Output command current of 1st clutch ECMV mA 0 – 1000
21 31603 2nd CLUTCH Output command current of 2nd clutch ECMV mA 0 – 1000
22 31604 3RD CLUTCH Output command current of 3rd clutch ECMV mA 0 – 1000
23 31606 Rev CLUTCH Output command current of reverse clutch ECMV mA 0 – 1000
24 31608 Frd CLUTCH Output command current of forward clutch ECMV mA 0 – 1000
25 31612 1 CLUTCH F Output FB current of 1st clutch ECMV mA 0 – 1000 18
26 31613 2 CLUTCH F Output FB current of 2nd clutch ECMV mA 0 – 1000 19
27 31614 3 CLUTCH F Output FB current of 3rd clutch ECMV mA 0 – 1000 20
28 31616 R CLUTCH F Output FB current of reverse clutch ECMV mA 0 – 1000 17
29 31618 BRAKE R.H. Output FB current of right brake ECMV mA 0 – 1000 13
30 31619 BRAKE L.H. Output FB current of left brake ECMV mA 0 – 1000 12
31 31620 BRAKE R.H. Output command current of right brake ECMV mA 0 – 1000
32 31621 BRAKE L.H. Output command current of left brake ECMV mA 0 – 1000
33 31622 F CLUTCH F Output FB current of forward clutch ECMV mA 0 – 1000 16
34 31623 FAN PUMP.O Output command current of cooling fan solenoid mA 0 – 1000
35 31624 FAN PUMP.F Output FB current of cooling fan pump solenoid mA 0 – 1000
36 31625 PITCH SOL. Drive current of blade pitch solenoid mA 0 – 1000
37 31628 E. BRAKE SL Drive current of sudden stop prevention valve mA 0 – 1000 26
38 32900 BODY ANGLE Machine pitch angle ° –30 – 30 30
39 36100 Q-INJECTOR Command value of fuel injection rate mm3/st –30 – 600
20-194 D275A-5
(1)
(4)
Auto-
matic
selec-
tion
40 36200 CRI. PRESS Command pressure of common rail Mpa 0 – 150
41 36300 CRI-TIMING Fuel injection timing CA –30.0 – 30.0
42 36400 CRI. PRESS Common rail pressure Mpa 0 – 200 5
43 36500 BOOST. PRES Boost pressure Kpa 0 – 300 6
44 36600 CRI. CONTRL Engine control mode Character
45 36700 CRI-TORQUE Converted torque of engine % 0 – 100
46 36800 CRI-Q-MOD1 Fuel injection amount adjustment command value 1 Character 0123456789abcdef
47 36801 CRI-Q-MOD2 Fuel injection amount adjustment command value 2 Character 0123456789abcdef
48 40001 VEHICLE SP Travel speed (Theoretical value) km/h 0 – 100 28
49 40900 ENG-SW 1 Engine controller input signal 1 Bit (See detailed information)
50 40901 ENG-SW 2 Engine controller input signal 2 Bit (See detailed information)
51 40905 T/M-SW1 Transmission controller input signal 1 Bit (See detailed information)
52 40906 T/M-SW2 Transmission controller input signal 2 Bit (See detailed information)
53 40907 T/M TGL. SW Input signal of blade lever knob switch Bit (See detailed information)
54 40908 T/M SW2 Input signal of blade lever oil pressure switch Bit (See detailed information)
55 40909 T/M SOL.2 Transmission controller output signal Bit (See detailed information)
56 40910 S/T-SW1 Steering controller input signal 1 Bit (See detailed information)
60 40914 S/T SOL.1 Output signal of steering controller Bit (See detailed information)
DESEL PED-
61 50000 Deceleration ratio % 0 – 100 3
AL
62 50100 SSC SSC ratio (SSC specification) % 0 – 100 4
DECEL PED-
63 50001 Voltage of deceleration potentiometer mV 0 – 5000
AL
64 50200 T/M LEVER 1 Voltage of forward-reverse potentiometer 1 mV 0 – 5000 7
65 50201 T/M LEVER 2 Voltage of forward-reverse potentiometer 2 mV 0 – 5000 8
66 50300 S/T LEVER 1 Voltage of steering potentiometer 1 mV 0 – 5000 9
67 50301 S/T LEVER 2 Voltage of steering potentiometer 2 mV 0 – 5000 10
68 50400 BRAKE PEDL Voltage of brake potentiometer mV 0 – 5000 11
69 50600 CLT L.H.F Output FB current of left clutch ECMV mA 0 – 1000 14
70 50601 CLT R.H.F Output FB current of right clutch ECMV mA 0 – 1000 15
71 50602 CLT L.H.O Output command current of left clutch ECMV mA 0 – 1000
72 50603 CLT L.H.O Output command current of right clutch ECMV mA 0 – 1000
73 50900 N-SAFETY Drive current of neutral safety relay mV 0 – 30000 27
74 60000 TRACTION Traction force (Theoretical value) W 0–0 29
75 60100 BODY ANGLE Machine pitch angle sensor voltage mV 0 – 5000
ACCELER-
76 60200 Acceleration sensor voltage (SSC specification) mV 0 – 5000
ATN
77 60300 SSC ORDER SSC command speed (SSC specification) rpm 0 – 5000
D275A-5 20-195
1
(7)
Auto-
matic
selec-
tion
ENG. CON.
79 60500 Drive voltage of engine controller relay mV 0 – 30000
PLT
80 60600 BR HOLD Drive voltage of battery relay mV 0 – 30000
81 60700 S/T MODE Steering state code Character
82 60800 FILL MODE Variable for setting fill condition Character
83 60909 MOD. MODE Setting of modulation condition Character
84 70000 CHG. P. MODE Variable for setting condition of gear shift point Character
85 70100 SLIP FLAG SSC slip flag (SSC specification) Bit (See detailed information)
86 70300 B. KNOB SW Input signal of blade lever knob switch Bit (See detailed information)
87 70304 T/M SOL.1 Transmission controller output signal Bit (See detailed information)
88 70305 T/M RIPPER Input signal of ripper lever oil pressure switch Bit (See detailed information)
89 70400 BACK ALARM Drive voltage of back-up alarm relay mV 0 – 30000

90 70500 regulation Command speed of engine controller 3rd throttle rpm 0 – 2200
91 70600 DUAL SOL. Drive current of blade dual solenoid mA 0 – 1000
92 70700 HYD. PUMP 1 Work equipment oil pressure Mpa 0 – 50
93 70701 HYD. PUMP 1 Voltage of work equipment oil pressure sensor mV 0 – 5000
20-196 D275A-5
1
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Detailed information on bit display codes

Examples of display of bit information
★ 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)”.
★ The bit information is displayed by [ ] for OFF
and [o] for ON in the places 1 – 8.
★ The state of each item shown below is the con-
dition for turning on the bit.
31520: Input state of transmission 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)
31521: Input state of steering 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: Left brake fill switch: ON
7: (Unused)
8: (Unused)
40900: Engine controller input signal 1

1: Starting switch signal C: Input
2: (Unused)
3: (Unused)
4: Low engine oil pressure switch: ON
5: High engine oil pressure switch: ON
6: (Unused)
7: (Unused)
8: Model selection signal 1: ON
D275A-5 20-197
(1)
(4)
40901: Engine controller input signal 2

3: (Unused)
4: (Unused)
5: N-signal 1: ON
6: N-signal 2: ON
7: (Unused)
8: (Unused)
40905: Transmission controller input signal 1

1: Gear shift-up switch: OFF
2: Gear shift-up switch: ON
3: Gear shift-down switch: OFF
4: Gear shift-down switch: ON
5: Parking brake switch: FREE
6: Parking brake switch: LOCK
7: (Unused)
8: (Unused)
40906: Transmission controller input signal 2

1: Automatic gear shift-down switch: ON
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
40907: Input signal of blade lever knob switch

1: (Unused)
2: (Unused)
3: (Unused)
4: (Unused)
5: Parking brake lever: FREE
6: Parking brake lever: LOCK
7: (Unused)
8: (Unused)
20-198 D275A-5
(1)
(4)
40908: Input signal of blade lever oil pressure switch

1: (Unused)
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
40909: Transmission controller output signal

1: N-signal 1: ON
2: N-signal 2: ON
3: (Unused)
4: Back-up alarm relay: ON
5: Neutral safety relay: ON
6: (Unused)
7: (Unused)
8: (Unused)
40910: Steering 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)

1: Buzzer cancel switch: At
2: Buzzer cancel switch: At
3: Information switch: At <
4: Information switch: At >
5: Service switch: ON
6: Pivot turn mode switch: ON
7: (Unused)
8: (Unused)
D275A-5 20-199
(1)
(4)

1: (Unused)
2: (Unused)
3: (Unused)
4: Ripper lift RAISE oil pressure switch:
ON (Operated)
5: Ripper lift LOWER oil pressure switch:
ON (Operated)
6: Ripper TILT-IN oil pressure switch:
ON (Operated)
7: (Unused)
8: (Unused)

1: ACC signal: ON
2: Turbocharger timer signal: ON
3: Engine Li signal: ON
4: Monitoring signal: ON
5: N-signal 1: ON
6: N-signal 2: ON
7: (Unused)
8: (Unused)
40914: Output signal of steering controller

1: (Unused)
2: (Unused)
3: (Unused)
4: (Unused)
5: Battery relay drive: ON
6: Sudden stop prevention valve: ON
7: (Unused)
8: (Unused)

1: Electrical intake air heater signal: ON
2: C-signal: ON
3: Air conditioner clutch signal: ON
4: Night lighting signal: ON
5: Hydraulic oil level switch signal: ON
6: (Unused)
7: (Unused)
8: (Unused)
20-200 D275A-5
(1)
(4)
70100: SSC slip flag (SSC specification)

1: Shoe slip rate: Min. 30%
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
70300: Input signal of blade lever knob switch

1: Blade lever tilt switch: DUAL
2: Blade lever tilt switch: SINGLE
3: Blade lever pitch switch: OFF
4: Blade lever pitch switch: ON
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
70304: 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)
70305: Input signal of ripper lever oil pressure

switch
1: (Unused)
2: Ripper lift RAISE oil pressure switch:
ON (Operated)
3: Ripper lift LOWER oil pressure switch:
ON (Operated)
4: Ripper lift TILT-IN oil pressure switch:
ON (Operated)
5: Ripper lift TILT-OUT oil pressure switch:
ON (Operated)
6: (Unused)
7: (Unused)
8: (Unused)
D275A-5 20-201
(6)
1
11. Dual display monitoring mode

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

i) Select “Dual display monitoring mode”
on the mode selection screen.
★ If the mode is selected, code (dR) is
ii) Display the monitoring code input screen
by operating buzzer cancel switch (4).
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit codes of the items to be monitored
to the upper and lower lines by operating
information switch (5), shift-up switch
(6), and shift-down switch (7).
ii) After inputting the codes, display the
monitoring screen by operating buzzer
cancel switch (4).
• [ ]: Enter input code.
★ If the input codes are normal, the
monitoring screen shown at right ap-
pears.
20-202 D275A-5
1
★ If the input codes are abnormal, the

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

(Right figure shows examples)
1: Code 1
2: Information 1
3: Code 2
4: Information 2
★ For the details, see the “MONITORING
MODE TABLE”.
4) When operating machine in monitoring

mode
position, gear speed display section (1) dis-
erated normally.
parking brake lever to the FREE position
D275A-5 20-203
1
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
TESTING AND ADJUSTING ADJUSTMENT
HANDLING OF METHOD
HIGH-VOLTAGE OF OF
CIRCUIT REPLACED
ENGINE CONTROLLER
HANDLING OF HIGH-VOLT- ADJUSTMENT METHOD OF

AGE CIRCUIT OF ENGINE REPLACED CONTROLLER
CONTROLLER
★ After the machine is assembled or transmission

controller or steering controller is replaced, ad-
just the system according to the following proce-
dure.
¤ 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. According-
ly, take a record of the next replacement periods
of the oils and filters.
★ Precautions for replacing a controller:
¤ The engine controller has a high-voltage circuit When replacing a controller, stop the machine in
(110 – 130V) to drive the fuel injector. This circuit a safe place and turn the starting switch off.
is connected to the wiring harness and connec-
tors between the engine controller and fuel injec- 1. Setting system in service mode
tor. Turn the starting switch on and set the monitor
★ Normally, the engine controller outputs the high panel in the “Adjustment mode” of the service
voltage to the fuel injector only while the engine mode.
is running and stops outputting if the engine
stops. 2. Adjusting steering controller
¤ If you touch the high-voltage circuit directly, you Select Steering controller specification set
may get an electric shock. To avoid this, observe (0002) and adjust the steering controller.
the following precautions. ★ Execute this code when only the transmis-
sion controller is replaced, too.
1. The following connectors are used in the high-
voltage circuit.
• Engine controller connector: ECN3
• Junction connector: E21
• Injector connectors:
CN1, CN2, CN3, CN4, CN5, CN6
• Injector head terminal (in head cover)
2. When disconnecting or connecting a connector

related to the high-voltage circuit, be sure to turn
off the starting switch.
3. If a T-adapter is inserted in or connected to a

connector related to the high-voltage circuit for
troubleshooting, do not start the engine.
★ You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
20-204 D275A-5
1
TESTING AND ADJUSTING ADJUSTMENT METHOD OF REPLACED CONTROLLER
3. Adjusting transmission controller

Select Transmission controller specification set
(0003) and adjust the transmission controller.
★ Execute this code when only the steering
controller is replaced, too.
7. Turning power on again

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

1) Set the monitor panel in the “Electric system
4. Turning power on again error code display mode” of the service
Turn the starting switch off and on, then set the mode.
monitor panel in the “Adjustment mode” of the 2) See if any error code is being output current-
service mode again. ly. If any error code is not being output, de-
lete the all error codes.
5. Adjusting machine specification ★ If any error code is being output, remove its
Select Machine specification set (0004) and ad- cause by troubleshooting and execute steps
just the machine specification. 7 and 8 again.
★ 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 actu-
al operating hours. To solve this problem, deter-
mine the first replacement periods of the oils and
filters after the replacement of the controller ac-
cording to the replacement periods recorded be-
fore the replacement of the controller.
6. Adjusting brake potentiometer

Select Brake potentiometer initial set (0005) and
adjust the brake potentiometer.
D275A-5 20-205
1
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC
TESTING AND ADJUSTING SYSTEM
PREPARATION WORK FOR TROUBLESHOOTING FOR ELEC-

TRIC SYSTEM
★ When carrying out troubleshooting for an electric 2. Engine controller

circuit related to the monitor panel, engine con- 1) Remove cover (3).
troller, transmission controller, or steering con-
troller, 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 operator’s seat.
2) Insert or connect T-adapters in or to connec-

tors ECN1, ECN2, and ECN3 of engine con-
troller (4).
★ If the connectors cannot be disconnect-
ed and connected easily, remove the
controller from the floor frame.
★ Since the connectors are secured with
screws, loosen those screws before dis-
3) Insert or connect T-adapters in or to connec- connecting.
tors S03 and S04 of monitor panel (2). ★ When connecting the connectors again,
tighten their screws to the specified
torque.
3 Screw: 2.82Nm {0.288kgm}
20-206 D275A-5
1
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC
TESTING AND ADJUSTING SYSTEM
3. Transmission controller 4. Steering controller

1) Remove cover (5). 1) Remove cover (5).
2) Insert or connect T-adapters in or to connec- 2) Insert or connect T-adapters in or to connec-

tors TMCN1, TMCN2, and TMCN3 of trans- tors STCN1, STCN2, and STCN3 of trans-
mission controller (6). mission controller (7).
★ If the connectors cannot be disconnect- ★ If the connectors cannot be disconnect-
ed and connected easily, remove the ed and connected easily, remove the
controller from the floor frame. controller from the floor frame.
★ Since the connectors are secured with ★ Since the connectors are secured with
screws, loosen those screws before dis- screws, loosen those screws before dis-
connecting. connecting.
★ When connecting the connectors again, ★ When connecting the connectors again,
tighten their screws to the specified tighten their screws to the specified
torque. torque.
3 Screw: 2.82Nm {0.288kgm} 3 Screw: 2.82Nm {0.288kgm}
D275A-5 20-207
1
TESTING AND ADJUSTING HANDLING OF OPTIONAL DEVICES
HANDLING OF OPTIONAL DEVICES
★ D275A-5 has connectors to install optional de- 4. Taking out C signal of starting switch
vices in its fuse box. When installing any optional If the C signal (starting signal) of the starting
device, receive the necessary signals and power switch is necessary to an optional device such
through those connectors without modifying the as the pre-lubricator, take it out through the fol-
wiring harness. lowing connector pin.
• CN-PRS (2-pole heavy duty wire connector)
1. Taking out ACC signal of starting switch ★ Remove the connector installed when the
If the ACC signal (ON signal) of the starting machine is shipped and connect pin 1 to the
switch is necessary to an optional device such starting signal to be output finally by the pre-
as the turbocharger timer, take it out through the lubricator and connect pin 2 to the input sig-
• Pin B of CN-ESD (3-pole heavy duty wire

following connector pin. nal from the starting switch.
connector) 5. Taking out external power source

★ A 20A fuse is installed on the upstream side If an external power source is necessary, take it
of this connector pin. through the following connectors.
• AUX1 (Plug connector)
2. Inputting engine controller holding signal • AUX2 (Plug connector)
If it is required to keep the engine running with ★ A 20A fuse is installed on the upstream side
the starting switch turned off for an optional de- of each of these connectors.
vice such as the turbocharger timer, connect the
• Pin A of CN-ESD (3-pole heavy duty wire

following connector pin to the chassis ground.
connector)
★ While this connector pin is connected to the
chassis ground, the starting switch works as
it is at the ON position even if it is at the OFF
position.
3. Inputting engine low-idling command

If it is required to keep the engine speed at low
idling for an optional device such as the engine
protector, connect the following connector pin to
• Pin C of CN-ESD (3-pole heavy duty wire

the chassis ground.
connector)
★ While this connector pin is connected to the
chassis ground, the engine speed is kept at
low idling, regardless of the position of the
fuel control dial.
20-208 D275A-5
1
TESTING AND ADJUSTING PM CLINIC SERVICE
Pm CLINIC SERVICE
Model Serial No Service meter
D275A-5 h
User name Date of clinic Serviceman
Specifications
Blade Rear attachment Shoe width
Semi-U blade Multi-shank ripper 610 mm
U-blade Variable giant ripper 710 mm
Dual tilt blade Counterweight kg 810 mm
Operating conditions
Quarry, mine Construction Type of soil (specific gravity ) Type of work
Coal Construction, Rock Dozing %
Gold civil engineering Gravel Side cutting %
Limestone Roads Sand Ripping %
Tunnels Clay Travel %
Existence of abnormalities
Oil, water level check
Engine coolant level When necessary
Engine oil level Power train Damper case
Hydraulic oil level Final drive ( )
Engine coolant temperature Max. range Power train oil temperature Max. range Ambient temperature
Max.
Min.
Height above sea level
m
Operator’s opinion
Visual check results
Service code history
E h E h
Content: Content:
E h E h
Content: Content:
D275A-5 20-209
1
Pm-clinic measuring points for D275A-5 (1/3)
q1. Engine speed: Measuring engine speed (Pages 20-103 - 104)

Reference items of measurement procedure (Pages)
q2. Blow-by pressure: Measuring blow-by pressure (Pages 20-113)

q3. Engine oil pressure: Measuring engine oil pressure (Pages 20-114)
q4. Boost pressure: Measuring intake air pressure (boost pressure) (Pages 20-106 - 107)
q5. Exhaust temperature: Measuring extreme temperature (Pages 20-108 - 109)
20-210 D275A-5
(4)
q6. Items related to torque converter: Measuring power train oil pressure (Pages 20-123 - 129-2)
Measurement procedure items (Pages)
q7. Items related to transmission: Measuring power train oil pressure (Pages 20-123 - 129-2)
q8. Items related to steering: Measuring power train oil pressure (Pages 20-123 - 129-2)
D275A-5 20-211
(4)
q9. Items related to work equipment: Testing and adjusting work equipment oil pressure, Testing and adjusting control circuit main pressure
Measurement procedure items (Pages)
q10.Items related to fan: Measuring fan motor speed, Measuring fan circuit oil pressure (Pages 20-154 - 154-1)
(Pages 20-140 - 144)
20-210
20-211-1 D275A-5
(4)
(4)
TESTING AND ADJUSTING Serial
PMNo
CLINIC SERVICE
Pm CLINIC CHECK SHEET D275A-5
Work order No. Date Service meter Serviceman
h
Item Measurement conditions Unit Standard value for new machine Service limit value Measurement results Pass Fail
Low idling 650 - 750 650 - 750
High idling Deceleration pedal depressed 850 - 950 850 - 950
Engine speed High idling (Deceleration cut-off mode) rpm 2100 - 2200 2100 - 2200
Torque converter stall 1570 - 1670 Min. 1510
Torque converter stall + work equipment relief 1530 - 1630 Min. 1450
kPa Max. 1.96 Max. 3.92
Blow-by pressure Torque converter stall <mmAg> <Max. 200> <Max. 400>
Engine
0.10 Min. 0.07

Engine at low idling <1.0> <Min. 0.7>
SAE10W
0.29 - 0.49 Min. 0.18
Engine oil Engine at high idling MPa <3.0 - 5.0> <Min. 1.8>
pressure <kg/cm2> 0.12 Min. 0.08
Engine at low idling
<1.2> <Min. 0.8>
SAE15W-40 SAE30
Engine at high idling 0.34 - 0.54 Min. 0.21
<3.5 - 5.5> <Min. 2.1>
kPa Min. 116.0 Min. 97.3
Boost pressure Torque converter stall <mmHg> <Min. 730>
<Min. 870>
Exhaust temperature Torque converter stall Max. 650 Max. 700
When measuring the oil pressure of the torque converter and transmission, use the adjustment mode of the monitor and set to "Both steering clutches release mode (Co mode)".
(Check that the left and right steering clutches are released.) When measuring the pressure of each transmission clutch, check only with the engine at low idling to ensure safety.
Max. 0.2 Max. 0.2
Torque converter
Inlet oil pressure <Max. 2> <Max. 2>

Transmission: Engine at low idling Max. 0.2 Max. 0.2
Outlet oil pressure
Neutral MPa <Max. 2> <Max. 2>
Inlet oil pressure Oil temperature: <kg/cm2> 0.49 - 1.0 0.49 - 1.0
70-90 Engine at high idling <5.0 - 10.0> <5.0 - 10.0>
0.39 - 0.59 0.39 - 0.59
Outlet oil pressure <4.0 - 6.0> <4.0 - 6.0>
Engine at low idling 2.84 - 3.14 Min. 2.65
<29.0 - 32.0> <Min. 27.0>
Main relief pressure
3.14 - 3.43 Min. 2.94
Transmission: Engine at high idling <32.0 - 35.0> <Min. 30.0>
Neutral Engine at low idling
Lubricating oil
pressure 0.05 - 0.29 0.05 - 0.29
Transmission
Engine at high idling <0.5 - 3.0> <0.5 - 3.0>

F clutch pressure Engine at low idling MPa 2.84 - 3.14 Min. 2.65
Transmission: F3 <kg/cm2> <29.0 - 32.0> <Min. 27.0>
R clutch pressure 2.84 - 3.14 Min. 2.65
Transmission: R3 Engine at low idling <29.0 - 32.0> <Min. 27.0>
2.84 - 3.14 Min. 2.65
1st clutch pressure Transmission: F1 Engine at low idling <29.0 - 32.0> <Min. 27.0>
Engine at low idling 2.84 - 3.14 Min. 2.65
2nd clutch pressure Transmission: F2 <29.0 - 32.0> <Min. 27.0>
3rd clutch pressure Engine at low idling 2.84 - 3.14 Min. 2.65
Transmission: F3 <29.0 - 32.0> <Min. 27.0>
1.77 0.20 1.77 0.29
Left cluthc pressure <18 > <18 >
2.84 - 3.14 Min. 2.26
Left brake pressure Transmission:
Steering clutch and brake
<29.0 - 32.0> <Min. 23.0>

Left cluthc pressure Neutral 1.77 0.20 1.77 0.29
Engine at high idling <18 > <18 >
3.14 - 3.43 Min. 2.45
Left brake pressure <32.0 - 35.0>
MPa <Min. 25.0>
<kg/cm2> 1.77 0.20 1.77 0.29
Right cluthc pressure <18 > <18 >
2.84 - 3.14 Min. 2.26
Right brake pressure Transmission: <29.0 - 32.0> <Min. 23.0>
Neutral 1.77 0.20 1.77 0.29
Right cluthc pressure <18 > <18 >
Engine at high idling
Right brake pressure 3.14 - 3.43 Min. 2.45
<32.0 - 35.0> <Min. 25.0>
Brake performance Engine at high idling, F2, brake actuated Machine must not move
20-212 D275A-5
(1)
(4)
TESTING AND ADJUSTING Serial
PMNo
CLINIC SERVICE
Pm CLINIC CHECK SHEET D275A-5
h
Ripper lift 26.1 - 28.8 26.1 - 28.8
relief Engine at low <266 - 294> <266 - 294>
idling
Hydraulic components
Blade tilt relief 26.1 - 28.8 26.1 - 28.8

(single tilt only) <266 - 294> <266 - 294>
Work equipment pump
Ripper lift MPa 26.1 - 28.8 26.1 - 28.8
relief <kg/cm2> <266 - 294> <266 - 294>
Blade tilt relief Engine at high 26.1 - 28.8 26.1 - 28.8

(single tilt only) idling <266 - 294> <266 - 294>
Control circuit main Lever: Neutral 3.43 - 3.92 3.23 - 3.92

pressure <30 - 40> <33 - 40>
Engine at low idling 8 - 15 Max. 20
Blade RAISE
Engine at high idling 3-5 Max. 6
Single tilt (left g right) Engine at low idling

Engine at high idling
3-5 Max. 7
Max. 3.5
2.3 - 3.3
Sec.
g right) Engine at low idling 5-8 Max. 10
Dual tilt (left
Engine at high idling 2.3 - 3.3 Max. 3.5
8 - 14 Max. 17
Ripper tilt (in g out) Engine at low idling
Engine at high idling 3-4 Max. 4.5
Hydraulic drift
Hydraulic oil temperature
Blade lift cylinder Engine stopped Max. 100 Max. 150

mm/5 min.
Ripper lift cylinder Max. 15 Max. 30
Item Conditions Unit Standard value for new machine Service limit value Measurement results Pass Fail
Engine at low 420 - 480 400

Fan speed rpm
Fan
Fan 100%
Engine at full 1000 - 1100 950
speed mode
Engine at full MPa 16.17 - 19.11 16.17 - 19.11

Fan oil pressure <kg/cm2> <165 - 195> <165 - 195>
Visual inspection of final drive drain plug Engine stopped There must be no excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
D275A-5 20-213
(1)
(4)
TESTING AND
PmADJUSTING
CLINIC Serial
PMNo
CLINIC SERVICE
UNDERCARRIAGE CHECK SHEET

D275A-5
h
Measure the bushing temperature immediately after operations

Left side of machine
Measurement
results Pass Fail
Right side of machine

Measurement
results Pass Fail
Opening of track link Left track A: Clearance between links Projection of pin
Pin No. 1.4 2.5 1
Right track A: Clearance between links Projection of pin

Pin No. 1.4 2.5 1
20-214 D275A-5
(1)
(4)
UNDERCARRIAGE
TESTING AND ADJUSTING TROUBLESHOOTING REPORT (NORMAL)
PM CLINIC SERVICE
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
Address:
Model D275A-5 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry Wet
Soil condition Dealer Shoe width (mm)
Working condition Inspector Shoe type SINGLE
Insp.Date(yy/mm/dd) (yyyy/m/d) Wear type NORMAL
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 1042.4 1054.4
LINK PITCH
R
M L L=l/4 RH 1042.4 1054.4
LH 260.60 263.60
master pin M
master l
i 1.3 RH 260.60 263.60
LH 166.0 148.0
H
RH 166.0 148.0
LINK HEIGHT1.3
New Turned
BUSHING d1 LH 90.5 82.0
New Turned
d
D is the smallest d RH 90.5 82.0
ofd1,,d2 and,d3 1
GROUSER HIGHT LH 88.0 30.0
H
0 RH 88.0 30.0
CARRIER
CARRIER LH 200.0 175.0
Front
RH 200.0 175.0
D LH 200.0 175.0
Rear
1.3 RH 200.0 175.0
IDLER
IDLER LH 21.0 33.5
Front
H RH 21.0 33.5
LH 21.0 33.5
Rear
1.3 RH 21.0 33.5
1 LH 255.0 195.0
2 LH 255.0 195.0
3 LH 255.0 195.0
4 LH 255.0 195.0
5 LH 255.0 195.0
6 LH 255.0 195.0
7 LH 255.0 195.0
TRACK ROLLER 8 LH 255.0 195.0
9 LH 255.0 195.0
10 LH 255.0 195.0
D 1 RH 255.0 195.0
h1 2 RH 255.0 195.0
h2
3 RH 255.0 195.0
4 RH 255.0 195.0
D=2(h1-h2)
5 RH 255.0 195.0
6 RH 255.0 195.0
7 RH 255.0 195.0
8 RH 255.0 195.0
9 RH 255.0 195.0
1.3 10 RH 255.0 195.0
SPROCKET h1 LH 0.0 8.0
H is the smallest of
h1,h2,h3 h3 h2
1.3 RH 0.0 8.0
Remarks:
D275A-5 20-215
(6)
1
UNDERCARRIAGE
TESTING AND ADJUSTING TROUBLESHOOTING REPORT PM
(IMPACT)
CLINIC SERVICE
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
Address:
Model D275A-5 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry Wet
Soil condition Dealer Shoe width (mm)
Working condition Inspector Shoe type SINGLE
Insp.Date(yy/mm/dd) (yyyy/m/d) Wear type IMPACT
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 1042.4 1054.4
LINK PITCH
R
M L L=l/4 RH 1042.4 1054.4
LH 260.60 263.60
master pin M
master l
i 1.3 RH 260.60 263.60
LH 166.0 148.0
H
RH 166.0 148.0
LINK HEIGHT1.3
New Turned
BUSHING d1 LH 90.5 84.5
New Turned
d
D is the smallest d RH 90.5 84.5
ofd1,,d2 and,d3 1
GROUSER HIGHT LH 88.0 30.0
H
0 RH 88.0 30.0
CARRIER
CARRIER LH 200.0 175.0
Front
RH 200.0 175.0
D LH 200.0 175.0
Rear
1.3 RH 200.0 175.0
IDLER
IDLER LH 21.0 33.5
Front
H RH 21.0 33.5
LH 21.0 33.5
Rear
1.3 RH 21.0 33.5
1 LH 255.0 195.0
2 LH 255.0 195.0
3 LH 255.0 195.0
4 LH 255.0 195.0
5 LH 255.0 195.0
6 LH 255.0 195.0
7 LH 255.0 195.0
TRACK ROLLER 8 LH 255.0 195.0
9 LH 255.0 195.0
10 LH 255.0 195.0
D 1 RH 255.0 195.0
h1 2 RH 255.0 195.0
h2
3 RH 255.0 195.0
4 RH 255.0 195.0
D=2(h1-h2)
5 RH 255.0 195.0
6 RH 255.0 195.0
7 RH 255.0 195.0
8 RH 255.0 195.0
9 RH 255.0 195.0
1.3 10 RH 255.0 195.0
SPROCKET h1 LH 0.0 8.0
H is the smallest of
h1,h2,h3 h3 h2
1.3 RH 0.0 8.0
Remarks:
20-216 D275A-5
(6)
1
TROUBLESHOOTING 20
TROUBLESHOOTING
Points to remember when troubleshooting .............................................................................................. 20-302

Sequence of events in troubleshooting ................................................................................................... 20-303
Points to remember when carrying out maintenance .............................................................................. 20-304
Checks before troubleshooting ............................................................................................................. 20- 307-5
Classification and procedures of troubleshooting .................................................................................... 20-308
Connector allocation drawing and electrical circuit diagram for each system ......................................... 20- 311
Circuit drawing for monitor panel system (M circuit) ................................................................................ 20-322
Circuit drawing for engine controller system (E circuit) ........................................................................... 20-324
Circuit drawing for transmission controller system (T circuit) ...................................................................... 20-326
Circuit drawing for steering controller system (S circuit) ......................................................................... 20-328
Connection table for connector pin numbers ........................................................................................... 20-330
D275A-5 20-301
1
3
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
¤ When carrying out the operation with two 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 water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
• Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
• It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. fl When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 – 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from fl The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-302 D275A-5
1
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite

TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points.
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the
failure
• Operating environment
• Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible Step
causes.
Repair at jobsite
Hurray !
It's repalred
Step 3
Preparation of troubleshooting tools
TEW00185
1) Look at the table of troubleshooting tools in
the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
• Check before starting items
• Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Re-enacting failure
• Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
Was there anything strange about the ma-

chine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out before the
TEW00189 failure?
TEW00190
D275A-5 20-303
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

1 Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2 Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
20-304 D275A-5
1
3 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
TEW00194
4 High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
5 Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
fl 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 clean-
ing with compressed air.
D275A-5 20-305
1
2) Removing, installing, and drying connectors and

wiring harnesses
· Disconnecting connectors
1 Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors 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 con-
nectors apart.
★ Never pull with one hand.
2 When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
★ If the connector is twisted up and down
or to the left or right, the housing may
break.
TBW00484
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.
★ If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEW00198
20-306 D275A-5
1
· Connecting connectors
1 Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
★ If there is any damage or breakage, re-
place the connector.
2 Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3 Correct any protrusion of the boot and any

TEW00200
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 po-
sition.
★ If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
4 If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. TBW00487
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type connectors
have 2 latches respectively, push them in until they
click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
D275A-5 20-307
1
TROUBLESHOOTING POINTS TO REMENBER WHEN CARRYING OUT MAINTENANCE
• 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 wa-
ter or using steam. If the connector must be
washed in water, do not use high-pressure water
or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows:
1 Disconnect the connector and wipe off the
s If the connector is blown dry with com-

water with a dry cloth.
pressed air, there is the risk that oil in the

air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2 Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dry-
s Hot air from the dryer can be used, but

er to dry the connector.
regulate the time that the hot air is used

in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3 Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
s After completely drying the connector,

caused by water.
blow it with contact restorer and reas-

semble.
20-307-1 D275A-5
3
3) Handling control box

1 The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2 Do not open the cover of the control box un-
less necessary.
3 Do not place objects on top of the control

box.
4 Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5 During rainy weather, do not leave the con-
trol box in a place where it is exposed to rain.
6 Do not place the control box on oil, water, or

soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand)
7 Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc weld-
ing ground close to the welding point.
4. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
s Disconnect and connect the related connectors several times to check.

2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
s If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
3) Always connect any disconnected connectors before going on to the next step.
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
s If there is any change, there is probably defective contact in that circuit.

of the tester.
D275A-5 20-307-2
3
5. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure 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 re-
pairing the machine in rain or high winds, or plac-
es where there is a lot of dust.
2) Disassembly and maintenance work in the

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

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil fill-
er 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.
20-307-3 D275A-5
3
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 possi-
ble of the old hydraulic oil must be drained out.
(Do not drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
in the circuit.) If any old oil is left, the contami-
nants and sludge in it will mix with the new oil
and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to re-
move the contaminants, sludge, and old oil from
the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
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 ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
D275A-5 20-307-4
3
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
Value
1. Check fuel level — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level — Add oil

Checks before starting
4. Check oil level in damper case — Add oil

5. Check power train oil level — Add oil
6. Check engine oil level (engine oil pan level) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check travel of brake pedal — Adjust
mechanical equipment
Electrical
10. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
12. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment
Hydraulic,
13. Check for abnormal noise, smell — Repair

14. Check for oil leakage — Repair
15. Carry out air bleeding — Bleed air
Other check items
16. Check battery voltage (engine stopped) 20 - 30 V Replace

17. Check battery electrolyte level — Add or replace
Electrical equipment
18. Check for discolored, burnt, exposed wiring — Replace

19. Check for missing wiring clamps, hanging wire — Repair
20. Check for water leaking on wiring (pay particularly careful attention — Disconnect connector
to water leaking on connectors or terminals) and dry
21. Check for water on wiring — Replace
22. Check alternator voltage (engine running at 1/2 throttle or above) After running for Replace
several minutes:
27.5 - 29.5 V
23. Check operating sound of battery relay (starting switch ON, OFF) — Replace
20-307-5 D275A-5
3
TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
Classification of Troubleshooting
Mode Explanation
Error code Troubleshooting when a error code is displayed
E Mode Troubleshooting of the electrical system
H Mode Troubleshooting of the hydraulic and mechanical systems
S Mode Troubleshooting of the engine body
Troubleshooting Procedures
When any phenomenon supposed to be a failure appeared on the machine, select a Troubleshooting No. ac-
cording to the procedures below and proceed to the text of the relevant troubleshooting:
1. Troubleshooting Procedures when any action code is displayed on the monitor panel:
When an action code is displayed on the monitor panel, display a error code in the error code display mode
(electrical system, mechanical system) on the monitor display (EMMS).
Execute a troubleshooting of the relevant [Error Code] in accordance with the displayed error code.
a Since a error code flashes when a problem was detected, the failure has not always been corrected
even if it lights when the starting switch is set to ON. (For some codes, problems can be detected only
when the starting switch is set to ON.)
a When a error code has been recorded, be sure to reproduce the code and check if the problem of the
code has still remained or has already been corrected. (For the reproducing method, refer to the trou-
bleshooting of the error code.)
2. Troubleshooting Procedures when error codes have been recorded:

When no action code is displayed on the monitor panel, check a error code in the error code display mode
(electrical system, mechanical system) on the monitor panel (EMMS).
When error codes have been recorded, execute a troubleshooting of the relevant [Error Code] in accor-
dance with the error code.
a Since a error code flashes when a problem was detected, the failure has not always been corrected
even if it lights when the starting switch is set to ON. (For some codes, problems can be detected only
when the starting switch is set to ON.)
a When a error code has been recorded, be sure to reproduce the code and check if the problem of the
code has still remained or has already been corrected. (For the reproducing method, refer to the trou-
bleshooting of the error code.)
3. Troubleshooting Procedures when no action code is displayed and error codes have not been re-
corded:
When error codes have not been recorded in the monitor panel (EMMS), a failure that the machine cannot
diagnose by itself is supposed to have occurred in the electrical system or the hydraulic/mechanical system
or engine body.
In this case, check again a phenomenon supposed to be a failure and select the relevant phenomenon out
of the table of “Phenomena supposed to be Failures and Troubleshooting No.” Then, execute the trouble-
shooting in the [E Mode] [H Mode] [S Mode] related to the phenomenon.
20-308 D275A-5
1
(7)
Phenomena supposed to be Failures and Troubleshooting No.

Troubleshooting
No. Phenomenon suppose to be Failure Error
E Mode H Mode S Mode
Code
Phenomenon related to action code/error code
1 An action code is displayed on the monitor panel. Check the error code.
2 A error code is displayed in the error code display mode. q
Phenomenon related to engine
3 The engine does not start smoothly. (Engine starting takes a time all the time.) S-1
4 The engine does not rotate. E-1 S-2a)
5 The engine does not start. The engine rotates but does not exhaust gas. S-2b)
6 The engine exhausts gas but does not rotate. S-2c)
7 The engine does not pick-up smoothly. (Poor follow-up performance) S-3
8 The engine stops during operation. S-4
9 The engine rotates abnormally. (Hunting) S-5
10 Insufficient output or no power S-6
11 Black exhaust (Imperfect combustion) S-7
12 Large oil consumption or blue exhaust S-8
13 Oil is contaminated fast. S-9
14 Large fuel consumption S-10
15 Oil mixes in coolant, spurts or water reduces. S-11
16 Engine oil pressure drops. S-12
17 Oil increases. S-13
18 Water temperature rises too high. (Overheat) S-14
19 An abnormal noise occurs. S-15
20 Large vibration S-16
21 The preheater does not work. E-2
Phenomenon related to power train
22 The power train has no power (no drawbar pull). H-1 S-6
23 The power train does not travel (in case of 2-spool or 3-spool). H-2
24 The power train does not start at all gear speeds. H-3
25 The power train travel forward or in reverse only H-4
26 Large time lag at any gear speed or at forward-reverse shifting H-5
27 Steering is not possible. (Machine does not turn to right or left.) H-6
28 The machine can be steered to only right or left. H-7
29 Steering system overruns. H-8
30 The brake does not work. H-9
31 The power train oil is overheated. H-10
Phenomenon related to work equipment
32 All the work equipment operates slowly. H-11
33 All the work equipment does not operate. H-12
34 The blade lift moves slowly or has no power. H-13
35 The blade tilt moves slowly or has no power. H-14
D275A-5 20-309
1
(7)
Troubleshooting
No. Phenomenon suppose to be Failure Error
E Mode H Mode S Mode
Code
36 The ripper lift moves slowly or has no power. H-15
37 The ripper tilt moves slowly or has no power. H-16
38 Large hydraulic drift of the blade lift H-17
39 Large hydraulic drift of the blade tilt H-18
40 Large hydraulic drift of the ripper lift H-19
The ripper pin puller cylinder does not operate.
41 E-3 H-20
(Giant ripper-mounted machine)
42 The blade pitcher does not operate. (Dual tilt-mounted machine) H-21
43 Abnormal noise from the work equipment pump H-22
Phenomenon related to monitor panel (Operator mode: Normal screen)
44 When the starting switch is set to ON, no light on the monitor panel comes on. E-4
When the starting switch is set to ON, all the lights on the monitor panel do
45 E-5
not go out.
46 When the starting switch is set to ON, the basic check items flash. E-6
47 While the engine is operating, the caution items flash. E-7
48 While the engine is operating, the emergency warning items flash. E-8
49 While the preheater is operating, the preheating pilot lamp does not come on. E-9
At the selecting time of dual tilt, the dual/single tilt selector lamp does not
50 E-10
come on. (Dual tilt-mounted machine)
51 Indication of the engine water temperature gauge is abnormal. E-11
52 Indication of the power train oil temperature gauge is abnormal. E-12
53 Indication of the hydraulic oil temperature gauge is abnormal. E-13
54 Indication of the fuel gauge is abnormal. E-14
55 Indications of gear speed and engine speed are abnormal. E-15
56 Indication of the shift mode service meter is abnormal. E-16
57 The warning lamp does not flash or does not go out. E-17
58 The alarm buzzer does not sound or does not stop. E-18
59 Auto shift down is not possible or is not released. E-19
60 The alarm buzzer cannot be cancelled. E-20
61 The operator mode cannot be operated. E-21
Phenomenon related to monitor panel (Service mode: Special function screen)
62 The service mode does not operate. E-22
Others
63 The back-up alarm does not sound. E-23
The night light, the headlamp, the working lamp and the rear lamp on the pan-
64 E-24
el do not come on.
65 The air conditioner does not operate. E-25
20-310 D275A-5
1
(7)
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR
TROUBLESHOOTING EACH SYSTEM
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIR-

CUIT DIAGRAM FOR EACH SYSTEM
TABLE OF CONNECTORS
★ Addresses show approximate positions of these devices in single view layout drawings of connectors and
electrical circuit diagrams of each system.
Connector Type of Number Address

Device name 3-dimensional
No. connector of pins M-circuit E-circuit T-circuit S-circuit
drawing
101 SWP 6 Intermediate connector C-1 H-7

201 SWP 6 Intermediate connector B-2 H-7
203 M 2 Right head lamp B-7 J-8
204 M 2 Left head lamp A-4
205 Terminal 1 Horn A-2
209 X 2 Intermediate connector A-6 J-8
214 DT-B 12 Intermediate connector N-3 D-8 G-3
215 DT-C 12 Intermediate connector N-2 D-6 E-3
216 DT-D 12 Intermediate connector N-3 H-3 E-3
217 DT 2 Caution buzzer P-1 A-4
218 4 Rear lamp switch N-5 B-1
219 4 Head lamp · Working lamp switch R-1 B-2
221 DT 2 Left working lamp F-1 L-8
223 DT 2 Left real lamp K-5 K-8
224 X 2 Pin puller solenoid valve K-6
241 DT 12 Intermediate connector C-7 H-7 J-9
242 DT 2 Right working lamp B-7 I-8
243 DT 2 Right rear lamp I-9 K-8
244 DT 2 Backup alarm J-9 L-2
262 X 2 Horn switch Q-8
263 X 2 Pin puller switch R-8
264 DT 4 Intermediate connector R-8
265 Terminal 1 Horn switch Q-7
266 Terminal 1 Horn switch Q-8
361 M 2 Front windshield washer motor I-3
362 M 2 Left windshield washer motor H-3
363 M 2 Right windshield washer motor I-3
364 M 2 Rear windshield washer motor H-3
423 X 2 Fuel level sensor J-4 K-8
453 DT 2 Torque converter oil temperature sensor AH-3 H-8
800 Plug 1 Intermediate connector (Service power source) N-9
801 Plug 1 Intermediate connector (Service power source) N-9
A/C X 1 Air conditioner compressor Y-7
AC1 17 Air conditioner control panel N-4
ADH 4 Heater switch Q-1
ASD 4 Auto shift-down switch N-5 H-2
BB1 Relay 5 Front lamp relay M-8 G-3
BB2 Relay 5 Front lamp relay M-7 G-2
D275A-5 20-311
1

drawing
BB3 Relay 5 Working lamp relay M-8 G-2

BKA Relay 5 Backup alarm relay M-8 I-3
BRK DT 3 Brake pedal potentiometer Q-1 B-1
BUZ 3 Buzzer cancel switch N-6 B-2 F-2
C Terminal 1 Battery relay (M-terminal) E-1 L-1 A-1 L-2 L-1
CA1 3 CAN terminating resistor W-5 F-1 J-1 D-2 D-9
CA2 3 CAN terminating resistor O-6 B-3 K-9 I-2 E-2
CAN DT-D 12 Intermediate connector W-7 D-8
CB1 — 2 Circuit breaker (20A) M-9 J-2
CB3 — 2 Circuit breaker (20A) M-9 J-2 C-1 K-2
CB4 — 2 Circuit breaker (20A) M-9
CB6 — 2 Circuit breaker (20A) M-8 J-1 C-2 K-2 J-1
CN1 DT 2 Engine No. 1 injector Y-7 L-4
CN2 DT 2 Engine No. 2 injector Z-7 L-3
CN3 DT 2 Engine No. 3 injector Z-8 L-3
CN4 DT 2 Engine No. 4 injector AA-8 L-3
CN5 DT 2 Engine No. 5 injector AB-9 L-4
CN6 DT 2 Engine No. 6 injector AC-8 L-3
CN-1 Plug 1 Lamp outlet connector [Cab] H-9
CN-2 Terminal 1 Rear right speaker [Cab] H-9
CN-3 Terminal 1 Rear right speaker [Cab] H-9
CN-4 4 Rear wiper motor [Cab] G-9
CN-5 Terminal 1 Rear left speaker [Cab] G-9
CN-6 Terminal 1 Rear left speaker [Cab] G-9
CN-9 6 Front wiper motor [Cab] D-8
CN-10 9 Radio [Cab] I-9
CN-11 6 Left wiper switch [Cab] E-9
CN-12 6 Front wiper switch [Cab] E-9
CN-13 6 Right wiper switch [Cab] E-9
CN-14 6 Rear wiper switch [Cab] F-9
CN-15 2 Lamp switch [Cab] F-9
CN-17 4 Right door wiper motor [Cab] D-8
CN-18 4 Left door wiper motor [Cab] J-9
CN-19 M 4 Intermediate connector [Cab] I-4
CN-20 DT 1 Cab power source connector [Cab] U-1
CN-21 DT 1 Cab power source connector [Cab] T-1
CN-22 Terminal 2 Cigarette lighter [Cab] J-9
CN-23 4 Converter [Cab] G-9
CN-24 2 Intermediate connector [Cab] K-7
CN-25 Plug 1 Revolving warning lamp outlet connector [Cab] I-9
CN-26 2 Revolving warning lamp switch [Cab] F-9
CN-81 2 Room lamp [Cab] E-8
CN-D 2 Accessory socket [Cab] K-8
20-312 D275A-5
1

drawing
CUR 3 Information switch N-6 B-3 F-2

DCL DT 3 Decelerator pedal potentiometer R-1 K-1
DL1 DT-D 12 Intermediate connector N-2 D-8 G-3 D-3
E21 24-31 31 Intermediate connector C-7 J-4
E22 24-31 31 Intermediate connector C-7 J-5 J-7 K-4
E51 24-31 31 Intermediate connector S-1 G-6 G-9 I-5 H-5
ECN1 DRC-26 24 Engine controller W-4 K-7 A-9
ECN2 DRC-26 40 Engine controller W-4 K-6 A-8 K-4 K-5
ECN3 DRC-26 40 Engine controller W-4 A-5 K-3 K-4
EGS SWP 6 Intermediate connector Q-1 G-7
ESD DT 3 Intermediate connector O-7 L-3
F1T DT 2 1st clutch ECMV (Fill switch) AG-7 K-6
F2T DT 2 2nd clutch ECMV (Fill switch) AE-3 K-5
F3T DT 2 3rd clutch ECMV (Fill switch) AF-7 K-5
FAC DT 2 Fan pump solenoid valve AE-4 K-8
FD5 DT 12 Intermediate connector V-2 J-4 B-1 J-2 K-2
FE2 24-23 23 Intermediate connector V-2 G-6 H-5
FFT DT 2 FWD clutch ECMV (Fill switch) AH-8 K-7
FLB DT 2 Left steering brake ECMV (Fill switch) AI-7 J-8
FLC DT 2 Left steering clutch ECMV (Fill switch) AH-8 J-8
FLS X 4 Intermediate connector (For 232C) U-1 D-5
FRB DT 2 Right steering brake ECMV (Fill switch) AJ-7 K-8
FRC DT 2 Right steering clutch ECMV (Fill switch) AH-8 J-8
FRT DT 2 REV clutch ECMV (Fill switch) AG-7 K-6
FS1 — — Fuse box 1 N-9 J-1 C-2 K-1 J-1
FS2 — — Fuse box 2 — J-2 C-2
FS4 — — Fuse box 4 O-9 J-2 C-1 K-1 J-1
FSB 24-31 31 Intermediate connector S-1 G-5 G-2 I-5 H-4
FTU 4 Pivot turn switch N-5 F-2
G DT 2 Engine G speed sensor AB-3 L-4 K-6
GND Terminal — GND [Cab] J-4
GND1 Terminal — GND H-2 C-1 C-1 C-1
GND1 Terminal — GND N-4 D-1 H-1 E-1
GND1 Terminal — GND T-1
GND1 Terminal — GND [Cab] —
GND2 Terminal — GND [Cab] —
H Terminal 1 Battery relay (B-terminal) F-1 L-1 A-1 L-1 L-1
H01 Plug 1 Intermediate connector S-9
H01 Plug 1 Intermediate connector S-9
HHP DT 3 Hydraulic oil pressure sensor C-7 K-8
HT Terminal 1 Ribbon heater (C-terminal) AD-5 L-3 K-5
HT/A Terminal 1 Ribbon heater (A-terminal) AD-5 L-3 L-5
HT/B Terminal 1 Ribbon heater (B-terminal) AD-4 L-2 L-5
KEY M 6 Starting switch O-7 B-3 K-8 H-2 E-2
M26 6 Air conditioner unit O-1
D275A-5 20-313
1

drawing
NE DT 2 Engine Ne speed sensor AD-4 L-4 K-6

NSF Relay 5 Neutral safety relay M-7 G-3 D-1 I-3
NSW DT 3 Safety lock switch O-9 G-4 L-3 L-4
P03 DT 6 Pitch mode switch Q-8 E-2
PCV1 DT 2 Fuel supply pump PCV1 AC-3 L-2
PCV2 DT 2 Fuel supply pump PCV2 AB-2 L-2
PDS-a DT 2 Blade pitch solenoid valve D-8 K-9
PDS-b DT 2 Blade pitch soleroid value D-8 K-9
PFUEL DT 3 Common rail fuel pressure sensor AC-3 K-8
PIM DT 3 Boost pressure sensor Z-7 K-8
PL1 24-31 31 Intermediate connector W-3 H-7
PL2 24-31 31 Intermediate connector W-3 G-8 H-8 H-7
PL4 DT12-B 12 Intermediate connector V-2 G-7 H-9
PL5 DT-A 12 Intermediate connector V-2 H-9 H-8
PPA DT 2 Blade dual solenoid valve —
PPR Relay 5 Pump power relay M-7 F-1
PRE DT 2 Pre-lubricator O-7 G-1 E-1 I-4
PRS DT 2 Pre-lubricator O-8 G-1 E-1 I-4
PSH Terminal 1 Engine oil pressure sensor (High pressure) AC-3 K-4 K-6
PSL Terminal 1 Engine oil pressure sensor (Low pressure) AD-3 K-5 K-7
PT1 DT 2 Pitch angle sensor D-1 L-8
PWR DT 2 Intermediate connector U-2 K-2 B-2 K-2 K-2
RHR Relay 5 Pre-heater relay N-7 G-1 F-1
RHT DT 3 Pre-heater timer O-8
RPD DT 2 Ripper LOWER oil pressure switch (SSC specification) Q-8 E-8
RPU DT 2 Ripper RAISE oil pressure switch (SSC specification) R-8 D-8
RTI DT 2 Ripper TILT-IN oil pressure switch (SSC specification) R-8 E-8
S01 AMP040 12 Monitor panel P-7 A-8 G-2 C-1
S02 M 2 Monitor panel O-6 A-7
S03 AMP070 20 Monitor panel P-7 A-7
S04 AMP070 12 Monitor panel P-7 A-5 J-9 G-2 D-1
S13 DT-A 12 Intermediate connector N-2 D-5 J-9 G-3 D-3
S1T DT 2 1st clutch ECMV (Solenoid valve) AF-6 K-6
S21 3 SSC initial jumper O-6 D-7
S24 Terminal 6 Service switch P-1 C-4 E-1
S2T DT 2 2nd clutch ECMV (Solenoid valve) AE-3 K-6
S3T DT 2 3rd clutch ECMV (Solenoid valve) AG-7 K-5
SDR Relay 5 Engine controller power relay N-7 E-1 L-3
SDS DT 2 Hydraulic oil temperature D-8 I-8 K-9
SFT DT 2 FWD clutch ECMV (Solenoid valve) AF-3 K-7
SLB DT 2 Left steering brake ECMV (Solenoid valve) AI-8 J-8
SLC DT 2 Left steering clutch ECMV (Solenoid valve) AI-8 I-8
SRB DT 2 Right steering brake ECMV (Solenoid valve) AJ-7 J-8
SRC DT 2 Right steering clutch ECMV (Solenoid valve) AH-8 I-8
SRT DT 2 REV clutch ECMV (Solenoid valve) AE-4 K-7
20-314 D275A-5
1

Device name
No. connector of pins 3-dimensional
M-circuit E-circuit T-circuit S-circuit
drawing
SS3 DT 4 Acceleration sensor (SSC specification) D-1 L-8

ST DT 2 Starting motor AB-2 L-3 K-4
STB DT 2 Emergency stop prevention solenoid valve AI-8 K-8
STCN1 DRC-26 24 Steering controller W-5 E-8 A-9
STCN2 DRC-26 40 Steering controller V-7 E-8 H-1 C-1 A-7
STCN3 DRC-26 40 Steering controller V-8 F-8 H-1 D-1 A-4
STF X 4 Software writing connector (Steering controller) V-8 D-9
SW Terminal 1 Battery relay (BR-terminal) E-1 L-1 A-1 L-1 L-1
THL DT 3 Fuel temperature sensor AD-6 K-5
TL1 24-23 23 PPC lever · Fuel control dial unit W-5 K-2 E-2 B-1
TM1 DT 2 Bevel speed sensor AJ-6 E-1 K-8
TMCN1 DRC-26 24 Transmission controller U-8 E-1 A-9 F-8
TMCN2 DRC-26 40 Transmission controller T-9 I-1 A-7 F-8
TMCN3 DRC-26 40 Transmission controller T-9 A-5 E-8
TMF X 4 Software writing connector (Transmission controller) U-8 F-2
TMV 24-23 23 Intermediate connector AH-7 J-7
TWH DT 2 Engine water temperature sensor (High temperature) AB-8 L-5 K-7
TWL DT 2 Engine water temperature sensor (Low temperature) AA-8 L-5 K-7
USB DT 2 Intermediate connector U-2 K-1 B-2 K-1 K-1
VHMS 2 Intermediate connector O-9
WLD X 2 Radiator water level sensor A-6 J-8
WLM X 2 Radiator water level sensor A-6 J-8
D275A-5 20-315
(6)
1
CONNECTOR ARRANGEMENT DRAWING
20-316 D275A-5
1
D275A-5 20-317
1
20-318 D275A-5
1
D275A-5 20-319
1
20-320 D275A-5
1
D275A-5 20-321
1
TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM

(M CIRCUIT)
20-322 D275A-5
1
TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
★ This circuit diagram was drawn by extracting the monitor panel system, the engine preheating, starting and
filling systems, the lighting system and the communication network system from the general electrical circuit
diagram.
D275A-5 20-323
1
TROUBLESHOOTING CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM

(E CIRCUIT)
20-324 D275A-5
1
TROUBLESHOOTING CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
★ This circuit diagram was drawn by extracting the engine controller system from the general electrical circuit
diagram.
D275A-5 20-325
1
TROUBLESHOOTING CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)
CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM

(T CIRCUIT)
20-326 D275A-5
1
TROUBLESHOOTING CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)
★ This circuit diagram was drawn by extracting the transmission controller system from the general electrical
circuit diagram.
D275A-5 20-327
1
TROUBLESHOOTING CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)
CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM

(S CIRCUIT)
20-328 D275A-5
1
TROUBLESHOOTING CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)
★ This circuit diagram was drawn by extracting the steering controller system from the general electrical circuit
diagram.
D275A-5 20-329
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X Type Connector
Number
of Pins T-adapter
Male (Female housing) Female (Male housing)
Part Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
3 799-601-7030
4 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
— —
• Grommet: red • Grommet: red
20-330 D275A-5
1
SWP Type Connector

Number
of Pins T-adapter Part
Number
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
D275A-5 20-331
1
SWP Type Connector

Number
of Pins T-adapter
Part Number
16 799-601-7320

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
20-332 D275A-5
1
M Type Connector
Number
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
D275A-5 20-333
1
(5)
S Type Connector
Number
of Pins T-adapter
Part Number
8 799-601-7140
10
799-601-7150
(white)
12
799-601-7350
(white)
16
799-601-7330
(white)
20-334 D275A-5
1
S Type Connector
Number
Number
10
—
(blue)
— —
12
799-601-7160
(blue)
16
799-601-7170
(blue)
D275A-5 20-335
1
MIC Type Connector

Number
of Pins T-adapter
Part Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 —
(Quantity: 5 pieces) (Quantity: 5 pieces)
11 —
5 799-601-2710

9 799-601-2950

13 799-601-2720

20-336 D275A-5
1
MIC Type Connector

Number
Number
17 799-601-2730

21 799-601-2740

—
D275A-5 20-337
1
AMP040 Type Connector

Number
of Pins T-adapter
Part Number
8 799-601-7180
Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)
12 799-601-7190

—
16 799-601-7210

—
20 799-601-7220

—
★ Terminal part number: 79A-222-3470 (for all numbers of pins).
20-338 D275A-5
1
AMP070 Type Connector

Number
Number
10 799-601-7510
— Part number: 08195-10210
12 799-601-7520
— Part number: 08195-12210
14 799-601-7530
— Part number: 08195-14210
18 799-601-7540
— Part number: 08195-18210
20 799-601-7550
— Part number: 08195-20210
D275A-5 20-339
1
L Type Connector
Number
of Pins T-adapter
Part Number
2 —
— —
PA Type Connector
Number
of Pins T-adapter
Part Number
9 —
— —
BENDIX (MS) Type Connector

Number
of Pins T-adapter
Part Number
10 799-601-3460
— —
20-340 D275A-5
1
KES1 Automobile Type Connector

Number
Number
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
D275A-5 20-341
1
KES1 Automobile Type Connector

Number
of Pins T-adapter
Part Number
8 —
08027-10820 (Black) 08027-10870 (Black)
20-342 D275A-5
1
F Type Connector
Number
of Pins T-adapter
Part Number
4 —
— —
D275A-5 20-343
1
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell size T-adapter
code) Body (plug) Body (receptacle)
Part Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
20-344 D275A-5
1

(shell size T-adapter Part
Number
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
D275A-5 20-345
1

Part Number
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
20-346 D275A-5
1

(shell size T-adapter Part
Number
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
D275A-5 20-347
1

Part Number
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
20-348 D275A-5
1
DT Series connector
Number
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
D275A-5 20-349
1
DT Series connector
Number
of Pins T-adapter
Part Number
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9080
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
20-350 D275A-5
1
(5)
DTM Series connector
Number
of Pins T-adapter
Part Number
2 799-601-9010
DTHD Series connector

Number
of Pins T-adapter
Part Number
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
D275A-5 20-351
1
TROUBLESHOOTING 20 TROUBLESHOOTING
TROUBLESHOOTING WHEN
ERROR CODE IS DISPLAYED
(ERROR CODE)
IInformation Described in Troubleshooting List ....................................................................................... 20-405

Trouble Code Table ................................................................................................................................. 20-406
Error code 1500LO (Transmission clutch: See the list. (L0)) ................................................................. 20-407
Error code 15SAL1 (Forward clutch: See the list. (L1)) ......................................................................... 20-408
Error code 15SALH (Forward clutch: See the list. (LH)) ........................................................................ 20-409
Error code 15SBL1 (Reverse clutch: See the list. (L1)) ......................................................................... 20-410
Error code 15SBLH (Reverse clutch: See the list. (LH)) ........................................................................ 20- 411
Error code 15SEL1 (1st clutch: See the list. (L1)) .................................................................................. 20-412
Error code 15SELH (1st clutch: See the list. (LH)) ................................................................................ 20-413
Error code 15SFL1 (2ND clutch: See the list. (L1)) ............................................................................... 20-414
Error code 15SFLH (2ND clutch: See the list. (LH)) .............................................................................. 20-415
Error code 15SGL1 (3RD clutch: See the list. (L1)) ............................................................................... 20-416
Error code 15SGLH (3RD clutch: See the list. (LH)) .............................................................................. 20-417
Error code 2201L1 (Right clutch: See the list. (L1)) ............................................................................... 20-418
Error code 2201LH (Right clutch: See the list. (LH)) .............................................................................. 20-419
Error code 2202L1 (Left clutch: See the list. (L1)) ................................................................................. 20-420
Error code 2202LH (Left clutch: See the list. (LH)) ................................................................................ 20-421
Error code 2301L1 (Right brake: See the list. (L1)) ............................................................................... 20-422
Error code 2301LH (Right brake: See the list. (LH)) .............................................................................. 20-423
Error code 2302L1 (Left brake: See the list. (L1)) .................................................................................. 20-424
Error code 2302LH (Left brake: See the list. (LH)) ................................................................................. 20-425
Error code AB00MA (Alternator: Malfunction (MA)) ............................................................................... 20-426
Error code AD00L2 (Common rail: See the list. (L2)) ............................................................................ 20-426
Error code AD00MA (Common rail: Defective function (MA)) ............................................................... 20-427
Error code AD10L3 (Fuel supply pump: See the list. (L3)) .................................................................... 20-427
Error code AD10MA (Fuel supply pump: DEFECTIVE FUNCTION (MA)) ............................................ 20-430
Error code AD10MB (Fuel supply pump: FUNCTION REDUCTION (MB)) ........................................... 20-430
Error code AD11KA (Fuel supply pump solenoid 1: Disconnection in wiring (KA)) ............................... 20-431
Error code AD11KB (Fuel supply pump solenoid 1: Short circuit (KB)) ................................................. 20-432
Error code AD51KA (Fuel supply pump solenoid 2: Disconnection in wiring (KA)) ............................... 20-433
Error code AD51KB (Fuel supply pump solenoid 2: Disconnection in short (KB)) ................................. 20-434
Error code ADA1KA (NO.1 injector solenoid: Disconnection in wiring (KA)) ......................................... 20-435
Error code ADAZKB (NO.1, 2, and 3 injector solenoids: short (KB)) ..................................................... 20-436
Error code ADB1KA (NO.2 injector solenoid: Disconnection in wiring (KA)) ......................................... 20-438
Error code ADC1KA (NO.3 injector solenoid: Disconnection in wiring (KA)) ......................................... 20-439
Error code ADD1KA (NO.4 injector solenoid: Disconnection in wiring (KA)) ......................................... 20-440
Error code ADDZKB (NO.4, 5, AND 6 injector solenoids: short (KB)) ................................................... 20-441
Error code ADE1KA (NO. 5 FUEL injector solenoid: disconnection (KA)) ............................................. 20-443
Error code ADF1KA (NO. 6 FUEL injector solenoid: disconnection (KA)) ............................................. 20-444
Error code B@BAZG (Engine oil: Oil pressure reduction (ZG)) ............................................................ 20-445
Error code B@BCNS (Radiator coolant: Overheat (NS)) ....................................................................... 20-445
Error code B@BCZK (Radiator coolant: Level reduction (ZK)) .............................................................. 20-446
Error code B@CENS (Power tran oil: Overheat (NS)) .......................................................................... 20-446
Error code B@HANS (Hydraulic oil: Overheat (NS)) ............................................................................. 20-447
Error code D110KA (Battery relay: Disconnection (KA)) ........................................................................ 20-448
Error code D110KB (Battery relay: Short circuit (KB)) ............................................................................ 20-449
Error code D130KA (Neutral safety relay: Disconnection (KA)) ............................................................. 20-450
D275A-5 20-401
1
TROUBLESHOOTING
Error code D130KB (Neutral safety relay: Short circuit (KB)) ................................................................. 20-452
Error code D161KA (Back-up alarm relay: Disconnection (KA)) ............................................................ 20-453
Error code D161KB (Back-up alarm relay: Short circuit (KB)) ................................................................ 20-455
Error code D1D0KB (Engine controller load power supply relay: Short circuit (KB)) .............................. 20-457
Error code DAFRKR (Monitor panel can communication: Defective communication (KR)) .................... 20-459
Error code DAQ0KK (Transmission controller: Source voltage reduction/input (KK)) ............................ 20-461
Error code DAQ0KT (Transmission controller: Abnormality in controller (KT)) ...................................... 20-462
Error code DAQ5KK (Transmission controller Potentiometer power supply:
Source voltage reduction/input (KK)) ...................................................................................... 20-463
Error code DAQ6KK (Transmission controller Sensor power supply:
Error code DAQ9KQ (Transmission controller type collation: Type select signal inconsistency (KQ)) .. 20-466
Error code DAQRKR (Transmission controller can communication: Defective communication (KR)) ... 20-467
Error code DAQSKR (transmission controller snet communication: Defective communication (KR)) .... 20-469
Error code DB20KT (Engine controller: Abnormality in controller (KT)) ................................................. 20-470
Error code DB22KK (Engine controller load power supply: Source voltage reduction/input (KK)) ......... 20-472
Error code DB29KQ (Engine controller type select: Type select signal inconsistency (KQ)) ................. 20-474
Error code DB2AMA (Fuel injection amount adjustment switch signal: Malfunction (MA)) .................... 20-475
Error code DB2RKR (Engine controller can communication: Defective communication (KR)) .............. 20-476
Error code DB30KK (Steering controller: Source voltage reduction/input (KK)) ..................................... 20-478
Error code DB30KT (Steering controller: Abnormality in controller (KT)) ............................................... 20-479
Error code DB35KK (Steering controller potentiometer power supply:
Error code DB36KK (Steering controller sensor power supply: Source voltage reduction input (KK)) ... 20-482
Error code DB39KQ (Steering controller type collation: Type select signal inconsistency (KQ)) ........... 20-484
Error code DB3RKR (Steering controller can communication: Defective communication (KR)) ............ 20-485
Error code DB3SKR (Steering controller snet communication: Defective communication (KR)) ........... 20-487
Error code DD11KB (Starting switch: Short circuit (KB)) ........................................................................ 20-488
Error code DD12KA (Shift up switch: Disconnection (KA)) .................................................................... 20-489
Error code DD12KB (Shift up switch: Short circuit (KB)) ........................................................................ 20-491
Error code DD13KA (Shift down switch: Disconnection (KA)) ................................................................ 20-493
Error code DD13KB (Shift down switch: Short circuit (KB)) ................................................................... 20-495
Error code DD14KA (Parking lever switch: Disconnection (KA)) ........................................................... 20-497
Error code DD14KB (Parking lever switch: Short circuit (KB)) ............................................................... 20-499
Error code DDE2L6 (Engine oil pressure switch: Refer to table (L6) ..................................................... 20-501
Error code DDN4LD (Ripper lift up pressure switch: Refer to table (LD) ................................................ 20-503
Error code DDN5LD (Ripper lift down pressure switch: Refer to table (LD) ........................................... 20-504
Error code DDN6LD (Ripper tilt in pressure switch: Refer to table (LD) ................................................. 20-505
Error code DDN7KA (Blade pitch switch: Disconnection (KA)) .............................................................. 20-506
Error code DDN7KB (Blade pitch switch: Short circuit (KB)) ................................................................. 20-508
Error code DDN9KA (Blade tilt switch: Disconnection (KA)) .................................................................. 20-510
Error code DDN9KB (Blade tilt switch: Short circuit (KB)) ...................................................................... 20-512
Error code DDQ2KA (Parking lever switch: Disconnection (KA)) ........................................................... 20-514
Error code DDQ2KB (Parking brake lever switch: Short circuit (KB)) .................................................... 20-516
Error code DDQ2L4 (Parking brake lever switch: See table (L4)) ......................................................... 20-518
Error code DGE2KX (Engine water temperature sensor (for high temperature):
Input signal is out of normal range (KX)) ............................................................................... 20-519
Error code DGE3L6 (Engine water temperature sensor (for low temperature): See table (L6)) ............ 20-520
Error code DGE4KX (Fuel temperature sensor: Input signal is out of normal range (KX)) .................... 20-521
Error code DGS1KX (Hydraulic oil temperature sensor: Input signal is out of normal range (KX)) ....... 20-522
Error code DH21KA (Work equipment pump oil pressure sensor: Disconnection (KA)) ........................ 20-523
Error code DH21KB (Work equipment pump oil pressure sensor: Short circuit (KB)) ........................... 20-524
Error code DH30KX (Boost pressure sensor: Input is out of normal range (KX)) .................................. 20-525
Error code DH40KX (Common rail pressure sensor: Input is out of normal range (KX)) ....................... 20-527
Error code DK10KX (Fuel control dial: Input is out of normal range (KX)) ............................................. 20-529
20-402 D275A-5
1
TROUBLESHOOTING
Error code DK12KX (Deceleration potentiometer: Input is out of normal range (KX)) .......................... 20-531
Error code DK30KA (Steering potentiometer 1: Disconnection (KA)) .................................................... 20-533
Error code DK30KB (Steering potentiometer 1: Short circuit (KB)) ....................................................... 20-535
Error code DK30KX (Steering potentiometer 1: Input signal is out of normal range (KX)) .................... 20-536
Error code DK30KZ (Steering potentiometer 1: Disconnection or short circuit (KZ)) ............................ 20-536
Error code DK30L8 (Steering potentiometer 1: See table (L8)) ............................................................ 20-537
Error code DK31KA (Steering potentiometer 2: Disconnection (KA)) .................................................... 20-538
Error code DK31KB (Steering potentiometer 2: Short circuit (KB)) ....................................................... 20-540
Error code DK40KA (Brake potentiometer: Disconnection (KA)) ........................................................... 20-541
Error code DK40KB (Brake potentiometer: Short circuit (KB)) .............................................................. 20-543
Error code DK55KX (Forward-reverse potentiometer: Input signal is out of normal range (KX)) .......... 20-544
Error code DK55KZ (Forward-reverse potentiometer: Disconnection or short circuit (KZ)) .................. 20-544
Error code DK55L8 (Forward-reverse potentiometer: See table (L8)) .................................................. 20-545
Error code DK56KA (Forward-reverse potentiometer 1: Disconnection (KA)) ....................................... 20-546
Error code DK56KB (Forward-reverse potentiometer 1: Short circuit (KB)) .......................................... 20-548
Error code DK57KA (Forward-reverse potentiometer 2: Disconnection (KA)) ....................................... 20-549
Error code DK57KB (Forward-reverse potentiometer 2: Short circuit (KB)) .......................................... 20-551
Error code DK60KA (Acceleration sensor: Disconnection (KA)) ......................................................... 20-551-1
Error code DK60KB (Acceleration sensor: Short circuit (KB)) ............................................................ 20-551-2
Error code DKH1KA (Pitch angle sensor: Disconnection (KA)) ............................................................. 20-552
Error code DKH1KB (Pitch angle sensor: Short circuit (KB)) ................................................................ 20-553
Error code DLE3LC (Engine Ne speed sensor: See table (LE)) ........................................................... 20-554
Error code DLF1KA (Transmission output speed sensor: Disconnection (KA)) ..................................... 20-556
Error code DLH1LC (Engine G speed sensor: See table (LC)) ............................................................. 20-557
Error code DV00KB (Caution buzzer: Short circuit (KB)) ...................................................................... 20-558
Error code DW59KA (Blade dual selector solenoid: Disconnection (KA)) ............................................. 20-559
Error code DW59KB (Blade dual selector solenoid: Short circuit (KB)) ................................................ 20-560
Error code DW5AKA (Blade pitch selector solenoid: Disconnection (KA)) ............................................ 20-561
Error code DW5AKB (Blade pitch selector solenoid: Short circuit (KB)) ............................................... 20-562
Error code DWN3KA (Sudden stop prevention solenoid: Disconnection (KA)) ..................................... 20-563
Error code DWN3KB (Sudden stop prevention solenoid: Short circuit (KB)) ........................................ 20-564
Error code DWN5KA (Fan pump solenoid: Disconnection (KA)) ........................................................... 20-565
Error code DWN5KB (Fan pump solenoid: Short circuit (KB)) .............................................................. 20-566
Error code DXH4KA (1st clutch ECMV: Disconnection (KA)) ................................................................ 20-567
Error code DXH4KB (1st clutch ECMV: Short circuit (KB)) ................................................................... 20-568
Error code DXH5KA (2nd clutch ECMV: Disconnection (KA)) ............................................................... 20-569
Error code DXH5KB (2nd clutch ECMV: Short circuit (KB)) .................................................................. 20-570
Error code DXH6KA (3rd clutch ECMV: Disconnection (KA)) ................................................................ 20-571
Error code DXH6KB (3rd clutch ECMV: Short circuit (KB)) ................................................................... 20-572
Error code DXH7KA (Reverse clutch ECMV: Disconnection (KA)) ........................................................ 20-573
Error code DXH7KB (Reverse clutch ECMV: Short circuit (KB)) ........................................................... 20-574
Error code DXH8KA (Forward clutch ECMV: Disconnection (KA)) ........................................................ 20-575
Error code DXH8KB (Forward clutch ECMV: Short circuit (KB)) ........................................................... 20-576
Error code DXH9KA (Right CLUTCH ECMV: Disconnection (KA)) ....................................................... 20-577
Error code DXH9KB (Right CLUTCH ECMV: SHORT CIRCUIT (KB)) ................................................. 20-578
Error code DXHAKA (LEFT CLUTCH ECMV: Disconnection (KA)) ....................................................... 20-579
Error code DXHAKB (LEFT CLUTCH ECMV: short circuit (KB)) .......................................................... 20-580
Error code DXHBKA (Right brake ECMV: Disconnection (KA)) ............................................................. 20-581
Error code DXHBKB (Right brake ECMV: Short circuit (KB)) ................................................................ 20-582
Error code DXHCKA (Left brake ECMV: Disconnection (KA)) ............................................................... 20-583
Error code DXHCKB (Left brake ECMV: Short circuit (KB)) .................................................................. 20-584
D275A-5 20-403
(6)
1
TROUBLESHOOTING INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST

★ The troubleshooting list and related circuit diagram summarize the following information. Understand their
contents well to advance troubleshooting.
Action code Error code
Trouble Trouble that appeared on machine
Panel display Panel display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of monitor
Action to be taken to protect the system and equipment when the monitor panel or controller detects a
panel or
trouble
controller
Problem that
Problem that appears as an abnormality in the main unit by the action taken by the monitor panel or con-
appears on
troller (above)
machine
Related
Information related to a detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state required to judge the assumed
cause (good or not)
1 • Remarks required to judge whether the cause is good
<Phenomenon of defective harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness is
disconnected.
• Grounding fault
A harness not connected to the ground (earth) circuit comes into
2
contact with the ground (earth) circuit.
• Defective hot short
A harness not connected to the power (24V) circuit comes into
contact with the power (24V) circuit.
• Defective short
Possible causes Cause by which a trouble is as- A harness of an independent circuit abnormally comes into con-
and standard sumed to be detected tact with one of another circuit.
value in normal 3 (The order number indicates a
state serial number, not a priority se- <Notes on troubleshooting>
quence.) 1Method of indicating connector numbers and handling T-junc-
tion
For troubleshooting, insert or connect the T-junction adapter as
shown below unless especially specified.
• When “male” or “female” is not indicated for a connector num-
4 ber, disconnect the connector, and insert the T-junction adapt-
er in both the male and female.
• When “male” or “female” is indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in
only either the male or female.
2Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as
5 • 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.
D275A-5 20-405
1
TROUBLESHOOTING TROUBLE CODE TABLE
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model-No. of pins) (Color).
• Arrow (⇔): Roughly indicates mounting place on machine.
TROUBLE CODE TABLE

★ Regarding trouble code provided with instruction “Refer to table”, check it against table below.
Trouble code Detail of trouble Trouble code Detail of trouble

KA Disconnection L4 ON/OFF signals do not agree with each other
Operation state and stop state do not agree
KB Short circuit L6
with signals
KK Lowering of source voltage (Input) L8 Analog signals do not agree with each other
KQ Disagreement of model selection signals LC Speed signals do not agree with each other
Communication defective (Abnormality in ob-
KR LD Switch is pressed for long time
jective component)
When command current is turned ON, fill sig-
KT Internal defect of controller LH
nal is turned OFF
KX Out of input signal range MA Malfunction
KZ Disconnection or short circuit MB Lowering of function
L0 Double engagement MW Slip
When command current is turned OFF, fill sig-
L1 NS Overheating
nal is turned ON
L2 Fuel pressure is too high ZG Lowering of oil pressure
L3 Objective part cannot be controlled ZK Lowering of level
20-406 D275A-5
(1)
(4)
TROUBLESHOOTING ERROR CODE 1500LO (TRANSMISSION CLUTCH: SEE THE LIST. (LO))
ERROR CODE 1500LO (TRANSMISSION CLUTCH: SEE THE LIST. (LO))
Action code Error code Transmission clutch: See the list. (LO)
Trouble
CALL E03 1500LO (Transmission controller system)
• Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Connection error)
1Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
• Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Disconnection error)
2Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
Contents of
3[DXH6KA] and [DXH6KB]
trouble
4[15SFL1] and [15SGL1]
5[15SFLH] and [15SGLH]
6[15SAL1], [15SBL1], and [15SEL1]
7[15SALH] and [15SBLH]
8[15SALH] and [15SELH]
9[15SBLH] and [15SELH]
Action of • Flashes caution lamp and turns on caution buzzer.
controller • Limits operation of engine and transmission.
Problem that • The auto shift down function does not start.
appears on • Once machine is stopped, engine speed is limited to medium (half).
machine • Once machine is stopped, running is limited to F3 and R3.
Related
• Method of reproducing error code: Engine start + Run
information

Possible causes Confirm the error codes displayed at the same time, then carry out troubleshooting for the codes.
and standard [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
value in normal [15SGLH]
state [DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB], [DXH8KA],
[DXH8KB]
D275A-5 20-407
1
TROUBLESHOOTING ERROR CODE 15SAL1 (FORWARD CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SAL1 (FORWARD CLUTCH: SEE THE LIST. (L1))
Action code Error code Forward clutch: See the list. (L1)
Trouble
CALL E03 15SAL1 (Transmission controller system)
Contents of
• The fill switch signal is not set OFF at output stop of the transmission forward clutch solenoid circuit.
trouble
• Flashes caution lamp and turns on caution buzzer.
Action of
• Decides that engine speed is neutral (N) at reverse operation.
controller
• Limits operation of engine and transmission.
Problem that
• Once machine is stopped, engine speed is limited to medium (half).
appears on
• Once machine is stopped, running is limited to F1.
machine
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
(Code 31520: Transmission fill switch input state)
information
• Method of reproducing error code: Engine start + Neutral running

★ Prepare with starting switch OFF, then start the engine for trouble-
shooting.
Defective forward clutch fill FFT (male) PCCS lever Resistance
1
switch (Internal short)
Between 1 – N Min. 1MΩ
chassis ground F (Forward) Max. 1Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective harness ground-
Possible causes without turning starting switch ON.
2 ing (Contact with ground cir-
and standard Wiring harness between TMCN1 (female) 5 –
cuit) Resistance Max. 1MΩ
value in normal FFT (female) 1 with chassis ground
state ★ Prepare with starting switch OFF, then start the engine for trouble-
shooting.
Defective transmission con- TMCN1 PCCS lever Voltage
3
troller
Between 5 – N 20 – 30V
chassis ground F (Forward) Max. 1V
When no fault is detected in the electric system, the hydraulic pres-
Defective hydraulic pres-
4 sure system is assumed to be abnormal. Carry out the related trou-
sure system
bleshooting (H mode).
Circuit diagram related to transmission forward clutch ECMV
20-408 D275A-5
1
TROUBLESHOOTING ERROR CODE 15SALH (FORWARD CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SALH (FORWARD CLUTCH: SEE THE LIST. (LH))
Action code Error code Forward clutch: See the list. (LH)
Trouble
CALL E03 15SALH (Transmission controller system)
Contents of
• The fill switch signal is not set ON at output to the transmission forward clutch solenoid circuit.
trouble
Action of
• Decides that engine speed is neutral (N) at forward operation.
controller
Problem that
appears on
• Once machine is stopped, running is limited to R1.
machine
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Engine start + Forward running

shooting.
Defective forward clutch fill FFT (male) PCCS lever Resistance
1
chassis ground F (Forward) Max. 1Ω
Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes ness (Disconnection in wir- without turning starting switch ON.
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) 5 –
Resistance Max. 1Ω
value in normal connector) FFT (female) 1
shooting.
3
troller
Between 5 – N 20 – 30V
chassis ground F (Forward) Max. 1V
sure system
D275A-5 20-409
1
TROUBLESHOOTING ERROR CODE 15SBL1 (REVERSE CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SBL1 (REVERSE CLUTCH: SEE THE LIST. (L1))
Action code Error code Reverse clutch: See the list. (L1)
Trouble
CALL E03 15SBL1 (Transmission controller system)
Contents of
• The fill switch signal is not set OFF at output stop of the transmission reverse clutch solenoid circuit.
trouble
Action of
• Decides that engine speed is neutral (N) at forward operation.
controller
Problem that
appears on
• Once machine is stopped, running is limited to R1.
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective reverse clutch fill FRT (male) PCCS lever Resistance
1
chassis ground R (Reverse) Max. 1Ω
and standard Wiring harness between TMCN1 (female) N –
value in normal FFT (female) 1 with chassis ground
shooting.
3
troller
Between N – N 20 – 30V
chassis ground R (Reverse) Max. 1V
sure system
Circuit diagram related to transmission reverse clutch ECMV
20-410 D275A-5
1
TROUBLESHOOTING ERROR CODE 15SBLH (REVERSE CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SBLH (REVERSE CLUTCH: SEE THE LIST. (LH))
Action code Error code Reverse clutch: See the list. (LH)
Trouble
CALL E03 15SBLH (Transmission controller system)
Contents of
• The fill switch signal is not set ON at output to the transmission reverse clutch solenoid circuit.
trouble
Action of
• Decides that engine speed is neutral (N) at reverse operation.
controller
Problem that
appears on
• Once machine is stopped, running is limited to F1.
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective reverse clutch fill FRT (male) PCCS lever Resistance
1
chassis ground R (Reverse) Max. 1Ω
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) N –
Resistance Max. 1MΩ
value in normal connector) FRT (female) 1
shooting.
3
troller
Between N – N 20 – 30V
chassis ground R (Reverse) Max. 1V
sure system
D275A-5 20-411
1
TROUBLESHOOTING ERROR CODE 15SEL1 (1ST CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SEL1 (1ST CLUTCH: SEE THE LIST. (L1))
Action code Error code 1st clutch: See the list. (L1)
Trouble
CALL E03 15SEL1 (Transmission controller system)
Contents of
• The fill switch signal is not set OFF at output stop of the transmission level 1 clutch solenoid circuit.
trouble
Problem that
appears on
• Once machine is stopped, running is limited to F1 and R1.
machine
• The input state (ON/OFF) from the level 1 clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 1st clutch fill F1T (male) PCCS lever Resistance
1
Between 1 – Other than F1/R1 Min. 1MΩ
chassis ground F1/R1 Max. 1Ω
Defective harness ground- without turning starting switch ON.
Possible causes
and standard Wiring harness between TMCN1 (female) M –
value in normal F1T (female) 1 with chassis ground
shooting.
3
troller
Between M – Other than F1/R1 20 – 30V
chassis ground F1/R1 Max. 1V
sure system
Circuit diagram related to transmission level 1 clutch ECMV
20-412 D275A-5
1
TROUBLESHOOTING ERROR CODE 15SELH (1ST CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SELH (1ST CLUTCH: SEE THE LIST. (LH))
Action code Error code Level 1 clutch: See the list. (LH)
Trouble
CALL E03 15SELH (Transmission controller system)
Contents of
• The fill switch signal is not set ON at output to the transmission 1st clutch solenoid circuit.
trouble
Problem that • The auto shift down function does not start.
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Engine start + F1 or R1 running

shooting.
Defective 1st clutch fill F1T (male) PCCS lever Resistance
1
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) M –
value in normal connector) F1T (female) 1
shooting.
3
troller
Between N – Other than F1/R1 20 – 30V
sure system
Circuit diagram related to transmission 1st clutch ECMV
D275A-5 20-413
1
TROUBLESHOOTING ERROR CODE 15SFL1 (2ND CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SFL1 (2ND CLUTCH: SEE THE LIST. (L1))
Action code Error code 2nd clutch: See the list. (L1)
Trouble
CALL E03 15SFL1 (Transmission controller system)
Contents of
• The fill switch signal is not set OFF at output stop of the transmission 2nd clutch solenoid circuit.
trouble
Problem that • The auto shift down function does not operate.
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 2nd clutch fill F2T (male) PCCS lever Resistance
1
chassis ground F2·R2 Max. 1Ω
Possible causes
and standard Wiring harness between TMCN1 (female) G –
shooting.
3
troller
Between G – Other than F2/R2 20 – 30V
chassis ground F2·R2 Max. 1V
sure system
Circuit diagram related to transmission 2nd clutch ECMV
20-414 D275A-5
1
TROUBLESHOOTING ERROR CODE 15SFLH (2ND CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SFLH (2ND CLUTCH: SEE THE LIST. (LH))
Action code Error code 2nd clutch: See the list. (LH)
Trouble
CALL E03 15SFLH (Transmission controller system)
Contents of
• The fill switch signal is not set ON at output to the transmission level 2 clutch solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 2nd clutch fill F2T (male) PCCS lever Resistance
1
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) G –
shooting.
3
troller
Between G – Other than F2/R2 20 – 30V
sure system
D275A-5 20-415
1
TROUBLESHOOTING ERROR CODE 15SGL1 (3RD CLUTCH: SEE THE LIST. (L1))
ERROR CODE 15SGL1 (3RD CLUTCH: SEE THE LIST. (L1))
Action code Error code 3rd clutch: See the list. (L1)
Trouble
CALL E03 15SGL1 (Transmission controller system)
Contents of
• The fill switch signal is not set OFF at output stop of the transmission 3rd clutch solenoid circuit.
trouble
Problem that • The auto shift down function does not operate.
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 3rd clutch fill F3T (male) PCCS lever Resistance
1
Possible causes
and standard Wiring harness between TMCN1 (female) A –
shooting.
3
troller
Between A – Other than F3/R3 20 – 30V
sure system
Circuit diagram related to transmission 3rd clutch ECMV
20-416 D275A-5
1
TROUBLESHOOTING ERROR CODE 15SGLH (3RD CLUTCH: SEE THE LIST. (LH))
ERROR CODE 15SGLH (3RD CLUTCH: SEE THE LIST. (LH))
Action code Error code 3rd clutch: See the list. (LH)
Trouble
CALL E03 15SGLH (Transmission controller system)
Contents of
• The fill switch signal is not set ON at output to the transmission 3rd clutch solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 3rd clutch fill F3T (male) PCCS lever Resistance
1
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) A –
shooting.
3
troller
Between A – Other than F3/R3 20 – 30V
sure system
D275A-5 20-417
1
TROUBLESHOOTING ERROR CODE 2201L1 (RIGHT CLUTCH: SEE THE LIST. (L1))
ERROR CODE 2201L1 (RIGHT CLUTCH: SEE THE LIST. (L1))
Action code Error code Right clutch: See the list. (L1)
Trouble
CALL E04 2201L1 (Steering controller system)
Contents of
• The fill switch signal is not set OFF at output stop of the right steering clutch solenoid circuit.
trouble
controller • Limits operation of engine, transmission, and brake.
Problem that
appears on
• Once machine is stopped, it cannot travel any more.
machine
• The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring mode.
Related
(Code 50601: Right clutch ECMV output current)
information
• Method of reproducing error code: Engine start + Parking brake lever reset

★ Prepare with starting switch OFF, then start the engine..
Defective right steering
FRC (male) PCCS Resistance
1 clutch fill switch (Internal
Between 1 – N (Neutral) Max. 1Ω
short)
chassis ground Right steering Min. 1MΩ
Defective harness without turning starting switch ON.
Possible causes
2 grounding (Contact with
and standard Wiring harness between STCN3 (female) ] –
ground circuit) Resistance Min. 1MΩ
value in normal FRC (female) 1 with chassis ground
state ★ Prepare with starting switch OFF, then start engine.
STCN3 PCCS Voltage
3 Defective steering controller
Between ] – N (Neutral) Max. 1V
chassis ground Right steering 20 – 30V
Defective hydraulic
pressure system
Circuit diagram related to right steering clutch ECMV
20-418 D275A-5
1
TROUBLESHOOTING ERROR CODE 2201LH (RIGHT CLUTCH: SEE THE LIST. (LH))
ERROR CODE 2201LH (RIGHT CLUTCH: SEE THE LIST. (LH))
Action code Error code Right clutch: See the list. (LH)
Trouble
CALL E04 2201LH (Steering controller system)
Contents of
• The fill switch signal is not set ON at output to the right steering clutch solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring mode.
Related
(Code 50601: Right clutch ECMV output current)
information

FRC (male) PCCS Resistance
1 clutch fill switch (Internal
Between 1 – N (Neutral) Max. 1Ω
short)
chassis ground Right steering Min. 1MΩ
Possible causes
2 grounding (Disconnection/
and standard Wiring harness between STCN3 (female) ] –
Defective contact) Resistance Min. 1MΩ
value in normal FRC (female) 1 with chassis ground
STCN3 PCCS Voltage
Between ] – N (Neutral) Max. 1V
chassis ground Right steering 20 – 30V
Defective hydraulic
pressure system
D275A-5 20-419
1
TROUBLESHOOTING ERROR CODE 2202L1 (LEFT CLUTCH: SEE THE LIST. (L1))
ERROR CODE 2202L1 (LEFT CLUTCH: SEE THE LIST. (L1))
Action code Error code Left clutch: See the list. (L1)
Trouble
Contents of
• The fill switch signal is not set OFF at output stop of the left steering clutch solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring mode.
Related
(Code 50600: Left clutch ECMV output current)
information

Defective left steering clutch FLC (male) PCCS Resistance
1
fill switch (Internal short) Between 1 – N (Neutral) Max. 1Ω
chassis ground Left steering Min. 1MΩ
Possible causes
and standard Wiring harness between STCN3 (female) S –
ground circuit) Resistance Min. 1 MΩ
value in normal FLC (female) 1 with chassis ground
STCN3 PCCS Voltage
Between S – N (Neutral) Max. 1V
chassis ground Left steering 20 – 30V
Defective hydraulic
pressure system
Circuit diagram related to left steering clutch ECMV
20-420 D275A-5
1
TROUBLESHOOTING ERROR CODE 2202LH (LEFT CLUTCH: SEE THE LIST. (LH))
ERROR CODE 2202LH (LEFT CLUTCH: SEE THE LIST. (LH))
Action code Error code Left clutch: See the list. (LH)
Trouble
Contents of
• The fill switch signal is not set ON at output to the left steering clutch solenoid circuit.
trouble
Problem that
appears on
machine
• The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring mode.
Related
(Code 50600: Left clutch ECMV output current)
information

Defective left steering clutch FLC (male) PCCS Resistance
1
fill switch (Internal short) Between 1 – N (Neutral) Max. 1Ω
chassis ground Left steering Min. 1MΩ
Possible causes
2 grounding (Disconnection/
and standard Wiring harness between STCN3 (female) S –
Defective contact) Resistance Min. 1MΩ
value in normal FLC (female) 1 with chassis ground
STCN3 PCCS Voltage
Between S – N (Neutral) Max. 1V
chassis ground Left steering 20 – 30V
sure system
D275A-5 20-421
1
TROUBLESHOOTING ERROR CODE 2301L1 (RIGHT BRAKE: SEE THE LIST. (L1))
ERROR CODE 2301L1 (RIGHT BRAKE: SEE THE LIST. (L1))
Action code Error code Right brake: See the list. (L1)
Trouble
Contents of
• The fill switch signal is not set OFF at output stop of the right steering brake solenoid circuit.
trouble
Problem that • The loose brake functions during running.
machine • Once machine is stopped, it never runs.
• The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring mode.
Related
(Code 31521: Steering fill switch input state)
information
• Method of reproducing error code: Engine start + Parking lever release

★ Prepare with starting switch OFF. Engine start.
FRB (male) PCCS lever Resistance
1 brake fill switch
Between 1 – N (Neutral) Min. 1MΩ
(Internal short)
chassis ground Right steering Max. 1Ω
Possible causes
and standard Wiring harness between STCN2 (female) O –
value in normal FRB (female) 1 with chassis ground
state ★ Prepare with starting switch OFF. Engine start.
STCN2 PCCS lever Voltage
Between O – N (Neutral) 20 – 30V
chassis ground Right steering Max. 1V
sure system
Circuit diagram related to right steering brake ECMV
20-422 D275A-5
1
TROUBLESHOOTING ERROR CODE 2301LH (RIGHT BRAKE: SEE THE LIST. (LH))
ERROR CODE 2301LH (RIGHT BRAKE: SEE THE LIST. (LH))
Action code Error code Right brake: See the list. (LH)
Trouble
Contents of
• The fill switch signal is not set ON at output to the right steering brake solenoid circuit.
trouble
• The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring mode.
Related
information

1 brake fill switch
(Internal short)
2
and standard ing or defective contact in Wiring harness between STCN2 (female) O –
value in normal connector) FRB (female) 1
Between O – N (Neutral) 20 – 30V
chassis ground Right steering Max. 1V
sure system
D275A-5 20-423
1
TROUBLESHOOTING ERROR CODE 2302L1 (LEFT BRAKE: SEE THE LIST. (L1))
ERROR CODE 2302L1 (LEFT BRAKE: SEE THE LIST. (L1))
Action code Error code Right brake: See the list. (L1)
Trouble
Contents of
• The fill switch signal is not set OFF at output stop of the left steering brake solenoid circuit.
trouble
• The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring mode.
Related
information

Defective left steering brake
1 fill switch
(Internal short)
Possible causes
and standard Wiring harness between STCN2 (female) Y –
value in normal FLB (female) 1 with chassis ground
Between Y – N (Neutral) 20 – 30V
chassis ground Left steering Max. 1V
sure system
Circuit diagram related to left steering brake ECMV
20-424 D275A-5
1
TROUBLESHOOTING ERROR CODE 2302LH (LEFT BRAKE: SEE THE LIST. (LH))
ERROR CODE 2302LH (LEFT BRAKE: SEE THE LIST. (LH))
Action code Error code Left brake: See the list. (LH)
Trouble
Contents of
• The fill switch signal is not set ON at output to the left steering brake solenoid circuit.
trouble
• The input state (ON/OFF) from the left steering brake fill switch can be checked in monitoring mode.
Related
information

Defective left steering brake
FLB (male) PCCS lever Resistance
1 fill switch
(Internal short)
chassis ground Left steering Max. 1Ω
2
and standard ing or defective contact in Wiring harness between STCN2 (female) Y –
value in normal connector) FLB (female) 1
Between Y – N (Neutral) 20 – 30V
chassis ground Left steering Max. 1V
sure system
D275A-5 20-425
1
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA))
TROUBLESHOOTING ERROR
ERRORCODE
CODEAB00MA
AD00L2 (ALTERNATOR:
(COMMON RAIL:
MALFUNCTION
SEE THE LIST.(MA))
(L2))
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA))

Trouble Alternator: Malfunction (MA) (Mechanical system)
— AB00MA
Contents of
• During rotation of engine, charge level caution lamp flashes.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, battery may be discharged.
machine
Related
• Method of reproducing error code: Start engine.
information

Defective battery charge It is suspected that problem causing defective battery charge is oc-
Possible causes
1 (When system is in normal curring at present or occurred in past. Investigate cause and damage
and standard
state) condition, and correct it.
value in normal
state Carry out troubleshooting of charge level caution lamp system in ac-
Defective charge level cau-
2 cordance with “During running of engine, emergency caution item
tion lamp system
flashes” in E mode.
ERROR CODE AD00L2 (COMMON RAIL: SEE THE LIST. (L2))
Action code Error code Common rail: See the list. (L2)
Trouble
E02 AD00L2 (Engine controller system)
Contents of
• The fuel pressure of common rail became high (level 1).
trouble
controller • Limits output for operation.
Problem that
appears on • Engine output reduces.
machine
• The fuel state (fuel pressure) of common rail can be checked in monitoring mode.
Related
(Code 36400: Common rail pressure)
information
• Method of reproducing error code: Engine start

Check the displayed error code. If another code is displayed, first car-
1 Defective related system
ry out troubleshooting for the code.
2 Inappropriate fuel The fuel used may be inappropriate; directly check it.
Defective electric system of
3 common rail pressure sen- Carry out troubleshooting for error code [DH40KX].
Possible causes sor
and standard
Defective mechanical sys-
value in normal The common rail pressure sensor is assumed to be defective me-
4 tem of common rail pres-
state chanically; directly check it.
sure sensor
The overflow valve may cause spring damage, sheet abrasion, or ball
5 Defective overflow valve
fixing; directly check it.
6 Clogged overflow pipe The overflow pipe is assumed to be clogged; directly check it.
The pressure limiter is assumed to be defective mechanically; directly
7 Defective pressure limiter
check it.
20-426 D275A-5
1
ERROR CODE AD00MA (COMMON RAIL: DEFECTIVE FUNCTION (MA))
ERROR
CODE
CODE
AD00MA
AD10L3
(COMMON
(FUEL SUPPLY
RAIL: DEFECTIVE
PUMP: SEE
FUNCTION
THE LIST.(MA))
(L3))
ERROR CODE AD00MA (COMMON RAIL: DEFECTIVE FUNCTION (MA))
Action code Error code Common rail: See the list. (MA)
Trouble
E02 AD00MA (Engine controller system)
Contents of
• The fuel pressure of common rail became high (level 2).
trouble
controller • Limits output and engine speed for operation.
Problem that
appears on • Engine output and speed reduces.
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for error code [AD00L2].
state
ERROR CODE AD10L3 (FUEL SUPPLY PUMP: SEE THE LIST. (L3))
Action code Error code Fuel supply pump: See the list. (L3)
Trouble
CALL E03 AD10L3 (Engine controller system)
Contents of
• Non-pressure transmission (level 1) occurred in fuel supply pump.
trouble
controller • Limits output for operation.
Problem that
machine
• The pressure transmission state (fuel pressure) of fuel supply pump can be checked in monitoring
Related
mode. (Code 36400: Common rail pressure)
information

Check the displayed error code. If another code is displayed, first car-
1 Defective related system
ry out troubleshooting for the code.
2 Inappropriate fuel The fuel used may be inappropriate; directly check it.
Defective low-pressure cir- The low-pressure circuit equipment is assumed to be defective; see
3
cuit equipment Note 2 for troubleshooting.
The filter strainer is assumed to be clogged; see Note 1 for trouble-
Possible causes 4 Clogged filter strainer
shooting.
and standard
Defective electric system of Carry out troubleshooting for error codes [AD11KA], [AD11KB],
value in normal 5
state fuel supply pump PCV [AD51KA], and [AD51KB].
6 Defective fuel supply pump The fuel supply pump is assumed to be defective; directly check it.
Defective common rail pres- The common rail pressure sensor is assumed to be defective; directly
7
sure sensor check it.
The pressure limiter is assumed to be defective mechanically; directly
8 Defective pressure limiter
check it.
The fuel injector is assumed to be defective; see Note 3 for trouble-
9 Defective fuel injector
shooting.
D275A-5 20-427
1
TROUBLESHOOTING ERROR CODE AD10L3 (FUEL SUPPLY PUMP: SEE THE LIST. (L3))
Note 1: Follow the procedure below to check, clean, and replace the filter and strainer.
1) Gauze filter: Disassemble and check. If the filter is clogged, clean it.
2) Gauze filter upstream strainer: If the gauze filter is clogged, also clean the upstream strainer.
3) Fuel filter: If abnormality is not yet recovered after steps 1) and 2), replace the fuel filter.
Note 2: When the low-pressure equipment is defective, check the following points:
1) Remaining fuel quantity
2) Feed pump fixing, abrasion, and filter clogging
3) Leak and clogging of low-pressure fuel pipe
4) Defective bypass valve function or other parts assembled erroneously (See the figure below.)
5) Clogged fuel filter
6) Fuel mix in oil pan (Fuel leak in head cover)
Figure: Overflow valve 1, bypass valve 2, and fuel inlet joint 3 mounting positions
• Overflow valve 1: Spring viewed from both holes
• Bypass valve 2: Spring viewed from nut hole side
• Fuel inlet joint 3: Gauze filter viewed from both holes
20-428 D275A-5
1
TROUBLESHOOTING ERROR CODE AD10L3 (FUEL SUPPLY PUMP: SEE THE LIST. (L3))
Note 3: When the fuel injector is defective, measure the fuel spill charge for decision.
¤ The temperature of spill fuel rises extremely (max. 90°C). Take care not to get burnt.
1) Disconnect the hose connected to the spill tube return set (in the rear of the engine).
2) Connect another hose to the end of the spill tube so that spill fuel can be poured in the container.
3) Start the engine and measure the spill fuel quantity per minute at stall for each engine speed.
★ Limit of fuel spill charge (6 cylinders in all)
Engine stall speed (rpm) Spill limit (cc/min.)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
D275A-5 20-429
1
ERROR CODE AD10MA (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA))
ERRORCODE
CODE AD10MB
AD10MA (FUEL
(FUELSUPPLY
SUPPLYPUMP:
PUMP:FUNCTION
DEFECTIVEREDUCTION
FUNCTION (MB))
(MA))
ERROR CODE AD10MA (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA))
Action code Error code Fuel supply pump: Defective function (MA)
Trouble
CALL E03 AD10MA (Engine controller system)
Contents of
• An abnormal pressure occurred in the common rail fuel pressure.
trouble
Action of
• Runs in normal control state.
controller
Problem that
appears on • Engine output and speed reduces.
machine
Related
information

and standard
state
ERROR CODE AD10MB (FUEL SUPPLY PUMP: FUNCTION REDUCTION (MB))
Action code Error code Fuel supply pump: Function reduction (MB)
Trouble
E02 AD10MB (Engine controller system)
Contents of
• Non-pressure transmission (level 2) occurred in the fuel supply pump.
trouble
Action of
• Limits output and engine speed for operation.
controller
Problem that
machine
• The pressure transmission state (fuel pressure) of fuel supply pump can be checked in monitoring
Related
mode. (Code 36400: Common rail pressure)
information

and standard
state
20-430 D275A-5
1
ERROR CODE AD11KA (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION
TROUBLESHOOTING IN WIRING (KA))
ERROR CODE AD11KA (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION IN

WIRING (KA))
Action code Error code Fuel supply pump solenoid 1: Disconnection in wiring (KA)
Trouble
CALL E03 AD11KA (Engine controller system)
Contents of
• Disconnection in wiring occurred in fuel supply pump solenoid 1 (PCV1).
trouble
Action of
• Limits engine and transmission operation.
controller
• Stops output to fuel supply pump solenoid 1 circuit.
Problem that • Once machine is stopped, engine speed is limited to medium (half).
appears on • Once machine is stopped, running is limited to F1 and R1.
machine • If codes [AD51KA] and [AD51KB] are displayed at the same time, engine stops.
Related • The special adapter (799-601-9430) is necessary for troubleshooting of fuel supply pump solenoid 1.
information • Method of reproducing error code: Engine start

Defective fuel supply pump without turning starting switch ON.
1 solenoid 1 (Internal discon- PCV1 (male) Resistance
nection in wiring) Between 1 – 2 2.3 – 5.3Ω
Between 1 – chassis ground Min. 1MΩ
Disconnection in wiring har- without turning starting switch ON.
ness (Disconnection in wir- Wiring harness between ECN3 (female) B –
2 Resistance Max. 1Ω
Possible causes ing or defective contact in PCV1 (female) 1
and standard connector) Wiring harness between ECN3 (female) L –
value in normal PCV1 (female) 2
state ★ Prepare with starting switch OFF, then carry out troubleshooting
cuit) Wiring harness between ECN3 (female) L –
Resistance Min. 1MΩ
PCV1 (female) 2 with chassis ground
without turning starting switch ON.
ECN3 (male) Resistance
4 Defective engine controller
Between B – L 2.3 – 5.3Ω
Between B L –
Min. 1MΩ
chassis ground
Circuit diagram related to fuel supply pump solenoid 1
D275A-5 20-431
1
ERROR CODE AD11KB (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT
TROUBLESHOOTING (KB))
ERROR CODE AD11KB (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB))
Action code Error code Fuel supply pump solenoid 1: Short circuit (KB)
Trouble
CALL E03 AD11KB (Engine controller system)
Contents of
• Overcurrent flowed in fuel supply pump solenoid 1 (PCV1) circuit.
trouble
Action of
controller
appears on • Once machine is stopped, travel is limited to F1 and R1.
machine • When code [AD51KA] and [AD51KB] appear at the same time, engine stops.
Related • For troubleshooting of fuel supply pump solenoid 1, special adaptor (799-601-9430) is required.
information • Method of reproducing error code: Start engine.

1 solenoid 1 (Internal short PCV1 (male) Resistance
circuit) Between 1 – 2 2.3 – 5.3Ω
Short circuit with chassis without turning starting switch ON.
2 ground in wiring harness
Wiring harness between ECN3 (female) B –
(Contact with ground circuit) Resistance Max. 1MΩ
Possible causes
★ Prepare with starting switch OFF, then turn starting switch ON and
and standard
carry out troubleshooting.
value in normal
state Short circuit of wiring harness between ECN3
Hot short circuit in wiring
(female) B – PCV1 (female) 1 with chassis Voltage Max. 1V
3 harness
ground
(Contact with 24V circuit)
Short circuit of wiring harness between ECN3
(female) L – PCV1 (female) 2 with chassis Voltage Max. 1V
ground
4 Defective engine controller ECN3 (male) Resistance
Between B – L 2.3 – 5.3Ω
Between B L – chassis ground Min. 1MΩ
20-432 D275A-5
1
ERROR CODE AD51KA (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION
TROUBLESHOOTING IN WIRING (KA))
ERROR CODE AD51KA (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN

WIRING (KA))
Action code Error code Fuel supply pump solenoid 2: Disconnection in wiring (KA)
Trouble
CALL E03 AD51KA (Engine controller system)
Contents of
• Disconnection in wiring occurred in fuel supply pump solenoid 2 (PCV2).
trouble
Action of
controller

ness (Disconnection in wir- Wiring harness between ECN3 (female) C –
Possible causes 2 Resistance Max. 1Ω
ing or defective contact in PCV2 (female) 1
and standard connector)
value in normal Wiring harness between ECN3 (female) M –
PCV2 (female) 2
state
cuit) Wiring harness between ECN3 (female) M –
Between C – M 2.3 – 5.3Ω
Between C M – chassis ground Min. 1MΩ
D275A-5 20-433
1
ERROR CODE AD51KB (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION
TROUBLESHOOTING IN SHORT (KB))
ERROR CODE AD51KB (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN

SHORT (KB))
Action code Error code Fuel supply pump solenoid 2: Short (KB)
Trouble
CALL E03 AD51KB (Engine controller system)
Contents of
• Overcurrent occurred in fuel supply pump solenoid 2 (PCV2).
trouble
Action of
controller

cuit) Wiring harness between ECN3 (female) C –
Possible causes Resistance Max. 1MΩ
PCV2 (female) 1
and standard
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state
Defective harness hot short Wiring harness between ECN3 (female) C –
3 Voltage Max. 1V
(Contact with 24V circuit) PCV2 (female) 1 with chassis ground
Wiring harness between ECN3 (female) M –
Voltage Max. 1V
Between C – M 2.3 – 5.3Ω
Between C M – chassis ground Min. 1MΩ
20-434 D275A-5
1
ERROR CODE ADA1KA (NO.1 INJECTOR SOLENOID: DISCONNECTION IN
TROUBLESHOOTING WIRING (KA))
ERROR CODE ADA1KA (NO.1 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))
Action code Error code No.1 injector solenoid: Disconnection in wiring (KA)
Trouble
E02 ADA1KA (Engine controller system)
Contents of
• Disconnection in wiring occurred in the No.1 injector solenoid (TWV#1) circuit.
trouble
controller • Stops output to the No.1 injector solenoid circuit.
Problem that
machine
Related
information

Defective No.1 injector sole- without turning starting switch ON.
1 noid (Internal disconnection
CN1 (male) Resistance
in wiring)
Between 1 and 2 0.4 – 1.1Ω
Possible causes
and standard
value in normal ness (Disconnection in wir- Wiring harness between ECN3 (female) D –
state ing or defective contact in CN1 (female) 1
connector) Wiring harness between ECN3 (female) N –
CN1 (female) 2
Between D and N 0.4 – 1.1Ω
Circuit diagram related to No.1 injector solenoid
D275A-5 20-435
1
ERROR CODE ADAZKB (NO.1, 2, AND 3 INJECTOR SOLENOIDS: SHORT
ERROR CODE ADAZKB (NO.1, 2, AND 3 INJECTOR SOLENOIDS: SHORT (KB))
Action code Error code No.1, 2, and 3 injector solenoids: Short (KB)
Trouble
CALL E03 ADAZKB (Engine controller system)
Contents of • Overcurrent occurred in the No.1 injector solenoid (TWV#1), No.2 injector solenoid (TWV#2), or No.3
trouble injector solenoid (TWV#3).
Action of
• Limits engine and transmission operations.
controller
• Stops output to the No.1, 2, and 3 injector solenoid circuits.
machine • Engine output reduces extremely.
Related
information

Defective No.1 injector sole- CN1 (male) Resistance
1
noid (Internal short)
Between 1 – 2 0.4 – 1.1Ω
Between 1 2 – chassis ground Min. 1MΩ
2
Between 1 – 2 0.4 – 1.1Ω
Possible causes Defective No.3 injector sole- CN3 (male) Resistance
3
and standard noid (Internal short)
Between 1 – 2 0.4 – 1.1Ω
value in normal
state
Wiring harness between ECN3 (female) D –
CN1 (female) 1 with chassis ground
Wiring harness between ECN3 (female) N –
Wiring harness between ECN3 (female) 6 –
4 ing (Contact with ground cir- Resistance Min. 1MΩ
cuit)
Wiring harness between ECN3 (female) F –
Wiring harness between ECN3 (female) E –
20-436 D275A-5
1
ERROR CODE ADAZKB (NO.1, 2, AND 3 INJECTOR SOLENOIDS: SHORT

★ Prepare with starting switch OFF, then turn starting switch ON for
troubleshooting.
Wiring harness between ECN3 (female) D –
Voltage Max. 1V
Wiring harness between ECN3 (female) N –
Possible causes Voltage Max. 1V
and standard
Defective harness hot short Wiring harness between ECN3 (female) 6 –
value in normal 5 Voltage Max. 1V
state (Contact with 24V circuit) CN2 (female) 1 with chassis ground
Wiring harness between ECN3 (female) F –
Voltage Max. 1V
Voltage Max. 1V
Wiring harness between ECN3 (female) E –
Voltage Max. 1V
Circuit diagram related to No.1, 2, and 3 injector solenoids
D275A-5 20-437
1
ERROR CODE ADB1KA (NO.2 INJECTOR SOLENOID: DISCONNECTION IN
ERROR CODE ADB1KA (NO.2 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))
Trouble
E02 ADB1KA (Engine controller system)
Contents of
trouble
Problem that
machine
Related
information

in wiring)
and standard Disconnection in wiring har-
ness (Disconnection in wir- Wiring harness between ECN3 (female) 6 –
value in normal 2 Resistance Max. 1Ω
ing or defective contact in CN2 (female) 1
state
connector) Wiring harness between ECN3 (female) F –
CN2 (female) 2
Between 6 and F 0.4 – 1.1Ω
20-438 D275A-5
1
ERROR CODE ADC1KA (NO.3 INJECTOR SOLENOID: DISCONNECTION IN
ERROR CODE ADC1KA (NO.3 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))
Trouble
E02 ADC1KA (Engine controller system)
Contents of
trouble
Problem that
machine
Related
information

in wiring)
ness (Disconnection in wir- Wiring harness between ECN3 (female) 5 –
state
connector) Wiring harness between ECN3 (female) E –
CN3 (female) 2
Between 5 and E 0.4 – 1.1Ω
D275A-5 20-439
1
ERROR CODE ADD1KA (NO.4 INJECTOR SOLENOID: DISCONNECTION IN
ERROR CODE ADD1KA (NO.4 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))
Trouble
E02 ADD1KA (Engine controller system)
Contents of
trouble
Problem that
machine
Related
information

in wiring)
ness (Disconnection in wir- Wiring harness between ECN3 (female) P –
state
connector) Wiring harness between ECN3 (female) Z –
CN4 (female) 2
Between P and Z 0.4 – 1.1Ω
20-440 D275A-5
1
ERROR CODE ADDZKB (NO.4, 5, AND 6 INJECTOR SOLENOIDS: SHORT
ERROR CODE ADDZKB (NO.4, 5, AND 6 INJECTOR SOLENOIDS: SHORT (KB))
Action code Error code No.4, 5, and 6 injector solenoids: Short (KB)
Trouble
CALL E03 ADDZKB (Engine controller system)
Contents of • Overcurrent occurred in the No.4 injector solenoid (TWV#4), No.5 injector solenoid (TWV#5), or No.6
trouble injector solenoid (TWV#6).
Action of
• Limits engine and transmission operations.
controller
• Stops output to the No.4, 5, and 6 injector solenoid circuits.
machine • Engine output reduces extremely.
Related
information

1
Between 1 – 2 0.4 – 1.1Ω
2
Between 1 – 2 0.4 – 1.1Ω
Possible causes Defective No.6 injector sole- CN6 (male) Resistance
3
and standard noid (Internal short)
Between 1 – 2 0.4 – 1.1Ω
value in normal
state
Wiring harness between ECN3 (female) P –
Wiring harness between ECN3 (female) Z –
Wiring harness between ECN3 (female) X –
4 ing (Contact with ground cir- Resistance Min. 1MΩ
cuit)
Wiring harness between ECN3 (female) W –
Wiring harness between ECN3 (female) O –
Wiring harness between ECN3 (female) Y –
D275A-5 20-441
1
ERROR CODE ADDZKB (NO.4, 5, AND 6 INJECTOR SOLENOIDS: SHORT

troubleshooting.
Wiring harness between ECN3 (female) P –
Voltage Max. 1V
Wiring harness between ECN3 (female) Z –
Possible causes Voltage Max. 1V
and standard
Defective harness hot short Wiring harness between ECN3 (female) X –
value in normal 5 Voltage Max. 1V
state (Contact with 24V circuit) CN5 (female) 1 with chassis ground
Wiring harness between ECN3 (female) W –
Voltage Max. 1V
Wiring harness between ECN3 (female) O –
Voltage Max. 1V
Wiring harness between ECN3 (female) Y –
Voltage Max. 1V
Circuit diagram related to No.4, 5, and 6 injector solenoids
20-442 D275A-5
1
ERROR CODE ADE1KA (NO. 5 FUEL INJECTOR SOLENOID:
TROUBLESHOOTING DISCONNECTION (KA))
ERROR CODE ADE1KA (NO. 5 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))
Action code Error code No. 5 fuel injector solenoid: Disconnection (KA)
Trouble
E02 ADE1KA (Engine controller system)
Contents of
• Disconnection occurred in No. 5 fuel injector solenoid (TWV#5) circuit.
trouble
controller • Stops output to No. 5 fuel injector solenoid circuit.
Problem that
appears on • Engine output lowers.
machine
Related
information

Defective No. 5 fuel injector without turning starting switch ON.
1 solenoid (Internal discon-
nection)
Between 1 – 2 0.4 – 1.1Ω
ness (Disconnection in wir- Wiring harness between ECN3 (female) X –
state
connector) Wiring harness between ECN3 (female) W –
CN5 (female) 2
Between X – W 0.4 – 1.1Ω
Circuit diagram related to No. 5 fuel injector solenoid
D275A-5 20-443
1
ERROR CODE ADF1KA (NO. 6 FUEL INJECTOR SOLENOID: DISCONNECTION
TROUBLESHOOTING (KA))
ERROR CODE ADF1KA (NO. 6 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))
Action code Error code No. 6 fuel injector solenoid: Disconnection (KA)
Trouble
E02 ADF1KA (Engine controller system)
Contents of
• Disconnection occurred in No. 6 fuel injector solenoid (TWV#6) circuit.
trouble
controller • Stops output to No. 6 fuel injector solenoid circuit.
Problem that
appears on • Engine output lowers.
machine
Related
information

Defective No. 6 fuel injector without turning starting switch ON.
1 solenoid (Internal discon-
nection)
Between 1 – 2 0.4 – 1.1Ω
ness (Disconnection in wir- Wiring harness between ECN3 (female) O –
state
connector) Wiring harness between ECN3 (female) Y –
CN6 (female) 2
Between O – Y 0.4 – 1.1Ω
Circuit diagram related to No. 6 fuel injector solenoid
20-444 D275A-5
1
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))
TROUBLESHOOTING ERROR ERROR
CODE B@BAZG
CODE B@BCNS
(ENGINE(RADIATOR
OIL: OIL PRESSURE
COOLANT:REDUCTION
OVERHEAT (ZG))
(NS))
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))

Trouble Engine oil: Oil pressure reduction (ZG) (Mechanical system)
— B@BAZG
Contents of
• During rotation of engine, engine oil pressure caution lamp flashes.
trouble
Action of
• Turns on caution buzzer. (Function of monitor panel)
controller
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
Related
information

Engine oil pressure reduc- It is suspected that problem causing engine oil pressure reduction is
Possible causes
1 tion (When system is in nor- occurring at present or occurred in past. Investigate cause and dam-
and standard
mal state) age condition, and correct it.
value in normal
state Carry out troubleshooting of engine oil pressure caution lamp system
Defective engine oil pres-
2 in accordance with “During running of engine, emergency caution
sure caution lamp system
item flashes” in E mode.
ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT (NS))

Trouble Radiator coolant: Overheat (NS) (Mechanical system)
— B@BCNS
Contents of
• During rotation of engine, engine water temperature caution lamp flashes.
trouble
Action of
controller
Problem that
machine
Related
information

Engine water temperature It is suspected that problem causing engine water temperature over-
Possible causes
1 overheat (When system is heat is occurring at present or occurred in past. Investigate cause and
and standard
in normal state) damage condition, and correct it.
value in normal
state Defective engine water tem- Carry out troubleshooting of engine water temperature caution lamp
2 perature caution lamp sys- system in accordance with “During running of engine, emergency
tem caution item flashes” in E mode.
D275A-5 20-445
1
ERROR CODE B@BCZK (RADIATOR COOLANT: LEVEL REDUCTION (ZK))
TROUBLESHOOTING ERROR CODE
ERROR
B@BCZK
CODE (RADIATOR
B@CENS (POWER
COOLANT:
TRAN
LEVEL
OIL:REDUCTION
OVERHEAT (NS))
(ZK))
ERROR CODE B@BCZK (RADIATOR COOLANT: LEVEL REDUCTION (ZK))

Trouble Radiator coolant: Level reduction (ZK) (Mechanical system)
— B@BCZK
Contents of
• When turning starting switch ON, radiator coolant caution lamp flashes.
trouble
Action of
controller
Problem that
machine
Related
• Method of reproducing error code: Turn starting switch ON.
information

Radiator coolant level re- It is suspected that problem causing radiator coolant level reduction
Possible causes
1 duction (When system is in is occurring at present or occurred in past. Investigate cause and
and standard
normal state) damage condition, and correct it.
value in normal
state Carry out troubleshooting of radiator coolant level caution lamp sys-
Defective radiator coolant
2 tem in accordance with “When turning starting switch ON, basic
level caution lamp system
check item flashes” in E mode.
ERROR CODE B@CENS (POWER TRAN OIL: OVERHEAT (NS))

Trouble Power train oil: Overheat (NS) (Mechanical system)
— B@CENS
Contents of
• During rotation of engine, power train oil temperature caution lamp flashes.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, power train may be damaged.
machine
Related
information

Power train oil temperature It is suspected that problem causing power train oil temperature over-
Possible causes
and standard
value in normal
state Defective power train oil Carry out troubleshooting of power train oil temperature caution lamp
2 temperature overheat cau- system in accordance with “During running of engine, emergency
tion lamp system caution item flashes” in E mode.
20-446 D275A-5
1
TROUBLESHOOTING ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (NS))
ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (NS))

Trouble Hydraulic oil: Overheat (NS) (Mechanical system)
— B@HANS
Contents of
• During rotation of engine, hydraulic oil caution lamp flashes.
trouble
Action of
controller
Problem that
appears on • If machine is operated as it is, work equipment circuit units may be damaged.
machine
Related
information

Hydraulic oil temperature It is suspected that problem causing hydraulic oil temperature over-
Possible causes
and standard
value in normal
state Defective hydraulic oil tem- Carry out troubleshooting of hydraulic oil temperature caution lamp
2 perature caution lamp sys- system in accordance with “During running of engine, emergency
tem caution item flashes” in E mode.
D275A-5 20-447
1
TROUBLESHOOTING ERROR CODE D110KA (BATTERY RELAY: DISCONNECTION (KA))
ERROR CODE D110KA (BATTERY RELAY: DISCONNECTION (KA))

Trouble Battery relay: Disconnection (KA) (Steering controller system)
— D110KA
Contents of
• Current does not flow when outputting it to battery relay circuit.
trouble
Action of
• Stops output to battery relay circuit.
controller
Problem that
appears on • Problem may occur in data writing to ROM (nonvolatile storage) of each controller.
machine
• Output state (voltage) to battery relay can be checked in monitoring mode.
Related
(Code 60600: Battery relay drive voltage)
information
• Method of reproducing error code: Switch starting switch from ON to OFF.

Defective battery relay (In-
1 Battery relay Continuity
ternal disconnection)
Between terminals SW – chassis
Continue
ground
ness (Disconnection in wir- Wiring harness between STCN3 (female) 4 –
Possible causes 2 Resistance Max. 1Ω
ing or defective contact in battery relay SW terminal
and standard connector)
value in normal Wiring harness between battery relay terminal
chassis groung – chassis ground
state
Hot short circuit in wiring carry out troubleshooting.
3 harness (Contact with 24V Short circuit of wiring harness between STCN3
circuit) (female) 4 – battery relay terminal SW – KEY Voltage Max. 1V
(female) 4 with chassis ground
STCN3 (female) Continuity
Between 4 – chassis ground Continue
Circuit diagram related to battery relay
20-448 D275A-5
1
TROUBLESHOOTING ERROR CODE D110KB (BATTERY RELAY: SHORT CIRCUIT (KB))
ERROR CODE D110KB (BATTERY RELAY: SHORT CIRCUIT (KB))
Action code Error code Battery relay: Short circuit (KB)

Trouble
— D110KB (Steering controller system)
Contents of
• Abnormal current flowed to battery relay circuit when outputting it.
trouble
Action of
• Stops output to battery relay circuit.
controller
Problem that
appears on • Problem may occur in data writing to ROM (nonvolatile storage) of each controller.
machine
• Output state (voltage) to battery relay can be checked in monitoring mode.
Related
(Code 60600: Battery relay drive voltage)
information
• Method of reproducing error code: Switch starting switch from ON to OFF.

Battery relay Continuity/resistance
Defective battery relay
1 Between terminals SW – chassis
(Internal short circuit) Continue
ground
Between terminal SW –
Min. 1MΩ
Possible causes chassis ground
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Short circuit with chassis without turning starting switch ON.
state 2 ground in wiring harness Short circuit of wiring harness between STCN3
(Contact with ground circuit) (female) 4 – battery relay terminal SW – KEY Resistance Min. 1MΩ
(female) 4 with chassis ground
3 Defective steering controller STCN3 Starting switch Voltage
Between 4 –
ON 20 – 30V
chassis ground
Circuit diagram related to battery relay
D275A-5 20-449
1
TROUBLESHOOTING ERROR CODE D130KA (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))
ERROR CODE D130KA (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))
Action code Error code Neutral safety relay: Disconnection (KA)

Trouble
E02 D130KA (Transmission controller system)
Contents of
• 24V is not generated when ground of neutral safety relay circuit is interrupted.
trouble
controller • Stops ground output to neutral safety relay circuit.
Problem that
appears on • Engine does not start.
machine
• Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Related
• Method of reproducing error code: Turn starting switch ON and operate parking lever (Lock position).
information
★ This error code detects abnormality in primary side (coil side) of neutral safety relay, but not in sec-
ondary side (contact side)

Defective circuit breaker If circuit breaker is tripped, circuit probably has short circuit with
1
(CB3) ground.
Defective neutral safety re- without turning starting switch ON.
2
lay (Internal disconnection) NSF (male) Resistance
Between 1 – 2 200 – 400Ω
Defective disconnection in without turning starting switch ON.
wiring harness (Disconnec- Wiring harness between TMCN2 (female) 8 –
tion in wiring or defective NSF (female) 2
Possible causes contact in connector) Wiring harness between NSF (female) 1 –
and standard Resistance Max. 1Ω
CB3 (1)
value in normal
Short circuit with chassis Short circuit of wiring harness between
4 ground in wiring harness TMCN2 (female) 8 – NSF (female) 2 with Resistance Min. 1MΩ
(Contact with ground circuit) chassis ground
Short circuit of wiring harness between NSF
(female) 1 – CB3 (1) with chassis ground
Defective transmission con- TMCN2 Parking lever Voltage
5
troller
Between 8 – Lock position Max. 1V
chassis ground Free position 20 – 30V
20-450 D275A-5
(1)
(4)
TROUBLESHOOTING ERROR CODE D130KA (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))
Circuit diagram related to neutral safety relay
D275A-5 20-451
1
TROUBLESHOOTING ERROR CODE D130KB (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB))
ERROR CODE D130KB (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB))
Action code Error code Neutral safety relay: Short circuit (KB)
Trouble
E02 D130KB (Transmission controller system)
Contents of
• Abnormal current flowed in neutral safety relay circuit at the time of ground output.
trouble
controller • Stops ground output to neutral safety relay circuit.
Problem that
appears on • Engine does not start.
machine
• Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Related
• Method of reproducing error code: Turn starting switch ON and operate parking lever (Free position).
information
★ This error code detects abnormality in primary side (coil side) of neutral safety relay, but not in sec-

Defective neutral safety re- without turning starting switch ON.
1
lay (Internal short circuit) NSF (male) Resistance
Between 1 – 2 200 – 400Ω
Possible causes carry out troubleshooting.
and standard
2 harness Short circuit of wiring harness between
value in normal
(Contact with 24V circuit) TMCN2 (female) 8 – NSF (female) 2 with Voltage Max. 1V
state
chassis ground
Defective transmission con- TMCN2 Parking lever Voltage
3
troller
Between 8 – Lock position Max. 1V
chassis ground Free position 20 – 30V
Circuit diagram related to neutral safety relay
20-452 D275A-5
(1)
(4)
TROUBLESHOOTING ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA))
ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA))
Action code Error code Back-up alarm relay: Disconnection

Trouble
E01 D161KA (Transmission controller system)
Contents of
• 24V is not generated when ground output of neutral safety relay circuit is interrupted.
trouble
Action of
• Stops output to back-up alarm relay circuit.
controller
Problem that
appears on • Back-up alarm is not turned on.
machine
• Output state (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70900: Back-up alarm relay drive voltage)
Related • Method of reproducing error code: Turn starting switch ON and operate parking lever (Neutral posi-
information tion).
★ This error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in sec-

If fuse is burnout, circuit probably has short circuit with chassis
1 Defective fuse FS4-1
ground.
Defective back-up alarm re- without turning starting switch ON.
2
lay (Internal disconnection) BKA (male) Resistance
Between 1 – 2 200 – 400Ω
Defective disconnection in without turning starting switch ON.
wiring harness (Disconnec- Wiring harness between TMCN2 (female) H –
tion in wiring or defective BKA (female) 2
Possible causes contact in connector) Wiring harness between BKA (female) 1 –
and standard FS4-1 outlet port
state without turning starting switch ON.
Short circuit of wiring harness between
Short circuit with chassis
TMCN2 (female) H – BKA (female) 2 with Resistance Min. 1MΩ
chassis ground
(Contact with ground circuit)
Short circuit of wiring harness between BKA
(female) 1 – FS4-1 outlet port with chassis Resistance Min. 1MΩ
ground
5
troller
Between H – Neutral position 20 – 30V
chassis ground Reverse position Max. 1V
D275A-5 20-453
(1)
(4)
TROUBLESHOOTING ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA))
Circuit diagram related to back-up alarm relay
20-454 D275A-5
1
TROUBLESHOOTING ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
Action code Error code Back-up alarm relay: Short circuit (KB)
Trouble
E01 D161KB (Transmission controller system)
Contents of
• Abnormal current flowed in back-up alarm relay circuit at the time of ground output.
trouble
Action of
• Stops output to back-up alarm relay circuit.
controller
Problem that
appears on • Back-up alarm is not turned on.
machine
• Output state (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
Related • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Reverse posi-
information tion).
★ This error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in sec-

Defective back-up alarm re- without turning starting switch ON.
1
lay (Internal short circuit) BKA (male) Resistance
Between 1 – 2 200 – 400Ω
Possible causes
and standard
2 harness (Contact with 24V Short circuit of wiring harness between
value in normal
circuit) TMCN2 (female) H – BKA (female) 2 with Voltage Max. 1V
state
chassis ground
Defective transmission con-
3 TMCN2 Parking lever Voltage
troller
Between H – Neutral position 20 – 30V
chassis ground Reverse position Max. 1V
D275A-5 20-455
(1)
(4)
TROUBLESHOOTING ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
Circuit diagram related to back-up alarm relay
20-456 D275A-5
1
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY
TROUBLESHOOTING RELAY: SHORT CIRCUIT (KB))
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY: SHORT
CIRCUIT (KB))
Action code Error code Engine controller load power supply relay: Short circuit (KB)
Trouble
CALL 04 D1D0KB (Engine controller system)
Contents of
• Voltage is generated in controller load power supply circuit when starting switch is turned OFF.
trouble
Problem that
appears on
machine
• Method of reproducing error code: Turn starting switch OFF.
Related
★ This error code detects abnormality in secondary side (contact side) of engine controller load power
information
supply relay, but not in primary side (coil side)

Defective engine controller without turning starting switch ON.
1 load power supply relay (In-
PPR (male) Resistance
ternal short circuit)
Between 3 – 5 Min. 1MΩ
Possible causes carry out troubleshooting.
and standard
2 harness (Contact with 24V Short circuit of wiring harness between ECN3
value in normal
circuit) (female) 1, 2, K – PPR (female) 3 with Voltage Max. 1V
state
chassis ground
with starting switch OFF or ON.
3 Defective engine controller ECN3 Starting switch Voltage
Between 1, 2, K – OFF position Max. 1V
chassis ground ON position Max. 8V
D275A-5 20-457
1
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY
TROUBLESHOOTING RELAY: SHORT CIRCUIT (KB))
Circuit diagram related to engine controller load powersupply relay
20-458 D275A-5
1
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION:
TROUBLESHOOTING DEFECTIVE COMMUNICATION (KR))
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE

COMMUNICATION (KR))
Action code Error code Monitor panel CAN communication: Defective communication (KR)
Trouble
CALL E03 DAFRKR (Monitor panel system)
Contents of
• Monitor panel cannot recognize steering controller with CAN communication circuit.
trouble
Problem that • System may not operate normally.
machine • Once machine is stopped, travel is limited to F1 and R1.
Related
information

Wiring harness between S04 (female) 1, 2 –
STCN2 (female) V – TMCN2 (female) V –
ECN2 (female) V – CA1 (female) A – CA2 (fe-
Disconnection in wiring har-
male) A
ness (Disconnection in wir-
1
ing or defective contact in
connector) Wiring harness between S04 (female) 3 4 –
STCN2 (female) L – TMCN2 (female) L –
ECN2 (female) L – CA1 (female) B – CA2 (fe-
male) B
Short circuit of wiring harness between S04
(female) 1, 2 – STCN2 (female) V – TMCN2
Short circuit with chassis Resistance Min. 1MΩ
(female) V – ECN2 (female) V – CA1 (female)
A – CA2 (female) A with chassis ground
Possible causes Short circuit of wiring harness between S04
and standard (female) 3, 4 – STCN2 (female) L – TMCN2
(female) L – ECN2 (female) L – CA1 (female)
B – CA2 (female) B with chassis ground
value in normal
state
Hot short circuit in wiring Voltage Max. 1V
3 harness (Contact with 24V
circuit)
hort circuit of wiring harness between S04 (fe-
male) 3, 4 – STCN2 (female) L – TMCN2
Voltage Max. 1V
Defective CAN terminal re- without turning starting switch ON.
4
sistance CA1 (male), CA2 (male) Resistance
Between A – B 40 – 80Ω
If no problem is found in causes 1 to 4, it is suspected that monitor
Defective monitor panel or
5 panel or steering controller is defective. (Troubleshooting cannot be
defective steering controller
carried out since it is internal defect.)
D275A-5 20-459
1
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION:
TROUBLESHOOTING DEFECTIVE COMMUNICATION (KR))
Circuit diagram related to CAN communication
20-460 D275A-5
1
ERROR CODE DAQ0KK (TRANSMISSION CONTROLLER: SOURCE VOLTAGE
TROUBLESHOOTING REDUCTION(INPUT) (KK))
ERROR CODE DAQ0KK (TRANSMISSION CONTROLLER: SOURCE VOLTAGE

REDUCTION(INPUT) (KK))
Action code Error code Transmission controller: Source voltage reduction(input) (KK) (Trans-
Trouble
CALL E04 DAQ0KK mission controller system)
Contents of
• Source voltage of transmission controller is below 17V.
trouble
• Monitor panel may not display normally.
Problem that
• Relays and solenoids cannot operate, not allowing system operate normally.
appears on
machine
• Charge level (voltage) of battery can be checked in monitoring mode.
Related
(Code 03200: Battery voltage)
information

Defective circuit breaker If circuit breaker is tripped, circuit probably has short circuit with chas-
1
(CB3) sis ground.
If fusible link is burnout, circuit probably has short circuit with chassis
2 Defective fusible link (96A)
ground.
Disconnection in wiring har- Wiring harness between TMCN3 (female) 1,
ness (Disconnection in wir- A – CB3 (1)
3
ing or defective contact in Wiring harness between CB3 (2) – fusible link
connector) – battery relay terminal C
Possible causes
Wiring harness between TMCN3 (female) K
U V W – chassis ground
value in normal
TMCN3 (female) 1, A – CB3 (1) with chassis Resistance Min. 1MΩ
ground
Short circuit of wiring harness between CB3 (2)
– fusible link – battery relay terminal C with Resistance Min. 1MΩ
chassis ground
Defective transmission con- carry out troubleshooting.
5
troller TMCN3 Voltage
Between 1, A – K, U, V, W 20 – 30V
D275A-5 20-461
(1)
(4)
ERROR CODE DAQ0KT (TRANSMISSION CONTROLLER: ABNORMALITY IN
TROUBLESHOOTING CONTROLLER (KT))
Circuit diagram related to transmission controller power supply
ERROR CODE DAQ0KT (TRANSMISSION CONTROLLER: ABNORMALITY IN

CONTROLLER (KT))
Action code Error code Transmission controller: abnormality in controller (KT)

Trouble
E02 DAQ0KT (Transmission controller system)
Contents of
• Information of ROM (nonvolatile storage) of transmission controller is not normal.
trouble
controller • Sets default internal adjustment value.
Problem that
appears on • Gear shift feeling of transmission may become worse.
machine
Related
information

and standard Troubleshooting cannot be carried out since it is internal defect.
value in normal 1 (It is no problem even if you use controller unless no visible problem
troller
state appears on machine.)
20-462 D275A-5
1
ERROR CODE DAQ5KK (TRANSMISSION CONTROLLER POTENTIOMETER
TROUBLESHOOTING POWER SUPPLY: SOURCE VOLTAGE REDUCTION(INPUT) (KK))
ERROR CODE DAQ5KK (TRANSMISSION CONTROLLER POTENTIOMETER POWER

SUPPLY: SOURCE VOLTAGE REDUCTION(INPUT) (KK))
Action code Error code Transmission controller potentiometer power supply: Source voltage
Trouble
CALL 03 DAQ5KK reduction(input) (KK) (Transmission controller system)
Contents of • Voltage of 5V power supply circuit of transmission controller sensor is below 4.5V or above 5.5V.
trouble • Abnormal current flowed in 5V power supply circuit of transmission controller sensor.
Action of
• Stops output to 5V power supply circuit if abnormal voltage flows
controller
machine • Once machine is stopped, travel is limited to F1 an R1.
Related
information

TL1 (male) Resistance
Defective forward-reverse Between L – J 2kΩ ± 20%
1 potentiometer (Internal Sensor 1 (FR3) Between L –
Min. 1MΩ
short circuit) chassis ground
Between O – Q 2kΩ ± 20%
Sensor 2 (FR4) Between O –
Min. 1MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit with chassis without turning starting switch ON.
value in normal 2 ground in wiring harness
(Contact with ground circuit) TMCN1 (female) L – TL1 (female) L – TL1 Resistance Min. 1MΩ
state
(female) O with chassis ground
3 harness (Contact with 24V Short circuit of wiring harness between
circuit) TMCN1 (female) L – TL1 (female) L – TL1
(female) O with chassis ground
Voltage Max. 1V
4
Between L – K 4.5 – 5.5V
D275A-5 20-463
(1)
(4)
ERROR CODE DAQ5KK (TRANSMISSION CONTROLLER POTENTIOMETER
Circuit diagram related to transmission controller 5V power supply
20-464 D275A-5
1
ERROR CODE DAQ6KK (TRANSMISSION CONTROLLER SENSOR POWER
TROUBLESHOOTING SUPPLY: SOURCE VOLTAGE REDUCTION(INPUT) (KK))
ERROR CODE DAQ6KK (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY:

SOURCE VOLTAGE REDUCTION(INPUT) (KK))
Action code Error code Transmission controller sensor power supply: Source voltage reduc-
Trouble
E01 DAQ6KK tion(input) (KK) (Transmission controller system)
Contents of • Voltage of 24V power supply circuit of transmission controller sensor is below 17V or above 30V.
trouble • Abnormal current flowed in 24V power supply circuit of transmission controller sensor.
Action of
• Stops output to 24V power supply circuit if abnormal voltage flows
controller
Problem that
appears on • Oil pressure of work equipment cannot be monitored in service mode.
machine
Related
information

It is internal defect if error code lights on (reset dis-
Defective work equipment
play) when disconnecting right connector.
large pump oil pressure HHP
1 ★ Disconnect connector with starting switch OFF, then
sensor (Internal short cir- connector
turn starting switch ON and carry out troubleshoot-
cuit)
ing.
value in normal
(Contact with ground circuit) TMCN1 (female) F – HHP (female) B with Resistance
state
Min. 1MΩ
chassis ground
3
F–K 20 – 30V
Circuit diagram related to transmission controller 24V power supply
D275A-5 20-465
(1)
(4)
ERROR CODE DAQ9KQ (TRANSMISSION CONTROLLER TYPE COLLATION:
TROUBLESHOOTING TYPE SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE DAQ9KQ (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE

SELECT SIGNAL INCONSISTENCY (KQ))
Action code Error code Transmission controller type collation/type select signal inconsisten-
Trouble
CALL E04 DAQ9KQ cy (KQ) (Transmission controller system)
Contents of
• Internal spec. setting of transmission controller is inconsistent with spec. set signal.
trouble
Action of
• Stops all outputs to transmission controller.
controller
• Limits operation of engine, transmission, and brake.
Problem that • Machine does not operate at all.
machine • Once machine is stopped, it cannot travel any more.
Related
information

It is normal if error code lights on (reset display) after carrying out ad-
1 justment mode.
troller adjustment
• Adjustment code: 0003: Transmission controller spec.
Possible causes Disconnection in wiring har- ★ Prepare with starting switch OFF, carry out troubleshooting without
and standard ness (Disconnection in wir- turning starting switch ON.
2
value in normal ing or defective contact in Short circuit of wiring harness between
state connector) TMCN3 (female) @ with chassis ground
3
Between @ – chassis ground Max. 1V
Circuit diagram related to transmission controller type select
20-466 D275A-5
1
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN
COMMUNICATION: DEFECTIVE COMMUNICATION(ABNORMALITY IN
TROUBLESHOOTING OBJECTIVE COMPONENT SYSTEM) (KR))
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN COMMUNICATION:

DEFECTIVE COMMUNICATION(ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM)
(KR))
Action code Error code Transmission controller CAN communication: Defective communica-
Trouble tion(Abnormality in objective component system) (KR) (Transmission
CALL E03 DAQRKR
controller system)
Contents of • Transmission controller cannot recognize monitor panel, steering controller, or engine controller with
trouble CAN communication circuit.
Related
information

male) A
1
male) B
Possible causes (female) 3, 4 – STCN2 (female) L – TMCN2
and standard (female) L – ECN2 (female) L – CA1 (female)
value in normal B – CA2 (female) B with chassis ground
state ★ Prepare with starting switch OFF, then turn starting switch ON and
3 harness
(female) 3, 4 – STCN2 (female) L – TMCN2
Voltage Max. 1V
4
Defective monitor panel, de- If no problem is found in causes 1 to 4, it is suspected that monitor
fective engine controller, de- panel, engine controller, transmission controller, or steering controller
5 fective transmission
controller or defective steer- is defective. (Troubleshooting cannot be carried out since it is internal
ing controller defect.)
D275A-5 20-467
(1)
(4)
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN
20-468 D275A-5
1
ERROR CODE DAQSKR (TRANSMISSION CONTROLLER SNET
ERROR CODE DAQSKR (TRANSMISSION CONTROLLER SNET COMMUNICATION:

DEFECTIVE COMMUNICATION(ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))
Action code Error code Transmission controller SNET communication: Defective communi-
Trouble cation(Abnormality in objective component system) (KR) (Transmis-
E01 DAQSKR
sion controller system)
Contents of
• Transmission controller cannot recognize S-NET.
trouble
Action of
• Takes no particular action.
controller
Problem that
appears on • Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine
Related
information

ness (Disconnection in wir- without turning starting switch ON.
1
ing or defective contact in Wiring harness between TMCN2 (female) K –
connector) S01 (female) 8
2 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) TMCN2 (female) K – S01 (female) 8 with Resistance Min. 1MΩ
chassis ground
Possible causes ★ Prepare with starting switch OFF, then turn starting switch ON and
and standard carry out troubleshooting.
value in normal 3 harness Short circuit of wiring harness between
state (Contact with 24V circuit) TMCN2 (female) K – S01 (female) 8 with Voltage Max. 1V
chassis ground
Defective monitor panel carry out troubleshooting.
4
(Switch module) S01 Voltage
Between 8 – chassis ground 6 – 9V
5
Between K – U 6 – 9V
Circuit diagram related to S-NET communication
D275A-5 20-469
(1)
(4)
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER (KT))
Action code Error code Engine controller: Abnormality in controller (KT)

Trouble
CALL E03 DB20KT (Engine controller system)
Contents of
• Problem occurred in transmission controller.
trouble
Action of
• Cannot operate fuel injector solenoid well or stops output.
controller
Problem that • Engine may stop during operation or engine may not start.
Related
information

Possible causes Disconnection in wiring har-
and standard ness (Disconnection in wir-
1 Short circuit of wiring harness between
value in normal ing or defective contact in
ECN3 (female) A, U, V with chassis Resistance Max. 1Ω
state connector)
ground
2 Defective engine controller Troubleshooting cannot be carried out since it is internal defect.
20-470 D275A-5
1
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN
Circuit diagram related to engine controller power supply
D275A-5 20-471
1
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY:
TROUBLESHOOTING SOURCE VOLTAGE REDUCTION(INPUT) (KK))
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE

VOLTAGE REDUCTION(INPUT) (KK))
Action code Error code Engine controller load power supply: Source voltage reduction(input)
Trouble
CALL E04 DB22KK (KK) (Engine controller system)
Contents of
• Load source voltage of engine controller is below 17V.
trouble
Problem that • Engine may stop during operation or engine may not start.
Related
information
★ This error code detects abnormality in secondary side (contact side) of engine controller load power
supply relay, but not in primary side (coil side)

If fuse is burnout, circuit probably has short circuit with chassis
1 Defective fuse (FS2-2)
ground.
ground.
★ Prepare with starting switch OFF, turn starting switch ON and carry
Defective engine controller out troubleshooting.
3 load power supply relay If error code lights on (reset display) by replacing right
(Internal disconnection) connector with other relay, engine controller load power PPR
supply relay is defective.
Disconnection in wiring har- Wiring harness between ECN3 (female) 1, 2,
ness (Disconnection in wir- K – PPR (female) 3
Possible causes 4
ing or defective contact in Wiring harness between PPR (female) 5 –
connector) FS2-2 outlet port
value in normal
state Wiring harness between FS2-2 inlet port – fus-
ible link – battery relay terminal C
Short circuit with chassis (female) C, I – KEY (female) 1 with chassis Resistance Min. 1MΩ
5 ground in wiring harness ground
(Contact with ground circuit) Short circuit of wiring harness between KEY
(female) 5 – CB6 (1) with chassis ground
Wiring harness between CB6 (2) – fusible link
– battery relay terminal H
out troubleshooting.
ECN3 Voltage
Between 1, 2, K – A, U, V 20 – 30V
20-472 D275A-5
(1)
(4)
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY:
TROUBLESHOOTING SOURCE VOLTAGE REDUCTION/INPUT (KK))
Circuit diagram related to engine controller power supply
D275A-5 20-473
1
ERROR CODE DB29KQ (ENGINE CONTROLLER TYPE SELECT: TYPE
TROUBLESHOOTING SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE DB29KQ (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL
INCONSISTENCY (KQ))
Action code Error code Engine controller type select: Type select signal inconsistency (KQ)
Trouble
CALL E03 DB29KQ (Engine controller system)
Contents of • Type select signal directly acquired by engine controller is inconsistent with type select signal acquired
trouble via communication.
Action of
• Controls it as default-set type.
controller
Problem that • Machine does not provide normal output.
Related
information

1
ing or defective contact in Wiring harness between ECN1 (female) 3 –
Possible causes Resistance Max. 1Ω
connector) chassis ground
and standard
value in normal
state
ECN1 Voltage
Between 3 – chassis ground Max. 1V
Between G, M –
20 – 30V
chassis ground
Circuit diagram related to engine controller type select
20-474 D275A-5
1
20
ERROR CODE DB2AMA (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH
TROUBLESHOOTING SIGNAL: MALFUNCTION (MA))
ERROR CODE DB2AMA (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL:

MALFUNCTION (MA))
Action code Error code Fuel injection amount adjustment switch signal: Malfunction (MA)
Trouble
CALL E03 DB2AMA (Engine controller system)
Contents of
• Fuel injection amount adjustment switch is not set at correct position.
trouble
Problem that • Fuel injection amount adjustment setting cannot be changed.
Related
information

Possible causes Defective fuel injection
If both fuel injection amount adjustment switches 1 and 2 are set at
and standard 1 amount adjustment switch
[F], fuel injection amount adjustment switch setting is defective.
value in normal setting
state If no problem is found in above cause, it is suspected that engine con-
troller is defective.
D275A-5 20-475
1
ERROR CODE DB2RKR (ENGINE CONTROLLER CAN COMMUNICATION:
DEFECTIVE COMMUNICATION(ABNORMALITY IN OBJECTIVE COMPONENT
TROUBLESHOOTING SYSTEM) (KR))
ERROR CODE DB2RKR (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE

COMMUNICATION(ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))
Action code Error code Engine controller CAN communication: Defective communication(Ab-
Trouble normality in objective component system) (KR) (Transmission con-
CALL E03 DB2RKR
troller and realer system)
Contents of • Engine controller cannot recognize transmission controller or steering controller with CAN communi-
trouble cation circuit.
Related
information

male) A
1
connector) Wiring harness between S04 (female) 3, 4 –
male) B
Possible causes
and standard Resistance Min. 1MΩ
value in normal B – CA2 (female) B with chassis ground
state
3 harness
Voltage Max. 1V
4
Defective engine controller,
If no problem is found in causes 1 to 4, it is suspected that engine con-
defective transmission con-
5 troller, transmission controller, or steering controller is defective.
troller, or defective steering
(Troubleshooting cannot be carried out since it is internal defect.)
controller
20-476 D275A-5
(1)
(4)
ERROR CODE DB2RKR (ENGINE CONTROLLER CAN COMMUNICATION:
D275A-5 20-477
1
ERROR CODE DB30KK (STEERING CONTROLLER: SOURCE VOLTAGE
TROUBLESHOOTING REDUCTION(INPUT) (KK))
ERROR CODE DB30KK (STEERING CONTROLLER: SOURCE VOLTAGE

REDUCTION(INPUT) (KK))
Action code Error code Steering controller power supply: Source voltage reduction(input)
Trouble
CALL E04 DB30KK (KK) (Steering controller system)
Contents of
• Source voltage of steering controller is below 17V.
trouble
• Monitor panel may not display normally.
Problem that
• Relays and solenoids cannot operate, not allowing system operate normally.
appears on
machine
Related
information

Defective circuit breaker If circuit breaker is tripped, circuit probably has short circuit with chas-
1
(CB1) sis ground.
ground.
Disconnection in wiring har- Wiring harness between STCN3 (female) 1 A
ness (Disconnection in wir- – CB1 1
3
ing or defective contact in Wiring harness between CB1 (2) – fusible link
Possible causes connector) – battery relay terminal C
and standard Wiring harness between STCN3 (female) K,
value in normal U, V, W – chassis ground
Short circuit with chassis Short circuit of wiring harness between STCN3
4 ground in wiring harness (female) 1, A – CB1 (1) with chassis ground
(Contact with ground circuit) Short circuit of wiring harness between CB1
(2)– fusible link – battery relay terminal C with Resistance Min. 1MΩ
chassis ground
STCN3 Voltage
Between 1, A – K, U, V, W 20 – 30V
20-478 D275A-5
(1)
(4)
ERROR CODE DB30KT (STEERING CONTROLLER: ABNORMALITY IN
Circuit diagram related to steering controller power supply
ERROR CODE DB30KT (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER

(KT))
Action code Error code Steering controller power supply: Abnormality in controller (KT)
Trouble
E01 DB30KT (Steering controller system)
Contents of
• Information of ROM (nonvolatile storage) of steering controller is not normal.
trouble
Action of
• Sets default internal adjustment value.
controller
Problem that
• Steering performance may be reduced.
appears on
• Brake performance may be reduced.
machine
Related
information

and standard Troubleshooting cannot be carried out since it is internal defect. (It is
value in normal 1 Defective steering controller no problem even if you use controller unless no visible problem ap-
state pears on machine.)
D275A-5 20-479
1
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY:

SOURCE VOLTAGE REDUCTION(INPUT) (KK))
Action code Error code Steering controller potentiometer power supply: Source voltage re-
Trouble
CALL E03 DB35KK duction(input) (KK) (Steering controller system)
Contents of • Voltage of 5V power supply circuit of steering controller sensor is below 4.5V or above 5.5V.
trouble • Abnormal current flowed in 5V power supply circuit of steering controller sensor.
Action of
• Stops output to 5V power supply circuit if abnormal voltage flows.
controller
Related
information

It is internal defect if error code lights on (reset display)
Defective brake potentiom- when disconnecting right connector. BRK
1
eter (Internal short circuit) ★ Disconnect connector with starting switch OFF, then connector
turn starting switch ON and carry out troubleshooting.
Defective acceleration sen- when disconnecting right connector. SS3
2
sor (Internal short circuit) ★ Disconnect connector with starting switch OFF, then connector
Defective steering potenti- Between A – G 2kΩ ± 20%
3 ometer (Internal short cir- Sensor 1 (ST1) Between A –
cuit) Min. 1MΩ
chassis ground
Possible causes Between M – F 2kΩ ± 20%
and standard Sensor 2 (ST2) Between M –
Min. 1MΩ
value in normal chassis ground
(female) L – TL1 (female) A – TL1 (female) M
Short circuit of wiring harness between STCN1
– BRK (female) C – SS3 (female) 1 with
(Contact with ground circuit) Resistance Min. 1MΩ
chassis ground
(female) L – TL1 (female) A – TL1 (female) M
5 harness (Contact with 24V Short circuit of wiring harness between STCN1
– BRK (female) C – SS3 (female) 1 with

circuit) Voltage Max. 1V
chassis ground
STCN1 Voltage
Between L – K 4.5 – 5.5V
20-480 D275A-5
(1)
(4)
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER
Circuit diagram related to steering controller 5V power supply
D275A-5 20-481
1
ERROR CODE DB36KK (STEERING CONTROLLER SENSOR POWER
TROUBLESHOOTING SUPPLY: SOURCE VOLTAGE REDUCTION(INPUT) (KK))
ERROR CODE DB36KK (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE

VOLTAGE REDUCTION(INPUT) (KK))
Action code Error code Steering controller sensor power supply: Source voltage reduction
Trouble
CALL E03 DB36KK (input) (KK) (Steering controller system)
Contents of • Voltage of 24V power supply circuit of steering controller sensor is below 17V or above 30V.
trouble • Abnormal current flowed in 24V power supply circuit of steering controller sensor.
Action of
• Stops output of 24V power supply circuit if abnormal voltage flows.
controller
Related
information

Defective pitch angle sen- when disconnecting right connector. PT1
1
sor (Internal short circuit) ★ Disconnect connector with starting switch OFF, then connector
(Contact with ground circuit) (female) F – PT1 (female) C – ST1 (female) Resistance Min. 1MΩ
value in normal Short circuit of wiring harness between STCN1
B – ST2 (female) B with chassis ground

state
STCN1 Voltage
Between F – K 20 – 30V
20-482 D275A-5
(1)
(4)
ERROR CODE DB36KK (STEERING CONTROLLER SENSOR POWER
TROUBLESHOOTING SUPPLY: SOURCE VOLTAGE REDUCTION INPUT (KK))
Circuit diagram related to steering controller 24V power supply
D275A-5 20-483
1
ERROR CODE DB39KQ (STEERING CONTROLLER TYPE COLLATION: TYPE
TROUBLESHOOTING SELECT SIGNAL INCONSISTENCY (KQ))
ERROR CODE DB39KQ (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT

SIGNAL INCONSISTENCY (KQ))
Action code Error code Steering controller type collation: Type select signal inconsistency
Trouble
CALL E04 DB39KQ (KQ) (Steering controller system)
Contents of
• Internal spec. setting of steering controller is inconsistent with spec. set signal.
trouble
Action of
• Stops all outputs of steering controller.
controller
Related
information

It is normal if error code indicates P (reset display) after carrying out
Defective steering controller
1 adjustment mode.
adjustment
• Adjustment code: 0002 (Steering controller spec. set)
Possible causes Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard ness (Disconnection in wir- without turning starting switch ON.
2
value in normal ing or defective contact in Wiring harness between STCN3 (female) J –
state connector) chassis ground
Prepare with starting switch OFF, turn starting switch ON and carry
STCN3 Voltage
Between J – chassis ground Max. 1V
Circuit diagram related to steering controller type select
20-484 D275A-5
1
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION:
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE

COMMUNICATION(ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))
Action code Error code Steering controller CAN communication: Defective communica-
Trouble tion(Abnormality in objective component system) (KR) (Steering con-
CALL E03 DB3RKR
troller system)
Contents of • Steering controller cannot recognize monitor panel, transmission controller, or engine controller with
trouble CAN communication circuit.
Related
information

Between wiring harness between S04 (female)
1, 2 – STCN2 (female) V – TMCN2 (female)
V – ECN2 (female) V – CA1 (female) A –
CA2 (female) A
1
male)
Possible causes (female) 3, 4 – STCN2 (female) L – TMCN2
and standard
value in normal
state ★ Prepare with starting switch OFF, turn starting switch ON and carry
circuit)
Voltage Max. 1V
4
Defective monitor panel, de-
If no problem is found in causes 1 to 4, it is suspected that monitor
fective engine controller, de-
panel, engine controller, transmission controller, or steering controller
5 fective transmission
is defective.(Troubleshooting cannot be carried out since it is internal
controller or defective steer-
defect.)
ing controller
D275A-5 20-485
(1)
(4)
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION:
20-486 D275A-5
1
ERROR CODE DB3SKR (STEERING CONTROLLER SNET COMMUNICATION:
ERROR CODE DB3SKR (STEERING CONTROLLER SNET COMMUNICATION:

DEFECTIVE COMMUNICATION(ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM) (KR))
Action code Error code Steering controller SNET communication: Defective communica-
Trouble tion(Abnormality in objective component system) (KR) (Steering con-
E01 DB3SKR
troller system)
Contents of
• Transmission controller cannot recognize S-NET.
trouble
Action of
• Takes no particular action.
controller
Problem that
appears on • Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine
Related
information

1
ing or defective contact in Wiring harness between STCN2 (female) K –
connector) S01 (female) 8
2 ground in wiring harness Short circuit of wiring harness between STCN2
(Contact with ground circuit) (female) K – S01 (female) 8 with chassis Resistance Min. 1MΩ
ground
Possible causes ★ Prepare with starting switch OFF, turn starting switch ON and carry
and standard out troubleshooting.
value in normal 3 harness (Contact with 24V Short circuit of wiring harness between STCN2
state circuit) (female) K – S01 (female) 8 with chassis Voltage Max. 1V
ground
Defective monitor panel out troubleshooting.
4
(Switch module) S01 Voltage
Between 8 – chassis ground 6 – 9V
STCN2 Voltage
Between K – U 6 – 9V
Circuit diagram related to S-NET communication
D275A-5 20-487
(1)
(4)
TROUBLESHOOTING ERROR CODE DD11KB (STARTING SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DD11KB (STARTING SWITCH: SHORT CIRCUIT (KB))

Trouble Starting switch: Short circuit (KB) (Engine controller system)
CALL E04 DD11KB
Contents of
• Signal C of starting switch is input during running of engine.
trouble
Related
information

Defective adjustment of with starting switch OFF or ON.
1
steering controller KEY (male) Starting switch Resistance
Between 5 – 3 When OFF/ON Min. 1MΩ
Possible causes
and standard Hot short circuit in wiring
(female) J – NSF (female) 5 with chassis Voltage Max. 1V
value in normal 2 harness (Contact with 24V
state ground
circuit)
Short circuit of wiring harness between NSF
(female) 3 – KEY (female) 3 with chassis Voltage Max. 1V
ground
ECN1 Voltage
Between J – chassis ground Max. 1V
Circuit diagram related to starting switch signal C
20-488 D275A-5
1
TROUBLESHOOTING ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION (KA))
ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION (KA))

Trouble Shift up switch: Disconnection (KA) (Transmission controller system)
E02 DD12KA
Contents of
• Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time.
trouble
controller • Recognizes that switch is not pressed.
Problem that
• Shift up is not possible.
appears on
• Auto shift down does not function.
machine
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
Related • Input state (ON/OFF) from shift up switch can be checked in monitoring mode.
information (Code 40905: Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate shift up switch.

Shift up switch
TL1 (male)
Defective shift up switch OFF (Release) ON (Press)
1
(Internal disconnection)
N–U
Resistance between
Max. 1Ω Min. 1MΩ
N–B
Resistance between
Min. 1MΩ Max. 1Ω

Disconnection in wiring har- Wiring harness between TMCN1 (female) 6 – Resistance
ness (Disconnection in wir- TL1 (female) U
Max. 1Ω
2
ing or defective contact in Wiring harness between TMCN2 (female) [ –
TL1 (female) B
connector)
Wiring harness between TMCN1 (female) 4,
@ – TL1 (female) N
and standard
value in normal ★ Prepare with starting switch OFF, turn starting switch ON and carry
state out troubleshooting.
TMCN1 (female) 6 – TL1 (female) U with

Voltage Max. 1V
chassis ground
circuit)
TMCN2 (female) [ – TL1 (female) B with

Voltage Max. 1V
chassis ground
Shift up switch
TMCN1,TMCN2
OFF (Release) ON (Press)
Defective transmission con- Voltage between
4
troller TMCN1 6 – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 [ – TMCN1 5 – 11V Max. 1V
4, @
D275A-5 20-489
(1)
(4)
TROUBLESHOOTING ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION (KA))
Circuit diagram related to shift up switch and shift down switch
20-490 D275A-5
1
TROUBLESHOOTING ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT (KB))

Trouble Shift up switch: Short circuit (KB) (Transmission controller system)
E02 DD12KB
Contents of
• Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
• Shift up is not possible.
appears on
machine
Related • Input state (ON/OFF) from shift up switch can be checked in monitoring mode.
• Method of reproducing error code: Turn starting switch ON and operate shift up switch.

Shift up switch
TL1 (male)
Defective shift up switch OFF (Release) ON (Press)
1
N–U
Resistance between
N–B
Resistance between

TMCN1 (female) 6 – TL1 (female) U with

Possible causes Short circuit of wiring harness between
and standard 2 ground in wiring harness
chassis ground
value in normal (Contact with ground circuit)
TMCN2 (female) [ – TL1 (female) B with

state Short circuit of wiring harness between
chassis ground
Shift up switch
TMCN1,TMCN2
3
troller TMCN1 6 – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 [ – TMCN1 5 – 11V Max. 1V
4, @
D275A-5 20-491
(1)
(4)
TROUBLESHOOTING ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT (KB))
20-492 D275A-5
1
TROUBLESHOOTING ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION (KA))
ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION (KA))
Action code Error code Shift down switch: Disconnection (KA)

Trouble
E02 DD13KA (Transmission controller system)
Contents of
• Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
• Shift down is not possible.
appears on
machine
Related • Input state (ON/OFF) from shift down switch can be checked in monitoring mode.
information (Code 40905:Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate shift down switch.

Shift down switch
TL1 (male)
Defective shift down switch OFF (Release) ON (Press)
1
D–V
Resistance between
D–C
Resistance between

Wiring harness between TMCN3 (female) I –
TL1 (female) V
Disconnection in wiring har- Resistance Max. 1Ω
2
ing or defective contact in Wiring harness between TMCN3 (female) S –
TL1 (female) C
connector)
Wiring harness between TMCN1 (female) 4,
@ – TL1 (female) D
and standard
TMCN3 (female) I – TL1 (female) V with

Voltage Max. 1V
chassis ground
circuit)
TMCN3 (female) S – TL1 (female) C with

Voltage Max. 1V
chassis ground
Shift down switch
TMCN1, TMCN3
4
troller TMCN3 S – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN3 S – TMCN1 5 – 11V Max. 1V
4, @
D275A-5 20-493
(1)
(4)
TROUBLESHOOTING ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION (KA))
20-494 D275A-5
1
TROUBLESHOOTING ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))

Trouble Shift down switch: Short circuit (KB) (Transmission controller system)
E02 DD13KB
Contents of
• Signals of two systems of shift down switch circuit were turned ON (CLOSE) or OFF at the same time.
trouble
Problem that
• Shift down is not possible.
appears on
machine
Related • Input state (ON/OFF) from shift down switch can be checked in monitoring mode.
• Method of reproducing error code: Turn starting switch ON and operate shift down switch.

Shift down switch
TL1 (male)
Defective shift down switch OFF (Release) ON (Press)
1
D–V
Resistance between
D–C
Resistance between

TMCN3 (female) I – TL1 (female) V with

chassis ground
TMCN3 (female) S – TL1 (female) C with

chassis ground
Shift down switch
TMCN1, TMCN3
3
troller TMCN3 I – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN3 S – TMCN1 5 – 11V Max. 1V
4, @
D275A-5 20-495
(1)
(4)
TROUBLESHOOTING ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))
20-496 D275A-5
1
TROUBLESHOOTING ERROR CODE DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
ERROR CODE DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
Action code Error code Parking lever switch: Disconnection (KA)

Trouble
CALL E03 DD14KA (Transmission controller system)
Contents of
• Signals of two systems of parking lever switch circuit were turned OFF (OPEN) at the same time.
trouble
Action of
• Recognizes parking lever is in Free position.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1 and R1.
machine
★ 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).
Related
information
• Input state (ON/OFF) from parking brake switch can be checked in monitoring mode.
(Code 40905: Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate parking lever.
When error code [DD14KA] occurred alone

ness (Disconnection in wir- Wiring harness between TMCN1 (female) H –
ing or defective contact in branched point of circuit
connector) Wiring harness between TMCN1 (female) B –
branched point of circuit
and standard
value in normal
state
Parking lever
TMCN1
Defective transmission con- Free position Lock position
2
troller Between H –
Max. 1V 5 – 11V
chassis ground
Between B –
5 – 11V Max. 1V
chassis ground
When error codes [DD14KA] and [DDQ2KA] occurred at the same time
Parking lever switch Parking lever
1 NSW
(Internal disconnection) Free position Lock position
Between A – B Max. 1Ω Min. 1MΩ
Between A – B
Possible causes
and standard
harness between NSW (female) B –
state
Disconnection in wiring har- Wiring
ness (Disconnection in wir- merged point of circuit
ing or defective contact in Wiring harness between NSW (female) C –
2
connector) merged point of circuit
Wiring harness between NSW (female) A –
chassis ground
D275A-5 20-497
(1)
(4)
TROUBLESHOOTING ERROR CODE DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
When error codes [DD14KA] and [DDQ2KA] occurred at the same time
Possible causes
(female) B – TMCN1 (female) H – STCN2 (fe- Voltage Max. 1V
and standard Short circuit of wiring harness between NSW
state male) 5 with chassis ground
circuit)
(female) C – TMCN1 (female) B – STCN2 (fe- Voltage Max. 1V

Short circuit of wiring harness between NSW
male) E with chassis ground
Circuit diagram related to parking brake switch
20-498 D275A-5
(1)
(4)
TROUBLESHOOTING ERROR CODE DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
Action code Error code Parking lever switch: Short circuit (KB)
Trouble
CALL E03 DD14KB (Transmission controller system)
Contents of
• Signals of two systems of parking lever switch circuit were turned ON (CLOSE) at the same time.
trouble
Action of
controller
Problem that
appears on
machine
Depending on where problem occurs, related codes may be displayed at the same time.
(Related code: DDQ2KB, DDQ2L4).
Related
information
(Code 40905: Transmission controller input signal 1)

1 NSW
Between A – B Min. 1MΩ Max. 1Ω
Wiring harness between NSW (female) B –
Possible causes Short circuit with chassis
and standard TMCN1 (female) H – STCN2 (female) 5 with Resistance Min. 1MΩ
chassis ground
Wiring harness between NSW (female) C –
state
TMCN1 (female) B – STCN2 (female) E with Resistance Min. 1MΩ
chassis ground
Parking lever
TMCN1
Defective transmission con- Free position Lock position
3
troller Between H –
Max. 1V 5 – 11V
chassis ground
Between B –
5 – 11V Max. 1V
chassis ground
D275A-5 20-499
(1)
(4)
TROUBLESHOOTING ERROR CODE DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
20-500 D275A-5
1
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE
TROUBLESHOOTING (L6)
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE (L6)
Action code Error code Engine oil pressure switch: Refer to table (L6)
Trouble
CALL E03 DDE2L6 (Engine controller system)
Contents of
• Signals of engine oil pressure switch are inconsistent with engine state.
trouble
Problem that
appears on
machine
• Input state (ON/OFF) from engine oil pressure switch can be checked in monitoring mode.
Related
(Code 40900: Engine controller input signal 1)
information
• Method of reproducing error code: Turn starting switch ON or start engine.

Defective low engine oil without turning starting switch ON or by starting engine.
1 pressure switch (Internal PSL Engine Resistance
disconnection/short circuit) Between terminal – Stop Max. 1Ω
chassis ground Min. 600rpm Min. 1MΩ
Defective high engine oil without turning starting switch ON or by starting engine.
2 pressure switch (Internal PSH Engine Resistance
disconnection/short circuit) Between terminal – Stop Max. 1Ω
chassis ground Min. 1,300rpm Min. 1MΩ
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wir- Wiring harness between ECN1 (female) K –
value in normal ing or defective contact in PSL
state connector) Wiring harness between ECN1 (female) E –
PSH
(female) K – PSH with chassis ground
without turning starting switch ON or by starting engine.
ECN1 Engine Voltage
5 Defective engine controller Between K – chassis Stop Max. 1V
ground Min. 600rpm 20 – 30V
Between E – chassis Stop Max. 1V
ground Min. 1,300rpm 20 – 30V
D275A-5 20-501
1
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE
TROUBLESHOOTING (L6)
Circuit diagram related to low engine oil pressure switch & high engine oil pressure switch
20-502 D275A-5
1
ERROR CODE DDN4LD (RIPPER LIFT UP PRESSURE SWITCH: REFER TO
TROUBLESHOOTING TABLE (LD)
ERROR CODE DDN4LD (RIPPER LIFT UP PRESSURE SWITCH: REFER TO TABLE (LD)
Action code Error code Ripper lift UP pressure switch: Refer to table (LD).
Trouble
— DDN4LD (Steering control system)
Contents of
• Signals from ripper lift UP pressure switch was continuously ON for 60 seconds.
trouble
Action of
• Recognizes ripper lift UP pressure switch is turned OFF.
controller
Problem that
appears on • Shoe slip control (SSC) does not operate normally.
machine
• Input state (ON/OFF) from ripper lift UP pressure switch can be checked in monitoring mode.
Related (Code 40912: Steering controller input signal 3)
information • Method of reproducing error code: Turn starting switch ON. (It is reproduced after a lapse of at least
60 seconds.)

If error code lights on (reset display) even after carrying out reset, it
Defective lever operation
1 is suspected that lever operation causing error was performed in
(Electric system is normal.)
past.
Defective ripper lift UP pres- carry out troubleshooting.
2 sure switch (Internal short RPU (male) Ripper lever Resistance
circuit) Neutral Min. 1MΩ
Possible causes Between 1 – 2
UP Max. 1Ω
and standard
state
(Contact with ground circuit) (female) 3 – RPU (female) 1 with chassis Resistance Min. 1MΩ
ground
4 Defective steering controller STCN1, STCN2 Ripper lever Voltage
Between STCN2 3 – Neutral 5 – 11V
STCN1 4, @ UP Max. 1V
Circuit diagram related to ripper lift UP pressure switch
D275A-5 20-503
(1)
(4)
ERROR CODE DDN5LD (RIPPER LIFT DOWN PRESSURE SWITCH: REFER TO
ERROR CODE DDN5LD (RIPPER LIFT DOWN PRESSURE SWITCH: REFER TO TABLE
(LD)
Action code Error code Ripper lift DOWN pressure switch: Refer to table (LD).
Trouble
Contents of
• Signals from ripper lift DOWN pressure switch was continuously ON for 60 seconds.
trouble
Action of
• Recognizes ripper lift DOWN pressure switch is OFF.
controller
Problem that
machine
• Input state (ON/OFF) from ripper lift DOWN pressure switch can be checked in monitoring mode.
Related (Code 40912: Steering controller input signal 3)
60 seconds.)

past.
Defective ripper lift DOWN carry out troubleshooting.
2 pressure switch (Internal RPD (male) Ripper lever Resistance
short circuit) Neutral Min. 1MΩ
DOWN Max. 1Ω
and standard
value in normal
state Short circuit with chassis without turning starting switch ON.
(Contact with ground circuit) (female) N – RPD (female) 1 with chassis Resistance Min. 1MΩ
ground
4 Defective steering controller STCN1 Ripper lever Voltage
Between STCN1 N – Neutral 5 – 11V
4, @ UP Max. 1V
Circuit diagram related to ripper lift DOWN pressure switch
20-504 D275A-5
(1)
(4)
ERROR CODE DDN6LD (RIPPER TILT IN PRESSURE SWITCH: REFER TO
ERROR CODE DDN6LD (RIPPER TILT IN PRESSURE SWITCH: REFER TO TABLE (LD)
Action code Error code Ripper tilt IN pressure switch: Refer to table (LD).
Trouble
Contents of
• Signals of ripper tilt IN pressure switch was continuously ON for 60 seconds.
trouble
Action of
• Recognizes ripper tilt IN pressure switch is OFF.
controller
Problem that
machine
• Input state (ON/OFF) from ripper tilt IN pressure switch can be checked in monitoring mode.
Related (Code 70305: Ripper lever pressure switch input signal)
60 seconds.)

past.
Defective ripper tilt IN pres- carry out troubleshooting.
2 sure switch (Internal short RTI (male) Ripper lever Resistance
circuit) Neutral Min. 1MΩ
Tilt IN Max. 1Ω
and standard
state
(Contact with ground circuit) (female) H – RTI (female) 1 with chassis Resistance Min. 1MΩ
ground
4 Defective steering controller STCN1 Ripper lever Voltage
Between STCN1 H – Neutral 5 – 11V
4, @ Tilt IN Max. 1V
Circuit diagram related to ripper tilt IN pressure switch
D275A-5 20-505
(1)
(4)
TROUBLESHOOTING ERROR CODE DDN7KA (BLADE PITCH SWITCH: DISCONNECTION (KA))
ERROR CODE DDN7KA (BLADE PITCH SWITCH: DISCONNECTION (KA))
Action code Error code Blade pitch switch: Disconnection (KA)

Trouble
E02 DDN7KA (Transmission controller system)
Contents of
• Signals of two systems of blade pitch switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
appears on • Blade pitch does not function. (Operating blade pitch causes tilt operation.)
machine
Related • Input state (ON/OFF) from blade pitch switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input signal)
• Method of reproducing error code: Turn starting switch ON (and operate blade tilt switch).

Blade pitch switch
P03 (male)
Defective blade pitch switch OFF (Release) ON (Press)
1
(Internal disconnection) Resistance between
1–5
Resistance between
1–2
Disconnection in wiring har- Wiring harness between TMCN2 (female) E –
ness (Disconnection in wir- P03 (female) 5
2
ing or defective contact in Wiring harness between TMCN2 (female) 5 –
connector) P03 (female) 2
Possible causes Wiring harness between TMCN1 (female) 4,
@ – P03 (female) 1
and standard
TMCN2 (female) E – P03 (female) 5 with Voltage Max. 1V
chassis ground
circuit)
TMCN2 (female) 5 – P03 (female) 2 with Voltage Max. 1V
chassis ground
Blade pitch switch
TMCN1, TMCN2
4
troller TMCN2 E – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 5 – TMCN1 5 – 11V Max. 1V
4, @
20-506 D275A-5
(1)
(4)
TROUBLESHOOTING ERROR CODE DDN7KA (BLADE PITCH SWITCH: DISCONNECTION (KA))
Circuit diagram related to blade pitch switch & blade tilt switch
D275A-5 20-507
1
TROUBLESHOOTING ERROR CODE DDN7KB (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDN7KB (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))
Action code Error code Blade pitch switch: Short circuit (KB) (Transmission controller sys-
Trouble
E02 DDN7KB tem)
Contents of
• Signals of two systems of blade pitch switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
appears on • Blade pitch does not function (Operating blade pitch causes tilt operation.)
machine
Related • Input state (ON/OFF) from blade pitch switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input)
• Method of reproducing error code: Turn starting switch ON and operate blade tilt switch.

Blade pitch switch
P03 (male)
Defective blade pitch switch OFF (Release) ON (Press)
1
1–5
Resistance between
1–2
TMCN2 (female) E – P03 (female) 5 with Voltage Max. 1V
chassis ground
TMCN2 (female) 5 – P03 (female) 2 with Voltage Max. 1V
chassis ground
Blade pitch switch
TMCN1, TMCN2
3
troller TMCN2 E – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 5 – TMCN1 5 – 11V Max. 1V
4, @
20-508 D275A-5
(1)
(4)
TROUBLESHOOTING ERROR CODE DDN7KB (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))
D275A-5 20-509
1
TROUBLESHOOTING ERROR CODE DDN9KA (BLADE TILT SWITCH: DISCONNECTION (KA))
ERROR CODE DDN9KA (BLADE TILT SWITCH: DISCONNECTION (KA))
Action code Error code Blade tilt switch: Disconnection (KA) (Transmission controller sys-
Trouble
E01 DDN9KA tem)
Contents of
• Signals of two systems of blade tilt switch circuit were turned OFF (OPEN) at the same time.
trouble
Action of
• Recognizes switch is set at SINGLE side.
controller
Problem that
appears on • Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.)
machine
Related • Input state (ON/OFF) from blade tilt switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input signal)

Blade tilt switch
P03 (male)
Defective blade tilt switch SINGLE DUAL
1
3–6
Resistance between
3–4
Disconnection in wiring har- Wiring harness between TMCN2 (female) Y – Resistance
Max. 1Ω
ness (Disconnection in wir- P03 (female) 6
2
ing or defective contact in Wiring harness between TMCN2 (female) O –
connector) P03 (female) 4
Possible causes Wiring harness between TMCN1 (female) 4,
@ – P03 (female) 3
and standard
TMCN2 (female) Y – P03 (female) 6 with Voltage Max. 1V
chassis ground
circuit)
TMCN2 (female) O – P03 (female) 4 with Voltage Max. 1V
chassis ground
Blade tilt switch
TMCN1, TMCN2
SINGLE DUAL
4
troller TMCN2 Y – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 O – TMCN1 5 – 11V Max. 1V
4, @
20-510 D275A-5
(1)
(4)
TROUBLESHOOTING ERROR CODE DDN9KA (BLADE TILT SWITCH: DISCONNECTION (KA))
D275A-5 20-511
1
TROUBLESHOOTING ERROR CODE DDN9KB (BLADE TILT SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDN9KB (BLADE TILT SWITCH: SHORT CIRCUIT (KB))

Trouble Blade tilt switch: Short circuit (KB) (Transmission controller system)
E01 DDN9KB
Contents of
• Signals of two systems of blade tilt switch circuit were turned ON (CLOSE) at the same time.
trouble
Action of
• Recognizes switch is set at SINGLE side.
controller
Problem that
appears on • Blade dual tilt does not function. (Operating dual tilt causes single tilt operation.)
machine
Related • Input state (ON/OFF) from blade tilt switch can be checked in monitoring mode.
information (Code 70300: Blade lever knob switch input state)

Blade tilt switch
P03 (male)
Defective blade tilt switch SINGLE DUAL
1
3–6
Resistance between
3–4
TMCN2 (female) Y – P03 (female) 6 with Voltage Max. 1V
chassis ground
TMCN2 (female) O – P03 (female) 4 with Voltage Max. 1V
chassis ground
Blade tilt switch
TMCN1, TMCN2
SINGLE DUAL
3
troller TMCN2 Y – TMCN1 Max. 1V 5 – 11V
4, @
Voltage between
TMCN2 O – TMCN1 5 – 11V Max. 1V
4, @
20-512 D275A-5
(1)
(4)
TROUBLESHOOTING ERROR CODE DDN9KB (BLADE TILT SWITCH: SHORT CIRCUIT (KB))
D275A-5 20-513
1
TROUBLESHOOTING ERROR CODE DDQ2KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
ERROR CODE DDQ2KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
Action code Error code Parking lever switch: Disconnection (KA)

Trouble
CALL E03 DDQ2KA (Transmission controller system)
Contents of
• Signals of two systems of parking lever switch circuit were turned OFF (OPEN) at the same time.
trouble
Action of
controller
Problem that
appears on
machine
Depending on where problem occurs, related codes may be displayed at the same time. (Related
code: DD14KA, DDQ2L4).
Related
information
(Code 40907: Blade lever knob switch input signal)
When error code [DDQ2KA] occurred alone

ing or defective contact in branched point of circuit
connector) Wiring harness between STCN2 (female) E –
branched point of circuit
and standard
value in normal
state
Parking lever
STCN2
Free position Lock position
Between 5 –
Max. 1V 5 – 11V
chassis ground
Between E –
5 – 11V Max. 1V
chassis ground
When error codes [DDQ2KA] and [DD14KA] occurred at the same time
1 NSW
Between A – B
Possible causes
and standard
harness between NSW (female) B –
state
Disconnection in wiring har- Wiring
ness (Disconnection in wir- merged point of circuit
ing or defective contact in Wiring harness between NSW (female) C –
2
connector) merged point of circuit
Wiring harness between NSW (female) A –
chassis ground
20-514 D275A-5
(1)
(4)
TROUBLESHOOTING ERROR CODE DDQ2KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
When error codes [DDQ2KA] and [DD14KA] occurred at the same time
Possible causes
(female) B – TMCN1 (female) H – STCN2
and standard Short circuit of wiring harness between NSW
Voltage Max. 1V
state (female) 5 with chassis ground
circuit)
(female) C – TMCN1 (female) B – STCN2 (fe- Voltage Max. 1V

D275A-5 20-515
(1)
(4)
ERROR CODE DDQ2KB (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT
ERROR CODE DDQ2KB (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB))
Action code Error code Parking brake lever switch: Short circuit (KB)
Trouble
CALL E03 DDQ2KB (Steering controller system)
Contents of
• Signals of both parking brake lever switch circuit systems are turned ON (closed) simultaneously.
trouble
Action of
• Recognizes that parking brake lever is at FREE position.
controller
Problem that
appears on
machine
★ Since parking brake switch signal is used by both transmission controller and steering controller, re-
lated codes may be displayed simultaneously, depending on troubled part. (Related codes: DD14KB,
DDQ2L4)
Related
• NO and NC signals of both switch systems are for detecting operation and error respectively.
information
• Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode.
(Code 40907: Blade control lever knob switch input signal)
• Method of reproducing error code: Turn starting switch ON and operate parking brake lever.
When error codes [DDQ2KA] and [DD14KA] are displayed simultaneously

Defective parking brake le- Parking brake lever
1 ver switch (Internal short cir- NSW
At FREE At LOCK
Between A – B
cuit)
Between A – B Min. 1MΩ Max. 1Ω
(female) B – TMCN1 (female) H – STCN2 (fe- Resistance Min. 1MΩ

Possible causes Short circuit with chassis
value in normal male) 5 with chassis ground
(female) C – TMCN1 (female) B – STCN2 (fe- Resistance Min. 1MΩ

state Short circuit of wiring harness between NSW

Parking brake lever
STCN2
At FREE At LOCK
Between 5 –
Max. 1V 5 – 11V
chassis ground
Between E –
5 – 11V Max. 1V
chassis ground
20-516 D275A-5
(1)
(4)
ERROR CODE DDQ2KB (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT
D275A-5 20-517
1
TROUBLESHOOTING ERROR CODE DDQ2L4 (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4))
ERROR CODE DDQ2L4 (PARKING BRAKE LEVER SWITCH: SEE TABLE (L4))
Action code Error code Parking brake lever switch: See table (L4)
Trouble
CALL E03 DDQ2L4 (Steering controller system)
Contents of • Switch input signal of steering controller disagrees with communication signal from transmission con-
trouble troller.
Problem that
appears on
machine
★ 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,
Related
DD14KB, DDQ2KA, DDN4LD, DDN5LD)
information
• Inputting from parking brake switch (ON·OFF) can be checked in monitoring mode.
(Code 40907: Parking brake lever switch input signal)
• Method of reproducing error code: Turn starting switch ON and operate parking brake lever.

See if error codes [DAFRKR], [DB2RKR], [DB3RKR], and [DAQRKR]
Defective CAN communica-
Possible causes 1 are displayed. If they are displayed, carry out troubleshooting for
tion signal system
and standard them first.
value in normal See if error codes [DD14KA], [DD14KB], [DDQ2KA], and [DDQ2KB]
state Defective parking brake le-
2 are displayed. If they are displayed, carry out troubleshooting for
ver switch signal system
them first.
3 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
20-518 D275A-5
1
ERROR CODE DGE2KX (ENGINE WATER TEMPERATURE SENSOR (FOR
TROUBLESHOOTING HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE DGE2KX (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH

TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
Action code Error code Engine water temperature sensor (for high temperature): Input signal
Trouble
CALL E03 DGE2KX is out of normal range (KX) (Engine controller system)
Contents of
• High engine water temperature sensor signal is out of normal range.
trouble
Action of
• Fixes water temperature signal output for monitor panel at 90%.
controller
Problem that • Monitor panel does not display engine water temperature normally.
• Engine water temperature (temperature) can be checked in monitoring mode.
Related
(Code 04102: Engine water temperature (High temperature side))
information

Defective high engine water without turning starting switch ON.
temperature sensor (Inter- TWH Resistance
1
nal disconnection or short
circuit) Between 1 – 2 3.5k – 90kΩ
Between 1, 2 – chassis ground Min. 1MΩ
ness (Disconnection in wir- Wiring harness between ECN2 (female) Q –
Possible causes ing or defective contact in TWH (female) 1
and standard connector) Wiring harness between ECN2 (female) ] –
value in normal TWH (female) 2
3 ground in wiring harness Short circuit of wiring harness between ECN2
(Contact with ground circuit) (female) Q – TWH (female) 1 with chassis Resistance Min. 1MΩ
ground
4 Defective engine controller ECN2 (female) Resistance
Between Q – ] 3.5k – 90kΩ
Between Q, ] – chassis ground Min. 1MΩ
Circuit diagram related to high engine water temperature sensor
D275A-5 20-519
1
ERROR CODE DGE3L6 (ENGINE WATER TEMPERATURE SENSOR (FOR
TROUBLESHOOTING LOW TEMPERATURE): SEE TABLE (L6))
ERROR CODE DGE3L6 (ENGINE WATER TEMPERATURE SENSOR (FOR LOW

TEMPERATURE): SEE TABLE (L6))
Action code Error code Engine water temperature sensor (for low temperature): See table
Trouble
E02 DGE3L6 (L6) (Engine controller system)
Contents of
• Low engine water temperature sensor signal is not input.
trouble
Action of
controller
Problem that
• Exhaust gas color is bad at low temperature.
appears on
• Engine does not start easily at low temperature.
machine
• Engine water temperature (temperature) can be checked in monitoring mode.
Related
(Code 04104: Engine water temperature (Low temperature side))
information

Defective low engine water without turning starting switch ON.
temperature sensor (Inter-
1 TWL (male) Resistance
nal disconnection or short
Between 1 – 2 0.3k – 9kΩ
circuit)
ness (Disconnection in wir- Wiring harness between ECN2 (female) [ –
Possible causes ing or defective contact in TWL (female) 1
value in normal TWL (female) 2
(Contact with ground circuit) (female) [ – TWL (female) 1 with chassis Resistance Min. 1MΩ
ground
Between [ – ] 0.3k – 9kΩ
Between [, ] – chassis ground Min. 1MΩ
Circuit diagram related to low engine water temperature sensor
20-520 D275A-5
1
ERROR CODE DGE4KX (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS
TROUBLESHOOTING OUT OF NORMAL RANGE (KX))
ERROR CODE DGE4KX (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF

NORMAL RANGE (KX))
Action code Error code Fuel temperature sensor: Input signal is out of normal range (KX)
Trouble
E01 DGE4KX (Engine controller system)
Contents of
• Fuel temperature sensor signal is out of normal range.
trouble
Action of
• Operates with normal control.
controller
Problem that
appears on • Engine output lowers a little at low temperature.
machine
Related • Fuel temperature (temperature) can be checked in monitoring mode. (Code 04204: Fuel temperature)
information • Method of reproducing error code: Turn starting switch ON or start engine.

Defective fuel temperature without turning starting switch ON.
1 sensor (Internal disconnec- THL (male) Resistance
tion or short circuit) Between 1 – 2 0.3k – 9kΩ
ness (Disconnection in wir- Wiring harness between ECN2 (female) G –
Possible causes ing or defective contact in THL (female) 1
value in normal THL (female) 2
(Contact with ground circuit) (female) G – THL (female) 1 with chassis Resistance Min. 1MΩ
ground
Between G – ] 0.3k – 9kΩ
Between G, ] – chassis ground Min. 1MΩ
Circuit diagram related to fuel temperature sensor
D275A-5 20-521
1
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT
TROUBLESHOOTING SIGNAL IS OUT OF NORMAL RANGE (KX))
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS

OUT OF NORMAL RANGE (KX))
Action code Error code Hydraulic oil temperature sensor: Input signal is out of normal range
Trouble
— DGS1KX (KX) (Transmission controller system)
Contents of
• Hydraulic oil temperature sensor signal is out of normal range.
trouble
Action of
• Does not take any particular action.
controller
Problem that
appears on • Hydraulic oil temperature gauge of monitor panel may not display normally.
machine
• Hydraulic oil temperature (temperature) can be checked in monitoring mode.
Related
(Code 04401: Hydraulic oil temperature)
information

Defective hydraulic oil tem- without turning starting switch ON.
perature sensor (Internal
1 SDS (male) Resistance
disconnection or short cir-
Between 1 – 2 3.5k – 90kΩ
cuit)
ness (Disconnection in wir- Wiring harness between TMCN2 (female) D –
ing or defective contact in SDS (female) 1
connector) Wiring harness between TMCN2 (female) K –
SDS (female) 2
Possible causes
value in normal
state 3 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) TMCN2 (female) D – SDS (female) 1 with Resistance Min. 1MΩ
chassis ground
Short circuit with power out troubleshooting.
4 source in wiring harness Short circuit of wiring harness between
(Contact with 24V circuit) TMCN1 (female) D – SDS (female) 1 with Voltage Max. 1V
chassis ground
Defective transmission con- TMCN1 (female) Resistance
5
troller
Between D – K 1k – 50kΩ
Between D – chassis ground Min. 1MΩ
Circuit diagram related to hydraulic oil temperature sensor
20-522 D275A-5
(1)
(4)
ERROR CODE DH21KA (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:
ERROR CODE DH21KA (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:

DISCONNECTION (KA))
Action code Error code Work equipment pump oil pressure sensor: Disconnection (KA)
Trouble
E01 DH21KA (Transmission controller system)
Contents of
• Signal voltage of work equipment pump oil pressure sensor circuit is below 0.5V.
trouble
Action of
controller
Problem that
appears on • Work equipment pump oil pressure cannot be monitored.
machine
• Input (Voltage) from work equipment pump oil pressure sensor can be checked in monitoring mode.
Related
(Code 70701: Voltage of work equipment oil sensor)
information

Defective 24V power source See if error code [DAQ6KK] is displayed. If it is displayed, carry out
1
system troubleshooting for it first.
Defective work equipment out troubleshooting.
2 pump oil pressure sensor
HHP Voltage
Between C – A
(Internal trouble)
0.5 – 6.0V
ness (Disconnection in wir- Wiring harness between TMCN1 (female) F –
ing or defective contact in HHP (female) B
Possible causes
and standard
value in normal connector) Wiring harness between TMCN1 (female) 9 –
HHP (female) C
state
(Contact with ground circuit) TMCN1 (female) 9 – HHP (female) C with
chassis ground
Defective transmission con- out troubleshooting.
5
troller TMCN1 (female) Voltage
Between 9 – K 0.5 – 6.0V
Circuit diagram related to work equipment pump oil pressure sensor
D275A-5 20-523
1
ERROR CODE DH21KB (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:
TROUBLESHOOTING SHORT CIRCUIT (KB))
ERROR CODE DH21KB (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: SHORT
CIRCUIT (KB))
Action code Error code Work equipment pump oil pressure sensor: Short circuit (KB)
Trouble
E01 DH21KB (Transmission controller system)
Contents of
• Signal voltage of work equipment pump oil pressure sensor circuit is above 6.0V
trouble
Action of
controller
Problem that
appears on • Work equipment pump oil pressure cannot be monitored.
machine
• Input (Voltage) from work equipment pump oil pressure sensor can be checked in monitoring mode.
Related
(Code 70701: Voltage of work equipment oil pressure sensor)
information

Defective 24V power source See if error code [DAQ6KK] is displayed. If it is displayed, carry out
1
Defective work equipment out troubleshooting.
2 pump oil pressure sensor
HHP Voltage
Between C – A
(Internal trouble)
Possible causes 0.5 – 6.0V
and standard ★ Prepare with starting switch OFF, turn starting switch ON and carry
value in normal Short circuit with power out troubleshooting.
state 3 source in wiring harness
TMCN1 (female) 9 – HHP (female) C with
(Contact with 24V circuit) Voltage Max. 1V
chassis ground
Defective transmission con- out troubleshooting.
4
troller TMCN1 (female) Voltage
Between 9 – K 0.5 – 6.0V
Circuit diagram related to work equipment pump oil pressure sensor
20-524 D275A-5
1
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF
TROUBLESHOOTING NORMAL RANGE (KX))
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL

RANGE (KX))
Action code Error code Boost pressure sensor: Input is out of normal range (KX)
Trouble
E02 DH30KX (Engine controller system)
Contents of
• Boost pressure sensor signal is out of normal range.
trouble
Action of
controller
Problem that
appears on • Machine is not affected seriously.
machine
• Special adapter (799-601-9420) is necessary for troubleshooting for boost pressure sensor.
Related • Boost pressure (pressure) can be checked in monitoring mode.
information (Code 36500: Boost pressure)

Defective boost pressure PIM Voltage
1
sensor (Internal trouble)
Between 1 – 3 4.6 – 5.4V
Between 2 – 3 0.3 – 5.7V
Disconnection in wiring har- Wiring harness between ECN2 (female) I –
ness (Disconnection in wir- PIM (female) 1
2
ing or defective contact in Wiring harness between ECN2 (female) J –
connector) PIM (female) 2
Wiring harness between ECN2 (female) ] –
Possible causes PIM (female) 3
value in normal without turning starting switch ON.
(female) I – PIM (female) 1 with chassis Resistance Min. 1MΩ
Short circuit with chassis ground
(Contact with ground circuit) (female) J – PIM (female) 2 with chassis Resistance Min. 1MΩ
ground
(female) ] – PIM (female) 3 with chassis Resistance Min. 1MΩ
ground
4 Defective engine controller ECN2 Voltage
Between I – ] 4.6 – 5.4V
Between J – ] 0.3 – 5.7V
D275A-5 20-525
1
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF
TROUBLESHOOTING NORMAL RANGE (KX))
Circuit diagram related to boost presure sensor
20-526 D275A-5
1
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT
TROUBLESHOOTING OF NORMAL RANGE (KX))
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF

NORMAL RANGE (KX))
Action code Error code Common rail pressure sensor: Input is out of normal range (KX)
Trouble
CALL E03 DH40KX (Engine controller system)
Contents of
• Common rail pressure sensor signal is out of normal range.
trouble
Problem that
appears on
machine
• Special adapter (799-601-9420) is necessary for troubleshooting for common rail pressure sensor.
Related • Common rail pressure (pressure) can be checked in monitoring mode.
information (Code 36400: Common rail pressure)

Defective common rail pres- out troubleshooting.
1 sure sensor (Internal trou- PFUEL Voltage
ble) Between 1 – 3 4.6 – 5.4V
Between 2 – 3 0.3 – 5.7V
Disconnection in wiring har- Wiring harness between ECN2 (female) I –
ness (Disconnection in wir- PFUEL (female) 1
2
ing or defective contact in Wiring harness between ECN2 (female) ^ –
connector) PFUEL (female) 2
Wiring harness between ECN2 (female) ] –
Possible causes PFUEL (female) 3
state Short circuit of wiring harness between N2 (fe-
male) I – PFUEL (female) 1 with chassis Resistance Min. 1MΩ
Short circuit with chassis ground
(Contact with ground circuit) (female) ^ – PFUEL (female) 2 with chassis Resistance Min. 1MΩ
ground
(female) ] – PFUEL (female) 3 with chassis Resistance Min. 1MΩ
ground
Between I – ] 4.6 – 5.4V
Between ^ – ] 0.3 – 5.7V
D275A-5 20-527
1
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT
Circuit diagram related to common rail presure sensor
20-528 D275A-5
1
20
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL
TROUBLESHOOTING RANGE (KX))
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE
(KX))
Action code Error code Fuel control dial: Input is out of normal range (KX)
Trouble
CALL E03 DK10KX (Engine controller system)
Contents of
• Signal voltage of fuel control dial circuit is below 0.5V or above 4.5V.
trouble
Action of
• Continues controlling with signal of decelerator pedal potentiometer.
controller
Problem that
appears on
machine
• Inputting from fuel control dial (Voltage) can be checked in monitoring mode.
Related
(Code 03000: Voltage of fuel control dial)
information

Defective fuel control dial TL1 (male) Resistance
Between R – T
1 (Internal disconnection or
4.0 – 6.0kΩ
Between R – S
short circuit)
0.25 – 7.0kΩ
Between S – T 0.25 – 7.0kΩ
TL1 (female) R
2
ing or defective contact in Wiring harness between ECN2 (female) @ –
TL1 (female) S
connector)
Wiring harness between ECN2 (female) S –
TL1 (female) T

and standard
(female) 9 – TL1 (female) R with chassis
value in normal Short circuit with chassis
state 3 ground in wiring harness
ground
(female) @ – TL1 (female) S with chassis

ground
(female) 9 – TL1 (female) R with chassis

Short circuit with power
Voltage Max. 1V
4 source in wiring harness
ground
(female) @ – TL1 (female) S with chassis

Voltage Max. 1V
ground
Between 9 – S 4.6 – 5.4V
Between @ – S 0.5 – 4.5V
D275A-5 20-529
1
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL
TROUBLESHOOTING RANGE (KX))
Circuit diagram related to fuel control dial
20-530 D275A-5
1
ERROR CODE DK12KX (DECELERATION POTENTIOMETER: INPUT IS OUT
ERROR CODE DK12KX (DECELERATION POTENTIOMETER: INPUT IS OUT OF

NORMAL RANGE (KX))
Action code Error code Deceleration potentiometer: Input is out of normal range (KX)
Trouble
CALL E03 DK12KX (Engine controller system)
Contents of
• Signal voltage of deceleration potentiometer circuit is below 0.3V or above 4.5V.
trouble
Action of
• Continues controlling with signal of fuel control dial.
controller
Problem that
appears on
machine
• Inputting from deceleration potentiometer (Voltage) can be checked in monitoring mode.
Related
(Code 50101: Voltage of deceleration potentiometer)
information

Defective deceleration po- DCL (male) Resistance
Between A – C
1 tentiometer (Internal discon-
4.0 – 6.0kΩ
Between A – B
nection or short circuit)
0.25 – 7.0kΩ
Between B – C 0.25 – 7.0kΩ
DCL (female) A
2
ing or defective contact in Wiring harness between ECN2 (female) \ –
DCL (female) B
connector)
Wiring harness between ECN2 (female) S –
DCL (female) C

and standard
(female) 9 – DCL (female) A with chassis
value in normal Short circuit with chassis
state 3 ground in wiring harness
ground
(female) Z – DCL (female) B with chassis

ground
(female) 9 – DCL (female) A with chassis

Short circuit with power
Voltage Max. 1V
ground
(female) Z – DCL (female) B with chassis

Voltage Max. 1V
ground
Between 9 – S 4.6 – 5.4V
Between \ – S 0.3 – 4.5V
D275A-5 20-531
1
ERROR CODE DK12KX (DECELERATION POTENTIOMETER: INPUT IS OUT
Circuit diagram related to deceleration potentiometer
20-532 D275A-5
1
ERROR CODE DK30KA (STEERING POTENTIOMETER 1: DISCONNECTION
ERROR CODE DK30KA (STEERING POTENTIOMETER 1: DISCONNECTION (KA))
Action code Error code Steering potentiometer 1: Disconnection (KA)

Trouble
CALL E03 DK30KA (Steering controller system)
Contents of
• Signal voltage of steering potentiometer 1 system (ST1) is below 0.5V.
trouble
Action of
• Continues controlling with signal of steering potentiometer 2 system (ST2).
controller
Problem that
appears on
machine
• Input (Voltage) from steering potentiometer 1 (ST1) can be checked in monitoring mode.
Related
(Code 50300: Voltage of steering potentiometer 1)
information
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).

Defective 5V sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out
1
source system troubleshooting for it first.
Defective steering potenti- TL1 (male) Resistance
Between A – G
2 ometer 1 (Internal discon-
2kΩ ± 20%
Between H – A
Between H – G
and standard ness (Disconnection in wir- Wiring harness between STCN1 (female) L –
ing or defective contact in TL1 (female) A
value in normal
state connector) Wiring harness between STCN1 (female) 2 –
TL1 (female) H

(Contact with ground circuit) (female) 2 – TL1 (female) H with chassis
ground
STCN1 Voltage
Between 2 – K 0.5 – 4.5V
D275A-5 20-533
1
Circuit diagram related to steering potentiometer
20-534 D275A-5
1
ERROR CODE DK30KB (STEERING POTENTIOMETER 1: SHORT CIRCUIT
ERROR CODE DK30KB (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))
Action code Error code Steering potentiometer 1: Short circuit (KB)

Trouble
CALL E03 DK30KB (Steering controller system)
Contents of
• Signal voltage of steering potentiometer 1 system (ST1) is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Between A – G
2kΩ ± 20%
Between H – A
Possible causes
and standard Between H – G
value in normal ★ Prepare with starting switch OFF, then turn starting switch ON and
state Short circuit with power carry out troubleshooting.
(female) 2 – TL1 (female) H with chassis
ground
STCN1 Voltage
Between 2 – K 0.5 – 4.5V
D275A-5 20-535
1
ERROR CODE
ERROR CODE DK30KX
DK30KX (STEERING(STEERING POTENTIOMETER
POTENTIOMETER 1:OFINPUT
1: INPUT SIGNAL IS OUT NORMALSIGNAL IS
RANGE (KX))
TROUBLESHOOTING ERROR CODE DK30KZ (STEERING POTENTIOMETER 1:OUT OF NORMAL
DISCONNECTION RANGE
OR SHORT (KX))
CIRCUIT (KZ))
ERROR CODE DK30KX (STEERING POTENTIOMETER 1: INPUT SIGNAL IS OUT OF

NORMAL RANGE (KX))
Action code Error code Steering potentiometer 1: Input signal is out of normal range (KX)
Trouble
CALL E04 DK30KX (Steering controller system)
Contents of • Either of error codes [DK30KA] and [DK30KB] of steering potentiometer systems 1 and 2 and error
trouble codes [DK31KA] and [DK31KB] are displayed simultaneously.
Problem that
appears on
machine
• Input (Voltage) from steering potentiometers can be checked in monitoring mode.
Related (Code 50300: Voltage of steering potentiometer 1)
information (Code 50301: Voltage of steering potentiometer 2)

and standard
value in normal Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
state
ERROR CODE DK30KZ (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT

CIRCUIT (KZ))
Action code Error code Steering potentiometer 1: Disconnection or short circuit (KZ))
Trouble
CALL E04 DK30KZ (Steering controller system)
• When starting switch is turned ON, either of steering potentiometer systems 1 and 2 is abnormal, then
Contents of
either of error codes [DK30KA] and [DK30KB] and error codes [DK31KA] and [DK31KB] are displayed
trouble
simultaneously.
Problem that
appears on
machine

and standard
state
20-536 D275A-5
1
TROUBLESHOOTING ERROR CODE DK30L8 (STEERING POTENTIOMETER 1: SEE TABLE (L8))
ERROR CODE DK30L8 (STEERING POTENTIOMETER 1: SEE TABLE (L8))
Action code Error code Steering potentiometer 1: See table (L8)

Trouble
CALL E03 DK30L8 (Steering controller system)
Contents of • Total signal voltage of each of steering potentiometer 1 system (ST1) and 2 system (ST2) is below
trouble 4.41V or above 5.59V.
Action of
• Continues controlling with signal of normal one of steering potentiometer 1 system (ST1) and 2 (ST2).
controller
Problem that
appears on
machine

and standard
state
D275A-5 20-537
1
ERROR CODE DK31KA (STEERING POTENTIOMETER 2: DISCONNECTION (KA))
Action code Error code Steering potentiometer 2: Disconnection (KA)

Trouble
Contents of
• Signal voltage of steering potentiometer 2 system (ST2) is below 0.5V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out
1
Between M – F
2kΩ ± 20%
Between E – M
Between E – F
and standard Wiring harness between STCN1 (female) L –
TL1 (female) M
value in normal ing or defective contact in
state connector) Wiring harness between STCN1 (female) I –
TL1 (female) E

(female) I – TL1 (female) E with chassis
ground
STCN1 Voltage
Between I – K 0.5 – 4.5V
20-538 D275A-5
1
D275A-5 20-539
1
ERROR CODE DK31KB (STEERING POTENTIOMETER 2: SHORT CIRCUIT
ERROR CODE DK31KB (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB))
Action code Error code Steering potentiometer 2: Short circuit (KB)

Trouble
Contents of
• Signal voltage of steering potentiometer 2 system (ST2) is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective sensor power See if error code [DB35KK] is displayed. If it is displayed, carry out
1
Defective steering potenti- TL1 (male) Voltage
Between M – F
2kΩ ± 20%
Between E – M
Possible causes
and standard Between E – F
(female) I – TL1 (female) E with chassis
(Contact with 24V circuit) Resistance Max. 1V
ground
STCN1 Voltage
20-540 D275A-5
1
TROUBLESHOOTING ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA))
ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA))
Action code Error code Brake potentiometer: Disconnection (KA)

Trouble
Contents of
• Signal voltage of brake potentiometer circuit is below 0.5V.
trouble
Action of
• Does not control with signal of brake potentiometer (Brake can be operated with pedal).
controller
Problem that • Brake control performance of brake pedal lowers.
• Input (Voltage) from brake potentiometer can be checked in monitoring mode.
Related
(Code 50400: Voltage of brake potentiometer)
information
• Method of reproducing error code: Turn starting switch ON and operate brake pedal.

1
Defective brake potentiom- BRK (male) Resistance
Between A – C
2 eter (Internal disconnection
4.0 – 6.0kΩ
Between A – B
or short circuit)
0.25 – 7.0kΩ
Between B – C 0.25 – 7.0kΩ
and standard ness (Disconnection in wir- Wiring harness between STCN1 (female) L –
ing or defective contact in BRK (female) C
value in normal
state connector) Wiring harness between STCN1 (female) 3 –
BRK (female) B

(Contact with ground circuit) (female) 3 – BRK (female) B with chassis
ground
STCN1 Voltage
Between 3 – B 0.5 – 4.5V
D275A-5 20-541
1
TROUBLESHOOTING ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA))
Circuit diagram related to brake potentiometer
20-542 D275A-5
1
TROUBLESHOOTING ERROR CODE DK40KB (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))
ERROR CODE DK40KB (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))
Action code Error code Brake potentiometer: Short circuit (KB)

Trouble
Contents of
• Signal voltage of brake potentiometer circuit is below 0.5V or above 4.5V.
trouble
Action of
• Does not control with signal of brake potentiometer (Brake can be operated with pedal).
controller
Problem that • Brake control performance of brake pedal lowers.
• Input (Voltage) from brake potentiometer can be checked in monitoring mode.
Related
(Code 50400: Voltage of brake potentiometer)
information
• Method of reproducing error code: Turn starting switch ON and operate brake pedal.

1
Defective brake potentiom- BRK (male) Resistance
A–C
2 eter (Internal disconnection
4.0 – 6.0kΩ
A–B
or short circuit)
Possible causes 0.25 – 7.0kΩ
and standard B–C 0.25 – 7.0kΩ
(female) 3 – BRK (female) B with chassis
ground
STCN1 Voltage
Between 3 – B 0.5 – 4.5V
Circuit diagram related to brake potentiometer
D275A-5 20-543
1
ERROR
ERROR CODE DK55KXCODE DK55KX (FORWARD-REVERSE
(FORWARD-REVERSE POTENTIOMETER:
POTENTIOMETER: INPUT SIGNAL INPUT
IS OUT OF NORMAL RANGE (KX))
TROUBLESHOOTING SIGNAL IS OUT
ERROR CODE DK55KZ (FORWARD-REVERSE POTENTIOMETER: OF NORMAL
DISCONNECTION RANGE
OR SHORT (KX))
CIRCUIT (KZ))
ERROR CODE DK55KX (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS

OUT OF NORMAL RANGE (KX))
Action code Error code Forward-reverse potentiometer: Input signal is out of normal range
Trouble
CALL E04 DK55KX (KX) (Transmission controller system)
Contents of • Either of error codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and 2 and
trouble either of error codes [DK57KA] and [DK57KB] are displayed simultaneously.
Problem that
appears on
machine
• Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
Related
information
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
verse travel).

and standard
state
ERROR CODE DK55KZ (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR

SHORT CIRCUIT (KZ))
Action code Error code Forward-reverse potentiometer: Disconnection or short circuit (KZ))
Trouble
CALL E04 DK55KZ (Transmission controller system)
• When starting switch is turned ON, either of forward-reverse potentiometer systems 1 and 2 is abnor-
Contents of
mal, then either of error codes [DK56KA] and [DK56KB] and either of error codes [DK57KA] and
trouble
[DK57KB] are displayed simultaneously.
Problem that
appears on
machine
Related • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
information verse travel).

and standard
state
20-544 D275A-5
1
ERROR CODE DK55L8 (FORWARD-REVERSE POTENTIOMETER: SEE TABLE
TROUBLESHOOTING (L8))
ERROR CODE DK55L8 (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))
Action code Error code Forward-reverse potentiometer: See table (L8)

Trouble
CALL E03 DK55L8 (Transmission controller system)
Contents of • Total signal voltage of each of forward-reverse potentiometer 1 system (FR3) and 2 system (FR4) is
trouble below 4.41V or above 5.59V.
Action of • Continues controlling with signal of normal one of forward-reverse potentiometer 1 system (FR3) and
controller 2 (FR4).
Problem that
appears on
machine
Related
information
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
verse travel).

and standard
state
D275A-5 20-545
1
ERROR CODE DK56KA (FORWARD-REVERSE POTENTIOMETER 1:
ERROR CODE DK56KA (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION

(KA))
Action code Error code Forward-reverse potentiometer 1: Disconnection (KA)

Trouble
CALL E03 DK56KA (Transmission controller system)
Contents of
• Signal voltage of forward-reverse potentiometer 1 system (FR3) is below 0.5V.
trouble
Action of
• Continues controlling with signal of forward-reverse potentiometer 2 system (FR4).
controller
Problem that
appears on
machine
• Input (Voltage) from forward-reverse potentiometer 1 (FR3) can be checked in monitoring mode.
Related (Code 50200: Voltage of forward-reverse potentiometer 1)
information • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/re-
verse travel).

Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
Defective forward-reverse without turning starting switch ON.
Between L – J
potentiometer 1 (Internal
2
disconnection or short cir- 2kΩ ± 20%
cuit) Between K – L
Between K – J
and standard ness (Disconnection in wir- Wiring harness between TMCN1 (female) L –
ing or defective contact in TL1 (female) L
value in normal
state connector) Wiring harness between TMCN1 (female) 2 –
TL1 (female) K

(Contact with ground circuit) TMCN1 (female) 2 – TL1 (female) K with
chassis ground
5
Between 2 – K 0.5 – 4.5V
20-546 D275A-5
1
Circuit diagram related to forward-reverse potentiometer
D275A-5 20-547
1
ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: SHORT
TROUBLESHOOTING CIRCUIT (KB))
ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT

(KB))
Action code Error code Forward-reverse potentiometer 1: Short circuit (KB)

Trouble
CALL E03 DK56KB (Transmission controller system)
Contents of
• Signal voltage of forward-reverse potentiometer 1 system (FR3) is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
verse travel).

Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
Between L – J
2
Possible causes cuit) Between K – L
and standard Between K – J
TMCN1 (female) 2 – TL1 (female) K with
(Contact with 24V circuit) Resistance Max. 1V
chassis ground
4
Between 2 – K 0.5 – 4.5V
20-548 D275A-5
1
ERROR CODE DK57KA (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION

(KA))
Action code Error code Forward-reverse potentiometer 2: Disconnection (KA)

Trouble
CALL E03 DK57KA (Transmission controller system)
Contents of
• Signal voltage of forward-reverse potentiometer 2 system (FR4) is below 0.5V.
trouble
Action of
controller
Problem that
appears on
machine
verse travel).

Defective 5V sensor power ★ See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
Between O – Q
2
cuit) Between P – O
Between P – Q
and standard ness (Disconnection in wir- Wiring harness between TMCN1 (female) L –
ing or defective contact in TL1 (female) O
value in normal
state connector) Wiring harness between TMCN1 (female) I –
TL1 (female) P

(Contact with ground circuit) TMCN1 (female) I – TL1 (female) P with
chassis ground
5
D275A-5 20-549
1
20-550 D275A-5
1
ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: SHORT
ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT

(KB))
Action code Error code Forward-reverse potentiometer 2: Short circuit (KB)

Trouble
CALL E03 DK57KB (Transmission controller system)
Contents of
• Signal voltage of forward-reverse potentiometer 2 system (FR4) is above 4.5V.
trouble
Action of
controller
Problem that
appears on
machine
verse travel).

ness (Disconnection in wir- See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
ing or defective contact in troubleshooting for it first.
connector)
Between O – Q
2
Between P – O
Possible causes
and standard cuit)
value in normal Between P – Q
Short circuit with power carry out troubleshooting.
TMCN1 (female) I - TL1 (female) P with
chassis ground
4
Between I - K 0.5 – 4.5V
D275A-5 20-551
1
20
TROUBLESHOOTING ERROR CODE DK60KA (ACCELERATION SENSOR: DISCONNECTION (KA))
ERROR CODE DK60KA (ACCELERATION SENSOR: DISCONNECTION (KA))

Trouble Acceleration sensor: Disconnection (KA) (Steering controller system)
E01 DK60KA
Contents of
• Signal voltage of acceleration sensor is below 0.3V.
trouble
Action of
• Turns shoe slip control (SSC) function OFF.
controller
Problem that
appears on • Even if shoe slips, engine speed does not change.
machine
• Input (Voltage) from acceleration sensor can be checked in monitoring mode.
Related
(Code 60200: Voltage of acceleration sensor)
information

Defective 24V power source See if error code [DB36KK] is displayed. If it is displayed, carry out
1
Defective acceleration sen- carry out troubleshooting.
2
sor (Internal trouble) SS3 Voltage
Between 2 – 3 0.75 – 4.25V
Possible causes ness (Disconnection in wir- Wiring harness between STCN1 (female) L –
and standard ing or defective contact in SS3 (female) 1
value in normal connector) Wiring harness between STCN1 (female) 1 –
state SS3 (female) 2
(Contact with ground circuit) (female) 1 – SS3 (female) 2 with chassis Resistance Min. 1MΩ
ground
STCN1 Voltage
Between 1 – K 0.75 – 4.25V
Circuit diagram related to acceleration sensor
20-551-1 D275A-5
(6)
TROUBLESHOOTING ERROR CODE DK60KB (ACCELERATION SENSOR: SHORT CIRCUIT (KB))
ERROR CODE DK60KB (ACCELERATION SENSOR: SHORT CIRCUIT (KB))

Trouble Acceleration sensor: Short circuit (KB) (Steering controller system)
E01 DK60KB
Contents of
• Signal voltage of acceleration sensor is above 4.7V.
trouble
Action of
• Turns shoe slip control (SSC) function OFF.
controller
Problem that
appears on • Even if shoe slips, engine speed does not change.
machine
• Input (Voltage) from acceleration sensor can be checked in monitoring mode.
Related
(Code 60200: Voltage of acceleration sensor)
information

1
Defective acceleration sen- carry out troubleshooting.
2
sor (Internal trouble) SS3 Voltage
Possible causes Between 2 – 3 0.75 – 4.25V
and standard ★ Prepare with starting switch OFF, then turn starting switch ON and
value in normal Short circuit with power carry out troubleshooting.
state 3 source in wiring harness Short circuit of wiring harness between
(Contact with 24V circuit) STCN1 (female) 1 – SS3 (female) 2 with Voltage Max. 1V
chassis ground
STCN1 Voltage
Between 1 – K 0.75 – 4.25V
Circuit diagram related to acceleration sensor
D275A-5 20-551-2
(6)
TROUBLESHOOTING ERROR CODE DKH1KA (PITCH ANGLE SENSOR: DISCONNECTION (KA))
ERROR CODE DKH1KA (PITCH ANGLE SENSOR: DISCONNECTION (KA))

Trouble Pitch angle sensor: Disconnection (KA) (Steering controller system)
CALL E03 DKH1KA
Contents of
• Signal voltage of pitch angle sensor is below 0.15V.
trouble
Action of
• Cannot recognize pitch angle.
controller
Problem that • Shocks are made when gear is shifted on slope and when machine is steered on level place.
• Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
Related
(Code 60100: Voltage of pitch angle sensor)
information

1
Defective pitch angle sen- carry out troubleshooting.
2
sor (Internal trouble) PT1 Voltage
Between B – A 0.15 – 4.85V
ness (Disconnection in wir- Wiring harness between STCN1 (female) F –
ing or defective contact in PT1 (female) C
Possible causes
and standard
value in normal connector) Wiring harness between STCN1 (female) C –
PT1 (female) B
state
(Contact with ground circuit) (female) C – PT1 (female) B with chassis
ground
STCN1 Voltage
Between C – K 0.15 – 4.85V
Circuit diagram related to pitch angle sensor
20-552 D275A-5
1
TROUBLESHOOTING ERROR CODE DKH1KB (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE DKH1KB (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB))

Trouble Pitch angle sensor: Short circuit (KB) (Steering controller system)
CALL E03 DKH1KB
Contents of
• Signal voltage of pitch angle sensor is above 4.85V.
trouble
Action of
• Cannot recognize pitch angle.
controller
Problem that • Shocks are made when gear is shifted on slope and when machine is steered on level place.
• Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
Related
(Code 60100: Voltage of pitch angle sensor)
information

1
Defective pitch angle sen- carry out troubleshooting.
2
sor (Internal trouble) PT1 Voltage
Possible causes Between B – A 0.15 – 4.85V
and standard ★ Prepare with starting switch OFF, then turn starting switch ON and
value in normal Short circuit with power carry out troubleshooting.
state 3 source in wiring harness
(female) C – PT1 (female) B with chassis
ground
STCN1 Voltage
Between C – K 0.15 – 4.85V
Circuit diagram related to pitch angle sensor
D275A-5 20-553
1
TROUBLESHOOTING ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: SEE TABLE (LC))
ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: SEE TABLE (LC))
Action code Error code Engine Ne speed sensor: See table (LC)
Trouble
CALL E03 DEL3LC (Engine controller system)
Contents of
• Cylinders cannot be identified by signal of engine NE speed sensor.
trouble
Problem that • Engine speed may become unstable or engine may stop.
Related • Special adapter (799-601-9410) is necessary for troubleshooting for engine Ne speed sensor.

Defective engine Ne speed without turning starting switch ON.
1 sensor (Internal disconnec- NE (male) Resistance
tion or short circuit) Between 1 – 2 85 – 210Ω
ness (Disconnection in wir- Wiring harness between ECN2 (female) Z –
ing or defective contact in NE (female) 1
connector) Wiring harness between ECN2 (female) P –
NE (female) 2
and standard
(female) Z – NE (female) 1 with chassis Resistance Min. 1MΩ
ground
(female) P – NE (female) 2 with chassis Resistance Min. 1MΩ
ground
Between Z – P 85 – 210Ω
Between Z, P – chassis ground Min. 1MΩ
20-554 D275A-5
1
TROUBLESHOOTING ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: SEE TABLE (LC))
Circuit diagram related to engine Ne speed sensor
D275A-5 20-555
1
ERROR CODE DLF1KA (TRANSMISSION OUTPUT SPEED SENSOR:
ERROR CODE DLF1KA (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION

(KA))
Action code Error code Transmission output speed sensor: Disconnection (KA)
Trouble
E01 DLF1KA (Engine controller system)
Contents of
• Signal is not input from transmission output speed sensor.
trouble
controller • Assumes that transmission output speed is 0rpm.
Problem that
• Transmission speed cannot be monitored.
appears on
• Traction force cannot be calculated.
machine
• Input (rpm) from transmission output speed sensor can be checked in monitoring mode.
Related
(Code 31400: Transmission speed
information
• Method of reproducing error code: Start engine and travel machine actually.

Defective transmission out- carry out troubleshooting.
put speed sensor (Internal
1 TM1 (male) Resistance
disconnection or short cir-
Between 1 – 2 500 – 1,000Ω
cuit)
ness (Disconnection in wir- Wiring harness between TMCN2 (female) T –
Possible causes ing or defective contact in TM1 (female) 1
and standard connector) Wiring harness between TMCN2 (female) ] –
value in normal TM1 (female) 2
(Contact with ground circuit) TMCN2 (female) T – TM1 (female) 1 with Resistance Min. 1MΩ
chassis ground
4
troller
Between T – ] 500 – 1,000Ω
Between T – chassis ground Min. 1MΩ
Circuit diagram related to transmission output speed sensor
20-556 D275A-5
1
TROUBLESHOOTING ERROR CODE DLH1LC (ENGINE G SPEED SENSOR: SEE TABLE (LC))
ERROR CODE DLH1LC (ENGINE G SPEED SENSOR: SEE TABLE (LC))
Action code Error code Engine G speed sensor: See table (LC)
Trouble
CALL E03 DLH1LC (Engine controller system)
Contents of
• Signal of engine G speed sensor does not match to signal of engine Ne speed sensor.
trouble
Problem that
appears on
machine
Related • Special adapter (799-601-9410) is necessary for troubleshooting for engine Ne speed sensor.

Defective engine G speed carry out troubleshooting.
1 sensor (Internal disconnec- G (male) Resistance
tion or short circuit) Between 1 – 2 1.4k – 3.5kΩ
ness (Disconnection in wir- Wiring harness between ECN2 (female) Y – G
ing or defective contact in (female) 1
connector) Wiring harness between ECN2 (female) O – G
Possible causes (female) 2
(female) Y – G (female) 1 with chassis Resistance Min. 1MΩ
ground
(female) O – G (female) 2 with chassis Resistance Min. 1MΩ
ground
ECN2 (female) Resistance
Between Y – O 1.4k – 3.5kΩ
Between Y, O –
Min. 1MΩ
chassis ground
Circuit diagram related to engine G speed sensor
D275A-5 20-557
1
TROUBLESHOOTING ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT (KB))
ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT (KB))

Trouble Caution buzzer: Short circuit (KB) (Monitor panel system)
E02 DV00KB
Contents of
• Abnormal current flowed when caution buzzer circuit output ground signal.
trouble
Action of • Flashes caution lamp.
controller • Stops caution buzzer circuit from outputting ground signal.
Problem that
appears on • Caution buzzer does not sound.
machine
Related • Method of reproducing error code: Turn starting switch ON (When it is turned ON, buzzer sounds for
information 1 second).

Defective caution buzzer without turning starting switch ON.
1
(Internal short circuit) 217 (male) Resistance
Between 1 – 2 200Ω
Possible causes Short circuit with power carry out troubleshooting.
and standard 2 source in wiring harness
Short circuit of wiring harness between 217 (fe-
value in normal (Contact with 24V circuit) Voltage Max. 1V
male) 1 – S03 (female) H with chassis ground
state
S03 Caution buzzer Voltage
3 Defective monitor panel
When turned OFF 20 – 30V
Between H –
When turned ON
chassis ground Max. 3V
(sounding)
Circuit diagram related to caution buzzer
20-558 D275A-5
1
ERROR CODE DW59KA (BLADE DUAL SELECTOR SOLENOID:
ERROR CODE DW59KA (BLADE DUAL SELECTOR SOLENOID: DISCONNECTION (KA))
Action code Error code Blade dual selector solenoid: Disconnection (KA)
Trouble
E01 DW59KA (Transmission controller system)
Contents of
• When signal is output to blade dual selector solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to blade dual selector solenoid circuit.
controller
Problem that
appears on • Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works).
machine
• Output (Current) to blade dual selector solenoid can be checked in monitoring mode.]
Related
(Code 70600: Blade dual solenoid drive current)
information
• Method of reproducing error code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selec- without turning starting switch ON.
1 tor solenoid (Internal short
PPA (male) Resistance
circuit)
Between 1 – 2 10 – 40Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) Q –
Possible causes ing or defective contact in PPA (female) 1
and standard connector) Wiring harness between TMCN3 (female) M –
value in normal PPA (female) 2
(Contact with 24V circuit) TMCN3 (female) Q – PPA (female) 1 with Voltage Max. 1V
chassis ground
4
troller TMCN3 (female) Resistance
Between Q – M 10 – 40Ω
Circuit diagram related to blade dual selector solenoid
D275A-5 20-559
1
ERROR CODE DW59KB (BLADE DUAL SELECTOR SOLENOID: SHORT
ERROR CODE DW59KB (BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Blade dual selector solenoid: Short circuit (KB)
Trouble
E01 DW59KB (Transmission controller system)
Contents of
• When signal is output to blade dual selector solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to blade dual selector solenoid circuit.
controller
Problem that
appears on • Blade dual tilt mechanism does not work (When it is operated, single tilt mechanism works).
machine
• Output (Current) to blade dual selector solenoid can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Turn starting switch ON and perform blade dual tilt operation.

Defective blade dual selec- without turning starting switch ON.
1 tor solenoid (Internal short PPA (male) Resistance
circuit) Between 1 – 2 10 – 40Ω
value in normal 2 ground in wiring harness Short circuit of wiring harness between
state (Contact with ground circuit) TMCN3 (female) Q – PPA (female) 1 with Resistance Min. 1MΩ
chassis ground
3
troller
Between Q – M 10 – 40Ω
Between Q – chassis ground Min. 1MΩ
Circuit diagram related to blade dual selector solenoid
20-560 D275A-5
1
ERROR CODE DW5AKA (BLADE PITCH SELECTOR SOLENOID:
ERROR CODE DW5AKA (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA))
Action code Error code Blade pitch selector solenoid: Disconnection (KA)
Trouble
E02 DW5AKA (Transmission controller system)
Contents of
• When signal is output to blade pitch selector solenoid circuit, any current does not flow.
trouble
controller • Stops outputting to blade pitch selector solenoid circuit.
Problem that
appears on • Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
machine
• Output (Current) to blade pitch selector solenoid can be checked in monitoring mode.
Related
(Code 31625: Blade pitch solenoid drive current)
information
• Method of reproducing service code: Turn starting switch ON and perform blade pitch operation.

Defective blade pitch selec- without turning starting switch ON.
1 tor solenoid (Internal short
PDS (male) Resistance
circuit)
Between 1 – 2 10 – 40Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) [ –
Possible causes ing or defective contact in PDS (female) 1
value in normal PDS (female) 2
(Contact with 24V circuit) TMCN3 (female) [ – PDS (female) 1 with Voltage Max. 1V
chassis ground
4
Between [ – M 10 – 40Ω
Circuit diagram related to blade pitch selector solenoid
D275A-5 20-561
1
ERROR CODE DW5AKB (BLADE PITCH SELECTOR SOLENOID: SHORT
ERROR CODE DW5AKB (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Blade pitch selector solenoid: Short circuit (KB)
Trouble
E02 DW5AKB (Transmission controller system)
Contents of
• When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.
trouble
controller • Stops outputting to blade pitch selector solenoid circuit.
Problem that
appears on • Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
machine
• Output (Current) to blade pitch selector solenoid can be checked in monitoring mode.
Related
information
• Method of reproducing service code: Turn starting switch ON and perform blade pitch operation.

Defective blade pitch selec- without turning starting switch ON.
1 tor solenoid (Internal short PDS (male) Resistance
circuit) Between 1 – 2 10 – 40Ω
value in normal 2 ground in wiring harness Short circuit of wiring harness between
state (Contact with ground circuit) TMCN3 (female) [ – PDS (female) 1 with Resistance Min. 1MΩ
chassis ground
3
troller
Between [ – M 10 – 40Ω
Between [ – chassis ground Min. 1MΩ
Circuit diagram related to blade pitch selector solenoid
20-562 D275A-5
1
ERROR CODE DWN3KA (SUDDEN STOP PREVENTION SOLENOID:
ERROR CODE DWN3KA (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION

(KA))
Action code Error code Sudden stop prevention solenoid: Disconnection (KA)
Trouble
CALL E04 DWN3KA (Steering controller system)
Contents of
• When signal is output to sudden stop prevention solenoid circuit, any current does not flow.
trouble
Problem that • Brake is applied lightly during travel.
• Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode.
Related
(Code 31628: Sudden stop prevention solenoid drive current)
information

Defective sudden stop pre- without turning starting switch ON.
1 vention solenoid (Internal
STB (male) Resistance
disconnection)
Between 1 – 2 5 – 25Ω
Possible causes ing or defective contact in STB (female) 1
and standard connector) Wiring harness between STCN3 (female) M –
value in normal STB (female) 2
3 source in wiring harness Short circuit of wiring harness between STCN3
(Contact with 24V circuit) (female) 7 – STB (female) 1 with chassis Voltage Max. 1V
ground
STCN3 Resistance
Between 7 – M 5 – 25Ω
Circuit diagram related to sudden stop prevention solenoid
D275A-5 20-563
1
ERROR CODE DWN3KB (SUDDEN STOP PREVENTION SOLENOID: SHORT
ERROR CODE DWN3KB (SUDDEN STOP PREVENTION SOLENOID: SHORT CIRCUIT

(KB))
Action code Error code Sudden stop prevention solenoid: Short circuit (KB)
Trouble
CALL E04 DWN3KB (Steering controller system)
Contents of
• When signal was output to sudden stop prevention solenoid circuit, abnormal current flowed.
trouble
• Output (Current) to sudden stop prevention solenoid can be checked in monitoring mode.
Related
(Code 31628: Sudden stop prevention solenoid drive current)
information

Defective sudden stop pre- without turning starting switch ON.
1 vention solenoid (Internal STB (male) Resistance
short circuit) Between 1 – 2 5 – 25Ω
Possible causes (Contact with ground circuit) (female) 7 – STB (female) 1 with chassis Resistance Min. 1MΩ
and standard ground
Short circuit in wiring har-
Short circuit in wiring harness between STCN3
3 ness (with another wiring
(female) 7 – STB (female) 1 with wiring har-
harness) Resistance Min. 1MΩ
ness between STCN3 (female) M – STB (fe-
male) 2
4 Defective steering controller STCN3 Resistance
Between 7 – M 5 – 25Ω
Circuit diagram related to sudden stop prevention solenoid
20-564 D275A-5
1
TROUBLESHOOTING ERROR CODE DWN5KA (FAN PUMP SOLENOID: DISCONNECTION (KA))
ERROR CODE DWN5KA (FAN PUMP SOLENOID: DISCONNECTION (KA))
Action code Error code Fan pump solenoid: Disconnection (KA)

Trouble
E01 DWN5KA (Transmission controller system)
Contents of
• When signal is output to fan pump solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to fan pump solenoid circuit.
controller
Problem that
appears on • Fan speed is kept at maximum level.
machine
• Output (Current) to fan pump solenoid can be checked in monitoring mode.
Related
(Code 31623, 31624: Cooling fan solenoid output current)
information
• Method of reproducing service code: Turn starting switch ON.

Defective fan pump sole- without turning starting switch ON.
1 noid (Internal disconnec-
FAC (male) Resistance
tion)
Between 1 – 2 15 – 25Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) G –
Possible causes ing or defective contact in FAC (female) 1
value in normal FAC (female) 2
(Contact with 24V circuit) TMCN3 (female) G – FAC (female) 1 with Voltage Max. 1V
chassis ground
4
Between G – M 15 – 25Ω
Circuit diagram related to fan pump solenoid
D275A-5 20-565
1
TROUBLESHOOTING ERROR CODE DWN5KB (FAN PUMP SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DWN5KB (FAN PUMP SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Fan pump solenoid: Short circuit (KB)
Trouble
E01 DWN5KB (Transmission controller system)
Contents of
• When signal was output to fan pump solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to fan pump solenoid circuit.
controller
Problem that
appears on • Fan speed is kept at maximum level.
machine
• Output (Current) to fan pump solenoid can be checked in monitoring mode.
Related
(Code 31623, 31624: Cooling fan solenoid output current)
information
• Method of reproducing service code: Turn starting switch ON.

Defective fan pump sole- FAC (male) Resistance
1
noid (Internal short circuit)
Between 1 – 2 15 – 25Ω
Possible causes (Contact with ground circuit) TMCN3 (female) G – FAC (female) 1 with Resistance Min. 1MΩ
and standard chassis ground
Short circuit in wiring harness between TMCN3
3 ness (with another wiring
harness) (female) G – FAC (female) 1 with wiring har-
ness between TMCN3 (female) M – FAC (fe-
male) 2
Defective transmission con- TMCN3 Resistance
4
troller
Between G – M 15 – 25Ω
Between G – chassis ground Min. 1MΩ
Circuit diagram related to fan pump solenoid
20-566 D275A-5
1
TROUBLESHOOTING ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code 1st clutch ECMV: Disconnection (KA)

Trouble
CALL E03 DXH4KA (Transmission controller system)
Contents of
• When signal is output to 1st clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 1st clutch solenoid circuit.
controller
Problem that • Automatic shift-down function does not work.
• Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
Related
(Code 31602, 31612: Output current of 1st clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine in F1 or R1.

Defective 1st clutch sole- without turning starting switch ON.
1
noid (Internal short circuit) S1T (male) Resistance
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) E –
Possible causes ing or defective contact in S1T (female) 1
and standard connector) Wiring harness between TMCN3 (female) 3 –
value in normal S1T (female) 2
(Contact with 24V circuit) TMCN3 (female) E – S1T (female) 1 with Voltage Max. 1V
chassis ground
Defective transmission con- without turning starting switch ON.
4
Between E – 3 5 – 15Ω
D275A-5 20-567
1
(5)
TROUBLESHOOTING ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code 1st clutch ECMV: Short circuit (KB)
Trouble
CALL E03 DXH4KB (Transmission controller system)
Contents of
• When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 1st clutch solenoid circuit.
controller
Problem that • Automatic shift-down function does not work.
• Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
Related
(Code 31602, 31612: Output current of 1st clutch ECMV)
information

Defective 1st clutch sole- S1T (male) Resistance
1
Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) TMCN3 (female) E – S1T (female) 1 with Resistance Min. 1MΩ
3 ness (with another wiring Short circuit in wiring harness between TMCN3
(female) E – S1T (female) 1 with wiring har-
ness between TMCN3 (female) 3 – S1T (fe-
male) 2
4
troller
Between E – 3 5 – 15Ω
Between E – chassis ground Min. 1MΩ
20-568 D275A-5
1
(5)
TROUBLESHOOTING ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code 2nd clutch ECMV: Disconnection (KA)

Trouble
Contents of
• When signal is output to 2nd clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 2nd clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
Related
(Code 31603, 31613: Output current of 2nd clutch ECMV)
information

Defective 2nd clutch sole- without turning starting switch ON.
1
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) Z –
and standard connector) Wiring harness between TMCN3 (female) C –
(Contact with 24V circuit) TMCN3 (female) Z – S2T (female) 1 with Voltage Max. 1V
chassis ground
4
Between Z – C 5 – 15Ω
D275A-5 20-569
1
(5)
TROUBLESHOOTING ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code 2nd clutch ECMV: Short circuit (KB)
Trouble
Contents of
• When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 2nd clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
Related
(Code 31603, 31613: Output current of 2nd clutch ECMV)
information

Defective 2nd clutch sole- S2T (male) Resistance
1
Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) TMCN3 (female) Z – S2T (female) 1 with Resistance Min. 1MΩ
(female) Z – S2T (female) 1 with wiring har-
ness between TMCN3 (female) C – S2T (fe-
male) 2
4
troller
Between Z – C 5 – 15Ω
Between Z – chassis ground Min. 1MΩ
20-570 D275A-5
1
(5)
TROUBLESHOOTING ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code 3rd clutch ECMV: Disconnection (KA)

Trouble
Contents of
• When signal is output to 3rd clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 3rd clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
Related
(Code 31604, 31614: Output current of 3rd clutch ECMV)
information

Defective 3rd clutch sole- without turning starting switch ON.
1
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) 5 –
and standard connector) Wiring harness between TMCN3 (female) 3 –
(Contact with 24V circuit) TMCN3 (female) 5 – S3T (female) 1 with Voltage Max. 1V
chassis ground
4
Between 5 – 3 5 – 15Ω
D275A-5 20-571
1
(5)
TROUBLESHOOTING ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code 3rd clutch ECMV: Short circuit (KB)
Trouble
Contents of
• When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission 3rd clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
Related
(Code 31604, 31614: Output current of 3rd clutch ECMV)
information

Defective 3rd clutch sole- S3T (male) Resistance
1
Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) TMCN3 (female) 5 – S3T (female) 1 with Resistance Min. 1MΩ
(female) 5 – S3T (female) 1 with wiring har-
ness between TMCN3 (female) 3 – S3T (fe-
male) 2
4
troller
Between 5 – 3 5 – 15Ω
20-572 D275A-5
1
(5)
TROUBLESHOOTING ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code Reverse clutch ECMV: Disconnection (KA)

Trouble
Contents of
• When signal is output to reverse clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission reverse clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1.
machine
• Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine in reverse.

Defective reverse clutch so- without turning starting switch ON.
1
lenoid (Internal short circuit) SRT (male) Resistance
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) O –
Possible causes ing or defective contact in SRT (female) 1
value in normal SRT (female) 2
(Contact with 24V circuit) TMCN3 (female) O – SRT (female) 1 with Voltage Max. 1V
chassis ground
4
Between O – C 5 – 15Ω
D275A-5 20-573
1
(5)
TROUBLESHOOTING ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Reverse clutch ECMV: Short circuit (KB)
Trouble
Contents of
• When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission reverse clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to F1.
machine
• Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine in reverse.

Defective reverse clutch so- SRT (male) Resistance
1
lenoid (Internal short circuit)
Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) TMCN3 (female) O – SRT (female) 1 with Resistance Min. 1MΩ
(female) O – SRT (female) 1 with wiring har-
ness between TMCN3 (female) C – SRT (fe-
male) 2
4
troller
Between O – C 5 – 15Ω
Between O – chassis ground Min. 1MΩ
20-574 D275A-5
1
(5)
TROUBLESHOOTING ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code Forward clutch ECMV: Disconnection (KA)

Trouble
Contents of
• When signal is output to forward clutch solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission forward clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to R1.
machine
• Output (Current) to forward clutch solenoid can be checked in monitoring mode.
Related
(Code 31608, 31622: Output current of forward clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine forward.

Defective forward clutch so- without turning starting switch ON.
1
lenoid (Internal short circuit) SFT (male) Resistance
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) Y –
Possible causes ing or defective contact in SFT (female) 1
value in normal SFT (female) 2
(Contact with 24V circuit) TMCN3 (female) Y – SFT (female) 1 with Voltage Max. 1V
chassis ground
4
Between Y – C 5 – 15Ω
D275A-5 20-575
1
(5)
TROUBLESHOOTING ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Forward clutch ECMV: Short circuit (KB)
Trouble
Contents of
• When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to transmission forward clutch solenoid circuit.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to R1.
machine
• Output (Current) to forward clutch solenoid can be checked in monitoring mode.
Related
(Code 31608, 31622: Output current of forward clutch ECMV)
information
• Method of reproducing service code: Start engine and drive machine forward.

Defective forward clutch so- SFT (male) Resistance
1
lenoid (Internal short circuit)
Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) TMCN3 (female) Y – SFT (female) 1 with Resistance Min. 1MΩ
(female) Y – SFT (female) 1 with wiring har-
ness between TMCN3 (female) C – SFT (fe-
male) 2
4
troller
Between Y – C 5 – 15Ω
Between Y – chassis ground Min. 1MΩ
20-576 D275A-5
1
(5)
TROUBLESHOOTING ERROR CODE DXH9KA (RIGHT CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXH9KA (RIGHT CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code Right clutch ECMV: Disconnection (KA)

Trouble
CALL E03 DXH9KA (Steering controller system)
Contents of
• Any current does not flow at output for the right steering clutch solenoid circuit.
trouble
Action of
• Stops outputting to the right steering clutch solenoid.
controller
Problem that • Machine cannot turn (cannot be steered) to right.
• The output state (current) to the right steering clutch solenoid can be checked in monitoring mode.
Related (Codes 50601, 50603: Right clutch ECMV output current)
information • Method of reproducing error code: Starting switch ON + Parking brake lever reset + PCCS lever op-
eration (Right steering)

Defective right steering without turning starting switch ON.
1 clutch solenoid (Internal
SRC (male) Resistance
short)
Between 1 – 2 5 – 15Ω
Disconnection of wiring
Wiring harness between STCN3 (female) Y –
Possible causes 2 harness (Disconnection/ Resistance Max. 1Ω
SRC (female) 1
and standard Defective contact)
Wiring harness between STCN3 (female) 3 –
value in normal Resistance Max. 1Ω
SRC (female) 2
state
Short circuit with power troubleshooting.
Wiring harness between STCN3 (female) Y –
(Contact with 24-V circuit) Voltage Max. 1V
SRC (female) 1 with chassis ground
STCN3 (female) Resistance
Between Y – 3 5 – 15Ω
D275A-5 20-577
1
(5)
TROUBLESHOOTING ERROR CODE DXH9KB (RIGHT CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXH9KB (RIGHT CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Right clutch ECMV: Short circuit (KB)
Trouble
CALL E03 DXH9KB (Steering controller system)
Contents of
• Abnormal current flows at output for the right steering clutch solenoid circuit.
trouble
Action of
• Stops outputting to the right steering clutch solenoid.
controller
Problem that • Machine cannot turn (cannot be steered) to right.
• The output state (current) to the right steering clutch solenoid can be checked in monitoring mode.
Related (Codes 50601, 50603: Right clutch ECMV output current)
eration (Right steering)

1 clutch solenoid (Internal SRC (male) Resistance
short) Between 1 – 2 5 – 15Ω
Possible causes ground circuit) Wiring harness between STCN3 (female) Y –
and standard SRC (female) 1 with chassis ground
state Short circuit in wiring without turning starting switch ON.
harness (Short circuit of
3 Wiring harness between TCN3 (female) Y -
wiring harnesses with each
SRC (female) 1 with wiring harness between Resistance Min. 1MΩ
other)
STCN3 (female) 3 - SRC (female) 2
Between Y – 3 5 – 15Ω
Between Y – chassis ground Min. 1MΩ
20-578 D275A-5
1
(5)
TROUBLESHOOTING ERROR CODE DXHAKA (LEFT CLUTCH ECMV: DISCONNECTION (KA))
ERROR CODE DXHAKA (LEFT CLUTCH ECMV: DISCONNECTION (KA))
Action code Error code Left clutch ECMV: Disconnection (KA)

Trouble
CALL E03 DXHAKA (Steering controller system)
Contents of
• Any current does not flow at output for the left steering clutch solenoid circuit.
trouble
Action of
• Stops outputting to the left steering clutch solenoid.
controller
Problem that • Machine cannot turn (cannot be steered) to left.
• The output state (current) to the left steering clutch solenoid can be checked in monitoring mode.
Related (Codes 50600, 50602: Left clutch ECMV output current)
eration (Left steering)

Defective left steering clutch without turning starting switch ON.
1
solenoid (Internal short) SLC (male) Resistance
Between 1 – 2 5 – 15Ω
Disconnection of wiring
Wiring harness between STCN3 (female) O –
Possible causes 2 harness (Disconnection/ Resistance Max. 1Ω
SLC (female) 1
and standard Defective contact)
Wiring harness between STCN3 (female) 3 –
SLC (female) 2
state
Short circuit with power troubleshooting.
Wiring harness between STCN3 (female) O –
(Contact with 24-V circuit) Voltage Max. 1V
SLC (female) 1 with chassis ground
Between O – 3 5 – 15Ω
D275A-5 20-579
1
(5)
TROUBLESHOOTING ERROR CODE DXHAKB (LEFT CLUTCH ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXHAKB (LEFT CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Left clutch ECMV: Short circuit (KB)
Trouble
CALL E03 DXHAKB (Steering controller system)
Contents of
• Abnormal current flows at output for the left steering clutch solenoid circuit.
trouble
Action of
• Stops outputting to the left steering clutch solenoid.
controller
Problem that • Machine cannot turn (cannot be steered) to left.
• The output state (current) to the left steering clutch solenoid can be checked in monitoring mode.
Related (Codes 50600, 50602: Left clutch ECMV output current)
eration (Left steering)

Defective left steering clutch
1 SLC (male) Resistance
solenoid (Internal short)
Between 1 – 2 5 – 15Ω
Possible causes ground circuit) Wiring harness between STCN3 (female) O –
and standard SLC (female) 1 with chassis ground
state Short circuit in wiring without turning starting switch ON.
harness (Short circuit of
3 Wiring harness between TCN3 (female) O -
wiring harnesses with each
SLC (female) 1 with wiring harness between Resistance Min. 1MΩ
other)
STCN3 (female) 3 - SLC (female) 2
Between O – 3 5 – 15Ω
Between O – chassis ground Min. 1MΩ
20-580 D275A-5
1
(5)
TROUBLESHOOTING ERROR CODE DXHBKA (RIGHT BRAKE ECMV: DISCONNECTION (KA))
ERROR CODE DXHBKA (RIGHT BRAKE ECMV: DISCONNECTION (KA))
Action code Error code Right brake ECMV: Disconnection (KA)

Trouble
CALL E04 DXHBKA (Steering controller system)
Contents of
• When signal is output to right steering brake solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to right steering brake solenoid circuit.
controller
• Limits operation of engine, transmission and brake.
• Output (Current) to right steering brake solenoid can be checked in monitoring mode.
Related
(Code 31620, 31618: Output current of right steering brake ECMV)
information
• Method of reproducing service code: Turn starting switch ON and release parking brake lever.

1 brake solenoid (Internal
SRB (male) Resistance
short circuit)
Between 1 – 2 5 – 15Ω
ness (Disconnection in wir- Wiring harness between STCN3 (female) E –
Possible causes ing or defective contact in SRB (female) 1
and standard connector) Wiring harness between STCN3 (female) C –
value in normal SRB (female) 2
(Contact with 24V circuit) (female) E – SRB (female) 1 with chassis Voltage Max. 1V
ground
Between E – C 5 – 15Ω
D275A-5 20-581
1
(5)
TROUBLESHOOTING ERROR CODE DXHBKB (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXHBKB (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB))
Action code Error code Right brake ECMV: Short circuit (KB)
Trouble
CALL E04 DXHBKB (Steering controller system)
Contents of
• When signal was output to right steering brake solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to right steering brake solenoid circuit.
controller
• Output (Current) to right steering brake solenoid can be checked in monitoring mode.
Related
(Code 31620, 31618: Output current of right steering brake ECMV)
information
• Method of reproducing service code: Start engine and release parking brake lever.

1 brake solenoid (Internal SRB (male) Resistance
short circuit) Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) (female) E – SRB (female) 1 with chassis Resistance Min. 1MΩ
and standard ground
3 ness (with another wiring Short circuit in wiring harness between STCN3
(female) E – SRB (female) 1 with wiring har-
ness between STCN3 (female) C – SRB (fe-
male) 2
Between E – C 5 – 15Ω
Between E – chassis ground Min. 1MΩ
20-582 D275A-5
1
(5)
TROUBLESHOOTING ERROR CODE DXHCKA (LEFT BRAKE ECMV: DISCONNECTION (KA))
ERROR CODE DXHCKA (LEFT BRAKE ECMV: DISCONNECTION (KA))
Action code Error code Left brake ECMV: Disconnection (KA)

Trouble
CALL E04 DXHCKA (Steering controller system)
Contents of
• When signal is output to left steering brake solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to left steering brake solenoid circuit.
controller
• Limits operation of engine, transmission and brake.
• Output (Current) to left steering brake solenoid can be checked in monitoring mode.
Related
(Code 31621, 31619: Output current of left steering brake ECMV)
information
• Method of reproducing service code: Turn starting switch ON and release parking brake lever.

Defective left steering brake without turning starting switch ON.
1 solenoid (Internal short cir-
SLB (male) Resistance
cuit)
Between 1 – 2 5 – 15Ω
Possible causes ing or defective contact in SLB (female) 1
and standard connector) Wiring harness between STCN3 (female) C –
value in normal SLB (female) 2
(Contact with 24V circuit) (female) 5 – SLB (female) 1 with chassis Voltage Max. 1V
ground
Between 5 – C 5 – 15Ω
D275A-5 20-583
1
(5)
TROUBLESHOOTING ERROR CODE DXHCKB (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))
ERROR CODE DXHCKB (LEFT BRAKE ECMV: SHORT CIRCUIT (KB))
Action code Error code Left brake ECMV: Short circuit (KB)
Trouble
CALL E04 DXHCKB (Steering controller system)
Contents of
• When signal was output to left steering brake solenoid circuit, abnormal current flowed.
trouble
Action of
• Stops outputting to left steering brake solenoid circuit.
controller
• Output (Current) to left steering brake solenoid can be checked in monitoring mode.
Related
(Code 31621, 31619: Output current of left steering brake ECMV)
information
• Method of reproducing error code: Start engine and release parking brake lever.

Defective left steering brake without turning starting switch ON.
1 solenoid (Internal short cir- SLB (male) Resistance
cuit) Between 1 – 2 5 – 15Ω
Possible causes (Contact with ground circuit) (female) 5 – SLB (female) 1 with chassis Resistance Min. 1MΩ
and standard ground
3 ness (with another wiring Short circuit in wiring harness between STCN3
(female) 5 – SLB (female) 1 with wiring har-
ness between STCN3 (female) C – SLB (fe-
male) 2
Between 5 – C 5 – 15Ω
20-584 D275A-5
1
(5)
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E-MODE)
Information described in troubleshooting list ........................................................................................... 20- 602

E-1 The engine does not start. ............................................................................................................... 20- 603
E-2 The preheater does not operate. (Manual preheating function) ....................................................... 20- 605
E-3 The ripper pin puller cylinder does not operate. ............................................................................... 20- 607
E-4 The monitor panel does not come on at all when the starting switch is turned ON. ....................... 20- 608
E-5 When the starting switch is turned ON, the monitor panel completely remains lighted
and does not go out. ......................................................................................................................... 20- 609
E-6 When the starting switch is turned on, the basic check items flash. ................................................ 20- 610
E-7 While the engine is operating, any caution item flashes. ................................................................. 20- 611
E-8 While the engine is operating, the emergency warning item flashes. .............................................. 20- 613
E-9 While the preheater is operating, the preheating pilot lamp does not come on. .............................. 20- 616
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on.
(Dual tilt-mounted machine) ........................................................................................................... 20- 618
E-11 The engine water temperature gauge does not indicate normally. ................................................. 20- 619
E-12 Indication of the power train temperature gauge is abnormal. ....................................................... 20- 620
E-13 The hydraulic oil temperature gauge does not indicate normally. .................................................. 20- 621
E-14 Indication of the fuel gauge is abnormal. ....................................................................................... 20- 622
E-15 Indications of gear speed and engine speed are abnormal. .......................................................... 20- 623
E-16 Indication of the shift mode service meter is abnormal. ................................................................. 20- 623
E-17 The warning lamp does not flash or does not go out. ..................................................................... 20- 624
E-18 The alarm buzzer does not sound or does not stop. ...................................................................... 20- 625
E-19 Auto shift down is not possible or is not released. ......................................................................... 20- 626
E-20 The alarm buzzer cannot be cancelled. ......................................................................................... 20- 627
E-21 The operator mode cannot be operated. ....................................................................................... 20- 628
E-22 The service mode cannot be operated. ......................................................................................... 20- 629
E-23 The back-up alarm does not sound. .............................................................................................. 20- 631
E-24 The night light, the headlamp, the working lamp and the rear lamp on the panel
do not come on. .............................................................................................................................. 20- 632
E-25 The air conditioner does not operate. ............................................................................................ 20- 636
D275A-5 20-601
1

★ Troubleshooting lists and related circuit diagrams contain the following information all together. Understand
the contents carefully and troubleshoot the machine.
Trouble Problem that appears on the machine.
Related
Information related to problems occurred or troubleshooting
information

<Described contents>
• Standard value in normal state required to judge the assumed
cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or the wiring harness is
disconnected.
• Grounding fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
• Defective hot short
2 A harness not connected to the power (24V) circuit comes into
contact with the power (24V) circuit.
• Defective short
Possible causes Cause by which a trouble is as- A harness of an independent circuit abnormally comes into con-
and standard sumed to be detected tact with one of another circuit.
value in normal (The order number indicates a
state serial number, not a priority se- <Notes on troubleshooting>
quence.) 1Method of indicating connector numbers and handling T-junc-
tion
3 For troubleshooting, insert or connect the T-junction adapter as
• When “male” or “female” is not indicated for a connector num-
ber, disconnect the connector, and insert the T-junction adapt-
er in both the male and female.
• When “male” or “female” is indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in
only either the male or female.
2Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as
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 trouble

• Connector No.: Indicates (Model-No. of pins) (Color).
• Arrow (⇔): Roughly indicates mounting place on machine.
20-602 D275A-5
1
TROUBLESHOOTING E-1
E-1 THE ENGINE DOES NOT START.
Trouble • The engine does not start.

• The engine start circuit has the neutral safety function, and the engine does not start unless the park-
ing lever is set to the lock position.
Related
• If “the monitor panel does not come on” or “the battery relay does not cause operating sound” when
information
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.

Battery voltage Battery specific gravity
1 Insufficient battery capacity
Min. 24V Min. 1.26
★ Prepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective starting switch (in- KEY (male) Switch position Resistance
2
ternal disconnection)
OFF Min. 1MΩ
Between 5 and 3
START Max. 1Ω
★ Prepare with the starting switch OFF, then start the engine and car-
ry out troubleshooting.
Defective neutral safety re-
3 If the engine starts in accordance with the engine starting arrange-
lay (internal disconnection)
ment after the neutral safety relay (NSF) is replaced with another one
while the starting switch is set to OFF, the relay is defective.
★ Prepare with the starting switch OFF, then turn the starting switch
Defective alternator (inter- ON and carry out troubleshooting.
4
nal short-circuit) Alternator Voltage
Between Terminal R and ground Max. 1V
Possible causes Starting motor Voltage
and standard Electric power supply : between
20 – 30V
value in normal Terminal ST/B and ground
state Detective starting motor (in- Charge : between ST/M2 2 and
5 Max. 1V
ternal defect) ground
Starting : between ST/M2 1 and
20 – 30V
ground
When the voltages of electric power supply, for charging and starting
are normal but the starting motor does not rotate, the starting motor
is defective.
Disconnection in wiring har- without turning the starting switch ON.
ness (disconnection in wir- Wiring harness between KEY (female) 3 and
ing or defective contact in NFS (female) 3
connector) Wiring harness between NSF (female) 5 and
ST/M2 (female) 1
ON and carry out troubleshooting.
Hot short circuit of wiring Hot short circuit of wiring harness between al-
ternator R terminal and ST/M2 (female) 2 or
TMCN1 (female) E or S04 (female) 9 with
ground (Note : While a hot short circuit occurs,
the battery charge level lamp comes on when
the starting switch is turned ON.)
D275A-5 20-603
1
TROUBLESHOOTING E-1
Engine start/charge-related circuit diagram
20-604 D275A-5
1
TROUBLESHOOTING E-2
E-2 THE PREHEATER DOES NOT OPERATE. (MANUAL PREHEATING FUNCTION)
Trouble • The preheater does not operate. (Manual preheating function)

★ This troubleshooting describes the procedures to be followed when the manual preheating function
cannot heat the electrical intake air heater mounting section. (When the preheating lamp only does
not come on, carry out the troubleshooting of “The preheating lamp does not come on.”)
Related • For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are
information available. When either function is performed, the preheating lamp comes on.
• If “the monitor panel does not come on” or “the battery relay does not cause operating sound” hen the
starting switch is turned ON, the main electric power supply system supposed to be out of order. So,
inspect the main electric power supply system.

Defective starting switch
1 KEY (male) Switch position Resistance
OFF Min. 1MΩ
Between 5 and 2
HEAT Max. 1Ω
★ Prepare with the starting switch OFF, then set the starting switch to
HEAT and carry out troubleshooting.
Heater relay Voltage
Electric power supply : between
Defective heater relay (in- 20 – 30V
2 Terminal HT/A (A) and ground
ternal defect)
Signal : between Terminal HT (C)
20 – 30V
and ground
When the both voltages of electric power supply and signal are nor-
Possible causes
and standard mal and no operating sound is caused, the heater relay is defective.
value in normal ★ Prepare with the starting switch OFF, then carry out troubleshooting
state Defective electrical intake without turning the starting switch ON.
3
air heater (internal defect) Electrical intake air heater Continuity
Between terminals Continue
Wiring harness between FS4-4 outlet and RHR
(female) 5
Disconnection in wiring har- Wiring harness between RHR (female) 3 and
ness (Disconnection in wir- KEY (female) 2 or heater relay HT (C) termi- Resistance Max. 1Ω
4
ing or defective contact in nal
connector) Wiring harness between battery relay c termi-
nal and starting motor, or heater relay A termi- Resistance Max. 1Ω
nal
Wiring harness between heater relay HT/B (B)
terminal and electrical intake air heater
D275A-5 20-605
1
TROUBLESHOOTING E-2
Engine preheat-related circuit diagram
20-606 D275A-5
1
TROUBLESHOOTING E-3
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE.
Trouble • The ripper pin puller cylinder does not operate.

Related
information

When the fuse is blown, a ground fault may have possibly occurred
to the circuit.
Defective pin puller switch without turning the starting switch ON.
2 (Internal disconnection or 263 (male) Switch Resistance
short circuit) Pull Max. 1Ω
Between 1 and 2
Press Min. 1MΩ
Defective pin puller solenoid without turning the starting switch ON.
3 (Internal disconnection or 224 (male) Resistance
short circuit) Between 1 and 2 10 – 80Ω
Between 1 and ground Min. 1MΩ
Possible causes ★ Prepare with the starting switch OFF, then carry out troubleshooting
and standard without turning the starting switch ON.
value in normal Disconnection of wiring har- Wiring harness between FS4-1 outlet and 263 Resistance
Max. 1Ω
state ness (Disconnection in wir- (female) 1
4
ing or defective contact in Wiring harness between 263 (female) 2 and
connector) 224 (female) 1
Wiring harness between 224 (female) 2 and
ground
Ground fault of wiring har-
Between wiring harness related to FS4-1 (out-
5 ness (Contact with ground Resistance Min. 1MΩ
let side) and ground
circuit)
Between wiring harness (between 263 (fe-
male) 2 and 224 (female) 1) and ground
Hot short circuit of wiring ON and carry out troubleshooting.
circuit) Between wiring harness (between 263 (fe-
Voltage Max. 1V
Circuit diagram related to ripper pin puller solenoid
D275A-5 20-607
1
TROUBLESHOOTING E-4
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH
IS TURNED ON.
Trouble • The monitor panel does not come on at all when the starting switch is turned ON.
Related • When the starting switch is turned ON, the gear speed indicator, the multi information section, the
information gauge section and the lamp section come on for 2 sec.

Defective circuit breaker When the circuit breaker is cut off, the circuit may have possibly been
1
(CB2) short-circuited with ground.
Disconnection of wiring har- without turning the starting switch ON.
ness (Disconnection in wir- Wiring harness between S03 (female) 1 2
ing or defective contact in and CB2 outlet
Possible causes connector) Wiring harness between S03 (female) 3 4
and ground
value in normal
state ★ Prepare with the starting switch OFF, then carry out troubleshooting
3 ness (Contact with ground
Between wiring harness related to CB2 (outlet
circuit) Resistance Min. 1MΩ
side) and ground
Defective monitor panel ON and carry out troubleshooting.
4
(Gauge/lamp module) S03 Voltage
Between 1 2 and 3 4 20 – 30V
Circuit diagram related to monitor panel electric power supply
20-608 D275A-5
1
TROUBLESHOOTING E-5
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL
COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.
• When the starting switch is turned ON, the monitor panel completely remains lighted and does not go
Trouble
out.
Related • When the starting switch is turned ON, the gear speed indicator, the multi information section, the
information gauge section and the lamp section come on for 2 sec. and go out.

and standard
Defective monitor panel
value in normal 1 This internal defect cannot be diagnosed.
state (Gauge/lamp module)
D275A-5 20-609
1
TROUBLESHOOTING E-6
E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHECK ITEMS FLASH.
Trouble • The radiator water level caution lamp flashes.

Related
• When any basic check items are detected to be abnormal before the engine starts, they will flash.
information

A drop of radiator water level (main radiator or sub radiator) was de-
Drop of radiator water level
1 tected, inspect the radiator water levels. (The lamp flashes when the
(when the system is normal)
level is below the specified level.)
The main radiator water lev- without turning the starting switch ON.
2 el sensor is defective. WLM (male) Radiator water level Resistance
(Internal disconnection) Normal level Max. 1Ω
Between 1 and 2
Lower level Min. 1MΩ
The sub radiator water level without turning the starting switch ON.
3 sensor is defective. WLD (male) Radiator water level Resistance
Possible causes (Internal disconnection) Normal level Max. 1Ω
and standard Between 1 and 2
Lower level Min. 1MΩ
value in normal
Disconnection of wiring har- Wiring harness between S03 (female) A and
ness (Disconnection in wir- WLM (female) 1
4
ing or defective contact in Wiring harness between WLM (female) 2 and
connector) WLD (female) 1
Wiring harness between WLD (female) 2 and
ground
Defective monitor panel S03 Radiator water level Voltage
5
(Gauge/lamp module)
Between A and Normal level Max. 1V
ground Lower level 20 – 20V
Circuit diagram related to monitor panel electric power supply
20-610 D275A-5
1
TROUBLESHOOTING E-7
E-7 WHILE THE ENGINE IS OPERATING, ANY CAUTION ITEM FLASHES.
Trouble • The battery charge level caution lamp flashes.

Related
• When any abnormality is detected during engine operation, the relevant caution item will flash.
information

Defective alternator (insuffi-
1 Alternator Engine speed Voltage
cient power generation)
Between Terminal R Min. medium speed
20 – 30V
and ground (half)
Disconnection of wiring har- ★ Prepare with the starting switch OFF, then carry out troubleshooting
ness (Disconnection in wir- without turning the starting switch ON.
2
ing or defective contact in Wiring harness between S04 (female) 9 and
Possible causes connector)
alternator R terminal
and standard
state without turning the starting switch ON.
Between wiring harness (between S04 (fe-
circuit) male) 9 and alternator R terminal, S04 (fe-
male) 9 and starting motor R terminal, S04
(female) 9 and TMCN1 (male) E) and ground
4 S04 Voltage
(Gauge/lamp module)
Between 9 and Min. medium speed
20 – 30V
ground (half)
D275A-5 20-611
1
TROUBLESHOOTING E-7
Engine start/charge-related circuit diagram
20-612 D275A-5
1
TROUBLESHOOTING E-8
E-8 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES.
Trouble (1) • The engine oil pressure caution lamp flashes.

• When any abnormality is detected during engine operation, the relevant emergency warning item will
Related
sound the alarm buzzer.
information
• The engine oil pressure switch signal is received from the engine controller through communication.

Drop of engine oil pressure Check the engine oil pressure as the drop of engine oil pressure is de-
1
(when the system is normal) tected.
The engine oil low pressure without turning the switch ON or after starting the engine.
2 switch is defective. PSL Engine Resistance
(Internal short circuit) Between terminal and Stop Max. 1Ω
ground Min. 600rpm Min. 1MΩ
The engine oil high pres- without turning the switch ON or after starting the engine.
3 sure switch is defective. PSH Engine Resistance
(Internal short circuit) Between terminal and Stop Max. 1Ω
Possible causes ground Min. 1,300rpm Min. 1MΩ
and standard ★ Prepare with the starting switch OFF, then carry out troubleshooting
value in normal without turning the starting switch ON.
state Ground fault of wiring har-
Between wiring harness (between ECN1 (fe-
male) K and PSL) and ground
circuit)
etween wiring harness (between ECN1 (fe-
male) E and PSH) and ground
without turning the switch ON or after starting the engine.
ECN1 Engine Voltage
5 Defective engine controller Between K and Stop Max. 1V
ground Min. 600rpm 20 – 30V
Between E and Stop Max. 1V
ground Min. 1,300rpm 20 – 30V
6 This is an internal defect, which cannot be troubleshot.
(Gauge/lamp module)
Circuit diagram related to engine oil low pressure switch and engine oil high pressure switch
D275A-5 20-613
1
TROUBLESHOOTING E-8
Trouble (2) • The engine water temperature caution lamp flashes.

Related sound the alarm buzzer.
information • The engine water temperature caution lamp flashes or goes out as it links with indication on the engine
water temperature gauge.

As overheated engine water was detected, check the engine water
Overheated engine water
temperature. (When the water temperature is over 102fC, the lamp
1 temperature (when the sys-
flashes. When the water temperature is over 108fC, the lamp flashes
tem is normal)
and the buzzer sounds.)
Check the indication on the engine water temperature gauge. If the
indication is abnormal, carry out the troubleshooting of “Indication on
the engine water temperature gauge is abnormal.”
★ Water temperatures are guides for select-
ing indications.
Possible causes
and standard The engine water tempera-
value in normal ture sensor system is defec- Water temperature
state 2 gauge
tive. (Engine controller
system)
White range/
Water temperature Red range
Green range
lamp
Goes out. Flashes.
When Causes 1 and 2 are not applicable, the monitor panel is sup-
3 posed to be defective. (This is an internal defect, which cannot be
(Gauge/lamp module)
troubleshot.)
Trouble (3) • The power train oil temperature caution lamp flashes.
information • The power train oil temperature caution lamp flashes or goes out as it links with indication on the power
train oil temperature gauge.

Overheated oil temperature As an overheated power train oil temperature was detected, check
1 of power train (when the the power train oil temperature. (When the oil temperature is over
system is normal) 130°C, the lamp flashes.)
Check the indication on the power train oil temperature gauge. If the
the power train oil temperature gauge is abnormal.”
★ Oil temperatures are guides for selecting
indications.
Possible causes
and standard The power train oil tempera-
value in normal 2 ture sensor system is defec- Oil temperature gauge
state tive. (Monitor panel system)
White range/
Red range
Oil temperature lamp Green range
Goes out. Flashes.
(Gauge/lamp module)
troubleshot.)
20-614 D275A-5
(1)
(4)
TROUBLESHOOTING E-8
Trouble (4) • The hydraulic oil temperature caution lamp flashes.

information • The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the hydrau-
lic oil temperature gauge.

Overheated hydraulic oil As an overheated hydraulic oil temperature was detected, check the
1 temperature (when the sys- hydraulic oil temperature. (When the oil temperature is over 130°C,
tem is normal) the lamp flashes.)
Check the indication on the engine water temperature gauge. If the
the hydraulic oil temperature gauge is abnormal.”
★ Oil temperatures are guides for selecting
indications.
Possible causes
and standard The hydraulic oil tempera-
value in normal 2 ture sensor system is defec- Oil temperature gauge
state tive. (Monitor panel system)
White range/
Red range
Oil temperature lamp Green range
Goes out. Flashes.
(Gauge/lamp module)
troubleshot.)
D275A-5 20-615
1
TROUBLESHOOTING E-9
E-9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES
NOT COME ON.
Trouble • While the preheater is operating, the preheating pilot lamp does not come on.
★ This troubleshooting describes the procedures to be followed when the preheating lamp doe not come
on. (When the preheater mounting section is not heated, carry out the troubleshooting of “The preheat-
Related
er does not work.”)
information
• For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are
available. Even when either function is performed, the preheating lamp comes on.

Disconnection of wiring har- ★ Prepare with the starting switch OFF, then carry out troubleshooting
1
ing or defective contact in Wiring harness between S03 (female) 9 and
connector) heater relay HT/B (B) terminal
Possible causes without turning the starting switch ON.
and standard
2 ness (Contact with ground Between wiring harness between S03 (female)
value in normal circuit) 9 and heater relay HT/B (B) terminal and Resistance Min. 1MΩ
state
ground
3 S03 Voltage
(Gauge/lamp module)
Between 9 and ON Max. 1V
ground HEAT 20 – 30V
20-616 D275A-5
1
TROUBLESHOOTING E-9
Engine preheat-related circuit diagram
D275A-5 20-617
1
TROUBLESHOOTING E-9
E-10, E-11
E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR
LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE)
• At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on. (Dual tilt-mounted
Trouble
machine)
• Before troubleshooting the blade, make sure that the dual tilt can operate. (When the blade does not
Related
operate normally, the electrical system on the machine side or the hydraulic/mechanical system is sup-
information
posed to be out of order. So, troubleshoot the relevant system.)

and standard
value in normal Defective monitor panel
(Gauge/lamp module)
state
20-618 D275A-5
1
TROUBLESHOOTING E-11
E-11 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.
Trouble (1) • The engine water temperature gauge does not indicate normally.
• Signals of the engine water high temperature sensor are received from the engine controller through
Related communication.
information • When any abnormality occurred in the engine hot water temperature sensor system, the failure code
[DGE2KX] is displayed sometimes.

The engine water high tem- without turning the starting switch ON.
perature sensor is defec-
1 TWH (male) Resistance
tive. (Internal disconnection
Between 1 and 2 3.5k – 90kΩ
or short circuit)
Between 1 2 and ground Min. 1MΩ
ness (Disconnection in wir- Wiring harness between ECN2 (female) Q and
ing or defective contact in TWH (female) 1
connector) Wiring harness between ECN2 (female) ] and Resistance Max. 1Ω
TWH (female) 2 Resistance Max. 1Ω
Possible causes
Ground fault of wiring har- without turning the starting switch ON.
value in normal 3 ness (Contact with ground
state circuit) Between wiring harness (between ECN2 (fe-
male) Q and TWH (female) 1) and ground
circuit) Between wiring harness (between ECN2 (fe-
Voltage Max. 1V
male) Q and TWH (female) 1) and ground
Between Q and ] 3.5k – 90kΩ
Between Q ] and ground Min. 1MΩ
(Gauge/lamp module)
Circuit diagram related to engine water high temperature sensor
D275A-5 20-619
1
E-12 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL.
Trouble • Indication of the power train temperature gauge is abnormal.

Related
information

The power train oil tempera- Torque converter oil
453 (male) Resistance
ture sensor is defective. temperature
1
(Internal disconnection or About 3.8k –
Between 1 and 2
short circuit) about 80kΩ
10 – 100°C
Between 1 and
Min. 1MΩ
ground
ness (Disconnection in wir- Wiring harness between S04 (female) B and Resistance Max. 1Ω
2
ing or defective contact in 453 (female) 1
Possible causes connector) Wiring harness between 453 (female) 1 and Resistance Max. 1Ω
and standard
ground Resistance Max. 1Ω
value in normal
male) B and 453 (female) 1) and ground
male) B and 453 (female) 1) and ground
Defective monitor panel Torque converter oil
5 S04 (female) Resistance
(Gauge/lamp module) temperature
Between B and About 3.8k –
10 – 100°C
ground about 80kΩ
Circuit diagram related to power train oil temperature sensor
20-620 D275A-5
1
E-13 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.
Trouble • The hydraulic oil temperature gauge does not indicate normally.
• Signals of the hydraulic oil temperature sensor are received from the transmission controller through
Related communication.
information • When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
[DGS1KX] is displayed sometimes.

The hydraulic oil tempera- without turning the starting switch ON.
ture sensor is defective. (In-
1 452 (male) Resistance
ternal disconnection or
Between 1 and 2 3.5k – 90kΩ
short circuit)
ness (Disconnection in wir- Wiring harness between TMCN1 (female) D
ing or defective contact in and 452 (female) 1
connector) Wiring harness between TMCN1 (female) K
and 452 (female) 2
Possible causes
and standard Ground fault of wiring har-
value in normal 3 ness (Contact with ground
state Between wiring harness (between TMCN1 (fe-
male) D and 452 (female) 1) and ground
Hot short circuit of wiring
Between wiring harness (between TMCN1 (fe-
male) D and 452 (female) 1) and ground
5
troller
Between D and K 3.5k – 90kΩ
Between D and ground Min. 1MΩ
(Gauge/lamp module)
Circuit diagram related to hydraulic oil temperature sensor
D275A-5 20-621
1
E-14 INDICATION OF THE FUEL GAUGE IS ABNORMAL.
Trouble • Indication of the fuel gauge is abnormal.

Related
information

Defective fuel level sensor. without turning the starting switch ON.
1 (Internal disconnection or 423 (male) Remained fuel level Resistance
short circuit) Between 1 and 2 Full About 4Ω
(ground) Empty About 85Ω
ness (Disconnection in wir- Wiring harness between S04 (female) @ and
ing or defective contact in 423 (female) 1
connector) Wiring harness between 423 (female) 2 and
ground
and standard
state 3 ness (Contact with ground
circuit) Between wiring harness (between S04 (fe-
male) @ and 423 (female) 1) and ground
circuit) Between wiring harness (between S04 (fe-
Voltage Max. 1V
male) @ and 423 (female) 1) and ground
5 S04 (female) Remained fuel level Resistance
(Gauge/lamp module)
Between @ and Full About 4Ω
ground Empty About 85Ω
Circuit diagram related to fuel level sensor
20-622 D275A-5
1
E-15, E-16
E-15 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL.
Trouble • Indications of gear speed and engine speed are abnormal.

Related • Signals of gear speed and engine speed are received from the transmission controller and the engine
information controller through communication.

and standard
value in normal 1 This is an internal defect, which cannot be troubleshot.
E-16 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL.
Trouble (1) • During engine operation, the service meter does not advance.
Related • The service meter measures time according to engine drive signals (alternator voltage and engine oil
information pressure).

When the battery charge level caution lamp flashes during engine op-
1 Defective alternator system eration, carry out the troubleshooting of “While the engine is operat-
Possible causes
ing, caution items flash.”
and standard
The engine oil pressure When the engine oil pressure caution lamp flashes during engine op-
value in normal
state 2 sensor system is defective. eration, carry out the troubleshooting of “While the engine is operat-
(Engine controller system) ing, emergency warning items flash.”
(Gauge/lamp module)
Trouble (2) • Shift mode and service meter are not displayed at all.
Related
information

and standard
value in normal Defective monitor panel
(Gauge/lamp module)
state
D275A-5 20-623
1
E-17 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT.
Trouble • The warning lamp does not flash or does not go out.
Related
information

and standard
value in normal 1 This is an internal defect, which cannot be troubleshot.
20-624 D275A-5
1
E-18 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP.
Trouble • The alarm buzzer does not sound or does not stop.
Related • When a short circuit occurs in the alarm buzzer system, the failure code is displayed but no other fail-
information ure codes are displayed.

Defective circuit breaker When the circuit breaker is cut off, a ground fault may have possibly
1
(CB2) occurred in the circuit.
Defective alarm buzzer (In- without turning the starting switch ON.
2 ternal disconnection or 217 (male) Resistance
short circuit) Between 1 and 2 200Ω
Possible causes ness (Disconnection in wir- Wiring harness between S03 (female) H and
and standard ing or defective contact in 217 (female) 1
value in normal connector) Wiring harness between 217 (female) 2 and
state CB2 outlet
circuit) Between wiring harness related to CB2 (outlet
side) and ground
Defective monitor panel S03 Alarm buzzer Voltage
5
(Gauge/lamp module) At stop 20 – 30V
Between H and
At operation
ground Max. 3V
(sounding)
Circuit diagram related to alarm buzzer
D275A-5 20-625
1
E-19 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED.
Trouble • Auto shift down is not possible or is not released.

Related
Defective auto shift down switch (Internal disconnection or short circuit)
information

Defective auto shift down without turning the starting switch ON.
1 switch (Internal disconnec- ASD (male) Auto shift down switch Resistance
tion or short circuit) OFF (0) Min. 1MΩ
Between 2 and 3
ON (1) Max. 1Ω
ness (Disconnection in wir- Wiring harness between TMCN3 (female) ]
ing or defective contact in and ADS (female) 3
Possible causes connector) Wiring harness between ADS (female) 2 and
and standard ground
state Ground fault of wiring har- without turning the starting switch ON.
circuit) Between wiring harness (between TMCN3 (fe-
male) ] and ASD (female) 3) and ground
4 TMCN3 Auto shift down switch Voltage
troller
Between ] and OFF (0) 20 – 30V
ground ON (1) Max. 3V
When Causes 1 to 4 are not applicable, the transmission control sys-
5 tem is supposed to be out of order. (Since the system is defective, the
trol system
control system cannot be troubleshot.)
Circuit diagram related to auto shift down switch
20-626 D275A-5
1
E-20 THE ALARM BUZZER CANNOT BE CANCELLED.
Trouble • The alarm buzzer cannot be cancelled.

Related
information

Defective buzzer cancel BUZ (male) Buzzer cancel switch Resistance
1 switch (Internal disconnec- OFF (0) Min. 1MΩ
Between 1 and 2
tion or short circuit) Max. 1Ω
OFF (0) Min. 1MΩ
Between 1 and 3
Max. 1Ω
Disconnection of wiring har- Wiring harness between STCN2 Z and BUZ
ness (Disconnection in (female) 2
2
wiring or defective contact Wiring harness between STCN2 P and BUZ
in connector) (female) 3
and standard
Wiring harness between BUZ (female) 1 and
ground
state
Between wiring harness (between STCN2 Z
and BUZ(female) 2) and ground
circuit)
Between wiring harness (between STCN2 P
and BUZ (female) 3) and ground
ON and carry out the troubleshooting.
STCN2 Buzzer cancel switch Voltage
4 Defective steering controller Between Z and OFF (0) 20 – 30V
ground Max. 1V
Between P and OFF (0) 20 – 30V
ground Max. 1V
Circuit diagram related to buzzer cancel switch
D275A-5 20-627
1
E-21 THE OPERATOR MODE CANNOT BE OPERATED.
Trouble • The operator mode cannot be operated.

Related
information

Since the buzzer cancel switch system is supposed to be out of order,
Defective buzzer cancel
1 carry out the troubleshooting of “The alarm buzzer cannot be can-
switch system
celled.”
Defective information switch CUR (male) Information switch Resistance
2 (Internal short circuit or dis- OFF (0) Min. 1MΩ
Between 1 and 2
connection) Max. 1Ω
OFF (0) Min. 1MΩ
Between 1 and 3
Max. 1Ω
Disconnection of wiring har- Wiring harness between STCN2 F and CUR
Possible causes ness (Disconnection in wir- (female)
3
and standard ing or defective contact in Wiring harness between STCN2 6 and CUR
value in normal connector) (female) 3
state Wiring harness between CUR (female) 1 and
ground
Between wiring harness (between STCN2 F
and CUR (female) 2) and ground
circuit)
Between wiring harness (between STCN2 6
and CUR (female) 3) and ground
STCN2 Buzzer cancel switch Voltage
5 Defective steering controller Between F and OFF (0) 20 – 30V
ground Max. 1V
Between 6 and OFF (0) 20 – 30V
ground Max. 1V
Circuit diagram related to information switch
20-628 D275A-5
1
E-22 THE SERVICE MODE CANNOT BE OPERATED.
Trouble • The service mode cannot be operated.

Related
information

Since the buzzer cancel switch system is supposed to be out of order,
Defective buzzer cancel
1 carry out the troubleshooting of “The alarm buzzer cannot be can-
switch system
celled.”
Since the information switch system is supposed to be out of order,
Defective information switch
2 carry out the troubleshooting of “The operator mode cannot be can-
system
celled.”
3
Defective service switch (In- without turning the starting switch ON.
4 ternal short circuit or discon- S24 Service switch Resistance
nection) Between 2 and 3, OFF Min. 1MΩ
Between 5 and 6 ON Max. 1Ω
Possible causes Disconnection of wiring har- Wiring harness between CB6 outlet and S24 3 Resistance Max. 1Ω
and standard ness (Disconnection in wir- Wiring harness between S24 6 and ground Resistance Max. 1Ω
5
value in normal ing or defective contact in Wiring harness between S03 (female) F and
state connector) S24 2
Wiring harness between STCN1 (female) 6
and S24 5
circuit) Between wiring harness related to CB6 (outlet
side) and ground
7 S03 Service switch Voltage
(Gauge/lamp module)
Between F and OFF Max. 1V
ground ON 20 – 30V
8 Defective steering controller STCN1 Service switch Voltage
Between 6 and OFF 20 – 30V
ground ON Max. 1V
D275A-5 20-629
1
Circuit diagram related to service switch
20-630 D275A-5
1
E-23 THE BACK-UP ALARM DOES NOT SOUND.
Trouble • The back-up alarm does not sound.

Related • When a failure occurs on the primary side (coil side) of the back-up alarm relay, a relevant failure code
information is displayed, but in case of failure on the secondary side (contact side), no failure code is displayed.

When the fuse is blown, a ground fault may have probably occurred
in the circuit.
Defective back-up relay (in- When the relay is replaced with another relay while the starting switch
2
ternal disconnection) 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
Disconnection of wiring har- Wiring harness between FS4-1 outlet and BKA
ness (Disconnection in wir- (female) 3
value in normal 3
ing or defective contact in Wiring harness between BKA (female) 5 and
state Resistance Max. 1Ω
connector) 244 (female) 2
ground
Between wiring harness related to FS4-1 (out-
circuit)
Between wiring harness (between BKA (fe-
Defective back-up alarm (in- When Causes 1 to 4 are not applicable, the back-up alarm is sup-
5
ternal defect) posed to be defective.
Circuit diagram related to back-up alarm
D275A-5 20-631
1
E-24 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP
ON THE PANEL DO NOT COME ON.
Trouble(1) • None of the night light, the headlamp, the working lamp and the rear lamp on the panel comes on.
Related
information

in the circuit.
★
Disconnection of wiring har- Prepare with the starting switch OFF, then carry out troubleshooting
2
ing or defective contact in Wiring harness between FS2-5 outlet and cir-
connector) cuit branching point
Possible causes ★ Prepare with the starting switch OFF, then carry out troubleshooting
and standard without turning the starting switch ON.
value in normal Between wiring harness related to FS2-5 (out-
state Resistance Min. 1MΩ
Ground fault of wiring har- Between wiring harness (between 219 (fe-
3 ness (Contact with ground male) 2 and S01 (female) @, S01 (female) 1,
circuit) S03 (female) 8, BB2 (female) 1 or BB3 (fe-
male) 1) and ground
Between wiring harness (between 218 (fe-
male) 3 and 223 (female) 1 or 243 (female) Resistance Min. 1MΩ
1) and ground
Trouble(2) • None of the night light, the headlamp and the working lamp on the panel comes on.
Related
information

Headlamp and working without turning the starting switch ON.
1 lamp switch (international 219 (male) Switch Resistance
disconnection) OFF Min. 1MΩ
Between 2 and 3
Possible causes ON Max. 1Ω
value in normal without turning the starting switch ON.
state Wiring harness between 219 (female) 3 and
Ground fault of wiring har- Resistance Max. 1Ω
circuit branching point
circuit) Resistance Max. 1Ω
BB2 (female) 1 or BB3 (female) 1
Wiring harness between BB2 (female) 2 or
BB3 (female) 1 and ground
20-632 D275A-5
1
Trouble(3) • Only the night light on the panel does not comes on. (whole or part)
Related
information

Defective night lamp The night lamp is supposed to be defective. Check if the bulb is
1
(blown) blown.
Wiring harness between S01 (female) @ and
Disconnection of wiring har- circuit branching point
ness (Disconnection in wir- Wiring harness between S02 (female) 1 and
ing or defective contact in circuit branching point
connector) Wiring harness between S02 (female) 1 and
ground
and standard
value in normal Wiring harness between S03 (female) 8 and
circuit branching point
state
Defective monitor panel Between S01 @
3
(Switch module) and 2
Light switch ON 20 – 30V
Between S02 1
and ground
Defective monitor panel ON and carry out troubleshooting.
4
(Gauge/lamp module) Between S03
Light switch ON 20 – 30V
8 and 3 4
Trouble(4) • Only the headlamp does not comes on. (Both right and left, or one side only)
Related
information

1 Defective headlamp (blown) The headlamp is supposed to be defective. Check if the bulb is blown.
2
Defective headlamp relay When the relay is replace with another relay while the starting switch
3
(Internal disconnection) 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
(BB2) is defective.
Possible causes
and standard
value in normal Disconnection of wiring har- without turning the starting switch ON.
state ness (Disconnection in wir- Wiring harness between CB5 outlet and BB2
connector) Wiring harness between BB2 (female) 5 and
203 (female) 1 or 204 (female) 1
Ground fault of wiring har- Between wiring harness related to CB5 (outlet
5 ness (Contact with ground side) and ground
circuit) Between wiring harness (between BB2(fe-
1) and ground
D275A-5 20-633
1
Trouble(5) • Only the working lamp does not comes on. (Both right and left, or one side only)
Related
information

Defective working lamp The working lamp is supposed to be defective. Check if the bulb is
1
(blown) blown.
in the circuit.
Defective working lamp re- When the relay is replace with another relay while the starting switch
3
lay (Internal disconnection) 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
Possible causes (BB3) is defective.
value in normal Disconnection of wiring har- without turning the starting switch ON.
state ness (Disconnection in wir- Wiring harness between Fs2-4 outlet and BB3
connector) Wiring harness between BB3 (female) 5 and
Ground fault of wiring har- Between wiring harness related to FS2-4 (out-
5 ness (Contact with ground let side) and ground
circuit) Between wiring harness (between BB3 (fe-
1) and ground
Trouble(6) • Only the rear lamp does not comes on. (Both right and left, or one side only)
Related
information

The working lamp is supposed to be defective. Check if the bulb is
1 Defective rear lamp (blown)
blown.
Defective rear lamp switch ON and carry out troubleshooting.
Possible causes 2 (international disconnec- 218 (male) Switch Resistance
and standard tion) OFF Min. 1MΩ
value in normal Between 2 and 3
ON Max. 1Ω
ness (Disconnection in wir- Wiring harness between 218 (female) 2 and
ing or defective contact in circuit branching point
connector) Wiring harness between 218 (female) 3 and
20-634 D275A-5
1
Circuit diagram related to night light, headlamp, working lamp and rear lamp on panel
D275A-5 20-635
1
E-25 THE AIR CONDITIONER DOES NOT OPERATE.
Trouble (1) • No air flow

Related
information

1
Defective blower main relay without turning the starting switch ON.
2
(coil side) CN-R1 (male) Resistance
Between (1) and (2) 240 ± 40Ω
Defective blower main relay ON and carry out troubleshooting.
3
(contact side) CN-R1 Voltage
Between (6C) and ground 20 – 30V
Defective blower Hi relay without turning the starting switch ON.
4
(coil side) CN-R2 (male) Resistance
Between (1) and (2) 240 ± 40Ω
Defective blower Hi relay ON and carry out troubleshooting.
5
(contact side) The relay is in order when the motor rotates after the starting switch
is turned ON and the blower Hi switch is turned on.
Defective blower Mi relay without turning the starting switch ON.
6
Possible causes (coil side) CN-R3 (male) Resistance
and standard Between (1) and (2) 240 ± 40Ω
value in normal ★ Prepare with the starting switch OFF, then turn the starting switch
state Defective blower Mi relay ON and carry out troubleshooting.
7
(contact side) The relay is in order when the motor rotates after the starting switch
is turned ON and the blower Mi switch is turned on.
8 Defective blower motor
The motor is in order when it rotates after the starting switch is turned
ON and the blower Lo switch is turned on.
Wiring harness between CN-R3 (female) (0B),
CN-AC1 (female) (0C), CN-R (female) (0D) or Resistance Max. 1Ω
CN-R2 (female) (0E) and ground
Wiring harness between CN-B(female) (10A)
Disconnection of wiring har- and CN-R1 (female) (10B)
ness (Disconnection in wir- Wiring harness between CN-B (female) (11A)
9
ing or defective contact in and CN-R2 (female) (11B) or CN-R (female) Resistance Max. 1Ω
connector) (11C)
Wiring harness between CB4 outlet and CN-
AC1 (female) (13C), CN-R1 (female) (13D),
CN-R2 (female) (13E) or CN-R3 (female)
(13H)
Wiring harness between CN-R1 (female) (14A)
and CN-AC1 (female) (14B)
20-636 D275A-5
1

ness (Disconnection in wir- Wiring harness between CN-R3 (female) (17A)
Possible causes ing or defective contact in and CN-AC1 (female) (17B)
and standard connector) Wiring harness between CN-R2 (female) (18A)
value in normal and CN-AC1 (female) (18B)
state When Causes 1 to 9 are not applicable, the control panel is supposed
10 Defective control panel
to be defective.
When any cause cannot be specified, failure phenomenon may have
Different failure phenome-
11 been mistaken. Carry out the troubleshooting of “Cooling is not pos-
non
sible.”
D275A-5 20-637
1
Trouble (2) • Cooling is not possible.

Related
information

1 Defective pressure switch CN-P Blower switch Voltage
Between (26A) and
ON 20 – 30V
ground
Defective compressor without turning the starting switch ON.
2
clutch relay (coil side) CN-R4 (male) Resistance
Between (1) and (2) 240 ± 40Ω
Defective compressor ON and carry out troubleshooting.
3
clutch relay (contact side) CN-R4 Voltage
Between (9B) and ground 20 – 30V
Defective condenser relay ON and carry out troubleshooting.
4
(contact side) CN-R5 Voltage
Between (7B) and ground 20 – 30V
5 Defective thermistor
CN-AC1 (male) Resistance
Possible causes Between (15B) and (16C) Max. 3,500Ω
value in normal Defective condenser blower without turning the starting switch ON.
state 6
resistor Condenser blower resistor Resistance
Between terminals 2.8Ω ± 5%
★ Turn the starting switch on and carry out the troubleshooting.
7 Defective condenser motor The motor is in order if it is rotating when the air conditioner is
switched ON.
★ Start the engine and carry out the troubleshooting.
Defective compressor mag-
8 The compressor magnet clutch is supposed to be out of order, so in-
net clutch
spect it directly.
★ Start the engine and carry out the troubleshooting.
9 Defective compressor
The compressor is supposed to be out of order, so inspect it directly.
Wiring harness between CB4 outlet and CN-
R5 (female) (6B) or CN-R4 (female) (6D)
Disconnection of wiring har- Wiring harness between CN-R5 (female) (7B)
ness (Disconnection in wir- and ARC (female) 2
10
ing or defective contact in Wiring harness between CN-R4 (female) (9B)
connector) and 351 (female) 1
Wiring harness between CB4 outlet and CN-R
(female) (131)
Wiring harness between CN-T (female) (15A)
and CN-AC1 (female) (15B)
20-638 D275A-5
1

Disconnection of wiring har- Wiring harness between CN-P (female) (19A)
ness (Disconnection in wir- and CN-R4 (female) (19C)
and standard 10
ing or defective contact in Wiring harness between CN-P (female) (26A)
connector) and CN-AC1 (female) (26B)
state
Wiring harness between ARC (female) 1 and
ground
When Causes 1 to 10 are not applicable, the control panel is sup-
11 Defective control panel
posed to be defective.
D275A-5 20-639
1
Circuit diagram related to air conditioner
20-640 D275A-5
1
TROUBLESHOOTING OF
HYDRAULIC AND MECHANICAL SYSTEM
(H-MODE)
Information described in troubleshooting list ........................................................................................... 20- 702

H-1 No travel power (No drawbar pull) ................................................................................................... 20- 703
H-2 Machine does not move (At 2nd or 3rd speed) ................................................................................ 20- 705
H-3 Machine does not move in any speed range ................................................................................... 20- 706
H-4 Machine travels only in one direction forward or in reverse ............................................................. 20- 707
H-5 When gear is shifted or travel direction is changed, large time lag is made .................................... 20- 708
H-6 Steering is not possible (Machine does not turn to right or left) ....................................................... 20- 709
H-7 Steering is possible only on one side ............................................................................................... 20- 709
H-8 Steering overrun occurs ................................................................................................................... 20- 710
H-9 Brake does not work ........................................................................................................................ 20- 710
H-10 Overheat of power train oil temperature ........................................................................................ 20- 711
H-11 All work equipment speeds are slow .............................................................................................. 20- 712
H-12 Work equipment does not move .................................................................................................... 20- 713
H-13 Blade lift speed is slow or lacks power .......................................................................................... 20- 713
H-14 Blade tilt speed is slow or lacks power .......................................................................................... 20- 714
H-15 Ripper lift speed is slow or lacks power ......................................................................................... 20- 714
H-16 Ripper tile speed is slow or lacks power ........................................................................................ 20- 715
H-17 Excessive hydraulic drift of blade lift .............................................................................................. 20- 715
H-18 Excessive hydraulic drift of blade tilt .............................................................................................. 20- 716
H-19 Excessive hydraulic drift of ripper lift ............................................................................................. 20- 716
H-20 Ripper pin puller cylinder does not work (Giant ripper attachment machine) ................................ 20- 717
H-21 Blade pitch does not work (Dual tilt attachment machine) ............................................................. 20- 717
H-22 Abnormal sound comes out from around work equipment pump .................................................. 20- 717
D275A-5 20-701
1

★ Troubleshooting lists contain the following information all together. Understand the contents carefully and
troubleshoot the machine.
Trouble Problem that appears on the machine.
Related
Information related to problems occurred or troubleshooting
information
Possible causes Cause supposed to have caused

2
and standard failure <Contents>
value in normal (The sequence shows reference • Standard values in normal state for judging possible causes
state numbers and does not mean pri- • Remarks for making judgment
3 ority.)
20-702 D275A-5
1
TROUBLESHOOTING H-1
H-1 NO TRAVEL POWER (NO DRAWBAR PULL)
Trouble • There is no travel power. (No drawbar pull).

Related
• Confirm that the oil quantity on the power train is normal before troubleshooting.
information

★ Prepare with starting switch OFF, then drive the engine in high
idling mode for troubleshooting.
1 Defective engine
Measurement conditions Number of engine rotations
F3 stall 1,510rpm
2 Defective power train pump The power train pump is assumed to be defective; directly check it.
Internally defective torque Original pressure of Torque converter
3 PCCS lever
converter torque converter delivery pressure
0.49 – 1.0MPa 0.49 ± 0.1MPa
Full neutral
{5 – 10kg/cm2} {5 ± 1kg/cm2}
PCCS lever
pressure
Full neutral Min. 2.94MPa {Min. 30kg/cm2}
Defective set pressure of
4 transmission main relief ★ Prepare with the starting switch OFF, then carry out troubleshooting
valve and internal defect without turning the starting switch ON.
Directly check that the spring length and the number of shims are nor-
mal and also that the spool rotates smoothly.
• Free length of large spring: 122mm
Possible causes • Free length of small spring: 108mm
and standard • Number of shims: 6
value in normal
★ Prepare with starting switch OFF, then drive the engine in low idling
state
mode for troubleshooting.
Transmission clutch Clutch pressure
Defective transmission FWD Min. 2.65MPa {Min. 27kg/cm2}
5
valve (ECMV) function REV Min. 2.65MPa {Min. 27kg/cm2}
1ST Min. 2.65MPa {Min. 27kg/cm2}
2ND Min. 2.65MPa {Min. 27kg/cm2}
3RD Min. 2.65MPa {Min. 27kg/cm2}
6 Defective brake valve Parking lever Left brake pressure Right brake pressure
Min. 2.45MPa Min. 2.45MPa
Free
{Min. 25kg/cm2} {Min. 25kg/cm2}
If the result of the troubleshooting in cause 5 is abnormal, the parking
Defective parking lever or
7 lever or brake pedal linkage is not assumed to be adjusted normally.
brake pedal linkage
Directly check it.
Internally defective trans- The transmission is assumed to be defective internally; directly check
8
mission it.
★ Move the machine to level place and start the engine for trouble-
shooting.
Defective operation of brake
9 Run the engine at low idling and set the gear in F2. If the machine
(Dragging)
does not move, the brake is dragging. (Carry out troubleshooting in
“Brake does not work”.)
D275A-5 20-703
1
TROUBLESHOOTING H-1

★ Prepare with starting switch OFF, then run the engine at high idling
for troubleshooting (after checking that the transmission main relief
pressure is normal).
PCCS lever Left stroke end Right stroke end
0 1.77 ± 0.29MPa
Left clutch pressure
{0} {18 ± 3kg/cm2}
Possible causes
1.77 ± 0.29MPa 0
and standard 10 Defective steering clutch Right clutch pressure
{18 ± 3kg/cm2} {0}
value in normal
state 0 Min. 2.45MPa
Left brake pressure
{0} {Min. 25kg./cm2}
Min. 2.45MPa 0
Right brake pressure
{Min. 25kg./cm2} {0}
If the oil pressure is abnormal, carry out troubleshooting in "Machine
cannot be steered".
The steering clutch is assumed to be defective internally; directly
11 Slip of steering clutch
check it.
20-704 D275A-5
1
TROUBLESHOOTING H-2
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)
Trouble • Machine does not move. (At 2nd or 3rd speed)

Related • Confirm that the oil quantity on the power train is normal before troubleshooting.
information • Confirm that the transmission main relief pressure is normal before troubleshooting. (See H-1.)

1 PCCS lever
0.49 – 1.0MPa 0.49 ± 0.1MPa
Full neutral
{5 – 10kg/cm2} {5 ± 1kg/cm2}
mode for troubleshooting.
Defective transmission
2 Transmission clutch Clutch pressure
valve (ECMV) function
Internally defective trans- The transmission clutch (2nd or 3rd speed) is assumed to be defec-
3
mission clutch tive internally; directly check it.
Defective parking brake The parking brake function is assumed to be defective (dragged);
4
function (Drag) check the linkage valves.
Possible causes ★ Move to a flat place, and start the engine for troubleshooting.
and standard Defective brake function
5 If the machine does not run by low idling + F2 operation, brake drag
value in normal (Drag)
occurs. (Carry out troubleshooting “Brake does not work.”)
state Internally defective trans- The transmission is assumed to be defective internally; directly check
6
mission it.
for troubleshooting.
0 1.77 ± 0.29MPa
{0} {18 ± 3kg/cm2}
1.77 ± 0.29MPa 0
Defective steering clutch/ Right clutch pressure
7 {18 ± 3kg/cm2} {0}
brake
0 Min. 2.45MPa
Left brake pressure
{0} {Min. 25kg./cm2}
Min. 2.45MPa 0
{Min. 25kg./cm2} {0}
cannot be steered".
check it.
D275A-5 20-705
1
TROUBLESHOOTING H-3
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE
Trouble • Machine does not move in any speed range.

Related
information

PCCS lever
pressure
Defective and Internally de- Full neutral Min. 2.94MPa {Min. 30kg/cm2}
2
fective set pressure of ★ Prepare with the starting switch OFF, then carry out troubleshooting
transmission main relief without turning the starting switch ON.
valve Directly check that the spring length and the number of shims are nor-
• Free length of small spring: 108mm
• Number of shims: 6
mode for troubleshooting. (Before this, confirm that the transmis-
sion main relief pressure is normal.)
3
REV Min. 2.65MPa {Min. 27kg/cm2}
Possible causes Internally defective trans- The transmission clutch (2nd or 3rd speed) is assumed to be defec-
and standard 4
mission clutch tive internally; directly check it.
value in normal ★ Move to a flat place, and drive the engine in high idling mode for
state troubleshooting. (Before this, confirm that the transmission main re-
lief pressure is normal.)
Brake hydraulic pressure
Brake pedal
5 Defective brake function (left/right)
Release Min. 2.45MPa {Min. 25kg/cm2}
Pedal 0 {0}
When the hydraulic pressure is abnormal, carry out troubleshooting
“Brake does not work.”
for troubleshooting (after checking that the transmission main relief
pressure is normal).
0 1.77 ± 0.29MPa
{0} {18 ± 3kg/cm2}
1.77 ± 0.29MPa 0
6 Defective steering clutch Right clutch pressure
{18 ± 3kg/cm2} {0}
0 Min. 2.45MPa
Left brake pressure
{0} {Min. 25kg./cm2}
Min. 2.45MPa 0
{Min. 25kg./cm2} {0}
cannot be steered".
check it.
20-706 D275A-5
1
TROUBLESHOOTING H-4
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE
Trouble • Machine travels only in one direction Forward or in reverse.

Related
information

PCCS lever
pressure
Full neutral Min. 2.94MPa {Min. 30kg/cm2}
valve or internal defect without turning the starting switch ON.
Possible causes • Number of shims: 6
and standard
value in normal
mode for troubleshooting. (Before this, confirm that the transmis-
state
Defective transmission sion main relief pressures is normal.)
3 Transmission clutch Clutch pressure
FWD Min. 2.65MPa {Min. 27kg/cm2}
Defective transmission When the troubleshooting in cause 3 is abnormal, the clutch seal is
4
clutch seal assume to be defective; directly check it.
Internally defective trans- The transmission clutch (forward or backward) is assumed to be de-
5
mission clutch fective internally; directly check it.
★ Move the machine to level place and start the engine for trouble-
shooting.
Defective operation of brake
6 Run the engine at low idling and set the gear in F2. If the machine
(Dragging)
does not move, the brake is dragging. (Carry out troubleshooting in
"Brake does not work".)
D275A-5 20-707
1
TROUBLESHOOTING H-5
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG
IS MADE
Trouble • Time lag is excessive when shifting gear or changing direction.

Related
information

PCCS lever
pressure
Full neutral Min. 2.94MPa{Min. 30kg/cm2}
valve or internal defect without turning the starting switch ON.
• Number of shims: 6
Possible causes
and standard ★ Prepare with starting switch OFF, then drive the engine in low idling
value in normal mode for troubleshooting. (Before this, confirm that the transmis-
state sion main relief pressure is normal.)
3
Defective transmission When the troubleshooting in cause 3 is abnormal, the clutch seal is
4
clutch seal assume to be defective; directly check it.
Internally defective trans- The transmission clutch is assumed to be defective internally; directly
5
mission clutch check it.
★ Move to a flat place, then start the engine for troubleshooting.
Defective brake function
6 If the machine does not run by low idling + F2 operation, brake drag
(Drag)
occurs. (Carry out troubleshooting “Brake does not work.”)
20-708 D275A-5
1
TROUBLESHOOTING H-6, H-7
H-5
H-6 STEERING IS NOT POSSIBLE (MACHINE DOES NOT TURN TO RIGHT OR LEFT)
Trouble • Steering is not possible.

Related • Before troubleshooting, check that the power train oil level is normal.
information • Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)

★ Start the engine for preparation and idle it at a low speed for trou-
bleshooting.
1 Defective operation of brake Life 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.”)
★ Set the starting switch to OFF for preparation and idle the engine at
a high speed for troubleshooting.
Possible causes
0 1.77 ± 0.29MPa
and standard Left clutch pressure
{0} {18 ± 3kg/cm2}
value in normal Defective operation of
state
2
steering clutch vale (ECMV) Right clutch pressure 1.77 ± 0.29MPa 0
{18 ± 3kg/cm2} {0}
0 Min. 2.45MPa
Left brake pressure
{0} {Min. 25kg./cm2}
Min. 2.45MPa 0
{Min. 25kg./cm2} {0}
Defective seal of steering When the cause 2 is not applicable, the clutch seal is supposed to be
3
clutch defective. Check it directly.
Internal defect of steering The inside of the steering clutch is supposed to be defective, check it
4
clutch directly.
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE
Trouble • Steering is possible only on one side.


★ Set the starting switch to OFF for preparation and idle the engine at
a high speed for troubleshooting.
0 1.77 ± 0.29MPa
{0} {18 ± 3kg/cm2}
Defective operation of
Possible causes 1
steering clutch vale (ECMV) Right clutch pressure 1.77 ± 0.29MPa 0
and standard {18 ± 3kg/cm2} {0}
value in normal 0 Min. 2.45MPa
state Left brake pressure
{0} {Min. 25kg./cm2}
Min. 2.45MPa 0
{Min. 25kg./cm2} {0}
Defective seal of steering When the cause 1 is not applicable, the clutch seal is supposed to be
2
clutch defective. Check it directly.
Internal defect of steering The inside of the steering clutch is supposed to be defective, check it
3
clutch directly.
D275A-5 20-709
1
H-9
H-8 STEERING OVERRUN OCCURS
Trouble • Steering overrun occurs.


★ Start the engine for preparation and idle it at a low speed for trou-
bleshooting.
Possible causes
1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for
and standard
F3 travel (or R3 travel). If the track shoe stops, the brake is defective.
value in normal
state (Execute the troubleshooting of “Brake does not work.”)
When the track shoe does not stop in the troubleshooting of the cause
Defective operation of
2 1, the steering clutch is defective. (Execute the troubleshooting of
steering clutch
“Steering is not possible.”)
H-9 BRAKE DOES NOT WORK
Trouble • Brake does not work.

Related • Confirm that the oil quantity on the power train is normal before troubleshooting.
information • Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.)

Defective brake value func- Brake pedal Brake hydraulic pressure
1
tion Min. 2.45MPa
Possible causes At release
{Min. 25kg/cm2}
and standard
At pedaling 0 {0}
value in normal
state Defective adjustment of If the troubleshooting in cause 1 is abnormal, the adjustment of the
2
brake pedal linkage brake pedal linkage is assumed to be abnormal; directly check it.
If the troubleshooting in cause 1 is abnormal, the brake seal is as-
3 Defective brake seal
sumed to be defective: directly check it.
Slipped or abrasive brake The brake disk plate is assumed to be slipped or abrasive; directly
4
disk plate check it.
20-710 D275A-5
1
TROUBLESHOOTING H-10
H-10 OVERHEAT OF POWER TRAIN OIL TEMPERATURE
Trouble • The oil temperature of the power train overheats.

• Confirm that the value of the oil temperature of the power train matches the actual oil temperature be-
Related
fore troubleshooting. (If they do not match, carry out troubleshooting “Abnormal Power Train Oil tem-
information
perature.”) Confirm that the main relief pressure for transmission is normal before troubleshooting.
(See H-1.)

The engine cooling system is assumed to be defective or the engine
1 Defective engine system
output is assumed to be increased; see the Shop Manual: Engine.
Defective power train pump ★ The power train pump is assumed to be defective or aired from the
2
or air from suction circuit suction circuit; directly check it.
3 PCCS lever
Possible causes
0.49 – 1.0MPa 0.49 ± 0.1MPa
and standard Full neutral
{5 – 10kg/cm2} {5 ± 1kg/cm2}
value in normal
state Defective transmission The transmission clutch is assumed to be defective internally
4
clutch function (Slip) (slipped); directly check it.
★ Prepare with starting the engine for troubleshooting.
1. Use the blades and ripper to float the machine from the ground.
5 2. Convert the drive position while low-idling.
(Drag)
3. If the track shoe does not rotate, brake drag occurs. (Carry out
troubleshooting "Brake does not work.")
★ Prepare with starting the engine for troubleshooting.
6 Carry out F3 stall. If the machine does not stop completely, brake slip
(Slip)
occurs.
D275A-5 20-711
1
TROUBLESHOOTING H-11
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW
Trouble • All work equipment speeds are slow.

Related
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information

Defective PTO (pump drive The PTO pump drive unit of the work equipment is assumed to be de-
1
unit of work equipment) fective; directly check it.
Defective work equipment The pump of the work equipment is assumed to be defective; directly
2
pump check it.
Defective unload valve
3 Work equipment lever Unload pressure
function
2.45 – 3.82MPa
Full neutral
{25 – 39kg/cm2}
Possible causes
and standard
Defective set pressure or idling mode for troubleshooting.
value in normal
state 4 defective function of main Work equipment lever Main relief pressure
relief valve 27.44 ± 1.37MPa
Stroke end
{280 ± 14kg/cm2}
Defective function of self-
Original pressure of control
5 pressure reducing valve Work equipment lever
circuit
(PPC original pressure)
3.23 – 3.92MPa
Full neutral
{33 – 40kg/cm2}
Internally defective PPC When the troubleshooting in cause 5 is abnormal, the PPC valve is
6
valve assumed to be defective internally; directly check it.
20-712 D275A-5
1
H-11
H-12 WORK EQUIPMENT DOES NOT MOVE
Trouble • Work equipment does not move.

Related
information

Defective PTO (Pump drive The PTO pump drive unit of the work equipment is assumed to be de-
1
unit of work equipment) fective; directly check it.
Defective work equipment The work equipment pump is assumed to be defective; directly check
2
pump it.
Defective unload valve
3 Work equipment lever Unload pressure
function
2.45 – 3.82MPa
Possible causes Full neutral
{25 – 39kg/cm2}
and standard
value in normal ★ Prepare with starting switch OFF, then drive the engine in high
state Defective set pressure or idling mode for troubleshooting.
4 defective function of main Work equipment lever Main relief pressure
relief valve 27.44 ± 1.37MPa
Stroke end
{280 ± 14kg/cm2}
Defective function of self-
Original pressure of control
5 pressure reducing valve Work equipment lever
circuit
(PPC original pressure)
3.23 – 3.92MPa
Full neutral
{33 – 40kg/cm2}
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER
Trouble • Blade lift speed is slow or lacks power.

Related • Confirm whether the blade is remodeled.
information • When the hydraulic drift rate of the blade lift is also high, carry out troubleshooting “High Hydraulic Drift
Rate of Blade Lift.”

Defective PPC valve func-
Possible causes 1 Blade lever PPC valve output pressure
tion
and standard 3.14 – 3.92MPa
Lift stroke end
value in normal {32 – 40kg/cm2}
state Defective function of blade The spool function of the blade lift operation valve is assumed to be
2
lift operation valve (Spool) defective; directly check it.
The blade lift cylinder is assumed to be aired; carry out the air bleed
3 Aired blade lift cylinder
and observe how the phenomenon changes.
D275A-5 20-713
1
H-11
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER
Trouble • Blade tilt speed is slow or lacks power.

information • When the hydraulic drift rate of the blade tilt is also high, carry out troubleshooting “High Hydraulic Drift
Rate of Blade Tilt.”

Possible causes 1 Blade lever PPC valve output pressure
tion
and standard 3.82 – 4.12MPa
Lift stroke end
value in normal {39 – 42kg/cm2}
state Defective function of blade The spool function of the blade tilt operation valve is assumed to be
2
tilt operation valve (Spool) defective; directly check it.
The blade tilt cylinder is assumed to be aired; carry out the air bleed
3 Aired blade tilt cylinder
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER
Trouble • Ripper lift speed is slow or lacks power.

Related • Confirm whether the ripper is remodeled.
information • When the hydraulic drift rate of the ripper lift is also high, carry out troubleshooting “High Hydraulic
Drift Rate of Ripper Lift.”

1 Ripper lever PPC valve output pressure
tion
3.82 – 4.12MPa
Lift stroke end
Possible causes {39 – 42kg/cm2}
and standard Defective function of ripper The spool function of the ripper lift operation valve is assumed to be
value in normal 2
lift operation valve (Spool) defective; directly check it.
state The suction valve of the ripper lift operation valve is assumed to be
Defective function of ripper
defective; directly check it.
3 lift operation valve (suction
★ Replace the suction valve in the head with one at the bottom, and
valve)
observe how the phenomenon changes.
The ripper lift cylinder is assumed to be aired; carry out the air bleed
4 Aired ripper lift cylinder
20-714 D275A-5
1
H-11
H-16 RIPPER TILE SPEED IS SLOW OR LACKS POWER
Trouble • Ripper tile speed is slow or lacks power.

Related • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
information • Confirm whether the ripper is remodeled.

1 Ripper lever PPC valve output pressure
tion
3.82 – 4.12MPa
Tilt stroke end
Possible causes {39 – 42kg/cm2}
and standard Defective function of ripper The spool function of the ripper tilt operation valve is assumed to be
value in normal 2
tilt operation valve (Spool) defective; directly check it.
state The suction valve of the ripper tilt operation valve is assumed to be
Defective function of ripper
defective; directly check it.
3 tilt operation valve (Suction
★ Replace the suction valve in the head with one at the bottom, and
valve)
observe how the phenomenon changes.
The ripper tilt cylinder is assumed to be aired; carry out the air bleed
4 Aired ripper tilt cylinder
H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT
Trouble • Excessive hydraulic drift of blade lift.

information • Confirm that no oil leaks the circuits in the work equipment before troubleshooting.

Prepare with starting the engine, then stop the engine for trouble-
shooting.
Follow the procedure below for troubleshooting. If the hydraulic drift
Possible causes speed becomes high, the spool seal of the blade lift operation valve
Defective seal of blade lift is assumed to be defective.
and standard 1
operation valve (Spool) 1. Prop up the machine using the blade lift, and lift the front of the
value in normal
state machine.
2. Stop the engine, and release the safety lock lever.
3. Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of blade lift The seal of the blade lift cylinder is assumed to be defective; directly
2
cylinder check it.
D275A-5 20-715
1
H-11
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT
Trouble • Excessive hydraulic drift of blade tilt.


★ Prepare with starting the engine, then stop the engine for trouble-
shooting.
speed becomes high, the spool seal of the blade tilt operation valve
Defective seal of blade tilt is assumed to be defective.
Possible causes 1
operation valve (Spool) 1. Prop up the machine using the blade tilt, and lift the right of the
and standard machine.
value in normal
2. Stop the engine, and release the safety lock lever.
state
3. Set the blade lever to the right tilt side, and confirm how the phe-
nomenon changes.
Defective seal of blade tilt idling mode for troubleshooting.
2
cylinder Blade tilt cylinder Cylinder leak quantity
Right tilt stroke end 16cc/min
H-19 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT
Trouble • Excessive hydraulic drift of ripper lift.

Related • Confirm whether the ripper is remodeled.

★ Prepare with starting the engine, then stop the engine for trouble-
shooting.
speed becomes high, the spool seal of the ripper lift operation valve
Defective seal of ripper lift (Hi) is assumed to be defective.
Possible causes 1
operation valve (Spool) 1. Prop up the machine using the blade tilt, and lift the rear of the
and standard
machine.
value in normal 2. Stop the engine, and release the safety lock lever.
state 3. Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of ripper lift idling mode for troubleshooting.
2
cylinder Ripper lift cylinder Cylinder leak quantity
Lowering stroke end 16cc/min
20-716 D275A-5
1
TROUBLESHOOTING H-20, H-21, H-22
H-11
H-20 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT
MACHINE)
Trouble • The ripper pin puller cylinder does not work.

Related
• Confirm that the main relief pressure for transmission is normal before troubleshooting.
information

Possible causes
Defective function of pin Pin puller working
and standard 1 Pin puller switch Measurement position
puller solenoid pressure
value in normal
state Push-in Cylinder bottom side Min. 2.45MPa
Pull-in Cylinder head side {Min. 25kg/cm2}
Internally defective pin pull- The pin puller cylinder is assumed to be defective internally; directly
2
er cylinder check it.
H-21 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE)
Trouble • The blade pitch does not work.

Related
information

Defective function of blade
The spool of the blade pitch operation valve is assumed to be defec-
1 pitch selection solenoid
Possible causes tive; directly check it.
valve
and standard
Defective function of blade
value in normal The function of the blade pitch cylinder is assumed to be defective;
state 2 pitch operation valve
directly check it.
(Spool)
Defective function of blade The function of the blade pitch selection solenoid valve is assumed to
3
pitch cylinder be defective; directly check it.
H-22 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP
Trouble • Abnormal noise from around work equipment pump.

Related
information

1 Inappropriate oil The oil used is assumed to be inappropriate; directly check it.
Possible causes Clogged hydraulic oil tank The strainer of the hydraulic oil tank is assumed to be clogged; direct-
2
and standard strainer ly check it.
value in normal Air is assumed to be inhaled in the suction circuit of the work machine
state 3 Air inhaled in suction circuit
pump; directly check the pipes.
Internally defective work The work equipment pump is assumed to be defective internally; di-
4
equipment pump rectly check it.
D275A-5 20-717
1
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE SYSTEM

(S-MODE)
Method of using troubleshooting charts ...... 20-802

S- 1 Starting performance is poor
(starting always takes time) ............... 20-806
S- 2 Engine does not start ........................ 20-807
a) Engine does not turn ................... 20-807
b) Engine turns but no exhaust
smoke comes out ........................ 20-808
c) Exhaust smoke comes out
but engine does not start
(Fuel is being injected) ................ 20-809
S- 3 Engine does not pick up smoothly
(follow-up is poor) .............................. 20-810
S- 4 Engine stops during operations ......... 20-811
S- 5 Engine does not rotate smoothly
(hunting) ............................................ 20-812
S- 6 Engine lacks output
(or lacks power) ................................. 20-813
S- 7 Exhaust smoke is black
(incomplete combustion) ................... 20-814
S- 8 Oil consumption is excessive
(or exhaust smoke is blue) ................ 20-815
S- 9 Oil becomes contaminated quickly .... 20-816
S-10 Fuel consumption is excessive .......... 20-817
S-11 Oil is in coolant (or coolant spurts
back, or coolant level goes down) ..... 20-818
S-12 Oil pressure caution lamp lights up
(drop in oil pressure) ......................... 20-819
S-13 Oil level rises (water, fuel in oil) ......... 20-820
S-14 Water temperature becomes
too high (overheating) ....................... 20-821
S-15 Abnormal noise is made .................... 20-822
S-16 Vibration is excessive ........................ 20-823
D275A-5 20-801
(7)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make fi-
nal confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in (B) are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under (C) in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the
user and the results of (C) that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-802 D275A-5
(7)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high prob-
ability are marked with w.
Check each of the [Questions] and [Check items]
in turn, taking note of the Q or w marks in the chart
for the horizontal lines of symptoms applicable to the
machine. The vertical column (Causes) that has the
highest number of applicable Q or w marks is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
*1. For (Confirm recent repair history) in the

[Questions] Section, ask the user, and mark
the Cause column with E to use as refer-
ence for locating the cause of the fairure.
However, do not use this when marking calu-
culations to narrow down causes.
*2. Use the E in the Cause column as reference
for [Degree of use (Operated for long peri-
od)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be in-
cluded if necessary to determine the order
for troubleshooting.
*1
*2
D275A-5 20-803
(7)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have a causal relationship with this problem: [Exhaust gas gradually became black], [Power gradually be-
came weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited be-
cause an error has occurred in the electrical
system.)
Legend
: Possible causes (judging from Questions and Check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
20-804 D275A-5
(7)
5 causes
Step 1
Clarify the relationship between the three symptoms in

the [Questions] and [Check items] section and the 5
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of and marked where the
horizontal limes for the three symptoms and the vertical
columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cyl. head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element]. Follow
this column down to the troubleshooting area and carry
out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
D275A-5 20-805
(7)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (starting always takes time)

General causes why starting performance is poor
• Defective electrical system
• Insufficient supply of fuel
a With the common rail fuel injection system, the fuel

injection timing is recognized electrically, so even
when the starting operation is carried out, the engine
may not start until the crankshaft has completed two
Wear-out failure inside fuel injector
rotations. However, this does not indicate any abnor-
mality.
When engine warm up like first thing the daytime, the start ability is worse
There is a large amount of the fuel spill (See error code "AD10L3")
20-806 D275A-5
(7)
TROUBLESHOOTING S-2
S-2 Engine does not start

a) Engine does not turn
General causes why engine does not turn
• Internal parts of engine seized
a See “Engine stops during operations.”
• Defective electrical system
• Failure in power train
a Carry out troubleshooting of the machine.
D275A-5 20-807
(7)
TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust
smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
20-808 D275A-5
(7)
TROUBLESHOOTING S-2
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
• Lack of rotating force due to defective electrical
system
D275A-5 20-809
(7)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly
(The injection amount (output) is limited because an
error has occurred in the electrical system.)
20-810 D275A-5
(7)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops
• Internal part of engine seized
• Failure in power train
a Carry out troubleshooting of the machine.
D275A-5 20-811
(7)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly
• Air in fuel system
• Speed sensor is not normal
(abnormality not big enough to generate error display)
20-812 D275A-5
(7)
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output
Carry out troubleshooting for error code"DGE4KX"
D275A-5 20-813
(7)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
• There is excessive fuel.
20-814 D275A-5
(7)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive
• Abnormal combustion of oil
• The engine has been run at low or high idling for a
long time continuously (more than 20 minutes contin-
uous operation is not allowed).
• External leakage of oil
• Wear of lubrication system
D275A-5 20-815
(7)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
• Improper oil used
• Operation under excessive load
20-816 D275A-5
(7)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
• Leakage of fuel
• Improper condition of fuel injection (injection pres-
sure, injection timing)
• Excessive injection of fuel
D275A-5 20-817
(7)
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)
General causes why oil is in coolant
• Internal leakage in lubrication system
• Internal leakage in cooling system
20-818 D275A-5
(7)
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure drops
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Carry out troubleshooting for error code "DDE2L6"
D275A-5 20-819
(7)
S-13 Oil level rises (water, fuel in oil)

General causes why oil level rises
• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
a If there is oil in the cooling water, carry out trouble-

shooting for “Oil is in cooling water.”
20-820 D275A-5
(7)
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train
a Carry out troubleshooting for machine.
D275A-5 20-821
(7)
S-15 Abnormal noise is made

General causes why abnormal noise is made
• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
a Judge if the noise is an internal noise or an external

noise.
a If the engine is not thoroughly warmed up, the engine
sound becomes slightly louder because it is operated
in the low temperature mode, but this is not an abnor-
mality.
a When the engine is accelerated, it enters the acceler-
ation mode and the engine noise is higher for 3 sec-
onds, but this is not an abnormality.
20-822 D275A-5
(7)
S-16 Vibration is excessive

General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment with machine
• Abnormal combustion
a If there is abnormal noise together with the vibration,

carry out troubleshooting also for “Abnormal noise is
made.”
D275A-5 20-823
(7)
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL . . . . . . . . . . . . 30-5 REMOVAL AND INSTALLATION OF HYDRAULIC

Removal and installation of assemblies . . . . 30-5 OIL COOLER ASSEMBLY . . . . . . . . . . . . . . . . 30-42
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
Removal of parts. . . . . . . . . . . . . . . . . . . . . . 30-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
Installation of parts . . . . . . . . . . . . . . . . . . . . 30-5 REMOVAL AND INSTALLATION OF RADIATOR
Sketches of special tools . . . . . . . . . . . . . . . 30-5 GUARD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 30-44
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
Disassembly and assembly of assemblies . . 30-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
REMOVAL AND INSTALLATION OF ENGINE 30-47
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-6 Special tools . . . . . . . . . . . . . . . . . . . . . . . . 30-47
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
Sketches of special tools . . . . . . . . . . . . . . . 30-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
PRECAUTIONS WHEN CARRYING OUT REMOVAL AND INSTALLATION OF DAMPER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . .30-8-1 Special tools . . . . . . . . . . . . . . . . . . . . . . . . 30-53
REMOVAL AND INSTALLATION OF FUEL SUPPLY
PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 30-9 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 DISASSEMBLY AND ASSEMBLY OF DAMPER
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 30-11 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
Special tools . . . . . . . . . . . . . . . . . . . . . . . . 30-57
REMOVAL AND INSTALLATION OF FUEL
INJECTOR ASSEMBLY. . . . . . . . . . . . . . . . . . 30-13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 30-58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 REMOVAL AND INSTALLATION OF POWER TRAIN
REMOVAL AND INSTALLATION OF NOZZLE UNIT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 30-62
TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
Special tools . . . . . . . . . . . . . . . . . . . . . . . . 30-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 DISCONNECTION AND CONNECTION OF POWER
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 TRAIN UNIT ASSEMBLY . . . . . . . . . . . . . . . . . 30-67
Disconnection . . . . . . . . . . . . . . . . . . . . . . . 30-67
Sketch of special tool . . . . . . . . . . . . . . . . . 30-21
Connection. . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
REMOVAL AND INSTALLATION OF ENGINE
FRONT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 Connection diagram of centralized oil pressure
Special tools . . . . . . . . . . . . . . . . . . . . . . . . 30-22 pick-up hoses. . . . . . . . . . . . . . . . . . . . . . . . 30-74
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 DISASSEMBLY AND ASSEMBLY OF PTO
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 30-76
REMOVAL AND INSTALLATION OF ENGINE REAR
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
Special tools . . . . . . . . . . . . . . . . . . . . . . . . 30-24 DISASSEMBLY AND ASSEMBLY OF TORQUE
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 CONVERTER ASSEMBLY . . . . . . . . . . . . . . . . 30-83
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 30-83
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
REMOVAL AND INSTALLATION OF CYLINDER
HEAD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . 30-26 DISASSEMBLY AND ASSEMBLY OF TORQFLOW
Special tools . . . . . . . . . . . . . . . . . . . . . . . . 30-26 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . 30-90
Special tools . . . . . . . . . . . . . . . . . . . . . . . . 30-90
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 30-90
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
REMOVAL AND INSTALLATION OF FUEL TANK
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 DISASSEMBLY AND ASSEMBLY OF STEERING
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-109
Special tools . . . . . . . . . . . . . . . . . . . . . . . 30-109
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 30-109
REMOVAL AND INSTALLATION OF MAIN
RADIATOR ASSEMBLY . . . . . . . . . . . . . . . . . 30-37 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37 REMOVAL AND INSTALLATION OF SCAVENGING
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 30-39 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
REMOVAL AND INSTALLATION OF SUB-
RADIATOR ASSEMBLY . . . . . . . . . . . . . . . . . 30-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
D275A-5 30-1
3
2
DISASSEMBLY
AND ASSEMBLY
REMOVAL AND INSTALLATION OF WORK DISASSEMBLY AND ASSEMBLY OF TRACK

EQUIPMENT PUMP ASSEMBLY . . . . . . . . . 30-128 ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . 30-169
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128 Special tools . . . . . . . . . . . . . . . . . . . . . . . 30-169
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-129 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 30-169
REMOVAL AND INSTALLATION OF FAN PUMP Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-170
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130 Sketch of special tool. . . . . . . . . . . . . . . . 30-172
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130 REMOVAL AND INSTALLATION OF CARRIER
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-131 ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . 30-173
REMOVAL AND INSTALLATION OF POWER Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-173
TRAIN AND STEERING LUBRICATING OIL PUMP Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-173
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132 DISASSEMBLY AND ASSEMBLY OF CARRIER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132 ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . 30-174
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-133 Special tools . . . . . . . . . . . . . . . . . . . . . . . 30-174
REMOVAL AND INSTALLATION OF FINAL DRIVE Disassembly . . . . . . . . . . . . . . . . . . . . . . . 30-174
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-175
Special tools . . . . . . . . . . . . . . . . . . . . . . 30-134
Sketch of special tool. . . . . . . . . . . . . . . . 30-177
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134
REMOVAL AND INSTALLATION OF 1ST BOGIE
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-135 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
Sketch of special tool . . . . . . . . . . . . . . . 30-136 Special tools . . . . . . . . . . . . . . . . . . . . . . . 30-178
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-137 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-180
Special tools . . . . . . . . . . . . . . . . . . . . . . 30-137
Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-137
REMOVAL AND INSTALLATION OF 2ND, 3RD
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-142 AND 4TH BOGIE ASSEMBLY . . . . . . . . . . . 30-184
REMOVAL AND INSTALLATION OF TRACK Special tools . . . . . . . . . . . . . . . . . . . . . . . 30-184
FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . 30-150 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
Special tools . . . . . . . . . . . . . . . . . . . . . . 30-150
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-186
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-150
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-153
DISASSEMBLY AND ASSEMBLY OF BOGIE
Sketch of special tool . . . . . . . . . . . . . . . 30-154 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-192
REMOVAL AND INSTALLATION OF IDLER Special tools . . . . . . . . . . . . . . . . . . . . . . . 30-192
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 30-192
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-192
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-155
DISASSEMBLY AND ASSEMBLY OF IDLER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156 EXPANDING AND INSTALLING TRACK SHOE
Special tools . . . . . . . . . . . . . . . . . . . . . . 30-156 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196
Check before expanding track shoe
Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-156
assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 30-196
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-157
Expanding track show assembly (Normal)
Sketch of special tool . . . . . . . . . . . . . . . 30-159
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196
REMOVAL AND INSTALLATION OF RECOIL
SPRING ASSEMBLY. . . . . . . . . . . . . . . . . . . 30-160 Expanding track shoe assembly . . . . . . . 30-197
Special tools . . . . . . . . . . . . . . . . . . . . . . 30-160 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-198
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160 WHOLE DISASSEMBLY AND WHOLE ASSEMBLY
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-163 OF TRACK SHOE ASSEMBLY . . . . . . . . . . . 30-199
Special tools . . . . . . . . . . . . . . . . . . . . . . . 30-199
DISASSEMBLY AND ASSEMBLY OF RECOIL
SPRING ASSEMBLY. . . . . . . . . . . . . . . . . . . 30-164 Whole disassembly . . . . . . . . . . . . . . . . . 30-200
Special tools . . . . . . . . . . . . . . . . . . . . . . 30-164 Whole assembly. . . . . . . . . . . . . . . . . . . . 30-202
Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-164 Dimension table of fitting jig of link press
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-213
REMOVAL AND INSTALLATION OF TRACK Disassembly of 1 link in the field . . . . . . 30-214
ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . 30-166 Assembly of 1 link in the field. . . . . . . . . 30-215
Special tools . . . . . . . . . . . . . . . . . . . . . . 30-166 Disassembly of master link . . . . . . . . . . . 30-216
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166 Assembly of master link . . . . . . . . . . . . . 30-217
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-167 REMOVAL AND INSTALLATION OF PIVOT SHAFT
Sketch of special tool . . . . . . . . . . . . . . . 30-168 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
Special tools . . . . . . . . . . . . . . . . . . . . . . . 30-219
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-219
REMOVAL AND INSTALLATION OF EQUALIZER
BAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 30-220
Special tools . . . . . . . . . . . . . . . . . . . . . . . 30-220
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-221
30-2 D275A-5
c
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF EQUILIZER

BAR BUSHING . . . . . . . . . . . . . . . . . . . . . . . 30-224
Special tools . . . . . . . . . . . . . . . . . . . . . . 30-224
Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-224
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
REMOVAL AND INSTALLATION OF WORK
EQUIPMENT CONTROL VALVE ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-228
DISASSEMBLY AND ASSEMBLY OF WORK
EQUIPMENT CONTROL VALVE ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . 30-231
Special tools . . . . . . . . . . . . . . . . . . . . . . 30-231
Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-231
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-234
REMOVAL AND INSTALLATION OF BLADE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-239
DISASSEMBLY AND ASSEMBLY OF RIPPER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-240
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-242
REMOVAL AND INSTALLATION OF ROPS
GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-244
REMOVAL AND INSTALLATION OF OPERATOR’S
CAB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 30-245
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-245
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-246
REMOVAL AND INSTALLATION OF FLOOR
FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . 30-247
Special tools . . . . . . . . . . . . . . . . . . . . . . 30-247
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-247
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-250
REMOVAL AND INSTALLATION OF
TRANSMISSION CONTROLLER ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-252
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-252
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-252
REMOVAL AND INSTALLATION OF STEERING
CONTROLLER ASSEMBLY . . . . . . . . . . . . . 30-253
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-253
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-253
CONTROLLER ASSEMBLY . . . . . . . . . . . . . 30-254
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-254
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-254
HOOD ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-255
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-255
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-256
REMOVAL AND INSTALLATION OF FAN DRIVE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-257
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-257
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-257
REMOVAL AND INSTALLATION OF FAN
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-258
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-258
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-258
D275A-5 30-3
c
DISASSEMBLY
AND ASSEMBLY HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL

REMOVAL AND INSTALLATION OF ASSEMBLIES
SPECIAL TOOLS INSTALLATION OF PARTS

• Special tools that are deemed necessary for • Except where otherwise instructed, install
removal or installation of parts are listed. parts in the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing
kind of information. parts are shown with 1 mark in the
1) Necessity INSTALLATION Section, identifying which
■: Special tools which cannot be substi- step the instructions are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
●: Special tools which are very useful if stand for the following.
available, can be substituted with This mark indicates safety-related pre-
commercially available tools. cautions which must be followed
2) Distinction of new and existing special when doing the work.
tools ★ This mark gives guidance or precau-
N: Tools with new part numbers, newly tions when doing the procedure.
developed for this model.
This mark stands for a specific coating
R: Tools with upgraded part numbers,
agent to be used.
remodeled from already available
This mark indicates the specified
tools for other models.
torque.
Blanks: Tools already available for
This mark indicates an amount of oil
other models, used without
or water to be added.
any modification.
3) Circle mark ({) in sketch column:
A circle mark means that a sketch of the SKETCHES OF SPECIAL TOOLS
special tool is presented in the section of
• Various special tools are illustrated for the
Sketches for Special Tools.
convenience of local manufacture.
★ Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
REMOVAL OF PARTS
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to
be drained.
• Various symbols used in the REMOVAL Sec-
tion are explained and listed below.
This mark indicates safety-related pre-
cautions which must be followed
when doing the work.
★ This mark gives guidance or precau-
tions when doing the procedure.
1 This mark shows that there are
instructions or precautions for install-
ing parts.
This mark shows oil or water to be
drained.
D275A-5 30-5
c
DISASSEMBLY
AND ASSEMBLY HOW TO READ THIS MANUAL
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS ASSEMBLY

• special tools which are deemed necessary for • Section titled ASSEMBLY contain procedures,
disassembly are listed in this section. precautions and the know-how for the work,
• List of the special tools contains the following as well as the amount of oil or water to be
kind of information. added.
1) Necessity • Various symbols used in the ASSEMBLY Sec-
■: Special tools which cannot be substi- tion are explained and listed below.
tuted, should always be used. This mark indicates safety-related pre-
●: Special tools which are very useful if cautions which must be followed
available, can be substituted with when doing the work.
commercially available tools. ★ This mark gives guidance or precau-
2) Distinction of new and existing special tions when doing the procedure.
tools This mark stands for a specific coating
N: Tools with new part numbers, newly agent to be used.
developed for this model. This mark indicates the specified
R: Tools with upgraded part numbers, torque.
remodeled from already available This mark indicates an amount of oil
tools for other models. or water to be added.
Blanks: Tools already available for
other models, used without
SKETCHES OF SPECIAL TOOLS
any modification.
3) Circle mark ({) in sketch column: • Various special tools are illustrated for the
A circle mark means that a sketch of the convenience of local manufacture.
special tool is presented in the section of
Sketches for Special Tools.
★ Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
DISASSEMBLY
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
This mark indicates safety-related pre-
cautions which must be followed
when doing the work.
★ This mark gives guidance or precau-
tions when doing the procedure.
1 This mark shows that there are
instructions or precautions for install-
ing parts.
This mark shows oil or water to be
drained.
30-6 D275A-5
c
DISASSEMBLY
AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precau-
tions given below when carrying out the operation.]
1. PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK

• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installed position, or 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, disconnect connectors by grasping the con-
nector, not the wire.
• Tag wires and hoses to show their installed position to prevent any mistake when reinstalling.
• 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 alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
s Precautions when handling piping during disassembling.

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal Number Plug (Nut end) Nut (Elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes

Nominal Number Flange (Hose end) Sleeve Head (Tube end) Split Flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
D275A-5 30-7
3
2
DISASSEMBLY
AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 to 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 eye bolts, check that there is no deformation or deterioration, screw them 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 idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 to 5 times, stopping
the cylinder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 to 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.
3. PRECAUTIONS WHEN COMPLETING THE OPERATION

• If the coolant has to be drained, tighten the valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the coolant water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related
parts.
30-8 D275A-5
c
DISASSEMBLY
AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

s Tools with number 799T-999-9999 cannot be supplied (they are items to be locally manufactured).
s Necessity: Cannot be substituted, should always be installed (used)
z: Extremely useful if available, can be substituted with commercially available part.
s New/removed;N ...... Tools with new part numbers, newly developed for this model
R ...... Tools with upgraded part numbers, remodeled from items already available for other models.
Blank ...... Tools already available for other models, used without any modification
s Tools marked 9 in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS)
New/remodel
Sketch
Qty
Component Symbol Part No. Part Name Nature of work, remarks
795-471-1500 Remover 1
e795-471-1520 eblock 1
e795-471-1530 ebolt
Removal of fuel supply pump
A1
1 assembly
e01435-01070 ebolt 2
795-521-1110 Push tool 1
Removal, installation
790-101-5221 Grip 1
A2 Installation of Engine front seal
01010-51225 Bolt 1
Engine assembly 01010-31640 Bolt 3
795-931-1210 Sleeve 1
795-931-1220 Sleeve 1
A3 Installation of Engine rear seal
01050-31625 Bolt 3
01050-31645 Bolt 3
A4 790-331-1110 Wrench 1 Tighten of cylinder head bolt
9
Removal, Installation of nozzle
A5 795T-471-1550 Wrench 1
tip
791-612-1100 Installer 1
Damper assembly B 790-101-4200 Puller (294kN {30ton}) 1 Press fitting of bearing
790-101-1102 Hydraulic pump 1

Disassembly, assembly
TORQFLOW transmission
D 799-301-1600 Oil leak tester 1 Checking actuation of piston
assembly
791-622-1110 Bracket 1
Removal, Installation of
1 01010-62095 Bolt 1
HSS case assembly E Brake•carrier assembly
01016-61690 Bolt 1
2 796-550-1301 Wrench 1 Removal, Installation of lock nut
790-337-1032 Lifting tool 1
791-627-1320 Shackle 2 Removal, Installation of final

9
1
791T-627-1810 Plate 1 drive assembly
01010-82090 Bolt 2
791-627-1400 Remover 1
Final drive assembly J

2 790-101-2102 Puller 1 Pulling out sprocket bearing
790-101-1102 Pump 1
791-627-1600 Remover 1
Removal of planetary gear
3 790-101-2102 Puller 1
shaft
790-101-1102 Pump 1
D275A-5 30-8-1
3
DISASSEMBLY
New/remodel
Sketch
Qty
791-627-1200 Remover 1
4 790-101-2102 Puller 1 Removal of hub assembly
790-101-1102 Pump 1
791-627-1300 Installer 1
5 790-101-2102 Puller 1 Press fitting of hub bearing
Final drive assembly J
790-101-1102 Pump 1
791-627-1500 Installer 1
6 790-101-2102 Puller 1 Press fitting of cover bearing
790-101-1102 Pump 1
7 791-627-1280 Installer 1 Installation of floating seal
791T-630-1310 Plate 1 N 9
791-630-1220 Rod 4
790-101-2510 Block 2
790-101-2570 Plate 4
1 Press fitting of bushing
01643-31445 Washer 4
Idler assembly 01580-01411 Nut 4
790-101-2102 Puller (294kN {30ton}) 1
790-101-1102 Pump 1
3 791-630-1240 Push tool 1 Press fitting of seal guide
4 791-601-1000 Oil pump 1 Filling with oil
790-401-1700 Lifting tool 1
Removal, installation Disassembly, assembly Removal, installation Disassembly, assembly Removal, installation
790-401-1761 Adapter 1 Installation of No.1track roller

5
790-401-1540 Shackle 2 assembly
790-401-1770 T-bolt 2
6 791T-630-1320 Plate 1 N 9 Press fitting of bushing
Track roller assembly 7 791T-630-1330 Push tool 1 N 9 Installation of floating seal

8 791-651-1510 Installer 1 Press fitting of seal guide
L
14 791T-630-1380 Bracket 4 9 Secure bogie assembly
10 790-102-1891 Nut wrench 1 Removal, Installation of nut

1 N 9
Carrier roller assembly
12 791T-630-2410 Push tool Press fitting of seal guide
Track frame assembly 14 791T-630-1380 Bracket 6 9 Secure bogie assembly

791-630-1360 Spacer 1 N
Removal of shaft e ring

No.2, 3, 4 Bogie assembly 790-101-2310 Block 1
15 790-101-2360 Plate 2
790-445-4130 Screw 2
30-8-2 D275A-5
3
DISASSEMBLY
New/remodel
Sketch
Qty
791-112-1180 Nut 2
15 790-101-4000 Puller (490kN {50ton}) 1
790-101-1102 Pump 1
790-201-2760 Spacer 1 N
Removal of shaft e ring

791-630-1370 Adapter 1
790-434-1060 Screw 2
16 01580-13024 Nut 2
01643-33080 Washer 1
790-101-4000 Puller (490kN {50ton}) 1
790-101-1102 Pump 1
No.2, 3, 4 Bogie assembly Check the airtight of the floating
18 790-701-3000 Seal checker 1
seal
1 N 9
Adjustment procedure for car-
19 791T-630-1390 Guide
tridge pin hole
790-101-2310 Block 1
790-445-4130 Screw 2
796T-470-1130 Plate 1 9
Press fitting of cartridge pin as-
L 20 790-101-2360 Plate 2
sembly
791-112-1180 Nut 2
790-101-4000 Puller (490kN {50ton}) 1
790-101-1102 Pump 1
790-101-2310 Block 1
Disassembly ,assembly
790-445-4130 Screw 2
796T-470-1130 Plate 1 9
Press fitting of cartridge pin as-
20 790-101-2360 Plate 2
Bogie assembly sembly
791-112-1180 Nut 2
790-101-4000 Puller (490kN {50ton}) 1
790-101-1102 Pump 1
790-401-1700 Lifting tool 1 Removal, Installation of track

22
No.1 Bogie assembly 790-401-1761 Adapter 1 roller assembly
791-630-1860 Bracket 1
23 Pull up of No.1bogie assembly
791-630-1870 Bracket 1
791-730-1110 Bolt 6
Disassembly of Idler yoke, re-

1 01580-12722 Nut 6
coil cylinder
01643-32780 Washer 6
791-630-1100 Installer 1
2 790-101-1600 Cylinder (686kN {70ton}) 1 Press fitting of bushing
790-101-1102 Pump 1
Recoil spring assembly M
791-685-8502 Compressor 1
790-201-2780 Spacer 1
Disassembly, assembly of Re-
3 791-635-3160 Extension 1
coil spring assembly
790-101-1600 Cylinder (686kN {70ton}) 1
790-101-1102 Pump 1
D275A-5 30-8-3
3
DISASSEMBLY
New/remodel
Sketch
Qty
791T-650-1930 Spacer 1 N 9
792-900-1520 Plate 1
791-520-4140 Screw 1
790-101-2470 Adapter 1
Equalizer bar assembly N1 Removal of center pin
790-101-2540 Washer 1
791-112-1180 Nut 1
790-101-2102 Puller (294kN {30ton}) 1
Removal, installation Disassembly, assembly

791-650-1800 Remover 1
Removal, Installation of spheri-
Equalizer bar bushing N2 790-101-2102 Puller (294kN {30ton}) 1
cal bushing
Removal, Installation of pivot
1 790-401-1700 Lifting tool 1
shaft assembly
Pivot shaft assembly P 791-650-1700 Installer 1
2 790-101-4200 Puller (294kN {30ton}) 1 Press fitting of seal
1 791-646-7531 Plug remover 1 Removal of pin plug
2 791-660-7460 Pin brush 1 Cleaning of pin hole
3 791-646-7900 Push tool 1 Press fitting of pin plug
4 791-932-1110 Push tool 1 Press fitting of pin plug
790-701-3000 Seal checker 1
5 Supply oil
791-601-1000 Pump 1
6 791-632-1070 Installer 1 N Installation of seal assembly
791-680-9802 Remover & installer 1
791-680-1520 Guide 1
7 790-101-4200 Puller (294kN {30ton}) 1 Disassembly of a link
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1
790-434-1110 Adapter 1
790-434-1610 Guide 1
11
195-32-61210 Bolt 1
Track shoe assembly R
01010-51440 Bolt 2
790-101-4300 Cylinder (1470kN {150ton}) 1
12
790-101-1102 Pump 1
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
Disassembly of a single link
791-685-9550 Nut 1
791-685-9560 Bolt 4
13
790-434-1110 Adapter 1
01010-51030 Bolt 1
04530-12030 Eyebolt 1
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1
791-685-9540 Rod 1
14
791-685-9550 Nut 1
30-8-4 D275A-5
3
DISASSEMBLY
New/remodel
Sketch
Qty
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
791-685-9550 Nut 2
791-685-9560 Bolt 4
791-126-0150 Adapter 1
791-680-5520 Guide 1
15
791-126-0140 Pusher 1
790-434-1110 Adapter 1 Disassembly of a single link
01010-51030 Bolt 1
04530-12030 Eyebolt 1
791-685-9620 Extension 1
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1
791-680-1630 Spacer 1
16 790-101-4200 Puller (294kN {30ton}) 1
790-101-1102 Pump 1
791-680-5543 Adapter (for pin) 1
791-680-9630 Adapter (for bushing) 1
17
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1
Track shoe assembly R 18 790-434-1130 Guide 1
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
791-685-9540 Rod 1
791-685-9550 Nut 3
791-685-9560 Bolt 4
19 791-126-0150 Adapter 1
01010-51030 Bolt 1
Assembly of a single link
791-685-9620 Extension 1
791-680-5543 Adapter 1
791-680-5551 Guide 1
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1
791-685-9510 Frame 1
791-685-9520 Frame 1
791-685-9530 Rod 1
791-685-9540 Rod 1
20
791-685-9550 Nut 3
791-685-9560 Bolt 4
791-126-0150 Adapter 1
01010-51030 Bolt 1
D275A-5 30-8-5
3
DISASSEMBLY
New/remodel
Sketch
Qty
791-685-9620 Extension 1
791-680-5551 Guide 1
790-434-1140 Adapter 1
20
791-680-9630 Adapter 1
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1
790-101-4200 Puller (294kN {30ton}) 1
21
790-101-1102 Pump 1
22 790-434-1160 Guide 1
791-685-9510 Frame 1
791-685-9520 Frame 1
Track shoe assembly R Assembly of a single link
791-685-9530 Rod 1
791-685-9540 Rod 1
791-685-9550 Nut 3
791-685-9560 Bolt 4
23 791-126-0150 Adapter 1
790-434-1151 Guide 1
790-434-1110 Adapter 1
01010-51030 Bolt 1
790-434-1160 Guide 1
790-101-4300 Cylinder (1470kN {150ton}) 1
790-101-1102 Pump 1
790-502-1003 Cylinder repair stand 1 Disassembly, assembly of hy-
1
790-101-1102 Pump 1 draulic cylinder
790-102-2303 Wrench 1 Removal and assembly of
2
790-102-3802 Wrench 1 round head
790-102-4300 Wrench 1 Removal and assembly of
3
790-102-4310 Pin 2 round piston
790-201-1702 Push tool kit 1 For press fitting coil bushing

e790-101-5021 eGrip 1
e01010-50816 eBolt 1
e790-201-1831 ePush tool
4
Hydraulic cylinder assembly U 1 (Blade lift)
e790-201-1851 ePush tool 1 (Blade tilt, ripper lift)
e790-201-1841 ePush tool 1 (Ripper tilt)
790-201-1500 Push tool kit 1 For press fitting dust seal
e790-101-5021 eGrip 1
e01010-50816 eBolt 1
e790-201-1640 ePlate
5
1 (Blade lift)
e790-201-1650 ePlate 1 (Ripper tilt)
e790-201-1660 ePlate 1 (Blade tilt, ripper lift)
6 790-720-1000 Expander 1 Expansion of piston ring
30-8-6 D275A-5
3
DISASSEMBLY
New/remodel
Sketch
Qty
Expansion of piston ring

796-720-1670 Ring 1
(Blade lift)
07281-01279 Clamp 1 (Blade lift)
796-720-1690 Ring 1 (Blade tilt, ripper lift)
Hydraulic cylinder assembly U 7
07281-01919 Clamp 1 (Blade tilt, ripper lift)
796-720-1680 Ring 1 (Ripper tilt)
07281-01589 Clamp 1 (Ripper tilt)
799-703-1200 Service tool kit 1
799-703-1100 Vacuum pump (100W) 1
799-703-1110 Vacuum pump (220W) 1 Filling with air conditioner
Related to air conditioner X
refrigerant (gas)
799-703-1120 Vacuum pump (240W) 1
799-703-1401 Gas leak detector 1
D275A-5 30-8-7
(7) 3
DISASSEMBLY
SKETCH OF SPECIAL TOOL

Note: We will not be liable for any result caused by a special tool made according to this drawing.
A5 Wrench
J1 Plate
30-8-8 D275A-5
3 (7)
DISASSEMBLY
L1 Plate
L6 Plate
D275A-5 30-8-9
(7) 3
DISASSEMBLY
L7 Push tool
L12 Push tool
30-8-10 D275A-5
3 (7)
(7)
DISASSEMBLY
L14 Bracket
L19 Guide
D275A-5 30-8-11
(7) 3
DISASSEMBLY
L20 Plate
N1 Spacer
30-8-12 D275A-5
3 (7)
(7)
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY

SPECIAL TOOLS
Sym New/
Part No. Part Name Nece Qty. Remo Sketch
bol ssity del
795-471-1500 Remover ■ 1
795-471-1520 Block 1
A1
795-471-1530 Bolt 1
01435-01070 Bolt 2
REMOVAL
WARNING! Disconnect the cable from

the negative (-) terminal of the battery. 8. Disconnect fuel supply pump wiring connec-
tors (5) and (6) and engine G speed sensor
1. Drain the cooling water. wiring connector (7).
9. Remove fuel filter bracket (8).
Cooling water: Approx. 130 l ★ Move the fuel filter bracket aside.
10. Remove common rail cover (9).
2. Release the residual pressure from the fuel
system. For details, see TESTING AND
ADJUSTING, Releasing residual pressure
from fuel system.
3. Open the left side cover of the engine.
4. Remove side cover (1).
11. Remove brackets (10) and (11) and 4 caps

(12).
12. Remove fuel filter tubes (13) and (14). 2
5. Remove bracket (2) and move it aside so that

it will not be an obstacle to removal of the
fuel supply pump assembly.
6. Remove the 2 clamps of 2 water separator
drain hoses (3).
7. Remove water pump tube (4). 1
D275A-5 30-9
c
DISASSEMBLY
13. Remove fuel tube (15) and lubrication tubes 18. Remove nut (23) and washer (24). 5
3
(16) and (17). ★ Take care not to drop the nut and washer
14. Disconnect fuel tube (18) and fuel hose (19). in the engine.
15. Disconnect sub-radiator outlet hose (20). 19. Remove filler gauge (25) and high-pressure
4 pipes (26) and (27). 6
16. Remove 3 nuts (21) and the water pump
assembly.
20. Remove cover (28) and bracket (29). 7
30-10 D275A-5
c
DISASSEMBLY
21. Set tool A1. 2
Eye-joint bolt of fuel filter tube:

14.8 ~ 19.6 Nm {1.5 ~ 2.0 kgm}
(Supply pump side)
24.5 ~ 34.3 Nm {2.5 ~ 3.5 kgm}
(Fuel filter side)
Eye-joint bolt of fuel tube (15):

14.8 ~ 19.6 Nm {1.5 ~ 2.0 kgm}
(Supply pump side)
9.8 ~ 12.7 Nm {1.0 ~ 1.3 kgm}
(Block side)
22. Remove 4 mounting bolts. Then, using tool
A1, remove fuel supply pump assembly (30).
8 Eye-joint bolt of lubrication tube
★ Take care not to drop key (31). (16):
7.9 ~ 12.7 Nm {0.8 ~ 1.3 kgm}
★ Do not remove tool A1 until the fuel sup-
(Supply pump side)
ply pump assembly is installed again. (If
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
tool A1 is removed, the idler gear and
(Cylinder block side)
fuel supply pump drive gear may be
meshed incorrectly.)
Eye-joint bolt of lubrication tube
(17):
19.6 ~ 29.4 Nm {2.0 ~ 3.0 kgm}
Clamp of lubrication tube:

9.8 ± 1 Nm {1.0 ± 0.1 kgm}
4
★ Set insertion length c of hose a and tube
b to the following value.
• Insertion length c of outlet hose: 50 mm
Clamp of outlet hose:

883 ± 49 Nm {90 ± 5 kgm}
INSTALLATION
• Carry out installation in the reverse order to
removal.
1
Water pump tube coupling nut:

14.7 ~ 18.6 Nm {1.5 ~ 1.9 kgm}
D275A-5 30-11
c
DISASSEMBLY
5 6 7 8
WARNING! Contact of the high-
Mounting nut of fuel supply pump pressure pipes with electrical wiring
drive gear: around them is dangerous. After
176 ~ 196 Nm {18 ~ 20 kgm} assembling, check that the distance
between the pipes and the wiring is
• Installation procedure for fuel supply pump at least 10 mm. If it is not, increase it
and tubes to 10 mm or more by moving the
wire.
WARNING! Do not bend and reuse

the high-pressure pipes or use them
for other parts.
6. Tighten upper and lower clamps securely in

the order of (31), (32), and (33).
★ Before tightening the stays, bend the rub-
ber.
Clamp bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
1. Install and tighten supply pump (30), bracket 7. Tighten the stays securely in the installation
(29), and high-pressure pipes (26) and (27) order of the upper and lower clamps.
with fingers.
2. Tighten high-pressure pipes (26) and (27) • Refilling with water
securely. Add water through the water fillers of the
main radiator and sub-radiator to the speci-
Sleeve nut: fied level. Run the engine to circulate the
39.2 ~ 58.8 Nm {4 ~ 6 kgm} water through the system. Then, check the
(Common rail side) water level again.
39.2 ~ 49 Nm {4 ~ 5 kgm}
(Supply pump side) Cooling water: Approx. 130 l
3. Tighten suction pump (30) securely.
★ When tightening, apply LOCTITE. • Bleeding air
4. Tighten bracket (29) securely. Bleed air from the fuel circuit. For details, see
5. Tighten the stays and upper and lower TESTING AND ADJUSTING, Bleeding air
clamps of high-pressure pipe clamps (31), from fuel circuit.
(32), and (33) with fingers.
WARNING! The high pressure

clamps are very important parts. If
they are loosened or their rubber
parts are hardened or they are
removed and the engine is kept
used, the contact parts of the high-
pressure pipes may be worn and the
pipes may be broken by vibration.
Accordingly, be sure to use the gen-
uine high-pressure pipe clamps and
tighten them to the specified torque.
30-12 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY

REMOVAL 15. Remove the 4 bracket mounting bolts, water
separator (17), and bracket.
the negative (-) terminal of the battery. 16. Remove fuel filter tubes (18) and (19). 7
17. Remove the 4 bracket mounting bolts, fuel fil-

1. Remove the engine hood. For details, see ter (20), and bracket.
REMOVAL OF ENGINE HOOD.
18. Remove corrosion resistor tubes (21) and
2. Loosen the hose clamp and disconnect (22). 8
Komaclone hose (1). 1
19. Remove the 4 bracket mounting bolts, corro-

3. Remove the 4 mounting bolts and bracket (2). sion resistor (23), and bracket.
4. Disconnect dust indicator hose (3). 2
5. Loosen 2 hose clamps and disconnect tube

(4). 3
6. Remove 2 bands (5) and air cleaner assembly

(6). 4
7. Remove the 4 mounting bolts and bracket (7).
8. Remove corrosion resistor tubes (8) and (9).

5
9. Remove oil tubes (10) and (11).
10. Remove the 4 bracket mounting bolts, oil fil-

ter (12), and bracket.
11. Close the fuel supply valve.
12. Disconnect priming pump hose (13) and

water separator hose (14). 6
13. Disconnect 2 drain hoses (15).
14. Remove the 2 priming pump mounting bolts

and priming pump (16).
D275A-5 30-13
c
DISASSEMBLY
20. Remove the 12 mounting bolts and 4 nuts, ★ To disconnect fuel injector connector c,
then lift off bracket (24). insert flat-head screwdriver b in stepped
★ If any shims are inserted, check their part a and move it in direction X, pressing
quantity and positions. stopper b.
d: Fuel injector wiring side
Bracket: 50 kg
25. Disconnect fuel supply pump wiring connec-

tors E41 (31) and E42 (32).
21. Disconnect intermediate wiring connectors

101 (25), E21 (26), and E22 (27).
22. Remove the 2 mounting bolts and bracket
(28).
23. Disconnect the wire clamp and remove wire

(29).
★ When disconnecting the wire clamp, take
care not to drop the spacer held under the
clamp.
24. Disconnect wiring connector E31 (30).
★ The photo shows removal of No. 1.
30-14 D275A-5
c
DISASSEMBLY
26. Remove head cover (33). 9
32. Loosen sleeve nut (43). 13
27. Loosen locknut (34) and adjustment screw

(35). 10
★ Loosen the locknut so that an excessive force

will not be applied to the push rod, then
loosen the adjustment screw by 2 - 3 turns.
33. Remove the mounting bolts of fuel injector

assembly (38) and put a small-sized L-lever
under connection (44) and pry the fuel injec-
tor assembly out slowly. 14
★ Never hold the solenoid valve above the
injector with priers, etc.
★ Loosen the bolts used to install high-pres-
28. Remove the 3 mounting bolts and remove sure pipe clamps No. 1 - No. 6 near the
rocker arm (36). 11 injector to the manifold.
★ Remove the sleeve of the high-pressure
29. Remove rubber cap (37). pipe on the injector side and pull out the
injector, keeping the high-pressure pipe
end off the hollow of the injector.
30. Remove 2 upper solenoid valve nuts (39) of

fuel injector assembly (38) and pull out spring
clamp (40). 12
31. Disconnect clamp (41) and move fuel injector

wiring (42) aside.
D275A-5 30-15
c
DISASSEMBLY
INSTALLATION
• Carry out installation in the reverse order to 10
removal. ★ After tightening the locknut, adjust the
1 valve clearance. For details, see TESTING
AND ADJUSTING, Adjusting valve clear-
Komaclone hose clamp: ance.
10.8 ~ 16.5 Nm {1.1 ~ 2.7 kgm}
Locknut:
2 53 ~ 64.7 Nm {5.4 ~ 6.6 kgm}
Dust indicator hose mounting nut: 11

17.6 Nm {1.8 kgm} ★ Check that the ball of the adjustment
screw is fitted to the push rod socket and
3
tighten the mounting bolts.
Hose clamp:
Rocker arm mounting bolt:
8.8 ± 0.5 Nm {90 ± 5 kgm}
93 ~ 103 Nm {9.5 ~ 10.5 kgm}
4 12
Band mounting bolt:

Terminal nut:
9.8 ~ 11.76 Nm {1.0 ~ 1.2 kgm}
1.8 ~ 2.2 Nm {0.18 ~ 0.22 kgm}
5 8 13
Eye-joint bolt of corrosion resistor ★ Check that the O-rings are fitted to both
tube: injector side and sleeve nut side.
24.5 ~ 34.3 Nm {2.5 ~ 3.5 kgm} ★ After sleeve nut (43) catches the threads
of the injector, turn it 2 turns with fingers,
6 then tighten it with a spanner.
★ Control the tightening torque with torque
Eye-joint bolt of priming pump wrench (2) of spanner type.
hose:
24.5 ~ 34.3 Nm {2.5 ~ 3.5 kgm} Sleeve nut:
39.2 ~ 49 Nm {4 ~ 5 kgm}
7
★ If sleeve nut (43) does not catch the
Eye-joint bolt of fuel filter tube: threads, push its end with a small spanner
14.8 ~ 19.6 Nm {1.5 ~ 2.0 kgm} and turn its hexagonal part with the
(Supply pump side) torque wrench.
24.5 ~ 34.3 Nm {2.5 ~ 3.5 kgm}
(Fuel filter side)
Head cover mounting bolt:

14.7 ~ 34.3 Nm {1.5 ~ 3.5 kgm}
30-16 D275A-5
c
DISASSEMBLY
★ After tightening the sleeve nut, check the

O-ring is not projected from the sleeve
nut end.
3) Fit the ball washer to bolt (46) and tighten

them into holder (45) with fingers. Insert
high-pressure pipe sleeve (47) through
the fuel high-pressure pipe insertion part
14
and tighten it with fingers, matching it to
injection (44). Tighten bolt (46) of holder
★ When installing the high-pressure pipe,
(45) securely.
check the paper seal of the joint (Part a:
Part of 2 mm from the end) for visible ★ Apply engine oil to the spherical part of
lengthwise split b and spot c and check the ball washer (to fit the ball washer).
part d (End of taper seal: Part of 2 mm
from the end) for stepped-type wear Holder mounting bolt:
(fatigue) which your nail can feel. If any of 58.8 ~ 73.5 Nm {6.0 ~ 7.5 kgm}
those defects may cause fuel leakage,
replace the high-pressure pipe.
★ Check that there is not dirt in the injector

sleeve.
1) Fit the gasket and O-ring to the fuel injec-
tor and apply engine oil (SAE 30) to them.
2) Insert holder (45) in fuel injector assembly
(38). Direct the injector connection toward
the high-pressure pipe insertion hole and
insert the fuel injector assembly holder
together.
D275A-5 30-17
c
DISASSEMBLY
★ It is difficult to insert the wiring connector

after the O-ring is fitted to it.
4) Take out the wiring connector (48)
through the connector insertion opening
with O-ring (49) removed. Fit O-ring (49)
and apply engine oil (SAE 30) and install
connector holder (50), then push them in
and secure connector holder (50) with
mounting bolt (51).
5) Install wiring terminal (52) to the terminal

of fuel injector assembly (38). Tighten 2
nuts (39) and insert wire holder clamp (40)
in the injector connection, then install
wire clamp (41) with the bolt.
Terminal nut:
1.8 ~ 2.2 Nm {0.18 ~ 0.22 kgm}
★ Tense the wires and press them against

the injector body.
30-18 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF NOZZLE TIP
REMOVAL AND INSTALLATION OF NOZZLE TIP

★ [EPA Regulation] 3. Using 19 mm deep socket d, loosen retaining
In a country where EPA regulation is applied, nut (4).
replace the nozzle of the common rail engine
by the assembly. In a country where EPA reg-
ulation is not applied, however, only the noz-
zle tip can be replaced according to the
★ All the nozzles shown in the following photos
are for the 125 Series engine. The removal
and installation procedures for them can be
applied as they are, however.
SPECIAL TOOLS
Sym Part Nece New/

bol Part No. Name ssity Qty. Remo Sketch
del
A5 795T-471-1550 Wrench ■ 1 { 4. Remove retaining nut (4) from injector

assembly (3).
5. Lift up and remove nozzle assembly (5) verti-
REMOVAL
cally.
1. Hold tool A5 with vice b. ★ Do not remove tip guide (6). (The tip
★ Do not hold the injector directly with the guide cannot be disassembled.)
vice. ★ Take care that dirt will not stick to the
parts.
2. Set injector assembly (3) to tool A5.
D275A-5 30-19
c
DISASSEMBLY
INSTALLATION
1. Hold tool A5 with vice b. 5. Install nozzle assembly (3) and tighten retain-
★ Do not hold the injector directly with the ing nut (2) with the fingers.
vice.
6. Set 19 mm deep socket c to a torque wrench

2. Set injector assembly (1) to tool A5. and tighten the retaining nut according to the
3. Clean the lower body and the threads of following procedure.
retaining nut (2) thoroughly with parts ★ Apply rust-preventive oil to the nozzle
cleaner and blow air against them. body.
1) Tighten the retaining nut to 88.3 Nm
{9.0 kgm}.
2) Make match marks (6) on retaining
nut (2) and lower body (5).
3) Tighten the retaining nut by 45°
(Angle tightening).
4. Install new nozzle assembly (3), matching it to

the dowel pin of tip guide (4).
★ Take care not to drop the tip.
30-20 D275A-5
c
DISASSEMBLY

A5 Wrench
D275A-5 30-21
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

SPECIAL TOOLS INSTALLATION
New/ • Carry out installation in reverse order to

Sym Part No. Part Name Nece Qty. Remo Sketch
bol ssity removal.
del
795-521-1110 Push tool ■ 1 1
790-101-5221 Grip ■ 1 ★ Match the taper pin of the damper pulley

A2 and tighten the 6 mounting bolts.
01010-51225 Bolt ■ 1
01050-31640 Bolt ■ 3 Mounting bolt:

245 ~ 309 Nm {25 ~ 31.5 kgm}
REMOVAL 2
1. Remove the radiator guard assembly. For • Installation procedure for front seal (2)
details, see REMOVAL OF RADIATOR GUARD ★ Before installing the seal, make sure that
ASSEMBLY. the end corners and lip sealing surfaces of
2. Sling damper pulley (1) temporarily and the crankshaft and housing are free from
remove the mounting bolts. 1 flaw, burr, fin, and rust.
3. Lift off damper pulley (1). ★ When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
off the oil from the shaft.
★ Never remove the inside plastic cylinder
for the replacement seal before installing
the seal.
4. Remove front seal (2). 2
30-22 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
1) Bring the large inside diameter side of

plastic inside cylinder (3) to the end of
crankshaft (4).
★ Take care not to mistake the installing
direction.
2) Hold the metal ring of seal (2) with both

hands and push it in firmly as if you are
passing over the large inside diameter
side of the plastic inside cylinder.
3) After pushing in seal (2), remove plastic
inside cylinder (3).
★ When removing the inside cylinder,
take care not to damage the seal lip.
4) Tighten the bolts of tool A2 evenly to

press fit seal (2) until the end of tool A2
reaches the end of crankshaft (4).
★ When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set, etc.
★ After press fitting the seal, remove the
red sealant layer from its periphery.
D275A-5 30-23
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
REMOVAL AND INSTALLATION 4. Remove rear seal (2). 2
OF ENGINE REAR SEAL

SPECIAL TOOLS
New/
Sym Part No. Part Name Nece
bol ssity Qty. Remo Sketch
del
795-931-1210 Sleeve jig ■ 1
791-931-1220 Sleeve jig ■ 1

A3
01050-31625 Bolt ■ 3
01050-31645 Bolt ■ 3
REMOVAL
INSTALLATION
1. Remove the damper assembly. For details,
see REMOVAL OF DAMPER ASSEMBLY. • Carry out installation in the reverse order
2. Using hanging bolt b, sling the flywheel to removal.
assembly temporarily. 1
★ Tighten the 6 flywheel mounting bolts in
the order of b ~ g as shown below.
3. Remove the 6 mounting bolts and lift off fly-

wheel assembly (1). 1
Flywheel assembly: 60 kg
30-24 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
2 3) After pushing in seal (2), remove plastic

• Installation procedure for rear seal (2) inside cylinder (3).
★ Before installing the seal, make sure ★ When removing the inside cylinder,
that the end corners and lip sliding take care not to damage the seal lip.
surfaces of the crankshaft and hous-
ing are free from flaw, burr, fin, and
rust.
★ When installing the seal, do not apply
oil or grease to the shaft and seal lip.
Wipe off the oil from the shaft.
★ Never remove the inside plastic cylin-
der of the replacement seal before
installing the seal.
4) Tighten the bolts of tool A3 evenly to

press fit seal (2) until the end of tool A3
reaches the end of crankshaft (4).
5) Using the 2 types of the bolts of tool A3,
tighten seal (2).
i) Tighten until the bolt 45 mm long
stops.
ii) Tighten until the bolt 25 mm long
1) Bring the large inside diameter side of stops.
plastic inside cylinder (3) to the end of ★ When press fitting the seal, take care
crankshaft (4). not to damage the lip on the PTO side
★ Take care not to mistake the installing with the tool set, etc.
direction. ★ After press fitting the seal, remove the
sealant layer.
2) Hold the metal ring of seal (2) with both

hands and push it in firmly as if you are
passing over the large inside diameter
side of the plastic inside cylinder.
D275A-5 30-25
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

SPECIAL TOOL 5. Loosen the band and disconnect Komaclone
hose (5). 3
New/ 6. Remove bracket (6).
bol ssity 7. Remove 2 bands (7) and air cleaner assembly
del
(8). 4
A4 790-331-1110 Wrench ■ 1
REMOVAL

the negative (-) terminal of the battery.
1. Remove the engine hood assembly. For

details, see REMOVAL OF ENGINE HOOD
ASSEMBLY.
2. Remove main radiator drain cover (1) sub-
radiator drain cover (2) and drain the cooling
water.
Cooling water: Approx. 130 l 8. Remove cover (9).

9. Remove water drain tube (10). 5
10. Remove the mounting bolts of muffler
bracket (11).
★ Sling the muffler assembly temporarily,
then remove the mounting bolts.
3. Loosen 2 hose clamps (3). 1

4. Loosen the band and disconnect dust indica-
tor hose (4). 2
30-26 D275A-5
c
DISASSEMBLY
11. Lift off muffler assembly (12).
Muffler assembly: 30 kg
19. Install 2 hanging bolts b and 2 guide bolts c

and lift off turbocharger and exhaust mani-
fold assembly (21).
Turbocharger and exhaust mani-

fold assembly: 30 kg
12. Disconnect 2 hose clamps (13). 6
13. Loosen 2 bands (14).
14. Remove tube (15) and bracket together.
15. Remove heat insulation panel (16).
20. Remove air cleaner bracket (22).

21. Remove oil tubes (23) and (24).
22. Remove bracket (25).
★ Remove the oil filter and bracket together.
17. Disconnect turbocharger lubrication tube 23. Disconnect priming pump hose (26) and
inlet (18) and turbocharger lubrication tube water separator hose (27). 8
outlet (19). 24. Disconnect 2 drain hoses (28).

18. Remove the mounting bolts and exhaust 25. Remove priming pump (29).
manifold assembly (20). 7
D275A-5 30-27
c
DISASSEMBLY
26. Remove water separator assembly (30). 32. Remove the mounting bolts and nuts and lift
★ Remove the water separator assembly off bracket (39).
and bracket together. ★ If any shims are inserted, check their
quantity and positions.
Bracket: 50 kg
27. Remove fuel filter tubes (31) and (32). 9

★ Remove the fuel filter and bracket
together.
29. Remove corrosion resistor tubes (34) and 33. Remove the tube bracket and tube clamp,
(35). 10 then remove engine oil supply tube (40) and
30. Remove bracket (36). damper oil supply tube (41).
★ Remove the corrosion resistor and 34. Remove aftercooler tubes (42) and (43). 12
bracket together.

31. Remove corrosion resistor tubes (37) and 101 (44), E21 (45), and E22 (46).
(38). 11 36. Remove bracket (47).
30-28 D275A-5
c
DISASSEMBLY
37. Disconnect boost pressure sensor wiring con-

nector (48).
★ To disconnect fuel injector connector c,

insert flat-head screwdriver d in stepped
part a and move it in direction X, pressing
38. Disconnect intermediate wiring connectors stopper b.
E41 (49) and E42 (50). b: Fuel injector wiring side
39. Disconnect 3 electrical intake air heater
ground wires.
43. Remove the mounting bolts. Using hanging

bolt (4), lift off air intake manifold assembly
40. Disconnect electrical intake air heater relay
(56). 13
terminal (52).
Air intake manifold assembly: 70 kg
41. Disconnect fuel return temperature sensor

wiring connector (53).
42. Disconnect the wire clamp, wire (54), and fuel
injector wiring connector (55).
★ When disconnecting the wire, take care
not to drop the spacer installed under the
clamp bolt.
D275A-5 30-29
c
DISASSEMBLY
44. Remove 5 high-pressure pipe clamps (57). 49. Pull out push rod (64).
14 50. Remove the mounting bolts and cylinder
head assembly (65). 18
45. Remove cooling water tube (58) and fuel spill

tube (59). 15
46. Remove rubber cap (60) and high-pressure

pipe (61). 16
47. Remove head cover (62). 17
48. Remove fuel injector assembly (63). For

details, see Removal of fuel injector assem-
bly.
30-30 D275A-5
c
DISASSEMBLY
INSTALLATION 8
• Carry out installation in the reverse order to Eye-joint bolt of priming pump
removal. hose:
1 6 24.5 ~ 34.3 Nm {2.5 ~ 3.5 kgm}
Hose clamp: 9
8.8 ± 0.5 Nm {90 ± 5 kgm}
Eye-joint bolt of fuel filter tube:
2 14.8 ~ 19.6 Nm {1.5 ~ 2.0 kgm}
(Supply pump side)
Dust indicator hose mounting nut: 24.5 ~ 34.3 Nm {2.5 ~ 3.5 kgm}
17.6 Nm {1.8 kgm} (Fuel filter side)
3 10 11
Komaclone hose clamp: Eye-joint bolt of corrosion resistor

10.8 ~ 26.5 Nm {1.1 ~ 2.7 kgm} tube:
24.5 ~ 34.4 Nm {2.5 ~ 3.5 kgm}
4
12
Band mounting bolt:
9.8 ~ 11.76 Nm {1.0 ~ 1.2 kgm} Coupling bolt of aftercooler tube:
14.7 ~ 18.6 Nm {1.5 ~ 1.9 kgm}
5
U-clamp nut of aftercooler tube:
Water drain tube: 10.8 ~ 26.5 Nm {1.1 ~ 2.7 kgm}
39.2 ~ 49 Nm {3 ~ 4 kgm}
13
7 Installation procedure for exhaust manifold
★ Install the gasket, then tighten the mount- assembly
ing bolts of the exhaust manifold assem- 1) Fit the gaskets to both sides of the electri-
bly in the order of b ~ 2$ as shown below. cal intake air heater.
2) Install the wiring harness to the electrical
Mounting bolt of exhaust manifold intake air heater and couple them with the
assembly: exhaust manifold.
59 ~ 74 Nm {6 ~ 7.5 kgm} 3) Tighten the mounting bolts of the exhaust
manifold assembly in the order of b ~ 2$
as shown below.
Mounting bolt of exhaust manifold

assembly:
59 ~ 74 Nm {6 ~ 7.5 kgm}
D275A-5 30-31
c
DISASSEMBLY
14 16 7. Tighten high-pressure pipe side clamp

• Assembly procedure for common rail injec- (57) securely.
tion pipe (Between common rail and injector)
Clamp bolt:
1. Install high-pressure pipe (61).
9.8 ± 1 Nm {1 ± 0.1 kgm}
Sleeve Nut:
8. Tighten stay (69) securely.
39.2 ~ 49 Nm {4 ~ 5 kgm}
★ Precautions for installing sleeve nut

on injector side
1) Insert the sleeve nut in the head hole
from outside.
★ Check that the O-rings are fitted to
both injector side and sleeve nut side.
2) After sleeve nut (43) catches the
threads of the injector, turn it 2 turns
with fingers, then tighten it with a
spanner.
★ Control the tightening torque with a
torque wrench of spanner type.
Sleeve Nut:
39.2 ~ 49 Nm {4 ~ 5 kgm}
★ If the sleeve nut does not catch the

threads, push its end with a small
spanner and turn its hexagonal part
with the torque wrench.
★ After tightening the sleeve nut, check
that the O-ring is not projected from
the sleeve nut end.
2. Tighten the stay and upper and lower
clamps of high-pressure pipe clamp (57)
with fingers.
3. Tighten upper and lower clamps (57) 15
securely.
★ Bend the rubber first. Eye-joint bolt of cooling water
tube: 9.8 ~ 12.7 Nm {1.0 ~ 1.3 kgm}
Clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm} Eye-joint bolt of fuel spill tube:
8 ~ 9.8 Nm {0.8 ~ 1.0 kgm}
4. Tighten the stay securely.
5. Tighten the stay and upper and lower
clamps of high-pressure pipe side clamp
(57) with fingers.
6. Install high-pressure pipe clamp (66) and
gate frame (67) temporarily.
1) Tighten high-pressure pipe clamp (66)
securely first.
2) Install gate frame (67) to special bolt
(68) securely.
Clamp bolt:
9.8 ± 1 Nm {1 ± 0.1 kgm}
30-32 D275A-5
c
DISASSEMBLY
16
Mounting bolt:
★ When installing the high-pressure pipe, Lubricant containing
check the paper seal of the joint (Part a: molybdenum disulfide (LM-P)
Part of 2 mm from the end) for visible
lengthwise slit b and spot c and check
part d (End of taper seal: Part of 2 mm ★ A special socket is required to tighten the
from the end) for stepped-type wear head bolts.
(fatigue) which your nail can feel. If any of
those defects may cause fuel leakage, Cylinder head mounting bolt:
replace the high-pressure pipe.
1st time: 137 ~ 157 Nm {14 ~ 16 kgm}
2nd time: 284 ~ 294 Nm {29.0 ~ 30.0 kgm}
3rd time:
i) When using tool A4

Using an angle tightening wrench
(tool A4), retighten each bolt by
90° + 30°
0 in the order of b ~ g.
17
Head cover mounting bolt:

14.7 ~ 34.3 Nm {1.5 ~ 3.5 kgm}
18
• Before tightening the cylinder head
mounting bolts, check the following mat-
ter.
★ If the mounting bolts are longer than the
following using limits or they have been
tightened 5 times (there are 5 punch
marks on them), do not reuse them but
replace them.
1) Measure stem length e of each
mounting bolt and check that the
result is less than the using limit.
2) Using limit of bolt
• Short bolt: Must be shorter than
170.8 mm.
• Long bolt: Must be shorter than
205.8 mm.
D275A-5 30-33
c
DISASSEMBLY
ii) When not using tool A4

Make marks on the all bolts and cylin-
der head, then retighten each bolt by
+ 30°
90° 0 in the order of b ~ g.
★ After tightening bolts b ~ g, tighten
bolt h to:
66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}.
• Refilling with water

Add water through the water fillers of the
fied level. Run the engine to circulate the
water through the system. Then, check the
water level again.
Cooing water: Approx. 130 l
30-34 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY

REMOVAL 6. Remove plate (6).

1. Remove step (1).

7. Disconnect fuel level sensor wiring connector

423 (7).
8. Disconnect 3 fuel hoses (8).
4. Close the fuel supply valve.

5. Remove drain hose clamp (4) and drain block
(5).
9. Remove 4 mounting bolts (9).
D275A-5 30-35
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
10. Lift off fuel tank assembly (10).
Fuel tank assembly:

390 kg (When empty)
1,100 kg (When full)
INSTALLATION
• Carry out installation in reverse order to
removal.
30-36 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF MAIN RADIATOR ASSEMBLY
REMOVAL AND INSTALLATION OF MAIN RADIATOR ASSEMBLY

REMOVAL 5. Remove the mounting bolts and open guard
(3).
6. Remove the mounting bolts and open under-
cover (4).
1. Drain the coolant water. Engine undercover: 250 kg
Cooling water: Approx. 130 l
2. Remove radiator upper cover (1).
7. Disconnect oil cooler hose (5) and radiator

outlet hose (6).
★ Disconnect the hose and tube together.
3. Raising the radiator upper cover, disconnect
head lamp wiring connector 209 (2).
4. Lift off the radiator upper cover.
D275A-5 30-37
c
DISASSEMBLY
8. Disconnect oil cooler hose (7) and radiator

inlet hose (8).
★ Disconnect the hose and tube together.
13. Remove baffles (19) and (20). 3

14. Remove mounting bolts (21) (4 pieces on
each side).
9. Disconnect wiring connectors (WLM) (9) and

(WLD) (10) and 2 clamps (11).
10. Disconnect reservoir hose (12), aeration hose
(13), and radiator inlet hose (14). 1
15. Lift off main radiator assembly (22).
Main radiator assembly: 310 kg
11. Remove 10 radiator mounting bolts (15) and

(16).
• (15): 2 pieces on each side
• (16): 3 pieces on each side
12. Remove baffles (17) and (18). 2
30-38 D275A-5
c
DISASSEMBLY
INSTALLATION
removal.
1
Reservoir hose clamp:

34 ± 5 Nm {3.4 ± 0.5 kgm}

b to the following values.
Hoses (12) and (13): Min. 25 mm
Hose (14): 60 mm
2 3
★ The rubber plates of the baffles must be
in contact with the radiator tank.

water level again.
D275A-5 30-39
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF SUB-RADIATOR ASSEMBLY
REMOVAL AND INSTALLATION OF SUB-RADIATOR ASSEMBLY

REMOVAL
cover (3).
Engine undercover: 250 kg
1. Drain the cooling water.
6. Disconnect sub-radiator outlet hose (4). 1
3. Raising the radiator upper cover, disconnect

head lamp wiring connector (CN-209) (2).
30-40 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF SUB-RADIATOR ASSEMBLY
7. Remove 4 mounting bolts (5) (2 pieces on INSTALLATION

each side of the lower part).
★ Or, remove the 2 lower bolts (1 piece on • Carry out installation in the reverse order to
each side). removal.
1 3
Hoses (4) and (11): 50 mm
8. Disconnect wiring connector (WLD) (6) and

clamp (7).
9. Disconnect hose clamp (8) and reservoir
hoses (9) and (10). 2
2
10. Disconnect sub-radiator inlet hose (11). 3
11. Remove 4 mounting bolts (12). Reservoir hose clamp:
34 ± 5 Nm {3.4 ± 0.5 kgm}

Hoses (9) and (10): Min. 25 mm (See the
above illustration)

water level again.

12. Lift off sub-radiator assembly (13).
Sub-radiator assembly: 75 kg
D275A-5 30-41
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER

ASSEMBLY
REMOVAL 5. Remove the mounting bolts and open under-
cover (3).
the negative (-) terminal of the battery. Engine undercover: 250 kg
1. Drain the hydraulic oil.
Hydraulic oil: Approx. 130 l
6. Disconnect aeration hose (4). 1
7. Disconnect main radiator inlet hose (5). 2

★ Drain the cooling water to a degree that it
will not leak when the radiator inlet hose
3. Raising the radiator upper cover, disconnect is disconnected.
head lamp wiring connector (CN-209) (2). 8. Remove cover (6).
30-42 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
9. Disconnect hose clamp (7) and hydraulic oil

cooler hose (8).
INSTALLATION
★ Disconnect the upper end of the hydraulic • Carry out installation in the reverse order to
oil cooler hose. removal.
1 2
Hose (4): Min. 25 mm
Hose (5): 60 mm
10. Remove bracket (9) and disconnect hydraulic

oil cooler hose (10).
• 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.
Hydraulic tank: Approx. 130 l
11. Remove the 4 upper and lower mounting

bolts and lift off hydraulic oil cooler assembly
(11).
Hydraulic oil cooler assembly:

35 kg
D275A-5 30-43
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY
REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY

REMOVAL 6. Remove the mounting bolts and open under-
cover (4).
the negative (-) terminal of the battery. Engine undercover: 250 kg
2. Drain the hydraulic oil.
Hydraulic oil: Approx. 130 l
3. Remove the engine hood. For details see

REMOVAL OF ENGINE HOOD ASSEMBLY.
4. Remove both side covers (1).
7. Disconnect main radiator outlet hose (5), oil

cooler hose (6), cooler hose (7), and sub-radi-
ator outlet hose (8). 2
5. Remove cap (2) and shim (3) from the blade

lift cylinder. 1
★ Check the thickness and quantity of the
inserted shims.
★ Run the engine and retract the piston rod
fully and bind it with wires so that it will
not come out.
★ Bind the piston rod on the opposite side
similarly.
30-44 D275A-5
c
DISASSEMBLY
8. Disconnect fan motor hoses (9), (10), and (11), 13. Sling the radiator guard assembly tempo-
blade lift cylinder hoses (12) and (13), oil rarily and remove the lock bolt (23) and pull
cooler hose (14), and main radiator inlet hose out left rear pin (24).
(15). ★ Remove the lock bolt and pin on the right
side similarly.
9. Disconnect wiring connector 201 (16).

10. Disconnect sub-radiator inlet hose (17), aera- 14. Remove lock plate (25).
tion hose (18), and main radiator inlet hose 15. Pull out left front pin (26).
(19). 3
★ Remove the lock plate and pin on the
11. Remove cover (20) and disconnect hydraulic
right side similarly.
oil cooler hose (21).
12. Remove condenser assembly (22).
★ Do not disconnect the hoses from the
condenser assembly. Remove only the
mounting bolts and move the hoses
aside.
16. Lift off radiator guard assembly (27).

★ Take care extremely not to damage the
radiator core, etc.
Radiator guard assembly: 2,450 kg
D275A-5 30-45
c
DISASSEMBLY
INSTALLATION 4
★ Tighten the locknut so that clearance e
• Carry out installation in the reverse order to between the radiator guard and nut will
removal. be in the following range.
1 Clearance e: 3 ~ 5 mm
• Install the blade lift cylinder according to
the following procedure.
1) Sling the blade lift cylinder tempo-
rarily.
2) Run the engine and extend the piston
rod slowly to couple it with the blade
assembly by cap (2) at the lift cylinder
end.
3) Adjust clearance a at the mating face
of the cap to the following value with
shims.
• Standard clearance a: 0.2 ~ 0.5 mm
• Standard shim thickness: 4 mm
★ Check that the shims rotate smoothly.
water level again.

again.
2 3
★ Set insertion length d of hose b and tube
c to the following value. Hydraulic tank: Approx. 130 l
Hoses (8) and (17): 50 mm
Hose (19): 60 mm
30-46 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE

SPECIAL TOOLS
New/
Sym- Part No. Part Name Nece Qty. Rem Sketch
bol ssity
odel
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump t 1

(100 V)
Vacuum pump
X 799-703-1110 (220 V) t 1
799-703-1120 Vacuum pump t 1

(240 V)
Gas leak
799-703-1401 detector t 1
5. Disconnect radiator outlet hose (6) and radia-

REMOVAL tor inlet hose (7).
a Plug the openings so that dirt will not
WARNING! Disconnect the cable from enter the piping.
the negative (-) terminal of the battery. 6. Disconnect sub-radiator outlet hose (8) from
the sub-water pump. 1
a For the method of changing the fuel injection
amount adjustment after replacement of the
engine assembly or engine controller, ask
your Komatsu distributor.
2. Remove the engine hood. For details, see

3. Remove floor covers (1) and (2) and step cov-
ers (3) and (4).
7. Remove the bolt and open inspection cover

(9).

cover (5).
4 Engine undercover: 250 kg
D275A-5 30-47
(7)2
DISASSEMBLY
8. Disconnect ground wire (10). 12. Disconnect wire clamp (16).

a Remove the cover and leave it as it is.
9. Disconnect heater hose (11), then disconnect

tube (12) from the main water pump.
10. Disconnect air condenser hoses (13) and (14). 14. Disconnect intermediate wiring connectors
2 101 (18), E21 (19), and E22 (20).
a Discharge the refrigerant (gas) from the
air conditioner circuit before disconnect-
ing the air conditioner hoses.
15. Remove the hose clamp and disconnect

heater hoses (21) and (22) and air conditioner
hoses (23) and (24). 3
11. Disconnect starting motor wiring harness a Close the heater hose valve on the engine
(15). side.
30-48 D275A-5
2 (7)
DISASSEMBLY
16. Remove cover (25). 19. Disconnect wire (29).
17. Loosen the hose clamp and remove hose (26). 20. Remove plate (30) and remove 3 partition
mounting bolts (31).
★ Remove the plate and partition mounting
bolts on the right side similarly.
18. Disconnect wiring connectors PT1 (27) and

SS3 (28).
21. Lift off partition (32).

★ After removing the partition, take out
cover (17) which has been removed.
Partition: 140 kg
D275A-5 30-49
c
DISASSEMBLY
22. Sling universal joint assembly (33) tempo- 27. Loosen the band and disconnect Komaclone
rarily. hose (37). 6
23. Remove the mounting bolts and lift off the 28. Remove bracket (38).
universal joint assembly. 4
Universal joint assembly: 30 kg
29. Disconnect sub-radiator inlet hose (39), aera-

tion hose (40), and main radiator inlet hose
(41) and remove reservoir tank (42). 7
★ Remove the reservoir tank and bracket
24. Close the fuel supply valve. together.
25. Disconnect fuel supply hose (34).
30. Disconnect intermediate wiring connector

26. Disconnect fuel return hoses (35) and (36). 201 (43).
5
30-50 D275A-5
c
DISASSEMBLY
31. Remove 4 front and rear engine mounting

bolts (44) and (45). 8
2 3
★ Install each hose so that it will not be
twisted.
★ When installing the air conditioner hoses,
32. Lift off engine assembly (46).
take care that dirt, dust, and water will not
★ Before lifting off the engine assembly, enter them.
check that the all wires and pipes are dis-
★ Before tightening each air conditioner
connected.
hose connector, check that the O-ring is
fitted to it.
Engine assembly: 2,050 kg ★ Apply compressor oil (Showa-Shell,
Sniso 4G or 5G) sufficiently to the O-rings
Tightening torque for refrigerant gas

pipes
INSTALLATION
Thread Size: Tightening Torque
• Carry out installation in the reverse order to 16 x 1.5 11.8 ~ 14.7 Nm {1.2 ~ 1.5 kgm}
removal. 22 x 1.5 19.6 ~ 24.5 Nm {2 ~ 2.5 kgm}
★ For the method of changing the fuel injection 24 x 1.5 29.4 ~ 34.3 Nm {3 ~ 3.5 kgm}
1
Insertion length c of outlet hose: 50 mm
Outlet hose clamp:

883 ± 48 Nm {90 ± 51 kgm}
D275A-5 30-51
c
DISASSEMBLY
Universal joint mounting bolt:

98.10 ~ 123 Nm {10 ~ 12.5 kgm}
Eye-joint bolt of fuel return hose:

24.5 ~ 34.3 Nm {2.5 ~ 3.5 kgm}
Komaclone hose clamp:

10.8 ~ 26.5 Nm {1.1 ~ 2.7 kgm}
7
★ Set insertion length d of hose b and tube
c to the following value.
Hoses (39): 50 mm
Hose (41): 60 mm
Engine mounting bolt:

824 ~ 1,030 Nm {84 ~ 105 kgm}

water level again.
• Charging air conditioner with refriger-

ant gas
Using tool X, charge the air conditioner cir-
cuit with refrigerant (R134a).
30-52 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY

SPECIAL TOOLS 5. Disconnect starting motor wiring harness (3),
then disconnect wire clamp (4) from the parti-
New/ tion.
bol ssity 6. Remove cover (5).
odel
a Remove the cover and leave it as it is.
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump t 1

(100 V)
Vacuum pump
X 799-703-1110 (220 V) t 1
799-703-1120 Vacuum pump t 1

(240 V)
Gas leak
799-703-1401 detector t 1
REMOVAL
1. Remove the engine hood. For details, see
2. Remove the mounting bolt and open the 7. Disconnect intermediate wiring connectors
undercover. 101 (6), E21 (7), and E22 (8).
4 Power train undercover: 320 kg
3. Drain the damper chamber oil.
Damper chamber oil: 1.5 l
4. Remove step covers (1) and (2).
8. Remove the hose clamp and disconnect

heater hoses (9) and (10) and air conditioner
hoses (11) and (12). 1
a Close the heater hose valve on the engine
side.
a Discharge the refrigerant (gas) from the
air conditioner curcuit before disconnect-
D275A-5 30-53
(7)2
DISASSEMBLY
9. Remove cover (13). 12. Disconnect wire (17).
10. Loosen the hose clamp and remove hose (14). 13. Remove plate (18) and remove partition
mounting bolts (19).
s Remove the plate and partition mounting
bolts on the right side similarly.
11. Disconnect wiring connectors PT1 (15) and

SS3 (16).
14. Lift off partition (20).

s After removing the partition, take out
cover (5) which has been removed.
Partition: 140 kg
30-54 D275A-5
2
DISASSEMBLY
15. Sling universal joint assembly (21) tempo- 21. Using 2 forcing screws c, lift off damper
rarily. cover assembly. 4
16. Remove the mounting bolts and lift off the
universal joint assembly. 2
Damper cover assembly: 55 kg
22. Using hanging bolt d, sling damper assembly

(26) and remove the mounting bolts. 5
17. Disconnect breather hose (22) and remove it
and oil level detection pipe (23) together.
23. Using 2 forcing screws e, lift off the damper

assembly.
18. Using hanging bolt b, sling damper cover
assembly (24) temporarily.
19. Disconnect ground wire (25). Damper assembly: 75 kg
20. Remove the mounting bolts of damper cover
assembly (24). 3
D275A-5 30-55
c
DISASSEMBLY
INSTALLATION 4
★ When installing the damper cover assem-
• Carry out installation in the reverse order to bly, degrease the shaft spline and apply
removal. dry lubricant A and leave it as it is for
2 ~ 3 minutes. Then, apply extreme pres-
1 sure lithium grease containing molybde-
★ Install each hose so that it will not be num B to the shaft spline.
twisted. Molybdenum disul-
A fide dry lubricant Sumiko, lubricant
★ When installing the air conditioner hoses,
• Kyodo Yushi, Molylex No. 2
take care that dirt, dust, and water will not Extreme pressure
B lithium grease con- • Showa-Shell, Letinax AM
enter them. taining molybdenum
• Nihon Sekiyu Molytex
★ Before tightening each air conditioner
hose connector, check that the O-ring is
fitted to it.
★ Apply compressor oil (Showa-Shell,
Sniso 4G or 5G) sufficiently to the O-rings.
Tightening torque for refrigerant Damper assembly mounting bolt:

gas pipes 98.10 ~ 123 Nm {10 ~ 12.5 kgm}
Thread size: Tightening torque

16 x 1.5 11.8 ~ 14.7Nm {1.2 ~ 1.5 kgm} • Refilling with oil.
22 x 1.5 19.6 ~ 24.5Nm {2 ~ 2.5 kgm} Add oil through the oil filler to the specified
24 x 1.5 29.4 ~ 34.3Nm {3 ~ 3.5kgm} level. Run the engine to circulate the oil
again.
2
Damper chamber oil:
Universal joint mounting bolt: 1.5 l (SAE30CD)
98.10 ~ 123 Nm {10 ~ 12.5 kgm}
3 Drain plug:
58.8 ~ 78.5 Nm {6 ~ 8 kgm}
Damper cover assembly mount-
ing bolt: Level plug:
98.10 ~ 123 Nm {10 ~ 12.5 kgm} 127 ~ 177 Nm {13 ~ 18 kgm}
ant gas
30-56 D275A-5
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY
SPECIAL TOOLS
New/
bol ssity
odel
791-612-1100 Installer ■ 1
B 790-101-4200 Puller (294 kN

{30 ton}) ■ 1
Hydraulic
790-101-1102 pump ■ 1
D275A-5 30-57
c
DISASSEMBLY
DISASSEMBLY 3) Bearing and oil seal

i) Remove oil seal (9) from cover (2),
1. Disassembly of damper cover assembly (1). then remove inner race (7-3) of bear-
1) Coupling ing (7).
Remove bolt (3) from cover (2), then
remove holder (4) and coupling (5).
ii) Remove inner races (7-4) and (7-5) of

bearing (7) from cover (2).
2) Shaft
i) Set damper cover assembly (1) on
block b.
ii) Push out shaft (6) by hitting it with a
plastic hammer from the output side.
★ Shaft (6) comes out together with
inner race (7-1) and oil seal (8) of bear-
ing (7).
iii) Remove the O-ring from shaft (6),

then remove collar (7-2) and inner
race (7-1) of bearing (7).
30-58 D275A-5
c
DISASSEMBLY
2. Disassembly of damper assembly (2)

1) Remove bolts (11) and flange (12).
2) Remove outer body (13), inner body (14),
and cushion (15).
3) Pull plug (17) out of flange (16).
★ Perform this procedure only when the
plug needs to be replaced.
D275A-5 30-59
c
DISASSEMBLY
ASSEMBLY
1. Assembly of damper assembly (10)
1) Set flange (16) and outer body (13) to cyl-
inder b, matching their bolt holes, and
install inner body (14).
Matching faces of flange and outer
body: Gasket sealant (LG-6)
Inside of outer body:Grease (G2-LI)
Cushion contact surface of inner

body: Grease (G2-LI) 4) Fill with grease.
Fill part C of the inner body with 80 g of
grease.:
Grease:
A Molybdenum disul- Sumiko, lubricant

fide dry lubricant
• Kyodo Yushi, Molylex No. 2
Extreme pressure
B lithium grease con- • Showa-Shell, Letinax AM
taining molybdenum
• Nihon Sekiyu Molytex
2) Install cushion (15).

★ Apply grease (G2-LI) all over the cushion.
★ After installing the cushion, fill the clear-
ance between the inner body and outer
body (16 places) with grease of 30%.
2. Assembly of damper cover assembly (1)

1) Using push tool c, press fit outer races (7-
4) and (7-5) of bearing (7) to cover (2).
3) Install flange (12) and secure it with bolts

(11).
Flange mounting bolt:

58.8 ~ 73.5 Nm {6 ~ 7.5 kgm}
30-60 D275A-5
c
DISASSEMBLY
2) Press fit inner race (7-1) of bearing (7) to 5) Fit oil seals (8) and (9) to cover assembly
shaft (6) with tool B. (2).
Press fitting face of seal:
Oil seal lip: Grease (G2-LI)
★ Apply the gasket sealant thinly to the oil

seal surface and wipe off projected part.
3) Install collar (7-2) and O-ring to shaft (6).
6) Install coupling (5) and holder (4) and

secure them with bolts (3).
Coupling mounting bolt:

245 ~ 309 Nm {25 ~ 31.5 kgm}
4) Set cover (2) to shaft (6). Using tool B,

press fit bearing inner race (7-3).
D275A-5 30-61
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY

REMOVAL

1. Drain the oil.
Power train case: Approx. 90 l
2. Remove the floor frame assembly. For

details, see REMOVAL OF FLOOR FRAME
ASSEMBLY. 9. Remove cover (6).
3. Remove the fuel tank assembly. For details,
see REMOVAL OF FUEL TANK ASSEMBLY.
4. Remove the undercover.
Power train undercover: 320 kg
5. Disconnect intermediate wiring connector

FE2 (1) from bracket (2).
10. Disconnect the following 4 oil filter hoses.

• (7): Power train oil filter inlet hose
• (8): Power train oil filter outlet hose
• (9): Steering oil filter inlet hose
• (10): Steering oil filter outlet hose
7. Disconnect wire clamp (3).

8. Disconnect fan pump discharge hose (4) and
drain hose (5).
30-62 D275A-5
c
DISASSEMBLY
11. Remove 4 hose clamps (11).

12. Remove clamp plate (12).
13. Disconnect the following 4 ripper hoses.
• (13): Ripper tilt port A5
• (14): Ripper tilt port B5
• (15): Ripper lift port A4
• (16): Ripper lift port B4
16. Disconnect the following 4 self-pressure

reducing valves.
• (19): Work equipment pump hose (Port P1)
• (20): Work equipment pump hose (Port PC)
• (21): Fan pump hose (Port PR)
• (22): Work equipment pump hose (Port LS)
14. Disconnect intermediate wiring connector 241

(17).
17. Disconnect oil cooler hose (23).

★ Move the hose to a place where it will not
be an obstacle when the power train unit
assembly is lifted up.
15. Disconnect work equipment pump tube cou- 18. Remove oil level detection pipe (24) for the
pling (18). power train.
19. Remove oil filler pipe (25) for the power train.
D275A-5 30-63
c
DISASSEMBLY
20. Disconnect pin puller solenoid valve hoses 24. Disconnect torque converter outlet hose (30)
(26) and (27). and transmission inlet hose (31).
21. Disconnect oil cooler hose (28). 25. Remove the mounting bolts and final drive
★ Remove the clamps of the oil cooler hose, shaft cover (32).
too. ★ Remove the final drive shaft cover on the
opposite side, too.
22. Sling universal joint assembly (29) tempo-

rarily.
23. Remove the mounting bolts and lift off uni-
versal joint assembly (29). 1
30-64 D275A-5
c
DISASSEMBLY
26. Pull out drive shaft (33) by the following

method.
Using forcing screw [1], pull out the drive
shaft until the spline on the steering case side
is separated.
★ If the shaft is difficult to pull out, set a jack
under the shoe grouser and push up the
shoe grouse to find a point where the
shaft is pulled out easily.
★ Pull out the drive shaft on the opposite
side, too.
29. Remove left (37) and right (38) mounting

bolts on the front side.
27. Remove both covers (34).
30. Lift off power train unit assembly (39). 3
Power train unit assembly: 2.500 kg
28. Loosen coupling clamp (35) and move seal

(36) outward. 2
D275A-5 30-65
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DISASSEMBLY
INSTALLATION
removal.
Universal joint mounting bolt:

98.10 ~ 123 Nm {10 ~ 12.5 kgm}
2
★ Clamp the peak of the coupling seal
securely and set the clamp threads in par-
allel with the cap mounting seat.
3
★ When installing the power train unit
assembly, take care extremely not to
damage seal (36).
• Refilling with oil

again.
• Bleeding air
Bleed air from the fan pump. For details, see
TESTING AND ADJUSTING, Bleeding air
from fan pump.
30-66 D275A-5
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DISASSEMBLY
AND ASSEMBLY DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY
DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT

ASSEMBLY
DISCONNECTION 5. Remove pin puller solenoid valve hoses (10)
and (11).
• Draining oil 6. Remove steering lubricating oil supply hose
Before setting the power train unit assembly (12).
to the block, drain the oil from the PTO case
and steering case.
1. Sling power train unit assembly (1) and set it
to block.
Power train unit assembly: 2,300 kg
7. Disconnect the following 6 wiring connectors.

• (13): SLC wiring connector (Left clutch
ECMV solenoid)
• (14): FLC wiring connector (Left clutch
ECMV fill switch)
• (15): FRC wiring connector (Right clutch
ECMV fill switch)
2. Remove cover (2). • (16): SRC wiring connector (Right clutch
3. Disconnect the following 5 wiring connectors. ECMV solenoid)
• (3): FRB wiring connector (Right brake • (17): STB wiring connector (Emergency
ECMV fill switch) stop prevention solenoid)
• (4): SRB wiring connector (Right brake • (18): TMI wiring connector (Bevel gear
ECMV fill switch) speed sensor.)
• (5): FLB wiring connector (Left brake
ECMV fill switch)
• (6): SLB wiring connector (Left brake
ECMV fill switch)
• (7): TMV intermediate connector
4. Disconnect the left brake and left clutch oil
pressure pickup hoses. 1
• (8): Left brake oil pressure pickup hose
(Color band: White)
• (9): Left clutch oil pressure pickup hose
(Color band: Black)
D275A-5 30-67
c
DISASSEMBLY
8. Disconnect transmission oil pressure pickup 11. Disconnect the following 5 transmission oil
hose (19) (Color band: not used) 1 pressure pickup hoses. 1
9. Disconnect the following 2 torque converter • (24): Transmission forward oil pressure
oil pressure pickup hoses. 1 pickup hose (Color band: White/
• (20): Torque converter outlet oil pressure Blue)
pickup hose (Color band: White/Red) • (25): Transmission 2nd oil pressure
• (21): Torque converter inlet oil pressure pickup hose (Color band: White/Yel-
pickup hose (Color band: Blue) low)
• (26): Transmission reverse oil pressure
pickup hose (Color band: Red/Blue)
• (27): Transmission 3rd oil pressure
pickup hose (Color band: Yellow/
Black)
• (28): Transmission 1st oil pressure pickup
hose (Color band: Red)
10. Disconnect the right brake and right clutch oil

pressure pickup hoses. 1
• (22): Right brake oil pressure pickup hose
(Color band: Yellow)
• (23): Right clutch oil pressure pickup hose
(Color band: White/Black)
12. Remove EPC valve basic pressure hose (29).

13. Remove power train filter hose (30).
30-68 D275A-5
c
DISASSEMBLY
14. Disconnect the following 2 wiring connectors.

• (31): FAC wiring connector (Fan pump
solenoid valve)
• (32): 453 wiring connector (Torque con-
verter oil temperature sensor)
15. Remove hose (33) between the transmission
and steering case.
16. Remove the 4 mounting bolts and fan pump
assembly (34).
Fan pump assembly: 30 kg
23. Remove steering filter hose (44) and power

train filter hose (45).
24. Disconnect pump drive gear lubrication tube
(46) and remove transmission lubrication
tube (47). 2
25. Disconnect suction tube (48) and remove
block (49).
26. Remove the 2 mounting bolts and lift off
power train and lubricating oil pump assem-
bly (50).
Power train lubricating oil pump

assembly: 30 kg
17. Disconnect the following 3 work equipment

pump hoses.
• (35): Work equipment pump hose (Port
PA1)
PP2)
PLS1)
18. Disconnect suction tubes (38) and (39).
19. Disconnect scavenging pump tube (40).
20. Remove the 2 mounting bolts and lift off work
equipment pump assembly (41).
Work equipment pump assembly:

70 kg
21. Remove the 2 mounting bolts and scavenging

pump (42).
22. Remove hose bracket (43).
D275A-5 30-69
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DISASSEMBLY
27. Remove 5 hose clamps (51) and oil pressure

pickup hose bracket assembly (52).
★ After removing the hose clamps, remove
the disconnected hoses.
★ Remove the oil pressure pickup hose
bracket assembly and oil pressure pickup
hose together.

steering case assembly (60).
Steering case assembly: 950 kg
28. Remove plate (53) and disconnect rod (54).

3
29. Remove brackets (55) and (56) and hose
bracket (57).
32. Remove coupling (61).
30. Remove torque converter oil temperature

sensor bracket (58) and pull out 2 sleeves
(59).
30-70 D275A-5
c
DISASSEMBLY
33. Loosen the 6 mounting bolts and remove 36. Remove the 19 mounting bolts and lift off
retainer (62) by using 2 forcing screws [2]. PTO assembly (66).
4
★ Check the thickness and quantity of shims
PTO assembly: 400 kg
(63).
34. Remove snap ring (64). 37. Sling the torque converter assembly tempo-
rarily and remove 11 mounting bolts (67).
5
35. Set the PTO, torque converter, and transmis-

sion assembly (65) with the PTO side up. 38. Lift off torque converter assembly (68).
Torque converter assembly: 160 kg
D275A-5 30-71
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DISASSEMBLY
CONNECTION ★ Measure clearance a at 4 places on the

periphery (A, B, C, and D) and obtain the
• Carry out connection in the reverse order to average.
disconnection.
1
★ The adapters of the oil pressure pickup
hose have their respective color codes.
(See the connection of the centralized
pressure pickup hoses.)
Joint bolt:
34.3 ~ 44.2 Nm {3.5 ~ 4.5 kgm}
3) Determine the thickness of the shims.

3 -0
• Thickness of shims = a-0.05 mm
★ Adjust the brake pedal. For details, see
• Types of shims:
TESTING AND ADJUSTING, Adjusting
brake pedal and parking brake lever. 0.15 mm, 0.2 mm, 0.5 mm
• Standard thickness of shims: 0.5 mm
4 4) Set the shims of the determined thickness
★ Adjust the shims of the retainer according and tighten the mounting bolts of retainer
to the following procedure. (62) to the specified torque.
1) Install retainer (62) and tighten the 6
Mounting bolts: Adhesive (LT-2)
mounting bolts to the following torque
without inserting any shim.
Mounting bolt:
Oil seal: Grease (LG2-LI) 58.8 ~ 73.6 Nm {6.0 ~ 7.5 kgm}
★ Check that the thickness and quantity of

Mounting bolt: 9.8 Nm {1 kgm} the shims on both sides are the same.
★ Set the shims as shown in the figure so
2) Using thickness gauges, measure clear- that they will not block the forcing tap of
ance a between retainer (62) and PTO the retainer.
housing (69).
• Standard clearance a: 0.48 ~ 1.32 mm
30-72 D275A-5
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DISASSEMBLY
★ Apply molybdenum disulfide lubricant

(LM-P) to part P of the PTO unit input
shaft and apply grease (G2-LI) to spline b.
Mounting bolt: Adhesive (LT-2)
Mounting bolt:
98.10 ~ 123 Nm (10 ~ 12.5 kgm}
D275A-5 30-73
c
DISASSEMBLY
CONNECTION DIAGRAM OF CENTRALIZED OIL PRESSURE PICK-UP HOSES
30-74 D275A-5
c
DISASSEMBLY
• (8): Left brake oil pressure pickup hose

(Color band: White)
• (9): Left clutch oil pressure pickup hose
(Color band: Black)
• (19): Transmission oil pressure pickup hose
(Color band: Not used)
• (20): Torque converter outlet oil pressure
pickup hose (Color band: White/Red)
• (21): Torque converter inlet oil pressure
pickup hose (Color band: Blue)
• (22): Right brake oil pressure pickup hose
(Color band: Yellow)
• (23): Right clutch oil pressure pickup hose
(Color band: White/Black)
• (24): Transmission forward oil pressure
pickup hose (Color band: White/Blue)
• (25): Transmission 2nd oil pressure pickup
hose (Color band: White/Yellow)
• (26): Transmission reverse oil pressure
pickup hose (Color band: Red/Blue)
• (27): Transmission 3rd oil pressure pickup
hose (Color band: Yellow/Black)
• (28): Transmission 1st oil pressure pickup
hose (Color band: Red)
D275A-5 30-75
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY

DISASSEMBLY ii) Remove bearing inner race (3B) and
bearing (6) from gear (7).
1. Lubrication tube
Remove shaft lubrication tube (1).
3. Hydraulic/HSS charge pump and power train/

lubrication pump drive gear, cover assembly
1) Remove mounting bolts, then using forc-
2. HSS pump/fan pump drive gear, cover
ing screws and guide bolts, remove pump
assembly
drive gear and cover assembly (8).
ing screws and guide bolts, remove pump
drive gear and cover assembly (2).
2) Disassemble pump drive gear and cover

assembly as follows.
2) Remove bearing outer race and roller (3A)
i) Remove cover (9) from gear and bear-
from PTO case.
ing (10).
3) Disassemble pump drive gear and cover
i) Remove cover (4) from gear and bear-
ing (5).
30-76 D275A-5
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DISASSEMBLY
ii) Remove 2 bearings (11) from gear 3) Remove snap ring (15), then remove bear-
(12). ing (16).
4. Scavenging pump drive gear

5. Idler gear assembly
1) Remove snap ring (13).
1) Remove plate (17).
2) Knock drive gear (14) out from snap ring

end to remove.
ing screws (1) and guide bolts (2), remove
shaft (18).
D275A-5 30-77
c
DISASSEMBLY
★ Bearing (19) and spacer (20) separate 7. Sleeve

from shaft (18) and gear (21) comes Remove sleeve (29) from PTO case.
off.
★ If the bearing is to be used again, do
not change the combination with the
outer race. Keep as a set in a safe
place.
3) Remove 2 outer races (22) and snap ring
(23) from gear (21).
8. Magnet assembly
1) Remove mounting bolts, then remove
cover (30).
6. Input shaft bearing

1) Knock input shaft bearing and race
assembly (24) out from inside PTO case to
remove.
2) Remove spacer (25) and outer race (26).
2) Remove 2 springs (31) and 2 magnet

assemblies (32).
3) Remove 2 bearings (28) from race (27).

★ If the bearing is to be used again, do
not change the combination with the
outer race. Keep as a set in a safe
place.
30-78 D275A-5
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DISASSEMBLY
ASSEMBLY 2. Sleeve
Install sleeve (29) to PTO case.
★ Clean all parts, check that there is no dirt or ★ Install the sleeve with the chamfered side
damage, and coat the sliding surfaces of all facing the inside of the PTO case.
parts with engine oil before assembling. ★ Expand fit the sleeve.
★ After press fitting the bearing, drop approx. 6
cc of oil (EO30-CD or EO10-CD) on the bear-
ing, and rotate it 10 times.
★ When expand fitting the bearing, before cool-
ing with dry ice, drop approx. 6 cc of oil
(EO30-CD or EO10-CD) on the bearing, and
rotate it 10 times.
★ Check that the snap ring is fitted securely in
the groove.
1. Magnet assembly
1) Assemble 2 magnet assemblies (32) and 2
springs (31) to PTO case.
3. Input shaft bearing

★ Match the production No. and set No. on
the bearing and spacer, and be sure to
use them as a set.
1) Using push tool d, press fit outer race (26)
to PTO case.
2) Install cover (30).
2) Using push tool e, press fit 2 bearings

(28) to race (27).
D275A-5 30-79
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DISASSEMBLY
3) Assemble input shaft bearing and race

assembly (24) to PTO case.
Surface of inside circumference of
race: Molybdenum disulfide lubri-
cant (LM-P)
4) Assemble spacer (25).
5) Using push tool f, press fit outer race
(26).
5) Install spacer (20).

6) Install bearing (19) to gear, then press fit
bearing by fitting plate (17).
Mounting bolt:
Thread tightener (LT-2)
Mounting bolt:
245.0 ~ 308.7 Nm
{25.0 ~ 31.5 kgm}
4. Idler gear
★ Match the production No. and set No. on
the bearing and spacer, and be sure to
use them as a set.
1) Install snap ring (23) to gear (21).
2) Using push tool g, press fit 2 outer races
(22) to gear (21).
7) Install mounting bolts of shaft (18).
3) Fit O-ring, then using 3 guide bolts h,

insert shaft to position shown in diagram.
★ If shaft (18) is inserted fully, it will
become impossible to install the idler
gear.
O-ring: Grease (G2-LI)
4) Hold down shaft from outside of case,

then using push tool i, press fit bearing
(19) to gear.
30-80 D275A-5
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DISASSEMBLY
5. Scavenging pump drive gear 6. Hydraulic/HSS charge pump and power train/
1) Press fit bearing (16) to PTO case. lubrication pump drive gear, cover assembly
2) Install snap ring (15). 1) Using push tool 1), press fit 2 bearings
(11) to gear (12).
3) Hold down inner race end of bearing with

push tool j, and press fit drive gear (14). 2) Using push tool 1!, press fit gear and
bearing (10) to cover (9).
4) Install snap ring (13). 3) Fit O-ring and install pump drive gear and
cover assembly (8) to PTO case.
Mounting bolt:
Mounting bolt:
98.0 ~ 122.5 Nm
{10.0 ~ 12.5 kgm}
D275A-5 30-81
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DISASSEMBLY
7. HSS pump/fan pump drive gear, cover 8. Lubrication tube

assembly Install shaft lubrication tube (1).
1) Using push tool 1@, press fit bearing (6) to
gear (7).
2) Using push tool 1#, press fit bearing inner
race (3B) to gear (7).
3) Using push tool 1$, press fit gear and

bearing (5) to gear (4).
4) Using push tool 1%, press fit bearing outer
race and roller (3A) to PTO case.
5) Fit O-ring and install pump drive gear and

cover assembly (2) to PTO case.
Mounting bolt:
Mounting bolt:
98.0 ~ 122.5 Nm {10.0 ~ 12.5 kgm}
30-82 D275A-5
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DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEM-

BLY
DISASSEMBLY
1. Input shaft
Remove the mounting bolts. Then, using
hanging bolt [1] remove input shaft (1).
2) Using forcing screws [3] from the turbine

side, remove bearing (6).
2. Drive case assembly

Remove 36 mounting bolts (2) between the
drive case and pump. Then, using hanging
bolt [2], remove drive case assembly (3).
3) Remove drive case (7) from turbine gear

(8).
3. Disassembly of drive case assembly

1) Remove snap ring (4) and spacer (5).
D275A-5 30-83
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DISASSEMBLY
4. Stator 4) Remove snap ring (13).

5. Pump
2) Remove stator and boss assembly (10). 1) Remove pump assembly (14) from stator
shaft housing assembly (15).
3) Remove boss (11) from stator (12).

2) Remove the mounting bolts. Then,
remove retainer (16) and bearing outer
race (17) from pump (18).
30-84 D275A-5
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DISASSEMBLY
6. Stator shaft housing assembly

1) Loosen the 3 mounting bolts gradually,
disconnect housing and shaft assembly
(19).
2) Disassemble the housing and shaft

assembly according to the following pro-
cedure.
i) Using forcing screw [4], remove shaft
and bearing assembly (20).
ii) Remove snap ring (21). Then, remove

bearing (22) from shaft (23).
iii) Remove seal ring (24) from shaft (23).
D275A-5 30-85
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DISASSEMBLY
ASSEMBLY
★ Clean all parts, check that there is no dirt or
damage, and coat the sliding surfaces of all
parts with engine oil before installing.
cc of oil (E030-CD or E010-CD) on the bearing,
and rotate it 10 times.
★ When expand fitting the bearing before cool-
(E030-CD or E010-CD) on the bearing, and
rotate it 10 times.
5) Set shaft and housing assembly (19) and
the groove.
install 3 mounting bolts a.
★ Tighten the 3 mounting bolts gradu-
1. Assembly of stator shaft housing assembly
ally and evenly.
1) Using push tool [5], fit bearing (22) to
shaft (23) with a press. Mounting bolt: Adhesive (LT-2)
2) Install seal ring (24) to shaft (23).
★ Fix the seal ring to the shaft with
grease securely. Mounting bolt:
98.0 ~ 122.5 Nm
Seal ring: Grease (G2-LI) {10.0 ~ 12.5 kgm}
3) Install snap ring (21).
6) Insert 11 mounting bolts b of the trans-

mission assembly and torque converter
4) Install shaft and bearing assembly (20) to assembly in the bolt holes before install-
housing (25). ing the pump.
Mounting bolt:
58.8 ~ 73.6 Nm {6.0 ~ 7.5 kgm}
30-86 D275A-5
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DISASSEMBLY
2. Pump 3. Snap ring

1) Press fit bearing outer race (17) to pump Install snap ring (13) to the shaft.
(18).
2) Install retainer (16) to the pump.
Mounting bolt:
58.8 ~ 73.6 Nm {6.0 ~ 7.5 kgm}
4. Stator
1) Install boss (11) to stator (12).
Mounting bolt:
3) Install pump assembly (14) to stator shaft 58.8 ~ 73.6 Nm {6.0 ~ 7.5 kgm}
housing assembly (15).
Mounting bolt:
58.8 ~ 73.6 Nm {6.0 ~ 7.5 kgm}
2) Install stator and boss assembly (10).
D275A-5 30-87
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DISASSEMBLY
3) Install snap ring (9) to the shaft. 3) Using hanging bolt [2], install drive case
assembly (3).
★ Match plug (26) of the pump to the oil
groove of the drive case.
Mounting bolt:
49.0 ~ 58.8 Nm {5.0 ~ 6.0 kgm}
Plug:
14.7 ~ 19.6 Nm {1.5 ~ 2.0 kgm}
5. Assembly of drive shaft case

1) Set drive case (7) on turbine gear (8).
4) Install spacer (5) and snap ring (4).
2) Using push tool [6], fit bearing (6) with a

press.
30-88 D275A-5
c
DISASSEMBLY
6. Input shaft
Use hanging bolt [1], install input shaft (1).
★ Match plug (26) of the pump to the oil
groove of the drive case.
Mounting bolt:
98.0 ~ 122.5 Nm {10.0 ~ 12.5 kgm}
D275A-5 30-89
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DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION

ASSEMBLY
SPECIAL TOOLS
3. Transmission control valve assembly
New/ 1) Remove 5 pressure detection nipples
bol ssity Qty. Remo Sketch (126).
del
D 799-301-1600 Oil leak
tester ■ 1
DISASSEMBLY
★ Store the discs and plates in a flat place to
prevent them from becoming deformed.
1. Elbow
Remove elbow (1).
3) Remove wiring connector (136) from

cover.
2. Main relief valve assembly

Remove main relief valve assembly (2).
5) Remove flanges (138) and (139) and

sleeves (140) and (141).
30-90 D275A-5
c
DISASSEMBLY
6) Remove 4 mounting bolts (4), then 2) Remove 13 tie bolts (8) used to tighten
remove transmission control valve transmission case.
assembly (5). ★ Do not remove 4 tie bolts (9) not used
★ Do not remove 2 connecting bolts (6) to tighten transmission case.
connecting the top and bottom con-
trol valve.
3) Using eyebolts c, remove transmission

case (10).
4. Sleeve
Remove sleeve (7).
6. Tie bolts
Remove 4 remaining tie bolts (9).
5. Transmission case
1) Set input shaft end at top and put on
block b.
D275A-5 30-91
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DISASSEMBLY
7. Input shaft, front cover, No. 1 carrier assem- vi) Remove snap ring (142), then remove
bly bearing (143) from front cover (19).
1) Using eyebolts d, remove input shaft, vii) Remove seal ring (121).
front cover, and No. 1 carrier assembly
(11).
viii) Remove spacer (144).

ix) Remove snap ring (20), then knock
input shaft (21) out from torque con-
2) Disassemble input shaft, front cover, and verter end, and remove from No. 1
No. 1 carrier assembly as follows. carrier assembly (118).
i) Remove snap ring (12), then remove x) Remove bearing (117) from input
No. 2 sun gear (13). shaft (21).
ii) Remove snap ring (14). xi) Remove seal ring (158) from input
iii) Remove snap ring (15), then remove shaft.
No. 1 sun gear (16) and spacer (17).
iv) Remove snap ring (18).

v) Using push tool h, push input shaft
and No. 1 carrier assembly, and
remove from front cover (19).
30-92 D275A-5
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DISASSEMBLY
3) Disassemble No. 1 carrier assembly as 3) Remove seal ring (145) from No. 1 hous-
follows. ing (33).
i) Remove snap ring (22) from No. 1 car- 4) Remove seal ring (146) from No. 1 piston
rier assembly, then remove No. 1 ring (34).
gear (23).
ii) Remove shaft (24) and ball (28).
★ Be careful not to lose the ball.
iii) Remove 2 thrust washers (25), needle
bearing (27), and planetary gear (26).
10. No. 2 discs, plates, springs, guide pins

1) Remove 6 guide pins (35).
2) Remove 12 No. 2 springs (36).
3) Remove 48 springs (37), 8 No. 2 discs (38),
and 7 No. 2 plates (39).
8. No. 1 discs, plates, springs
9. No. 1 housing assembly

1) Using eyebolts e, remove No. 1 housing
(33).
2) Remove No. 1 piston (34) from No. 1
housing.
D275A-5 30-93
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DISASSEMBLY
11. Sleeves 5) Remove snap ring (44).

Remove 17 sleeves (40). 6) Using push tool i, push No. 2 carrier
12. Lubrication relief valve assembly (45), and remove from No. 2
Remove lubrication relief valve (41) and housing (46).
spring (120).
7) Remove snap ring (58), then remove bear-

ing (59) from No. 2 housing (46).
13. No. 2 housing, No. 2 carrier assembly
8) Remove seal ring (57).
1) Using eyebolts f, remove No. 2 housing
and No. 2 carrier assembly (42).
2) Remove No. 2 piston (43).
3) Remove seal ring (147) from No. 2 hous-

ing (46).
4) Remove seal ring (148) from No. 2 piston
(43).
30-94 D275A-5
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DISASSEMBLY
9) Disassemble No. 2 carrier assembly as 15. No. 3 ring gear

follows. Remove No. 3 ring gear (64).
i) Remove spacer (47) and No. 2 ring
gear (48) from No. 2 carrier assembly.
ii) Remove shaft (50) and ball (54).
★ Be careful not to lose the ball.
iii) Remove 2 thrust washers (51), needle
bearing (53), and planetary gear (52).
16. No. 3, No. 4 carrier assembly

1) Using eyebolts j, remove No. 3 and No. 4
carrier assembly (65).
iv) Remove snap ring (55), then remove

ring gear (56).

D275A-5 30-95
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DISASSEMBLY
2) Disassemble No. 3 and No. 4 carrier

i) Remove seal ring (66)
ii) Using round bar, knock pin (67) into
shaft (68).
iii) Using round bar, knock No. 4 shaft
(68) out from No. 3 carrier and
remove.
★ Pull the pin out from the shaft.
iv) Remove 2 thrust washers, needle
bearing (71), and No. 4 planetary gear
(70).
v) Remove No. 3 shaft (72) and ball (76).
★ Be careful not to lose the ball. 18. No. 4 discs, plates, springs, guide pins
vi) Remove 2 thrust washers (73), needle 1) Remove 6 guide pins (83).
bearing (75), and No. 3 planetary gear 2) Remove 12 No. 4 springs (79).
(74). 3) Remove 24 springs (80), 4 No. 4 discs (81),
vii) Remove snap ring (156), then remove and 5 No. 4 plates (82).
bearing (157).
19. No. 5 carrier, No. 4 ring gear assembly

1) Remove 8 mounting bolts (84).
2) Remove No. 5 carrier and No. 4 ring gear
1) Using eyebolts 1) remove No. 3 housing
assembly (85).
(77).

ing (77).
(78).
30-96 D275A-5
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DISASSEMBLY
3) Disassemble No. 5 carrier and No. 4 ring 3) Remove seal ring (151) from No. 4 hous-
gear as follows. ing (94).
i) Remove shaft (86) and ball (90). 4) Remove seal ring (152) from No. 4 piston
★ Be careful not to lose the ball. (95).
ii) Remove 2 thrust washers (87), needle
bearing (89), and planetary gear (88)
from No. 5 carrier (93).

iii) Remove snap ring (91), then remove and 4 No. 5 plates (98).
No. 4 ring gear (92) from No. 5 carrier
(93).

1) Using eyebolts 1!, remove No. 4 housing
(94).
D275A-5 30-97
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DISASSEMBLY
22. No. 5 ring gear

Remove No. 5 ring gear (100).
23. Spacer, No. 4 sun gear, bearing
2) Remove spacer (102), No. 4 sun gear
(103), and bearing and spacer (104).
24. No. 5 sun gear
Remove No. 5 sun gear (105).
25. No. 5 piston
Remove No. 5 piston (106).

1) Remove snap ring (110), then remove
bearing (111) from No. 5 housing.
2) Remove snap ring (112), then remove
bearing (113) from No. 5 housing.
3) Remove cage (114).
4) Remove seal rings (115) and (116) from
cage (114).
26. Seal rings

ing (109).
(106).
ASSEMBLY
cc of oil (EO30-CD or EO10-CD) on the bear-
ing, and rotate it 10 times.
27. Output shaft, spacer ★ When expand fitting the bearing, before cool-
1) Remove spacer (108). ing with dry ice, drop approx. 6 cc of oil
2) Remove snap ring (155), then remove out- (EO30-CD or EO10-CD) on the bearing, and
put shaft (107) from No. 5 housing (109). rotate it 10 times.
the groove.
★ Coat the blind plugs with thread tightener
(LT-2), then after assembling, caulk 2 places
on diagonally opposite sides.
30-98 D275A-5
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DISASSEMBLY
1. No. 5 housing assembly 3) Install spacer (108) to shaft (107).

1) Install seal rings (116) and (115) to cage
(114).
Seal ring: Grease (G2-LI)
2) Install cage (114) to No. 5 housing (109).

3) Using push tool (12), press fit bearing
(113) to No. 5 housing with press.
3. Seal ring
1) Install seal ring (154) to No. 5 piston (106).
★ The seal ring must be installed facing
in the correct direction. Assemble as
shown in the diagram.
4) Install snap ring (112). Seal ring: Grease (G2-LI)

6) Using push tool 1#, press fit bearing (111) 2) Install seal ring (153) to No. 5 housing
until it contacts snap ring (110). (109).
2. Output shaft, spacer

1) Install snap ring (155) to output shaft
(107).
2) Support inner side of bearing (111) of No.
5 housing with tool 1$, then using push
tool 1%, press fit output shaft with press.
★ Press fit bearing (111) until it contacts
snap ring (155).
D275A-5 30-99
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DISASSEMBLY
4. No. 5 piston
Install No. 5 piston (106).
5. No. 5 sun gear
Install No. 5 sun gear (105).
6. No. 5 ring gear
Install No. 5 ring gear (100).

7. Bearing, No. 4 sun gear, spacer 2) Install seal ring (151) to No. 4 housing
1) Using push tool 1^, press fit bearing (156) (94).
to spacer (157). ★ The seal ring must be installed facing
2) Install bearing and spacer (104). in the correct direction. Assemble as
3) Install No. 4 sun gear (103) and spacer
(102).
3) Install No. 4 piston (95) to No. 4 housing

8. No. 5 discs, plates, springs, guide pins (94).
1) Install guide pin (83). 4) Using eyebolts 1!, install No. 4 housing
2) Install 4 No. 5 plates (98), 3 No. 5 discs (94).
(97), and 18 springs (99). ★ Check that the spring is fitted securely
3) Install 12 springs (96). in the groove.
★ Free length of spring: 70 mm
30-100 D275A-5
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DISASSEMBLY
10. No. 5 carrier, No. 4 ring gear assembly

1) Assemble No. 5 carrier and No. 4 ring
gear assembly as follows.
i) Set No. 4 ring gear (92) to No. 5 car-
rier (93), and install snap ring (91).

1) Install 5 No. 4 plates (82), 4 No. 4 discs
(81), and 24 springs (80).
2) Install 12 No. 4 springs (79).
ii) Assemble needle bearing (89) to plan-

etary gear (88), put 2 thrust washers
(87) in contact on both sides, and set
to No. 5 carrier (93).
★ Be careful not to damage or dent the
thrust washers.
iii) Install shaft (86) and ball (90).
★ Check that the gear rotates smoothly.

2) Install seal ring (149) to No. 3 housing

(77).
2) Using guide bolt 1&, install No. 5 carrier in the correct direction. Assemble as
and No. 4 ring gear assembly (85). shown in the diagram.
Mounting bolt:
Thread tightener (LT-2) Seal ring: Grease (G2-LI)
Mounting bolt:
58.8 ~ 73.5 Nm {6.0 ~ 7.5 kgm}
D275A-5 30-101
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DISASSEMBLY
3) Install No. 3 piston (78) to No. 3 housing 2) Align meshing of gears, then using eye-
(77). bolts (9), install No. 3 and No. 4 carrier
4) Using eyebolts 1), install No. 3 housing assembly (65).
(77).
★ Check that the spring is fitted securely
in the groove.
14. No. 3 ring gear

Install No. 3 ring gear (64).
13. No. 3, No. 4 carrier assembly

1) Assemble No. 3 and No. 4 carrier assem-
bly as follows.
i) Assemble needle bearing (75) to No. 3
planetary gear (74), put 2 thrust wash-
ers (73) in contact on both sides, and
set to No. 3 carrier.
thrust washers.
ii) Install No. 3 shaft (72) and ball (76).
iii) Assemble needle bearing (71) to No. 4
planetary gear (70), put 2 thrust wash-
ers (69) in contact on both sides, and 15. No. 3 discs, plates, springs
set to No. 4 carrier. 1) Install 5 No. 3 plates (63), 4 No. 3 discs
★ Be careful not to damage or dent the (62), and 24 springs (61).
thrust washers. 2) Install 12 No. 4 springs (60).
iv) Install No. 4 shaft (68).
v) Check that the position of the pin
holes matches, then install pin (67) to
No. 4 shaft (68).
30-102 D275A-5
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DISASSEMBLY
16. No. 2 housing, No. 2 carrier assembly 2) Using push tool 1*, press fit bearing (59)
1) Assembly No. 2 carrier assembly as fol- to No. 2 housing (46).
lows.
i) Set ring gear (56) to No. 2 carrier (45),
and install snap ring (55).
3) Using push tool 1(, press fit No. 2 housing

(46) to No. 2 carrier assembly (45).
★ Push the bearing inner race to press
fit.
ii) Assemble needle bearing (53) to plan-
to No. 2 carrier.
thrust washers.
iii) Install shaft (50) and ball (54).
iv) Install No. 2 ring gear (48).

v) Install spacer (47).
★ Install with the cut side facing the car-
rier.
D275A-5 30-103
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DISASSEMBLY
5) Install seal ring (57) to No. 2 housing (46).


(46).
★ The seal ring must be installed facing 19. No. 2 discs, plates, springs, guide pins
in the correct direction. Assemble as 1) Install guide pins (35).
(38), and 48 springs (37).

8) Install No. 2 piston (43) to No. 2 housing ★ The seal ring must be installed facing
(46). in the correct direction. Assemble as
9) Using eyebolts f, install No. 2 housing shown in the diagram.
and No. 2 carrier assembly (42).

(33).
17. Sleeves
Install 17 sleeves (40).
18. Lubrication relief valve
Install lubrication relief valve (41) and spring
(120).
30-104 D275A-5
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DISASSEMBLY
3) Install No. 1 piston (34) to No. 1 housing

(33).
4) Using eyebolts e, align No. 2 piston (34)
with guide pin position, then install No. 1
housing (33).
★ Check that the spring is fitted securely
in the groove.
4) Using push tool 2! press fit bearing outer

end of input shaft (21) to No. 1 carrier
assembly (118).
21. Input shaft, No. 1 carrier assembly

1) Assemble No. 1 carrier assembly as fol-
lows.
i) Assemble needle bearing (27) to plan-
to No. 2 carrier.
★ Be careful not to damage or dent
the thrust washers.
ii) Install shaft (24) and ball (28).
★ Check that the gear rotates 5) Install spacer (17).
smoothly. 6) Fit No. 1 sun gear and install snap ring
iii) Set No. 1 ring gear (23) to No. 1 car- (15) to input shaft.
rier, and install snap ring (22). 7) Install snap ring (14).
2) Install seal ring (158) to input shaft (21).
3) Using push tool 2), press fit bearing (117)

to input shaft (21) with press.
D275A-5 30-105
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DISASSEMBLY
8) Fit No. 2 sun gear (13) and install snap 24. Front cover
ring (12) to input shaft. 1) Using push tool 2@, press fit bearing (143)
to front cover (19).
9) Align meshing of No. 2 sun gear and No.

1 planetary gear, then using eyebolts d,
install input shaft and No. 1 carrier assem- 3) Install seal ring (121) to front cover (19).
bly (119).
4) Using eyebolts g, install front cover (19).

22. Spacer ★ Check that the spring is fitted securely
Install spacer (144). in the groove.
(31), and 36 springs (30).
30-106 D275A-5
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DISASSEMBLY
5) Using push tool 2#, press fit inner side of 27. Transmission case
bearing (143) inside front cover (19). 1) Fit O-ring, then using eyebolts c, install
6) Install snap ring (18). transmission case (10).
25. Tie bolts

Install 4 tie bolts (9).
Tie bolt:
2) Install remaining 13 tie bolts (8).
156.8 ~ 176.4 Nm {16.0 ~ 18.0 kgm}
Tie bolt:
156.8 ~ 176.4 Nm {16.0 ~ 18.0 kgm}
26. Piston actuation check

Using tool D, check stroke and actuation con-
dition of each clutch piston.
Piston Standard stroke (mm)
28. Sleeve
No.1 6 Fit O-ring and install sleeve (7).
No.2 8.8
No.3 6.4
No.4 6.4
No.5 6
D275A-5 30-107
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DISASSEMBLY
29. Transmission control valve assembly 5) Fit gasket and install cover (3).
1) Fit O-ring and install transmission control 6) Install 5 pressure detection nipples (126).
valve assembly (5).
Mounting bolt:
44.1 ~ 53.9 Nm {4.5 ~ 5.5 kgm}
30. Main relief valve assembly

Install main relief valve assembly (2).
2) Fit O-ring and install sleeves (140) and
(141), and sleeves (138) and (139). Mounting bolt:
44.1 ~ 53.9 Nm {4.5 ~ 5.5 kgm}
3) Fit gasket and install cover (137).

31. Elbow
★ Coat both the cover and transmission
Install elbow (1).
case with gasket sealant.
Cover: Gasket sealant (LG-6)
4) Fit wiring connector (136) to cover (137).

Mounting bolt:
39.6 ~ 42.4 Nm {4.0 ~ 4.3 kgm}
30-108 D275A-5
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DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY

SPECIAL TOOLS
2) Remove 16 mounting bolts, then using
New/ tool E1, remove steering case assembly
bol ssity (4).
del
★ Do not remove the 4 hexagon socket
791-622-1110 Bracket ■ 1 head bolts.
1 01010-62095 Bolt ■ 1 ★ Remove the steering case assembly
E on the opposite side in same way.
01016-61690 Bolt ■ 1
2 791-550-1301 Wrench ■ 1
DISASSEMBLY
1. Drain hose, joint
1) Remove drain hose (1).
2) Remove joint (2).
3. Disassembly of clutch, brake assembly

1) Disassembly of brake assembly
i) Remove flange (5).
ii) Remove collar assembly (6) and bush-
ing (7).
2. Clutch, brake assembly

1) To install tool E1 perpendicularly, use
block [1] and jack [2], and set steering
case assembly (3) at an angle of 15°.
iii) Remove plate (8).
D275A-5 30-109
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DISASSEMBLY
iv) Loosen 4 hexagon socket head bolts

uniformly and remove, then using
eyebolts [3] remove case (9).
★ The inner race of the bearing will
come out.
v) Remove bearing (10) from case (9).
x) Using eyebolts, remove drum (15)

together with disc and plate.
xi) Remove 7 discs (16), 6 plates (17), and
7 springs (18) from drum (15).
vi) Remove 2 brake spring case (11).

vii) Remove brake piston (12).
2) Disassembly of clutch assembly

i) Remove 22 mounting bolts and hub
(19).
ii) Remove bearing (20) from hub.
viii)Using puller [4], remove cylinder (13).

★ The outer race of the bearing will
come out.
ix) Remove 3 seal rings (14) from hub.
30-110 D275A-5
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DISASSEMBLY
iii) Remove snap ring (21) and stopper

(22).
4. Tubes
Remove 6 tubes (33).
iv) Remove snap ring (23). ★ When removing the tubes, be careful not
v) Remove the 24 mounting bolts and to damage the O-rings.
hub (24).
vi) Remove snap ring (25).
vii) Remove bearing (26) from hub (24).
5. Steering control valve assembly

1) Remove mounting bolts, then using eye-
bolts [5], remove steering control valve
viii)Remove piston (27) from the clutch
assembly (34).
drum.
2) Remove 2 sleeves (35) from steering case.
ix) Remove 7 discs (28) and 6 plates (29).
x) Remove plate (30).
xi) Separate hub (31) and clutch drum
(32).
D275A-5 30-111
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DISASSEMBLY
6. Suction tube ii) Remove pin (40).

Remove suction tube (36).
iii) Hole with press so that bevel pinion

7. Bevel pinion assembly does not move, and use tool E2 to
1) Using guide bolts [6] and forcing screws remove locknut (41).
[7], remove bevel pinion assembly (37)
and shims (38).
★ Check the number and thickness of
the shims, and keep in a safe place.
iv) Support cage (42), and use push tool

[8] to remove bevel pinion and bear-
ing (43).
2) Disassemble bevel pinion as follows.

i) Remove plate (39).
30-112 D275A-5
c
DISASSEMBLY
v) Remove bearing (44). ★ When removing the bevel pinion output

vi) Remove outer races (45) and (46) from speed sensor from the flange and replac-
cage (42). ing it, measure distance L between the
flange and the tip of the speed sensor.
When replacing the speed sensor, install
so that the installation dimension of the
speed sensor is L ± 0.2 mm.
vii) Remove spacer (47) and bearing (48)

from bevel pinion (49).
9. Bevel gear shaft, bevel gear assembly

1) Set with right side of steering case at top.
ing screws [9]. remove right cage (51) and
shims (52).
8. Bevel pinion output speed sensor

Remove bevel pinion output speed sensor
(50) together with flange.
D275A-5 30-113
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DISASSEMBLY
3) Remove outer race (53) from cage (51). 7) Disassembly of bevel gear shaft, bevel
gear assembly
i) Using puller [12], remove bearing (57)
from bevel gear shaft (56).
ii) Remove reamer bolt (58), then
remove bevel gear (59) from bevel
gear shaft (56).
4) Using forcing screws [10], disconnect

retainer (54) from case.
5) Remove forcing screws [10], then using
eyebolts [11], remove retainer (54).
iii) Using puller [13], remove bearing (60)

from bevel gear shaft (56).
6) Lift off bevel gear shaft, bevel gear

assembly (55).
8) Turn over steering case, then remove left

cage (61) and shims (62).
30-114 D275A-5
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DISASSEMBLY
9) Remove outer race (63) from cage (61). ASSEMBLY

cc of oil (E030-CD or E010-CD) on the bearing,
and rotate it 10 times.
★ When expand fitting the bearing before cool-
(E030-CD or E010-CD) on the bearing, and
rotate it 10 times.
the groove.
★ Coat blind plugs with thread tightener (LT-2),
then after assembly, caulk, 2 places on oppo-
site sides.
1. Bevel gear shaft, bevel gear assembly

1) Using push tool [14], press fit outer race
(63) to cage (61).
2) Assemble shim (62) and install cage (61).

★ Assemble the same amount and thick-
ness of shims that was removed.
• Standard shim thickness: 2mm
• Types of shim thickness:
0.1 mm, 0.2 mm, 0.5 mm
Mounting bolt:
98.1 ~ 122.6 Nm {10 ~ 12.5 kgm}
D275A-5 30-115
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DISASSEMBLY
3) Set with right side of steering case at top. 5) Turn over steering case so that right side
4) Assemble bevel gear and shaft assembly is at top, then install bevel gear shaft and
as follows. bevel gear assembly (55).
i) Using push tool [15], press fit bearing
(60) to shaft (56).
6) Using eyebolts [11] and guide bolt [17],

install retainer (54).
ii) Set bevel gear (59) to bevel gear shaft
(56), then fit reamer bolt (58) and Mounting bolt:
tighten nut. 98.1 ~ 122.6 Nm {10 ~ 12.5 kgm}
Mounting bolt:
215.6 ~ 274.4 Nm {22 ~ 28 kgm}
iii) Using push tool [16], press fit bearing

(57) to shaft (56).
30-116 D275A-5
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DISASSEMBLY
7) Using push tool [14], press fit outer race ★ Standard value for rotating torque
(53) to cage (51). (center of bevel gear shaft):
3.9 ~ 4.9 Nm {0.4 ~ 0.5 kgm}
(At tip of bevel gear tooth):
18.6 ~ 23.7 Nm {1.9 ~ 2.4 kgm}
★ When measuring the rotating torque,
rotate the bevel gear thoroughly (10 ~
20 times) before measuring.
★ If the rotating torque is not within the
standard value, adjust the shim thick-
ness at the left and right cages as fol-
lows:
If value is LOW, ADD shims
If value is HIGH, REMOVE shims
8) Using guide bolt [18], install right case

(51) and shims (52).
★ Assemble the same amount and thick-
ness of shims that was removed.
• Standard shim thickness: 2mm
• Types of shim thickness:
0.1 mm, 0.2 mm, 0.5 mm
Mounting bolt:
98.1 ~ 122.6 Nm {10 ~ 12.5 kgm}
2. Bevel pinion
1) Assemble bevel pinion as follows.
i) Using push tool [20], press fit bearing
(48) to bevel pinion (49) with press.
ii) Install spacer (47).
9) Set steering case assembly horizontally.

10) Adjust preload of cage bearing.
• Push tip of tooth of bevel gear (59)
with push-pull scale [19] and measure
rotating torque of bevel gear shaft.
D275A-5 30-117
c
DISASSEMBLY
iii) Using push tool [21], press fit outer

race (46) to cage (42).
★ Press fit outer race (46) in the same
way.
vii) After tightening locknut, turn locknut

in direction of loosening to a point
where 1 of 5 pin insertion holes in pin-
ion shaft and 1 of 8 pin insertion holes
iv) Install cage (42) to bevel pinion (49).
in locknut are aligned.
v) Using push tool [22], press fit bearing
(44) with press. • Angle to loosen: 0 ~ 9°
viii) Install pin (40) in aligned hole.
vi) Hold with press so that bevel pinion

does not move, use tool E2 to tighten
locknut (41). ix) Fit plate (39).
★ Rotate the cage while tightening.
Mounting bolt: Thread tight-
★ After tightening the locknut, check ener (LT-2)
that the bevel pinion rotates
smoothly. Mounting bolt:
11.8 ~ 14.7 Nm {1.2 ~ 1.5 kgm}
Locknut: Thread tightener (LT-2)
Mounting bolt:
392 ~ 441 Nm {40 ~ 45 kgm}
30-118 D275A-5
c
DISASSEMBLY
2) Using guide bolt [6], install bevel pinion iii) If the result of the measurement
assembly (37) and shims (38). shows that the backlash is not correct,
★ Assemble the same amount and thick- adjust as follows.
ness of shims that was removed. ★ When adjusting the shim thickness,
• Standard shim thickness: 2mm add or remove shims on the left or
• Types of shim thickness: right sides. However, to prevent the
preload of the bearing from changing,
0.1 mm, 0.2 mm, 0.5 mm always keep the same total thickness
of shims on the left and right. (Adjust
Mounting bolt:
by moving shims from one side to the
98.1 ~ 122.6 Nm {10 ~ 12.5 kgm}
opposite side.)
• When backlash is too small
Reduce the shim thickness on the
right side of the chassis and add the
same shim thickness to the left side.
(Move the bevel gear in direction A.)
3. Adjusting backlash, tooth contact

1) Adjusting backlash
i) Put probe of dial gauge [23] in contact
with tooth face at tip of bevel gear.
ii) Fix bevel pinion in position, and read
• When backlash is too large
scale when bevel gear is moved back-
ward and forward (in direction of rota- Reduce the shim thickness on the left
tion). side of the chassis and add the same
shim thickness to the right side.
• Standard value of backlash:
(Move the bevel gear in direction B.)
0.25 ~ 0.33 mm
★ Measure at 3 places on diametrically
opposite sides.
D275A-5 30-119
c
DISASSEMBLY
2) Adjusting tooth contact

Testing
i) Coat the tooth face of the bevel pinion
lightly with red lead (minimum), then
rotate the bevel gear forward and
backward and inspect the tooth con-
tact pattern left on the bevel gear
teeth.
ii) The standard value for the tooth con-
tact is as follows. (from tip of bevel
pinion tooth)
a. Center of tooth contact: 20 ~ 40%
of tooth width (from small end)
b. Width of tooth contact: 30 ~ 50% Adjusting
of tooth width. If the result of the inspection shows that
c. Center of tooth contact: 35 ~ 65% the correct tooth contact is not being
of tooth height (from root of obtained adjust again as follows.
tooth) i) When bevel pinion is too far from cen-
d. Width of tooth contact: 60 ~ 80% ter line of bevel gear:
of tooth height Contact is at small end of the convex
In addition, check that there is no tooth face of the bevel gear and at the
strong contact at the tip or root of the big end of the concave tooth face.
teeth or at the big and small ends. • Correct as follows:
★ If the gears are adjusted to this pat- Adjust the shim thickness at the bevel
tern, the tooth contact will be correct pinion end and move the bevel pinion
when load is applied. in direction A.
Or, adjust the shim thickness and
move the bevel gear in direction B.
After adjusting, check the tooth con-
tact pattern and backlash again.
30-120 D275A-5
c
DISASSEMBLY
ii) When bevel pinion is too close to cen-

ter 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 as follows:
Adjust the shim thickness at the bevel
pinion end and move the bevel pinion
in direction A.
Or, adjust the shim thickness and
move the bevel gear in direction B.
After adjusting, check the tooth con-
tact pattern and backlash again.
5. Suction tube
Install suction tube (36).
4. Bevel pinion output speed sensor

Install bevel pinion output speed sensor (50).
★ Install the stamped make [CB UP] at the
rotation sensor flange portion so that it
faces to the top of the steering case. 6. Steering control valve assembly
★ Adjust the transmission speed sensor. For 1) Install 2 sleeves (35) to steering case.
details, see TESTING AND ADJUSTING,
Adjusting transmission speed sensor. O-ring: Grease (G2-LI)
2) Fit O-ring to steering case end, then using

guide bolt [24] and eyebolts [5], install
steering control assembly (34).
D275A-5 30-121
c
DISASSEMBLY
3) Install 6 tubes (33). v) Install seal rings (64) and (65) to hub
(24).
O-ring: Grease (G2-LI) ★ Install the seal rings as shown in the
figure.
Seal rings: Grease (G2-LI)
7. Assembly of clutch, brake assembly

★ Use the same procedure to assembly on
bolt the left and right sides. vi) Install bearing (26) and snap ring (25)
1) Assembly of clutch assembly to hub (24).
i) Instal clutch drum (32) and hub (31) to vii) Set hub (24) to the clutch drum, and
the shaft. install snap ring (23).
ii) Install plate (30). viii) Install hub (24) with the 24 mounting
iii) Install 6 plates (29) and 7 discs (28). bolts.
iv) Install piston (27) to clutch drum.
Mounting bolt:
98.1 ~ 122.6 Nm {10 ~ 12.5 kgm}
30-122 D275A-5
c
DISASSEMBLY
ix) Install stopper (22) and snap ring (21)

to the hub.
ii) Install 3 seal rings (14) to brake hub

x) Install bearing (20) to hub (24). (19).
xi) Install hub (19) with the 22 mounting iii) Install cylinder (13) to brake hub (19).
bolts. ★ The outer race of the bearing is press
fitted.
Mounting bolt:
157 ~ 196 Nm {16 ~ 20 kgm}
iv) Fit O-ring and install brake drum.

2) Assembly of brake assembly
i) Install seal rings (66) and (67) to cylin- v) Set brake outer drum (15) to clutch
der (13). outer drum.
★ The seal ring must be installed facing vi) Assemble discs (16), plates (17), and
in the correct direction. Assemble as springs (18).
Seal rings: Grease (G2-LI)
D275A-5 30-123
c
DISASSEMBLY
viii) Using push tool [25], press fit bearing

(10) to brake case (9).
ix) Install bushing (7) and collar assem-
bly (5).
vii) Install piston (12), and brake springs

(11).
★ Install 2 pieces as 1 set.
★ Install stamped mark A facing the x) Install guide bolts [26] to cylinder (13).
position shown in the diagram.
xi) Fit O-ring, then using eyebolts [3],

install case (9).
xii) Using push tool [26], push inner side
of bearing (10) and press fit with
press.
★ After press fitting with the press,
install 4 hexagon socket head bolts.
★ After removing from the press, fully
tighten the hexagon socket head bolts
uniformly.
30-124 D275A-5
c
DISASSEMBLY
8. Clutch, brake assembly

1) To install tool E1 perpendicularly, use
block [1] and jack [2], and set steering
case assembly (3) at an angle of 15°.
2) Fit O-ring using tool E1. Install brake and

carrier assembly (4).
Mounting bolt:
98.1 ~ 122.6 Nm {10 ~ 12.5 kgm}
xiii)Install plate (8).
Mounting bolt:
58.8 ~ 73.5 Nm {6.0 ~ 7.5 kgm}
xiv)Fit O-ring and install flange (5).
Mounting bolt:
58.8 ~ 73.5 Nm {6.0 ~ 7.5 kgm}
9. Drain hose, joint

1) Install joint (2).
2) Install drain hose (1).
D275A-5 30-125
c
DISASSEMBLY
10. Cover
If cover (68) at rear of steering case has been
removed, install new gasket.
★ Coat both surfaces of the gasket with gas-
ket sealant.
Gasket: Gasket sealant (LG-1)
★ Tighten connector (69) of the bevel pinion

output speed sensor with the cover
mounting bolts.
30-126 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF SCAVENGING PUMP
REMOVAL AND INSTALLATION OF SCAVENGING PUMP

REMOVAL INSTALLATION
1. Remove inspection cover (1). • Carry out installation in the reverse order to
removal.
• Refilling with oil (Power train case)
again.
2. Drain the power train oil.
3. Remove tube (2).

4. Remove the 5 mounting bolts and scavenging
pump assembly (3).
D275A-5 30-127
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF WORK EQUIPMENT PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF WORK EQUIPMENT PUMP

ASSEMBLY
REMOVAL 5. Remove floor plate (6).
WARNING! Disconnect the cable from Floor plate: 35 kg


cover (1).
6. Disconnect tubes (7) and (8).
7. Disconnect plate (9).

8. Disconnect 2nd pump pressure input hose
(10) and load pressure input hose (11).
9. Disconnect discharge hose (12) and drain
hose (13).
10. Remove the 2 mounting bolts and lift off work
3. Disconnect wiring connectors DCL (3) and equipment pump assembly (14).
BRK (4).
4. Disconnect brake linkage (5) from the turn- Work equipment pump assembly:
buckle 1
70 kg
★ Before disconnecting the linkage, mea-
sure its installed length.
30-128 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF WORK EQUIPMENT PUMP ASSEMBLY
INSTALLATION
removal.
1
brake pedal and parking brake lever.
D275A-5 30-129
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF FAN PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF FAN PUMP ASSEMBLY

REMOVAL


cover (1).
5. Remove plate (6).

★ Plate (6) may be removed altogether with
operator’s seat sliding plate (5).
2. Remove mounting nuts (2) and operator’s

seat assembly (3).
Operator’s seat assembly: 40 kg
7. Disconnect wiring connectors DCL (8) and

BRK (9).
8. Disconnect brake linkage (10) from the turn-
buckle. 1
9. Remove floor plate (11).
Floor plate: 35 kg

4. Remove the mounting bolts and operator’s
seat sliding plate (5).
★ Operator’s seat sliding plate (5) may be
removed together with plate (6).
Operator’s seat sliding plate (5):

25 kg
Operator’s seat sliding plate (5)

and plate (6): 40 kg
30-130 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF FAN PUMP ASSEMBLY
10. Disconnect hose clamps (12), (13). INSTALLATION

removal.
1
• Bleeding air
Bleed air from the fan pump. For details, see
from fan pump.
11. Disconnect wiring connectors FAC (14).

12. Disconnect EPC valve main pressure hose
(15).
13. Disconnect suction tube (16).
14. Disconnect discharge hose (17) and drain
hose (18).
15. Remove the 4 mounting bolts and fan pump
assembly (19).
Fan pump assembly: 30 kg
D275A-5 30-131
c
DISASSEMBLY REMOVAL AND INSTALLATION OF POWER TRAIN AND STEERING LUBRI-
AND ASSEMBLY CATING OIL PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF POWER TRAIN AND STEERING

LUBRICATING OIL PUMP ASSEMBLY
REMOVAL


cover (1).

★ Plate (6) may be removed altogether with
operator’s seat sliding plate (5).
2. Remove mounting nuts (2) and operator’s

seat assembly (3).
7. Disconnect wiring connectors DCL (8) and

BRK (9).
buckle. 1
9. Remove floor plate (11).
Floor plate: 35 kg

4. Remove the mounting bolts and operator’s
seat sliding plate (5).
★ Operator’s seat sliding plate (5) may be
removed together with plate (6).
Operator’s seat sliding plate (5):

25 kg
Operator’s seat sliding plate (5)

and plate (6): 40 kg
30-132 D275A-5
c
DISASSEMBLY REMOVAL AND INSTALLATION OF POWER TRAIN, STEERING, AND LUBRI-
10. Disconnect suction tube (12). INSTALLATION

removal.
1
11. Disconnect hose clamps (13) and (14).

12. Disconnect discharge hoses (15), (16).
power train and steering lubricating oil pump
assembly (17).
Power train and steering lubricat-

ing oil pump assembly: 30 kg
D275A-5 30-133
c
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
SPECIAL TOOLS 6. Remove the 3 final drive bolts and install tool
J1. 1
New/ 7. Using tool J1, sling final drive assembly (5)
bol ssity Qty. Remo Sketch temporarily.
del
790-337-1032 Lifting ■ 1
tool
791-627-1320 Shackle ■ 2
J1
791T-627-1810 Plate ■ 1 {
01010-82090 Block ■ 2
REMOVAL
1. Expand the track shoe assembly. For details,
see EXPANDING TRACK SHOE ASSEMBLY.
2. Raise the machine body with a jack or the rip-
per and set stand b under the frame.
3. Remove guards (1) and (2).
8. Remove inside mounting bolts (6) of the final
drive assembly. 2
Guard (2): 30 kg

5. Using a forcing screw, pull out the drive shaft 9. Remove the mounting bolts and lift off the
(4). final drive assembly. 3
★ If the shaft cannot be pulled out, raise the ★ Remove the sprocket teeth first so that the
shoe grouser with a jack and move the mounting bolts can be removed easily.
sprocket forward or in reverse until the
shaft can be pulled out. Sprocket tooth: 25 kg
★ Pull out the shaft until it comes in contact
with the sprocket.
Final drive assembly: 1,700 kg
30-134 D275A-5
c
INSTALLATION
removal.
Mounting bolt:
456 ~ 569 Nm {46.5 ~ 58 kgm}
2 3
Mounting bolt:
1,160 ~ 1,440 Nm {118 ~ 147 kgm}
Sprocket tooth mounting bolt:

1,080 ~ 1,270 Nm {110 ~ 130 kgm}
• Refilling with oil (Final drive case)

level.
Final drive case:

Approx. 40 l (E030-CD)
D275A-5 30-135
c

J1 Plate
30-136 D275A-5
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

SPECIAL TOOLS 3. Cover
Using hanging bolt b, remove cover (4).
Sy New/
mb Part No. Part Name Nece
ssity Qty. Remo Sketch
ol del
791-627-1400 Remover ■ 1
2 790-101-2102 Puller ■ 1
790-101-1102 Pump ■ 1
791-627-1600 Remover ■ 1
3 790-101-2102 Puller ■ 1
790-101-1102 Pump ■ 1
791-627-1200 Remover ■ 1
4 790-101-2102 Puller ■ 1
J
790-101-1102 Pump ■ 1
791-627-1300 Installer ■ 1
4. Hub
1) Remove plate (5).
5 790-101-2102 Puller ■ 1 2) Using hanging bolt c, remove hub (6).
790-101-1102 Pump ■ 1
791-627-1500 Installer ■ 1
6 790-101-2102 Puller ■ 1
790-101-1102 Pump ■ 1
7 791-628-1280 Installer ■ 1
DISASSEMBLY
1. Draining oil
Remove the drain plug and drain the oil from
the final drive case.
Final drive case: 38 l

5. Sprocket assembly
2. Sprocket, wear guard, and plate 1) Remove holder (7).
1) Set the final drive assembly on a block
with the sprocket side up.
2) Remove the mounting bolts and sprocket
(1).
3) Remove wear guard (2) and plate (3).
D275A-5 30-137
c
DISASSEMBLY
2) Using tool J2, disconnect sprocket hub

assembly (8) and case cover assembly (9).
3) Using hanging bolt d, remove sprocket
hub assembly (8).
6. Cover assembly
1) Using a hanging bolt, remove cover
assembly (15).
2) Disassemble the cover assembly accord-

ing to the following procedure.
4) Remove bearing (10) from the sprocket i) Remove floating seal cover (16).
hub assembly. ii) Remove floating seal (17) from float-
ing seal cover (16).
★ Store the floating seal in a safe place
so that it will not be damaged.
5) Turn over the sprocket hub assembly and

remove floating seal cover (11) and bear-
ing outer races (12) and (13).
6) Remove floating seal (14) from floating
seal cover (11).
★ Store the floating seal in a safe place
so that it will not be damaged.
30-138 D275A-5
c
DISASSEMBLY
iii) Remove spacer (18), bearing (19), and

spacer (20).
4) Remove bearing outer race (26D).

5) Remove spacer (26E) and snap ring (26F).
iv) Remove the plate and ring gear (21).
7. Carrier assembly
1) Using hanging bolt e, remove carrier
assembly (22).
6) Remove collar (27) and bearing (28) from

the carrier.
2) Disassemble the carrier assembly accord-

i) Remove holder (23).
ii) Using tool J3, remove planetary gear
shaft (24).
3) Remove planetary gear (25), bearings

(26A) and (26B), and spacer (26C).
D275A-5 30-139
c
DISASSEMBLY
8. Sun gear shaft assembly

1) Remove sun gear shaft assembly (29).
5) Remove 2 bearing outer races (39) from

hub (40).
2) Remove the mounting bolts and holders

(30) and (31) from the sun gear shaft
assembly.
3) Remove bearing inner race (32).
4) Using push tool f, remove sun gear shaft
(34) from sun gear (33).
6) Remove the mounting bolts and shaft

assembly (41) from the case.
7) Disassemble the shaft assembly accord-
i) Remove collar (42).
ii) Remove bearing (43).
9. Hub and shaft assembly

1) Remove gear (35).
2) Remove the mounting bolts and plate
(36).
3) Using tool J4, remove hub assembly (37).

4) Remove bearing (38).
30-140 D275A-5
c
DISASSEMBLY
10. Cage assembly 12. Outer race and oil seal

1) Using hanging bolt g, remove cage 1) Using puller j, remove bearing outer race
assembly (45). (54).
2) Remove shim (46). 2) Remove oil seals (55) and (56).
★ Check the thickness and quantity of
the inserted shims, then store them.
3) Disassemble the cage assembly accord-

i) Using puller h, remove outer race
(47).
ii) Remove oil seals (48) and (49).
11. No. 1 Pinion assembly

1) Remove No. 1 pinion assembly (50).
2) Using puller i, remove bearings (51) and
(52) from No. 1 pinion (53).
D275A-5 30-141
c
DISASSEMBLY
ASSEMBLY 3. No. 1 Pinion assembly

1) Using push tool 1#, press fit bearings (52)
★ Clean the all parts and check them for dirt or and (51) to No. 1 pinion (53).
damage before installing. • Press fitting force for bearing:
★ Coat sliding surfaces of each part with engine 0.9 ~ 2.6 kN {9 ~ 25 tons}
oil before installing. 2) Install No. 1 pinion assembly (50).
★ Check that each snap ring is fitted to the ★ Lower and install the gear assembly
groove securely. slowly so that the oil seal lip will not
be damaged.
1. Oil seal
1) Using push tools 1) and 1!, install oil seals
(56) and (55).
★ Install the lower oil seal with the pres-
sure receiving side down and the
upper oil seal with the pressure
receiving side up.
★ Apply gasket sealant thinly to the
inside of the housing hole and wipe
off the projected part.
Oil seal fitting surface:

4. Cage assembly
1) Assemble the cage assembly according to
the following procedure.
i) Using push tools 1$ and 1%, install oil
seals (49) and (48).
★ Install the lower oil seal with the pres-
sure receiving side down and the
upper oil seal with the pressure
receiving side up.
★ Apply gasket sealant thinly to the
inside of the housing hole and wipe
off the projected part.
2. Outer race Oil seal fitting surface:

Using push tool 1@, press fit bearing outer Gasket sealant (LG-5)
race (54).
• Press fitting force for bearing outer race:
1 ~ 13 kN {0.1 ~ 1.3 tons}
30-142 D275A-5
c
DISASSEMBLY
2) Using push tool 1^, press fit bearing outer

race (47).
• Press fitting force for bearing outer
race: 1 ~ 13 kN {0.1 ~ 1.3 tons}
3) Using hanging bolt g, install case assem-

bly (45).
4) Adjust the clearance of the No. 1 pinion

bearing according to the following proce-
dure.
i) Tighten mounting bolts C, D, G, and
H of cage A evenly, then loosen them.
Mounting bolt: 49 Nm {5 kgm}
ii) Tighten mounting bolts C, D, G, and

H of cage A evenly again.
Mounting bolt: 20 Nm {2 kgm}
iii) Under this condition, measure clear-

ances a and b between cage A and
case B with thickness gauge.
iv) Set shim thickness c from the total of
clearances a and b, referring to Table
1.
v) Install the shim set in step iv) to cage
A and tighten the 6 mounting bolts of
cage A evenly.
Mounting bolt:
98 ~ 123 Nm {10 ~ 12.5 kgm}
D275A-5 30-143
c
DISASSEMBLY
Table 1
a + b (mm) Number of shims to use Total
Thick-
Not less Not more ness of
than than t=0.15 t=0.5 t=1.0 shims
(mm)
3.05 3.15 5 1 1.75
3.15 3.25 2 1 1 1.80
3.25 3.35 9 1 1.85
3.35 3.45 6 1 1.90
3.45 3.55 3 1 1 1.95
3.55 3.65 2 2.00
3.65 3.75 7 1 2.05
3.75 3.85 4 1 1 2.10
3.85 3.95 1 2 2.15
3.95 4.05 8 1 2.20
4.05 4.15 5 1 1 2.25
4.15 4.25 2 2 2.30 2) Install the O-ring and shaft assembly (41)
4.25 4.35 9 1 2.35
to the case.
4.35 4.45 6 1 1 2.40
4.45 4.55 3 2 2.45 Mounting bolt:
4.55 4.65 1 2 2.50
4.65 4.75 7 1 1 2.55
4.75 4.85 4 2 2.60
4.85 4.95 1 1 2 2.65 Mounting bolt:
4.95 5.05 8 1 1 2.70 235 ~ 285 Nm {23.5 ~ 29.5 kgm}
5.05 5.15 5 2 2.75
5.15 5.25 2 1 2 2.80
5.25 5.35 9 1 1 2.85
5.35 5.45 6 2 2.90
5.45 5.55 3 1 2 2.95
5.55 5.65 3 3.00
5.65 5.75 7 2 3.05
5.75 5.85 4 1 2 3.10
5.85 5.95 1 3 3.15
5.95 6.05 8 2 3.20
6.05 6.15 5 1 2 3.25
6.15 6.25 2 3 3.30
6.25 6.35 9 3 3.35
6.35 6.45 6 1 2 3.40
6.45 6.55 3 3 3.45
6.55 6.65 1 3 3.50
6.65 6.75 7 1 2 3.55
6.75 6.85 4 3 3.60 3) Using push tool 1*, press fit 2 bearing
6.85 6.95 1 1 3 3.65 outer races (39) to hub (40).
6.95 7.05 8 1 2 3.70 • Press fitting force for bearing outer
7.05 7.15 5 3 3.75
7.15 7.25 2 1 3 3.80
race: 2 ~ 16 kN {0.2 ~ 1.6 tons}
7.25 7.35 9 1 2 3.85
5. Hub and shaft assembly

1) Assemble the shaft assembly according
i) Install collar (44).
ii) Using push tool 1&, press fit bearing
(43).
• Press fitting force for bearing:
11 ~ 32 kN {1.1 ~ 3.2 tons}
iii) Install collar (42).
30-144 D275A-5
c
DISASSEMBLY
4) Set hub assembly (37) and bearing (38) to

the shaft.
5) Using push tool J5, press fit bearing (38).
11 - 32 kN {1.1 - 3.2 tons}
iii) Install spacer (26C) and bearings (26B)

and (26A) to planetary gear (25), then
set them to the carrier.
★ Direct the planetary gear end hav-
ing a level difference out of the
machine body.
6) Install gear (35) to hub (40).
Mounting bolt:
Mounting bolt:
235 ~ 285 Nm {23.5 ~ 29.5 kgm}
7) Install plate (36).
Mounting bolt:
Mounting bolt:
235 ~ 285 Nm {23.5 ~ 29.5 kgm}
iv) Using tool J3, press fit planetary gear
shaft (24).
★ Match the holes of the bearing and
spacer and press fit the shaft
slowly.
v) Install holder (23).
Mounting bolt:
Mounting bolt:
455 ~ 565 Nm {46.5 ~ 58 kgm}
6. Carrier assembly
1) Assemble the carrier assembly according ★ After tightening the holder bolts,
to the following procedure. check that the gear turns lightly.
★ Since each bearing of the planetary
gear is an assembly, match the identi-
fication marks of the inner race, outer
race, and spacer when assembling.
i) Install snap ring (26F) and spacer
(26E) to the planetary gear.
★ Install the snap ring and spacer so
that the spacer will be under the snap
ring when the planetary gear is placed
with the end having a level difference
up.
ii) Using push tool 1(, press fit 2 bearing
outer races (26D).
race: 5 - 20 kN {0.5 - 2 tons}
D275A-5 30-145
c
DISASSEMBLY
vi) Using push tool 2), press fit bearing

(28) to the carrier.
0 - 12 kN {0 - 1.2 tons}
vii) Install collar (27).
8. Carrier assembly
Using hanging bolt e, install carrier assembly
(22).
7. Sun gear shaft assembly

1) Using push tool 2!, press fit sun gear shaft
(34) to sun gear (33) with a press.
• Press fitting force for shaft:
103 ~ 156 kN {10.5 ~ 15.9 tons}
2) Install holder (31).
Mounting bolt:
3) Using push tool 2@, press fit bearing inner
race (32) to sun gear shaft (34). 9. Cover assembly
• Press fitting force for bearing inner 1) Install ring gear (21) and plate.
race: 13 ~ 25 kN {1.3 ~ 2.6 tons} ★ Install the gear with the cut end in.
Mounting bolt:
3) Using tool J6, press fit bearing (19).
11 ~ 53 kN {1.1 ~ 5.4 tons}

Mounting bolt:
5) Install sun gear shaft assembly (29).
30-146 D275A-5
c
DISASSEMBLY
5) Using tool J7, press fit floating seal (17) 10. Sprocket hub assembly
to floating seal cover (16). 1) Using tool J7, press fit floating seal (14)
★ Degrease the O-ring and O-ring fitting to floating seal cover (11).
surfaces thoroughly and dry them ★ Degrease the O-ring and O-ring fitting
before installing. surfaces thoroughly and dry them
★ After installing the floating seal, check before installing.
that its slant is within 1mm. ★ After installing the floating seal, check
that its slant is within 1mm.
6) Install the O-ring and floating seal cover

(16).
★ Set the outside cut part of the floating
seal cover down. 2) Using push tool 2# press fit bearing outer
races (13) and (12).
races: 17 - 36 kN {1.7 - 3.7 tons}
7) Using a hanging bolt, install the O-ring

and cover assembly (15).
★ The mating faces of the case and
cover must be free from bruise, rust,
oil, grease, dirt, and water.
Mounting faces of case and 3) Install the O-ring and floating seal cover
cover: Gasket sealant (TB1216) (11).
Mounting bolt:
455 ~ 565 Nm {46.5 ~ 58 kgm}
D275A-5 30-147
c
DISASSEMBLY
4) Set bearing (10) to sprocket hub assembly

(8).
11. Hub
5) Using hanging bolt d, set sprocket hub 1) Using hanging bolt c, install hub (6).
assembly (8) to the case and cover assem- 2) Install plate (5).
bly.
★ Check that the sliding surfaces of the Mounting bolt:
floating seal are free from dirt and Thread tightener (LT-2)
apply engine oil to them thinly.
Mounting bolt:
6) Using tool J6, press fit bearing (10). 235 ~ 285 Nm {23.5 ~ 29.5 kgm}
★ Press fit the bearing, turning the
sprocket hub assembly.
11 ~ 53 kN {1.1 ~ 5.4 tons}
12. Cover
Using hanging bolt b, install the O-ring and
cover (4).
Mounting bolt:
235 ~ 285 Nm {23.5 ~ 29.5 kgm}

Mounting bolt:
Mounting bolt:
235 ~ 285 Nm {23.5 ~ 29.5 kgm}
30-148 D275A-5
c
DISASSEMBLY
13. Sprocket, wear guard, and plate

1) Install plate (3).
Mounting bolt:
455 ~ 565 Nm {46.5 ~ 58 kgm}
2) Install wear guard (2).
Mounting bolt:
785 ~ 980 Nm {80 ~ 100 kgm}
3) Install sprocket (1).
Mounting bolt:
1078 ~ 1274 Nm {110 ~ 130 kgm}
14. Refilling with oil (Final drive case)

Tighten the drain plug and add oil through
the oil filler.
★ After installing the final drive assembly to
the machine body, check the oil level
finally in the specified position.
Mounting bolt:
127 ~ 176 Nm {13 ~ 18 kgm}
Final drive case: 40 l
D275A-5 30-149
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY
REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY

SPECIAL TOOLS 2) Set stands c on both sides of the front
main frame of the machine body.
New/ 3) Set hydraulic jack d under the center of
bol ssity the equalizer bar and raise the front part
del
of the machine body.
L14 791T-630-1380 Bracket ■ 6 { 4) Set a block under the raised front part of
the track frame to secure safety during
REMOVAL work.
★ After setting stands b and c, set the jacks
1. Remove the blade assembly. For details, see or ripper again as auxiliary supports.
REMOVAL OF BLADE ASSEMBLY.
3. Using tool L14, secure the bogie assembly.
5. Temporarily sling the track frame assembly to

be removed.
4. Raise the machine body according to the fol-

lowing procedure.
1) Raise the machine body with a jack or the
ripper and set stands b under both sides
of the frame to float the rear part of the
machine body.
30-150 D275A-5
c
DISASSEMBLY
7. Remove the mounting nuts and cover (2). 12. Remove cover (8).
1
8. Disconnect grease tube (3).
13. Disconnect hose (9) on the bottom side of the

10. Pull out pin (5). 2 blade cylinder and hose (10) on the head side.
★ If the equalizer bar hole is not aligned ★ Perform this step for only the right side of
with the track frame hole, the pin cannot the single tilt specification or both track
be pulled out easily. Accordingly, adjust frames of the dual tilt specification.
the slinging height of the track frame 14. Remove the mounting bolts and pull out
when pulling out the pin. cover (11).
WARNING! If the track frame ★ Take care since hoses are connected
assembly on the opposite side is inside the cover.
raised before the pin is pulled out,
support it with a block.
11. Remove guards (6) and (7).
Guard (7): 30 Kg
D275A-5 30-151
c
DISASSEMBLY
15. Disconnect hoses (12) and (13) connected 18. Remove spacer (16).
inside cover (11) pulled out and remove cover
(11).
★ Perform this step for only the right side of
the single tilt specification or both track
frames of the dual tilt specification.
19. Remove the mounting bolts and disconnect

cover (17) from the track frame. 4

★ There are 2 mounting bolts on the track
frame side and 6 on the pivot shaft side.
★ Take care not to damage the O-ring.
★ Prepare an oil container to receive the oil
from the pivot shaft case.
Pivot shaft case: 10 l
20. Lift off track frame assembly (18). 5
Track frame assembly: 5,050 kg
17. Remove seal (15) and cover (14) together.

3
★ Perform this step for only the right side of
the single tilt specification or both track
frames of the dual tilt specification.
30-152 D275A-5
c
DISASSEMBLY
INSTALLATION 4
★ Degrease the fitting face of the seal and
• Carry out installation in the reverse order to apply gasket sealant (LG-6) to it.
removal. ★ Do not install the track frame with tor-
sional deformation left in seal (19).
1
Installation procedure for cover (4)
1) Tighten the mounting bolts of cover (4)
with fingers.
2) Install cover (2) and secure it with the
nuts.
securely.
4) Install grease tube (3).
Bushing contact surface of pivot

shaft:
Lubricant containing
molybdenum disulfide (LM-P)
★ When replacing the pivot shaft bush-
ing of the track frame assembly, press
fit a new bushing with the bushing
mating face up.
2
• Refilling with oil (Pivot shaft case)
WARNING! When aligning the pin
holes, never insert your fingers in
level.
the pin holes
★ Direct the grease holes of the pins down. Plug: 127 ~ 177 Nm {13 ~ 18 kgm}
• Left pin: Outside of machine body
• Right pin: Inside of machine body Pivot shaft case: 10 l (E030-CD)
Equalizer bar side bushing:
Grease (G2-LI)
3
★ When fitting the seal, degrease the fitting
face and apply gasket sealant (LG-6) to it.
★ Do not fit the seal with torsional deforma-
tion left in it.
D275A-5 30-153
c
DISASSEMBLY

L14 Bracket
30-154 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF IDLER ASSEMBLY
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY

1. Remove the blade assembly. For details, see • Carry out installation in the reverse order to
REMOVAL OF BLADE ASSEMBLY. removal.
see EXPANDING TRACK SHOE ASSEMBLY. 1
3. Remove covers (1) and (2). ★ Install both idler assemblies with the oil
supply plugs directed to the left.
★ Tighten the idler cap mounting bolts in
the following order.
Tightening order:
1) 2 bolts on a side
2) 2 bolts on b side
3) 2 bolts on a side
4) Tighten the all bolts to the specified
torque.
Mounting bolt:
Mounting bolt:
1,180 ~ 1,470 Nm {120 ~ 150 kgm}
4. Sling idler assembly (3) temporarily and
remove cap (4). 1 ★ After tightening the idler cap mounting
5. Lift off idler assembly (3). bolts, check that clearance c between the
idler cab bottom and the yoke is 0.
Idler assembly: 340 kg
D275A-5 30-155
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY

SPECIAL TOOLS 6. Using puller e, remove seal guide (6),
retainer (7), and plate (8).
Sym New/
bol ssity del
791T-630-1310 Plate ■ 1 N {
791-630-1220 Rod ■ 4
790-101-2510 Block ■ 2
790-101-2570 Plate ■ 4
1 01643-31445 Washer ■ 4
01580-01411 Nut ■ 4
L
Puller
790-101-2102 (294 kN ■ 1
{30 ton})
790-101-1102 Pump ■ 1 7. Remove seal guides (2) and (6) from retainers
2 791-515-1520 Installer ■ 1 (3) and (7).
3 791-630-1240 Push tool ■ 1
4 791-601-1000 Oil pump ■ 1
DISASSEMBLY
1. Remove the oil filler plug and drain the oil.
Idler: 0.8 ~ 0.9 l (G0140)
2. Set idler assembly (1) to block b.

3. Remove the mounting bolts, then remove 8. Remove floating seals (9) from seal guides (2)
seal guide (2), retainer (3), and plate (4), using and (6).
forcing screw c.
★ Keep the floating seals so that they will
not be damaged.
9. Remove floating seals (10) from seal guides
(3) and (7).
not be damaged.
4. Turn over the idler assembly.

5. Remove the mounting bolts, then remove
shaft (5) and retainer, using hanging bolt d.
30-156 D275A-5
c
DISASSEMBLY
10. Remove bushing (11) from idler (12).
3. Fit the O-ring and install retainer (3) and plate

ASSEMBLY
(4) to the idler.
★ Clean the all parts and check them for dirt or
damage.
1. Set bushing (11) and tool L1 to idler (12) to
press fit bushing (11).
★ Center the bushing with a plastic hammer
first, then press fit it with the puller.
★ Press fit the bushing so that distance a
from the idler end to the bushing top will
be as follows.
• Press fitting distance a: 17 ± 0.5 mm
4. Using hanging bolt d, set idler (12) to shaft

(5).
★ Set a block (about 200 mm) under the
idler.
5. Turn over the idler assembly.
★ Bind the shaft with wires so that it will not
drop.
6. Fit the O-ring and install retainer (7) and plate
(8) to the idler.
2. Using tool L2, install floating seals (10) to
retainers (3) and (7).
★ When installing the floating seals, thor-
oughly degrease and dry the contact sur-
faces of them and O-rings (hatched
portion). Take care that dirt will not stick
to the contact surfaces of the floating
seals.
★ After installing each floating seal, check
that its slant is within 1mm and its projec-
tion a is 7 - 11 mm.
D275A-5 30-157
c
DISASSEMBLY
7. Using tool L2, install floating seals (9) to seal 9. Using tool L4, supply the specified quantity
guides (2) and (6). of oil and tighten the oil filler plug.
★ For precautions for installing the floating
seals, see ★ in step 2 above. Idler: 0.8 ~ 0.9 l (G0140)
Oil filler plug:

156.8 ~ 254.8 Nm {16 ~ 26 kgm}
8. Set seal guide (2) to the shaft and press fit

seal guide (2) by using tools L1 and L3.
• Press fitting force for seal guide:
49 ~ 83.4 kN {5 ~ 8.5 tons}
★ Press fit the seal guide so that distance b

from the shaft end to the seal guide top
will be as follows.
• Press fitting distance b: 96 ± 0.2 mm
★ Turn over the idler assembly and press fit
seal guide (6) on the opposite side simi-
larly.
30-158 D275A-5
c
DISASSEMBLY

L1 Bracket
D275A-5 30-159
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY

SPECIAL TOOLS
Sym New/
bol ssity del
791-730-1110 Bolt ■ 6
1 01580-12722 Nut ■ 6
01643-32780 Washer ■ 6
M 791-630-1100 Installer ■ 1
Cylinder
2 790-101-1600 (686 kN ■ 1
{70 ton})
790-101-1102 Pump ■ 1
6. Remove covers (4). 2

REMOVAL ★ Remove both inside and outside covers.
1. Expand the track shoe assembly. For details, 7. Using hanging bolt b, pull out pin (5). 3
WARNING! Never stand in front of

the idler yoke to prevent danger.
2. Using an oil pump, drain the oil from the

recoil cylinder.
Recoil spring chamber:

Approx. 83 l

4. Loosen mounting bolts (2) of the guide plate.
1
8. Lift off idler and recoil spring assembly (6).

★ Set the assembly on the level by using
lever blocks, etc. and remove it so care-
fully that the oil seal on the track frame
will not be damaged.
Idler and recoil spring assembly:
2,300 kg
5. Remove the mounting bolts and lift off trun-

nion (3).
Trunnion: 60 kg
30-160 D275A-5
c
DISASSEMBLY
9. Disconnect recoil spring assembly (8) from

idler yoke assembly (7) according to the fol-
lowing procedure. 4
1) Lower idler yoke assembly (8) to the
ground and sling recoil cylinder assembly
(7).
★ At this time, check that the welded parts
of recoil cylinder assembly (7) are not
damaged.
★ Protect the chromium-plated bushing by
covering it with cloths.
WARNING! If the loosening torque

does not lower after steps 2) and 3)
above, recoil spring set bolt (10) may
be broken or shaft end nut (11) may
have come off. Since the idler yoke
assembly can jump out forward in
this case, remove the bolts accord-
WARNING! Do not stand in front of
the idler yoke and at the rear of the
recoil cylinder until the idler yoke
2) Loosen idler yoke assembly mounting assembly and recoil cylinder assem-
bolts (9) gradually in the diagonal order. bly are disassembled and the recoil
5 spring is taken out and the safety is
WARNING! Never stand in front of confirmed.
the idler yoke and at the rear of the
recoil cylinder to prevent danger.
i) Prepare the following parts (Tool M1).

• Bolt c (6 pieces): 791-730-1110
WARNING! Since the installed load • Nut d (6 pieces): 01580-12722
of about 372,700 N {38,000 kg} for • Washer e (6 pieces): 01643-32780
the recoil spring is applied to the (Reused)
idler yoke, do not loosen the mount-
ii) Remove the 6 bolts marked with and
ing bolts suddenly but loosen them
install bolts c, nuts d, and washers e.
gradually until clearance a between
the idler yoke and recoil spring
becomes 8 ~ 12 mm.
3) Check that the loosening torque of the
bolts has lowered suddenly and the
installed load for the recoil spring is not
applied to the bolts, remove all the bolts.
★ If the loosening torque increases (If the
installed load for the recoil spring is
applied) during the work, stop the work
and remove the bolts according to the fol-
lowing procedure.
D275A-5 30-161
c
DISASSEMBLY
★ Check that dimension L is less than 11. Supply grease through lubricator (13) and
361 mm. remove cylinder (14) and piston assembly
★ Tighten bolts c until they come in contact (15). 6
with the bottom of the yoke threads.
iii) Remove the 12 bolts other than the ones
marked with .
iv) Secure bolts c with a spanner and loosen
2 nuts on a diagonal line simultaneously
and gradually.
★ Take care that the load will not be applied
to only 1 bolt.
v) Loosen nuts d until the recoil spring is
expanded fully and the loosening torque
on them lowers totally, then remove bolts
c.
12. Disassemble piston assembly (15) according

i) Remove wear ring (16) from the piston.
ii) Remove snap ring (17) and packing (18).
★ If clearance b becomes 186 mm, the

spring is expanded fully.
13. Lift off recoil spring assembly (19).
Recoil spring assembly: 355 kg
10. Remove ring (12).
30-162 D275A-5
c
DISASSEMBLY
14. Remove holder (20) from the recoil spring 4

assembly. ★ If the recoil spring set bolt is broken or the
shaft end nut has come off, assemble
according to Assembly of recoil spring
assembly.
Idler yoke assembly mounting

bolt: Thread tightener (LT-2)
Idler yoke assembly mounting bolt:

1,150 ~ 1,440 Nm {118 ~ 147 KGM}
15. Remove bushing (21). 6

★ Supply grease to the cylinder to prevent
air from staying in the cylinder according
i) Supply grease of about 0.9 l into the cylin-
der.
ii) Set the cylinder with the drain hole up
and loosen the lubricator.
iii) Push in the piston until it is stopped by
the stopper to discharge air and excessive
grease.
iv) Tighten the lubricator.
Lubricator:
59 ~ 88 Nm {6 ~ 9 kgm}
INSTALLATION
7
• Carry out installation in the reverse order to ★ Using tool M2, press fit bushing (21).
removal. Press fitting force:
44.1 - 228.3 kN {4.5 - 23.3 tons}
1
Case to press fit
★ Adjust the clearance of the idler. For Thread tightener (LT-2)
details, see TESTING AND ADJUSTING,
Adjusting clearance of idler.
Cover mounting bolt:

Cover mounting bolt:

245 ~ 309 Nm {25 ~ 31.5 kgm}
WARNING! When aligning the pin • Refilling with oil

holes, never insert your fingers in Pour engine oil (EO30) in the spring chamber
the pin holes.
up to the center.
★ Before inserting the pin, align the recoil Plug: 127 ~ 177 Nm {13 ~ 18 kgm}
cylinder hole with the track frame hole.
Recoil spring chamber (Each side):
Approx. 83 l
D275A-5 30-163
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY

SPECIAL TOOLS 3. Release the oil pressure gradually to reduce
the spring tension to 0 (zero).
New/ Ske 4. Remove rear pilot (5), spacer (6), bolt (7), and
Sym Part No. Part Name Nece Qty. Remo
bol ssity tch pilot (8) from spring (4).
del
791-685-8502 Compressor ■ 1
790-201-2780 Spacer ■ 1
791-635-3160 Extension ■ 1
M3
Cylinder
790-101-1600 (686 kN {70 ■ 1
ton})
790-101-1102 Pump ■ 1
DISASSEMBLY
1. Set recoil spring assembly (1) to tool M3.

WARNING! Since the installed load ASSEMBLY
of the spring is large and dangerous,
set the spring assembly securely. 1. Install pilot (8), bolt (7), spacer (6), and rear
pilot (5) to spring (4) and set them to M3.
★ Installed load of spring:
372,700 N {38,000 kg} WARNING! Since the installed load
of the spring is large and dangerous,
set each part securely.
2. Apply oil pressure gradually and compress
the spring to the standard length.
★ Installed length of spring a:
Approx. 1,045 mm
★ Installed load of spring:
272,700 N {38,000 kg}
2. Apply oil pressure gradually and compress

the spring and remove lock plate (2) and nut
(3).
30-164 D275A-5
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
3. Install nut (3) to bolt (7), then install lock plate

(2).
★ When securing the recoil spring mounting
nut, make clearance b (0 ~ 1.0 mm)
between lock plate (2) and nut (3) and fix
lock plate (2) and bolt (7) together.
Lock plate mounting bolt:
4. Release the oil pressure gradually to reduce

the spring tension to 0 (zero), then remove
recoil spring assembly (1) from tool M3.
D275A-5 30-165
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY

SPECIAL TOOLS
Sym- New/ Ske

Nece Qty. Remo
Part No. Part Name
bol ssity del tch
790-401-1700 Lifting tool ■ 1
790-401-1761 Adapter ■ 1
5
L 790-401-1540 Shackle ■ 2
790-401-1770 T-bolt ■ 2
14 791T-630-1380 Bracket ■ 4 {
REMOVAL
1. Loosen the track shoe tension. For details, see Note 2: Sling and secure 1st bogie assembly
EXPANDING TRACK SHOE ASSEMBLY. (1) with a lever block, etc.
2. Install tool L14 and secure bogie assembly A fixing tool can not be used for the
(1). 1st bogie assembly.
3. Operate the blade and ripper to raise the

★ When removing track roller assembly (2), machine body until track roller assembly (2) is
secure the related bogie assemblies floated above the track shoe.
according to the following table. ★ Operate the blade and ripper slowly with
Track roller Bogie assembly to be the engine at low speed.
assembly to be secured with tool
removed
4. Loosen the mounting bolts of roller cap (3).
Location Related bogie
1
1st roller Note 1 2nd bogie
2nd roller 2nd bogie Note 2
★ Loosen both inside and outside mounting
3rd roller 2nd bogie 3rd bogie
bolts.
4th roller 3rd bogie 2nd bogie ★ Do not remove the mounting bolts.
5th roller 3rd bogie 4th bogie
6th roller 4th bogie 3rd bogie
7th roller 4th bogie —
Note 1: Set block b to prevent 1st bogie

assembly (1) from lowering.
A fixing tool can not be used for the
1st bogie assembly.
30-166 D275A-5
c
DISASSEMBLY
5. Operate the blade and ripper to lower the

Roller cap mounting bolt:
machine body.
824 ~ 1,030 Nm {84 ~ 105 kgm}
★ Operate the blade and ripper slowly.
6. Remove the mounting bolts and roller cap.
2
★ Take care not to damage the dowel pin.
machine body until track roller assembly (2) is
separated from the bogie. 3
3
Types of track roller assembly
S: Track roller assembly (Single flange)
D: Track roller assembly (Double flange)
★ Install the track roller assembly with the
oil filler plug out.
8. Pull track roller assembly (2) out of the

machine body. 4
Track roller assembly (Single

flange): 150 kg
Track roller assembly (Double

flange): 165 kg
INSTALLATION
removal.
4
1 2
When installing the 1st track roller assembly
(single flange) by using tool L5;
Install the track roller assembly according to the
1) Set tool L5 under the track roller assem-
bly.
1. Set the track roller assembly on the track
2) Sling 1st track roller assembly (2) and set
shoe.
it to the track frame.
★ Direct the oil filler of the track roller
assembly out of the machine body.
2. Lower the machine body until the roller cap
bolts can be installed and install roller cap (3)
temporarily.
★ Direct roller cap protector a out of the
bogie.
3. Align dowel pin (4) with the dowel pin hole of
the track roller and tighten roller cap bolts (3).
★ Take care not to break the dowel pin.
D275A-5 30-167
c
DISASSEMBLY

L14 Bracket
30-168 D275A-5
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY

SPECIAL TOOLS 6. Using a press, remove seal guide (6), retainer
(7), and plate (8) from the shaft.
New/ Ske 7. Remove seal guides (2) and (6) from the
Sym- Part No. Part Name Nece Qty. Remo
bol ssity tch retainers (3) and (7).
del
6 791T-630-1320 Plate ■ 1 N {
7 791T-630-1330 Push tool ■ 1 N {

L
8 791-651-1510 Installer ■ 1
9 791-601-1000 Oil pump ■ 1
DISASSEMBLY
Track roller: Approx. 0.75 ~ 0.85 l
2. Set track roller assembly (1) to block b.

8. Remove floating seals (9) from seal guides (2)
3. Remove the mounting bolts and remove seal
and (6).
guide (2), retainer (3), and plate (4) together
by using forcing screw c. ★ Keep the floating seals so that they will
4. Turn over the track roller assembly. not be damaged.
5. Remove the mounting bolts and remove shaft 9. Remove floating seals (10) from seal guides
(5) and retainer together by using hanging (3) and (7).
bolt d. ★ Keep the floating seals so that they will
not be damaged.
10. Remove 2 bushings (11) from roller (12).
D275A-5 30-169
c
DISASSEMBLY
ASSEMBLY 5. Using tool L7, install floating seals (9) to seal

guides (2) and (6).
★ Clean the all parts and check them for dirt or ★ When installing the floating seals, thor-
damage. oughly degrease and dry the contact sur-
1. Set roller (12) to a press and press fit bushing faces of them (hatched portion) and O-
(11) by using tool L6. rings. Take care that dirt will not stick to
★ Center the bushing with a plastic hammer the contact surfaces of the floating seals.
first, then press fit it with the press. ★ After installing each floating seal, check
★ Press fit the bushing so that distance "a" that its slant is within 1mm and its projec-
from the roller end to the bushing top will tion a is 7 ~ 11 mm.
be as follows.
• Press fitting distance a: 17 ± 0.5 mm
• Press fitting force for bushing:
29 ~ 132 kN {3 ~ 13.5 tons}
2. Set shaft (5) to the roller.
6. Using tool L8, press fit seal guide (2) to the

shaft.
• Press fitting force for seal guide:
39 ~ 69 kN {4 ~ 7 tons}
3. Using tool L7, install floating seals (10) to

retainers (3) and (7).
faces of them (hatched portion) and O-
rings. Take care that dirt will not stick to
the contact surfaces of the floating seals.
that its slant is within 1mm.
4. Fit the O-ring and install retainers (3) and (7)
and plates (4) and (8) to the roller.
★ Check that the plates can be turned
smoothly with hand.
30-170 D275A-5
c
DISASSEMBLY
★ Press fit the seal guide so that distance c

will be as follows.
Press fitting distance c: 64.2 ± 0.2 mm
★ After press fitting the seal guide, check
that its slant from the shaft is less than 0.4
mm.
★ Turn over the track roller assembly and
press fit seal guide (6) on the opposite
side similarly.
7. Using tool L9, supply the specified quantity

of oil and tighten the oil filler plug.
Track roller: 0.75 ~ 0.85 l (G0140)
Oil filler plug:

156.8 ~ 254.8 Nm {16 ~ 26 kgm}
D275A-5 30-171
c
DISASSEMBLY

L16 Plate
L7 Bush tool
30-172 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY

REMOVAL
1. Loosen the track shoe tension. For details, see
EXPANDING TRACK SHOE ASSEMBLY.
2. Using hydraulic jack b, raise the track shoe.
3. Lift off carrier roller assembly (1). 1
Carrier roller assembly: 60 kg
INSTALLATION
removal.
Carrier roller assembly mounting

bolt: Thread tightener (LT-2)
D275A-5 30-173
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY

SPECIAL TOOLS 7. Remove bearing outer race (7) from the roller.
8. Using puller d, remove seal guide (8) and
New/ Ske bearing inner race (9) together.
Sym- Part No. Part Name Nece Qty. Remo
bol ssity del tch
10 790-102-1891 Nut wrench ■ 1
11 791-675-1510 Installer ■ 1
L
12 791T-630-2410 Push tool ■ 1 N {
13 791-601-1000 Oil pump ■ 1
DISASSEMBLY
★ Drain the oil, turning the shaft.
Carrier roller: Approx. 0.6 ~ 07 l

9. Remove floating seal (10) from seal guide (8).
2. Set carrier roller assembly (1) to block b.
3. Remove the mounting bolts and cover (2).
4. Remove ring (3).
10. Using push tool e, remove seal guide (11).

11. Remove floating seal (12) from seal guide
(11).
5. Using tool L10, remove nut (4).

6. Using puller c, remove the fitted part of the
seal guide. Using hanging bolts, remove
bearing (5) and roller (6) together.
30-174 D275A-5
c
DISASSEMBLY
ASSEMBLY
★ Clean the all parts and check them for dirt or
damage.
1. Using push tool f, press fit bearing inner race
(9).
2. Using push tool g, press fit bearing outer
race (7).
7. Fit the O-ring and install cover (2).
3. Set roller (6) and bearing inner race (5) to the

shaft.
4. Using push tool h, press fit bearing inner race
(5) to the shaft.
★ Press fit the bearing inner race, turning
the roller. Continue press fitting until the 8. Using tool L11, install floating seal (10) to
roller becomes heavy to turn. seal guide (8).
seals.
tion a is 7 - 11 mm.
5. Using tool L10, tighten nut (4).
Nut: 98 Nm {10 kgm}
★ After the nut is tightened, if the nut hole is

not aligned with the shaft hole, align them
by loosening the nut.
6. Install ring (3).
★ Check that the end play (the clearance
between the bearing and nut) is
0 ~ 0.22 mm.
D275A-5 30-175
c
DISASSEMBLY
9. Fit the O-ring and install seal guide (8), 12. Using tool L13, supply the specified quantity
matching it to the dowel pin. of oil and tighten the oil filler plug.
Carrier roller: 0.6 ~ 0.7 l (G0140)
Oil filler plug:

157 ~ 255 Nm {16 ~ 26 kgm}
10. Using tool L11, install floating seal (12) to

seal guides (11).
★ For precautions for installing the floating
seal, see ★ in step 8 above.
11. Using tool L12, press fit seal guide (11).

★ Press fit the seal guide so that distance b
will be 160 ± 0.2 mm.
★ After press fitting the seal guide, check
that its slant from the shaft is less than 0.4
mm.
30-176 D275A-5
c
DISASSEMBLY

L12 Push tool
D275A-5 30-177
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF 1ST BOGIE ASSEMBLY
REMOVAL AND INSTALLATION OF 1ST BOGIE ASSEMBLY

SPECIAL TOOLS
Sym- New/ Ske

Nece Qty. Remo
Part No. Part Name
bol ssity del tch
14 791T-630-1380 Bracket ■ 2 {
790-401-1700 Lifting tool ■ 1

22
L 790-401-1761 Adapter ■ 1
791-630-1860 Bracket ■ 1
23
791-630-1870 Bracket ■ 1
REMOVAL
1. Remove the undercover. 8. Set tool L22 and remove roller caps (3).
2. Using tool L14, secure 2nd bogie assembly
(1).
9. Using tool L22, remove track roller assembly

(6).
3. Expand the track shoe assembly. For details, ★ When removing the track roller assembly,
see EXPANDING TRACK SHOE ASSEMBLY. balance it.
machine body until the track roller of 2nd
bogie assembly (1) is floated above the track Track roller assembly: 150 kg
link.
WARNING! Set stands or blocks

under the front and rear parts of the
frame so that the machine body will
not lower.
5. Set block b between the 1st track roller and

2nd track roller so that 1st bogie assembly (2)
will not lower.
6. Loosen the mounting bolts of roller caps (3)
by about 20 mm.
★ Loosen both inside and outside bolts.
7. Hit the end of shaft (4) with a plastic hammer
to disconnect the track roller from the bogie.
★ Take care not to damage dowel pin (5).
30-178 D275A-5
c
DISASSEMBLY
3) Remove floating seals (10) from the end

faces of rings (9) and (12).
11. Using tool L23, sling and hold the 1st bogie. not be damaged.
4) Set pulling out tool L16.

12. Pull out the shaft and ring.
1) Set tool L15.
2) Push shaft (8) with tool L15 to push out
ring (9) to the opposite side.
★ When the ring is pushed out, it interferes
with the idler. To prevent this, supply
grease to the lubricator to push out the
idler cushion assembly forward.
• Pushing force (Reference):
275 ~ 490 kN {28 ~ 50 tons}
D275A-5 30-179
c
DISASSEMBLY
5) Pull out spacer (11) and rings (12) and INSTALLATION

(13).
• Pulling out force (Reference): 1. Assemble the cartridge pin.
275 ~ 490 kN {28 ~ 50 tons}
6) Remove spacer (11).

7) Remove spacer (14) and floating seal (14)
between rings (12) and (13). 1) Using tool L17, install floating seals (10)
★ Keep the floating seals so that they will to rings (9) and (12) and install floating
not be damaged. seal (15) to the opposite side of ring (12)
and ring (13).
8) Remove the shaft and rings from the

bogie on the opposite side according to
steps 1) - 7) above. ★ When installing the floating seals, thor-
13. Sling 1st bogie (16) and pull it out. oughly degrease and dry the contact sur-
★ When the 1st bogie is removed, it inter- faces of them and O-rings (hatched
feres with 2nd bogie assembly (1). To pre- portion). Take care that dirt will not stick
vent this, lower the 2nd bogie assembly. to the contact surfaces of the floating
seals.
Bogie assembly: 100 kg ★ After installing each floating seal, check
tion a is 3 ~ 5 mm.
30-180 D275A-5
c
DISASSEMBLY
2) Install spacer (11) and ring (12) to shaft (8)

and ring (9). WARNING! When aligning the pin
3) Install spacer (14) to ring (12) and press fit holes, never insert your fingers in
ring (13) with tool c. the pin holes.
• Press fitting force for ring (13):
4. Support 1st bogie (16) with hydraulic jack c
4.9 ~ 35.3 kN {0.5 ~ 3.6 tons} and remove guide tool L19 and sling tool
Between shaft (8) and ring (13): L23.
5. Insert cartridge pin assembly (17) in the pin

4) Using tool L18, check the airtightness of hole.
the floating seal.
★ Insert the cartridge pin assembly with
arrow b on its end face up (in the mount-
ing state on the machine body).
6. Using tool L20, press fit cartridge pin assem-
bly (17).
2. Using the tool, sling and install 1st bogie (16).

★ Keep 2nd bogie assembly (1) lowered.
★ Sling 1st bogie (16) and put it in from the
front side and set it in position.
3. Align the pin holes of the track frame and

bogie assembly and insert guide tool L19.
D275A-5 30-181
c
DISASSEMBLY
★ Press fit the cartridge pin assembly to the

machined surface c of the bogie.
Outside surface of pin:

★ Press fitting force for cartridge pin assem-

bly: 275 ~ 490 kN {28 ~ 50 tons}
11. Install covers (7).

★ Install 2 covers, outside and inside ones.

of oil to the cartridge pin assembly.
★ Oil supply pressure: 0.49 MPa {5kg/cm 2}
Cartridge pin assembly (81 ~ 95%

of fuel level): 61 ~ 71 cc (GO-140)
12. Using tool L22, sling and set track roller

assembly (6).
★ When setting the track roller assembly,
balance it.
Track roller assembly: 150 kg
8. Press fit the cartridge pin assembly on the

opposite side according to steps 5 - 7 above.
9. Raise 2nd bogie assembly (1) with a hydraulic
jack and install fixing tool L14.
10. Set block b between 1st bogie (16) and 2nd
bogie assembly (1) so that 1st bogie (16) will
not lower.
30-182 D275A-5
c
DISASSEMBLY
13. Install roller cap (3) and secure it with the 14. Align the dowel pin holes and tighten the
bolts temporarily. bolts.
★ Direct roller cap protectors b out of the
bogie.
824 ~ 1,030 Nm {84 ~ 105 kgm}
15. Adjust the track shoe tension. For details, see

TESTING AND ADJUSTING, Testing and
adjusting track shoe tension.

L14 Bracket
D275A-5 30-183
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF 2ND, 3RD AND 4TH BOGIE ASSEMBLY
REMOVAL AND INSTALLATION OF 2ND, 3RD AND 4TH BOGIE

ASSEMBLY
SPECIAL TOOLS 3. Using tool L14, secure bogie assembly (1).
Sym- New/ Ske
Nece Qty. Remo ★ Remove the cover on the opposite side,
Part No. Part Name
bol ssity del tch too.
14 791T-630-1380 Bracket ■ 2 {
791-630-1360 Spacer ■ 1 N
790-101-2310 Block ■ 1
790-101-2360 Plate ■ 2
790-445-4130 Screw ■ 2
15
791-112-1180 Nut ■ 2
Puller
790-101-4000 (490kN ■ 1
{50ton})
790-101-1102 Pump ■ 1
790-201-2760 Spacer ■ 1 N
791-630-1370 Adapter ■ 1
790-434-1060 Screw ■ 2
01580-13024 Nut ■ 2
16
01643-33080 Washer ■ 1
L Puller 5. Operate the blade and ripper to raise the
790-101-4000 (490kN ■ 1 machine body until the track roller is floated
{50ton})
above the track link.
790-101-1102 Pump ■ 1
17 796-230-1120 Installer ■ 1 WARNING! Set a block between the
18 790-701-3000 Seal checker ■ 1 track roller and track link so that the
19 791T-630-1390 Guide ■ 1 N { machine body will not lower.
790-101-2310 Block ■ 1
790-445-4130 Screw ■ 2 6. Set steel plate e on the track shoe and block
796T-470-1130 Plate ■ 1 {
d.
790-101-2360 Plate ■ 2 ★ Set block d according to the height of the
20
791-112-1180 Nut ■ 2
track link.
Puller 7. Operate the blade and ripper to lower the
790-101-4000 (490kN ■ 1 machine body until the track roller of the
{50ton})
bogie assembly comes in contact with steel
790-101-1102 Pump ■ 1 plate e.
21 791-601-1000 Oil pump ■ 1
★ Operate the blade and ripper slowly.
REMOVAL
1. Loosen the track shoe tension. For details, see
EXPANDING TRACK SHOE ASSEMBLY.
2. Remove the undercovers.
★ Remove the following undercovers which
will be obstacles to removal of the bogie
assembly.
Engine undercover: 250 kg
30-184 D275A-5
c
DISASSEMBLY
8. Remove the shaft and ring. 4) Set pulling out tool L16.
1) Set tool L15.
2) Push shaft (3) with tool L15 to push out
ring (4) to the opposite side.
• Pushing force (Reference):
275 - 490 kN {28 - 50 tons}
5) Pull out spacer (6) and rings (7) and (8).

• Pulling out force (Reference):
275 - 490 kN {28 - 50 tons}
6) Remove spacer (6).

7) Remove spacer (9) and floating seal (10)
3) Remove floating seals (5) from the ends between rings (7) and (8).
of rings (4) and (7). ★ Keep the floating seals so that they
★ Keep the floating seals so that they will not be damaged.
will not be damaged.
D275A-5 30-185
c
DISASSEMBLY
8) Remove the shaft and rings from the INSTALLATION

bogie on the opposite side according to
steps 1) - 7) above. 1. Assemble the cartridge pin assembly.
machine body until the bogie assembly can
be pulled out.
WARNING! Set a block between the

track roller and track link of the bogie
which will not be removed so that the
machine body will not lower.
10. Sling bogie assembly (1) and slide it out on

steel plate e and remove it.
Bogie assembly: 550 kg
1) Using tool L17, install floating seals (5) to

rings (4) and (7) and install floating seal
(10) to the opposite side of ring (7) and
ring (8).

seals.
tion a is 3 - 5 mm.
30-186 D275A-5
c
DISASSEMBLY
2) Install spacer (6) and ring (7) to shaft (3) 2. Lift off bogie assembly (1) onto block d and
and ring (4). steel plate e.
3) Install spacer (9) to ring (7) and press fit
ring (8) with tool f.
• Press fitting force for ring (8):
4.9 ~ 35.3 kN {0.5 ~ 3.6 tons}
Between shaft (3) and ring (8):
3. Apply lever block g between the guard of

bogie assembly (1) and that of the bogie
assembly on the opposite side.
4. Slide bogie assembly (1) on the steel plate
with lever block g to the mounting position.
4) Using tool L18, check the airtightness of

the floating seal.

machine body.
6. Adjustment procedure for cartridge pin hole.
1) Set block c and hydraulic jack h on the
rear side of the machine body.
D275A-5 30-187
c
DISASSEMBLY
2) Set stand b and hydraulic jack h on the

front side of the machine body.
5) Insert guide tool L19 in the pin hole.
3) Operate front and rear hydraulic jacks h

to lower the machine body and install fix-
ing tool L14 to bogie assembly (1).
7. Insert cartridge pin assembly (11) in the pin

hole.
★ Insert the cartridge pin assembly with
4) Adjust front and rear hydraulic jacks h to arrow b on its end face up (in the mount-
align the pin holes of the track frame and ing state on the machine body).
bogie assembly.
holes, never insert your fingers in the
pin holes.
★ If the pin holes cannot be aligned by
adjusting the front and rear hydraulic
jacks, align them by slinging the front part
of the opposite track or applying a
hydraulic jack to the bogie assembly.
30-188 D275A-5
c
DISASSEMBLY
8. Using tool L20, press fit cartridge pin assem-

bly (11).
★ Press fit the cartridge pin assembly to
machined surface c of the bogie.
Outside surface of pin:
bly: 275 ~ 490 kN {28 ~ 50 tons}
10. Press fit the cartridge pin assembly on the

opposite side according to steps 6-5) - 9
above.
11. Install cartridge pin assembly covers (2) and
tighten the bolts.
★ Install 2 covers, outside and inside ones.
12. Adjust the track shoe tension. For details, see

TESTING AND ADJUSTING, Testing and
adjusting track shoe tension.

of oil to the cartridge pin assembly.
★ Oil supply pressure: 0.49 MPa {5kg/cm2}
Cartridge pin assembly

(81 ~ 95% of fuel level):
61 ~ 71 cc (GO-140)
D275A-5 30-189
c
DISASSEMBLY

L14 Bracket
L19 Guide
30-190 D275A-5
c
DISASSEMBLY
L20 Plate
D275A-5 30-191
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY

SPECIAL TOOLS 3. Cartridge pin assembly
Remove cartridge pin assembly (4) according
Sym- Nece New/ Ske to the procedure in REMOVAL OF BOGIE
Part No. Part Name ssity Qty. Remo
bol del tch ASSEMBLY.
790-101-2310 Block ■ 1 ★ See step 8.
790-445-4130 Screw ■ 2
796T-470-1130 Plate ■ 1 {
790-101-2360 Plate ■ 2
20
L 791-112-1180 Nut ■ 2
Puller
790-101-4000 (490kN ■ 1
{50ton})
790-101-1102 Pump ■ 1
21 791-601-1000 Oil pump ■ 1
DISASSEMBLY
1. Track roller assembly
1) Turn over bogie assembly (1).
2) Remove the roller cap and lift off 2 track 4. Bogie
roller assemblies (2). Disconnect inner bogie (5) and outer bogie
★ Take care not to break the dowel pin. (6).

flange): 150 kg

flange): 165 kg
ASSEMBLY
1. Assembly of cartridge pin assembly
Assemble the cartridge pin assembly accord-
ing to the procedure in INSTALLATION OF
BOGIE ASSEMBLY.
★ See step 1.
2. Cover
Remove cover (3).
30-192 D275A-5
c
DISASSEMBLY
2. Bogie 4. Refilling with oil

Set inner bogie (5) to outer bogie (6). Using tool L21, supply the specified quantity
3. Cartridge pin assembly of oil to the cartridge pin assembly.
1) Set tool L20. ★ Oil supply pressure: 0.49 MPa {5kg/cm2}
Cartridge pin assembly

(81 ~ 95% of fuel level):
61 ~ 71 cc (GO-140)
2) Press fit cartridge pin assembly (4).

★ Press fit the cartridge pin assembly with
the cover. 5. Cartridge pin assembly (Opposite side)
★ Insert the cartridge pin assembly with Press fit the cartridge pin assembly on the
arrow a on its end face up (in the mount- opposite side according to steps 3 - 4 above.
ing state on the machine body). ★ After press fitting the cartridge pin assem-
★ Press fit the cartridge pin assembly to the bly, adjust it so that the inner bogie can
machined surface of the bogie. slide lightly.
Outside surface of pin: 6. Covers
Lubricant containing Install covers (3).
molybdenum disulfide (LM-P) ★ Install 2 covers, outside and inside ones.
bly: 275 - 490 kN {28 - 50 tons}
D275A-5 30-193
c
DISASSEMBLY
7. Track roller assembly

1) Sling 2 track roller assemblies (2) and set
them on the bogie.
★ Install the track roller assemblies with the
oil fillers out.

flange): 150 kg

flange): 165 kg
2) Install the roller caps to track roller

assemblies (2) and secure them with the
mounting bolts.
★ Direct roller cap protectors b out of the
bogie.

824 ~ 1,030 Nm {84 ~ 105 kgm}
30-194 D275A-5
c
DISASSEMBLY

L20 Plate
D275A-5 30-195
2
(4)
DISASSEMBLY
AND ASSEMBLY EXPANDING AND INSTALLING TRACK SHOE ASSEMBLY
EXPANDING AND INSTALLING TRACK SHOE ASSEMBLY

CHECK BEFORE EXPANDING TRACK EXPANDING TRACK SHOE ASSEM-
SHOE ASSEMBLY BLY (NORMAL)
WARNING! Since it may be very dan- s If CHECKING BEFORE REMOVAL OF TRACK

gerous to expand the track shoe assem- SHOE ASSEMBLY shows that there is no
bly, check the following items in abnormality, do as follows.
1. Set master link (3) in position.
s Bring the master link above the idler (just
advance.
behind the center).

s Set blocks [1] and [2] at the front end of
WARNING! Do not loosen the lubricator
more than 1 turn. If the grease does not
come out well, move the machine forward the idler and between the carrier rollers
and in reverse. so that the mating faces of the master link
will not open until the master bolt is
1. Remove cover (1) and loosen lubricator (2) of removed.
the adjustment cylinder to discharge the
grease.
WARNING! Do not loosen the lubri-

cator more than 1 turn.
2. Relieve track shoe tension. 1
WARNING! Never loosen lubrica-

tor. (1) more than one turn.
s If the track is not relieved by loosening

the lubricator, move the machine back-
2. After the shoe is loosened, perform EXPAND-
wards and forwards.
ING TRACK SHOE ASSEMBLY (NORMAL).
3. If the track shoe is not loosened by the above
work, perform EXPANDING TRACK SHOE
ASSEMBLY (WHEN TRACK FRAME HAS
INTERNAL TROUBLE).
s The track frame may have an internal
trouble (damage of the recoil spring or
recoil spring set bolt, fall of the shaft end
nut, etc.)
3. Remove track shoe (2).

s Loosen each of the 4 bolts by 1 - 2 turns.
2
Check that the 4 bolts can be turned

lightly, then pull them out. Do not pull out
30-196 D275A-5
(4)
DISASSEMBLY
only 1 bolt without loosening the other 1. Remove the work equipment. For details, see
three. REMOVAL OF WORK EQUIPMENT ASSEM-
s If a bolt is turned forcibly while it cannot BLY.
be turned lightly, the threads of it and 2. Loosen the track shoe. 1
master link (3) may be damaged.
WARNING! Do not loosen the lubri-
cator more than 1 turn.
s If the track shoe is not loosened by loos-

ening the lubricator, move the machine
forward and in reverse to discharge the
grease.
s Check that the all grease has been dis-
charged.
4. Raise tip of master link, move machine

towards rear slowly, and lay out track shoe
assembly (4).
s Length of track : Approx. 10.5 m
WARNING! To prevent danger,

never stand in front of the idler yoke
assembly.
3. Move the machine slowly forward against

large block d or a wall (or the blade of another
machine of the similar size of the machine to
be repaired, if available) to press the track
shoe on the idler side. When the recoil spring
and track shoe are distorted, stop and apply
the brake. At this time, set the master link
between the idler and front carrier roller.
s For safe work, apply lever block e between
the carrier roller support and link.
EXPANDING TRACK SHOE ASSEM-

BLY
(When a trouble is inside the track frame)
s If any abnormality is detected by CHECK
BEFORE EXPANDING TRACK SHOE ASSEM-
BLY, perform the following procedure.
WARNING! If the track shoe is removed

while the track frame has an internal
trouble, it may spring back. Even if the
track shoe is removed, the idler may 4. Remove track shoe (4) and disconnect master
jump out, and that can cause a serious link (3). 2
result. Accordingly, expand the track 5. Move the machine slowly in reverse to
shoe according to the following proce- expand track shoe assembly.
dure.
D275A-5 30-197
(4)
DISASSEMBLY
INSTALLATION
• Carry out expansion (normal) in the reverse
order to removal.
s Adjust the track shoe tension. For details,

1
see TESTING AND ADJUSTING, Testing

and adjusting track shoe tension.
s Tighten the shoe mounting bolts for the

2
master link in the following order.

Shoe mounting bolt:
Anti-seizure agent
(Maruzen MOLYMAX No. 2 or
equivalent)
Shoe mounting bolt:

1st time: 490 ± 49 Nm {50 ± 5 kgm}
Shoe mounting bolt:

2nd time: Retighten by 180° ± 10°
s Tighten the all 4 bolts with fingers until

the master link mating faces are fitted.
s If the bolts are tightened forcibly before
the master link mating faces are fitted, the
threads of the bolts and master link may
be damaged.
30-198 D275A-5
2
(4)
DISASSEMBLY WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEM-
AND ASSEMBLY BLY
WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE

ASSEMBLY
SPECIAL TOOLS
Sym- Neces New/ Sketc Sym- Neces New/ Sketc
bol Part No. Part name sity Qty Remode h bol Part No. Part name sity Qty Remode h
l l
1 791-646-7531 Plug remover ■ 1 Cylinder
2 791-660-7460 Pin brush ■ 1 790-101-4300 (1,470 kN ■ 1
15 {150ton})
Push tool
3 791-646-7900 (For large ■ 1 790-101-1102 Hydraulic ■ 1
plug) pump
Push tool 791-680-1630 Spacer ■
4 791-932-1110 (For small ■ 1 790-101-4200 Puller (294kN ■ 1
plug) 16 {30ton})
790-701-3000 Seal checker ■ 1 Hydraulic
5 790-101-1102 pump ■ 1
791-601-1000 Oil pump ■ 1
6 791-632-1070 Installer ■ 1 N 791-680-5541 Adapter (For ■ 1
pin)
791-680-9802 Remover and ■ 1 Adapter (For
installer 791-680-9630 bushing) ■ 1
791-680-1520 Guide ■ 1 17
Puller (294kN 790-101-4300 Puller (294kN
{30ton}) ■ 1
790-101-4200 ■ 1
{30ton}
7
Cylinder 790-101-1102 Hydraulic ■ 1
pump
790-101-4300 (1,470 kN ■ 1
{150ton}) 18 790-434-1130 Guide ■ 1
Hydraulic 791-685-9510 Frame ■ 1
790-101-1102 ■ 1
pump 791-685-9520 Frame ■ 1
790-434-1110 Adapter ■ 1 791-685-9530 Rod ■ 1
790-434-1610 Guide ■ 1 791-685-9540 Rod ■ 1
11 Bolt (Shoe 791-685-9550 Nut ■ 3
195-32-61210 bolt may be ■ 1 791-685-9560 Bolt ■ 4
used)
791-126-0150 Adapter ■ 1
01010-51440 Bolt ■ 2
19 01010-51030 Bolt ■ 1
Cylinder
790-101-4300 (1,470 kN ■ 1 791-685-9620 Extension ■ 1
12 {150ton}) R 791-680-5541 Adapter ■ 1
R 790-101-1102
Hydraulic
■ 1 791-680-5550 Guide ■ 1
pump Cylinder
791-685-9510 Frame ■ 1 790-101-4300 (1,470 kN ■ 1
791-685-9520 Frame ■ 1 {150ton})
791-685-9530 Rod ■ 1 Hydraulic
790-101-1102 pump ■ 1
791-685-9550 Nut ■ 1
791-685-9510 Frame ■ 1
791-685-9560 Bolt ■ 4
791-685-9520 Frame ■ 1
790-434-1120 Adapter ■ 1
13 791-685-9530 Rod ■ 1
01010-51030 Bolt ■ 1
791-685-9540 Rod ■ 1
04530-12030 Eyebolt ■ 1
791-685-9550 Nut ■ 3
Cylinder
790-101-4300 (1,470 kN ■ 1 791-685-9560 Bolt ■ 4
{150ton}) 791-126-0150 Adapter ■ 1
790-101-1102 Hydraulic ■ 1 01010-51030 Bolt ■ 1
pump 20
791-685-9620 Extension ■ 1
791-685-9540 Rod ■ 1
14 791-680-5550 Guider ■ 1
791-685-9550 Nut ■ 1 790-434-1140 Adapter ■ 1
791-685-9510 Frame ■ 1 791-680-9630 Adapter ■ 1
791-685-9520 Frame ■ 1
Cylinder
791-685-9530 Rod ■ 1 790-101-4300 (1,470kN ■ 1
791-685-9550 Nut ■ 2 {150ton})
791-685-9560 Bolt ■ 4 790-101-1102 Hydraulic
pump ■ 1
791-126-0150 Adapter ■ 1
15 Puller
791-680-5520 Guide ■ 1 790-101-4200 (294kN ■ 1
791-126-0140 Pusher ■ 1 21 {30ton})
790-434-1120 Adapter ■ 1 Hydraulic
790-101-1102 ■ 1
01010-51030 Bolt ■ 1 pump
04530-12030 Eyebolt ■ 1
791-685-9620 Extension ■ 1
D275A-5 30-199
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AND ASSEMBLY BLY
New/ Sketc WHOLE DISASSEMBLY

Sym- Neces
bol Part No. Part name sity Qty Remode h
l
1. Removal of shoe
22 790-434-1160 Guide ■ 1
Sling the shoe assembly and set it with the
791-685-9510 Frame ■ 1
791-685-9520 Frame ■ 1
shoe up on the floor and remove the shoe by
791-685-9530 Rod ■ 1 using a shoe bolt impact wrench.
791-685-9540 Rod ■ 1 ★ If a shoe bolt is not loosened after it is
791-685-9550 Nut ■ 3 unscrewed by 1 turn (If its torque is not
791-685-9560 Bolt ■ 4 reduced to 0), loosen the other bolts first,
791-126-0150 Adapter ■ 1 and it will be removed smoothly.
R
23 790-434-1150 Guide ■ 1
★ If a shoe bolt is turned forcibly while its
790-434-1120 Adapter ■ 1
01010-51030 Bolt ■ 1
torque is not 0, it and link will adhere to
790-434-1160 Guide ■ 1 each other and they will need to be
Cylinder repaired.
790-101-4300 (1,470kN ■ 1 ★ When moving the shoe assembly, take
{150ton})
Hydraulic care not to damage the master link.
790-101-1102 ■ 1
pump ★ If it is obliged to cut a shoe nut with gas,
★ When disassembling the track shoe, see keep the seal temperature below 80°C to
"Parts judgment guide, Undercarriage, Lubri- prevent thermal deterioration of the seal
cated track" and "Parts judgment guide, and take measures to prevent the spatters
Undercarriage, Reversing procedure for lubri- from entering through the clearances
cated track". among the links.
2. Disassembly of link
1) Set the link assembly on a link press (Tool
R7) and hit it with a hammer so that the
bushing will be fitted to the jaw.
30-200 D275A-5
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AND ASSEMBLY BLY
★ If the link tread, outside of the bushing,

etc. are worn, adjust the height of the jaw
or guide plate and align the pin and bush-
ing with the disassembly jig so that the
link hole will not be damaged during dis-
assembly work.
★ If the pin and bushing are not aligned
well, the link hole may be damaged and
the pin and bushing may be broken dur-
ing disassembly work.
3) Return the left cylinder and operate the

right cylinder to pull out the pin and bush-
ing from the right link simultaneously.
★ Using tool R1, drive the small plug of the

pin inward after the disassembly work so
that the workplace will not become dirty.
4) Return the right cylinder and take out the

links, pins, bushings, and spacers on both
sides and feed the next 1 set of the link
assembly to the jaw.
★ If the bushing ends and sealing surfaces
are damaged, oil will leak. Accordingly,
handle them carefully.
2) Operate the left cylinder to pull out the

pin and bushing from the left link simulta-
neously.
★ Check the pulling out force of the pin and
bushing to see if the necessary press fit-
ting force for the pin and bushing can be
obtained when reversed and assembled
again.
D275A-5 30-201
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AND ASSEMBLY BLY
3. Inspection ★ Precautions for storage

Check the parts for the following items to see if 1) Store the seal without removing it from the
they can be used for a lubricated track or a link so that the counterbore portion will not
grease-filled track, then examine them generally be rusted and take care not to damage the
and determine to use them for a lubricated track seal lip.
or grease-filled track. 2) Apply rust-preventive oil to the pin and bush-
★ For judgment of reuse of the parts, see ing fitting parts, shoe mating surface, and
"Parts judgment guide, Undercarriage, master link mating surface of the link.
Lubricated track". 3) When storing, apply rust-preventive oil to the
1) Check the parts visually for damage. If a all surfaces of the pin, bushing, and spacer.
part seems to be damaged, check it by Take care not to damage the ends of the
dye penetrant test or magnaflux inspec- bushing in particular.
tion. If it has any crack, it cannot be used
again. Discard it.
WHOLE ASSEMBLY
2) Measure the outside diameter of the When recycling for lubricated track
press fitting parts of the pin and bushing 1. Preparation work
and the inside diameter of the pin and 1) Cleaning seal assembly
bushing fitting parts of the link with a Remove the seal assembly from the link
micrometer and a cylinder gauge to see if and divide it into the seal ring and load
the allowable fitting allowance is ring, then clean them.
obtained. When using the pin, bushing, ★ Since the seal ring and load ring are dete-
and link for a lubricated track, however, riorated easily by the cleaning liquid
secure the standard fitting allowance (trichloroethylene etc.), clean them
between the pin and link. quickly. After cleaning them, wipe off the
cleaning agent from them.
★ If the allowable fitting allowance is not
obtained, replace the parts with new
ones.
★ For the dimensional criteria, see MAINTE-
NANCE STANDARD.
30-202 D275A-5
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AND ASSEMBLY BLY
2) When reusing the pin, chamfer its end iv) Drive in the bar with a hammer.
corners smoothly with a grinder. Remove ★ Driving distance a from pin end:
the nodules sticking to the press fitting 10 ± 1 mm
parts with the grinder, too.
★ If the chamfered part of the pin hole has
★ If the ends are worn and sharpened, they been worn, chamfer it with a small-sized
may scuff the press fitting parts and cause grinder (grindstone tip angle: 45° ~ 60°) so
oil leakage. that the plug will not be damaged.
★ Coat the plug with GO90 and drive it with
the small diameter end ahead.
3) If the link, pin, bushing, and spacer are

dirty, clean them. Remove the nodules
sticking to the link and bushing with the 5) Installation of seal assembly
grinder, too. Clean the counterbore portion of the link
★ Since these parts rust easily, clean them carefully and push in the seal to the bot-
just before assembling them. tom by using tool R6.
★ Do not polish the bushing ends. If they ★ If oil is sticking to the counterbore portion
are polished, oil may leak. of the link or seal assembly, the seal will
4) If the large plug was pulled out, drive it in turn and its sealing performance will
by using tool R3. lower. Accordingly, do not apply any oil.
★ Using tool R2, clean the pin hole in When inserting the seal in the counter-
advance. bore portion, take care that oil not stick to
the seal and counterbore portion.
i) Insert the plug through the plug inser-

tion window into the guide hole.
ii) Push the bar with the hand until the
plug stops.
iii) Push the plug with the bar to press
the guide against the pin.
D275A-5 30-203
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AND ASSEMBLY BLY
6) Adjust the dimensions of the press fitting

jig of the link press to keep the projection
of the pin and bushing constant and keep
the installed dimensions of the seal within
the standard range.
★ For the standard dimensions, see DIMEN-
SIONS TABLE OF FITTING JIG OF LINK
PRESS.
★ If the pin end (part P) or link sides (parts
Q and R) are worn, add the dimensions of
the worn parts when adjusting the stan-
dard dimensions so that the projections
of the pins and bushings on both sides
will be even. 2) Press fit the master links on both bushing
sides to the bushing with the shoe fitting
faces up.
★ At this time, use the master links on the
pin side as supports.
★ Press fitting force for bushing:
137 ~ 274 kN {14 ~ 28 tons}
7) Adjust the relief pressure of the link press

so that the pressing force of the press will
not exceed the standard value.
★ If the pressing force is too strong, the
spacer will be pressed forcibly against the
bushing. As a result, the spacer may be
broken and it and bushing may be worn
abnormally. 3) Using the shoe bolt hole pitch gauge,
★ Pushing force of pin and bushing: press fit the master links until the distance
between the shoe bolt holes of both links
1,274 kN {130 tons}
is the standard value.
Pushing force ≈ 1.8 x Average pressure
★ Remove the all steel chips caused by
(Adjust the relief pressure of the link press
press fitting of the bushing with com-
to set the press cutting force.)
pressed air.
2. Assembly of link
1) Apply oil (GO90) to the mating surfaces of 4) Turn over the master links and check that
the pin and bushing with a clean brush they are press fitted in parallel.
and assemble them, then set them before
the jaw of the link press.
★ When reusing (reversing) the bushing, set
the worn outside surface of the bushing
on the shoe fitting side of the link (set the
bushing with the worn outside surface up
on the link press).
30-204 D275A-5
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AND ASSEMBLY BLY
5) Measure the projections of the bushing 8) Set the right link and install the spacer to
on both sides with a depth gauge. the pin.
★ Adjust the press fitting jig of the link press ★ Check that the seal surface and bushing
so that the projections on both sides will end are free from dirt and apply oil
be even. (GO90) to them with a clean cloth or
brush.
★ When installing the spacer, wipe it with a
clean cloth.
6) Send the master links and set the next pin

and bushing.
★ When reusing a pin, install it so that its
side hole will be the link tread side simi- 9) Set the right jig on the receiving side and
larly to a new one. If it is not installed so, the left one on the pushing side and press
its strength may be lowered. Accordingly, fit the pin and bushing simultaneously.
indicate the direction of the side hole on ★ If the pin and bushing have play when
the end face to prevent a mistake. they are press fitted, the seal may come
off the link. To prevent this, press fit
smoothly. If the seal comes off the link,
stop press fitting and set the seal to the
link correctly, then start press fitting
again.
★ Press fitting force for pin and bushing:
529 - 862 kN {54 - 88 tons}
7) Apply gasket sealant (198-32-19890) to

the pin fitting parts of the links to prevent
oil from oozing out of the scuffed parts of
the pin fitting parts.
D275A-5 30-205
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AND ASSEMBLY BLY
10) Using the spacer for fine adjustment, 13) Press fit until the link, spacer, and bushing
press fit the pin and bushing until the pin are fitted together.
end is fitted to the bottom of the receiving ★ Actually, you cannot see from outside if
jig. the above parts are fitted. Accordingly,
★ Adjust the depth of the receiving jig hole control the hydraulic pressure of the link
so that the projections of the pin on both press. Set the relief pressure to a proper
sides will be even. level and heighten the hydraulic pressure
to that level.
For setting of the relief pressure, see
PREPARATION WORK.
★ Check that adjacent 2 links can turn
around each other.
11) Set the left link and install the spacer to

the pin.
★ Apply oil similarly to the right link.
14) Using a shoe bolt hole pitch gauge, mea-

sure the distance between the shoe bolt
holes and check that the result is within
the standard range.
★ If the distance between the shoe bolt
holes is longer than the standard range,
disassemble and check for abnormality,
then press fit again.
★ If the distance between the shoe bolt
holes is shorter than the standard range
and the shoe cannot be installed, the
spacer or bushing end may be worn more
12) Set the left jig on the receiving side and than the allowable limit. In this case, dis-
the right one on the pushing side and assemble and replace the parts.
press fit the left link.
★ When press fitting, take care that both
seals and spacers will not come off.
Press fitting force for link:
529 ~ 862 kN {54 ~ 88 tons}
30-206 D275A-5
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AND ASSEMBLY BLY
15) After each link is assembled, bleed air

from the pin by using tool R5 and check
the sealing performance.
★ Keep the degree of vacuum inside the pin
at 91 ~ 95 kPa {680 ~ 710 mmHg} for 5 sec-
onds and check that the pressure does not
change. If the pressure changes, disas-
semble and check the seal. If the seal is
free from abnormality, assemble again.
17) After supplying oil, drive in the small plug

to the specified position, using tool R4.
★ Apply G090 around the small plug.
★ Drive in the plug to the following depth.
Driving depth from end: 7.5 ± 1 mm
16) Using tool R5, supply oil (G090) until the

oil supply pressure rises to 196 - 294 kPa
{2 - 3 kg/cm2}.
★ In a cold or very cold district, supply
Komatsu genuine oil (150-09-19270 or
195-32-61990) having better low-tempera- 18) Assemble the master link on the pin side
ture characteristics instead of G090. at last.
★ If the oil pressure is heightened too much, ★ Check that the master links on both sides
it has bad effects on the seal. Take care. 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.
Shoe bolt:
Shoe bolt (Regular link)
Initial torque:
784 ± 78 Nm {80 ± 8 kgm}
Retightening angle: 120° ± 10°
★ Supply oil so that 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: 50 - 80 mm
D275A-5 30-207
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AND ASSEMBLY BLY
2) When installing a double track, place the

assembled double shoes on a level place
in 1 line with the shoe side up.
3) Pull pin-side master link (1) and bushing-
side master link (2) together and set them
to each other by the mating faces.
4) Place shoe (3) on the links and fits the
mating faces of the links.
5) Check that shoe bolts (4) can be tightened
easily, then connect the links with the
master bolts.
2) When reusing the pin, chamfer its end

corners carefully with a grinder so that it
will be press fitted smoothly.
Shoe bolts:
Anit-friction compound (LM-P)
Shoe bolt (Master link)

Initial torque:
490 ± 49 Nm {50 ± 5 kgm}
★ Tighten the bolts in the order of b - e.
When recycling for grease-filled track

1. Preparation work
1) Cleaning seal assembly
Remove the seal assembly from the link
and divide it into the seal ring and load
ring, then clean them.
★ Since the seal ring and load ring are dete-
riorated easily by the cleaning liquid,
clean them quickly. After cleaning them,
wipe off the cleaning agent from them.
30-208 D275A-5
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AND ASSEMBLY BLY
3) Drive in the large and small plugs by

using tools R3 and R5.
i) Insert each plug through the plug insertion
window into the guide hole.
★ Apply oil to each plug.
v) Push the bar with the hand until the
plug stops.
vi) Push the plug with the bar to press
the guide against the pin.
vii) Drive in the bar with a hammer.
★ Driving distance a from pin end:
Small plug: 7.5 ± 1 mm
Large plug: 10 ± 2 mm 7) Adjust the dimensions of the press fitting
★ If the plugs were not pulled out when the jig of the link press to keep the projection
shoe was disassembled, reuse them as of the pin and bushing constant and keep
they are. the installed dimensions of the seal within
4) If the outside of the pin, surfaces of the the standard range.
spacer, and ends and inside of the bush- ★ For the standard dimensions, see DIMEN-
ing are dirty, clean them. SIONS TABLE OF FITTING JIG OF LINK
5) Apply grease to the outside of the pin and PRESS.
surfaces of the spacer. ★ If the pin end (part P) or link sides (parts
will be even.
6) Installation of seal assembly

Clean the counterbore portion of the link
carefully and push in the seal to the bot-
tom by using tool R6.
★ If grease is sticking to the counterbore
portion of the link or seal assembly, the
seal will turn and its sealing performance
will lower. Accordingly, do not apply any
oil.
D275A-5 30-209
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AND ASSEMBLY BLY
2. Assembly of link
1) Apply lithium grease (G2-LI) to the mating
surfaces of the pin and bushing and
assemble them, then set them before the
jaw of the link press.
★ When reusing (reversing) the bushing, set
the worn outside surface of the bushing
on the shoe fitting side of the link (set the
bushing with the worn outside surface up
on the link press).
5) Measure the projections of the bushing

on both sides with a depth gauge.
★ Adjust the press fitting jig of the link press
so that the projections on both sides will
be even.
2) Press fit the master links on both bushing

sides to the bushing with the shoe fitting
faces up.
★ At this time, use the master links on the
pin side as supports.
137 ~ 274 kN {14 ~ 28 tons}
6) Send the master links and set the next pin

and bushing.
★ When reusing a pin, install it so that its
side hole will be the link tread side simi-
larly to a new one. If it is not installed so,
its strength may be lowered. Accordingly,
indicate the direction of the side hole on
the end face to prevent a mistake.
★ If the outside of the pin is worn, install it
so that the un-worn surface will be on the
traction side. In this case, install the pin so
that its side hole will be the link tread
side, too.
3) Using the shoe bolt hole pitch gauge,

press fit the master links until the distance
between the shoe bolt holes of both links
is the standard value.
★ Remove the all steel chips caused by
press fitting of the bushing with com-
pressed air.
4) Turn over the master links and check that
they are press fitted in parallel.
30-210 D275A-5
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AND ASSEMBLY BLY
7) Set both links and operate both pushing 3. Installation of Shoe

jigs to press fit the pin and bushing simul- 1) Set the link assembly on the bed and
taneously. install the shoe with a shoe bolt impact
★ If the pin and bushing have play when wrench and a torque wrench.
they are press fitted, the seal may come
Shoe bolt:
off the link. To prevent this, press fit
smoothly. If the seal comes off the link,
stop press fitting and set the seal to the
link correctly, then start press fitting
again.
Initial torque:
★ Pushing force of pin and bushing: 784 ± 78 Nm {80 ± 8 kgm}
1,274 kN {130 tons}
Pushing force ≈ 1.8 x Average pressure Retightening angle:
(Adjust the relief pressure of the link press 120° ± 10°
to set the press cutting force.)
8) Using a shoe bolt hole pitch gauge, mea- 2) In case of the 2-piece shoe assembly,
sure the distance between the shoe bolt assemble the shoes, and then place on a
holes. When the distance is in the stan- level place in 1 line with the shoe side up.
dard range, stop press fitting. 3) Pull pin-side master link (1) and bushing-
side master link (2) together and set them
to each other by the mating faces.
4) Place shoe (3) on the links and fit the mat-
ing faces of the links.
5) Check that shoe bolts (4) can be tightened
easily, then connect the links with the
master bolts.
9) Assemble the master link on the pin side

at last.
★ Check that the master links on both sides
are press fitted in parallel.
D275A-5 30-211
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AND ASSEMBLY BLY
Shoe bolt:

Initial torque:
490 ± 49 Nm {50 ± 5 kgm}
★ Tighten the bolts in the order of b - e.
30-212 D275A-5
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AND ASSEMBLY BLY
DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS
Precaution
Unit: mm
1. The link receiving faces of jaw (5) must be
Dimensions of jig vertical.
2. Replaceable wear plate (6) is desirable.
a 2.5
b 2.0
c 46
Adjust the dimensions of the press fitting jig

of the link press to keep the projection of the
pin and bushing constant and keep the
installed dimensions of the seal within the
standard range.
★ If the pin end (part P) or link sides (parts
will be even.
D275A-5 30-213
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AND ASSEMBLY BLY
DISASSEMBLY OF 1 LINK IN THE FIELD

4. Set tool R15 and apply oil pressure to pull out
WARNING! Only how to use the tools pin (3).
is explained below. For details of disas- ★ After the cylinder reaches the stroke end,
sembly and assembly, see WHOLE DIS- install extension tool R15 between the
ASSEMBLY (OR ASSEMBLY) OF TRACK adapter and guide, then repeat the work.
SHOE.
1. Using 2 bolts (2), install tool R11 to link (1).

★ As 2 bolts (2) for this step, 2 track bolts
may be used.
5. Set tool R16 and spacer b at the center of

roller tread side of the link to be disassem-
bled and apply oil pressure to the puller to
open the link by a (5 - 6 mm) to disconnect it.
2. Assemble tools R12 and R13, then sling
them together and set them on the track.
3. Insert the rod of tool R14 from the cylinder

side and install it with 2 nuts.
★ Install the rod through the hole of link (1).
30-214 D275A-5
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AND ASSEMBLY BLY
ASSEMBLY OF 1 LINK IN THE FIELD

1. Assembly of link sub-assembly 3. Set link (4) on the opposite side and support it
1) Set tool R17 to the link end and press fit with tool R18.
bushing (1).
137 ~ 274 kN {14 ~ 28 tons}
4. Set tools R19 and R20 as for pin pulling work

and press the pin end c with tool R19 and the
bushing end d with tool R20 alternately.
2) Set tool R17 to the link end (on the pin ★ Press fitting force for pin:
side) and press fit pin (2). 392 ~ 588 kN {40 ~ 60 tons}
★ Set the pin with side hole a toward ★ Press fitting force for bushing:
link tread b.
137 ~ 274 kN {14 ~ 28 tons}
★ Press fitting force for pin:
392 ~ 588 kN {40 ~ 60 tons}
5. Using tool R21 as for disassembly, push link

(5) on the bushing side open.
2. Set link sub-assembly (3) to the link to be con-
nected.
D275A-5 30-215
c
AND ASSEMBLY BLY
6. Set pin-side link (6) to bushing-side link (5) DISASSEMBLY OF MASTER LINK
and connect them by tool R22, then remove
tool R21. ★ For the method of using tool R7, see DISAS-
SEMBLY OF 1 LINK IN THE FIELD.
1. Removal of track shoe assembly
Remove the track shoe assembly from the
track frame. For details, see EXPANDING
TRACK SHOE ASSEMBLY.
2. Removal of master link
1) Cutting and removal of master link on
bushing side with gas
Cut the parts marked with gas cut and
remove the parts marked . Move mas-
ter 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.
7. Set tool R19 to pin (7) side and press fit pin Necessary special tools:
(7), using tool R23. 1. Gas cutting machine
2. Tool R7
Pin fitting hole of link:
Gasket sealant (198-32-19890)
Cylinder: b
Frame side: e
★ Set the pin with the side hole toward the
link tread.
★ Press fitting force for pin:
784 ~ 1,176 kN {80 ~ 120 tons}
2) Removal of master link on pin side

Cut the parts marked with gas cut and
remove the parts marked . Push pin
(10) out of link (11) in the direction of
with a press. Then, pull pin (10) and link
(12) together out of bushing (13).
Necessary special tools:
1. Gas cutting machine
2. Tool R7
30-216 D275A-5
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AND ASSEMBLY BLY
ASSEMBLY OF MASTER LINK

★ For the method of using tool R7, see DISAS- 2) Set spacer (3) and seal assembly (4) to the
SEMBLY OF 1 LINK IN THE FIELD. counterbore of the link of the connecting
1. Assembly of bushing-side link part.
1) Press fit bushing-side master link (1) to
bushing (2) with a press.
★ When press fitting both master links,
take care that they will be in parallel
with each other.
★ Do not damage the mating surfaces of
the master links and end faces of the
bushing.
Unit: mm
L1 184.15 ± 0.7
L2 234.95 ± 0.7
D1 Drill 30 in
diameter
D2 27 x 2.0
3) Match the pin hole and bushing hole to
each other and connect the pin and bush-
ing with guide pin b.
2. Installation of bushing-side link

1) Expand the center of the link tread with
tool R7 as shown in the figure. (Expand
the link end by 10 mm.)
a: 5 mm
4) Press fit pin (5) with tool R7 and install
bushing-side master link (1).
Pin fitting hole of link:
Gasket sealant (198-32-19890)
★ Set the pin with its side hole on the link
tread side.
D275A-5 30-217
c
AND ASSEMBLY BLY
5) Install the shoe to the link of the connect- 2) Pass pin (10) through bushing (9) and set
ing part. and press fit pin-side master links (11)
from both sides with tool R7.
6) Drive large plug (6) with tool R3 and sup- 3) Drive large plug (13) with tool R3 and
ply oil with tool R5, then drive small plug supply oil with tool R5, then drive small
(7) with tool R4. plug (14) with tool R4.
★ When press fitting both master links,
take care that they will be in parallel
with each other (Bushing side and pin
side).
★ Do not damage the mating surfaces of
the master links and end faces of the
bushing.
★ Take care that dirt and sand will not
stick to the seal, spacer, end of bush-
ing, and tap-hole mating face of the
master link.
4. Connection of the master links

1) In case of 2-piece shoe assembly, assem-
ble the shoes, and then place them on a
level place in 1 line with the shoe side up.
2) Pull pin-side master link (15) and bushing-
side master link (16) together and set
them to each other by the mating faces.
3) Place the shoe on the links and fits the
mating faces of the links.
4) Check that the shoe bolts can be tight-
3. Assembly of pin-side link ened easily, then connect the links with
1) Set spacer (3) and seal assembly (4) to the the master bolts.
counterbore of the master link. Shoe bolt:

Initial torque:
490 ± 49 Nm {50 ± 5 kgm}
30-218 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY

SPECIAL TOOLS INSTALLATION
New/ Ske • Carry out installation in the reverse order to

Sym Part No. Part Name Nece Qty. Remo
bol ssity tch removal.
del
1 790-401-1700 Lifting tool ■ 1 1

791-650-1700 Installer ■ 1 ★ Using tool P2, press fit seal (2) to the
pivot shaft.
P Puller
2 790-101-4200 (294kN ■ 1 Press fitting face of seal:
{30ton})
Hydraulic ■
790-101-1102 pump 1 ★ Check that press fitting distance a of the
seal from the shaft end is as follows.
• Press fitting distance a:
REMOVAL 493.5 ± 1.0 mm
1. Remove the track frame assembly. For

details, see REMOVAL OF TRACK FRAME
ASSEMBLY.
2. Using tool P1, sling pivot shaft assembly (1)
temporarily.
3. Remove the mounting bolts. Using forcing
screw b, pull out pivot shaft assembly.
Pivot shaft assembly: 145 kg
4. Remove seal (2) and cover (3). 1
D275A-5 30-219
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY
REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY

SPECIAL TOOLS 4. Remove mounting nuts and cover (2). 1
5. Disconnect grease tube (3).
Sym Nece New/ Ske 6. Remove cover (4).
bol Part No. Part Name ssity Qty. Remo tch
del
791T-650-1930 Spacer ■ 1 N {
792-900-1520 Plate ■ 1
791-520-4140 Screw ■ 1
790-101-2470 Adapter ■ 1
790-101-2540 Washer ■ 1
N1
791-112-1180 Nut ■ 1
Puller
790-101-2102 (294kN ■ 1
{30ton})
Hydraulic
790-101-1102 ■ 1
pump
REMOVAL
1. Remove the engine undercover and power 7. Pull out side pin (5). 2
train undercover.
★ If the equalizer bar hole is not aligned
Engine undercover: 250 kg with the track frame hole, the pin cannot
be pulled out easily. Accordingly, adjust
the height of the equalizer bar side with
Power train undercover: 320 kg hydraulic jack c.
★ Remove the pin on the opposite side by
2. Set stand b and hydraulic jack c under the
repeating steps 3 - 7.
radiator guard.
30-220 D275A-5
c
DISASSEMBLY
8. Operate hydraulic jack c slowly to lower the 13. Sling equalizer bar (8) and lower it, bypassing
machine body until the equalizer bar touches both track frames.
both track frames.
9. Disconnect lubrication tube (6). WARNING! After removing the
10. Remove lock plate (7). equalizer bar, do not lower the
machine body.
Equalizer bar: 275 kg
11. Using tool N1, remove center pin (8). 3

★ If the equalizer bar hole is not aligned
with the main frame hole, the pin cannot
be pulled out easily. Accordingly, adjust
the height of the main frame side with the
INSTALLATION
hydraulic jack.
removal.
1
Installation procedure for cover (2)
1) Tighten the 5 mounting bolts of cover (4)
lightly.
2) Install cover (2) and secure it with the 2
nuts.
permanently.
4) Install grease tube (3).
12. Operate the blade to raise the front part of the

machine body and set a hydraulic jack under
the radiator guard.
D275A-5 30-221
c
DISASSEMBLY

the pin holes.
★ Before installing the side pin, operate the

hydraulic jack to adjust the main frame
height and align the equalizer bar hole
with the track frame hole.
★ Set the grease holes of the pins in the fol-
lowing directions.
• Left pin: Outside of machine body
• Right pin: Inside of machine body
Equalizer bar side bushing:
Grease (G2-LI)

the pin holes.
★ Before installing the center pin, sling the

equalizer bar and align the equalizer bar
hole with the main frame hole.
Equalizer bar center bushing and
main frame bushing:
Grease (G2-LI)
30-222 D275A-5
c
DISASSEMBLY

N1 Spacer
D275A-5 30-223
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING

SPECIAL TOOLS 3) Using tool N2, remove spherical bushing
(5) from equalizer bar (6).
Sym New/ Ske
Nece Qty. Remo ★ Remove the parts on the opposite simi-
Part No. Part Name
bol ssity del tch larly.
791-650-1800 Remover ■ 1
Puller
790-101-2102 (294kN ■ 1
N2
{30ton})
Hydraulic
790-101-1102 ■ 1
pump
DISASSEMBLY
1. Center bushing
Remove center bushing (1).
ASSEMBLY
1. Side bushing
1) Set spherical bushing (5) and tool N2 and
press fit spherical bushing (5) to equalizer
bar (6).
2. Side bushing
1) Remove ring (2) and seal (3).
2) Remove ring (4).
★ Install the spherical bushing as shown in

the figure.
i) Set bushing end a on the level.
ii) Install the bushing with grease hole b
slant.
30-224 D275A-5
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING
2) Install ring (4).

3) Using a press, press fit seal (3) and ring
(2).
Part c between side bushing and
seal:
Supply 0.3 liters of grease (G2-LI)
(on each side)
★ Install the ring and seal so that they will
be flush with the equalizer bar.
Seal lip: Grease (G2-LI)
2. Center bushing
Using the press, press fit center bushing (1).
D275A-5 30-225
c
DISASSEMBLY REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE AS-
AND ASSEMBLY SEMBLY
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL

VALVE ASSEMBLY
REMOVAL 4. Disconnect 3 PPC hose clamps and plate (5).

the negative (–) terminal of the battery.
WARNING! Lower the work equipment to

the ground and release the residual pres-
sure from the piping, referring to TESTING
AND ADJUSTING, Releasing residual
pressure from work equipment cylinders.
Then, set the safety lock lever in the LOCK
position.
★ Plug the disconnected pipes and hoses to pre-

vent foreign matter from entering them.
★ Put tags to the disconnected pipes to prevent 5. Disconnect hydraulic tank return hose (6).
a mistake in re-connecting them. 6. Disconnect blade PPC hose (7) and ripper PPC
1. Drain the oil from the hydraulic tank. hose (8).
• (7): Coupler (Color band: Blue)
Hydraulic tank: Approx. 130 l • (8): Coupler (Color band: Blue)
2. Remove covers (1), (2), and (3) from the right

side of the machine body.
3. Disconnect hydraulic oil pressure sensor wir-

ing connector HHP (4).
30-226 D275A-5
c
AND ASSEMBLY SEMBLY
7. Disconnect PPC hoses (9) on the right side. 9. Disconnect accumulator hose (PPC main
1 pressure port) (11).
★ There 5 PPC hoses in the dual tilt machine
and 4 in the single tilt machine.
The PPC hoses are as follows from the top
(Dual tilt machine).
• Ripper tilt BACK hose
(Color band: Brown) (Coupler) (Port PA5)
• Ripper lift LOWER hose
(Color band: Black) (Coupler) (Port PA4)
• LEFT tilt cylinder hose
(Color band: Yellow) (Port PA3)
• Blade lift LOWER hose
(Color band: Not colored) (Port PA2)
• RIGHT tilt cylinder hose
(Color band: Brown) (Coupler) (Port PA1)
10. Remove accumulator bracket (12).
8. Disconnect PPC hoses (10) on the left side.

2
★ There 5 PPC hoses in the dual tilt machine
and 4 in the single tilt machine.
The PPC hoses are as follows from the top
• Ripper tilt BACK hose
(Color band: White) (Coupler) (Port PB5)
• Ripper RAISE hose
(Color band: Not colored) (Coupler) (Port
PB4)
• LEFT tilt cylinder hose
(Color band: Green) (Port PB3)
• Blade lift RAISE hose
(Color band: Black) (Coupler) (Port PB2)
• RIGHT tilt cylinder hose
(Color band: White) (Port PB1)
D275A-5 30-227
c
AND ASSEMBLY SEMBLY
11. Disconnect the work equipment hoses. 16. Remove the 4 mounting bolts. Using hanging
★ There are 10 work equipment hoses for bolt b, lift off work equipment control valve
the dual tilt machine and 8 for the single assembly (20).
tilt machine.
• Hoses (13) are as follows from the top Work equipment control valve
(Dual tilt machine). assembly: 155 kg
Ripper tilt IN hose (Port A5)
Ripper lift LOWER hose (Port A4)
LEFT tilt cylinder hose (Port A3)
Blade lift LOWER hose (Port A2)
RIGHT tilt cylinder hose (Port A1)
• Hoses (14) are as follows from the top
Ripper tilt BACK hose (Port B5)
Ripper lift RAISE hose (Port B4)
LEFT tilt cylinder hose (Port B3)
Blade lift RAISE hose (Port B2)
RIGHT tilt cylinder hose (Port B1)
INSTALLATION
Carry out installation in the reverse order to
removal.
1 2
★ Since the connecting positions of the PPC
hoses are indicated by their band colors,
check the band colors when connecting
those hoses.
• PPC hose band colors (Dual tilt machine)
12. Disconnect work equipment pump hoses

(Port P1) (15) and (Port PC) (16).
13. Disconnect PPC main pressure hose (Port PR)
(17).
14. Disconnect drain hose (Port TS) (18).
15. Disconnect work equipment pump hose (Port
LS) (19).
• PPC hose band colors (Single tilt

machine)
30-228 D275A-5
c
AND ASSEMBLY SEMBLY

again.
• Bleeding air
Bleed air from the piping. For details, see
from work equipment cylinders.
D275A-5 30-229
c
DISASSEMBLY DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE
AND ASSEMBLY ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL

VALVE ASSEMBLY
★ This chapter deals only with precautions to be
followed when reassembling the DISASSEM-
BLY AND ASSEMBLY OF WORK EQUIPMENT
CONTROL VALVE ASSEMBLY.
★ Only the precautions for assembling the work
equipment control valve assembly are
described below.
★ For the tightening torque for each part, see
STRUCTURE AND OPERATION, Maintenance
standard.
ASSEMBLY
★ Clean the all parts and check them for dirt
or damage. Coat their sliding surfaces
with engine oil before installing.
★ When assembling the suction valve,
check that the spring is installed in the
sleeve normally.
★ When assembling a relief valve or a plug,
check that the cut part of the backup ring
is closed and apply grease (G2-LI) to the
periphery of the backup ring.
★ After installing the main relief valve
assembly, adjust it. For details, see TEST-
ING AND ADJUSTING, Testing and
adjusting work equipment oil pressure.
30-230 D275A-5
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEM-

BLY
SPECIAL TOOLS DISASSEMBLY
New/ 1. Cylinder tube

Sym- Part No. Part name Neces Qty Remo Sket
bol sity ch Remove the cylinder tube.
del
2. Quick drop valve
790-502-1003 Cylinder repair ■ 1 • Perform this procedure for only the blade
stand
1 lift cylinder.
790-101-1102 Pump ■ 1 1) Remove quick drop valve (1).
Other 2) Disassemble the quick drop valve assem-
790-102-2303
than
Wrench blade ■ 1 bly according to the following procedure.
2 lift i) Remove block (2).
ii) Remove spring (3), spacer (4), valves
790-102-3802 Wrench Blade
lift ■ 1 (5) and (6), and collar (7).
790-102-4300 Wrench Ripper ■ 1

3 lift
Ripper
790-102-4310 Pin tilt ■ 2
790-201-1702 Push tool kit ■ 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Blade
790-201-1831 lift 1
4
Blade
• Push tilt
790-201-1851 1
tool Ripper
lift
Ripper 3. Piston rod assembly

U 790-201-1841 1
tilt • Blade lift cylinder
790-201-1500 Push tool kit ■ 1 1) Set the cylinder assembly to tool U1.
2) Using a hydraulic pump or a power
790-101-5021 • Grip 1 wrench and tool U2, remove head assem-
01010-50816 • Bolt 1 bly (8).
3) Pull piston rod assembly (9) out of cylin-
790-201-1640 Blade 1 der (10).
lift
5 ★ Put an oil pan under the cylinder to
790-201-1650
Blade
1 receive the oil.
• Plate tilt
Ripper
790-201-1660 lift 1
Ripper
tilt
6 790-720-1000 Expander ■ 1
796-720-1670 Ring ■ 1
Blade
lift
07281-01279 Clamp ■ 1
796-720-1690 Ring Blade ■ 1

7 tilt
Ripper
07281-01919 Clamp lift ■ 1
796-720-1680 Ring ■ 1
Ripper
tilt
07281-01589 Clamp ■ 1
D275A-5 30-231
c
DISASSEMBLY
• Blade tilt cylinder, ripper lift cylinder,

and ripper tilt cylinder
1) Remove the mounting bolt and discon-
nect head assembly (11).
2) Pull piston rod assembly (12) out of cylin-
der (13).
★ Put an oil pan under the cylinder to
receive the oil.
• Ripper lift and ripper tilt cylinders

1) Set piston rod assembly (12) to tool U1.
4. Piston assembly
• Blade lift cylinder and blade tilt cylin-
der
1) Remove the mounting bolts and 2 spacers
(14).
2) Remove 4 valves (15).
3) Remove piston assembly (16) from piston
2) Remove lock screw (24) of piston assem-
rod (17).
bly (23).
4) Remove retainer (18).
• Screw size: M12 x Pitch 1.75
5) Disassemble the piston assembly accord-

i) Remove wear rings (19).
★ The blade lift cylinder has 2 wear
rings and the dual tilt cylinder has
1 wear ring.
ii) Remove piston ring (20) from the pis-
ton.
★ Do not remove 2 seats (21) and
valve (22).
30-232 D275A-5
c
DISASSEMBLY
★ If screw (24) is crushed so much that it 5. Head assembly

cannot be removed, tighten it and cut 1) Remove head assembly (8) or (11) from
threads of the screw hole, then piston rod (17) or (25).
remove it.
2) Disassemble the head assembly accord-

3) Using tool U3, remove piston assembly ing to the following procedure.
(23) from piston rod (25). i) Remove O-ring and backup ring (29).
ii) Remove snap ring (30) and dust seal
(31).
iii) Remove packing (32), buffer ring (33),
and bushing (34).
4) Disassemble the piston assembly accord-

i) Remove backup ring and O-ring (26).
ii) Remove wear ring (27).
iii) Remove piston ring (28). 6. O-ring and backup ring
• Perform this procedure for only the
blade lift cylinder and blade tilt cylin-
der.
Remove O-ring and backup ring (35) from
piston rod (17).
D275A-5 30-233
c
DISASSEMBLY
ASSEMBLY
★ Take care not to damage the packings, dust
seals, O-rings, etc.
★ Clean each part and block the piping ports
and pin holes so that dirt will not enter them.
1. O-ring and backup ring
blade lift cylinder and blade tilt cylinder.
Install O-ring and backup ring (35) to piston
rod (17).
★ When installing the backup ring, warm it 2) Install the O-ring and head assembly (8)
in water at 50 - 60°C. or (11) to piston rod (17) or (25).
2. Head assembly 3. Assembly of piston assembly

1) Assemble the head assembly according 1) Set piston ring (28) to tool U6 and turn
to the following procedure. the handle of the tool by 8 ~ 10 turns to
i) Using tool U4, press fit bushing (34). expand the piston ring.
ii) Install buffer ring (33) and packing 2) Remove piston ring (28) from tool U6 and
(32). install it to the piston.
iii) Using tool U5, install dust seal (31) 3) Using tool U7, shrink piston ring (28).
iv) Install snap ring (30).
v) Install O-ring and backup ring (29).
★ When installing the backup ring,
warm it in water at 50 ~ 60°C.
30-234 D275A-5
c
DISASSEMBLY
4) Install wear ring (27). ii) Install screw (24).

5) Install backup ring and O-ring (26). ★ Before installing the screw, degrease and
★ When installing the backup ring, warm it dry it well.
in water at 50 ~ 60°C. ★ After installing the screw, bend 4 places
of the periphery of the screw.
Threads:
Adhesive (LOCTITE No. 262)
Screw:
58.9 ~ 73.6 Nm {6 ~ 7.5 kgm}
4. Piston assembly
• Ripper lift cylinder and ripper tilt cyl-
inder
1) Install piston assembly (23) to piston rod
(25) and set them to tool U1.
3) When either or both of piston rod (25) and

piston assembly (23) are new, install them
i) Using tool U3, tighten piston assembly
(23).
Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
ii) Make 1 screw hole to install the screw.

★ Apply the drill to the groove in the
threads between the piston and piston
rod and cut threads horizontally.
2) When reusing piston rod (25) and piston • Thread cutting dimensions (mm):
assembly (23), install them according to Tap drill diameter: 10.3
the following procedure. Tap drill depth: 27
★ Remove burrs and fins from the threads Tap size: 12 x 1.75
with a file. Tapping depth: 20
★ Clean the parts thoroughly and remove iii) After making the screw hole, remove
metal chips and dirt. chips and dirt and clean thoroughly.
i) Using tool U3, tighten piston assem-
bly (23) in piston rod (25) until the
screw holes are matched.
D275A-5 30-235
c
DISASSEMBLY
iv) Install screw (24). 5. Piston rod assembly

★ Before installing the screw, degrease and • Blade tilt cylinder, ripper lift cylinder,
dry it well. and ripper tilt cylinder
★ After installing the screw, bend 4 places 1) Insert piston rod assembly (12) in the cyl-
of the periphery of the screw. inder (13).
Threads: ★ Push in the piston rod to the stroke end.
Adhesive (LOCTITE No. 262) Sealing part:
Grease (G2-LI)
Screw:
2) Tighten the mounting bolts of head
58.9 ~ 73.6 Nm {6 ~ 7.5 kgm}
assembly (11).
Mounting bolt (Ripper tilt):

250 ± 24.5 Nm {25.5 ± 2.5 kgm}
Mounting bolt (Blade tilt, ripper

lift):
343 ± 34.3 Nm {35 ± 3.5 kgm}
• Blade lift cylinder and blade tilt cylin-

der
1) Install retainer (18) and piston assembly
(16) to piston rod (17).
2) Install 4 valves (15).
3) Install 2 spacers (14).
★ Clean and degrease the piston and
threads of the mounting bolts thoroughly.
★ After tightening the mounting bolts, leave • Blade lift cylinder
them for about 30 minutes. 1) Set cylinder (10) to tool U1.
2) Install piston rod assembly (9) to cylinder
Apply hardener (LOCTITE (10).
Primer T or equivalent) to the
piston and 6 mounting bolts, ★ Push in the piston rod to the stroke end.
then apply adhesive (LOCTITE
No. 262 or equivalent) to the Sealing part: Grease (G2-LI)
piston and 6 mounting bolts by
0.5 ~ 0.7 cc each 3) Using tool U2, tighten head assembly (8).
Screw: Head assembly:

98.1 ~ 122.6 Nm {10 ~ 12.5 kgm} 1,010 ± 2.9 Nm {103 ± 0.3 kgm}
30-236 D275A-5
c
DISASSEMBLY
6. Quick drop valve

blade lift cylinder.
1) Assemble the quick drop valve assembly
i) Install collar (7), valves (6) and (5),
spacer (4), and spring (3).
ii) Install block (2).
2) Install quick drop valve assembly (1).
D275A-5 30-237
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF BLADE ASSEMBLY
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY

REMOVAL 3. Using plate (3), fix the lift cylinder assembly
to the radiator guard.
WARNING! Lower the work equipment to ★ Bind the piston rod with wires so that it
a level place and set blocks b under both will not come out.
straight frames securely.
4. Similarly, disconnect the lift cylinder assem-

1. Remove cap (1) from the lift cylinder. 1
bly on the opposite side from the blade.
★ Check the quantity and thickness of the
inserted shims. WARNING! After stopping the engine,
release the residual pressure from the
piping, referring to TEST AND ADJUST-
ING, Releasing residual pressure from
hydraulic circuit.

6. Disconnect hose (5).
★ Plug the openings so that dirt will not
enter the piping.
★ Hose (5) is connected to only the right
side of the single-tilt machine and to both
sides of the dual-tilt machine.
7. Remove both trunnion caps (6). 2
2. Sling lift cylinder assembly (2) temporarily.

Start the engine and retract the piston rod
fully.
30-238 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF BLADE ASSEMBLY
8. Remove blade assembly (7). 3 3

★ Start the engine and move the machine in ★ Adjust height b and width c of both
reverse slowly to disconnect the blade straight frames to the following values
assembly from the trunnion. with block b, etc.
• Trunnion height b: Approx. 860 mm
• Frame width c: Approx. 2,930 mm
INSTALLATION
removal.
1
★ Adjust clearance a at the mating face of
the cap to the following value with shims
and check that the shims rotate smoothly.
• Standard clearance a: 0.2 - 0.5 mm
• Standard shim thickness: 4 mm
★ After installing the blade, adjust its tilting
distance, referring to TESTING AND
ADJUSTING, Adjusting blade.
again.
• Bleeding air
Bleed air from the work equipment cylinders.
For details, see TESTING AND ADJUSTING,
Bleeding air from work equipment cylinders.
2
★ Adjust the shims of the trunnion, referring
to TESTING AND ADJUSTING, Adjusting
blade.
D275A-5 30-239
c
DISASSEMBLY
AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF RIPPER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RIPPER ASSEMBLY

DISASSEMBLY 5. Set stand c between the arm and beam.
1. Remove right step (1). 7. Remove the lock plate and pin (4).
★ Start the engine and retract the piston rod
fully and lower it onto the arm.
8. Sling tilt cylinder assembly (5) temporarily.
9. Remove the lock plate and pin (6).
★ Start the engine and retract the piston rod
fully and lower it onto the lift cylinder
assembly.
2. Set block b and drive the machine over it and

lower the blade.
WARNING! Lock the brake securely.
3. Sling shank (2) temporarily and operate the

pin puller cylinder to pull out the pin.
★ Remove the pins on the opposite side
★ The pin puller cylinder is installed to only similarly.
the giant ripper machine.
10. Sling beam (7) temporarily and remove the
4. Start the engine and raise the ripper assem- lock plate.
bly fully, then lower and remove shank (2) 11. Using forcing screw d, pull out both pins (8).
gradually. 12. Lift off beam (7).
Shank (Multi-shank ripper):

350 kg (1 piece) Beam: 1,750 kg
Shank (Giant ripper): 500 kg
30-240 D275A-5
c
DISASSEMBLY
WARNING! Release the residual pres-

sure from the work equipment cylin-
ders, referring to TESTING AND
ADJUSTING, Releasing residual pres-
sure from work equipment cylinders.
13. Disconnect tilt cylinder hose (9) and lift cylin-

der hose (10).
18. Sling arm (13) and remove the lock plate.

19. Using forcing screw e, pull out both pins (14).
14. Sling tilt cylinder assembly (5) temporarily

and remove the lock plate and pin (11).
15. Lift off tilt cylinder assembly (5).
Tilt cylinder assembly: 160 kg
★ Remove the tilt cylinder assembly on the 20. Lift off arm (13).
opposite side similarly.
Arm: 750 kg
16. Sling lift cylinder assembly (3) temporarily

and remove pin (12).
17. Lift off lift cylinder assembly (3).
Lift cylinder assembly: 185 kg
★ Remove the lift cylinder assembly on the

opposite side similarly.
D275A-5 30-241
c
DISASSEMBLY
ASSEMBLY 6. Connect lift cylinder hose (10) and tilt cylinder

hose (9).
1. Set a stand under arm (13) and set arm (13) in
position.
2. Install pins (14) to both sides and secure them
with the lock plates.
★ When installing the tilt cylinder hose, set

the angle between the hose adapter and
cylinder to a (50°) at the all 4 places.
3. Set lift cylinder assembly (3) in position and
install pin (12).
★ After installing the lift cylinder assembly,
lower it onto the arm.
★ Install the lift cylinder on the opposite
side similarly.
★ When installing tilt cylinder hose (9) to the

machine rear block, set the angle between
the hose adapter and machine rear block
(in the longitudinal direction) to b (10°) at
the all 4 places.
4. Set tilt cylinder assembly (5) in position.
5. Install pin (11) and secure it with the lock ★ When installing the tilt cylinder hose
plate. clamp, set the distance between the
machine body rear block adapter and the
★ After installing the tilt cylinder assembly,
tilt cylinder hose clamp to c (560 mm).
lower it onto the lift cylinder assembly.
★ Install the tilt cylinder on the opposite
side similarly.
30-242 D275A-5
c
DISASSEMBLY
7. Set beam (7) in position. 17. Pass a wire through the shank holder and
8. Install pins (8) to both sides and secure them raise shank (2) slowly to align it with the pin
with the lock plates. hole.

pin holes.
18. Operate the pin puller cylinder to insert the

pin.
★ The pin puller cylinder is installed to only
the giant ripper machine.
19. Raise the blade and lower the machine body
from block b.
9. Sling tilt cylinder assembly (5) temporarily.

10. Start the engine and extend the piston rod to
align the pin holes.

pin holes.
11. Install pin (6) and secure it with the lock plate.
★ Install the pin on the opposite side simi-
larly.
13. Start the engine and extend the piston rod to
align the pin holes. 20. Install right step cover (1).

pin holes.
14. Install pin (4) and secure it with the lock plate.
★ Install the pin on the opposite side simi-
larly.
• Bleeding air
★ Bleed air from the work equipment cylin-
ders. For details, see TESTING AND
ADJUSTING, Bleeding air from work
equipment cylinder.
★ Supply grease (G2-LI) to each connecting
15. Set block b and drive the machine over it and pin.
lower the blade.
WARNING! Lock the brake securely.
16. Start the engine and raise the ripper assem-

bly fully.
D275A-5 30-243
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF ROPS GUARD
REMOVAL AND INSTALLATION OF ROPS GUARD

REMOVAL
1. Sling the ROPS guard temporarily and
remove mounting bolts (1). 1
2. Lift off ROPS guard (2).
ROPS guard: 700 kg
INSTALLATION
removal.
Mounting bolt:
1,180 ~ 1,470 Nm {120 ~ 150 kgm}
30-244 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY

REMOVAL 5. Remove covers (6) and (7).
6. Remove step (8) and covers (9) and (10).
WARNING! Disconnect the cable from ★ Remove these parts from both sides.
1. Remove the ROPS guard. For details, see

REMOVAL OF ROPS GUARD.
2. Open operator's cab left cover (1).
7. Remove mounting bolts (11) under the opera-

tor's cab.
★ Remove the bolts from both sides.

(CN-19) (2) and cab power supply connectors
(CN-20) (3) and (CN-21) (4).
★ After disconnecting the connectors, pull
out the wires from inside of the operator's
cab.
4. Disconnect 4 windshield washer hoses (5).
1
★ After disconnecting the hoses, pull out
them from inside of the operator's cab.
8. Remove mounting bolts (12) on the front side

and mounting bolts (13) inside the operator's
cab.
D275A-5 30-245
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY
9. Remove cigarette lighter cover (14) and dis- INSTALLATION

connect accessory socket wiring connector
CN-D. • Carry out installation in the reverse order
10. Remove garnishes (15), (16), and (17). to removal.
1
★ When connecting the windshield washer
hoses, match the colors of their bands.
11. Remove mounting bolts (18) inside the opera-

tor's cab.
★ Remove the mounting bolts from both
sides and rear side.
12. Lift off operator's cab assembly (19).
Operator’s cab assembly: 420 kg
30-246 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY

SPECIAL TOOLS
New/
Sym Part No. Part Name Nece Qty. Rem Ske
bol ssity tch
odel
799-703-1200 Service tool t 1

kit
Vacuum
799-703-1100 pump t 1
(100 V)
Vacuum
X 799-703-1110 pump t 1
(220 V)
Vacuum
799-703-1120 pump t 1
(240 V) 4. Remove left cover (8), armrest (9), and right
cover (10).
Gas leak
799-703-1401 t 1
detector
REMOVAL

WARNING! Lower the work equipment

to the ground and release the residual
pressure from the piping, referring to
TESTING AND ADJUSTING, Releasing
residual pressure from work equipment 5. Remove bracket (11).
cylinders.
1. Remove the operator's cab. For details, see

REMOVAL OF OPERATOR'S CAB.
2. Remove covers (1), (2), (3), and (4).

101 (5), E21 (6), and E22 (7).
D275A-5 30-247
(7)2
(7)(7)
DISASSEMBLY
7. Disconnect wiring connectors DCL (13) and 12. Lift off floor plate (17).
BRK (14).
buckle. Flower plate: 35 kg
s Before disconnecting the linkage, mea-
1
9. Remove the mounting bolts of lower plate 13. Disconnect brake lever linkage (19).
(16).
10. Remove the mounting bolts of floor plate
(17).
14. Remove cover (20) and duct hose (21).

11. Lift off operator's seat assembly (18). s Loosen the bracket of receiver tank.
s Remove the operator's seat assembly and
lower plate (16) together.
30-248 D275A-5
2
DISASSEMBLY
15. Disconnect receiver tank hose (23) and air 20. Disconnect 5 blade PPC hoses (37), 5 ripper
conditioner compressor hose (24). 2 PPC hoses (38), and accumulator hose (39).
a Discharge the refrigerant (gas) from the 3
air conditioner curcuit before disconnect-
16. Disconnect heater hoses (25) and (26).
a Close the heater hose valve on the engine
side.
a Plug the disconnected hoses.
21. Disconnect floor front support ground wire

(40) on the right side of the machine body.

PWR (28), USB (29), PL4 (30), PL5 (31), PL1
(32), PL2 (33), and FE2 (34).
22. Disconnect 2 front mount bolts (41).

23. Remove 5 rear mount bolts (42) from each
side.
19. Disconnect wiring connectors PPA (35) and

PDS-b (36).
D275A-5 30-249
(7)2
(7)
DISASSEMBLY
24. Lift off floor frame (43).

s Since the connecting positions of the PPC
3
Floor frame: 550 kg hoses are indicated by their clamp colors,

check the clamp colors when connecting
those hoses.
• Blade PPC hose clamp colors
(Dual tilt machine)
Green (44): Solenoid valve hose (Outside of
machine body)
Yellow (45): Solenoid valve hose (Inside of
machine body)
Not colored (46): Work equipment control
valve hose (port PA2)
Black (47): Work equipment control valve
hose (port PB2)
Blue (48): Drain centralized block hose (Rear
side of machine body)
• Ripper PPC hose clamp colors
(Dual tilt machine)
INSTALLATION Brown (49): Work equipment control valve
hose (port PA5)
removal.
hose (port PA4)
White (51): Work equipment control valve
s Adjust the brake pedal. For details, see

1 hose (port PB5)
TESTING AND ADJUSTING, Adjusting valve hose (port PB4)
brake pedal and parking lever. Blue (53): Drain centralized block hose
(Front side of machine body)
s Install each hose so that it will not be

2 • Clamp colors between block and
work equipment control valve (Dual
twisted. tilt machine)
s When installing the air conditioner hoses, Yellow (54): Work equipment control valve
take care that dirt, dust, and water will not hose
enter them. Brown (55): Work equipment control valve
s Before tightening each air conditioner hose
hose connector, check that the O-ring is Green (56): Work equipment control valve
fitted to it. hose
s Apply compressor oil (Showa-Shell, White (57): Work equipment control valve
Suniso 4G or 5G) sufficiently to the O- hose
rings.
Tightening torque for refrigerant gas

pipes
Thread size: Tightening torque
16-1.5 11.8-14.7Nm {1.2-1.5kgm}
22-1.5 19.6-24.5Nm {2-2.5kgm}
24-1.5 29.4-34.3Nm {3-3.5kgm}
30-250 D275A-5
2
DISASSEMBLY
★ Hose clamp colors seen from the right of

the machine body are shown.
• Blade PPC hose clamp colors
(Single tilt machine)
valve hose
hose
Green (58): Work equipment control valve
hose
Yellow (59): Work equipment control
valve hose
• Ripper PPC hose clamp colors
(Single tilt machine)
Brown (49): Work equipment control
valve hose
hose
White (51): Work equipment control valve
hose
valve hose
★ Hose clamp colors seen from the right of

the machine body are shown.

ant gas
D275A-5 30-251
c
DISASSEMBLY REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEM-
AND ASSEMBLY BLY
REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER

ASSEMBLY
REMOVAL

1. Remove operator's seat rear cover (1).
2. Disconnect 3 wiring connectors TMCN1,

TMCN2, and TMCN3 of the transmission con-
troller assembly.
3. Remove the mounting bolts and transmission
controller assembly (2). 1
INSTALLATION
removal.
Screw: 2.82 Nm {0.288 kgm}
30-252 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF STEERING CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF STEERING CONTROLLER

ASSEMBLY
REMOVAL

1. Remove operator's seat rear cover (1).
2. Disconnect 3 wiring connectors STCN1,

STCN2, and STCN3 of the steering controller
assembly.
3. Remove the mounting bolts and steering con-
troller assembly (2). 1
INSTALLATION
removal.
Screw: 2.82 Nm {0.288 kgm}
D275A-5 30-253
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEM-

BLY
REMOVAL

1. Remove operator's seat left rear cover (1).
2. Disconnect 3 wiring connectors ECN1, ECN2,

and ECN3 of the engine controller assembly.
3. Remove the mounting bolts and engine con-
troller assembly (2). 1
INSTALLATION
removal.
★ For the method of changing the fuel injection
Screw: 2.82 Nm {0.288 kgm}
30-254 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY

REMOVAL 4. Remove both side plates (3).
6. Open the left inspection cover of engine hood
assembly (5).
1. Remove mounting bolt of radiator top cover

(1).
7. Loosen the clamp and disconnect air condi-

tioner duct hose (6).
2. Raise the radiator top cover and disconnect

head lamp wiring connector 209 (2).

★ Loosen the bracket of receiver tank (8)
and move it a side.
3. Lift off the radiator top cover.
D275A-5 30-255
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
9. Lift off engine hood assembly (9).

★ Open the 5 locks on both sides before lift-
ing up the engine hood assembly.
Engine hood assembly: 210 kg
INSTALLATION
removal.
30-256 D275A-5
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY
REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY

REMOVAL 4. Sling fan drive assembly (6) temporarily and
remove the mounting bolts.
1. Drain the oil from the hydraulic tank. 5. Sling fan drive assembly (6) temporarily and
remove the mounting bolts. 1
Fan drive assembly: 135 kg
2. Remove the mounting bolts and open fan

guard (1).
INSTALLATION
3. Disconnect fan motor hoses (2), (3), and (4) removal.
and remove plate (5).
★ Plug the openings so that dirt will not
1
enter the piping.
★ If plate (5) is not an obstacle to removal of Upper mounting bolt:
the fan drive assembly, it does not need 235 ~ 285 Nm {23.5 ~ 29.5 kgm}
to be removed.
again.
D275A-5 30-257
c
DISASSEMBLY
AND ASSEMBLY REMOVAL AND INSTALLATION OF FAN MOTOR
REMOVAL AND INSTALLATION OF FAN MOTOR

1. Remove the fan drive assembly. For details, • Carry out installation in the reverse order to
see REMOVAL OF FAN DRIVE ASSEMBLY. removal.
2. Remove bolt (1). 1
1
Mounting bolt:
147 ~ 196 Nm {15 ~ 20 kgm}
2
★ Wipe the tapered fitting parts of the fan
motor shaft and fan to remove all dirt and
dust, and then degrease them.
3. Using puller b, remove fan (2). 2
4. Remove the 4 mounting bolts and fan motor

assembly (3).
Fan motor assembly: 40 kg
30-258 D275A-5
c
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ................................................................................ 90- 2

WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (SINGLE TILT SPEC) .................................... 90- 5
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILT SPEC) ........................................ 90- 5-1
DIAGRAM FOR ELECTRICAL CIRCUIT (1/4) ........................................................................................ 90- 7
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER ......................................................... 90- 15
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB .................................................................................. 90- 16
D275A-5 90-1
(4)
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
1. Main relief valve A. Torque converter relief pressure pick-up port

Set pressure: 3.2 ± 0.1 MPa {32.7 ± 1 kg/cm2} B. 1st clutch pressure pick-up port
2. Torque converter relief valve C. 2nd clutch pressure pick-up port
Set pressure: D. 3rd clutch pressure pick-up port
0.98 ± 0.05 MPa {10.2 ± 0.5 kg/cm2} E. F clutch pressure pick-up port
3. Torque converter F. R clutch pressure pick-up port
4. PTO lubrication G. Left clutch pressure pick-up port
5. Oil cooler H. Left brake pressure pick-up port
6. Pilot filter I. Right brake pressure pick-up port
7. 1st clutch modulating valve (ECMV) J. Right clutch pressure pick-up port
8. 1st clutch
9. 2nd clutch modulating valve (ECMV)
10. 2nd clutch
11. 3rd clutch modulating valve (ECMV)
12. 3rd clutch
13. F clutch modulating valve (ECMV)
14. F clutch
15. R clutch modulating valve (ECMV)
16. R clutch
17. Pin puller cylinder
18. Right clutch
19. Right clutch (ECMV)
20. Right brake
21. Right brake (ECMV)
22. Parking brake valve
23. Sudden brake prevention valve
24. Left brake
25. Left brake (ECMV)
26. Left clutch
27. Left clutch (ECMV)
28. Last-chance filter
29. Clutch and brake lubrication
30. Scavenging pump (BAR(3)140)
31. Transmission lubrication valve
Cracking pressure:
0.3 ± 0.03 MPa {3.0 ± 0.3 kg/cm2}
32. Transmission lubrication
33. Steering lubricating oil filter
Cracking pressure: 0.3 MPa {3.0 kg/cm2}
34. Steering lubricating oil pump (SAR50)
35. Power train pump (SAR100)
36. Power train oil filter BY-PASS VALVE
Cracking pressure: 0.3 MPa {3.0 kg/cm2}
37. Power train oil strainer
38. Torque converter case
39. Transmission oil pan
40. Steering case oil pan
90-2 D275A-5
(7)
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
D275A-5
D275A-5 90-3
(7)
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(SINGLE TILT SPEC)
★ For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.
D275A-5 90-3
90-5
(4)
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(DUAL TILT SPEC)
★ For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.
D275A-5 90-5-1
90-5
(4)
DIAGRAM FOR ELECTRICAL CIRCUIT (1/4)
D275A-5 90-7
(6)
DIAGRAM FOR ELECTRICAL CIRCUIT (2/4))
D275A-5 90-9
(6)
D275A-5 90-11
D275A-5 90-13
(6)
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER
D275A-5 90-15
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB
90-16 D275A-5

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SEBM026308

Machine model Serial number

D275A-5 25001 and up

• D275A-5 mounts the SDA6D140E-3 engine.

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1

20 TESTING AND ADJUSTING ............................................................. 20-1

30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1

90 OTHERS ............................................................................................ 90-1

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

q 00- 1 (8) 10- 9 10-57 10-104 (4) 10-149

30- 89 (2) 30-148 (2) 30-207 (2) 90- 9 (6)

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS