Seb D 027501

SEBM027501
BASE MANUAL
D475A-3
(PALM CONTROL SPECIFICATION)
MACHINE MODEL SERIAL No.

D475A-3 10695 and up
This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
D475A-3 mounts the SDA12V140E-1 engine.

For details of the engine, see the 12V140-1 Series Engine Shop Manual.
2004 1
All Rights Reserved 00-1
Printed in Japan 01-04(01) (1)
CONTENTS
No. of page
01 GENERAL ........................................................................ 01-1
10 STRUCTURE AND FUNCTION ...................................... 10-1
20 TESTING AND ADJUSTING .......................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ................................. 30-1
40 MAINTENANCE STANDARD ......................................... 40-1
90 OTHERS........................................................................... 90-1
00-2 D475A-3
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

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

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

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
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D475A-5 00-2-5
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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 or ide) ,
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 (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
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 0
8 2 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
TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.
mm Nm kgm
1 / 16 0
3 1 0.31 0 0.10
1/8 0
8 2 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
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- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR 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

l
1 = 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

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

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

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

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

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

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

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

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

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

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

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

Specifications ............................................... 01- 4
Weight table ................................................ 01-13
Table of fuel, coolant and lubricants ........ 01-17
D475A-3 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
SPECIFICATION DIMENSION DRAWINGS

SEMI U-TILTDOZER + GIANT RIPPER Unit: mm
U-TILTDOZER + GIANT RIPPER
01-2 D475A-3
GENERAL SPECIFICATION DIMENSION DRAWINGS
SUPER DOZER + COUNTERWEIGHT Unit: mm
D475A-3 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
SEMI U-TILTDOZER, U-TILTDOZER
Machine model D475A-3
Serial No. 10695 and up
Operating weight
Bare tractor 75,700

Weight
With above + semi U-dozer kg 91,850
With above + variable giant ripper 99,150
With above + ROPS cab + air conditioner 100,500

+ perforated side cover
Min. turning radius m 4.6
Gradeability deg 30
Stability (front, rear, left, fight) deg 35
Forward 1st 0 3.5
Forward 2nd km/h 0 6.3

Speed ranges
Forward 3rd 0 10.9

Performance
Reverse 1st 0 4.7
Reverse 2nd km/h 0 8.4
Reverse 3rd 0 14.3
Bare tractor 119 {1.22}

Ground pressure
With semi U-dozer 145.2 {1.48}

kPa
With semi U-dozer + variable giant ripper {kg/cm2} 156 {1.60}
With above + ROPS cab + air conditioner 159 {1.62}

+ perforated side cover
Bare tractor 6,420

Overall length
With semi U-dozer 8,710

mm
With semi U-dozer + variable giant ripper 11,570
With U-dozer + variable giant ripper 11,950

Dimensions
Overall height Overall Width
Bare tractor 3,610
With semi U-dozer mm 5,265
With U-dozer 6,205
To top of ROPS 4,570
To tip of exhaust pipe mm 4,420
To top of intake duct 3,760
01-4 D475A-3
Track gauge 2,770

Dimensions
Length of track on ground 4,365

mm
Track shoe width 710
Min. ground clearance 655
Name SDA12V140E-1
Type 4-cycle, water-cooled, V-type, vertical type,

direct injection, with turbocharger, aftercooler
No. of cylinders bore x stroke mm 12 140 x 165
Piston displacement {cc} 30.48 (30,480)
Rated horsepower kW/rpm {HP/rpm} 641/2,000 {860/2,000}

Performance
Max. torque Nm/rpm {kgm/rpm} 3,825/1,400 {390/1,400}

Engine
Max. speed at no load rpm 2,150
Min. speed at no load rpm 600
Min. fuel consumption ratio g/kWh {g/HPh} 204 {152}
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 75 A
Battery 12 V, 200 Ah x 4
Radiator core type D type
3-element, single stage, single phase

Torque coveter
(with lock up clutch)
Planetary gear type, multiple disc clutch,

Transmission hydraulically actuated, force-feed lubrication
gear pump, forward 3 speed, reverse 3 speed
Power train system
Bevel gear shaft Spiral bevel gear, splash type lubrication
Wet type, multiple clutch disc, spring boosted,

Steering clutch hydraulically actuated (manual type),
interconnected with brake

Steering brake hydraulically actuated (pedal operated,
manually operated), interconnected with clutch
Spur gear 1-stage, planetary gear 1-stage

Final drive
reduction gear, splash type lubrication
D475A-3 01-5
Suspension Rigid, balancing beam type

Undercarriage
Carrier roller 2 on each side
Track roller 7 on each side
Track shoe Assembly type, single grouser, 40 each side,

pitch: 317.5 mm, width: 710 mm
Power train + lubrication pump (tendem) Gear type (BAL160 + 160 + 112)
Scavenging pump (tandem) Gear type (BAR63 + 320)
PPC control pump (tandem with assist pump) Gear type (SAR(1)032)
MPa
Max. pressure 20.6 {210}
{kg/cm2}
Hydraulic
Type Gear type, tandem (SAL(4)140 + (3)100)

pump
Discharge (at engine speed 2,000 rpm) /min 465
Type Gear type (SAR(3)100)

Assist
pump
(tandem with PPC control pump)
Type
Main control
Work equipment hydraulic system
For blade lift 1-spool pilot spool type, with demand spool
valve
For blade tilt, ripper (Lo) 3-spool pilot spool type
For ripper (Hi) 2-spool pilot spool type
Type Double acting, piston type

Dimensions of blade Dimensions of blade
Cylinder bore 180

lift cylinder
Outside diameter of piston rod 110
Piston stroke mm 1,781

Hydraulic cylinders
Max. distance between pins 3,121 (3,121)
Min. distance between pins 1,340 (1,340)
Cylinder bore 250

tilt cylinder
Piston stroke mm 285
Max. distance between pins 1,983
Min. distance between pins 1,698
The figures in ( ) show the dimensions for the U-blade.
01-6 D475A-3
Cylinder bore (both left and right) 250

Dimensions of blade

dual tilt cylinder
(both left and right)
Piston stroke (both left and right) mm 285


Hydraulic cylinders
Dimensions of ripper Dimensions of ripper
Cylinder bore 250

lift cylinder
Cylinder bore 250

tilt cylinder
Control valve assembled type

Hydraulic tank
(externally installed)
Hydraulic semi U-tiltdozer,

Type
Hydraulic U-tiltdozer
Blade support method Brace type
Max. blade lifting height

mm 1,620
(from ground level)
Work equipment
Performance
Max. blade lowering depth

mm 800
(from ground level)
Semi U-dozer
Max. tilt mm 1,250
Blade cutting angle variation deg 6
Blade capacity m3 35.9 <SAE25.6>

Dimensions
Blade width mm 5,265
Blade height mm 2,610
Blade cutting angle deg 52
D475A-3 01-7

mm 1,620
(from ground level)
Performance

mm 800
(from ground level)
Max. tilt mm 1,345

U-dozer

Dimensions Performance Dimensions Performance Performance Performance Dimensions
Blade cutting angle deg 52

Semi U-dozer
Max. tilt mm 1,410

+ pitch
Max. pitch angle deg 6
Max. pitch-back angle deg 6

Work equipment
Max. tilt mm 1,660

U-dozer
+ pitch
Max. pitch angle deg 6
Max. pitch-back angle deg 6
Max. digging depth mm 1,180

Multi-shank ripper
Max. lifting height mm 1,140
Ripping angle of point (standard) deg 45 (adjustable steplessly 32.5 54.0)
Max. width of beam mm 3,080
No. of shanks 3
Max. digging depth mm 1,800
Max. lifting height mm 1,140

Giant ripper
Ripping angle (standard) deg 45 (adjustable steplessly 34 56)
Max. width of beam mm 1,477
No. of shanks 1
01-8 D475A-3
SUPER DOZER
Operating weight
Weight
Bare tractor 75,700

kg
Super dozer + ROPS cab + air conditioner 105,000
+ counterweight
Min. turning radius m 4.6
Gradeability deg 30
Stability (front, rear, left, fight) deg 35
Forward 1st 0 3.5
Forward 2nd km/h 0 6.3

Performance
Speed ranges
Forward 3rd 0 10.9
Reverse 1st 0 4.7
Reverse 2nd km/h 0 8.4
Reverse 3rd 0 14.3

pressure
Bare tractor 104.25 {1.07}

Ground
Super dozer + ROPS cab + air conditioner mm 146.19 {1.49}

+ counterweight
Overall
Width length
Bare tractor 6,420

mm
Super dozer + counterweight 10,370
Overall height Overall
Dimensions
Bare tractor 3,610

mm
With super dozer 6,465
To top of ROPS 4,570
To tip of exhaust pipe mm 4,420
To top of intake duct 3,760
D475A-3 01-9
Track gauge 2,770

Dimensions
Length of track on ground 4,365

mm
Track shoe width 810
Min. ground clearance 655
Name SDA12V140
Type 4-cycle, water-cooled, V-type, vertical type,

direct injection, with turbocharger, aftercooler
No. of cylinders bore x stroke mm 12 140 x 165
Piston displacement {cc} 30.48 (30,480)
Rated horsepower kW/rpm {HP/rpm} 632/2,000 {848/2,000}

Performance
Max. torque Nm/rpm {kgm/rpm} 3,825/1,400 {390/1,400}

Engine
Max. speed at no load rpm 2,150
Min. speed at no load rpm 600
Min. fuel consumption ratio g/kWh {g/HPh} 204 {152}
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 75 A
Battery 12 V, 200 Ah x 4
Radiator core type D type
3-element, single stage, single phase

Torque coveter
(with lock up clutch)
Planetary gear type, multiple disc clutch,

Transmission hydraulically actuated, force-feed lubrication
gear pump, forward 3 speed, reverse 3 speed
Power train system
Bevel gear shaft Spiral bevel gear, splash type lubrication

Steering clutch hydraulically actuated (manual type),
interconnected with brake

Steering brake hydraulically actuated (pedal operated,
manually operated), interconnected with clutch
Spur gear 1-stage, planetary gear 1-stage

Final drive
reduction gear, splash type lubrication
01-10 D475A-3
Suspension Rigid, balancing beam type

Undercarriage
Carrier roller 2 on each side
Track roller 7 on each side
Track shoe Assembly type, single grouser, 40 each side,

pitch: 317.5 mm, width: 810 mm
Power train + lubrication pump (tendem) Gear type (BAL160 + 112 + 112)
Scavenging pump (tandem) Gear type (BAR63 + 280)
PPC control pump (tandem with assist pump) Gear type (SAR(1)032)
MPa
Max. pressure 20.6 {210}
{kg/cm2}
Hydraulic
Type Gear type, tandem (SAL(4)140 + (3)100)

pump
Type Gear type (SAR(3)100)

Assist
pump
(tandem with PPC control pump)

Main control
Type
valve
For blade lift 1-spool pilot spool type, with demand spool
For blade pitch 3-spool pilot spool type
Type Double acting, piston type

Dimensions of blade Dimensions of blade
Cylinder bore 200

lift cylinder
Piston stroke mm 1,781

Hydraulic cylinders
Max. distance between pins 3,121 (3,121)
Min. distance between pins 1,340 (1,340)
Cylinder bore 250

pitch cylinder
Control valve assembled type

Hydraulic tank
(externally installed)
D475A-3 01-11
Type Hydraulic super dozer (pitch dozer)
Blade support method Cylinder type

mm 1,620
(from ground level)
Performance
Work equipment

mm 800
(from ground level)
Super dozer
Max. tilt mm 1,660 (blade tip angle: 52)

Dimensions
Blade cutting angle deg 42 67
01-12 D475A-3
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or when handling components.
SEMI U-TILTDOZER, U-TILTDOZER Unit: kg
Engine, damper assembly 3,940
Engine assembly 3,740
Damper assembly 214
Main radiator assembly 528
Sub. radiator assembly 162
Oil cooler assembly 157
Fuel tank assembly (when full) 858 (2,330)
Power train unit 4,990
Torque converter, PTO assembly 750
Transmission assembly 1,350
Transmission valve assembly 40
Steering clutch, brake assembly 2,295
Steering valve assembly 13
Final drive assembly (each side) 3,575
Main frame assembly 9,120
Track group assembly (each side) 11,180
Track frame (each side) 2,996
Idler assembly (each side) 708
Track roller assembly (single, each) 222
Track roller assembly (double, each) 237
Carrier roller assembly (each) 106
Track shoe assembly (710 mm width) 13,220
Pivot shaft assembly (each side) 370
Equalizer bar 598
Hydraulic tank assembly 498
Main control valve (blade lift) 69
Main control valve (blade tilt, ripper) 46
D475A-3 01-13
Unit: kg
Blade lift cylinder assembly (each side) 445
Blade tilt cylinder assembly 519
Tiltdozer assembly 14,500 (17,700)
Blade 7,420 (10,750)
Straight frame (L.H.) 1,817 (1,817)
Straight frame (R.H.) 1,817 (1,817)
Tilt cylinder assembly 519 (519)
Variable giant ripper assembly 5,698
Shank assembly 1,040
Ripper lift cylinder assembly 386
Ripper tilt cylinder assembly 392
Radiator guard assembly 5,020
Radiator guard 2,280
Radiator mask (with grille) (each side) 99
Engine underguard (front) 267
Engine underguard (rear) 324
Power train underguard (front) 340
Power train underguard (rear) 448
Hood 160
Fender (L.H.) 430
Fender (R.H.) 540
ROPS mount assembly 1,034
ROPS assembly 982
Floor frame assembly 600
Cab assembly 415
Operators seat assembly 64
01-14 D475A-3
SUPER DOZER Unit: kg
Engine, damper assembly 3,940
Engine assembly 3,740
Damper assembly 214
Main radiator assembly 528
Sub. radiator assembly 162
Oil cooler assembly 157
Fuel tank assembly (when full) 858 (2,330)
Power train unit 4,980
Torque converter, PTO assembly 750
Transmission assembly 1,350
Transmission valve assembly 70
Steering clutch, brake assembly 2,290
Steering valve assembly 26
Final drive assembly (each side) 3,575
Main frame assembly 9,120
Track group assembly (each side) 11,180
Track frame (each side) 2,996
Idler assembly (each side) 708
Track roller assembly (single, each) 222
Track roller assembly (double, each) 237
Carrier roller assembly (each) 100
Track shoe assembly (810 mm width) 14,060
Pivot shaft assembly (each side) 370
Equalizer bar 598
Hydraulic tank assembly 498
Main control valve (blade lift) 69
Main control valve (blade tilt, ripper) 46
D475A-3 01-15
Unit: kg
Blade pitch cylinder assembly (each side) 530
Super dozer assembly 19,700
Blade 11,620
Straight frame (L.H.) 1,818
Straight frame (R.H.) 1,818
Pitch cylinder assembly (each side) 530
Counterweight 6,040
Radiator guard assembly 5,020
Radiator guard 2,280
Radiator mask (with grille) (each side) 99
Engine underguard (front) 267
Engine underguard (rear) 324
Power train underguard (front) 340
Power train underguard (rear) 448
Hood 160
Fender (L.H.) 430
Fender (R.H.) 540
ROPS mount assembly 1,034
ROPS assembly 982
Floor frame assembly 600
Cab assembly 415
Operators seat assembly 64
01-16 D475A-3
(1)
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT AND LUBRICANTS
KIND OF AMBIENT TEMPERATURE CAPACITY ()

RESERVOIR 22 4 14 32 50 68 86 104F
FLUID Specified Refill
30 20 10 0 10 20 30 40C
SAE 30
SAE 10W
Engine oil pan 126 121
SAE 10W-30
SAE 15W-40
Power train oil pan
(incl. torque converter, SAE 30
transmission and 410 210
SAE 10W
bevel gear cases)
Damper case 2.4 2.4
Engine SAE 30
Recoil spring oil 145 145
Pivot shaft (each) 24 24
SAE 10W
Hydraulic system SAE 10W-30 420 140
SAE 15W-40
SAE 140
Final drive case (each) SAE 85W-140 75 75
SAE 80W-90
Gear oil
Idler (each) 1.4 1.5 1.4 1.5
Track roller (each) GO 140B 1.4 1.5 1.4 1.5
Carrier roller (each) 1.25 1.35 1.25 135
Diesel ASTM D975 No. 2

Fuel tank 1,670
fuel ASTM D975 No. 1
Main circuit: 230

Cooling system Coolant Add antifreeze
Sub circuit: 65
D475A-3 01-17
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
NOTE:
(1) When fuel sulphur content is less than 0.5 (2) When starting the engine in an atmospheric
%, change oil in the oil pan every periodic temperature of lower than 0C, be sure to
maintenance hours described in this manual. use engine oil of SAE10W, SAE10W-30 and
Change oil according to the following table SAE15W-40, even though an atmospheric
if fuel sulphur content is above 0.5 %. temperature goes up to 10C more or less in
the day time.
Change interval of oil in (3) Use API classification CD as engine oil and if
Fuel sulphur content API classification CC, reduce the engine oil
engine oil pan
change interval to half.
0.5 to 1.0 % 1/2 of regular interval (4) There is no problem if single grade oil is
mixed with multigrade oil (SAE10W-30, 15W-
Above 1.0 % 1/4 of regular interval 40), but be sure to add single grade oil that
matches the temperature in the table on the
left.
(5) We recommend Komatsu genuine oil which
ASTM: American Society of Testing and Material has been specifically formulated and ap-
SAE: Society of Automotive Engineers proved for use in engine and hydraulic work
API: American Petroleum Institute equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-18 D475A-3
10 STRUCTURE AND FUNCTION
Engine, power train cooling system Sudden stop prevention valve ................. 10- 57
drawing ................................................... 10- 2 Final drive ................................................... 10- 58
Power train ................................................... 10- 3 Track frame ................................................. 10- 62
Power train skeleton .................................... 10- 4 Hydraulic tank ............................................ 10- 65
Power train hydraulic piping diagram ....... 10- 5 PPC valve .................................................... 10- 66
Power train hydraulic circuit diagram ....... 10- 6 Main control valve ..................................... 10- 78
Torque converter and PTO ......................... 10- 9 Pin-puller hydraulic system drawing ....... 10- 86
Torque converter valve ............................... 10-16 Pin-puller hydraulic circuit drawing ......... 10- 86
Transmission ................................................ 10-25 Pin-puller solenoid valve ........................... 10- 87
Transmission control ................................... 10-32 Air conditioner ........................................... 10- 89
Transmission ECMV .................................... 10-34 Engine control ............................................ 10- 90
Transmission clutch ECMV ......................... 10-36 Engine control system ............................... 10- 91
Transmission lubrication relief valve ........ 10-40 Deceleration potentiometer ...................... 10- 92
Priority valve ................................................ 10-41 Engine control system with electronic
Steering, brake control ................................ 10-42 engine throttle controller .................... 10- 94
Transfer, bevel gear shaft, steering ........... 10-44 Monitor system .......................................... 10- 96
Transfer, bevel pinion ................................. 10-45 Monitor panel ............................................. 10- 98
Steering ECMV ............................................. 10-48 Mode selection system ............................. 10-106
Steering clutch ECMV, Electrical equipment .................................. 10-112
Steering brake ECMV ............................ 10-50 Steering electronic control ........................ 10-116
D475A-3 10-1
STRUCTURE AND FUNCTION ENGINE, POWER TRAIN COOLING SYSTEM DRAWING
ENGINE, POWER TRAIN COOLING SYSTEM DRAWING
1. Main radiator Outline

2. Sub radiator The radiator consists of two systems: The
3. Turbocharger main radiator and sub radiator.
4. Aftercooler The main radiator system carries out cool-
5. Engine ing for the engine and power train oil cooler;
6. Power train oil cooler the sub radiator system carries out cooling
7. Water pump (for main radiator) for the aftercooler.
8. Water pump (for sub radiator) There are water pumps for each system.
10-2 D475A-3
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
Outline
The power generated by engine (1) has its speed reduced. Its speed is further reduced
torsional vibration dampened by damper (2), by the bevel pinion and bevel gear of the
and then passes through universal joint (3), bevel gear shaft, and it is then divided at
and is transmitted to torque converter (7). right angles to the left and right and trans-
The power from the engine is transmitted mitted to the respective steering clutches
through oil by torque converter (7) to the (9). The power transmitted from the bevel
input shaft (turbine shaft) of transmission gear shaft to the final drive is used to steer
(8) in accordance with the change in the load. the machine by engaging or disengaging
There is a lock-up clutch assembled to the steering clutch (9).
torque converter, and when the rotating The steering lever is operated to disengage
speed beyond the torque converter becomes the steering clutch on the side to which the
higher, the lock-up clutch is engaged. When machine is to be steered in order to change
this happens, the drive case and turbine form the direction of travel. The size of the turn-
one unit, so the power from the engine is ing radius is controlled by steering brake
transmitted directly to the transmission in- (10) installed to the outside of the steering
put shaft. clutch.
Transmission (8) uses a combination of a Steering brake (10) uses the same disc sys-
planetary gear system and hydraulic equip- tem that is used for the steering clutch.
ment to reduce the speed and shift the gears The power output from the steering clutch
(forward: 3 gears, reverse: 3 gears). It con- enters final drive (11), where it is reduced,
nects two sets of clutches selected with the and rotates sprocket (12).
gear shift lever according to the change in Final drive is a double reduction type con-
the load, and transmits the power from the sisting of a single stage spur gear and single
transmission to transfer (14) from output stage planetary gear system.
shaft. It rotates the sprocket to drive track shoe
The power entering transfer (14) has its (13) and move the machine.
D475A-3 10-3
STRUCTURE AND FUNCTION POWER TRAIN SKELETON
POWER TRAIN SKELETON
1. Engine (SDA12V140) 6. Hydraulic pump 11. Final drive 17. Bevel gear
2. Damper (SAR100+32) 12. Sproket 18. PTO
3. Universal joint 7. Torque converter 13. Track shoe 19. Scavenging pump
4. Power train, hydraulic, 8. Transmission 14. Transfer
lubricating pump 9. Steering clutch 15. Transfer drive gear
(BAL160+160+112) 10. Steering brake 16. Bevel pinion
5. Hydraulic pump
(SAL140+100)
10-4 D475A-3
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC PIPING DIAGRAM
POWER TRAIN HYDRAULIC PIPING DIAGRAM
1. Torque converter oil filter a. Torque converter inlet pressure pick-up port (IN)
2. Power train oil filter b. Torque converter lock-up pressure pick-up port (LU)
3. Power train lubricating oil filter c. Transmission relief pressure pick-up port (TM)
4. Torque converter valve d. Transmission reverse clutch pressure pick-up port
5. Transmission control valve (REV)
6. Steering control valve e. Transmission forward clutch pressure pick-up port
7. Power train oil strainer (FWD)
8. Oil tank f. Left clutch pressure pick-up port (LC)
9. Power train pump (BAL160+160+112) g. Left brake pressure pick-up port (LB)
10. Scavenging pump h. Right brake pressure pick-up port (RB)
11. Power train oil cooler i. Right clutch pressure pick-up port (RC)
j. Transmission 1st clutch pressure pick-up port (1st)
k. Transmission 2nd clutch pressure pick-up port (2nd)
l. Transmission 3rd clutch pressure pick-up port (3rd)
m. Torque converter stator clutch pressure (SC)
n. Torque converter outlet pressure pick-up port (OUT)
D475A-3 10-5
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
10-6 D475A-3
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
1. Oil tank A. Transmission main relief pressure pickup port

2. Power train oil strainer B. Transmission reducing pressure pickup port
3. Power train pump C. Transmission pilot pressure pickup port
4. Torque converter charge pump D. Torque converter relief pressure pickup port
5. Power train lubrication pump E. Torque converter regulator pressure pickup
6. Power train oil filter port
7. Torque converter oil filter F. Torque converter lockup pressure pickup port
8. Power train lubrication oil filter G. Torque converter stator clutch pressure
9. Main relief valve pickup port
10. Priority valve H. R.H. steering clutch pressure pickup port
11. Modulating valve I. R.H. steering brake pressure pickup port
12. Quick return valve J. L.H. steering brake pressure pickup port
13. Reducing valve K. L.H. steering clutch pressure pickup port
14. Pilot valve L. Reverse oil pressure switch
15. Reverse spool M. Forward oil pressure switch
16. Forward spool N. 3rd speed oil pressure switch
17. 3rd speed spool O. 2nd speed oil pressure switch
18. 2nd speed spool P. 1st speed oil pressure switch
19. 1st speed spool Q. Modulating oil pressure sensor
20. Transmission speed spool
21. Transmission F-R spool
22. Reverse clutch
23. Forward clutch
24. 3rd clutch
25. 2nd clutch
26. 1st clutch
27. Torque converter relief valve
28. Torque converter
29. Oil cooler
30. Steering clutch and brake lubrication
31. Torque converter case
32. Torque converter lock-up valve
33. Modulating valve
34. Torque converter lock-up clutch
35. Modulating valve
36. Stator clutch
37. Torque converter lock-up solenoid valve
38. Steering check valve
39. R.H. steering valve
40. R.H. brake valve
41. L.H. brake valve
42. L.H. steering valve
43. Steering clutch
44. Steering brake
45. Steering case
46. Transmission lubrication valve
47. Transmission lubrication
48. PTO Lubrication
49. Scavenging pump
50. Solenoid for pin puller
D475A-3 10-7
STRUCTURE AND FUNCTION TORQUE CONVERTER AND PTO
TORQUE CONVERTER AND PTO
A. Power train pump installed position

B. Scavenging pump installed position
C. Assist pump installed position
D. Hydraulict pump installed position
D475A-3 10-9
10-9
(1)
10-10 D475A-3
1. Coupling
2. Seal cage
3. Input shaft (59 teeth)
4. Front housing
5. Idler gear (74 teeth)
6. Idler gear shaft
7. Clutch housing
8. Drive case
9. Turbine
10. Rear housing
11. Stator
12. Pump
13. Stator shaft
14. Bearing cage
15. Retainer
16. Shaft
17. Transmission input shaft
18. Stator shaft boss
19. Stator clutch housing
20. Return spring
21. Stator clutch plate
22. Stator clutch disc
23. Stator clutch piston
24. Turbine boss
25. Lock-up clutch disc
26. Lock-up clutch plate
27. Lock-up clutch piston
28. Scavenging pump gear (65 teeth)
29. Seal seat
30. Spacer
31. Cover
32. Hydraulic pump gear (61 teeth)
33. Power train pump drive gear (61 teeth)
34. Drive shaft
35. Cover
D475A-3 10-11
Outline Structure
The torque converter is a 3-element, single-stage, Pump (12) forms one unit with coupling
1-phase torque converter, and it forms a single (1), shaft (3), clutch housing (7), and drive
structure with the transmission. case (8), and is rotated by the power from
To improve the fuel consumption and ease of the engine.
operation and to reduce consumption of the Turbine (9) forms one unit with turbine
engine horsepower, a wet-type, multiple-disc boss (24) and transmission input shaft (tur-
clutch type torque converter lock-up device and bine shaft) (17), and is rotated by oil from
a wet-type, double-disc stator clutch device are the pump.
assembled inside it. Stator (11) forms one unit with stator shaft
When the machine is carrying out continuous (13) and stator shaft boss (18), and is
low-load dozing or grading operations, it is more locked to rear housing (10) by the stator
efficient if the power of the engine is transmit- clutch.
ted directly to the transmission input shaft. The lock-up clutch consists of three parts:
To achieve this, a lock-up clutch actuated by clutch plate (26) (meshed with drive case
hydraulic pressure is assembled inside the (8)), clutch disc (25) (meshed with turbine
torque converter. boss (24)), and clutch piston (27) (that
When the torque converter is locked up (the slides inside housing (7), which forms one
pump and turbine form one unit), the oil sup- unit with the drive case).
plied from the torque converter relief valve does The stator clutch consists of three parts:
not stop, so the oil leaving the turbine from the clutch disc (22) (meshed with boss (18)
pump is given unneeded direction by the stator, that is connected by a spline to stator
and this resists the rotation of the pump and shaft (13)), clutch plate (21) (supported by
turbine (the oil is churned). a pin to clutch housing (19) and rear hous-
To prevent this, a stator clutch similar to the ing (10)), and clutch piston (23) (that slides
lock-up clutch is built in. This allows the stator inside the rear housing).
to rotate freely when the torque converter is The PTO consists of input shaft (3), idler
locked up. The oil then moves together with gear (5), scavenging pump drive gear (28),
rotation of the pump and turbine; it is discharged hydraulic pump drive gear (32), and power
from the pump and turbine with little resistance, train pump drive gear (33).
and is returned to the pump.
The condition for the torque converter to enter
the lock-up range and torque converter range
are as follows.
Lock-up range
When both of the following conditions are ful-
filled:
Torque converter output shaft speed:
Above 1,360 rpm
Transmission set pressure:
Above 1.96 MPa {20 kg/cm2}
Torque converter range
When either of the following conditions are ful-
filled.
Torque converter output shaft speed:
Below 1,330 rpm
Transmission set pressure:
Below 1.5 MPa {15 kg/cm2}
10-12 D475A-3
Path of transmission of motive force

1. Lock-up clutch OFF, stator clutch ON
When lock-up clutch (25) is OFF, the connection
between drive case (8) and turbine (9) is cut;
and when stator clutch (22) is ON, rear housing
(10) and stator shaft (13) are connected, so stator
(11) is locked and the torque converter provides
the normal functions of a torque converter.
The power generated by the engine passes
through the damper and universal joint, and is
transmitted to coupling (1). Input shaft (3), clutch
housing (7), drive case (8), and pump (12) rotate
as one unit.
The motive force from the pump uses oil to
rotate turbine (9), and is transmitted to trans-
mission input shaft (17), which forms one unit
with the turbine.
2. Lock-up clutch ON, stator clutch OFF

When lock-up clutch (25) is ON, drive case (8)
and turbine (9) are connected to form one unit;
and when stator clutch (22) is OFF, the connec-
tion between rear housing (10) and stator shaft
(13) is cut, so stator (11) follows the rotation of
pump (12) and turbine (9).
The power generated by the engine passes
through the damper and universal joint, and is
transmitted to coupling (1). Input shaft (3), clutch
housing (7), drive case (8), and pump (12) rotate
as one unit. In addition, the drive case and tur-
bine (9) are connected by the clutch, so the oil is
not used. The motive force is transmitted di-
rectly to the turbine and transmission input shaft
(17).
D475A-3 10-13
Flow of oil
Oil set to within 0.87 MPa {8.7 kg/cm2} by the
torque converter relief valve flows from port A,
passes through the oil hole inside rear housing
(10), and enters pump (12).
The pump is always being rotated by the power
from the engine, so the oil entering the pump is
given centrifugal force, and enters turbine (9).
The turbine is rotated by the centrifugal force of
the oil.
The turbine forms one unit with transmission
input shaft (17), so the motive force received by
the turbine is transmitted to the transmission.
The oil leaving the turbine is sent to stator (11)
and enters the pump again, but some of the oil
passes from the stator through port B and is
sent to the oil cooler.
10-14 D475A-3
STRUCTURE AND FUNCTION TTORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
1. Valve body 16. Valve spring (Outer) 32. Valve seat

2. Torque converter relief 17. Valve spring (Inner) 33. Spring
valve 18. Stopper 34. Valve seat
3. Valve spring 19. Load piston 35. Cap
4. Valve spring 20. Cover
5. Main relief valve 21. Cover P. Stator clutch pressure
6. Cover 22. Valve spring pickup port
7. Piston 23. Valve body P3. Lock-up clutch pressure
8. Piston spring 24. Lock-up selector valve pickup port
9. Piston 25. Piston P8. Main relief pressure
10. Stator clutch modulating 26. Cover pickup port
valve Lock-up solenoid valve P10. Lock-up clutch initial
11. Lock-up clutch modulating assembly pressure pickup port
valve 27. Cover P11. Stator clutch initial
12. Cover 28. Coil pressure pickup port
13. Piston 29. Spring T. From torque converter
14. Piston spring (Small) 30. Plunger pump
15. Piston 31. Valve seat holder
10-16 D475A-3
1 2 3 4 5 6 21 22 23 24 25 26
10 EE
11
12 27
28
13
29
30
20 19 18 17 16 15 14 31
32
DD 33
34
35
SBD00662
Outline
The torque converter valve is installed at the 4. Torque converter lock-up solenoid valve
top of the rear housing of the torque con- Solenoid valve receives an electrical signal
verter and consists of the following six types from the lock-up controller and switches the
of valves. pilot pressure to lock-up selector valve (24).
1. Main relief valve It operates lock-up selector valve (24) and
Main relief valve (5) sets the hydraulic pres- switches the two clutches ON OFF.
sure to 2.7 3.0 MPa {27.0 30.4 kg/cm2} in 5. Stator clutch modulating valve
the transmission, steering clutch, brake and Modulating valve (10) sets the clutch pres-
torque converter lock-up clutch, and stator sure to 2.7 MPa {27 kg/cm2} to protect the
clutch circuits. stator clutch from abnormally high pressure
2. Torque converter relief valve and acts to raise the pressure of oil from
Torque converter relief valve (2) sets the in- lock-up selector valve (24) gradually until it
let pressure of the torque converter to within reaches the set pressure.
0.87 MPa {8.7 kg/cm2} to protect the torque 6. Lock-up clutch modulating valve
converter from abnormally high pressure. Modulating valve (11) acts in the same way
3. Torque converter lock-up valve as stator clutch modulating valve (10) and
Lock-up selector valve (24) acts to switch sets the clutch pressure to 1.3 MPa {13 kg/
the lock-up clutch and stator clutch ON cm2} to protect the stator clutch from ab-
OFF. normally high pressure.
D475A-3 10-17
To torque
converter To oil tank
2
Operation of main relief valve E
The oil from the power train pump passes 3
through the oil filter, and enters port A of D
the main relief valve. It then passes through
orifice a and enters port B.
When the oil from the pump fills the circuit, 9 A
the pressure starts to rise.
b
When the pressure in the circuit rises, the
oil entering port B pushes piston (9). The 5
reaction force compresses spring (4), moves C 9
main relief valve (5) to the left in the direc-
tion of the arrow, and opens ports A and C.
When this happens, the oil from the pump B
is relieved from port A to port C, and flows 4
port C to the torque converter. a
The pressure in the circuit at this point is 2.7
From pump SBD00663
3.0 MPa {27.0 30.4 kg/cm2}. To torque
Operation of torque converter relief valve 2
The oil relieved from the main relief valve E
and the oil from torque converter charge 3
pump flows into the torque converter from D
port C, and at the same time passes through
orifice b and enters port D.
When the oil fills the torque converter, the 9 A
pressure starts to rise.
b
5
C 9
B
4
a
From pump
20 SBD00664
To torque
If the pressure in the torque converter rises
2
abnormally high, the oil entering port D
pushes piston (9). The reaction force com- E
presses spring (3), moves relief valve (2) to 3
D
the right in the direction of the arrow, and
opens ports C and E.
When this happens, the oil at port C is re- 9
lieved to port E, and is drained to the oil A
tank. b
The pressure in the circuit at this point is 5
below 0.87 MPa {8.7 kg/cm2}.
C 9
B
4
a
From pump SBD00665
10-18 D475A-3
Operation of torque converter lock-up valve,

solenoid valve
The torque converter lock-up valve supplies
oil to switch the lock-up and stator clutch
built into the torque converter ON OFF.
The lock-up valve is actuated by the pilot
pressure from the solenoid valve that is ac-
tuated when it receives an electrical signal
from the lock-up controller.
When the lock-up switch on the panel at the
front of the operators compartment is
pressed ON (the indicator lamp inside the
switch lights up), the auto-lock-up system is
actuated, and when the torque converter
reaches the lock-up range, the lock-up con-
troller, which has received signals from the
two sensors, connects the solenoid to the
ground and current flows. The hydraulic cir-
cuit is switched and pilot pressure is sent to
the lock-up valve to lock up the torque con-
verter.
D475A-3 10-19
1. Travel in torque converter drive
When the machine is in the torque converter The oil from the pump flows ports P and N into
range, the solenoid valve is DEACTIVATED, so port L of the lock-up valve. When the pressure
valves (32) is pushed to the left in the direction inside the circuit rises, piston (25) is pushed to
of the arrow by the tension of spring (29). Ports the left in the direction of the arrow, and the
N and P open. piston pushes out lock-up selector valve (24) to
the left.
10-20 D475A-3
When lock-up selector valve (24) moves to the pressure of the stator clutch piston. When the
left in the direction of the arrow, ports F and G pressure in the circuit rises, the stator clutch is
and ports H and K close, and ports F and H and engaged.
ports G and J open. At the same time, the oil that is the back pressure
When this happens, the oil from the pump flows of the lock-up clutch piston is drained from port
from port F to port H, and becomes the back G to port J, and the lock-up clutch is disengaged.
2. Travel in direct drive
When the machine is in the direct drive range, Ports F and H and ports G and J close, and
the solenoid valve is EXCITED, so plunger (30) ports F and G and ports H and K open.
is pushed to the right in the direction of the When this happens, the oil from the pump flows
arrow and valve (32) is moved. Port P closes from port F to port G, and becomes the back
and ports N and M open. pressure of the lock-up clutch piston. When the
When this happens, oil from the pump stops at pressure in the circuit rises, the lock-up clutch is
P. The high-pressure oil at port L is drained engaged.
from port N to port M. At the same time, the oil that is the back pressure
When the pilot pressure at port L is lost, piston of the stator clutch piston is drained from port H
(25) and lock-up selector valve (24) are returned to port K, and the stator clutch is disengaged.
to the right in the direction of the arrow by the
tension of spring (22).
D475A-3 10-21
Operation of stator clutch, lock-up clutch modu-

lating valve
The modulating valves are in the circuit be-
tween the lock-up selector valve and the in-
let ports of the two sets of clutches. When
the clutch is switched ON, the modulating
valve acts to raise the pressure on the pis-
ton gradually until it reaches the set pres-
sure so that the clutch is engaged smoothly,
thereby reducing any shock to the torque
converter or transmission.
The following explanation of operation takes
the stator clutch as the example, but the
operation of the lock-up clutch is the same.
However, the oil flow to the clutch during
direct drive or torque converter drive is the
reverse.
1. Travel in direct drive

When the machine enters the direct drive
range, the oil at port L of lock-up selector
valve (24) returns to the solenoid valve and
is drained.
When this happens, lock-up selector valve
(24) is pushed to the right in the direction of
the arrow by the tension of spring (22). Ports
F and H close, and ports H and K open, and
the oil at port H is drained from port K.
When the hydraulic pressure at port H is
lost, modulating valve (10) is returned to the
right in the direction of the arrow by the
tension of spring (16), and ports H and Q
open fully. At this point, the actuating pres-
sure of the stator clutch is drained from port
H to port K, and the clutch is disengaged.
10-22 D475A-3
2. Travel in torque converter drive

When the machine is in the torque converter
drive range, the oil from the solenoid valve
enters port L of lock-up selector valve (24)
and moves the lock-up selector valve to the
left in the direction of the arrow. Ports F and
G, and ports H and K close, and ports F and
H open. A circuit is then formed from port F
through modulating valve (10) to the stator
clutch. The oil from the pump flows from
port F to the stator clutch, and the pressure
in the circuit starts to rise.
As the hydraulic pressure in the circuit rises,

the oil passing through orifice d in modulat-
ing valve (10) pushes piston (13), and the
reaction force moves the modulating valve
to the left in the direction of the arrow to
throttle ports Q and H.
Port Q is connected with port S that applies
back pressure to load piston (19), and moves
the load piston to the right in the direction
of the arrow to compress spring (16). The
tension of spring opens port Q and H. This
operation is repeated intermittently to in-
crease the load of spring (16). While this is
happening, the hydraulic pressure gradually
increases, and finally stops at the position
where ports Q and H are closed to complete
the rise in hydraulic pressure.
The hydraulic pressure at this point is 2.5
0.1 MPa {25 1 kg/cm2}.
The hydraulic pressure of the lock-up clutch
is 1.3 +0.1 +1 2
+0 MPa {13 +0 kg/cm }.
D475A-3 10-23
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
1. Input shaft
2. Transmission ECMV
3. Front case
4. Rear case
D475A-3 10-25
10-26 D475A-3
5. Front cover
6. Sun gear for REVERSE (32 teeth)
7. Ring gear for REVERSE (89 teeth)
8. Pinion shaft
9. Planet pinion for REVERSE (25 teeth)
10. Ring gear for REVERSE (82 teeth)
11. Pinion shaft
12. Ring gear for FORWARD (89 teeth)
13. Planet pinion for FORWARD (25 teeth)
14. Sun gear for FORWARD (39 teeth)
15. Ring gear for 3rd (89 teeth)
16. Planet pinion for 3rd (25 teeth)
17. Sun gear for 3rd (39 teeth)
18. Ring gear for 2nd (89 teeth)
19. Planet pinion for 2nd (21 teeth)
20. Pinion shaft
21. Sun gear for 2nd (47 teeth)
22. Carrier for 2nd
23. 1st clutch inner drum
24. 1st clutch piston
25. 1st clutch piston housing
26. Output shaft
27. Collar
28. Drive shaft (for sensor)
29. 2nd clutch piston
30. Piston housing for 2nd
31. Carrier for FORWARD, 3rd
32. 3rd clutch piston
33. Piston housing for FORWARD, 3rd
34. Clutch piston for FORWARD
35. Carrier for REVERSE
36. Piston housing for REVERSE
37. REVERSE clutch piston
38. Tie rod pin
39. Clutch spring
40. Washer spring
41. Clutch disc
42. Tie bolt
43. Clutch plate
D475A-3 10-27
Outline
The transmission is a forward 3 gear, reverse
3 gear transmission that consists of a com-
bination of a planetary gear system and disc
clutches.
The transmission actuates the control valve
to use hydraulic pressure to fix two of the
clutches in the five sets of planetary gears
and disc clutches to select one rotating
direction and one gear speed.
The clutches are locked as follows: No. 1
clutch for REVERSE, No. 2 clutch for
FORWARD, No. 3 clutch for 3rd, No. 4 clutch
for 2nd and No. 5 clutch for 1st.
No. of plates and discs used
Clutch No. No. of plates No. of discs
No. 1 clutch 6 7
No. 2 clutch 6 7
No. 3 clutch 4 5
No. 4 clutch 3 4
No. 5 clutch 5 6
Gear speed, clutch combination
Gear speed Clutch combination (engaged)
FORWARD
1st No. 2 No. 5
2nd No. 2 No. 4
3rd No. 2 No. 3
NEUTRAL No.5
REVERSE
1st No. 1 No. 5
2nd No. 1 No. 4
3rd No. 1 No. 3
10-28 D475A-3
Operation of disc clutch

To lock ring gear (7), a disc clutch is used.
The clutch consists of piston (36), plates (38),
discs (39), pins (42) and piston return springs
(37).
The internal teeth of the disc engage with
the external teeth of the ring gear.
The teeth on the outside diameter of the
plate engage with pins (42) secured by hous-
ing (35).
Clutch engaged (locked)

Oil from the control valve flows under pres-
sure through the port in housing (35) to the
back of piston (36). The piston presses plates
(38) and discs (39) together, and the result-
ing frictional force stops the rotation of discs
(39), so ring gear (7) meshing with the inter-
nal teeth of the disc is locked.
Clutch disengaged (free)

When the supply of pressure oil from the
control valve is shut off, piston (36) is re-
turned to its original position by the force of
piston return spring (37). This relieves the
frictional force between plates (38) and discs
(39), making ring gear (7) free.
Washer spring (43) installed between the
plates at the pin acts to speed up the return
of the piston when the clutch is disengaged,
and also to separate the plate and disc
cleanly to prevent continued rotation.
D475A-3 10-29
OPERATION OF TRANSMISSION
FORWARD 1ST
For FORWARD 1st, No. 2 clutch and No. 5 Ring gear (13) is locked in position by No. 2
clutch are engaged. The motive force trans- clutch, so planet pinion (12) rotates carrier
mitted from the torque converter to input (32), which is on the inside of ring gear (13).
shaft (1) is transmitted to output shaft (25). No. 5 clutch is also engaged, so the No. 5
No. 2 clutch is actuated by the hydraulic gear (22), sun gears (17) and (21), planet
pressure applied by the clutch piston and pinions, ring gears (15) and (18), and No. 4
locks ring gear (13) in position. No. 5 clutch carrier (30) form one unit. In addition, car-
is actuated by hydraulic pressure applied by rier (32) rotates as one unit with the gears of
the clutch piston and engages No. 5 gear No. 3, 4 and 5 clutches to rotate output shaft
(22) and No. 4 ring gear (18). (25).
The motive force from the torque converter Output shaft (25) rotates at the same speed
is transmitted to input shaft (1). The rotation as carrier (32).
of the input shaft is transmitted through sun
gear (11) to planet pinion (12).
10-30 D475A-3
REVERSE 1ST
For REVERSE 1st, No. 1 clutch and No. 5 Carrier (34) is locked in position by No. 1
clutch are engaged. The motive force trans- clutch, so the rotation of planet pinion (9)
mitted from the torque converter to input rotates ring gear (10).
shaft (1) is transmitted to output shaft (25). Ring gear (10) rotates in the opposite direc-
No. 1 clutch is actuated by the hydraulic tion from the input shaft, and it rotates car-
pressure applied by the clutch piston and rier (32).
locks carrier (34) in position. No. 5 clutch is No. 5 clutch is engaged, so No. 5 gear (22),
actuated by hydraulic pressure applied by sun gears (17) and (21), planet pinions, ring
the clutch piston and engages No. 5 gear gears (15) and (18), and No. 4 carrier (30)
(22) and No. 4 ring gear (18). form one unit.
The motive force from the torque converter In addition, carrier (32) rotates as one unit
is transmitted to input shaft (1). The rotation with the gears of No. 3, 4 and 5 clutches to
of the input shaft is transmitted through sun rotate output shaft (25).
gear (6) to planet pinion (9).
D475A-3 10-31
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL
For steering operation concerned to opera- PCCS: Abbreviation for Palm Command Con-
tion of the Palm Command Steering Control trol System
lever (PCCS lever), see STEERING AND BRAKE
CONTROL.
1. Brake pedal Lever or switch positions

2. Safety lever 1: Neutral
3. PCCS lever (Forward-Reverse, gear shift) 2: OFF
3A. FORWARD switch 3: Forward
(Machine travels forward when this switch 4: Reverse
is pressed.) 5: Neutral
3B. REVERSE switch 6: Shift UP/DOWN
(Machine travels reverse when this switch 7: Free
is pressed.) 8: Lock
3C. SHIFT switch
(Gear is shifted to 1st 2nd 1st each
time this switch is pressed.) Outline
4. NEUTRAL switch The transmission is controlled with PCCS le-
5. Transmission neutral safety switch ver (3) and NEUTRAL switch (4).
6. Cable The PCCS lever is used to select the travel
7. Transmission control valve direction and shift the gear.
Since the safety mechanism is employed,
transmission neutral safety switch (5) does
not work and the engine does not start un-
less safety lever (2) is in the LOCK position.
10-32 D475A-3
STRUCTURE AND FUNCTION TRANSMISSION ECMV
TRANSMISSION ECMV
(Electronic Control Modulation Valve)
10-34 D475A-3
STRUCTURE AND FUNCTION TRANSMISSION ECMV
A: 1st clutch pressure detection port

B: 2nd clutch pressure detection port
C: 3rd clutch pressure detection port
D: F clutch pressure detection port
E: R clutch pressure detection port
1. Filter
2. Priority valve
3. Transmission lubrication relief valve
4. 1st clutch ECMV
5. 2nd clutch ECMV
6. 3rd clutch ECMV
7. F clutch ECMV
8. R clutch ECMV
9. Valve seat
D475A-3 10-35
STRUCTURE AND FUNCTION TRANSMISSION CLUTCH ECMV
TRANSMISSION CLUTCH ECMV

A: To clutch 1. Fill switch connector

B: From pump 2. Proportional solenoid connector
T: Drain 3. Pressure detection valve
Dr: Drain 4. Fill switch
P1: Clutch pressure detection port 5. Proportional solenoid
P2: Pilot pressure detection port 6. Pressure control valve
10-36 D475A-3
OUTLINE OF ECMV ECMV and proportional solenoid

The ECMV (Electronic Control Modulation Valve) There is one proportional solenoid installed
consists of two components: the pressure con- to each ECMV.
trol valve and the fill switch. It generates propulsion as shown in the dia-
Pressure control valve gram below according to the command cur-
The proportional solenoid receives the flow rent from the controller.
of electricity sent from the transmission con- The propulsion generated by the proportional
troller, and the pressure control valve con- solenoid acts on the pressure control valve
verts this into hydraulic pressure. spool and generates oil pressure as shown
Fill switch in the diagram below. In this way, the com-
This detects when oil has filled the clutch. It mand current is controlled and the propul-
has the following functions. sion force varies to actuate the pressure con-
1) When the clutch is filled with oil, it sends trol valve and control the oil flow and oil
a signal (fill signal) to the controller to pressure.
inform the controller that the filling is
completed.
2) While oil pressure is applied to the clutch,
it outputs a signal (fill signal) to the con-
troller to inform the controller of the ex-
istence of the oil pressure.
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
ECMV and fill switch

There is one fill switch installed to each
ECMV.
When the filling of the clutch is completed,
the fill switch is turned on by the clutch pres-
sure. With this signal, the oil pressure starts
to build up.
D475A-3 10-37
OPERATION OF ECMV 1. When gear shifting (during draining)

The ECMV is controlled by the command (Range A in graph)
current from the transmission controller to When no current is flowing to proportional
the proportional solenoid and the fill switch solenoid (1), pressure control valve spool (3)
output signal. drains the oil at clutch port A through drain
The relationship between the ECMV propor- port Dr.
tional solenoid command current and the When this happens, there is no hydraulic
clutch input pressure and fill switch output force acting on pressure detection valve (4),
signal is as shown in the diagram below. so fill switch (6) is turned OFF.
A range: Before gear shifting (drained)

B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
10-38 D475A-3
STRUCTURE AND FUNCTION TTRANSMISSION CLUTCH ECMV
2. When filling (when trigger command is in- 3. Adjusting pressure (Range D in graph)
put to pressure control valve) When electric current flows to proportional
(Range B and C in graph) solenoid (1), the solenoid generates a pro-
When there is no oil inside the clutch, if elec- pulsion force proportional to the current. The
tric current is applied to proportional sole- pressure is adjusted so that the total of this
noid (1), a hydraulic force balancing the force propulsion force of the solenoid, the propul-
of the solenoid acts on chamber B, and pression force of the oil pressure at the clutch
sure control valve spool (3) moves to the left. port, and the reaction force of pressure con-
As a result, the circuit between pump port P trol valve spring (2) is balanced.
and clutch port A opens, and oil starts to fill
the clutch. When the clutch is filled with oil,
fill switch (6) is turned ON.
D475A-3 10-39
STRUCTURE AND FUNCTION TRANSMISSION LUBRICATION RELIEF VALVE
TRANSMISSION LUBRICATION RELIEF VALVE
1. Lubrication oil pressure measurement plug Function

2. Lubrication relief spool The lubrication relief valve is installed to the
3. Valve body right side face of the transmission, and acts
to prevent any abnormal pressure in the trans-
mission lubricating oil.
Cracking pressure: 0.26 MPa {2.7 kg/cm2}
10-40 D475A-3
STRUCTURE AND FUNCTION PRIORITY VALVE
PRIORITY VALVE
Outline
The priority valve is installed on the circuit
between the pump and the clutch ECMV.
When the transmission circuit hydraulic pres-
sure drops drastically during gear shifting,
this valve closes the passages of the trans-
mission and pilot circuits to keep the hy-
draulic pressure of the pilot circuit operating
five clutch ECMVs, enabling it to endure gear
shifting operation.
Operation
1. During gear shifting
The oil enters priority valve port A from the
pump, then chamber C via orifice a.
As the oil flow rate increases the hydraulic
pressure inside the chamber C rises, caus-
ing the oil to push piston (1), and its reac-
tion force retracts spring (2) to move valve
(3) to the left.
Subsequently, ports A and B are opened, al-
lowing the oil to flow from port B to the
ECMV. At this time, the hydraulic pressure
(cracking pressure) is 1.13 MPa {11.5 kg/cm2},
and the oil flowing from port B to the ECMV
raises the clutch set pressure up to 2.65 MPa
{27 kg/cm2}.
2. Immediately after gear shifting

Operating the gear shift lever causes the
ECMV to reduce the hydraulic pressure be-
hind port B drastically to almost zero.
This also causes the hydraulic pressure of
port A to fall, and when it falls below 1.13
MPa {11.5 kg/cm2}, valve (3) is turned back
to the right by the tension of spring (2) to
close passages A and B.
This prevents the hydraulic pressure of port
A (pilot valve port pressure) from falling any
more, enabling to keep the pilot pressure
1.13 MPa {11.5 kg/cm2} (the specified pres-
sure) or more.
D475A-3 10-41
STRUCTURE AND FUNCTION STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL

Regarding the transmission-related descrip-
tion of the operation of the PCCS lever, refer
to the Transmission Control.
PCCS: Palm Command Control System
10-42 D475A-3
STRUCTURE AND FUNCTION STEERING, BRAKE CONTROL
1. Brake pedal Positions of lever and pedal

2. Safety lever 1: Neutral
3. PCCS lever (Steering) 2: Forward straight-travel
4. Steering controller 3: Reverse straight-travel
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 RELEASE
9: Brake ON
0: Free
A: Lock
Outline
PCCS lever (3) sends an electric signal to If you completely tilt PCCS lever (3) leftward,
steering controller (4). After receiving it, the left steering clutch is turned OFF com-
steering controller (4) sends a proportional pletely and the left steering brake is turned
current to steering ECMV (6) to operate the ON, causing the machine to make a sud-
steering clutch and brake. den left swing.
The brake pedal (1) sends an electric signal Safety lever (2) is connected to parking brake
to steering controller (4) via potentiometer lever (8) and it also serves as a parking brake.
(11). After receiving it, steering controller (4)
sends a proportional current to steering
ECMV (6) to operate the brake. In this case,
the right and left brakes operate at the same
time to activate braking. Rod (10) operates
the brake via brake valve (7) for redundant
use. (Only at the time of complete braking)
If you slightly tilt PCCS lever (3) leftward,
the left steering clutch is partially disen-
gaged, causing the machine to make a slow
left swing.
D475A-3 10-43
STRUCTURE AND FUNCTION TRANSFER, BEVEL GEAR SHAFT, STEERING
TRANSFER, BEVEL GEAR SHAFT, STEERING
1. Transmission
2. Steering ECMV
3. Steering unit
4. Breather
5. Torque converter output
shaft speed sensor
A. Center of bevel gear shaft

B. Center of crankshaft
C. Center of bevel gear
10-44 D475A-3
STRUCTURE AND FUNCTION TRANSFER, BEVEL PINION
TRANSFER, BEVEL PINION
1. Input shaft
2. Drive shaft
3. Drive gear (27 teeth)
4. Rear cover
5. Support
6. Torque converter output
shaft speed sensor
7. Bearing cage
8. Drum
9. Cover
10. Bearing cage
11. Driven gear (30 teeth)
12. Bevel pinion (22 teeth)
D475A-3 10-45
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
10-46 D475A-3
1. Brake output shaft Outline

2. Bushing The steering clutches are wet, multiple-disc
3. Pin clutches with a spring booster. They are in-
4. Clutch piston terconnected with the brakes and are hy-
5. Pin draulically actuated by a steering valve that
6. Clutch plate (8 each) is actuated when the joystick is operated.
7. Clutch disc (8 each) A forced lubrication system is employed in
8. Stopper which the oil from the power train oil cooler
9. Inner drum passes through the passage inside the steer-
10. Cylinder ing case, enters the housing and cage, and
11. Bearing cage is then sent to the discs and plates.
12. Bevel gear (37 teeth)
13. Bearing cage The steering brakes are wet, multiple-disc
14. Steering shaft clutches with a spring booster. They are in-
15. Piston spring terconnected with the clutch and are hydrau-
16. Outer drum lically actuated by a steering valve that is
17. Stopper actuated when the brake pedal and joystick
18. Clutch plate (8 each) are operated.
19. Clutch disc (9 each) A forced lubrication system is employed in
20. Inner drum which the oil from the power train oil cooler
21. Cylinder passes through the passage inside the steer-
22. Clutch piston ing case, enters the housing and cage, and
23. Piston spring is then sent to the discs and plates.
24. Housing The steering brakes are designed so that
when the engine has stopped, the back pres-
sure of the brake piston drops and the brakes
are applied without the brake pedal being
depressed. However, when the engine is
started again, the brake is released as the
hydraulic pressure inside the circuit rises, so
the parking brake lever must always be
locked.
D475A-3 10-47
STRUCTURE AND FUNCTION STEERING ECMV
STEERING ECMV
10-48 D475A-3
STRUCTURE AND FUNCTION STEERING ECMV
A. Left clutch operating pressure pick-up port Outline

B. Right clutch operating pressure pick-up port The machine employs four ECMV (electronic-
C. Left brake operating pressure pick-up port controlled modulation valve) on the steering
D. Right brake operating pressure pick-up port control valve.
E. To left clutch The steering control valve is provided on
F. To left lubrication respective valve sheets as the assembly.
G. To left brake The steering control valve is situated in the
H. To right clutch circuit between the power train pump via
J. To right lubrication the main relief valve and the piston of the
K. To right brake steering clutch and the brake. It is config-
L. Bevel gear shaft lubrication inlet ured with two pairs of the steering ECMV
M. To pin puller solenoid valve (right and left) and the brake ECMV (right
N. From pin puller solenoid valve and left).
P. From pump Shifting the PCCS lever (steering and for-
ward/reverse) right or left disconnects the
steering clutch. Shifting it further turns ON
the brake.
1. Filter The controller sends the instruction to re-
2. ECMV (For right clutch) spective ECMV to cause the gradual or sud-
3. ECMV (For left clutch) den turn whichever is designated by the
4. Sudden braking prevention valve operating position of the PCCS lever (steer-
5. ECMV (For right brake) ing lever).
6. ECMV (For left brake) Depending on depth of the pedal depres-
7. Parking braking valve sion, the controller instructs ECMV to apply
8. Valve seat the right and left brakes to stop the ma-
chine.
The controller that is electrically connected
to the PCCS lever and pedal performs above
operations 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 disc clutches.
The sudden stop prevention valve disables
sudden braking that can result when a fail-
ure is detected in the electric systems.
Shifting the parking brake lever to the Lock
position switches the port of the parking
brake valve, thereby draining the oil between
the ECMV for left-and-right brakes and the
brake. As the result, the machine brake is
turned on.
The parking brake is also connected to the
brake pedal via the linkage.
D475A-3 10-49
10-49
(1)
STRUCTURE AND FUNCTION STEERING CLUTCH, STEERING BRAKE ECMV
STEERING CLUTCH, STEERING BRAKE ECMV

A: To clutch or brake 1. Fill switch connector

P: From pump 2. Proportional solenoid connector
T: Drain 3. Pressure detection valve
Dr: Drain 4. Fill switch
P1: Clutch or brake pressure pick-up port 5. Proportional solenoid
P2: Pilot pressure pick-up port 6. Pressure control valve
10-50 D475A-3
ECMV outline
The ECMV (Electronic Control Modulation
Valve) consists of a pressure control valve
and a fill switch.
Pressure control valve
Proportional solenoid of this valve receives
current from the steering controller, then the
valve converts it to hydraulic pressure.
Fill switch
This switch detects the completion of the
clutch oil replenishment. The detailed func-
tions are as follows.
1) Signal (fill signal) of completion of oil
replenishment is given from the valve to
the controller.
2) This signal is kept while the pressure is
applied to the clutch.
ECMV and proportional solenoid

Each ECMV is equipped with one propor-
tional solenoid. A thrust is generated by its
controller command current.
The hydraulic pressure is generated by acti-
vating the generated thrust on the pressure
control valve spool.
Therefore, the oil flow and the hydraulic pres-
sure are controlled by controlling the com-
mand current volume to change the thrust.
ECMV operation
The ECMV is controlled by the command
current running from the controller to the
proportional solenoid and the fill switch out-
put signal.
Steering clutch and steering brake ECMVs

Outline
They are used to set the steering clutch and
steering brake hydraulic pressures to the
specified settings, as well as to serve as
valves to switch the circuits connected to
the clutch and brake chambers.
D475A-3 10-51
Operation
1. In case of PCCS lever Neutral, brake pedal Released: Straight travel
(Left and right clutch ON, left and right brake Released, parking brake OFF)
In the position of PCCS lever Neutral and Further, the proportional solenoid valve (5)
brake pedal Released, because the sole- of the brake ECMV is energized and pushes
noid valve (1) of the steering ECMV is the ball (6) to the left direction, then closes
deenergized, the sealing portion of the ball the sealing portion. The oil that entered the
(2) is opened. pump port Pb enters the E port, pushes the
The oil from the power train pump enters the valve (7) left, opens the Pb and B ports, and
port Pc of the steering ECMV via the main closes the B and Dr ports. The oil that en-
relief valve. The oil that entered the port Pc tered the Pb port passes through the B port
passes through the orifice a and passes and flows into the back pressure port of the
through the sealing portion of the ball (2), brake piston. Subsequently, the piston moves
then is drained. to the left direction waiting for the rise of
The valve (3) is moved right by the tension the circuit oil pressure and compresses the
of the spring (4) and closes the Pc and C brake spring, then sets the brake Released.
ports, then opens the C and Dr ports. At this In the parking brake OFF, the parking brake
time, the oil from the back pressure port of is closed and the oil of the brake circuit is
a clutch piston is drained from the port C not drained.
and the clutch is set to ON by the tension
of the clutch spring. The oil pressure of the
brake circuit is ensured by the orifice a.
10-52 D475A-3
2. When the PCCS lever is actuated halfway to the left: Slow swing
(Left clutch OFF, left brake Semi-released, right clutch ON, right brake Released, parking
brake OFF)
When the PCCS lever is actuated halfway to later outputs a command current from the
the left, the solenoid valve (1) of the left steer- controller to the proportional solenoid valve
ing ECMV is energized and pushes the ball (5) in accordance with the stroke of the PCCS
(2) to the left direction, then closes the seal- lever. When the current flows into the pro-
ing portion. portional solenoid (5), the solenoid generates
The oil from the power train pump passes a thrust in proportion to the current. The sum
through the orifice a from the port Pc and of the thrust of this solenoid, the thrust caused
enters F. Subsequently, the oil pushes the by the brake port oil pressure, and the resti-
valve (3) to the left and opens the Pc and C tution of the pressure control valve spring (8)
ports, then closes the C and Dr ports. The oil is balanced and pressure-adjusted.
of the C port flows into the clutch piston Accordingly, if the stroke of the PCCS lever is
port and becomes the back pressure, then small, the oil pressure of the port B and later
sets the left clutch to OFF. is also specified high and the brake changes
Further, the proportional solenoid valve (5) from Released to Semi-released. If the
of the left ECMV is energized and pushes the stroke is large, the oil pressure is specified
ball (6) to the left direction, then closes the low and the bake changes from Semi-re-
sealing portion. The oil that entered the pump leased to ON
port Pb enters the E port and pushes the In the parking brake OFF, the parking brake
valve (7) to the left. valve is closed and the oil of the brake cir-
Besides, the oil pressure of the port B and cuit is not drained.
D475A-3 10-53
3. When the PCCS lever is actuated fully to the left: Sudden swing
(Left clutch OFF, left brake ON, right clutch ON, right brake Released, parking brake OFF)
When the PCCS lever is actuated fully to the The left brake is set to ON by the tension
left from the state of Section 2, the propor- of the brake spring.
tional solenoid valve (5) of the left brake ECMV In the parking brake OFF, the parking brake
is deenergized and sets the ball (6) free, then valve is closed and the oil of the brake cir-
opens the sealing portion. cuit is not drained.
Because the oil of the port E passes through
the sealing portion and is drained, the valve
(7) is moved right by the tension of the spring
(8).
At this time, the port Pb closes and the port
B and drain port Dr open.
The oil from the power train pump passes
through the orifice b from the port Pb and
passes through the sealing portion, then is
drained. The oil pressure of the clutch cir-
cuit is ensured by the orifice b. On the other
hand, the oil that flows into the brake piston
port and reached the back pressure is drained
from the port B to Dr.
10-54 D475A-3
4. In case of brake pedal Stepped on

(Clutch ON, brake ON, parking brake OFF)
When the brake pedal is stepped on, the right steering ECMVs is deenergized and the
proportional solenoid valve (5) of the left left and right clutches are set to ON.
and right brake ECMVs is deenergized from Further, when the brake pedal is stepped
energization by the pedal full actuation. on, the parking brake valve linked using a
A command current is output from the con- linkage is actuated and drains the oil of the
troller to the proportional solenoid valve (5) brake circuit.
in accordance with the actuation stroke of
the brake pedal. When the current flows into
the proportional solenoid valve (5), the sole-
noid generates a thrust that is proportional
to the current. The sum of the thrust of this
solenoid, the thrust caused by the oil pres-
sure of the brake port, and the restitution of
the pressure control valve spring (8) is bal-
anced and oil pressure is specified, thereby
enabling adjustment of the effect of the
brake.
Besides, because the PCCS lever is not actu-
ated, the solenoid valve (1) of the left and
D475A-3 10-55
5. In case of brake pedal ON

(Clutch ON, brake ON, PCCS lever Neutral, braking pedal Released)
When the safety lever for the PCCS lever is the port A, port B and drain port C, then the
set to the position of Locked, the parking brake is set Released by oil pressure.
brake valve (1) moves to the left direction
and the ports A, B and C open. Accordingly,
the oil that flows into the brake piston port
and reached the back pressure passes through
the port C from the ports A and B and is
drained. The back pressure of the brake pis-
ton port continues decreasing and the brake
is fully set to ON, then is held in the state.
Further, because the ports A and B continue
being opened together with the drain port C
even if the engine is restarted, the state of
the brake ON is held.
In the parking brake OFF, the parking brake
valve (1) moves right and is closed between
10-56 D475A-3
STRUCTURE AND FUNCTION SUDDEN STOP PREVENTION VALVE
SUDDEN STOP PREVENTION VALVE
Outline
This sudden stop prevention valve is installed
to prevent a vehicle from being braked sud-
denly when an error occurs in an electrical
system.
When the sudden stop prevention valve (1)
is installed in the drain circuit of the brake
ECMV and the solenoid valve (2) of the brake
ECMV is deenergized, the oil of the brake
circuit D is drained and sudden braking is
prevented from being applied. Accordingly,
when the solenoid valve (3) of the sudden
stop prevention valve (1) is deenergized, the
brake is set to Semi-released by throttling
the brake drain circuit D that works as the
orifice a circuit.
D475A-3 10-57
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
Outline
The final drive is a single stage spur gear, Floating seal (1) is installed to the rotating
single stage planetary gear reduction type. sliding portion of the sprocket to prevent
The lubrication is of splash type using the the entry of dirt or sand and to prevent leak-
rotation of the gears. age of lubricating oil.
The final drive can be removed and installed
as a single unit.
10-58 D475A-3
1. Floating seal 8. Floating seal guard 15. No. 1 pinion

2. Sun gear 9. Cover 16. Final drive case
3. Carrier 10. Planetary pinion 17. Bearing cage
4. Hub 11. Ring gear 18. Boss
5. Cover 12. Cover 19. Shaft
6. Sprocket boss 13. No. 1 gear 20. Wear guard
7. Sprocket teeth 14. No. 1 gear hub
D475A-3 10-59
PATH OF POWER TRANSMISSION
10-60 D475A-3
The power from the bevel gear and steering

clutch is transmitted to No. 1 pinion (15). It
then passes through No. 1 gear (13), which
is meshed with the No. 1 pinion, and is trans-
mitted to sun gear (2) to rotate it.
The rotation of sun gear (2) is transmitted to
planet pinion (10), but ring gear (11), which
is meshed with the planet pinion, is fixed to
cover (9), so the planet pinion rotates on its
own axis and moves around the sun gear
along the ring gear.
Then, the rotating force of sun gear (2) forms
the rotating force of carrier (3), which sup-
ports the planet pinion, and is transmitted
to sprocket hub (4).
The direction of rotation of carrier (3) is the
same as that of sun gear (2).
The rotating force transmitted to sprocket
hub (4) is transmitted to sprocket teeth (7).
D475A-3 10-61
STRUCTURE AND FUNCTION TRACK FRAME
TRACK FRAME
Outline
The track roller uses an K-shape bogie mount
to increase the ground contact area between
the track shoe and ground surface on rough
surfaces, thereby increasing the drawbar pull.
The K-shape bogie is fitted with rubber pads
to absorb the shock from the ground sur-
face.
Track roller, bogie
Track roller flange type arrangement

Applicable
1st 2nd 3rd 4th 5th 6th 7th
S D D D D D S Semi U, U specification
10-62 D475A-3
STRUCTURE AND FUNCTION TRACK FRAME
1. Idler
2. Recoil spring assembly
3. Carrier roller
4. Track frame
5. Sprocket
6. Sprocket guard
7. Track roller bogie
8. Track roller
9. Cap
10. Idler yoke
11. Cylinder
12. Guide
D475A-3 10-63
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
1. Oil level gauge P1: From large pump B1: To blade tilt cylinder bottom
2. Blade lift valve P2: From small pump A2: To ripper lift cylinder head
3. Blade tilt, ripper low valve A: To blade lift cylinder head B2: To ripper lift cylinder bottom
4. Oil filler B: To blade lift cylinder bottom A3: To ripper tilt cylinder head
5. Breather A1: To blade tilt cylinder head B3: To ripper tilt cylinder bottom
6. Bypass valve
7. Filter
8. Tube
D475A-3 10-65
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
FOR BLADE LIFT, TILT
P. From PPC charge valve port P2 (through

PPC lock valve)
T. To hydraulic tank
P1. To blade lift valve (LOWER) port PA
P2. To blade lift valve (RAISE) port PB
P3. To blade tilt valve (Left tilt) port PA1
P4. To blade tilt valve (right tilt) port PB1
10-66 D475A-3
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
D475A-3 10-67
Operation
1) At neutral
(i) PPC valve for blade lift
Ports PA and PB of the blade lift control
valve, and ports P1 and P2 of the PPC valve
are connected to drain chamber D through
fine control notch f2 in spool (1).
(ii) PPC valve for blade tilt

Ports PA1 and PB1 of the blade tilt control
valve, and ports P3 and P4 of the PPC valve
are connected to drain chamber D through
fine control notch f2 in spool (1).
10-68 D475A-3
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, notch f2 for fine control
is shut off from drain chamber D, and at
almost the same time, it is connected to
pump pressure chamber PP, so pilot pres-
sure oil from the charging pump passes
through notch f1 for fine control and goes
from port P1 to port PA.
When the pressure at port P1 becomes
higher, spool (1) is pushed back and notch
f1 for fine control 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 balanced with pressure at port P1.
The relationship in the position of the spool
(1) and body (10) (notch f1, f2 for fine con-
trol is at a point midway between drain
chamber 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 rises in proportion to the travel in
the control lever.
In this way the control valve spool moves to
a position where the pressure in chamber
PA (the same as the pressure at port P1) and
the force of the control valve spool return
spring are balanced.
D475A-3 10-69
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 P1.
When this happens, notch f2 for fine control
is connected 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 notch f1 for fine control 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 notch
f2 for fine control in the valve on the side
that is not working.
The oil passes through port P2 and enters
chamber PB to fill the chamber with oil.
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), notch f2
for fine control is shut off from drain cham-
ber D, and is connected with pump pressure
chamber PP.
Therefore, the pilot pressure oil from the
charging pump passes through notch f1 for
fine control and flows to chamber PA from
port P1, and pushes the control valve spool.
The oil returning from chamber PB from port
P2 through notch f2 for fine control and
flows to drain chamber D.
10-70 D475A-3
5) Blade operated to FLOAT

When piston (4) at port P1 (LOWER side) is
pushed by disc (5) and moves down, protru-
sion a of the piston contacts ball (11) during
the downward stroke. (The detent starts to
be actuated.)
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 passes over protrusion a of the pis-
ton. 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
piston (4) follows disc (5). Passage d is in-
terconnected with port P1, so it is under more
or less the same pressure as port P1.
Chamber E is normally interconnected with
drain chamber D, but when ball (11) passes
over protrusion a of the piston, passage d
and chamber E (which were shut off) are
interconnected and pressurized oil flows. At
the same time, the control 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 if the lever is released, it is held at
the FLOAT position.
6) Blade released from FLOAT

When disc (5) is returned from the FLOAT
position, 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
passage d and is connected to the drain
chamber. Therefore, the oil pressure inside
chamber E is lost, and the FLOAT position is
released.
D475A-3 10-71
FOR RIPPER
A C
C A
B
E E
D D
a B b
c d
f e
SYD00313
a. P port (from charge pump) d. P4 port (blade LOWER/ripper RAISE)

b. T port (to hydraulic tank) e. P1 port (blade LEFT TILT/ripper TILT BACK)
c. P2 port (blade RIGHT TILT/ripper TILT IN) f. P3 port (blade RAISE/ripper LOWER)
10-72 D475A-3
7
5
4
8
3 9
2 10
1
A-A B-B
11
D-D
C-C
E-E
SYD00314
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)
D475A-3 10-73
Operation
1) At neutral
Ports A and B of the control valve and ports
P1, P2, P3, and P4 of the PPC valve are con-
nected to drain chamber D through fine con-
trol hole f of spool (1).
10-74 D475A-3
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 al-
most 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 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 pres-
sure chamber PP. At almost the same time,
it is connected to drain chamber D to re-
lease the pressure at port P1.
When this happens, spool (1) moves up or
down so that the force of metering spring
(2) is balanced with the pressure at port P1.
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 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 rises in proportion to the travel in
the control lever.
In this way the control valve spool moves to
a position 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 balanced.
D475A-3 10-75
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
connected to drain chamber D and the pres-
sure 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
chamber B to fill the chamber with oil.
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP.
Therefore, the pilot pressure oil from the
charging 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
from port P2 through fine control hole f and
flows to drain chamber D.
10-76 D475A-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE

BLADE LIFT VALVE
Outline P1. From large pump

Demand valve is assembled to the blade lift P2. From small pump
valve, and the oil from the two hydraulic A. To blade lift cylinder head
pumps is merged by check valve. B. To blade lift cylinder bottom
With the demand valve, the oil from the large T. To hydraulic tank
pump becomes the pilot pressure, and at PA. From blade lift PPC valve port P2
the same time, the oil from the ripper circuit PB. From blade lift PPC valve port P1
or the blade lift circuit through shuttle valve PL. From ripper Lo valve
also becomes the pilot pressure, so the oil
from the two hydraulic pumps is used effi-
ciently.
10-78 D475A-3
1. Check valve spring 8. Shuttle valve seat (plug) 15. Demand valve
2. Small pump circuit check valve 9. Shuttle valve ball 16. RAISE suction valve
3. Check valve 10. Shuttle valve seat (plug) 17. Suction valve spring
4. Check valve spring 11. Retainer 18. LOWER suction valve
5. Valve body 12. Return spring (for FLOAT) 19. Main relief valve
6. Return spring 13. Case 20 Main relief, shuttle valve
7. Blade lift valve 14. Demand valve spring 21. Shuttle valve
D475A-3 10-79
BLADE LIFT VALVE

MAIN RELIEF, SHUTTLE VALVE
10-80 D475A-3
1. Valve body Outline

2. Piston The main relief valve is in the circuit be-
3. Shuttle valve tween the hydraulic tank and the ripper cir-
4. Shuttle valve spring cuit and blade lift circuit through shuttle valve
5. Plug (3). The oil pressure in the blade lift circuit,
6. Valve seat that is, the large pump circuit, is set at 20.6
7. Main relief valve poppet MPa {210 kg/cm2}.
8. Main relief valve spring The shuttle valve is in the circuit between
9. Sleeve the demand valve through the main relief
10. Main relief pressure adjustment screw valve and the blade lift circuit and ripper
circuit. It selects the two circuits to apply the
PL. From shuttle valve inside ripper valve pilot pressure to the demand valve.
PB. From shuttle valve inside blade lift valve In other words, it selects either the blade lift
PD. To demand valve pilot port circuit or the ripper circuit.
T. To hydraulic tank When the work equipment is not being used
(when the control lever is at neutral) the
shuttle valve connects the blade lift circuit
and the pilot port of the demand valve by
the tension of spring (4).
D475A-3 10-81
BLADE TILT, RIPPER LO VALVE
P. From small pump CO. To demand valve

A1. To blade tilt cylinder head PL. To shuttle valve inside blade lift valve
B1. To blade tilt cylinder bottom PA1. To blade tilt PPC valve P3 (left tilt)
A2. To ripper tilt cylinder head PA2. To ripper tilt PPC valve P2 (tilt in)
(through ripper Hi valve PA1) PA3. To ripper lift PPC valve P3 (lower)
B2. To ripper tilt cylinder bottom PB1. To blade tilt PPC valve P4 (right tilt)
(through ripper Hi valve PB1) PB2. To ripper tilt PPC valve P1 (tilt back)
A3. To ripper lift cylinder head PB3. To ripper lift PPC valve P4 (raise)
(through ripper Hi valve PB2)
B3. To ripper lift cylinder bottom
(through ripper Hi valve PA2)
10-82 D475A-3
1. Blade tilt valve 9. Sleeve 18. Check valve spring

2. Ripper tilt valve 10. Main relief valve body 19. Valve seat
3. Ripper lift valve 11. Poppet spring 20. Shuttle valve seat (plug)
4. Valve body 12. Main relief valve poppet 21. Shuttle valve ball
5. Return spring 13. Valve seat 22. Shuttle valve seat
6. O-ring 14. Main relief valve spring
7. Case 15. Main relief valve
8. Main relief pressure 16. Valve seat
adjustment screw 17. Check valve
D475A-3 10-83
RIPPER HIGH VALVE
P: From large pump

PA1: From low valve tilt back
PB1: From low valve tilt on
PA2: From low valve ripper raise
PB2: From low valve ripper lower
A1-1: To right tilt cylinder head
B1-1: To right tilt cylinder bottom
A1-2: To left tilt cylinder head
B1-2: To left tilt cylinder bottom
A2-1: To right lift cylinder head
B2-1: To right lift cylinder bottom
A2-2: To left lift cylinder head
B2-2: To left lift cylinder bottom
T: To hydraulic tank
10-84 D475A-3
1. Check valve 12. Fixed differential pressure valve

2. Check valve spring (for ripper lift)
3. Plug 13. Fixed differential pressure valve
4. Fixed differential pressure valve (for ripper tilt)
(for ripper tilt) 14. Ripper tilt high valve
5. Valve body 15. Valve return spring
6. Shuttle valve seat 16. Plug
7. Shuttle valve ball 17. Ripper lift high valve
8. Valve body 18. Suction valve spring
9. Plug 19. Suction valve
10. Fixed differential pressure valve spring
11. Fixed differential pressure valve
(for ripper lift)
D475A-3 10-85
PIN-PULLER HYDRAULIC SYSTEM DRAWING
STRUCTURE AND FUNCTION PIN-PULLER HYDRAULIC CIRCUIT DRAWING
PIN-PULLER HYDRAULIC SYSTEM DRAWING
PIN-PULLER HYDRAULIC CIRCUIT DRAWING
1. Power train oil tank

2. Oil strainer
3. Power train pump
4. Oil filter
5. Main relief valve
6. Steering control
valve
7. Pin-puller solenoid
valve
8. Pin-puller cylinder
9. Steering case
10. Scavenging pump
10-86 D475A-3
STRUCTURE AND FUNCTION PIN-PULLER SOLENOID VALVE
PIN-PULLER SOLENOID VALVE
1. Plug
2. Spring
3. Spring retainer
4. Valve body
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
A. To pin-puller cylinder head

B. From power train pump
C. To pin-puller cylinder bottom
D. To steering case
D475A-3 10-87
STRUCTURE AND FUNCTION PIN-PULLER SOLENOID VALVE
Operation
1. Pin-puller switch at PUSH IN position

When the pin-puller switch is turned to the
PUSH IN position, no current flows to sole-
noid (9) and it is deactivated.
When this happens, spool (5) opens ports A
and B and ports C and D, and the oil from
the power train pump flows from port A to
port B and enters the bottom of pin-puller
cylinder (10).
The oil entering the bottom end of the cylin-
der increases the hydraulic pressure in the
circuit and extends the cylinder. Shank
mounting pin (11) is pushed into shank (13).
2. Pin-puller switch at PULL OUT position

When the pin-puller switch is turned to the
PULL OUT position, current flows to sole-
noid (9) and it is excited.
When this happens, the solenoid pushes out
push pin (8), and spool (5) moves to the left
in the direction of the arrow.
Ports A and B and ports C and D close, and
ports A and C and ports B and D open. The
oil from the power train pump flows from
port A to port C and enters the head of pin-
puller cylinder (10).
The oil entering the head end of the cylinder
increases the hydraulic pressure in the cir-
cuit and retracts the cylinder. Shank mount-
ing pin (11) is pulled out of shank (13).
10-88 D475A-3
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Air conditioner compressor 10. Hot water pickup piping

2. Condenser 11. Receiver tank
3. Refrigerant piping 12. Hot water return piping
4. Window defroster 13. Valve (hot water inlet)
5. Side defroster
6. Air conditioner unit A. Fresh air
7. Vent B. Recirculated air
8. Blower motor C. Hot air/cold air
9. Valve (hot water outlet)
D475A-3 10-89
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
1. Battery relay (Right) Outline

2. Battery (Right) Engine control is carried out in the following
3. Decelerator pedal two systems.
4. Starting switch 1. When the fuel control dial and decelera-
5. Decelerator pedal potentiometer tor pedal are operated, it controls the
6. Engine controller fuel injection pump with an electric sig-
7. Steering controller nal.
8. Transmission controller 2. When mode selection system is actuated
9. Fuel control dial The throttle signal and decelerator pedal
10. Battery (left) signal enter the steering controller, are
11. Battery relay (left) processed together with other data, and
12. Starting motor are sent to the electronic engine control-
13. Fuel injection pump (left) ler as the throttle command.
(electronic engine controller) The electronic engine controller controls
the fuel injection pump according to the
command.
A fuel injection pump with electronic gover-
nor is employed. (For details, see ENGINE
CONTROL SYSTEM WITH ELECTRONIC EN-
GINE THROTTLE CONTROLLER.)
10-90 D475A-3
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
Outline
The engine controller receives the manual The information of the engine controller is
signals of the 1st throttle, 2nd throttle and used commonly by the all controllers through
the 3rd throttle signals which is the control the network for the optimum control of the
signals from the machine body, then selects engine and machine body.
the lower engine speed and controls the Elec- The automatic deceleration function sets the
tronic engine throttle. engine speed to 1,000 rpm temporarily when
The 3rd throttle control signals contain the the travel direction is changed from F3, R3,
following. or R2 (to protect the transmission clutch).
1 High idling speed control
2 SSC (Shoe Slip Control) control
3 Automatic deceleration (F3, R3, R2)
The steering controller selects the lowest

engine speed from information 1, 2, and
3 and transmits it as the throttle to the en-
gine controller.
D475A-3 10-91
STRUCTURE AND FUNCTION DECELERATION POTENTIOMETER
DECELERATION POTENTIOMETER
1. Connector Outline
2. Lever The deceleration potentiometer is installed
3. Body to the front lower part of the operators cab
4. Potentiometer and connected to the decelerator pedal by
5. Coupling linkage.
6. Shaft
7. Stopper If the decelerator pedal is pressed, the throttle
potentiometer shaft rotates by the linkage
and the potentiometer resistance changes.
Constant voltage is applied between pins A
and C of the potentiometer and an electric
signal is sent through pin B to the engine
controller according to the position of the
decelerator pedal.
10-92 D475A-3
ENGINE CONTROL SYSTEM WITH
STRUCTURE AND FUNCTION ELECTRONIC ENGINE THROTTLE CONTROLLER

ELECTRONIC ENGINE THROTTLE CONTROLLER
SYSTEM DRAWING
Outline
A fuel injection pump with electronic gover-
nor is used.
The engine controller receives the signals
from the sensor and switches, and transmits
the control signal to the governor solenoid
and pre-stroke solenoid (proportional sole-
noid).
10-94 D475A-3
STRUCTURE AND FUNCTION ELECTRONIC ENGINE THROTTLE CONTROLLER
FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR
STRUCTURAL DIAGRAM
1. Delivery valve Function

2. Plunger barrel After the governor actuation pressure is ad-
3. Plunger justed by the hydraulic control valve in ac-
4. Hydraulic piston cordance with the command from the en-
5. Hydraulic control valve gine controller, it acts on the piston at the
(quantity adjustment) rear of the rack and moves the control rack
6. Hydraulic control valve to adjust the fuel injection amount.
(injection timing adjustment) The fuel injection timing is adjusted by
7. Gear pump (as seen from rear, changing the length of the injection pump
left: oil, right: fuel) plunger. The plunger is formed of two parts,
8. Center bearing and by sending electronically controlled hy-
9. Cam shaft draulic pressure between these two parts,
10. Roller the length is changed to adjust the pre-
11. Tappet stroke.
12. Pump housing The governor solenoid and pre-stroke sole-
13. Tappet guide noid are proportional solenoid, and they con-
14. Spring nut vert the input current from the controller into
propulsion. This propulsion controls the
spool of the hydraulic control valves (two
valves: one for the governor and the other
for the injection timing adjustment), and
converts the input current into hydraulic
power.
D475A-3 10-95
STRUCTURE AND FUNCTION MONITOR SYSTEM
MONITOR SYSTEM
The monitor system monitors the machine The monitor panel has the functions of dis-
condition with the sensors installed to vari- playing data and selecting the SSC mode.
ous parts of the machine and processes and The CPU (Central Processing Unit) in it pro-
displays the obtained information on the cesses, displays, and outputs the informa-
panel quickly to notify the operator of the tion. The display unit is LCD (Liquid Crystal
machine condition. Display) and the switches are seat switches.
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, hydraulic oil level, etc.)
3) Function of displaying error codes.
4) Function of monitoring the current and
voltage of the sensors and solenoids.
In the monitor panel, there are various mode

selector switches of the SSC (Shoe Slip Con-
trol), which are used to operate the machine
control system.
10-96 D475A-3
STRUCTURE AND FUNCTION MONITOR SYSTEM
Processing in monitor panel (Common to all specifications)

Display of monitor panel
1 Contents and conditions of processing 2 Method 3 Flow of signals
1) Display of travel direction and gear speed. Transmission controller Steering

F1, R3, etc. are notified by CAN according to controller Monitor panel
information of transmission controller.
2) Display of engine speed in gauge number. CAN Engine speed sensor Steering
The number of pulses the engine rotation is controller Monitor panel
converted into a gauge number and notified
to the monitor panel by CAN.
3) Display of troubleshooting CAN Engine sensor/solenoid Steering

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

1) The communication conditions of each sen- CAN Each sensor Steering controller
sor, each solenoid, and CAN are displayed. or transmission controller Moni-
The item Nos. and device conditions are noti- tor panel
fied to the monitor panel by CAN.
The monitor panel displays the items and each Sensors Engine controller Steer-
value on its multi-information section. ing controller Monitor panel
2) Each items is selected by using the cursor Monitor panel Controller Moni-
switches, selector switches, buzzer cancel tor panel
switch, and shift UP/DOWN switches.
Other items
1) Function selection mode (Displayed each time CAN Steeging controller Monitor panel
cancel switch is turned to left)
1 Replacement periods of oil filter and oil
are displayed.
2 Engine speed, oil pressure in work equip-
ment circuit, etc. are displayed.
3 Failure codes related to electronic control
are displayed.
4 Brightness of display, etc. are adjusted.
2) Mode to change replacement periods of main-
tenance mode
3) Mode to display failure codes related to ma-
chine body such as overheating, abnormal
water temperature, etc.
4) Mode to display service meter and informa-
tion related to load on machine
D475A-3 10-97
STRUCTURE AND FUNCTION MONITOR PANEL
MONITOR PANEL
Monitor portion
1. Engine cooling water temperature gauge 14. Engine preheating pilot lamp
2. Power train oil temperature gauge 15. Maintenance caution lamp
3. Hydraulic oil temperature gauge 16. Warming lamp
4. Fuel gauge 17. Filter, oil change interval lamp
5. Radiator coolant level check lamp 18. Display panel A (Speed range, Engine speed)
6. Hydraulic oil level check lamp 19. Display panel B (Multi-information)
7. Engine oil level check lamp 20. Dual/single tilt selector display lamp
8. Charge level monitor 21. Lock up mode switch
9. Engine oil pressure caution lamp 22. Economy mode selector switch
10. Engine cooling water temperature caution lamp 23. Reverse slow mode selector switch
11. Power train oil temperature caution lamp 24. Shoe slip selection mode switch
12. Hydraulic oil temperature caution lamp 25. Rock selection mode selector switch
13. Air cleaner clogging caution lamp
Outline 2. Start-up inspection

The monitor potion consists of a monitor 1) After all lighting of Section 1 is termi-
that issues an alarm when an error occurred nated, if there is an error in a start-up
in a vehicle, a gauge that always displays inspection item, the item flashes.
the state of the vehicle, and the service meter. 2) If the engine is started, the check items
The monitor portion installs a microcomputer before starting go off. (If the engine run-
and processes and displays signals from ning is judged by the signal (CAN) from
each sensor. the engine controller.)
Besides, the items displayed on the monitor
portion and gauge portion are listed in the 3. Cautions
table on the next page. Caution items are checked until the engine
stops after the engine starts.
Operation If an error occurs, the error is displayed by
1. When the power turns on (When the start- flashing and the alarm lamp synchronously
ing switch is ON) flashes.
1) All items of the gauge and monitor por- Further, if an emergency item flashes, the
tions come on for three seconds. alarm buzzer also sounds synchronously.
2) The alarm lamp comes on for two sec- Flashing of the monitor and alarm lamp is
onds. repeated. They come on and off for about
0.8 second.
The flashing period of the monitor slightly
changes when atmospheric temperature is
low (below about 10C), but this case is not
abnormal.
10-98 D475A-3
Monitor panel display

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

Check
Engine oil level mal or when wiring

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

Caution 1
SAP00522 ON and engine is running

Display when abnormal: Flashes
When clogged: CAUTION lamp flashes
Air cleaner clogging
Less than 650 mmH2O
Engine oil pressure Below 49.0 kPa

{0.5 kg/cm2}
Radiator water level Below low level
When at highest level

Engine water temperature (108C or above) on Displays when starting switch is
engine water
temperature gauge ON and engine is running
Caution 2
When at highest level Display when abnormal: Flashes

Torque converter (130C or above) on CAUTION lamp flashes
oil temperature torque converter Alarm buzzer sounds
temperature gauge
Hydraulic oil 105 3C or above

temperature
Hydraulic oil level Below low level
When replacement time

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

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

Displays lights at the time of op-
eration.
Dual tilt All the time of operation
It goes off at the time non-opera-
tion.
D475A-3 10-99
Display Display range

Symbol Display item Display method
category
Engine water
temperature
Torque converter oil One place lights up to

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

applicable level
Multi information
Service meter Actuated when the engine

From 0 to 99999
(Hours meter) is rotating.
10-100 D475A-3
Switch portion
1. Switch functions
a) ON-OFF switching in lock-up mode
b) Economy mode setting OFF, mode 1, mode 2
c) ON-OFF switching in reverse slow mode
d) ON-OFF switching in SSC mode
e) SSC mode level setting Mode 1 to 5
a), b), and c) are mounted for all specifications and d) and e) are mounted for the SSC specifica-
tions.
SSC specifications
Without SSC specifications
2. Initial Setup at key ON Economy Mode Function

The function the operator desires according In a field, such as a rock-bed place where many
to the situation of an operating place is se- shoe slips are generated, the following power is
lected and all functions shall be set to the output in each mode so that the frequency of
OFF state. decelerator operation can decrease.
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.
D475A-3 10-101
SENSORS
Type of sensor Sensor method When normal When abnormal
Engine oil pressure Contact OFF ON
Engine water temperature Resistance
Torque converter oil temperature Resistance
Hydraulic oil temperature Resistance
Radiator water level Contact ON OFF
Fuel level Resistance
Engine oil level Contact ON OFF
All cleaner clogging Contact ON OFF
Engine oil pressure sensor
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
10-102 D475A-3
(1)
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
D475A-3 10-103
Fuel level sensor
1. Connector Function
2. Float The fuel sensor is installed to the side face
3. Arm of the fuel tank. The float moves up and
4. Body down according to the fuel level. This move-
5. Spring ment of the float is transmitted by the arm
6. Contact and actuates a variable resistance. This sends
7. Spacer a signal to the monitor panel to indicate the
remaining fuel level. When the display on
the monitor panel reaches a certain level, a
warning lamp flashes.
10-104 D475A-3
Engine oil level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
Air cleaner clogging sensor
1. Boss 4. Wire
2. Switch 5. Connector
3. Conduit
D475A-3 10-105
STRUCTURE AND FUNCTION MODE SELECTION SYSTEM
MODE SELECTION SYSTEM

(SSC (Shoe Slip Control) System)
System diagram
Outline
The mode selection system automatically The lock-up control mode is the same as the
carries out engine control to match the op- conventional lock-up function. It cannot be
erating mode selected by the operator, and selected in combination with the above
acts to reduce fuel consumption, extend the modes.
life of the track shoes, and reduce the fre-
quency of operation of the deceleration.
The engine control modes consist of the
economy mode control used when dozing,
the SSC (shoe slip control) used when rip-
ping, and the reverse slow mode control,
which can be used for either operation.
10-106 D475A-3
Function of mode selection system Function of engine controller

The system consists of the mode selection The engine controller controls the fuel injec-
panel (containing a microcomputer) to se- tion pump according to the lowest engine
lect working condition, steering controller speed (highest voltage) in the 3 signals of
(containing a microcomputer) to control the the manual command input from the decel-
engine, engine controller to receive the com- eration potentiometer, manual signal of the
mands from the steering controller and con- throttle dial, and the SSC command signal.
trols the fuel injection pump, transmission
controller to turn on and off the lock-up sys-
tem of the torque converter according to the
signals from the transmission output speed
sensor, and various sensors.
The function of each controller is explained
below.
Functions of steering controller and

transmission controller
1. The steering controller calculates the travel
speed of the ground from the signals of the
acceleration sensor and inputs the transmis-
sion output speed sensor signal to it to cal-
culate the shoe speed, then obtains the shoe
slip rate.
2. If the engine speed sensor signal and trans-
mission output speed sensor signal are in-
put, the steering controller calculates the trac-
tion force.
3. The steering controller calculates the opti-
mum engine speed from the results of 1 and
2 above, mode set signal of the monitor
panel, and speed information from the trans-
mission controller, then sends it as the SSC
command to the engine controller.
4. The transmission controller sends the lock-
up signal to the lock-up solenoid valve, judg-
ing from the input gear speed information
of the transmission controller.
See OPERATION OF TORQUE CON-
VERTER LOCK-UP CONTROL SYSTEM.
D475A-3 10-107
Operation of mode selection system

Work can be performed under the optimum conditions by simply or simultaneously selecting five
modes in accordance with the contents of work.
Single Simulta-
Work Mode selection neous Mode work conditions Mode operation, characteristic
switch
selection
ON/OFF switching is automatically per- 1. When the torque converter approaches to the
formed in accordance with the load. stall area or performs gear shift operation, lock-
up is set to OFF. When the torque converter
Speed number of F1, F2, F3 reaches a light load, lock-up is set to ON.
gear ratios R1, R2, R3
2. Can be used in all number of gear ratios.
Lock-up
Low ON 1,360 rpm or more 3. Simultaneous selection disabled with another

speed mode
T/C side OFF 1,330 rpm or more 4. Suitable for dozing work of comparatively a few
output
shaft load fluctuations.
speed High ON 2,570 rpm or more
speed
side OFF 2,600 rpm or more
Dozing
1. When F1 is shifted with the economy 1. When the economy mode (1 or 2) and SSC are
mode switch 1 or 2 ON set simultaneously, the F1 shift economy con-
trol is performed. When the ripper lever is actu-
ated and the switch is turned on, the slip control
Economy
is performed.
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 about 40% and performs the engine output con-
ON trol if a ripper down signal is input.
SSC (Shoe Slip Control)
2. The steering controller performs the engine out-

put control in accordance with the index force
characteristic (refer to the rock-bed selection
Ripping
shown below) selected by the operator among

the index force characteristics set in five stages
and suppresses the generation of a slip.
3. The steering controller regards the index force
immediately before the slip (exceeding the shoe
slipping ratio of 30% is generated, as the maxi-
mum, and performs the engine output control.
At this time, the steering controller performs
index characteristic down of about 30 to 80%
and performs the engine output control if a rip-
per tilt or ripper up signal is input.
4. At neutral time, the engine speed is suppressed
partially.
Rock-bed
selection
Set to ON in connection with SSC 1. When the SSC is set to ON, the selection mode
3 comes on.
2. 1 3 5 is selected in accordance with the
state and load of the rock-bed.
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.
10-108 D475A-3
SENSORS
Transmission output shaft speed sensor
1. Magnet
2. Terminal
3. Case
5. Boots
6. Connector
D475A-3 10-109
Torque converter speed sensor
1. Connector
2. Flange
3. Sensor
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
The acceleration sensor is installed under

the front of the operators cab.
With the acceleration sensor, the position of
the ball inside the sensor changes according
to the acceleration.
Inside the sensor, there is a coil that detects
the position of the ball. This is amplified by
the amp and is sent as a voltage change to
the SSC controller.
The input and output characteristics of the
sensor are shown in the diagram on the right.
10-110 D475A-3
Pitch angle sensor
1. Body
2. Tube
3. Wire
4. Connector
D475A-3 10-111
STRUCTURE AND FUNCTION ELECTRICAL EQUIPMENT
ELECTRICAL EQUIPMENT
Relay box
10-112 D475A-3
Operation of lamp system
Lamp system circuit diagram
D475A-3 10-113
Preheating (Electrical intake air heater) control
Preheating circuit
10-114 D475A-3
STRUCTURE AND FUNCTION STEERING ELECTRONIC CONTROL
STEERING ELECTRONIC CONTROL
1. Monitor panel (Speed range display) 6. Steering control valve

2. Auto shift down switch 7. Transmission output shaft speed sensor
3. Engine controller ( Torque converter output shaft speed sensor)
4. Transmission controller 8. Transmission control valve
5. Steering controller 9. Engine speed sensor
Serial No.: 10695, 10698, 10700 10704
10-116 D475A-3
STRUCTURE AND FUNCTION STEERING ELECTRONIC CONTROL
Shift Mode Function

1. Function
If you shift the lever to the forward or re-
verse, 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-R2A
3 F1-R1 (Manual mode)
3. Selecting method
Shift the steering or forward-reverse lever
to N.
Shift switch ON Shift switch ON
Manual mode Shift mode 1 Shift mode 2
Neutral switch ON Neutral 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 machine is in operation.
2. Selecting method
Turn auto shift-down switch (1) ON.
3. Operation and features of the mode
1) This function turns on the shift-down au-
tomatically by calculating the drawbar pull
(load to the machine body) based the
engine speed, transmission speed and
throttle information from the steering con-
troller.
2) Once the machine is automatically shifted
down, shift-up wont be turned on auto-
matically (shift up from the manual switch
is available, though).
1) This function is available for both the
forward and reverse travel.
D475A-3 10-117
20 TESTING AND ADJUSTING
Standard value table for engine related parts .................................................................................... 20- 2

Standard value table for chassis related parts .................................................................................... 20- 3
Standard value table for electrical related parts ................................................................................. 20- 9
Testing and adjusting ............................................................................................................................. 20-101
Troubleshooting ...................................................................................................................................... 20-201
Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results
of various tests. It is used for reference together with the state of repair and the history of operation to judge
if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
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.
D475A-3 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Engine SDA12V140-1
Item Measurement conditions Unit Standard value Service limit

for new machine value
High idling 2,100 2,200
Engine speed Low idling rpm 600 700
Rated speed 2,000
Air supply pressure At rated output kPa Min. 120 {900} Min. 107 {800}
(boost pressure) {mmHg}
Whole speed range

Exhaust temperature (ambient temperature: C Max. 650 Max. 750
20C)
At sudden acceleration Bosch Max. 4.0 7.0

Exhaust gas color index
At high idling Max. 1.0 2.5
Valve clearance Intake valve 0.43

(normal temperature) mm
Exhaust valve 0.80
Compression pressure Engine oil temperature: MPa 2 Min. 3.63 {37} Min. 2.65 {27}
(SAE15W-40 or 40 60C {kg/cm }
SAE30 oil) (Engine speed) (rpm) (160 200) (160 200)
Blow-by pressure At rated output kPa Max. 1.47 Max. 2.94

(SAE15W-40 or (SAE15W-40 or SAE30) {mmH2O} {Max. 150} {Max. 300}
SAE30 oil) (SAE10)
At high idling
(SAE15W-40 or SAE30) 0.39 0.54 {4.0 5.5} Min. 0.25 {2.5}
(SAE10) 0.29 0.44 {3.0 4.5} Min. 0.20 {2.0}
Oil pressure MPa
(Water temperature: {kg/cm2}
Min. 80C) At low idling
(SAE15W-40 or SAE30) Min. 0.12 {1.2} Min. 0.10 {1.0}
(SAE10) Min. 0.10 {1.0} Min. 0.08 {0.8}
Whole speed range

Oil temperature (oil pan) C 80 110 120
Fuel injection timing Before top dead center 12 1
Alternator belt
tension 20 2
Deflection when pressed
with finger force of mm
Air conditioner approx. 58.8 N {6kg}
compressor 20 2
belt tension
20-2 D475A-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Model D475A-3
Cate- Standard Permissible

gory Item Measurement conditions Unit value value
Deceleration Engine water temperature:
low idling Within operating range 850 950 850 950
speed Power train oil temperature:
Within operating range
Deceleration Hydraulic oil temperature:
high idling 45 55C 2,000 50 2,000 50
Engine speed
speed
Deceleration Lo:
Torque Decelerator pedal depressed rpm
converter stall Deceleration Hi: 1,630 1,730 Min. 1,590
speed Directional lever at N + work equipment
control levers at HOLD
Torque converter Torque converter stall: F3 stall
stall + work Torque converter stall + work equipment
equipment relief relief: F3 stall + pitch back relief 1,480 1,600 Min. 1,420
speed
Engine stopped Neutral 30 5 Max. 8.0

Center of lever knob FORWARD
Direction
Neutral 30 5 30 5
PCCS lever
REVERSE
mm
Full stroke (Neutral 40 5 40 5
Left, right) (Play: Max. 3) (Play: Max. 3)
Steering Until clutch is
completely 95 95
disengaged
Control lever, pedal stroke
Engine stopped 45 15 45 15
Deceleration pedal Center of pedal mm
Engine at low idling 75 10 75 10

Center of pedal Full stroke
mm
Brake pedal
Stroke until oil
pressure 54 10 54 10
becomes 0
Engine at low idling HOLD RAISE, 72 10 72 10

Hydraulic oil FLOAT
Blade lever temperature: 45 55C mm
Center of lever knob HOLD Left, 53 10 53 10
right tilt
Engine at low idling HOLD RAISE, 81 10 81 10

Hydraulic oil LOWER
Ripper lever temperature: 45 55C mm
Center of lever knob HOLD Tilt in, 81 10 81 10
tilt out
D475A-3 20-3
Model D475A-3

Engine stopped Neutral 53.9 9.8 53.9 9.8
Center of lever knob FORWARD {5.5 1.0} {5.5 1.0}
Direction
Neutral 53.9 9.8 53.9 9.8
REVERSE {5.5 1.0} {5.5 1.0}
Until clutch is 14.7 4.9 14.7 4.9

completely {1.5 0.5} {1.5 0.5}
PCCS lever
disengaged
Left N
Until brake takes {kg} 26.5 4.9 26.5 4.9
effect and {2.7 0.5} {2.7 0.5}
machine turns
Control lever, pedal operating effort
Steering Until clutch is 16.7 4.9 16.7 4.9

completely {1.7 0.5} {1.7 0.5}
disengaged
Right
Until brake takes 29.4 4.9 29.4 4.9

effect and {3.0 0.5} {3.0 0.5}
machine turns
Engine stopped N 49.0 9.8 49.0 9.8
Deceleration pedal Center of pedal {kg} {5.0 1.0} {5.0 1.0}
Engine at low idling N 460.6 49.0 460.6 49.0
Brake pedal Center of pedal {kg} {47.0 5.0} {47.0 5.0}
Engine at low idling 32.7 4.9 32.7 4.9
Hydraulic oil HOLD RAISE
{3.3 0.5} {3.3 0.5}
temperature: 45 55C
Center of lever knob N 80.0 3.9 80.0 3.9
Blade lever HOLD FLOAT {kg} {8.2 0.4} {8.2 0.4}
HOLD 27.7 9.8 27.7 9.8
Left, right tilt {2.8 1.0} {2.8 1.0}
Engine at low idling HOLD 18.6 4.9 18.6 4.9
Hydraulic oil RAISE, LOWER {1.9 0.5} {1.9 0.5}
Ripper lever temperature: 45 55C N
Center of lever knob HOLD {kg} 18.6 4.9 18.6 4.9
Tilt in, tilt out {1.9 0.5} {1.9 0.5}
Torque converter oil 0.03 0.20 0.03 0.20
temperature: Within Low idling
{0.3 2.0} {0.3 2.0}
Torque converter operating range
inlet pressure 0.8 1.0 0.8 1.0
High idling
{8.0 10.0} {8.0 10.0}
Power train oil pressure
Low idling 0.03 0.15 0.03 0.15

{0.3 1.5} {0.3 1.5}
Torque converter
outlet pressure 0.44 0.64 0.44 0.64
High idling MPa {4.5 6.5} {4.5 6.5}
{kg/
cm2} 1.12 1.42 1.12 1.42
Low idling
Torque converter {11.5 14.5} {11.5 14.5}
lock-up clutch
pressure High idling 1.12 1.42 1.12 1.42
{11.5 14.5} {11.5 14.5}
Low idling 2.55 2.74 Min. 2.45

Torque converter {26.0 28.0} {Min. 25}
stator clutch
pressure High idling 2.55 2.74 Min. 2.55
{26.0 28.0} {Min. 26}
20-4 D475A-3
Model D475A-3

Torque converter oil 2.56 2.91 Min. 2.45
Transmission main {26.1 29.7} {Min. 25}
operating range
relief pressure
High idling 2.65 3.03 Min. 2.55
{27.0 30.9} {Min. 26}

Transmission F MPa {24.0 28.0} {Min. 23}
clutch pressure {kg/
High idling cm2} 2.50 2.74 Min. 2.40
{25.5 28.0} {Min. 24.5}

Transmission R {24.0 28.0} {Min. 23}
clutch pressure
{25.5 28.0} {Min. 24.5}
Transmission 1st {20.0 24.0} {Min. 1.9}
operating range
clutch pressure
{21.7 24.0} {Min. 20.5}

Transmission 2nd {24.0 28.0} {Min. 23}
clutch pressure MPa 2.50 2.74 Min. 2.40
Power train oil pressure
High idling {kg/ {25.5 28.0} {Min. 24.5}

cm2}
Transmission 3rd {24.0 28.0} {Min. 23}
clutch pressure
{25.5 28.0} {Min. 24.5}
Transmission 0.1 0.2 0.1 0.2
lubrication pressure High idling
{1.0 2.0} {1.0 2.0}
Steering left clutch {26.1 29.7} {Min. 25}
operating range
pressure
{27.0 30.9} {Min. 26}

Steering left brake {26.1 29.7} {Min. 25}
pressure
MPa {27.0 30.9} {Min. 26}
{kg/
Low idling cm2} 2.56 2.91 Min. 2.45
Steering right {26.1 29.7} {Min. 25}
clutch pressure
{27.0 30.9} {Min. 26}

Steering right {26.1 29.7} {Min. 25}
brake pressure
{27.0 30.9} {Min. 26}
Torque converter oil MPa 2.65 3.03 Min. 2.55
Pin puller temperature: Within High idling
actuation pressure {kg/ {27.0 30.9} {Min. 26}
operating range cm2}
D475A-3 20-5
Model D475A-3

Level road surface FORWARD
1st 3.4 0.2 3.4 0.2
Engine at high idling
Lock-up switch OFF

Engine water FORWARD
temperature: 2nd 6.3 0.3 6.3 0.3
Within operating FORWARD
range 3rd 10.9 0.5 10.9 0.5
Economy mode: OFF
REVERSE
REVERSE slow mode: 1st 4.3 0.2 4.3 0.2
OFF
Run-up distance: REVERSE
2nd 7.9 0.4 7.9 0.4
10 30 m
Power trainl
Measurement REVERSE
3rd 13.9 0.7 13.9 0.7
distance: 20 m km/h
Travel speed
FORWARD 3.5 0.2
1st 3.5 0.2
Lock-up switch ON
FORWARD 6.4 0.3

2nd 6.4 0.3
FORWARD 11.4 0.6
3rd 11.4 0.6
REVERSE 4.7 0.2
1st 4.7 0.2
REVERSE 8.2 0.4
2nd 8.2 0.4
REVERSE 14.5 0.7
3rd 14.5 0.7
Hydraulic oil Engine at low 18.6 20.6 Min. 18.1

Front pump relief temperature: idling {190 210} {Min. 185}
pressure 45 55C Engine at high 20.1 21.6 Min. 19.6
Relieve only circuit idling {205 220} {Min. 200}
that is being
measured Engine at low 18.6 20.6 Min. 18.1
Work equipment pressure
Rear pump relief idling {190 210} {Min. 185}

pressure Engine at high 20.1 21.6 Min. 19.6
idling {205 220} {Min. 200}
MPa
Engine at low {kg/ 18.6 20.6 Min. 18.1
Assist pump relief idling cm2} {190 210} {Min. 185}
pressure Engine at high 20.1 21.6 Min. 19.6
idling {205 220} {Min. 200}
Hydraulic oil temperature: Engine at low 3.73 4.41 Min. 3.53
Work equipment 45 55C idling {38.0 45.0} {Min. 36.0}
control pressure All work equipment 4.02 4.71 Min. 3.92
control levers at HOLD Engine at high
idling {41.0 48.0} {Min. 40.0}
PPC valve pressure Hydraulic oil temperature:
Engine at high 4.02 4.71 Min. 3.92
outlet port 45 55C
Lever, stroke end idling {41.0 48.0} {Min. 40.0}
pressure
Blade tilt
Oil leakage from cylinder
Hydraulic oil temperature: 45 55C

Work equipment
cylinder Engine at high idling

Blade pitch Measure oil leakage during 1 minute
cylinder when cylinder is relieved cc/
Ripper lift min
cylinder
Ripper tilt
cylinder
20-6 D475A-3
Model D475A-3

Measurement posture Low
13.0 18.0 Max. 20.0
idling
RAISE
Blade lift High
3.6 4.6 Max. 5.0
(Single tiltdozer idling
specification) sec
(Dual tiltdozer Low
specification) 1.0 1.5 Max. 2.0
LOWER
idling
Blade: No load
Blade in contact with ground Raised High
1.0 1.5 Max. 2.0
to max. height idling

18.0 25.0 Max. 28
idling
RAISE
High
5.5 6.5 Max. 8.0
Blade lift idling
(Superdozer sec
specification) Low
1.2 1.8 Max. 2.8
LOWER
idling
Work equipment
Blade: No load
Blade speed
Blade in contact with ground Raised High

to max. height 1.2 1.8 Max. 2.0
idling

14.1 17.3 Max. 19.0
Left tilt
idling
High
4.3 5.3 Max. 7.0
Blade tilt idling
(Single tiltdozer sec
specification) Low
9.7 11.9 Max. 14.0
Right tilt
idling
Hydraulic oil temperature:
45 55C High
Blade: No load 3.0 3.6 Max. 5.0
Full left tilt Full right tilt idling

Left tilt
idling
High
Blade tilt idling
(Dual tiltdozer sec
specification) Low
Right tilt
idling
45 55C High
Blade: No load
D475A-3 20-7
Model D475A-3


Left tilt
idling
High
4.0 5.0 Max. 7.0
Blade tilt idling
(Superdozer sec
specification) Low

Right tilt
idling
45 55C High

Pitch dump
idling
Blade pitch High

(Dual tiltdozer idling
specification) sec
Serial No.: Low
Pitch back
10601 to 8.0 12.0 Max. 14.0

idling
Work equipment
45 55C
Blade speed
High
Full pitch back full pitch dump idling

Pitch dump
idling
High
Blade pitch idling
(Dual tiltdozer sec
specification)
Serial No.: Low
Pitch back
10.0 13.0 Max. 15.0

and up idling
45 55C High

Pitch dump

idling
High
7.0 9.0 Max. 10.0
Blade pitch idling
(Superdozer sec
specification) Low
Pitch back
20.0 30.0 Max. 35.0

idling
45 55C High
20-8 D475A-3
Model D475A-3

idling 7.4 9.0 Max. 12.0
RAISE
High
idling 2.2 2.8 Max. 4.0
Ripper lift sec
Low
Hydraulic oil temperature: 2.2 3.2 Max. 5.0
LOWER
idling
45 55C
Lowest shank hole
Ripper speed
High
Ripper in contact with ground 2.0 3.0 Max. 4.0
Raised to max. height idling

Tilt in
idling 15.7 19.1 Max. 24.0
High
idling 4.8 5.8 Max. 7.0
Ripper tilt sec
Low
10.0 15.0 Max. 18.0
Tilt out
idling
Lowest shank hole High
Ripper in contact with ground 3.5 4.5 Max. 5.0
Raised to max. height idling
Blade Hydraulic oil temperature: Low

45 55C idling Max. 10.0 Max. 10.0
(Single tiltdozer
Work equipment
Raise blade to maximum height, then

specification) lower blade and measure time taken from sec
(Dual tiltdozer point where blade contacts ground to High
idling Max. 1.8 2.5
specification) point where idler comes off ground
Hydraulic oil temperature: Low
Time lag
Blade 45 55C idling Max. 12.0 Max. 12.0

(super dozer Raise blade to maximum height, then sec
lower blade and measure time taken from
specificaiton) point where blade contacts ground to High
idling Max. 2.0 3.0
point where idler comes off ground
45 55C
Raise ripper to maximum height, then High
Ripper lower ripper and measure time taken from idling sec Max. 0.5 1.5
point where ripper contacts ground to
point where final drive comes off ground
Measurement posture
Hydraulic drift
mm/ Max. 150/15

Blade lif min Max. 300/15

Engine stopped
Raise blade to maximum height, then
measure hydraulic drift for 15 minutes at
bottom edge of blade (change in height h)
D475A-3 20-9
Model D475A-3
Cate- Item Measurement conditions Unit Standard Permissible

gory value value
Measurement posture
Blade tilt
mm/
min Max. 50/5 Max. 100/5

Lowest shank hole
Tilt blade fully to raise track on one side, then
measure hydraulic drift for 5 minutes at bottom tip
shoe (change in height h)
Measurement posture
Hydraulic drift
mm/
of chassis min Max. 50/5 Max. 100/5
Work equipment
(blade)
Hydraulic drift

Engine stopped
Raise front of machine with blade, then measure
hydraulic drift for 5 minutes at center of idler (change
in height h)
Measurement posture
Ripper lift mm/

min Max. 80/15 Max. 160/15
Engine stopped
Raise ripper fully, then measure hydraulic drift for
15 minutes at bottom tip of shank (change in
height h)
Measurement posture
Hydraulic drift
mm/
of chassis min Max. 30/5 Max. 60/5
(ripper)
Engine stopped
Raise rear of machine with ripper, then measure
hydraulic drift for 5 minutes at center of final drive
(change in height h)
20-10 D475A-3
Table of tools for testing, adjusting, and troubleshooting .................................................................................. 20-102

Measuring engine speed .......................................................................................................................................... 20-103
Measuring air supply pressure (boost pressure) .................................................................................................. 20-106
Measuring exhaust temperature ............................................................................................................................. 20-107
Measuring exhaust color ......................................................................................................................................... 20-108
Adjusting valve clearance ........................................................................................................................................ 20-109
Measuring compression pressure ........................................................................................................................... 20-110
Measuring blow-by pressure ................................................................................................................................... 20-111
Measuring engine oil pressure ............................................................................................................................... 20-112
Testing and adjusting fuel injection timing ........................................................................................................... 20-113
Testing and adjusting alternator belt tension ....................................................................................................... 20-114
Testing and adjusting belt tension for air conditioner compressor ................................................................... 20-114
Adjusting engine speed sensor ............................................................................................................................... 20-115
Adjusting fuel control dial and decelerator pedal ................................................................................................ 20-116
Measuring power train oil pressure ....................................................................................................................... 20-118
Simple method of testing brake performance ...................................................................................................... 20-127
Adjusting brake pedal and parking brake lever .................................................................................................... 20-128
Adjusting PCCS lever console position .................................................................................................................. 20-131
Emergency escape method when power train has trouble ................................................................................. 20-132
Adjusting clearance of idler ..................................................................................................................................... 20-135
Testing and adjusting track shoe tension .............................................................................................................. 20-136
Measuring and adjusting work equipment oil pressure ...................................................................................... 20-137
Testing and adjusting work equipment control circuit pressure ........................................................................ 20-142
Measuring PPC valve and pitch tilt control valve output pressure .................................................................. 20-144
Adjusting PPC valve ................................................................................................................................................. 20-148
Measuring output pressure of demand solenoid valve ....................................................................................... 20-149
Measuring output pressure of ripper pin-puller solenoid valve ......................................................................... 20-150
Checking location of cause of hydraulic drift of blade and ripper ..................................................................... 20-151
Measuring leakage inside hydraulic cylinder ........................................................................................................ 20-152
Releasing remaining pressure in hydraulic circuit ............................................................................................... 20-153
Bleeding air from hydraulic cylinders .................................................................................................................... 20-153
Adjusting work equipment safety lever ................................................................................................................. 20-154
Adjusting ripper lever position ............................................................................................................................... 20-155
Procedure for adjusting blade tilt limit angle (dual tilt dozer specification) ..................................................... 20-156
Special function of monitor panel (EMMS) ........................................................................................................... 20-158
Adjustment method of replaced controller ............................................................................................................ 20-202
Preparation work for troubleshooting for electric system ................................................................................... 20-204
Handling of optional devices ................................................................................................................................... 20-206
Pm clinic service ....................................................................................................................................................... 20-207
Undercarriage troubleshooting report .................................................................................................................... 20-215
D475A-3 20-101
TABLE OF TOOLS FOR TESTING, ADJUSTING,
TESTING AND ADJUSTING AND TROUBLESHOOTING
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND

TROUBLESHOOTING
Check or measurement item Symbol Part No. Part Name Remarks
Air supply pressure 101 199.9 kPa {760 1,500 mmHg}
A 7992012202 Boost gauge kit
(boost pressure) Negative pressure measurement type
Water temperature, oil tem-
B 7991011512 Digital temperature gauge 99.9 1.299C
perature, exhaust temperature
1 7992019000 Handy smoke checker Discoloration: 0 70% (with

standard color)
Exhaust color C
Commercially (discoloration x 1/10 = Bosch
2 available Smoke meter index)
Valve clearance D 7951251210 Feeler gauge Intake: 0.43 mm, exhaust: 0.80 mm
7955021205 Compression gauge 0 6.9 MPa {0 70 kg/cm2}
Compression pressure E 7955021510 Adapter

For 140 Engine Series
7955021520 Plate
Blow-by pressure F 7992011504 Blow-by checker 0 4.9 kPa {0 500 mmH2O}
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa

7991015002 Hydraulic tester
{25, 60, 400, 600 kg/cm2}
Pressure gauge:
7902611203 Digital hydraulic tester 58.8 MPa {600 kg/cm2}
1
Oil pressure G 7991015220 Nipple
For 10 x 1.25 plug
0700211023 O-ring
Pressure gauge:
2 7994012320 Hydraulic gauge
0.98 MPa {10 kg/cm2}
Blade tilt control angle J 7994023800 Angle gauge
79A2640021 Push-pull scale 0 294 N {0 30 kg}

Operating effort K
79A2640091 Push-pull scale 0 490 N {0 50 kg}
Commercially
Stroke, hydraulic drift L available Scale
Commercially
Work equipment speed M available Stopwatch
Voltage, resistance value N 79A2640211 Tester
7996018000 T-adapter assembly

Troubleshooting of wiring
P
harness, sensor
7996017360 Adapter For relay (5 pin)
20-102 D475A-3
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED
Measure the engine speed under the follow- The engine speed can be measured in the
ing condition. Pm Clinic auxiliary mode of the monitor
Engine water temperature: panel (Measure the high idling speed of the
Within operating range engine in the Adjustment mode, however).
Torque converter oil temperature:
Power train oil temperature:
1. Preparation work
Turn the starting switch ON and set the
monitor panel in the Monitoring mode to
prepare for measurement of the engine
speed.
For the operating method, see SPECIAL
FUNCTIONS OF MONITOR PANEL
(EMMS).
Monitoring code: 01000 (Engine speed)
2. Measuring low idling speed

1) Start the engine and set the fuel control
dial in the low idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the
engine speed.
D475A-3 20-103
3. Measuring high idling speed 5. Measuring torque converter stall speed

1) Start the engine and set the fuel control 1) Start the engine and set the fuel control
dial in the high idling position. dial in the low idling position.
2) Set the PCCS lever and work equipment 2) Press the brake pedal securely and set
control lever in neutral and measure the the parking brake lever in the FREE posi-
engine speed. tion and push the FORWARD switch and
The high idling speed measured in the 2nd gear speed position.
Monitoring mode or in the Pm Clinic Before going to the next step, check
auxiliary mode is the auto-deceleration that the upper display unit of the
speed. monitor panel is set in the normal
When measuring the high idling speed display state and it displays [F2].
of the engine, use the Adjustment Keep the steering unit in neutral.
mode. 3) Press the decelerator pedal and set the
Adjustment code: fuel control dial in the high idling posi-
0007 (Engine decelerator cut mode) tion.
4) Return the decelerator pedal slowly to
stall the torque converter with the en-
gine at high idling.
Keep pressing the brake pedal se-
curely and keep your right foot on
the decelerator pedal for safety until
the work is finished.
5) Just after the power train oil tempera-
ture gauge reads the top line of the green
range, push the neutral switch to neu-
tral.
6) Repeat above steps 2) 5) 3 times.

7) Perform steps 2) 4) again and measure
the engine speed about 5 seconds after
the power train oil temperature gauge
4. Measuring decelerator pedal speed reads the top line of the green range.
1) Start the engine and set the fuel control After finishing measurement, push
dial in the high idling position. the neutral switch to neutral and
2) Set the PCCS lever and work equipment lower the power train oil tempera-
control lever in neutral and press the ture with the engine at high idling.
decelerator pedal and measure the en-
gine speed.
20-104 D475A-3
6. Torque converter stall + Work equipment 7) Perform steps 2) 4) again and relieve
relief speed (Full stall speed) the ripper in the raising direction and
1) Start the engine and set the fuel control measure the engine speed about 5 sec-
dial in the low idling position and raise onds after the power train oil tempera-
the ripper to the stroke end. ture gauge reads the top line of the green
2) Keep pressing the brake pedal securely range.
and set the parking brake lever in the After finishing measurement, push
FREE position and push the FORWARD the neutral switch to neutral and
switch and 2nd gear speed position. lower the power train oil tempera-
Before going to the next step, check ture with the engine at high idling.
that the upper display unit of the
monitor panel is set in the normal
display state and it displays [F2].
Set the steering unit in neutral.
3) Press the decelerator pedal and set the
fuel control dial in the high idling posi-
tion.
4) Return the decelerator pedal slowly to
stall the torque converter with the en-
gine at high idling.
Keep pressing the brake pedal se-
curely and keep your right foot on
the decelerator pedal for safety until
the work is finished.
5) Just after the torque converter oil tem-
perature gauge reads the top line of the
green range, push the neutral switch to
neutral.
6) Repeat above steps 2) 5) 3 times.
D475A-3 20-105
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY

PRESSURE
(BOOST PRESSURE)
Be careful not to touch any hot parts when re-

moving or installing the measuring tools.
Measure the air supply pressure separately for
the left and right banks.
Measure the air supply pressure under the fol-
lowing conditions.
Coolant temperature: Within operating range
Power train oil temperature: Within operat-
ing range
Hydraulic temperature: 45 55C
1. Remove air supply pressure measurement plugs

(1) or (2) (PT1/8).
Plug (1): For right bank
Plug (2): For left bank
2. Fit nipple 1 (PT 1/8) and hose 2 of oil pressure

gauge kit H1, then connect boost gauge A.
3. Run the engine at a mid-range speed or above

to bleed the oil from the hose.
Insert the connection of the hose and pres-
sure gauge about half way, repeat the ac-
tion to open the self-seal portion at the hose
end, and bleed the oil.
If Pm kit (A) is available, the air bleed cou-
pling (790-261-1130) inside the kit can be
used.
If there is oil inside the hose, the gauge will
not work, so always bleed the oil.
4. Run the engine at high idling to stall the torque

converter, and read the air supply pressure (boost
pressure).
For details of the procedure for stalling the
torque converter, see MEASURING TORQUE
CONVERTER STALL SPEED.
The air supply pressure (boost pressure)
should be measured with rhe engine run-
ning at rated output. However,when meas-
uring in the field, a similar value can be
obtained at torque converter stall speed.
20-106 D475A-3
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST
TEMPERATURE
Wait for the mainfold temperature to go down
before removing or installing the sensor.
Measure the exhaust temperature under the fol-
lowing conditions.
ing range
1. Remove the engine right bank adiabatic cover.
2. Remove exhaust temperature measurement plug

(1) or (2) (PT 1/8).
Plug (1): For right bank
Plug (2): For left bank
3. Fit sensor 1 of digital temperature gauge B,

then connect digital temperature gauge B.
Clamp the wiring harness of the tempera-
ture gauge to prevent it from touching any
hot part during measurement.
4. Carry out actual work at engine high idling and

measure the maximum value for the exhaust
temperature during operation.
Use the PEAK mode of the digital tempera-
ture gauge.
The exhaust temperature varies greatly ac-
cording to the ambient temperature (tem-
perature of the engine intake air), so if any
abnormal value is obtained, carry out tem-
perature compensation using the following
formula.
Compensation value [C] = Measured
value + 2 x (20 ambient temperature)
D475A-3 20-107
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

Be careful not to touch any hot parts when re-
moving or installing the measuring tools.
When measuring in the field where there is no
air or electric power supply, use Handy Smoke
Checker C1; when recording formal data, use
Smoke Meter C2.
Measure the exhaust color under the following
conditions.
Engine water temperature: Within operating
range
1. Measuring with Handy Smoke Checker C1.

1) Install fillter paper to Handy Smoke Checker
C1.
2) Insert the exhaust gas suction port into the
exhaust pipe.
3) Accelerate the engine suddenly, and operate
the handle of Handy Smoke Checker C1 at
the same time to collect the exhaust gas on
the filter paper.
4) Remove the filter paper and compare it with
the scale supplied to judge the condition.
2. Measuring with Smoke Meter C2

1) Insert probe 1 of Smoke Meter C2 into the
outlet port of exhaust pipe, and tighten the
clip to secure it to the exhaust pipe.
2) Connect the air hose and the socket of the
probe hose and accelerator switch to Smoke
Meter C2.
Keep the pressure of the air supply be-
low 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC socket.
When connecting the cord, check that
the power switch of the Smoke Meter is
OFF.
4) Loosen the cap nut of the suction pump and
fit the filter paper.
Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of Smoke Meter C2
ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of Smoke Meter C2 at
the same time to collect the exhaust gas
color on the filter.
7) Place the filter paper used to catch the ex-
haust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
20-108 D475A-3
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover.
REMOVAL OF CYLINDER HEAD ASSEMBLY.
2. Rotate the crankshaft in the normal direction to

align the R1.6TOP line on crankshaft pulley (1)
with pointer (2) and set the R1 cylinder to com-
pression top dead center.
At the compression top dead center, the
rocker arms for both the intake and exhaust
move.
If the rocker arms do not move, the cylinder
is not at compression top dead center, so
rotate the crankshaft one more turn and align
the lines again.
Use the hexagonal shaft of the alternator
drive pulley when cranking.
3. Insert feeler gauge D between crosshead (4) and

rocker arm (3) of the R1 cylinder, adjust with
adjustment screw (5) until the clearance is a
sliding fit, then tighten locknut (6) to hold ad-
justment screw (5) in position.
3 Locknut: 58.8 5.9 Nm {6 0.6 kgm}
After tightening the locknut, check the valve
clearance again.
4. After adjusting the R1 cylinder at compression

top dead center, turn the crankshaft 120 each
time, align each TOP line on crankshaft pulley
(1) with pointer (2), and adjust the clearance of
the valves of each cylinder according to the fir-
ing order.
Firing order :
R1 L1 R5 L5 R3 L3 R6 L6 R2
L2 R4 L4
D475A-3 20-109
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
When measuring the compression pressure, be
extremely careful not to touch the exhaust mani-
fold or any other hot parts or get caught in the
fan belt or any other rotating parts.
1. Adjust the valve clearance.

For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Warm up the engine so that the engine oil tem-

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

cylinder which is to be measured.
For details, see DISASSEMBLY AND ASSEM-
BLY, REMOVAL OF NOZZLE HOLDER AS-
SEMBLY.
4. Fit adapter 1 of compression gauge E, then

connect compression gauge E.
5. Disconnect governor solenoid connector E15 (1)

of the right fuel injection pump and governor
solenoid connector E11 (2) of the left fuel
injection pump.
6. Turn the starting switch on and set the monitor

panel to monitoring code [99].
For details, see MEASURING ENGINE SPEED.
7. Crank the engine with the starting motor and

measure the compression pressure.
Measure the compression pressure at the
point where the pressure gauge indicator
remains steady.
When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.
20-110 D475A-3
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
Measure the blow-by pressure under the follow-
ing conditions.
ing range
1. Install nozzle (1) of blow-by checker F to blow-

by hose 2 of the left bank, then block the hose
connection.
Connect the short hose and throttle the out-
let port.
2. Install nozzle 1 and hose (2) of blow-by checker

F to blow-by hose (2) of the right bank, then
connect blow-by checker F.
3. Run the engine at engine high idling and meas-

ure the value on the gauge when the torque
converter is stalled.
For details of the procedure for torque con-
verter stall, see MEASURING TORQUE CON-
VERTER STALL SPEED.
The blow-by should be measured with the
engine running at rated output. However,
when measuring in the field, a similar value
can be obtained at torque converter stall.
If it is impossible to check at rated output or
stall speed, measure at high idling.
In this case, the blow-by value will be about
80% of the value at rated output.
Blow-by varies greatly according to the con-
dition of the engine. Therefore, if the blow-
by value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defec-
tive exhaust gas color, and prematurely dirty
or deteriorated oil.
D475A-3 20-111
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
Measure the engine oil pressure under the fol-
lowing conditions.
1. Remove engine pressure pickup plug (1) (PT 1/8).
2. Fit nipple 1 and hose 2 of oil pressure gauge

G1, then connect to oil pressure gauge G2 (0.98
MPa {10 kg/cm2}).
3. Start the engine, and measure the oil pressure

at low idling and high idling.
20-112 D475A-3
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
Carry out testing and adjusting fuel injection
timing for the left and right banks at the same
time.
Testing
1. Remove the fuel injection pump cover.
2. Crank the engine to rotate the crankshaft in the

normal direction and align 12 line (1) on the
crankshaft pulley with pointer (2).
When doing this, check that line (3) on the
coupling of the fuel injection pump is close
to line (4) on the body.
If line (3) on the coupling cannot be seen,
rotate the crankshaft one more turn.
Use the hexagonal shaft of the alternator
drive pulley when cranking.
3. Check that line (3) on the coupling of the fuel

injection pump is aligned with line (4) on the
body.
Adjusting
If the fuel injection timing is not correct, adjust

as follows.
1. Loosen 2 sets of mounting bolts and nuts (5) in
the oblong hole of the coupling and lock bolt (6)
to make the coupling free.
2. Rotate the coupling and align line (3) on the

coupling with line (4) on the body.
3. Tighten lock bolt (6) and 2 sets of mounting

bolts and nuts (5).
3 Lock bolt: 157 196 Nm {16 20 kgm}
Mounting bolt, nut:
98.0 122.6 Nm {8.5 9.5 kgm}
D475A-3 20-113
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING BELT TENSION
TESTING AND ADJUSTING FOR AIR CONDITIONER COMPRESSOR

ALTERNATOR BELT TENSION
Testing
Measure deflection a of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
alternator pulley and the drive pulley.
Deflection a of belt: 20 2 mm
Adjusting
If the belt tension is not correct, adjust as follows.
1. Loosen the mounting bolt and nut, mounting
bolt (1), and locknut (2).
2. Turn adjustment nut (3) and move alternator (4)

to adjust the tension of the belt.
3. Tighten locknut (2), mounting bolt (1) and the

mounting bolt and nut.

BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
Testing
Measure deflection a of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
compressor pulley and the engine drive pulley.
Deflection a of belt: 20 2 mm
Adjusting
If the belt tension is not correct, adjust as fol-
lows.
1. Loosen 3 mounting bolts and nuts (1) and locknut
(2).
2. Turn the adjustment nut and move air condi-

tioner compressor (3) together with the bracket
to adjust the tension of the belt.
3. Tighten locknut (2) and 3 mounting bolts and

nuts (1).
20-114 D475A-3
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED

SENSOR
Adjust both left bank speed sensor (1) and right
bank speed sensor (2) in the same way.
1. Screw in sensor body (3) so that the tip contacts

ring gear (2).
Be careful not to damage the sensor tip or
let iron particles stick to it.
2 Sensor thread: Gasket sealant (LG-6)
2. After sensor body (3) contacts ring gear (4), turn

it back 3/4 1 turn to adjust clearance a.
Clearance a: 1.2 1.5 mm
3. Tighten locknut (5).

3 Locknut : 49.0 68.6 Nm {5.0 7.0 kgm}
When fixing the wiring in position, be careful

that no excessive force is brought to bear on
the sensor wiring.
D475A-3 20-115
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
1. Outline of fuel control system

The speed signals from the fuel control dial
and the decelerator pedal potentiometers are
each input to the engine controller.
The engine controller gives priority to the
lower speed of the two input signals and
sends a command to the fuel injection pump.
Adjustment of the engine speed is all car-
ried out by the decelerator pedal linkage.
20-116 D475A-3
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 Set the fuel control dial in the high idling
panel in the Adjustment mode to pre- position and press decelerator pedal (2) to
pare for measurement of the engine the stopper and check that the decelerator
speed. pedal speed is normal.
For the operating method, see SPE- Decelerator pedal speed: 800 850 rpm
CIAL FUNCTIONS OF MONITOR If the decelerator pedal speed is abnor-
PANEL (EMMS). mal, adjust dimension a of rod (1).
Adjustment code: Standard dimension a of rod:
0007 (Engine decelerator cut mode) 122 mm (For reference)
The unit of displayed engine speed
is 1 rpm. 4. High idling speed
Set the fuel control dial in the high idling
position and check that the high idling speed
is normal.
High idling speed: 2,150 50 rpm
When engine speed is above 1,950 rpm:
Lower the engine speed below 1,900 rpm
temporarily with stopper bolt (3) to elimi-
nate the play of the decelerator pedal,
then heighten it to the high idling speed.
When engine speed is below 1,950 rpm:
Heighten the engine speed to the high
idling speed with stopper bolt (3).
2) Set the fuel control dial in the high idling

position and check that the engine speed
is above 1,000 rpm.
If the engine speed is below 1,000 rpm,
heighten it above 1,000 rpm by increas-
ing dimension a of rod (1).
D475A-3 20-117
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE

Measuring instrument for power train pressure
Symbol Part No. Name
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
G
Hydraulic tester
2 799-401-2320
(1.0 MPa {10 kg/cm2})
Stop the machine on a level place, lower the

work equipment to the ground, and set the park-
ing brake lever and safety lock lever in the LOCK
position.
Measure the power train oil pressure under the
following condition.
The centralized power train pressure pick-up
ports are installed inside the inspection cover
on the right outside of the operators cab.
List of oil pressure measuring points and gauges

to be used
Gauge
No. Mark Measured oil pressure MPa {kg/cm2}
Torque converter inlet
1 IN pressure 2.5 {25}
Torque converter outlet

2 OUT pressure 0.98 {10}
Torque converter lock-

3 LU up clutch pressure 5.9 {60}
Torque converter stator

4 SC clutch pressure 5.9 {60}
Transmission main
5 TM relief pressure 5.9 {60}
Transmission forward
6 FWD clutch pressure 5.9 {60}
Transmission reverse
7 R clutch pressure 5.9 {60}
Transmission 1st clutch

8 1ST pressure 5.9 {60}
Transmission 2nd
9 2ND clutch pressure 5.9 {60}
Transmission 3rd clutch

10 3RD pressure 5.9 {60}
Steering left clutch

11 LC pressure 5.9 {60}
Steering left brake

12 LB pressure 5.9 {60}
Steering right clutch

13 RC pressure 5.9 {60}
Steering right brake

14 RB pressure 5.9 {60}
Transmission
15 lubrication pressure 0.98 {10}
20-118 D475A-3
1. Measuring torque converter inlet pressure 2. Measuring torque converter outlet pres-
(IN) sure (OUT)
1) Connect oil pressure gauge 1 of hydrau- 1) Connect hydraulic tester G2 to oil
lic tester G1 to oil pressure pick-up nipple pressure pick-up nipple (2).
(1). Use an oil pressure gauge of 0.98
Use an oil pressure gauge of 2.5 MPa MPa {10 kg/cm2}.
{25 kg/cm2}.
2) Start the engine and set the PCCS le-

2) Start the engine and set the PCCS lever ver in the full neutral position.
in the full neutral position. 3) Measure the oil pressure while the
3) Measure the oil pressure while the en- engine is running at low idling and
gine is running at low idling and high high idling.
idling.
4) After finishing measurement, remove

4) After finishing measurement, remove the the measuring instrument and return
measuring instrument and return the re- the removed parts.
moved parts.
D475A-3 20-119
3. Measuring torque converter lock-up clutch

pressure (LU)
1) Connect oil pressure gauge 1 of hydrau-
lic tester G1 to oil pressure pick-up nipple
(3).
Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
6) After finishing measurement, remove the

measuring instrument and return the re-
moved parts.
2) Run the engine and lift up the machine

body with the blade and ripper so that
the track shoes can run idle.
After lifting up the machine body,
set the safety lock lever in the LOCK
position.
3) Turn on the lock-up mode switch.

4) Press the forward switch of the PCCS
lever and 1st speed position and make
the shoes run idle.
Take care not to be caught in the
track shoes during measurement.
5) Raise the engine speed gradually and
measure the oil pressure when the lock-
up pilot lamp lights up.
20-120 D475A-3
4. Measuring torque converter stator clutch 5. Measuring transmission main relief pressure
pressure (SC) (TM)
1) Connect oil pressure gauge 1 of hydrau- 1) Connect oil pressure gauge 1 of hydrau-
lic tester G1 to oil pressure pick-up nipple lic tester G1 to oil pressure pick-up nipple
(4). (5).
Use an oil pressure gauge of 5.9 MPa Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the PCCS lever 2) Run the engine and set the PCCS lever
in the full neutral position. in the full neutral position.
3) Measure the oil pressure while the en- 3) Measure the oil pressure while the en-
gine is running at low idling and high gine is running at low idling and high
idling. 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.
D475A-3 20-121
6. Measuring transmission forward clutch pres- 7. Measuring transmission reverse clutch pres-
sure (FWD) sure (R)
(6). (7).
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the parking brake 2) Run the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) Press the brake pedal and set the PCCS 3) Press the brake pedal and set the PCCS
lever in the FORWARD and 3rd speed lever in the REVERSE 3rd speed posi-
position. tion.
gine is running at high idling. gine is running at high idling.
Since the torque converter will be Since the torque converter will be
stalled, press the brake pedal se- stalled, press the brake pedal se-
curely and keep your right foot on curely and keep your right foot on
the decelerator pedal for safety until the decelerator pedal for safety until
the work is finished. the work is finished.
20-122 D475A-3
8. Measuring transmission 1st clutch pressure 9. Measuring transmission 2nd clutch pressure
(1ST) (2ND)
(8). (9).
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the parking brake 2) Run the engine and set the parking brake
lever in the FREE position. lever in the FREE position.
3) Press the brake pedal and set the PCCS 3) Press the brake pedal and set the PCCS
lever in the FORWARD and 1st speed lever in the FORWARD and 2nd speed
position. position.
gine is running at low idling. gine is 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 high
idling during measurement. idling during measurement.
D475A-3 20-123
10. Measuring transmission 3rd clutch pressure 11. Measuring left steering clutch pressure (LC)
(3RD) 1) Connect oil pressure gauge 1 of hydrau-
1) Connect oil pressure gauge 1 of hydraulic tester G1 to oil pressure measurement
lic tester G1 to oil pressure pick-up nipple nipple (11).
(10). Use a 5.9 MPa {60 kg/cm2} oil pres-
Use an oil pressure gauge of 5.9 MPa sure gauge.
{60 kg/cm2}.
2) Start the engine and set the parking le-

2) Run the engine and set the parking brake ver to the FREE position.
lever in the FREE position. 3) Operate the PCCS lever fully to the left.
3) Press the brake pedal and depress the Set the direction to the neutral posi-
forward switch and 2nd speed position. tion.
4) Measure the oil pressure while the en- 4) Measure the oil pressure with the en-
gine is running at low idling. gine at low idling and high idling.
Since the torque converter will be Check that the oil pressure becomes
stalled, keep pressing the brake pedal 0 when the PCCS lever is returned to
securely. neutral.
Do not raise the engine speed to high
idling during measurement.
5) After completing the measurement, re-

move the measuring equipment and set
5) After finishing measurement, remove the to the original condition.
measuring instrument and return the re-
moved parts.
20-124 D475A-3
12. Measuring left steering brake pressure (LB) 13. Measuring right steering clutch pressure (RC)
lic tester G1 to oil pressure measurement lic tester G1 to oil pressure measurement
nipple (12). nipple (13).
Use a 5.9 MPa {60 kg/cm2} oil pres- Use a 5.9 MPa {60 kg/cm2} oil pres-
sure gauge. sure gauge.
2) Start the engine and set the parking le- 2) Start the engine and set the parking le-
ver to the FREE position. ver to the FREE position.
3) Measure the oil pressure with the en- 3) Operate the PCCS lever fully to the right.
gine at low idling and high idling. Set the direction to the neutral posi-
Check that the oil pressure becomes tion.
0 when the PCCS lever is operated 4) Measure the oil pressure with the en-
fully to the left. gine at low idling and high idling.
Check that the oil pressure becomes Check that the oil pressure becomes
0 when the brake pedal is depressed 0 when the PCCS lever is returned to
or the parking lever is operated to neutral.
the LOCK position.

4) After completing the measurement, remove the measuring equipment and set
move the measuring equipment and set to the original condition.
to the original condition.
D475A-3 20-125
14. Measuring right steering brake pressure (RB) 15. Measuring transmission lubrication pressure
1) Connect oil pressure gauge 1 of hydrau- 1) Remove oil pressure measurement plug
lic tester G1 to oil pressure measurement (15) (PT1/8).
nipple (14). 2) Fit nipple 1 and hose 2 of oil pressure
Use a 5.8 MPa {60 kg/cm2} oil pres- gauge G1, then connect oil pressure
sure gauge. gauge G2 (0.98 MPa {10 kg/cm2}) .
3) Start the engine and set all the functions
of the full PCCS lever to neutral.
Any position can be used for the
speed range.
4) Measure the oil pressure at engine high
idling.
2) Start the engine and set the parking le-

ver to the FREE position.
3) Measure the oil pressure with the en-
gine at low idling and high idling.
Check that the oil pressure becomes
0 when the PCCS lever is operated
fully to the right.
Check that the oil pressure becomes
0 when the brake pedal is depressed
or the parking lever is operated to
the LOCK position.

move the measuring equipment and set
to the original condition.
20-126 D475A-3
TESTING AND ADJUSTING SIMPLE METHOD OF TESTING BRAKE PERFORMANCE
SIMPLE METHOD OF TEST-

ING BRAKE PERFORMANCE
Carry out the simple test of brake perfor-
mance under the following condition.
1. Set the blade and ripper in the travel posi-

tion 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 depress the forward switch
and 2nd speed position.
If this test is carried out in the 1st gear
position, the brake will be overloaded.
Accordingly, be sure to carry out in the
2nd speed.
Set the steering unit in neutral.
4. Press the decelerator pedal and set the fuel

control 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.
D475A-3 20-127
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER

Adjusting brake pedal
1. Adjusting brake pedal stroke 3. Checking brake pedal stroke

Adjust stroke a of brake pedal (1) by adjust- 1) Press brake pedal (1) and check that its
ing dimension b of stopper bolt (2). stroke is as set in step 1 above.
Adjust the brake pedal stroke with the 2) Press brake pedal (1) and check that it is
brake rod separated from the pedal. stopped by stopper (6).
Pedal stroke a: 74 mm 3) Press brake pedal (1) and check that
Dimension b of stopper bolt: 42 mm spool stroke e of brake valve (4) is in the
normal range.
2. Adjusting brake rod length Spool stroke e: 19 23 mm
(Temporary installation)
1) Install brake rod (3) and release brake
pedal (1) (Do not press the brake pedal).
2) Adjust dimensions c and d of brake rod
(3) with turnbuckle (5) so that the spool
of brake valve (4) will be at the OFF po-
sition.
The locknut on the brake pedal side
of the turnbuckle is a left-handed (re-
versing) screw.
Dimension c: 32 mm
Dimension d: 14 mm
3 Locknut:
34.3 58.8 Nm {3.5 6.0 kgm}
20-128 D475A-3
4. Adjusting brake After starting the engine, enter into the

For the method of measuring the brake Service Adjustment mode and, under the
oil pressure, see MEASURING POWER Service Adjustment mode, input the ser-
TRAIN OIL PRESSURE. vice mode No. 9996 (electric brake re-
Since electrical control by the potentiometer lease mode) to the 0000-SELECT NO.
being built into the brake pedal and me- in the multi-information indication col-
chanical control (at emergencies and when umn and turn the brake cancel switch to
parking the machine) by the control rod and the select potion (). Then,
push-pull cable are being commonly used 9996-MECHA BRAKE BASE
for the brake, it becomes necessary to make 2500 mV
adjustment to synchronize these two control will be indicted. (This indication means
methods. that the voltage is 2450 2550 mV under
1) Initial setting for the brake potentiom- the state where the brake pedal is not
eter being depressed.)
Make this adjustment to correct the out- Under the above state, when the park-
put voltage error occurring from the ing brake lever is turned to the FREE
mounting deviation of the brake poten- position, the Bourdon tube for the LB
tiometer. pressure will indicate 2.5 2.7 MPa {25
Enter into the Service Adjustment mode 27 kg/cm2}.
and, under the Service Adjustment mode,
input the service mode No. 0005 (initial When the brake pedal is depressed, the
setting mode for the brake potentiom- indicated voltage value will increase but
eter) to the 0000-SELECT NO. in the adjust the brake rod so that the indica-
multi-information indication column and tion on the Bourdon tube for the LB pres-
turn the brake cancel switch to the se- sure may drop below 8 kg/cm2 within
lect potion (). Then, the range when the aforementioned in-
0005-BRAKE BASE creasing voltage value exceeds 3060 mV
**mV until the stroke end of the brake pedal.
will be indicted. (Here, ** is the value of
the deviation from the specified voltage When the brake pedal is depressed
at the neutral position.) gradually, in case the oil pressure will
not drop below 8 kg/cm2 even at the
Under the above state, turn the buzzer stroke end:
cancel switch to the select potion () Adjust the turnbuckle to shorten
and the buzzer will sound and the set- the brake rod.
ting will be completed. When the brake pedal is depressed
(The value being indicated on the lower gradually, in case the oil pressure starts
line as above will not change even when dropping before the aforementioned in-
this adjustment has been finished.) creasing voltage value reaches 3060 mV:
Adjust the turnbuckle to prolong
2) Adjustment of the brake rod the brake rod.
Stop the electric control for the brake to
make adjustment of the mechanical When the above adjustment has been
brake. finished, turn the buzzer cancel switch
Connect the Bourdon tube (5.9 MPa {60 to the cancel position () and the elec-
kg/cm2} meter) to the LB port (LH brake tric brake release mode will be cancelled.
pressure) in the centralized pressure (Turning OFF the starting key will also
checking ports. cancel the electric brake release mode
and, when the starting key is turned on
after that, the normal mode will be
called.)
D475A-3 20-129
Adjusting at parking brake lever end
5. Assembling and installing lever assembly 7. Checking brake oil pressure

1) Assemble lever assembly (7) and adjust Check that the brake oil pressure is as fol-
the operation of limit switch (8). lows when the parking brake lever is set in
When assembling the lever assem- the FREE and ROCK positions.
bly, disconnect the parking brake For the method of measuring the brake
cable from the lever. oil pressure, see MEASURING POWER
When lever is raised: OFF, TRAIN OIL PRESSURE.
lowered: ON LOCK position: 0
Operation stroke of limit switch: 3 mm FREE position: Specified pressure
2) Install lever assembly (7).
8. Checking limit switch
6. Adjusting length of parking brake cable Change the monitor panel to the monitoring
1) Connect parking brake cable (9) to the display mode and set the parking brake le-
lever and valve and adjust dimensions f ver in the FREE and ROCK positions. Check
and g. that the limit switch signal is normal at this
Dimension f of cable: 112.8 mm time.
Dimension g of cable: 114.0 mm For the operating method of the moni-
2) Operate parking brake lever (10) between toring display mode, see SPECIAL FUNC-
the FREE and LOCK positions and adjust TIONS OF MONITOR PANEL (EMMS).
rod end (11) so that spool stroke h of Monitoring code:
brake valve will be normal. 40910 (Steering controller switch input 1)
Spool stroke h: 30.0 mm
20-130 D475A-3
TESTING AND ADJUSTING ADJUSTING PCCS LEVER CONSOLE POSITION
ADJUSTING PCCS LEVER CONSOLE POSITION
1. Set operators seat (1) in the forward (doz-

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

is in parallel with operators seat (1).
If the console is not parallel with the
operators seat, adjust dimension a of
rod (3).
Standard dimension a: 179 mm
The locknut on the rear side of the turn-
buckle is a left-handed (reversing) screw.
D475A-3 20-131
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
Symbol Part No. Part name a vinyl sheet, etc.
19M-06-32820 Switch assembly Put switch assembly 1 in the cab
1 7824-66-6430 Resistor through the cab window.
H
195-06-71220 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 fol-
lowing procedure. If the engine cannot
be started, see EMERGENCY ESCAPE
WITH BRAKE RELEASING DEVICE.
1) Connect switch assembly 1 and resistor 3) Disconnect neutral safety relay (NSF) in
2 to wiring harness 3 of emergency the fuse room and connect pins 3 and
escape device H1. 5 of the connector on the wiring har-
Since resistor 2 controls the drive ness side.
voltage of the solenoid, connect it to Perform this operation only when the
the wiring harness before connect- engine does not start electrically be-
ing to the machine. cause of a trouble in the transmis-
Set the all gear speed switches of sion controller.
switch assembly 1 in the OFF posi- If the engine is started by this
tion and the direction switch in the P method, the neutral safety function
position to prevent the machine from does not work. Accordingly, before
starting suddenly. starting the engine, set the parking
brake lever in the 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.
20-132 D475A-3
4) Start the engine and set the parking brake 2. Escape with brake releasing device (Use H2)
lever in the FREE position. If the engine cannot be started and the
5) Operate switch assembly 1 and move parking brake cannot be released, escape
the machine to a safe place. according to the following procedure.
The gear speed switch is so made The engine must be startable for the fol-
that the switch on the lower gear lowing procedure. If the engine cannot
speed will be operated first. be started, see EMERGENCY ESCAPE
WITH BRAKE RELEASING DEVICE.
1) Assemble pump assembly H2.
2) Install volume pump 1 of pump assem-

bly H2 to the outside of the operators
cab.
3) Remove the fuel tank undercover and

disconnect supply hose (3) of the pin
puller solenoid valve.
D475A-3 20-133
4) Connect end hose (3) of pump assembly

H2 to the supply hose.
Block the solenoid valve side with
plug.
5) Turn the starting switch ON and set the

parking 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. 2.74 MPa {28 kg/cm2}
Since an accumulator is installed in
the circuit, the handle must be oper-
ated 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 low-
ers gradually because of internal leak-
age and the brake is applied again
about 1 minute after. Accordingly,
work quickly.
If the brake releasing pressure low-
ers to about 1.5 MPa {16 kg/cm2}, the
brake is applied. In this case, oper-
ate the volume pump again to raise
the brake releasing pressure to the
initial pressure.
20-134 D475A-3
TESTING AND ADJUSTING ADJUSTING CLEARANCE OF IDLER
ADJUSTING CLEARANCE OF
IDLER
The idler moves forward and backward under
external pressure. When this happens, side guide
(1) and guide plate (2) become worn. As they become
worn, there is side play in the idler, or the idler
turns at an angle, causing the track to come off or
resulting in uneven wear, so adjust as follows.
Adjustment
1. Drive the machine for 1 2 m on flat ground,
then measure clearance a (4 places: left, right,
inside, outside) between the track frame and
side guide (1).
2. If clearance a is more than 3 mm, remove bolt

(3), then take out shim (4), and adjust so that
the clearance on one side is less than 0.5 mm.
a
There are two types of shim (thickness: 0.5
mm and 1.0 mm).
D475A-3 20-135
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TRACK SHOE TENSION
Testing
1. Drive the machine forward and stop on a hori-
zontal surface.
Stop the machine without using the brake.
2. Pull steel rod (1) between the idler and carrier

roller, and measure clearance a from the bot-
tom of the rod to the track shoe grouser.
Standard clearance a: 20 30 mm
Adjusting
If the track shoe tension is not normal, adjust as
follows.
1. Remove cover (2).
2. If tension is too high:

Loosen plug (3) and release some of the grease.
There is danger that the plug may fly out
under the high internal pressure of the
grease, so never loosen the plug more than
1 turn.
3. If tension is too low:

Pump in grease through grease fitting (4).
If the track tension is poor, move the ma-
chine backwards or forwards slowly.
After complection of the adjustment, repeat the

above procedure to check the tension again.
20-136 D475A-3
TESTING AND ADJUSTING MEASURING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
MEASURING AND ADJUSTING

WORK EQUIPMENT OIL
PRESSURE
Installing oil pressure gauges

Stop the machine on level ground, lower the
work equipment completely to the ground, then
set the parking lever and safety lever to the
LOCK position.
1. Installing oil pressure gauge to front pump

1) Remove the control valve cover.
2) Remove oil pressure measurement plug (1)
(PT 1/8).
3) Fit nipple 1 and hose 2 of oil pressure
gauge G1, then connect oil pressure gauge
G1 (39.2 MPa {400 kg/cm2}).
2. Installing oil pressure gauge to rear pump

(PT 1/8).
G1 (39.2 MPa {400 kg/cm2}).
3. Installing oil pressure gauge to assist pump

(PT 1/8).
G1 (39.2 MPa {400 kg/cm2}).
D475A-3 20-137
Measuring (single tiltdozer specification) Lever operation

Pump Front Rear Assist
Hydraulic pump combination chart RAISE
: Pump is actuated, relief pressure can be Blade lift
LOWER

measured Right
Blade single tilt
: Pump is actuated, but relief pressure cannot Left
be measured Blade dual tilt
Right

: Flow merges if lever is operated fully Left
: Cylinder is drained at end of stroke (but it is Blade pitch
DUMP
possible to measure relief pressure by BACK
RAISE
switching panel to monitoring mode [5A]) Ripper lift
LOWER
IN
1. Measuring front pump relief pressure Ripper tilt
BACK
1) Turn the starting switch ON.
2) Change the monitor panel indication to the
monitoring mode to prepare for measure-
ment of the work equipment oil pressure.
Monitoring Code: 70700 (Work equip-
ment oil pressure high)
3) Start the engine and set the safety lever to
the FREE position.
4) Operate the ripper lever to the end of the
stroke to relieve the ripper lift cylinder or
ripper tilt cylinder, and measure the oil pres-
sure with the engine at low idling and high
idling.
2. Measuring rear pump relief pressure

the FREE position.
2) Operate the blade lever to the end of the
stroke to relieve the blade tilt cylinder, and
measure the oil pressure with the engine at
low idling and high idling.
3. Measuring assist pump relief pressure

1) Turn the starting switch ON.
2) Change the monitor panel indication to the
monitoring mode to prepare for measure-
ment of the work equipment oil pressure.
Monitoring Code: 70700 (Work equip-
ment oil pressure high)
the FREE position.
20-138 D475A-3
4) Operate the ripper lever to the end of the

stroke to relieve the ripper lift cylinder or
sure with the engine at low idling and high
idling.
Measuring (dual tiltdozer specification)

Hydraulic pump combination chart
: Pump is actuated, relief pressure can be
measured
: Pump is actuated, but relief pressure cannot
be measured
Flow merges if lever is operated fully
: Lever operation
Pump Front Rear Assist
: Cylinder is drained at end of stroke RAISE
Blade lift
LOWER

1. Measuring front pump relief pressure Right
Blade single tilt
1) Start the engine and set the safety lever to Left
the FREE position. Right
Blade dual tilt
2) Operate the ripper lever to the end of the Left
stroke to relieve the ripper lift cylinder or DUMP
Blade pitch
BACK
RAISE
sure with the engine at low idling and high Ripper lift
LOWER

idling. IN
Ripper tilt
BACK

2. Measuring rear pump relief pressure
the FREE position.
pitch back stroke to relieve the blade pitch
cylinder, and measure the oil pressure with
the engine at low idling and high idling.
3. Measuring assist pump relief pressure

the FREE position.
pitch back stroke to relieve the blade pitch
cylinder, and measure the oil pressure with
the engine at low idling and high idling.
D475A-3 20-139
Adjusting
1. Adjusting main relief valve for blade lift valve
If the front pump relief pressure is not cor-
rect, adjust main relief valve (8) of the blade
lift valve as follows.
1) Remove cover (9), then loosen locknut (10).
2) Turn adjustment screw (11) to adjust.
Turn the adjustment screw as follows.
To INCREASE pressure, turn CLOCK-
WISE
To DECREASE pressure, turn COUN-
TERCLOCKWISE
Amount of adjustment for one turn of
adjustment screw:
2.43 MPa {24.8 kg/cm2}
3 Locknut:
11.8 14.7 Nm {1.2 1.5 kgm}
Cover: 29.4 39.2 Nm {3.0 4.0 kgm}
2. Adjusting main relief valve for blade tilt, ripper

Lo valve
If the rear pump relief pressure is not cor-
rect, adjust main relief valve (12) of the blade
tilt and ripper Lo valve as follows.
WISE
TERCLOCKWISE
adjustment screw:
2.43 MPa {24.8 kg/cm2}
3 Locknut:
11.8 14.7 Nm {1.2 1.5 kgm}
Cover: 29.4 39.2 Nm {3.0 4.0 kgm}
20-140 D475A-3
3. Adjusting main relief valve for assist valve

If the assist pump relief pressure is not cor-
rect, adjust main relief valve (16) of the as-
sist valve as follows.
WISE
TERCLOCKWISE
adjustment screw:
2.43 MPa {24.8 kg/cm2}
3 Locknut:
11.8 14.7 Nm {1.2 1.5 kgm}
Cover: 29.4 39.2 Nm {3.0 4.0 kgm}
D475A-3 20-141
TESTING AND ADJUSTING WORK EQUIPMENT
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE

WORK EQUIPMENT CONTROL
CIRCUIT PRESSURE
Measuring
LOCK position.
Measure the work equipment hydraulic pressure
under the following conditions.
1. Remove the control valve cover.
2. Remove oil pressure measurement plug (1) (10

x 1.25).
3. Fit nipple 1 and hose 2 of oil pressure gauge

G1, then connect oil pressure gauge G1 (5.9
MPa {60 kg/cm2}).
4. Start the engine, then measure the oil pressure

with the engine at low idling and high idling.
20-142 D475A-3
TESTING AND ADJUSTING WORK EQUIPMENT
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE
Adjusting
If the oil pressure is not correct, adjust PPC re-
lief valve (2) as follows.
1. Loosen locknut (3).
2. Turn adjustment screw (4) to adjust.

To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTER-
CLOCKWISE
3 Locknut: 9.8 Nm {1.0 kgm}
After complection of the adjustment, repeat the

above procedure to check the oil pressure again.
D475A-3 20-143
MEASURING PPC VALVE AND PITCH TILT
TESTING AND ADJUSTING CONTROL VALVE OUTPUT PRESSURE
MEASURING PPC VALVE AND

PITCH, TILT CONTROL VALVE
OUTPUT PRESSURE

LOCK position.
Measure the PPC valve output pressure under
the following conditions.
1. Method of measuring PPC valve portion

Measure the following circuits at the PPC
valve.
i) Blade lift RAISE circuit which does not
pass through the relay block.
ii) Blade tilt circuit before it enters the pitch,
tilt control valve
1) Disconnect hose (1) from the circuit to be
measured.
See the circuit drawing on the next page
2) Fit adapter 1 and nipple 2 of oil pressure
G1 (5.9 MPa {60 kg/cm2}) with hose 3.
the FREE position.
4) Operate the control lever of the circuit to be
measured, and measure the oil pressure at
engine high idling.
Operate the control lever fully when
measuring.
For blade LOWER, operate to the FLOAT
position.
2. Method of measuring relay block portion

Measure the following circuits at the PPC
valve.
i) Blade lift LOWER circuit
ii) Blade tilt circuit after it passes through
the pitch, tilt control valve
iii) Ripper lift circuit
iv) Ripper tilt circuit
1) Disconnect hose (2) from the circuit to be
measured.
See the circuit drawing on the next page.
20-144 D475A-3
2) Fit adapter 1 and nipple 2 of oil pressure

G1 (5.9 MPa {60 kg/cm2}) with hose 3.
the FREE position.
4) Operate the control lever or knob switch of
the circuit to be measured, and measure the
oil pressure at engine high idling.
Operate the control lever fully when
measuring.
When measuring the output pressure of
the pitch dump solenoid valve or pitch
back solenoid valve, set the blade lever
at HOLD and operate the knob switch.
When measuring the output pressure of
the tilt limit solenoid valve, operate the
blade lever in the tilt direction. When
the blade reaches the tilt limit angle, shut
off the output pressure from the PPC
valve.
D475A-3 20-145
20-146 D475A-3
D475A-3 20-147
TESTING AND ADJUSTING ADJUSTING PPC VALVE
ADJUSTING PPC VALVE

If there is excessive play at the tip of the blade
lever and ripper lever, adjust the PPC valve as
follows.
Standard play dimension a:
1 5 mm at point 250 mm from center of
lever (both front-to-rear and left-right)
The diagram shows the ripper PPC valve.
1. Remove boot (1).
2. Loosen locknut (2), then turn disc (3) to adjust

the play.
When doing this, do not move the piston.
3. Secure disc (3) in position and tighten locknut

(2).
3 Locknut: 98.07 127.49 Nm {10 13 kgm}
4. Install boot (1).
20-148 D475A-3
MEASURING OUTPUT PRESSURE OF
TESTING AND ADJUSTING DEMAND SOLENOID VALVE
MEASURING OUTPUT
PRESSURE OF DEMAND
SOLENOID VALVE

LOCK position.
Measure the solenoid valve output pressure un-
der the following conditions. .
1. Disconnect hose (1).
2. Fit adapter 1 and nipple 2 of oil pressure gauge

MPa {400 kg/cm2}) with hose 3.
The blade Lo circuit is used for the basic
pressure of the solenoid valve of the de-
mand valve.
3. Start the engine and set the safety lever to the

FREE position.
4. Run the engine at full throttle and measure the

oil pressure when the blade lever is returned to
HOLD and when it is operated in the lift direc-
tion.
The pressure should be as follows.
When lever is at HOLD:
Approx. 0 MPa {0 kg/cm2}
When lever is operated to lift:
Almost same as blade lift circuit pressure
D475A-3 20-149
MEASURING OUTPUT PRESSURE OF
TESTING AND ADJUSTING RIPPER PIN-PULLER SOLENOID VALVE
MEASURING OUTPUT
PRESSURE OF RIPPER
PIN-PULLER SOLENOID VALVE
LOCK position.
Measure the output pressure of the ripper pin
puller solenoid valve under the following condi-
tions.
Power train oil temperature: 45 55C
1. Disconnect output hoses (1) and (2).
2. Fit adapter 1 and nipple 2 of oil pressure gauge

MPa {60 kg/cm2}) with hose 3.
The power train circuit is used for the basic
pressure of the ripper pin puller solenoid
valve.
3. Start the engine and run at low idling.
4. Operate the pin-puller switch and measure the

oil pressure when the ripper pin-puller cylinder
is operated fully.
20-150 D475A-3
CHECKING LOCATION OF CAUSE OF
TESTING AND ADJUSTING HYDRAULIC DRIFT OF BLADE AND RIPPER
CHECKING LOCATION OF
CAUSE OF HYDRAULIC DRIFT
OF BLADE AND RIPPER
If hydraulic drift occurs in the blade and ripper,
check as follows to see if the cause is in the
cylinder packing or in the control valve.
1. Set the cylinder to be inspected to the following

inspection posture, then stop the engine.
1) Blade lift cylinder
Push the blade against the ground to raise
the front of the chassis.
The blade lift cylinder has a built-in pis-
ton valve, so do not operate the cylinder
to the end of the stroke.
2) Blade tilt cylinder
Extend the tilt cylinder rod fully (maximum
right tilt), then push the blade against the
ground to raise the right side of the chassis.
3) Ripper lift cylinder
Push the ripper against the ground to raise
the rear of the chassis.
2. Operate the control lever in the direction to ex-

tend the cylinder rod, and check the movement
of the cylinder.
If the downward movement becomes faster,
the packing is defective.
If there is no change, the control valve is
defective.
If there is no more pressure in the accumu-
lator, run the engine for approx. 10 seconds
to charge the accumulator before carrying
out the operation.
Reference:
If the cause of the hydraulic drift is in the pack-
ing, the speed of downward movement in the
above operation will become faster for the fol-
lowing reasons.
1) With the work equipment in the posture
given above, (holding pressure applied to
3) In this condition, if the lever is oper-
the bottom end), the oil will leak from the
ated as shown above, the circuit at
bottom end to the head end. However, the
the head end is connected to the drain
volume at the head end is smaller than at
circuit (the bottom end is closed by a
the bottom end (by an amount proportional
check valve), and the oil at the head
to the volume of the rod), so if the oil flows
end flows to the drain circuit. As a
in from the bottom end, the internal pres-
result, the balance is lost and the
sure at the head end will rise.
speed of downward movement in-
2) If the internal pressure at the head end rises,
creases.
a balance will be made in proportion to this
at a certain pressure (this differs according
to the amount of leakage). When the pres-
sure becomes balanced, the speed of down-
ward movement becomes slower.
D475A-3 20-151
MEASURING LEAKAGE INSIDE
TESTING AND ADJUSTING HYDRAULIC CYLINDER
MEASURING LEAKAGE INSIDE

HYDRAULIC CYLINDER
Measure the oil leakage inside the hydraulic cyl-
inder under the following conditions.
The blade lift cylinder has a built-in piston valve,

so the internal leakage cannot be measured.
1. Fully extend the cylinder to be measured, and

set to the measurement posture.
1) Blade tilt cylinder:
Tilt the blade fully to the right.
2) Ripper lift cylinder:
Remove the shank pin and lower the ripper
fully.
3) Ripper tilt cylinder:
Tilt the ripper fully to the front.
2. Disconnect the piping at the head end of the

cylinder and block the piping at the chassis end
with a blind plug.
Remove the cover when disconnecting the
blade tilt cylinder hose.
Be careful not to disconnect the piping at

the bottom end.
3. Run the engine at high idling and apply the

relief pressure to the bottom end of the cylin-
der.
Blade tilt cylinder: Tilt blade to right
Ripper lift cylinder: Lower ripper
Ripper tilt cylinder: Tilt ripper to front
4. Wait for 30 seconds, then measure the amount

of leakage over the next 1 minute.
20-152 D475A-3
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CYLINDERS
RELEASING REMAINING BLEEDING AIR FROM

PRESSURE IN HYDRAULIC HYDRAULIC CYLINDERS
CIRCUIT After replacing or installing hydraulic cylin-
ders or disconnecting and connecting hy-
draulic piping, bleed the air from the cir-
When disconnecting the piping between the
cuit as follows.
hydraulic cylinder and control valve, first re-
lease the remaining pressure inside the pip-
1. Start the engine and run at low idling for
ing as follows.
about 5 minutes.
1. Loosen the oil filler cap slowly to release
2. Run the engine at low idling, and extend
the pressure inside the hydraulic tank.
and retract the hydraulic cylinders 4 5
times.
2. Operate the work equipment control levers
Stop the position rod about 100 mm from
to the front, rear, left, and right.
the end of the stroke. Never operate it to
When the levers are operated 2 3 times,
the relief position.
the pressure inside the accumulator is
released.
3. Run the engine at high idling and repeat the
procedure in Step 2.
3. Start the engine, run at low idling for approx.
5 minutes, then stop the engine and operate
4. Then run the engine at low idling and oper-
the work equipment control levers to the
ate the pistpn rod to the end of the stroke to
front, rear, left, and right.
relieve the circuit.
If the above operation is repeated 2 3
times, the remaining pressure will be
completely released.
For the ripper cylinder, the remaining
pressure is released through the ripper
Hi valve, so repeat the above procedure
several times.
D475A-3 20-153
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT SAFETY LEVER
ADJUSTING WORK
EQUIPMENT SAFETY LEVER
1. Adjust dimension a between the pins of rod (1),
then connect to safety lever (2) and PPC lock
valve (3).
Dimension a between pins: 330 mm
20-154 D475A-3
TESTING AND ADJUSTING ADJUSTING RIPPER LEVER POSITION
ADJUSTING RIPPER LEVER POSITION
Adjust the ripper lever to the best position 5) Loosen nut (3).
according to the following procedure. 6) Reverse knob (4).
The ripper lever can be adjusted forward 7) Tighten nut (3) to secure knob (4).
and in reverse within the range of 40 mm
from the center of the lever shaft.
1. Adjusting within range of backward 40 mm

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 40 mm

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).
D475A-3 20-155
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE
TESTING AND ADJUSTING (DUAL TILT DOZER SPECIFICATION)
PROCEDURE FOR ADJUSTING

BLADE TILT LIMIT ANGLE
(DUAL TILT DOZER
SPECIFICATION)
If the blade and blade cylinder potentiometer
have been removed and installed again, or the
machine controller has been replaced, adjust the
blade tilt limit angle as follows.
If this adjustment is not carried out, the amount
of tilt will be reduced, or will become too large
and will interfere with the track, so always carry
out this adjustment.
Carry out the adjustment on a level ground
surface.
1. Start the engine, run at low idling, and set the

blade at the following basic posture.
1) Set the tilt angle to horizontal (0).
2) Set the pitch angle to the maximum pitch
back.
3) Lower the blade to the ground.
2. Adjust installation dimension a of rod (1), and

connect to potentiometer lever (2) and yoke (3).
Installation dimension a: 376.5 mm
3. The diagram on the right is the mode used to

set the tilt limit. The method for setting the tilt
limit is as follows.
4. Hold the buzzer cancel switch at the SELECT

position () for 3 seconds.
(This enters the user adjustment mode)
5. When the information switch is turned to the

right or left, the service mode on the multi-in-
formation display changes, and 04: TILT LIMIT
is displayed.
Following this, if the buzzer cancel switch is op-
erated to the SELECT position (), the system
enters the control adjustment mode, but before
starting, there are operations necessary for ad-
justing the tilt limit, so follow the procedure
below.
20-156 D475A-3
PROCEDURE FOR ADJUSTING BLADE TILT LIMIT ANGLE
TESTING AND ADJUSTING (DUAL TILT DOZER SPECIFICATION)
6. Use the toggle switch on the work equipment

control lever to select DUAL TILT, tilt the work
equipment back fully, then lower it to the ground.
7. Operate the buzzer cancel switch to the SELECT

position () to enter the tilt limit adjustment
mode.
When the pitch switch on the work equipment
control lever is pressed, the buzzer sounds and
the basic position of the work equipment is saved
to memory.
8. Raise the work equipment 1000 mm (39.4 in),

then tilt it 12 to the left.
In this condition, use the toggle switch on the
work equipment control lever to switch to
SINGLE TILT, then switch back to DUAL TILT.
The buzzer sounds and the left limit position is
saved to memory.
9. Set the buzzer cancel switch to the CANCEL po-

sition () to exit the tilt limit adjustment mode.
10. Operate the work equipment to pitch dump to

set to the full pitch dump position. (Keep the
work equipment horizontal.)
11. Operate the buzzer cancel switch to the SELECT

position () to enter the tilt limit adjustment
mode again.
12. Raise the work equipment 1000 mm (39.4 in),

then tilt it 12 to the right.
13. In this condition, use the toggle switch on the

work equipment control lever to switch to
SINGLE TILT, then switch back to DUAL TILT.
The buzzer sounds and the right limit position is
saved to memory.
This completes the adjustment operation, so set

the buzzer cancel switch to the CANCEL posi-
tion () to exit the tilt limit adjustment mode,
then lower the work equipment to the ground
and stop the engine.
14. Start the engine again, operate the left and right
tilt, and check that the blade does not interfere
with the track when the blade is raised to any
height.
D475A-3 20-157
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Display section of special Operation section 1 of special Operation section 2 of special

functions functions functions
(Basic operation) (Changeover operation)
1. Upper display section 3. Service switch 5. Information switch
(Gear speed display section) 4. Buzzer cancel switch 6. Shift switch
2. Lower display section 7. Neutral switch
(Multi-information section)
EMMS: Equipment Management Monitoring System
20-158 D475A-3
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: Operator mode
With this function, the operator can display and change the items displayed normally.
2. Special function 1: Service mode
With this function, a serviceman can display and change the displayed items with special switches
for testing, adjusting, and troubleshooting.
Flow of modes and functions
Operator mode
Normal display (Default) 1 Maintenance mode Maintenance item: 12 items

[>] [<]
2 Pm clinic auxiliary mode Auxiliary menu: 4 items
Travel direction/Gear speed
[ ] [>] [<]
+
() 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] & []() []
Service mode
Maintenance interval
5 change mode Maintenance item: 12 items
[>] [<]
Electric system error code
6 display mode
[>] [<]
Mechanical system error
7 code display mode
[>] [<]
8 Adjustment mode Adjustment menu: 25 items
[>] [<]
9 Load memory mode Display menu: 3 items
[>] [<]
10 Real-time monitoring mode
[>] [<] [ON]: Service switch
11 Dual display monitoring mode []: Buzzer cancel switch (Left)
[>] [<] []: Buzzer cancel switch (Right)
[>]: Information switch (Right)
Maintenance interval [<]: Information switch (Left)
5 change mode (): Min. 2.5 sec
D475A-3 20-159
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 informa-
tion normally.
Gear speed display section (1):
Front side: Travel direction (PNFR)
Rear side: Gear speed (123)
Graphics: Engine speed
Multi-information section (2):
Information is displayed in 2 lines of 16 charac-
ters each.
Front side:
Gear shift mode (F1-R1F1-R2F2-R2)
Rear side:
Service meter (Unit: 0.1 h)
1. Maintenance mode
(1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replace-
ment of oils and filters is displayed on the multi-
information section (2) and reset after the re-
placement.
Gear speed display section (1) keeps dis-
playing normally.
No. Maintenance item

01 Engine oil
02 Engine oil filter
03 Fuel filter
04 Hydraulic oil filter
05 Corrosion resistor
06 Bypass filter
07 Damper oil
08 Final drive oil
09 Hydraulic oil
10 Power train oil
11 Power train oil filter
12 HSS charge filter (not use)
20-160 D475A-3
2. Pm clinic auxiliary mode

(2-PM CLINIC MODE)
In this mode, the condition of the machine is
displayed on multi-information section (2) as an
auxiliary function of the periodic diagnoses such
as the Pm clinic, even if any measuring instru-
ment is not connected.
playing normally.
No. Pm clinic auxiliary item

01 Engine speed
02 Hydraulic oil pressure (large)
03 Work equipment pressure (assist)
04 Battery voltage
3. Error code display mode

(3-ERROR 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.)
D475A-3 20-161
Error codes table

Error code Failure phenomenon Controller Action code Alarm lamp Alarm buzzer
1500L0 Transmission double failure 1, 2 TM CALL E03
15SAL1 Forward clutch oil pressure 1 TM CALL E03
15SALH Forward clutch oil pressure 2 TM CALL E03
15SBL1 Reverse clutch oil pressure 1 TM CALL E03
15SBLH Reverse clutch oil pressure 2 TM CALL E03
15SEL1 1st speed clutch oil pressure 1 TM CALL E03
15SELH 1st speed clutch oil pressure 2 TM CALL E03
15SFL1 2nd speed clutch oil pressure 1 TM CALL E03
15SFLH 2nd speed clutch oil pressure 2 TM CALL E03
15SGL1 3rd speed clutch oil pressure 1 TM CALL E03
15SGLH 3rd speed clutch oil pressure 2 TM CALL E03
1800MW P/L clutch slip TM E02
2201L1 RH clutch oil pressure 1 ST CALL E04
2201LH RH clutch oil pressure 2 ST CALL E04
2202L1 LH clutch oil pressure 1 ST CALL E04
2202LH LH clutch oil pressure 2 ST CALL E04
2301L1 RH brake oil pressure 1 ST CALL E04
2301LH RH brake oil pressure 2 ST CALL E04
2302L1 LH brake oil pressure 1 ST CALL E04
2302LH LH brake oil pressure 2 ST CALL E04
A70XLK Failure with the governor servo circuit, RH ENG CALL E04
A70YLK Failure with the governor servo circuit, LH ENG CALL E04
AA1ANX Air cleaner clogging Mechanical
AB00MA Battery charge failure Mechanical
B@BAZG Engine oil pressure drop Mechanical
B@BAZK Engine oil quantity decrease Mechanical
B@BCNS Coolant overheated Mechanical
B@BCZK Coolant level drop Mechanical
B@CENS Power train overheated Mechanical
B@HANS Hydraulic oil overheated Mechanical
B@HAZK Hydraulic oil level drop Mechanical
D110KA BR relay holding 2 ST
D110KB BR relay holding 1 ST
D130KA N safety relay 2 TM E02
D130KB N safety relay 1 TM E02
D161KA Back alarm relay 2 TM E01
D161KB Back alarm relay 1 TM E01
D1D0KA Governor cut relay, RH disconnected ENG E01
D1D0KB Governor cut relay, RH shorting ENG E01
D1D1KA Governor cut relay, LH disconnected ENG E01
D1D1KB Governor cut relay, LH shorting ENG E01
D5ZFKA N signal 1 - 2 TM E01
D5ZFKB N signal 1 - 1 TM E01
D5ZFL4 N signal abnormality ENG E01
D5ZGKA N signal 2 - 2 TM E01
D5ZGKB N signal 2 - 1 TM E01
D5ZKKX Chassis throttle signal failure ENG CALL E03
DAFRKR RTCDB failure MON CALL E03
DAQ0KK Supply voltage failure TM CALL E04
20-162
20-162 D475A-3
(1)
DAQ0KT Memory value failure TM E01
DAQ5KK Potentiometer power failure TM CALL E03
DAQ6KK Sensor power failure TM E01
DAQ9KQ Model selection 1, 2, 3 TM CALL E04
DAQRKR RTCDB failure TM CALL E03
DAQSKR Network failure TM E01
DB30KK Supply voltage failure ST CALL E04
DB30KT Memory value failure ST E01
DB35KK Potentiometer power failure ST CALL E03
DB36KK Sensor power failure ST CALL E03
DB39KQ Model selection 1, 2, 3 ST CALL E04
DB3RKR RTCDB failure ST CALL E03
DB3SKR Network failure ST E01
DB40KK Supply voltage failure ENG CALL E04
DB41KK Switch power failure ENG CALL E03
DB42KK Solenoid power 1 failure ENG CALL E04
DB43KK Backup power failure ENG CALL E03
DB44KK Solenoid power 2 failure ENG CALL E04
DB45KP Rack sensor power failure ENG CALL E03
DB49KM Connector connection error ENG CALL E04
DB49KQ Model selection abnormality ENG E02
DD14KA Travel lock SW 2 TM CALL E03
DD14KB Travel lock SW 1 TM CALL E03
DDB9KA Reverse SW 2 TM CALL E03
DDB9KB Reverse SW 1 TM CALL E03
DDK3KA Forward SW 2 TM CALL E03
DDK3KB Forward SW 1 TM CALL E03
DDK5KA Shift SW 2 TM E02
DDK5KB Shift SW 1 TM E02
DDN2LD PPC tilt, RH oil pressure SW TM E02
DDN3LD PPC tilt, LH oil pressure SW TM E02
DDN7KA Pitch SW 2 TM E02
DDN7KB Pitch SW 1 TM E02
DDN9KA Dual tilt SW 2 TM E01
DDN9KB Dual tilt SW 1 TM E01
DDNALD PPC lift up full oil pressure SW TM
DDNBLD PPC ripper up oil pressure SW TM
DDNCLD PPC ripper down oil pressure SW TM
DDNDLD PPC ripper tilt oil pressure SW TM
DDNELD PPC ripper tilt back oil pressure SW TM
DDNFLD PPC lift down full oil pressure SW TM
DDQ2KA Travel lock SW 2 ST CALL E03
DDQ2KB Travel lock SW 1 ST CALL E03
DDQ2L4 Travel lock discordance 1, 2 ST CALL E03
DDT5KA Neutral SW 2 TM CALL E04
DDT5KB Neutral SW 1 TM CALL E04
DDT5KQ Lever spec. selection error TM CALL E04
DGE2KX Water temperature sensor failure ENG E02
DGS1KX Hydraulic oil temperature sensor TM
D475A-3 20-163
20-163
(1)
DH22KA Hydraulic oil pressure 1 (L, F) sensor 2 TM
DH22KB Hydraulic oil pressure 1 (L, F) sensor 1 TM
DH23KA Hydraulic oil pressure 1 (S, R) sensor 2 TM
DH23KB Hydraulic oil pressure 1 (S, R) sensor 1 TM
DK01KA LH yoke corner sensor 2 TM E02
DK01KB LH yoke corner sensor 1 TM E02
DK03KA RH yoke corner sensor 2 TM E02
DK03KB RH yoke corner sensor 1 TM E02
DK10KX Fuel dial failure ENG CALL E03
DK11KA Decelerator potentiometer failure (ST) ST E01
DK11KB Decelerator potentiometer failure (ST) ST E01
DK12KX Decelerator potentiometer failure ENG CALL E03
DK30KA Swing potentiometer 1 disconnected ST CALL E03
DK30KB Swing potentiometer 1 shorting ST CALL E03
DK30KX Swing circuit 2 circuit ST CALL E04
DK30KZ One is defective and others become defective when the starting key is turned on. ST CALL E04
DK30L8 Swing potentiometer deviation ST CALL E03
DK31KA Swing potentiometer 2 shorting ST CALL E03
DK31KB Swing circuit 2 circuit ST CALL E03
DK40KA Brake potentiometer 2 ST CALL E03
DK40KB Brake potentiometer 1 ST CALL E03
DK60KA Acceleration sensor 2 ST E01
DK60KB Acceleration sensor 1 ST E01
DKF1KX Rack sensor, RH failure ENG CALL E03
DKF2KX Rack sensor, LH failure ENG CALL E03
DKH1KA Inclination angle sensor 1 ST CALL E03
DKH1KB Inclination angle sensor 2 ST CALL E03
DLE1KA Engine revolution sensor ST E01
DLE4LC Engine revolution sensor A failure ENG CALL E03
DLE5LC Engine revolution sensor B failure ENG CALL E03
DLF1KA Transmissions revolution sensor TM E01
DV00KB Alarm buzzer MON E01
DW55KA Pitch back solenoid 2 TM CALL E03
DW55KB Pitch back solenoid 1 TM CALL E03
DW56KA Pitch dump solenoid 2 TM CALL E03
DW56KB Pitch dump solenoid 1 TM CALL E03
DW57KA LH tilt limiting solenoid 2 TM E02
DW57KB LH tilt limiting solenoid 1 TM E02
DW58KA RH tilt limiting solenoid 2 TM E02
DW58KB RH tilt limiting solenoid 1 TM E02
DW5AKA Pitch selection solenoid 2 TM E02
DW5AKB Pitch selection solenoid 1 TM E02
DW5JKA Pitch independent solenoid 2 (PIT) TM CALL E03
DW5JKB Pitch independent solenoid 1 (PIT) TM CALL E03
DW5LKA Dump support solenoid 2 (PDA) TM CALL E03
DW5LKB Dump support solenoid 1 (PDA) TM CALL E03
DW98KA Unload valve 2 (UNL) TM CALL E03
DW98KB Unload valve 1 (UNL) TM CALL E03
DWN3KA Abrupt stop preventive solenoid 2 ST CALL E04
20-164
20-164 D475A-3
(1)
DWN3KB Abrupt stop preventive solenoid 1 ST CALL E04
DXH1KA Lock up solenoid 2 TM E01
DXH1KB Lock up solenoid 1 TM E01
DXH4KA 1st speed clutch ECMV2 TM CALL E03
DXH4KB 1st speed clutch ECMV1 TM CALL E03
DXH5KA 2nd speed clutch ECMV2 TM CALL E03
DXH5KB 2nd speed clutch ECMV1 TM CALL E03
DXH6KA 3rd speed clutch ECMV2 TM CALL E03
DXH6KB 3rd speed clutch ECMV1 TM CALL E03
DXH7KA Reverse clutch ECMV2 TM CALL E03
DXH7KB Reverse clutch ECMV1 TM CALL E03
DXH8KA Forward clutch ECMV2 TM CALL E03
DXH8KB Forward clutch ECMV1 TM CALL E03
DXH9KA RH clutch ECMV2 ST CALL E03
DXH9KB RH clutch ECMV1 ST CALL E03
DXHAKA LH clutch ECMV2 ST CALL E03
DXHAKB LH clutch ECMV1 ST CALL E03
DXHBKA RH brake ECMV2 ST CALL E04
DXHBKB RH brake ECMV1 ST CALL E04
DXHCKA LH brake ECMV2 ST CALL E04
DXHCKB LH brake ECMV1 ST CALL E04
DXHDKA Governor solenoid, RH disconnected ENG CALL E04
DXHDKB Governor solenoid, RH shorting ENG CALL E04
DXHEKA Governor solenoid, LH disconnected ENG CALL E04
DXHEKB Governor solenoid, LH shorting ENG CALL E04
DXHFKA Pre-stroke solenoid, RH disconnected ENG CALL E03
DXHFKB Pre-stroke solenoid, RH shorting ENG CALL E03
DXHGKA Pre-stroke solenoid, LH disconnected ENG CALL E03
DXHGKB Pre-stroke solenoid, LH shorting ENG CALL E03
D475A-3 20-165
20-165
(1)
Separate table: Detailed faults

Error code Details of fault Error code Details of fault
Clutch fill signals which are not in combination table are turned
KA Disconnection L0
on in 2 or more channels.
When command current for ECMV is turned OFF, fill signal is
KB Short circuit L1
turned ON.
Lowering of source
KK L2 Fuel pressure is higher than maximum specified value.
voltage/Input
Nonconformance of
KQ L3 Corresponding part cannot be controlled.
model selection signal
KR Defective communication L4 ON and OFF signals of 2 systems are not matched.
Engine speed signal, terminal-C signal, oil pressure switch
KT Fault in controller L6 signal, water temperature sensor signal, etc. are not matched
to operating or stopping condition.
KX Out of input signal range L8 Analog signals of 2 systems are not matched.
Disconnection or short
KZ LC Speed signals of 2 systems are not matched.
circuit
MA Malfunction LD Switch is pressed and held for abnormally long time.
When command current to ECMV is turned ON, fill signal is
MB Defective function LH
turned OFF.
MW Slip
NS Overheat
NX Clogging
ZG Oil pressure reduction
ZK Level reduction
4. Adjustment mode (4-USER ADJUST MODE)

In this mode, the display condition of the moni-
tor panel can be adjusted and the fan speed (for
cleaning the radiator) can be changed on the
multi-information section (2).
playing normally.
No. Adjustment item

01 Brightness of LCD
02 Brightness of display
03 Contrast of display
04 Tilt limit mode (dual tilt type)
20-166 D475A-3
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
caution lamp flashes and the caution buzzer
sounds.
<Reference>
An action code is displayed only when a serious
fault occurs.
Even if an action code is not displayed, a fault may
have occurred. If you feel any abnormality, be sure
to check for a error code in the 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
Torque converter is not locked up. normal function stops par-
E01 Only action code is displayed. Blade dual tilt mechanism does tially but 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.
Engine speed does not rise fully.
Action code is displayed. Gear shifting shocks become Move machine to safe place.
CALL E03 Caution lamp flashes. large. Call your Komatsu distributor
Caution buzzer sounds. Steering performance lowers. for repair.
Brake shocks become large.
Blade is pitched by tilt operation.
Blade pitch operation stops.
Action code is displayed. Engine cannot be controlled. Stop machine immediately.

CALL E04 Caution lamp flashes. Machine cannot travel. Call your Komatsu distributor
Caution buzzer sounds. Machine stops for repair.
D475A-3 20-167
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
operating 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 is set in the service
mode, [1C] is displayed on the gear speed
display section.
Each time the monitor panel is set in the
service mode, the Maintenance interval
change mode is displayed first.
2) Selecting and executing mode to be used

Select the mode to be used with information
switch (5) and execute it with buzzer cancel
switch (4).
[ > ]: Next mode No.
[ < ]: Previous mode No.
[ ]: Execute mode.
For the details of operation in each mode,
see the following pages. Gear speed
No. display section Service mode item
3) Finishing mode and function Maintenance interval change
5 1C
The current mode and function can be finished mode
by either of the following method, regardless of Electric system error code dis-
6 EE
the current mode and hierarchy. play mode
1 When continuing the operation in another Mechanical system error code
7 bE
mode or function or in the operator mode: display mode
Return to the mode screen or function screen 8 Cb Adjustment mode
to be used next by operating buzzer cancel 9 Ld Load memory display mode
switch (4). 10 5R Real-time monitoring mode
[ ]: Screen returns. 11 dR Dual display monitoring mode
2 When finishing the all operation:
Turn off the starting switch.
20-168 D475A-3
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 sec-
tion (1) and the title is displayed on
ii) Display the maintenance item selection
screen by operating buzzer cancel switch
(4).
[ ]: Execute mode.
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
screen by operating buzzer cancel switch
(4).
[ ]: Execute item.
3) Contents of information section

The following items are displayed on the
information section.
1: Code
2: Maintenance item
3: Replacement interval time (Set time)
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).
D475A-3 20-169
4) Changing replacement interval time

i) Change the set time by operating infor-
mation switch (5), shift switch (6), and
neutral switch (7).
[ > ]: Move cursor to right.
[ < ]: Move cursor to left.
Shift switch: Increase number.
Neutral switch: 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 ap-
pears after the screen shown at
right.
If the change is not finished nor-

mally, the information display
screen before the change appears
after the screen shown at right. In
this case, execute the above opera-
tion again.
20-170 D475A-3
Maintenance items table
Replacement interval time

Code Maintenance item
1st time 2nd time and after
(Cannot be changed) (Can be changed)
01 ENG OIL Engine oil 0250 h 0500 h
02 ENG FILT Engine oil filter 0250 h 0500 h
03 FUEL FILT Fuel filter 0250 h 0500 h
04 HYD FILT Hydraulic oil filter 0250 h 2000 h
05 CORR RES Corrosion resistor 1000 h 1000 h
06 BYPS FILT Bypass filter 0250 h 0500 h
07 DAMP OIL Damper oil 2000 h 2000 h
08 FNL OIL Final drive oil 0250 h 2000 h

09 HYD OIL Hydraulic oil 0250 h 2000 h
10 POWL OIL Power train oil 0250 h 1000 h
11 POWL FILT Power train oil filter 0250 h 0500 h
12 HSS FILT HSS charge filter (HSS specification)
The first interval time cannot be changed. If it needs to be changed for a particular reason, assume
that the first maintenance has been finished in the maintenance mode of the operator mode, then
change the 2nd and after interval times.
D475A-3 20-171
6. Electric system error code display mode

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

i) Select Electric system error code dis-
play 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).
[ ]: Execute mode.
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 D475A-3
Flashing and lighting of error code

Flashing: Code is being output currently.
Lighting: Code is not being output cur-
rently.
Condition for detecting and keeping er-
ror code
If a error code of any item other than
communication is output, it keeps flash-
ing until the starting switch is turned off.
After the starting switch is turned 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).
[ > ]: Next code
The error codes are displayed from the
oldest one in order of length of time af-
ter they were output.
5) Method of deleting error code

While a error code to be deleted, operate
shift switch (6) or neutral switch (7).
Shift or neutral switch: Delete error code.
A error code which is being output cur-
rently (which is flashing) cannot be de-
leted.
D475A-3 20-173
7. Mechanical system error code display mode

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

i) Select Mechanical system error code
display mode on the mode selection
screen.
If the mode is selected, code (bE) is
ii) Display the error code display screen by
operating buzzer cancel switch (4).
[ ]: Execute mode.
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 D475A-3
Flashing and lighting of error code

Flashing: Code is being output currently.
Lighting: Code is not being output cur-
rently.
Condition for detecting and keeping er-
ror code
If an 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 turned on or
the engine is started again, the error code
keeps lighting until the same fault is de-
tected.
An error code of communication starts
lighting when the fault is solved, even if
the starting switch is turned off.
4) Operation to take when multiple codes are

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

The mechanical system error codes cannot
be deleted.
D475A-3 20-175
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 screen
by operating buzzer cancel switch (4).
[ ]: Execute mode.
2) Selecting adjustment items

On the adjustment code input screen, input
the 4-digit code of the item to be adjusted
by operating information switch (5), shift
switch (6), and neutral 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 PRO-
CEDURE.
20-176 D475A-3
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 (2) dis-
plays normally and the machine can be op-
erated normally.
To select another screen, return the park-
ing brake lever to the LOCK position and
perform the necessary procedure.
5) Changing adjustment item (Limited function)

Once the adjustment items are selected, they
can be selected with the information switch
without inputting the codes again.
[ > ]: Next code
This function is limited to Nos. 1 6 in
the Adjustment mode table and adjust-
ment procedure.
This operation is not accepted while the
parking brake lever is in the FREE posi-
tion. Take care.
An adjustment item can be selected by
returning to the input screen and input-
ting the code for that item.
D475A-3 20-177
Adjustment mode table and adjustment procedure
Related
No. Code Adjustment item Indication
information
1 0002 S/T S. CODE Steering controller specification set CODE D475-3 AAA, D475m/c 666
2 0003 T/M S. CODE Transmission controller spedification set CODE D475-3 999, D475m/c 555
ABB 3 digit indication

Machine specification set A Section 0: PCCS, 1: SW type lever
3 0004 BODY TYPE CODE
4: Retro-machine PCCS,
5 Retro-machine SW type lever
4 0005 BRAKE BASE Brake potentiometer initial set mv Offset value
5 0007 ENG. FULL CH Engine deceleration-cut mode rpm Engine revolution
Pitch angle sensor initial set Inclination angle sensor offsetting

6 0009 PITCH SENS. mV
voltage
7 0001 INP TEL NO. Phone number input mode Telephone number
8 1012 S/T N-SET Steering lever neutral set mV S/T potentiometer 2 voltage mV
9 1013 S/T M. L-SET Steering lever left set mV S/T potentiometer 2 voltage mV
0 1014 S/T M. R-SET Steering lever right set mV S/T potentiometer 2 voltage mV
A 1031 BR AUTO-SET Brake automatic adjustment MPa Brake pressure setting MPa
B 1015 BRK LH. OFST Left brake oil pressure offset MPa Offsetting oil pressure
C 1016 BRK RH. OFST Right brake oil pressure offset MPa Offsetting oil pressure
D 2223 R SLOW CUT Reverse slow stop set DEACTIVE or ACTIVE
E 5535 CLUTCH OPEN Both steering clutches released rpm Transmission revolution rpm
F 5536 CL AUTO-SET Steering clutch automatic adjustment MPa Brake pressure setting MPa
G 5537 CLT LH. OFST Left steering clutch oil pressure offset MPa Offsetting oil pressure
H 5538 CLT RH. OFST Right steering clutch oil pressure offset MPa Offsetting oil pressure
I 9993 HYD. LEVEL Hydraulic oil level setting mode DEACTIVE or ACTIVE
J 9994 BRAKE DECEL Decelerator interlocking setting mode DEACTIVE or ACTIVE
K 9995 LOCK BRAKE Electric brake normally ON mode mV Brake potentiometer voltage mV
L 9996 MECHA BRAKE Electric brake release mode mV Brake potentiometer voltage mV
M 9997 HI IDLE SET High Idling limit mode rpm
N 9998 SFT INHIBIT Gear speed limit mode Bit
O 0523 SMR SET Service meter adjustment SMR
20-178 D475A-3
1 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 (HSS specification):
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 control-
ler unit may be defective.
Even if this code is turned off, the setting is
effective.
2 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:
sounds.
2) Check that the displayed specification code
has changed from [9*9] to [999].
If specification code [999] is not displayed,
the controller wiring harness or the control-
ler unit may be defective.
effective.
D475A-3 20-179
3 0004: Machine specification set

This code is used to have the machine specifica-
tion recognized by the controllers which com-
pose the system.
The machine specification code is displayed on
the lower line.
Adjustment method:
Since this code is reset when Transmission
controller specification set is executed, ad-
just it after that.
1) Select the code of the machine specification
by setting information switch (5) in the [ > ]
position.
Be sure to select SSC power setting 1
as the SSC type. Section A
2) Set buzzer cancel switch (4) in the [ ] posi- Travel control Factory shipment or
tion and check that the caution buzzer No. local modification
lever spec.
sounds. 0 PCCS Factory shipment
If the machine specification is different from
the setting in the controller, the machine may 1 PCCS R type Factory shipment
move abnormally or an error may be made. 4 PCCS Local modification
Accordingly, be sure to match the setting to
the machine specification. 5 PCCS R type Local modification
effective.
Section B
No. Work equipment type SSC type
00 Single tilt SSC function OFF
01 Single tilt SSC power setting 1
02 Single tilt SSC power setting 2
10 Dual tilt SSC function OFF

11 Dual tilt SSC power setting 1
12 Dual tilt SSC power setting 2
4 0005: Brake potentiometer initial set

This code is used to adjust the neutral position
of the brake pedal.
The deviation from the standard neutral posi-
tion is displayed by voltage on the lower line
(Display range: 0 5000).
Adjustment method:
Set buzzer cancel switch (4) in the [ ] position
and check that the caution buzzer sounds.
Even if the neutral position of the brake pedal
is adjusted, the display of the lower line does
not change.
effective.
20-180 D475A-3
5 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
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.
6 0009: Pitch angle sensor initial set

This code is used to adjust the zero point and
installation error of the pitch angle sensor.
The deviation from the standard neutral posi-
tion is displayed by voltage on the lower line
Adjustment method:
effective.
7 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
switch (6), and neutral switch (7), input a phone
number and symbols.
[ > ]: Moves the cursor rightward.
[ < ]: Moves the cursor leftward.
Shift switch: Advance the numeric charac-
ter or character (in the order
of available characters).
Neutral switch:Reverse the numeric charac-
ter or character (in the reverse
order of available characters).
Sixteen digits of numeric characters are pro-
vided. To avoid confusion, input symbols
other 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 con-
dition.)
The setting is enabled even after ending this
code.
D475A-3 20-181
8 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
voltage on the lower line (Display range: 0
5000).
Adjustment method:
effective.
9 1013: Steering lever left set

This code is used to adjust the maximum left
steering position of the PCCS lever.
the standard maximum left position is displayed
by voltage on the lower line (Display range: 0
5000).
Adjustment method:
1) Set the PCCS lever to the left steering stroke
end.
sounds.
effective.
0 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 dis-
played by voltage on the lower line (Display
range: 0 5000).
Adjustment method:
1) Set the PCCS lever to the right steering stroke
end.
sounds.
effective.
20-182 D475A-3
A 1031: Brake automatic adjustment

This code is the function to maintain the perfor-
mance of the brake control by automatically ad-
justing any changes in the performance caused
by variation or wear in the brake parts.
The bottom display shows the brake command
oil pressure (unit: 0.01 kg/cm2).
With this adjustment, the machine moves
approx. 1 2 m forward, so carry out the adjust-
ment on flat ground where it is possible to en-
sure safety in the surrounding area.
Method of adjustment 1 (preparatory work)
Check that the torque converter oil tempera-
ture is in the operating range when carrying
1) Start the engine and select this code.
2) Set the parking lever to the FREE position.
3) Set the auto shift down switch to OFF
4) Run the engine at low idling.
5) Depress the brake pedal and decelerator
pedal to hold the machine.
6) Operate the PCCS lever direction to F and
the speed to 2.
Keep the steering at the neutral posi-
tion.
7) Gradually release the decelerator pedal and
brake pedal and check that the machine does
not move.
If the machine moves, there is an abnor-
mality, so stop the adjustment immedi-
ately.
If it is confirmed that the machine does
not move, go on to the following Method
of adjustment 2.
Method of adjustment 2 (adjusting left clutch)
1) Operate the PCCS lever steering fully to the
left.
2) Check that the display for the command oil
pressure changes automatically.
3) Drive the machine forward 1 2 m, then
stop the machine and check that the alarm
buzzer sounds.
4) Return the PCCS lever steering to the neu-
tral position.
After completing the adjustment of the
left clutch, go on to the following Method
of adjustment 3.
It is possible to check the compensation
value for the left brake oil pressure with
adjustment code 1015.
Method of adjustment 3 (adjusting right brake)
right.
D475A-3 20-183
3) Drive the machine forward 1 2 m, then

stop the machine and check that the alarm
buzzer sounds.
tral position.
value for the right brake oil pressure with
Even when this code is finished, the setting
remains effective.
B 1015: Left brake oil pressure offset

This code is the function to adjust the left brake
oil pressure manually.
The bottom display shows the offset oil pres-
sure (unit: 0.01 kg/cm2). (If it has already been
adjusted, the value is displayed, but if it is within
the permitted range, it is possible to adjust fur-
ther.).
Method of adjustment
The maximum permitted range for adjust-
ment is 3 kg/cm2 (display: 300).
1) Operate the shift switch and set the offset
oil pressure.
Shift switch (6): Oil pressure increases
Neutral switch (7): Oil pressure increases
The offset oil pressure changes 0.5 kg/
cm2 (display: 50) at a time.
2) Turn the buzzer cancel switch (4) toward the
[ ] side and check that the alarm buzzer
sounds.
remains effective.
C 1016: Right brake oil pressure offset

This code is the function to adjust the right brake
oil pressure manually.
ther.).
1) Operate the shift switch or neutral switch
and set the offset oil pressure.
sounds.
remains effective.
20-184 D475A-3
D 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.
Adjustment method:
Change the setting by operating information
switch (5).
[ < ], [ > ]: Change setting.
[DEACTIVE]: Turn off reverse slow function.
[ACTIVE]: Turn on reverse slow function.
If the reverse slow function is turned off, the
reverse travel speed is not lowered even if
the reverse slow mode switch on the moni-
tor panel is turned on.
effective.
E 5535: Both steering clutches released

This code is the function to engage the trans-
mission clutch without allowing the machine to
move when carrying out inspection, mainte-
nance, troubleshooting, or Pm clinic.
The bottom display shows the transmission
speed (unit: rpm).
Method of use
The function is effective when this code is being
displayed. Both steering clutches are disengaged,
so the machine does not travel even if the PCCS
lever is operated.
When this code is finished, the function be-
comes ineffective.
D475A-3 20-185
F 5536: Steering clutch automatic adjustment

This code is the function to maintain the perfor-
mance of the steering control by automatically
adjusting any changes in the performance
caused by variation or wear in the steering clutch
parts.
The bottom display shows the clutch command
oil pressure (unit: 0.01kg/cm2).
Method of adjustment 1 (preparatory work)
Check that the torque converter oil tempera-
ture is in the operating range when carrying
1) Start the engine and select this code.
2) Set the parking lever to the FREE position.
3) Set the auto shift down switch to OFF.
4) Run the engine at low idling.
5) Depress the brake pedal and decelerator
pedal to hold the machine.
6) Operate the PCCS lever direction to F and
the speed to 2.
Keep the steering at the neutral posi-
tion.
7) Gradually release the decelerator pedal and
brake pedal and check that the machine does
not move.
If the machine moves, there is an abnor-
mality, so stop the adjustment immedi-
ately.
If it is confirmed that the machine does
not move, go on to the following Method
of adjustment 2.
Method of adjustment 2 (adjusting left clutch)
left.
3) Raise the engine speed and check that the
alarm buzzer sounds.
tral position.
After completing the adjustment of the
left clutch, go on to the following Method
of adjustment 3.
value for the left clutch oil pressure with
20-186 D475A-3
Method of adjustment 3 (adjusting right clutch)

right.
3) Raise the engine speed and check that the
alarm buzzer sounds.
tral position.
value for the right clutch oil pressure
with adjustment code 5538.
remains effective.
G 5537: Left steering clutch oil pressure offset

This code is the function to adjust the left steer-
ing clutch oil pressure manually.
ther.)
sounds.
remains effective.
D475A-3 20-187
H 5538: Right steering clutch oil pressure offset

This code is the function to adjust the right steer-
ing clutch oil pressure manually.
ther.)
[ ] and check that the alarm buzzer sounds.
remains effective.
I 9993: Hydraulic oil level setting mode

This code is for the function to make settings
for activation of the hydraulic oil level caution.
On the lower line, activation or cancellation of
the hydraulic oil level caution will be indicated
by characters.
Adjustment method
Change the setting by use of the information
switch (5).
[ < ] [ > ]: The indication will change.
[DEACTIVE]: Cancels the hydraulic oil level
cautioning function.
[ACTIVE]: Activates the hydraulic oil level
cautioning function.
To use this function, it is necessary to install the
hydraulic oil level switch (option). If the above
[ACTIVE] setting is made without installation of
the hydraulic oil level switch, the caution will
keep sounding and be careful about this point.
The setting will be valid even after ending this
code.
20-188 D475A-3
J 9994: Decelerator interlocking brake setting mode

This code is for the function to make settings
for activation of the decelerator interlocking
brake.
On the lower line, activation or cancellation of
the decelerator interlocking brake will be indi-
cated by characters.
Adjustment method
Change the setting by use of the information
switch (5).
[ < ] [ > ]: The indication will change.
[DEACTIVE]: Cancels the decelerator inter-
locking brake function.
[ACTIVE]: Activates the decelerator interlock-
ing brake function.
The setting will be valid even after ending this
code.
K 9995: Electric brake normally ON mode

This code is used to check that the sudden stop
prevention 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.
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.
off.
D475A-3 20-189
M 9997: High idling limit mode

This code is used to limit the use of the high
idling speed.
The engine speed (set value) is displayed on the
lower line.
Limit range: High idling speed High idling
speed 400 rpm
Using method:
1) Select a limit speed by setting information
switch (5) in the [ > ] position or [ < ] posi-
tion.
sounds.
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.
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.
20-190 D475A-3
O 0523: Service meter adjustment

This code is used to match the value of a new
service meter to the value of the machine.
Since this code can only put the service meter
forward and cannot put it back, operate care-
fully.
The service meter reading is displayed on the
lower line (Display range: 00000 99999).
Using method:
If you input a wrong value, do not enter the
setting but cancel this code, then execute
the setting again.
1) Set the service meter reading by operating
information switch (5) and shift switch (6).
The actual service meter displays by the
unit of 0.1h, but this code displays by
the unit of 1h.
sounds.
Even if the adjustment mode is turned off,
the setting is effective.
D475A-3 20-191
9. Load memory display mode

(9-LOAD MEMORY DISPLAY MODE)
In this mode, you can check the load on the
machine, 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 screen
[ ]: Execute mode.
2) Changing information screen No. Displayed information

Change the information screen by operating
information switch (5). 01 1,000 rpm service meter
[ > ]: Next screen. 02 Forward odometer
[ < ]: Previous screen.
03 Reverse odometer
3) Display of 1,000 rpm 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 1,000
rpm.
The data cannot be reset.
20-192 D475A-3
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 section displays
normally and the machine can be operated
normally.
ing brake lever to the LOCK position and
D475A-3 20-193
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
[ ]: Execute mode.
2) Selecting and entering monitored items

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

monitoring screen by operating buzzer
cancel switch (4).
[ ]: Enter input code.
If the input code is normal, the moni-
toring screen shown at right appears.
20-194 D475A-3
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
letter 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.
ing brake lever to the FREE position and
D475A-3 20-195
6) Changing monitored items (Limited function)

Once the monitoring screen is selected in
step 2), the monitored item can be changed
by operating only information switch (5) with-
out inputting the code again.
[ > ]: Next code
This function is applicable to only Nos. 1
29 in the Monitoring mode table.
This operation is not accepted while the
parking brake lever is in the FREE posi-
tion. Take care.
20-196 D475A-3
Monitoring mode table

No. Code Monitored item Unit Display range
1 01002 ENG. SPEED1 Engine revolution A rpm 0 3000
2 51100 FUEL DIAL Fuel control command rpm 0 3000
3 50002 DECEL PEDL Decelerator command rpm 0 3000
4 60300 SSC ORDER Track shoe control command rpm 0 3000
5 50200 T/M LEVR 1 T/M controller FR potentiometer 1 voltage mV 0 5000
6 50201 T/M LEVR 2 T/M controller FR potentiometer 2 voltage mV 0 5000
7 50300 S/T LEVR 1 S/T potentiometer 1 voltage mV 0 5000
8 50301 S/T LEVR 2 S/T potentiometer 2 voltage mV 0 5000
9 50400 BRAKE PEDL Brake potentiometer voltage mV 0 5000
10 31619 BRAKE L.H. LH brake ECMV output current (F/B) mA 0 1000
11 31618 BRAKE R.H. RH brake ECMV output current (F/B) mA 0 1000
12 90600 S/T CLT LH LH clutch ECMV output current (F/B) mA 0 1000
13 90601 S/T CLT RH RH clutch ECMV output current (F/B) mA 0 1000
14 31622 F CLUTCH F Forward ECMV output current (F/B) mA 0 1000
15 31606 R CLUTCH F Reverse ECMV output current (F/B) mA 0 1000
16 31602 1 CLUTCH F 1st ECMV output current (F/B) mA 0 1000
17 31603 2 CLUTCH F 2nd ECMV output current (F/B) mA 0 1000
18 31604 3 CLUTCH F 3rd ECMV output current (F/B) mA 0 1000
19 04102 WATER HIGH Water temperature sensor C 0 150
20 30100 T/C TEMP. Torque converter oil temperature sensor C 0 150
21 04200 FUEL SENS Fuel level sensor mV 0 5000
22 31400 T/M OUT T/M controller T/M revolution rpm 0 5000
23 31628 E. BRAKE SL S/T controller abrupt stop preventive solenoid voltage value mA 0 1000
24 31627 L/U SOL T/M controller lockup solenoid voltage value mA 0 1000
25 50900 N-SAFTY T/M controller neutral safety relay voltage value mV 0 30000
26 40001 VEHICLE SP Logical travel speed km/h 0 100
27 60000 TRACTION Logical traction force W 05
28 32900 BODY ANGLE S/T controller pitch angle sensor 30 30
29 03200 BATTERY Battery voltage mV 0 30000
30 60100 BODY ANGLE S/T controller pitch angle sensor voltage mV 0 5000
31 60200 ACCELERATN S/T controller acceleration sensor voltage mV SSC spec only 0 5000
32 04401 HYD. TEMP. Hydraulic oil temperature C 0 150
33 40910 S/T-SW1 S/T controller SW input 1 bit 5Parking lever SW: Free
6Parking lever SW: Lock
34 40911 S/T-SW2 S/T controller SW input 2 bit 1Buzzer cancel SW: Cancel
2Buzzer cancel SW: Select
3Information SW: LH
4Information SW: RH
5Service SW
35 40913 S/T-SW5 S/T controller SW input 5 bit 1ACC signal: When turned ON
2Turbo timer signal: When turned ON
3Engine Li signal: When turned ON
4Monitoring signal: When turned ON
5N signal 1: When turned ON
36 60400 S/T-SW6 S/T controller SW input 6 bit 1Electrical intake air heater signal: When turned ON
2C signal: When turned ON
4Night time lighting signal: When turned ON
5Hydraulic oil level SW signal: When turned ON
D475A-3 20-197

37 31521 S/T FILL S/T controller fill SW input bit 1LH brake fill SW: When turned ON
2LH clutch fill SW: When turned ON
5RH clutch fill SW: When turned ON
6RH brake fill SW: When turned ON
38 31621 BRAKE L.H. LH brake ECMV current command mA 0 1000
39 31620 BRAKE R.H. RH brake ECMV current command mA 0 1000
40 90602 S/T CLT LH LH clutch ECMV current command mA 0 1000
41 90603 S/T CLT RH RH clutch ECMV current command mA 0 1000
42 40914 S/T SOL. 1 S/T comptroller on/off output bit 4Engine controller drive: When turned ON
5Battery relay drive: When turned ON
6Abrupt stop preventive solenoid: When turned ON
43 60500 ENG. CON. PW S/T controller engine control drive command mV 0 30000
44 60600 BR HOLD S/T controller battery relay drive voltage value mV 0 30000
45 70100 SLIP FLAG Slip flag bit 1Track shoe slippage ratio: 30% or more
46 20200 MON. PROGRM Tachometer module program No. Letter
47 20201 T/M. PROGRM T/M controller program No. Letter
48 20202 S/T. PROGRM S/T controller program No. Letter
49 60700 S/T MODE Steering state code Letter
50 60800 FILL MODE Fill condition setting parameter Letter
51 60909 MOD. MODE Modulation condition setting parameter Letter
52 70000 CHG. P. MODE Speed changing point condition setting parameter Letter
53 70200 T/M OUT T/M controller T/M revolution sensor voltage mV
54 40905 T/M-SW1 T/M controller SW input 1 bit 1Forward SW: When turned OFF
2Forward SW: When turned ON
3Reverse SW: When turned OFF
4Reverse SW: When turned ON
5Parking lever SW: Free
6Parking lever SW: Lock
55 40906 T/M-SW2 T/M controller SW input 2 bit 1Auto shift down SW: When turned ON
2Neutral SW: When turned OFF
3Neutral SW: When turned ON
4Shift SW: When turned OFF
5Shift SW: When turned ON
56 31520 T/M-FILL T/M controller fill SW input 1Forward clutch fill SW: When turned ON
2Reverse clutch fill SW: When turned ON
31st speed clutch fill SW: When turned ON
42nd speed clutch fill SW: When turned ON
53rd speed clutch fill SW: When turned ON
57 31608 Frd CLUTCH Forward clutch ECMV current command mA 0 1000
58 31606 Rev CLUTCH Reverse clutch ECMV current command mA 0 1000
59 31602 1st CLUTCH 1st clutch ECMV current command mA 0 1000
60 31603 2nd CLUTCH 2nd clutch ECMV current command mA 0 1000
61 31604 3rd CLUTCH 3rd clutch ECMV current command mA 0 1000
62 40909 T/M SOL. 2 T/M controller on/off output bit 1N signal 1: When turned ON
4Backup alarm relay: When turned ON
5Neutral safety relay: When turned ON
6Lockup: When turned ON
63 70400 BACK ALARM T/M controller back alarm relay voltage value mV 0 30000
20-198 D475A-3

64 40908 T/M SW2 T/M controller blade oil pressure SW input bit 1Blade lift up oil pressure SW: When turned ON
2Blade lift down oil pressure SW: When turned ON
5Blade lift LH tilt oil pressure SW: When turned ON
6Blade lift RH tilt oil pressure SW: When turned ON
65 70300 B. KONB SW T/M controller toggle SW input bit 1Blade lever tilt SW: When using DUAL
2Blade lever tilt SW: When using SINGLE
3Blade lever pitch SW: When turned OFF
4Blade lever pitch SW: When turned ON
66 70700 HYD. PUMP 1 T/M controller work equipment oil pressure 1 MPa 0 50
67 70701 HYD. PUMP 1 T/M controller work equipment oil pressure 1 sensor voltage mV 0 5000
68 70702 HYD. PUMP 2 T/M controller work equipment oil pressure 2 MPa 0 50
69 70703 HYD. PUMP 2 T/M controller work equipment oil pressure 2 sensor voltage mV 0 5000
70 70305 T/M RIPER2 T/M controller ripper oil pressure SW input bit 2Ripper lift up oil pressure SW: When turned ON
3Ripper lift down oil pressure SW: When turned ON
4Ripper tilt in oil pressure SW: When turned ON
5Ripper tilt back oil pressure SW: When turned ON
71 90000 T/M SOL. 3 T/M controller on/off output 3 bit 1Unload solenoid: When turned ON
2Dump support solenoid: When turned ON
3LH tilt limiting solenoid: When turned ON
4RH tilt limiting solenoid: When turned ON
5Pitch selecting solenoid: When turned ON
6Pitch independent solenoid: When turned ON
72 90001 T/M SOL. 4 T/M controller on/off output 3 bit 1Pitch dumping solenoid: When turned ON
2Pitch back solenoid: When turned ON
73 90002 BL YOKE L LH yoke angle sensor mV 0 5000
74 90003 BL YOKE R RH yoke angle sensor mV 0 5000
75 01004 ENG. SPEED2 Engine revolution B rpm 0 3000
76 31703 FUEL DIAL Accelerator voltage mV 0 5000
77 50001 DECEL PEDL Decelerator voltage mV 0 5000
78 51200 RACK S. RH RH rack sensor voltage mV 0 5000
79 51300 RACK S. LH LH rack sensor voltage mV 0 5000
80 51400 GOV. SOL RH RH governor solenoid current value mA 0 1000
81 51500 GOV. SOL LH LH governor solenoid current value mA 0 1000
82 51600 PRE. SOL RH RH pre-stroke solenoid current value mA 0 1000
83 51700 PRE. SOL LH LH pre-stroke solenoid current value mA 0 1000
84 60301 CNTR. THRTL Track shoe controller voltage mV 0 5000
85 51800 NEUTRAL S. T/M N signal bit data bit
86 51000 FINL. THRTL Regulation command rpm 0 3000
87 04102 ENG. W. TEMP Water temperature sensor mV 0 5000
D475A-3 20-199
11. Dual display monitoring mode

(11-DUAL DISPLAY MONITORING MODE)
In this mode, 2 monitored items can be dis-
played 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
[ ]: Execute mode.
2) Selecting and entering monitored items

i) On the code input screen, input the 5-
digit codes of the items to be monitored
to the upper and lower lines by operat-
ing information switch (5), shift switch
(6), and neutral 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
appears.
20-200 D475A-3
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-
plays normally and the machine can be op-
erated normally.
ing brake lever to the FREE position and
D475A-3 20-201
TESTING AND ADJUSTING ADJUSTMENT METHOD OF REPLACED CONTROLLER
ADJUSTMENT METHOD OF
REPLACED CONTROLLER
After the machine is assembled or transmis- 3. Adjusting transmission controller
sion controller or steering controller is re- Select Transmission controller specification
placed, adjust the system according to the set (0003) and adjust the transmission con-
following procedure. troller.
If the system is not adjusted, the machine Execute this code when only the steer-
may not operate normally and may move ing controller is replaced, too.
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. Ac-
cordingly, take a record of the next replace-
ment periods of the oils and filters.
Precautions for replacing a controller:
When replacing a controller, stop the ma-
chine in a safe place and turn the starting
switch off.
1. Setting system in service mode

Turn the starting switch on and set the moni-
tor panel in the Adjustment mode of the
service mode. 4. Turning power on again
Turn the starting switch off and on, then set
2. Adjusting steering controller the monitor panel in the Adjustment mode
Select Steering controller specification set of the service mode again.
(0002) and adjust the steering controller.
Execute this code when only the trans- 5. Adjusting machine specification
mission controller is replaced, too. Select Machine specification set (0004) and
adjust the machine specification.
20-202 D475A-3
TESTING AND ADJUSTING ADJUSTMENT METHOD OF REPLACED CONTROLLER
6. Adjusting brake potentiometer

Select Brake potentiometer initial set (0005)
and adjust the brake potentiometer.
7. Turning power on again

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

1) Set the monitor panel in the Electric
system error code display mode of the
service mode.
2) See if any error code is being output
currently. If any error code is not being
output, delete the all error codes.
If any error code is being output, remove
its cause by troubleshooting and execute
steps 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 pe-
riod displayed on the monitor panel may be
different from the actual operating hours.
To solve this problem, determine the first
replacement periods of the oils and filters
after the replacement of the controller ac-
cording to the replacement periods recorded
before the replacement of the controller.
D475A-3 20-203
PREPARATION WORK FOR TROUBLESHOOTING FOR
TESTING AND ADJUSTING ELECTRIC SYSTEM
PREPARATION WORK FOR TROUBLESHOOTING FOR

ELECTRIC SYSTEM
When carrying out troubleshooting for an 2. Engine controller
electric circuit related to the monitor panel, 1) Remove cover (3).
engine controller, transmission controller, or
steering controller, expose the related con-
nectors according to the following procedure.
1. Monitor panel
1) Remove cover (1).
2) Remove the 2 mounting bolts and pull
out monitor panel (2) toward the operators
seat.
2) Insert or connect T-adapters in or to con-

nectors ECN1, ECN2, ECN3, ECN4 con-
nectors and ECN5 connectors of engine
controller (4).
If the connectors cannot be discon-
nected and connected easily, remove
the controller from the floor frame.
3) Insert or connect T-adapters in or to con-

nectors S01, S02, S03, and S04 of moni-
tor panel (2).
20-204 D475A-3
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC
TESTING AND ADJUSTING ELECTRIC SYSTEM
3. Transmission controller 4. Steering controller

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

nectors TMCN1, TMCN2, and TMCN3 of nectors STCN1, STCN2, and STCN3 of
transmission controller (6). transmission controller (7).
If the connectors cannot be discon- If the connectors cannot be discon-
nected and connected easily, remove nected and connected easily, remove
the controller from the floor frame. the controller from the floor frame.
Since the connectors are secured Since the connectors are secured
with screws, loosen those screws with screws, loosen those screws
before disconnecting. before disconnecting.
When connecting the connectors When connecting the connectors
again, tighten their screws to the again, tighten their screws to the
specified torque. specified torque.
3 Screw: 2.82 Nm {0.288 kgm} 3 Screw: 2.82 Nm {0.288 kgm}
D475A-3 20-205
TESTING AND ADJUSTING HANDLING OF OPTIONAL DEVICES
HANDLING OF OPTIONAL DEVICES

D475A-3 has connectors to install optional 4. Taking out C signal of starting switch
devices in its fuse box. When installing any If the C signal (starting signal) of the starting
optional device, receive the necessary sig- switch is necessary to an optional device
nals and power through those connectors such as the pre-lubricator, take it out through
without modifying the wiring harness. the following connector pin.
CN-PRS (2-pole heavy duty wire connec-
1. Taking out ACC signal of starting switch tor)
If the ACC signal (ON signal) of the starting Remove the connector installed when the
switch is necessary to an optional device machine is shipped and connect pin 1
such as the turbocharger timer, take it out to the starting signal to be output finally
through the following connector pin. by the pre-lubricator and connect pin 2
Pin B of CN-ESD (3-pole heavy duty wire to the input signal from the starting
connector) switch.
A 20A fuse is installed on the upstream
side of this connector pin. 5. Taking out external power source
If an external power source is necessary,
2. Inputting engine controller holding signal take it through the following connectors.
If it is required to keep the engine running AUX1 (Plug connector)
with the starting switch turned off for an AUX2 (Plug connector)
optional device such as the turbocharger A 20A fuse is installed on the upstream
timer, connect the following connector pin side of each of these connectors.
to the chassis ground.
Pin A of CN-ESD (3-pole heavy duty wire 6. Inputting the engine shut down command
connector) If it is necessary to stop the engine for an
While this connector pin is connected to optional device, modify the following con-
the chassis ground, the starting switch nector pin circuit to connect to the ground-
works as it is at the ON position even if ing circuit.
it is at the OFF position. No. 1 pin of the SDC (2-pole heavy duty
wire connector)
3. Inputting engine low-idling command While this connector pin is being con-
If it is required to keep the engine speed at nected to the GND circuit, the engine
low idling for an optional device such as the will not start.
engine protector, connect the following con-
nector pin to the chassis ground.
Pin C of CN-ESD (3-pole heavy duty wire
connector)
While this connector pin is connected to
the chassis ground, the engine speed is
kept at low idling, regardless of the po-
sition of the fuel control dial.
20-206 D475A-3
Pm CLINIC SERVICE
Model Serial No. Service meter
D475A-3 h
User name Date of clinic Serviceman
Specifications
Blade Rear attachment Shoe width
Semi-U blade Multi-shank ripper 710 mm
U-blade Variable giant ripper 810 mm
Dual tilt blade Counterweight ( kg) 910 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:
D475A-3 20-207
Pm-clinic measuring points for D475A-3 (1/2)
Reference Page for Measurement Procedure designated

1. Engine speed: 20-103 page
2. Blow-by pressure: 20-111 page
3. Lubricating oil pressure: 20-112 page
4. Boost pressure: 20-106 page
5. Exhaust gas temperature: 20-107 page
20-208 D475A-3
Pm-clinic measuring points for D475A-3 (2/2)
Reference Page for Measurement Procedure designated

6. Centralized pressure pickup points: 20-124 126 page
8. Lubricating oil filter portion of transmission: 20-126 page
10. Hydraulic pressure: 20-142 page
D475A-3 20-209
MEASURING
POWER TRAIN OIL PRESSURE AND OTHERS
Connect the measuring equipment to the engine and machine body.
Always carry out removal or installation of equipment for measuring the hydraulic pressure with the
engine stopped.
Always carry out removal or installation of measuring equipment with the engine stopped, and be
careful not to touch any high temperature part.
20-210 D475A-3
Serial No.
Pm CLINIC CHECK SHEET D475A-3
Work order No. Date Service meter Serviceman
h
ITEM Condition Unit STD. PMS. Result Sat Us

1 1-1 Eng. Low idling 600 700 600 700
Eng. Speed Deceleration slow 850 950 850 950
Super & Dual tilt dozer Eng. Full (Display A must show 0007) rpm 2100 2200 2100 2200
Blade pitch back relief T/C Stall 1630 1730 Min. 1590
Single tilt dozer
Unnecessary T/C Stall & Relief (1480 1600) Min. 1420
1-2 T/C Stall kPa Max. 1.47 Max. 2.94
Blow-by Press. {mmH2O} {Max. 150} {Max. 300}
1-3 Eng. Min. 0.10 Min. 0.08
Low idling {Min. 1.0} {Min. 0.8}
SAE10W-30
0.29 0.44 Min. 0.20
ENGINE
Eng. Full {3.0 4.5} {Min. 2.0}

Lub. Oil Press. MPa
Eng. {kg/cm2} Min. 0.12 Min. 0.10
Low idling SAE15W-40, {Min. 1.2} {Min. 1/0}
SAE30 0.39 0.54 Min. 0.25
Eng. Full
{4.0 5.5} {Min. 2.5}
1-4 Min. 120 Min. 107
R.H. Bank {Min. 900} {Min. 800}
Boost Press. T/C Stall kPa
{mmHg} Min. 120 Min. 107
L.H. Bank {Min. 900} {Min. 800}
1-5 R.H. Bank Max. 650 Max. 750
T/C Stall
Exhaust Gas Temp. L.H. Bank C Max. 650 Max. 750
(at 20C) Ambient Temp.
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.
2 2-1 0.03 0.20 0.03 0.20
Inlet Oil Press. {0.3 2.0} {0.3 2.0}
2-2 0.03 0.15 0.03 0.15
Outlet Oil Press. Eng. {0.3 1.5} {0.3 1.5}
2-3 Low idling 00 00
Lock-up Clutch Press. {0 0} {0 0}
TORQUE CONVERTER
2-4 Transmission: 2.55 2.74 2.45

Stator Clutch Press. Neutral {26 28} {Min. 25}
2-5 Oil temperature: 0.8 1.0 0.8 1.0
Inlet Oil Press. 70 90 C MPa {8.0 10.0} {8.0 10.0}
2-6 {kg/cm2} 0.44 0.64 0.44 0.64
Outlet Oil Press. Eng. {45 6.5} {4.5 6.5}
2-7 High idling 00 00
Lock-up Clutch Press. {0 0} {0 0}
2-8 2.55 2.74 Min. 2.55
Stator Clutch Press. {26 28} {Min. 26}
2-9 Raise engine 1.12 1.42 1.12 1.42
Lock-up Clutch Press. Transmission: speed, when {11.5 14.5} {11.5 14.5}
2-10 F1 lock-up lamp 00 00
Stator Clutch Press. lights up {0 0} {0 0}
3 3-1 Eng. 2.56 2.91 Min. 2.45

Low idling {26.1 29.7} {Min. 25}
Main Relief Press.
Eng. 2.65 3.03 Min. 2.55
Transmission: High idling {27 30.9} {Min. 26}
3-2 Neutral Eng.
Low idling
TRANSMISSION
Lub. Oil Press. Eng. 0.1 0.2 0.1 0.2

High idling {1 2} {1 2}
3-3 Transmission: Eng. MPa 2.35 2.74 Min. 2.25
F Clutch Press. F3 Low idling {kg/cm2} {24 28} {Min. 23}
3-4 Transmission: Eng. 2.35 2.74 Min. 2.25
R Clutch Press. R3 Low idling {24 28} {Min. 23}
1st Clutch Press. F1 Low idling {20 24} {Min. 19}
2nd Clutch Press. F2 Low idling {24 28} {Min. 23}
3rd Clutch Press. F3 Low idling {24 28} {Min. 23}
D475A-3 20-211
Pm-CLINIC SERVICE
ITEM Condition Unit STD. PMS. Result Sat Us
4 4-1 2.56 2.91 Min. 2.45
L.H. Clutch Press. Eng. Low idling {26.1 29.7} {Min. 25}
4-2 T/M : N 2.56 2.91 Min. 2.45
L.H. Brake Press. {26.1 29.7} {Min. 25}
4-1 2.65 3.03 Min. 2.55
L.H. Clutch Press. Eng. Full {27 30.9} {Min. 26}
4-2 T/M : N 2.65 3.03 Min. 2.55
STEERING
L.H. Brake Press. MPa {27 30.9} {Min. 26}

4-3 {kg/cm2} 2.56 2.91 Min. 2.45
R.H. Clutch Press. Eng. Low idling {26.1 29.7} {Min. 25}
4-4 T/M : N 2.56 2.91 Min. 2.45
R.H. Brake Press. {26.1 29.7} {Min. 25}
4-3 2.65 3.03 Min. 2.55
R.H. Clutch Press. Eng. Full {27.0 30.9} {Min. 26}
4-4 T/M : N 2.65 3.03 Min. 2.55
R.H. Brake Press. {27 30.9} {Min. 26}
Brake Eng. Full
Performance T/M : F2 No movement No movement
Single or Dual Tilt Dozer Spec.

5 5-1 Eng. Low idling 3.73 4.41 Min. 3.53
T/M : N {38.0 45.0} {Min. 36.0}
PPC Press.
Eng. Full 4.02 4.71 Min. 3.92
T/M : N {41.0 48.0} {Min. 40.0}
5-2 Eng. Low idling 18.6 20.6 Min. 18.1
HYDRAULIC PRESSURE
(Single spec.) Single tilt relief {190 210} {Min. 185}

(Dual spec.) Pitch back relief
Rear Pump Press.
Eng. Full 20.1 21.6 Min. 19.6
(Single spec.) Single tilt relief {205 220} {Min. 200}
(Dual spec.) Pitch back relief MPa
5-3 Eng. Low idling {kg/cm2} 18.6 20.6 Min. 18.1
(Single spec.) Unnecessary {190 210} {Min. 185}
Assist Pump Press.
Eng. Full 20.1 21.6 Min. 19.6
(Single spec.) Unnecessary {205 220} {Min. 200}
5-4 Eng. Low idling 18,6 20.6 Min. 18.1
Ripper relief {190 210} {Min. 185}
Front Pump Press.
Eng. Full 20.1 21.6 Min. 19.6
Ripper relief {205 220} {Min. 200}
6 6-1 Eng. Low idling 13 18 Max. 20
Blade Lift Speed
WORK EQUIPMENT SPEED
(G.L END) Eng. Full 3.6 4.6 Max. 5.0
6-2 (#10601 10672) Eng. Low idling 8 12 Max. 14

Blade pitch Speed
(Pitch dump Pitch back) Eng. Full 2.7 3.7 Max. 4.5
sec
6-2 (#10673 and up) Eng. Low idling 10 13 Max. 15
Blade pitch Speed
(Pitch dump Pitch back) Eng. Full 3.8 4.8 Max. 5.5
6-3 Eng. Low idling 10 15 Max. 18

Ripper Tilt Speed
(Tilt in Tilt out) Eng. Full 3.5 4.5 Max. 5.0
20-212 D475A-3
Machine Serial No.
Pm-CLINIC SERVICE D475A-3 #
SDA12V140 Engine Serial No.
#
HOUR INSPECTION
WORK ORDER No. CARRIED OUT DATE SERVICE METER INSPECTED BY
Month Day Year
hrs.
OPERATORS OPINION Sat Us

Any abnormality ?
Coolant Temp. max. range ? T/C, T/M oil . max. range ? Ambient Temp.
White Green Red Green Red Max. C (F)
Min. C (F)
1 2 3 4 5 6 7 1 2 3 4 5 6 7
Altitude m (Ft)
(during operation) (during operation)
HOT BUSHING CHECKING RIGHT AFTER WORKING !
H: HOT
Can not keep to be
touched.
(Min. 50C)
W: WARM
Hotter than link
temp.
(Approx. 35C)
C: COOL
Similar to link
temp.
(Approx. 25C)
H: HOT
Can not keep to be
touched.
(Min. 50C)
W: WARM
Hotter than link
temp.
(Approx. 35C)
C: COOL
Similar to link
temp.
(Approx. 25C)
Track link loosening A: Protrusion of pin B: Clearance between links

L.H. SIDE R.H. SIDE
Pin No. Bush Temp. A (Inner) A (Outer) B (Inner) B (Outer) Pin No. Bush Temp. A (Inner) A (Outer) B (Inner) B (Outer)
Standard value 4.4 mm 4.4 mm 1.6 mm 1.6 mm Standard value 4.4 mm 4.4 mm 1.6 mm 1.6 mm
D475A-3 20-213
Pm-CLINIC SERVICE
SET BLADE, PITCH & RIPPER, THEN STOP THE ENGINE !
7 Hyd. Oil Temp. Condition C(F)
Blade Lift cylinder Max. 60 Max. 100
DRIFT
Eng. Stopped mm/

Pitch cylinder (Super) Max. 10 Max. 20
Hyd. Oil Temp.: 45 55C 5 min.
Ripper Lift cylinder Max. 30 Max. 50
8 Final Drive
Lub. Filter Eng. Stopped No excessive metallic powder
F/D
Visual Check
NOTE: Write-down any phenomena or information you found by your five sences during
todays inspection.
Hydraulic pump usage

Dual Tilt Dozer Single Tilt Dozer
No. Blade & Ripper
Lever position Front Rear Assist Front Rear Assist
Pump Pump Pump Pump Pump Pump
1 Blade lift (Raise & Lower)
2 Blade single tilt
3 Blade dual tilt
4 Blade pitch dump
5 Blade pitch back
6 Ripper lift & tilt
: Its worked when lever is applied. : Its worked at lever stroke end only.
(Relief pressure can be measured)
: Its worked when lever is applied. : Its drained at cylinder stroke end.
(Relief pressure cant be measured)
20-214 D475A-3
D475A-3 20-215
20-216 D475A-3
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................................................................................................................. 20-312
Classification and procedures of troubleshooting .................................................................................... 20-313
Table of connectors .................................................................................................................................. 20-314
Connector arrangement drawing .............................................................................................................. 20-318
Connection table for connector pin numbers ........................................................................................... 20-326
Troubleshooting when error code is displayed (error code) ..................................................................... 20-401
Troubleshooting of electrical system (E-mode) ........................................................................................ 20-601
Troubleshooting of hydraulic and mechanical system (H mode) .............................................................. 20-701
D475A-3 20-301
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. 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 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 D475A-3
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
D475A-3 20-303
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 D475A-3
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.
When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
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.
D475A-3 20-305
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 D475A-3
Connecting connectors
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.
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.
TEW00200
Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
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
D475A-3 20-307
Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
+ If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
+ Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
+ After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-308 D475A-3
1. 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 con-
trol box.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control box.

4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
5) During rainy weather, do not leave the control
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 con-
nected to the control box. Fit an arc welding
ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
+ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or cur-
rent), move the related wiring and connectors several times and check that there is no change in the
reading of the tester.
+ If there is any change, there is probably defective contact in that circuit.
D475A-3 20-309
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of hydrau-

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

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

field
If disassembly or maintenance work is carried out
on hydraulic equipment in the field, there is dan-
ger of dust entering the equipment. It is also diffi-
cult to confirm the performance after repairs, so it
is desirable to use unit exchange. Disassembly
and main-tenance of hydraulic equipment should
be carried out in a specially prepared dustproof
workshop, and the performance should be con-
firmed 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 of dirt entering or of the sur-
rounding 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 refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil filler
and the area around it clean, and also use clean
pumps and oil containers. If an oil cleaning device
is used, it is possible to filter out the dirt that has
collected during storage, so this is an even more
effective method.
20-310 D475A-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 possible of the
old hydraulic oil must be drained out. (Drain the oil
from the hydraulic tank; also drain the oil from the
filter and from the drain plug in the circuit.) If any
old oil is left, the contaminants and sludge in it will
mix with the new oil and will shorten the life of the
hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil from
the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and 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 con-
taminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3) particles that the filter built into
the hydraulic equipment cannot remove, so it is an
extremely effective device.
D475A-3 20-311
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level, type of fuel Add fuel
2. Check for impurities in fuel Clean, drain
Lubricating oil,
3. Check hydraulic oil level Add oil

4. Check hydraulic oil strainer Clean, drain
coolant
5. Check engine oil level (oil pan oil level) Add oil
6. Check coolant level Add water
7. Check dust indicator for clogging Clean or replace
8. Check hydraulic filter Replace
9. Check final drive oil level Add oil
mechanical equipment
1. Check for looseness, corrosion of battery terminal, wiring Tighten or replace

Hydraulic, Electrical
2. Check for looseness, corrosion of alternator terminal, wiring Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring Tighten or replace
equipment
1. Check for abnormal noise, smell Repair

2. Check for oil leakage Repair
3. Carry out air bleeding Bleed air
1. Check battery voltage (engine stopped) 20 30V Replace
2. Check battery electrolyte level Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring Replace

4. Check for missing wiring clamps, hanging wiring Repair
5. Check for water leaking on wiring (be particularly careful attention Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 29.5V
8. Check operating sound of battery relay Replace
(when switch is turned ON/OFF)
20-312 D475A-3
TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
Classification of Troubleshooting
Mode Explanation
Error code Troubleshooting when a service code is displayed
E Mode Troubleshooting of the electrical system
H Mode Troubleshooting of the hydraulic and mechanical systems
(Engine) Troubleshooting of the engine body (Refer to the Shop Manual for 12V140-1 Series Engine.)
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 an 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.
+ Since an 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.)
+ When an 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 an 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.
+ 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.)
+ When an 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.
In this case, check again a phenomenon supposed to be a failure and select the relevant phenomenon out
of the table of Phenomena supposed to be Failures and Troubleshooting No. Then, execute the trouble-
shooting in the [E Mode] or [H Mode] related to the phenomenon.
D475A-3 20-313
TROUBLESHOOTING TABLE OF CONNECTORS
TABLE OF CONNECTORS
+ Addresses show approximate posititions of these devices in arrangement drawings.
Connector Number Connector Number
Type Description Address Type Description Address
No. of Pins No. of Pins
101 X 16 Intermediate connector J2, Q2 Electrical intake air heater
414 Terminal 1 A3
103 X 2 Intermediate connector H1 relay (left bank)
104 X 2 Intermediate connector H1 422 X 2 Fuel level sensor V2

111 X 4 Intermediate connector J2, Q2 431 X 2 Intermediate connector I9
112 X 4 Intermediate connector J2, Q1 452 X 1 Hydraulic oil sensor R1
122 DT 12 Intermediate connector U1 Torque converter oil

453 X 2 K3
temperature sensor
Electrical intake air heater
135 Terminal 1 C7 578 23 Intermediate connector V2
(right bank)
Electrical intake air heater 653 DT 2 L/U solenoid H9
136 Terminal 1 B7
(left bank) One pin
Electrical intake air heater 800 connec- 1 Intermediate connector
137 Terminal 1 C8 tor
(right bank)
201 SWP 12 Intermediate connector B2 One pin
801 connec- 1 Intermediate connector
202 X 3 Intermediate connector C2 tor
203 M 1 Right headlamp A7 I1, Q2,
995 SWP 14 Intermediate connector
204 M 1 Left headlamp A5 AP7
205 Terminal 1 Horn A3 AF1 Terminal 1 Air cleaner clogging sensor C8, AM6
206 M 1 Right headlamp A7 AFL X 4 Intermediate connector C8, I1
206 Terminal 1 Horn A5 ANB Terminal 1 Alternator (Terminal B) A3
207 M 1 Left headlamp A6 ANE Terminal 1 Alternator (Terminal E) A4
209 X 4 Intermediate connector A6 ANR Terminal 1 Alternator (Terminal R) A4
213 4 Preheater switch B14 L 2 Intermediate connector
214 DT 12 Intermediate connector Blade LOWER oil pressure
BLD X 2 P6
switch
215 DT 12 Intermediate connector
Blade LIFT oil pressure
216 DT 12 Intermediate connector BLU X 2 Q7
switch
218 4 Rear lamp switch
BSW 14 Intermediate connector AI6
220 2 Diode
CA1 DT 3 CAN terminating resistance AI6
221 M 1 Left working lamp J2, S1
CA2 DT 3 CAN terminating resistance
223 M 1 Left rear lamp L6
One pin
241 SWP 4 Intermediate connector E9 CN-1 connec- 1 Lamp connector
One pin tor
241 connec- 1 Back alarm lamp R4 CN-2 Terminal 1 Right rear speaker U8
tor
CN-3 Terminal 1 Right rear speaker V8
242 SWP 6 Intermediate connector P2
CN-4 4 Rear wiper motor U8
243 M 1 Right rear lamp H9
CN-5 Terminal 1 Left rear speaker S9
Ripper pin puller solenoid
244 X 2 I9 CN-6 Terminal 1 Left rear speaker T9
valve
CN-9 6 Front wiper motor Q7
250 Terminal 1 Starting switch (Terminal B) P9
CN-10 9 Radio R8
255 Terminal 1 Starting switch (Terminal R1) P9
CN-11 6 Left wiper switch X8
260 Terminal 1 Starting switch (Terminal BR) P8
CN-12 6 Front wiper switch X8
262 2 Horn switch W6
CN-13 6 Right wiper switch X8
263 2 Ripper pin puller switch W5
CN-14 6 Rear wiper switch X8
264 SWP 6 Intermediate connector W5
CN-15 2 Lamp switch
Starting switch (Terminal
270 Terminal 1 Q8 CN-17 4 Right door wiper motor
ACC)
280 Terminal 1 Starting switch (Terminal C) P9 CN-18 4 Left door wiper motor P5
301 X 4 Intermediate connector I1 CN-19 4 Intermediate connector
351 X 1 Air conditioner compressor CN-22 Terminal 1 Cigarette lighter
371 M 2 Window washer motor CN-23 Terminal 1 Converter U9
372 M 2 Window washer motor One pin
CN-23 connec- 1 Converter T9
373 M 2 Window washer motor
tor
374 M 2 Window washer motor
One pin
375 M 4 Caution lamp CN-24 connec- 1 Converter T9
Engine water temperature tor
402 X 2 A3
sensor One pin
Revolving warning lamp
403 Terminal 1 Engine oil pressure sensor B7 CN-25 connec- 1
connector
tor
404 X 2 Engine oil level sensor C2
Revolving warning lamp
Engine water level sensor CN-26 2
405 X 2 B7 switch
(main)
CN-81 2 Room lamp S9
20-314 D475A-3
Connector Number Connector Number

Type Description Address Type Description Address
No. of Pins No. of Pins
CN-C 2 Accessory socket Hydraulic oil level sensor
H0L X 1 D8, O4
One pin [machine with sensor]
CN-C1 connec- 1 Converter U8 Work equipment oil pressure
HP1 X 3 G9
tor sensor (Pump 140)
One pin Work equipment oil pressure
HP2 X 3 G9
CN-C2 connec- 1 Converter U8 sensor (Pump 100)
tor KEY M 6 Starting switch
CSL X 3 Right cylinder stroke sensor Left bottom drain solenoid
LBD X 2 J2
CSR X 3 Left cylinder stroke sensor A4 valve
CUR 3 Cursor switch LUG 2 Diode
Radiator coolant level sensor M11 MIC 13 Machine controller
DRT X 2 B7
(dual) M21 MIC 21 Machine controller
DST X 2 Dual selection solenoid valve E9 M26 6 Air conditioner controller
Left fuel injection pump rack M31 AMP040 20 Machine controller
E9 4 AP4
sensor
M32 AMP040 16 Machine controller
Left fuel injection pump
E10 3 AP4 M41 AMP 12 Machine controller
prestroke solenoid
Left fuel injection pump M51 MIC 17 Machine controller
E11 2 AP3
governor solenoid NSW DT 3 Travel lock switch
E11 MIC 17 Engine controller AE4 One pin
Blade control lever front
E12 2 Engine speed sensor (left) AP5 P01 connec- 1
button switch
tor
Right fuel injection pump rack
E13 4 AN7 One pin
sensor Blade control lever upper
P02 connec- 1
Right fuel injection pump button switch
E14 3 AN7 tor
prestroke solenoid
One pin
Right fuel injection pump Blade control lever front
E15 2 AO7 P03 connec- 1
governor solenoid button switch
tor
E16 2 Engine speed sensor (right) AM7 Pitch back support solenoid
PBA X 2 D8
E21 MIC 21 Engine controller AI4 valve
E31 AMP040 20 Engine controller AI4 PCV X 2 Demand solenoid valve O5
E32 AMP040 16 Engine controller AI4 Pitch dump support solenoid
PDA X 2 D8
E41 AMP040 12 Engine controller AI4 valve
E51 AMP040 20 Engine controller AI4 Pitch independent solenoid

PIT X 2 K3
valve
E52 AMP040 16 Engine controller AI4
PL1 23 Intermediate connector W3
Transmission 1st speed
F1T8 DT 2 H9 PL2 31 Intermediate connector W3
ECMV
Transmission 2nd speed PPB X 2 Pitch back solenoid valve P6
F2T6 DT 2 I9
ECMV PPD X 2 Pitch dump solenoid valve P6
Transmission 3rd speed PRE DT 2 Pre-lubrication
F3T4 DT 2 I9
ECMV PST X 2 Pitch selection solenoid valve D9
FCD X 3 Decelerator potentiometer PT1 DT 3 Each inclination sensor Q2
FD5 DT 12 Intermediate connector U1 PWR1 DT 1 Intermediate connector U2
FFT2 DT 2 Transmission F clutch ECMV J9 PWR2 DT 1 Intermediate connector U2
FL82 DT 2 Left brake ECMV L7 Electrical intake air heater
RHT DT 3
FLC6 DT 2 Left clutch ECMV K8 timer
FR84 DT 2 Right brake ECMV K8 Ripper tilt back oil pressure
RTB X 2
FRC8 DT 2 Right clutch ECMV K8 switch
FRT1 DT 2 Transmission R clutch ECMV Ripper tilt-in oil pressure

RT1 X 2 Q6
switch
FSB 31 Intermediate connector AE1
Ripper LOWER oil pressure
G3 2 Diode RPD X 2 Q6
switch
G4 2 Diode Ripper LIFT oil pressure
RPU X 2 Q7
G5 2 Diode switch
G6 2 Diode S01 12 Monitor panel
GCL R 5 Left governor cut relay AI5 S02 2 Monitor panel
GCR R 5 Right governor cut relay AI5 S03 20 Monitor panel
GND1 Terminal Grounding to machine body AE1 S04 12 Monitor panel
Grounding to machine body Transmission 1st speed
GND2 Terminal S1T7 DT 2 H9
(transmission) ECMV
Grounding to machine body S12 DT 12 Intermediate connector
GND3 Terminal
(left fender) SSC initialization jumper
S21 3
Grounding to machine body connector
GND5 Terminal
(floor frame) SSC initialization jumper
S22 3
Grounding to machine body connector
GNDE Terminal
(damper governor) S24 Terminal 6 Service switch
GNDR Terminal Grounding to machine body
D475A-3 20-315
Connector Number
Type Description Address
No. of Pins
Machine controller writing
S25 X 4
connector
Engine controller writing
S26 X 4
connector
S28 X 4 LE controller memory writing AG2
Transmission 2nd speed
S2T5 DT 2 I9
ECMV
Transmission 3rd speed
S3T3 DT 2 J9
ECMV
S40 M 3 Connector
SDC DT 2 Engine shut-down connector AG1
Hydraulic oil temperature
SDS DT 2 G9
sensor
SFT1 DT 2 Transmission F clutch ECMV J9
SLC5 DT 2 Left clutch ECMV K8
Upper starting motor
SR1 Terminal 1 C1
(Terminal C)
SR2 Terminal 1 C1
(Terminal R)
SR3 Terminal 1 B2
(Terminal B)
SR4 Terminal 1 D1
(Terminal C)
SR5 Terminal 1 D1
(Terminal R)
SR6 Terminal 1 D1
(Terminal B)
SR83 DT 2 Right brake ECMV L7
SRC7 DT 2 Right clutch ECMV K8
SRT1 DT 2 transmission R clutch ECMV K3
SS3 X 4 Acceleration sensor
SSA DT 4 Acceleration sensor R1
Sudden stop prevention
ST8 DT 2
solenoid
STCN1 24 Steering controller AI6
STCN2 40 Steering controller AH7
STCN3 40 Steering controller AG8
Blade lever front button
SW1 3
switch
Blade lever upper button
SW2 3
switch
SX8 Terminal 1 Grounding to machine body
Torque converter speed
TC1 X 2 L3
sensor
Left tilt restriction solenoid
TLL X 2 P5
valve
Right tilt restriction solenoid
TLR X 2 P5
valve
Blade tilt left oil pressure
TRS X 2
switch
Transmission 1st speed oil
TM1 X 2 L7
pressure switch
TMCN1 24 Transmission controller AG9
TMCN2 40 Transmission controller AF9
TMCN3 40 Transmission controller AF9
Blade tilt right oil pressure
TRS X 2
switch
UNL X 2 Unload solenoid valve K2
USB DT 1 Intermediate connector
VHMS DT 2 Constant power supply
WRL X 2 Intermediate connector E9, O4
20-316 D475A-3
TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING
CONNECTOR ARRANGEMENT DRAWING
20-318 D475A-3
D475A-3 20-319
20-320 D475A-3
D475A-3 20-321
20-322 D475A-3
20-324 D475A-3
D475A-3 20-325
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
20-326 D475A-3
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
D475A-3 20-327
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
20-328 D475A-3
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
8 799-601-7390
D475A-3 20-329
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)
20-330 D475A-3
S Type Connector
Number
Number
10

(blue)
12
799-601-7160
(blue)
16
799-601-7170
(blue)
D475A-3 20-331
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

20-332 D475A-3
MIC Type Connector

Number
Number
17 799-601-2730

21 799-601-2740


D475A-3 20-333
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).
20-334 D475A-3
AMP070 Type Connector

Number
Number
10 799-601-7510
Part number: 08195-10210
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
D475A-3 20-335
L Type Connector
Number
of Pins T-adapter
Part Number
PA Type Connector
Number
of Pins T-adapter
Part Number
BENDIX (MS) Type Connector

Number
of Pins T-adapter
Part Number
10 799-601-3460
20-336 D475A-3
KES1 Automobile Type Connector

Number
Number
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
08027-10420 (Black) 08027-10470 (Black)
08027-10620 (Black) 08027-10670 (Black)
D475A-3 20-337
KES1 Automobile Type Connector

Number
of Pins T-adapter
Part Number
08027-10820 (Black) 08027-10870 (Black)
20-338 D475A-3
F Type Connector
Number
of Pins T-adapter
Part Number
D475A-3 20-339
[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
20-340 D475A-3

(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
D475A-3 20-341

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
20-342 D475A-3

(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
D475A-3 20-343

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
20-344 D475A-3
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
D475A-3 20-345
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
10
12G: 799-601-9130
12BR: 799-601-9140
20-346 D475A-3
DTM Series connector
Number
of Pins T-adapter
Part Number
2 799-601-9010
DTHD Series connector

Number
of Pins T-adapter
Part Number
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)
D475A-3 20-347
TROUBLESHOOTING 20 TROUBLESHOOTING
TROUBLESHOOTING WHEN
ERROR CODE IS DISPLAYED
(ERROR CODE)
Information 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 1800MW (Power train clutch: Slip (MW)) ............................................................................. 20-418
Error code 2201L1 (Right clutch: See the list. (L1)) ............................................................................... 20-419
Error code 2201LH (Right clutch: See the list. (LH)) .............................................................................. 20-420
Error code 2202L1 (Left clutch: See the list. (L1)) ................................................................................. 20-421
Error code 2202LH (Left clutch: See the list. (LH)) ................................................................................ 20-422
Error code 2301L1 (Right brake: See the list. (L1)) ............................................................................... 20-423
Error code 2301LH (Right brake: See the list. (LH)) .............................................................................. 20-424
Error code 2302L1 (Left brake: See the list. (L1)) .................................................................................. 20-425
Error code 2302LH (Left brake: See the list. (LH)) ................................................................................ 20-426
Error code A70XLK (Governor servo system right: Refer to table (LK))............................................... 20-426-1
Error code A70YLK (Governor servo system left: Refer to table (LK)) ................................................. 20-426-2
Error code AA1ANX (Air cleaner: CLOGGING (NX)) ............................................................................ 20-427
Error code AB00MA (Alternator: Malfunction (MA)) ............................................................................... 20-428
Error code B@BAZG (Engine oil: Oil pressure reduction (ZG)) ............................................................ 20-429
Error code B@BAZK (Engine oil: Level reduction (ZK)) ........................................................................ 20-429
Error code B@BCNS (Radiator coolant: Overheat (NS)) ....................................................................... 20-430
Error code B@BCZK (Radiator coolant: Level reduction (ZK)) .............................................................. 20-431
Error code B@CENS (Power train oil: Overheat (NS)) .......................................................................... 20-431
Error code B@HANS (Hydraulic oil: Overheat (NS)) ............................................................................. 20-432
Error code B@HAZK (Hydraulic oil: Level reduction (ZK)) .................................................................... 20-432
Error code D110KA (Battery relay: DISCONNECTION (KA)) ................................................................. 20-433
Error code D110KB (Battery relay: Short circuit (KB)) ............................................................................ 20-434
Error code D130KA (Neutral relay: Disconnection (KA)) ........................................................................ 20-435
Error code D130KB (Neutral relay: Short circuit (KB)) ........................................................................... 20-437
Error code D161KA (Back-up alarm relay: Disconnection (KA)) ............................................................ 20-438
Error code D161KB (Back-up alarm relay: Short circuit (KB)) ............................................................... 20-440
Error code D1D0KA (Governor cutout relay right: Disconnection (KA)) ............................................... 20-441-1
Error code D1D0KB (Governor cutout relay right: short circuit (KB)) ................................................... 20-441-2
Error code D1D1KA (Governor cutout relay left: Disconnection (KA)) ................................................. 20-441-4
Error code D1D1KB (Governor cutout relay left: Short circuit (KB))..................................................... 20-441-6
Error code D5ZFKA (Neutral signal 1: Disconnection (KA)) .................................................................. 20-442
Error code D5ZFKB (Neutral signal 1: SHORT CIRCUIT (KB)) ............................................................ 20-443
Error code D5ZFL4 (Engine controller neutral signal: ON and OFF signals do not agree (L4))........... 20-443-1
Error code D5ZGKA (Neutral signal 2: DISCONNECTION (KA)) .......................................................... 20-444
Error code D5ZGKB (Neutral signal 2: SHORT CIRCUIT (KB)) ............................................................ 20-445
D475A-3 20-401
(1)
TROUBLESHOOTING
Error code D5ZKKX (Chassis throttle signal: Out of input signal range (KX)) ..................................... 20-445-1
Error code DAFRKR (Monitor panel can communication: Defective communication (KR)) ................. 20-446
Error code DAQ0KK (Transmission controller: Source voltage reduction/input (KK)) ............................ 20-448
Error code DAQ0KT (Transmission controller: Abnormality in controller (KT)) ...................................... 20-449
Error code DAQ5KK (Transmission controller potentiometer power supply:
Source voltage reduction/input (KK)) ................................................................... 20-450
Error code DAQ6KK (Transmission controller sensor power supply:
Source voltage reduction/input (KK)) ................................................................... 20-452
Error code DAQ9KQ (Transmission controller type collation: Type select signal inconsistency (KQ)) .. 20-453
Error code DAQRKR (Transmission controller can communication: Defective communication (KR)) ... 20-454
Error code DAQSKR (Transmission controller S-NET communication: Defective communication (KR)) 20-456
Error code DB30KK (Steering controller: Source voltage reduction/input (KK)) ..................................... 20-458
Error code DB30KT (Steering controller: Abnormality in controller (KT)) ............................................... 20-459
Error code DB35KK (Steering controller potentiometer power supply:
Source voltage reduction/input (KK)) .................................................................... 20-460
Error code DB36KK (Steering controller sensor power supply:
Source voltage reduction input (KK)) .................................................................... 20-462
Error code DB39KQ (Steering controller type collation: Type select signal inconsistency (KQ)) ........... 20-463
Error code DB3RKR (Steering controller can communication: Defective communication (KR)) ............ 20-464
Error code DB3SKR (Steering controller S-NET communication: Defective communication (KR)) ....... 20-466
Error code DB40KK (Engine controller: Lowering of source voltage (KK)) .......................................... 20-466-1
Error code DB41KK (Switch power supply: Lowering of source voltage (KK)) .................................... 20-466-2
Error code DB42KK (Solenoid power supply 1: Lowering of source voltage (KK)).............................. 20-466-4
Error code DB43KK (Backup power supply: Lowering of source voltage (KK))................................... 20-466-6
Error code DB44KK (Solenoid power supply 2: Lowering of source voltage (KK)).............................. 20-466-8
Error code DB45KP (Rack sensor power supply: Lowering of output voltage (KP)).......................... 20-466-10
Error code DB49KM (Wrong connection of connector: Mistake in operation or setting (KM)) ........... 20-466-12
Error code DB49KQ (Engine controller specification:
Disagreement of model selection signals (KQ))............................................... 20-466-13
Error code DD14KA (Parking lever switch: Disconnection (KA)) ............................................................ 20-468
Error code DD14KB (Parking lever switch: Short circuit (KB)) ............................................................... 20-470
Error code DDB9KA (Reverse switch: Disconnection (KA)) ................................................................... 20-472
Error code DDB9KB (Reverse switch: Short circuit (KB)) ...................................................................... 20-474
Error code DDK3KA (Forward switch: Disconnection (KA)) ................................................................... 20-476
Error code DDK3KB (Forward switch: Short circuit (KB)) ...................................................................... 20-478
Error code DDK5KA (Shift switch: Disconnection (KA)) ......................................................................... 20-480
Error code DDK5KB (Shift switch: Short circuit (KB)) ............................................................................ 20-482
Error code DDN2LD (See table (LD) Blade tilt right oil pressure switch system) ................................... 20-483
Error code DDN3LD (See table (LD) Blade tilt left oil pressure switch system) ..................................... 20-484
Error code DDN7KA (Blade pitch switch: DIsconnection (KA)) .............................................................. 20-486
Error code DDN7KB (Blade pitch switch: Short circuit (KB)) ................................................................. 20-488
Error code DDN9KA (Blade tilt switch: Disconnection (KA)) .................................................................. 20-490
Error code DDN9KB (Blade tilt switch: Short circuit (KB)) ...................................................................... 20-492
Error code DDNALD (Blade lift up full pressure switch: Refer to table (LD)) ......................................... 20-494
Error code DDNBLD (Ripper lift up pressure switch: Refer to table (LD)) .............................................. 20-495
Error code DDNCLD (Ripper lower pressure switch: Refer to table (LD)) ............................................. 20-496
Error code DDNDLD (Ripper tilt in pressure switch: Refer to table (LD)) ............................................... 20-497
Error code DDNELD (Ripper tilt back pressure switch: Refer to table (LD)) .......................................... 20-498
Error code DDNFLD (Blade lower full pressure switch: Refer to table (LD)) .......................................... 20-499
Error code DDQ2KA (Parking brade lever switch: Disconnection (KA)) ................................................. 20-500
Error code DDQ2KB (Parking brake lever switch: Short circuit (KB)) .................................................... 20-502
Error code DDQ2L4 (Parking brake lever switch: See table (L4)) ......................................................... 20-504
Error code DDT5KA (Neutral switch: Disconnection (KA)) ..................................................................... 20-506
Error code DDT5KB (Neutral switch: Short circuit (KB)) ........................................................................ 20-508
20-402 D475A-3
(1)
TROUBLESHOOTING
Error code DDT5KQ (PCCS lever specification signal inconsistency (KQ)) .......................................... 20-510
Error code DGE2KX (Engine coolant temperature: Out of input signal range (KX)) ............................ 20-510-1
Error code DGS1KX (Hydraulic oil temperature sensor: Input signal is out of normal range (KX)) ....... 20- 511
Error code DH22KA (Work equipment large pump oil pressure sensor: Disconnection (KA)) ............... 20-512
Error code DH22KB (Work equipment large pump oil pressure sensor: Short circuit (KB)) .................. 20-513
Error code DH23KA (Work equipment assistance pump oil pressure sensor: Disconnection (KA)) ...... 20-514
Error code DH23KB (Work equipment assistance pump oil pressure sensor: Short circuit (KB)) ......... 20-515
Error code DK01KA (Left yoke angle sensor: Disconnection (KA)) ....................................................... 20-516
Error code DK01KB (Left yoke angle sensor: Short circuit (KB)) .......................................................... 20-517
Error code DK03KA (Right yoke angle sensor: Disconnection (KA)) ..................................................... 20-518
Error code DK03KB (Right yoke angle sensor: Short circuit (KB)) ........................................................ 20-519
Error code DK10KX (Fuel dial: Out of input signal range (KX))............................................................ 20-519-1
Error code DK11KA (Deceleration potentiometer: Disconnection (KA)) ................................................ 20-520
Error code DK11KB (Deceleration potentiometer: Short circuit (KB)) .................................................... 20-522
Error code DK12KX (Decelerator potentiometer: Out of input signal range (KX))................................ 20-523-1
Error code DK30KA (Steering potentiometer 1: Disconnection (KA)) .................................................... 20-524
Error code DK30KB (Steering potentiometer 1: Short circuit (KB)) ....................................................... 20-526
Error code DK30KX (Steering potentiometer 1: Input signal is out of normal range (KX)) .................... 20-527
Error code DK30KZ (Steering potentiometer 1: Disconnection or short circuit (KZ)) ............................ 20-527
Error code DK30L8 (Steering potentiometer 1: See table (L8)) ............................................................ 20-528
Error code DK31KA (Steering potentiometer 2: Disconnection (KA)) .................................................... 20-530
Error code DK31KB (Steering potentiometer 2: Short circuit (KB)) ....................................................... 20-532
Error code DK40KA (Brake potentiometer: Disconnection (KA)) ........................................................... 20-533
Error code DK40KB (Brake potentiometer: Short circuit (KB)) .............................................................. 20-534
Error code DK55KX (Forward-reverse potentiometer: Input signal is out of normal range (KX)) .......... 20-535
Error code DK55KZ (Forward-reverse potentiometer: Disconnection or short circuit (KZ)) .................. 20-535
Error code DK55L8 (Forward-reverse potentiometer: See table (L8)) .................................................. 20-536
Error code DK56KA (Forward-reverse potentiometer 1: Disconnection (KA)) ....................................... 20-537
Error code DK56KB (Forward-reverse potentiometer 1: Short circuit (KB)) .......................................... 20-538
Error code DK57KA (Forward-reverse potentiometer 2: Disconnection (KA)) ....................................... 20-540
Error code DK57KB (Forward-reverse potentiometer 2: Short circuit (KB)) .......................................... 20-542
Error code DK60KA (Acceleration sensor: Disconnection (KA)) ............................................................ 20-543
Error code DK60KB (Acceleration sensor: Short circuit (KB)) ............................................................... 20-544
Error code DKF1KX (Rack sensor right: Out of input signal range (KX)) ............................................. 20-544-1
Error code DKF2KX (Rack sensor left: Out of input signal range (KX)) ............................................... 20-544-3
Error code DKH1KA (Pitch angle sensor: Disconnection (KA)) ............................................................. 20-545
Error code DKH1KB (Pitch angle sensor: Short circuit (KB)) ................................................................ 20-546
Error code DLE1KA (Engine NE speed sensor: Disconnection (KA)) ................................................... 20-548
Error code DLE4LC (Engine speed sensor A: Refer to table (LC)) ...................................................... 20-549-1
Error code DLE5LC (Engine speed sensor B: Refer to table (LC)) ...................................................... 20-549-3
Error code DLF1KA (Torque converter output speed sensor: Disconnection (KA)) ............................... 20-550
Error code DV00KB (Caution buzzer: Short circuit (KB)) ...................................................................... 20-551
Error code DW55KA (Blade pitch back solenoid: Disconnection (KA)) ................................................. 20-552
Error code DW55KB (Blade pitch back solenoid: Short circuit (KB)) ..................................................... 20-553
Error code DW56KA (Blade pitch dump solenoid: Disconnection (KA)) ................................................ 20-554
Error code DW56KB (Blade pitch dump solenoid: Short circuit (KB)) ................................................... 20-555
Error code DW57KA (Blade pitch selector solenoid: Disconnection (KA)) ............................................ 20-556
Error code DW57KB (Blade pitch selector solenoid: Short circuit (KB)) ................................................ 20-557
Error code DW58KA (RIGHT tilt solenoid: Disconnection (KA)) ............................................................ 20-558
Error code DW58KB (RIGHt tilt solenoid: Short circuit (KB)) ................................................................. 20-559
Error code DW5AKA (Blade pitch selector solenoid: Disconnection (KA)) ............................................ 20-560
Error code DW5AKB (Blade pitch selector solenoid: Short circuit (KB)) ............................................... 20-561
Error code DW5JKA (Blade pitch selector solenoid: Disconnection (KA)) ............................................. 20-562
Error code DW5JKB (Blade pitch selector solenoid: Short circuit (KB)) ................................................ 20-563
D475A-3 20-403
(1)
TROUBLESHOOTING
Error code DW5LKA (Blade pitch dump assist solenoid: Disconnection (KA)) ...................................... 20-564
Error code DW5LKB (Blade pitch dump assist solenoid: Short circuit (KB)) .......................................... 20-565
Error code DW98KA (Unload solenoid: Disconnection (KA)) ................................................................. 20-566
Error code DW98KB (Unload solenoid: Short circuit (KB)) .................................................................... 20-567
Error code DWN3KA (Sudden stop prevention solenoid: Disconnection (KA)) ...................................... 20-568
Error code DWN3KB (Sudden stop prevention solenoid: Short circuit (KB)) ......................................... 20-569
Error code DXH1KA (Lock-up solenoid: Disconnection (KA)) ................................................................ 20-570
Error code DXH1KB (Lock-up solenoid: Short circuit (KB)) ................................................................... 20-571
Error code DXH4KA (1st clutch ECMV: Disconnection (KA)) ................................................................. 20-572
Error code DXH4KB (1st clutch ECMV: Short circuit (KB)) .................................................................... 20-573
Error code DXH5KA (2nd clutch ECMV: Disconnection (KA)) ............................................................... 20-574
Error code DXH5KB (2nd clutch ECMV: Short circuit (KB)) ................................................................... 20-575
Error code DXH6KA (3rd clutch ECMV: Disconnection (KA)) ................................................................ 20-576
Error code DXH6KB (3rd clutch ECMV: Short circuit (KB)) ................................................................... 20-577
Error code DXH7KA (Reverse clutch ECMV: Disconnection (KA)) ........................................................ 20-578
Error code DXH7KB (Reverse clutch ECMV: Short circuit (KB)) ........................................................... 20-579
Error code DXH8KA (Forward clutch ECMV: Disconnection (KA)) ........................................................ 20-580
Error code DXH8KB (Forward clutch ECMV: Short circuit (KB)) ........................................................... 20-581
Error code DXH9KA (Right steering clutch ECMV system: Disconnection (KA)) ................................... 20-582
Error code DXH9KB (Right steering clutch ECMV: Short circuit (KB)) .................................................. 20-583
Error code DXHAKA (Left steering clutch ECMV: Disconnection (KA)) ................................................. 20-584
Error code DXHAKB (Left steering clutch ECMV: Short circuit (KA)) .................................................... 20-585
Error code DXHBKA (Right brake ECMV: Disconnection (KA)) ............................................................. 20-586
Error code DXHBKB (Right brake ECMV: Short circuit (KB)) ................................................................ 20-587
Error code DXHCKA (Left brake ECMV: Disconnection (KA)) ............................................................... 20-588
Error code DXHCKB (Left brake ECMV: Short circuit (KB)) .................................................................. 20-589
Error code DXHDKA (Governor solenoid right: Disconnection (KA))................................................... 20-589-1
Error code DXHDKB (Governor solenoid right: Short circuit (KB)) ...................................................... 20-589-2
Error code DXHEKA (Governor solenoid left: Disconnection (KB)) ..................................................... 20-589-3
Error code DXHEKB (Governor solenoid left: Short circuit (KB))......................................................... 20-589-4
Error code DXHFKA (Pre-stroke solenoid right: Disconnection (KA)).................................................. 20-589-5
Error code DXHFKB (Pre-stroke solenoid right: Short circuit (KB)) ..................................................... 20-589-6
Error code DXHGKA (Pre-stroke solenoid left: Disconnection (KA)) ................................................... 20-589-7
Error code DXHGKB (Pre-stroke solenoid left: Short circuit (KB))....................................................... 20-589-8
20-404 D475A-3
(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.
D475A-3 20-405
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 Contents of trouble Trouble code Contents of trouble

Fill signals at two or more channels which are not set
KA Disconnection in wiring L0
as combination are turned ON at the same time.
KB Short circuit L1 Fill signal is ON when command current to ECMV is OFF.
Source voltage reduction/
KK L2 Fuel pressure is above maxim specified value.
input
Type select signal inconsis-
KQ L3 Object part is uncontrollable.
tency
KR Defective communication L4 ON and OFF signals at two systems are inconsistent.
Engine rotation signal, terminal C signal, oil pressure switch sig-
KT Abnormality in controller L6 nal, water temperature sensor signal, etc. are inconsistent with
operation state or stop state.
KX Outside input signal range L8 Analog signals in two systems are inconsistent.
Disconnection or short cir-
KZ LC rpm signals in two systems are inconsistent.
cuit
MA Malfunction LD Switch is pressed for usually unthinkable long time.
MB Performance reduction LH Fill signal is OFF when command current to ECMV is ON.
MW Sliding
NS Overheat
NX Clogging
ZG Oil pressure reduction
ZK Level reduction
20-406 D475A-3
TROUBLESHOOTING ERROR CODE 1500LO (TRANSMISSION CLUTCH: SEE THE LIST. (L0))
ERROR CODE 1500LO (TRANSMISSION CLUTCH: SEE THE LIST. (L0))
Action code Error code Transmission clutch: See the list. (LO)
Trouble
CALL E03 1500L0 (Transmission controller system)
Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Connection error)
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]
D475A-3 20-407
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 FFT2 (male) PCCS lever Resistance
1
switch (Internal short)
Between 1 N Min. 1M
chassis ground F (Forward) Max. 1
+ 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. 1M
value in normal FFT2 (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 D475A-3
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 off at output to the transmission forward clutch solenoid circuit.
trouble
Action of
Decides that engine speed is neutral (N) at forward operation.
controller
Problem that
appears on
Once machine is stopped, running is limited to R1.
machine
The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
information
Method of reproducing error code: Engine start + Forward running

shooting.
Defective forward clutch fill FFT2 (male) PCCS lever Resistance
1
Between b N Min. 1M
chassis ground F (Forward) Max. 1
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) f
Resistance Max. 1
value in normal connector) FFT2 (female) b
shooting.
3
troller
Between f N 20 30V
chassis ground F (Forward) Max. 1V
sure system
D475A-3 20-409
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 FRT2 (male) PCCS lever Resistance
1
Between 1 N Min. 1M
chassis ground R (Reverse) Max. 1
Defective harness ground-
Possible causes without turning starting switch ON.
and standard Wiring harness between TMCN1 (female) N
value in normal FRT2 (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 D475A-3
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 off at output stop of 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 FRT2 (male) PCCS lever Resistance
1
Between 1 N Min. 1M
chassis ground R (Reverse) Max. 1
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) N
Resistance Max. 1M
value in normal connector) FRT2 (female) 1
shooting.
3
troller
Between N N 20 30V
chassis ground R (Reverse) Max. 1V
sure system
D475A-3 20-411
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 F1T8 (male) PCCS lever Resistance
1
Between 1 Other than F1/R1 Min. 1M
chassis ground F1R1 Max. 1
Defective harness ground- without turning starting switch ON.
Possible causes
and standard Wiring harness between TMCN1 (female) M
value in normal F1T8 (female) 1 with chassis ground
shooting.
3
troller
Between M Other than F2/R2 20 30V
chassis ground F2R2 Max. 1V
sure system
Circuit diagram related to transmission level 1 clutch ECMV
20-412 D475A-3
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 off at output to the transmission 1st clutch solenoid circuit.
trouble
Problem that The auto shift down function does not start.
The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Related
information
Method of reproducing error code: Engine start + F1 or R1 running

shooting.
Defective 1st clutch fill F1T8 (male) PCCS lever Resistance
1
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) M
Resistance Max. 1M
value in normal connector) F1T8 (female) 1
shooting.
3
troller
Between N Other than F1/R1 20 30V
sure system
Circuit diagram related to transmission 1st clutch ECMV
D475A-3 20-413
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 stop of output to the transmission 2nd clutch solenoid circuit.
trouble
Problem that The auto shift down function does not operate.
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance
1
Possible causes
and standard Wiring harness between TMCN1 (female) G
shooting.
3
troller
Between G Other than F2/R2 20 30V
sure system
Circuit diagram related to transmission 2nd clutch ECMV
20-414 D475A-3
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 off at output to the transmission level 2 clutch solenoid circuit.
trouble
Problem that
appears on
machine
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 2nd clutch fill F2T6 (male) PCCS lever Resistance
1
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) G
Resistance Max. 1M
shooting.
3
troller
Between G Other than F2/R2 20 30V
sure system
D475A-3 20-415
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 F3T4 (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 D475A-3
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 off at output to the transmission 3rd clutch solenoid circuit.
trouble
Problem that
appears on
machine
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

shooting.
Defective 3rd clutch fill F3T4 (male) PCCS lever Resistance
1
2
and standard ing or defective contact in Wiring harness between TMCN1 (female) A
Resistance Max. 1
shooting.
3
troller
Between A Other than F3/R3 20 30V
sure system
D475A-3 20-417
TROUBLESHOOTING ERROR CODE 1800MW (POWER TRAIN CLUTCH: SLIP (MW))
ERROR CODE 1800MW (POWER TRAIN CLUTCH: SLIP (MW))
Action code Error code Power train clutch slip

Trouble
E02 1800MW (Transmission controller system)
Contents of At lock-up of the torque converter, the number of transmission rotations obtained from the number of
trouble engine rotations is different from the actual number of rotations by 200rpm or more.
Action of
controller
Problem that
appears on The auto shift down function does not operate.
machine
The number of engine rotations and the number of transmission rotations can be checked in monitor-
Related ing mode.
information (Code 01000: Number of engine rotations, code 31400: Number of transmission rotations)
Method of reproducing error code: Engine start + Lock-up switch ON + Actual running

Power train clutch slip
+ Clutch slip was detected; check the cause and machine damage
1 (When the system is nor-
state, then repair the machine.
mal)
Possible causes
Defective engine rotation Check whether error codes [DLE3LE], [DLH1LC], and [DLH1LF] are
and standard 2
sensor displayed. If they are displayed, carry out the troubleshooting.
value in normal
state Defective transmission rota-Check whether error code [DLF1KA] is displayed. If it is displayed,
3
tion sensor system carry out the troubleshooting.
Internally trouble; troubleshooting is impossible.
Defective transmission con-
4 (If no visible abnormality is detected on the machine, the controller
troller
may be used continuously.)
20-418 D475A-3
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 left steering clutch solenoid circuit.
trouble
controller Limits operation of engine, transmission, and brake.
Problem that
appears on
Once machine is stopped, it never runs.
machine
The input state (ON/OFF) from the left steering clutch fill switch can be checked in monitoring mode.
Related
(Code 31521: Steering fill switch input state)
information
Method of reproducing error code: Engine start.

+ Prepare with starting switch OFF. Engine start.
Defective left steering clutch
FRC8 (male) PCCS lever Resistance
1 fill switch
Between 1 N (Neutral) Min. 1M
(Internal short)
chassis ground Right steering Max. 1
Possible causes
and standard Wiring harness between STCN3 (female) ]
value in normal FRC8 (female) 1 with chassis ground
state + Prepare with starting switch OFF. Engine start.
STCN3 PCCS lever Voltage
3 Defective steering controller
Between ] N (Neutral) 20 30V
chassis ground Right steering Max. 1V
sure system
Circuit diagram related to right steering clutch ECMV
D475A-3 20-419
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 off at output to the right steering clutch solenoid circuit.
trouble
Problem that
appears on
machine
The input state (ON/OFF) from the right steering clutch fill switch can be checked in monitoring mode.
Related (Code 31521: Steering fill switch input state)
information Method of reproducing error code: Engine start+ Parking lever release + PCCS lever operation
(right streering)

Defective right steering FRC8 (male) PCCS lever Resistance
1 clutch fill switch
(Internal short) Between 1 N (Neutral) Min. 1M
2
and standard ing or defective contact in Wiring harness between STCN3 (female) ]
Resistance Max. 1M
value in normal connector) FRC8 (female) 1
Between ] N (Neutral) 20 30V
sure system
20-420 D475A-3
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
Related
information
Method of reproducing error code: Engine start

FLC6 (male) PCCS lever Resistance
1 fill switch
Between 1 N (Neutral) Min. 1M
(Internal short)
Possible causes
and standard Wiring harness between STCN3 (female) S
value in normal FLC6 (female) 1 with chassis ground
Between S N (Neutral) 20 30V
sure system
Circuit diagram related to left steering clutch ECMV
D475A-3 20-421
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 off at output to the left steering clutch solenoid circuit.
trouble
Problem that
appears on
machine
Related (Code 31521: Steering fill switch input state)
information Method of reproducing error code: Engine start + Parking lever release + PCCS lever operation
(left streering)

Defective left steering clutch FLC6 (male) PCCS lever Resistance
1 fill switch
(Internal short) Between 1 N (Neutral) Min. 1M
chassis ground Left steering Max. 1
Possible causes
and standard Wiring harness between STCN3 (female) S
value in normal FLC6 (female) 1 with chassis ground
Between S N (Neutral) 20 30V
chassis ground Left steering Max. 1V
sure system
20-422 D475A-3
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
information

+ Prepare with starting switch OFF. Engine start + Parking lever
Defective right steering release
1 clutch fill switch FRB4 (male) PCCS lever Resistance
(Internal short) Between 1 N (Neutral) Max. 1
chassis ground Right steering Min. 1M
Possible causes
and standard Wiring harness between STCN2 (female) O
value in normal FRB4 (female) 1 with chassis ground
state + Prepare with starting switch OFF. Engine start + Parking lever
release
3 Defective steering controller STCN2 PCCS lever Voltage
Between O N (Neutral) Max. 1V
chassis ground Right steering 20 30V
sure system
Circuit diagram related to right steering brake ECMV
D475A-3 20-423
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 off at output to the right steering brake solenoid circuit.
trouble
The input state (ON/OFF) from the right steering brake fill switch can be checked in monitoring mode.
Related
information
Method of reproducing error code: Engine start + Parking lever release

Defective right steering release
1 clutch fill switch FRB4 (male) PCCS lever Resistance
2
and standard ing or defective contact in Wiring harness between STCN2 (female) O
Resistance Max. 1M
value in normal connector) FRB4 (female) 1
release
Between O N (Neutral) Max. 1V
chassis ground Right steering 20 30V
sure system
20-424 D475A-3
TROUBLESHOOTING ERROR CODE 2302L1 (LEFT BRAKE: SEE THE LIST. (L1))
ERROR CODE 2302L1 (LEFT BRAKE: SEE THE LIST. (L1))
Action code Error code Left 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 release
1 fill switch FLB2 (male) PCCS lever Resistance
Possible causes
and standard Wiring harness between STCN2 (female) Y
value in normal FLB2 (female) 1 with chassis ground
state + Prepare with starting switch OFF. Engine start + Parking lever re-
lease.
Between Y N (Neutral) Max. 1V
chassis ground Left steering 20 30V
sure system
Circuit diagram related to left steering brake ECMV
D475A-3 20-425
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 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 release.
1 fill switch FLB2 (male) PCCS lever Resistance
chassis ground Left steering Min. 1M
2
and standard ing or defective contact in Wiring harness between STCN2 (female) Y
Resistance Max. 1M
value in normal connector) FLB2 (female) 1
release.
Between Y N (Neutral) Max. 1V
chassis ground Left steering 20 30V
sure system
20-426 D475A-3
TROUBLESHOOTING A70XLK
ERROR CODE [A70XLK] (GOVERNOR SERVO SYSTEM RIGHT: * REFER TO TABLE

(LK))
Action code Error code Governor servo system right: Refer to table (LK)
Trouble
CALL E04 A70XLK (Engine controller system)
Contents of Abnormality was detected in the governor solenoid system or rack sensor system of the right bank (The
trouble governor command value does not agree with the rack sensor signal).
Action of Flashes the caution lamp and turns on the caution buzzer.
controller Stops the right bank fuel injection pump injecting.
Problem that
appears on Only the left bank of the engine operates.
machine
Related
Method of reproducing error code: Start the engine.
information

Defective solenoid power The solenoid power supply R system may be defective. Carry out trou-
1
Possible causes supply R system bleshooting for error code [DB42KK].
and standard Defective right bank fuel The right bank fuel injection pump may have a defect in it. Check it
2
value in normal injection pump directly.
state If neither of causes 1 and 2 is the cause of the trouble, the engine con-
3 Defective engine controller troller may be defective (Troubleshooting cannot be carried out since the
defect is in the engine controller).
D475A-3 20-426-1
(1)
TROUBLESHOOTING A70YLK
ERROR CODE [A70YLK] (GOVERNOR SERVO SYSTEM LEFT: * REFER TO TABLE

(LK))
Action code Error code Governor servo system left: Refer to table (LK)
Trouble
CALL E04 A70YLK (Engine controller system)
Contents of Abnormality was detected in the governor solenoid system or rack sensor system of the left bank
trouble (The governor command value does not agree with the rack sensor signal).
controller Stops the left bank fuel injection pump injecting.
Problem that
appears on Only the right bank of the engine operates.
machine
Related
information

Defective solenoid power The solenoid power supply L system may be defective. Carry out trou-
1
Possible causes supply L system bleshooting for error code [DB43KK].
and standard Defective left bank fuel The left bank fuel injection pump may have a defect in it. Check it
2
value in normal injection pump directly.
20-426-2 D475A-3
(1)
TROUBLESHOOTING A70YLK
Circuit diagram related to right governor cutout relay
D475A-3 20-426-3
(1)
TROUBLESHOOTING ERROR CODE AA1ANX (AIR CLEANER:CLOGGING (NX))
ERROR CODE AA1ANX (AIR CLEANER:CLOGGING (NX))

Trouble Air Cleaner:Clogging (NX)
AA1ANX
Contents of
During rotation of engine, air cleaner clogging caution lamp flashes.
trouble
Action of
Sounds caution buzzer (monitor panel function.)
controller
Problem that
appears on If machine is operated as it is, engine may be damaged.
machine
Related
Method of reproducing error code: Start engine.
information

Air cleaner clogging It is suspected that problem causing air cleaner clogging is occurring
Possible causes
1 (When system is in normal at present or occurred in past. Investigate cause and damage condi-
and standard
state) tion, and correct it.
value in normal
state Carry out troubleshooting of air cleaner clogging caution lamp system
Defective air cleaner clog-
2 in accordance with While the engine is operating, the emergency
ging caution lampsystem
warning item flashes in E mode.
D475A-3 20-427
TROUBLESHOOTING ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA))
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
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 While the engine is operating, the emergency warning
tion lamp system
item flashes in E mode.
20-428 D475A-3
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))
TROUBLESHOOTING ERROR CODE
ERROR
B@BAZG
CODE B@BAZK
(ENGINE (ENGINE
OIL: OIL PRESSURE
OIL: LEVEL REDUCTION (ZG))
(ZK))
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
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 While the engine is operating, the emergency
sure caution lamp system
warning item flashes in E mode.
ERROR CODE B@BAZK (ENGINE OIL: LEVEL REDUCTION (ZK))

Trouble Engine oil: Level reduction (ZK) (Mechanical system)
B@BAZK
Contents of
During rotation of engine, engine oil level caution lamp flashes.
trouble
Action of
controller
Problem that
machine
Related
information

Engine oil level reduction It is suspected that problem causing engine oil level reduction is oc-
Possible causes
and standard
value in normal
state Carry out troubleshooting of engine oil level caution lamp system in
Defective engine oil level
2 accordance with While the engine is operating, the emergency warn-
caution lamp system
ing item flashes in E mode.
D475A-3 20-429
TROUBLESHOOTING ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT (NS))
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 While the engine is operating, the emer-
tem gency warning item flashes in E mode.
20-430 D475A-3
ERROR CODE B@BCZK (RADIATOR COOLANT: LEVEL REDUCTION (ZK))
TROUBLESHOOTING ERROR CODE
ERROR
B@BCZK
CODE (RADIATOR
B@CENS (POWER
COOLANT:
TRAIN
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 the starting switch is turned on, the ba-
level caution lamp system
sic check items flash in E mode.
ERROR CODE B@CENS (POWER TRAIN OIL: OVERHEAT (NS))

Trouble Power train oil: Overheat (NS) (Mechanical system)
B@CENS
Contents of
During rotation of engine, power train oil temperature caution lamp flashes.
trouble
Action of
controller
Problem that
appears on If machine is operated as it is, power train may be damaged.
machine
Related
information

Power train oil temperature It is suspected that problem causing power train oil temperature over-
Possible causes
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 While the engine is operating, the emer-
tion lamp system gency warning item flashes in E mode.
D475A-3 20-431
ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (NS))
TROUBLESHOOTING ERROR
ERROR CODE CODE B@HANS
B@HAZK (HYDRAULIC
(HYDRAULIC OIL:
OIL: LEVEL OVERHEAT (ZK))
REDUCTION (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 temperature 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.
ERROR CODE B@HAZK (HYDRAULIC OIL: LEVEL REDUCTION (ZK))

Trouble Hydraulic oil level reduction (ZK) (Mechanical system)
B@HAZK
Contents of
During rotation of engine, hydraulic oil caution lamp flashes.
trouble
Action of
controller
Problem that
appears on If machine is operated as it is, work equipment circuit units may be damaged.
machine
Related
information

Hydraulic oil level reduction It is suspected that problem causing hydraulic oil level reduction is oc-
Possible causes
and standard
value in normal
state Defective hydraulic oil level Carry out troubleshooting of hydraulic oil level caution lamp system in
2 reduction caution lamp sys- accordance with During running of engine, emergency caution item
tem flashes in E mode.
20-432 D475A-3
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- without turning starting switch ON.
1
ternal disconnection) Battery relay Continuity
Between terminals SW E Continue
Disconnection in wiring har- without turning starting switch ON.
ness (Disconnection in wir- Wiring harness between STCN3 (female) 4
2 Resistance Max. 1
Possible causes ing or defective contact in battery relay SW terminal
and standard connector) Wiring harness between battery relay terminal
Resistance Max. 1
value in normal E chassis ground
state + Prepare with starting switch OFF, then turn starting switch ON and
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 BR KEY Voltage Max. 1V
(female) 4 with chassis ground
without turning starting switch ON.
STCN3 (female) Continuity
Between 4 chassis ground Continue
Circuit diagram related to battery relay
D475A-3 20-433
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.

Defective battery relay Battery relay Continuity/resistance
1
(Internal short circuit) Between terminals SW E Continue
Between terminal SW
Min. 1M
chassis ground
Possible causes
and standard
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 BR KEY Resistance Min. 1M
(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
20-434 D475A-3
TROUBLESHOOTING ERROR CODE D130KA (NEUTRAL RELAY: DISCONNECTION (KA))
ERROR CODE D130KA (NEUTRAL 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 2 200 400
Defective disconnection in without turning starting switch ON.
wiring harness (Disconnec- Wiring harness between TMCN2 (female) 8
3 Resistance Max. 1
tion in wiring or defective NSF (female) 2
Possible causes contact in connector) Wiring harness between NSF (female) 1
and standard Resistance Max. 1
CB3 (1)
value in normal
state + Prepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis Short circuit of wiring harness between
4 ground in wiring harness TMCN2 (female) 8 NSF (female) 2 with Resistance Min. 1M
(Contact with ground circuit) chassis ground
Short circuit of wiring harness between NSF
Resistance Min. 1M
(female) 1 CB3 (1) with chassis ground
+ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective transmission con- TMCN2 Parking lever Voltage
5
troller
Between 8 Lock position 20 30V
chassis ground Free position Max. 1V
D475A-3 20-435
TROUBLESHOOTING ERROR CODE D130KA (NEUTRAL RELAY: DISCONNECTION (KA))
Circuit diagram related to neutral safety relay
20-436 D475A-3
TROUBLESHOOTING ERROR CODE D130KB (NEUTRAL RELAY: SHORT CIRCUIT (KB))
ERROR CODE D130KB (NEUTRAL 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 2 200 400
Possible causes carry out troubleshooting.
Hot short circuit in wiring
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
3
troller
Between 8 Lock position 20 30V
chassis ground Free position Max. 1V
Circuit diagram related to neutral safety relay
D475A-3 20-437
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 back-up alarm 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 2 200 400
Defective disconnection in without turning starting switch ON.
wiring harness (Disconnec- Wiring harness between TMCN2 (female) H
3 Resistance Max. 1
tion in wiring or defective BKA (female) 2
contact in connector) Wiring harness between BKA (female) 1
Possible causes Resistance Max. 1
FS4-1 outlet port
and standard
value in normal + Prepare with starting switch OFF, then carry out troubleshooting
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. 1M
4 ground in wiring harness
chassis ground
(Contact with ground circuit)
Short circuit of wiring harness between BKA
(female) 1 FS4-1 outlet port with chassis Resistance Min. 1M
ground
5
troller Neutral position 20 30V
Between H
Max. 1V 20 30V
chassis ground Reverse position
(Alternately)
20-438 D475A-3
TROUBLESHOOTING ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA))
Circuit diagram related to back-up alarm relay
D475A-3 20-439
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 2 200 400
Possible causes Hot short circuit in wiring carry out troubleshooting.
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
3
troller Neutral position 20 30V
Between H
Max. 1V 20 30V
chassis ground Reverse position
(Alternately)
20-440 D475A-3
TROUBLESHOOTING ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB))
Circuit diagram related to back-up alarm relay
D475A-3 20-441
TROUBLESHOOTING D1D0KA
ERROR CODE [D1D0KA] (GOVERNOR CUTOUT RELAY RIGHT: DISCONNECTION (KA))
Action code Error code Governor cutout relay right: Disconnection (KA)
Trouble
E01 D1D0KA (Engine controller system)
Contents of
The output voltage to the right governor cutout relay is below 2 V.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related If cause 4 occurs, circuit breaker CB6 is turned OFF and other systems will also have abnormalities.
information Method of reproducing error code: Turn the starting switch ON.

aPrepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
Defective right governor
GCR (male) Resistance
1 cutout relay
(Internal disconnection) Between (1) and (2) 200 900 z
You may replace the right governor cutout relay with another one and
check by reproducing the error code.
Defective engine shut down
SDR (male) Resistance
2 relay
(Internal disconnection) Between (3) and (6) Max. 1 z
You may replace the engine shut down replay with another one and
Possible causes Disconnection in wiring
and standard Wiring harness between starting switch termi-
harness Resistance Max. 1 z
value in normal nal ACC and SDR (female) (3)
3 (Disconnection in wiring
state Wiring harness between SDR (female) (6) and
harness or defective contact Resistance Max. 1 z
GCR (female) (1)
in connector)
Wiring harness between GCR (female) (2) and
Resistance Max. 1 z
LE1 (female) (4)
Wiring harness between starting switch termi-
nal ACC and SDR (female) (3), and other Resistance Min. 1 Mz
related circuits and chassis ground
Wiring harness between SDR (female) (6) and
GCR (female) (1), and other related circuits and Resistance Min. 1 Mz
chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
5 Defective engine controller
LE1 Voltage
Between (4) and (13) 20 30 V
20-441-1 D475A-3
(1)
TROUBLESHOOTING D1D0KB
ERROR CODE [D1D0KB] (GOVERNOR CUTOUT RELAY RIGHT: SHORT CIRCUIT (KB))
Action code Error code Governor cutout relay right: short circuit (KB)
Trouble
E01 D1D0KB (Engine controller system)
Contents of
The output voltage to the right governor cutout relay is 5 15 V.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
Method of reproducing error code: Turn the starting switch OFF, then ON.
information

Defective right governor
GCR (male) Resistance
1 cutout relay
(Internal short circuit) Between (1) and (2) 200 900 z
You may replace the right governor cutout relay with another one and
Possible causes check by reproducing the error code.
and standard aPrepare with starting switch OFF, then carry out troubleshooting with-
value in normal Short circuit with power out turning starting switch ON.
state 2 source in wiring harness Between wiring harness between GCR
(Contact with 24-V circuit) (female) (2) and LE1 (female) (4) and chassis Voltage Max. 1 V
ground
LE1 Voltage
Between (4) and (13) Max. 1 V
D475A-3 20-441-2
(1)
20-441-3 D475A-3
(1)
ERROR CODE [D1D1KA] (GOVERNOR CUTOUT RELAY LEFT: DISCONNECTION (KA))
Action code Error code Governor cutout relay left: Disconnection (KA)
Trouble
E01 D1D1KA (Engine controller system)
Contents of
The output voltage to the left governor cutout relay is below 2 V.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine

Defective left governor
GCL (male) Resistance
1 cutout relay
You may replace the left governor cutout relay with another one and
2 relay
Possible causes Disconnection in wiring
and standard Wiring harness between starting switch termi-
value in normal nal ACC and SDR (female) (3)
state Wiring harness between SDR (female) (6) and
harness or defective contact Resistance Max. 1 z
GCL (female) (1)
in connector)
Wiring harness between GCL (female) (2) and
Resistance Max. 1 z
LE1 (female) (5)
GCL (female) (1), and other related circuits and Resistance Min. 1 Mz
chassis ground
LE1 Voltage
Between (5) and (14) 20 30 V
D475A-3 20-441-4
(1)
Circuit diagram related to left governor cutout relay
20-441-5 D475A-3
(1)
ERROR CODE [D1D1KB] (GOVERNOR CUTOUT RELAY LEFT: SHORT CIRCUIT (KB))
Action code Error code Governor cutout relay left: Short circuit (KB)
Trouble
E01 D1D1KB (Engine controller system)
Contents of
The output voltage to the left governor cutout relay is 5 15 V.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
Method of reproducing error code: Turn the starting switch OFF, then ON.
information

Defective left governor
GCL (male) Resistance
1 cutout relay
(Internal short circuit) Between (1) and (2) 200 900 z
You may replace the left governor cutout relay with another one and
Possible causes check by reproducing the error code.
and standard
value in normal aPrepare with starting switch OFF, then carry out troubleshooting with-
Short circuit with power
state out turning starting switch ON.
2 source in wiring harness
(Contact with 24-V circuit) Between wiring harness between GCL (female)
Voltage Max. 1 V
(2) and LE1 (female) (5) and chassis ground
LE1 Voltage
Between (5) and (14) Max. 1 V
D475A-3 20-441-6
(1)
20-441-7 D475A-3
(1)
TROUBLESHOOTING ERROR CODE D5ZFKA (NEUTRAL SIGNAL 1: DISCONNECTION (KA))
ERROR CODE D5ZFKA (NEUTRAL SIGNAL 1: DISCONNECTION (KA))
Action code Error code Neutral signal 1: Disconnection

Trouble
E01 D5ZFKA (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 neutral signal 1 circuit.
controller
Problem that
appears on
machine
Output state (ON OFF) to Neutral signal 1 can be checked in monitoring mode.
Related (Code 40909: transmission controller ON/OFF output)
information Method of reproducing error code: Turn starting switch ON and operate parking lever (Neutral posi-
tion).

Defective disconnection in Prepare with starting switch OFF, then carry out troubleshooting
wiring harness (Disconnec- without turning starting switch ON.
1
tion in wiring or defective Wiring harness between TMCN2 (female) I
Resistance Max. 1
contact in connector) CN5 (female) 5
Prepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis without turning starting switch ON.
2 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) TMCN2 (female) I CN5 (female) 5 with Resistance Min. 1M
Possible causes chassis ground
and standard Prepare with starting switch OFF, then turn starting switch ON and
value in normal carry out troubleshooting.
state
Defective transmission con- TMCN2 (male) PCCS lever Voltage
3
troller Neutral position Max.1V
Between I
Forward-reverse
chassis ground 20 30V
position
Prepare with starting switch OFF, then turn starting switch ON and
4 Defective engine controller ECN5 (male) Voltage
Between 5 chassis
20 30V
ground
Circuit diagram related to Neutral signal 1
20-442 D475A-3
(1)
TROUBLESHOOTING ERROR CODE D5ZFKB (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB))
ERROR CODE D5ZFKB (NEUTRAL SIGNAL 1: SHORT CIRCUIT (KB))
Action code Error code Neutral signal 1: Short circuit (KB)

Trouble
E01 D5ZFKB (Transmission controller system)
Contents of
Abnormal current flowed in Neutral signal 1 circuit at the time of ground output.
trouble
Action of
Stops output to Neutral signal 1 relay circuit.
controller
Problem that
appears on
machine
information Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Reverse posi-
tion).

1 harness (Contact with 24V Short circuit of wiring harness between
circuit) TMCN2 (female) I CN5 (female) 5 with Voltage Max. 1V
chassis ground
and standard
value in normal 2
state Between I
Forward - Reverse
position
3 Defective engine controller CN5 (male) Voltage
Between 5 chassis
20 30V
ground
Circuit diagram related to Neutral signal 1
D475A-3 20-443
(1)
TROUBLESHOOTING D5ZFL4
ERROR CODE [D5ZFL4] (ENGINE CONTROLLER NEUTRAL SIGNAL: ON AND OFF

SIGNALS DO NOT AGREE (L4))
Action code Error code Engine controller neutral signal: ON and OFF signals do not agree (L4)
Trouble
E01 D5ZFL4 (Engine controller system)
Contents of The neutral signal circuit from the transmission controller to the engine controller is disconnected or has
trouble a grounding fault.
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Wiring harness between TMCN2 (female) (9)
and LE51 (female) (6)
harness or defective contact aPrepare with starting switch OFF, then carry out troubleshooting with-
in connector) out turning starting switch ON.
Wiring harness between TMCN2 (female) (19)
Resistance Max. 1 z
and LE51 (female) (5)
Between wiring harness between TMCN2
(female) (9) and LE51 (female) (6) and chassis Resistance Min. 1 Mz
ground
ground in wiring harness
Possible causes (Contact with ground circuit) aPrepare with starting switch OFF, then carry out troubleshooting with-
and standard
value in normal
(female) (19) and LE51 (female) (5) and chas- Resistance Min. 1 Mz
state
2 sis ground
Voltage Max. 1 V
Short circuit with power (female) (9) and LE51 (female) (6)
source in wiring harness aPrepare with starting switch OFF, then turn starting switch ON and
(Contact with 24 V circuit) carry out troubleshooting.
(female) (19) and LE51 (female) (5) and chas- Voltage Max. 1 V
sis ground
3 Defective engine controller TMCN2 PCCS lever Voltage
Between (9), (19) and Neutral Max. 1V
chassis ground Forward or reverse 20 30 V
20-443-1 D475A-3
(1)
TROUBLESHOOTING D5ZFL4
Circuit diagram related to engine controller neutral signal
D475A-3 20-443-2
(1)
TROUBLESHOOTING ERROR CODE D5ZGKA (NEUTRAL SIGNAL 2: DISCONNECTION (KA))
ERROR CODE D5ZGKA (NEUTRAL SIGNAL 2: DISCONNECTION (KA))
Action code Error code Neutral signal 2: Disconnection

Trouble
E01 D5ZGKA (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 Neutral signal 2 circuit.
controller
Problem that
appears on
machine
information Method of reproducing error code: Turn starting switch ON and operate parking lever (Neutral posi-
tion).

Defective disconnection in Prepare with starting switch OFF, then carry out troubleshooting
wiring harness (Disconnec- without turning starting switch ON.
1
tion in wiring or defective Wiring harness between TMCN2 (female) 9
Resistance Max. 1
contact in connector) BKA (female) 6
Prepare with starting switch OFF, then carry out troubleshooting
(Contact with ground circuit) TMCN2 (female) 9 CN5 (female) 6 with Resistance Min. 1M
and standard Prepare with starting switch OFF, then turn starting switch ON and
state
3
Between 9
Forward Reverse
position
Between 6 chassis
20 30V
ground
Circuit diagram related to Newtral signal 2
20-444 D475A-3
(1)
TROUBLESHOOTING ERROR CODE D5ZGKB (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB))
ERROR CODE D5ZGKB (NEUTRAL SIGNAL 2: SHORT CIRCUIT (KB))
Action code Error code Neutral signal 2: Short circuit (KB)

Trouble
E01 D5ZGKB (Transmission controller system)
Contents of
Abnormal current flowed in Neutral signal 2 circuit at the time of ground output.
trouble
Action of
Stops output to Neutral signal 2 circuit.
controller
Problem that
appears on
machine
information Method of reproducing error code: Turn starting switch ON and operate PCCS lever (Reverse posi-
tion).

1 harness (Contact with 24V Short circuit of wiring harness between
circuit) TMCN2 (female) 9 CN5 (female) 6 with Voltage Max. 1V
chassis ground
and standard
value in normal 2
state Between 9
Forward Reverse
position
Between 6-chassis
20 30V
ground
Circuit diagram related to Newtral signal 2
D475A-3 20-445
(1)
TROUBLESHOOTING D5ZKKX
ERROR CODE [D5ZKKX] (CHASSIS THROTTLE SIGNAL: OUT OF INPUT SIGNAL

RANGE (KX))
Action code Error code Chassis throttle signal: Out of input signal range (KX)
Trouble
CALL E03 D5ZKKX (Engine controller system)
Contents of
The input voltage of the shoe slip control signal is below 0.3 V or above 4.75 V.
trouble
Flashes the caution lamp and turns on the caution buzzer.
Action of
Keeps the last value in the normal range.
controller
Stops the shoe slip function after the machine stops.
Problem that
appears on The shoe slip control does not operate normally.
machine
Related
Method of reproducing error code: Turn the starting switch ON or start the engine in the SSC mode.
information

Disconnection in wiring aPrepare with starting switch OFF, then carry out troubleshooting with-
harness (Disconnection in out turning starting switch ON.
1
wiring harness or defective Wiring harness between LE31 (female) (9) and
Resistance Max. 1 z
contact in connector) STCN2 (female) (11)
Short circuit with chassis out turning starting switch ON.
2 ground in wiring harness Between wiring harness between LE31
(Contact with ground circuit) (female) (9) and STCN 2 (female) (11) and Resistance Min. 1M z
chassis ground
Possible causes aPrepare with starting switch OFF, then turn starting switch ON and
and standard Short circuit with power carry out troubleshooting.
value in normal 3 source in wiring harness Between wiring harness between LE31
state (Contact with 24-V circuit) (female) (9) and STCN 2 (female) (11) and Voltage Max. 1 V
chassis ground
LE31 Voltage
Between (9) and chassis ground 0.3 4.75 V
STCN2 Voltage
Between (11) and chassis ground 0.3 4.75 V
Circuit diagram related to shoe slip control signal
20-445-1 D475A-3
(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

Disconnection in wiring har- Wiring harness between S04 (female) 1, 2
ness (Disconnection in wir- STCN2 (female) V TMCN2 (female) V Resistance Max. 1
CA1 (female) A CA2 (female) A
1
ing or defective contact in
connector) Wiring harness between S04 (female) 3 4
STCN2 (female) L TMCN2 (female) L Resistance Max. 1
CA1 (female) B CA2 (female) B
Short circuit of wiring harness between S04
(female) 1, 2 STCN2 (female) V TMCN2
(female) V CA1 (female) A CA2 (female)
Short circuit with chassis Resistance Min. 1M
A with chassis ground

Possible causes (female) 3, 4 STCN2 (female) L TMCN2
(female) L CA1 (female) B CA2 (female)
Resistance Min. 1M
and standard
value in normal B with chassis ground
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
B with chassis ground
Defective CAN terminal re- without turning starting switch ON.
4
sistance CA1 (male), CA2 (male) Resistance
Between A B 40 80
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.)
20-446 D475A-3
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION:
Circuit diagram related to CAN communication
D475A-3 20-447
ERROR CODE DAQ0KK
ERROR (TRANSMISSION
CODE DAQ0KK CONTROLLER: SOURCE
(TRANSMISSION VOLTAGE
CONTROLLER:
TROUBLESHOOTING REDUCTION/INPUT (KK))
SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE DAQ0KK (TRANSMISSION CONTROLLER: SOURCE VOLTAGE

REDUCTION/INPUT (KK))
Action code Error code Transmission controller power supply: Source voltage reduction/input
Trouble
CALL E04 DAQ0KK (KK) (Transmission controller system)
Contents of
Source voltage of transmission controller is below 17V.
trouble
Monitor panel may not display normally.
Problem that
Relays and solenoids cannot operate, not allowing system operate normally.
appears on
machine
Once machine is stopped, it cannot travel any more.
Charge level (voltage) of battery can be checked in monitoring mode.
Related
(Code 03200: Battery voltage)
information

Defective circuit breaker If circuit breaker 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,
Resistance Max. 1
ness (Disconnection in wir- A CB3 (1)
3
ing or defective contact in Wiring harness between CB3 (2) fusible link
Resistance Max. 1
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. 1M
ground
Short circuit of wiring harness between CB3 (2)
fusible link battery relay terminal C with Resistance Min. 1M
chassis ground
Defective transmission con- carry out troubleshooting.
5
troller TMCN3 Voltage
Between 1, A K, U, V, W 20 30V
20-448 D475A-3
ERROR CODE DAQ0KT (TRANSMISSION
ERROR CODE CONTROLLER: ABNORMALITY
DAQ0KK (TRANSMISSION CONTROLLER:IN
TROUBLESHOOTING CONTROLLER (KK))
SOURCE VOLTAGE REDUCTION/INPUT (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
E01 DAQ0KT (Transmission controller system)
Contents of
Information of ROM (nonvolatile storage) of transmission controller is not normal.
trouble
controller Sets default internal adjustment value.
Problem that
appears on Gear shift feeling of transmission may become worse.
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard Troubleshooting cannot be carried out since it is internal defect.
value in normal 1 (It is no problem even if you use controller unless no visible problem
state troller
appears on machine.)
D475A-3 20-449
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

+ Prepare with starting switch OFF, then and hold it in the OFF posi-
tion during troubleshooting.
TL1 (male) Resistance
Defective forward-reverse Between L J 2k 20%
1 potentiometer (Internal Sensor 1 (FR3) Between L
Min. 1M
short circuit) chassis ground
Between O Q 2k 20%
Sensor 2 (FR4) Between O
Min. 1M
chassis ground
+ Prepare with starting switch OFF, then hold it in the OFF position
during troubleshooting.
CSL (male) Resistance
Between A C 4.6 6.0k
Between C chassis
Left yoke angle sensor
Defective yoke angle sen-
2 Min. 1M
sor ground
Possible causes CSR (male) Resistance
and standard Right yoke angle sen- Between A C 4.6 6.0k
Between C chassis
value in normal sor
state Min. 1M
ground
+ Prepare with starting switch OFF, then hold it in the OFF position
during troubleshooting.
(Contact with ground circuit) TMCN1 (female) L TL1 (female) L TL1 Resistance Min. 1M
(female) O CSL (female) A, CSR (female)
TMCN1 (female) L TL1 (female) L TL1
(female) O CSL (female) A, CSR (female)
circuit) Voltage Max. 1V
5
Between L K 4.5 5.5V
20-450 D475A-3
ERROR CODE DAQ5KK (TRANSMISSION CONTROLLER POTENTIOMETER
Circuit diagram related to transmission controller 5V power supply
D475A-3 20-451
ERROR CODE DAQ6KK (TRANSMISSION CONTROLLER SENSOR POWER
TROUBLESHOOTING SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
ERROR CODE DAQ6KK (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY:

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 HP 1
1 + Disconnect connector with starting switch OFF, then
sensor (Internal short cir- connector
turn starting switch ON and carry out troubleshoot-
cuit)
ing.
It is internal defect if error code lights on (reset dis-
Defective work equipment
play) when disconnecting right connector.
large pump oil pressure HP 2
Possible causes 2 + Disconnect connector with starting switch OFF, then
sensor (Internal short cir- connector
and standard turn starting switch ON and carry out troubleshoot-
cuit)
value in normal ing.
(Contact with ground circuit) TMCN1 (female) F HHP (female) B with Resistance Min. 1M
chassis ground
4
FK 20 30V
Circuit diagram related to transmission controller 24V power supply
20-452 D475A-3
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
Resistance Max. 1
state connector) TMCN3 (female) @ with chassis ground
3
Between @ chassis ground Max. 1V
Circuit diagram related to transmission controller type select
D475A-3 20-453
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN
TROUBLESHOOTING COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN COMMUNICATION:

DEFECTIVE COMMUNICATION (KR))
Action code Error code Transmission controller CAN communication: Defective communica-
Trouble
CALL E03 DAQRKR tion (KR) (Transmission controller and realer system)
Contents of Transmission controller cannot recognize monitor panel or steering controller, with CAN communica-
trouble tion circuit.
Related
information

Disconnection in wiring har- Wiring harness between S04 (female) 1, 2
ness (Disconnection in wir- STCN2 (female) V TMCN2 (female) V Resistance Max. 1
CA1 (female) A CA2 (female) A
1
CA1 (female) B CA2 (female) B

(female) 3, 4 STCN2 (female) L TMCN2
Possible causes Resistance Min. 1M

and standard
value in normal
3 harness
(Contact with 24V circuit)
Voltage Max. 1V
4
Between A B 40 80
Defective monitor panel, de- If no problem is found in causes 1 to 4, it is suspected that monitor
fective transmission control-
5 panel, transmission controller, or steering controller is defective.
ler or defective steering
controller (Troubleshooting cannot be carried out since it is internal defect.)
20-454 D475A-3
ERROR CODE DAQRKR (TRANSMISSION CONTROLLER CAN
D475A-3 20-455
ERROR CODE DAQSKR (TRANSMISSION CONTROLLER S-NET
ERROR CODE DAQSKR (TRANSMISSION CONTROLLER S-NET COMMUNICATION:

Action code Error code Transmission controller S-NET communication: Defective communi-
Trouble
E01 DAQSKR cation (KR) (Transmission controller system)
Contents of
Transmission controller cannot recognize S-NET.
trouble
Action of
Takes no particular action.
controller
Problem that
appears on Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine
Related
information

ness (Disconnection in wir- without turning starting switch ON.
1
ing or defective contact in Wiring harness between TMCN2 (female) K
Resistance Max. 1
connector) S01 (female) 8
(Contact with ground circuit) TMCN2 (female) K S01 (female) 8 with Resistance Min. 1M
chassis ground
3 harness Short circuit of wiring harness between
(Contact with 24V circuit) TMCN2 (female) K S01 (female) 8 with Voltage Max. 1V
and standard + Prepare with starting switch OFF, then turn starting switch ON and
value in normal Defective monitor panel carry out troubleshooting.
state 4
(Switch module) S01 Voltage
Between 8 chassis ground 6 9V
5
Between K U 6 9V
STCN2 Voltage
Between K U 6 9V
ECN4 Voltage
Between 0 6, B 6 9V
20-456 D475A-3
ERROR CODE DAQSKR (TRANSMISSION CONTROLLER S-NET
Circuit diagram related to S-NET communication
D475A-3 20-457
ERROR CODE DB30KK
ERROR(STEERING CONTROLLER:
CODE DB30KK SOURCE
(STEERING VOLTAGE
CONTROLLER:
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 (KK)
Trouble
CALL E04 DB30KK (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
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
(CB1) 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 STCN3 (female) 1 A
Resistance Max. 1
ness (Disconnection in wir- CB1 1
3
ing or defective contact in Wiring harness between CB1 (2) fusible link
Resistance Max. 1
Possible causes connector) battery relay terminal M
and standard Wiring harness between STCN3 (female) K,
Resistance Max. 1
value in normal U, V, W chassis ground
Short circuit with chassis Short circuit of wiring harness between STCN3
Resistance Min. 1M
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 M with Resistance Min. 1M
chassis ground
+ Prepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
STCN3 Voltage
Between 1, A K, U, V, W 20 30V
20-458 D475A-3
ERROR CODE DB30KT (STEERING
ERROR CODE CONTROLLER:
DB30KK ABNORMALITY
(STEERING CONTROLLER:IN
TROUBLESHOOTING CONTROLLER (KK))
SOURCE VOLTAGE REDUCTION/INPUT (KT))
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.)
D475A-3 20-459
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER POWER SUPPLY:

Action code Error code Steering controller potentiometer power supply: Source voltage re-
Trouble
CALL E03 DB35KK duction (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. SSA
2
sor (Internal short circuit) + Disconnect connector with starting switch OFF, then connector
TL1 (male) Resistance
Defective steering potenti- Between A G 2k 20%
3 ometer (Internal short cir- Sensor 1 (ST1) Between A
cuit) Min. 1M
chassis ground
Possible causes Between M F 2k 20%
and standard Sensor 2 (ST2) Between M
Min. 1M
value in normal chassis ground
Short circuit of wiring harness between STCN1
(female) L TL1 (female) A TL1 (female) M
BRK (female) C SSA (female) 1 with
(Contact with ground circuit) Resistance Min. 1M
chassis ground
Short circuit of wiring harness between STCN1
(female) L TL1 (female) A TL1 (female) M
BRK (female) C SSA (female) 1 with
chassis ground
STCN1 Voltage
Between L K 4.5 5.5V
20-460 D475A-3
ERROR CODE DB35KK (STEERING CONTROLLER POTENTIOMETER
Circuit diagram related to steering controller 5V power supply
D475A-3 20-461
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/in-
Trouble
CALL E03 DB36KK put (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 blade pitch angle
when disconnecting right connector. PAS
1 sensor (Internal short cir-
+ Disconnect connector with starting switch OFF, then connector
cuit)
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 Short circuit of wiring harness between STCN1
state (Contact with ground circuit) (female) F PT1 (female) C with chassis Resistance Min. 1M
ground
STCN1 Voltage
Between F K 20 30V
Circuit diagram related to steering controller 24V power supply
20-462 D475A-3
ERROR CODE
ERROR DB39KQ
CODE (STEERING
DB39KQ CONTROLLER
(STEERING CONTROLLERTYPETYPE
COLLATION: TYPE
COLLATION:
TROUBLESHOOTING SELECTSIGNAL
TYPE SELECT SIGNALINCONSISTENCY
INCONSISTENCY (KQ))
(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
Problem that Machine does not operate at all.
Related
information

It is normal if error code indicates P (reset display) after carrying out
Defective steering controller
1 adjustment mode.
adjustment
Adjustment code: 0002 (Steering controller spec. set)
Possible causes Disconnection in wiring har- + 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
Resistance Max. 1
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
D475A-3 20-463
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION:
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE

COMMUNICATION (KR))
Action code Error code Steering controller CAN communication: Defective communication
Trouble
CALL E03 DB3RKR (KR) (Transmission controller and realer system)
Contents of Steering controller cannot recognize monitor panel or transmission controller with CAN communica-
trouble tion circuit.
Related
information

Disconnection in wiring har- Between wiring harness between S04 (female)
ness (Disconnection in wir- 1, 2 STCN2 (female) V TMCN2 (female) Resistance Max. 1
V CA1 (female) A CA2 (female) A
1
CA1 (female) B CA2 (female)

Possible causes Resistance Min. 1M

and standard
value in normal
state
circuit)
Voltage Max. 1V
4
Between A B 40 80
Defective monitor panel, de-
If no problem is found in causes 1 to 4, it is suspected that monitor
fective transmission control-
5 panel, transmission controller, or steering controller is defec-
ler or defective steering
tive.(Troubleshooting cannot be carried out since it is internal defect.)
controller
20-464 D475A-3
ERROR CODE DB3RKR (STEERING CONTROLLER CAN COMMUNICATION:
D475A-3 20-465
ERROR CODE DB3SKR (STEERING CONTROLLER S-NET COMMUNICATION:

Action code Error code Steering controller S-NET communication: Defective communication
Trouble
E01 DA3SKR (KR) (Transmission controller system)
Contents of
Transmission controller cannot recognize S-NET.
trouble
Action of
Takes no particular action.
controller
Problem that
appears on Machine may not acquire switch signal of monitor panel, not allowing normal operation of system.
machine
Related
information

ness (Disconnection in wir- without turning starting switch ON.
1
ing or defective contact in Wiring harness between STCN2 (female) K
Resistance Max. 1
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. 1M
ground
Hot short circuit in wiring out troubleshooting.
3 harness (Contact with 24V Short circuit of wiring harness between STCN2
circuit) (female) K S01 (female) 8 with chassis Voltage Max. 1V
Possible causes ground
and standard + Prepare with starting switch OFF, turn starting switch ON and carry
value in normal Defective monitor panel out troubleshooting.
state 4
Between 8 chassis ground 6 9V
STCN2 Voltage
Between K U 6 9V
6
troller STCN2 Voltage
Between K U 6 9V
ECN4 Voltage
Between 0 6, B 6 9V
20-466 D475A-3
TROUBLESHOOTING DB40KK
ERROR CODE [DB40KK] (ENGINE CONTROLLER: LOWERING OF SOURCE VOLTAGE

(KK))
Action code Error code Engine controller: Lowering of source voltage (KK)
Trouble
CALL E04 DB40KK (Engine controller system)
Contents of
The source voltage of the engine controller is below 17 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
Method of reproducing error code: Turn the starting switch ON.
information

Defective switch power The switch power supply system of the controller may be defective.
1
Possible causes supply system of controller Carry out troubleshooting for error code [DB41KK].
and standard Defective backup power The backup power supply system of the controller may be defective.
2
value in normal supply system of controller Carry out troubleshooting for error code [DB43KK].
D475A-3 20-466-1
(1)
ERROR CODE [DB41KK] (SWITCH POWER SUPPLY: LOWERING OF SOURCE VOLT-

AGE (KK))
Action code Error code Switch power supply: Lowering of source voltage (KK)
Trouble
Contents of
The switch source voltage of the controller is 5 V or more below the backup source voltage.
trouble
controller Controls with the backup power supply.
Problem that
appears on
machine

1 relay
Disconnection in wiring out turning starting switch ON.
harness (Disconnection in Wiring harness between starting switch termi-
2 Resistance Max. 1 z
wiring harness or defective nal ACC and SDR (female) (3)
Possible causes
contact in connector) Wiring harness between SDR (female) (6) and
and standard Resistance Max. 1 z
value in normal LE1 (female) (9), (17)
state aPrepare with starting switch OFF, then carry out troubleshooting with-
LE1 (female) (9), (17), and other related circuits Resistance Min. 1 Mz
and chassis ground
LE1 Voltage
Between (9), (17) and (8), (16) 20 30 V
20-466-2 D475A-3
(1)
Circuit diagram related to controller power source (constant and switch)
D475A-3 20-466-3
(1)
ERROR CODE [DB42KK] (SOLENOID POWER SUPPLY 1: LOWERING OF SOURCE

VOLTAGE (KK))
Action code Error code Solenoid power supply 1: Lowering of source voltage (KK)
Trouble
Contents of While the switch source voltage of the controller is above 24 V, the voltage of solenoid power supply R
trouble is below 5 V.
Action of
controller
Problem that
machine
Related
Method of reproducing error code: Turn the starting switch OFF.
information

Defective right governor Replace the right governor cutout relay with another relay.
1 GCR
cutout relay (Internal defect) If the condition becomes normal, the relay is defective.
2
Possible causes contact in connector) Resistance Max. 1 z
GCR (female) (6)
and standard
value in normal Short circuit with chassis
state 3 ground in wiring harness
(Contact with ground circuit) Between wiring harness between LE2 (female)
Resistance Min. 1 Mz
(1) and GCR (female) (6) and chassis ground
LE2 Voltage
Between (1) and (21) 20 30 V
20-466-4 D475A-3
(1)
D475A-3 20-466-5
(1)
ERROR CODE [DB43KK] (BACKUP POWER SUPPLY: LOWERING OF SOURCE VOLT-

AGE (KK))
Action code Error code Backup power supply: Lowering of source voltage (KK)
Trouble
Contents of
The backup source voltage of the controller is 5 V or more below the switch source voltage.
trouble
controller Controls with the switch power supply.
Problem that
appears on
machine

1
wiring harness or defective Wiring harness between FSB (male) (3) and
contact in connector) Resistance Max. 1 z
LE1 (female) (7)
Possible causes
and standard Short circuit with chassis
value in normal 2 ground in wiring harness
state (Contact with ground circuit) Between wiring harness between FSB (male)
(3) and LE1 (female) (7) and chassis ground
LE1 Voltage
Between (7) and (8), (16) 20 30 V
20-466-6 D475A-3
(1)
Circuit diagram related to controller power supply (constant/switch)
D475A-3 20-466-7
(1)
ERROR CODE [DB44KK] (SOLENOID POWER SUPPLY 2: LOWERING OF SOURCE

VOLTAGE (KK))
Action code Error code Solenoid power supply 2: Lowering of source voltage (KK)
Trouble
Contents of While the switch source voltage of the controller is above 24 V, the voltage of solenoid power supply L
trouble is below 5 V.
Action of
controller
Problem that
machine
Related
information

Defective left governor cut- Replace the left governor cutout relay with another relay. If
1 GCL
out relay (Internal defect) the condition becomes normal, the relay is defective.
2
Possible causes contact in connector) Resistance Max. 1 z
GCL (female) (6)
and standard
value in normal Short circuit with chassis
state 3 ground in wiring harness
(12) and GCL (female) (6) and chassis ground
LE2 Voltage
Between (12) and (21) 20 30 V
20-466-8 D475A-3
(1)
D475A-3 20-466-9
(1)
TROUBLESHOOTING DB45KP
ERROR CODE [DB45KP] (RACK SENSOR POWER SUPPLY: LOWERING OF OUTPUT

VOLTAGE (KP))
Action code Error code Rack sensor power supply: Lowering of output voltage (KP)
Trouble
CALL E03 DB45KP (Engine controller system)
Contents of
The source voltage of the rack sensor is below 3.4 V.
trouble
controller Lowers the engine output by 20%.
Problem that
appears on The output is lowered.
machine
Related
Method of reproducing error code: Turn the starting switch OFF.
information

Disconnect the devices
Rack sensor of
Defective rack sensor of at right in order. If the Connector E13
right bank
right or left bank error code disappears
1
(Internal disconnection or when a device is dis-
Rack sensor of
short circuit) connected, that device Connector E9
left bank
has a defect in it.
Wiring harness between LE2 (female) (16) and
E13 (female) (1) [Rack sensor system of right Resistance Max. 1 z
bank]
Disconnection in wiring Wiring harness between LE2 (female) (16) and
harness (Disconnection in E9 (female) (1) [Rack sensor system of left Resistance Max. 1 z
2
wiring harness or defective bank]
Possible causes contact in connector) Wiring harness between LE31 (female) (16)
and standard
and E13 (female) (2) [Rack sensor system of Resistance Max. 1 z
value in normal
right bank]
state
Wiring harness between LE31 (female) (16)
and E9 (female) (2) [Rack sensor system of left Resistance Max. 1 z
bank]
Between wiring harness between LE2 (female)
(16) and E13 (female) (1) and chassis ground Resistance Min. 1 Mz
[Rack sensor system of right bank]
(16) and E9 (female) (1) and chassis ground Resistance Min. 1 Mz
[Rack sensor system of left bank]
LE2, LE31 Voltage
Between LE2 (16) and LE31 (16) 4.6 5.4 V
20-466-10 D475A-3
(1)
TROUBLESHOOTING DB45KP
Circuit diagram related to right bank rack sensor and left bank rack sensor
D475A-3 20-466-11
(1)
TROUBLESHOOTING DB49KM
ERROR CODE [DB49KM] (WRONG CONNECTION OF CONNECTOR: MISTAKE IN

OPERATION OR SETTING (KM))
Action code Error code Wrong connection of connector: Mistake in operation or setting (KM)
Trouble
CALL E04 DB49KM (Engine controller system)
Contents of
Wrong connection of connectors LE31 and LE51 of the controller is detected.
trouble
Action of
controller
Problem that
appears on The engine cannot be started.
machine
Related
information

Wrong connection of Connectors LE31 and LE51 may be connected wrongly (inversely).
1
controller connectors Check them directly.
Possible causes out turning starting switch ON.
harness (Disconnection in
and standard 2
value in normal
contact in connector) Resistance Max. 1 z
chassis ground
state
LE51 Voltage
Between (1) and chassis ground Max. 1 V
Circuit diagram related to connection of connector check harness
20-466-12 D475A-3
(1)
TROUBLESHOOTING DB49KQ
ERROR CODE [DB49KQ] (ENGINE CONTROLLER SPECIFICATION: DISAGREEMENT

OF MODEL SELECTION SIGNALS (KQ))
Action code Error code Engine controller specification: Disagreement of model selection signals
Trouble (KQ)
E02 DB49KQ (Engine controller system)
Contents of
Model selection circuit of engine controller is defective.
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Cause
Possible causes
D475A-3 20-466-13
(1)
Circuit diagram related to S-NET communication
D475A-3 20-467
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
Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
information
Input state (ON/OFF) from parking brake switch can be checked in monitoring mode.
(Code 40905: Transmission controller input signal 1)
Method of reproducing error code: Turn starting switch ON and operate parking lever.
When error code [DD14KA] occurred alone

ness (Disconnection in wir- Wiring harness between CN1 (female) H
1 Resistance Max. 1
ing or defective contact in branched point of circuit
connector) Wiring harness between CN1 (female) B
branched point of circuit
and standard
value in normal
state
Parking lever
CN1
Defective transmission con- Free position Lock position
2
troller Between H
Max. 1V 20 30V
chassis ground
Between B
20 30V 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. 1 Min. 1M
Between A B
Possible causes
Min. 1M Max. 1
and standard
Disconnection in wiring har- Wiring harness between NSW (female) B
Resistance Max. 1
ness (Disconnection in wir- merged point of circuit
ing or defective contact in Wiring harness between NSW (female) C
2
Resistance Max. 1
connector) merged point of circuit
Wiring harness between NSW (female) A
Resistance Max. 1
chassis ground
20-468 D475A-3
TROUBLESHOOTING ERROR CODE DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA))

Possible causes
Short circuit of wiring harness between NSW
(female) B TMCN1 (female) H STCN2 (fe- Voltage Max. 1V
and standard Hot short circuit in wiring
value in normal 3 harness (Contact with 24V
state male) 5 with chassis ground
circuit)
(female) C TMCN1 (female) B STCN2 (fe- Voltage Max. 1V
male) E with chassis ground
Circuit diagram related to parking brake switch
D475A-3 20-469
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. 1M Max. 1
Wiring harness between NSW (female) B
Possible causes Short circuit with chassis
and standard CN1 (female) H CN2 (female) 5 with chas- Resistance Min. 1M
sis ground
Wiring harness between NSW (female) C
value in normal (Contact with ground circuit)
state
CN1 (female) B CN2 (female) E with chas- Resistance Min. 1M
sis ground
Parking lever
CN1
Defective transmission con- Free position Lock position
3
troller Between H
Max. 1V 20 30V
chassis ground
Between B
20 30V Max. 1V
chassis ground
20-470 D475A-3
TROUBLESHOOTING ERROR CODE DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
Circuit diagram related to parking lever switch
D475A-3 20-471
TROUBLESHOOTING ERROR CODE DDB9KA (REVERSE SWITCH: DISCONNECTION (KA))
ERROR CODE DDB9KA (REVERSE SWITCH: DISCONNECTION (KA))
Action code Error code Reverse switch: Disconnection (KA)

Trouble
CALL E03 DDB9KA (Transmission controller system)
Contents of
Signals of two systems of reverse switch circuit were turned OFF (OPEN) at the same time.
trouble
controller Recognizes that switch is not pressed.
Problem that
Reverse is not possible.
appears on
Auto shift down does not function.
machine
Related Input state (ON/OFF) from reverse 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 reverse switch.

Reverse switch
TL1 (male)
Defective reverse switch OFF (Release) ON (Press)
1
(Internal disconnection) Resistance between
DV
Max. 1 Min. 1M
Resistance between
DC
Min. 1M Max. 1

Disconnection in wiring har- Wiring harness between TMCN3 (female) I Resistance
ness (Disconnection in wir- TL1 (female) V
Max. 1
2
ing or defective contact in Wiring harness between TMCN3 (female) S
TL1 (female) C
Resistance Max. 1
connector)
Wiring harness between TMCN1 (female) 4,
@ TL1 (female) D
and standard
value in normal + Prepare with starting switch OFF, turn starting switch ON and carry
state out troubleshooting.
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
Reverse switch
TMCN1, TMCN3
OFF (Release) ON (Press)
Defective transmission con- Voltage between
4
troller TMCN3 S TMCN1 Max. 1V 20 30V
4, @
Voltage between
TMCN3 S TMCN1 20 30V Max. 1V
4, @
20-472 D475A-3
TROUBLESHOOTING ERROR CODE DDB9KA (REVERSE SWITCH: DISCONNECTION (KA))
Circuit diagram related to forwrd switch and reverse switch
D475A-3 20-473
TROUBLESHOOTING ERROR CODE DDB9KB (REVERSE SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDB9KB (REVERSE SWITCH: SHORT CIRCUIT (KB))

Trouble Reverse switch: Short circuit (KB) (Transmission controller system)
CALL E03 DDB9KB
Contents of
Signals of two systems of reverse switch circuit were turned ON (CLOSE) or OFF at the same time.
trouble
Problem that
Reverse is not possible.
appears on
machine
Related Input state (ON/OFF) from reverse 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 reverse switch.

Reverse switch
TL1 (male)
Defective reverse switch OFF (Release) ON (Press)
1
DV
Max. 1 Min. 1M
Resistance between
DC
Min. 1M Max. 1

TMCN3 (female) I TL1 (female) V with
Resistance Min. 1M
and standard 2 ground in wiring harness
chassis ground
TMCN3 (female) S TL1 (female) C with
state
Resistance Min. 1M
chassis ground
Reverse switch
TMCN1, TMCN3
3
troller TMCN3 I TMCN1 Max. 1V 20 30V
4, @
Voltage between
TMCN3 S TMCN1 20 30V Max. 1V
4, @
20-474 D475A-3
TROUBLESHOOTING ERROR CODE DDB9KB (REVERSE SWITCH: SHORT CIRCUIT (KB))
Circuit diagram related to forwrd switch and reverse switch
D475A-3 20-475
TROUBLESHOOTING ERROR CODE DDK3KA (FORWARD SWITCH: DISCONNECTION (KA))
ERROR CODE DDK3KA (FORWARD SWITCH: DISCONNECTION (KA))

Trouble Forward switch: Disconnection (KA) (Transmission controller system)
CALL E03 DDK3KA
Contents of
Signals of two systems of forward switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
Forward 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 forward switch.

Forward switch
TL1 (male)
Defective forward switch OFF (Release) ON (Press)
1
NU
Max. 1 Min. 1M
Resistance between
NB
Min. 1M Max. 1

Disconnection in wiring har- Wiring harness between TMCN1 (female) 6 Resistance
ness (Disconnection in wir- TL1 (female) U
Max. 1
2
ing or defective contact in Wiring harness between TMCN2 (female) [
TL1 (female) B
Resistance Max. 1
connector)
@ TL1 (female) N
and standard
TMCN1 (female) 6 TL1 (female) U with
Voltage Max. 1V
chassis ground
circuit)
TMCN2 (female) [ TL1 (female) B with Voltage Max. 1V
chassis ground
Forward switch
TMCN1,TMCN2
4
troller TMCN1 6 TMCN1 Max. 1V 20 30V
4, @
Voltage between
TMCN2 [ TMCN1 20 30V Max. 1V
4, @
20-476 D475A-3
TROUBLESHOOTING ERROR CODE DDK3KA (FORWARD SWITCH: DISCONNECTION (KA))
Circuit diagram related to forward switch and reverse switch
D475A-3 20-477
TROUBLESHOOTING ERROR CODE DDK3KB (FORWARD SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDK3KB (FORWARD SWITCH: SHORT CIRCUIT (KB))

Trouble Forward switch: Short circuit (KB) (Transmission controller system)
CALL E03 DDK3KB
Contents of
Signals of two systems of forward switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
Forward is not possible.
appears on
machine
Related Input state (ON/OFF) from forward switch can be checked in monitoring mode.
Method of reproducing error code: Turn starting switch ON and operate forward switch.

Forward switch
TL1 (male)
Defective forward switch OFF (Release) ON (Press)
1
NU
Max. 1 Min. 1M
Resistance between
NB
Min. 1M Max. 1

TMCN1 (female) 6 TL1 (female) U with
Resistance Min. 1M
chassis ground
TMCN2 (female) [ TL1 (female) B with
state
Resistance Min. 1M
chassis ground
Forward switch
TMCN1,TMCN2
3
troller TMCN1 6 TMCN1 Max. 1V 20 30V
4, @
Voltage between
TMCN2 [ TMCN1 20 30V Max. 1V
4, @
20-478 D475A-3
TROUBLESHOOTING ERROR CODE DDK3KB (FORWARD SWITCH: SHORT CIRCUIT (KB))
Circuit diagram related to forward switch and reverse switch
D475A-3 20-479
TROUBLESHOOTING ERROR CODE DDK5KA (SHIFT SWITCH: DISCONNECTION (KA))
ERROR CODE DDK5KA (SHIFT SWITCH: DISCONNECTION (KA))
Action code Error code Shift switch: Disconnection (KA)

Trouble
E02 DDK5KA (Transmission controller system)
Contents of
Signals of two systems of shift switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
Shift down or shift up 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 switch.

Shift switch
BSW (male)
Defective shift switch OFF (Release) ON (Press)
1
AB
Min. 1M Max. 1
Resistance between
AC
Max. 1 Min. 1M

Disconnection in wiring har- Wiring harness between TMCN2 (female) 7 Resistance
ness (Disconnection in wir- BSW (female) B
Max. 1
2
ing or defective contact in Wiring harness between TMCN2 (female) 0
BSW (female) C
Resistance Max. 1
connector)
@ BSW (female) A
and standard
TMCN2 (female) 7 BSW (female) B with
Voltage Max. 1V
chassis ground
circuit)
TMCN2 (female) 0 BSW (female) C with Voltage Max. 1V
chassis ground
Shift switch
TMCN1, TMCN2
4
troller TMCN2 7 TMCN1 20 30V Max. 1V
4, @
Voltage between
TMCN2 @ TMCN1 Max. 1V 20 30V
4, @
20-480 D475A-3
TROUBLESHOOTING ERROR CODE DDK5KA (SHIFT SWITCH: DISCONNECTION (KA))
Circuit diagram related to shift switch
D475A-3 20-481
TROUBLESHOOTING ERROR CODE DDK5KB (SHIFT SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDK5KB (SHIFT SWITCH: SHORT CIRCUIT (KB))

Trouble Shift switch: Short circuit (KB) (Transmission controller system)
E02 DDK5KB
Contents of
Signals of two systems of shift switch circuit were turned ON (CLOSE) or OFF at the same time.
trouble
Problem that
Shift down or shift up is not possible.
appears on
machine
Related Input state (ON/OFF) from shift switch can be checked in monitoring mode.
Method of reproducing error code: Turn starting switch ON and operate shift switch.

Shift switch
BSW (male)
Defective shift switch OFF (Release) ON (Press)
1
AB
Min. 1M Max. 1
Resistance between
AC
Max. 1 Min. 1M

TMCN2 (female) 7 BSW (female) B with
Resistance Min. 1M
chassis ground
TMCN2 (female) 0 BSW (female) C with
state
Resistance Min. 1M
chassis ground
Shift switch
TMCN1, TMCN2
3
troller TMCN2 7 TMCN1 20 30V Max. 1V
4, @
Voltage between
TMCN2 0 TMCN1 Max. 1V 20 30V
4, @
Circuit diagram related to shift switch
20-482 D475A-3
ERROR CODE DDN2LD (SEE TABLE (LD) BLADE TILT RIGHT OIL PRESSURE
TROUBLESHOOTING SWITCH SYSTEM)
ERROR CODE DDN2LD (SEE TABLE (LD) BLADE TILT RIGHT OIL PRESSURE SWITCH
SYSTEM)
Action code Error code See table (LD) blade tilt right oil pressure switch system
Trouble
E02 DDN2LD (Transmission controller system)
Contents of trouble Signal of blade tilt right oil pressure switch circuit was kept turned ON for 180 seconds.
Action of controller
Judges that oil pressure switch is turned OFF.
Problem that When pitch and dump operation or right dual tilt operation is performed, right single tilt mechanism
appears on machine operates.
Inputting from blade tilt right oil pressure switch (ONOFF) can be checked in monitoring mode.
(Code 40908: Blade lever oil pressure switch input)
Related information
Method of reproducing service code:
Turn starting switch ON (Error code is reproduced after 180 seconds).

After return operation, if Error code P is still displayed (to indicate that
Defective operation of lever
1 trouble is repaired), lever may have been so operated that error would
(Electric system is normal)
be detected.
+ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective blade tilt right oil
2 pressure switch TRS (male) Blade lever Resistance
(Internal short circuit) Neutral Min. 1 M
Between 1 2
Possible causes Right tilt Max. 1
and standard val- + Prepare with starting switch OFF, then carry out troubleshooting
ue in normal state Short circuit with chassis without turning starting switch ON.
(Contact with ground circuit) TMCN2 (female) 6 TRS (female) 1 with Max.
Resistance
1 M
chassis ground
troubleshooting.
Defective transmission con- TMCN2, TMCN1 Blade lever Voltage
4
troller
Between TMCN2 6 Neutral 20 30 V
TMCN1 4, @ Right tilt Max. 1 V
Circuit diagram related to blade tilt right oil pressure switch
D475A-3 20-483
ERROR CODE DDN3LD (SEE TABLE (LD) BLADE TILT LEFT OIL PRESSURE
TROUBLESHOOTING SWITCH SYSTEM)
ERROR CODE DDN3LD (SEE TABLE (LD) BLADE TILT LEFT OIL PRESSURE SWITCH
SYSTEM)
Action code Error code See table (LD) blade tilt left oil pressure switch system
Trouble
E02 DDN3LD (Transmission controller system)
Contents of trouble Signal of blade tilt left oil pressure switch circuit was kept turned ON for 180 seconds.
Action of controller
Judges that oil pressure switch is turned OFF.
Problem that When pitch and dump operation or right dual tilt operation is performed, left single tilt mechanism op-
appears on machine erates.
Inputting from blade tilt left oil pressure switch (ONOFF) can be checked in monitoring mode.
(Code 40908: Blade lever oil pressure switch input)
Related information
Method of reproducing service code:
Turn starting switch ON (Error code is reproduced after 180 seconds).

After return operation, if error code P is still displayed (to indicate that
Defective operation of lever
1 trouble is repaired), lever may have been so operated that error would
(Electric system is normal)
be detected.
troubleshooting.
Defective blade tilt left oil
2 pressure switch TLS (male) Blade lever Resistance
(Internal short circuit) Neutral Min. 1 M
Between 1 2
Possible causes Left tilt Max. 1
and standard val- + Prepare with starting switch OFF, then carry out troubleshooting
ue in normal state Short circuit with chassis without turning starting switch ON.
(Contact with ground circuit) TMCN2 (female) F TLS (female) 1 with Max.
Resistance
1 M
chassis ground
troubleshooting.
4
troller
Between TMCN2 F Neutral 20 30 V
TMCN1 4, @ Left tilt Max. 1 V
Circuit diagram related to blade tilt left oil pressure switch
20-484 D475A-3
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 1)
Method of reproducing error code: Turn starting switch ON (and operate blade tilt switch).

Blade pitch switch
P03 (male)
Defective blade pitch switch OFF (Release) ON (Press)
1
Max. 1 Min. 1M
15
Resistance between
Min. 1M Max. 1
12
Disconnection in wiring har- Wiring harness between TMCN2 (female) E
Resistance Max. 1
ness (Disconnection in wir- P03 (female) 5
2
ing or defective contact in Wiring harness between TMCN2 (female) 5
Resistance Max. 1
connector) P03 (female) 2
Possible causes Wiring harness between TMCN1 (female) 4,
Resistance Max. 1
@ 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 20 30V
4, @
Voltage between
TMCN2 5 TMCN1 20 30V Max. 1V
4, @
20-486 D475A-3
TROUBLESHOOTING ERROR CODE DDN7KA (BLADE PITCH SWITCH: DISCONNECTION (KA))
Circuit diagram related to blade pitch switch & blade tilt switch
D475A-3 20-487
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
Max. 1 Min. 1M
15
Resistance between
Min. 1M Max. 1
12
Possible causes Short circuit of wiring harness between
TMCN2 (female) E P03 (female) 5 with Voltage Max. 1V
chassis ground
state Short circuit of wiring harness between
TMCN2 (female) 5 P03 (female) 2 with Voltage Max. 1V
chassis ground
Blade pitch switch
TMCN1, TMCN2
3
troller TMCN2 E TMCN1 Max. 1V 20 30V
4, @
Voltage between
TMCN2 5 TMCN1 20 30V Max. 1V
4, @
20-488 D475A-3
TROUBLESHOOTING ERROR CODE DDN7KB (BLADE PITCH SWITCH: SHORT CIRCUIT (KB))
D475A-3 20-489
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 pitch switch
P03 (male)
Defective blade tilt switch SINGLE DUAL
1
Max. 1 Min. 1M
36
Resistance between
Min. 1M Max. 1
34
Disconnection in wiring har- Wiring harness between TMCN2 (female) Y Resistance
Max. 1
ness (Disconnection in wir- P03 (female) 6
2
ing or defective contact in Wiring harness between TMCN2 (female) O
Resistance Max. 1
connector) P03 (female) 4
Resistance Max. 1
@ 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 pitch switch
TMCN1, TMCN2
SINGLE DUAL
4
troller TMCN2 Y TMCN1 Max. 1V 20 30V
4, @
Voltage between
TMCN2 O TMCN1 20 30V Max. 1V
4, @
20-490 D475A-3
TROUBLESHOOTING ERROR CODE DDN9KA (BLADE TILT SWITCH: DISCONNECTION (KA))
D475A-3 20-491
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 DD9NKB
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 pitch switch
P03 (male)
Defective blade pitch switch SINGLE DUAL
1
Max. 1 Min. 1M
36
Resistance between
Min. 1M Max. 1
34
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 pitch switch
TMCN1, TMCN2
SINGLE DUAL
3
troller TMCN2 Y TMCN1 Max. 1V 20 30V
4, @
Voltage between
TMCN2 O TMCN1 20 30V Max. 1V
4, @
20-492 D475A-3
TROUBLESHOOTING ERROR CODE DDN9KB (BLADE TILT SWITCH: SHORT CIRCUIT (KB))
D475A-3 20-493
ERROR CODE
ERROR DDNALD
CODE (BLADE
DDNALD LIFT UP
(BLADE FULL
LIFT UP PRESSURE SWITCH:
FULL PRESSURE REFER
SWITCH:
TROUBLESHOOTING TOTABLE
REFER TO TABLE (LD)
ERROR CODE DDNALD (BLADE LIFT UP FULL PRESSURE SWITCH: REFER TO TABLE (LD)
Action code Error code Blade lift up full pressure switch: Refer to table (LD).
Trouble
DDNALD (Steering control system)
Contents of
Signals of Blade lift up full pressure switch was continuously ON for 180 seconds.
trouble
Action of
Recognizes ripper tilt IN pressure switch is OFF.
controller
Problem that
appears on Blade lift up speed is slow.
machine
Input state (ON/OFF) from blade lift up full pressure switch can be checked in monitoring mode.
Related (Code 40908: Blade lever pressure switch input)
information Method of reproducing error code: Turn starting switch ON. (It is reproduced after a lapse of at least
180 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 blade lift up full carry out troubleshooting.
2 pressure switch (Internal BLU (male) Blade lever Resistance
short circuit) Neutral Min. 1M
Possible causes Between 1 2
UP Max. 1
and standard
state
(Contact with ground circuit) TMCN2 (female) Z BLU (female) 1 with Resistance Min. 1M
chassis ground
4
troller
Between TMCN2 Z Neutral 20 30V
TMCN1 4, @ UP Max. 1V
Circuit diagram related to blade lift UP full pressure switch
20-494 D475A-3
ERROR ERROR
CODE DDNBLD (RIPPER (RIPPER
CODE DDNBLD LIFT UP PRESSURE SWITCH: REFER
LIFT UP PRESSURE TO
SWITCH:
TROUBLESHOOTING TABLE (LD)
REFER TO TABLE (LD)
ERROR CODE DDNBLD (RIPPER LIFT UP PRESSURE SWITCH: REFER TO TABLE (LD)
Action code Error code Ripper lift UP pressure switch: Refer to table (LD).
Trouble
DDNBLD (Transmission 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
Shoe slip control (SSC) does not operate normally.
appears on
Ripper raise speed is slow.
machine
Input state (ON/OFF) from ripper lift UP pressure switch can be checked in monitoring mode.
Related (Code 70305: Steering controller input signal 3)
60 seconds.)

past.
Defective ripper lift UP pres- carry out troubleshooting.
2 sure switch (Internal short RPU (male) Ripper lever Resistance
circuit) Neutral Min. 1M
UP Max. 1
and standard
state
(Contact with ground circuit) TMCN2 (female) C RPU (female) 1 with Resistance Min. 1M
chassis ground
Defective transmission con- TMCN1, TMCN2 Ripper lever Voltage
4
troller
Between TMCN2 C Neutral 20 30V
Circuit diagram related to ripper lift UP pressure switch
D475A-3 20-495
ERROR ERROR
CODE DDNCLD (RIPPER (RIPPER
CODE DDNCLD LOWER PRESSURE SWITCH: REFER
LOWER PRESSURE TO
SWITCH:
TROUBLESHOOTING TABLE (LD)
REFER TO TABLE
ERROR CODE DDNCLD (RIPPER LOWER PRESSURE SWITCH: REFER TO TABLE (LD)
Action code Error code Ripper lower pressure switch: Refer to table (LD).
Trouble
DDNCLD (Transmission control system)
Contents of
Signals from ripper lower pressure switch was continuously ON for 60 seconds.
trouble
Action of
Recognizes ripper lower pressure switch is OFF.
controller
Problem that
appears on
Ripper lower speed is slow.
machine
Input state (ON/OFF) from ripper lower pressure switch can be checked in monitoring mode.
Related (Code 70305: Steering controller input signal 3)
60 seconds.)

past.
Defective ripper lower pres- carry out troubleshooting.
2 sure switch (Internal short RPD (male) Ripper lever Resistance
Lower Max. 1
and standard
state
(Contact with ground circuit) TMCN2 (female) 3 RPD (female) 1 with Resistance Min. 1M
chassis ground
4
troller
Between TMCN2 3 Neutral 20 30V
Circuit diagram related to ripper lower pressure switch
20-496 D475A-3
ERROR ERROR
CODE DDNDLD (RIPPER TILT
CODE DDNDLD IN PRESSURE
(RIPPER SWITCH: REFER
TILT IN PRESSURE TO
SWITCH:
TROUBLESHOOTING TABLE (LD))
REFER TO TABLE (LD))
ERROR CODE DDNDLD (RIPPER TILT IN PRESSURE SWITCH: REFER TO TABLE (LD))
Action code Error code Ripper tilt IN pressure switch: Refer to table (LD).
Trouble
DDNDLD (Transmission control system)
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
appears on
Ripper tilt IN speed is slow.
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)
60 seconds.)

past.
Defective ripper tilt IN pres- carry out troubleshooting.
2 sure switch (Internal short RTI (male) Ripper lever Resistance
Tilt IN Max. 1
and standard
state
(Contact with ground circuit) (female) 2 RTI (female) 1 with chassis Resistance Min. 1M
ground
4
troller
Between TMCN2 2 Neutral 20 30V
TMCN1 4, @ Tilt IN Max. 1V
Circuit diagram related to ripper tilt IN pressure switch
D475A-3 20-497
ERRORERROR
CODE DDNELD (RIPPER (RIPPER
CODE DDNELD TILT BACK PRESSURE
TILT SWITCH: REFER
BACK PRESSURE TO
SWITCH:
TROUBLESHOOTING TABLE (LD))
ERROR CODE DDNELD (RIPPER TILT BACK PRESSURE SWITCH: REFER TO TABLE (LD))
Action code Error code Ripper tilt BACK pressure switch: Refer to table (LD).
Trouble
DDNELD (Transmission control system)
Contents of
Signals of ripper tilt BACK pressure switch was continuously ON for 60 seconds.
trouble
Action of
Recognizes ripper tilt BACK pressure switch is OFF.
controller
Problem that
appears on
Ripper tilt back speed is slow.
machine
Input state (ON/OFF) from ripper tilt BACK pressure switch can be checked in monitoring mode.
Related (Code 70305: Ripper lever pressure switch input)
60 seconds.)

past.
Defective ripper tilt BACK carry out troubleshooting.
2 pressure switch (Internal RT8 (male) Ripper lever Resistance
Tilt IN Max. 1
and standard
state
(Contact with ground circuit) TMCN2 (female) \ RT8 (female) 1 with Resistance Min. 1M
chassis ground
4
troller
Between TMCN2 \ Neutral 20 30V
TMCN1 4, @ Tilt IN Max. 1V
Circuit diagram related to ripper tilt Back pressure switch
20-498 D475A-3
20
ERROR CODE
ERROR DDNFLD
CODE (BLADE
DDNFLD LOWER
(BLADE FULL PRESSURE
LOWER SWITCH:
FULL PRESSURE REFER
SWITCH:
TROUBLESHOOTING TOTABLE
(LD))
ERROR CODE DDNFLD (BLADE LOWER FULL PRESSURE SWITCH: REFER TO TABLE (LD))
Action code Error code Blade lower full pressure switch: Refer to table (LD).
Trouble
DDNFLD (Transmission control system)
Contents of
Signals of blade lower full pressure switch was continuously ON for 180 seconds.
trouble
Action of
Recognizes blade lower full pressure switch is OFF.
controller
Problem that
appears on Blade lower speed is slow.
machine
Input state (ON/OFF) from blade lower full pressure switch can be checked in monitoring mode.
Related (Code 40908: blade lever pressure switch input)
180 seconds.)

past.
Defective Blade lower full carry out troubleshooting.
2 pressure switch (Internal BLD (male) Blade lever Resistance
Lower full Max. 1
and standard
state
(Contact with ground circuit) (female) P BLD (female) 1 with chassis Resistance Min. 1M
ground
4
troller
Between TMCN2 P Neutral 20 30V
TMCN1 4, @ Down full Max. 1V
Circuit diagram related to blade lower full pressure switch
D475A-3 20-499
ERROR CODE DDQ2KA (PARKING BRAKE LEVER SWITCH:
TROUBLESHOOTING DISCONNECTION (KA))
ERROR CODE DDQ2KA (PARKING BRAKE 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

1 Resistance Max. 1
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 20 30V
chassis ground
Between E
20 30V Max. 1V
chassis ground
When error codes [DDQ2KA] and [DD14KA] occurred at the same time
1 NSW
Between A B
Possible causes
Min. 1M Max. 1
and standard
Disconnection in wiring har- Wiring harness between NSW (female) B
Resistance Max. 1
ness (Disconnection in wir- merged point of circuit
ing or defective contact in Wiring harness between NSW (female) C
2
Resistance Max. 1
connector) merged point of circuit
Wiring harness between NSW (female) A
Resistance Max. 1
chassis ground
20-500 D475A-3
ERROR CODE DDQ2KA (PARKING BRAKE LEVER SWITCH:

Possible causes
(female) B TMCN1 (female) H STCN2
and standard Hot short circuit in wiring
3 Voltage Max. 1V
value in normal harness (Contact with 24V
state (female) 5 with chassis ground
circuit)
(female) C TMCN1 (female) B STCN2 (fe- Voltage Max. 1V
D475A-3 20-501
ERROR CODEERROR
DDQ2KB (PARKING
CODE BRAKE
DDQ2KB LEVER SWITCH:
(PARKING SHORTSWITCH:
BRAKE LEVER CIRCUIT
TROUBLESHOOTING (KB))
SHORT CIRCUIT (KB))
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 (ONOFF) can be checked in monitoring mode.
(Code 40907: Blade control lever knob switch input signal)
Method of reproducing error code: Turn starting switch ON and operate parking brake lever.
When error codes [DDQ2KA] and [DD14KA] are displayed simultaneously

Defective parking brake le- Parking brake lever
1 ver switch (Internal short cir- NSW
At FREE At LOCK
Between A B
cuit)
Max. 1 Min. 1M
Between A B Min. 1M Max. 1
(female) B TMCN1 (female) H STCN2 (fe- Resistance Min. 1M
value in normal male) 5 with chassis ground
(female) C TMCN1 (female) B STCN2 (fe- Resistance Min. 1M
state

Parking brake lever
STCN2
At FREE At LOCK
Between 5
Max. 1V 20 30V
chassis ground
Between E
20 30V Max. 1V
chassis ground
20-502 D475A-3
ERROR CODEERROR
DDQ2KB (PARKING
CODE BRAKE
DDQ2KB LEVER SWITCH:
(PARKING SHORTSWITCH:
BRAKE LEVER CIRCUIT
SHORT CIRCUIT (KB))
D475A-3 20-503
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 (ONOFF) can be checked in monitoring mode.
(Code 40905, 40910: 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.
20-504 D475A-3
TROUBLESHOOTING ERROR CODE DDT5KA (NEUTRAL SWITCH: DISCONNECTION (KA))
ERROR CODE DDT5KA (NEUTRAL SWITCH: DISCONNECTION (KA))
Action code Error code Neutral switch: Disconnection (KA)

Trouble
CALL E04 DDT5KA (Transmission controller system)
Contents of
Signals of two systems of Neutral switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
Travel is not possible.
appears on
machine
Related Input state (ON/OFF) from neutral switch can be checked in monitoring mode.
Method of reproducing error code: Turn starting switch ON and operate neutral switch.

Neutral switch
NTL (male)
Defective neutral switch OFF (Release) ON (Press)
1
Max. 1 Min. 1M
13
Resistance between
Min. 1M Max. 1
23
Disconnection in wiring har- Wiring harness between TMCN2 (female) Q Resistance
Max. 1
ness (Disconnection in wir- NTL (female) 1
2
ing or defective contact in Wiring harness between TMCN2 (female) G
Resistance Max. 1
connector) NTL (female) 2
Resistance Max. 1
@ NTL (female) 3
and standard
TMCN2 (female) Q NTL (female) 1 with Voltage Max. 1V
chassis ground
circuit)
TMCN2 (female) G NTL (female) 2 with Voltage Max. 1V
chassis ground
Neutral switch
TMCN1, TMCN2
4
troller TMCN2 Q TMCN1 Max. 1V 20 30V
4, @
Voltage between
TMCN2 G TMCN1 20 30V Max. 1V
4, @
20-506 D475A-3
TROUBLESHOOTING ERROR CODE DDT5KA (NEUTRAL SWITCH: DISCONNECTION (KA))
Circuit diagram related to neutral switch disconnection
D475A-3 20-507
TROUBLESHOOTING ERROR CODE DDT5KB (NEUTRAL SWITCH: SHORT CIRCUIT (KB))
ERROR CODE DDT5KB (NEUTRAL SWITCH: SHORT CIRCUIT (KB))

Trouble Neutral switch: Short circuit (KB) (Transmission controller system)
CALL E04 DDT5KB
Contents of
Signals of two systems of neutral switch circuit were turned ON (CLOSE) or OFF at the same time.
trouble
Problem that
Travel is not possible.
appears on
machine
Related Input state (ON/OFF) from neutral switch can be checked in monitoring mode.
Method of reproducing error code: Turn starting switch ON and operate neutral switch.

Neutral switch
NTL (male)
Defective neutral switch OFF (Release) ON (Press)
1
DV
Max. 1 Min. 1M
Resistance between
DC
Min. 1M Max. 1

TMCN2 (female) Q NTL (female) 1 with Resistance Min. 1M
chassis ground
TMCN2 (female) G NTL (female) 2 with Resistance Min. 1M
chassis ground
Neutral switch
TMCN1, TMCN2
3
troller TMCN2 Q TMCN1 Max. 1V 20 30V
4, @
Voltage between
TMCN2 G TMCN1 20 30V Max. 1V
4, @
20-508 D475A-3
TROUBLESHOOTING ERROR CODE DDT5KB (NEUTRAL SWITCH: SHORT CIRCUIT (KB))
Circuit diagram related to neutral switch short circuit
D475A-3 20-509
ERROR CODE DDT5KQ (PCCS LEVER SPECIFICATION SIGNAL
TROUBLESHOOTING INCONSISTENCY (KQ))
ERROR CODE DDT5KQ (PCCS LEVER SPECIFICATION SIGNAL INCONSISTENCY (KQ))
Action code Error code PCCS lever specification signal inconsistency (KQ) (Transmission
Trouble
CALL E04 DDT5KQ controller system)
Contents of
.
trouble
Problem that Travel is not possible.
Related
information

When PCCSR type is installed, it is normal if error code lights on (re-
Defective setting for PCCS
1 set display) after carrying out adjustment mode.
lever specification
Adjustment code: 0004: Transmission controller spec.
+ Prepare with starting switch OFF, carry out troubleshooting without
Possible causes turning starting switch ON.
and standard Short circuit in wiring har- Short circuit of wiring harness between
2 Resistance Min. 1
value in normal ness TMCN2 (female) Q with chassis ground
Resistance Min. 1
TMCN2 (female) G with chassis ground
3
Between Q chassis ground 20 30V
Circuit diagram related to PCCS lever specification
20-510 D475A-3
TROUBLESHOOTING DGE2KX
ERROR CODE [DGE2KX] (COOLANT TEMPERATURE SENSOR: OUT OF INPUT SIG-

NAL RANGE (KX))
Action code Error code Engine coolant temperature: Out of input signal range (KX)
Trouble
E02 DGE2KX (Engine controller system)
Contents of
The input voltage from the engine coolant temperature sensor is below 0.3 V or above 4.7 V.
trouble
Action of
Assumes the engine coolant temperature to be 90C for control.
controller
Problem that
appears on
machine
The signals of the engine coolant temperature sensor are used by the monitor panel, too. Depending
Related
on the cause of the trouble, the engine coolant temperature gauge may not indicate normally.
information
Method of reproducing error code: Turn the starting switch ON or start the engine.

Defective engine coolant out turning starting switch ON.
temperature sensor 402 (male) Resistance
1
(Internal disconnection or Between (1) and (2) 3.8 k 80 kz
short circuit) Between (1), (2) and
Min. 1 Mz
chassis ground
harness (Disconnection in Wiring harness between LE32 (female) (5) and
wiring harness or defective 402 (female) (1)
contact in connector) Wiring harness between LE31 (female) (16)
Resistance Max. 1 z
and 402 (female) (2)
Possible causes aPrepare with starting switch OFF, then carry out troubleshooting with-
and standard Short circuit with chassis out turning starting switch ON.
value in normal 3 ground in wiring harness Between wiring harness between LE32
state (Contact with ground circuit) (female) (5), 402 (female) (1), or S04 (female) Resistance Min. 1 Mz
(11) and chassis ground
Short circuit with power carry out troubleshooting.
4 source in wiring harness Between wiring harness between LE32
(Contact with 24-V circuit) (female) (5), 402 (female) (1), or S04 (female) Voltage Max. 1 V
(11) and chassis ground
LE31 (female), LE32 (female) Resistance
Between LE32 (5) and LE31 (16) 3.8 k 80 kz
If none of causes 1 5 is the cause of the trouble, the monitor panel may
6 Defective monitor panel be defective (Troubleshooting cannot be carried out since the defect is
in the monitor panel).
D475A-3 20-510-1
(1)
TROUBLESHOOTING DGE2KX
Circuit diagram related to engine coolant temperature sensor
20-510-2 D475A-3
(1)
ERROR CODE
ERROR DGS1KX
CODE (HYDRAULIC
DGS1KX OIL TEMPERATURE
(HYDRAULIC SENSOR:
OIL TEMPERATURE INPUT
SENSOR:
TROUBLESHOOTING SIGNAL
INPUT SIGNAL ISISOUT
OUTOFOFNORMAL
NORMALRANGE
RANGE (KX))
(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
Method of reproducing error code: Turn starting switch ON or start engine.

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 90k
cuit)
Between 1 chassis ground Min. 1M
ness (Disconnection in wir- Wiring harness between TMCN1 (female) D
2 Resistance Max. 1
ing or defective contact in SDS (female) 1
connector) Wiring harness between TMCN1 (female) K
Resistance Max. 1
SDS (female) 2
Possible causes
and standard + Prepare with starting switch OFF, then carry out troubleshooting
value in normal
state 3 ground in wiring harness Short circuit of wiring harness between
(Contact with ground circuit) TMCN1 (female) D SDS (female) 1 with Resistance Min. 1M
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 3.5k 90k
Between D chassis ground Min. 1M
Circuit diagram related to hydraulic oil temperature sensor
D475A-3 20-511
ERROR CODE DH22KA (WORK EQUIPMENT LARGE PUMP OIL PRESSURE
TROUBLESHOOTING SENSOR: DISCONNECTION (KA))
ERROR CODE DH22KA (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR:
DISCONNECTION (KA))
Action code Error code Work equipment large pump oil pressure sensor: Disconnection (KA)
Trouble
DH22KA (Transmission controller system)
Contents of
Signal voltage of work equipment large pump oil pressure sensor circuit is below 0.5V.
trouble
Action of
controller
Problem that
appears on Work equipment large pump oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment large pump oil pressure sensor can be checked in monitoring
Related
mode. (Code 70701: Voltage of work equipment large pump 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 large pump oil pressure
HP1 Voltage
Between C A
sensor (Internal trouble)
0.5 6.0V
Possible causes ness (Disconnection in wir- Wiring harness between TMCN1 (female) F
ing or defective contact in HP1 (female) B
3 Resistance Max. 1
and standard
value in normal connector) Wiring harness between TMCN1 (female) 9
HP1 (female) C
Resistance Max. 1
state
(Contact with ground circuit) TMCN1 (female) 9 HP1 (female) C with Resistance Min. 1M
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 large pump oil pressure sensor
20-512 D475A-3
ERROR CODE DH22KB (WORK EQUIPMENT LARGE PUMP OIL PRESSURE
TROUBLESHOOTING SENSOR: SHORT CIRCUIT (KB))
ERROR CODE DH22KB (WORK EQUIPMENT LARGE PUMP OIL PRESSURE SENSOR:
SHORT CIRCUIT (KB))
Action code Error code Work equipment large pump oil pressure sensor: Short circuit (KB)
Trouble
E01 DH22KB (Transmission controller system)
Contents of
Signal voltage of work equipment large pump oil pressure sensor circuit is above 6.0V
trouble
Action of
controller
Problem that
appears on Work equipment large pump oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment large pump oil pressure sensor can be checked in monitoring mode.
Related
(Code 70701: Voltage of work equipment large pump oil pressure sensor)
information

1
2 large pump oil pressure
HP1 Voltage
Between C A
Possible causes 0.5 6.0V
value in normal Short circuit with power out troubleshooting.
state 3 source in wiring harness Short circuit of wiring harness between
(Contact with 24V circuit) TMCN1 (female) 9 HP1 (female) C with Voltage Max. 1V
chassis ground
4
Circuit diagram related to work equipment large pump oil pressure sensor
D475A-3 20-513
ERROR CODE DH23KA (WORK EQUIPMENT ASSISTANCE PUMP OIL
TROUBLESHOOTING PRESSURE SENSOR: DISCONNECTION (KA))
ERROR CODE DH23KA (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE

SENSOR: DISCONNECTION (KA))
Action code Error code Work equipment assistance pump oil pressure sensor: Disconnection
Trouble (KA)
E01 DH23KA
(Transmission controller system)
Contents of
Signal voltage of work equipment assistance pump oil pressure sensor circuit is below 0.5V.
trouble
Action of
controller
Problem that
appears on Work equipment assistance pump oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment assistance pump oil pressure sensor can be checked in monitor-
Related
ing mode. (Code 70701: Voltage of work equipment assistance pump oil sensor)
information

1
Defective work equipment + Prepare with starting switch OFF, turn starting switch ON and carry
assistance pump oil pres- out troubleshooting.
2
sure sensor (Internal trou- HP2 Voltage
ble) Between C A 0.5 6.0V
Possible causes ness (Disconnection in wir- Wiring harness between TMCN1 (female) F
ing or defective contact in HP2 (female) B
3 Resistance Max. 1
and standard
value in normal connector) Wiring harness between TMCN1 (female) 3
HP2 (female) C
Resistance Max. 1
state
(Contact with ground circuit) TMCN1 (female) 3 HP2 (female) C with Resistance Min. 1M
chassis ground
5
Circuit diagram related to work equipment assistance pump oil pressure sensor
20-514 D475A-3
ERROR CODE DH23KB (WORK EQUIPMENT ASSISTANCE PUMP OIL
TROUBLESHOOTING PRESSURE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE DH23KB (WORK EQUIPMENT ASSISTANCE PUMP OIL PRESSURE

SENSOR: SHORT CIRCUIT (KB))
Action code Error code Work equipment assistance pump oil pressure sensor: Short circuit
Trouble
DH23KB (KB)(Transmission controller system)
Contents of
Signal voltage of work equipment assistance pump oil pressure sensor circuit is above 6.0V
trouble
Action of
controller
Problem that
appears on Work equipment assistance pump oil pressure cannot be monitored.
machine
Input (Voltage) from work equipment assistance pump oil pressure sensor can be checked in monitoring
Related
mode. (Code 70703: Voltage of work equipment assist pump oil pressure sensor)
information

1
2 assist pump oil pressure
HP2 Voltage
Between C A
Possible causes 0.5 6.0V
value in normal Short circuit with power out troubleshooting.
(Contact with 24V circuit) TMCN1 (female) 3 HP2 (female) C with Voltage Max. 1V
chassis ground
4
Circuit diagram related to work equipment assistance pump oil pressure sensor
D475A-3 20-515
ERROR CODE ERROR
DK01KA CODE
(LEFT YOKE ANGLE
DK01KA SENSOR:
(LEFT DISCONNECTION
YOKE ANGLE SENSOR:
TROUBLESHOOTING (KA))
DISCONNECTION (KA))
ERROR CODE DK01KA (LEFT YOKE ANGLE SENSOR: DISCONNECTION (KA))
Action code Error code Left yoke angle sensor: Disconnection (KA)
Trouble
E02 DK01KA (Transmission controller system)
Contents of
Signal voltage of left yoke angle sensor circuit is below 0.5V.
trouble
Action of
controller
Problem that
appears on Tilt limit function does not work.
machine
Input (Voltage) from left yoke angle sensor can be checked in monitoring mode.
Related
(Code 90002: Voltage of left yoke angle sensor)
information

Defective 5V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
source system troubleshooting for it first.
Defective left yoke angle CSL (male) Resistance
Between A C
2 sensor (Internal disconnec-
4.0 6.0k
Between A B
tion or short circuit)
0.25 7.0k
Between B C 0.25 7.0k
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wir- Wiring harness between TMCN1 (female) L
ing or defective contact in CSL (female) A
value in normal 3 Resistance Max. 1
state connector) Wiring harness between TMCN1 (female) 7
CSL (female) B
Resistance Max. 1

(Contact with ground circuit) TMCN1 (female) 7 CSL (female) B with Resistance Min. 1M
chassis ground
5
Circuit diagram related to left yoke angle sensor
20-516 D475A-3
TROUBLESHOOTING ERROR CODE DK01KB (LEFT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB))
ERROR CODE DK01KB (LEFT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB))
Action code Error code Left yoke angle sensor: Short circuit (KB)
Trouble
E02 DK01KB (Transmission controller system)
Contents of
Signal voltage of left yoke angle sensor circuit is below 0.5V or above 4.5V.
trouble
Action of
controller
Problem that
machine
Input (Voltage) from left yoke angle sensor can be checked in monitoring mode.
Related
(Code 90002: Voltage of left yoke angle sensor)
information

1
Defective left yoke angle CSL (male) Resistance
AC
4.0 6.0k
AB
Possible causes 0.25 7.0k
and standard BC 0.25 7.0k
value in normal + Prepare with starting switch OFF, then turn starting switch ON and
state Short circuit with power carry out troubleshooting.
(Contact with 24V circuit) TMCN1 (female) 7 CSL (female) B with Voltage Max. 1V
chassis ground
4 Defective transmission
TMCN1 Voltage
Circuit diagram related to left yoke angle sensor
D475A-3 20-517
ERROR CODE DK03KA
ERROR (RIGHT
CODE YOKE ANGLE
DK01KA SENSOR:
(LEFT DISCONNECTION
YOKE ANGLE SENSOR:
DISCONNECTION (KA))
ERROR CODE DK03KA (RIGHT YOKE ANGLE SENSOR: DISCONNECTION (KA))
Action code Error code Right yoke angle sensor: Disconnection (KA)
Trouble
CALL E02 DK03KA (Transmission controller system)
Contents of
Signal voltage of right yoke angle sensor circuit is below 0.5V.
trouble
Action of
controller
Problem that
machine
Input (Voltage) from right yoke angle sensor can be checked in monitoring mode.
Related
(Code 90003: Voltage of right yoke angle sensor)
information

1
Defective right yoke angle CSR (male) Resistance
Between A C
4.0 6.0k
Between A B
0.25 7.0k
ing or defective contact in CSR (female) A
state connector) Wiring harness between TMCN1 (female) C
CSR (female) B
Resistance Max. 1

(Contact with ground circuit) TMCN1 (female) C CSR (female) B with Resistance Min. 1M
chassis ground
TMCN1 Voltage
Between C K 0.5 4.5V
Circuit diagram related to right yoke angle sensor
20-518 D475A-3
ERROR CODEERROR
DK03KB (RIGHT
CODE YOKE ANGLE
DK03KB (RIGHTSENSOR: SHORTSENSOR:
YOKE ANGLE CIRCUIT
SHORT CIRCUIT (KB))
ERROR CODE DK03KB (RIGHT YOKE ANGLE SENSOR: SHORT CIRCUIT (KB))
Action code Error code Right yoke angle sensor: Short circuit (KB)
Trouble
CALL E02 DK03KB (Transmission controller system)
Contents of
Signal voltage of right yoke angle sensor circuit is below 0.5V or above 4.5V.
trouble
Action of
controller
Problem that
machine
Input (Voltage) from right yoke angle sensor can be checked in monitoring mode.
Related
(Code 90003: Voltage of right yoke angle sensor)
information

1
Defective right yoke angle CSR (male) Resistance
AC
4.0 6.0k
AB
(Contact with 24V circuit) TMCN1 (female) C CSR (female) B with Voltage Max. 1V
chassis ground
Defective transmission carry out troubleshooting.
4
controller TMCN1 Voltage
Circuit diagram related to right yoke angle sensor
D475A-3 20-519
TROUBLESHOOTING DK10KX
ERROR CODE [DK10KX] (FUEL DIAL: OUT OF INPUT SIGNAL RANGE (KX))
Action code Error code Fuel dial: Out of input signal range (KX)
Trouble
CALL E03 DK10KX (Engine controller system)
Contents of
The input voltage from the fuel dial is below 0.3 V or above 4.75 V.
trouble
Action of
controller
Fixes the engine speed at 1,300 rpm after the machine is stopped (and set in neutral).
Problem that
appears on The engine speed cannot be controlled.
machine
Related
information

Defective fuel dial DIAL (male) Resistance
1 (Internal disconnection or
Between (1) and (3) 4.0 6.0 kz
short circuit)
Between (1) and (2) 0.25 7.0 kz
Between (3) and (2) 0.25 7.0 kz
harness (Disconnection in DIAL (female) (1)
2
wiring harness or defective Wiring harness between LE31 (female) (16)
contact in connector) Resistance Min. 1 Mz
and DIAL (female) (3)
Wiring harness between LE32 (female) (1) and
DIAL (female) (2)
Possible causes Between wiring harness between LE31
(female) (6) and DIAL (female) (1) and chassis Resistance Min. 1 Mz
ground
state (Contact with ground circuit)
Between wiring harness between LE32
(female) (1) and DIAL (female) (2) and chassis Resistance Min. 1 Mz
ground
(female) (6) and DIAL (female) (1) and chassis Voltage Max. 1 V
ground
(Contact with 24-V circuit)
(female) (1) and DIAL (female) (2) and chassis Voltage Max. 1 V
ground
LE31, LE32 Voltage
5 Defective engine controller Between LE31 (6)
Power supply 4.6 5.4 V
and (16)
Between LE32 (1)
Signal 0.3 4.75 V
and LE31 (16)
20-519-1 D475A-3
(1)
Circuit diagram related to fuel dial
D475A-3 20-519-2
(1)
ERROR CODE DK11KA (DECELERATION POTENTIOMETER:
ERROR CODE DK11KA (DECELERATION POTENTIOMETER: DISCONNECTION (KA))
Action code Error code Deceleration potentiometer Disconnection (KA)

Trouble
E01 DK11KA (Steering controller system)
Contents of
Signal voltage of deceleration potentiometer circuit is below 0.5V.
trouble
Action of
Recognizes full deceleration.
controller
Problem that
Transmission shift shock becomes heavy.
appears on
Auto-shift down function does not work properly.
machine
Related
information

Defective deceleration po- FCD (male) Resistance
Between A C
1 tentiometer (Internal discon-
4.0 6.0k
Between A B
nection or short circuit)
0.25 7.0k
Possible causes ness (Disconnection in wir- Wiring harness between CN3 (female) 6
FCD (female) A
and standard 2 Resistance Max. 1
value in normal connector) Wiring harness between STCN1 (female) 9
FCD (female) B
state Resistance Max. 1

(Contact with ground circuit) (female) 9 FCD (female) B with chassis Resistance Min. 1M
ground
STCN1 Voltage
Between 9 ground 0.5 4.5V
20-520 D475A-3
ERROR CODE DK11KA (DECELERATION POTENTIOMETER:
Circuit diagram related to decel potentiometer
D475A-3 20-521
ERROR CODEERROR
DK11KB (DECELERATION
CODE POTENTIOMETER:
DK11KB (DECELERATION SHORT CIRCUIT
POTENTIOMETER:
SHORT CIRCUIT (KB))
ERROR CODE DK11KB (DECELERATION POTENTIOMETER: SHORT CIRCUIT (KB))
Action code Error code Deceleration potentiometer: short circuit (KB)

Trouble
CALL E01 DK11KB (Engine controller system)
Contents of
Signal voltage of deceleration potentiometer circuit is above 4.5V.
trouble
Action of
Confirms that the speed went down to the deceleration speed.
controller
Problem that
appears on
Transmission shift shock becomes heavy.
machine
Auto-shift down function does not work properly.
Related
information

Defective deceleration po- DCL (male) Resistance
Between A C
1 tentiometer (Internal discon-
4.0 6.0k
Between A B
0.25 7.0k
Possible causes Between B C 0.25 7.0k
value in normal Short circuit with power carry out troubleshooting.
state 2 source in wiring harness Short circuit of wiring harness between STCN1
(Contact with 24V circuit) (female) 9 DCL (female) B with chassis Voltage Max. 1V
ground
STCN1 Voltage
Between 9 ground 0.5 4.5V
20-522 D475A-3
ERROR CODEERROR CODE
DK11KB DK11KB (DECELERATION
(DECELERATION POTENTIOMETER:
POTENTIOMETER: SHORT CIRCUIT
TROUBLESHOOTING SHORT CIRCUIT (KB))
(KB))
Circuit diagram related to decel potentiometer
D475A-3 20-523
ERROR CODE [DK12KX] (DECELERATOR POTENTIOMETER: OUT OF INPUT SIGNAL

RANGE (KX))
Action code Error code Decelerator potentiometer: Out of input signal range (KX)
Trouble
CALL E03 DK12KX (Engine controller system)
Contents of
The input voltage from the decelerator potentiometer is below 0.3 V or above 4.75 V.
trouble
Action of
controller
Fixes the engine speed at 1,300 rpm after the machine is stopped (and set in neutral).
Problem that
appears on The engine speed cannot be controlled.
machine
Related
information

Defective decelerator out turning starting switch ON.
potentiometer FCD (male) Resistance
1
(Internal disconnection or Between (A) and (C) 4.0 6.0 kz
short circuit) Between (A) and (B) 0.25 7.0 kz
Between (C) and (B) 0.25 7.0 kz
harness (Disconnection in FCD (female) (A)
2
wiring harness or defective Wiring harness between LE31 (female) (16)
contact in connector) Resistance Min. 1 Mz
and FCD (female) (C)
Wiring harness between LE32 (female) (11)
and FCD (female) (B)
Possible causes Between wiring harness between LE31
(female) (6) and FCD (female) (A) and chassis Resistance Min. 1 Mz
ground
state (Contact with ground circuit)
(female) (11) and FCD (female) (B) and chassis Resistance Min. 1 Mz
ground
(female) (6) and FCD (female) (A) and chassis Voltage Max. 1 V
ground
(female) (11) and FCD (female) (B) and chassis Voltage Max. 1 V
ground
LE31, LE32 Voltage
5 Defective engine controller Between LE31 (6)
Power supply 4.6 5.4 V
and (16)
Between LE32 (6)
Signal 0.3 4.75 V
and LE31 (16)
20-523-1 D475A-3
(1)
Circuit diagram related to decelerator potentiometer
D475A-3 20-523-2
(1)
ERROR CODE ERROR
DK30KACODE
(STEERING POTENTIOMETER
DK30KA 1: DISCONNECTION
(STEERING POTENTIOMETER 1:
DISCONNECTION (KA))
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
Defective steering potenti- TL1 (male) Resistance
Between A G
2 ometer 1 (Internal discon-
2k 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
state connector) Wiring harness between STCN1 (female) 2
TL1 (female) H
Resistance Max. 1

(Contact with ground circuit) (female) 2 TL1 (female) H with chassis Resistance Min. 1M
ground
STCN1 Voltage
20-524 D475A-3
ERROR CODE ERROR
DK30KACODE
DISCONNECTION (KA))
Circuit diagram related to steering potentiometer
D475A-3 20-525
ERROR CODEERROR
DK30KB (STEERING
CODE DK30KBPOTENTIOMETER 1: SHORT CIRCUIT
SHORT CIRCUIT (KB))
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
2k 20%
Between H A
Possible causes
and standard Between H G
3 source in wiring harness Short circuit of wiring harness between STCN1
(Contact with 24V circuit) (female) 2 TL1 (female) H with chassis Voltage Max. 1V
ground
STCN1 Voltage
20-526 D475A-3
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
D475A-3 20-527
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
20-528 D475A-3
ERROR CODE ERROR
DK31KACODE
DISCONNECTION (KA))
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
2k 20%
Between E M
Between E F
TL1 (female) M
state connector) Wiring harness between STCN1 (female) I
TL1 (female) E
Resistance Max. 1

(Contact with ground circuit) (female) I TL1 (female) E with chassis Resistance Min. 1M
ground
STCN1 Voltage
Between I K 0.5 4.5V
20-530 D475A-3
ERROR CODE ERROR
DK31KACODE
DISCONNECTION (KA))
D475A-3 20-531
ERROR CODEERROR
DK31KB (STEERING
CODE DK31KBPOTENTIOMETER 2: SHORT CIRCUIT
SHORT CIRCUIT (KB))
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
2k 20%
Between E M
Possible causes
and standard Between E F
(Contact with 24V circuit) (female) I TL1 (female) E with chassis Resistance Max. 1V
ground
STCN1 Voltage
20-532 D475A-3
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 6.0k
Between A B
or short circuit)
0.25 7.0k
ing or defective contact in BRK (female) C
BRK (female) B
Resistance Max. 1

(Contact with ground circuit) (female) 3 BRK (female) B with chassis Resistance Min. 1M
ground
STCN1 Voltage
Circuit diagram related to brake potentiometer
D475A-3 20-533
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
AC
2 eter (Internal disconnection
4.0 6.0k
AB
or short circuit)
(Contact with 24V circuit) (female) 3 BRK (female) B with chassis Voltage Max. 1V
ground
STCN1 Voltage
Circuit diagram related to brake potentiometer
20-534 D475A-3
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
D475A-3 20-535
ERROR CODE
ERRORDK55L8
CODE (FORWARD-REVERSE POTENTIOMETER:
DK55L8 (FORWARD-REVERSE SEE TABLE
POTENTIOMETER:
TROUBLESHOOTING (L8))
SEE TABLE (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
20-536 D475A-3
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
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).

1
Defective forward-reverse without turning starting switch ON.
potentiometer 1 (Internal TL1 (male) Resistance
Between L J
2
disconnection or short cir- 2k 20%
cuit) Between K L
Between K J
ing or defective contact in TL1 (female) L
TL1 (female) K
Resistance Max. 1

(Contact with ground circuit) (female) 2 TL1 (female) K with chassis Resistance Min. 1M
ground
5
troller STCN1 Voltage
Circuit diagram related to forward-reverse potentiometer
D475A-3 20-537
ERROR CODE
ERROR DK56KB
CODE (FORWARD-REVERSE
DK56KB POTENTIOMETER
(FORWARD-REVERSE 1: SHORT
POTENTIOMETER 1:
TROUBLESHOOTING CIRCUIT (KB))
SHORT CIRCUIT (KB))
ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT

(KB))
Action code Error code Forward-reverse potentiometer 1: Short circuit (KB)

Trouble
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).

1
Between L J
2
Possible causes cuit) Between K L
and standard Between K J
(Contact with 24V circuit) TMCN1 (female) 2 TL1 (female) K with Resistance Max. 1V
chassis ground
4
20-538 D475A-3
ERROR CODE DK57KA (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION

(KA))
Action code Error code Forward-reverse potentiometer 2: Disconnection (KA)

Trouble
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
ing or defective contact in TL1 (female) O
state connector) Wiring harness between TMCN1 (female) I
TL1 (female) P
Resistance Max. 1

(Contact with ground circuit) TMCN1 (female) I TL1 (female) P with Resistance Min. 1M
chassis ground
5
20-540 D475A-3
D475A-3 20-541
ERROR CODE
ERROR DK57KB
CODE (FORWARD-REVERSE
DK57KB POTENTIOMETER
(FORWARD-REVERSE 2: SHORT
POTENTIOMETER 2:
SHORT CIRCUIT (KB))
ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT

(KB))
Action code Error code Forward-reverse potentiometer 2: Short circuit (KB)

Trouble
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).

Disconnection in wiring har-
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
Possible causes disconnection or short cir- 2k 20%
and standard cuit) Between P O
value in normal Between P Q
(Contact with 24V circuit) TMCN1 (female) I - TL1 (female) P with Voltage Max. 1V
chassis ground
4
Between I - K 0.5 4.5V
20-542 D475A-3
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 0.5V.
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) SSA Voltage
Between 2 3 0.75 4.25V
Possible causes ness (Disconnection in wir- Wiring harness between STCN1 (female) L
3 Resistance Max. 1
and standard ing or defective contact in SSA (female) 1
value in normal connector) Wiring harness between STCN1 (female) 1
Resistance Max. 1
state SSA (female) 2
(Contact with ground circuit) (female) 1 SSA (female) 2 with chassis Resistance Min. 1M
ground
STCN1 Voltage
Circuit diagram related to acceleration sensor
D475A-3 20-543
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) SSA Voltage
Possible causes Between 2 3 0.75 4.25V
(Contact with 24V circuit) STCN1 (female) 1 SSA (female) 2 with Voltage Max. 1V
chassis ground
STCN1 Voltage
Circuit diagram related to acceleration sensor
20-544 D475A-3
TROUBLESHOOTING DKF1KX
ERROR CODE [DKF1KX] (RACK SENSOR RIGHT: OUT OF INPUT SIGNAL RANGE
(KX))
Action code Error code Rack sensor right: Out of input signal range (KX)
Trouble
CALL E03 DKF1KX (Engine controller system)
Contents of
The input voltage from the right bank rack sensor is below 0.1 V or above 4.4 V.
trouble
controller Stops injection from the right bank fuel pump.
Problem that
machine
Related
information

Defective sensor power
1 If error code [DB45KP] is displayed, carry out troubleshooting for it first.
supply system
aPrepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
E13 Voltage
Between (1) and (2) Power supply 4.6 5.4 V
Defective right bank rack Between (3) and (2) Signal (+) 0.1 4.4 V
2
sensor (Internal defect) Between (4) and (2) Signal () 0.1 4.4 V
The voltage of the rack sensor is measured with the wiring harness con-
nected. Accordingly, if the voltage is abnormal, check the wiring har-
ness and controller, too, for another cause of the trouble, and then
judge.
wiring harness or defective E13 (female) (3)
Possible causes contact in connector) Wiring harness between LE31 (female) (17)
and standard Resistance Max. 1 z
and E13 (female) (4)
value in normal
state
(female) (7) and E13 (female) (3) and chassis Resistance Min. 1 Mz
ground
ground
(16), JE2, and E13 (female) (1) and chassis Voltage Max. 1 V
Short circuit with power ground
(Contact with 24-V circuit) (female) (7) and E13 (female) (3) and chassis Voltage Max. 1 V
ground
(female) (17) and E13 (female) (4) and chassis Voltage Max. 1 V
ground
D475A-3 20-544-1
(1)

Possible causes LE2, LE31 Voltage
and standard Between LE2 (16)
value in normal Power supply 4.6 5.4 V
6 Defective engine controller and LE31 (16)
state Between LE31 (7)
Signal (+) 0.1 4.4 V
and LE31 (16)
Between LE31 (17)
Signal () 0.1 4.4 V
and LE31 (16)
Circuit diagram related to right bank rack sensor
20-544-2 D475A-3
(1)
ERROR CODE [DKF2KX] (RACK SENSOR LEFT: OUT OF INPUT SIGNAL RANGE (KX))
Action code Error code Rack sensor left: Out of input signal range (KX)
Trouble
CALL E03 DKF2KX (Engine controller system)
Contents of
The input voltage from the left bank rack sensor is below 0.1 V or above 4.4 V.
trouble
controller Stops injection from the left bank fuel pump.
Problem that
machine
Related
information

Defective sensor power
1 If error code [DB45KP] is displayed, carry out troubleshooting for it first.
supply system
aPrepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
E9 Voltage
Between (1) and (2) Power supply 4.6 5.4 V
Defective left bank rack Between (3) and (2) Signal (+) 0.1 4.4 V
2
sensor (Internal defect) Between (4) and (2) Signal () 0.1 4.4 V
The voltage of the rack sensor is measured with the wiring harness con-
nected. Accordingly, if the voltage is abnormal, check the wiring har-
ness and controller, too, for another cause of the trouble, and then
judge.
Possible causes wiring harness or defective E9 (female) (3)
and standard contact in connector) Wiring harness between LE31 (female) (18)
Resistance Max. 1 z
value in normal and E9 (female) (4)
state aPrepare with starting switch OFF, then carry out troubleshooting with-
ground
ground
Voltage Max. 1 V
(16) and E9 (female) (1) and chassis ground
(Contact with 24-V circuit) (female) (8) and E9 (female) (3) and chassis Voltage Max. 1 V
ground
(female) (18) and E9 (female) (4) and chassis Voltage Max. 1 V
ground
D475A-3 20-544-3
(1)

Possible causes LE2, LE31 Voltage
and standard Between LE2 (16)
value in normal Power supply 4.6 5.4 V
6 Defective engine controller and LE31 (16)
state Between LE31 (8)
Signal (+) 0.1 4.4 V
and LE31 (16)
Between LE31 (18)
Signal () 0.1 4.4 V
and LE31 (16)
Circuit diagram related to left bank rack sensor
20-544-4 D475A-3
(1)
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
Possible causes ness (Disconnection in wir- Wiring harness between STCN1 (female) F
ing or defective contact in PT1 (female) C
3 Resistance Max. 1
and standard
value in normal connector) Wiring harness between STCN1 (female) C
PT1 (female) B
Resistance Max. 1
state
(Contact with ground circuit) (female) C PT1 (female) B with chassis Resistance Min. 1M
ground
STCN1 Voltage
Circuit diagram related to pitch angle sensor
D475A-3 20-545
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
state 3 source in wiring harness Short circuit of wiring harness between STCN1
(Contact with 24V circuit) (female) C PT1 (female) B with chassis Voltage Max. 1V
ground
STCN1 Voltage
Circuit diagram related to pitch angle sensor
20-546 D475A-3
ERROR CODE ERROR
DLE1KACODE
(ENGINE NE SPEED
DLE1KA SENSOR:
(ENGINE DISCONNECTION
NE SPEED SENSOR:
DISCONNECTION (KA))
ERROR CODE DLE1KA (ENGINE NE SPEED SENSOR: DISCONNECTION (KA))
Action code Error code Engine Ne speed sensor: Disconnection (KA)

Trouble
E01 DLE1KA (Steering controller system)
Contents of
Engine Ne speed sensor signal cannot be input to the controller.
trouble
Action of
After stopping the machine, the controller recognizes that the engine speed is 0.
controller
Problem that
appears on Excessive shift shock of transmission.
machine
Related
information

Defective engine Ne speed without turning starting switch ON.
1 sensor (Internal disconnec- E12 (male) Resistance
tion or short circuit) Between 1 2 500 1000
ness (Disconnection in wir- Wiring harness between STCN2 (female) ^
2 Resistance Max. 1
Possible causes ing or defective contact in E12 (female) 1
and standard connector) Wiring harness between ECN2 (female) S
Resistance Max. 1
value in normal E12 (female) 2
(Contact with ground circuit) (female) ^ E12 (female) 1 with chassis Resistance Min. 1M
ground
4 Defective steering controller STCN2 (female) Resistance
Between S ^ 500 1000
Between ^ chassis ground Min. 1M
20-548 D475A-3
ERROR CODE ERROR
DLE1KACODE
(ENGINE NE SPEED
DLE1KA SENSOR:
(ENGINE DISCONNECTION
NE SPEED SENSOR:
DISCONNECTION (KA))
Circuit diagram related to engine speed sensor
D475A-3 20-549
TROUBLESHOOTING DLE4LC
ERROR CODE [DLE4LC] (ENGINE SPEED SENSOR A: * REFER TO TABLE (LC))
Action code Error code Engine speed sensor A: Refer to table (LC)
Trouble
CALL E03 DLE4LC (Engine controller system)
Contents of
After the engine is started, the input value from engine speed sensor A is below 300 rpm.
trouble
controller Controls with the signals from engine speed sensor B.
Problem that
appears on
machine
Related
information

Defective engine speed out turning starting switch ON.
1 sensor A (Internal discon- E16 (male) Resistance
nection or short circuit) Between (1) and (2) 500 1,000 z
Between (1) and chassis ground Min. 1 Mz
Defective adjustment of
2 Refer to TESTING AND ADJUSTING, Adjusting engine speed sensor.
engine speed sensor A
Possible causes harness (Disconnection in Wiring harness between LE31 (female) (2) and
and standard wiring harness or defective E16 (female) (1)
value in normal contact in connector) Wiring harness between LE31 (female) (14)
state Resistance Max. 1 z
Short circuit with chassis out turning starting switch ON.
4 ground in wiring harness Between wiring harness between LE31
(Contact with ground circuit) (female) (2) and E16 (female) (1) and chassis Resistance Min. 1 Mz
ground
5 Defective engine controller LE31 (female) Resistance
Between (2) and (14) 500 1,000 z
20-549-1 D475A-3
(1)
Circuit diagram related to engine speed sensor A
D475A-3 20-549-2
(1)
ERROR CODE [DLE5LC] (ENGINE SPEED SENSOR B: * REFER TO TABLE (LC))
Action code Error code Engine speed sensor B: Refer to table (LC)
Trouble
CALL E03 DLE5LC (Engine controller system)
Contents of
After the engine is started, the input value from engine speed sensor B is below 300 rpm.
trouble
controller Controls with the signals from engine speed sensor A.
Problem that
appears on
machine
The signals of engine speed sensor B are used by the steering controller, too. Depending on the cause
Related
of the trouble, error code [DLE1KA] may be displayed at the same time.
information

Defective engine speed out turning starting switch ON.
sensor B
1 E12 (male) Resistance
(Internal disconnection or
short circuit) Between (1) and (2) 500 1,000 z
Defective adjustment of
2 Refer to TESTING AND ADJUSTING, Adjusting engine speed sensor.
engine speed sensor B
Possible causes
and standard 3 Resistance Max. 1 z
value in normal
contact in connector) Wiring harness between LE31 (female) (14)
state Resistance Max. 1 z
(Contact with ground circuit) Between wiring harness between LE31
(female) (3) and E12 (female) (1)
5 Defective engine controller LE31 (female) Resistance
Between (3) and (14) 500 1,000 z
20-549-3 D475A-3
(1)
Circuit diagram related to engine speed sensor B
D475A-3 20-549-4
(1)
ERROR CODE DLF1KA (TORQUE CONVERTER OUTPUT SPEED SENSOR:
ERROR CODE DLF1KA (TORQUE CONVERTER OUTPUT SPEED SENSOR: DISCONNECTION

(KA))
Action code Error code Torque converter output speed sensor: Disconnection (KA)
Trouble
E01 DLF1KA (Transmission controller system)
Contents of
Signal is not input from torque converter 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 torque converter 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 torque converter carry out troubleshooting.
output speed sensor (Inter-
1 TC1 (male) Resistance
nal disconnection or short
Between 1 2 500 1,000
circuit)
Between 1, 2 chassis ground Min. 1M
ness (Disconnection in wir- Wiring harness between TMCN2 (female) J
2 Resistance Max. 1
Possible causes ing or defective contact in TC1 (female) 1
and standard connector) Wiring harness between TMCN2 (female) ]
Resistance Max. 1
value in normal TC1 (female) 2
(Contact with ground circuit) TMCN2 (female) J TC1 (female) 1 with Resistance Min. 1M
chassis ground
4
troller
Between J ] 500 1,000
Between J chassis ground Min. 1M
Circuit diagram related to torque converter output speed sensor
20-550 D475A-3
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)
E01 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 2 200
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) 2 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
D475A-3 20-551
ERROR CODE ERROR
DW55KACODE
(BLADE PITCH BACK
DW55KA SOLENOID:
(BLADE DISCONNECTION
PITCH BACK SOLENOID:
DISCONNECTION (KA))
ERROR CODE DW55KA (BLADE PITCH BACK SOLENOID: DISCONNECTION (KA))
Action code Error code Blade pitch back solenoid: Disconnection (KA)
Trouble
CALL E03 DW55KA (Transmission controller system)
Contents of
When signal is output to blade pitch back solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to blade pitch back solenoid circuit.
controller
Problem that
appears on Blade pitch back mechanism does not work.
machine
Output (ON OFF) to blade pitch back solenoid can be checked in monitoring mode.]
Related
(Code 90001: transmission controller ON OFF output 3.4)
information
Method of reproducing error code: Turn starting switch ON and perform blade pitch back operation.

Defective blade pitch back without turning starting switch ON.
1 solenoid (Internal short cir-
PPB (male) Resistance
cuit)
Between 1 2 20 60
ness (Disconnection in wir- Wiring harness between TMCN3 (female) P
2 Resistance Max. 1
Possible causes ing or defective contact in PPB (female) 1
and standard connector) Wiring harness between TMCN3 (female) M
Resistance Max. 1
value in normal PPB (female) 2
(Contact with 24V circuit) TMCN3 (female) P PPB (female) 1 with Voltage Max. 1V
chassis ground
4
troller TMCN3 (female) Resistance
Between P M 20 60
Circuit diagram related to blade pitch back solenoid
20-552 D475A-3
ERROR CODEERROR
DW55KB (BLADE
CODE PITCH (BLADE
DW55KB BACK SOLENOID: SHORT
PITCH BACK CIRCUIT
SOLENOID:
DISCONNECTION (KB))
ERROR CODE DW55KB (BLADE PITCH BACK SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Blade pitch back solenoid: Short circuit (KB)
Trouble
CALL E03 DW55KB (Transmission controller system)
Contents of
When signal is output to blade pitch back solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to blade pitch back solenoid circuit.
controller
Problem that
appears on Blade pitch back mechanism does not work.
machine
Output to blade pitch back solenoid can be checked in monitoring mode.
Related
(Code 90001: Transmission controller ON-OFF output 4)
information
Method of reproducing error code: Turn starting switch ON and perform blade pitch back operation.

Defective blade pitch back without turning starting switch ON.
1 solenoid (Internal short cir- PPB (male) Resistance
cuit) Between 1 2 20 60
value in normal 2 ground in wiring harness Short circuit of wiring harness between
state (Contact with ground circuit) TMCN3 (female) P PPB (female) 1 with Resistance Min. 1M
chassis ground
3
troller
Between P M 20 60
Between P chassis ground Min. 1M
Circuit diagram related to blade pitch back solenoid
D475A-3 20-553
ERROR CODE ERROR
DW56KACODE
(BLADE PITCH DUMP
DW56KA SOLENOID:
(BLADE DISCONNECTION
PITCH DUMP SOLENOID:
DISCONNECTION (KA))
ERROR CODE DW56KA (BLADE PITCH DUMP SOLENOID: DISCONNECTION (KA))
Action code Error code Blade pitch dump solenoid: Disconnection (KA)
Trouble
E03 DW56KA (Transmission controller system)
Contents of
When signal is output to blade pitch dump solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to blade pitch dump solenoid circuit.
controller
Problem that
appears on Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
machine
Output (ON OFF) to blade pitch dump solenoid can be checked in monitoring mode.
Related
(Code 90001: Transmission controller ON OFF output 4)
information
Method of reproducing service code: Turn starting switch ON and perform blade pitch dump operation.

Defective blade pitch dump without turning starting switch ON.
PPD (male) Resistance
cuit)
Between 1 2 20 60
ness (Disconnection in wir- Wiring harness between TMCN3 (female) F
2 Resistance Max. 1
Possible causes ing or defective contact in PPD (female) 1
Resistance Max. 1
value in normal PPD (female) 2
(Contact with 24V circuit) TMCN3 (female) F PPD (female) 1 with Voltage Max. 1V
chassis ground
4
Between F M 10 40
Circuit diagram related to blade pitch dump solenoid
20-554 D475A-3
ERROR CODEERROR CODE
DW56KB DW56KB
(BLADE PITCH (BLADE PITCH DUMP
DUMP SOLENOID: SOLENOID:
SHORT CIRCUIT
TROUBLESHOOTING SHORT CIRCUIT (KB))
(KB))
ERROR CODE DW56KB (BLADE PITCH DUMP SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Blade pitch dump solenoid: Short circuit (KB)
Trouble
Contents of
When signal is output to blade pitch dump solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to blade pitch dump solenoid circuit.
controller
Problem that
appears on Blade pitch dump mechanism does not work (When it is operated, single tilt mechanism works).
machine
Output (ON OFF) to blade pitch dump selector solenoid can be checked in monitoring mode.
Related
information
Method of reproducing error code: Turn starting switch ON and perform blade pitch dump operation.

1 solenoid (Internal short cir- PPD (male) Resistance
state (Contact with ground circuit) TMCN3 (female) F PPD (female) 1 with Resistance Min. 1M
chassis ground
3
troller
Between F M 20 60
Between F chassis ground Min. 1M
Circuit diagram related to blade pitch dump solenoid
D475A-3 20-555
TROUBLESHOOTING ERROR CODE DW57KA (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA))
ERROR CODE DW57KA (LEFT TILT LIMIT SOLENOID: DISCONNECTION (KA))
Action code Error code Left tilt limit solenoid: Disconnection (KA)
Trouble
Contents of
When signal is output to left tilt limit solenoid circuit, any current does not flow.
trouble
controller Stops outputting to left tilt limit solenoid circuit.
Problem that
Blade pitch back mechanism does not work.
appears on
Left tilt limit function does not operate.
machine
Output (Current) to left tilt limit solenoid can be checked in monitoring mode.
Related
information
Method of reproducing service code: Turn starting switch ON and perform dual tilt mode.

Defective left tilt limit sole- without turning starting switch ON.
1
noid (Internal short circuit) TLL (male) Resistance
Between 1 2 20 60
ness (Disconnection in wir- Wiring harness between TMCN3 (female) Q
2 Resistance Max. 1
Possible causes ing or defective contact in TLL (female) 1
Resistance Max. 1
value in normal TLL (female) 2
(Contact with 24V circuit) TMCN3 (female) Q TLL (female) 1 with Voltage Max. 1V
chassis ground
4
Between Q M 20 60
Circuit diagram related to left tilt limit solenoid
20-556 D475A-3
ERROR CODE DW57KB (LEFT TILT LIMIT SOLENOID:
TROUBLESHOOTING ERROR CODE DW57KB (LEFT TILT LIMIT SOLENOID:SHORT
SHORTCIRCUIT
CIRCUIT (KB))
(KB))
ERROR CODE DW57KB (LEFT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Left tilt limit solenoid: Short circuit (KB)
Trouble
E02 DW57KB (Transmission controller system)
Contents of
When signal was output to left tilt limit solenoid circuit, abnormal current flowed.
trouble
controller Stops outputting to left tilt limit solenoid circuit.
Problem that
appears on
Left tilt limit function does not operate.
machine
Output (ON OFF) to left tilt limit solenoid can be checked in monitoring mode.
Related
(Code 90000: Transmission controller ON-OFF output.)
information

Defective left tilt limit sole- TLL (male) Resistance
1
noid (Internal short circuit)
Between 1 2 20 60
state (Contact with ground circuit) TMCN3 (female) Q TLL (female) 1 with Resistance Min. 1M
chassis ground
3
troller
Between Q M 20 60
Between Q chassis ground Min. 1M
Circuit diagram related to left tilt limit solenoid
D475A-3 20-557
ERROR CODE ERROR
DW58KACODE
(RIGHT TILT LIMIT
DW58KA SOLENOID:
(RIGHT DISCONNECTION
TILT LIMIT SOLENOID:
DISCONNECTION (KA))
ERROR CODE DW58KA (RIGHT TILT LIMIT SOLENOID: DISCONNECTION (KA))
Action code Error code Right tilt limit solenoid: Disconnection (KA)
Trouble
Contents of
When signal is output to right tilt limit solenoid circuit, any current does not flow.
trouble
controller Stops outputting to right tilt limit solenoid circuit.
Problem that
appears on
Right tilt limit function does not operate.
machine
Output (ON OFF) to right tilt limit solenoid can be checked in monitoring mode.
Related
(Code 90000: Transmission controller ON OFF output 3.)
information

Defective right tilt limit sole- without turning starting switch ON.
1
noid (Internal short circuit) TLR (male) Resistance
Between 1 2 20 60
ness (Disconnection in wir- Wiring harness between TMCN3 (female) [
2 Resistance Max. 1
Possible causes ing or defective contact in TLR (female) 1
Resistance Max. 1
value in normal TLR (female) 2
(Contact with 24V circuit) TMCN3 (female) [ TLR (female) 1 with Voltage Max. 1V
chassis ground
4
Between [ M 20 60
Circuit diagram related to right tilt limit solenoid
20-558 D475A-3
TROUBLESHOOTING ERROR CODE DW58KB (RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DW58KB (RIGHT TILT LIMIT SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Right tilt limit solenoid: Short circuit (KB)
Trouble
E02 DW58KB (Transmission controller system)
Contents of
When signal was output to right tilt limit solenoid circuit, abnormal current flowed.
trouble
controller Stops outputting to right tilt limit solenoid circuit.
Problem that
Blade pitch dump mechanism does not work.
appears on
Right tilt limit function does not operate.
machine
Output (ON OFF) to right tilt limit solenoid can be checked in monitoring mode.
Related
(Code 90000: Transmission controller ON OFF output.)
information

Defective Right tilt limit sole- TLR (male) Resistance
1
Between 1 2 20 60
state (Contact with ground circuit) TMCN3 (female)[ TLR (female) 1 with Resistance Min. 1M
chassis ground
3
troller
Between [ M 20 60
Between [ chassis ground Min. 1M
Circuit diagram related to right tilt limit solenoid
D475A-3 20-559
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
Blade pitch back mechanism does not work (When it is operated, pitch back mechanism works).
appears on
Left dual tilt does not work (Single tilt works when dual tilt is operated)
machine
Output (ON OFF) 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 back operation.

Defective blade pitch selec- without turning starting switch ON.
1 tor solenoid (Internal short
PST (male) Resistance
circuit)
Between 1 2 10 40
ness (Disconnection in wir- Wiring harness between TMCN3 (female) R
2 Resistance Max. 1
Possible causes ing or defective contact in PST (female) 1
and standard connector) Wiring harness between TMCN3 (female) 3
Resistance Max. 1
value in normal PST (female) 2
(Contact with 24V circuit) TMCN3 (female) R PST (female) 1 with Voltage Max. 1V
chassis ground
4
Between R 3 10 40
Circuit diagram related to blade pitch selector solenoid
20-560 D475A-3
ERROR CODECODE
ERROR DW5AKB (BLADE
DW5AKB PITCHPITCH
(BLADE SELECTOR SOLENOID:
SELECTOR SHORT
SOLENOID:
SHORT CIRCUIT (KB))
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
Blade pitch back mechanism does not work (When it is operated, pitch back mechanism works).
appears on
Left dual tilt does not work.
machine
Output (ON OFF) 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 back operation.

Defective blade pitch selec- without turning starting switch ON.
1 tor solenoid (Internal short PST (male) Resistance
circuit) Between 1 2 10 40
state (Contact with ground circuit) TMCN3 (female) R PST (female) 1 with Resistance Min. 1M
chassis ground
3
troller
Between R 3 10 40
Between R chassis ground Min. 1M
Circuit diagram related to blade pitch selector solenoid
D475A-3 20-561
TROUBLESHOOTING ERROR CODE DW5JKA (BLADE PITCH SOLENOID: DISCONNECTION (KA))
ERROR CODE DW5JKA (BLADE PITCH SOLENOID: DISCONNECTION (KA))
Action code Error code Blade pitch solenoid: Disconnection (KA)

Trouble
CALL E03 DW5JKA (Transmission controller system)
Contents of
When signal is output to blade pitch solenoid circuit, any current does not flow.
trouble
controller Stops outputting to blade pitch solenoid circuit.
Problem that
Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
appears on
Dual tilt does not work (Single tilt works when dual tilt is operated).
machine
Output (Current) to blade pitch 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 sole- without turning starting switch ON.
1
noid (Internal short circuit) PIT (male) Resistance
Between 1 2 10 40
ness (Disconnection in wir- Wiring harness between TMCN3 (female) 6
2 Resistance Max. 1
Possible causes ing or defective contact in PIT (female) 1
and standard connector) Wiring harness between TMCN3 (female) C
Resistance Max. 1
value in normal PIT (female) 2
(Contact with 24V circuit) TMCN3 (female) 6 PIT (female) 1 with Voltage Max. 1V
chassis ground
4
Between 6 C 10 40
Circuit diagram related to blade pitch solenoid
20-562 D475A-3
TROUBLESHOOTING ERROR CODE DW5JKB (BLADE PITCH SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DW5JKB (BLADE PITCH SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Blade pitch solenoid: Short circuit (KB)
Trouble
CALL E03 DW5JKB (Transmission controller system)
Contents of
When signal was output to blade pitch solenoid circuit, abnormal current flowed.
trouble
controller Stops outputting to blade pitch solenoid circuit.
Problem that
Blade pitch mechanism does not work (When it is operated, blade tilt mechanism works).
appears on
Dual tilt does not work (Single tilt works when dual tilt is operated).
machine
Output (ON OFF) to blade pitch solenoid can be checked in monitoring mode.
Related
information

Defective blade pitch sole- PIT (male) Resistance
1
Between 1 2 10 40
state (Contact with ground circuit) TMCN3 (female) 6 PIT (female) 1 with Resistance Min. 1M
chassis ground
3
troller
Between 6 C 10 40
Circuit diagram related to blade pitch solenoid
D475A-3 20-563
ERROR CODE DW5LKA (BLADE PITCH DUMP ASSIST SOLENOID:
ERROR CODE DW5LKA (BLADE PITCH DUMP ASSIST SOLENOID: DISCONNECTION (KA))
Action code Error code Blade pitch dump assist solenoid: Disconnection (KA)
Trouble
CALL E03 DW5LKA (Transmission controller system)
Contents of
When signal is output to blade pitch dump assist solenoid circuit, any current does not flow.
trouble
controller Stops outputting to blade pitch dump assist solenoid circuit.
Problem that
Blade pitch dump mechanism does not work (When it is operated, blade tilt mechanism works).
appears on
Right dual tilt does not work
machine
Output (ON OFF) to blade pitch dump assist solenoid can be checked in monitoring mode.
Related
information

1 assist solenoid (Internal
PDA (male) Resistance
short circuit)
Between 1 2 10 40
ness (Disconnection in wir- Wiring harness between TMCN3 (female) G
2 Resistance Max. 1
Possible causes ing or defective contact in PDA (female) 1
Resistance Max. 1
value in normal PDA (female) 2
(Contact with 24V circuit) TMCN3 (female) G PDA (female) 1 with Voltage Max. 1V
chassis ground
4
Between G M 10 40
Circuit diagram related to blade pitch dump assist solenoid
20-564 D475A-3
ERROR CODE
ERROR DW5LKB
CODE (BLADE
DW5LKB PITCHPITCH
(BLADE DUMPDUMP
ASSISTASSIST
SOLENOID: SHORT
SOLENOID:
TROUBLESHOOTING
SHORT CIRCUIT (KB))
ERROR CODE DW5LKB (BLADE PITCH DUMP ASSIST SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Blade pitch dump assist solenoid: Short circuit (KB)
Trouble
CALL E03 DW5LKB (Transmission controller system)
Contents of
When signal was output to blade pitch dump assist solenoid circuit, abnormal current flowed.
trouble
controller Stops outputting to blade pitch dump assist solenoid circuit.
Problem that
Blade pitch dump mechanism does not work (When it is operated, blade tilt mechanism works).
appears on
Right dual tilt does not work
machine
Output (ON OFF) to blade pitch dump assist solenoid can be checked in monitoring mode.
Related
information

1 assist solenoid (Internal PDA (male) Resistance
short circuit) Between 1 2 10 40
state (Contact with ground circuit) TMCN3 (female) G PDA (female) 1 with Resistance Min. 1M
chassis ground
3
troller
Between G M 10 40
Between G chassis ground Min. 1M
Circuit diagram related to blade pitch dump assist solenoid
D475A-3 20-565
TROUBLESHOOTING ERROR CODE DW98KA (UNLOAD SOLENOID: DISCONNECTION (KA))
ERROR CODE DW98KA (UNLOAD SOLENOID: DISCONNECTION (KA))
Action code Error code Unload solenoid: Disconnection (KA)

Trouble
CALL E03 DW98KA (Transmission controller system)
Contents of
When signal is output to unload solenoid circuit, any current does not flow.
trouble
controller Stops outputting to unload solenoid circuit.
Problem that
Blade lift speed is slow
appears on
Ripper speed is slow
machine
Output (Current) to unload solenoid can be checked in monitoring mode.
Related
information
Method of reproducing service code: Turn starting switch ON and perform blade lift full operation.

Defective unload solenoid without turning starting switch ON.
1
(Internal short circuit) UNL (male) Resistance
Between 1 2 40 80
2 Resistance Max. 1
Possible causes ing or defective contact in UNL (female) 1
Resistance Max. 1
value in normal UNL (female) 2
(Contact with 24V circuit) TMCN3 (female) 7 UNL (female) 1 with Voltage Max. 1V
chassis ground
4
Between 7 M 40 80
Circuit diagram related to unload solenoid
20-566 D475A-3
TROUBLESHOOTING ERROR CODE DW98KB (UNLOAD SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DW98KB (UNLOAD SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Unload solenoid: Short circuit (KB)

Trouble
Contents of
When signal was output to unload solenoid circuit, abnormal current flowed.
trouble
controller Stops outputting to unload solenoid circuit.
Problem that
Blade lift speed is slow
appears on
Ripper speed is slow
machine
Output (ON OFF) to unload solenoid can be checked in monitoring mode.
Related
information
Method of reproducing service code: Turn starting switch ON and perform blade lift full operation.

Defective unload solenoid UNL (male) Resistance
1
(Internal short circuit)
Between 1 2 40 80
state (Contact with ground circuit) TMCN3 (female) 7 UNL (female) 1 with Resistance Min. 1M
chassis ground
3
troller
Between 7 M 40 80
Circuit diagram related to unload solenoid
D475A-3 20-567
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 25
2 Resistance Max. 1
Possible causes ing or defective contact in STB (female) 1
and standard connector) Wiring harness between STCN3 (female) C
Resistance Max. 1
value in normal STB (female) 2
(Contact with 24V circuit) (female) 7 STB (female) 1 with chassis Voltage Max. 1V
ground
STCN3 Resistance
Between 7 C 5 25
Circuit diagram related to sudden stop prevention solenoid
20-568 D475A-3
ERROR CODE
ERROR DWN3KB
CODE (SUDDEN
DWN3KB STOP STOP
(SUDDEN PREVENTION SOLENOID:
PREVENTION SHORT
SOLENOID:
SHORT CIRCUIT (KB))
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
Possible causes (Contact with ground circuit) (female) 7 STB (female) 1 with chassis Resistance Min. 1M
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. 1M
ness between CN3 (female) C STB (female)
2
4 Defective steering controller STCN3 Resistance
Between 7 C 5 25
Circuit diagram related to sudden stop prevention solenoid
D475A-3 20-569
TROUBLESHOOTING ERROR CODE DXH1KA (LOCK-UP SOLENOID: DISCONNECTION (KA))
ERROR CODE DXH1KA (LOCK-UP SOLENOID: DISCONNECTION (KA))
Action code Error code Lock-up solenoid: Disconnection (KA)

Trouble
E01 DXH1KA (Transmission controller system)
Contents of
When signal is output to torque converter lock-up solenoid circuit, any current does not flow.
trouble
Action of
Stops outputting to torque converter lock-up solenoid circuit.
controller
Problem that
appears on Torque converter is not locked-up.
machine
Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode.
Related
(Code 31627: Torque converter lock-up solenoid drive current)
information
Method of reproducing service code: Start engine and turn lock-up switch ON and drive machine.

Defective torque converter without turning starting switch ON.
1 lock-up solenoid (Internal
653 (male) Resistance
short circuit)
Between 1 2 40 80
ness (Disconnection in wir- Wiring harness between TMCN3 (female) \
2 Resistance Max. 1
Possible causes ing or defective contact in 653 (female) 1
Resistance Max. 1
value in normal 653 (female) 2
(Contact with 24V circuit) TMCN3 (female) \ 653 (female) 1 with Voltage Max. 1V
chassis ground
4
Between \ M 40 80
Circuit diagram related to torque converter lock-up solenoid
20-570 D475A-3
TROUBLESHOOTING ERROR CODE DXH1KB (LOCK-UP SOLENOID: SHORT CIRCUIT (KB))
ERROR CODE DXH1KB (LOCK-UP SOLENOID: SHORT CIRCUIT (KB))
Action code Error code Torque converter lock-up solenoid: Short circuit (KB)
Trouble
E01 DXH1KB (Transmission controller system)
Contents of
When signal was output to torque converter lock-up solenoid circuit, abnormal current flowed.
trouble
Action of
Stops outputting to torque converter lock-up solenoid circuit.
controller
Problem that
appears on Torque converter is not locked-up.
machine
Output (Current) to torque converter lock-up solenoid can be checked in monitoring mode.
Related
(Code 31627: Torque converter lock-up solenoid drive current)
information
Method of reproducing service code: Start engine and turn lock-up switch ON and drive machine.

Defective torque converter without turning starting switch ON.
1 lock-up solenoid (Internal 653 (male) Resistance
Possible causes (Contact with ground circuit) TMCN3 (female) \ 653 (female) 1 with Resistance Min. 1M
and standard chassis ground
Short circuit in wiring harness between TMCN3
3 ness (with another wiring
harness) (female) \ 653 (female) 1 with wiring har-
Resistance Min. 1M
ness between TMCN3 (female) M 653 (fe-
male) 2
Defective transmission con- TMCN3 Resistance
4
troller
Between \ M 40 80
Between \ chassis ground Min. 1M
Circuit diagram related to torque converter lock-up solenoid
D475A-3 20-571
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) S1T7 (male) Resistance
Between 1 2 5 25
ness (Disconnection in wir- Wiring harness between TMCN3 (female) E
2 Resistance Max. 1
Possible causes ing or defective contact in S1T7 (female) 1
Resistance Max. 1
value in normal S1T7 (female) 2
(Contact with 24V circuit) TMCN3 (female) E S1T7 (female) 1 with Voltage Max. 1V
chassis ground
Defective transmission con- without turning starting switch ON.
4
Between E 3 5 25
20-572 D475A-3
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- S1T7 (male) Resistance
1
Between 1 2 5 25
Possible causes (Contact with ground circuit) TMCN3 (female) E S1T7 (female) 1 with Resistance Min. 1M
3 ness (with another wiring Short circuit in wiring harness between TMCN3
(female) E S1T7 (female) 1 with wiring har-
ness between TMCN3 (female) 3 S1T7 (fe-
male) 2
4
troller
Between E 3 5 25
Between E chassis ground Min. 1M
D475A-3 20-573
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 25
ness (Disconnection in wir- Wiring harness between TMCN3 (female) Z
2 Resistance Max. 1
Resistance Max. 1
(Contact with 24V circuit) TMCN3 (female) Z S2T5 (female) 1 with Voltage Max. 1V
chassis ground
4
Between Z C 5 25
20-574 D475A-3
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- S2T5 (male) Resistance
1
Between 1 2 5 25
Possible causes (Contact with ground circuit) TMCN3 (female) Z S2T5 (female) 1 with Resistance Min. 1M
(female) Z S2T5 (female) 1 with wiring har-
ness between TMCN3 (female) C S2T5 (fe-
male) 2
4
troller
Between Z C 5 25
Between Z chassis ground Min. 1M
D475A-3 20-575
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 25
2 Resistance Max. 1
Resistance Max. 1
(Contact with 24V circuit) TMCN3 (female) 5 S3T3 (female) 1 with Voltage Max. 1V
chassis ground
4
Between 5 3 5 25
20-576 D475A-3
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- S3T3 (male) Resistance
1
Between 1 2 5 25
Possible causes (Contact with ground circuit) TMCN3 (female) 5 S3T3 (female) 1 with Resistance Min. 1M
(female) 5 S3T3 (female) 1 with wiring har-
ness between TMCN3 (female) 3 S3T3 (fe-
male) 2
4
troller
Between 5 3 5 25
D475A-3 20-577
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) SRT1 (male) Resistance
Between 1 2 5 25
ness (Disconnection in wir- Wiring harness between TMCN3 (female) O
2 Resistance Max. 1
Possible causes ing or defective contact in SRT1 (female) 1
Resistance Max. 1
value in normal SRT1 (female) 2
(Contact with 24V circuit) TMCN3 (female) O SRT1 (female) 1 with Voltage Max. 1V
chassis ground
4
Between O C 5 25
20-578 D475A-3
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- SRT1 (male) Resistance
1
lenoid (Internal short circuit)
Between 1 2 5 25
Possible causes (Contact with ground circuit) TMCN3 (female) O SRT1 (female) 1 with Resistance Min. 1M
(female) O SRT1 (female) 1 with wiring har-
ness between TMCN3 (female) C SRT1 (fe-
male) 2
4
troller
Between O C 5 25
Between O chassis ground Min. 1M
D475A-3 20-579
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) SFT1 (male) Resistance
Between 1 2 5 25
ness (Disconnection in wir- Wiring harness between TMCN3 (female) Y
2 Resistance Max. 1
Possible causes ing or defective contact in SFT1 (female) 1
Resistance Max. 1
value in normal SFT1 (female) 2
(Contact with 24V circuit) TMCN3 (female) Y SFT1 (female) 1 with Voltage Max. 1V
chassis ground
4
Between Y C 5 25
20-580 D475A-3
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- SFT1 (male) Resistance
1
lenoid (Internal short circuit)
Between 1 2 5 25
Possible causes (Contact with ground circuit) TMCN3 (female) Y SFT1 (female) 1 with Resistance Min. 1M
(female) Y SFT1 (female) 1 with wiring har-
ness between TMCN3 (female) C SFT1 (fe-
male) 2
4
troller
Between Y C 5 25
Between Y chassis ground Min. 1M
D475A-3 20-581
ERROR CODE DXH9KA (RIGHT STEERING CLUTCH ECMV :
ERROR CODE DXH9KA (RIGHT STEERING CLUTCH ECMV : DISCONNECTION (KA))
Action code Error code Disconnection in right steering clutch ECMV (KA)
Trouble
CALL E03 DXH9KA (Steering controller system)
Contents of trouble When signal is output to right steering clutch solenoid circuit, current does not flow.
Action of controller Stops outputting to right steering clutch solenoid circuit.
Machine cannot be steered to right.
Problem that
appears on machine
Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
(Code 90603, 90601: Right steering clutch ECMV output current)
Related information
Method of reproducing error code:
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).

Defective right steering without turning starting switch ON.
1 clutch solenoid
SRC7 (male) Resistance
Between 1 2 5 25
ness
2 (Disconnection in wiring or Wiring harness between STCN3 (female) Y Resistance Max. 1
SRC7 (female) 1
Possible causes defective contact in connec-
and standard val- tor) Wiring harness between STCN3 (female) M
Resistance Max. 1
ue in normal state SRC7 (female) 2
(Contact with 24 V circuit) STCN3 (female) Y SRC7 (female) 1 with Voltage Max. 1 V
chassis ground
STCN3 (female) Resistance
Between Y M 5 25
20-582 D475A-3
ERROR CODEERROR
DXH9KB (RIGHT
CODE STEERING
DXH9KB CLUTCH
(RIGHT ECMV: CLUTCH
STEERING SHORT CIRCUIT
ECMV:
SHORT CIRCUIT (KB))
ERROR CODE DXH9KB (RIGHT STEERING CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code Error code Short circuit in right steering clutch ECMV (KB)
Trouble
CALL03 DXH9KB (Steering controller system)
Contents of trouble When signal was output to right steering clutch solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to right steering clutch solenoid circuit.
Machine cannot be steered to right.
Problem that
appears on machine
Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
(Code 90603, 90601: Right steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).

Defective right steering
1 clutch solenoid SRC7 (male) Resistance
(Internal short circuit) Between 1 2 5 25
Between 1 chassis ground Min. 1 M
(Contact with ground circuit) STCN3 (female) Y SRC7 (female) 1 with Resistance Min. 1 M
Possible causes
chassis ground
and standard val-
ue in normal state + Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring har- without turning starting switch ON.
ness Short circuit of wiring harness between
3
(with another wiring har- STCN3 (female) Y SRC7 (female) 1 with
ness) Resistance Min. 1 M
wiring harness between STCN3 (female) M
SRC7 (female) 2
Between Y M 5 25
Between Y chassis ground Min. 1 M
D475A-3 20-583
ERROR CODE ERROR
DXHAKACODE
(LEFTDXHAKA
STEERING(LEFT
CLUTCH ECMV : DISCONNECTION
STEERING CLUTCH ECMV :
DISCONNECTION (KA))
ERROR CODE DXHAKA (LEFT STEERING CLUTCH ECMV : DISCONNECTION (KA))
Action code Service code Disconnection in left steering clutch ECMV (KA)
Trouble
CALL E03 DXHAKA (Steering controller system)
Contents of trouble When signal is output to left steering clutch solenoid circuit, current does not flow.
Action of controller Stops outputting to left steering clutch solenoid circuit.
Machine cannot be steered to left.
Problem that
appears on machine
Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
(Code 90602, 90600: Left steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).

Defective left steering clutch without turning starting switch ON.
1 solenoid
SLC5 (male) Resistance
Between 1 2 5 25
ness
2 (Disconnection in wiring or Wiring harness between STCN3 (female) O Resistance Max. 1
SLC5 (female) 1
Possible causes defective contact in connec-
and standard val- tor) Wiring harness between STCN3 (female) M
Resistance Max. 1
ue in normal state SLC5 (female) 2
(Contact with 24 V circuit) STCN3 (female) O SLC5 (female) 1 with Voltage Max. 1 V
chassis ground
Between O M 5 25
20-584 D475A-3
ERROR CODEERROR
DXHAKB (LEFT
CODE STEERING
DXHAKB CLUTCH
(LEFT ECMV :CLUTCH
STEERING SHORT CIRCUIT
ECMV :
SHORT CIRCUIT (KB))
ERROR CODE DXHAKB (LEFT STEERING CLUTCH ECMV : SHORT CIRCUIT (KB))
User code Service code Short circuit in left steering clutch ECMV (KB)
Trouble
CALL E03 DXHAKB (Steering controller system)
Contents of trouble When signal was output to left steering clutch solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to left steering clutch solenoid circuit.
Machine cannot be steered to left.
Problem that
appears on machine
Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
(Code 90602, 90600: Left steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).

1 solenoid SLC5 (male) Resistance
(Internal short circuit) Between 1 2 5 25
Between 1 chassis ground Min. 1 M
(Contact with ground circuit) STCN3 (female) O SLC5 (female) 1 with Resistance Min. 1 M
Possible causes
chassis ground
and standard val-
ue in normal state + Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring har- without turning starting switch ON.
ness Short circuit of wiring harness between
3
(with another wiring har- STCN3 (female) O SLC5 (female) 1 with
ness) Resistance Min. 1 M
wiring harness between STCN3 (female) M
SLC5 (female) 2
Between O M 5 25
Between O chassis ground Min. 1 M
D475A-3 20-585
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
SRB3 (male) Resistance
short circuit)
Between 1 2 5 25
ness (Disconnection in wir- Wiring harness between STCN3 (female) E
2 Resistance Max. 1
Possible causes ing or defective contact in SRB3 (female) 1
Resistance Max. 1
value in normal SRB3 (female) 2
(Contact with 24V circuit) (female) E SRB3 (female) 1 with chassis Voltage Max. 1V
ground
Between E C 5 25
20-586 D475A-3
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 SRB3 (male) Resistance
Possible causes (Contact with ground circuit) (female) E SRB3 (female) 1 with chassis Resistance Min. 1M
and standard ground
3 ness (with another wiring Short circuit in wiring harness between STCN3
(female) E SRB3 (female) 1 with wiring har-
ness between STCN3 (female) C SRB3 (fe-
male) 2
Between E C 5 25
Between E chassis ground Min. 1M
D475A-3 20-587
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.
SLB1 (male) Resistance
cuit)
Between 1 2 5 25
2 Resistance Max. 1
Possible causes ing or defective contact in SLB1 (female) 1
Resistance Max. 1
value in normal SLB1 (female) 2
(Contact with 24V circuit) (female) 5 SLB1 (female) 1 with chassis Voltage Max. 1V
ground
Between 5 C 5 25
20-588 D475A-3
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- SLB1 (male) Resistance
Possible causes (Contact with ground circuit) (female) 5 SLB1 (female) 1 with chassis Resistance Min. 1M
and standard ground
3 ness (with another wiring Short circuit in wiring harness between STCN3
(female) 5 SLB1 (female) 1 with wiring har-
ness between STCN3 (female) C SLB1 (fe-
male) 2
Between 5 C 5 25
D475A-3 20-589
TROUBLESHOOTING DXHDKA
ERROR CODE [DXHDKA] (GOVERNOR SOLNOID RIGHT: DISCONNECTION (KA))
Action code Error code Governor solenoid right: Disconnection (KA)

Trouble
CALL E04 DXHDKA (Engine controller system)
Contents of
The output current to the right bank governor solenoid is below 0.1 A.
trouble
Action of
controller
Problem that
machine
Related
information

Defective right bank
E15 (male) Resistance
1 governor solenoid
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes 2 Resistance Max. 1 z
and standard
contact in connector) Wiring harness between LE2 (female) (17) and
value in normal Resistance Max. 1 z
state E15 (female) (2)
LE2 (female) Resistance
Between (7) and (17) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to right bank governor solenoid
20-589-1 D475A-3
(1)
TROUBLESHOOTING DXHDKB
ERROR CODE [DXHDKB] (GOVERNOR SOLNOID RIGHT: SHORT CIRCUIT (KB))
Action code Error code Governor solenoid right: Short circuit (KB)
Trouble
CALL E04 DXHDKB (Engine controller system)
Contents of
The output current to the right bank governor solenoid is above 2.1 A.
trouble
Action of
controller
Problem that
machine
Related
information

1 governor solenoid
Min. 1 Mz
chassis ground
Possible causes Resistance Min. 1 Mz
and standard
value in normal aPrepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
3 source in wiring harness Voltage Max. 1 V
Voltage Max. 1 V
Between (7) and (17) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to right bank governor solenoid
D475A-3 20-589-2
(1)
TROUBLESHOOTING DXHEKA
ERROR CODE [DXHEKA] (GOVERNOR SOLNOID LEFT: DISCONNECTION (KA))
Action code Error code Governor solenoid left: Disconnection (KA)

Trouble
CALL E04 DXHEKA (Engine controller system)
Contents of
The output current to the left bank governor solenoid is below 0.1 A.
trouble
Action of
controller
Problem that
machine
Related
information

Defective left bank governor
1 solenoid
Min. 1 Mz
chassis ground
and standard
state E11 (female) (2)
Between (8) and (18) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to left bank governor solenoid
20-589-3 D475A-3
(1)
TROUBLESHOOTING DXHEKB
ERROR CODE [DXHEKB] (GOVERNOR SOLNOID LEFT: SHORT CIRCUIT (KB))
Action code Error code Governor solenoid left: Short circuit (KB)
Trouble
CALL E04 DXHEKB (Engine controller system)
Contents of
The output current to the left bank governor solenoid is above 2.1 A.
trouble
Action of
controller
Problem that
machine
Related
information

Defective left bank governor
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard aPrepare with starting switch OFF, then turn starting switch ON and
state Between wiring harness between LE2 (female)
(8) and E11 (female) (1) and short circuit or
short circuit with chassis ground in wiring
between
Voltage Max. 1 V
Between (8) and (18) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to left bank governor solenoid
D475A-3 20-589-4
(1)
TROUBLESHOOTING DXHFKA
ERROR CODE [DXHFKA] (PRE-STROKE SOLENOID RIGHT: DISCONNECTION (KA))
Action code Error code Pre-stroke solenoid right: Disconnection (KA)

Trouble
CALL E03 DXHFKA (Engine controller system)
Contents of
The output current deviation to the right bank pre-stroke solenoid is above 0.2 A.
trouble
controller Reduces the engine output by 20%.
Problem that
appears on The output is reduced.
machine
Related
information

1 pre-stroke solenoid
(Internal disconnection) Between (A) and (B) 10 21 z
Between (A), (B) and
Min. 1 Mz
chassis ground
wiring harness or defective E14 (female) (A)
and standard
state E14 (female) (B)
(9) and E14 (female) (B) and chassis ground
Between (9) and (19) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to right bank pre-stroke solenoid
20-589-5 D475A-3
(1)
TROUBLESHOOTING DXHFKB
ERROR CODE [DXHFKB] (PRE-STROKE SOLENOID RIGHT: SHORT CIRCUIT (KB))
Action code Error code Pre-stroke solenoid right: Short circuit (KB)
Trouble
CALL E03 DXHFKB (Engine controller system)
Contents of
The output current to the right bank pre-stroke solenoid is above 4 A.
trouble
Problem that
machine
Related
information

Min. 1 Mz
chassis ground
Possible causes Resistance Min. 1 Mz
(9) and E14 (female) (A) and chassis ground
and standard
value in normal aPrepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
Voltage Max. 1 V
Between (9) and (19) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to right bank pre-stroke solenoid
D475A-3 20-589-6
(1)
TROUBLESHOOTING DXHGKA
ERROR CODE [DXHGKA] (PRE-STROKE SOLENOID LEFT: DISCONNECTION (KA))
Action code Error code Pre-stroke solenoid left: Disconnection (KA)

Trouble
CALL E03 DXHGKA (Engine controller system)
Contents of
The output current deviation to the left bank pre-stroke solenoid is above 0.2 A.
trouble
Problem that
machine
Related
information

Defective left bank
Min. 1 Mz
chassis ground
wiring harness or defective E10 (female) (A)
and standard
state E10 (female) (B)
Between (10) and (20) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to left bank pre-stroke solenoid
20-589-7 D475A-3
(1)
TROUBLESHOOTING DXHGKB
ERROR CODE [DXHGKB] (PRE-STROKE SOLENOID LEFT: SHORT CIRCUIT (KB))
Action code Error code Pre-stroke solenoid left: Short circuit (KB)
Trouble
CALL E03 DXHGKB (Engine controller system)
Contents of
The output current to the left bank pre-stroke solenoid is above 4 A.
trouble
Problem that
machine
Related
information

Defective left bank
Min. 1 Mz
chassis ground
Possible causes
and standard aPrepare with starting switch OFF, then turn starting switch ON and
state Between wiring harness between LE2 (female)
(10) and E10 (female) (A) and short circuit or
short circuit with chassis ground in wiring
between
Voltage Max. 1 V
Between (10) and (20) 10 21 z
Min. 1 Mz
chassis ground
Circuit diagram related to left bank pre-stroke solenoid
D475A-3 20-589-8
(1)
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E-MODE)

E-1 The engine does not start. ................................................................................................................ 20-604
E-2 The preheater does not operate. (Manual preheating function) ........................................................ 20-606
E-3 The ripper pin puller cylinder does not operate.................................................................................. 20-608
E-4 The monitor panel does not come on at all when the starting switch is turned ON. .......................... 20-609
E-5 When the starting switch is turned ON, the monitor panel completely remains lighted and
does not go out................................................................................................................................. 20-610
E-6 When the starting switch is turned on, the basic check items flash
(The radiator water level caution lamp flashes)................................................................................ 20- 611
(The hydraulic oil temperature caution lamp flashes)....................................................................... 20-612
(The engine oil level caution lamp flashes). ..................................................................................... 20-613
E-9 While the engine is operating, any caution item flashes. ................................................................... 20-614
E-10 While the engine is operating, the emergency warning item flashes. .............................................. 20-616
E-11 While the preheater is operating, the preheating pilot lamp does not come on. .............................. 20-620
E-12 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on.
(Dual tilt-mounted machine) ............................................................................................................ 20-622
E-13 At the locking-up of the torque converter,
the torque converter lock-up display lamp does not come on. ......................................................... 20-622
E-14 The engine water temperature gauge does not indicate normally. .................................................. 20-623
E-15 Indication of the power train temperature gauge is abnormal.......................................................... 20-624
E-16 The hydraulic oil temperature gauge does not indicate normally. .................................................... 20-625
E-17 Indication of the fuel gauge is abnormal. ......................................................................................... 20-626
E-18 Indications of gear speed and engine speed are abnormal. ............................................................ 20-627
E-19 Indication of the shift mode service meter is abnormal.................................................................... 20-627
E-20 The switch module cannot be operated. .......................................................................................... 20-628
E-21 The warning lamp does not flash or does not go out. ...................................................................... 20-629
E-22 The alarm buzzer does not sound or does not stop......................................................................... 20-630
E-23 Auto shift down is not possible or is not released. ........................................................................... 20-631
E-24 The alarm buzzer cannot be cancelled. ........................................................................................... 20-632
E-25 The operator mode cannot be operated. ......................................................................................... 20-633
E-26 The service mode cannot be operated. ........................................................................................... 20-634
E-27 The back-up alarm does not sound. ................................................................................................ 20-636
E-28 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on.. 20-637
E-29 The air conditioner does not operate. .............................................................................................. 20-642
D475A-3 20-601

+ 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>
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 D475A-3
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 if the parking
lever is set to the lock position.
Related
If the monitor panel does not come on or the battery relay does not cause operating sound when
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. 1M
Between 5 and 3
START Max. 1
+ Prepare with the starting switch OFF, then turn the starting switch
to START and carry 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.
Defective alternator (inter- ON and carry out troubleshooting.
4
nal short-circuit) Alternator Voltage
Between Terminal R and ground Max. 1V
to START and carry out troubleshooting.
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 103 or 104 2
5 Max. 1V
ternal defect) and ground
Starting : between 103 or 104 1
20 30V
and ground
When the voltages of electric power supply, for charging and starting
are normal but the starting motor does not rotate, the starting motor
is defective.
Disconnection in wiring har- without turning the starting switch ON.
ness (disconnection in wir- Wiring harness between KEY (female) 3 and
6 Resistance Max. 1
ing or defective contact in NFS (female) 3
connector) Wiring harness between NSF (female) 5 and
Resistance Max. 1
103 or 104 (female) 2
ON and carry out troubleshooting.
Hot short circuit of wiring Hot short circuit of wiring harness between al-
ternator R terminal and 103 or 104(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.)
20-604 D475A-3
TROUBLESHOOTING E-1
Engine start/charge-related circuit diagram
D475A-3 20-605
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. (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 when
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
(Internal disconnection)
OFF Min. 1M
Between 5 and 2
HEAT Max. 1
+ 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
Possible causes When the both voltages of electric power supply and signal are nor-
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 without turning the starting switch ON.
Defective electrical intake
3
air heater (internal defect) Electrical intake air heater Continuity
Between terminals Continue
Wiring harness between KEY (female) 2 and
Resistance Max. 1
heater relay 137 terminal or 136 terminal
Disconnection in wiring har-
ness (Disconnection in wir- Wiring harness between RHR (female) 3 and
4 KEY (female) 2, or between RHR (female) 3 Resistance Max. 1
and 136, or between RHR (female) 3 and 137
connector)
Wiring harness between battery relay M and
starting motor, or between starting motors, or
Resistance Max. 1
between starting motor and electrical intake air
heater.
20-606 D475A-3
TROUBLESHOOTING E-2
Engine preheat-related circuit diagram
D475A-3 20-607
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
1 Defective fuse (FS4-1)
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. 1
Between 1 and 2
Press Min. 1M
Defective pin puller solenoid without turning the starting switch ON.
3 (Internal disconnection or 224 (male) Resistance
short circuit) Between 1 and 2 40 80
Between 1 and ground Min. 1M
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. 1
state ness (Disconnection in wir- (female) 1
4
ing or defective contact in Wiring harness between 263 (female) 2 and
Resistance Max. 1
connector) 224 (female) 1
Wiring harness between 224 (female) 2 and
Resistance Max. 1
ground
Ground fault of wiring har-
Between wiring harness related to FS4-1 (out-
5 ness (Contact with ground Resistance Min. 1M
let side) and ground
circuit)
Between wiring harness (between 263 (fe-
Resistance Min. 1M
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
20-608 D475A-3
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
2 Resistance Max. 1
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. 1M
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
D475A-3 20-609
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)
20-610 D475A-3
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. 405 (male) Radiator water level Resistance
(Internal disconnection) Normal level Max. 1
Between 1 and 2
Lower level Min. 1M
The sub radiator water level without turning the starting switch ON.
3 sensor is defective. DRT (male) Radiator water level Resistance
Possible causes (Internal disconnection) Normal level Max. 1
and standard Between 1 and 2
Lower level Min. 1M
value in normal
Disconnection of wiring har- Wiring harness between S03 (female) A and
Resistance Max. 1
ness (Disconnection in wir- 405 (female) 1
4
ing or defective contact in Wiring harness between 405 (female) 2 and
Resistance Max. 1
connector) DRT (female) 1
Wiring harness between DRT (female) 2 and
Resistance Max. 1
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 radiator water level sensor power supply
D475A-3 20-611
TROUBLESHOOTING E-7
Trouble The hydraulic oil temperature caution lamp flashes.

Related
information

Drop of hydraulic oil temper- A drop of hydraulic oil temperature (hydraulic oil tank) was detected,
1 ature (when the system is inspect the hydraulic oil temperatures. (The lamp flashes when the
normal) level is below the specified level.)
The main hydraulic oil tem- without turning the starting switch ON.
perature sensor is defec- HLS (male) Radiator water level Resistance
2
tive.
Between 1 and 2
Lower level Min. 1M
Possible causes Disconnection of wiring har- Wiring harness between STCN3 (female) A Resistance Max. 1
and standard ness (Disconnection in wir- and HLS(female) 1
3
value in normal ing or defective contact in Wiring harness between HLS (female) 2 and
Resistance Max. 1
state connector) LLS (female) 2
Wiring harness between LLS (female) 2 and
Resistance Max. 1
ground
Defective monitor panel STCN3 Radiator water level Voltage
4
(Gauge/lamp module)
Between A and Normal level Max. 1V
When the hydraulic oil level sensor is not installed, and when perform
Defective setting for hydrau- the adjusting mode, if the failure code(resetting display) is flashing, it
5
lic oil level sensor is normal.
Adjusting code: 9993 (hydraulic oil level display mode)
Circuit diagram related to hydraulic oil temperature electric power supply
20-612 D475A-3
TROUBLESHOOTING E-8
Trouble The engine oil level caution lamp flashes.

Related
information

A drop of engine oil level (engine oil pan) was detected, inspect the
Drop of engine oil level
1 engine oil levels. (The lamp flashes when the level is below the spec-
(when the system is normal)
ified level.)
The main engine oil level without turning the starting switch ON.
2 sensor is defective. 404 (male) Engine oil level Resistance
Between 1 and 2
Possible causes Lower level Min. 1M
and standard + Prepare with the starting switch OFF, then carry out troubleshooting
value in normal Disconnection of wiring har- without turning the starting switch ON.
state ness (Disconnection in wir- Wiring harness between S03 (female) 0 and
3 Resistance Max. 1
ing or defective contact in 404 (female) 1
connector) Wiring harness between 404 (female) 2 and
Resistance Max. 1
ground
Defective monitor panel S03 Engine oil Voltage
4
(Gauge/lamp module)
Between 0 and Normal level Max. 1V
Circuit diagram related to engine oil level electric power supply
D475A-3 20-613
TROUBLESHOOTING E-9
E-9 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

+ Prepare with the starting switch OFF, then start the engine and car-
ry out troubleshooting.
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)
Resistance Max. 1
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, 103 (fe-
Resistance Min. 1M
male) 1, 104(female) 1or TMCN2 (female)
0) and ground
4 S04 Voltage
(Gauge/lamp module)
Between 9 and Min. medium speed
20 30V
ground (half)
20-614 D475A-3
TROUBLESHOOTING E-9
Engine start/charge-related circuit diagram
D475A-3 20-615
TROUBLESHOOTING E-10
E-10 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 monitor panel through communication.
Possible causes
and standard
value in normal
state
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 switch is de- without turning the switch ON or after starting the engine.
2 fective. 403 Engine Resistance
(Internal short circuit) Between terminal and Stop Max. 1
ground Min. 600rpm Min. 1M
Ground fault of wiring har- without turning the starting switch ON.
male) B and 301 3)
4 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
20-616 D475A-3
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.

Overheated engine water As overheated engine water was detected, check the engine water
1 temperature (when the sys- temperature. (When the water temperature is over 108C, the lamp
tem is normal) flashes.)
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
The engine water tempera-
and standard
ture sensor system is defec- Water temperature
value in normal 2
tive. (Engine controller gauge
state
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) 130C, 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.)
D475A-3 20-617
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 130C,
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.)
20-618 D475A-3
Trouble (5) Air cleaner clogging caution lamp flashes.

Related When any abnormality is detected during engine operation, the relevant emergency warning item will
information sound the alarm buzzer.

Air cleaner clogging (when Check the air cleaner clogging as the drop of air cleaner clogging is
1
the system is normal) detected.
The HSS charge oil pres- without turning the switch ON or after starting the engine.
2 sure switch is defective.
AF1 (male) Resistance
(Internal disconnection)
Between 1 and 2 Max. 1
Possible causes
and standard
state ness (Disconnection in wir- Wiring harness between S03 (female) C and
3 Resistance Min. 1M
ing or defective contact in AFI (female) 1
connector) Wiring harness between AFI (female) 2 and
Resistance Min. 1M
ground
Defective monitor panel without turning the switch ON or after starting the engine.
4
(Gauge/lamp module) S03 Voltage
Between C and ground Max. 1V
Circuit diagram related to air cleaner clogging switch
D475A-3 20-619
E-11 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-
1 ness (Disconnection in wir-
ing ) Wiring harness between S03 (female) 9 and
Resistance Max. 1
heater relay
value in normal circuit) Between wiring harness between S03 (female)
Resistance Min. 1M
state 9 and ground
Defective monitor panel S03 Starting switch Voltage
3
(Gauge/lamp module)
Between 9 and ON Max. 1V
ground HEAT 20 30V
20-620 D475A-3
Engine preheat-related circuit diagram
D475A-3 20-621
E-12, E-13
E-12 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
E-13 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER

LOCK-UP DISPLAY LAMP DOES NOT COME ON.
Trouble At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on.
Before troubleshooting the torque converter, make sure that the lock-up is operating. (When the lock-
Related
up does not operate normally, the electrical system on the machine side or the hydraulic/mechanical
information
system is supposed to be out of order. So, troubleshoot the relevant system.)

and standard
(Gauge/lamp module)
state
20-622 D475A-3
E-14 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 monitor panel through com-
Related munication.
information When any abnormality occurred in the engine hot water temperature sensor system, the failure code
[DGE2KX] is displayed sometimes.

The engine water high tem- without turning the starting switch ON.
perature sensor is defec-
1 402 Resistance
tive. (Internal disconnection
Between 1 and 2 3.5k 90k
or short circuit)
Between 1 2 and ground Min. 1M
ness (Disconnection in wir- Wiring harness between S04 (female) A and
2 Resistance Max. 1
Possible causes ing or defective contact in 402 (female) 1
and standard connector) Resistance Max. 1
value in normal Wiring harness between ground and 402 2
Resistance Max. 1
state
circuit) Between wiring harness (between S04 A and
Resistance Min. 1M
402 (female) 1) and ground
circuit) Between wiring harness (between S04 (fe-
Voltage Max. 1V
male) A and 402 (female) 1) and ground
(Gauge/lamp module)
Circuit diagram related to engine water high temperature sensor
D475A-3 20-623
E-15 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 80k
10 100C
Between 1 and
Min. 1M
ground
ness (Disconnection in wir- Wiring harness between S04 (female) B and Resistance Max. 1
Possible causes 2
and standard connector) Wiring harness between 453 (female) 1 and Resistance Max. 1
value in normal
ground Resistance Max. 1
state
male) B and 453 (female) 1) and ground
male) B and 453 (female) 1) and ground
5 Defective wiring harness
453 (female) Resistance
Between 2 and ground Max. 1
Circuit diagram related to power train oil temperature sensor
20-624 D475A-3
E-16 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 SDS (male) Resistance
ternal disconnection or
Between 1 and 2 3.5k 90k
short circuit)
ness (Disconnection in wir- Wiring harness between TMCN1 (female) D
2 Resistance Max. 1
ing or defective contact in and SDS (female) 1
connector) Wiring harness between TMCN1 (female) K
Resistance Max. 1
and SDS (female) 2
Possible causes
and standard Ground fault of wiring har-
value in normal 3 ness (Contact with ground
state Between wiring harness (between TMCN1 (fe-
male) D and SDS (female) 1) and ground
Hot short circuit of wiring
Between wiring harness (between TMCN1 (fe-
male) D and SDS (female) 1) and ground
5
troller
Between D and K 3.5k 90k
Between D and ground Min. 1M
(Gauge/lamp module)
Circuit diagram related to hydraulic oil temperature sensor
D475A-3 20-625
E-17 INDICATION OF THE FUEL GAUGE IS ABNORMAL.
Trouble Indication of the fuel gauge is abnormal.

Related
information

Defective fuel level sensor. without turning the starting switch ON.
1 (Internal disconnection or 422 (male) Remained fuel level Resistance
short circuit) Between 1 and 2 Full About 4
(ground) Empty About 85
ness (Disconnection in wir- Wiring harness between S04 (female) @ and
2 Resistance Max. 1
ground
and standard
state 3 ness (Contact with ground
Resistance Min. 1M
male) @ and 422 (female) 1) and ground
Voltage Max. 1V
male) @ and 422 (female) 1) and ground
5 S04 (female) Remained fuel level Resistance
(Gauge/lamp module)
Between @ and Full About 4
ground Empty About 85
Circuit diagram related to fuel level sensor
20-626 D475A-3
E-18, E-19
E-18 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 steering
information controller through communication.

and standard
value in normal 1 This is an internal defect, which cannot be troubleshot.
E-19 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
(Gauge/lamp module)
state
D475A-3 20-627
E-20 THE SWITCH MODULE CANNOT BE OPERATED.
Trouble (1) Though the switch is used, lamps do not change.

Related
information

and standard
state (Switch module)
Trouble (2) Though the switch is used, the system setting does not change.
Related
Switch module signals are transmitted to each controller through communication.
information

Disconnection of wiring har-
ness (Disconnection in wir-
Possible causes 1 Wiring harness between S01 (female) 8 and
and standard connector) STCN2 (female) K, or TMCN2 (female) K, Resistance Max. 1
value in normal ECN4 6 and B
state + Prepare with the starting switch OFF, then start the engine and car-
Defective monitor panel ry out the troubleshooting.
Between 8 and ground 6 9V
Circuit diagram related to S-NET Communication
20-628 D475A-3
E-21 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
D475A-3 20-629
E-22 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 2 200
Possible causes ness (Disconnection in wir- Wiring harness between S03 (female) H and
3 Resistance Max. 1
and standard ing or defective contact in 217 (female) 1
value in normal connector) Wiring harness between 217 (female) 2 and
Resistance Max. 1
state CB2 outlet
circuit) Between wiring harness related to CB2 (outlet
Resistance Min. 1M
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
20-630 D475A-3
E-23 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. 1M
Between 2 and 3
ON (1) Max. 1
ness (Disconnection in wir- Wiring harness between TMCN3 (female) ]
2 Resistance Max. 1
ing or defective contact in and ASD (female) 2
Possible causes connector) Wiring harness between ADS (female) 2 and
Resistance Max. 1
and standard ground
state Ground fault of wiring har- without turning the starting switch ON.
circuit) Between wiring harness (between CN3 (fe-
Resistance Min. 1M
male) ] and ASD (female) 2) and ground
4 CN3 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
D475A-3 20-631
E-24 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. 1M
Between 1 and 2
tion or short circuit) Max. 1
OFF (0) Min. 1M
Between 1 and 3
Max. 1
Disconnection of wiring har- Wiring harness between CN2 Z and BUZ (fe-
Resistance Max. 1
ness (Disconnection in male) 2
2
wiring or defective contact Wiring harness between CN2 P and BUZ (fe-
in connector) male) 3
and standard
Wiring harness between BUZ (female) 1 and
value in normal Resistance Max. 1
ground
state
Between wiring harness (between CN2 Z and
BUZ (female) 2) and ground
circuit)
Between wiring harness (between CN2 P and
Resistance Min. 1M
BUZ (female) 3) and ground
ON and carry out the troubleshooting.
CN2 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
20-632 D475A-3
E-25 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. 1M
Between 1 and 2
connection) Max. 1
OFF (0) Min. 1M
Between 1 and 3
Max. 1
Disconnection of wiring har- Wiring harness between CN2 F and CUR (fe-
Resistance Max. 1
Possible causes ness (Disconnection in wir- male)
3
and standard ing or defective contact in Wiring harness between CN2 6 and CUR (fe-
value in normal connector) male) 3
state Wiring harness between CUR (female) 1 and
Resistance Max. 1
ground
Between wiring harness (between CN2 F and
CUR (female) 2) and ground
circuit)
Between wiring harness (between CN2 6 and
Resistance Min. 1M
CUR (female) 3) and ground
CN2 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
D475A-3 20-633
E-26 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. 1M
Between 5 and 6 ON Max. 1
Possible causes Disconnection of wiring har- Wiring harness between CB6 outlet and S24 3 Resistance Max. 1
and standard ness (Disconnection in wir- Wiring harness between S24 6 and ground Resistance Max. 1
5
value in normal ing or defective contact in Wiring harness between S03 (female) F and
Resistance Max. 1
state connector) S24 2
Wiring harness between CN1 (female) 6 and
Resistance Max. 1
S24 5
circuit) Between wiring harness related to CB6 (outlet
Resistance Min. 1M
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 CN1 Service switch Voltage
Between 6 and OFF 20 30V
ground ON Max. 1V
20-634 D475A-3
Circuit diagram related to service switch
D475A-3 20-635
E-27 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. 1
connector) 244 (female) 2
Resistance Max. 1
ground
Between wiring harness related to FS4-1 (out-
circuit)
Between wiring harness (between BKA (fe-
Resistance Min. 1M
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
20-636 D475A-3
E-28 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
ness (Disconnection in wir- without turning the starting switch ON.
2
ing or defective contact in Wiring harness between FS2-5 outlet and cir-
Resistance Max. 1
connector) cuit branching point
value in normal Between wiring harness related to FS2-5 (out-
state Resistance Min. 1M
Ground fault of wiring har- Between wiring harness (between 219 (fe-
3 ness (Contact with ground male) 2 and S01 (female) @, S02 (female) 1,
Resistance Min. 1M
circuit) S03 (female) 8, BB1 (female) 1 or BB3 (fe-
male) 3) and ground
Between wiring harness (between 218 (fe-
male) 3 and 233 (female) 1 or 431 (female) Resistance Min. 1M
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. 1M
Between 2 and 3
Possible causes ON Max. 1
value in normal without turning the starting switch ON.
state Wiring harness between 219 (female) 3 and
Ground fault of wiring har- Resistance Max. 1
circuit branching point
circuit) Resistance Max. 1
BB1 (female) 1 or BB3 (female) 1
Wiring harness between BB1 (female) 2 or
Resistance Max. 1
BB3 (female) 1 and ground
D475A-3 20-637
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.
Disconnection of wiring har- Wiring harness between S01 (female) @ and Resistance Max. 1
ness (Disconnection in wir- circuit branching point
2
ing or defective contact in Wiring harness between S02 (female) 1 and
Resistance Max. 1
connector) circuit branching point
Possible causes
Wiring harness between S03 (female) 8 and
circuit branching point
value in normal
state + Prepare with the starting switch OFF, then turn the starting switch
Defective monitor panel Between S01 @
3
(Switch module) and 2
Light switch ON 20 30V
Between S02 1
and 2
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
(BB1) is defective.
Possible causes
and standard
state ness (Disconnection in wir- Wiring harness between CB5 outlet and BB1
4 Resistance Max. 1
ing or defective contact in (female) 3
connector) Wiring harness between BB1 (female) 5 and
Resistance Max. 1
203 (female) 1 or 204 (female) 1
Ground fault of wiring har- Between wiring harness related to CB5 (outlet
Resistance Min. 1M
5 ness (Contact with ground side) and ground
circuit) Between wiring harness (between BB1(fe-
male) 5 and 203 (female) 1 or 204 (female) Resistance Min. 1M
1) and ground
20-638 D475A-3
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.
state ness (Disconnection in wir- Wiring harness between FS2-4 outlet and BB3
4 Resistance Max. 1
ing or defective contact in (female) 3
connector) Wiring harness between BB3 (female) 5 and
Resistance Max. 1
Ground fault of wiring har- Between wiring harness related to FS2-4 (out-
Resistance Min. 1M
5 ness (Contact with ground let side) and ground
circuit) Between wiring harness (between BB3 (fe-
male) 5 and 221 (female) 1 or WRL (female) Resistance Min. 1M
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. 1M
value in normal Between 2 and 3
ON Max. 1
ness (Disconnection in wir- Wiring harness between 218 (female) 2 and
4 Resistance Max. 1
ing or defective contact in circuit branching point
Resistance Max. 1
D475A-3 20-639
Circuit diagram related to night light, headlamp, working lamp and rear lamp on panel
20-640 D475A-3
E-29 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 40
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 40
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 40
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. 1
CN-R2 (female) (0E) and ground
Wiring harness between CN-B(female) (10A)
Resistance Max. 1
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. 1
connector) (11C)
Wiring harness between CB4 outlet and CN-
AC1 (female) (13C), CN-R1 (female) (13D),
Resistance Max. 1
CN-R2 (female) (13E) or CN-R3 (female)
(13H)
Wiring harness between CN-R1 (female) (14A)
Resistance Max. 1
and CN-AC1 (female) (14B)
20-642 D475A-3

ness (Disconnection in wir- Wiring harness between CN-R3 (female) (17A)
9 Resistance Max. 1
Possible causes ing or defective contact in and CN-AC1 (female) (17B)
and standard connector) Wiring harness between CN-R2 (female) (18A)
Resistance Max. 1
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.
D475A-3 20-643
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 40
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. 3,500
value in normal Defective condenser blower without turning the starting switch ON.
state 6
resistor Condenser blower resistor Resistance
Between terminals 2.8 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-
Resistance Max. 1
R5 (female) (6B) or CN-R4 (female) (6D)
Disconnection of wiring har- Wiring harness between CN-R5 (female) (7B)
Resistance Max. 1
ness (Disconnection in wir- and ARC (female) 2
10
ing or defective contact in Wiring harness between CN-R4 (female) (9B)
Resistance Max. 1
connector) and 351 (female) 1
Wiring harness between CB4 outlet and CN-R
Resistance Max. 1
(female) (131)
Wiring harness between CN-T (female) (15A)
Resistance Max. 1
and CN-AC1 (female) (15B)
20-644 D475A-3

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)
value in normal Resistance Max. 1
connector) and CN-AC1 (female) (26B)
state
Wiring harness between ARC (female) 1 and
Resistance Max. 1
ground
When Causes 1 to 10 are not applicable, the control panel is sup-
11 Defective control panel
posed to be defective.
D475A-3 20-645
Circuit diagram related to air conditioner
20-646 D475A-3
TROUBLESHOOTING OF
HYDRAULIC AND MECHANICAL SYSTEM
(H-MODE)

H-1 No travel power (No drawbar pull) ................................................................................................... 20-703
H-2 Machine does not move (At 2nd or 3rd speed) ................................................................................ 20-704
H-3 Machine does not move in any speed range ................................................................................... 20-705
H-4 Machine travels only in one direction in forward or in reverse ......................................................... 20-706
H-5 When gear is shifted or travel direction is changed, large time lag is made .................................... 20-707
H-6 Steering is not possible ..................................................................................................................... 20-708
H-7 Steering is possible only on one side .............................................................................................. 20-708
H-8 Steering overrun occurs ................................................................................................................... 20-709
H-9 Brake does not work ........................................................................................................................ 20-709
H-10 Torque converter does not lock-up ................................................................................................ 20-710
H-11 Overheat of power train oil temperature ........................................................................................ 20- 711
H-12 All work equipment speeds are slow ............................................................................................. 20-712
H-13 All work equipment does not operate ............................................................................................ 20-713
H-14 Blade lift raising speed is slow or the blade lift has no power ........................................................ 20-714
H-15 Blade tilt raising speed is slow or the blade tilt has no power ........................................................ 20-714
H-16 Ripper lift raising speed is slow or the ripper lift has no power ...................................................... 20-715
H-17 Ripper tilting speed is slow or the blade tilt has no power ............................................................. 20-715
H-18 Excessive hydraulic drift of blade lift .............................................................................................. 20-716
H-19 Excessive hydraulic drift of blade tilt .............................................................................................. 20-717
H-20 Excessive hydraulic drift of ripper lift ............................................................................................. 20-717
H-21 Ripper pin puller cylinder does not work (Giant ripper attachment machine) ................................ 20-718
H-22 Blade pitch does not work (Dual tilt attachment machine) ............................................................. 20-718
H-23 Abnormal sound comes out from around work equipment pump .................................................. 20-720
D475A-3 20-701

+ 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 D475A-3
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 1,590rpm
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
0.8 1.0MPa 0.3 0.6MPa
Full neutral
{8 10kg/cm2} {3 6kg/cm2}
Transmission main relief
PCCS lever
pressure
Defective set pressure of
Full neutral Min. 2.4MPa{Min. 24.0kg/cm2}
4 transmission main relief
valve and internal defect + Prepare with the starting switch OFF, then carry out troubleshooting
Possible causes without turning the starting switch ON.
and standard Directly check that the spring length are normal and also that the
value in normal spool rotates smoothly.
state Free length of spring: 120.3mm
+ Prepare with starting switch OFF, then drive the engine in low idling
mode for troubleshooting.
Transmission clutch Clutch pressure
Defective transmission FWD Min. 2.35MPa {Min. 24kg/cm2}
5
valve (ECMV) function REV Min. 2.35MPa {Min. 24kg/cm2}
1ST Min. 1.96MPa {Min. 20kg/cm2}
2ND Min. 2.35MPa {Min. 24kg/cm2}
3RD Min. 2.35MPa {Min. 24kg/cm2}
6 Defective brake valve Parking lever Left brake pressure Right brake pressure
Min. 2.26MPa Min. 2.26MPa
Free
{Min. 23kg/cm2} {Min. 23kg/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.
D475A-3 20-703
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
0.78 1.0MPa 0.29 0.59MPa
Full neutral
{8 10kg/cm2} {3 6kg/cm2}
mode for troubleshooting.
Possible causes Defective transmission
2 Transmission clutch Clutch pressure
and standard valve (ECMV) function
value in normal
state 3RD Min. 2.35MPa {Min. 24kg/cm2}
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.
+ Move to a flat place, and start the engine for troubleshooting.
Defective brake function
5 If the machine does not run by low idling + F2 operation, brake drag
(Drag)
occurs. (Carry out troubleshooting Brake does not work.)
Internally defective trans- The transmission is assumed to be defective internally; directly check
6
mission it.
20-704 D475A-3
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
Defective and Internally de- pressure
fective set pressure of Full neutral Min. 2.35MPa {Min. 24kg/cm2}
2
transmission main relief + Prepare with the starting switch OFF, then carry out troubleshooting
valve without turning the starting switch ON.
Directly check that the spring length are normal and also that the
spool rotates smoothly.
Free length of spring:120.3mm
mode for troubleshooting. (Before this, confirm that the transmis-
sion main relief pressure is normal.)
Possible causes
and standard Transmission clutch Clutch pressure
value in normal Defective transmission FWD Min. 2.35MPa {Min. 24kg/cm2}
3
state valve (ECMV) function
REV Min. 2.35MPa {Min. 24kg/cm2}
Internally defective trans- The transmission clutch (2nd or 3rd speed) is assumed to be defec-
4
mission clutch tive internally; directly check it.
+ Move to a flat place, and drive the engine in high idling mode for
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. 2.26MPa {Min. 23kg/cm2}
Pedal 0 {0}
When the hydraulic pressure is abnormal, carry out troubleshooting
Brake does not work.
D475A-3 20-705
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. 2.35MPa {Min. 24kg/cm2}
2 transmission main relief
valve or internal defect + Prepare with the starting switch OFF, then carry out troubleshooting
Possible causes Directly check that the spring length are normal and also that the
and standard spool rotates smoothly.
value in normal Free length of spring: 120.3mm
state + Prepare with starting switch OFF, then drive the engine in low idling
mode for troubleshooting. (Before this, confirm that the transmis-
Defective transmission sion main relief pressures is normal.)
3
valve (ECMV) function Transmission clutch Clutch pressure
FWD Min. 2.35MPa {Min. 24kg/cm2}
Defective transmission When the troubleshooting in cause 4 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.
20-706 D475A-3
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. 2.35MPa{Min. 24kg/cm2}
2 transmission main relief + Prepare with the starting switch OFF, then carry out troubleshooting
valve or 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
Free length of small spring: 108mm
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.)
Transmission clutch Clutch pressure
Defective transmission FWD Min. 2.35MPa {Min. 24kg/cm2}
3
valve (ECMV) function
Defective transmission When the troubleshooting in cause 4 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.
6 If the machine does not run by low idling + F2 operation, brake drag
(Drag)
occurs. (Carry out troubleshooting Brake does not work.)
D475A-3 20-707
STEERING IS NOT POSSIBLE
TROUBLESHOOTING STEERING IS POSSIBLE ONLY ON ONE SIDE
H-5
H-6 STEERING IS NOT POSSIBLE
Trouble Steering is not possible.

Before troubleshooting, check that the power train oil level is normal.
Related 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 Lift the machine with the blade and the ripper and steer the wheel for
F3 travel (or R3 travel). If the track shoe stops, the brake is defective.
(Execute the troubleshooting of Brake does not work.)
+ Set the starting switch to OFF for preparation and idle the engine at
a high speed for troubleshooting.
PCCS lever Left stroke end Right stroke end
Possible causes 0 Min. 2.4 MPa
Left clutch pressure
and standard val- {0} {Min. 24 kg/cm2}
Defective operation of steer-
ue in normal state 2 Min. 2.26 MPa 0
ing clutch valve (ECMV) Right clutch pressure
{Min. 24 kg/cm2} {0}
0 Min. 2.26 MPa
Left brake pressure
{0} {Min. 23 kg/cm2}
Min. 2.26 MPa 0
Right brake pressure
{Min. 23 kg/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.

Related information

PCCS lever Left stroke end Right stroke end
0 Min. 2.4 MPa
Left clutch pressure
{0} {Min. 24 kg/cm2}
1 Min. 2.4 MPa 0
Possible causes ing clutch valve (ECMV) Right clutch pressure
{Min. 24 kg/cm2} {0}
and standard val-
ue in normal state 0 Min. 2.26 MPa
Left brake pressure
{0} {Min. 23 kg/cm2}
Min. 2.26 MPa 0
{Min. 23 kg/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.
20-708 D475A-3
STEERING OVERRUN OCCURS
TROUBLESHOOTING BRAKE DOES NOT WORK
H-5
H-8 STEERING OVERRUN OCCURS
Trouble Steering overrun occurs.

Related information

+ 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 val- F3 travel (or R3 travel). If the track shoe stops, the brake is defective.
ue in normal state (Execute the troubleshooting of Brake does not work.)
When the track shoe does not stop in the troubleshooting of the cause
2 1, the steering clutch is defective. (Execute the troubleshooting of
ing clutch
Steering is not possible.)
H-9 BRAKE DOES NOT WORK
Trouble Brake does not work.

Related information

+ Start the engine for troubleshooting.
1 Degradation of brake Step on the brake pedal, shift the gear to F2 and idle the engine at a
high speed. When the machine moves, the brake performance is de-
graded.
Defective operation of brake The brake pedal and the brake valve are supposed not to work nor-
2
pedal mally. Check them directly.
Possible causes PCCS lever Left stroke end Right stroke end
and standard val- 0 Min. 2.4 MPa
ue in normal state Left clutch pressure
{0} {Min. 24 kg/cm2}
3 Min. 2.4 MPa 0
ing brake valve (ECMV) Right clutch pressure
{Min. 24 kg/cm2} {0}
0 Min. 2.26 MPa
Left brake pressure
{0} {Min. 23 kg/cm2}
Min. 2.26 MPa 0
{Min. 23 kg/cm2} {0}
When the brake seal is not normal in the troubleshooting of the cause
4 Defective brake seal
3, the brake seal is supposed to be defective. Check it directly.
5 Internal defect of brake The inside of the brake is supposed to be defective. Check it directly.
D475A-3 20-709
TROUBLESHOOTING H-10
H-5
H-10 TORQUE CONVERTER DOES NOT LOCK-UP
Trouble Torque converter does not lock-up.

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 torque converter
2 Torque converter Lock-up clutch pressure
lock-up valve function
Min.1.08 MPa
Possible causes At lock-up
{Min. 18kg/cm2}
and standard
Defective lock-up clutch If the troubleshooting in cause 2 is abnormal, the lock-up clutch seal
value in normal 3
state seal is assumed to be defective; directly check it.
Internally defective lock-up The lock-up clutch is assumed to be defective internally; directly
4
clutch check it.
Internally defective torque idling mode for troubleshooting.
5
converter Measurement conditions Number of engine rotations
F3 stall 1,590rpm
20-710 D475A-3
H-11 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
0.78 1.0MPa 0.29 0.59MPa
and standard Full neutral
{8 10kg/cm2} {3 6kg/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.
D475A-3 20-711
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY
Trouble All work equipment operates slowly.

Related information Before troubleshooting, check that the hydraulic tank oil level is normal.

Defective PTO (work equip- The work equipment pump drive of the PTO is supposed to be defec-
1
ment pump drive) tive. Check it directly.
Defective work equipment The work equipment large pump is supposed to be defective. Check
2
large pump it directly.
Defective work equipment The work equipment small pump is supposed to be defective. Check
3
small pump it directly.
4 Defective PPC charge pump The PPC charge pump is supposed to be defective. Check it directly.
Improper pressure set to a high speed for troubleshooting.
5 main relief valve for blade lift
Blade lever Main relief pressure
valve
Raise Min. 19.6 MPa {Min. 200 kg/cm2}
Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be
Possible causes 6
valve for blade lift valve defective. Check it directly.
and standard val-
ue in normal state + Set the starting switch to OFF for preparation and idle the engine at
7 main relief valve for blade tilt
ripper Lo valve
Internal defect of main relief
The inside of the main relief valve for blade tilt ripper Lo valve is sup-
8 valve for blade tilt ripper Lo
posed to be defective. Check it directly.
valve
9
charge relief valve Work equipment lever Control relief pressure
Full neutral Min. 3.9 MPa {Min. 40.0 kg/cm2}
Internal defect of charge re- The inside of the charge relief valve is supposed to be defective.
10
lief valve Check it directly.
11 Internal leak of PPC valve Internal leak of PPC valve is supposed. Check it directly.
20-712 D475A-3
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE
Trouble All work equipment does not operate.

Related information Before troubleshooting, check that the hydraulic tank oil level is normal.

Defective PTO (work equip- The work equipment pump drive of the PTO is supposed to be defec-
1
ment pump drive) tive. Check it directly.
Defective work equipment The work equipment large pump is supposed to be defective. Check
2
large pump it directly.
Defective work equipment The work equipment small pump is supposed to be defective. Check
3
small pump it directly.
4 Defective PPC charge pump The PPC charge pump is supposed to be defective. Check it directly.
5 main relief valve for blade lift
valve
Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be
6
Possible causes valve for blade lift valve defective. Check it directly.
and standard val- + Set the starting switch to OFF for preparation and idle the engine at
ue in normal state Improper pressure set to a high speed for troubleshooting.
7 main relief valve for blade tilt
ripper Lo valve
Internal defect of main relief
The inside of the main relief valve for blade tilt ripper Lo valve is sup-
8 valve for blade tilt ripper Lo
posed to be defective. Check it directly.
valve
9
charge relief valve Work equipment lever Control relief pressure
Full neutral Min. 3.9 MPa {Min. 40.0 kg/cm2}
Internal defect of charge re- The inside of the charge relief valve is supposed to be defective.
10
lief valve Check it directly.
Defective operation of PPC The PPC lock valve is supposed to operate abnormally. Check the le-
11
lock valve ver linkage or the lock valve directly.
D475A-3 20-713
TROUBLESHOOTING H-14, H-15
H-14
H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER
Trouble Blade lift raising speed is slow or the blade lift has no power.
Before troubleshooting, check that the hydraulic tank oil level is normal.
Check if the blade has been modified.
Related information
In case of large hydraulic drift of the blade lift, execute the troubleshooting of Hydraulic drift of blade
lift is large.

Defective operation of PPC a high speed for troubleshooting.
1
valve Blade lever PPC valve output pressure
Raising stroke end Min. 3.9 MPa {Min. 40 kg/cm2}
Possible causes Defective operation of blade The spool of the blade lift control valve is suppose to operate abnor-
2
and standard val- lift control valve (spool) mally. Check it directly.
ue in normal state The suction valve of the blade lift control valve is suppose to operate
Defective operation of blade abnormally. Check it directly.
3 lift control valve + It is also acceptable to replace the suction valve on the head side
(suction valve) with the one on the bottom side to check change of the phenome-
non as another method.
Air is supposed to enter the blade lift cylinder. Bleed air and check the
4 Air entry in blade lift cylinder
change of phenomenon.
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
Trouble Blade tilt raising speed is slow or the blade tilt has no power.
Check if the blade has been modified.
Related information
lift is large.

1
Possible causes valve Blade lever PPC valve output pressure
and standard val- Tilt stroke end Min. 3.9 MPa {Min. 40 kg/cm2}
ue in normal state Defective operation of blade The spool of the blade tilt control valve is suppose to operate abnor-
2
tilt control valve (spool) mally. Check it directly.
Air is supposed to enter the blade tilt cylinder. Bleed air and check the
3 Air entry in blade tilt cylinder
20-714 D475A-3
H-17
H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER
Trouble Ripper lift raising speed is slow or the ripper lift has no power.
Check if the ripper has been modified.
Related information
lift is large.

1
valve Ripper lever PPC valve output pressure
Raising stroke end Min. 3.9 MPa {Min. 40 kg/cm2}
Possible causes Defective operation of ripper The spool of the ripper lift control valve (Lo, Hi) is suppose to operate
2
and standard val- lift control valve (spool) abnormally. Check it directly.
ue in normal state The constant differential pressure valve of the ripper lift control valve
Defective operation of ripper
(Hi) is suppose to operate abnormally. Check it directly.
lift control valve
3 + It is also acceptable to replace the constant differential pressure
(constant differential pres-
valve on the head side with the one on the bottom side to check
sure valve)
change of the phenomenon as another method.
Air is supposed to enter the ripper lift cylinder. Bleed air and check the
4 Air entry in ripper lift cylinder
H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
Trouble Ripper tilting speed is slow or the ripper has no power.

Related information
Check if the ripper has been modified.

1
valve Ripper lever PPC valve output pressure
Tilt end Min. 3.9 MPa {Min. 40 kg/cm2}
Possible causes Defective operation of ripper The spool of the ripper tilt control valve (Lo, Hi) is suppose to operate
2
and standard val- tilt control valve (spool) abnormally. Check it directly.
ue in normal state The constant differential pressure valve of the ripper tilt control valve
Defective operation of ripper
(Hi) is suppose to operate abnormally. Check it directly.
tilt control valve
3 + It is also acceptable to replace the constant differential pressure
(constant differential pres-
valve on the head side with the one on the bottom side to check
sure valve)
change of the phenomenon as another method.
Air is supposed to enter the ripper tilt cylinder. Bleed air and check the
4 Air entry in ripper tilt cylinder
D475A-3 20-715
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT
Trouble Excessive hydraulic drift of blade lift.

Related Confirm whether the blade is remodeled.
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
speed becomes high, the spool seal of the blade lift operation valve
Possible causes
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
machine.
state
2. Stop the engine, and release the safety lock lever.
3. Set the blade lever to the lift lowering side, and confirm how the
phenomenon changes.
Defective seal of blade lift The seal of the blade lift cylinder is assumed to be defective; directly
2
cylinder check it.
20-716 D475A-3
H-20
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT
Trouble Excessive hydraulic drift of blade tilt.

Related Confirm whether the blade is remodeled.

+ 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 12cc/min
H-20 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
D475A-3 20-717
H-21 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 2.3 2.9MPa
Pull-in Cylinder head side {23.5 30.0kg/cm2}
Internally defective pin pull- The pin puller cylinder is assumed to be defective internally; directly
2
er cylinder check it.
H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE)
Trouble The blade pitch does not work.

Related
information

Defective function of work The spool of the work equipment valve is assumed to be defective;
1
equipment solenoid valve directly check it.
Possible causes
The function of the blade pitch cylinder is assumed to be defective;
and standard Defective function of blade
directly check it.
value in normal 2 pitch operation valve
state Operations of solenoids during pitch and tilt operation are indicated in
(Spool)
the following chart.
Defective function of blade The function of the blade pitch selection solenoid valve is assumed to
3
pitch cylinder be defective; directly check it.
20-718 D475A-3
SINGLE TILT DOZER
Solenoid name UNLOAD Pump
Connector UNL Applicable sensor or switch Large Small Assist
ON OFF 140 100 100
D475A-3
Operation
All in neutral
RAISE (Short stroke)
{ {
RAISE (Long stroke) Blade RAISE PPC pressure sensor
z
z
LIFT LOWER (Short stroke)

z z z
z z z
{
Blade LOWER
TROUBLESHOOTING
Blade LOWER PPC pressure sensor
z
z
z
z
(long stroke), FLOAT

SINGLE LEFT SINGLE TILT
TILT RIGHT SINGLE TILT
{ {
RAISE, RAISE Ripper RAISE PPC pressure sensor
LOWER LOWER Ripper LOWER PPC pressure sensor
Ripper
TILT IN Ripper TILT IN PPC pressure sensor
TILT
TILT BACK Ripper TILT BACK PPC pressure sensor
z z z z
z z z z
Relief at ripper Each PPC pressure sensor+Large pump pressure sensor

z z z z z
z z z z z z z
{
stroke end
DUAL TILT DOZER

Solenoid name PITCH DUMP PITCH BACK LEFT TILT LIMIT RIGHT TILT LIMIT UNLOAD PITH DUMP ASSIST PITCH SELECTION Pump
Connector PPD PPB TLL TLR UNL PIT PDA PST Applicable sensor or switch Large Small Assist
WORK EQUIPMENT SOLENOID OPERATION CHART
Operation ON OFF ON OFF ON OFF ON OFF ON OFF ON ON OFF ON 140 100 100
Single tilt mode
{
{
NEUTRAL
Dual tilt mode
z
z
RAISE (Short stroke)
{ { {
RAISE (Long stroke) Blade RAISE PPC pressure sensor
z
z
LIFT LOWER (Short stroke)
{
LOWER Blade LOWER PPC pressure sensor
z
z z z z
z
(long stroke), FLOAT

LEFT SINGLE TILT
{ { { { {
LEFT SINGLE TILT Left and right yoke angle sensor
z
SINGLE LIMIT
TILT RIGHT SINGLE TILT
{ { { { { { {
Blade
RIGHT SINGLE TILT Left and right yoke angle sensor
{ { { { { { { { { {
{ { { {
{ { { { { { { { { {
LIMIT
LEFT DUAL TILT z Dual switch ON+Left tilt PPC pressure sensor
z
{ { {
LEFT DUAL TILT LIMIT Left and right yoke angle sensor
z z
z
{ { { { { { { { { { { {
{
{
DUAL
RIGHT DUAL TILT Dual switch ON+Right tilt PPC pressure sensor
z
z
TILT
{ { {
R I G H T D U A L T I LT Left and right yoke angle sensor
z z
{ {
{
{
LIMIT
PITCH DUMP Pitch switch ON+Right tilt PPC pressure sensor
z
z z
z
{
{ { {
PITCH
PITCH BACK Pirct switch ON+Left tilt PPC pressure sensor
z
z
z z
z
{
{
RAISE, RAISE Ripper PAISE PPC pressure sensor
LOWER LOWER Ripper LOWER PPC pressure sensor
Ripper TILT IN Ripper TILT IN PPC pressure sensor

TILT
TILT BACK Ripper TILT BACK PPC pressure sensor
z z z z z z z z z z z
z z z z
Relief at ripper Each ripper PPC pressure sensor+Large pump pressure sensor
z z z z z z z z z z z z z z z z z z z
z z z z z
20-719
H-22
stroke end
H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP
Trouble Abnormal noise from around work equipment pump.

Related
Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
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.
20-720 D475A-3
30 DISASSEMBLY AND ASSEMBLY
marks show the items which are common to D475A-3 SHOP MANUAL.
As to the common items, see D475A-3 SHOP MANUAL (Form No. SEBM017207).
METHOD OF USING MANUAL .......... 30- 3 TORQFLOW TRANSMISSION

PRECAUTIONS WHEN CARRYING ASSEMBLY
OUT OPERATION .......................... 30- 6 * Removal and Installation ........... 30- 79
SPECIAL TOOL LIST ............................ 30- 8 Disassembly and Assembly ....... 30- 80
SKETCHES OF SPECIAL TOOLS ........ 30-15 STEERING CASE ASSEMBLY
ENGINE OIL COOLER ASSEMBLY Disassembly and Assembly ....... 30-100
Removal and Installation ............. 30-23 * STEERING CLUTCH, BRAKE
FUEL INJECTION PUMP ASSEMBLY ASSEMBLY
Removal and Installation ............. 30-24 Disassembly and Assembly ....... 30-108
AFTERCOOLER CORE ASSEMBLY TRANSFER GEAR HOUSING
Removal and Installation ............. 30-25 ASSEMBLY
NOZZLE HOLDER ASSEMBLY Disassembly and Assembly ....... 30-116
Removal and Installation ............. 30-27 POWER TRAIN PUMP ASSEMBLY
ENGINE FRONT SEAL Removal and Installation ........... 30-120
Removal and Installation ............. 30-28 SCAVENGING PUMP ASSEMBLY
ENGINE REAR SEAL Removal and Installation ........... 30-121
Removal and Installation ............. 30-30 TORQUE CONVERTER OIL
CYLINDER HEAD ASSEMBLY COOLER
Removal and Installation ............. 30-33 Removal and Installation ........... 30-122
FUEL TANK ASSEMBLY TORQUE CONVERTER VALVE
MAIN RADIATOR ASSEMBLY Removal and Installation ........... 30-123
Removal and Installation ............. 30-38 Disassembly and Assembly ....... 30-124
SUB RADIATOR ASSEMBLY TRANSMISSION CONTROL VALVE
RADIATOR GUARD ASSEMBLY Removal and Installation ............. 30-127
Removal and Installation ............. 30-41 STEERING CONTROL VALVE
ENGINE ASSEMBLY ASSEMBLY
Removal and Installation ............. 30-43 Removal and Installation ............. 30-135
DAMPER ASSEMBLY FINAL DRIVE ASSEMBLY
Disassembly and Assembly ......... 30-49 Disassembly and Assembly ....... 30-141
POWER TRAIN UNIT ASSEMBLY TRACK FRAME ASSEMBLY
PTO, TORQUE CONVERTER IDLER ASSEMBLY
ASSEMBLY Disassembly and Assembly ....... 30-161
Removal and Installation ............. 30-56 RECOIL SPRING ASSEMBLY
Disconnection and connection .... 30-59 Removal and Installation ........... 30-165
TORQUE CONVERTER ASSEMBLY Disassembly and Assembly ....... 30-171
Disassembly and Assembly ......... 30-61 TRACK ROLLER ASSEMBLY
PTO ASSEMBLY Removal and Installation ............. 30-173
Disassembly and Assembly ......... 30-72 Disassembly and Assembly ......... 30-175
D475A-3 30-1
CARRIER ROLLER ASSEMBLY RIPPER HI VALVE ASSEMBLY
Removal and Installation .......... 30-177-4 Removal and Installation ............. 30-212
Disassembly and Assembly ...... 30-177-5 Disassembly and Assembly ......... 30-214
BOGIE ASSEMBLY PPC RELIEF VALVE ASSEMBLY
Disassembly and Assembly ......... 30-180 HYDRAULIC CYLINDER ASSEMBLY
NO.1 BOGIE ASSEMBLY Disassembly and Assembly ......... 30-217
Removal and Installation ............. 30-189 RIPPER PIN-PULLER CYLINDER
TRACK SHOE ASSEMBLY ASSEMBLY
Removal and Installation ............. 30-195 Disassembly and Assembly ......... 30-223
Overall disassembly .................. 30-197-4 BLADE ASSEMBLY
Overall assembly ....................... 30-197-8 Removal and Installation ............. 30-226
PRESS-FITTING JIG DIMENSION GIANT RIPPER ASSEMBLY
TABLE FOR LINK PRESS ......... 30-197-23 Disassembly and Assembly ......... 30-228
FIELD DISASSEMBLY OF ROPS GUARD
ONE LINK .................................. 30-197-24 Removal and Installation ............. 30-232
FIELD ASSEMBLY OF ONE LINK .. 30-197-27 OPERATORS CAB ASSEMBLY
MASTER LINK Removal and Installation ............. 30-233
Disassembly and Assembly .... 30-197-30 FLOOR FRAME ASSEMBLY
PIVOT SHAFT ASSEMBLY Removal and Installation ............. 30-235
Removal and Installation ............. 30-198 DASHBOARD ASSEMBLY
EQUALIZER BAR Removal and Installation ............. 30-240
Removal and Installation ............. 30-199 CONTROLLER ASSEMBLY
EQUALIZER BAR BUSHING Removal and Installation ............. 30-242
Disassembly and Assembly ......... 30-202 AIR CONDITIONER COMPRESSOR
HYDRAULIC PUMP ASSEMBLY ASSEMBLY
BLADE LIFT VALVE ASSEMBLY AIR CONDITIONER CONDENSER
Disassembly and Assembly ......... 30-206 Removal and Installation ............. 30-245
BLADE TILT, RIPPER LO VALVE AIR CONDITIONER UNIT ASSEMBLY
ASSEMBLY Removal and Installation ............. 30-246
Removal and Installation ............. 30-208 HOOD ASSEMBLY
Disassembly and Assembly ......... 30-210 Removal and Installation ............. 30-250
30-2 D475A-3
DISASSEMBLY AND ASSEMBLY POWER TRAIN UNIT
REMOVAL OF POWER TRAIN

UNIT ASSEMBLY
1. Drain oil from hydraulic tank and power train
case.
6 Hydraulic tank : Approx. 140
6 Power train case : Approx. 210
2. Remove floor frame assembly.

For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
3. Remove fuel tank assembly.
For details, see REMOVAL OF FUEL TANK AS-
SEMBLY.
4. Disconnect lubrication hoses (1) and (3).
5. Disconnect pin-puller hoses (2).
6. Disconnect connectors. (241, 242, BR)
7. Disconnect connectors. (PL1, PL2, 578)
30-52 D475A-3
8. Remove hydraulic pump inlet tube coupling (8)

and tube (9).
9. Disconnect hoses (10).
10. Disconnect ripper hose (11), then disconnect

clamp (1 place) on top of steering case.
11. Remove universal joint (12). 1
4 Universal joint : 65 kg
D475A-3 30-53
12. Remove front mount bolt (13). 2
13. Remove rear mount bolt (14), then remove

mount cap (15). 3
4 Mount cap : 30 kg
14. Remove housing clip (16), and move flange (17)

towards final drive end. 4
15. Using forcing screws 1, remove cover (18).
16. Remove shaft (19).

Pull out the shaft with forcing screws 2.
If the shaft will not come out, set jack 3 on
the ground and push the shoe grouser up,
then move the sprocket to the front or rear
to a position where the shaft will come out,
and remove the shaft.
17. Lift off power train unit assembly (20). 5
4 Power train unit assembly : 5,500 kg
30-54 D475A-3
INSTALLATION OF POWER
TRAIN UNIT ASSEMBLY
Carry out installation in the reverse order to
removal.
1
3 Universal joint mounting bolt :
156.8 196 Nm {16 20 kgm}
2
3 Front mount bolt :
1,519 1,911 Nm {155 195 kgm}
3
3 Rear mount bolt :
823.2 1,029 Nm {84 105 kgm}
4
Check that the housing clip is fitted securely
in the flange.
3 Housing clip :
4.9 8.8 Nm {0.5 0.9 kgm}
5
When installing the power train unit assem-
bly, pay attention to the mating surface of
the coupling, and be careful not to damage
the seal of the rear mount coupling.
Refilling with oil

Add oil through the oil filler to the specified
level, and run the engine to circulate the oil
through the system. Then check the oil level
again.
5 Power train case : Approx. 210
5 Hydraulic tank : Approx. 140
D475A-3 30-55
DISASSEMBLY AND ASSEMBLY PTO, TORQUE CONVERTER
REMOVAL OF PTO, TORQUE

CONVERTER ASSEMBLY
1. Remove power train unit assembly.
For details, see REMOVAL OF POWER TRAIN
UNIT ASSEMBLY.
2. Raise power train unit assembly (1) and set on

block 1.
Set blocks under the front of the oil pan,
transmission rear case, and steering case.
3. Remove brake rod (2) and parking brake cable

(20). 1
4. Disconnect central pressure detection hose (3),

then remove together with central pressure de-
tection bracket (4).
Before removing the pressure detection
hoses, mark them with tags to prevent any
mistake in the mounting position when in-
stalling.
5. Remove oil filler tube (5).
6. Sling filter assembly (6), then remove.
4 Filter assembly : 40 kg
7. Remove power train pump (7) and strainer as-

sembly (8).
Sling the power train pump, then remove
together with the strainer.
4 Power train pump, strainer assembly :

100 kg
8. Lift off mount bracket (9). 2
4 Mount bracket : 70 kg
9. Remove tube (10) and scavenging pump (11).

Sling the scavenging pump, then remove
the mounting bolts.
4 Scavenging pump : 24 kg
30-56 D475A-3
10. Remove hose (12).
11. Remove gauge guide (13).
12. Removal of hydraulic pump

1) Remove tube (14).
2) Remove tube (15).
3) Lift off right pump assembly (16).
4 Pump assembly : 40 kg
4) Lift off left pump assembly (17).
4 Pump assembly : 25 kg
13. Remove oil pan (18).

Remove the block under the oil pan, sling
the oil pan, then remove the mounting bolts
and disconnect the oil pan.
4 Oil pan : 120 kg
14. Remove PTO and torque converter assembly

(19). 3
Sling the PTO and torque converter assem-
bly, then remove the mounting bolts.
Using a lever block, lift off the PTO and
torque converter assembly horizontally.
4 PTO, torque converter assembly :

850 kg
D475A-3 30-57
INSTALLATION OF PTO,
TORQUE CONVERTER
ASSEMBLY
removal.
Bend the cotter pin securely.
2 PTO boss rotating portion :

Grease (G2-LI)
3
Using a lever block, raise the PTO and torque
converter assembly horizontally, align it with
the spline of the shaft at the steering case
end, then install.
30-58 D475A-3
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DISASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
Put transmission assembly on the block.
1. Transmission control valve assembly

Remove transmission control valve assembly (1).
Remove four bolts marked by and each
bolt marked by , , and .
2. Valve sheet, sleeve

1) Remove valve sheet (2).
Remove seven bolts marked by .
2) Pull out sleeves (3).
3. Transmission case
1) Turn over transmission assembly, and re-
move plate (10).
2) Using eyebolts, remove transmission case
(11).
30-80 D475A-3
4. Housing
1) Remove 17 tie bolts (12).
2) Using eyebolts, remove housing (13).
3) Remove seal ring (14) from housing.
5. Spring
Remove spring (15).
6. Discs, plates, springs

Remove discs (16), plates (17), and springs (18)
in turn.
Keep the discs and plates in a flat place to
prevent them from becoming deformed.
7. No. 1 ring gear

Remove ring gear (19).
8. No. 1 housing, piston

1) Using eyebolts, remove No. 1 housing and
piston assembly (20).
2) Remove piston (22) from housing (21).
9. Spring
Remove spring (23).

in turn.
11. Sleeve, guide pin

1) Remove sleeve (27).
2) Remove guide pin (28).
D475A-3 30-81
12. Shaft, No. 1, 2, 3 carrier assembly

Using eyebolts, remove No. 1, 2, and 3 carrier
assembly (29).
4 Shaft, No. 1, 2, 3 carrier assembly :

200 kg
1) Disassemble the shaft and carrier assembly

as follows.
i) Remove snap ring (130), then remove
sun gear (30).
ii) Using eyebolts, remove shaft and No. 1

carrier assembly (31) from No. 2 and 3
carrier assembly (32).
2) Disassemble the shaft and No. 1 carrier as-

sembly as follows.
i) Raise the assembly, then using forcing
screw 2, remove shaft and cage assem-
bly (33).
ii) Using plastic hammer, remove cage as-

sembly (34), spacer (35), and bearing (36).
iii) Remove seal ring (37) from cage assem-
bly.
iv) Remove seal ring (38) from cage.
v) Remove seal ring (40) from shaft (39).
vi) Remove shaft (42), ball (43), thrust

washer (44), gear (45), and bearing (46)
from No. 1 carrier assembly (41).
vii) Remove seal rings (47) and (131).
30-82 D475A-3
3) Disassemble the No. 2, No.3 carrier assem-

bly as follows.
i) Remove sun gear (48).
ii) Using eyebolts, remove plate and gear
assembly (49).
iii) Remove ring (50), and disassemble plate

(51) and gear (52).
iv) Remove plate (54) from No. 2, 3 carrier
assembly (53).
v) Remove seal ring (55) from plate.
vi) Remove shaft (56), ball (57), thrust

washer (58), gear (59), and bearing (60).
vii) Using push tool, remove collar and bear-

ing assembly (61) from carrier.
viii)Using push tool, remove bearing (62).
D475A-3 30-83
ix) Using puller and push tool, remove bear-

ing (63) and spacer (64) from collar (65).
x) Remove seal ring (66).
13. No. 2 ring gear

Remove ring gear (67).

1) Using eyebolts, remove No. 2 housing and
piston assembly (68).
4 No. 2 housing, piston : 80 kg
2) Remove piston (70) from housing (69).
15. No. 3 piston

Remove No. 3 piston (71).
16. Spring
Remove spring (72).

in turn.
18. Seat
Remove seat (76).
19. No. 3 housing

Using eyebolts, remove No. 3 housing (77).
4 No. 3 housing : 55 kg
20. No. 4 piston

Remove No. 4 piston (78).
30-84 D475A-3
21. Spring
Remove spring (79).

in turn.
23. Guide pin

Remove guide pin (83).
24. Sun gear

Remove snap ring (132), then remove sun gear
(84).
25. Plate, bearing

1) Using eyebolts, remove plate and bearing
assembly (85).
2) Using push tool 3, remove bearing (87) from
plate (86).
3) Using puller 4 and push tool 3, remove

bearing (88).
4) Using push tool, remove bearing (90) from
collar (89).
26. No. 3 ring gear

1) Remove ring gear (91).
2) Remove ring (92) from ring gear.
D475A-3 30-85
27. Plate, ring gear

1) Using forcing screws, remove plate and ring
gear assembly (93).
2) Remove ring gear (94).
28. No. 4 carrier, No. 5 clutch assembly

Using eyebolts, remove No. 4 carrier and No. 5
clutch assembly (95).
1) Disassemble the No. 4 carrier and No. 5

clutch assembly as follows.
i) Remove 2 mounting bolts, then install guide
bolts.
ii) Remove remaining mounting bolts, then
loosen guide bolts 5 slowly, and remove
No. 4 carrier assembly (96) from No. 5 clutch
assembly (97).
4 No. 4 carrier assembly, No. 5 clutch

assembly : 160 kg
iii) Remove shaft (98), ball (99), thrust washer

(100), gear (101), and bearing (102).
iv) Remove spring (103) and pin (104).

v) Remove discs (105), plates (106), and springs
(107).
Keep the discs and plates in a flat place
to prevent them from becoming
deformed.
vi) Remove guide pin (108).
vii) Remove inner gear (109).
viii)Remove seal ring (110) from inner gear.
30-86 D475A-3
ix) Remove piston (112) from No. 5 housing

(111).
x) Remove spacer (113) and seal ring (114) from
No. 5 housing.
29. Shaft
Remove shaft (115).
30. Shaft assembly

Set case so that shaft is at bottom, then using
eyebolts, remove shaft assembly (117) from case
(116).
4 Shaft assembly: 80 kg
1) Disassemble the shaft assembly as follows.

i) Remove snap ring, then using eyebolts, sling
shaft assembly, knock out bearing portion,
and remove shaft assembly (118).
ii) Remove cage (119).

iii) Using stand 6, remove bearing (120).
iv) Remove snap ring (134), then remove

bearing (121) from cage (133).
v) Remove seal ring (122).
vi) Remove cover (123).
D475A-3 30-87
vii) Remove bearing (124).

viii)Remove seal ring (126).
ix) Remove snap ring (135), then remove boss

and bearing (127).
x) Remove snap ring (136), then using push
tool, remove bearing (129) from boss (128).
30-88 D475A-3
ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
Wash all parts in clean flushing oil (in particular,
oil holes, etc.), then dry them, and check for dirt
or damage. Coat the sliding surfaces of all parts
with engine oil before installing.
Set the seal ring with the side taking the pres-
sure facing the housing, then coat with grease
(G2-LI) and install uniformly so that it is posi-
tioned correctly.
Align the notches of the oil groove when install-
ing the discs.
1. Shaft assembly
1) Assemble the shaft assembly as follows.
i) Install seal ring (126).
ii) Using push tool, install baring (124).
iii) Install cover (123).

iv) Install seal ring (122).
v) Install bearing (121) to cage (133) and secure
with snap ring (134).
vi) Using push tool, press fit bearing (120).

vii) Fit seal ring and install cage (119).
D475A-3 30-89
viii)Using eyebolts, sling shaft assembly (118),

then press fit bearing, and secure with snap
ring.
2) Set the case so that the side for installing

the steering assembly is at the top, then
using eyebolts, install shaft assembly (117)
in the case (116).
2. No. 4 carrier, No. 5 clutch assembly

1) Assemble the No. 4 carrier and No. 5 clutch
assembly as follows.
i) Using push tool, install spacer (113) to No. 5
housing (111).
ii) Install seal ring (114).
iii) Install piston assembly (112) to No. 5 housing
(111).
iv) Install seal ring (110) to inner gear.

v) Install inner gear (109).
vi) Install guide pin (108).
vii) Install springs (107), plates (106), and discs
(105) in turn.
viii)Install pin (104) and spring (103).
Free length of spring : 103.5 mm
ix) Assemble bearing (102) in gear (101), and fit

thrust washers (100) to both sides, then set
in position in carrier.
x) Assemble ball (99) to shaft (98), and push
shaft into carrier.
30-90 D475A-3
xi) Set No. 4 carrier assembly (96) to No. 5

clutch assembly (97), and using 2 guide bolts
5, compress spring, then tighten mounting
bolts.
Check that the spring is fitted securely in
the hole of the housing, then tighten the
mounting bolts.
2 Mounting bolt :
Thread tightener (LT-2)
3 Mounting bolt :
157 196 Nm {16 20 kgm}
2) Using eyebolts, install No. 4 carrier and No.

5 clutch assembly (95).
3. Plate, ring gear

1) Using eyebolts, align with dowel pin, then
install plate (93).
To ensure that the plate is fitted facing
in the correct direction, check the bolt
hole, then knock in the dowel pin por-
tion with a plastic hammer until there is
no clearance at the mating surface.
2) Install ring gear (94).
4. No. 3 ring gear

1) Install ring gear (92).
2) Install No. 3 ring gear (91).
5. Plate, bearing
1) Using push tool, press fit bearing (90) in
collar (89).
2) Using push tool, press fit bearing (88).
D475A-3 30-91
3) Using push tool, press fit bearing (87) in

plate (86).
Set the large protrusion of the bearing
assembly on top as shown in the
diagram right, and install to the plate.
4) Using eyebolts, install plate and bearing as-
sembly (85).
6. Sun gear
Install sun gear (84), and secure with snap ring
(132).
7. Guide pin
Install guide pin (83).

Install springs (82), plates (81), and discs (80) in
turn.
9. Spring
Install spring (79).
Free length of spring : 81.7 mm
10. No. 4 piston

Fit seal ring and install No. 4 piston (78).
11. No. 3 housing

Using eyebolts, fit seal ring and install No. 3
housing (77).
12. Seat
Install seat (76).
30-92 D475A-3

turn.
14. Spring
Free length of spring : 84 mm
15. No. 3 piston

Fit seal ring and install No. 3 piston (71).

1) Fit seal ring, and install piston (70) to hous-
ing (69).
2) Using eyebolts, install No. 2 housing and
piston (68).
the hole of the housing.
17. No. 2 ring gear

Install ring gear (67).
18. Shaft, No. 1, 2, 3 carrier assembly

1) Assemble the No. 2, No. 3 carrier as follows.
i) Install seal ring (66) to carrier.
ii) Using push tool, press fit spacer (64) and
bearing (63) in collar (65).
iii) Using push tool, press fit bearing (62).

iv) Using push tool, press fit collar and bearing
(61) in carrier.
D475A-3 30-93
v) Assemble bearing (60) in gear (59), then fit

thrust washers (58) to both sides, and set in
carrier.
vi) Assemble ball (57) to shaft (56), and push
shaft into carrier.
vii) Install seal ring (55) to plate.

viii)Install plate (54) to No. 2, 3 carrier assembly
(53).
ix) Set plate (51) to gear (52), and install ring
(50).
x) Using eyebolts, install plate and gear

assembly (49).
xi) Install sun gear (48), and secure with snap
ring.
2) Assemble the shaft and No. 1 carrier assem-

bly as follows.
i) Install seal ring (47), (131) to carrier.
ii) Assemble bearing (46) in gear (45), then fit
thrust washers (44) to both sides, and set in
carrier.
iii) Assemble ball (43) to shaft (42), and push
shaft into carrier case (41).
30-94 D475A-3
iv) Install seal ring (40) to shaft (39).

v) Install seal ring (38) to cage.
vi) Using push tool, press fit bearing (37) in

cage.
vii) Press fit bearing (36) in shaft.
viii)Set spacer (35) to bearing and cage assem-

bly (34), and press fit shaft (39).
ix) Using eyebolts, install shaft and cage as-

sembly (33).
3) Assemble the shaft and carrier assembly as

follows.
i) Using eyebolts, install shaft and No. 1 carrier
assembly (31) to No. 2, 3 carrier assembly
(32).
Align the sun gear with the tooth face of
the planetary gear, and tap with a plastic
hammer to install.
D475A-3 30-95
ii) Set carrier assembly on its side, then install

sun gear (30), and secure with snap ring
(130).
4) Using eyebolts, install shaft and No. 1, 2, 3

carrier assembly (29) to housing.
19. Sleeve, guide pin

1) Install guide pin (28).
2) Install sleeve (27).

turn.
21. Spring

1) Fit seal ring and install piston (22) to hous-
ing (21).
2) Using eyebolts, install No. 1 housing and
piston (20).
the hole of the housing.
23. No. 1 ring gear

Install ring gear (19).
24. Discs, plates, springs.

turn.
25. Spring
30-96 D475A-3
26. Housing
1) Install seal ring (14) to housing.
2) Using eyebolts, set housing (13) in position.
3) Tighten 17 tie bolts (12) in turn.
3 Tie bolts:
353 392 Nm { 36 40 kgm}
27. Checking piston stroke

Using tool D, check each piston stroke.
Air pressure : 0.5 0.6 MPa {5 6 kg/cm2}
Unit : mm
Piston Standard stroke
No. 1 (R) 7.4
No. 2 (F) 8.4
No. 3 (3) 4.8
No. 4 (2) 5.0
No. 5 (1) 7.1
28. Transmission case

1) Using eyebolts, install transmission case (11).
2) Install plate (10).
D475A-3 30-97
29. Rotation detection shaft

1) Set case so that valve mounting surface is
at top, then insert rotation detection shaft
(115) from output end.
Check that the tip of the shaft is mated
with the lock portion of its mating boss.
2) Using push tool, install bearing (129) to boss

(128), and secure with snap ring (136).
3) Install boss and bearing assembly (127) to
output shaft, and secure with snap ring (135).
Install the bearing slowly and be careful
that shaft (115) is mated with the lock
portion of boss (128).
30. Sleeve, valve sheet

1) Mount sleeves (3).
2 Sleeve (4 pieces): Grease (G2-LI)
2) Mount valve sheet (2).

3 Mounting bolt: 59 74Nm {6 7 kgm}
2 Mounting bolt (7 pieces):
Liquid gasket (LG-5)
30-98 D475A-3
31. Transmission control valve assembly

1) Mount transmission control valve assembly
(1).
3 Mounting bolt marked by (4 pieces):
59 74 Nm {6 7 kgm}
Mounting bolt marked by (1 piece):
59 74 Nm {6 7 kgm}
59 74 Nm {6 7 kgm}
27 34 Nm {2.8 3.5 kgm}
D475A-3 30-99
DISASSEMBLY AND ASSEMBLY STEERING CASE
DISASSEMBLY OF STEERING
CASE ASSEMBLY
1. Clutch, brake assembly
Using tool E1, sling clutch and brake assembly,
then remove mounting bolts, and remove clutch
and brake assembly.
Remove the clutch and brake assembly on
the opposite side in the same way. When
pulling out the clutch and brake assembly,
be careful not to damage the discs and
plates.
2. Shafts
Remove left and right shafts (4).
3. Lubrication tube
Remove lubrication tube (5).
4. Pipes
1) Remove left and right pipes (6).
2) Remove pipe (7).
5. Steering valve assembly

1) Remove protection cover (2A).
2) Remove bracket (2B).
3) Remove steering valve assembly (1).
6. Input shaft
1) Remove cage assembly (8).
2) Remove snap ring, and pull out input shaft
(9) from case.
30-100 D475A-3
7. Transfer, gear housing assembly

Fit guide bolt and screw in forcing screws 1,
then remove housing assembly (10).
8. Cage
1) Turn over so that right cage is at top, then
remove bearing cage (11).
Check the number and thickness of the
shims, and keep in a safe place.
2) Using eyebolts 2, remove cage (12).
9. Bevel gear, shaft assembly

Using eyebolts, remove bevel gear and shaft
assembly (13).
1) Disassemble the bevel gear and shaft as-

sembly as follows.
i) Pull out reamer bolt, and remove bevel gear
(14) from shaft (15).
ii) Using puller 3, remove bearings (16) and
(17) from shaft.
10. Cage
1) Turn over steering case, and remove bear-
ing cage (18).
Check the number and thickness of the
shims, and keep in a safe place.
2) Remove outer race (19) from bearing cage.
D475A-3 30-101
ASSEMBLY OF STEERING
CASE ASSEMBLY
Wash all parts, then dry them, and check for dirt
or damage. Coat the sliding surfaces of all parts
with engine oil before installing.
1. Cage
1) Using push tool, press fit outer race (19)
2) Assemble shim, and install bearing cage (18).
Standard shim thickness : 2 mm
3 Mounting bolt :
245 308.7 Nm {25 31.5 kgm}
2. Bevel gear, shaft assembly

1) Assemble bevel gear and shaft as follows.
i) Using tool E2, press fit bearings (17) and
(16).
ii) Set bevel gear (14) to shaft (15), and tighten
reamer bolt.
3 Reamer bolt :
490 607.6 Nm {50 62 kgm}
iii) Using eyebolts, install bevel gear and shaft

assembly (13).
3. Cage
1) Using eyebolts 2, install cage (12).
3 Mounting bolt :
245 308.7 Nm {25 31.5 kgm}
2) Assemble shim, and install bearing cage (11).

Standard shim thickness : 2 mm
3 Mounting bolt :
245 308.7 Nm {25 31.5 kgm}
4. Adjusting preload
Rotate bevel gear 2 3 turns, and fit push-pull
scale 4 to tip of teeth, then measure rotating
torque of bevel gear shaft.
Standard value of rotating torque:
9.8 11.8 Nm {1.0 1.2 kgm}
30-102 D475A-3
5. Transfer, gear housing assembly

Fit guide bolt 5 to steering case, and install
housing assembly (10).
3 Mounting bolt :
245 308.7 Nm {25 31.5 kgm}
6. Adjusting tooth contact, backlash

1) Adjusting backlash
Put the probe of dial gauge 6 in contact
with the tip of the bevel gear teeth at right
angles. Hold the bevel pinion in position,
and read the measurement when the bevel
gear is moved forward and backward.
Standard value for backlash :
0.3 0.4 mm
Measure at a minimum of three points
on diagonally opposite sides.
Adjusting
If the result of the inspection shows that the
correct backlash is not being obtained, ad- When backlash is small
just as follows.
i) If backlash is too small:
Adjust the shim thickness at the bevel
pinion end to move the bevel pinion in
direction A, or adjust the shim thickness
at the bearing cage of the bevel gear
shaft to move the bevel gear in direc-
tion B.
DBD02993
ii) If backlash is too large:
Adjust the shim thickness at the bevel
pinion end to move the bevel pinion in When backlash is large
direction A (the opposite direction from
A above), or adjust the shim thickness
at the bearing cage of the bevel gear
shaft to move the bevel gear in direc-
tion B (the opposite direction from B
above).
When adjusting the shim thickness at
the bearing cage of the bevel gear shaft,
do not change the preload of the bear-
ing. Adjust by moving shims between
the bearing cage and the bevel pinion. DBD02994
Always keep the same total thickness of
shims.
D475A-3 30-103
2) Adjusting tooth contact

Testing Dedendum (root of tooth)
i) Coat the tooth face of the bevel pinion Addendum (tip of tooth)
lightly with red lead (minium). Rotate
the bevel gear in both the forward and Big end
reverse directions, and inspect the pat-
tern left on the teeth.
ii) The standard tooth contact should be as
follows:
(from small end of pinion)
a) Width of tooth contact: 30 75%
Small end
b) Center of tooth contact: 20 40% DBD02995
c) Position of tooth contact: 20 40%
It must be within the standard value
when preload is given to the taper roller
bearing which is supporting the bevel
gear, and only the bevel pinion is
meshed, with no load.
The tooth contact should be in the center
of the tooth height and there should be
no strong contact at the root of the teeth.
The contact should be in about the same
position when the gear is rotated in for-
ward or reverse.
30-104 D475A-3
Adjustment
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) If bevel pinion is too far from center line
of bevel gear. B
Contact is at the small end of the con-
vex tooth face of the bevel gear and at
the big end of the concave tooth face.
[Correct the tooth contact as follows.]
Adjust the thickness of the shims at the A
bevel pinion to move the bevel pinion DBD00161
in direction A.
Or adjust the thickness of the shims at
the bearing cage of the bevel gear shaft
to move the bevel gear in direction B,
then check the tooth contact pattern and
backlash again.
ii) If bevel pinion is too close to center line B

of bevel gear.
Contact is at the big end of the convex
tooth face of the bevel gear and the
small end of the concave tooth face.
[Correct the tooth contact as follows.] A
Adjust the thickness of the shims at the DBD00162
bevel pinion to move the bevel pinion

in direction A (the opposite direction
from A above).
Or adjust the thickness of the shims at
the bearing cage of the bevel gear shaft
to move the bevel gear in direction B
(the opposite direction from B above),
then check the tooth contact pattern and
backlash again.
When adjusting the movement in or out
of the bevel gear, do not change the
preload of the bearing. Adjust by mov-
ing shims between the bearing cage and
the bevel pinion. Always keep the same
total thickness of shims.
D475A-3 30-105
7. Input shaft
1) Assemble input shaft (9) in case, and secure
with snap ring.
2) Install cage assembly (8).
8. Steering valve assembly

1) Mount steering valve assembly (1).
245 309 Nm {25 31.5 kgm}
2) Tighten bracket (2B) together with steering
case.
3 Mounting bolt marked by (1 piece):
245 309 Nm {25 31.5 kgm}
3) Tighten protection cover (2A) together with
steering case.
245 309 Nm {25 31.5 kgm}
245 309 Nm {25 31.5 kgm}
9. Pipes
1) Install pipe (7).
2) Install left and right pipes (6).
Coat the O-rings thinly with grease (G2-
LI), and be careful not to damage them
when installing.
10. Lubrication tube

Install lubrication tube (5).
11. Clutch, brake assembly

Using tool E1, install clutch and brake assembly
(3).
3 Mounting bolt :
279 30 Nm {28.5 3 kgm}
30-106 D475A-3
12. Shafts
Install left and right shafts (4).
If it is difficult to insert the shafts with the
bevel locked, release the steering brake be-
fore inserting.
1) Remove plugs (20), then remove bolts (21),
and tighten them in plug holes to compress
clutch spring and release brake.
D475A-3 30-107
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY
1. Remove operators cab assembly.
For details, see REMOVAL OF OPERATOR CABS
ASSEMBLY.
2. Remove operators seat and floor frame cover.

Use turnbuckle (1) when disconnecting the
brake rod. Check the mounting dimensions
of the rod before disconnecting. 1
3. Disconnect wires, cables, and rods.
4. Remove transmission control valve assembly (2).

Remove four bolts marked by and each
bolt marked by , , and . 2
D475A-3 30-127
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
INSTALLATION OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
removal.
1
Adjust the brake pedal and parking lever.
adjusting brake pedal and parking brake le-
ver.
3 Turnbuckle locknut :
34.3 58.8 Nm {3.5 6 kgm}
2
2 Mounting bolt (4 pieces):
59 74 Nm {6 7 kgm}
59 74 Nm {6 7 kgm}
59 74 Nm {6 7 kgm}
27 34 Nm {2.8 3.5 kgm}
30-128 D475A-3
DISASSEMBLY AND ASSEMBLY STEERING CONTROL VALVE
REMOVAL OF STEERING
1. Remove fuel tank assembly.
For details, see REMOVAL OF FUEL TANK AS-
SEMBLY.
2. Disconnect wires, cables, and rods.
3. Steering control valve assembly

1) Remove protection cover (2A).
2) Remove bracket (2B). 1
3) Remove steering control valve assembly (1).
INSTALLATION OF STEERING
1
3 Steering control valve assembly
Mounting bolt marked by (2 pieces):
245 309 Nm {25 31.5 kgm}
245 309 Nm {25 31.5 kgm}
Mounting bolt marked by (4 pieces):
245 309 Nm {25 31.5 kgm}
245 309 Nm {25 31.5 kgm}
D475A-3 30-135
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

ASSEMBLY
For details, see REMOVAL OF OPERATORS CAB
ASSEMBLY.
2. Remove covers (1), (2) and (3).
3. Remove step cover (5).
4. Lift off operators seat (6).

Remove the seat together with the under-
cover.
4 Operators seat : 108 kg
5. Disconnect 2 air conditioner hoses (7). 1

Loosen the sleeve nut slightly and release
the air conditioner gas (R134a) completely
before disconnecting the hoses.
Disconnect at the air conditioner end, then
move the hoses towards the engine.
Fit blind plugs to prevent dirt or moisture
from entering the hoses.
Be careful not to damage or drop the O-
rings.
6. Disconnect 2 heater hoses (8).

Close the heater valve at the engine end.
7. Disconnect blade PPC hose (10) and hose clamp

(11).
8. Disconnect blade PPC hoses (12), (13), and (14).

Single tilt specification machine only. 2
D475A-3 30-235
9. Disconnect ripper PPC hoses (15), (16), (17), and

(18). 3
10. Disconnect accumulator hose (19).
11. Disconnect tank return hoses (20) and (21).
12. Disconnect clamps (22) (2 places) for wiring har-

ness and washer tank hose.
13. Disconnect ground wiring (23) (SX-8).
14. Disconnect wiring connectors CN-PL1, CN-PL2,

CN-578, CN-PWR1, CN-PWR2, CN-USB, CN-FD5,
CN-122, and CN-599.
15. Disconnect parking brake cable (34) on lever side,

then remove it from bracket.
Before disconnection, check cable mounting
length. 4
16. Disconnect brake pedal linkage (35) on turn

buckle unit. 5
Before disconnection, check brake rod
mounting length.
Be careful that turn buckle unit is mounted
with reverse helical screws.
30-236 D475A-3
17. Remove arm rest (36).
18. Remove right console (37).

Disconnect cable connectors (CN-262 and
CN263) in console.
Remove lever boots from console, then re-
move console.
19. Remove left console cover (38).
20. Remove eight bolts (four on each side) on the

left and right of rear mounting bolts (39). 6
21. Remove earth cable (40).
22. Remove one left front mounting bolt (41). 7
23. Remove one right front mounting bolt (42).

7
24. Lift off floor frame assembly (45) to remove.
4 Floor frame assembly: 600 kg
Use chain block to lift floor frame assembly

by degrees while balancing front, rear, left,
and right.
D475A-3 30-237
INSTALLATION OF FLOOR
FRAME ASSEMBLY
removal.
1
Install the hoses without twisting or interfer-
ence.
Install the air conditioner circuit hoses care-
fully to prevent dirt, dust, or water from
getting inside the hoses. O-ring
Check that there are O-rings at the piping
connection of the air conditioner hoses be- DBD02985
fore installing.
Coat the O-rings thoroughly with compres-
sor oil (Shell Suniso 4G or 5G).
3 Tighten the air conditioner gas pip-
ing to the following tightening tor-
ques.
Thread size Tightening torque (Nm {kgm})
16 1.5 13.231.47 {1.350.15}
22 1.5 22.052.45 {2.250.25}
24 1.5 31.852.45 {3.250.25}

M6 bolt (receiver
portion) 5.391.47 {0.550.15}
M6 bolt (com-
pressor portion) 9.81.96 {1.00.2}
23
Adjust the directional, speed control, and
parking brake linkage.
4
Adjust parking brake lever linkage, referring
to Adjustment of Brake Pedal and Parking
Lever in TESTING and ADJUSTING.
5
Adjust brake pedal linkage, referring to Ad-
justment of Brake Pedal and Parking Lever
in TESTING AND ADJUSTING.
3 Brake pedal linkage turn buckle:
45.56 12.25 Nm {4.76 1.25 kgm}
67
3 Rear mounting bolt:
279 30 Nm {28.5 3 kgm}
3 Front mounting bolt:
1,320 140 Nm {135 15 kgm}
D475A-3 30-239
DISASSEMBLY AND ASSEMBLY DASHBOARD
REMOVAL OF DASHBOARD
ASSEMBLY
For details, see REMOVAL OF OPERATORS CAB
ASSEMBLY.

rings.

4. Disconnect cable connectors ((CN-S13), (CN-214),

(CN-215), (CN-216), and (CN-DL1)), and earth
cable.
5. Lift off dashboard assembly (7).
4 Dashboard assembly : 120 kg
30-240 D475A-3
DISASSEMBLY AND ASSEMBLY DASHBOARD
INSTALLATION OF
DASHBOARD ASSEMBLY
removal.
1
Install the hoses without twisting or inter-
ference.
fully to prevent dirt, dust, or water from O-ring
getting inside the hoses.
Check that there are O-rings at the piping DBD02985
connection of the air conditioner hoses be-

fore installing.
3 Tighten the air conditioner gas piping to
the following tightening torques.
16 1.5 13.231.47 {1.350.15}
22 1.5 22.052.45 {2.250.25}
24 1.5 31.852.45 {3.250.25}

M6 bolt (receiver
portion) 5.391.47 {0.550.15}
M6 bolt (com-
Charging with air conditioner gas

Using tool X, charge the air conditioner circuit
with air conditioner gas (R134a).
Refilling with water

Add water to the specified level, and run the
engine to circulate the water through the sys-
tem. Then check the water level again.
D475A-3 30-241
DISASSEMBLY AND ASSEMBLY CONTROLLER
REMOVAL OF CONTROLLER
ASSEMBLY
Disconnect the cable from the negative () ter-
minal of the battery.
1. Remove cover (1).
2. Disconnect wiring connectors of main controller

(2). (CN- S40, M11, M21, M31, M41, M51)
3. Disconnect wiring connectors of engine control-

ler (3). (CN-E11, E21, E31, E32, E41, E51, E52)
4. Remove main controller (2) and engine control-

ler (3).
INSTALLATION OF
CONTROLLER ASSEMBLY
removal.
30-242 D475A-3
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT
ASSEMBLY
1. Remove left and right covers (1) and cover (2).

rings.

4. Disconnect cable connectors ((5) (CN-S13), (6)

(CN-214), (7) (CN-215), (8) (CN-216), and (9) (CN-
DL1)), and earth cable (CN-GND1).
5. Remove covers (12) and (13).
30-246 D475A-3
6. Remove panel (16), then remove cover (17).
7. Remove ducts (18) and (19).
8. Remove monitor (20) and cover (21).
9. Remove RECIRC air filter (22) and FRESH air

filter (23).
There is 1 mounting bolt for the air condi-
tioner unit beyond the FRESH air filter
bracket.
D475A-3 30-247
10. Disconnect bracket (24) and clamp (25).
11. Disconnect relays (26) (CN-R1), (27) (CN-R2), (28)

(CN- R3) and connector (29) (CN-M26) inside right
side of dashboard.
12. Remove air conditioner unit (30).
13. Remove blower motor (31).
30-248 D475A-3
INSTALLATION OF AIR
CONDITIONER UNIT
removal.
1
Install the hoses without twisting or interfer-
ence.
fully to prevent dirt, dust, or water from O-ring
getting inside the hoses.
Check that there are O-rings at the piping DBD02985
connection of the air conditioner hoses be-

fore installing.
3 Tighten the air conditioner gas piping to
the following tightening torques.
16 1.5 13.231.47 {1.350.15}
22 1.5 22.052.45 {2.250.25}
24 1.5 31.852.45 {3.250.25}

M6 bolt (receiver
portion) 5.391.47 {0.550.15}
M6 bolt (com-
Charging with air conditioner gas

Using tool X, charge the air conditioner circuit
with air conditioner gas (R134a).
Refilling with water

Add water to the specified level, and run the
engine to circulate the water through the sys-
tem. Then check the water level again.
D475A-3 30-249
40 MAINTENANCE STANDARD
Engine mount ............................................... 40- 2

Damper, universal joint .............................. 40- 3
Torque converter ........................................ 40- 4
Torque converter valve ............................... 40- 6
TORQFLOW transmission ........................... 40- 8
Power train, hydraulic,
lubrication pump ................................... 40-10
Transfer, bevel pinion ................................. 40-11
Bevel gear shaft, steering clutch,
brake ...................................................... 40-12
Parking brake valve .................................... 40-14
Final drive ..................................................... 40-16
Main frame ................................................... 40-18
Track frame ................................................... 40-20
Recoil spring ................................................. 40-21
Idler ................................................................ 40-22
Track roller .................................................... 40-24
Carrier roller ................................................ 40-26
Track shoe ................................................... 40-28
Equalizer bar ................................................ 40-32
Pivot shaft ..................................................... 40-34
Hydraulic pump ........................................... 40-35
Work equipment control pump ................. 40-36
Main control valve ...................................... 40-37
PPC valve ..................................................... 40-41
Work equipment cylinder ........................... 40-44
Cylinder stay ................................................ 40-46
Blade ............................................................. 40-48
Ripper equipment ....................................... 40-54
D475A-3 40-1
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
1 Clearance between bracket
and cushion 0.030 +0.006 0.018
78 0.1
0.060 0.048 0.066
Clearance between bracket 0.043 +0.072 0.043 Replace

2 200 0.1
and bushing 0.083 0 0.155
Standard size Repair limit
3 Free height of rubber
mount 118 116
40-2 D475A-3
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
Unit: mm

Clearance between size Shaft Hole clearance limit
1 flywheel housing and
cover 647.7 0.224 +0.080 0.024 0.2
0.105 0 0.185
Clearance between 571.5 0.022 +0.070 0.022 0.2

2
flywheel and damper 0.092 0 0.162 Replace
3 Outer diameter of oil seal
contact face on coupling 120 119.9
Outer diameter of bearing

4 contact face on output shaft 55 54.9
D475A-3 40-3
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
40-4 D475A-3
MAINTENANCE STANDARD TORQUE CONVERTER
Unit: mm
Standard size Tolerance Repair limit

Outside diameter of oil seal
1 contact surface of coupling 0
125 0.100 124.8
Inside diameter of seal ring Repair hard

+0.035
2 contact surface of seat 115 chrome
0
plating or
Inside diameter of seal ring replace
+0.046
3 contact surface of retainer 190 190.5
0
Inside diameter of seal ring +0.035

4 contact surface of sleeve 120 120.2
0
Backlash of input shaft Standard clearance Clearance limit

5 gear and scavenging
pump drive gear 0.250 0.420
Backlash of input shaft

6 gear and driven gear 0.204 0.516

7 Wear of stator shaft
seal ring Width: 5.95 Width: 5.35
Height: 6.50 Height: 5.85
5.4 5.0
Lock-up clutch
Thickness of disc
8 Thickness of plate 5.0 4.5
Thickness of total Replace

assembly 26.2 24.0
Thickness of disc 5.4 5.1

Stator clutch
9 Thickness of plate 5.0 4.5
Thickness of total
assembly 15.8 14.7

Free Installation Installation Free Installation
length length load length load
10 Stator clutch spring
25.5N 106.9N
54.1 37.0 {12.8 kg} 50.9 {10.9 kg}
D475A-3 40-5
MAINTENANCE STANDARD TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
40-6 D475A-3
MAINTENANCE STANDARD TORQUE CONVERTER VALVE
Unit: mm

Clearance between main size Shaft Hole clearance limit
1 relief valve and valve
body 0.035 +0.016 0.035
40 0.08
0.045 0 0.061
Clearance between torque
converter relief valve and 0.035 +0.016 0.035
2 40 0.08
valve body 0.045 0 0.061
Clearance between stator
clutch modulating valve 0.035 +0.013 0.035
3 25 0.08
and valve body 0.045 0 0.058
Clearance between lock-up
clutch modulating valve 0.035 +0.013 0.035
4 25 0.08
and valve body 0.045 0 0.058
Clearance between lock-up 0.035 +0.016 0.035

5 40 0.08
valve and valve body 0.045 0 0.061
Replace
6 Main relief valve spring length length load length load
1495.5 N 1346.4 N
120.3 101.5 {152.5 kg} 116.7 {137.3 kg}
Torque converter relief 550.4 N 495.2 N

7 valve spring 116.92 90.8 {56.16 kg} 113.41 {50.5 kg}
Stator clutch modulating 197.1 N 117.5 N

8 valve spring 103.5 92.7 {20.1 kg} 100.4 {18.1 kg}
Lock-up clutch modulating 158.6 N 150.7 N

9 valve spring (outer) 141.4 88.7 {16.18 kg} 137.16 {15.37 kg}
41.8 N 675.7 N
Lock-up clutch modulating 72.5 {4.26 kg}
10 valve spring (inner) 80.5 (Normal height) (Normal load) 78.09 {68.9 kg}
29.4 N 27.9 N
11 Lock-up valve spring 110.07 100.0 97
{3.0 kg} {2.85 kg}
D475A-3 40-7
MAINTENANCE STANDARD TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION
Unit: mm

No. 1 clutch spring length length load length load
1
(12 pcs)
40.2 N 119.6 N
100.0 90.0 {14.3 kg} 94.0 {12.2 kg}
No. 2 clutch spring 83.4 N 70.6 N

2 (12 pcs) 100.0 94.0 {8.5 kg} 94.0 {7.2 kg} Replace
No. 3 clutch spring 150 N 127.4 N

3 (12 pcs) 84.0 72.0 {15.3 kg} 79.0 {13 kg}
No. 4 clutch spring 119.6 N 102.0 N

4 81.7 63.0 {12.2 kg} 76.5 {10.4 kg}
(12 pcs)
No. 5 clutch spring 238.3 N 203 N

5 103.5 76.0 {24.3 kg} 97.0 {20.7 kg}
(12 pcs)
40-8 D475A-3
MAINTENANCE STANDARD TORQFLOW TRANSMISSION
Unit: mm

Thickness of total
6
assembly for No. 1 clutch
72.6 0.36 68.9
Thickness of total
7 72.6 0.36 68.9
Thickness of total
8 50.2 0.30 47.5
Thickness of total
9 assembly for No. 4 clutch 39.0 0.26 36.9
Thickness of total
10 assembly for No. 5 clutch 61.4 0.33 58.2
11 Thickness of a clutch disc 5.4 0.1 4.9
12 Thickness of a clutch plate 5.8 0.1 5.2
Replace
0.01
Wear of seal Width 3.0 0.03 2.6
13 ring on trans-
mission input
shaft Thickness 4.0 0.12 3.85
0.01
Wear of seal Width 4.0 0.03 3.5
14 ring on trans-
mission output
shaft Thickness 5.0 0.15 4.85
0.01
Width 6.0 0.03 5.65
Wear of seal
15 ring for No. 5
clutch Thickness 6.8 0.15 6.65
Backlash between each

16 sun gear and planetary 0.16 0.35
pinion
Backlash between each
17 planetary pinion and inner 0.18 0.38
gear on ring gear
D475A-3 40-9
MAINTENANCE STANDARD POWER TRAIN, HYDRAULIC, LUBRICATION PUMP
POWER TRAIN, HYDRAULIC, LUBRICATION PUMP

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

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

3
depth 0
14
0.5
BAL112
Rotating torque of spline

4 shaft 5.88 Nm {0.6 kgm}
Delivery Standard Delivery

Type Speed (rpm) pressure delivery limit
MPa {kg/cm2} (/min.) (/min.)
Delivery 2.94
EO10 CD BAL160 2,000 288 266
{30}
45 55C
2.94
BAL112 2,000 {30} 205 188
40-10 D475A-3
MAINTENANCE STANDARD TRANSFER, BEVEL PINION
TRANSFER, BEVEL PINION
Unit: mm
Standard clearance Clearance limit

Adjust or
1 Backlash of transfer gear
0.26 0.67 0.75 replace

Thickness of collar
2 between transfer gear and Replace
bearing 19.3 18.9
Thickness of shims for Adjust

3 2.0
bearing cage
D475A-3 40-11
MAINTENANCE STANDARD BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
40-12 D475A-3
MAINTENANCE STANDARD BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
Unit: mm

Thickness of brake, clutch Replace
plate 4.2 3.9
1
Tolerance Repair limit
Warping of brake, clutch Correct or
plate less than 0.3 0.4 replace
Thickness of brake, clutch
disc Replace
5.4 5.1
2
Tolerance Repair limit Correct or
Warping of brake, clutch
disc less than 0.3 0.4 replace

Thickness of total brake
3 plate and disc assembly 82.2 78.5
Thickness of total brake 76.8 74.1 Replace
4 plate and disc assembly
Backlash of brake, clutch Standard clearance Repair limit

5 disc, and brake hub 0.4 07 1.0
Backlash between bevel Adjust or
6 gear and pinion 0.3 0.4 0.75 replace
Clearance between seal ring
7 and piston seal ring groove 0.5 0.8 0.8
Clearance between seal ring

8 and cage seal ring groove 0.5 0.8 0.8

Inside diameter of seal size Shaft Hole clearance limit
9 ring contact surface of
cage 0.5 +0.089 0.5
350 0.7 0 0.789
10 Inside diameter of seal ring 0.110 +0.052 0.110 Replace

contact surface of piston 300 0.191 0 0.243

11 Brake belleville spring length length load length load
46.97 kN 44.62 kN
19.7 12.9 {4,790 kg} 19.1 {4,550 kg}
55.7 kN 53.35 kN
12 Clutch belleville spring 20.4 12.9 {5,680 kg} 20.0 {5,440 kg}
Standard Tolerance Standard Interference

Interference between bevel size Shaft Hole interference limit
13 Replace
gear and reamer bolt
+0.023 +0.033 0.032
20 +0.002 0 0.019 0.02
Runout of rear face of Service limit: 0.05 Correct or

14 bevel gear (measure after installing to bevel gear shaft) replace
Standard rotating torque: 9.8 11.8 Nm {1.0 1.2 kgm}
Preload of bevel gear shaft (When bevel pinion and gear are not meshed, Adjust
15
taper roller bearing at tip of bevel gear: 51.0 61.8 N {5.2 6.3 kg}
Standard shim thickness Adjust
16 2.0 shim
of bearing cage
D475A-3 40-13
MAINTENANCE STANDARD PARKING BRAKE VALVE
PARKING BRAKE VALVE
Unit: mm

Clearance between parking size Shaft Hole clearance limit
1 brake valve spool and Replace
valve body 14 0.020 +0.011 0.020 0.05
0.030 0 0.041
Tolerance Repair limit Modify or
Outer diameter of sliding
replace the
2 section (spool) between 14 0.020 13.9 hard chrome
dust seal and V-packing 0.030 plating.
Free Installed Installed Free Installed
Parking brake valve spool length length load length load Replace
3 spring
38.2 N 36.3 N
65 47.7 {3.9 kg} 63.1 {3.71 kg}
40-14 D475A-3
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
40-16 D475A-3
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

1 Backlash between No. 1
pinion and No. 1 gear 0.26 0.96 1.5
Backlash between sun

2 0.25 0.70 1.5
gear and planet pinion
Backlash between planet

3 pinion and ring gear 0.26 0.83 1.5

Outside diameter of
4 No. 1 pinion oil seal
120.0 119.9
contact surface
Replace
Thickness of thrust collar
5 of inner body roller 24.8 24.6
bearing
Thickness of thrust collar
6 of No. 1 gear boss roller 14.0 13.5
bearing
Dimension from mounting
7 face of cover to head of 72.0 70.5
button
Clearance between pinion size Shaft Hole clearance limit
8 shaft and carrier
0.035 0.024 0.024
110 0.054 0.059 0.030 0.1
Standard shim thickness

9 for No. 1 pinion bearing 2
cage
Dimension of end face of
10 final drive cover and end 7.3 8.3 Adjust
face of bearing
Clearance of floating seal
11 guard 3.1 4.7

12 Wear of sprocket teeth
bottom 30 24 Rebuild or
replace
13 Wear of sprocket teeth tip 486 470
D475A-3 40-17
MAINTENANCE STANDARD MAIN FRAME
MAIN FRAME
40-18 D475A-3
MAINTENANCE STANDARD MAIN FRAME
Unit: mm

Interference between size Shaft Hole clearance limit
1 steering case and bushing (Std.
+0.108 +0.052 interference)
315 +0.056 0 0.004 Above 0
0.108
Clearance between
steering frame and final 0.018 +0.057 0.018
2 390 0.075 0 0.132 0.2
drive cage
Clearance between bracket 0.030 +0.006 0.018
3 78 0.060 0.048 0.066 0.1
and cushion
Clearance between ripper 0.043 +0.210
arm mounting pin and 0.093
4 140 0.106 +0.050 0.316 1.5
bushing
Clearance between ripper 0.036 +0.301
cylinder mounting pin and 0.154
5 110 0.090 +0.118 1.5
bushing 0.371
Clearance between 0.036 +0.164 0.298 Replace
radiator guard mounting Hole 100.2
6 0.090 +0.062 0.454 1.5
pin and bushing Shaft 100
Clearance between 0.043 +0.140 0.274
radiator guard mounting Hole 115.2
7 0.106 +0.031 0.446 1.5
pin and bushing Shaft 115
Clearance between
0.043 +0.208 0.174
8 equalizer bar shaft and 140 0.083 +0.131 1.5
0.291
bushing
9 Protrusion of rubber at
end face of seal
1 0.5
10 Free height of front mount

rubber 118 116
11 Free height of rear mount

rubber 58 56
Press-fitting force for

12 ripper arm mounting 126.5 253 kN {12.9 25.8 ton}
bushing
13 ripper cylinder mounting 111.8 267.7 kN {11.4 27.3 ton}
bushing
14 radiator guard mounting 62.8 142.2 kN {6.4 14.5 ton} Adjust
bushing
15 radiator guard mounting 53.9 106.9 kN {5.5 10.9 ton}
bushing
16 equalizer bar shaft 65.7 153 kN {6.7 15.6 ton}
mounting bushing
D475A-3 40-19
MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
Unit: mm
Item Repair limit

Deformation of track Curvature 7 (for length of 3,000) Repair or
1 Replace
frame outer pipe Twisting 3 (for level length of 3,000)
Dents (pipe portion) 12

Clearance between inner size Shaft Hole clearance limit
2 pipe and adjustment Replace
cylinder protrusion 0.15 +0.3 0.15
70 0.35 0 0.65 2.0

Clearance between idler
3 Adjust
bogie and guide 0 0.5 3.0

4 cartridge 275 510 kN {28 52 ton}
40-20 D475A-3
MAINTENANCE STANDARD RECOIL SPRING
RECOIL SPRING
Unit: mm

1 Recoil spring length length load length load
788.3 N 715.4 N
1,731 1,455 {80,435 kg} 1,705 {73,000 kg}
Tolerance Replace
Standard Standard Clearance
Clearance between inner size Shaft Hole clearance limit
2 cylinder and outer cylinder
of outer cylinder bushing 0.068 +0.323 0.128
445 0.165 +0.060 0.488 0.8
Clearance between adjust- 0.100 +0.063 0.100

3 165 0.550 0 0.613
ment cylinder and bushing
Press-fitting force for outer
4 cylinder bushing (outer 51.0 99 kN {5.2 10.1 ton}
cylinder side)
Press-fitting force for outer
5 cylinder bushing (inner 129.4 389.1 kN {13.2 39.7 ton} Adjust
cylinder side)
Clearance between recoil
6 spring mount nut and lock 0 1.0
plate
D475A-3 40-21
MAINTENANCE STANDARD IDLER
IDLER
40-22 D475A-3
MAINTENANCE STANDARD IDLER
Unit: mm

1 Outside diameter of
protruding part 1,043
2 Outside diameter of tread

surface 990 959
Rebuild or
3 Depth of tread 26.5 42 replace
4 Thickness of tread 36 20.5
5 Overall width 347
6 Width of tread 96 105
Standard Tolerance Standard Clearance Replace

Clearance between shaft size Shaft Hole clearance limit bushing
7 and bushing
0.350 +0.168 0.353
180 0.413 +0.003 0.581

Rebuild or
8 Width of shaft flange replace
335.0

size Shaft Hole interference limit
9 Interference between ring Replace ring
and shaft
+0.046 0.15 0.15
115 0 0.20 0.246

10 End play Replace ring
0.52 0.98
D475A-3 40-23
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
40-24 D475A-3
MAINTENANCE STANDARD TRACK ROLLER
Unit: mm

Outside diameter of
1
flange (outside) 344
Outside diameter of 332

2
flange (inside)
Outside (Single flange) 300 230

3 diameter
of tread
(Double flange) 300 246
(Single flange) 71.5 36.5

Thickness
4
of tread Rebuild or
(Double flange) 7.15 44.5 replace
5 Overall width 423
Width of tread 99.5

6
(single flange)
Width of tread 99.5

7
(double flange)
Width of flange 34.5 19.5

8
(Outside of double flange)
Width of flange 27.5 12.5

9
(Inside of double flange)
10 Width of shaft flange 379

Clearance between shaft size Shaft Hole clearance limit
11 Replace
and bushing bushing
0.350 +0.170 0.350
147
0.413 0 0.583

Interference between size Shaft Hole interference limit
12 Replace
shaft and ring
+0.046 0.15 0.150
84 0 0.20 0.246
Adjust or
13 End play 0.44 0.91 replace
D475A-3 40-25
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

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

Interference between size Shaft Hole interference limit
6 shaft and ring
+0.046 0.15 0.150
95
0 0.20 0.246
Clearance between shaft 0 +0.35 Replace

7 90 0 0.55
and support 0.2 0
Play in axial direction of
8
roller 0 0.22 0.3
40-26 D475A-3
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
Portion P shows the link on the side where the bushing is pressed fitted.
40-28 D475A-3
Unit: mm

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

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

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

Clearance
8
between links
Both sides 3.2
Standard Tolerance Standard Adjust or

size Shaft Hole interference replace
Interference between
9
bushing and link +0.652 +0.087
113 0.465 0.652
+0.522 0
Interference between 70 +0.496 +0.124

10 0.312 0.446
regular pin and link +0.436 +0.050
Tightening torque Tightening angle

(Nm {kgm}) (deg)
a. Regular link
11 Shoe bolt 785 78 {80 8} 180 10 Retighten
b. Master link 980 98 {100 10} 180 10
Note 1: If wear has reduced the outside diameter of the double flange track roller to less than 250
mm, the limit is 183 mm.
Note 2: If wear has reduced the outside diameter of the double flange track roller to less than 250
mm, the limit is 37.5 mm.
D475A-3 40-29
SHINGLE SHOE
Unit: mm

1 Height
105 35
Repair by
2 Thickness 28 build-up
welding or
replace
3 Length of base 52
4 Length at tip 36
40-30 D475A-3
MAINTENANCE STANDARD EQUALIZER BAR
EQUALIZER BAR
40-32 D475A-3
MAINTENANCE STANDARD EQUALIZER BAR
Unit: mm

1 Clearance between center
pin and bushing
0.043 +0.225 0.186
140 0.083 +0.143 0.308 1.0
Clearance between side 0.048 +0.015 0.033

2 pin and bushing 115 0.078 0.015 0.093 1.0
Replace
Clearance between side 0.1 +0.3 bushing
3 pin and spherical surface 130 0.2 0.6 1.0
of bushing 0.3 +0.1

Interference between side size Shaft Hole interference limit
4 pin boss and bushing
+0.051 0.033 0.064
200 +0.031 0.079 0.130
Press-fitting force for side

5 121.5 294 kN {12.4 30 ton}
pin bushing

6 center pin bushing 68.6 232.2 kN {7 23.8 ton}
Press-fitting force for side

7 47.0 96.0 kN {4.8 9.8 ton}
pin bushing
D475A-3 40-33
MAINTENANCE STANDARD PIVOT SHAFT
PIVOT SHAFT
Unit: mm

size Shaft Hole interference limit
1 Interference between
thrust washer and seal
+0.216 0.234 0.320
270
+0.086 0.286 0.502
Replace
Interference between +0.096 0.075 0.125
2 thrust washer and seal 194
+0.050 0.147 0.243
Interference between pivot +0.108 0.122 0.178

3 263
shaft and seal +0.056 0.203 0.311

Clearance between pivot size Shaft Hole clearance limit
4 shaft and bushing
0.190 +0.138 0.216 Replace
260 1.0
0.271 +0.026 0.409 bushing
Clearance between pivot 0.170 +0.114 0.208

5 220 1.0
shaft and bushing 0.242 +0.038 0.356
40-34 D475A-3
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
(SAL140 + 100)
Unit: mm

Clearance
between gear SAL140 0.11 0.16
1 case and side
plate gear 0.22
SAL100 0.13 0.18
Clearance SAL140 0.069 0.140

between plain
2 0.20
bearing I.D. and Replace
gear shaft O.D. SAL100 0.078 0.149
SAR-140 SAR-100
3 Pin insertion depth
0 0
21 0.5 14 0.5
Rotational torque of spline

4 shaft 16.67 26.48 Nm {1.7 2.7 kgm}
Revolution Discharge Standard Discharge

Type pressure discharge limit
(rpm) (/min) (/min)
Discharge
EO10 CD SAL140 260 236
45 55C 20.6 MPa
2,000
{210 kg/cm2}
SAL100 180 163
D475A-3 40-35
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL PUMP
WORK EQUIPMENT CONTROL PUMP

(SAR100 + 32)
Unit: mm

Clearance
between gear SAR100 0.13 0.18
1 case and side
0.22
plate, gear
SAR32 0.10 0.15
Clearance
between inside SAR100 0.078 0.149
diameter of plain
2 bearing and 0.20 Replace
outside diameter SAR32
0.060 0.149
of gear shaft
0
SAR100 14 0.5
Pin insertion
3 depth
0
SAR32 10 0.5
Rotatinal torque of spline

4 shaft 8.83 16.67 Nm {0.9 1.7 kgm}
Speed Delivery Standard Delivery

Type pressure delivery limit
(rpm) (/min.) (/min.)
Delivery
EO10 CD SAR100 231 214
45 55C 20.6 MPa
2,500
{210 kg/cm2}
SAR32 75 67
40-36 D475A-3
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

BLADE LIFT VALVE
D475A-3 40-37
BLADE LIFT VALVE

Main relief, shuttle
valve
Unit: mm

1 Spool return spring length length load length load
116.6 N 93.3 N
104.35 103
{11.9 kg} {9.5 kg}
764.6 N 611.5 N
2 Spool return spring 130.62 124
{78 kg} {62.4 kg}
Spool return spring 744.4 N 595.8 N

3 56.29 45
(For FLOAT) {76 kg} {60.8 kg}
7.3 N 5.8 N
4 Check valve spring 95 77 69.3
{0.74 kg} {0.59 kg}
Replace
44.1 N 35.3 N
5 Check valve spring 32.7 24.5 31.0
{4.5 kg} {3.6 kg}
11.38 N 9.12 N
6 Suction valve spring 75.9 38.5 68.4
{1.16 kg} {0.93 kg}
401.8 N 321.4 N
7 Demand spool spring 94.03 60 114.7
{41 kg} {32.8 kg}
258.9 N 206.9 N
8 Main relief valve spring 41.1 32.6 {26.4 kg} 39.4
{21.1 kg}
8.14 N 6.47 N
9 Shuttle valve spring 42.7 22.0 38.6
{0.83 kg} {0.66 kg}
Height of main relief

10 pressure adjustment screw 8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2}) Adjust
40-38 D475A-3
BLADE TILT, RIPPER LOW VALVE
Unit: mm

156.8 N 125.4 N
48.14 46
{16.0 kg} {12.8 kg}
3.82 N 3.0 N Replace

{0.39 kg} {0.31 kg}
31.4 N 25.1 N
3 Main relief valve spring 24.2 18.3 23.0
{3.2 kg} {2.56 kg}
Main relief valve poppet 258.9 N 206.9 N
4 spring 41.1 32.6 39.4
{26.4 kg} {21.1 kg}
Height of main relief
5 pressure adjustment screw 8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2}) Adjust
D475A-3 40-39
RIPPER HIGH VALVE
Unit: mm

229.5 N 183.4 N
92.6 52.0 74.1
{23.4 kg} {18.7 kg}
8.8 N 7.1 N Replace

{0.9 kg} {0.72 kg}
5.59 N 4.4 N
3 Suction valve spring 75.8 57.5 60.7
{0.57 kg} {0.45 kg}
Fixed differential pressure 224.6 N 179.5 N

4 61.9 37.0 49.5
valve spring {22.9 kg} {18.3 kg}
40-40 D475A-3
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
FOR RIPPER
112.814.7Nm
(11.51.5kgm)
13.21.5Nm
(1.350.15kgm)
1
44.14.9Nm
(4.50.5kgm)
39.24.9Nm
(40.5kgm)
8.52.5Nm
(0.850.25kgm)
3 6.52.5Nm
(0.650.25kgm)
SYD00454
Unit: mm

Free length Installation Installation Free Installation
1 Centering spring x OD length load length load
(for P3, P4)
71.39 N 56.9 N
50.05 x 15.5 34 Replace
{7.28 kg} {5.8 kg}
spring
if damaged
Centering spring 55.9N 45.1 N
2 50.35 x 15.5 34 or deformed
(for P1, P2) {5.7 kg} {4.6 kg}
16.7 N 17.7 N
3 Metering spring 26.53 x 8.15 24.9 {1.7 kg} {1.4 kg}
D475A-3 40-41
FOR BLADE LIFT, BLADE TILT
40-42 D475A-3
Unit: mm

Free length Installation Installation Free Installation
1 Centering spring (for P1) x O.D. length load length load
156 N 124.5 N
37.9 x 15.6 32.5 {12.7 kg}
{15.9 kg}
16.7 N 13.7 N
2 Metering spring 26.53 x 8.15 24.9
{1.7 kg} {1.4 kg} Replace
spring if
108 N 86.2 N damaged or
3 Centering spring (for P2) 48.6 x 15.5 32.5
{11.0 kg} {8.8 kg} deformed
Centering spring 108 N 86.2 N
4 48.6 x 15.5 32.5
(for P3, P4) {11.0 kg} {8.8 kg}
168 N 134 N
5 Detent spring (for P1) 20.39 x 19.5 12.7
{17.1 kg} {13.7 kg}
38.44 N 30.79 N
6 Detent spring (for P2) 45.36 x 7.5 26
{3.92 kg} {3.14 kg}
D475A-3 40-43
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

BLADE LIFT CYLINDER
BLADE TILT CYLINDER, SUPER DOZER PITCH CYLINDER
RIPPER CYLINDER
PIN PULLER CYLINDER
40-44 D475A-3
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
Unit: mm

Blade 0.036 +0.274 0.096

lift 110 0.123 +0.060 0.397 0.72
Blade 0.043 +0.277 0.104

Clearance tilt 140 0.143 +0.061 0.480 0.82
1 between piston
rod and bushing Ripper 0.036 +0.277 0.098
lift 120 0.123 +0.062 0.400 0.70
Ripper 0.043 +0.277 0.104

tilt 140 0.143 +0.061 0.420 0.72
Pin 0.065 +0.133 0.072

puller 30 0.117 +0.007 0.250 0.55
Blade Ball 0.300 +0.300 0.300

lift 125 0.200 0 0.500 0.8
Blade 0.200 +0.100 0.200

tilt 90 0.300 0 0.400 1.0
Clearance
between piston
2 Ripper +0.207
rod support shaft lift 110 1.0 Replace
+0.120
and bushing
Ripper +0.207
tilt 110 1.0
+0.120
Pin Ball 0.100

puller 29 0.200
Clearance
between cylinder Blade 0.145
3 145
support shaft lift 0.245
bushing and yoke
Blade 0.200 +0.457 0.570

90 1.0
tilt 0.300 +0.390 0.757
Clearance
between cylinder Ripper +0.207
4 110 1.0
bottom support lift +0.120
shaft and bushing
Ripper 110 +0.195
tilt +0.122 1.0
Clearance between
13 cylinder bottom support 26 0.1
shaft and boss
D475A-3 40-45
MAINTENANCE STANDARD CYLINDER STAY
CYLINDER STAY
Unit: mm

1 Clearance between
cylinder yoke and bushing
0.050 +0.167 0.145
210 0.5
0.122 +0.005 0.289
Replace
2 160 0.5
cylinder yoke and bushing 0.106 +0.129 0.298
Clearance between lift 0.145 +0.040 0.145
3 cylinder supporting shaft 145 0.5
and bushing 0.245 0 0.285
40-46 D475A-3
MAINTENANCE STANDARD BLADE
BLADE
SEMI U-BLADE
40-48 D475A-3
Unit: mm

Clearance between brace size Shaft Hole clearance limit
1
pin and brace
90 0.2 +0.5 2
0.5 0.8
0.3 +0.3
Clearance between brace 0.2 +0.3

2 90 0.3 0.6 2
pin and bracket 0.3 +0.1
Replace
3 90 0.2 0.4 1
pin and bracket 0.3 0

4 90 0.2 0.4 1
pin and joint bushing 0.3 0
Spherical clearance 0.2 +0.3 Adjust shim

5 200 0.2 0.6 1
between arm and cap 0.3 0 or replace
Clearance between joint 0.2 +0.3

6 240 0.3 0.7 3
and bracket 0.4 +0.1
Clearance between frame 0.3 +0.3

7 120 0.3 0.8 3
pin and joint 0.5 0

8 120 0.5 1.0 2
Spherical clearance
9 between joint bushings of 165 0.3 0.4 1
straight frames
Replace
Spherical clearance 0.5 +0.5
10 250 0.5 1.5 8
between trunnion and cap 1.0 0

11 240 0.3 0.7 3
Clearance between blade 0.3 +0.3

12 120 0.3 0.8 3
pin and joint 0.5 0

13 120 0.5 1.0 2
Spherical clearance 0.2 +0.3 Adjust shim

14 200 0.2 0.6 1
between arm and cap 0.3 0 or replace
Clearance between arm 0.3 +0.5

15 90 0.6 1.0 2
pin and arm 0.5 +0.3
Replace
Clearance between arm 0.3 +0.3
16 90 0.4 0.8 2
D475A-3 40-49
U-DOZER, SUPER DOZER
40-50 D475A-3
Unit: mm

1 Clearance between brace
pin and brace
90 0.2 +0.3
0.3 0.6 2
0.3 +0.1

2 pin and bracket 90 0.3 0.6 2 Replace
0.3 +0.1

3 pin and bracket 90 0.3 0.5 1
0.4 0

4 pin and bushing 90 0.3 0.5 1
0.4 0
Clearance between center
brace and cap spherical 0.2 +0.3 Adjust shim
5 200 0.2 0.6 1
surface 0.3 0 or replace

6 240 1.2 1.9 3

7 120 0.3 0.8 3
pin and joint 0.5 0
Clearance between frame 0.3 +0.207 0.420

8 120 2
pin and bracket 0.5 +0.120 0.707
Clearance between
straight frame joint +0.206 0.014 0.152
9 185
bushings +0.166 0.060 0.266
Clearance between trun-
nion and cap spherical 250 0.5 +1.0
10 0.5 2.0 8
surface 1.0 0

11 240 0.3 0.7 3 Replace

12 pin and joint 120 0.3 0.8 3
0.5 0
Clearance between blade 0.3 +0.208 0.418

13 120 2
pin and bracket 0.5 +0.118 0.708
Clearance between center 0.043 +0.225 0.149

14 145 2
link pin and blade bracket 0.108 +0.106 0.333
Clearance between center 0.043 +0.225 0.149

15 145 2
link pin and center link 0.108 +0.106 0.333
Clearance between center 0.2 +0.3

16 550 0.2 1.1 2
link and blade bracket 0.8 0.
Clearance between center 0.2 +0.3
17 brace spherical surface 200 0.2 0.6 1 Adjust shim
0.3 0. or replace
and cap
D475A-3 40-51
CUTTING EDGE, END BIT
Unit: mm

1 Height of end bit outside
510 383
2 Width of end bit 720 635 Replace
3 Height of end bit inside 393 330
Replace
4 Height of cutting edge 405 351 (240 after turned) or turn
40-52 D475A-3
MAINTENANCE STANDARD RIPPER EQUIPMENT
RIPPER EQUIPMENT
VARIABLE GIANT RIPPER
40-54 D475A-3
MAINTENANCE STANDARD RIPPER EQUIPMENT
Unit: mm

Clearance between bush- size Shaft Hole clearance limit
1 ing and bracket and arm
mount pin 0.043 +0.193 0.093
140 0.106 +0.050 0.299 1.5
Clearance between bush- 0.043 +0.500 0.343

2 ing and beam and arm 140 1.5
mount pin 0.106 +0.300 0.606
3 cylinder mount pin and 110 1.5
bushing 0.090 +0.123 0.379
Replace
Clearance between shank
4
and mount pin 100 0.3

5 Wear of point
460 300
6 Wear of protector 224 184
D475A-3 40-55
90 OTHERS
Work equimpmet hydraulic circuit diagram

Single tilt specification ......................................................................... 90- 3
Dual tilt specfication ............................................................................. 90- 5
Super dozer specfication ...................................................................... 90- 7
Electrical circuit diagram
Single tilt and dual tilt specifications
Chassis electrical circuit diagram (1/4) ......................................... 90- 9
Chassis electrical circuit diagram (2/4) .........................................90-11
Super dozer specfication
Electrical circuit diagram for inside cab ............................................. 90-23
D475A-3 90-1
OTHERS WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIMPMET HYDRAULIC CIRCUIT DIAGRAM

SINGLE TILT SPECIFICATION
D475A-3 90-3

DUAL TILT SPECIFICATION
D475A-3 90-5

SUPER DOZER SPECIFICATION
D475A-3 90-7
OTHERS ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

CHASSIS ELECTRICAL CIRCUIT DIAGRAM
(SINGLE TILT AND DUAL TILT SPECIFICATIONS) (1/4)
D475A-3 90-9

D475A-3 90-11

D475A-3 90-13

D475A-3 90-15

(SUPER DOZER SPECIFICATION) (1/3)
D475A-3 90-17

D475A-3 90-19

D475A-3 90-21

ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB
D475A-3 90-23

Seb D 027501

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SEBM027501

MACHINE MODEL SERIAL No.

D475A-3 mounts the SDA12V140E-1 engine.

01 GENERAL ........................................................................ 01-1

10 STRUCTURE AND FUNCTION ...................................... 10-1

20 TESTING AND ADJUSTING .......................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................. 30-1

40 MAINTENANCE STANDARD ......................................... 40-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

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